If it is suspected that more than one Dicorotron or Ozac connector is arcing, remove all dicorotrons, and reinstall them one at a time to see if the fault can be recreated. Multiple arcing is not uncommon.
When replacing a Dicorotron or Ozac connector, check the mating connector for signs of arc-ing, wear, contamination, and looseness.
Loose, intermittent or arcing connections on AC Motors or components can cause electrical noise to be introduced into the system and result in false shutdowns (e.g. cooling fans, main drive motors, vent fans).
The purpose of this procedure is to identify known causes of false 6-xxx fault codes being declared by electrical noise.
The purpose of this procedure is to allow running the Printer with selected functions turned off.
It is expected that when the output generating the noise is turned off, the noise also will be turned off.
Use this procedure to disable outputs by using dC131 and other dC routines.
PROCEDURE
NOTE: The ROS components are prone to electrical noise generated by other components in the Printer. Some of the following checks ensure that the latest electrical noise resistant com-ponents have been added to the system. Others ensure that the most likely electrical noise generators in the Printer are not causing the false fault codes.
1. If 6-xxx faults are being declared, perform the following steps to ensure that the latest electrical noise resistant components have been added to the system:
a. Inspect for 9-201 faults. Components associated with 9-201 faults can cause false 6 ROS faults. Ensure that all repairs have been made to eliminate the 9-201 faults.
b. Check that the routing of the OZAC high voltage wiring is correct (PL 9.4).
c. Check the routing of the harnesses in and around the Compressor and the rear of the Electrical Module.
2. If 6-xxx faults are NOT being declared or if the previous step has been completed, per-form steps a, b, c, and d to determine which part of this procedure to go to:
NOTE: Before beginning the 9-xxx procedure, enter dC314 and ensure that all the Dicorotron Power Supply calibrations are correct.
a. If one of the 9-201, 9-203, 9-213, 9-215, or 9-3XX fault codes are occurring, go to the appropriate 9-XXX Fault Code Procedure in Part 1: 9-XXX Fault Code Proce-dures of this NRD.
b. If the faults are related to a PHN, MIN, or FSN node, go to the appropriate Electrical Node Procedure in Part 2: Electrical NODE Procedures . If no problem is found, con-tinue to step c.
c. If 6-xxx fault codes are occurring, go to the 6-xxx Fault Code Procedure in Part 3:
06-XXX Fault Code Procedure. If no problem is found, continue to Part 4: Defeature Isolation Procedure.
d. For all other faults, go to the Defective Isolation Procedure in Part 4: Defeature Isola-tion Procedure.
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Part 1: 9-XXX Fault Code Procedures
Section Name Preliminary Working Document
Part 1: 9-XXX Fault Code Procedures
Table 1 Part 1: 9-XXX Fault Code Procedures
Code Procedures
9-201 The most common causes of 9-201 faults are as follows:
- Cracked dicorotron wire glass coating - Dicorotron contamination - Contamination by conductive brush fibers
1. Perform the following steps:
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing.
- Inspect the Ozac connectors and the dicorotron connectors for the following symptoms:
- A yellow, gray or light brown film (most common) - Cracks on the connectors
- Pitting on the AC Dicorotron connectors
- Inspect the Ozac ducts where they pass near the machine frame. It is possible for the wires inside the duct to arc to the frame (discoloration of the tube will be noticeable).
- Inspect the Dicorotrons for cracked glass, very excessive contamination, or for brush fibers on the wire or at the end blocks.
- Inspect for proper P/J mating at the Ozac and HVAC PWB connectors.
- Inspect the HVAC Output Module. Remove the module, and look for signs of arcing at the output lead or between the resistor and frame.
2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. High suspect causes are the Cleaner and Developer subsystems.
3. If the above efforts have not corrected the problem, replace the HVAC PWB or the HV Output Module one at a time. (An intermittent component is sus-pected.
4. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
BSD 9.1 (Sheet 1) 5. 9-201 faults have been caused by broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll.
9-203 A true 9-203 fault indicates that the Photoreceptor is at end of life. As a general guideline, PR belts with less than 500K copies on them should not be at end of life. There are other causes that can trigger the fault code.
The most common causes of 9-203 faults are as follows:
Charging system problems
- Incorrect dicorotron height. Check/adjust the Charge Dicorotron Height and Balance adjustment (ADJ 9-7 and ADJ 9-6 ) - Process Control feedback problems
- Incorrect ESV spacing. Check/adjust the ESV Height adjustment (ADJ 9-12 ).
- Stray light
- Ensure that all inner and outer covers are installed correctly.
The most common electrical causes of 9-203 faults are as follows:
- Poor or faulty Ozac connectors - Poor Dicorotron connectors
- System electrical noise
1. Check the PR Belt for physical damage, delamination of the belt seam, and ground strip damage. If any is noted find and repair the cause of the damage before replacing the PR Belt.
2. Perform the following:
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing.
- Inspect the Ozac connectors and the dicorotron connectors for the following symptoms:
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Preliminary Working Document Section Name
- A yellow, gray or light brown film (most common) - Cracks in the connectors
- Pitting on the AC Dicorotron connectors
- Inspect for proper P/J mating at the Ozac and HVPS connectors. Ensure that the connections to the HVDC PWB are correct and tight. If the above efforts have not corrected the problem, replace the HVDC PWB. (An intermittent PWB is suspected.)
3. Enter dC140 [Dicorotron Values]. In Standby, if any Dicorotron value is greater than 0.3 VDC replace the HVDC PWB (PL 1.7 ).
4. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The high suspect causes are the Cleaner and Developer subsystems.
BSD 9.4 (Sheet 1) 5. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
9-213 The most common cause of 9-213 faults is incorrect ESV spacing.
- Check/adjust the ESV Height Adjustment (ADJ 9-12 ).
The most common electrical causes of 9-213 faults are as follows:
- Poor or faulty Ozac connectors - Poor PR grounding - Poor Dicorotron connectors - High voltage PWB connector problems
- Loss of ESV signal or faulty ESV 1. Perform the following steps:
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and a hotspot.
- Inspect the Ozac connectors and dicorotron connectors for the following:
- A yellow, gray or light brown film (most common) - Cracks in the connectors
- Pitting on the AC Dicorotron connectors - Loose, missing, or broken fibers on the PR Ground Brush
- Vacuum the belt module, the PR Ground Brush (replace if necessary), and the surrounding area - Inspect Ozac contacts for arcing and reseat all Dicorotrons.
- Inspect for proper P/J mating at Ozac and HVPS connectors.
2. Enter dC140 [Dicorotron Values]. In Standby, if any Dicorotron value is greater than 0.3 VDC replace the HVDC PWB (PL 1.7 ).
3. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. High suspect causes are the Cleaner and Developer subsystems. If developer beads are noted outside the Developer Housing check the developer drive gears for wear.
4. 9-201 faults have been caused by broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll.
5. Go to PQ 9-619, ESV RAP in Section 3, IQ.
6. Look for a loss of the +24 VDC, ESV components failure, or an ADA PWB problem.
7. If the problem has not been resolved, replace the ESV assembly.
BSD 9.4 (Sheet 1) 8. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
9-212 9-215 Intermittent electrical noise induced on the DSS signal line can cause a false 9-212.
The most common electrical causes of 9-212 and / or 9-215 faults are as follows:
- Poor or faulty Ozac connectors - Loose dicorotron connectors - Poor or missing PR ground brush Table 1 Part 1: 9-XXX Fault Code Procedures
Code Procedures
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Section Name Preliminary Working Document
Part 2: Electrical NODE Procedures
1. Perform the following:
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and hotspots.
- Inspect the Ozac connectors and the dicorotron connectors for the following symptoms:
- A yellow, gray or light brown film - Cracks in the connectors
- Loose, missing, or broken fibers on the PR Ground Brush
- Vacuum the belt module, the PR Ground Brush (replace if necessary), and the surrounding area.
- Inspect the Dicorotrons for frosted glass, excessive contamination of the glass coated wire or the end block.
2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. The high suspect causes are the Cleaner and Developer subsystems.
3. If the above efforts have not corrected the problem, replace the DSS (an intermittent DSS is suspected).
BSD 9.5 4. If any other 9-XXX faults are present, go to the appropriate procedure within this NRD.
9-32X 9-330 The most common electrical causes for 9-32X and 9-330 (current out of range) faults are as follows:
- Poor or dirty connections of the Dicorotron shields causing current or voltage out of range conditions - Loose, intermittent, or faulty high voltage connections between the supply PWB and the dicorotron shield connector
- Either arcing Dicorotrons shield contact connectors or Dicorotron contact arcing, causing excessive contamination of the dicorotron shield, and a frosted appearance of the Dicorotron wire glass coating
- Poor seating of plug/jacks to the HVAC and HVDC PWB connectors 1. Perform the following steps:
- Ensure that the HVDC PWB is installed correctly, the harness is connected properly, and that the quarter-turn screws are secured.
- Enter dC910 [High Stress]. Select [Continue]. Check the Dicorotrons for arcing and hotspots.
- Inspect the Ozac connectors and the dicorotron connectors for the following symptoms:
- A yellow, gray or light brown film - Cracks in the connectors - Pitting on the AC Dicorotron connector
- Inspect the Dicorotrons for frosted glass and for excessive contamination of the glass coated wire or the end block.
- Inspect all HVPS connectors for proper P/J mating.
2. If excessive developer or toner contamination is noted in the Xerographic area, find and repair the cause of the contamination. High suspect causes are the Cleaner and Developer subsystems.
BSD 9.1 and BSD 9.2 3. If the problem has not been resolved, replace the HVDC PWB (An intermittent HVDC PWB is suspected.) Table 1 Part 1: 9-XXX Fault Code Procedures
Code Procedures
Table 1 Part 2: Electrical NODE Procedures
Node Procedures
MIN The most common causes of non-repeatable electrical noise in the MIN are:
- Poorly seated Dicorotrons - Poor Dicorotron and Ozac connectors
-- Inspect the connectors for a yellow or light brown (most common) or gray film, or cracks
-- Inspect the Dicorotrons for excessive contamination from conductive fibers or from cracked glass coating on the wires -- Inspect for proper mating of the Ozac connectors and the correct mating of HVAC and HVDC connectors
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Defea-Preliminary Working Document Section Name
Part 3: 06-XXX Fault Code Procedure
PROCEDURE
1. The purpose of this procedure is to identify known causes of false 6-XXX fault codes being declared by electrical noise.
Listed below are known causes of false 6-XXX fault codes. It does not contain all causes, only those that have been identified to date. Any AC Motor or component with loose, inter-mittent or arcing contacts can cause electrical noise to be introduced into the system and result in false 06-XXX fault codes.
2. Check the following components:
a. Faulty UI Power Supply generating electrical noise
-- Inspect for arcing between the Charge 1 and 2 Dicorotron connectors and the backside of the HVPS Card Cage. Remove the back covers and swing out the card cage. The arcing occurs on the inside half of the metal card cage panel. Look for discolored metal and replace the Dicorotron connectors as
required.
-- Inspect for cuts in or belts rubbing on the Ozac tubes, wires, and connectors -- Inspect the Ozac tubes for leaks, discoloration, and other signs of arcing
- An intermittent Core PWB, which can cause 3-203 faults. Before replacing any Core PWB for an intermittent fault, attempt to reseat the Local Bus, Shared Lines, and the Power and Identification connectors. Also inspect for any spreading (marginally touching) contacts.
- Excessive developer or toner contamination in the Xerographic area. Find and repair the cause of the contamination. The high suspect causes are the Cleaner and Developer subsystems.
- Developer beads or conductive fibers in the dicorotrons. Arcing can occur when a new cleaner brush is installed. The new brush may have loose conduc-tive fibers and should be vacuumed prior to installation.
- HVDC wires (red) out of the HVPS Card Cage that are pinched and/or shorted to machine frame.
- Loose, missing, or broken fibers on the PR Ground Brush. 9-201 and 9-32x faults can occur when the brush fibers get into the Dicorotrons.
- Poor PR belt Ground Brush contact. The brush must make good contact to the PR.
- Poor harness routing may cause ESV faults. Avoid wrapping or routing the ESV Probe or harness near AC harnesses.
- Broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll.
- Check the HVAC Output Module output cables for arcing to a metal bracket near the cable.
PHN The most common causes of non-repeatable electrical noise in the PHN are:
- An intermittent Core PWB, which can cause 3-204 faults. Before replacing any Core PWB for an intermittent fault, attempt to reseat the Local Bus, Shared Lines, and the Power and Identification connectors.
- Broken ground wires in the Metering Assembly or the Transfer Assist Device. Ensure that all the ground wires in the fuser area & transfer assist device area are installed correctly, especially the ground wire that attaches to the Metering Roll. Also inspect for any spreading (marginally touching) contacts.
FSN The most common causes of non-repeatable electrical noise in the FSN are:
- Static problems
- Poor or missing machine grounds, including the strapping between the modules
- Poorly routed Shared Communication Lines. The cables may be shorted intermittently or bent to the point that the line shield becomes intermittent.
- An intermittent +24 VDC Stacker interlock circuit can cause crashes. Check the Printer Fault History (Last 50 faults) for +24 VDC failures at or near the same time as the FSN faults. Troubleshoot as required.
- An intermittent Core PWB, which can cause 3-205 faults. Before replacing any Core PWB for an intermittent, try reseating the local bus, shared line, and the power and identification connectors. Also inspect for any spreading (marginally touching) connector contacts.
Table 1 Part 2: Electrical NODE Procedures
Node Procedures
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Defea-Section Name Preliminary Working Document
b. Cavity Cooling Fan P/J loose or arcing contacts
c. Loose ground wires in the Fuser Metering Roll assembly & Transfer Assist Device areas.
d. The HVAC Output Module output cables for arcing to a metal bracket near the cable.
e. Motor and capacitors in Feeder/Stacker loose connectors improper fastening or arc-ing contacts.
3. If no problem is found, continue to Part 4: Defeature Isolation Procedure.
Part 4: Defeature Isolation Procedure
PROCEDURE
1. The purpose of this procedure is to allow running the Printer with selected functions turned off. It is expected that when the output generating the noise is turned off, the noise also will be turned off.
Use this procedure to disable outputs by using dC131 and other dC routines.
NOTE: Use extreme care when making the changes in NVM. Ensure that the correct Node is selected and that a record is made of all NVM values that are being changed prior to the change. This will enable the locations to be reset to their original values after the troubleshoot-ing is complete. Ensure that all values changed durtroubleshoot-ing troubleshoottroubleshoot-ing are reset back to their original values prior to completion of the service call.
Refer to the appropriate level Software dC131 Table (Section 6, General Procedures, in the Service Manual) for current Data default values.
2. Refer to the Features Bypass chart. Functions can be bypassed by changing the values for the appropriate address. To enable or disable a function, add or subtract the value in the table, from the value found in that address in dC131.
Run the machine with the disabled feature in an attempt to determine if the fault also has been disabled. It may be helpful to disable more than one function at a time. If the cause of the electrical noise can be isolated to a specific Node, go to Part 2: Electrical NODE Procedures, and perform the activities listed.
Disconnect inputs or outputs as required in an attempt to isolate the cause of the fault or noise. Use care when disconnecting the wires. An intermittent connection may occur, which can cause more problems than were originally present. Also, be sure to use the Molex Pin Extractor, when appropriate, to avoid damaging the wires or connectors.
3. If the non-repeatable fault or noise can be isolated to a specific PWB, use the PWB Input/
Output tables to isolate the cause of the fault to a specific component or its associated wiring. Refer to the appropriate PWB Input/Output chart.
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