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Service Tests
HP DesignJet 430, 450C and 455CA Printers
4-1
Introduction
This chapter explains how to use the built in Service Tests (Diagnostics) and what to do if the tests fail. If possible, always perform a Service Test on the component that you are about to replace, just to make sure that is the component that has failed. If the test on that component passes, there is no need to replace it.
Power On
The Printers automatically perform a series of internal self tests and mechanical initialization sequences whenever the user switches the Printer on. If a failure occurs, an error is indicated on the front panel LEDs. You can perform a failure analysis by interpreting the LED error code. (Details ' Chapter 2.) Self Test and Normal Initialization The power on self test and initialization procedure does the following: 1 Initializes the servo processor. 2 Initializes the main processor. 3 Tests communication between the main processor and the servo processor. 4 Tests the EEROM checksum. 5 Tests the servo processor transfer buffer and interrupt tracking. 6 Tests the ROM checksum. 7 Causes the main processor to initialize certain firmware modules. 8 Performs a subset of the electrical service test. 9 Checks the cover sensor. If the cover is open, nothing further happens until you close it. 10 Initializes the carriage axis (Y axis). 11 Uses the mark encoder to check the start of the drive roller. 12 Ejects any loaded sheet. Does not eject roll media if loaded. 13 Checks the media sensor. 14 Sets the Printer to accept media.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
Service Tests
Which Service Test to Perform
Use the following table as a rough guide:
Assembly/Feature Bail system Carriage Carriage motor and drive system (including belt, pulley and slider rod) Cartridge identification Cartridge nozzles Communication between computer and Printer Cover sensor DRAM SIMM EEROM Electronics module Tested by ... Bail cycle test, Bench run, Modular Test Carriage test, Electrical test, Modular test Carriage-axis test, Bail cycle test, Modular test, Bench run Carriage test, Modular test Carriage test, Modular test Service monitor Sensors test, Modular test Electrical test, Power-on tests, Bench run Electrical test, Power-on tests, Bench run Electrical test, Power-on tests, Servo/Encoder test, Sensors test, Bail cycle test, Front-panel test, Media-axis test, Carriage test, Carriage-axis test, Bench run, Modular test Carriage-axis test, Servo/Encoder test, Modular test, Bench run Front-panel test, Modular test Servo/Encoder test, Media-axis test, Modular test, Bench run Media-axis test, Modular test, Bench run Sensors test, Modular test Sensors test, Modular test Carriage test, Modular test Electrical test, Power-on tests, Bench run Bail cycle test Electrical test, Power-on tests, Bench run
Encoder strip Front-panel keys and LEDs Media-axis encoder and cable Media motor and drive system (including drive roller and overdrive) Media sensor Pinch-arm sensor Optical sensor (on carriage) ROM Service station Trailing cable
Service Tests
HP DesignJet 430, 450C and 455CA Printers
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Service Tests (Diagnostics)
The following is a list of all internal service tests available in the Printers. Instructions for entering service mode 1 are given on page 4 6. Instructions for entering service mode 2 are given on page 4 22. 1 Bail Cycle Test ' page 4 8 This tests the operation of the bail system, Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping/uncapping the cartridges to ensure a correct lifting action. 2 Front Panel Test ' page 4 9 The purpose of this test is to verify the operation of the front panel keys and LEDs. 3 Carriage Axis (Y axis) Test ' page 4 10 The purpose of this test is to verify the operation of the components of the Carriage Axis. 4 Carriage Test ' page 4 12 The purpose of this test is to verify the operation of the Carriage subsystems, like the Line Sensor and analog multiplexer. This test also checks the connection between the carriage flex circuit and the cartridges. 5 Sensors Test ' page 4 15 This tests the operation of the cover sensor, pincharm sensor and media sensor. 6 Media Axis (X Axis) Test ' page 4 16 The purpose of this test is to verify the operation of the components of the Media Axis. 7 Bench Run ' page 4 18 This test has been designed to be used during the manufacturing stage and not in the field. do not at anytime enter this test when troubleshooting the Printer. 8 Modular Test ' page 4 19 This test has been created to check the interaction between various components of the Printer. It combines the following tests:
D D D D D
Carriage axis test. Carriage test. Media axis test. Front panel test. Sensors test.
HP DesignJet 430, 450C and 455CA Printers
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Service Tests
9 Electronics Test ' page 4 21 The purpose of this test is to verify the operation of the FIBIS Column address and the shuffler. 10 Bail Test ' page 4 23 This tests the operation of the bail system, Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping/uncapping the cartridges. 11 Electrical Test ' page 4 24 This tests the operation of some of the electrical components of the electronics module. 12 Servo/Encoder Test ' page 4 25 The servo/encoder test performs the following:
D D D
Media axis encoder test: Verifies the operation of the servo loop (media axis feedback). Carriage axis encoder test: Verifies the operation of the servo loop (carriage axis feedback). Records the maximum friction detected in the EEROM. You can view this information on the service configuration plot.
13 Service Monitor ' page 4 26 The service monitor is useful to find out why the Printer is not plotting what you expect it to plot. It enables you to read the graphics language instructions that the Printer is receiving from the computer. Instead of plotting the drawing that you send, the Printer prints the beginning and end of the code that would otherwise have been used to plot the drawing. 14 EEROM Model ID Configuration Procedure ' page 4 27 This procedure is necessary if the Printer needs to be reconfigured as a DesignJet 430, 450C or 455CA. 15 Service Configuration Plot ' page 4 29 Gives a service report of the Printer. 16 Clearing the EEROM ' page 4 32 Instructions on how to clear the EEROM.
Service Tests
HP DesignJet 430, 450C and 455CA Printers
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Service Mode 1
Service Mode 1 contains tests that do not need a complete initialization of the Printer. This means if there is a system error in normal mode, it is still possible to enter into Service Mode 1. Also, the Sensors are disabled in Service Mode 1, which means it will not be possible to load media. The only time that the sensors will be functional is during the Sensors Test. THE COVER SENSOR IS DISABLED WHEN IN SERVICE MODE 1. IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE COVER IS OPENED. BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE. Some of the tests in service mode 1 send test information to the printer's serial port. To view the information perform the procedure on page 4 7. The Electronics Test is continuously done in the background during Service Mode 1. If you are viewing information via the serial port, you will see output similar to the following:
Test Mode EE test: 0 Test Mode EE test: 1 ...........
Stopping a Test The service tests are continuously repeated until you stop them. To exit a test, press the Cancel and Media Source keys (some tests may take a short while before exiting). To exit Service Mode 1, you must power OFF the Printer. Entering Service Mode 1 1 While holding the Reprint key down, switch the Printer ON. 2 Once the the LEDs begin to light up one by one, release the Reprint key. The printer performs the electrical power on tests and then the fan turns on and remains on. All LEDs remain off for a few seconds. Then, all LEDs begin to flash, waiting for you to perform a test. If there are any system failures during Service Mode 1 initialization, the Sheet LED (LED O) will be lit. This failure means that the Electronics Module has failed and needs to be replaced. Reprint
SERVICE MODE 1
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Service Tests
Viewing Test Output via the Serial Port Some of the tests in service mode 1 send test information to the printer's serial port. To view the information via the Serial Port: Using Windows 3.1 1 Turn the printer and PC OFF. 2 Connect the Printer to the PC using a serial interface cable and switch the PC ON. 3 Select the Terminal Icon in the Accessories Group in Windows. 4 In Terminal, select Settings and then select Communications from the pull down menu. 5 Make sure you use the following configuration: D Baud Rate = 9600 D Data Bits = 8 D Stop Bits = 1 D Parity = None D Flow Control = None D Connector = Select the Communications Port that you are using. 6 Select OK and Switch the Printer ON. 7 Perform the service tests on the Printer. Using an HP Palmtop PC 1 Use HP cable number F1015 80002 and adapter number 5181 6640 to connect the Palmtop to the Printer's serial interface port. Both cable and adaptor are included in the HP F1021B Connectivity Pack. 2 Turn the Printer on in service mode 1. 3 Turn the Palmtop on. 4 Open the Data Comm application on the Palmtop and press MENU. 5 Move to the Connect menu and press ENTER. 6 Ensure that Settings are the same for both Printer and Palmtop. 7 Again move to the Connect menu and press ENTER. 8 With Connect highlighted in the Connect menu, press ENTER. 9 Perform the service tests on the Printer. To stop communication between the Printer and the Palmtop, highlight Hangup in the Connect menu and press ENTER.
Service Tests
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Bail Cycle Test This tests the operation of the bail system, Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping/uncapping the cartridges. The test will perform the number of cycles as specified in the EEROM, but if the EEROM is cleared this test will not function. This Test has been designed to be used during the manufacturing stage and not in the field. If the Bail needs to be tested, please use the Bail Test in Service Mode 2. If a system error prevents you from entering into Service Mode 2, you may try this test instead. Perform the Bail Cycle test as follows: 1 In service mode 1, press Bail Cycle Test (Setup Key). 2 The test will start and the Carriage will move out of the Service Station and activate the engaging lever which causes the Bail Assembly to be gently raised and then lowered. 3 The test repeats the number of cycles as defined in the EEROM, unless you press the Cancel and Media Source keys. 4 If the test passes, the Best LED (LED C) will light up after the first cycle. 5 If there is a shutdown in the Y axis, the Best LED (LED C) will start to flash. 6 If the Printer does not raise the Bail Assembly then the test has failed.
If the bail fails the test, try replacing the following component: 1 Bail lift mechanism ' page 8 28.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
Front Panel Test The purpose of this test is to verify the operation of the front panel keys and LEDs. Perform the Front Panel test as follows: 1 In service mode 1, press Front Panel Test (Form Feed Key). If you are viewing information via the serial port, you will see output similar to the following:
1. - Front Panel Test
This message only informs you that the test has started, and a message will not appear if the test passes or fails. 2 The test will start and all the LEDs will flash for 2 seconds after which they will all be turned OFF. Check that all LEDs are functioning correctly when they flash. 3 To check that the front panel keys function correctly, press them one by one. Each time a key is pressed, the Coated LED (LED I) will be lit. 4 If a key is not functioning, the Coated LED (LED I) will remain OFF. 5 The test continuously repeats itself until you press the Cancel and Media Source keys.
If the test fails, to resolve the problem, try one of the following: 1 Check that the cable for the Front Panel Assembly is connected to the Electronics Module. Also make sure that the cable is NOT damaged or twisted. 2 Replace the Front Panel Assembly ' page 8 12. 3 Replace the Electronics Module ' page 8 13.
Service Tests
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Carriage Axis (Y axis) Test The purpose of this test is to verify the operation of the components of the Carriage Axis. This Service Mode does not include carriage axis initialization. If the carriage starts somewhere out of the Service Station, it will hit the right hand side of the Printer when the test begins, and the test will fail. Always make sure that the carriage is parked in the service station before starting this test. Perform the Carriage Axis test as follows: 1 Make sure that the carriage is parked in the service station. 2 In service mode 1, press Carriage Axis Test (Reprint Key). 3 The test will start and the carriage moves towards the right hand side of the printer. It then begins cycles of moving from side to side over the drive roller. 4 If the test passes, the Fast LED (LED A) will light up after the first cycle. If you are viewing information via the serial port, you will see output similar to the following:
2. - Y-AXIS TEST Test Mode Y-axis cycle: 26.67 speed and 66 pwm Test Mode Y-axis cycle 50.00 speed and 100 pwm Test Mode Y-axis cycle: 26.67 speed and 68 pwm ...............
5 If there is a Y axis shutdown, the Fast LED (LED A) will start to flash. If you are viewing information via the serial port, you will see output similar to the following:
2. - Y-AXIS TEST Test Mode Y-axis cycle: 26.67 speed and 0 pwm Test Mode Error: 2 on y-axis test
6 The test continuously repeats itself until you press the Cancel and Media Source keys.
The test is continued on the next page.
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Service Tests
If the test fails, to resolve the problem, try one of the following: 1 Clear any binding due to a media jam. 2 Turn the Printer off. Manually move the carriage along the carriage axis. Check for any areas where the carriage may be binding. 3 Ensure that the belt and belt pulley are in correct working order. Remove dirt from the pulley that could cause the belt to slip. 4 Remove dirt from the slider rod and chassis beam. Apply oil (Anderol 4068, HP part number: 6040 0858) to the carriage bushings. 5 At high temperatures, and if the fan is not working correctly, the internal resistance of the motor driver may increase, causing a decrease in the voltage between the motor contacts, and a shutdown of the motor. 6 Ensure that the encoder strip is not inverted, damaged or absent. 7 Reconnect or replace the trailing cable ' page 8 8. 8 Replace the carriage assembly ' page 8 37. Only replace one component at a time and perform the test again before replacing another component. Using this procedure you will be able to determine exactly which component failed.
Service Tests
HP DesignJet 430, 450C and 455CA Printers
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Carriage Test The purpose of this test is to verify the operation of the Carriage subsystems, like the Line Sensor and analog multiplexer. This test also checks the connection between the carriage flex circuit and the cartridges. Perform the Carriage test as follows: 1 In service mode 1, press Carriage Test (Print Quality Key). 2 The test will start and all the LEDs will turn OFF. There will be no movement in the Printer and you must wait for the Front Panel to indicate if the test has passed or failed. 3 Refer to the following figure to check which LED is associated with which test. If the test passes, the following LEDs will be lit (ON). If the test fails, the following LEDs will be flashing:
If you are viewing information via the serial port, you will see output similar to the following if the Test Passes:
4. - Carriage Test 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Calvin: 13643 1960 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Yellow: 11361 1953 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Cyan: 11361 1953 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Magenta: 11361 1953 Pen BLACK continuity: WORKS Pen CYAN continuity: WORKS Pen MAGENTA continuity: WORKS Pen YELLOW continuity: WORKS Pen BLACK has 1cd4 identification. Pen CYAN has 400 identification. Pen MAGENTA has 1f00 identification. Pen YELLOW has 1900 identification. Optical sensor samples: 253 255 255 254 253 252 252 250 249 248 247 246 245 244 243 241 Optical Sensor: WORKS Carriage MUX : WORKS Pen BLACK continuity: WORKS ...........
The test is continued on the next page.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
If you are viewing information via the serial port, you will see output similar to the following if the Test Fails:
4. - Carriage Test 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Calvin: 13643 1960 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Yellow: 12160 1899 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Cyan: 12160 1899 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Magenta: 12160 1899 Pen BLACK continuity: FAILS Pen CYAN continuity: FAILS Pen MAGENTA continuity: FAILS Pen YELLOW continuity: FAILS Pen BLACK has 3ffe identification. Pen CYAN has 3ffe identification. Pen MAGENTA has 3ffe identification. Pen YELLOW has 3ffe identification. Optical sensor samples: 215 252 243 232 221 208 194 179 166 151 135 119 103 87 71 54 Optical Sensor: WORKS Carriage MUX : FAILS Pen BLACK continuity: FAILS ................
4 The test continuously repeats itself until you press the Cancel and Media Source keys. Cartridge Continuity Test Failure If any cartridge Continuity test fails, to resolve the problem, try one of the following: 1 Remove the failing Cartridge and clean the flex contacts on the Carriage and the Cartridge. Reseat the Cartridge and try the test again. 2 Replace the Cartridge of the relevant failing color and perform this test again. 3 Check and if necessary replace the Trailing Cable ' page 8 8. 4 Replace the Carriage Assembly ' page 8 37. 5 Replace the Electronics Module ' page 8 13. Only replace one component at a time and perform the test again before replacing another component. Using this procedure you will be able to determine exactly which component failed.
The test is continued on the next page.
Service Tests
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Line Sensor Test Failure If the Line Sensor test fails, to resolve the problem, try one of the following: 1 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. 2 Check and if necessary replace the Trailing Cable ' page 8 8. 3 Replace the Carriage Assembly ' page 8 37. 4 Replace the Electronics Module ' page 8 13. Only replace one component at a time and perform the test again before replacing another component. Using this procedure you will be able to determine exactly which component failed. Analog Multiplexer Test Failure If the Analog Multiplexer test fails, to resolve the problem, try one of the following: 1 Check and if necessary replace the Trailing Cable ' page 8 8. 2 Replace the Carriage Assembly ' page 8 37. 3 Replace the Electronics Module ' page 8 13. Only replace one component at a time and perform the test again before replacing another component. Using this procedure you will be able to determine exactly which component failed.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
Sensors Test This tests the operation of the cover sensor, pincharm sensor and media sensor. Perform the Sensors test as follows: 1 In service mode 1, press Sensors Test (Media Type Key). 2 Activate the necessary sensor and check that the relevant LED status changes (ON/OFF). Refer to the following figure to check which LED is associated with which sensor. 3 The test continuously repeats itself until you press the Cancel and Media Source keys.
If you are viewing information via the serial port, you will see output similar to the following:
5. - SENSORS TEST
This message only informs you that the test has started, and a message will not appear if the test passes or fails. If the test fails, to resolve the problem, try one of the following: 1 If the cover sensor fails, check that the front panel assembly is correctly connected to the electronics module. Try replacing the front panel assembly. 2 If the Pincharm sensor fails, check that the sensor cable is correctly connected to the electronics module. Try replacing the pincharm sensor. 3 If the Media sensor fails, check that the sensor cable is correctly connected to the electronics module. Try replacing the overdrive assembly (the media sensor is included as part of the overdrive assembly). 4 Replace the Electronics Module ' page 8 13. Only replace one component at a time and perform the test again before replacing another component. Using this procedure you will be able to determine exactly which component failed.
Service Tests
HP DesignJet 430, 450C and 455CA Printers
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Media Axis (X Axis) Test The purpose of this test is to verify the operation of the components of the Media Axis. Perform the Media Axis test as follows: 1 In service mode 1, press Media Axis Test (Media Load Button). 2 The test will start and the drive roller rotates in steps, each equivalent to one swath advance. 3 If the test passes, the Glossy LED (LED J) will light up after the first cycle. If you are viewing information via the serial port, you will see output similar to the following:
3. - X-AXIS TEST Test Mode X-Axis Cycle: 92 pwm Test Mode X-Axis Cycle: 65 pwm Test Mode X-Axis Cycle: 66 pwm ...............
4 If there is a shutdown, the Glossy LED (LED J) will start to flash after the first cycle. If you are viewing information via the serial port, you will see output similar to the following:
3. - X-AXIS TEST Test Mode X-Axis Cycle: 79 pwm Test Mode X-Axis Cycle: 115 pwm Test Mode X-Axis Cycle: 127 pwm Test Mode Error: 1 on X-axis test
5 The test continuously repeats itself until you press the Cancel and Media Source keys.
The test is continued on the next page.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
If the test fails, to resolve the problem, try one of the following: 1 Switch OFF the Printer and manually moving the carriage along the slider rod, check for obstacle or friction in the X axis. 2 Check for a faulty or badly connected X axis Encoder Cable. 3 Replace media motor ' page 8 23. 4 Replace electronics module ' page 8 13. Only replace one component at a time and perform the test again before replacing another component. Using this procedure you will be able to determine exactly which component failed.
Service Tests
HP DesignJet 430, 450C and 455CA Printers
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Bench Run The bench run is a routine that each Printer performs before it leaves the manufacturing site. It attempts to filter out Printers that could have an early breakdown due to a fault in manufacturing. The bench run tests the operation of the electronics, carriage axis system, media axis system, bail lift mechanism, and service station. The bench run is performed at the manufacturing site by sending special commands to the Printer and then pressing the indicated front panel keys. If the Printer is switched OFF during the Bench Run, the Bench Run will be resumed at exactly the same point before the Printer was switched OFF, until the Bench Run is completed.
THIS TEST HAS BEEN DESIGNED TO BE USED DURING THE MANUFACTURING STAGE AND NOT IN THE FIELD. DO NOT AT ANYTIME ENTER THIS TEST WHEN TROUBLESHOOTING THE PRINTER.
1 The way to enter to Bench Run is to press the Media Source and Form Feed keys in Service Mode 1. If these keys are accidently pressed, you must immediately EXIT the Bench Run by switching OFF the Printer and powering ON again while pressing the Print Quality and Media Source keys.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
Modular Test This test has been created to check the interaction between various components of the Printer. It combines the following tests:
D D D D D
Carriage axis test. Carriage test. Media axis test. Front panel test. Sensors test.
This Service Mode does not include carriage axis initialization. If the carriage starts somewhere out of the Service Station, it will hit the right hand side of the Printer when the test begins, and the test will fail. Always make sure that the carriage is parked in the service station before starting this test. If one part of the test fails, the other parts continue regardless. Perform the Modular test as follows: 1 Make sure that the carriage is parked in the service station. 2 In service mode 1, press Modular Test (Media Source Key). 3 The printer first performs the Front panel Test and once it is fully completed (once all the keys are pressed) then continues with the rest of the above tests in parallel. 4 Refer to the following figure to check which LED is associated with which test. If the test passes, the following LEDs will be lit (ON). If the test fails, the following LEDs will be flashing:
The test is continued on the next page.
Service Tests
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5 The test continuously repeats itself until you press the Cancel and Media Source keys. If you are viewing information via the serial port, you will see output similar to the following if the Test Passes:
1. - FRONT PANEL TEST 2. - Y AXIS TEST 3. - X AXIS TEST 4. - CARRIAGE TEST 5. - SENSORS TEST Test Mode Xaxis cycle : 87 pwm. 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Calvin: 13643 1960 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Yellow: 11361 1953 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Cyan: 11361 1953 0x57c7c350 (carrPCBTest): Forcing use of R10X method for Magenta: 11361 1953 Test Mode Y-axis cycle : 26.67 speed and 68 pwm. Test Mode X-axis cycle : 67 pwm. Test Mode Y-axis cycle : 50.00 speed and 100 pwm. Test Mode X-axis cycle : 66 pwm. Test Mode Y-axis cycle : 26.67 speed and 66 pwm. Test Mode X-axis cycle : 65 pwm. Test Mode Y-axis cycle : 50.00 speed and 98 pwm. Pen BLACK continuity: WORKS Pen CYAN continuity: WORKS Test Mode X-axis cycle : 64 pwm. Pen MAGENTA continuity: WORKS Pen YELLOW continuity: WORKS Pen BLACK has 1cd4 identification. Pen CYAN has 400 identification. Pen MAGENTA has 1f00 identification. Pen YELLOW has 1900 identification. Optical sensor samples: 255 255 255 255 255 254 254 253 253 252 252 251 251 250 250 249 Optical Sensor: WORKS Encoder sensor: WORKS Pen BLACK continuity: WORKS Test Mode Y-axis cycle : 26.67 speed and 68 pwm .............
The result of the Encoder sensor test is only reported via the serial output and not via the front panel. In order to perform the encoder sensor test, you must move the carriage slightly so that the encoder sensor can detect the change in status. If the carriage is not moved at all, the Encoder Sensor test will always fail. If the carriage is moved and ONLY the Encoder Sensor test fails, then you need to replace the Carriage Assembly ' page 8 37. If any of the tests fail, refer to the individual test documented in this chapter for the correct troubleshooting procedure.
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Service Tests
Electronics Test The purpose of this test is to verify the operation of the FIBIS Column address and the shuffler. THIS TEST HAS BEEN FOUND TO BE VERY UNSTABLE DUE TO SOME INTERACTIONS BETWEEN SOME OF THE COMPONENTS OF THE ELECTRONICS MODULE. IT IS SOMETIMES IMPOSSIBLE TO EXIT THIS TEST WITHOUT SWITCHING OFF THE PRINTER. Perform the Electronics test as follows: 1 In service mode 1, press Electronics Test (Media Source and Reprint Keys). 2 The test will start and all the LEDs will turn OFF. There will be no movement in the Printer and you must wait for the Front Panel to indicate if the test has passed or failed. 3 If the test passes, the Sheet LED (LED O) will light up. 4 If the test fails, the Sheet LED (LED O) will start to flash. 5 The test continuously repeats itself until you press the Cancel and Media Source keys.
If the test fails, try replacing the following component: 1 Electronics Module ' page 8 13.
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Service Mode 2
Service Mode 2 contains tests that do need a complete initialization of the Printer. This means if there is a system error in normal mode, it is NOT possible to enter into Service Mode 2. If possible try entering into Service Mode 1 and performing the tests there. The tests in service mode 2 DO NOT send test information to the printer's serial port. For some of the tests you will need to print the Service Configuration Plot (Details ' page 4 29) in order to check the results. Stopping a Test The service tests are continuously repeated until you stop them. To exit a test, press any of the front panel keys. To exit Service Mode 2, you must power OFF the Printer. Entering Service Mode 2 1 While holding the Media Source key down, switch the printer ON. 2 Once the the LEDs begin to light up one by one, release the Media Source key. The printer performs the electrical power on tests and initializes the mechanics as in normal user mode. When you are in Service Mode 2, All the LEDs will go off except the ones that have been selected. Once inside a test, all the LEDs, except for the LEDs in the Error Group, will begin to flash.
+
Media Source SERVICE MODE 2
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Service Tests
Bail Test This tests the operation of the bail system, Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping/uncapping the cartridges. Perform the Bail test as follows: 1 In service mode 2, press Bail Test (Setup Key). 2 The test will start and the Carriage will move out of the Service Station and activate the engaging lever which causes the Bail Assembly to be gently raised and then lowered. 3 If the Printer does not raise the Bail Assembly then the test has failed. 4 The test continuously repeats itself until you press any of the front panel keys.
If the bail fails the test, try replacing the following component: 1 Bail lift mechanism ' page 8 28.
Service Tests
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Electrical Test This tests the operation of some of the electrical components of the electronics module. THIS TEST HAS BEEN FOUND TO BE VERY UNSTABLE DUE TO SOME INTERACTIONS BETWEEN SOME OF THE COMPONENTS OF THE ELECTRONICS MODULE. IT IS SOMETIMES IMPOSSIBLE TO EXIT THIS TEST WITHOUT SWITCHING OFF THE PRINTER. Perform the Electrical test as follows: 1 In service mode 2, press Electrical Test (Form Feed Key). 2 The test will start and the Printer will check some of the electrical parts. 3 If the test fails, an error code will appear on the front panel. Refer to Chapter 2 in order to correctly troubleshoot the failure.
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Service Tests
Servo/Encoder Test The servo/encoder test performs the following: Media axis encoder test: Verifies the operation of the servo loop (media axis feedback). D Carriage axis encoder test: Verifies the operation of the servo loop (carriage axis feedback). D Records the maximum friction detected in the EEROM. You can view this information on the service configuration plot.
D
Perform the Servo/Encoder test as follows: 1 In service mode 2, press Servo/Encoder Test (Media Type Key). 2 The test will start and there will be slight movements in the X and Y axis. After every 5 movements, the direction of the movement will change in both axis. The maximum PWM of both axis will be saved in the EEROM. 3 To view the results of the test, you must print the Service Configuration Plot (Print Quality and Media Type keys). 4 If the test fails, an error code will appear on the front panel. Refer to Chapter 2 in order to correctly troubleshoot the failure.
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Service Monitor (Data Display) The service monitor is useful to find out why the Printer is not plotting what you expect it to plot. It enables you to read the graphics language instructions that the Printer is receiving from the computer. Instead of plotting the drawing that you send, the Printer prints the beginning and end of the code that would otherwise have been used to plot the drawing. You need a basic knowledge of the graphics language instructions to be able to pick out the important information from the printed code. Perform the Service Monitor as follows: 1 In service mode 2, load a sheet of media (A3 size or B size minimum) in portrait orientation. 2 Press Service Monitor (Media Type and Media Source Keys). 3 Send the file from the computer through the serial or parallel ports. The Ready LED begins to flash. 4 Wait until the computer has indicated that it has sent the file. The Ready LED continues to flash. 5 While the Ready LED is flashing, press Service Monitor (Media Type and Media Source Keys) again. The Ready LED continues to flash. After a minute, the fan turns on, and the carriage moves to the right side of the Printer. Instead of printing the drawing that you sent, the Printer prints the first and last Kbytes of the code for that drawing. The code is printed in hexadecimal and ASCII format. (If the total size of the file(s) sent is not bigger than one Kbyte, only the first buffer is printed.) The Printer exits the service monitor mode if the file(s) sent contain PJL universal exit language.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
EEROM Model ID Configuration Procedure The EEROM model ID configuration procedure only needs to be carried out if: A pre configured board is being reused. D The current board is incorrectly configured to the wrong model ID. D The Printer shows an unconfigured model ID system error (Steady EKL).
D
It is very rare that these situations will ever occur. Configure the Printer model ID as follows: 1 Remove the right end cover ' page 8 11. 2 Disconnect the media motor encoder cable from the main PCA (connector ENC X). 3 Turn the Printer ON while holding the Reprint key down. 4 Press the Media Source and Media Type keys together to enter the deconfiguration mode. The Fast, Normal and Best LEDs (LEDs ABC) will light up.
5 Using a suitable tool, short circuit pins 1 and 2 (the first two pins on the right) of the media motor encoder connector (ENC X). The Cartridges, Data and Media LEDs (LEDs KLM) should light up as you short circuit the two pins. 6 Once you have short circuited the two pins, the Fast, Normal and Best LEDs (LEDs ABC) should light up again. 7 Press the Cancel and Media Source keys together to exit the deconfiguration mode.
The instructions are continued on the next page.
Service Tests
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8 Configure the Printer with the correct model ID as follows: Only one opportunity is given to perform this procedure and there is no indication that it was successful. If the Printer is to be configured as a DesignJet 450C (Color) Printer, hold the Media Source key down and press the two Color Configuration (Print Quality + Media Type) keys at the same time. If the Printer is to be configured as a DesignJet 430 (Monochrome)Printer, hold the Media Source key down and press the two Mono Configuration (Print Quality + Setup) keys at the same time. If the Printer is to be configured as a DesignJet 455CA (LFP) Printer, hold the Media Source key down and press the two LFP Configuration (Print Quality + Reprint) keys at the same time.
9 Turn the Printer OFF. 10 Reconnect the media motor encoder cable to the main PCA (connector ENC X). 11 Turn the Printer ON. After initializing, error code DLM" will appear because the Accuracy Calibration must still be performed. 12 Press the Cancel key and print the Demo Plot to check if the Printer has been correctly configured as a DesignJet 430, 450C or 455CA. If the Printer is still incorrectly configured then Error Code EKL will " be displayed on the front panel. Turn the Printer OFF and perform the EEROM Model ID configuration procedure again from step 2. 13 Perform the accuracy calibration (refer to Chapter 5).
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
Service Configuration Plot The service configuration plot contains the following information: DesignJet 4XX Service Configuration Plot Firmware Release: X.XX.XX SPROC release: X.X (Servo-Processor Code revision number.)
EEROM Contents
EEROM CONTENTS (This is for the Printer design engineers to interpret.)
NOTE: All EEPROM Parameters are since last EEROM Reset. Number of Power Cycles: Number of Color Plots: Number of Black Plots: Number of Pens: Factory Spittoon: Number of Bail Errors: Number of System Errors: Last System Error: Last System Error at file media_load.c line 2810 Bench Run: Bench Run Maximum Y-Axis (Carriage-Axis) PWM: Bench Run Maximum X-Axis (Media-Axis) PWM: Encoder-Tests Maximum Y-Axis (Carriage-Axis) PWM: Encoder-Tests Maximum X-Axis (Media-Axis) PWM: X-axis Calibration: 127 87 62 62 19 13 15 7666 0% used 0 2 0x00000550 (errno = 0x3c0001)
Amp1 = 7.467, Phase1 = 0.450, Amp2 = 8.956, Phase2 = 2.325, Factor = 0.000500
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HP DesignJet 430, 450C and 455CA Printers
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Printing the Service Configuration Plot To print the service configuration plot: 1 In service mode 2, load a sheet in portrait orientation. In normal mode, load a sheet in portrait orientation. The service configuration plot can be plotted without the need to enter the service mode. This is because the customer will be requested to plot the service configuration plot and he will be given the following instructions to plot it without entering the service mode. 2 When the Ready LED lights up, press the Print Quality and Media Type keys. 3 The Ready light begins to flash and then remains on (steady). The Printer plots the service configuration plot and ejects the media. 4 Unload the media.
Interpreting the Service Configuration Plot The parameters on the Service Configuration Plot can help you to troubleshoot the Printer more effectively. Here is a short description of the all the parameters. Number of Power Cycles How many times the Printer has been powered ON.
Number of Color Plots
How many color plots have been produced since the EEROM was last erased.
Number of Black Plots
How many mono plots have been produced since the EEROM was last erased.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
Number of Pens
The number of times each cartridge has been replaced. The numbers refer to (from left to right): Cyan, Magenta, Yellow, Black.
Factory Spittoon
The estimated level of ink in the spittoon. This level will be incorrect if the EEROM has been cleared.
Number of Bail Errors
How many shutdowns there have been because of the Bail life mechanism.
Number of System Errors
How many System Errors have occurred.
Last System Error
The last System error that occurred. This information might be requested in the event of an escalation in order to understand any problems.
Last System Error Data
Information on exactly which line of the firmware the error occurred in. This information might be requested in the event of an escalation in order to understand any problems.
Bench Run
Whether the Bench Run has been performed.
Bench Run Maximum Y Axis (Carriage Axis) PWM
This Value should be less than 144. Typical Value = 90 100.
Bench Run Maximum X Axis (Media Axis) PWM
This Value should be less than 100. Typical Value = 60 70.
Encoder Tests Maximum Y Axis (Carriage Axis) PWM
This Value should be less than 144. Typical Value = 90 100.
Encoder Tests Maximum X Axis (Media Axis) PWM
This Value should be less than 100. Typical Value = 60 70.
X axis Calibration
This shows the information related to the Accuracy Calibration. This information might be requested in the event of an escalation in order to understand any problems.
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Clearing the EEROM If you clear the calibration parameters, you will then need CAUTION to perform the Printer calibrations. (Details ' chapter 5.) Clearing the EEROM also resets the factory spittoon value to 0% used. Keep in mind that the value printed on the service configuration plot may greatly underestimate the amount of ink in the spittoon. Clearing Just the Benchrun and Calibration Parameters 1 Switch the Printer OFF. 2 While holding down the Form Feed, Cancel and Media Type keys down, switch the Printer ON. 3 Once the the LEDs begin to light up one by one, release the keys.
Clearing Just the User Defined Setup Parameters 1 Switch the Printer OFF. 2 While holding down the Reprint, Cancel, Media Type and Media Source keys down, switch the Printer ON. 3 Once the the LEDs begin to light up one by one, release the keys.
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HP DesignJet 430, 450C and 455CA Printers
Service Tests
Clearing All Parameters 1 Switch the Printer OFF. 2 While holding down the Setup, Form Feed, Reprint, Print Quality and Media Type keys down, switch the Printer ON. 3 Once the the LEDs begin to light up one by one, release the keys
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HP DesignJet 430, 450C and 455CA Printers
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