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HP LaserJet P3010 Series Printers Service Manual
Additional product information: www.hp.com/support/ljp3010series
HP LaserJet P3010 Series Printers
Service Manual
Copyright and License © 2009 Copyright Hewlett-Packard Development Company, L.P. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. The information contained herein is subject to change without notice. The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein. Part number: CE524-90909 Edition 1, 7/2009
Trademark Credits Adobe® is a trademark of Adobe Systems Incorporated. Microsoft®, Windows®, Windows® XP, and Windows Vista® are U.S. registered trademarks of Microsoft Corporation. ENERGY STAR and the ENERGY STAR mark are registered U.S. marks.
Conventions used in this guide
TIP: Tips provide helpful hints or shortcuts. NOTE: Notes provide important information to explain a concept or to complete a task. CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging the product. WARNING! Warnings alert you to specific procedures that you should follow to avoid personal injury, catastrophic loss of data, or extensive damage to the product.
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Conventions used in this guide
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Table of contents
1 Theory of operation Basic operation ..................................................................................................................................... 2 Major printer systems .......................................................................................................... 2 Printer block diagram ........................................................................................................... 2 Sequence of operation ......................................................................................................... 3 Normal sequence of operation ............................................................................ 3 Formatter-control system ..................................................................................................................... 4 Sleep mode .......................................................................................................................... 4 Input/output .......................................................................................................................... 4 CPU ..................................................................................................................................... 4 Memory ................................................................................................................................ 5 Optional hard disk ............................................................................................... 5 Firmware ............................................................................................................. 5 Nonvolatile memory ............................................................................................ 5 PJL overview ....................................................................................................................... 5 PML ..................................................................................................................................... 5 Control panel ....................................................................................................................... 5 Engine-control system .......................................................................................................................... 6 Motors, fans, clutches, solenoids, switches, and sensors ................................................... 7 DC controller operations .................................................................................................... 14 Fuser-control circuit ........................................................................................................... 16 Fuser failure detection ....................................................................................... 17 Fuser temperature control ................................................................................. 18 Fuser protective function ................................................................................... 19 Low-voltage power supply ................................................................................................. 20 Overcurrent/overvoltage protection ................................................................... 21 High-voltage power supply ................................................................................................ 22 Formatter ........................................................................................................................... 23 Formatter heartbeat LED .................................................................................. 23 DIMM slots ........................................................................................................ 23 Laser/scanner system ........................................................................................................ 24 Laser failure detection ....................................................................................... 25 Image-formation system ..................................................................................................................... 26 Electrophotographic process ............................................................................................. 26
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Image formation process ................................................................................................... 27 Latent-image formation stage ........................................................................... 28 Primary charging .............................................................................. 28 Laser beam exposure ....................................................................... 28 Developing stage .............................................................................................. 29 Print cartridge ................................................................................... 29 Transfer stage ................................................................................................... 30 Fusing stage ..................................................................................... 30 Cleaning stage .................................................................................. 31 Toner detection .................................................................................................................. 32 Pickup, feed, and delivery system ...................................................................................................... 33 Paper trays ........................................................................................................................ 33 Photo sensors and switches .............................................................................................. 34 Solenoids and clutches ...................................................................................................... 36 Tray 1 or Tray 2 .................................................................................................................................. 38 Pickup and feed unit .......................................................................................................... 38 Cassette paper size detection/cassette paper detection ................................... 38 Cassette pickup ................................................................................................. 38 Tray 1 paper pickup ........................................................................................................... 38 Paper pickup and feed ....................................................................................................... 39 Jam detection .................................................................................................................... 40 Additional tray ..................................................................................................................................... 41 Tray driver PCA ................................................................................................................. 41 Paper pickup and feed ....................................................................................................... 42 Media level and size detection ........................................................................................... 43 Jam detection .................................................................................................................... 43 2 Removal and replacement Removal and replacement strategy ................................................................................................... 46 General cautions during removal and replacement ........................................................... 46 Electrostatic discharge ...................................................................................... 46 Required tools ................................................................................................... 46 Types of screws ................................................................................................ 47 Service approach ............................................................................................................................... 48 Before performing service .................................................................................................. 48 After performing service ..................................................................................................... 48 Post-service test ................................................................................................................ 48 Print-quality test ................................................................................................ 48 Parts removal order ........................................................................................................... 50 Removal and replacement procedures .............................................................................................. 52 Print cartridge, cassettes, and sub cover ........................................................................... 52 Print cartridge .................................................................................................... 52 Tray cassette (Tray 2, Tray 3, or Tray 4) .......................................................... 54
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Sub cover .......................................................................................................... 55 External panels, covers, doors, formatter PCA, DIMM, and EIO disk ............................... 56 EIO disk ............................................................................................................. 56 DIMM cover and DIMM ..................................................................................... 57 Reinstall the DIMM ........................................................................... 58 Formatter cover and formatter PCA .................................................................. 60 Rear-door assembly .......................................................................................... 62 Left cover .......................................................................................................... 66 Right-rear cover ................................................................................................ 68 Tray 1 (multipurpose tray) cover ....................................................................... 69 Cartridge-door assembly ................................................................................... 71 Top-right cover .................................................................................................. 73 Control panel ..................................................................................................... 74 Front-right and right-side cover assembly ......................................................... 76 Lower-right cover and bracket ........................................................................... 80 Reinstall the lower-right cover .......................................................... 82 Top cover .......................................................................................................... 84 Main assemblies ................................................................................................................ 86 Tray 1 (multipurpose tray) pickup roller ............................................................. 86 Tray 1 (multipurpose tray) separation pad ........................................................ 87 Tray 2, Tray 3, or Tray 4 pickup roller ............................................................... 88 Tray 2, Tray 3, or Tray 4 separation pad ........................................................... 90 Tray 2, Tray 3, or Tray 4 base-plate roller assembly ........................................ 91 Transfer roller .................................................................................................... 92 USB port PCA ................................................................................................... 94 Power-switch assembly ..................................................................................... 96 Main fan, fan duct, and environmental sensor .................................................. 98 Fuser ............................................................................................................... 100 Registration assembly ..................................................................................... 102 Duplex media-feed assembly .......................................................................... 104 Laser/scanner ................................................................................................. 107 Engine control unit (ECU) ............................................................................... 110 Cassette pickup (Tray 2) solenoid or Tray 1 (multipurpose tray) pickup solenoid ........................................................................................................... 115 Fuser motor ..................................................................................................... 117 Sub fan and fan duct ....................................................................................... 118 High-voltage power supply (HVPS) ................................................................. 121 3 Solve problems Solve problems checklist .................................................................................................................. 128 Menu map ........................................................................................................................................ 130 Troubleshooting process .................................................................................................................. 131 Determine the problem source ........................................................................................ 131 Power subsystem ............................................................................................................ 132
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Power-on checks ............................................................................................. 132 Tools for troubleshooting .................................................................................................................. 133 Individual component diagnostics .................................................................................... 133 LED diagnostics .............................................................................................. 133 LED indicators ................................................................................ 133 Formatter heartbeat LED ................................................................ 133 HP Jetdirect LEDs .......................................................................... 134 Engine diagnostics .......................................................................................... 134 Engine-test button .......................................................................... 134 Fuser test page ............................................................................................... 135 Paper-path test (and automatic sensors test) ................................................. 136 Sensor test (interactive) .................................................................................. 137 A TOP (Top-of-Page) sensor .......................................................... 140 B Fuser output sensor .................................................................... 141 C Duplex sensor ............................................................................. 142 D Paper width sensor 1 .................................................................. 143 E Tray 3 feed sensor ...................................................................... 144 F Tray 4 feed sensor ...................................................................... 145 G FD tray full sensor ....................................................................... 146 H Face up detect sensor ................................................................ 147 I Cartridge-door open switch .......................................................... 148 J Rear cover open sensor .............................................................. 149 K Tray 1 paper sensor .................................................................... 150 L Tray 2 paper sensor .................................................................... 151 M Tray 2 detect switch .................................................................... 152 N Tray 3 paper sensor .................................................................... 153 O Tray 3 detect switch .................................................................... 154 P Tray 4 paper sensor .................................................................... 155 Q Tray 4 detect switch .................................................................... 156 Print/stop test .................................................................................................. 157 Component tests ............................................................................................. 158 Half self-test .................................................................................... 158 Drum rotation test check ................................................................. 158 Diagnostics menu components test ................................................ 158 Diagrams ......................................................................................................................... 160 Block diagrams ................................................................................................ 160 Plug/jack locations .......................................................................................... 162 Location of connectors .................................................................................... 163 ECU controller connections ............................................................ 163 Locations of major components ...................................................................... 165 General timing charts ...................................................................................... 169 General circuit diagram ................................................................................... 170 Internal print quality test pages ........................................................................................ 171 Cleaning page ................................................................................................. 172
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Configuration page .......................................................................................... 172 Print quality troubleshooting tools .................................................................................... 173 Repetitive image-defect ruler .......................................................................... 173 Control-panel menus ....................................................................................................... 174 Use the menus ................................................................................................ 174 Show Me How menu ....................................................................................... 174 Retrieve job menu ........................................................................................... 175 Information menu ............................................................................................ 176 Paper handling menu ...................................................................................... 177 Manage supplies menu ................................................................................... 177 Configure device menu ................................................................................... 178 Printing menu ................................................................................. 178 Print Quality menu .......................................................................... 180 System setup menu ........................................................................ 183 I/O menu ......................................................................................... 187 Resets menu .................................................................................. 194 Diagnostics menu ............................................................................................ 194 Service menu .................................................................................................. 196 Interpret control-panel messages .................................................................................... 197 Control-panel message types ......................................................................... 197 Control-panel messages ................................................................................. 197 Event-log messages ........................................................................................................ 215 Print an event log ............................................................................................ 215 Show an event log ........................................................................................... 215 Sample event-log page ................................................................................... 216 Clear an event log ........................................................................................... 216 Event-log messages ........................................................................................ 217 Clear jams ........................................................................................................................................ 219 Common causes of jams ................................................................................................. 219 Jam locations ................................................................................................................... 220 Clear jams from the input trays ........................................................................................ 222 Clear jams from the duplexer ........................................................................................... 226 Clear jams from the output areas .................................................................................... 231 Clear jams from inside the product .................................................................................. 234 Registration and transfer area ......................................................................... 234 Jam causes and solutions ............................................................................................... 236 Avoid repeated jams ....................................................................................................... 240 Change jam recovery ....................................................................................................... 241 Solve paper-handling problems ........................................................................................................ 242 Product feeds multiple sheets .......................................................................................... 242 Product feeds incorrect page size ................................................................................... 242 Product pulls from incorrect tray ...................................................................................... 243 Paper does not feed automatically .................................................................................. 243 Paper does not feed from Tray 2, 3, or 4 ......................................................................... 244
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Transparencies or glossy paper will not feed .................................................................. 244 Envelopes jam or will not feed in the product .................................................................. 245 Output is curled or wrinkled ............................................................................................. 245 Product does not duplex or duplexes incorrectly (duplex models) .................................. 246 Solve image-quality problems .......................................................................................................... 247 Image defect examples .................................................................................................... 247 Clean the product ............................................................................................................................. 254 Solve performance problems ........................................................................................................... 257 Solve connectivity problems ............................................................................................................. 258 Solve direct-connect problems ........................................................................................ 258 Solve network problems .................................................................................................. 258 Service mode functions .................................................................................................................... 259 Service menu ................................................................................................................... 259 Product resets .................................................................................................................. 260 Restore factory settings .................................................................................. 260 Hard disk initialization ..................................................................................... 260 Skip disk-load .................................................................................................. 260 NVRAM initialization ........................................................................................ 260 Service ID ....................................................................................... 261 Restore service ID .......................................................................... 261 Convert the service ID to an actual date ........................................ 261 Reset serial number ....................................................................... 262 Reset page counts .......................................................................... 262 Product cold reset ........................................................................................... 262 Product updates ............................................................................................................................... 263 Determine the current firmware version ........................................................................... 263 Download new firmware from the HP Web site ............................................................... 263 Transfer the new firmware to the product ........................................................................ 263 Use the flash executable file to update the firmware ...................................... 263 Use FTP to upload the firmware through a browser ....................................... 264 Use FTP to upgrade the firmware on a network connection ........................... 264 Use HP Web Jetadmin to upgrade the firmware ............................................. 265 Use Microsoft Windows commands to upgrade the firmware ......................... 265 Upgrade the HP Jetdirect firmware .................................................................................. 265 4 Parts and diagrams Order parts by authorized service providers .................................................................................... 268 Order parts, accessories, and supplies ........................................................................... 268 Related documentation and software .............................................................................. 268 Supplies part numbers ..................................................................................................... 268 Accessories part numbers ............................................................................................... 269 Whole-unit replacement part numbers ............................................................................. 270 How to use the parts lists and diagrams .......................................................................................... 271
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Assembly locations ........................................................................................................................... 272 Base product (no optional trays or accessories) .............................................................. 272 Base product (optional trays or accessories) ................................................................... 273 Covers .............................................................................................................................................. 274 Internal assemblies (1 of 6) .............................................................................................................. 276 Internal assemblies (2 of 6) .............................................................................................................. 278 Internal assemblies (3 of 6) .............................................................................................................. 280 Internal assemblies (4 of 6) .............................................................................................................. 282 Internal assemblies (5 of 6) .............................................................................................................. 284 Internal assemblies (6 of 6) .............................................................................................................. 286 Input devices .................................................................................................................................... 288 500-sheet input tray (Tray 3 and Tray 4) ......................................................................... 288 Alphabetical parts list ....................................................................................................................... 290 Numerical parts list ........................................................................................................................... 293 Appendix A Service and support Hewlett-Packard limited warranty statement .................................................................................... 298 HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ................ 299 End User License Agreement .......................................................................................................... 300 Customer self-repair warranty service .............................................................................................. 302 Customer support ............................................................................................................................. 303 Repack the product .......................................................................................................................... 304 Service information form .................................................................................................................. 305 Appendix B Specifications Physical specifications ..................................................................................................................... 308 Electrical specifications .................................................................................................................... 308 Acoustic specifications ..................................................................................................................... 308 Environmental specifications ............................................................................................................ 309 Appendix C Regulatory information FCC regulations ............................................................................................................................... 312 Environmental product stewardship program ................................................................................... 313 Protecting the environment .............................................................................................. 313 Ozone production ............................................................................................................ 313 Power consumption ......................................................................................................... 313 Toner consumption .......................................................................................................... 313 Paper use ........................................................................................................................ 313 Plastics ............................................................................................................................ 313 HP LaserJet print supplies ............................................................................................... 313 Return and recycling instructions ..................................................................................... 314 United States and Puerto Rico ........................................................................ 314 Multiple returns (more than one cartridge) ..................................... 314
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Single returns ................................................................................. 314 Shipping .......................................................................................... 314 Non-U.S. returns ............................................................................................. 314 Paper ............................................................................................................................... 314 Material restrictions .......................................................................................................... 315 Disposal of waste equipment by users in private households in the European Union .... 315 Chemical substances ....................................................................................................... 315 Material Safety Data Sheet (MSDS) ................................................................................ 316 For more information ....................................................................................................... 316 Declaration of conformity .................................................................................................................. 317 Safety statements ............................................................................................................................. 318 Laser safety ..................................................................................................................... 318 Canadian DOC regulations .............................................................................................. 318 VCCI statement (Japan) .................................................................................................. 318 Power cord statement (Japan) ......................................................................................... 318 EMC statement (Korea) ................................................................................................... 318 Laser statement for Finland ............................................................................................. 319 Substances Table (China) ............................................................................................... 320 Index ................................................................................................................................................................. 321
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Theory of operation
Basic operation Formatter-control system Engine-control system Image-formation system Pickup, feed, and delivery system Tray 1 or Tray 2 Additional tray
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Basic operation
Major printer systems
The product contains the following five systems: Engine-control system Laser/scanner system Image-formation system Media feed system Option
Printer block diagram
Figure 1-1 Printer block diagram
LASER SCANNER SYSTEM
IMAGE-FORMATION SYSTEM
ENGINE CONTROL SYSTEM
MEDIA FEED SYSTEM
OPTION
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Sequence of operation
The DC controller in the engine-control system controls the operational sequences of the printer. The table below describes durations and operations for each period of a print operation from when the printer is turned on until the motor stops rotating
Normal sequence of operation
Table 1-1 Sequence of operation
Name WAIT Timing From the time the power switch is turned on or the door is closed until the printer is ready for a print operation. Purpose Brings the product to printable condition. The product performs the following during the operation: Detects the print cartridge
STBY (standby)
From the end of the WAIT or LSTR period until either a print command is sent or the power switch is turned off. From the time the print command is received until the temperature of the fuser unit reaches its targeted temperature. From the end of the INTR period until the last sheet completes the fuser operation.
Maintains the product in printable condition.
INTR (initial rotation)
Starts up the high-voltage biases, the laser/scanner and the fuser unit for printing.
PRINT
Forms the image on the photosensitive drum based on the VIDEO signals from the formatter. Transfers and fuses the toner image to the paper. Moves the last printed sheet out of the product. The product enters the INTR period as the LSTR period is completed, if the formatter sends another print command.
LSTR (last rotation)
From the end of the PRINT period until the main motor stops rotating.
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Formatter-control system
The formatter is responsible for the following procedures: Controlling sleep mode Receiving and processing print data from the various product interfaces Monitoring control-panel functions and relaying product-status information (through the control panel and the network or bidirectional interface) Developing and coordinating data placement and timing with the DC controller PCA Storing font information Communicating with the host computer through the network or the bidirectional interface
The formatter receives a print job from the network or bidirectional interface and separates it into image information and instructions that control the printing process. The DC controller PCA synchronizes the image-formation system with the paper-input and -output systems, and then signals the formatter to send the print-image data. The formatter also provides the electrical interface and mounting locations for one EIO card and an additional DIMM.
Sleep mode
NOTE: In the SYSTEM SETUP menu, this item is termed SLEEP DELAY. This feature conserves power after the product has been idle for an adjustable period of time. When the product is in SLEEP DELAY, the control-panel backlight is turned off, but the product retains all settings, downloaded fonts, and macros. The default setting is for SLEEP DELAY to be enabled, and the product enters SLEEP DELAY after a 30-minute idle time. The product exists SLEEP DELAY and enters the warm-up cycle when any of the following events occur: A print job, valid data, or a PML or PJL command is received A control-panel button is pressed A cover is opened A paper tray is opened The engine-test switch is pressed
NOTE: Product error messages override the Sleep message. The product enters SLEEP DELAY at the appropriate time, but the error message continues to appear.
Input/output
The product receives print data primarily from the embedded HP Jetdirect print server. The product also has a USB 2.0 port for connecting directly to a computer.
CPU
The formatter incorporates a 540 MHz Coldfire processor.
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Memory
The random access memory (RAM) on the formatter PCA contains the page, I/O buffers, and the font storage area. It stores printing and font information received from the host system, and can also serve to temporarily store a full page of print-image data before the data is sent to the print engine. Memory capacity can be increased by adding a DIMM to the formatter. Note that adding memory might also increase the print speed for complex graphics. NOTE: If the product encounters a problem when managing available memory, a clearable warning message appears on the control-panel display.
Optional hard disk
This product supports an optional EIO hard disk or an optional secure hard disk as an accessory.
Firmware
The firmware is contained on NAND flash memory soldered on the formatter board. A remote firmware upgrade process is available, which overwrites the firmware in the NAND flash.
Nonvolatile memory
The product uses nonvolatile memory (NVRAM) to store device and user configuration settings. The contents of NVRAM are retained when the product is turned off or disconnected.
PJL overview
The printer job language (PJL) is an integral part of configuration, in addition to the standard printer command language (PCL). With standard cabling, the product can use PJL to perform a variety of functions such as these: Two-way communication with the host computer through a network connection or a USB connection. The product can inform the host about such things as the control-panel settings, and the control-panel settings can be changed from the host. Dynamic I/O switching. The product uses this switching to be configured with a host on each I/O. The product can receive data from more than one I/O simultaneously, until the I/O buffer is full. This can occur even when the product is offline. Context-sensitive switching. The product can automatically recognize the personality (PS or PCL) of each job and configure itself to serve that personality. Isolation of print environment settings from one print job to the next. For example, if a print job is sent to the product in landscape mode, the subsequent print jobs print in landscape mode only if they are formatted for landscape printing.
PML
The printer management language (PML) allows remote configuration and status read-back through the I/O ports.
Control panel
The formatter sends and receives product status and command data to and from the control-panel PCA.
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Engine-control system
The engine-control system coordinates all product functions, according to commands that the formatter sends. The engine-control system drives the laser/scanner system, the image formation system, and the pickup/feed/delivery system. The engine control system contains the following major components: Engine-control unit (ECU) DC controller Low-voltage power supply
High-voltage power supply
Figure 1-2 Engine-control system
ENGINE CONTROL SYSTEM
Engine controller LASER SCANNER SYSTEM
DC controller
IMAGE-FORMATION SYSTEM Formatter Low-voltage power supply MEDIA FEED SYSTEM
High-voltage power supply OPTION
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Motors, fans, clutches, solenoids, switches, and sensors
Figure 1-3 Motors
Fuser motor Main motor
Table 1-2 Motors
Description Main motor (M8001) Components driven Fuser motor (M8002) Pickup roller Feed roller Transfer roller Photosensitive drum Developing roller Duplex repickup roller (duplex models only) Pressure roller Delivery roller Fuser-delivery roller Duplex-feed roller (duplex models only) Yes Fault detection Yes
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Figure 1-4 Fans
Main fan
Sub fan
Table 1-3 Fans
Description Main fan (FM1) Sub fan (FM2) Area cooled Inside the product Inside the product Type Intake Intake Speed Full Full
Figure 1-5 Solenoids and clutches (product)
PS4 PS1 M8001 SW501 PS8001 PS2 PS215 SL1 PS205 PS225
PS502 SL2 M8002 PS3 SW235
Table 1-4 Solenoids and clutches (product)
Item SL1 SL2 Description Tray 1 (multipurpose tray) pickup solenoid Cassette (Tray 2) pickup solenoid
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Figure 1-6 Solenoids and clutches (Tray 3 and Tray 4)
M8001
CL1
SL3 PS451
PS8008
SW461
Table 1-5 Solenoids and clutches (Tray 3 and Tray 4)
Item SL3 CL1
1
Description Paper feeder pickup solenoid Paper feeder pickup clutch
Tray 3 and Tray 4 are identical 500-sheet input trays.
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Figure 1-7 Switches (product)
PS4 PS1 M8001 SW501 PS8001 PS2 PS215 SL1 PS205 PS225
PS502 SL2 M8002 PS3 SW235
Table 1-6 Switches (product)
Item SW235 SW501 Description Cassette presence switch Cartridge-door switch
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Figure 1-8 Switches (Tray 3 and Tray 4)
M8001
CL1
SL3 PS451
PS8008
SW461
Table 1-7 Switches (Tray 3 and Tray 4)
Item SW461
1
Description Paper feeder cassette presence switch
Tray 3 and Tray 4 are identical 500-sheet input trays.
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Figure 1-9 Sensors
PS4 PS1
PS205 PS2 PS8001 PS225 PS215
PS502 PS3
PS8008 PS451
PS8008 PS451
Table 1-8 Sensors
Item PS1 PS2 PS3 Description Face-up sensor Fuser delivery sensor Cassette media-presence sensor Item PS225 PS502 PS451 Description Media width sensor Duplex media-feed sensor (duplex models only) Paper feeder cassette media-presence sensor NOTE: PS451 is used in Tray 3, and Tray 4
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Table 1-8 Sensors (continued)
Item PS4 PS205 Description Face-down tray media-full sensor Tray 1 (multipurpose tray) media-presence sensor Item PS8001 PS8008 Description Rear door sensor Paper feeder media-feed sensor NOTE: PS215 Top-of-Page (TOP) sensor PS8008 is used in Tray 3, and Tray 4
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DC controller operations
The DC controller controls the operational sequences of the product systems. Figure 1-10 DC controller block diagram
Engine controller
Motor
AC input Low-voltage power supply
Fan
Solenoid
Photointerrupter
Fuser
DC controller Switch
Print cartridge
High-voltage power supply
Optional paper-feeder
Laser/scanner Formatter
Control panel
Table 1-9 DC controller controlled components
Component Motor Designator M8001 M8002 Fan FM1 FM2 Solenoid SL1 SL2 Description Main motor Fuser motor Main fan Sub fan Tray 1 (multipurpose tray) pickup solenoid Cassette (Tray 2) pickup solenoid
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Table 1-9 DC controller controlled components (continued)
Component Photointerrupter Designator PS1 PS2 PS3 PS4 PS205 PS215 PS225 PS451 Description Face-up sensor Fuser delivery sensor Cassette media presence sensor Face-down tray (output bin) media-full sensor Tray 1 (multipurpose tray) presence sensor Top-Of-Page (TOP) sensor Media width sensor Paper feeder cassette media-presence sensor NOTE: PS502 PS8001 PS8008 Switch SW235 PS451 is used in Tray 3, and Tray 4
Duplex media-feed sensor (duplex models only) Rear door sensor Paper feeder media-feed sensor Cassette-presence switch NOTE: PS8008 is used in Tray 3, and Tray 4
SW240 SW250 SW501
Power switch Test Print switch Cartridge-door switch
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Fuser-control circuit
The fuser-control circuit monitors and controls the temperature in the fuser. The product uses ondemand fusing. The fuser-control circuit consists of the following major components: Fuser heater (H1); heats the fusing film Thermistor (TH1 and TH2); detects the fuser temperature (contact type) Main thermistor (TH1); controls the temperature in the fuser (contact type) Sub thermistor (TH2); detects a one-sided temperature rise in the fuser and controls the temperature in the fuser (contact type)
Thermoswitch (TP1); prevents abnormal temperature rise in the fuser (contact type)
Fuser film
Figure 1-11 Fuser control circuit
H1 TP1 TH1 Pressure roller
TH2
FUSER TEMPERATURE signal
FUSER HEATER CONTROL signal
DC controller
Fuser heater control circuit
Fuser heater safety circuit
Fuser control circuit Engine controller unit
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Fuser failure detection
The DC controller determines a fuser unit failure, deactivates the FUSER HEATER CONTROL signal, releases the relay to interrupt power supply to the fuser heater and notifies the formatter of a failure state when it encounters the following conditions: Start-up failure If the main thermistor does not detect a specified temperature during the start-up process of the heater in the wait period. If the main thermistor does not detect a specified temperature during the heater temperature control in the initial rotation period.
Abnormal low temperature If the main thermistor detects an abnormal low temperature of the fuser unit during the printing operation. If the sub thermistor detects an abnormal low temperature of the fuser unit during the printing operation.
Abnormal high temperature If the main thermistor detects an abnormal high temperature of the fuser unit. If the sub thermistor detects an abnormal high temperature of the fuser unit.
Frequency detection circuit failure If a specified frequency of the ZERO CROSSING signal is not detected within a specified period after the product is turned on.
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Fuser temperature control
The fuser temperature control maintains the temperature of the fuser heater at its targeted temperature. The DC controller monitors the FUSER TEMPERATURE (FSRTH1, FSRTH2) signals and sends the FUSER HEATER CONTROL (FSRD) signal according to the detected temperature. The fuser heater control circuit controls the fuser heater depending on the signal so that the heater remains at the targeted temperature. Figure 1-12 Fuser-heater control circuit
Engine controller unit Fuser control circuit DC controller ZEROX
Frequency detection circuit RL1001 RL1002 Relay control circuit
RLYD
Fuser heater safety circuit FSRTH2 FSRTH1 Fuser heater control circuit FSRD
Fuser film
TH2 TP1 TH1
H1 Pressure roller H1: Fuser heater TP1:Thermoswitch TH1: Main thermistor TH2: Sub thermistor
Fuser
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Chapter 1 Theory of operation
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Fuser protective function
The protective function detects an abnormal temperature rise of the fuser unit and interrupts power supply to the fuser heater. The following three protective components prevent an abnormal temperature rise of the fuser heater: DC controller The DC controller interrupts power supply to the fuser heater when it detects an abnormal temperature of the fuser heater.
Fuser heater safety circuit The fuser heater safety circuit interrupts power supply to the fuser heater when the detected temperature of the main and sub thermistors is abnormal.
Thermoswitch The contact of the thermoswitch is broken to interrupt power supply to the fuser heater when the thermoswitch detects an abnormal temperature of the fuser heater.
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Low-voltage power supply
The low-voltage power supply (LVPS) converts ac input voltage to dc voltage. The LVPS has two fuses on the PCA. The LVPS 24 V output is interrupted to the fuser and the high-voltage power supply if the cartridge-door interlock switch (SW501) is in the off position (cover open). WARNING! The product power switch only interrupts dc voltage from the LVPS. The ac voltage is present in the product when the power cord is plugged into a power receptacle and the power switch is in the off position. You must unplug the product power cord before servicing the product. Figure 1-13 Low-voltage power supply (LVPS)
Engine controller unit
Low-volt age power supply Fuse(FU1001) Noise filter
Fuser control circuit
Fuser
Fuse(FU1002)
Power-switch control circuit
Noise filter
Power switch (SW240) High-volt age power supply +24R +24V REM24 Door switch (SW501)
/FDOORSNS
+24V generation circuit
+3.3V generation circuit Protection circuit +5V generation circuit
+3.3V DC controller +24U +3.3V +5V
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Chapter 1 Theory of operation
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Overcurrent/overvoltage protection
The low-voltage power supply has a protective function against overcurrent and overvoltage to prevent failures in the power supply circuit. If an overcurrent or overvoltage condition occurs, the system automatically cuts off the output voltage. If the DC power is not being supplied from the low-voltage power supply, the protective function might be running. In such case, turn off the power switch and unplug the power cord. Do not plug in the power cord or turn on the power switch again until the cause is found. WARNING! If you believe the overcurrent or overvoltage protection circuits have been activated, do not plug in the product power cord or turn on the product power until the cause of the failure is found and corrected. In addition, two fuses in the low-voltage power supply protect against overcurrent. If overcurrent flows into the AC line, the fuses melt and cut off the power distribution.
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High-voltage power supply
The high-voltage power supply (HVPS) applies biases to the following components: Primary charging roller Developing roller Transfer roller Fusing film
Figure 1-14 High-voltage power supply
Engine controller unit DC controller FSRB Fuser film bias circuit FILMB Pressure roller High-voltage power supply Fuser Fuser film
Cartridge Primary charging bias circuit PRI To primary charging roller To developing roller
Developing bias circuit
DEV Photosensitive drum Transfer roller
Transfer bias circuit
TR
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Formatter
Formatter heartbeat LED
The heartbeat LED indicates that the formatter is functioning correctly. While the product is initializing after you turn the product on, the LED blinks rapidly, and then turns off. When the product has finished the initialization sequence, the heartbeat LED pulses on and off. For more information abut the heartbeat LED see Formatter heartbeat LED on page 133.
DIMM slots
CAUTION: Single inline memory modules (SIMMs) used in previous HP LaserJet products are not compatible with the product. The formatter has one dual inline memory module (DIMM) slot for upgrading the product with more memory. To find out how much memory is installed in the product, print a configuration page. For more information about memory, see DIMM cover and DIMM on page 57.
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Laser/scanner system
The laser/scanner system receives VIDEO signals from the ECU and the formatter and converts the signals into latent images on the photosensitive drum. The main components of the laser/scanner are the laser unit and the scanner motor unit. The DC controller sends signals to the laser/scanner to control the functions of these components. Figure 1-15 Laser/scanner system
Formatter Engine controller unit DC controller
LASER CONTROL signal
VIDEO signal
SCANNER MOTOR CONTROL signal
Laser unit
Scanning mirror BD sensor
Scanner motor unit
Photosensitive drum
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BDI signal
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Laser failure detection
The DC controller determines an optical unit failure and notifies the formatter, if the laser/scanner encounters the following conditions: The scanner motor does not reach a specified rotation within a specified period of the scanner motor start up. The rotation of the scanner motor is out of specified range for a specified period during the scanner motor drive. The BD interval is out of a specified value during a print operation.
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Image-formation system
Electrophotographic process
The electrophotographic process forms an image on the paper. Following are the major components used in the process: Print cartridge Transfer roller Fuser Laser/scanner
The DC controller uses the laser/scanner and HVPS to form the toner image on the photosensitive drum. The image is transferred to the print media and then fused onto the paper. Figure 1-16 Electrophotographic process block diagram
Laser beam
Cartridge Laser scanner
Fuser
Transfer roller
High-voltage power supply
DC controller Engine controller unit
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Image formation process
Each of the following process function independently and must be coordinated with the other product processes. Image formation consists of the following processes: Latent-image formation block Step 1: primary charging Step 2: laser-beam exposure
Developing block Step 3: developing
Transfer block Step 4: transfer Step 5: separation
Fusing block Step 6: fusing
Drum cleaning block Step 7: drum cleaning
: Media path : Direction of drum rotation : Block Latent image formation : Step 2. Laser-beam exposure
Figure 1-17 Image formation process
1. Primary charging Developing 3. Developing Drum cleaning 7. Drum cleaning
Delivery
6. Fusing (Fixing) Fusing (Fixing)
5. Separation
4. Transfer
Pickup
Transfer
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Latent-image formation stage
During the latent-image formation stage, the laser/scanner forms an invisible image on the photosensitive drum in the print cartridge. Primary charging Step 1: DC and AC biases are applied to the primary charging roller, which transfers a uniform negative potential to the photosensitive drum. Figure 1-18 Primary charging
Primary charging roller
Primary charging bias Photosensitive drum
Laser beam exposure Step 2: The laser beam scans the photosensitive drum to neutralize negative charges on parts of the drum surface. An electrostatic latent image is formed on the drum where negative charges were neutralized. Figure 1-19 Laser beam exposure
Laser beam
Unexposed area
Exposed area
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Developing stage
Print cartridge Step 3: In the print cartridge, the developing cylinder comes in contact with the photosensitive drum to deposit toner onto the electrostatic latent image. Figure 1-20 Print cartridge
Blade Developing roller
Exposed area Unexposed area
Unexposed area Exposed area Developing bias
Photosensitive drum
Toner acquires a negative charge from the friction that occurs when the developing roller rotatesagainst the developing blade. The developing bias is applied to the developing roller to make a potential difference between the developing roller and the photosensitive drum. The negatively charged toner is attracted to the latent image on the photosensitive drum because the drum surface has a higher potential.
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Transfer stage
Step 4: The transfer charging roller, to which a DC positive bias is applied, imparts a positive charge on the print media. When the print media comes in contact with the photosensitive drum, the toner is transferred to the print media. Figure 1-21 Transfer
Photosensitive drum
Media Transfer roller
Transfer bias
Step 5: The elasticity of the print media causes its separation from the photosensitive drum. A static charge eliminator aids separation by weakening any electrostatic adhesion. Figure 1-22 Separation
Photosensitive drum
Media Static charge eliminator Transfer roller
Fusing stage Step 6: The DC negative bias applied to the fusing film strengthens the holding force of the toner on the print media and prevents the toner from scattering.
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The product uses an on-demand fuser method. The toner image is permanently affixed to the printing paper by heat and pressure. Figure 1-23 Fusing
Fuser heater Brush Fuser film Toner
Media Pressure roller
Fuser bias
Cleaning stage Step 7: The cleaning blade scrapes the residual toner off of the photosensitive drum and deposits it into the waste toner case. Figure 1-24 Drum cleaning
Cleaning blade
T oner collection box
Photosensitive drum
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Toner detection
The product uses a nonvolatile memory tag built into the print cartridge. Print-cartridge detection happens when the engine controller detects the presence of a genuine HP print-cartridge that contains a memory tag. Toner detection happens as the engine controller reads or writes the data that is stored on the memory tag. The engine controller renews the information in the prescribed timing and reads or writes it from or to the memory tag. The engine controller commands the memory tag to read or write with the following conditions: Read Power is on The cartridge door is closed A command is received from the formatter
Write A page of media is printed A command is received from the formatter
When the engine controller fails to read or write three times in a row, it determines that the memory tag is abnormal and sends a cartridge memory abnormality warning to the formatter. Figure 1-25 Print cartridge memory tag
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Pickup, feed, and delivery system
The pickup/feed/delivery system consists of several types of feed rollers and sensors. The ECU uses a motor and two solenoids to drive the rollers. Three media-detection sensors detect paper as it passes through the product. If media does not reach or pass each sensor within a specified time, the ECU determines that a jam has occurred and alerts the formatter.
Paper trays
The product has the following paper trays: Tray 1 (multipurpose tray; all models) Tray 2 (500-sheet tray; all models) Tray 3 (optional 500-sheet input tray; HP LaserJet P3015x) Tray 4 (optional 500-sheet input tray)
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Photo sensors and switches
Figure 1-26 Photo sensors and switches (product)
PS4 PS1 M8001 SW501 PS8001 PS2 PS215 SL1 PS205 PS225
PS502 SL2 M8002 PS3 SW235
Table 1-10 Photo sensors and switches (product)
Item PS1 PS2 PS3 PS4 PS205 Description Face-up sensor Fuser delivery sensor Cassette media-presence sensor Face-down tray media-full sensor Tray 1 (MP tray) media-presence sensor Item PS215 PS225 PS502 PS8001 SW235 Description Top-of-Page (TOP) sensor Media width sensor Duplex media-feed sensor (duplex models only) Rear door sensor Cassette presence sensor
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Figure 1-27 Photo sensors and switches (Tray 3 and Tray 4)
M8001
CL1
SL3 PS451
PS8008
SW461
Table 1-11 Photo sensors and switches (Tray 3 and Tray 4)
Item PS451 PS8008 SW461
1
Description Paper feeder cassette-media presence sensor Paper feeder media-feed sensor Paper feeder cassette presence switch
Tray 3 and Tray 4 are identical 500-sheet input trays.
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Solenoids and clutches
Figure 1-28 Solenoids and clutches (product)
PS4 PS1 M8001 SW501 PS8001 PS2 PS215 SL1 PS205 PS225
PS502 SL2 M8002 PS3 SW235
Table 1-12 Solenoids and clutches (product)
Item SL1 SL2 Description Tray 1 (multipurpose tray) pickup solenoid Cassette (Tray 2) pickup solenoid
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Figure 1-29 Solenoids and clutches (Tray 3 and Tray 4)
M8001
CL1
SL3 PS451
PS8008
SW461
Table 1-13 Solenoids and clutches (Tray 3 and Tray 4)
Item SL3 CL1
1
Description Paper feeder pickup solenoid Paper feeder pickup clutch
Tray 3 and Tray 4 are identical 500-sheet input trays.
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Tray 1 or Tray 2
Pickup and feed unit
The pickup and feed unit uses the following components and processes.
Cassette paper size detection/cassette paper detection
NOTE: To find the following components, see Photo sensors and switches on page 34. PS3; cassette media-presence sensor PS225; media width sensor (detects media width after the media enters the paper path)
Cassette pickup
NOTE: To find the following com