Error Codes Rev7

Unisys e-@ction Network Document Processor 1150/1600/ 1825/2000
Servicing Guide: Maintenance Procedures (DL3)
Unisys Proprietary This document is confidential and proprietary to Unisys Corporation. It is not to be used, reproduced, or disclosed outside Unisys without the written consent of Unisys Corporation. The information in this document is furnished solely for use by, or under the direction of, Unisys support personnel in servicing customers equipment. This document is the property of, and must be returned to Unisys Corporation, Global Network Services, PO Box 500, Blue Bell, PA 19424. 2000 Unisys Corporation. Unpublished Material - All rights reserved.
Class C
June 2000 Printed in USA 3998 5593007
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Unisys
Unisys Proprietary This document is confidential and proprietary to Unisys Corporation. It is not to be used, reproduced, or disclosed outside Unisys without the written consent of Unisys Corporation. The information in this document is furnished solely for use by, or under the direction of, Unisys support personnel in servicing customers equipment. This document is the property of, and must be returned to Unisys Corporation, Global Network Services, PO Box 500, Blue Bell, PA 19424. 2000 Unisys Corporation. Unpublished Material - All rights reserved.
Class C
June 2000 Printed in USA 3998 5593007
NO WARRANTIES OF ANY NATURE ARE EXTENDED BY THIS DOCUMENT. Any product or related information described herein is only furnished pursuant and subject to the terms and conditions of a duly executed agreement to purchase or lease equipment or to license software. The only warranties made by Unisys, if any, with respect to the products described in this document are set forth in such agreement. Unisys cannot accept any financial or other responsibility that may be the result of your use of the information in this document or software material, including direct, special, or consequential damages. You should be very careful to ensure that the use of this information and/or software material complies with the laws, rules, and regulations of the jurisdictions with respect to which it is used. The information contained herein is subject to change without notice. Revisions may be issued to advise of such changes and/or additions. Notice to Government End Users: The software and accompanying documentation are delivered and licensed as commercial computer software and commercial computer software documentation as those terms are used in 48 C.F.R. 12.212 and 48 C.F.R. 227.7202-1 through 227.7202-4, as applicable. The Government shall receive only those rights provided in the standard commercial software license, or where applicable, the restricted and limited rights provisions of the contract FAR or DFARS (or equivalent agency) clause. Correspondence regarding this publication can be e-mailed to [email protected]. FCC Statement The statement below is included in this document to comply with a Federal Communications Commission (FCC) regulation. The FCC is an agency of the United States government; thus, the statement below applies to computing equipment installed in the United States of America. Unisys is taking appropriate steps to be in compliance with FCC regulations and similar regulations of other countries. WARNING: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Subpart J of Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. Canadian Regulatory Statement This class A digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations. Cet appareil numrique de la classe A respecte toutes les exigences du Rglement sur le matriel brouilleur du Canada.
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Unisys Proprietary Class C
Unisys e-@ction Network Document Processor 1150/ 1600/1825/2000

Servicing Guide: Maintenance Procedures (DL3) Unisys Proprietary Class C
3998 5593 007
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Section 1. Introduction
CAPI Configuration ................................................................ Non-CAPI Configuration ......................................................... User Interface ........................................................................ Diagnostic Flow ...................................................................... Failures .................................................................................. Manual Procedure Format .................................................... Line Number/Failure Code Index .......................................... Power-On Confidence Tests (CAPI Configurations) ............... Starting the System POC Test From The Transport Exerciser ............................................................ Starting the System POC Test From the MTR Application Program ............................................. Viewing the DOS Window of the Track Control Program For POC Test Status ............................................ Description of POC Tests .......................................... Transport Hardware (AA Gate) Tests .................. Option Module Tests ........................................ POC Test Error Display Description ........................... Bypass POC Tests ................................................... Maintenance Test Routines (CAPI Configuration) .................. Description of Maintenance Test Routines: ................. Transport Tests ............................................... Basic Microfilmer Tests .................................... MultiJet Endorser Tests .................................... Impact Endorser Tests ..................................... E13B MICR Reader Tests ................................. Dual Image Module Tests ................................. High Speed Encoder Module Tests .................... High Speed OCR Reader Tests .......................... 1150 Multi-Jet Endorser Tests .......................... Power-On Confidence Tests (Non-CAPI Configurations) ........ Description of POC Tests .......................................... NDP CPU PCBA Kernel Tests ............................ AA Gate Tests ................................................. AA Gate MULTIBUS Loop Test .................. Configuration Bus Error Test .................... Character Recognition System Test .......... Z80 CPU Test ......................................... AA Gate Test Errors ................................. 12 1 3 14 14 15 16 17 19 110 117 120 121 121 123 124 125 126 130 130 130 132 133 134 134 134 136 137 138 138 138 139 140 141 141 142 143
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Option Module Tests ........................................ Programmable Endorser Printer/Stamp Test ................................................... Unisys Microfilmer Test ............................ High Speed Optical Character Recognition Reader (HSOCR) Tests ......................... Multiline Ink Jet Endorser Tests ................. Imaging Module ....................................... POC Repair Procedure .............................................. Additional Diagnostic Features (Non-CAPI Configuration) ...................................................... Bypass POC Tests ........................................... NDP Debugger Program ................................... Display/Set Register ................................ Block of Memory Test (BT) ....................... Display Formatted Registers (DF) .............. Execute Program (G) ................................ Memory Display/Disassembly (MD) ............ Memory Modify/Disassembly/Assembly (M) ..................................................... Memory Set (MS) ..................................... Loading an Application from the Debugger Program ..................................................... Enabling the MULTIBUS Address Line Toggle Utility .......................................................... NDP CPU PWBA Hardware Indicators ................. Maintenance Test Routines (Non-CAPI) ................................. NDP 030 Configurations ........................................... NDP Ready Configurations ........................................ Description of Disk-Based Tests ................................ Transport Tests ............................................... Multi-Jet Endorser Tests ................................... 1150 Multi-Jet Endorser Tests .......................... Microfilmer Tests ............................................. Basic Microfilm Tests ............................... Film Transport ......................................... Lamps/ALMs ........................................... ICM Test ................................................. Galvo Tests ............................................. ID Display ................................................ Human Readable Headers ......................... Capping Shutter ...................................... Hardware Parameter Adjustment Routines . Impact Endorser Test ....................................... Display Scans .................................................. Gate/Light Exerciser ........................................ E13B Magnetic Ink Character Recognition Test ... AC Reader Tests ...................................... DC Reader Tests ..................................... CMC7 MICR Reader Tests .................................
144 144 145 146 146 146 149 149 149 150 151 151 152 152 153 153 154 155 155 156 160 160 161 162 164 166 170 172 173 174 175 175 175 176 176 176 177 179 181 181 182 183 185 187
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Imaging Module Tests ...................................... U4/JPEG Imaging Module ......................... Select/De-select Extended Power On Confidence Tests ................................ POC Execution / Default Flag Selection ..... Communication Link Test ......................... IIB Interface Test ..................................... IM Lamp Supply Test ............................... Turn IM Lamp On ..................................... Turn IM Lamp Off ..................................... View Current POC Results ........................ Calibrate the Scanner .............................. Selecting and Executing POC Tests .......... Dual Imaging Module ............................... HS OCR Reader Tests ...................................... OCR Maintenance Test Routines ............... OCR Reader Utilities ................................ Transport Operations ............................... CAR Module Tests ........................................... CAR Module Tests (U4/JPEG Imaging System) .............................................. CAR Module Tests: Dual Imaging System ... DEBUGGER ..................................................... Description of Additional Information (Non-CAPI Configuration) .................................................................... Character Recognition Stress Decks .......................... Condition, Cause, Correction (CCC) Table .................. Snapshot ................................................................. Machine Checks .......................................................
189 189 190 190 190 190 191 191 191 192 192 192 197 199 1100 1100 1100 1101 1101 1103 1103 1104 1104 1104 1104 1105
Section 2.
Power-On Confidence Tests

Word Loop Test Failure ............................................. 210
Section 3.
Transport Basic Tests: Tracking Logic and AA Backplane Types
Section 4.
Transport Basic Subtest 1: Tracking Logic and AA Backplane Types
Section 5.
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Section 6.
Section 7.
Section 8.
Section 9.
Section 10. E13B Double Read Character Recognition Test
Section 11. General Assistance Aids

General Troubleshooting Suggestions ................................... 1111
Section 12. Condition, Cause, Correction Tables

General Maintenance Hints .................................................... Reference Documentation ..................................................... General Conditions, Causes, and Corrections ....................... Missorts .................................................................................. Jams ....................................................................................... BOLs ....................................................................................... Track ERR (Areas 2, 3, or 4) ................................................. Feed Errors ............................................................................ Batch Ticket ........................................................................... Interlocks ............................................................................... Endorsers ............................................................................... PEP ......................................................................... Stamp ..................................................................... HSEM ...................................................................................... Unisys NDP 1xxx Cinemode Microfilmer ............................... 121 122 123 125 127 1213 1214 1215 1218 1219 1224 1225 1227 1229 1230
Section 13. Power Supply
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Section 14. Machine Checks

Machine Check Screen .......................................................... 142 Diagnosis of Machine Check Conditions ............................... 144 General Causes ...................................................................... 144 EEW Definitions ...................................................................... 145 Machine Check Type ............................................................. 146 Description Lines ................................................................... 146 Machine Check Cause ........................................................... 146 Task ....................................................................................... 146 NDP 1150/NDP 1825 Task Number .......................... 146 SVC Message Opcodes ............................................ 147 Local Environment Task ................................... 148 Firmware Screen Task ...................................... 149 Host Interface Task .......................................... 1410 Sort Task ........................................................ 1411 PC (Program Counter) ........................................................... 1411 Machine Check Error Number .............................................. 1412 Offload and Emulation Machine Check Error Numbers . 1412 0001-0092, 00C1 (MTOS SVC) ................................. 1413 0100-0112 (File Manager) ........................................ 1415 0200 (Forms Manager) ............................................. 1415 0300 (Program/Task Loading Routine) ...................... 1416 0401-0405 (Miscellaneous PIO Routines) ................... 1416 0611-0613 (Literal Handling) .................................... 1417 1001-1353 (Local Environment Task) ........................ 1418 2001-2401 (Firmware Screen Task) .......................... 1422 3001-3500 (Status Monitor Task) .............................. 1426 4001-4002 (Snapshot Task) ..................................... 1428 5000-5901, 5AF8-5C02 (Host Interface) .................... 1429 6001-6093, 60A0-60F0, 6200-6802 (Sort Task) ........ 1435 A001-A102 (Utility Task) ........................................... 1456 CAR Task Error Code ............................................... 1458 CAR Unit Message Opcode Definitions (CM) ................ 1459 CAR Unit Message Response Status Definitions (CR) ... 1459 EEW (Extended Error Word) .................................................. 1461 CS -- CAR Driver SVC Result Status ............................ 1462 DS -- Data Comm EEW .............................................. 1466 DS -- Menu Display State Error Codes ........................ 1476 EF -- 4A Driver SVC Function Definitions - Emulation ..... 1478 ES -- Datacomm PIO SVC Result Status: Emulation ...... 1479 FI -- File Manager Error Codes ................................... 1482 FM -- Forms Manager Error Codes ............................. 1484 KS -- Datacomm PIO SVC Result Status: KLUDGE 4A ... 1485 PS -- Poll-Select Driver (CRT) PIO SVC Result Status .... 1488 ST -- CAR Unit Operating State Definitions ................... 1489 TF -- Transport Driver SVC Function Definitions ........... 1490 TS -- Transport Driver PIO SVC Result Status .............. 1492 Routine TXT_TO_FID Error Codes .............................. 14101
Section 15. CMC7 Tests

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Section 16. NDP 1xxx-65 Cinemode Microfilmer Test
Section 17. Microfilmer Hardware Parameters

General Operation of Parameter Routines ............................ Continuing with Adjustment Routine ................... Picking a New Value ......................................... Lamp Intensity/Density Procedure and ALM Adjustment ...... LED/TED Adjustment Procedure ........................................... ID Display Intensity Adjustment Procedure ............................ Galvo Home Adjustment Procedure ....................................... Modify Nonvolatile RAM Values ............................................. 172 173 174 175 177 1710 1712 1713
Section 18. Imaging Module (U4/JPEG)
Section 19. Multiline Ink Jet Endorser Manual Procedures

Extended Error Word Format ................................................. Fault Code Definitions ............................................................ Run Time Fault Code Definitions ............................................ MJE Manual Procedures ........................................................ Print Problems as Seen in Print Samples .............................. Suggestions to Fault Isolation if Procedures Fail to Correct Problem .............................................................................. Procedure End ....................................................................... Condition, Cause, Correction Chart ....................................... Command Names and Descriptions ...................................... FRU Mnemonic Names ........................................................... 192 193 1933 1935 19108 19110 19113 19114 19116 19121
Section 20. PEP/Stamp Tests
Section 21. CAR Diagnostics (U4/JPEG Imaging System)
Section 22. Dual Image Manual Procedures

Additional POC Test Status Information ................................. Dual Image Camera Module Error Codes (DIMG xx xx) ........ (DIMG xx xx) Image Camera Module Common Failures ....................................................... (DIMG 01 xx) Interface MTR ............................ (DIMG 22 xx) Analog Interface Test .................. (DIMG 23 xx) Calibrate Front Camera ............... (DIMG 24 xx) Calibrate Rear Camera ................ 221 224 225 226 229 2211 2212
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(DIMG 40 xx) Normalizer and Diagnostics RAM Test ........................................................... (DIMG 41 xx) Digitizer Framing Logic Test ....... (DIMG 80 xx) Background Suppression Test ..... (DIMG 81 xx) CAR Spot/Void Threshold Test .... (DIMG 82 xx) CAR Interface Test ..................... (DIMG 83 xx) Get CAR POC .............................. (DIMG A7 xx) Image Interface Confidence Test . (DIMG C3 xx) Valid Image Gate Configuration Test ........................................................... (DIMG C4 xx) Image Bus Test .......................... (DIMG D0 xx) JPEG Compressor Test .............. (DIMG D1 xx) JPEG Built-In Self-Test ................. (DIMG D2 xx) CCITT Compressor Test ............. (DIMG D3 xx) CCITT Built-In Self-Test ................ Dual Image M&D Procedures ................................................ Front Normalizer Framer Not Found or Front Normalizer Framer CI Errors Flow ....................................................... Rear Normalizer Framer Not Found or Rear Normalizer Framer CI Errors Flow ....................................................... Image Bus Test Failure Flow .................................................. CAR Port Not Found or CAR Port CI Errors Flow .................. White Digital-to-Analog Converter and Analog Interface Failure Flow ....................................................................... CAR Module POC Failure Flow ............................................... CAR SCSI Communication Failure Flow ................................. Image Interface Communication Failure Flow ....................... Camera Resolution Incorrect Flow ........................................ Configuration and Parameter File Access Failures Flow ...... Compressor Not Found or Compressor CI Errors Flow ......... Slot Errors Flow ..................................................................... Fitted/Not Fitted Errors Flow ................................................. High Speed Digitizer Not Found or High Speed Digitizer CI Errors Flow ........................................................................ Image Slot Locations ............................................................. Dual Image Camera Module Fault Code List .........................
2213 2214 2215 2216 2217 2217 2219 2220 2222 2226 2229 2230 2233 2234 2235 2238 2240 2241 2242 2243 2244 2246 2247 2248 2249 2250 2251 2252 2254 2256
Section 23. High Speed Encoder Module

Using the Maintenance Keypad ............................................. Keypad ................................................... Display ................................................... POC/MTR Error Display ......................................................... HSEM Diagnostic Flows ......................................................... HSEM Fault Code Definitions (HSEM xxxx) .................. Main Diagnostic Flow ................................................ Print Quality Diagnostic Flow ..................................... Maintenance Mode Diagnostic Flow ........................... Track Motors Diagnostic Flow ................................... HSEM Outsort MTR Procedures ................................. HSEM Fault Code List and FRU Description ................. 232 233 233 234 236 236 2314 2325 2326 2327 2328 2331
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HSEM Tests .............................................................
2333
Section 24. CAR Diagnostic Procedures (Dual Image System)

Introduction ............................................................................ POC Test ................................................................................ Interpreting the Error Indicator LEDs .......................... Executing the POC Test ............................................ Card Cage Test Slot ............................................................... Testing the CAR Unit .............................................................. Error Code Format ................................................................. Message Qualifiers ................................................... Source Identification ................................................. Number ................................................................... String ...................................................................... Notation Conventions ................................................ CAR Error Codes .................................................................... CAR Diagnostic Flows ............................................................ 241 242 242 244 245 247 247 248 249 249 249 249 2411 2450
Section 25. NDP 1150 MJE Diagnostic Procedures

MJE Operation ....................................................................... Field Replacement Units (FRUs) ............................................. 251 257
Section 26. Full-Height OCR Reader Procedures

The FH OCR Reader Diagnostic System ................................ Error Handling .......................................................... General Repair Guidelines .......................................... FH OCR Reader System Block Diagram ...................... FH OCR Fault Recovery Procedures ...................................... FH OCR Reader to Track Communication Errors Manual Procedures .......................................................... FH OCR MTR Failures Manual Procedures .................. FH OCR CCC TABLE ................................................. 261 261 263 264 265 2619 2620 2624
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11. 12. 13. 14. 15. 16. 17. 18. 19. 110. 111. 112. 113. 114. 115. 116. 117. 118. 119. 120. 121. 122. 123. 124. 125. 126. 127. 128. 129. 130. 131. 132. 133. 134. 135. 136. 137. 138. 139. 140. 141. 142. 143. CAPI Configuration ................................................................................ Non-CAPI, NDP 030 Configuration .......................................................... Non-CAPI, NDP Ready Configuration ........................................................ Troubleshooting Flow Chart .................................................................... Track Control Program Icon ................................................................... Selecting the Transport Exerciser Program ............................................. Exerciser - Track Status Screen .............................................................. POC Test Executing Status Display ......................................................... Sample POC Transport Error Screen ....................................................... Sample POC Option Module Error Screen ................................................ Exerciser - DP1XXX Options Screen ........................................................ Power Down Prompt Screen .................................................................. Transport Powered Off Status Display ..................................................... Selecting the DP1XXX Maintenance Test Routines .................................... Transport Not Powered On Screen ......................................................... Track Control Status Screen .................................................................. Power Down/Up Test Selection .............................................................. Track Control Program DOS Window ....................................................... Selecting the Track Startup Program ...................................................... DP 1XXX MTR Screen ............................................................................ Maintenance Test Routine Main Menu ...................................................... Function Key Test Mode Selection Menu .................................................. Basic Tests Menu .................................................................................. MJE Main Menu ..................................................................................... MJE Run Time Commands Menu ............................................................. MJE POC Commands Menu .................................................................... MJE Extended Diagnostic Commands Menu ............................................. LCMJE Module Main Menu ...................................................................... Microfilm MTR Menu .............................................................................. Basic Microfilm Tests Menu .................................................................... Microfilm Film Transport Tests Menu ....................................................... Hardware Parameter Adjustment Routines Menu ...................................... PEP/Stamp Endorser Tests Menu ........................................................... E13B MICR Reader Tests Menu .............................................................. AC Reader Tests Menu .......................................................................... DC Reader Tests Menu .......................................................................... CMC7 MTR Test Menu ........................................................................... IIPS Maintenance Test Routines: Select IM Unit Test Menu ....................... IIPS Maintenance Test Routines Select IM Board Type Menu ...................... IIPS Maintenance Test Routines: Select 286 Main Processor Extended POC Test Set Menu ........................................................................... Power On Confidence Execution Menu .................................................... Dual Image Module Main Menu ............................................................... OCR Reader System Main Menu .............................................................. 12 1 3 1 3 14 19 110 111 112 113 114 115 116 116 117 118 118 119 120 126 127 162 163 164 166 167 168 169 170 172 173 174 177 179 182 183 185 187 189 193 194 195 197 199
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144. 141. 142. 171. 172. 173. 221. 222. 231. 232. 233. 241. 242.
CAR System MTR Test Menu .................................................................. Diagnostic Flow Chart ............................................................................ Machine Check Screen ........................................................................... Parameter Routines Screen Format ......................................................... Film Format ........................................................................................... Nonvolatile RAM Screen Format .............................................................. Card Locator - NDP 1150 Dual Image ..................................................... Card Locator - NDP 1825 Dual Image ..................................................... HSEM Hand-held Maintenance Keypad and Display Unit ............................. POC Error Display .................................................................................. MTR Error Display .................................................................................. LEDs on Recognition Unit (RU) PCBA ....................................................... LEDs on Adaption Unit (AU) and Pixel Unit (PU) PCBAs ..............................
1101 141 142 172 179 1714 2254 2255 233 234 235 243 243
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11. 12. 13. 14. 15. 16. 17. 18. 19. 110. 111. 112. 113. 114. 21. 22. 23. 24. 25. 26. 27. 31. 32. 101. 121. 122. 123. 124. 125. 126. 127. 128. 129. 1210. 1211. 1212. 1213. Failure Codes by Manual Section ............................................................ Transport Hardware (AA Gate) Tests ....................................................... AA Gate Test Fault Code Options ............................................................ Hardware-Controlled LEDs ...................................................................... POC Test Reference Table ..................................................................... Functions of the Subtests from the Transport Tests Menu ........................ Functions of the Subtests from the Basic Microfilm Tests Menu ................ Functions of the Subtests from the Microfilm Film Transport Tests Menu ... Functions of the Hardware Parameter Adjustment Routines Menu .............. Functions of the Subtests from the PEP/Stamp Endorser Tests Menu ........ Functions of the Subtests from the AC Reader Tests Menu ....................... DC Reader Tests Menu Options .............................................................. CMC7 MTR Test Menu Options ............................................................... Datacomm Loopback MTR Menu Options ................................................ LED Fault Code Conditions: NDP030 CPU PCBA ..................................... Address Bus and Data Bus .................................................................... Card AA02 TEST A/ TEST B Outputs (DL3) .............................................. Card AA05 TEST A/ TEST B Outputs (DL3) .............................................. Card AA08 TEST A/ TEST B Outputs (DL3) .............................................. Card AA10 TEST A/ TEST B Outputs (DL3) .............................................. Diagnostic Control Register (DCR) addresses for AA Gate PCBAs .............. Troubleshooting Chart for Unexpected Bus Exceptions (TB 00 0010) with the NDP 1150 68030-Based Main CPU Board ..................................... Troubleshooting Chart for Unexpected Bus Exceptions (TB 00 0010) with the NDP 18xx 68030-Based Main CPU Board ...................................... Card AA12 TEST A/TEST B Outputs ....................................................... General Conditions, Causes, and Corrections .......................................... Missorts CCC ........................................................................................ Jams CCC ............................................................................................ BOLs CCC ............................................................................................ Track ERR (Areas 2, 3, or 4) CCC ........................................................... Feed Errors CCC ................................................................................... Batch Ticket CCC .................................................................................. Interlocks CCC ...................................................................................... Endorsers CCC ..................................................................................... PEP CCC .............................................................................................. Stamp CCC .......................................................................................... HSEM CCC ........................................................................................... NDP 1xxx Cinemode Microfilmer CCC ..................................................... 1 7 121 143 156 158 165 173 175 178 180 184 186 188 191 2 1 211 233 235 236 238 247
3 3 3 4 106 123 125 127 1213 1214 1215 1218 1219 1224 1225 1227 1229 1230
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141. 142. 143. 144. 145. 146. 147. 148. 149. 1410. 1411. 1412. 1413. 1414. 1415. 1416. 1417. 1418. 1419. 1420. 1421. 1422. 1423. 1424. 1425. 1426. 1427. 191. 192. 193. 194. 195. 196. 197. 198. 199. 1910. 1911. 1912. 221. 222. 223. 224. 225. 226. 227. 228. 229.
Field Descriptions for Machine Check Screen ........................................... 143 Machine Check General Definitions .......................................................... 145 NDP 1150/NDP 1825 Task Number ....................................................... 146 SVC Message Opcodes -- Local Environment Task .................................... 148 SVC Message Opcodes -- Firmware Screen Task ...................................... 149 SVC Message Opcodes -- Host Interface Task .......................................... 1410 SVC Message Opcodes -- Sort Task ........................................................ 1411 Offload and Emulation Machine Check Error Numbers ............................... 1412 CAR Task Error Code ............................................................................. 1458 CAR Unit Message Opcode Definitions (CM) ............................................. 1459 CAR Unit Message Response Status Definitions (CR) ................................. 1459 EEW (Extended Error Word) Codes .......................................................... 1461 CS -- CAR Driver SVC Result Status ......................................................... 1462 DS -- EEWs for Data Comm (Part Numbers 2973 2112, 2973 1866, 2973 1403, and 2494 4555) ..................................................................... 1467 DS -- EEWs for Data Comm (Part Numbers 2973 4282, 2973 4316, and 2973 4449) ...................................................................................... 1470 DS -- EEWs for Data Comm (All Other Data Comm PROMs) ........................ 1473 DS -- Menu Display State Error Codes ...................................................... 1476 EF -- 4A Driver SVC Function Definitions - Emulation .................................. 1478 ES -- Datacomm PIO SVC Result Status: Emulation .................................... 1479 FI -- File Manager Error Codes ................................................................. 1482 FM -- Forms Manager Error Codes ........................................................... 1484 KS -- Datacomm PIO SVC Result Status: KLUDGE 4A ................................ 1485 PS -- Poll-Select Driver (CRT) PIO SVC Result Status .................................. 1488 ST -- CAR Unit Operating State Definitions ................................................ 1489 TF -- Transport Driver SVC Function Definitions ......................................... 1490 TS -- Transport Driver PIO SVC Result Status ............................................ 1492 Routine TXT_TO_FID Error Codes ............................................................ 14101 Fault Code Definitions ............................................................................ Run Time Fault Code Definitions .............................................................. MJE Manual Procedures ......................................................................... Commands Available in Different States ................................................... Address: Board Correspondence Table ................................................... Print Problems as Seen in Print Samples ................................................. Suggestions to Fault Isolation if Procedures Fail to Correct Problem .......... Normal Bar Up State (States 0-11) .......................................................... Normal Bar Up State (States 12-22) ........................................................ Condition, Cause, Correction Chart ......................................................... Command Names and Descriptions ......................................................... FRU Mnemonic Names ........................................................................... (DIMG xx xx) Image Camera Module Common Failures ............................. (DIMG 01 xx) Interface MTR ................................................................. (DIMG 22 xx) Analog Interface Test ....................................................... (DIMG 23 xx) Calibrate Front Camera .................................................... (DIMG 24 xx) Calibrate Rear Camera ..................................................... (DIMG 40 xx) Normalizer and Diagnostics RAM Test ............................... (DIMG 41 xx) Digitizer Framing Logic Test ............................................. (DIMG 80 xx) Background Suppression Test .......................................... (DIMG 81 xx) CAR Spot/Void Threshold Test .......................................... 193 1933 1935 19102 19106 19108 19110 19111 19112 19114 19116 19121 225 226 229 2211 2212 2213 2214 2215 2216
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2210. 2211. 2212. 2213. 2214. 2215. 2216. 2217. 2218. 2219. 2220. 2221. 2222. 2223. 2224. 2225. 2226. 2227. 2228. 2229. 2230. 2231. 2232. 2233. 231. 232. 233. 234. 235. 236. 237. 238. 241. 242. 243. 244. 251. 252. 261.
(DIMG 82 xx) CAR Interface Test ........................................................... (DIMG 83 xx) Get CAR POC ................................................................... (DIMG A7 xx) Image Interface Confidence Test ....................................... (DIMG C3 xx) Valid Image Gate Configuration Test .................................. (DIMG C4 xx) Image Bus Test ............................................................... (DIMG D0 xx) JPEG Compressor Test .................................................... (DIMG D1 xx) JPEG Built-In Self-Test ...................................................... (DIMG D2 xx) CCITT Compressor Test ................................................... (DIMG D3 xx) CCITT Built-In Self-Test ..................................................... Front Normalizer Framer Not Found or Front Normalizer Framer CI Errors Flow ................................................................................................. Rear Normalizer Framer Not Found or Rear Normalizer Framer CI Errors Flow ................................................................................................. Image Bus Test Failure Flow ................................................................... CAR Port Not Found or CAR Port CI Errors Flow ....................................... White Digital-to-Analog Converter and Analog Interface Failure Flow ............ CAR Module POC Failure Flow ................................................................. CAR SCSI Communication Failure Flow .................................................... Image Interface Communication Failure Flow ............................................ Camera Resolution Incorrect Flow ........................................................... Configuration and Parameter File Access Failures Flow ............................. Data File List ......................................................................................... Compressor Not Found or Compressor CI Errors Flow ............................. Slot Errors Flow .................................................................................... Fitted/Not Fitted Errors Flow .................................................................. High Speed Digitizer Not Found or High Speed Digitizer CI Errors Flow ...... HSEM Fault Code Definitions (HSEM xxxx) ................................................ Main Diagnostic Flow ............................................................................. Print Quality Diagnostic Flow .................................................................. Maintenance Mode Diagnostic Flow ......................................................... Track Motors Diagnostic Flow ................................................................ HSEM Outsort MTR Procedures .............................................................. HSEM Fault Code List and FRU Description .............................................. HSEM Tests .......................................................................................... Test Slot Steps and Related LED Displays for RU and AU PCBAs .............. Test Slot Steps and Related LED Displays for PU PCBA ............................ CAR Error Codes ................................................................................... CAR Diagnostic Flows ............................................................................ Main Flow ............................................................................................. MTR Error Code Index ........................................................................... FH OCR CCC Table ................................................................................
2217 2217 2219 2220 2222 2226 2229 2230 2233 2235 2238 2240 2241 2242 2243 2244 2246 2247 2248 2248 2249 2250 2251 2252 236 2314 2325 2326 2327 2328 2331 2333 246 246 2411 2450 253 255 2624
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Section 1 Introduction
About This Guide
This servicing guide includes maintenance test routine (MTR) information for the Network Document Processor 1150/1600/1825/2000. The Network Document Processor will be referred to as NDP throughout this guide. This manual is intended to help the CSE analyze and resolve electronic, electromechanical, and mechanical failures on the NDP 1XXX. The NDP has two possible hardware/software configurations: Common Application Programming Interface (CAPI) and non-CAPI.
Purpose
This guide provides the maintenance procedures for the NDP 1150/1600/1825/2000 selectable speed processors. It presents all required information for the client service engineer (CSE) and support personnel to troubleshoot problems with the document processors.
Audience
The primary audience for this guide includes the CSE and support center personnel.
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CAPI Configuration
Figure 11 shows the CAPI configuration.
Document Processor PC PC CPU PC Interface Card AA Logic Gate CAPRI PCBA MULTIBUS
Figure 11. CAPI Configuration In this configuration, the PC is running Windows NT 4.0 (or later), and the code to operate the sorter is resident on the PC. The software modules that run the sorters transport and communicate with its devices are accessed via application programs written under the Windows programming environment. The PC Interface (PCI) card is resident in one of the PCs option slots. An interface cable connects the PCI card to the sorters AA gate backplane. This connection allows the PC to talk with the Common API Power Encode Reader Interface (CAPRI) PCBA (slot 10 in the AA gate). The CAPRI PCBA provides the PC with access to the sorters MULTIBUS. The PCs CPU is directly controlling the operation of the sorter hardware in this configuration. The software layers connecting the application program to the sorter driver routines provide the application programmer with a common interface that can be used across Unisys document processor product lines.
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Non-CAPI Configuration
There are two non-CAPI configurations that are available for the NDP. They are the NDP 030 and the NDP Ready. Figure 12 shows the non-CAPI, NDP 030 configuration.
PC PC CPU
Document Processor 33 Mhz NPD030 CPU PCBA MULTIBUS
SCSI Cable
Figure 12. Non-CAPI, NDP 030 Configuration In this configuration, the PC is running Windows NT 3.51 and the code to operate the sorter is not resident on the PC, but rather on the NDP030 CPU PCBA. The PC runs a terminal emulation program that allows the code executing on the NDP030 CPU PCBA to drive the PCs screen display as well as process its keyboard inputs. The PC essentially handles the systems networking capabilities, while the NDP030 CPU handles the operation of the sorter. The NDP030 CPU PWBA plugs into slot 17 of the sorters AA gate and directly accesses the MULTIBUS. The interface between the NDP030 CPU PCBA and the PC is a SCSI. Figure 13 shows the non-CAPI, NDP Ready configuration.
PC PC CPU
Document Processor 25 Mhz 68030 CPU PCBA MULTIBUS
RS232 Cable
Figure 13. Non-CAPI, NDP Ready Configuration In the NDP Ready configuration, the PC is running Windows 3.11 and the code to operate the sorter is resident on the 68030 CPU PCBA. This PCBA is the same one used in the non-NDP environment (DP 1000 and DP 1825). Its clock speed is lower than the NDP030 CPU PCBA (25MHZ compared to 33MHZ) and its firmware is partially stored in a standard EPROM and the rest is loaded using 5 1/4-inch floppy disks (as in the DP 1xxx), where as the NDP030 CPU PCBA has its firmware split between a flash (i.e. downloadable from the PC hard disk) EPROM and a standard EPROM. The PC only runs a terminal emulation program that allows the code executing on the NDP Ready 68030 CPU PCBA to drive the PC screen display and process keyboard inputs. The Data Comm or $A Interface PCBA in
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slot 16 of the AA gate handles the host interface, while the NDP Ready 68030 CPU handles the operation of the sorter. The NDP Ready 68030 CPU PCBA plugs into slot 17 of the sorters AA gate and directly accesses the MULTIBUS. The interface between the NDP Ready 68030 CPU PCBA and the PC is an RS-232.
User Interface
The user interface for both CAPI and Non-CAPI configurations is significantly different. The non-CAPI configurations interface is similar to the original DP1XXX user interface. The CAPI configurations interface follows the format of a Windows application. This volume serves as a reference to the error codes and messages that are displayed by both NDP configurations.
Diagnostic Flow
This manual provides step-by-step procedures for troubleshooting failures displayed by the Power-On Confidence (POC) test, failures displayed by the Maintenance Test Routines (MTRs), machine checks displayed by non-CAPI system software, and performance problems. Figure 14 provides a quick visual guide to troubleshooting.
Diagnostic Flow
CAPI Non-CAPI
POC/MTR error code displayed
Performance or other problem
POC/MTR error code displayed
Machine check displayed
Follow screen prompts
Read introduction and refer to CCC chart in Section 12 for diagnostic procedure
Go to appropriate section and follow diagnostic procedure under Error Code
Go to Section 14 and review machine check probable causes
Read introduction and refer to CCC chart in Section 12 for diagnostic procedure
For Dual Image, go to Section 22 For HSEM, go to Section 23
Figure 14. Troubleshooting Flow Chart
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This section of the manual provides the following information:
Definitions of failures Descriptions of POC tests and MTRs for CAPI and non-CAPI configurations Procedures for selecting and executing POC tests and MTRs for CAPI and non-CAPI configurations.
The rest of the manual presents manual procedures that follow up on the failure codes returned by POC tests and MTRs. Note: For Image/CAR and OCR, see the related document section.
Failures
Electronic, electromechanical, and mechanical failures in the NDP Document processors fall into three categories:
Failures that are obvious and require no additional direction to be corrected. Failures in this category are generally corrected by procedures derived from product knowledge. Failures that are obvious but require additional direction to be corrected. Failures in this category require use of the Condition/Cause/Correction (CCC) table, line 100000, for direction to perform necessary corrective action. This category is associated with failures that have hidden causes, failures that do not have obvious corrections, and failures that do not generate a failure message or fault code when POC tests or MTRs are executed. Failures that prevent or hamper operations but, by their nature, are either subtle or difficult to isolate. Failures in this category display a failure message or code on the screen when the POC tests or MTRs are executed.
After you execute the POC tests, the rules that apply when the failures and corrections are not obvious are as follows:
If the POC reports a failure message, the corrective action is to perform the procedure dictated by the message. If the POC fails to complete and does not display a failure message, the exit is to consult the CCC chart (Section 10) for an analysis procedure. If the POC completes without reporting a failure, you must execute the MTRs. You can analyze an MTR failure by following the reported failure code or message.
Caution
If you do not follow the steps within a failure procedure in proper order, review the notes within the procedure, or evaluate the correct test points, you will be unable to locate the failure or will spend excessive time in isolating the failure.
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Manual Procedure Format

Their are three manual procedure formats presented in this servicing guide. The standard format is shown below. The majority of the manual procedures in this book follow that format. The numbers in parentheses refer to the notes below the example.
51100 (#1) Z-80 POWER ON CONFIDENCE TEST HAS NOT PASSED (#3) Note: This failure should have been indicated during the POC test.(#4) TB 00 0130 (#2)
STEP 100 (#5) 150 (#6)
PROCEDURE Is AA08 FEED/ a constant low?
YES 150 (#6)
NO 16350 (#8)
Replace AA10, and rerun test.
Does the problem still exist?
99000 (#8)
950 (#7)
950
Verify proper operation. End of procedure.
In this manual procedure format,

#1 #2 #3 #4 The line number assigned to the failure code. The failure code reported on the screen. It indicates the failure detected. The failure detected. Information about the failure or additional aids for the failure analysis. When this information is an aid to failure analysis, it is also referred to in the step of the procedure to which it applies. Three-digit number indicating the initial step of this procedure. Next step to perform, within this procedure, when the question asked is true. Next step to perform, within this procedure, when the question asked is false. Five-digit reference indicating that the next step is an exit to a new procedure (line 16350 or 99000).
#5 #6 #7 #8
Note:
Numbers 92000 through 99999 indicate that the failure procedure did not isolate the failure cause. A review of the indicated line number provides additional failure analysis information.
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The second manual procedure format uses a "Fault Code Table" to reference a corrective action procedure from a "Manual Procedure Table." The "corrective action" procedure indexed can then reference other procedures within the "Manual Procedure Table." This manual procedure format is used in the following sections:
Multi-Jet Endorser Manual Procedures Dual Image Manual Procedures High Speed Encoder Module
There are slight variations between each of the sections, but the overall format is the same. For more detailed information, see the desired section. The third manual procedure format is exclusively used by the CAR module designed to work with the Dual Imaging system. There is a single CAR DIAGNOSTIC FLOW (a series of steps and procedures) that is always followed for all CAR error conditions in this system. See Section 22 for details.
Line Number/Failure Code Index

Table 11 identifies the failure code line numbers and failure codes within each section of this manual. This table applies to the NDP 1000 and NDP 1825 Document Processors. Table 11. Failure Codes by Manual Section
Line Numbers
Section Number 1 Introduction PC XX XXXX TB 00 XXXX TB 01 XXXX TB 02 XXXX TB 03 XXXX TB 04 XXXX TB 05 XXXX TB 06 XXXX CR XX XXXX
Failure Code
10000 - 49999 50000 - 59999 60000 - 62999 63000 - 67999 68000 - 70999 71000 - 72999 73000 - 76999 77000 - 89999 90000 - 91999 92000 - 99999 100000 - 149999 150000 160000 - 160999
2 3 4 5 6 7 8 9 10 11 12 13 15
General Assistance Aids Condition, Cause, and Correction Table Power Supply CMC7 CM XX XXXX
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Table 11. Failure Codes by Manual Section
Line Numbers 161000 - 169999 No line numbers used 170000 - 179999 No line numbers used 190000---199999 180000189999 No line numbers used No line numbers used No line numbers used No line numbers used
Section Number 16 17 18 19 20 21 22 23 24 25
Failure Code Unisys Cinemode Microfilmer MM XX XXXX, WR XX XXXX Hardware Parameter Adjustments for Unisys Microfilmer Imaging Module IM XX XXXX* MJE XX XX (and run-time hex fault codes) PP XX XXXX CAR (U4/JPEG Image) CAR XXXX Dual Image module DIMG XX XX High Speed Power Encode Module HSEM XXXX CAR (Dual Image) NDP 1150 MJE LCMJE XX XX
* The majority of the NDP 1000 and NDP 1825 Imaging System diagnostic procedures are in the Image Item Processing (IIPS) Maintenance Manual.
Note:
All failure codes for the OCR reader ("OCR XX XX") are covered in the DP 1800 OCR Reader Installation and Servicing Guide.
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Power-On Confidence Tests (CAPI Configurations)

In the CAPI configuration of the NDP, Power-On Confidence (POC) tests are executed in a different manner than in the Non-CAPI configuration. In the Non-CAPI environment, the diagnostic code that drives the overall system POC test is resident on the NDP CPU PCBA. This PCBA is physically part of the sorter in that it resides in slot 17 of the sorters AA gate. The POC code that runs on the NDP CPU PCBA tests the transport hardware, establishes communications with the microprocessors running POC tests on the option modules within the sorter (i.e. microfilmer, MJE, etc.), and processes their POC status. In the Non-CAPI configuration, when the sorter power is turned on or when the MASTER RESET push-button is activated, POC is automatically started on the NDP CPU PCBA as well as on the option module PWBAs. In the CAPI environment this is not true. Powering on the sorter or pressing the MASTER RESET push-button will start the POC test cycle only on the option modules in the CAPI environment. These modules complete their testing and then wait for the POC test code running on the CAPI PC to request status from them. If the CAPI PC is not running its POC code, the sorter option modules will wait indefinitely, in POC test mode, for communications to be established. It is important to remember that resetting the sorter, does not reset the CAPI PC. In the CAPI environment, the diagnostic code that drives the overall system POC test is resident on the CAPI PC. This code is part of the executable DP1XCTRL.EXE. There are two ways to start the overall system POC test in the CAPI environment. When the CAPI PC is turned on, it runs through its standard power up diagnostics. When these are completed, a menu is displayed allowing the user to choose the Windows operating environment. For CAPI, the user should select Windows NT Workstation 4.0 (or later versions). After this selection is made, the user is prompted to press the Ctrl+Alt+Del keys to log on. At the log on window, a user name and password are required to allow Windows NT to operate. Once Windows NT is operational, the system automatically starts the Track Control Program. This program provides an interface to the sorters MULTIBUS and allows application programs, running under Windows, to communicate with the sorter transport and its various devices. You can tell that the Track Control Program is running by checking the Windows NT Task Bar. A Track Control Program icon will be active in the Task Bar (Figure 15).
Figure 15. Track Control Program Icon Once the Track Control Program is running, the system POC can be started from either the Transport Exerciser or the Maintenance Test Routines application programs.
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Starting the System POC Test From The Transport Exerciser

To run the system POC test from the Transport Exerciser, start the exerciser application by selecting DP1XXX from the Windows NT Start Menu. When the submenu for DP1XXX is displayed, select Transport Exerciser (Figure 16).
Figure 16. Selecting the Transport Exerciser Program The screen shown in Figure 17 will be displayed after the Transport Exerciser has been selected.
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Figure 17. Exerciser - Track Status Screen To begin the system POC test, click on the Power Up button on the Exerciser-Track Status screen. When this selection has been made, the CAPI PC will check to see if the sorter is powered on. If it is not, you are prompted to turn on the sorter and continue. Once the Track Control Program has determined that the sorter is powered up, it issues a reset to the transport hardware. This resets all of the track hardware as well as all of the option modules (i.e. microfilmer, MJE, etc.). After the reset has been issued, the POC application program is started on the PC. This program tests the transport hardware and establishes communications with all of the option modules so that their POC test status can be processed. When the system POC test is executing, the Exerciser - Track Status screen displays the status shown in Figure 18.
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Figure 18. POC Test Executing Status Display The status of individual POC tests is not displayed unless a failure condition occurs. This is a departure from the non-CAPI environment which prompts you whenever a test completes, whether or not it has passed or failed. If a failure occurs in the transport hardware portion of the system POC test, the error is displayed and further POC testing is aborted. Under these circumstances, the only option you are provided with is to reset the sorter and rerun the entire system POC test again. Consequently, transport hardware POC errors are considered fatal to sorter operation. This is consistent with the non-CAPI environment. A sample transport error screen is shown in Figure 19.
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Figure 19. Sample POC Transport Error Screen If the transport hardware portion of the POC test passes, the option modules are queried for their POC test status. If an option module fails it POC test, the error code is placed in an error buffer and the POC status from the next option module is processed. The error buffer is always overwritten with an error code from the last option module to report a failure condition. For example, assuming the HSOCR and the Dual Image Module fail their respective POC tests, if the Dual Image Module is queried last, its error code will replace the HSOCR error code in the error buffer. Only one error code will be displayed and it will be the one pertaining to the Dual Image Module. This is significantly different from the Non-CAPI method for dealing with option module POC errors. In the non-CAPI environment multiple error conditions are reported. In the CAPI environment, the error status from the last option module to fail its POC test is displayed. A sample option module, POC test error screen is shown in Figure 110.
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Figure 110. Sample POC Option Module Error Screen POC test failures that occur in optional devices do not prevent you from running the sorter. Devices that do not pass their POC tests are simply disabled. This is implied by the previous screen display. Even though the CAPI PC is unable to communicate with the HSOCR, you can press the F5 key to proceed with accessing the Transport Exerciser menu. The Exerciser - DP1XXX Options screen (Figure 111) is displayed when the system POC has completed.
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Figure 111. Exerciser - DP1XXX Options Screen If you want to rerun the system POC test after running the exerciser, you need to click on the Power Down button on Exerciser screen. This will initiate a power down sequence to the Track Control Program. Part of this sequence is resetting a flag that is used by the Track Control Program to determine if the transport has been reset. Whenever a track reset command is issued to the Track Control Program by an application, this flag is set. The Track Control Program uses the flag to determine if it needs to reset the transport and, consequently, run the system POC test. If this has already been done, running the POC test again is not necessary. When the program completes its software power down sequence, you are prompted to turn off the transport power (Figure 112).
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Figure 112. Power Down Prompt Screen After the sorter has powered down, the Transport Exerciser displays the status shown in Figure 113.
Figure 113. Transport Powered Off Status Display
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To start the system POC test again, click on the select Power Up button. To exit the Transport Exerciser application, click on the Exit button.
Starting the System POC Test From the MTR Application Program
To run the system POC test from the MTR program, start the MTR application by selecting DP1XXX from the Windows NT Start Menu. When the DP1XXX submenu is displayed, select CSE Utilities. When the CSE Utilities submenu is displayed, select DP1XXX Maintenance Test Routines (see Figure 114).
Figure 114. Selecting the DP1XXX Maintenance Test Routines The MTR application program communicates with the Track Control Program, which in turn, determines if the sorter transport is powered on. If there is no power applied to the transport, the screen shown in Figure 115 is displayed.
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Figure 115. Transport Not Powered On Screen Once the sorter power has been turned on, click on the Retry[F4] button (or press the F4 key) to instruct the Track Control Program to check for transport power once again. With the sorter powered up, the MTR application issues a reset transport request to the Track Control Program, which in turn issues a reset to the transport hardware and starts the POC application program on the PC. When the system POC test is executing, the screen shown in Figure 116 is displayed.
Figure 116. Track Control Status Screen When the system POC completes, the Track Control Program sets the transport reset flag indicating that the transport has been reset, and either an error status or the MTR main menu is displayed. A sample error screen is shown in Figure 110.
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The transport reset flag is used by the Track Control Program to determine if the system POC should be rerun when other applications issue a reset transport request. If the flag is active, the Track Control Program ignores the request. If you want to rerun the system POC test after running the MTR application, the you need to return to the MTR main menu and select Power Down/Up from the Test pull down menu (see Figure 117).
Figure 117. Power Down/Up Test Selection This will initiate a power down sequence to the Track Control Program, followed by a track reset request. Part of the power down sequence is clearing the transport reset flag that is used by the Track Control Program to determine if the transport has been reset. Whenever a track reset command is issued to the Track Control Program by an application, this flag is set after the reset has been issued to the transport hardware. The Track Control Program uses the flag to determine if it needs to reset the transport and, consequently, run the system POC test. If this has already been done, running the POC test again is not necessary. When the program completes its software power down sequence, the user is prompted to turn off the transport power (see Figure 112). After the sorter has powered down, the MTR application issues a transport reset command to the Track Control Program and the system POC is started again.
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Viewing the DOS Window of the Track Control Program For POC Test Status
In the Non-CAPI environment, multiple error conditions in the sorter option modules are displayed. This is not the case for CAPI. Only one error condition is reported if more than one option module fails its POC test. The fault code displayed is that of the last option module tested which produced an error condition. There is, however, a way to view ongoing POC test status, as well as multiple error conditions, outside of the normal display modes used by the Transport Exerciser and the MTR application. The Track Control Program outputs status messages passed to it by applications to a DOS window that the user can access. The system POC program sends such test status messages to the Track Control Program for display. These messages indicate which tests have passed as well as which option module tests have failed. Access the DOS window by holding the Alt key down once the system POC has started, and pressing the Tab key. This will display a window showing icons for all of the applications that are currently running. Holding the Alt key down and pressing Tab, cycles through the icon display. Selecting the DP1X00 Track Control icon will display the DOS window. From this window, the ongoing status of the system POC test is displayed (see Figure 118).
Figure 118. Track Control Program DOS Window
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Description of POC Tests

The overall, system POC test can be broken down into two stages: transport hardware (AA gate) tests and option module tests.
Transport Hardware (AA Gate) Tests

Table 12 lists and describes the transport hardware (AA gate) tests. Table 12. Transport Hardware (AA Gate) Tests
Test Test 1: PBLINK clock signal test Test 2: PCI Interface Loop test
Description Verifies PBLINK clock signal is active and at the correct frequency. The integrity of the PCI Interface address and data lines is confirmed by a simple loop test from the PCI interface to a register on the Reader Configuration PCBA (slot AA10). The successful completion of this test indicates that these lines are free from shorts an can be controlled by the CAPI PC. This test verifies that all non-optional AA gate PWBAs are installed by accessing an exclusive MULTIBUS address for each PCBA and verifying that a bus error condition does not occur. Non-operational PWBAs are those that handle: Area 1 tracking Area 2 tracking Clock circuitry for the AA gate Reader configuration processing
Test 3: AA gate hardware configuration test
Once the presence of all non-option PWBAs is verified, the status of the optional PWBAs is checked. Test 4: MICR reader test The CAPI PC sends a series of commands via the MULTIBUS to the recognition control and analog PWBAs of the Magnetic Ink Character Recognition (MICR) reader. These commands result in the chronological execution of the following tests: Test 5: AA gate I-signal test Processor subtest Maintenance register subtest Result PROM subtest Quantizer subtest Segmentation subtest MCR test FIFO test Maintenance RAM subtest Analog board subtest
This test verifies the operation of the address decoding and internal data bus for each AA gate PCBA placed in I-test
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Table 12. Transport Hardware (AA Gate) Tests
Test
Description mode. Enabling I-test mode for an AA gate PCBA allows all MULTIBUS registers on the PCBA to be written to at the same time. Data written to any one register is stored in all other registers on the PCBA.
Test 6: AA gate A/B signal test
This test drives all of the outputs of the AA gate PCBA under test high or low, and then reads status from the other PWBAs in the gate to verify that their corresponding input levels are in the correct state. This test verifies the functionality of the following modules which reside on the Reader Configuration PCBA (AA gate slot 10).: Z80 registers and instruction set RAM and ROM CTC timers PIOs A and B buffers 4 Mhz clock
Test 7: Reader/Configuration interface test
Upon completion of these tests, communications between the CAPI PC and the Z80 CPU are established. Test 8: AA gate transport status test This test checks the status of various hardware devices to ensure that they are in a correct state for operation. Items checked are: * Circuit breakers * Motor status * Jam status * "Gate fault/track error" reset capability * Primary and secondary clutch separator status
As in the NDP, any errors that occur in the non-option module portion of the CAPI POC test are considered fatal to system operation.
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Option Module Tests

After successfully completing the transport hardware portion of the POC test, the CAPI PC requests POC status from each of the sorters devices. The devices currently supported are:
Pep/Stamp module MJE module Microfilmer module HSOCR reader module Image module (IC1000 and Dual Image) High Speed Encoder module
Option module error codes are displayed in the same format as the non-option module error codes. However, you are allowed to operate the sorter if any of the option modules fail their power up test. Each module has an interface PCBA usually residing in the AA gate that allows the CAPI PC to communicate with it. Each interface PCBA runs its own self test and then processes status from the device it is linking to the CAPI PC. The POC application running on the CAPI PC establishes communication with each interface PCBA and processes the POC status that the interface PCBA has retrieved from the device. If the option module fails its POC test, a fault code buffer is updated with the appropriate error message and the next option module is queried for status. The fault code buffer only holds the error code for the last option module to fail its POC test. At the conclusion of the system POC test, the error code stored in the fault code buffer is displayed. You can select click on the Retry[F4] button (or press the F4 key) to rerun the entire system POC test or click on the Continue[F5] button (or press the F5 key) to run the application that issued the track reset command to the Track Control Program, either the Transport Exerciser or the MTR program.
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POC Test Error Display Description

Errors that occur during POC are displayed by the DP1XXX Common API Exception Handler program. This program handles the display of all transport exception/error conditions. The POC application passes data to the Exception Handler that references an error code message from an exception/error code data base. A standard error code display is shown in Figure 110. The POC error display consists of the following components.
The five byte error code passed to the Exception Handler by the application, in this case the POC test program. This code is to the immediate right of the Exception Handler revision level and is in parenthesis. The format is AA BB XX XX XX where AA: indicates the error exception type 00 = Power on Confidence Test Program exception 01 = Track Control Program exception 02 = Cage Program exception 03 = Fatal system exception BB: the device ID the exception is associated with 00 = Transport 01 = MICR Reader 02 = OCR 1 03 = OCR 2 04 = PEP module 05 = Stamp endorser module 06 = Front MJE module 07 = Rear MJE module The remaining three bytes are used to identify the test executing and the specific error condition. This information is not in the Servicing Guide manual procedure format and is used by the Exception Handler to access the appropriate entry in the error data base. 08 = Microfilmer module 09 = IC 1000 Image module 0A = High Speed Encoder module 0B = Secondary feeder module 0C = Dual Image module 0D = DC Feeder module 64 = General device
Eight bytes of additional data that each option module can use for extended status information. See the appropriate option module section for information on how these eight bytes are used, if at all. An Error name field that briefly describes the error condition reported. A Detailed error description field that contains a more complete description of the error condition. If more detailed information is not required, this field matches the Error name field. A Manual Procedure field that is used to index the error condition into a manual procedure in the Servicing Guide. For example, the Exception Handler error code "00 00 08 02 05" has a manual procedure index of "PC 08 0002".
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Suspect Component 1: The most likely field replacement unit (FRU) to have failed, causing the error condition. Suspect Component 2: The 2nd most likely FRU to have failed, causing the error condition. Suspect Component 3: The 3rd most likely FRU to have failed, causing the error condition. Suspect Component 4: The 4th most likely FRU to have failed, causing the error condition. Suspect Component 5: The 5th most likely FRU to have failed, causing the error condition.
Bypass POC Tests

The system POC can be partially bypassed to allow quicker access of either the Transport Exerciser or the Maintenance Test Routines. POC Bypass mode is enabled by editing the file DP1XXXSTART.BAT in the directory %DP1X00TRKBASE%\BIN, where %DP1X00TRKBASE% is a Windows environmental variable set up by the CAPI software installation. It specifies the directory in which the Track Control Program is located. POC bypass is enabled by changing the command line start /MIN %dp1x00trkbase%\bin\trkctrld in DP1XXXSTART.BAT to start /MIN %dp1x00trkbase%\bin\trkctrld -p After this file has been changed, the Track Control Program should be brought down, if it is running, and started again. To exit the Track Control Program, display its DOS window and click on the X icon in the top right corner of the window with the right mouse key. Refer to "Viewing the DOS Window of the Track Control Program For POC Test Status" earlier in this section. To restart the Track Control Program select DP1XXX from the Windows NT Start Menu. When the DP1XXX submenu is displayed, select Track Startup. When an application issues a transport reset command to the Track Control Program, the TCP will issue the reset to the transport hardware but it will not start the POC test program. Instead the POC Bypass program is started. This program skips all transport hardware testing and gets all of the option modules out of test mode and into operational firmware. To disable POC Bypass mode, bring down the Track Control Program, remove the "-p" parameter from the command line mentioned above in DP1XXXSTART.BAT, and restart the Track Control Program.
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Maintenance Test Routines (CAPI Configuration)

The rest of the diagnostic system tests are the Maintenance Test Routines. In order to run the MTRs, the Track Control Program must be running. This program is automatically started after the user logs on to Windows NT 4.0 after powering up the CAPI PC. If the Track Control Program has been shutdown due to previous user activity, it can be started again by selecting DP1XXX from the Windows NT Start Menu. When the NDP1XXX submenu is displayed, select Track Startup (see Figure 119).
Figure 119. Selecting the Track Startup Program Once the Track Control Program is started, the MTRs can be run. To start the MTR application select DP1XXX from the Windows NT Start Menu. When the submenu for DP1XXX is displayed, select CSE Utilities. When the CSE Utilities submenu is displayed, select DP1XXX Maintenance Test Routines (see Figure 114). This will start the MTR application program and display the DP1XXX MTR Screen (see Figure 120).
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Figure 120. DP 1XXX MTR Screen Note: The MTR application should never be run concurrently with the transport exerciser application. Under the Windows environment it is possible to start up both applications. However, the Track Control Program is only designed to interface one application program at a time with the transport MULTIBUS. If the Transport Exerciser is running and you wish to run the MTRs, access the exercisers main menu and select Exit, or press the Esc key (see Figure 111). This will shutdown the exerciser program, allowing the MTR application to be run. When the MTR application starts up, it sends a transport reset command to the Track Control Program. The Track Control Program knows whether or not it has previously issued a transport reset command. If it has, it does not issue the track reset and waits for the next request from the MTR application. If a previous transport reset was not issued, the Track Control Program issues a reset to the transport hardware and starts the system POC test. After the system POC test completes, the Track Control Program waits for the next request from the MTR application. The MTR application always sends a transport reset request to the Track Control Program when it is started. The Track Control Program will only run the system POC if it has not previously received a transport reset request.
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After the transport reset request has been handled, the MTR main menu is displayed (see Figure 120). Screen Format The API screen uses the following format:
At the top of the screen a menu bar provides various commands. Below the menu bar a toolbar displays the function keys. Below the function key toolbar is a list of the available tests. On the right of the list of tests, a description of the highlighted test is displayed. The results of a test are displayed on the lower part of the screen.
Menu Bar and Function Keys

Menu Option File View Toolbar Status Bar Test Results Option... Test Loop Execute once Stop F9 F10 F1 Exit Command Function Enables you to exit the MTR dialog. Enables you to choose how you want to view the screen. Toggles on or off the display of function keys. Toggles on or off the status bar at the bottom of the screen. Toggles on or off the test results description at the bottom of the screen. Displays the View Options dialog, which enables you to change the fonts for the menu and for the test description. Enables you to select test options. Specifies that the diagnostic routine you chose from the test module submenu will be executed repeatedly. Specifies that the diagnostic routine you chose from the test module submenu will be executed one time only. Exits loop mode operation. Returns you to the MTR Test Main Menu (Figure 120) from the full screen display mode of the test results grid. Powers the track down or up.
Return to menu F2 Power Down/Up
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Procedure Use the following procedure to access test descriptions and tests: 1. Click the box at the left of the name of the module test (for example, Dual Image Module Tests). Note: If the box at the left of a test name has a plus sign (+), it can be expanded into subtests. If the box has a minus sign (), it has already been expanded.
A list of the tests for that module is displayed (for example, Calibrate Scanner Utility and Run Lamps). If a box appears at the left of one of these tests, you can click it for a further list of subtests (for example, Calibrate Front Camera and Calibrate Rear Camera). 2. Click and highlight the name of a test to view a description of the test.
Run the highlighted test by clicking on either F9 (Loop Mode) or F10 (Execute Once) on the toolbar or by pressing the F9 or F10 keys, respectively.
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Description of Maintenance Test Routines:

The following are descriptions of the MTR tests.
Transport Tests
Beam of Light Bias Values This utility graphically displays the Beam Of Light (BOL) bias values for the transport. Checks for Transport Ready and the ability to feed items from both feeders in a single item mode. Too Late To Pocket (TLTP), document data interrupts, pocket selection, gate operation, and proper document track timing are checked. This test demand feeds 20 documents from the primary hopper and records the time it takes each document to travel between adjacent BOL pairs. After flow has stopped, the recorded times are compared to predetermined timing windows to verify that the transport is operating within tolerance. Adjacent BOL pairs with track times that are out of tolerance are identified. Note: Six inch documents must be used to insure proper track timing measurements. This test is based on Subtest 05 from the NDP Transport Tests submenu.
Document Flow Test
Beam of Light Timing Test
Basic Microfilmer Tests

Microfilm Scan Test This routine allows you to place a document in the optical gate and film it repeatedly. In this way you can check for vibrations in the galvo assembly. This routine diagnoses problems in the height detector BOLs, determining if the fault lies with the BOL or with its associated control circuitry.
Height BOL Test
Film Transport Tests Capstan Motor Tests These tests execute seven selectable moves of the Capstan Motor at the selected motor speeds. The movement can be executed one time, or it can be continually repeated. The tests are executed with or without film. Tests the loop arm sensors by having you press the take-up and the supply loop arms to ensure that each of the three sensors on both arms are operating correctly. This test executes without film.
Loop Arm Sensor Test
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Reel Motor Test
In this routine the CSE tests the reel motors by pressing on the loop arms while visually checking for the correct reel motor movements. This test is executed without film. Tests the idler encoder by having the CSE manually turn and check the idler encoder count. This test executes without film. Enables the supply encoder motor and verifies the supply encoder count. The test loops until the CSE stops it. An exception is a register failure. This will halt the test.
Idler Encoder Test
Supply Encoder Test
Galvo Tests Galvo Home Routine This routine finds the actual galvo home position and verifies that it is within range ($10 - $70). This routine implements a continuous loop of two scans: a short (5 inch) scan, followed by a long (9 inch) scan. The routine is designed so that the two scans fit on an oscilloscope trace. Errors detected are reported only after the test is terminated.
Galvo Scan Routine
Hardware Parameter Adjustment Routines This utility sets up the following operational parameters required for the microfilmer:
Lamp Intensity/Density adjustment ALM adjustment LED/TED adjustment ID display adjustment Galvo adjustment Modify NVRAM parameters
ID Display Tests The CSE selects one of two test display patterns and visually verifies the ID display is correct. The display patterns used are
Enable ID display with 0s Enable ID display with blocks
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Miscellaneous Tests Lamps Test The Lamps test turns on the lamps in the following sequence. A visual check of the lamps is conducted to ensure the lamps are illuminating properly. 1. Front lamp only 2. Rear lamp only 3. Both front and rear lamps ICM Test The Image Count Mark Test individually enables ICMs 1 and 2 and requests a visual verification of their operation. Part 1 of the test displays three characters that light up every segment on the Human Readable Header display. This should be visually verified by removing the film cartridge and observing the display. Part 2 of the test cycles through the Human Readable Headers character set. The correct display of the character set should be visually verified. The Capping Shutter Test opens and closes the capping shutter and verifies that the open/close sensors correctly report the changing status. A visual verification of the shutters status is also requested by the test.
Human Readable Header Test
Capping Shutter Test
MultiJet Endorser Tests

The following are phase/voltage tests and adjustments: Head Phase Sweep The Head Phase Sweep will print the test pattern graphic on documents at various head phase values. By viewing the documents, the best head phase setting can be determined. The Charge Voltage Sweep will print the test pattern graphic on documents at various charge voltage values. By viewing the documents, the best head charge voltage setting can be determined. Set Head Phase will read the current head phase setting for the specified MJE unit, and allow this value to be changed. Set Charge Voltage will read the current charge voltage setting for the specified MJE unit, and allows this value to be changed.
Charge Voltage Sweep
Set Head Phase
Set Charge Voltage
In addition, you can select Run Time Commands and Extended Diagnostic Commands from the MultiJet Endorser tests menu.
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Impact Endorser Tests

Stamp Home Sensor Test: This test places the PEP microprocessor into diagnostic test mode and sends a "home stamp sensor" request to it. The test waits five seconds for the stamp sensor to be placed at its home position and a status condition to be returned. If a timeout condition occurs, an error is flagged. If the stamp sensor cannot be placed at its home position, the particular failure condition is reported.
Stamp Phase Motor Tests: Phase Driver Test: This test checks the functionality of the Stamp Motor Phase Driver circuitry for motor phases A, B, C, and D. To run the Phase Driver Test, the Stamp motor must be disconnected from the Stamp Driver board. This test allows the user to enable the Stamp Motor Phase current at one of four selectable levels. At the conclusion of the test, the Stamp Motor Phase current is disabled. This utility enables Stamp Motor phases A and B, which effectively hold the stamp in a fixed position. This test checks the functionality of the PEP hole detect circuitry. Twenty test documents, with a fixed number of holes, are demand fed. After each document is transported, the PEP module is placed in diagnostic mode and the current status of the hole count register is uploaded and saved in an array. The PEP module is then restored to normal operation mode. After all twenty documents have been processed in this manner, and average of the hole count values stored in the array is calculated. If this average is less than 48 or greater than 66, an error condition is reported. This test verifies that all of the print needles for character generator banks A, B, and C are functioning correctly. Eighteen documents are demand fed and endorsed during the test, one for each print needle being exercised. The test labels the documents with the bank (A, B, or C) and the print needle (1 - 6) from that bank, being tested. If the needle under test is jammed or firing continuously, flow is stopped and an error message is displayed identifying the needle. When failures occur, the document for the failing needle can be inspected to provide additional information as to the nature of the failure.
Phase Current Test:
Hold Stamp Utility:
PEP Hole Detect Test:
PEP Print Needle Test:
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E13B MICR Reader Tests

AC Reader Pixel Data Display This test will demand feed a document from the primary hopper and use the AC recognition system to read the MICR code line on the document. The MICR code is displayed and the user is given the option to view the character pixel data from the recognition board.
Dual Image Module Tests

Calibrate Front Camera This MTR creates information used to compensate for analog and optical variations in the front digitizer and camera combination. The results for this MTR are stored on the Image Capture Server (ICS) hard drive in C:\dpimage\frontX.cfg and C:\dpimage\frontX.tbl. These data files are used by the ICS during document flow for setup of the normalizer framer and camera/digitizer. This MTR creates information used to compensate for analog and optical variations in the rear digitizer and camera combination. The results for this MTR are stored on the ICS hard drive in C:\dpimage\rearX.cfg and C:\dpimage\rearX.tbl. These data files are used by the ICS during document flow for setup of the normalizer framer and camera/digitizer. This MTR enables you to turn the lamp lights on and off to verify that they are working.
Calibrate Rear Camera
Run Lamps
High Speed Encoder Module Tests

STATIC 1:
Track Sensor Current Monitor Test Track Sensors Input Simulation Test Track Sensors Normal Mode Test Servo-Skew Interrupt Test Skew Sensor Test Skew Sensor Compensation Skew Read Result NVRAM Test External Bus Wrap-Around Test Power Control Circuitry Test Servo Velocity Adjust Servo Slip Reference Servo Voltage Monitor Test
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Servo Driver Voltage Monitor Test Servo Normal Mode Test Skew Table Calibration Test
STATIC 2: Enter Print on Outsort Mode Exit Print on Outsort Mode Printer-Microprocessor Instruction Set Test Printer-Prom Checksum Test Printer-RAM test Printer-NVRAM test Printer-External Bus Wrap-Around Test Printer-External Control Signal Wrap-Around Test Hammer Supply Monitor Test Hammer Clock Verification Test Hammer Voltage Monitor Test Hammer Impact Monitor Test Hammer VCL Test Sensor State Sensor Compensation
DYNAMIC: Drum Sensors Test Ribbon Sensors Test Ribbon Stepper Motor Test Ribbon Tracking Adjustment Test Ribbon Skew Sensors Status
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High Speed OCR Reader Tests

Non-Volatile RAM Utilities: Initialize NV RAM: This utility clears the OCR modules non-volatile RAM and then automatically initializes the following parameters:
Lamp intensity Transport speed Signature values for the OCR diagnostic bus POC tests
The user is then prompted to enter initialization values for the following non-volatile RAM parameters:

Edit NV RAM Parameters:
Classifier configuration OCR unit serial number Month Date Year
This utility allows the user to edit the OCR modules nonvolatile RAM parameters.
Elevator Tests Locking Mechanism Test: Checks the functionality of the elevator lock and verifies that the lock status is correctly interpreted. This test verifies the functionality of the camera elevator and its associated travel limit switches. The camera elevator is dropped to its bottom travel limit and the status of the bottom travel limit switch is checked. The elevator is then moved to its upper limit and the status of the top travel limit switch is checked. With the successful conclusion of the test, the elevator is moved to the bottom travel limit position.
Travel Limit Sensor Test:
Lamp Test Enable Lamp (NVRAM Value): This test turns on the lamp with the lamp intensity value stored in the OCRs non-volatile RAM. The lamp current sensing circuitry is checked and any error is reported. The NVRAM lamp intensity value is also displayed. This test turns on the lamp with a lamp intensity value entered by the user. The lamp current sensing circuitry is checked and any error is reported. The user is then offered the option of storing the lamp intensity value into NVRAM.
Enable Lamp (User entered value):
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1150 Multi-Jet Endorser Tests

1. Print Head Present Test This test detects if the print head is present. The user is prompted at the beginning of the test to choose which module to check, the front MJE or the rear MJE. 2. Read Dot Count Utility This utility returns the most significant 8 bits of the 32 bit print fire dot counter. The user is prompted at the beginning of the utility to choose which module to check, the front MJE or the rear MJE. The information returned lets the user know the percentage of ink left in the ink cartridge. 3. Reset Dot and Document Count Utility This utility resets the dot and document counter. The user is prompted at the beginning of the utility to choose which module to check, the front MJE or the rear MJE. 4. Non-volatile RAM Test The test verifies the write/read functionality of the non-volatile RAM. 5. Head Purge Test This test verifies the operation of the print head purge circuitry. During the test, ink is emitted from the head. The user is prompted at the beginning of the test to choose which module to check, the front MJE or the rear MJE. 6. Print Logic Test This test verifies the operation of the print logic circuitry by sending two blank columns of character data to the print driver board. The user is prompted at the beginning of the test to choose which module to check, the front MJE or the rear MJE. 7. Dual Port RAM Test This test checks the write/read operation of the MJEs dual port RAM. 8. Print Head Alignment Utility This utility endorses ten documents for each of the sixteen possible head phase positions of the MJE. The endorsed documents are sorted to the last pocket in the first pocket module. The user is then prompted to inspect the documents and select the most desirable head phase position. If the user exits without making a choice, the head phase is automatically set to position eight by default. The user is prompted at the beginning of the test to choose which module to check, the front MJE or the rear MJE. 9. Firmware Version Level Utility This utility displays the version level of the MJE Interface PCBAs resident firmware. It also displays the date that the code was compiled on.
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Power-On Confidence Tests (Non-CAPI Configurations)

POC tests are executed each time the system power is turned on or when the MASTER RESET push-button is activated. For the NDP 030 configuration, the main POC test routines reside on the NDP030 CPU PCBA (slot 17). For the NDP Ready configuration, the main POC test routines reside on the NDP Ready 68030 CPU PCBA (slot 17). Other PCBAs in the AA gate, as well as devices outside of the AA gate, have their own POC test routines that reside on their on-board EPROMs. When the sorter is reset, all of the POC tests begin execution simultaneously. The main CPU PCBA (either the NDP030 CPU PCBA or the NDP Ready 68030 PCBA) processes the POC test status and transfers it to the NDP PC via the communications link (SCSI or RS-232) between the NDP PC and the main CPU PCBA. Note: From this point on, the term "NDP CPU" will pertain to both the NDP 030 CPU and the NDP Ready 68030 CPU. In instances where there are differences between the operation of the two configurations, they will be noted.
Description of POC Tests

The overall, system POC tests can be broken down into three stages: 1. 2. 3. NDP CPU PCBA kernel tests AA gate tests Option module tests
The following subsections describe in detail the three stages and their corresponding tests.
NDP CPU PCBA Kernel Tests

The kernel tests verify the functionality of the NDP CPU PCBA. The PCBAs hardware functional blocks are identified below. They are tested in the following order: 1. 2. 3. 4. 5. 6. 7. 8. 9. Motorola 68030 CPU test RAM memory configuration test RAM address line and write/read test (1st megabyte) SCSI initialization (not a test) (NDP 030 configuration only) EPROM checksum test RAM address line and write/read test (remaining memory after 1st megabyte) Privilege exception test Dead bus timer test Programmable timer module test
10. Flash EPROM checksum test (NDP 030 configuration only)
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If any of the above tests fail, with the exception of the "Flash EPROM checksum test," a 68030 CPU halt condition occurs. If tests 1 through 3 fail, no screen message is displayed because the communications link between the PC and the NDP CPU PCBA is not established. If tests 5 through 9 fail, the following message may be displayed on the NDP PCs monitor, depending on whether or not communications between the PC and the NDP CPU PCBA have been established. MAIN PROCESSOR: Note: POWER UP TEST EXECUTING . . .
Errors in tests 1 through 9 do not result in a standard failure code screen display.
If no screen message appears or if the "MAIN PROCESSOR: POWER UP TEST EXECUTING..." message is displayed indefinitely, the NDP CPU PCBA has failed its POC kernel test. Observe the MTR LEDs on the NDP CPU PCBA (slot AA17). The LEDs indicate the last test executed. If the initial pattern (FF - all LEDs on) is displayed, the POC test never started executing. Use the "LED Fault Code Conditions" table at the beginning of Section 2 to determine which test was executing when the system halted. This table references manual procedure line numbers for analysis procedures. For the NDP 030 CPU, if a failure occurs in the Flash EPROM checksum test, a standard failure code message is displayed. All the NDP030 CPU kernel tests reside on the PCBAs EPROM. If the kernel tests pass, a screen message is displayed listing all the tests. Then program control is passed to the POC Test Handler. This handler manages the execution of AA gate POC tests and the option module POC tests. Note: For the NDP Ready CPU PCBA, all test code is resident on an EPROM. For the NDP 030 configuration, the kernal tests are resident on an EPROM and the remaining tests are resident on a "flash" EPROM.
AA Gate Tests
The AA gate tests verify the functionality of the AA gate backplane, ensure that the physical sorter configuration matches the reported (hardware configured) configuration, and guarantee the operation of the Reader Configuration Interface PCBA (slot AA10). The AA gate hardware functional blocks are identified below. They are tested in the following order: 1. 2. 3. 4. AA gate MULTIBUS loop test Configuration bus error test Character recognition system test Z80 CPU test
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AA Gate MULTIBUS Loop Test The integrity of the MULTIBUS address and data lines is confirmed by a simple loop test from the NDP CPU PCBA to a register on the Reader Configuration PCBA (slot AA10). The successful completion of this test indicates that these lines are free from shorts and can be controlled by the NDP CPU.
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Configuration Bus Error Test This test verifies that all nonoptional, AA gate PCBAs are installed by accessing an exclusive MULTIBUS address for each PCBA and verifying that a bus error condition does not occur. Nonoptional PCBAs are those that handle
Area 1 tracking Area 2 tracking Clocking circuitry for the AA gate Reader Configuration processing
Once the presence of all nonoptional PCBAs is verified, the status of the optional PCBAs is checked. These PCBAs are typically interface cards that allow the NDP CPU to communicate with option modules added to the basic transport (that is, the microfilmer, imaging module, endorser, etc.). The MULTIBUS configuration registers are checked to see what option modules the sorter is configured to have. MULTIBUS addresses exclusive to each option modules interface PCBA are then read. If an option module is reported present by the configuration registers, the MULTIBUS address on its corresponding interface card should not cause a bus trap when read. Correspondingly, a read of the address should cause a bus trap if the option module is reported not present by the appropriate configuration register. Character Recognition System Test The NDP CPU sends a series of commands via the MULTIBUS to the recognition control and analog PCBAs of the magnetic ink character recognition (MICR) reader. These commands result in the execution of the tests identified below. They are tested in the following order:
Processor subtest Result PROM subtest Maintenance register subtest Quantizer subtest Segmentation subtest MCR subtest FIFO subtest Maintenance RAM subtest Analog board subtest
Each of these subtests can also be accessed from the MTRs.
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Z80 CPU Test The Z80 CPU is located on the Reader Configuration PCBA (slot AA10). This test verifies the functionality of the following modules, which reside on the Reader Configuration PCBA:
Z80 registers and instruction set RAM and ROM CTC timers PIOs A and B buffers 4 Mhz clock PBLINK signal
Upon completion of these tests, communications between the NDP CPU and the Z80 CPU are established, and test results are passed to the NDP CPU.
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AA Gate Test Errors Errors that occur in the AA gate POC tests result in a failure code being displayed on the NDP PC monitor. The failure screen gives the fault code with a brief description and allows the user four function key selectable options. These options are described in Table 13. Table 13. AA Gate Test Fault Code Options
Function Key <F1> Additional information
Description
Selecting this option displays additional text describing the operational intent of the POC test and identifies probable suspects for the failure. <F2> Transport status Selecting this option checks the current status of the MULTIBUS registers. <F3> Load MTR software NDP 030 Configuration: Selecting this option transfers program control to the BOOTLOAD routine. This routine automatically downloads the software that the NDP PC has been configured to download (normally, the system software application program). Note: If the MTRs are to be downloaded, the appropriate changes must be made on the NDP PC to enable CSE mode. These change are described later in this section in the subsection "Maintenance Test Routines."
NDP Ready Configuration: Selecting this option transfers program control to the BOOTLOAD routine. This routine automatically downloads the software from the Versa-DOS formatted floppy disk currently in the 5 1/4 inch drive located at the front of the PC slice. The drive is mounted just below the bottom right corner of the PCs monitor. Disks usually loaded after the POC test are the system software disk or the MTR disk. <F4> Motorola debugger Selecting this option accesses the Motorola debugger routine.
When an AA gate POC test completes without error, a "passed" status message, identifying the test, is added to the screen display. This enables the user to visually track the progress of the POC test. If all the AA gate tests complete without error, the OPTION MODULE POC TEST STATUS screen is displayed. At this point, the POC TEST HANDLER begins calling communications routines that report the POC status of the option modules within the sorter that have been running their own separate POC tests concurrently with the NDP CPU PCBA. This is the third stage of the system POC test, the option module tests.
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Option Module Tests

The NDP currently has the following available option modules: 1. 2. 3. 4. 5. Programmable Endorser Printer/Stamp (PEP/Stamp) Unisys Cinemode Microfilmer High Speed Optical Character Recognition reader (HSOCR) Multiline Ink Jet Endorser (MJE) Imaging Module
Each module has an interface PCBA residing in the AA gate that enables the NDP CPU PCBA to communicate with it. Each interface PCBA runs its own self-test and then processes status from the device it is linking to the NDP CPU PCBA. The POC TEST HANDLER running on the NDP CPU PCBA calls a status routine for each option module. The option module then establishes communications with the appropriate interface PCBA and processes the POC status that the interface PCBA has retrieved from the device. If the option module passes its POC test, a status message indicating that the option module has completed its POC test is added to the OPTION MODULE POC STATUS display screen. If the option module fails its POC test, the option module status routine displays the appropriate fault code reported by the device. Keyboard input is then requested to continue the processing of POC status for the remaining option modules. Successful completion of the system POC test causes the BOOTLOAD program to download an application program. For normal operation in the NDP 030 configuration, the application is the Sorter Control Program (SCP). If it is desirable to run the MTRs in this configuration, CSE Mode must be enabled on the PC prior to the completion of the POC test. For the NDP Ready configuration, BOOTLOAD downloads the contents of the disk currently in the 5 1/4 inch floppy drive. The following subsections briefly describe the option module self-tests. Programmable Endorser Printer/Stamp Test The Endorser Controller PCBA (slot AA09) test includes subtests for the CPU, the RAM, the ROM, and the programmable timer modules for both the PEP and Stamp processors. The communications link between the PEP CPU and the Stamp CPU is also verified. The stamp motor is tested and is driven to its home position. A dualport RAM test checks the functionality of the communications link between the Endorser Controller PCBA and the NDP030 CPU PCBA. If any of the PEP/Stamp POC subtests fail, the appropriate module (PEP or Stamp) is disabled and made inoperable. Stamp POC errors are not reported if the Stamp Error Bypass jumper is installed on the NDP030 CPU PCBA (slot AA17). The location of this jumper is W4/W3-C (Reference: SH 09.01.02, part number 2493 5900). For the NDP Ready 68030 CPU PCBA, the location of the jumper is W2/W3-C (Reference: SH 09.01.02, part number 2494 4200)
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Unisys Microfilmer Test The microfilmer POC consists of two separate test systems. Both the Controller PCBA and the Microfilmer/Image Interface Board (MIIB) have individual test routines that run in parallel with the sorter POC test. The Controller exercises as much of the microfilmer unit as possible, depending on the configuration. For example, if film is present, the human readable header cannot be tested. In general, the following components of the microfilmer unit are tested:
Registers Timers Board presence levels Capstan Galvo Shutter Lamps ID display Human readable header Image presence level Image count marks Height detector BOLs Automatic light meters
In addition, the data communications between the Controller PCBA and the MIIB is verified. The MIIB executes its own set of tests that include an A/B signal test, a register test, and a dualport RAM test. Fault codes are passed back to the NDP030 CPU by way of the dualport RAM interface. Faults are split into errors and warnings. They are defined as follows:
Error: The microfilmer unit is not available. The sorter can be used without the microfilmer. Warning: Both the microfilmer and the sorter are available, but in a degraded state. For example, having the Galvo Home Bypass jumper on causes this type of message.
Every error displays a fault code.
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High Speed Optical Character Recognition Reader (HSOCR) Tests The HSOCR reader executes its own set of POC tests and sends status to the NDP030 CPU PCBA upon completion. The following components of the HSOCR module are tested:
Dynamic RAM Nonvolatile RAM (NVRAM) ROM MULTIBUS memory Timers Recognition electronics Camera elevator Lamps
The error code format used by the HSOCR reader is slightly different from the format used by other sorter modules. The format is as follows: OCR xx yy In this format, xx = Test number yy = Error number For additional information on the HSOCR reader diagnostic system, refer to the DP 1800 OCR Reader Installation and Servicing Guide. All manual procedures for the HSOCR reader are covered in that guide. Note: If the HSOCR reader fails its POC test, system software cannot download controlware to the HSOCR reader.
Multiline Ink Jet Endorser Tests The MJE executes its own POC test and sends the status to the NDP CPU when requested. Imaging Module There are two imaging systems supported by the NDP POC when running in the non-CAPI configuration: U4/JPEG and Dual Image. Both systems cannot be present at the same time. U4/JPEG Imaging Module In the U4/JPEG imaging system, POCs reside in programmable read-only memory (PROM) locations on individual PCBAs within the imaging unit. POC results are displayed at the host data communications terminal and the NDP PC monitor.
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When the imaging module is powered on, the power-on confidence tests are run. The Point-to-Point Optical Link (POL) PCBA, the Diagnostic Transport Interface (DTI) PCBA, and the Main Processor PCBA have their own power-on confidence tests. The Point-toPoint Optical Link (POL) PCBA also controls the initiation of power-on confidence tests for the remainder of the imaging module. Examples of these power-on confidence tests are
Verification tests to exercise the image pipeline and associated hardware with pattern stimulus to verify the proper responses. Basic communication tests with the Image Interface Board (IIB) PCBA and the Storage Retrieval Module (SRM).
For further information about imaging system POCs, refer to the IC 1000/IC 1825 Imaging Module Installation and Servicing Guide. Dual Imaging Module The Dual Imaging system consists of five basic components: the image camera, the image electronics gate, the Image Capture Server (ICS), the CAR Unit, and the Dual Microfilm Image Interface Board (DMIIB). The NDP CPU communicates with the ICS via the DMIIB. At power up, the ICS initializes itself and enters an idle state, waiting for commands from the NDP CPU. When the NDP CPU is ready to execute the Dual Image POC, it sends an "Enter Test Mode" command to the ICS. After this command has been processed, the ICS is ready to except POC test commands from the NDP CPU. Commands for the following tests are then sent to the ICS:
Get Image Gate Configuration PCI Image Interface Confidence Test Image Gate Bus Test Framing Logic Test Normalization Look-up-Table(LUT)/Diagnostic RAM Test Analog Interface Test
When the ICS receives a test command, it executes the appropriate test on either the image camera hardware, the image electronics gate hardware, or the CAR unit. Pass/fail is reported back to the NDP CPU. The tests defined above are always executed. Additional tests are run once the configuration of the system has been determined. If JPEG compression hardware is present in the system, the following tests are executed:
Run JPEG Self Test JPEG Compressor Test
If CCITT compression hardware is present in the system, the following tests are executed:
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Run CCITT Self Test CCITT Compressor Test
If the CAR unit is present, the following tests are executed:
CAR Port Background Suppression Test CAR Port Spot/Void Threshold Test CAR Unit Interface Test Get CAR Unit POC Test
The last test executed is the "Validate Image Gate Configuration Test." If any of the tests fail, the Dual Image POC is terminated and the error condition is displayed. If the Dual Image POC successfully completes, the ICS is taken out of test mode and returned to its normal idle mode of operation.
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POC Repair Procedure

The POC tests display repair messages on the NDP PC monitor for you. The POC tests generally diagnose to the board level. In this case, the failure code is identified by the primary error screen display. The board that is at fault is identified by accessing the "Additional Information" screen, which can be selected by pressing function key <F1> from the primary error screen. The standard corrective action is to replace the indicated board and rerun the tests. Note: When replacing a board, verify that the board was not loose in its socket before removing it. While a board is removed from its socket, carefully examine the socket for bent, corroded, or otherwise damaged contacts.
Some faults cannot be diagnosed to a single board. These faults may have been caused by one of two boards or by the interconnecting circuitry between them. The corrective action in this case is to go to the manual procedures specified by the message on the screen and carefully follow the procedure outlined there. Some messages may identify a board as the "primary suspect" and another board as the "secondary suspect." Note: The manual procedures refer to these boards by identification number. A typical board identification number could be AA02. The first 2 characters identify the gate that the board resides in; the next two characters identify the card slot. For example, AA02 is interpreted as card slot 2 in the AA gate. Wiring information is interpreted as follows: AA02-J1-21 is J1, pin 21, of card slot 7 in the AA gate.
Additional Diagnostic Features (Non-CAPI Configuration)

The following subsections describe additional diagnostic system features available you.
Bypass POC Tests

The system POC can be partially bypassed to enable quicker access to either system software or MTR software following a reset condition. To perform this bypass, install a jumper at jumper position W1/W2-0 on the NDP030 CPU PCBA (slot AA17). Refer to SH 09.01.02, part number 2493 5900, for details. To bypass the POC test on the NDP Ready 68030 CPU, install a jumper at jumper position W1/W4-0. Refer to SH 09.01.04, part number 2493 4200, for details. With this jumper installed, the NDP CPU skips its kernel test, as well as the AA gate tests. A POC TEST HANDLER routine is accessed instead. This routine communicates with all the option modules that are present and sends them codes requesting that they abort their POC self-tests and jump to their controlware operating systems. In essence, a partial POC is run because many of the option modules complete a significant part of their respective POC tests before processing the bypass command sent by the NDP CPU. Any error status relayed to the NDP CPU is ignored by the POC TEST HANDLER. At the conclusion of the POC bypass sequence, all option modules that did not respond or that sent back failure codes are listed in a screen message by the POC TEST HANDLER. The message indicates that these option modules did not successfully complete their POC bypass sequence and may not be operational for system use.
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After the screen message is displayed, program control is passed to a debugger program, as indicated by the appearance on the monitor of the debugger prompt: NDP 030BUG X.X.X > In this prompt, X.X.X is the current version level of the debugger program. Note: The prompt shown above, NDP 030BUG X.X.X >, is the one displayed in the NDP 030 configuration. The prompt for the NDP Ready configuration is DP030 BUG X.X. The debugger command examples that follow will show the NDP 030 configuration prompt, although the information also pertains to the NDP Ready configuration.
NDP Debugger Program

The NDP debugger program resides on the NDP030 CPU PCBA EPROM. This program is primarily used to aid engineering software debugging. It is case sensitive; to use it, activate the Caps Lock key. You can use this debug aid to display program information when you encounter bus traps, address traps, or illegal instructions during normal system operations. You can access the debugger by three methods:
Enabling POC bypass Selecting the debugger option from an AA gate POC test failure code screen Selecting the debugger menu option from the MTR MAIN MENU after the MTRs have been loaded
Some useful debugger commands are described below. The format of the command line is NDP 030BUG X.X.X > <command> [<parameters>] [;<options>] In this format,
NDP 030BUG X.X.X > command parameters
Is the prompt generated by the debugger Is the debugger command Are separated by spaces and can be of the form <expression> or <address> Are one or more options that may be selected
options
At the conclusion of each command line, press the <xmit> key to execute the command.
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Display/Set Register NDP 030BUG X.X.X >.<register> [<expression>] Individual registers can be displayed and/or altered by using this format: .<register> [<expression>]. Commands with the leading period and the registers displayed/altered by these commands are .A0 - .A7 .D0 - .D7 .PC .SR .SS .US address register data register program counter status register supervisor stack pointer user stack pointer
Example NDP 030BUG X.X.X >.PC .PC=00001010 NDP 030BUG X.X.X >.A7 1300 Display program counter
Set address register 7 to 1300
Block of Memory Test (BT) NDP 030BUG X.X.X >BT <address1> <address2> The BT command is a destructive test of a block of memory beginning at <address1> through <address2> (both at word boundaries = even addresses). If this test runs to completion without detecting errors, the memory tested will be set to all zeros. If memory problems are found, a message is displayed indicating the address, the data stored, and the data read of the failing address. This command may take several seconds to test large blocks of memory. Examples NDP 030BUG X.X.X >BT 5000 5FFE PHYSICAL ADDRESS=00005000 00005FFE NDP 030BUG X.X.X >BT F70000 F70040 PHYSICAL ADDRESS=00F70000 00F70040 FAILED AT F70000 WROTE=FFFE READ=FF00
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Display Formatted Registers (DF) NDP 030BUG X.X.X >DF The DF command is used to display the CPU registers and the disassembled mnemonics of the instruction pointed to by the program counter. The trace display is displayed whenever the debugger gains control of the program execution. Note: Any single register can be displayed with the .A0 - .A7, .D0 - .D7, etc., commands.
Example NDP 030BUG X.X.X >DF PC=00001010 SR=FFFF=TS7XNZVC US=0005BFF0 SS=00001300 D0=0000D0D0 D1=0000D1D1 D2=0000D2D1 D3=00D3D3D3 D4=D4D4D4D4 D5=000000D5 D6=00000000 D7=000000D7 A0=000000A0 A1=000000A1 A2=0000A2A2 A3=000000A3 A4=000000A4 A5=000A5555 A6=000000A6 A7=00001300 --------------------000010+R1 00000000 OR.B #0,D0 Execute Program (G) NDP 030BUG X.X.X >G [<address>] The G (or GO) command causes the target program to execute (free run in real time). The G sequence starts by tracing one instruction, setting any breakpoints, and then free running. Command Format NDP 030BUG X.X.X >G Description Begin or resume execution at the address in the program counter. Set program counter = address and begin execution at that address.
NDP 030BUG X.X.X >G <address>
Example NDP 030BUG X.X.X >G 500 PHYSICAL ADDRESS=00000500
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Memory Display/Disassembly (MD) MD[S] <address1> [<count>] [;DI] The MD command is used to display a section of memory beginning at <address1> and displaying the number of bytes given as <count>. If <count> is not specified, the default is 16 ($10 or hexadecimal 10) bytes. The optional form MDS gives a display of 16 lines of 16 bytes each. The display is in hex and in ASCII characters. Once the MD command is entered, it continues with the next 16 lines of output each time a carriage return (CR) is entered. Any other command exits MD and enters the new command. The ;DI option is supported. This option causes one-line disassembly to occur on the number of bytes specified. The default count for ;DI is one instruction. Examples NDP 030BUG X.X.X >MD 2003 12 2003 44 45 46 47 00 00 00 00 00 00 00 00 00 00 00 00 DEFG.. 2013 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 ...... NDP 030BUG X.X.X >MD 9528 48B800010406 952E 40F80406 9532 48E7FFFE 9536 4FF8095A 9528 10;DI MOVEM.W MOVE.W MOVEM.L LEA D0,$0406 SR,$0406 D0-D7/A0-A6,-(A7) $95A,A7
Memory Modify/Disassembly/Assembly (M) NDP 030BUG X.X.X >M[M] <address> [;options>] The M (or MM) <address> command is used to display memory and enter the subcommand mode (defaults to byte size). The M command causes the debugger to display the address and the data at that location. The size option (default one byte) controls the number of bytes displayed for each address. The option ;W sets the size option for a word (that is, two bytes). The option ;L sets the size option for long word (that is, four bytes). Once entered, the M command has several submodes of operation. The subcommands are in this format: [<data>] (CR) [<data>]^(CR) [<data>]=(CR) [<data>].(CR) Update location and sequence forward. Update location and sequence backward. Update location and reopen same location. Update location and terminate.
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The following options are supported: ;W ;L ;O ;V ;N Set size to word (2 bytes). Set size to long word (4 bytes). Set size to byte; access only odd address bytes. Set size to byte; access only even address bytes. Do not verify that data is stored correctly (that is, do not read data stored). This option is useful for writing data to some hardware without reading from that hardware. Perform a one-line disassembly, and then perform a one-line assembly if a new instruction is input. This option supports the (CR) and the .(CR) submodes of operation. The user must enter a space at the beginning of each instruction line to be assembled in order to get past the instruction label field. If an error occurs during assembly of an instruction, X? is displayed beneath the field of the input line that is suspected to be in error.
;DI
Example NDP 030BUG X.X.X >MM 4000;W ;N 4000 ? 555 4002 ? 34. Memory Set (MS) NDP 030BUG X.X.X >MS <address> data The MS command alters memory by setting data into the address specified. Command Format NDP 030BUG X.X.X >MS 2000 ABC NDP 030BUG X.X.X >MS 2003 4445 Description Set memory to ASCII string. Set memory to hex data.
Examples NDP 030BUG X.X.X >MS 2000 'ABC' NDP 030BUG X.X.X >MD 2000 2000 41 42 43 71 4E 71 4E 71 4E 71 4E 71 4E 71 4E 71 ABCQNQNQN
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Loading an Application from the Debugger Program

Either the application program or the MTRs can be loaded by entering the following commands at the debugger prompt: NDP 030BUG X.X.X >.SR 2700 NDP 030BUG X.X.X >G 10000DA The first command disables interrupts to the NDP CPU. The second command sets the program counter to address "10000DA" and begins program execution there. The jump table address of the BOOTLOAD routine is "10000DA". Executing a GO command at this address invokes this EPROM-resident routine. In the NDP 030 configuration, the BOOTLOAD routine automatically loads the application file that the NDP PC has defined as its download file. The default download file is the Sorter Control Program. This can be changed on the NDP PC so that the MTRs are the downloaded file. Details on enabling the MTR file download are covered in the MTR portion of this section. In the NDP Ready configuration, the BOOTLOAD routine downloads the contents of the disk currently in the 5 1/4 inch floppy disk drive.
Enabling the MULTIBUS Address Line Toggle Utility

If an error occurs in the MULTIBUS loop test, check the integrity of the MULTIBUS address lines. A utility is available that alternately reads MULTIBUS addresses $3FF5555 and $3FFAAAA. This enables you to monitor address lines 0 to 15 anywhere on the AA gate backplane and verify that the lines toggle periodically. This utility can be accessed by entering the following commands at the debugger prompt: NDP 030BUG X.X.X >.SR 2700 NDP 030BUG X.X.X >G 10000AA The first command disables interrupts to the NDP CPU. The second command sets the program counter to address "10000AA" and begins program execution there. The jump table address of the MULTIBUS address line toggle routine is "10000AA." Executing a GO command at this address invokes this EPROM resident routine, which begins toggling the MULTIBUS address lines. The toggle pattern is shown here: Toggle period 1 2 3 4 . . A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0 0 1 0 1 . . 1 0 1 0 . . 0 1 0 1 . . 1 0 1 0 . . 0 1 0 1 . . 1 0 1 0 . . 0 1 0 1 . . 1 0 1 0 . . 0 1 0 1 . . 1 0 1 0 . . 0 1 0 1 . . 1 0 1 0 . . 0 1 0 1 . . 1 0 1 0 . . 0 1 0 1 . . 1 0 1 0 . .
A keyboard entry enables you to exit the utility and return to the debugger program.
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NDP CPU PWBA Hardware Indicators

The NDP CPU PWBA has 12 light-emitting diodes (LEDs) that can provide you with useful status information during the system POC test. Eight of these LEDs are software controlled. The other four are hardware controlled. With the NDP CPU PWBA installed in the AA gate, the top four LEDs are the hardware-controlled LEDs. Table 14 shows these LEDs, read from top to bottom. Table 14. Hardware-Controlled LEDs
LED Label NDP 030 CPU PCBA: RST STA SCSI LCA
Description
68030 CPU RESET. LED is lit while the 68030 reset signal is active. 68030 CPU STATUS. LED is solidly lit on a CPU HALT condition. Flashes for many situations. 53C710 BUS ACTIVE. LED is lit while SCSI chip has control of the CPU bus. LCA DONE. LED is lit while the onboard programmable LCA device loads, which is every reset.
NDP Ready 68030 CPU PCBA: RST STA DONEA DONEB 68030 CPU RESET. LED is lit while the 68030 reset signal is active. 68030 CPU STATUS. LED is solidly lit on a CPU HALT condition. Flashes for many situations Xlinks configuration error. DMA logic cell array. Xlinks configuration error. Miscellaneous logic cell array.
The remaining LEDs beneath the hardware status LEDs are the software-controlled MTR LEDs. The POC test programs running on the NDP CPU PWBA can activate these LEDs by writing to address $1FFFFB1. The standard convention is to write a unique LED pattern to this register at the beginning of each POC test. This enables you to determine the last test executed when the screen status is not provided (for example, kernel test failures or a processor HALT condition). Table 15 lists the POC test LED codes. A similar table, with manual procedure line numbers added, is located in Section 2.
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Notes:
Read the table as follows: If the last pattern on the LEDs was $0C, then the last test that was successfully run was the Flash EPROM checksum test. For additional help in using the LEDs for diagnosis, see the LED Fault Code Conditions table in Section 2 and the CCC table in Section 13. In Table 15, "1" indicates that the LED is on. The Character Recognition POC is for MICR readers. The test LED codes apply to the NDP 030 CPU PCBA and the NDP Ready 68030 CPU PCBA.
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Table 15. POC Test Reference Table
Test 7 Power-up POC bypass CPU test RAM bus trap RAM configuration test RAM W/R test EPROM check sum test RAM address line test RAM parity test Privilege exception test Dead bus timer test PTM test SCSI initialization Flash EPROM checksum test MULTIBUS loop test Pblink test Configuration test Character Recognition Test I-test A/B test Reader/Config test Transport status test PEP/Stamp status Microfilmer status MJE status HSOCR status NIE status Image status 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
LED MSB Bottom 6 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 5 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 1 1 4 1 1 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 1 0 1 0 1 3 1 1 0 0 0 0 0 0 0 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
LED LSB Top 2 1 1 0 0 0 1 1 1 1 0 0 0 0 1 0 0 0 0 1 1 1 1 0 0 0 0 0 0 1 1 1 0 1 1 0 0 1 1 0 0 1 1 0 0 0 1 1 0 0 1 1 0 0 0 0 0 0 0 1 1 0 0 1 0 1 0 1 0 1 0 1 0 0 1 0 1 0 1 0 1 0 0 0 0 0 0
Hex Pattern
FF FF 01 02 03 04 05 06 07 08 09 0A 0B 0C 10 11 12 13 14 15 16 17 20 30 40 50 60 70
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Table 15. POC Test Reference Table
Test 7 Address exception Bus exception Unexpected exception Instruction exception Unexpected interrupt Unexpected privilege instruction Spurious interrupt Transport interrupt exception 1 1 1 1 1 1 1 1
LED MSB Bottom 6 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 3 0 0 0 0 0 0 0 1
LED LSB Top 2 0 0 0 1 1 1 1 0 1 0 1 1 0 0 1 1 0 0 1 0 1 0 1 0 1 0
Hex Pattern
F1 F2 F3 F4 F5 F6 F7 F8
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Maintenance Test Routines (Non-CAPI)

This subsection describes the Maintenance Test Routines (MTRs) for non-CAPI systems. Both NDP 030 and NDP Ready configurations are described.
NDP 030 Configurations

The rest of the diagnostic system tests are the MTRs. These routines are contained in a file called INITM030.LO, which is resident on the NDP PC hard disk. To access these test routines, INITM030.LO must be downloaded from the NDP PC hard disk to the NDP030 CPU PWBAs RAM. This can be accomplished by enabling the CSE mode on the NDP PC, changing the default sorter boot program to the MTR file (INITM030.LO), and accessing the BOOTLOAD routine on the NDP030 CPU PWBA. A more detailed description of this procedure is given next: 1. Enable CSE mode on the NDP PC by bringing up the NDP Unit Manager Logical Unit Main Dialog box. (The Unit Manager Logical Unit is started automatically when the NDP comes up, so you dont have to start the program.) You can switch to the Unit Manager by either of these two methods:
Press Tab while holding down the Alt key until the Unit Manager Logical Unit comes up. Switch to it directly by bringing up the Task List by pressing the Esc key while holding the Ctrl key and then selecting the Unit Manager Logical Unit and pressing the Enter key.
2.
Click on the Enabled radio button (or press Alt-E) in the Privileged CSE Functionality for this unit box. A dialog box is displayed that asks for the CSE password (which changes monthly) and is the same as the current InfoAdvisor password.
3.
Enter the password. CSE mode is enabled on the NDP PC.
4.
Change the default sorter boot program to load: a. b. c. Press the Alt-Tab keys to switch to the NDP Accessory Manager, which is running the Terminal Emulator for the sorter. Press the F12 key to activate the File Selection Dialog box. Switch to the Boot tab and select M&D (Maintenance & Diagnostics). This configures the NDP PC so that the MTR file, INITM030.LO, will be download the next time the BOOTLOAD routine on the NDP030 CPU PWBA is executed. d. Choose OK. You are returned to the Terminal Emulator.
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5.
Use one of the following methods to access the NDP030 CPU PWBA BOOTLOAD routine:
Reset the sorter. If the kernel tests and the AA gate tests of the system POC test successfully complete, the BOOTLOAD routine is automatically executed. This results in the new default sorter boot program being downloaded. Reset the sorter. If one of the AA gate tests in the system POC test fails, the primary failure code screen display provides you with an option to Load MTR software. When you select function key F3 from this display, the BOOTLOAD routine is called. If the NDP PC has had its default sorter boot program changed to the MTR, INITM030.LO file, the MTRs are downloaded. If this change has not been made, the current default boot file is downloaded. Access the debugger program in either of these ways:
Install the POC bypass jumper and reset the sorter. Select function key F4 Debugger from the primary failure code screen if an AA gate POC test failure occurs. NDP 030BUG X.X.X >.SR 2700 NDP 030BUG X.X.X >G 10000DA
At the debugger prompt enter the following commands:
This executes the BOOTLOAD routine and loads the default boot file.
NDP Ready Configurations

The MTRs for the NDP Ready configuration reside on a file called INITM030.LO, which is resident on the NDP Ready MTR floppy disk. To access these test routines, INITM030.LO must be downloaded from the NDP PCs floppy disk drive to the NDP Ready 68030 CPU PCBAs RAM. This can be accomplished by inserting the NDP Ready MTR disk into the 5 1/4 inch floppy disk drive and accessing the BOOTLOAD routine on the NDP Ready 68030 CPU PCBA. Use one of the following methods to access the NDP Ready 68030 CPU PCBA BOOTLOAD routine:
Reset the sorter. If the kernel tests and the AA gate tests of the system POC test successfully complete, the BOOTLOAD routine is automatically executed. Reset the sorter. If one of the AA gate tests in the system POC test fails the primary failure code screen display provides you with an option to LOAD MTR SOFTWARE. When you select function key F3 from this display, the BOOTLOAD routine is called. Access the debugger program in either of these ways:
Install the POC bypass jumper and reset the sorter. Select function key F4 DEBUGGER from the primary failure code screen if an AA gate POC test failure occurs. >.SR 2700 >G 10000DA
At the debugger prompt enter the following commands:
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This executes the BOOTLOAD routine and downloads the contents of the floppy disk.
Description of Disk-Based Tests

Following the downloading of the MTR file, INITM030.LO, a menu of available tests is presented on the PC screen, as shown in Figure 121.
MAINTENANCE TEST ROUTINE MAIN MENU Enter the desired selection then press <XMIT> 1 2 3 4 5 6 7 8 9 10 11 12 = = = = = = = = = = = = TRANSPORT TESTS NON-IMPACT ENDORSER TESTS MICROFILMER TESTS IMPACT ENDORSER TEST DISPLAY SCANS UTILITY GATE/LIGHT EXERCISER E13B MICR READER TESTS CMC7 MICR READER TESTS IMAGING MODULE TESTS HSOCR READER TESTS COURTESY AMOUNT READER TESTS DEBUGGER
Figure 121. Maintenance Test Routine Main Menu All menu options except DEBUGGER access diagnostic routines that exercise functional test modules within the sorter. When you make a selection from the main menu, a submenu is displayed for the test module that you chose. You then choose your desired diagnostic routine from the submenu.
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After you choose your diagnostic routine from the submenu, some of the test modules display a function key menu, as shown in Figure 122.
Select one of the following functions: <F8> AUTO SEQ. <F9> LOOP TEST <F10> EXECUTE ONCE <SPCFY> MENU
Figure 122. Function Key Test Mode Selection Menu AUTO SEQUENCE When you select AUTO SEQ., upon completion of the diagnostic routine that you chose from the test module submenu, the next test from the submenu is automatically executed. This continues until the last diagnostic routine listed on the submenu is executed. When the routine is completed, the test module submenu is displayed. LOOP TEST When you select LOOP TEST, the diagnostic routine that you chose from the test module submenu is repeatedly executed. At the conclusion of the routine, you are prompted to either press the F1 soft function key to return to the main menu or the F2 soft function key to return to the test module submenu. You then have 5 seconds to decide to exit the loop. If you do not enter F1 or F2 within 5 seconds, the diagnostic routine is rerun. LOOP TEST mode does not halt on error conditions. The error code is displayed for 5 seconds, along with the prompt from which you choose F1 or F2 to exit the loop. EXECUTE ONCE When you select EXECUTE ONCE, the diagnostic routine that you chose from the test module submenu is executed one time only. The following subsections provide information about each of the tests shown on the screen in Figure 1-2 and any subsequent menus.
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Transport Tests
When you select option 1 from the Maintenance Test Routine Main Menu (Figure 123), the menu shown in Figure 123 is displayed.
TRANSPORT TESTS MENU Enter the desired selection then press <XMIT> 1 = Sorter configuration test 2 = Beam of light bias test 3 = Pocket light/jam circuitry test 4 = Document flow test 5 = Reject window/beam of light timing test 6 = Feed error stress deck test 99 = Return to MTR main menu
Figure 123. Basic Tests Menu The six subtests within the basic tests check for constant status and exact results to the diagnostic stimuli. Be sure that you follow exactly the directions for the running of the tests that appear on the screen, or failure codes may be generated for failures that do not exist. The failure codes that appear on the screen when a test failure is detected lead to a failure diagnostic procedure that you must follow exactly to isolate the failure. In some cases a list of cards is called out for probable cause of the failure. This is usually done with the source card of the failed signal first and the signals fanout cards as a secondary suspect.
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Table 16 describes the functions of the Transport Tests. Table 16. Functions of the Subtests from the Transport Tests Menu
Subtest Sorter configuration test Beam of light bias test
Function Checks the configuration of system options and checks for power-on constants before the Start/Stop bar is pressed. Both hoppers must be empty and all interlocks closed. Checks for proper status after a Start/Stop bar is pressed with all interlocks closed and both hoppers empty. If the status is proper, the test continues by forcing bias levels at all BOLs and checking appropriate status. Next, all BOLs are forced ON for Areas A and B, and status for each location in both areas is checked. Checks first for the last pocket. It then checks Motor Up status and Ready. After the motors are ready, the test checks various statuses. Next it checks out the Pocket Light command and communication to the 4-pocket base plate assemblies by lighting pocket lights R, 0, 1, 2, 4, 8, and 16 in rapid succession and then lighting all lights in order at 1/2 second intervals. Checks for Ready and the ability to feed items from both feeders in a single item mode. Too Late to Pocket (TLTP), document data interrupts, pocket selection, gate operations, and proper document tracking timing are checked. Consists of the two parts of the Transport Margin Test. Part 1 verifies the Reject Window Override Control in areas 1 and 1B. This test ensures that all documents following the track error are sent to the reject pocket regardless of assignment. The statuses as a result of the track error are also verified (missort, missort location, feed error, MTWE location, etc.). Part 2 verifies that the speed between BOLs is within tolerance. There are 20 samples per BOL pair, and times out of tolerance are displayed on the cathode ray tube (CRT). Runs the Feed Error Test Deck (see Spec. 3125 6332) on the sorter. A running count of double documents, overlength documents, underspaced documents, mechanical window timing errors, almost feed errors, and black bands is kept. Any error counts that do not match the test deck are displayed on the NDP PC monitor.
Pocket light/jam circuitry test
Document flow test
Reject window/beam of light timing test
Feed error stress deck test
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Multi-Jet Endorser Tests

There are two nonimpact endorser systems supported by the NDP MTRs when running in the non-CAPI configuration. Both systems cannot be present at the same time. When the user selects "Nonimpact Endorser Tests" from the Maintenance Test Routines Main Menu, the sorter configuration is checked to determine which endorsement module is present. Based on this information the appropriate endorser system submenu is displayed. A description of each systems MTRs follows. The MJE Main Menu offers three options, as shown in Figure 124.
MJE MAIN MENU SELECT ONE OF THE FOLLOWING, THEN PRESS <XMIT 1 2 3 99 = = = = RUN TIME COMMANDS POC COMMANDS ENDED DIAGNOSTIC COMMANDS RETURN TO MAIN MENU
Figure 124. MJE Main Menu Select 99 to return to the Main Menu, or select one of the following options:
Option 1 2 3
Function Perform MJE run-time tests and operations. Refer to Figure 125 for the MJE Run Time Commands Menu. Perform MJE POC tests. Refer to Figure 126 for the MJE POC Commands Menu. Perform MJE extended diagnostic tests and operations. Refer to Figure 127 for the MJE Extended Diagnostics Commands Menu.
Note:
The DP 1825 Tests and Adjustments (T&As), the Special Engineering Instructions (SEIs), and the MJE Manual Procedures (found in Section 20) direct you to the appropriate menu and commands.
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MJE Run Time Commands Figure 125 shows the MJE Run Time Commands and Options Menus.
MJE RUN TIME COMMANDS SELECT ONE OF THE FOLLOWING, THEN PRESS <XMIT 1 SEND STATUS (81) 2 SEND ERRORS/WARNINGS (82) 3 BAR UP TO STATE XX (83) 4 BAR DOWN (84) 5 BAR UP - EYID CLOSED (85) 6 BAR CLEAN (86) 7 BAR EVACUATE (87) 8 ST BR STATE TABLE XX (88) 9 SET PHASE/VOLTAGE XX/YY (89) 10 READ PHASE/VOLTAGE (8A) 11 BAR TO LOW CROSS FLUSH (8C) 12 BAR TO SUPER TIM (8D) 13 BAR TO HIGH CROSS FLUSH (8E) 14 BAR TO READY TO PRINT (8F) MENU OPTIONS 15 16 17 99 POC COMMAND MENU ENDED DIAGNOSTIC COMMAND MENU RETURN TO MJE MAIN MENU RETURN TO MAIN MENU
Figure 125. MJE Run Time Commands Menu
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MJE POC Commands Figure 126 shows the MJE POC Commands and Options Menus.
MJE POC COMMANDS SELECT ONE OF THE FOLLOWING, THEN PRESS <XMIT 1 2 3 4 5 6 7 8 9 10 11 12 13 = = = = = = = = = = = = = RE-SYNC HO TEST (A0) TEST INTERRUPT ENABLE PORT (A1) TEST AC RAY DRIVERS (A2) TEST SOLENOIDS AND CATCHER HEATER DRIVERS TEST PRINT MODE CONTROL (A4) ERCISE 7-SEGMENT DISPLAY (A7) READ AND REPORT D SWITCH SETTINGS (A8) TEST SOLENOID MOTION (A9) TEST INK PUMP/TRANSDUCER (AA) EMERGENCY STOP INK SYSTEM TEST (AB) TEST POSITIVE AIR SYSTEM (AC) TEST VACUUM SYSTEM/STEPPER MOTOR (AD) TEST UMBILICAL (AE) MENU OPTIONS 14 15 16 99 = = = = RUN TIME COMMAND MENU ENDED DIAGNOSTIC COMMAND MENU RETURN TO MJE MAIN MENU RETURN TO MAIN MENU
(A3)
Figure 126. MJE POC Commands Menu
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MJE Extended Diagnostics Commands Figure 127 shows the MJE Extended Diagnostics Commands and Options Menus.
MJE EXTENDED DIAGNOSTIC COMMANDS SELECT ONE OF THE FOLLOWING, THEN PRESS <XMIT 1 2 3 4 5 6 = = = = = = RESET (80) RUN DIAGNOSTIC ROUTINE XX (B4 XX) STREAKER TEST MULTLE RE-SYNC HO TEST (A0) LED SEQUENCE TEST (A4, AE, AC) COLUMN PRINT MENU OPTIONS 7 8 9 99 = = = = RUN TIME COMMAND MENU POC COMMAND MENU RETURN TO MJE MAIN MENU RETURN TO MAIN MENU
Figure 127. MJE Extended Diagnostic Commands Menu
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1150 Multi-Jet Endorser Tests

The LCMJE Main Menu offers eight options, as shown in Figure 128.
LCMJE MODULE MAIN MENU SELECT ONE OF THE FOLLOWING FOLLOWED BY THE <XMIT KEY 1 2 3 4 5 6 7 8 99 = = = = = = = = = PRINT HEAD PRESENT TEST READ DOT COUNT UTILITY RESET DOT AND DOCUMENT COUNT UTILITY NON-VOLATILE RAM TEST HEAD PURGE TEST PRINT LOGIC TEST DUAL PORT RAM TEST FIRMWARE VERSION LEVEL UTILITY RETURN TO MAIN MENU
Figure 128. LCMJE Module Main Menu 1150 Multi-Jet Endorser Tests Print Head Present Test: This test detects if the print head is present. The user is prompted at the beginning of the test to choose which module to check, the front MJE or the rear MJE. This utility returns the most significant 8 bits of the 322 bit print fire dot counter. The user is prompted at the beginning of the utility to choose which module to check, the front MJE or the rear MJE. The information returned lets the user know the percentage of ink left in the ink cartridge.
Read Dot Count Utility:
Reset Dot and Document Count Utility: This utility resets the dot and document counter. The user is prompted at the beginning of the utility to choose which module to check, the front MJE or the rear MJE. Non-volatile RAM Test: The test verifies the write/read functionality of the non-volatile RAM. This test verifies the operation of the print head purge circuitry. During the test, ink is emitted from the head. The user is prompted at the beginning of the test to choose which module to check, the front MJE or the rear MJE.
Head Purge Test:
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Print Logic Test:
This test verifies the operation of the print logic circuitry by sending two blank columns of character data to the print driver board. The user is prompted at the beginning of the test to choose which module to check, the front MJE or the rear MJE. This test checks the write/read operation of the MJEs dual port RAM. This utility displays the version level of the MJE Interface PCBAs resident firmware. It also displays the date that the code was compiled on.
Dual Port RAM Test:
Firmware Version Level Utility:
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Microfilmer Tests
The microfilm MTR for the Unisys microfilmer is divided into many subroutines that exercise a specific area/module of the microfilm. When you select option 3 on the Maintenance Test Routine Main Menu (Figure 1-2), the menu shown in Figure 129 is displayed.
MICROFILM MTR MENU SELECT ONE OF THE FOLLOWING BY ENTERING A DIGIT <XMIT> 1 2 3 4 5 6 7 8 9 99 = = = = = = = = = = BASIC MICROFILM TESTS FILM TRANSPORT LAMP/ALMS ICM TEST GALVO TESTS ID DISPLAY HUMAN READABLE HEADERS CAPPING SHUTTER HARDWARE PARAMETER ADJUSTMENT ROUTINES RETURN TO MAIN MENU
Figure 129. Microfilm MTR Menu The following subsections show the menus for each routine and briefly describe each test. Note: It is not necessary to wait for the imaging module to complete if you select option 1, 2, or 4.
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Basic Microfilm Tests When you select option 1 from the Microfilm MTR Menu (Figure 129), the menu shown in Figure 130 is displayed.
BASIC MICROFILM TESTS MENU SELECT ONE OF THE FOLLOWING BY ENTERING A DIGIT <XMIT 1 2 3 4 5 6 7 = = = = = = = SYSTEM RUN CHK FOR "SYSTEM READY" BASIC FUNIONS TEST MICROFILM SCAN TEST HEIGHT BOL DATA COMM TEST QUIT TO MICROFILM MTR MENU
Figure 130. Basic Microfilm Tests Menu Table 17 describes the functions of the subtests from the Basic Microfilm Tests Menu. Table 17. Functions of the Subtests from the Basic Microfilm Tests Menu
Subtest SYSTEM RUN
Function This routine does not define faults using fault codes. This is a good place to start if the problem cannot be defined or if a customer is complaining of run-time problems. This subtest uses the same firmware to film documents as used in a normal run, but it films a small number of documents (approximately 1,000). It identifies run-time errors with appropriate messages that point to an area in the CCC table. You can take the necessary diagnostic steps. This routine is much the same as the SYSTEM RUN, only it looks for general Not Ready conditions without document flow. You can use it if you are trying to correct a Not Ready condition. Only one Not Ready condition is displayed at a time, and you can exit or loop to clear the condition. Again, no fault codes are displayed. You can use this routine as an initial entry to find a problem. This routine takes you through a few basic steps of operation of the sorter/microfilmer. Microfilm on/off is verified, lamps are checked for on/off only, motors are brought up, and microfilm is checked for signal. Either a fault code is displayed, or you are directed to another area of the MTR. This routine enables you to place a document in the optical gate and film it repeatedly. In this way you can check for vibrations in the galvo assembly. This routine diagnoses problems in the BOLs, determining if the fault lies with the BOL or with the control circuitry.
CHK FOR "SYSTEM READY"
BASIC FUNCTIONS TEST MICROFILM SCAN TEST HEIGHT BOL
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Table 17. Functions of the Subtests from the Basic Microfilm Tests Menu
Subtest DATA COMM TEST
Function Choosing this option executes DATACOMM LOOP TEST on the MIIB and Controller cards. Both cards have a loop test resident on the card. The MIIB is software controlled, whereas the controller test is started by pressing a button on the Controller card. Both are executed without the cable connected to isolate problems in this area.
Film Transport When you select option 2 from the Microfilm MTR Menu (Figure 129), the menu shown in Figure 131 is displayed.
MICROFILM FILM TRANSPORT TESTS SELECT ONE OF THE FOLLOWING FOLLOWED BY "XMIT": 1 = CAPSTAN MOTOR TEST 2 = LOOP ARM SENSOR TEST 3 = REEL MOTOR TEST 4 = IDLER ENCODER TEST 5 = SUPPLY ENCODER TEST 6 = RETURN TO MICROFILM MENU 99 = RETURN TO MAIN MENU
Figure 131. Microfilm Film Transport Tests Menu
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Table 18 describes the functions of the subtests from the Microfilm Film Transport Tests Menu. Table 18. Functions of the Subtests from the Microfilm Film Transport Tests Menu
Subtest CAPSTAN MOTOR TEST LOOP ARM SENSOR TEST RE MOTOR TEST IDLER ENCODER TEST SUPPLY ENCODER TEST
Function Can execute seven different moves, which can be looped or executed one at a time. This test executes with or without film. Tests the loop arm sensors by having you press the take-up and supply loop arms to ensure that each of the three sensors on both arms is activated. This test executes without film. Verifies that the reel motors operate correctly. This test executes without film. Tests the idler encoder by having you manually turn and check the idler encoder count. This test executes without film. Enables the supply encoder motor and verifies the supply encoder count. The test loops until you stop it. (An exception is a register failure. This will halt the test.)
Lamps/ALMs When you select option 3 from the Microfilm MTR Menu (Figure 129), you enable the Lamps/ALMs test. It verifies that the present lamp values are in range. It displays the values so that they can be verified as the desired values. Each lamp is turned on individually and verified. Then the ALM values are completed and compared against the NVRAM values to ensure that they are within range. ICM Test When you select option 4 from the Microfilm MTR Menu (Figure 129), you enable the ICM test. ICM 1 and ICM 2 are individually turned on and checked visually as well as electrically. Galvo Tests When you select option 5 from the Microfilm MTR Menu (Figure 129), you enable the Galvo test. The galvo routines have two parts:
Galvo Home routine Galvo Scan routine Finds the actual galvo home position and checks that it is in range ($20-60). Does a continuous loop of two scans: short (5 inch), followed by long (9 inch). The test is designed so that two scans fit on an oscilloscope trace. Errors detected are reported only after the test is stopped.
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ID Display When you select option 5 from the Microfilm MTR Menu (Figure 129), you enable the ID Display test. This routine has seven parts, some of which share functions:
Fixed ID pattern and Check fixed ID pattern Selectable ID pattern and Check selectable ID pattern results Turn on ID display with 0s Turn on ID display with blocks Exit this test Flow documents using a fixed pattern. Eight documents are fed for each of 12 patterns; 20 documents for a 13th pattern. Selection 1 flows the documents; selection 2 verifies that the IDs were correct. Allow you to choose the ID pattern and flow as many documents as desired.
Opens the capping shutter and displays zeros on the ID display. Opens the capping shutter and displays blocks on the ID display. Enables you to exit the test.
Human Readable Headers When you select option 7 from the Microfilm MTR Menu (Figure 129), you enable the Human Readable Headers test. Three characters are displayed that light up all dots and can be seen with film not loaded. The second part of this test flashes the complete character set on the header display. You must visually confirm that the character set is being displayed correctly. Capping Shutter When you select option 8 from the Microfilm MTR Menu (Figure 129), you enable the Capping Shutter test. The capping shutter is opened and shut and verified to be in the correct position using the sensors and a visual check.
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Hardware Parameter Adjustment Routines In any parameter routine that flows documents, the human readable header and (in most cases) the ID number are used to indicate what test value is being filmed. The human readable header also identifies the specific test that is being executed so that film can be referred to later and the module easily identified. The film is developed, and the appropriate measurements are taken. The list of settings are displayed whenever you choose to change any setting. When you select option 9 from the Microfilm MTR Menu (Figure 129), the menu shown in Figure 132 is displayed.
MICROFILM HARDWARE PARAMETER ADJUSTMENT ROUTINES SELECT ONE OF THE FOLLOWING FOLLOWED BY "XMIT": 1 = LAMP INTENSITY/DENSITY 2 = ALM ADJUSTMENT 3 = LED/TED 4 = ID DISPLAY INTENSITY 5 = GALVO ADJUSTMENT 6 = MODIFY NON-VOLATILE RAM VALUES 7 = RETURN TO MICROFILM MENU 99 = RETURN TO MAIN MENU
Figure 132. Hardware Parameter Adjustment Routines Menu Table 19 describes the functions of the options on the Hardware Parameter Adjustment Routines Menu. On the NDP 1000 Document Processor, before adjusting the parameters, you are prompted to select the film speed to be used. After you select either medium- or high-speed film, the Microfilmer Hardware Parameters Adjustment Routine menu is displayed. See Section 18 for more detailed instructions on running parameter routines.
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Table 19. Functions of the Hardware Parameter Adjustment Routines Menu
Option LAMP INTENSITY/DENSITY
Function Flows documents with varied lamp settings ($80-$E8 varied by $08). Each setting flows two documents and then goes into the next setting. The human readable header and UL display are used to identify the lamp setting on film. The ALM bypass jumper is in place. Is executed automatically after the LAMP routines or when chosen from the menu. The lamp is enabled at the present NVRAM lamp setting, and the front and rear A/D ALM values are read and put into NVRAM. No documents are fed, and you do not need to intervene. Adjusts both LED and TED values at the same time. Twenty documents per setting are flowed. After document flow and film processing, the desired values are entered. Both values are entered at the same time. Values are listed in milliseconds. Functions like the Lamp Intensity test. After document flow and film processing, the desired ID density value is entered. Settings are done in milliseconds and are entered as such. Each setting flows four documents. The difference in this routine is that the ID does not match the human readable header. The first two documents have an ID of 000xxx00. The second two documents have an ID of 111xxx11. This aids in distinguishing between intensities. Has two parts, either of which you can choose individually. The first part of the routine flows documents with the Galvo Home ByPass jumper in place. The Galvo home is set in a variety of settings, and 10 documents are flowed for each setting. The second part of the routine enables setting the Galvo Home sensor. After this is complete, the chosen home is verified against the actual home position. If the actual home is more than 4 counts off the chosen home, a message is given to redo either 1 or 2. For related information, see T&As 3304 4439 and 3304 4447 in the DP 1000/DP 1800 Cinemode Microfilmer Field Test and Reference Document. Enables you to display the current Hardware Parameter values, modify the values stored in nonvolatile RAM, and store the modified values into nonvolatile RAM.
ALM ADJUSTMENT
LED/TED
ID DISPLAY INTENSITY
GALVO ADJUSTMENT
MODIFY NONVOLATILE RAM VALUES
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Impact Endorser Test

When you select option 4 from the Maintenance Test Routine Main Menu (Figure 121) the menu shown in Figure 133 is displayed.
PEP/STAMP MTR MAIN MENU SELECT ONE OF THE FOLLOWING FUNCTIONS<XMIT> 1=ENDORSEMENT TESTS 2=STAMP HOME SENSOR TEST 3=STAMP MOTOR PHASE TEST 4=HOLE DETECT TEST 5=PRINT NEEDLE TEST 99=RETURN TO MAIN MENU DO NOT RUN THESE TESTS IN AUTO SEQUENCE. STAMP MOTOR PHASE TEST SHOULD ONLY BE EXECUTED WHEN INSTRUCTED VIA MANUAL PROC.
Figure 133. PEP/Stamp Endorser Tests Menu The PEP/stamp tests consist of five subtests to exercise the endorser functions. Whenever possible, fault codes and suspect modules are displayed on the screen.
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Table 110 describes the functions of the PEP/stamp endorser tests. Tests can be executed in singular mode or loop mode. None of the tests should be executed in auto sequence mode. Table 110. Functions of the Subtests from the PEP/Stamp Endorser Tests Menu
Subtest ENDORSEMENT TESTS
Function Enables you to select the mode of printing on a document. You have the option of selecting stamp only, printer only, or both endorsements. The routine prints in all zones. Any errors that occur are displayed on the screen. Flow continues until a hopper empty, a full pocket, or an error condition occurs. You must visually inspect the printed documents to confirm test results. Duplicates the POC test that attempts to home the stamp. The difference lies in the interpretation of the test results. In the disk-based test, you may be directed to visually check the movement of the stamp during the execution of the test. This aids in isolating the fault. Is two tests. The first test checks the phase drivers by pulsing all four motor phases, one at a time. You verify that the signal is present at the output of the driver circuitry for each phase. The second test prompts you to choose one of four phase currents: standby, low, medium, or high. The current level is applied to phase A. You then measure I1REF. Choose each current in increasing order to vary V1REF. Uses a special document that forces the hole condition. The MTR monitors the count and compares it with the expected results. This test verifies that all the print needles for character generator banks A, B, and C are functioning correctly. Eighteen documents are endorsed during the test, one for each print needle. The endorsed documents are labeled with the back (A, B, or C) and the print needle (1 - 6), from the bank being tested. The print needle under test is fired at various intervals so that a repeating pattern of dots is printed on the document. If the needle under test is jammed or firing continuously, flow is stopped and an error message is displayed identifying the needle. The 18 endorsed documents are sent to pocket 2 if no failures occur. As soon as the 18th document is endorsed, flow is stopped and the remaining documents in the track are sent to the reject pocket. If a failure occurs, flow is stopped and all documents remaining in the track are sent to the reject pocket. The document on which the error occurred is sent to pocket 2. If fewer than 18 documents are loaded into the primary hopper, a screen message tells the user that not enough documents were loaded to complete the test.
STAMP HOME SENSOR TEST
STAMP MOTOR PHASE TEST
HOLE DETECTION TEST
PRINT NEEDLE TEST
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Display Scans
This option is not currently available.
Gate/Light Exerciser
The Gate/Light Exerciser MTR is used to mechanically check and adjust the pocket selector gate position and throw. The first part of the exerciser opens all the pocket gates and enables all the pocket lights. You are then prompted to visually verify that all of the pocket gates are open and all the pocket lights are on. If this condition is not met, you are prompted to run Subtest 03 of the Transport MTRs. The second part of the exerciser closes all the pocket gates and disables all the pocket lights. It is executed regardless of the pass/fail status reported in part one. You are then prompted to visually verify that all the pocket gates are closed and all the pocket lights are off. If this condition is not met, you are prompted to run Subtest 03 of the Transport MTRs.
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E13B Magnetic Ink Character Recognition Test

The primary tool for diagnosing E13B character recognition problems double read, AC read, or DC read is the Magnetic Ink Character Recognition Stress Deck (#2758 2618) and the MICR test and adjustment found in the NDP Field Test and Reference Document . See T&A 2974 4901 or T&A 3304 4660 (for units equipped with the single-board DC MICR reader). If you suspect MICR reader problems and the MTR fails to detect a problem, you should verify the adjustments in accordance with those T&As, and you should run the Character Recognition Stress Deck in all three read modes. When you select option 7 from the Maintenance Test Routine Main Menu (Figure 121), the menu shown in Figure 134 is displayed.
E13B MICR READER TESTS Enter the desired selection then press <XMIT> 1 = AC Reader Tests 2 = DC Reader Tests 99 Return to MTR Main Menu
Figure 134. E13B MICR Reader Tests Menu The following subsections discuss the AC and DC MICR reader options.
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AC Reader Tests When you select option 1 from the E13B MICR Reader Tests Menu (Figure 134), the AC Reader Tests Menu is displayed, as shown in Figure 135.
AC READER TESTS Enter the desired selection then press <XMIT> 1 2 3 4 5 6 7 8 9 10 11 12 99 = = = = = = = = = = = = = START CONFIDENCE TESTS PROCESSOR TEST RESULT PROM TEST MAINTENANCE REGISTER TEST QUANTIZER TEST SEGMENTATION TEST MCR TEST FIFO TEST MAINTENANCE RAM TEST ANALOG BOARD TEST CAPTURE IMAGE-NEXT DOCUMENT CAPTURE IMAGE-REJECT DOCUMENT RETURN TO MTR MAIN MENU
Figure 135. AC Reader Tests Menu
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Table 111 describes the subtests from the AC Reader Tests Menu. Table 111. Functions of the Subtests from the AC Reader Tests Menu
Subtest START CONFIDENCE TESTS PROCESSOR TEST RESULT PROM TEST MAINTENANCE REGISTER TEST QUANTIZER TEST SEGMENTATION TEST MCR TEST
Function Starts execution of subtests 02 through 10. If any test fails, the appropriate fault code is displayed. Checks the operation of the recognition processor and its PROM. Validates the contents of the Test Result PROM. Verifies the operation of the maintenance input and output registers, multiplexors, and some address decoding. Verifies the functional operation of the quantizer circuit. Verifies proper operation of the segmentation state machine. Exercises the Magnetic Card Reader (MCR) Large Scale Integration (LSI) chip in three ways: an internal self-test, character image patterns, and functional exercises. Verifies the operation of the recognition First In First Out (FIFO). Verifies the operation of the Maintenance RAM used during capture modes. Checks for activity on each of the ten channels of the analog board. It looks only for activity and does not make quality measurements. Captures the document data from the next document in the primary hopper. The data is displayed as the read head sees it, individually displaying each channel. Data can be displayed in two ways: a single character or all the characters read. Captures the data on the next document containing a reject character. Data can be displayed in the same manner as for subtest 11.
FIFO TEST MAINTENANCE RAM TEST ANALOG BOARD TEST CAPTURE IMAGE NEXT DOC
CAPTURE IMAGE REJECT DOC
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DC Reader Tests The DC single-board MICR reader, which resides in card slot 13 of the sorter, has logic, switches, and LEDs specifically implemented for diagnostic purposes. Although you can use any type E13B documents for the test, for maximum fault detection you should use 2730 5192 low-level test documents when running this MTR. When you select option 2 from the E13B MICR Reader Tests Menu (Figure 134), the DC Reader Tests Menu is displayed, as shown in Figure 136.
DC READER MTR MENU SELECT ONE OF THE FOLLOWING FOLLOWED BY "XMIT": 1 = SCAN A SINGLE DOCUMENT 2 = SCAN DOCUMENTS UNTIL A REJECT IS DETECTED 3 = SCAN AND COMPARE DOCUMENTS 99 RETURN TO MAIN MENU
Figure 136. DC Reader Tests Menu
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Table 112 explains the options on the DC Reader MTR Test Menu. Table 112. DC Reader Tests Menu Options
SCAN A SINGLE DOCUMENT A single item is fed from the sorters primary hopper to pocket 0. When the item passes the DC read head, the MICR line is read, and the data is processed. The resultant MICR line information is returned to the MTR program, which displays it on the sorter screen. At that time, a message appears on the screen requesting that you compare the data displayed on the screen with the MICR line of the item in pocket 0. A question requiring a Yes/No response is displayed asking whether the two compared. If the two do not compare, an error code directs you to the manual procedures. Items are flowed from the primary hopper to pocket 0 until a reject item is detected. When a reject is found, that item and all subsequent items in the track are sent to the reject pocket, and flow is halted. The MICR line of the rejected item is displayed along with a message that a reject has been found or that an illegal character has been detected. An error code is displayed to direct you to a manual procedure. If no rejects are encountered, all except the last three documents are sent to pocket zero. The last three are sent to the reject pocket. Initially a single item fed from a test deck you placed in the sorter primary hopper is scanned. It sends that item to pocket 0. The resultant MICR line information is returned to the MTR program, which displays it on the sorter screen. In addition, a message is displayed requesting that you compare the data displayed on the screen with the MICR line of the item in pocket 0. A question requiring a Yes/No response on whether the two compared is also displayed. If the two do not compare, you have the option to try again or to exit to the DC Reader MTR Test Menu. If they do compare, the test proceeds as follows. You are requested to initiate flow of the remaining items in the sorter primary hopper. The items are scanned by the DC MICR reader and deposited into pocket 0. The MICR data read from each item is compared with the data read from the first item fed. When an invalid comparison occurs, the reject item and all subsequent items in the track are deposited in the reject pocket, and flow is halted. The MICR line of the rejected item is displayed along with the verified MICR data scanned from the first item. An error code is also displayed to direct you to the appropriate path of action by using the manual procedures. If no rejects are encountered, all except the last three documents are sent to pocket zero. The last three are sent to the reject pocket.
SCAN DOCUMENTS UNTIL A REJECT IS DETECTED
SCAN AND COMPARE DOCUMENTS
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CMC7 MICR Reader Tests

The CMC7 single-board MICR reader, which resides in card slot 13 of the sorter, has an 8035 microcontroller and associated logic, switches, and LEDs specifically implemented for diagnostic purposes. The 8035 microcontroller has an on-board self-test that is invoked automatically when the sorter is powered on or reset. Also, you can invoke it by selecting the appropriate switches (refer to SEI 3304 3688). The only function of this built-in test is to verify that the microcontroller and the LEDs are operational. It does not test the head or the MICR processing logic. The test results are reported back visually through the LEDs. Although you can use any type CMC7 documents for the test, for maximum fault detection you should use high-level and low-level signal documents 3126 8931 and 3126 8923 when running this MTR. When you select option 8 from the Maintenance Test Routine Main Menu (Figure 121), the menu shown in Figure 137 is displayed.
CMC7 MTR TEST MENU SELECT ONE OF THE FOLLOWING FOLLOWED BY "XMIT": 1 2 3 99 = = = = SCAN A SINGLE DOCUMENT SCAN DOCUMENTS UNTIL A REJECT IS DETECTED SCAN AND COMPARE DOCUMENTS RETURN TO MAIN MENU
Figure 137. CMC7 MTR Test Menu Note: The new CMC7 Reader (PCBA 4331 8658-xxx) uses the same CMC7 Test Menu as above. The PCBA is located in slot #11 in the AA-Gate.
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Table 113 explains the options on the CMC7 MTR Test Menu. Table 113. CMC7 MTR Test Menu Options
Option SCAN A SINGLE DOCUMENT
Function A single item is fed from the sorters primary hopper to pocket 0. When the item passes the CMC7 reader head, the MICR line is read, and the data is processed. The resultant MICR line information is returned to the MTR program, which displays it on the sorter screen. At that time, a message appears on the screen requesting that you compare the data displayed on the screen with the MICR line of the item in pocket 0. A question requiring a Yes/No response is displayed asking whether the two compared. If the two do not compare, an error code directs you to the manual procedures. Items are flowed from the primary hopper to pocket 0 until a reject item is detected. When a reject is found, that item and all subsequent items that are in the track are sent to the reject pocket, and flow is halted. The MICR line of the rejected item is displayed along with a message that a reject has been found or that an illegal character has been detected. An error code is displayed to direct you to a manual procedure. If no rejects are encountered, all except the last three documents are sent to pocket zero. The last three are sent to the reject pocket. Initially a single item fed from a test deck you placed in the sorter primary hopper is scanned. It sends that item to pocket 0. The resultant MICR line information is returned to the MTR program, which displays it on the sorter screen. In addition, a message is displayed requesting that you compare the data displayed on the screen with the MICR line of the item in pocket 0. A question requiring a Yes/No response on whether the two compared is also displayed. If the two do not compare, you have the option to try again or to exit to the CMC7 MTR Test Menu. If they do compare, the test proceeds as follows. You are requested to initiate flow of the remaining items in the sorter primary hopper. The items are scanned by the CMC7 MICR reader and deposited into pocket 0. The MICR data read from each item is compared with the data read from the first item fed. When an invalid comparison occurs, the reject item and all subsequent items in the track are deposited in the reject pocket, and flow is halted. The MICR line of the rejected item is displayed along with the verified MICR data scanned from the first item. An error code is also displayed to direct you to the appropriate path of action by using the manual procedures. If no rejects are encountered, all except the last three documents are sent to pocket zero. The last three are sent to the reject pocket.
SCAN DOCUMENTS UNTIL A REJECT IS DETECTED
SCAN AND COMPARE DOCUMENTS
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Imaging Module Tests

There are two imaging systems supported by the NDP MTRs when running in the non-CAPI configuration. Both systems cannot be present at the same time. When the user selects "Image Module Tests" from the Maintenance Test Routines Main Menu, the sorter configuration is checked to determine which imaging system is present. Based on this information the appropriate imaging system submenu is displayed. A description of each systems MTRs follows. U4/JPEG Imaging Module When you select option 10, Image Module Tests, from the MTR Main Menu (Figure 121), and the system has a U4/JPEG Imaging Module, the menu shown in Figure 138 is displayed.
IIPS MAINTENANCE TEST ROUTINES SELECT IM UNIT TEST 1> 2> 3> 4> 5> 6> 7> 8> 9> F1>
MTR039
SELECT/DE-SELECT EXTENDED POWER ON CONFIDENCE TESTS POC EXECUTION / DEFAULT FLAG SELECTION COMMUNICATION LINK TEST IIB INTERFACE TEST IM LAMP SUPPLY TEST TURN IM LAMP ON TURN IM LAMP OFF VIEW CURRENT POC RESULTS CALIBRATE THE SCANNER RETURN TO MAIN MTR MENU
Figure 138. IIPS Maintenance Test Routines: Select IM Unit Test Menu The functions of the options on this menu are presented in the subsections below. Almost all the options on the menu are also available when you invoke the IS exerciser program from a host NDP console or a workstation. The submenus and screens that are presented when you select any of these choices are shown in Appendix B, "Maintenance Test Routine (MTR) Program Screens," of the Image Item Processing System Servicing Guide: Maintenance. The two options that are not available from a host terminal are option 4, IIB Interface Test, and option 9, Calibrate the Scanner. The "IIB Interface Test" later in this subsection describes the Datacomm Loopback MTR Menu options and screen operations for option 4. Calibration of the scanner is selected on the sorter, but the manual procedures related to it are covered in Section 6 of the Image Item Processing System Servicing Guide: Maintenance.
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Following the discussion of the imaging module test options, this subsection presents an example of a procedure for selecting specific power-on confidence tests. It then reviews sources of additional information regarding unit operation. Select/De-select Extended Power On Confidence Tests Option 1 on the IIPS MTR Select IM Unit Test Menu (Figure 138), Select/De-select Extended Power On Confidence Tests, enables you to select specific extended POC tests for the imaging module 286 Main Processor board, the POL board, or the DTI board. The system records your test requests in NVRAM, which resides on the POL board. The values are pointers to the Optional Extended tests, which run during the next power-on confidence test. Refer to "Selecting and Executing POC Tests" later in this section for a description of the submenu options that display when you choose Select/De-select Extended Power On Confidence Tests. POC Execution / Default Flag Selection Option 2 on the IIPS MTR Select IM Unit Test Menu (Figure 138), POC Execution / Default Flag Selection, runs on the Main Processor PWBA in the imaging module. It enables you to
Restore the default POC test selection after the presently selected POC tests have been executed Keep the current POC selection in nonvolatile memory as the new default test set for the next POC execution Execute the selected POC tests
POC execution causes a hard reset of the imaging module hardware under software control. The default flag selection option causes POC test selections in NVRAM to be permanent or temporary. Refer to "Selecting and Executing POC Tests" later in this section for a description of the POC Execution / Default Flag Selection screen options. Communication Link Test Option 3 on the IIPS MTR Select IM Unit Test Menu (Figure 138) runs the Communication Link test on the Main Processor PWBA in the imaging module. This test checks communication links between the test requester and the imaging module. IIB Interface Test Option 4 on the IIPS MTR Select IM Unit Test Menu (Figure 138), IIB Interface Test, executes the Parallel Interface Loopback test and the Serial Interface Loopback test on the MIIB PWBA in the imaging module. Both tests use loopback connectors on the MIIB or interconnect cables to test the appropriate interface's ability to transmit and receive data. The connectors loop back data patterns transmitted by the MIIB to the MIIB receive circuitry. A pass/fail status message is displayed on the sorter screen.
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When you select option 4, the Datacomm Loopback MTR Menu is displayed. Table 114 explains the options available on this menu. Table 114. Datacomm Loopback MTR Menu Options
Option Parallel Interface Loopback test
Function The Parallel Interface Loopback test exercises the parallel interface cable between the MIIB and the DTI boards. A series of screen messages indicates loopback connector options. You make a keyboard entry to select the desired option, the test executes, and a pass/fail status message is displayed on the sorter screen. The Serial Interface Loopback test exercises the serial interface cable between the MIIB and the DTI boards. A series of screen messages indicates loopback connector options. You make a keyboard entry to select the desired option, the test executes, and a pass/fail status message is displayed on the sorter screen.
Serial Interface Loopback test
IM Lamp Supply Test Option 5 on the IIPS MTR Select IM Unit Test Menu (Figure 138), IM Lamp Supply Test, turns the image system lamps on and off and checks various status registers to verify that the lamps are functioning correctly. This test runs on the Diagnostic and TRANSPORT Interface PWBA in the imaging module. If the status is positive, a "test passed" message is displayed on the sorter screen. If the status is negative, an error message is displayed. Turn IM Lamp On Option 6 on the IIPS MTR Select IM Unit Test Menu (Figure 138), Turn IM Lamp On, turns on the xenon lamp in the imaging module. This test runs on the Diagnostic and TRANSPORT Interface PWBA in the imaging module. You run this test when the IM Lamp Supply Test indicates an error. When you select this test, a message instructs you to verify visually that the imaging lamps are on. After the check, you are prompted to return to the image MTR menu. Turn IM Lamp Off Option 7 on the IIPS MTR Select IM Unit Test Menu (Figure 138), Turn IM Lamp Off, turns off the xenon lamp. This test runs on the Diagnostic and TRANSPORT Interface PWBA in the imaging module. You run this test when the IM Lamp Supply Test indicates an error. When you select this test, a message instructs you to verify visually that the imaging lamps are off. After the check, you are prompted to return to the image MTR menu. View Current POC Results Option 8 on the IIPS MTR Select IM Unit Test Menu (Figure 138), View Current POC Results, enables you to see the results of the imaging system's POC tests. The imaging
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system runs a series of tests during power-on. When an error occurs, the error code is placed in a buffer. Only the first error that occurred is displayed at the end of the sorters POC test. If multiple image POC errors occur, you can view all the error codes using this option. Calibrate the Scanner Option 9 on the IIPS MTR Select IM Unit Test Menu (Figure 138), Calibrate the Scanner, enables you to calibrate the image scanner when problems arise with image quality. Note: Refer to Section 6, error code line 10300, of the IIPS Maintenance Manual for more information about the Calibrate Scanner routine. Refer to Appendix J of the same manual for a discussion of procedures related to image quality.
Selecting and Executing POC Tests To select and execute POC tests, you use the first two options on the IIPS MTR Select IM Unit Test Menu (Figure 138). You use option 1, Select/De-select Extended Power On Confidence Tests, to specify the imaging module board to be tested and to select the specific tests to be executed for that board. You use option 2, POC Execution / Default Flag Selection, to save test selections or accept default tests before the tests execute. Each test set contains tests specific to the selected board.
Direct, single execution tests execute on the board and test the board only once. Direct, multiple execution tests execute on the board and can be selected so that one test runs a multiple number of times. Note: Only one multiple execution test can be run per board at any one time.
Indirect single execution tests execute on the board, test parts of the module other than the board, and test the board only once. Note: The POL and DTI Boards do not run indirect tests.
Indirect multiple execution tests execute on the board, test parts of the module other than the board, and can be selected so that one test runs a multiple number of times. Note: Only one multiple execution test can be run per board at any one time.
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Default POC tests are system-specified tests that always run unless deselected. Deselection is discussed in step 6 of the following procedure. The following is a sample of the procedural steps required to select imaging module board tests. 1. Select option 1 from the IIPS MTR Select IM Unit Tests Menu. The menu shown in Figure 139 is displayed.
IIPS MAINTENANCE TEST ROUTINES
MTR039
SELECT IM BOARD TYPE FOR EXTENDED POC TEST SELECTION SELECT/DESELECT POC TESTS FROM ONE OF THE FOLLOWING IM BOARD TESTS SETS 1 2 3 4 5 = = = = = 286 MAIN PROCESSOR BOARD POL BOARD DTI BOARD RETURN TO PREVIOUS MENU RETURN TO MAIN MENU
Figure 139. IIPS Maintenance Test Routines Select IM Board Type Menu 2. Press the number associated with the board you wish to test, and press the Xmit key. This example assumes that you choose option 1. In this case, the system displays the test sets for the 286 Main Processor board.
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The menu shown in Figure 140 is displayed.
IIPS MAINTENANCE TEST ROUTINES SELECT 286 MAIN PROCESSOR EXTENDED POC TEST SET DIRECT TEST - TESTS THE BOARD IT EXECUTES ON INDIRECT TEST TESTS HARDWARE OTHER THAN THE BOARD IT EXECUTES ON 1 = SELECT DIRECT SINGLE EXECUTION 286 MAIN PROCESSOR EXTENDED POC TEST SET 2 = SELECT DIRECT MULTLE EXECUTION 286 MAIN PROCESSOR EXTENDED POC TEST SET 3 = SELECT INDIRECT SINGLE EXECUTION 286 MAIN PROCESSOR EXTENDED POC TEST SET 4 = SELECT INDIRECT MULTLE EXECUTION 286 MAIN PROCESSOR EXTENDED POC TEST SET 5 = SELECT DEFAULT 286 MAIN PROCESSOR POC (TESTS NORMALLY EXECUTED) 6 = RETURN TO PREVIOUS MENU 7 = RETURN TO MAIN MENU
Figure 140. IIPS Maintenance Test Routines: Select 286 Main Processor Extended POC Test Set Menu 3. Press the number associated with the test set for which you want to select tests, and press the Xmit key. This example assumes that you choose option 1 to view the contents of the direct single execution 286 Main Processor Board test set. The menu listing the 25 tests in the direct single execution 286 Main Processor Board test set is displayed. Note: 4. 5. This menu appears in Appendix B of the IIPS Maintenance Manual as MTR042.
Press the number associated with the test you want to select, and press the Xmit key. Deselect any currently selected test that you do not want by entering the number associated with the test and pressing the Xmit key. The asterisk next to the test disappears, indicating that the test is no longer currently selected.
6.
Repeat steps 4 and 5 until all desired tests are selected.
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Note:
Unless an on-screen message indicates otherwise, you may select as many tests as are listed. In this test set, the menu indicates that only 18 tests can be selected.
Once you have selected all desired tests for this board, follow the next series of steps to select tests for another imaging module board. 7. Type 0 (zero), and press the Xmit key. The test set selection screen is redisplayed. In this case, the Select 286 Main Processor Extended POC Test Set reappears. (Refer to Figure 140.) 8. Choose one of these options:

9.
To select another test set, repeat steps 3 through 7. If you do not wish to select another test set, proceed to step 9.
Select the number associated with Return to Previous Menu, and press the Xmit key. Note: For this sample procedure, you would select number 6. The Select IM Board Type Screen (Figure 139) reappears.
10. Press the number associated with the next desired imaging module board, and press the Xmit key. 11. Repeat steps 3 through 9 until you have selected all desired tests. When all desired tests are selected and you are ready to execute the tests, proceed to step 12. 12. Select option 5 (Return to Main Menu) on the Select IM Board Type Menu (Figure 1 39). The IIPS Maintenance Test Routines Select IM Unit Tests Menu (Figure 138) is displayed. 13. Select option 2, POC Execution / Default Flag Selection. The Power On Confidence Execution Menu is displayed, as shown in Figure 141.
POWER ON CONFIDENCE EXECUTION SELECT ONE OF THE FOLLOWING FOLLOWED BY "XMIT": 1 = *SET DEFAULT FLAG (RESTORE DEFAULT POC TESTS AFTER POC EXECUTION) 2 = RESET DEFAULT FLAG (LEAVE CURRENT POC SELECTION INTACT) 3 = EXECUTE POC 4 = RETURN TO PREVIOUS MENU
Figure 141. Power On Confidence Execution Menu 14. Decide if you want the system to save your test choices after the tests execute for use in the next POC function.
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Note:
You must make this decision before you execute the selected tests.
The Power On Confidence Execution Menu has the following options. An asterisk next to either option 1 or option 2 indicates which option is currently selected:
Option 1, Set Default Flag, restores the system-specified default tests and deletes any additional tests you selected after POC execution. Select 1 if you wish to restore only the default POC tests after POC execution for use in the next POC function.
Option 2, Reset Default Flag, leaves your test selections intact. The system does not delete the test set you selected. Select 2 if you wish to keep the current test selections intact after POC execution for use in the next POC function. Note: If the option you desire is already selected, skip to step 16.
15. Press the number associated with the desired option, and press the Xmit key. The asterisk moves to the option you selected. 16. Select 3 and then press the Xmit key to execute the imaging module POC tests.
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Dual Imaging Module When you select option 10, Image Module Tests, from the MTR Main Menu (Figure 121), and the system has a Dual Imaging Module, (Figure 121), the menu shown in Figure 142 is displayed.
DUAL IMAGE MODULE MAIN MENU
Select one of the following followed by the "XMIT" key 1 2 3 4 5 99 = = = = = = Calibrate Front Camera Calibrate Rear Camera Run Front Lamp Run Rear Lamp Loop Back Test Return to MTR Main Menu
Figure 142. Dual Image Module Main Menu The functions of the options on this menu are presented in the following subsections. Calibrate Front Camera This MTR creates information used to compensate for the analog and optical variations in the front digitizer and camera combination. The results for this MTR are stored on the ICS hard drive in C:\dpimage\frontX.cfg and C:\dpimage\frontX.tbl. The image control program uses these data files during document flow for setup of the normalizer/framer and camera/digitizer. Calibrate Rear Camera This MTR creates information used to compensate for the analog and optical variations in the rear digitizer and camera combination. The results for this MTR are stored on the ICS hard drive in C:\dpimage\rearX.cfg and C:\dpimage\rearX.tbl. The image control program uses these data files during document flow for setup of the normalizer/framer and camera/digitizer. Run Front Lamp This MTR enables you to turn the front lamp on and off to visually verify that it is working. Run Rear Lamp This MTR enables you to turn the rear lamp on and off to visually verify that it is working. Loop Back Test This test must be executed with the PCI cable disconnected from the DIIM PCBA and the dual image PC. This test verifies the FIFOs are functioning properly.
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HS OCR Reader Tests

When you select option 10, HS OCR Reader Tests, from the MTR Test Main (Figure 121), the menu shown in Figure 143 is displayed.
OCR READER SYSTEM MAIN MENU TESTING OCR #1 SELECT ONE OF THESE OPTIONS FOLLOWED BY <XMIT 1 2 3 OCR MAINTENANCE TEST ROUTINES OCR READER UTILITIES TRANSPORT OPERATIONS
PRESS <SPCFY> TO RETURN TO THE DP 1X00 MAIN MTR MENU
Figure 143. OCR Reader System Main Menu The functions of the options on this menu are presented in the following subsections.
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OCR Maintenance Test Routines Option 1 on the OCR Reader System Main Menu enables you to execute the following options.
Option Camera elevator test Lamp test Rerun OCR reader POC tests
Function Checks the elevator lock sensor, exercises the elevator motor, and verifies the elevator travel limit circuitry. Tests the functionality of the OCR reader lamp. Enables you to rerun either a single test from the OCR reader POC or the entire OCR reader POC. A "loop mode" is available that continually reruns a single test or the entire POC. Verifies the functionality of the BOL E circuitry by having you cover or uncover BOL E while checking for the correct BOL E status on the OCR reader. Uses an RS-232 loopback connector to exercise the laptop PC interface on the OCR readers CPU board. It writes the test data to the interface and reads it back to verify the functionality of the interface.
BOL E test
PC port test
OCR Reader Utilities Option 2 on the OCR Reader System Main Menu provides the following options.
Option Display OCR reader POC error log Edit non-volatile RAM Display current OCR status
Function Displays the 10 most recent OCR reader POC errors stored in NVRAM Enables you to initialize the OCR readers NVRAM and edit the parameters stored in it Displays the current status of the OCR reader registers
Transport Operations Option 3 is currently not available.
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CAR Module Tests

There are two CAR modules supported by the NDP MTRs when running in the non-CAPI configuration. Each CAR module is designed to work with one of the two imaging systems: U4/JPEG imaging module or dual imaging module. CAR Module Tests (U4/JPEG Imaging System) The CAR MTRs that are accessible from the Maintenance Test Routine Main Menu, are for the U4/JPEG imaging module CAR system. When you select option 11, CAR Interface Tests, from the Maintenance Test Routine Main Menu (Figure 121), the CAR System MTR Test Menu is displayed, as shown in Figure 1 44.
CAR SYSTEM MTR TEST MENU Press the appropriate number, then press <XMIT. 1 2 3 4 5 99 EXECUTE THE CONTROL INTERFACE TEST RETRIEVE THE CAR UNIT POC TEST RESULTS EXECUTE THE CAR UNIT RECOGNIZE TEST IMAGE TEST RETRIEVE THE CAR UNIT STATUS RUN THE CAR TEST DECK WITHOUT POWERING DOWN Return to the main menu.
Figure 144. CAR System MTR Test Menu The following subsections describe the options on the CAR System MTR Test Menu and outline the procedures for using them. Note: It is not necessary to wait for the Image Module POC test to complete if option 1, 2, or 4 is selected.
Control Interface Test When you select option 1 from the CAR System MTR Test Menu (Figure 144), the system displays instructions for executing the Control Interface Test. This test determines whether a communications link can be established over the SCSI Control Interface, which is the interface between the document processor and the CAR module.
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Press the F1 key to return to the CAR System MTR Test Menu without executing the Control Interface Test, or press the Spcfy key to execute the test. The test executes very quickly. The system displays a result screen displaying a success or failure message. If an error message is displayed, refer to error/status code lines in the CAR Module section of this book. Retrieve CAR Unit POC Test Results When you select option 2 from the CAR System MTR Test Menu (Figure 144), the system displays instructions for retrieving CAR module POC test results: 1. 2. 3. 4. Turn the CAR module OFF. Wait 5 seconds. Turn the CAR module back ON. Press the Spcfy key. The system displays this message: "Waiting 60 seconds for the CAR Unit to complete POC." Once that test is completed, the system displays a message stating that the tests have passed successfully or an error message identifying units that did not pass the POC tests. 5. Press the Spcfy key again to return to the CAR System MTR Test Menu (Figure 144).
CAR Unit Recognize Test Image Test The Image Test using the USBI classifier is part of the system exerciser. Refer to the NDP/DP1000/DP1825 Servicing Guide: Analysis and Test Software for information on running the test. Retrieve CAR Unit Status Option 4 displays the current CAR module operating state, the character recognition units (CRUs) that are enabled, and information about any error conditions that may be present on the CAR module. When you select option 4 from the CAR System MTR Test Menu (Figure 144), the system displays instructions for retrieving the CAR module status. Press the F1 key to return to the CAR System MTR Test Menu without retrieving CAR status, or press the Spcfy key to retrieve the information.
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Running the CAR Test Deck When you select option 5 from the CAR System MTR Test Menu (Figure 144), the system displays instructions for loading the CAR exerciser disk to run the CAR Test Deck without powering down the document processor. This saves time because the document processor, IM, and CAR POC tests do not have to be repeated. The test deck enables you to test the CAR module read results. Press the F1 key to return to the CAR System MTR Menu (Figure 144) without running the CAR Test Deck, or follow these steps to load the Exerciser without powering down: 1. 2. 3. 4. 5. Display the Unit Manager and select Disable. Minimize the Unit Manager. Select F12 under the heading BOOT. Select SCP as the default program to boot. Select OK. Select Debugger by typing 12 and pressing the Xmit key. Observe the prompt at the bottom of the screen. It should display the following: NDP 030BUG 2.0 6. Place the cursor at the top left of the screen, type the following (in all caps), and press the Xmit key. G 10000DA This takes the system into the load routine for loading the system software. 7. Run the CAR test deck as directed by the NDP/DP1000/DP1825 Servicing Guide: Analysis and Test Software.
CAR Module Tests: Dual Imaging System The MTRs for the dual imaging module CAR system are not accessible from the Maintenance Test Routine Main Menu. These MTRs are run from the ICS PC. See Section 25, "CAR Diagnostic Procedures (Dual Image System) for details.
DEBUGGER
When you select the DEBUGGER option from the Maintenance Test Routine Main Menu (Figure 121), the debugger routine is accessed. For details on the debugger, see the "NDP Debugger Program" description in the "Maintenance Test Routine Tests," earlier in this section.
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Description of Additional Information (Non-CAPI Configuration)

In addition to the tests already described, you can also use the character recognition stress deck, the CCC table, the Snapshot utility, and the list of machine check error codes.
Character Recognition Stress Decks

Two character recognition stress decks contain many different types of documents designed to test the performance of the MICR and OCR readers. MICR stress deck documents test the performance of both the AC multitrack and DC E13B MICR readers. The OCR recognition stress deck tests the performance of the OCR1 and OCR2 readers. These decks are powerful tools to maintain proper read system performance and to help diagnose faults. The decks should be used as a part of normal PM and whenever a read problem is suspected. Refer to the NDP/DP 1000/DP 1825 Servicing Guide: Analysis and Test Software for information about how to run the MICR recognition (MCRR) program and for a detailed procedure for using the MICR recognition stress deck. Also, refer to T&A 3304 4660 in the NDP Field Test and Reference Document for diagnosis of errors and for adjustments. Refer to the DP 1800 OCR Reader Installation and Servicing Guide for information about the OCR recognition stress deck and instructions for running the OCR recognition (OCRR) test.
Condition, Cause, Correction (CCC) Table

The CCC table provides a list of failure conditions that do not display a failure code if a failure occurs during the POC tests or when a failure is detected that does not have an obvious correction. A complete CCC table is in Section 13. Notes:
The CCC table for imaging system conditions is in the Image Item Processing System (IIPS) Maintenance Manual. The CCC table for the OCR reader is in the DP 1800 OCR Reader Installation and Servicing Guide.
Snapshot
SNAPSHOT is a field engineering tool that enables you to examine relevant data regarding unit operation. A complete description of SNAPSHOT and its application is in the NDP/DP 1825 Servicing Guide: Analysis and Test Software.
Machine Checks
A list of the Machine Check Error Codes is in Section 15 of this document.
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Section 2 Power-On Confidence Tests

This section provides manual procedures covering AA gate, microfilmer, and PEP/stamp Power On Confidence (POC) error codes. 00000 NO ERROR STATUS DISPLAYED
The procedures for line numbers 00000 through 10000 cover POC Test errors that do not result in the display of an error status on the NDP PCs display monitor. A critical error condition has occurred if two minutes after powering on the NDP, no message describing the status of the POC tests has been displayed. At this point, the CSE should inspect the MTR LEDs on the NDP030 CPU PCBA (card AA17). The MTR LEDs are labeled on the PCBA and are read from top (least significant bit) to bottom (most significant bit). LEDs that are "on" are interpreted as logical ones. Those that are "off" are interpreted as logical zeroes. The LED patterns are hexadecimal codes that indicate which NDP030 CPU PCBA POC test failed prior to the establishment of SCSI communications with the PC. Table 21 indexes the LED codes to fault descriptions. The procedure for diagnosing and correcting the error starts on the following page. Table 21. LED Fault Code Conditions: NDP030 CPU PCBA
LED Fault Code (Hex) 01 02 03 04 05 06 07 08 09 0A CPU test failure
Fault Description
Bus trap accessing RAM in address range: $0000 - $003F FFFF RAM memory configuration test failure. RAM write/read test failure. EPROM checksum test failure. RAM address line test failure. RAM parity test failure. Privilege exception test failure. Dead Bus Timer test failure. Programmable Timer Module failure.
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Table 21. LED Fault Code Conditions: NDP030 CPU PCBA
LED Fault Code (Hex) 0B 0C 10 11 12 13 14 15 16 17 20 30 40 50 60 70 F1 F2 F3 F4 F5 F6 F7 F8 SCSI initialization error.
Fault Description
Flash EPROM checksum failure MULTIBUS loop test Pblink test Configuration test Character Recognition Test I-test A/B test Reader/Config test Transport status test PEP/Stamp status Microfilmer status MJE status HSOCR status NIE status Image status Unexpected address exception. Unexpected bus exception. Unexpected exception. Unexpected instruction exception. Unexpected interrupt level. Unexpected privilege instruction level. Unexpected spurious interrupt level. Unexpected transport interrupt exception.
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00000
No Error Status Displayed STEP 000 PROCEDURE Replace the NDP030 CPU PCBA (card AA17) and rerun the POC test. Is a POC test status message displayed on NDP PCs display monitor? 002 004 008 Did the POC test pass? Follow manual procedure for displayed fault code. End of procedure. Remove all PCBAs from the AA gate except the NDP030 CPU PCBA (card AA17). Disconnect the SCSI connector J1 from the NDP030 CPU PCBA. Rerun the POC test. Does the LED fault code on the NDP030 CPU PCBA indicate a SCSI initialization error (LED=0C)? 010 Replace the NDP030 CPU PCBA (card AA17) and rerun the POC test. Is a POC test status message displayed on the NDP PCs display monitor? 020 Re-attach the SCSI cable to connector J1 on the NDP030 CPU PCBA and rerun the POC test. Is a POC test status message displayed on the NDP PCs display monitor? 030 Re-install the Area 1 Tracking Logic PCBA (card AA02). Rerun the POC test. Is a POC test status message displayed on the NDP PC? 040 Replace the Area 1 Tracking Logic PCBA (card AA02). Rerun the POC test. Does the original problem still exist? 050 Re-install the Area 2/3/4 Tracking Logic PCBA (card AA05). Rerun the POC test. Is a POC test status message displayed on the NDP PC? 060 Replace the Area 2/3/4 Tracking Logic PCBA (card AA05). Rerun the POC test. Does the original problem still exist? 070 Re-install the Main Clock PCBA (card AA08). Rerun the POC test. Is a POC test status message displayed on the NDP PC? 080 Replace the Main Clock PCBA (card AA08). Rerun the POC test. Does the original problem still exist? 290 900 090 080 290 900 070 060 290 900 050 040 030 310 002 290 020 290 950 004 YES 002 NO 008
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STEP 090
PROCEDURE Re-install the MICR/Reader Configuration PCBA (card AA10). Rerun the POC test. Is a POC test status message displayed on the NDP PC?
YES 110
NO 100
100
Replace the MICR/Reader Configuration PCBA (card AA10). Rerun the POC test. Does the original problem still exist?
290
900
110 120
Is the Recognition/Control PCBA (card AA11) present? Re-install the Recognition/Control PCBA (card AA11) and rerun the POC test. Is a POC test status message displayed on the NDP PC?
120 140
140 130
130
Replace the Recognition/Control PCBA (card AA11) and rerun the POC test. Does the original problem still exist?
290
900
140 150
Is the Analog Interface PCBA (card AA12) present? Re-install the Analog Interface PCBA (card AA12) and rerun the POC test. Is a POC test status message displayed on the NDP PC?
150 170
170 160
160
Replace the Analog Interface PCBA (card AA12) and rerun the POC test. Does the original problem still exist?
290
900
170 180
Is the DC Recognition PCBA (card AA13) present? Re-install the DC Recognition PCBA (card AA13) and rerun the POC test. Is a POC test status message displayed on the NDP PC?
180 200
200 190
190
Replace the DC Recognition PCBA (card AA13) and rerun the POC test. Does the original problem still exist?
290
900
200
Is the Microfilmer/Image Interface Board (MIIB) PCBA (card AA03) present?
210
230
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STEP 210
PROCEDURE Re-install the MIIB PCBA (card AA03) and rerun the POC test. Is a POC test status message displayed on the NDP PC?
YES 230
NO 220
220
Replace the MIIB PCBA (card AA03) and rerun the POC test. Does the original problem still exist?
290
900
230 240
Is the Microfilmer/Image Interface Board (MIIB) PCBA (card AA15) present? Re-install the MIIB PCBA (card AA15) and rerun the POC test. Is a POC test status message displayed on the NDP PC?
240 260
260 250
250
Replace the MIIB PCBA (card AA15) and rerun the POC test. Does the original problem still exist?
290
900
260 270
Is an Endorser Interface PCBA (card AA09) present? Re-install the Endorser Interface PCBA (card AA09) and rerun the POC test. Is a POC test status message displayed on the NDP PC?
270 290
290 280
280
Replace the Endorser Interface PCBA (card AA09) and rerun the POC test. Does the original problem still exist?
290
900
290
Verify that the +12v, -12v, +5v, and GND levels for the NDP030 CPU PCBA (card AA17) are stable and within tolerance. If they are not, make the necessary adjustments. Re- install any PCBAs previously removed and rerun the POC test. Does the problem still exist?
300
900
300
Verify that none of the backplane signals for the NDP030 CPU PCBA (card AA17) are shorted. If a short condition is encountered, make the necessary adjustments. Does the problem still exist?
910
900
310
Replace the SCSI cable between the PC and the NDP030 CPU PCBA. Rerun the POC test. Does the problem still exist?
320
900
320
The PCs SCSI hardware is interfering with the operation of the NDP030 CPU PCBA (card AA17). Make the necessary adjustments to the PCs hardware and rerun the POC test. Does the problem still exist?
910
900
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STEP 900
PROCEDURE Re-install all PCBAs and connectors removed during previous manual procedure steps. Verify proper operation. End of procedure.
YES
NO
910
Contact the Unisys Support Center for technical assistance. The error condition and the repair procedures followed should be described in a UCF. End of procedure.
950
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10000
Flash memory checksum test failed. STEP 000 PROCEDURE Power down the sorter and install the POC bypass jumper (W1/W2-0) on the NDP030 CPU PCBA (card AA17). Reset the sorter and wait for POC bypass to complete. At the debugger prompt "NDP 030BUG X.X.X>" enter the following command: FE<xmit> This will erase the flash EPROM on the NDP030 CPU PCBA. Go to step 00010. 010 At the debugger prompt "NDP 030BUG X.X.X>" enter the following command: DL FLASH.LO<xmit> This command will download the Sorter Control Program and the rest of the POC code into the RAM of the NDP030 CPU PCBA. When the debugger program indicates the download operation is complete, Go to step 00020. 020 At the debugger prompt "NDP 030BUG X.X.X>" enter the following command: FW 200000 400000 1400000 This command will program the flash EPROM with the code downloaded into the NDP030 CPU PCBAs RAM. When the debugger program indicates the operation is complete, go to step 00030. YES
PC 00 0001
NO
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PC 00 0001
STEP 030 PROCEDURE Power down the sorter and remove the POC bypass jumper installed in step 00000. Rerun the POC test. Does the original problem still exist? 040 Replace the NDP030 CPU PCBA (card AA17) and rerun the POC test. Does the original problem still exist? 050 060 Is another error condition being reported? Follow manual procedure for displayed fault code. End of procedure. 070 The FLASH.LO file on the NDP PC may be corrupted. Contact the Unisys Support Center for technical assistance. The error condition and the repair procedures followed should be described in a UCF. End of procedure. 950 Verify proper operation. End of procedure 060 950 070 050 YES 040 NO 050
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Note: 10100
The same procedure is used to resolve each of the failure codes on this page. PC 00 0100
Unexpected address exception occurred.
10110
Unexpected exception occurred.
PC 00 0110
10120
Unexpected instruction trap exception occurred.
PC 00 0120
10140
Unexpected bus error exception occurred.
PC 00 0140
10150
Unexpected spurious interrupt occurred.
PC 00 0150
10170
Unexpected interrupt exception occurred. STEP 000 PROCEDURE Replace the NDP030 CPU PCBA (card AA17) and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure.
PC 00 0170
YES 92000
NO 950
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Word Loop Test Failure

11500 PC 02 0010 Entrance to this failure indicates the word loop register did not respond to a legitimate address. This failure could be caused by:
CAPI Configuration
A failure of the CAPI interface cable that connects the PCI PCBA (resident in the CAPI PC) with card AA 10. Bad address decoding logic on the Reader/Configuration board, AA10. An improperly functioning PCI PCBA.
Non-CAPI Configuration The CPU board, AA17, not putting the correct addresses on the MULTIBUS address bus. Shorts or open lines corrupting the MULTIBUS address bus. Shorts could be on any board connected to the address bus or on the bus itself. Opens could be on the bus or in a board slot connector. Bad address decoding logic on the Reader/Configuration board, AA10.
For diagnosis of this error code in the Non-CAPI configuration, refer to Table 2-2 for the backplane distribution of the MULTIBUS address bus. The tables on the following pages are used in diagnosing PC 02 XXXX failures that occur in the Non-CAPI configuration. The CAPI "Word Loop Test" checks the interface between the CAPI PC and card AA 10, not the AA gate MULTIBUS.
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Table 22. Address Bus and Data Bus

ADDRESS BUS SIGNAL ADR0/ ADR1/ ADR2/ ADR3/ ADR4/ ADR5/ ADR6/ ADR7/ ADR8/ ADR9/ ADRA/ ADRB/ ADRC/ ADRD/ ADRE/ ADRF/ CONNECTS TO AA01-J1-79 thru AA15-J1-79 AA01-J1-80 thru AA15-J1-80 AA01-J1-77 thru AA15-J1-77 AA01-J1-78 thru AA15-J1-78 AA01-J1-75 thru AA15-J1-75 AA01-J1-76 thru AA15-J1-76 AA01-J1-73 thru AA15-J1-73 AA01-J1-74 thru AA15-J1-74 AA01-J1-71 thru AA15-J1-71 AA01-J1-72 thru AA15-J1-72 AA01-J1-69 thru AA15-J1-69 AA01-J1-70 thru AA15-J1-70 AAO1-J1-67 thru AA15-J1-67 AA01-J1-68 thru AA15-J1-68 AA01-J1-65 thru AA15-J1-65 AA01-J1-66 thru AA15-J1-66 and and and and and and and and and and and and and and and and AA16-J1-57 thru AA22-J1-57 AA16-J1-58 thru AA22-J1-58 AA16-J1-55 thru AA22-J1-55 AA16-J1-56 thru AA22-J1-56 AA16-J1-53 thru AA22-J1-53 AA16-J1-54 thru AA22-J1-54 AA16-J1-51 thru AA22-J1-51 AA16-J1-52 thru AA22-J1-52 AA16-J1-49 thru AA22-J1-49 AA16-J1-50 thru AA22-J1-50 AA16-J1-47 thru AA22-J1-47 AA16-J1-48 thru AA22-J1-48 AA16-J1-45 thru AA22-J1-45 AA16-J1-46 thru AA22-J1-46 AA16-J1-43 thru AA22-J1-43 AA16-J1-44 thru AA22-J1-44
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DATA BUS
SIGNAL DATA0/ DATA1/ DATA2/ DATA3/ DATA4/ DATA5/ DATA6/ DATA7/ DATA8/ DATA9/ DATAA/ DATAB/ DATAC/ DATAD/ DATAE/ DATAF/ CONNECTS TO AA01-J1-82 thru AA15-J1-82 AA01-J1-84 thru AA15-J1-84 AA01-J1-86 thru AA15-J1-86 AA01-J1-88 thru AA15-J1-88 AA01-J1-90 thru AA15-J1-90 AA01-J1-92 thru AA15-J1-92 AA01-J1-94 thru AA15-J1-94 AA01-J1-96 thru AA15-J1-96 AA10-J1-95 and AA15-J1-95 AA10-J1-93 and AA15-J1-93 AA10-J1-91 and AA15-J1-91 AA10-J1-89 and AA15-J1-89 AA10-J1-87 and AA15-J1-87 AA10-J1-85 and AA15-J1-85 AA10-J1-83 and AA15-J1-83 AA10-J1-81 and AA15-J1-81 and and and and and and and and and and and and and and and and AA16-J1-73 thru AA22-J1-73 AA16-J1-74 thru AA22-J1-74 AA16-J1-71 thru AA22-J1-71 AA16-J1-72 thru AA22-J1-72 AA16-J1-69 thru AA22-J1-69 AA16-J1-70 thru AA22-J1-70 AA16-J1-67 thru AA22-J1-67 AA16-J1-68 thru AA22-J1-68 AA16-J1-65 thru AA22-J1-65 AA16-J1-66 thru AA22-J1-66 AA16-J1-63 thru AA22-J1-63 AA16-J1-64 thru AA22-J1-64 AA16-J1-61 thru AA22-J1-61 AA16-J1-62 thru AA22-J1-62 AA16-J1-59 thru AA22-J1-59 AA16-J1-60 thru AA22-J1-60
212
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STEP 10 15 PROCEDURE Is the sorter in the CAPI configuration? Replace the CAPI interface cable that connects the PCI PCBA (resident within the CAPI PC) to connector P3 on the CAPRI board, AA10. Rerun the POC test. Does the problem still exist? 20 Replace AA10 and rerun the POC test. Does the problem still exist? 25 Replace the PCI PCBA resident within the CAPI PC and rerun the POC test. Does the problem still exist? 100 From the Error Display Screen, select <F4> to access the debugger. At the debugger prompt "NDP 030BUG X.X.X>", enter the following command: G $10000AA<XMIT> This will access a test routine that continuously reads addresses $3FFAAAA and $3FF5555. Using a BDM grounded to a ground post on the AA gate backplane measure the logic levels of the address bus at board slot AA10. Do all the address lines toggle? 110 Repeat the measurements made in step 100 at board slot AA17. Do all the address lines toggle? 120 Replace AA10 and rerun test. Does the problem still exist? 130 140 150 Is the fault code the same as before? Follow new fault code. End of procedure. Open exists on backplane. Using Table 2-2, trace address signal that did not toggle at AA10. Make necessary corrections. Rerun test. Does the problem still exist? 160 Did more than one line fail to toggle? 160 170 130 190 150 120 92000 25 20 YES 15
PC 02 0010
NO 100
950
950
950
110
160
950 140
950 210
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STEP 170
PROCEDURE Problem could be a short between lines on the backplane or ground. Check for shorts. Does the problem still exist?
YES
NO
180
950
180
The CPU card (AA17) may not be driving the signal(s). Replace AA17 and rerun test. Does the problem still exist? 190 950
190
Another card on backplane could be causing the problem. Remove all cards from AA gate except AA08, AA10, and AA17. Ignoring all other messages, does word loop test pass? 200 220
214
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11500
STEP 200 PROCEDURE Replace cards in the AA gate one at a time, rerunning POC test after inserting each card. Last card inserted before word loop test fails is suspect card. Replace it and rerun test. Does the problem still exist? 210 This line could be shorted to ground. Check for shorts. Rerun test. Does the problem still exist? 220 Problem is with one of boards remaining in AA gate. Replace each board in AA gate, one at a time, rerunning POC after each exchange. Ignoring all other messages, does work loop test pass? 230 Check backplane and connectors. Verify no visible damage. Make necessary corrections. Rerun POC. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 950 180 92000 YES
PC 02 0010
NO
950
950
230
950
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11550
PC 02 0020
Entrance to this failure indicates that data written to the word loop register was not properly read back. This failure could be caused by
CAPI Configuration
A failure of the CAPI interface cable that connects the PCI PCBA (resident in the CAPI PC) with card AA 10. Bad address decoding logic on the Reader/Configuration board, AA10. An improperly functioning PCI PCBA.
Non-CAPI Configuration The CPU board, AA17, not putting the correct addresses on the MULTIBUS address bus. Shorts or open lines corrupting the MULTIBUS address bus. Shorts could be on any board connected to the address bus or on the bus itself. Opens could be on the bus or in a board slot connector. Bad address decoding logic on the Reader/Configuration board, AA10.
For the Non-CAPI configuration, the word loop test displays both the data written to the MULTIBUS and the pattern actually read. The pattern displayed on the screen is a hexadecimal representation of the logic levels which were read on the data bus. The hexadecimal display on the screen relates to the data bus as follows:
HEXADECIMAL BINARY A 1 0 1 0 D D D D A A A A DATA T T T T A A A A F E D C / / / / A 1 0 1 0 D D D D A A A A T T T T A A A A B A 9 8 / / / / A 1 0 1 0 D D D D A A A A T T T T A A A A 7 6 5 4 / / / / A 1 0 1 0 D D D D A A A A T T T T A A A A 3 2 1 0 / / / /
1 = HIGH (GREATER THAN 2.4 VDC) 0 = LOW (LESS THAN 0.8 VDC) HEXADECIMAL A = BINARY 1010 HEXADECIMAL 5 = BINARY 0101 HEXADECIMAL F = BINARY 1111 HEXADECIMAL C = BINARY 1100 HEXADECIMAL 6 = BINARY 0110
For diagnosis of this error code in the Non-CAPI configuration, refer to Table 2-2 for the backplane distribution of the MULTIBUS address bus.
216
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STEP 10 15 PROCEDURE Is the sorter in the CAPI configuration?? Replace the CAPI interface cable that connects the PCI PCBA (resident within the CAPI PC) to connector P3 on the CAPRI board, AA10. Rerun the POC test. Does the problem still exist? 20 Replace AA10 and rerun the POC test. Does the problem still exist? 25 Replace the PCI PCBA resident within the CAPI PC and rerun the POC test. Does the problem still exist? 100 Measure data line(s) in error for continuity, using Table 2-2 (under line 11500), from AA17 to AA10. Is data line(s) in error continuous? 110 Make necessary corrections on backplane. Does the problem still exist? 120 No open exists. Problem is either a short on the backplane or a problem with the card driving signals (AA17 or AA10). Check the backplane for shorts between adjacent lines using Table 2-2 (under line 11500). Make necessary corrections. Does the problem still exist? 130 Replace AA17 and rerun test. Does the problem still exist? 140 Problem could be another board in AA gate pulling data line low. Remove all boards from AA gate except AA08, AA10, and AA17. Ignoring all other messages, does the word loop test pass? 150 Replace AA10 and rerun test. Does the problem still exist? 160 Replace boards in AA gate, one at a time, rerunning POC test after each board. Replace the last board inserted before test failed. Does the problem still exist? 950 Verify proper operation. End of procedure. 98000 98000 160 140 130 140 120 92000 25 20 YES 15
PC 02 0020
NO 100
950
950
950
110
950
950
950
150
950
950
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11600
AA Gate hardware configuration error. STEP 10 15 PROCEDURE Is the sorter in the CAPI configuration? Replace the card identified as "Suspect 1", make note of the AA gate slot number, and rerun the POC test. Does the problem still exist? 20 Replace the CAPI interface cable that connects the PCI PCBA (resident within the CAPI PC) to connector P3 on the CAPRI board, AA10. Rerun the POC test. Does the problem still exist? 25 30 Was card AA10 replaced in step 15? Replace AA10 and rerun the POC test. Does problem still exist? 35 Replace the PCI PCBA resident within the CAPI PC and rerun the POC test. Does the problem still exist? 40 Remove the card identified in step 15 and examine the card socket for bent or otherwise damaged contacts. Are there any obvious contact problems? 45 Make corrections as required. Re-insert the card and rerun the POC test. Does the problem still exist? 50 55 Has the card socket for slot AA10 already been examined for physical defects? Remove the card AA10 and examine the card socket for bent or otherwise damaged contacts. Are there any obvious contact problems? 60 Make corrections as required. Re-insert all cards and rerun the POC test. Does the problem still exist? 100 From the POC error display screen, select "<F1> Extended error status." Is the "Primary Suspect Component" identified on the screen present and properly inserted in its socket? 92000 110 60 50 92000 45 40 35 25 35 20 YES 15
PC 02 0030
NO 100
950
950 30
950
950
50
950 55
92000
950 130
218
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STEP 110
PROCEDURE Remove power. Remove the board identified on the screen and examine the board socket for bent or otherwise damaged contacts. Are there any obvious contact problems?
YES
NO
120
140
120
Make corrections as required. Insert the board, restore power, and rerun the test. Does this part of the word loop test pass? 950 150
130
Obtain and install the board identified on the screen. Does this part of the word loop test pass? 950 110
140
Replace the board identified on the screen, restore power, and rerun the test. Does this part of the word loop test pass? 950 160
150
Remove power and replace the board identified on the screen. Restore power and rerun the test. Does this part of the word loop test pass? 950 92000
160
Replace AA17 and rerun test. Does the problem still exist? 950 92000
950
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11650
AA Gate option module configuration error. STEP 10 15 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 20 25 30 35 Is a "Suspect 2" identified by the error display message? Replace the FRU identified as "Suspect 2" and rerun the POC test. Is a "Suspect 3" identified by the error display message? Replace the FRU identified as "Suspect 3" and rerun the POC test. Does the problem still exist? 40 45 Is a "Suspect 4" identified by the error display message? Replace the FRU identified as "Suspect 4" and rerun the POC test. Does the problem still exist? 50 55 Is a "Suspect 5" identified by the error display message? Replace the FRU identified as "Suspect 5" and rerun the POC test. Does the problem still exist? 100 From the POC error display screen, select "<F1> Extended error status." Is more than one "Suspect Component" identified? Replace the "Suspect Component" and rerun the POC test. Does the problem still exist? 110 Replace the "Primary Suspect Component" and rerun the POC test. Does the problem still exist? 115 Are multiple "Secondary Suspect Components" identified in the extended error message? Replace the "Secondary Suspect Component" and rerun the POC test. Does the problem still exist? 150 115 130 150 150 110 50 55 40 45 20 25 30 35 YES 15
PC 02 0040
NO 100
950 150 950 150
950 150
950 150
950 105
105
950
950 120
120
950
220
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STEP 130
PROCEDURE Replace the "Secondary Suspect Component" displayed first and rerun the POC test. Does the problem still exist?
YES
NO
140
950
140
Replace the "Secondary Suspect Component" displayed last and rerun the POC test. Does the problem still exist? 150 950
150
Check the configuration jumpers on card AA10 using schematic SH 09.01.01 and verify that they reflect the sorters actual configuration. Make any necessary corrections and rerun the POC test. Does the problem still exist? 92000 950
950
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221
Note: 13000
PBLINK clock is not active.
13025
PBLINK clock period out of tolerance. STEP 100 PROCEDURE Observe the LED on bard AA08. Is the LED blinking approx. every second? 120 Replace board AA10 and rerun test. Does problem still exist? 130 Replace board AA08 and rerun test. Does problem still exist? 140 Turn off power and remove the following boards: AA05 and AA10. Turn on power and observe the LED on board AA08. Is the LED blinking approx. every second? 150 Replace board AA08 and rerun test. Does problem still exist? 160 Turn off power and insert one of the boards removed previously. Turn on power and observe the LED on board AA08. Is the LED blinking approx. every second? 170 Faulty board was the one just inserted. Replace board and rerun test. Does problem still exist? 180 950 Have all the boards that were removed been reinserted? Verify proper operation. End of procedure. 92000 92000 180 92000 160 92000 130 120 YES
PC 05 0001
NO
140
950
950
150
950
170
950 160
222
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Note: 13050
Different procedures are used to resolve each of the failure codes on this page. PC 05 0002
A 10-second timeout elapsed without the reader/configuration PCBA reporting a "POC test complete" status to the sorter main processor.
STEP 100
PROCEDURE Remove power. Replace card AA10. Restore power and rerun the test. Does the problem still exist?
YES
NO
93000
950
950
13075
The "Z80 OK" status in $3FFFC1A conflicts with the "Z80 OK" status in $3FFFC69. STEP 100 PROCEDURE Replace board AA10 and rerun the test. Does problem still exist? 120 Replace board AA08 and rerun the test. Does problem still exist? 950 Verify proper operation. End of procedure. 93000 120 YES
PC 05 0003
NO
950
950
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223
Note: 13100
Data transferred by the sorter main processor to the Reader/configuration PCBA was not correctly echoed back by the Z80 processor.
STEP 100
PROCEDURE Replace board AA10 and rerun the test. Does problem still exist?
YES
NO
93000
950
950
13125
Entrance to this failure indicates that the Z-80 bit did not reset from the first command given. STEP 100 PROCEDURE Remove power. Replace card AA10. Restore power and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 93000 YES
PC 05 0005
NO
950
13150
Entrance to this failure indicates that the Z-80 and overload bits were not reset. STEP 100 PROCEDURE Replace board AA08 and rerun the test. Does problem still exist? 950 Verify proper operation. End of procedure. 93000 YES
PC 05 0006
NO
950
224
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Note: 13175
A 2-second timeout elapsed without the Reader/configuration PCBA acknowledging the transfer of data from the sorter main processor.
13200
The sorter main processor was unable to write data to Port 41 of the Reader/configuration PCBA.
PC 05 0008
13225
The sorter main processor placed the Reader/configuration PCBA in test mode by enabling Test A/B in Diagnostic Control Register 10. However, the status of Port 40 on the Reader/configuration PCBA indicates that the appropriate test mode has not been enabled.
PC 05 0009
13250
Entrance to this failure indicates that no bus error trap occurred during reading of empty document data buffer. STEP 100 PROCEDURE Remove power. Replace board AA10 restore power and rerun the test. Does problem still exist? 950 Verify proper operation. End of procedure. YES
PC 05 0010
NO
93000
950
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225
13275
Entrance to this failure indicates that no interrupt occurred with doc data set. STEP 100 PROCEDURE Replace board AA08 and rerun the test. Does problem still exist? 950 Verify proper operation. End of procedure. YES
PC 05 0011
NO
93000
950
226
3998 5593007
Note: 13300
Entrance to this failure indicates that a document was available but there was no interrupt or doc data.
13325
Entrance to this failure indicates that E.O.D. Did not generate an interrupt from buffer A.
PC 05 0013
13350
Entrance to this failure indicates that an interrupt was generated but doc data was not set.
PC 05 0014
13375
Entrance to this failure indicates that an interrupt was not properly generated. STEP 100 PROCEDURE Remove power. Replace board AA10 restore power and rerun the test. Does problem still exist? 950 Verify proper operation. End of procedure. YES
PC 05 0015
NO
93000
950
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227
13400
Entrance to this failure indicates that reading register "03FFFC00" did not clear and interrupt. STEP 100 PROCEDURE Remove power. Replace board AA08 restore power and rerun the test. Does problem still exist? 950 Verify proper operation. End of procedure. 93000 YES
PC 05 0016
NO
950
228
3998 5593007
Note: 13425
Entrance to this failure indicates that reading register "03FFFC10" did not clear and interrupt.
13450
Entrance to this failure indicates that no overflow bit set on buffer A.
PC 05 0018
13475
Entrance to this failure indicates that no overflow interrupt occurred but the bit was set.
PC 05 0019
13500
Entrance to this failure indicates that a buffer overflow did not cause an interrupt. STEP 100 PROCEDURE Remove power. Replace board AA10 restore power and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 93000 YES
PC05 0020
NO
950
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229
Note: 13525
The Reader/configuration PCBA failed its AC/DC PIO test
13550
The reader/configuration PCBA failed its PIO status interrupt test.
PC 05 0022
13575
The Reader/configuration PCBA failed to process configuration data from $3FFFC12 and $3FFFC13 correctly.
PC 05 0023
13600
Entrance to this failure indicates that incorrect data was received from the Z80 buffers.
PC 05 0024
13625
The Reader/configuration PCBA failed its self test. STEP 100 PROCEDURE Remove power. Replace board AA10 restore power and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 93000 YES
PC 05 0025
NO
950
230
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15000
AA gate backplane design level unknown STEP 100 PROCEDURE Count the number of card slots, not the number of cards, in the AA gate. Are there 22 card slots? 110 The backplane is at Design Level 1 (DL1). This is the backplane configuration the POC test defaults to. In DL1 sorters this error can only occur if the POC test code has been corrupted. Follow the procedure for error code "PC 00 0001" and reprogram the NDP030 CPU PCBAs flash EPROM. End of procedure. 120 130 Are there 17 card slots? The backplane is at Design Level 2 (DL2). Check signal "DL2PLN", pin P2-86 on slot AA10. This signal should be grounded for DL2 backplanes. Is "DL2PLN" a constant low? 140 Ground "DL2PLN", pin P2-86 on slot AA10 and rerun the POC test. Does the problem still exist? 150 The DL2 backplane presence signal "DL2PLN" is not properly grounded. Ensure that the signal "DL2PLN" is permanently grounded an rerun the POC test. Does the problem still exist? 160 Replace AA10 and rerun the POC test. Does the problem still exist? 170 The backplane is at Design Level 3 (DL3). Replace AA08 and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 92000 160 160 160 130 110 YES
PC 08 0001
NO
120
170
140
150
950
950
950
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15050
Test mode active on AA gate PCBA STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the card identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 30 From the POC error display screen, select "<F1> Extended error status." Replace the "Primary Suspect Component" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 92000 YES 20
PC 08 0002
NO 30
950
950
15100
I-test not exclusive to the PCBA under test.
PC 08 0003
15150
I-test failure. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 30 Replace the FRU identified as "Suspect 2" and rerun the POC test. Does the problem still exist? 100 From the POC error display screen, select "<F1> Extended error status." Replace the "Primary Suspect Component" and rerun the POC test. Does the problem still exist? 120 Replace the "Secondary Suspect Component" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 120 92000 30 YES 20
PC 08 0004
NO 100
950
950
950
950
232
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15500 Test A failure
PC 09 0010
Entrance to this failure indicates that a problem exists between the secondary board and the primary board. This failure could be caused by:
The primary board fails to drive its outputs low. An open exists between the primary board and the secondary board. The secondary board fails to detect inputs properly driven by the primary board.
Use the tables below for the specificied PCBA that describe the destination of the outputs of the primary board. Tables 2-3 through 2-6 are located on the following pages. The manual procedure follows the last table. Table 23. Card AA02 TEST A/ TEST B Outputs (DL3)
SIGNAL BADBOLCN DIRTYCN PKTDSTRN PSRINT0N PSRINT1N PSRINT2N PSRINT3N MISSALLN PSRINT4N PSRINT5N PSRINT6N PSRINT7N COMPDPN
AA02 J1-12 J1-14 J1-19 J1-21 J1-23 J1-25 J1-27 J1-28 J1-31 J1-33 J1-37 J1-39 J1-42 AA08-J1-16 AA08-J1-27 AA05-J1-18 AA05-J1-21 AA05-J1-23 AA05-J1-25 AA05-J1-27 AA05-J1-31 AA05-J1-32 AA05-J1-33 AA05-J1-37 AA05-J1-39 AA03-J1-34 AA05-J1-36 AA09-J1-34 AA14-J1-34 AA15-J1-34
TO
BOLLN BOLLN BOLI1N
J1-46 J1-48 J1-49
AA09-J1-40 AA03-J1-48 AA03-J1-53 AA15-J1-53
continued
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Table 23. Card AA02 TEST A/ TEST B Outputs (DL3) (cont.)
SIGNAL OKADJN
AA02 J1-83 AA03-J1-83 AA05-J1-83 AA08-J1-83
TO
INTLCK1CN
J1-91
AA03-J1-91 AA05-J1-91 AA08-J1-91
JAMCN
J1-93
AA03-J1-93 AA05-J1-93 AA08-J1-93
DSINTN STLPN A1BERRN UFMISN REGFAILN MTWEN
J2-07 J2-13 J2-15 J2-16 J2-17 J2-19
AA08-J2-07 AA08-J2-15 AA08-J2-17 AA08-J2-16 AA10-J2-18 AA03-J2-18 AA10-J2-20
UVRST A1DPLN A1ERRN BOLADIRN JAMBNSN DDADN ALMSTFEN OLADN USADN BOLDN BOLEN BOLFN BOLHOP1
J2-20 J2-21 J2-22 J2-23 J2-24 J2-35 J2-36 J2-38 J2-39 J2-41 J2-43 J2-46 J2-47
AA08-J2-19 AA08-J2-21 AA08-J2-23 AA08-J2-26 AA08-J2-25 AA10-J2-35 AA10-J2-36 AA10-J2-38 AA10-J2-39 AA10-J2-41 AA10-J2-43 AA09-J2-46 AA08-J2-47
continued
234
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Table 23. Card AA02 TEST A/ TEST B Outputs (DL3) (cont.)
SIGNAL BTDPN BOLHOP2 BOLSN BOLBN BOLPE2N BOLPE3N BOLGN ATMDOCN BOLJN
AA02 J2-48 J2-49 J2-57 J2-61 J2-65 J2-67 J2-70 J2-93 J2-95 AA08-J2-45 AA08-J2-49 AA08-J2-53 AA08-J2-55 AA10-J2-58 AA10-J2-60 AA09-J2-70 AA10-J2-96 AA09-J2-92
TO
Table 24. Card AA05 TEST A/ TEST B Outputs (DL3)
SIGNAL MISORTCN BADBOLCN GFAULTCN FULLPOCN DIRTYCN JAMA2N TRACERCN J1-9
AA05 AA08-J1-14 AA08-J1-16 AA08-J1-22 AA08-J1-26 AA08-J1-27 AA02-J1-15 AA02-J1-16 AA08-J1-28
TO
J1-10 J1-11 J1-13 J1-14 J1-15 J1-16
JAMA4N JAMA3N LOCK234N NPRMIS2N A234DPLN A3ERRN A4ERRN A2ERRN
J1-17 J1-19 J1-40 J1-41 J2-31 J2-93 J2-95 J2-96
AA02-J1-17 AA02-J1-20 AA08-J1-40 AA02-J1-44 AA08-J1-31 AA08-J1-91 AA08-J1-93 AA08-J1-95
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SIGNAL GFTERSTN
AA08 J1-10 AA02-J1-9 AA05-J1-7
TO
ERRENBLN
J1-12
AA02-J1-10 AA05-J1-8
FLWSTPDN
J1-18
AA02-J1-18 AA03-J1-18 AA10-J1-18 AA14-J1-7 AA15-J1-18
JCFFX2N
J1-24
AA02-J1-13 AA05-J1-12
A1CLRN
J1-31
AA02-J1-24 AA10-J1-23
C2MSPN MOTOR1N
J1-50 J1-51
AA02-J1-54 AA02-J1-50 AA03-J1-50 AA05-J1-51 AA09-J1-50 AA10-J1-50 AA14-J1-50 AA15-J1-50
INTLCKN
J1-53
AA02-J1-53 AA05-J1-53
READCLRN
J1-59
AA02-J1-59 AA03-J1-59 AAO9-J1-59 AA10-J1-59 AA14-J1-59 AA15-J1-59
PBLINKN
J1-60
AA05-J1-60 AA09-J1-60
236
3998 5593007
SIGNAL
AA08 AA10-J1-60
TO
PPC-ON
J1-81
AA02-J1-81 AA03-J1-81 AA04-J1-81
INTLCLK1N
J1-85
AA02-J1-85 AA03-J1-85 AA05-J1-85
BOLERSTN
J1-87
AA02-J1-87 AA03-J1-87 AA05-J1-87
PLHN
J1-89
AA02-J1-89 AA03-J1-89 AA05-J1-89
PLPIHN STSPCN SWONLN RDYN A3LITEN A4LITEN A2LITEN
J2-27 J2-35 J2-61 J2-71 J2-85 J2-87 J2-89
AA05-J2-27 AA10-J2-34 AA03-J2-53 AA05-J2-71 AA05-J2-87 AA05-J2-89 AA05-J2-91
3998 5593007
237
SIGNAL FDERRORN
AA10 J1-27 AA02-J1-41 AA08-J1-33
TO
DDINTN STPFDAN OCRPLN CKGMN
J2-31 J2-32 J2-33 J2-37
AA08-J2-32 AA08-J2-33 AA02-J2-33 AA02-J2-37 AA08-J2-39
FDR2PLN
J2-44
AA02-J2-44 AA08-J2-41
NREADYBN BTDE
J2-82 J2-88
AA08-J2-65 AA02-J2-88
The error displays for the CAPI and Non-CAPI configurations have slightly different naming convention for the "primary" and "secondary" boards referenced in this procedure. The differences are given below:
Procedure "primary" board "secondary" board CAPI "Suspect 1" "Suspect 2" Non-CAPI Primary Suspect Component Secondary Suspect Component
238
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15500
Test A failure. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? From the POC error status display screen, select "<F1> Extended error status". Using a BDM or Fluke Model 77 Digital Voltage Meter (DVM) grounded to a ground post on the AA gate backplane measure the logic levels of the lines going from the primary board to the secondary board at the secondary board Do any of the lines measure greater than 0.8 VDC? 100 Using a BDM or a Fluke Model 77 Digital Voltage Meter (DVM) grounded to a ground post on the AA gate backplane measure the logic levels of the lines going from the primary board to the secondary board at the secondary board. Do any of the lines measure greater than 0.8 VDC? 110 Remove the secondary suspect. Using the BDM or DVM as an ohmmeter, check continuity of the line measured in step 100 from the card side of the socket to the backplane side of the socket. Did all of the lines show proper continuity? 130 Make appropriate corrections, insert the board removed in step 110, restore power, and rerun the test. Does this portion of TEST A now pass? 140 Replace the board removed in step 110, restore power and rerun the test. Does TEST A now pass? 150 160 Do any of the lines measure greater than .8 VDC but less than 2.4 VDC? Replace the primary board, restore power and rerun the test. Does TEST A now pass? 950 950 165 140 140 110 150 YES 100
PC 09 0010
NO 20
110
150
130
130
100 160
100
3998 5593007
239
165
Measure the logic level of the line which measured between 0.8 V and 2.4 V in step 100 at the primary card socket. Does the line measure between 0.8 V and 2.4 V? 170 175
170
Remove the primary suspect card. Using the BDM or DVM as an ohmmeter, check continuity of the line measured in step 165 from the board side of the socket to the backplane side of the socket. Did all of the lines show proper continuity? 160 180
175
An open exists between the line connecting the primary and secondary boards. Make appropriate corrections, restore power, and rerun test. Does TEST A now pass? 950 100
180
Make appropriate corrections, insert the primary board, restore power and rerun the test. Does this portion of TEST A now pass? 950 100
950
240
3998 5593007
16000 Test B Failure
PC 09 0020
The primary board fails to drive its outputs high. An open exists between the primary board and the secondary board. The secondary board fails to detect inputs properly driven by the primary board.
Use the tables below for the specified PCBA that describes the destination of the outputs of the primary board. Tables 2-3 through 2-6 are located on the previous pages. The manual procedure follows the table index charts.
Test B failure. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? From the POC error status display screen, select "<F1> Extended error status". Using a BDM or Fluke Model 77 Digital Voltage Meter (DVM) grounded to a ground post on the AA gate backplane measure the logic levels of the lines going from the primary board to the secondary board at the secondary board Do any of the lines measure less than 2.4 VDC? 100 Using a BDM or a Fluke Model 77 DVM grounded to a ground post on the AA gate backplane measure the logic levels of the lines going from the primary board to the secondary board at the secondary board. Do any of the lines measure less than 2.4 VDC? 110 Remove power. Replace the secondary board. Restore power and rerun the test. Does TEST B now pass? 120 Remove power. Remove the secondary board and the primary board. Refer to the destination table. Do any of the lines from the primary board to the secondary board go to other boards? 130 140 950 100 120 110 120 110 YES 100 NO 20
3998 5593007
241
130
Remove all other boards which are connected to lines which go from the primary board to the secondary board. Using the BDM or DVM as an ohmmeter, check for continuity between the failed line and adjacent lines and/or between the failed line and ground. Does the ohmmeter read less than 100K ohms on any line? 150 160
140
Using the BDM or DVM as an ohmmeter, check for continuity between the failed line and adjacent lines and/or between the failed line and ground. Does the ohmmeter read less than 100K ohms on any line? 150 160
150
Locate the short and make corrections as required. Insert all boards which were removed in previous steps, restore power and rerun the test. Does TEST B now pass? 950 100
160
Replace the primary board and insert all boards that were removed in previous steps. Restore power and rerun the test. Does TEST B now pass? 950 100
950
242
3998 5593007
16100
Unable to enable TEST A on AA gate PCBA STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 100 From the POC error status display screen, select "<F1> Extended error status". Replace the "Primary Suspect Component" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 92000 YES 20
PC 09 0030
NO 100
950
950
3998 5593007
243
16110
INTEST not active in Main DCR with TEST A enabled. STEP 10 PROCEDURE Replace PCBA AA08. Make note of the PCBA replaced and rerun the POC test. Does the problem still exist? 20 Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 2" and rerun the POC test. Does the problem still exist? 120 From the POC error status display screen, select "<F1> Extended error status". Replace the "Secondary Suspect Component" and rerun the POC test. Does the problem still exist? 130 Remove the "Secondary Suspect Component"/"Suspect 2" just replaced. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket. Does the line show proper continuity? 140 Make appropriate corrections, insert the card removed in step 130, and rerun the POC test. Does the problem still exist? 150 Re-insert the card removed in step 130. Remove the card replaced in step 10. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket. Does the line show proper continuity? 160 Make appropriate corrections, insert the card removed in step 150, and rerun the POC test. Does the problem still exist? 170 Re-insert the card removed in step 150. Using a BDM or DVM as an ohmmeter, check the continuity of the backplane signal "INTESTN" (J1-61) from the card replaced in step 10 to the card removed in step 130. 170 170 150 150 130 130 20 30 YES
PC 09 0031
NO
950 950
950
950
140
950
160
950
244
3998 5593007
Does the line show proper continuity? 180 Make appropriate corrections to the backplane and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure.
92000
180
92000
950
3998 5593007
245
16120
Unable to disable TEST A on AA gate PCBA. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 100 From the POC error display screen, select "<F1>Extended error status." Replace the "Primary Suspect Component" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 92000 YES 20
PC 09 0032
NO 100
950
950
246
3998 5593007
16130
INTEST active in Main DCR with test modes disabled.
PC 09 0033
Table 27. Diagnostic Control Register (DCR) addresses for AA Gate PCBAs
Non-CAPI AA Gate PCBA AA02 AA05 AA08 AA10 03FFFC70 03FFFC6A 03FFFC01 03FFFC63 DCR Address
STEP 10
PROCEDURE Replace PCBA AA08. Make note of the PCBA replaced and rerun the POC test. Does the problem still exist?
YES
NO
120
950
120
From the POC error status display screen, select "<F1> Extended error status". Replace the "Secondary Suspect Component" and rerun the POC test. Does the problem still exist? 130 950
130
Remove the "Secondary Suspect Component" replaced in step 120. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket. Does the line show proper continuity? 150 140
140
Make appropriate corrections, insert the card removed in step 130, and rerun the POC test. Does the problem still exist? 150 950
150
Remove the card replaced in step 10. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket.
3998 5593007
247
Does the line show proper continuity? 160 Make appropriate corrections, re-insert all cards removed in previous steps, and rerun the POC test. Does the problem still exist? 170 If not already done, re-insert all cards removed in previous steps. Using a BDM or DVM as an ohmmeter, check the continuity of the backplane signal "INTESTN" (J1-61) from the card replaced in step 10 to the card removed in step 130. Does the line show proper continuity? 180 Make appropriate corrections to the backplane and rerun the POC test. Does the problem still exist? 190 The problem may be another PCBA in the AA gate holding the "INTESTN" signal low. Remove option module cards AA03, AA09, and AA15, if they are present. If card AA09 is a PEP/Stamp endorser interface, be sure to remove the impact endorser presence jumper from card AA10. Rerun the POC test. Does the problem still exist? 200 Re-install the option module PCBAs. Restore the impact endorser presence jumper on card AA10, if it was removed in step 190. Rerun the POC test. From the main error display screen select option <F4> to access the Motorola debugger. For all of the cards referenced in Table 2-7 that are present in the AA gate, read the contents of their Diagnostic Control Registers (DCRs). This is done by entering the following command at the debugger prompt: NDP 030BUG X.X.X>MM XXXXXXXX<xmit> ..where XXXXXXXX is the DCR address from Table 2-7. When the contents of the register are displayed, make a note of the value (the number to the immediate left of the question mark) and terminate the "Memory Modify" (MM) command by entering a period character, followed by <Xmit>.
170
160
170
950
190
180
190
950
200
400
248
3998 5593007
Note:
For more information on using the debugger see Section 1 of this manual.
Replace any PCBAs that have bits 7, 6, 5, or 4 set in their DCR, unless they have been replaced in previous steps of this procedures. Does the problem still exist? 230 One of the character recognition cards may be holding "INTESTN" low. Is AA11 present in the AA gate? 240 Replace AA11 and rerun the POC test. Does the problem still exist? 250 260 Is AA12 present in the AA gate? Replace AA12 and rerun the POC test. Does the problem still exist? 270 280 Is AA13 present in the AA gate? Replace AA13 and rerun the POC test. Does the problem still exist? 290 Check the "INTESTN" signal (J1-61) across the entire backplane. Check each card slot and verify that no adjacent pins are making contact with "INTESTN", resulting in a short to ground condition. Make any necessary adjustments and rerun the POC test. Does the problem still exist? 300 Replace the AA gate backplane and rerun the POC test. Does the problem still exist? 400 Problem is being caused by one of the option module PCBAs. Restore the option module PCBAs one at a time and rerun the POC test after each card is inserted. Note: If the PEP/Stamp interface PCBA is being re-installed, be sure to restore the impact endorser presence jumper on card AA10. 92000 950 300 950 290 950 270 280 950 290 250 260 950 270 240 950 230 950
Replace the PCBA that, upon reinsertion, causes the "PC 09 0033" error.
3998 5593007
249
Once all option cards have been reinstalled or replaced, rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 290 950
250
3998 5593007
16200
Unable to enable TEST B on AA gate PCBA STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 100 From the POC error status display screen, select "<F1> Extended error status". Replace the "Primary Suspect Component" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 92000 YES 20
PC 09 0040
NO 100
950
950
3998 5593007
251
16210
INTEST not active in Main DCR with TEST B enabled. STEP 10 PROCEDURE Replace PCBA AA08. Make note of the PCBA replaced and rerun the POC test. Does the problem still exist? 20 30 Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 2" and rerun the POC test. Does the problem still exist? 120 From the POC error status display screen, select "<F1> Extended error status". Replace the "Secondary Suspect Component" and rerun the POC test. Does the problem still exist? 130 Remove the "Secondary Suspect Component"/"Suspect 2" just replaced. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket. Does the line show proper continuity? 140 Make appropriate corrections, insert the card removed in step 130, and rerun the POC test. Does the problem still exist? 150 Remove the card replaced in step 10. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket. Does the line show proper continuity? 160 Make appropriate corrections, insert the card removed in step 150, and rerun the POC test. Does the problem still exist? 170 Using a BDM or DVM as an ohmmeter, check the continuity of the backplane signal "INTESTN" (J1-61) from the card replaced in step 10 to the card removed in step 130. Does the line show proper continuity? 92000 170 170 150 150 130 130 20 30 YES
PC 09 0041
NO
950 120
950
950
140
950
160
950
180
252
3998 5593007
180
Make appropriate corrections to the backplane and rerun the POC test. Does the problem still exist? 92000 950
950
3998 5593007
253
16220
Unable to disable TEST B on AA gate PCBA. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 100 From the POC error display screen, select "<F1> Extended error status." Replace the "Primary Suspect Component" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 92000 YES 20
PC 09 0042
NO 100
950
950
254
3998 5593007
16300
INTEST not active in the Main Diagnostic Control Register when all PCBAs with test mode capability are in TEST A mode (outputs low). STEP 100 PROCEDURE Replace AA 08 and rerun the POC test. Does the problem still exist? 110 Remove AA 08. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket. Does the line show proper continuity? 120 Make appropriate corrections, re-insert the card and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 130 110 YES
PC 09 0050
NO
950
120
950
3998 5593007
255
16310
TEST A failure. PCBA placed in TEST A mode reported itself in error. STEP 100 PROCEDURE Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 YES
PC 09 0051
NO
950
256
3998 5593007
16400
INTEST not active in the Main Diagnostic Control Register when all PCBAs with test mode capability are in TEST B mode (outputs low). STEP 100 PROCEDURE Replace AA 08 and rerun the POC test. Does the problem still exist? 110 Remove AA 08. Using a BDM or DVM as an ohmmeter, check the continuity of signal "INTESTN" (J1-61) from the card side of the PCBAs socket to the backplane side of the socket. Does the line show proper continuity? 120 Make appropriate corrections, re-insert the card and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 130 110 YES
PC 09 0060
NO
950
120
950
16410
TEST B failure. PCBA placed in TEST B mode, reported itself in error. STEP 100 PROCEDURE Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 YES
PC 09 0061
NO
950
3998 5593007
257
17625
Power on switch not indicating power in the AC controls register. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 100 Replace the FRU identified as the suspect card and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 92000 YES 20
PC 12 0005
NO 100
950
950
258
3998 5593007
17650
Motors signals incorrect in the AC controls register. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace the FRU identified as "Suspect 1" and rerun the POC test. Does the problem still exist? 100 150 Replace the FRU identified as the suspect card and rerun the POC test. Check the motor up signals (MTR1UPN,MTR2UPN,MTR3UPN, MTR4UPN) coming into the FRU replaced in the previous step. These signals originate in the AC controls. Secondary suspect boards are the AC control logic cards in the first pocket module and/or the control module. Make necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 150 150 YES 20
PC 12 0006
NO 100
950 950
950
3998 5593007
259
17675
Entrance to this failure indicates that the jam bits did not set with TEST A enabled. STEP 10 PROCEDURE Replace AA08 and rerun the POC test? Does the problem still exist? 20 Replace AA02 and rerun the POC test. Does the problem still exist? 30 Replace AA05 and rerun the POC test. Does the problem still exist? 40 Replace card CABB1 in the AC controls and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 40 30 20 YES
PC 12 0007
NO
950
950
950
950
260
3998 5593007
17700
Entrance to this failure indicates that BOL and GF/TE reset did not reset the jam bits. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace AA08 and rerun the POC test. Does the problem still exist? 30 Replace AA01 and rerun the POC test. Does the problem still exist? 40 Replace AA08 and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 40 92000 YES 20
PC 12 0009
NO 30
950
950
950
3998 5593007
261
17725
Primary feeder/seperator status error STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace AA08 and rerun the POC test. Does the problem still exist? 30 Replace AA01 and rerun the POC test. Does the problem still exist? 40 Replace AA08 and rerun the POC test. Does the problem still exist? 50 Check the primary feeder clutch/brake fuse. Make any necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 50 40 50 YES 20
PC 12 0010
NO 30
950
950
950
950
262
3998 5593007
17750
Secondary feeder/seperator status error. STEP 10 20 PROCEDURE Is the sorter in the CAPI configuration? Replace AA08 and rerun the POC test. Does the problem still exist? 30 Check the 3-amp fuse on card AA01. Make the necessary corrections and rerun the test. Does the problem still exist? 40 Replace AA01 and rerun the POC test. Does the problem still exist? 50 Replace AA08 and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 50 40 92000 YES 20
PC 12 0011
NO 30
950
950
950
950
3998 5593007
263
17775
Entrance to this failure indicates that the clutch solenoid is faulty. STEP 10 PROCEDURE Replace AA08 and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 YES
PC 12 0012
NO
950
264
3998 5593007
19000
Entrance to this failure indicates that the solenoid on is not reset after 110 MS. STEP 100 PROCEDURE Remove power. Replace board AA08. Restore power and rerun the test. Does problem still exist? 950 Verify proper operation. End of procedure. 92000 YES
PC 14 0001
NO
950
3998 5593007
265
Note: 19000
Master (PEP) CPU failed POC test.
19005
Master (PEP) CPU port failure.
PC 14 0002
19010
Master (PEP) CPU ROM failure.
PC 14 0003
19015
Master (PEP) CPU internal RAM failure.
PC 14 0004
19020
PEP external RAM failure.
PC 14 0005
19025
PEP internal timer failure.
PC 14 0006
19030
PEP PTM (6840) timer failure.
PC 14 0007
19035
PEP loopback failure. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 97000 YES
PC 14 0008
NO
950
266
3998 5593007
Note: 19040
Matrix status failure.
STEP 100
PROCEDURE Check connectors (J321, J322, J323) on the printer driver PCBA and on the cables. Make the necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Replace the printer driver PCBA and rerun the test. Does the problem still exist? 97000 950
950
19045
Data communication error. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 97000 YES
PC 14 0010
NO
950
19047
Dual port failure. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 110 Replace AA17 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 97000 110 YES
PC 14 0011
NO
950
950
3998 5593007
267
19048
Unexpected exception occurred while accessing endorser interface. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 110 Replace AA17 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 97000 110 YES
PC 14 0012
NO
950
950
268
3998 5593007
Note: 19050
Stamp CPU failure.
19055
Stamp port failure.
PC 14 0014
19060
Stamp ROM failure.
PC 14 0015
19065
Stamp internal RAM failure.
PC 14 0016
19070
Stamp CPU internal timer failure. STEP PROCEDURE Note: Stamp POC errors are not reported if the Stamp Error Bypass jumper is installed on the Main CPU board (AA17). This jumper is located at W4/W3-C on the NDP030 CPU PCBA (SH 09.01.02). YES
PC 14 0017
NO
100
950
3998 5593007
269
19075
Stamp Jam: Either the Stamp is unable to move or the home/encoder assembly is not working. Note: Stamp POC errors are not reported if the Stamp Error Bypass jumper is installed on the Main CPU board (AA17). This jumper is located at W4/W3-C on the NDP030 CPU PCBA (SH 09.01.02). YES
PC 14 0018
STEP 100
PROCEDURE Check connectors (J1, J2, J3, J4) on the stamp driver board and their respective cables. Make necessary corrections. Does the problem still exist?
NO
110
950
110
On stamp driver board, remove connector J2 and place DVM probe on U9-4 (HOMEN). Rotate stamp by hand, make measurement, and then put J2 back on the board. Does the signal switch between logic 1 (>2.4 VDC) and logic 0 (<0.8 VDC)? 140 120
120
Measure U3-10 on stamp driver board while rotating the stamp. Does the signal switch between 0 V and +24 VDC? 830 130
130
Measure P1-7 (HOMELED) on stamp driver board. Does signal measure between 0.6 VDC and 1.2 VDC? 830 820
140
On Stamp driver board, remove connector J2 and place DVM probe on U9-10 (ENCODER). Rotate stamp by hand, make measurement, and then put J2 back on the board. Does signal switch from logic 1 to logic 0 to logic 1? 190 150
150
Measure U3-4 on stamp driver board while rotating the stamp. Does the signal switch between 0 V and +24 VDC? 830 160
160
Measure P1-6 (ENCODLED) on stamp driver board. Does the signal measure between 0.6 VDC and 1.2 VDC? 830 820
270
3998 5593007
PC 14 0018
Stamp Jam (continued) STEP 190 PROCEDURE Using MTR disk, go to PEP/Stamp Endorser Test menu. Select Stamp Motor Phase Tests. On submenu, select Phase Driver Check. If J4 on the Stamp Driver board is connected, turn power off and remove it. Select PHASE A from the menu and measure Q13 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 200 Measure Q11 collector. Does it switch between +24 VDC and 0 VDC? 210 Measure U8-8 (CHOPAC). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? 220 Measure U1-8 (PHAENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? 230 On AA09, measure P1 pin 25. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? 240 From the MTR Phase Driver Check submenu, select PHASE B and measure Q15 collector (metal chase of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 250 260 Measure Q12 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-9 (CHOPBD). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-4 (PHBENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 23. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? 800 810 250 260 300 270 830 830 800 810 830 230 240 830 210 830 200 220 YES NO
270
830
290
290
3998 5593007
271
PC 14 0018
Stamp Jam (continued) STEP 300 PROCEDURE From the MTR Phase Driver Check submenu, select PHASE C and measure Q14 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 310 320 Measure Q11 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-8 (CHOPAC). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-6 (PHCENN).Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 21. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? From the MTR Phase Driver Check submenu, select PHASE D and measure Q16 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 360 370 Measure Q12 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-9 (CHOPBD). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-2 (PHDENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 19. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? If J4 on the stamp driver board is still removed, plug it back in. Using MTR disk, go to PEP/Stamp endorser test. On submenu, select Stamp Motor Phase Test. On submenu, select Phase Current Check. Select Standby Current. On the stamp driver board put a voltmeter between U2-8 and U2-12. Do not use a scope! Does it measure between 0.2 VDC and 0.3 VDC? 450 410 360 370 400 380 830 830 310 320 350 330 830 830 YES NO
330 340
830 800
340 810
350
380
830
390
390
800
810
400
272
3998 5593007
PC 14 0018
Stamp Jam (continued) STEP 410 PROCEDURE On stamp driver board, put a meter or scope probe on U1-13. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 15. Does it measure more than 2.4 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 17. Does it measure more than 2.4 VDC? In the MTR menu choose low current. On the stamp driver board put a voltmeter between U28 and U2-12. Do not use a scope! Does it measure between 0.4 VDC and 0.5 VDC? 460 On stamp driver board, put a meter or scope probe on U1-13. Does it measure less than 0.7 VDC? On AA09 measure P1 pin 15. Does it measure less than 0.7 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 17. Does it measure more than 2.4 VDC? In the MTR menu choose medium current. On the stamp driver board put a voltmeter between U2-8 and U2-12. Do not use a scope! Does it measure between 0.6 VDC and 0.7 VDC? 510 On stamp driver board, put a meter or scope probe on U1-13. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 15. Does it measure more than 2.4 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 0.7 VDC? On AA09 measure P1 pin 17. Does it measure less than 0.7 VDC? 550 530 510 520 500 480 460 470 YES 430 NO 420
420 430
800 830
810 440
440 450
800
810
470 480
800 830
810 490
490 500
800
810
520 530
800 830
810 540
540
800
810
3998 5593007
273
PC 14 0018
Stamp Jam (continued) STEP 550 PROCEDURE In the MTR menu choose high current. On the stamp driver board put a voltmeter between U28 and U2-12. Do not use a scope! Does it measure between 0.8 VDC and 0.9 VDC? 560 On stamp driver board, put a meter or scope probe on U1-13. Does it measure less than 0.7 VDC? On AA09 measure P1 pin 15. Does it measure less than 0.7 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure less than 0.7 VDC? On AA09 measure P1 pin 17. Does it measure less than 0.7 VDC? Replace Stamp Control Cable. Does the problem still exist? Replace AA09. Does the problem still exist? Replace home/encoder sensor assembly. Does the problem still exist? Replace stamp driver PCBA. Does the problem still exist? Replace the stamp motor. Does the problem still exist? Verify proper operation. End of procedure. 97000 97000 950 950 840 580 560 570 YES NO
570 580
800 830
810 590
590 800 810 820 830 840 950
800 97000 97000
810 950 950
274
3998 5593007
19080
Stamp home sensor error (found home position but could not stay home). Note: Stamp POC errors are not reported if the Stamp Error Bypass jumper is installed on the Main CPU board (AA17). This jumper is located at W4/W3-C on the NDP030 CPU PCBA (SH 09.01.02). YES
PC 14 0019
STEP 100
NO
110
950
110
Using MTR disk, go to PEP/Stamp Endorser Tests menu and select Stamp Motor Phase Tests. On submenu, select Hold Stamp. Execute T&A 3304 3654 to home adjust the home sensor. Is T&A setting OK? 120 130
120
Reset to correct setting. Does the problem still exist? 130 950
130 950
Go to line 19075 STEP 190. Verify proper operation. End of procedure.
3998 5593007
275
19085
Stamp Driver Board Failure.(Hardware status reporting stamp failure.) Note: Stamp POC errors are not reported if the Stamp Error Bypass jumper is installed on the Main CPU board (AA17). This jumper is located at W4/W3-C on the NDP030 CPU PCBA (SH 09.01.02). YES
PC 14 0020
STEP 100
NO
110
950
110
On AA09, measure P1-9 (STAMPBADN). Does the signal measure less than 2.4 VDC? 120 130
120
On stamp driver board place DVM probe on chip U6 pin 8 (STAMPBADN). Does the signal measure less than 2.4 VDC? 830 800
130 800
Go to line 19075 STEP 190. Replace Stamp Control Cable. Does the problem still exist? 97000 950
830
Replace stamp driver PCBA. Does the problem still exist? 97000 950
950
276
3998 5593007
19090
Hole Detect Sensor Error. STEP 100 PROCEDURE Check the two connectors on the hole detect board and their respective cables. Make necessary corrections. Does the problem still exist? 110 With power on, check to see if hole detect lamp in the endorser track wall is on. This is located inside a housing about two inches upstream of the endorser print head. Is the lamp on? 120 Measure J326 pin 2 on the Matrix Endorse Hole Sense board. Does it measure between 4.75 VDC and 5.25 VDC? Measure J326 pin 2 on the Matrix Endorse Hole Sense board. Does it measure between 4.75 VDC and 5.25 VDC? Measure J321 pin 49 on the Printer Driver board. Does it measure between 4.75 VDC and 5.25 VDC? Put a probe on AA09 P2-45. Place a document in the track in front of the hole detect lamp and then take it away. Do this several times while monitoring the signal. Does the signal switch between logic 0 (<0.8VDC) and logic 1 (>2.5 VDC)? Repeat STEP 150 with a probe on Printer Driver board chip U24 pin 12. Does the signal switch between logic 0 (<0.8VDC) and logic 1 (>2.5 VDC)? Repeat STEP 150 with a probe on Printer Driver board chip U22 pin 12. Does the signal switch between 12 VDC and 15 VDC? Replace the Hole Sense PCBA. Does the problem still exist? Replace the lamp. Does the problem still exist? 810 150 800 110 YES
PC 14 0021
NO
950
120 130
130
820
140
140
830
840
150
850
160
160
860
170
170
840
180
180 800
830
950
950
3998 5593007
277
PC 14 0021
Hole Detect Sensor Error (continued). STEP 810 820 830 840 850 860 870 950 PROCEDURE Replace lamp harness assembly. Does the problem still exist? Replace the Matrix Endorse Hole Sense board. Does the problem still exist? Replace the Printer Drive Cable. Does the problem still exist? Replace the Printer Driver PCBA. Does the problem still exist? Replace AA09. Does the problem still exist? Replace the Printer Control Harness. Does the problem still exist? Replace the Hole Detect Harness. Does the problem still exist? Verify proper operation. End of procedure. YES 97000 97000 870 97000 97000 97000 97000 NO 950 950 950 950 950 950 950
19095
Invalid Configuration. STEP 100 PROCEDURE On AA02 check jumpers J1 and J2, make any necessary corrections. Does the problem still exist? 200 950 Replace AA09. Does the problem still exist? Verify proper operation. End of procedure. 200 97000 YES
PC 14 0022
NO
950 950
278
3998 5593007
Note: 19100
Microfilmer POC failure. MIIB MPU failure.
19110
Microfilmer POC failure. MIIB ROM failure.
PC 15 0002
19120
Microfilmer POC failure. MIIB RAM failure.
PC 15 0003
19130
Dual-port RAM failure (MIIB). STEP 100 PROCEDURE Replace AA03, and rerun the test. Does the problem still exist? 110 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
PC 15 0004
NO
950
950
3998 5593007
279
19140
MIIB A/B failure. STEP 100 PROCEDURE Replace AA03, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
PC 15 0005
NO
950
280
3998 5593007
Note: 19150
MIIB interrupt source register error.
19160
MIIB track status register failure. STEP 100 PROCEDURE Replace AA03 (MIIB), rerun the test. Does the problem still exist? 110 950 Run the Transport Basic MTRs to isolate the problem. End of procedure. Verify proper operation. End of procedure. 110 YES
PC 15 0007
NO
950
3998 5593007
281
Note: 19170
MIIB track status register B error.
STEP 100
PROCEDURE Replace AA03, and rerun the test. Does the problem still exist?
YES
NO
99600
950
950
19180
MIIB track status register C error. STEP 100 PROCEDURE Replace AA03 (MIIB), and rerun the test. Does the problem still exist? 110 950 Run the Transport Basic MTRs to isolate the problem. End of procedure. Verify proper operation. End of procedure. 110 YES
PC 15 0009
NO
950
19190
Serial data comm failure. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check data communication cables Controller J1, J3, and AA03-J5 corrections.) Make necessary corrections. Does the problem still exist? 110 Use the manual procedure for PC 15 0014 to troubleshoot the problem. End of procedure. Verify proper operation. End of procedure. 110 YES
PC 15 0010
NO
950
950
282
3998 5593007
Note: 19200
IPL: Track Status register error
STEP 100
PROCEDURE Replace AA03 (MIIB), and rerun the test. Does the problem still exist?
YES
NO
110
950
110
Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 99600 950
950
19210
IPL: Microfilmer Controller Signal Error. STEP 100 PROCEDURE Check connector J1 on the Microfilm Controller PCBA and the cable. Make the necessary correction. Does the problem still exist? 110 Replace the Microfilm Controller PCBA. Does the problem still exist? 120 Replace the cable, and rerun the test. Does the problem still exist? 130 Replace AA03, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure 99600 130 120 110 YES
PC 15 0012
NO
950
950
950
950
3998 5593007
283
19220
IPLN/PSDIPLN Signal mismatch. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA. Does the problem still exist? 110 Replace AA03 (MIIB), and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure 99600 110 YES
PC 15 0013
NO
950
950
284
3998 5593007
19230
Data comm test timeout error. STEP 100 PROCEDURE Select the Data Comm Tests from the Basic Microfilm Test menu. Select the Microfilmer Controller Wraparound Test. Execute the test procedure, following the instructions displayed on the screen. Did the test complete with all the Microfilm Controller PCBA LEDs off? 110 Did the LEDs show the code below? D7 OFF D6 ON D5 OFF D4 OFF D3 ON D2 OFF D1 OFF D0 OFF 120 Repeat the test, ensuring that you hold the MTR switch depressed during the test. Is the test result completed with all the LEDs off? 130 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 140 Select the Microfilm Interface Wraparound Test and execute. Did the test pass? 150 Check the interface cable between J1 on the AA gate motherboard and J1 on the Microfilm Controller PCBA. Repair as necessary. Does the problem still exist? 170 150 99600 140 140 140 YES
PC 15 0014
NO
110 120
130
950
160
950
3998 5593007
285
19230
Data comm test timeout error STEP 160 PROCEDURE Execute the manual procedure for the error code reported by the test. Repair as required. Does problem still exist? 170 Replace Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 YES
PC 15 0014
NO
950
950
286
3998 5593007
19240
Data comm test echo error. STEP 100 PROCEDURE Select the Data Comm Tests from the Basic Microfilm Test menu. Select the Microfilmer Controller Wraparound Test. Execute the test procedure, following the instructions displayed on the screen. Did the test complete with all the Microfilm Controller PCBA LEDs off? 110 Did the LEDs show the code below? D7 OFF D6 ON D5 OFF D4 OFF D3 ON D2 OFF D1 OFF D0 OFF 120 Repeat the test, ensuring that you hold the MTR switch depressed during the test. Is the test result completed with all the LEDs off? 130 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 140 Select the Microfilm Interface Wraparound Test, and execute it. Did the test pass? 150 Check the interface cable between J1 on the AA gate motherboard and J1 on the Microfilm Controller PCBA. Repair as necessary. Does the problem still exist? 160 Execute the manual procedure for the error code reported by the test. Repair as required. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 150 99600 140 140 YES
PC 15 0015
NO
110
130
950
160
950
950
3998 5593007
287
Note: 19250
Microfilmer POC failure. Semaphore not correct.
19260
Microfilmer POC failure. Microfilm Image Interface Board (MIIB) not responding to command. STEP 100 PROCEDURE Replace AA03, and rerun the test. Does the problem still exist? 110 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
PC 15 0017
NO
950
950
288
3998 5593007
Note: 19270
BOL N is reported blocked.
STEP 100
PROCEDURE Check the document track for documents. Clear the track; clear the BOL. Rerun the test. Does the problem still exist?
YES
NO
110
950
110
Replace the MIIB PCBA (AA03), and rerun the test. Does the problem still exist? 120 950
120
Replace AA02, and rerun the test. Does the problem still exist? 99600 950
950
19290
Microfilmer dual-port RAM failure. Sorter timed out waiting for the MIIB. STEP 100 PROCEDURE Replace AA03, and rerun the test. Does the problem still exist? 110 Replace AA17, and rerun the test. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 130 Check the serial interface cable for proper operation. Make the necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
PC 15 0020
NO
950
950
950
950
3998 5593007
289
Note: 19300
Microfilmer POC failure. Controller MPU test failed.
19310
Microfilmer POC failure. Controller ROM failure.
PC 15 0022
19320
Microfilmer POC failure. Controller RAM test failed. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 110 Replace AA03, and rerun the test. Does the problem still exist? 120 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
PC 15 0023
NO
950
950
950
290
3998 5593007
Note: 19330
Microfilm Controller Interrupt Source register error.
STEP 100
PROCEDURE Replace the Microfilm Controller PCBA. Does the problem still exist?
YES
NO
99600
950
950
Verify proper operation. End of procedure
19340
Microfilm Controller Configuration register error. STEP 100 PROCEDURE Check jumpers W3 and W4 at BY22 and BY25. Make sure that they match the configuration, and rerun the POC test. Does the problem still exist? 110 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
PC 15 0025
NO
950
950
3998 5593007
291
Note: 19350
Controller Input Port 4 register failure.
STEP 100
PROCEDURE Check for Galvo PCBA present. Make the necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Verify that all cables are correctly connected. (Especially check Controller J5.) Make the necessary corrections. Does the problem still exist? 120 950
120
130
Replace AA03 (the MIIB PCBA), and rerun the test. Does the problem still exist? 99600 950
950
19360
Microfilm Controller solenoid/reel port failure. STEP 100 PROCEDURE Check connector P5 on the Microfilm Controller PCBA and the cable. Make the necessary corrections. Does the problem still exist? 110 Replace the Reel/Sol. Driver PCBA. Does the problem still exist? 120 Replace the Microfilm Controller PCBA. Does the problem still exist? 130 Replace the cable at J5 on the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
PC 15 0027
NO
950
950
950
950
292
3998 5593007
19370
Front Lamp Control register failure. STEP 100 PROCEDURE Check that the Lamp Driver PCBA is installed and seated correctly. Reseat as required. Rerun the test. Does the problem still exist? 110 Replace the Lamp Driver PCBA, and rerun the test. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 130 Using the schematics, check the continuity of signals FLCSELN, WEN, and REN on the motherboard and P4-J4. Repair and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
PC 15 0028
NO
950
950
950
950
3998 5593007
293
19380
Rear Lamp Control register failure. STEP 100 PROCEDURE Check that the Lamp Driver PCBA is installed and seated correctly. Reseat as required. Rerun the test. Does the problem still exist? 110 Replace the Lamp Driver PCBA, and rerun the test. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 130 Using the schematics, check the continuity of signals RLCSELN, WEN, and REN on the motherboard and P4-J4. Repair and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
PC 15 0029
NO
950
950
950
950
294
3998 5593007
19390
Galvo Home Control register failure. STEP 100 PROCEDURE Check that the Galvo Amp PCBA is installed and seated correctly. Reseat as required. Does the problem still exist? 110 Replace the Galvo Amp PCBA, and rerun the test. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 130 Using the schematics, check the continuity of signals OCSLEN, WEN, and REN on the motherboard and P4-J4. Repair, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
PC 15 0030
NO
950
950
950
950
3998 5593007
295
19400
Optical Status register failure. STEP 100 PROCEDURE Check that the OSM PCBA is installed and seated correctly. Reseat as required. Does the problem still exist? 110 Replace the OSM PCBA, and rerun the test. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 125 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 130 Using the schematics, check the continuity of signals OSRSELN and RWN on the motherboard and P4-J4. Repair, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 125 120 110 YES
PC 15 0031
NO
950
950
950
950
950
296
3998 5593007
Note: 19410
Microfilm Controller timer #1 failed.
19420
Microfilm Controller timer #2 failed. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure 99600 YES
PC 15 0033
NO
950
3998 5593007
297
Note: 19430
Galvo Amp PCBA presence failure.
STEP 100
PROCEDURE Check that the Galvo Amp PCBA is present and seated correctly. Install or reseat the PCBA as required. Does the problem still exist?
YES
NO
110
950
110
Using the schematics, check the continuity of signal GALVPLN on P1-55 through to the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 120 950
120
950
19440
Lamp Driver PCBA presence failure. STEP 100 PROCEDURE Check that the Lamp Driver PCBA is present and seated correctly. Install or reseat the PCBA as required. Does the problem still exist? 110 Using the schematics, check the continuity of signal LAMPLN on P1-51 through to the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
PC 15 0035
NO
950
950
950
298
3998 5593007
Note: 19450
OSM PCBA presence failure.
STEP 100
PROCEDURE Check that the OSM PCBA is present and seated correctly. Install or reseat the PCBA as required. Does the problem still exist?
YES
NO
110
950
110
Using the schematics, check the continuity of signal OSMPLN on P1-52 through to the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 99600 950
950
19460
Reel/Sol. Driver PCBA presence failure. STEP 100 PROCEDURE Check that the Reel/Sol. Driver PCBA is present and seated correctly. Install or reseat the PCBA as required. Does the problem still exist? 110 Using the schematics, check the continuity of signal REELPLN on P1-49 through to the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
PC 15 0037
NO
950
950
950
3998 5593007
299
Note: 19470
Servo Amp PCBA presence failure.
STEP 100
PROCEDURE Check that the Servo Amp PCBA is present and seated correctly. Install or reseat the PCBA as required. Does the problem still exist?
YES
NO
110
950
110
Using the schematics, check the continuity of signal SERVPLN on P1-56 through to the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 120 950
120
950
19480
Film sensor error: Film loaded sensor, loop arm sensor, or cover closed sensor failed. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check Controller J2 and Distribution B J2.) Make the necessary corrections. Does the problem still exist? 110 Using the MTR disk, go to the Microfilm Tests Menu. Select FILM TRANSPORT. Then run the loop arm sensor test. If the test passes, select BASIC MICROFILM TEST in the Microfilm Tests Menu, and select SYSTEM CHECK. Verify proper operation. End of procedure. 110 YES
PC 15 0039
NO
950
950
2100
3998 5593007
Note: 19490
Supply Encoder register failed.
STEP 100
PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution A J3.) Make the necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Replace the Microfilm Controller PCBA. Does the problem still exist? 99600 950
950
19500
Slip encoder failure. STEP 100 PROCEDURE Check the cable and connectors at J2 and J5 on the Distribution B PCBA. Make the necessary corrections. Does the problem still exist? 110 Using the MTR disk, go to the Microfilm Tests Menu. Select FILM TRANSPORT. Then select IDLER ENCODER TEST. Follow the new fault code. Verify proper operation. End of procedure 110 YES
PC 15 0041
NO
950
950
3998 5593007
2101
19510
MFC capstan did not reach home in time. STEP 100 PROCEDURE Run the capstan motor MTR according to the following two conditions: YES
PC 15 0042
NO
WITHOUT FILM In nonloop mode 101 106
Is the capstan motor in a runaway condition? 101 Verify that the following main harness connectors are correctly connected, and rerun the POC: Cable from the capstan motor to the connector SHSP2 on the Servo Heat Sink Assembly Tachometer feedback wires from the capstan motor to connector P9 on the Servo Amp PCBA Does the problem still exist? 102 Replace the Servo Amp PCBA. Run the capstan motor MTR according to the following two conditions:
102
950
WITHOUT FILM In nonloop mode 103 105
Is the capstan motor in a runaway condition? 103 Replace the Servo Amp Heat Sink Assembly, and rerun the POC. Does the problem still exist? 104 Replace the capstan motor, and rerun the POC. Does the problem still exist? 105 Using T&A 3304 4488, check the adjustment of the capstan velocity. Readjust if required. Does the problem still exist?
104
105
99600
105
99600
950
2102
3998 5593007
19510
MFC capstan did not reach home in time STEP 106 PROCEDURE Verify that all cables are correctly connected. (Especially check the cable on the Servo Heatsink PCBA J1, J2, and J7 and P9/P10 on the motherboard.) Make the necessary corrections. Does the problem still exist? 107 Rerun the POC with film removed if not done already. Follow the appropriate fault code. Did PC 15 0042 occur again? 110 Using T&A 3304 4488, check the adjustment of the capstan velocity. Readjust if required. Does the problem still exist? 120 Run the Film Transport MTR, and select CAPSTAN MOTOR TEST. Remove any film, and keep the film plate in a raised position. Select LARGE FAST MOVES and nonlooping mode. Did the capstan rotate when you pressed the Xmit key? 130 Press key F10 to exit the routine, and deselect the capstan motor. Rotate the capstan roller by hand. Is it free to rotate? 140 On microfilm backplane slot 7, connect an oscilloscope probe to J1 pin 44, and ground to J1 pin 29. Time base set to 20 msec/cm, auto trigger. Using a fast twisting action, rotate the capstan roller in a clockwise direction. Is the waveform triangular with a peak of approximately 2 V? 170 140 130 120 110 107 YES
PC 15 0042
NO
950
950
950
350
250
150
3998 5593007
2103
19510
MFC capstan did not reach home in time STEP 150 PROCEDURE Check the continuity of the connections from J1 pins 29 and 44 on slot 7 of the motherboard to the capstan motor. Repair as required. Does the problem still exist? 160 Replace the capstan motor, and adjust to T&A 3304 4488. Does the problem still exist? 170 On motherboard slot 7, connect oscilloscope probe 1 to pin 48 and probe 2 to pin 50. Set time base to 20 msec/cm, auto trigger. Rotate the capstan roller slowly and uniformly. Do both channels show square waves in phase quadrature with switching levels < 0.8 V to > 2.4 V? 180 Replace the Servo Amp PCBA, and adjust to T&A 3304 4488. Retest. Does the problem still exist? 190 Check the continuity of the connections from J1 pins 48 and 50 on slot 7 of the motherboard to the capstan motor. Repair as required. Does the problem still exist? 200 Replace the capstan motor, and adjust to T&A 3304 4488. Does the problem still exist? 250 Monitor pin 25 of backplane slot 7, signal MOTEN. Is pin 25 < 0.8 V? 260 570 200 570 180 99600 160 YES
PC 15 0042
NO
950
950
190
950
950
950
280
2104
3998 5593007
19510
MFC capstan did not reach home in time STEP 260 PROCEDURE Replace the Servo Heatsink Assembly, and retest. Does the problem still exist? 270 Check the continuity of the harness between slot 7 and the Servo Heatsink Assembly. Repair and retest. Does the problem still exist? 280 Unplug connector P1 from the Servo Heatsink Assembly, and retest. Select CAPSTAN MOTOR TEST from the Film Transport Menu. Do not execute moves at this point. Monitor pin 25 of backplane slot 7, signal MOTEN. Is pin 25 < 0.8 V? 290 Replace the Servo Heatsink Assembly, and retest. Does the problem still exist? 300 Check the continuity of the harness between slot 7 and the Servo Heatsink Assembly. Repair and retest. Does the problem still exist? 310 Replace the Servo Amp PCBA, and adjust to T&A 3304 4488. Retest. Does the problem still exist? 350 360 Is the Capstan Motor Roller free to rotate? Replace the Servo Amp PCBA, and adjust to T&A 3304 4488. Retest. Does the problem still exist? 370 On motherboard slot 7, is pin 43 (CAPDR) < 0.8 V? 570 380 570 360 570 300 290 570 270 YES
PC 15 0042
NO
950
950
310
950
950
950 370
950 500
3998 5593007
2105
19510
MFC capstan did not reach home in time STEP 380 390 400 410 420 PROCEDURE On motherboard slot 7, is pin 25 (MOTEN) > 2.4 V? On motherboard slot 7, is pin 26 (CAMPWR) > 2.4 V? On the Servo Heatsink PCBA, is J2 pin 2 (CAPMOTHI) > 15 V? On the Servo Heatsink PCBA, is J2 pin 4 (CAPMOTLO) < 0.8 V? Replace the Servo Heatsink PCBA, and retest. Does the problem still exist? 430 Check on the Servo Heatsink Assembly that J2 pin 5 > 23 V, J2 pin 3 is more negative than -23 V. If not, find power supply or harness problem, and retest. Does the problem still exist? 440 Check the continuity of the connections from J2 pins 2 and 4 on the Servo Heatsink PCBA to the capstan motor. Repair as required. Does the problem still exist? 450 Replace the capstan motor, and adjust to T&A 3304 4488. Does the problem still exist? 500 Unplug P1 from the Servo Heatsink Assembly. Run the Film Transport MTR, and select CAPSTAN MOTOR TEST. Remove any film, and keep the film plate in a raised position. Select LARGE FAST MOVES and looping mode. Monitor slot 7 pin 83 of the motherboard (CAMPWR). Is pin 83 > 2.4 V? 510 570 450 570 430 YES 390 400 410 420
PC 15 0042
NO 500 500 440 440
950
950
950
950
520
2106
3998 5593007
19510
MFC capstan did not reach home in time STEP 510 PROCEDURE Trace signal CAMPWR from slot 7 pin 83 back to slot 8 pin 83. Repair and retest. Does the problem still exist? 520 530 540 On motherboard slot 7, is pin 43 (CAPDR) < 0.8 V? On motherboard slot 7, is pin 25 (MOTEN) > 2.4 V? Replace the Servo Heatsink assembly, and retest. Does the problem still exist? 560 Replace the Servo Amplifier PCBA, and adjust to T&A 3304 4488. Retest. Does the problem still exist? 570 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 570 570 570 530 540 YES
PC 15 0042
NO
950 560 560
950
950
950
3998 5593007
2107
Note: 19520
Servo Amp PCBA register read back error.
STEP 100
PROCEDURE Check that the Servo Amp PCBA is installed and seated correctly. Reseat as required. Does the problem still exist?
YES
NO
110
950
110
Replace the Servo Amp PCBA, and retest. Does the problem still exist? 120 950
120
Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 130 950
130
Using the schematics, check the continuity of signals CDSELN, WEN, and REN on the motherboard and P4-J4. Repair and retest. Does the problem still exist? 99600 950
950
19530
Takeup loop arm sensor error. STEP 100 PROCEDURE Check connectors J2, J7, J8, and J9 of the Distribution B PCBA and the cables. Make the necessary corrections Does the problem still exist? 110 Using the MTR disk, go to the Microfilm Tests Menu. Select FILM TRANSPORT. Then select LOOP ARM SENSOR TEST. End of procedure. Verify proper operation. End of procedure 110 YES
PC 15 0044
NO
950
950
2108
3998 5593007
Note: 19540
Supply loop arm sensor error.
STEP 100
PROCEDURE Check connectors J2, J10, J11, and J12 of the Distribution B PCBA. Make the necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Using the MTR disk, go to the Microfilm Tests Menu. Select FILM TRANSPORT. Then select LOOP ARM SENSOR TEST. Verify proper operation. End of procedure
950
19550
Film loop error. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution B J7.) Make the necessary corrections. Does the problem still exist? 105 Using the MTR disk, go to the Microfilm Tests Menu. Select FILM TRANSPORT. Then select REEL MOTOR TEST. Does the test pass? 110 120 Follow the new fault code. Run loop arm sensor test. Does the test pass? 130 950 Follow the new fault code. End of procedure. 99600 120 105 YES
PC 15 0046
NO
950
110
130
3998 5593007
2109
19560
MFC Galvo home error #1Home register readback failure. STEP 100 PROCEDURE Check that the Galvo Amplifier PCBA is installed and seated correctly. Reseat as required. Does the problem still exist? 110 Replace the Galvo Amplifier PCBA, and retest. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 130 Using the schematics, check the continuity of signals OCSLEN, WEN, and REN on the motherboard and P4-J4. Repair and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
PC 15 0047
NO
950
950
950
950
2110
3998 5593007
19570
MFC Galvo home error #2Galvo home value out of range. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution A J1 and Distribution B J3 and J5 from the motherboard.) Make the necessary corrections. Does the problem still exist? 105 Check F1 on the Galvo PCBA. Make the necessary corrections, and rerun the test. Does the problem still exist? 110 Execute manual procedure MM 14 0007. Does the problem still exist? 120 Adjust the Galvo Home Sensor to T&A 3304 4447. Does the problem still exist? 130 Replace the Galvo PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 105 YES
PC 15 0048
NO
950
950
950
950
950
3998 5593007
2111
19580
Galvo voltage error. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA. Rerun the test. Does the problem still exist? 110 Replace AA03. Rerun the test. Does the problem still exist? 120 Replace AA17. Rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
PC 15 0049
NO
950
950
950
2112
3998 5593007
19590
MFC Galvo current error during SCAN. STEP 100 PROCEDURE Reseat the Galvo PCBA, and retest. Does the problem still exist? 110 Using schematics and a DVM, check that supplies +12V, -12V, +24V, and +5V are within +/- 10%. Are supplies within tolerance at backplane slot 1? 120 Replace the Galvo Amplifier PCBA, adjust to T&A 3304 4470, and retest. Does the problem still exist? 130 Check the backplane connections, repair as required, and retest. Does the problem still exist? 140 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 150 Check the adjustment of the galvo to T&A 3304 4470. Does the problem still exist? 160 Replace the galvanometer and adjust to T&As 3304 4447 and 3304 4470. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 160 150 140 130 120 110 YES
PC 15 0050
NO
950
130
950
950
950
950
950
3998 5593007
2113
19600
Galvo voltage error. STEP 100 PROCEDURE Check connector J5 on the Microfilm Controller PCBA and P4 on the motherboard and connecting cable. Reseat the Galvo PCBA. Rerun the test. Does the problem still exist? 110 Disconnect the P4 connector on the motherboard. Measure pin 91 on slot 1 using a DVM. Does the DVM read + 5 V? 120 Replace the Microfilm Controller PCBA. Rerun the test. Does the problem still exist? 130 Replace the controller signal jumper cable (part 2193 1354). Does the problem still exist? 140 Using a DVM, measure the voltage at pin 47 on slot 1 of the motherboard. Does the DVM read + 12 volts +/- 1%? 150 Replace the Galvo PCBA and adjust per T&A. Rerun the test. Does the problem still exist? 160 Disconnect the J5 connector on the motherboard, and measure the voltage at pin 47 on slot 1 of the motherboard. Does the DVM read + 12 volts +/- 1%? 170 Reconnect J5 on the motherboard, and disconnect the galvo connector. Measure the voltage at pin 47, slot 1. Does the DVM measure + 12 volts +/1%? 180 170 160 150 150 130 120 110 YES
PC 15 0051
NO
950
140
950
950
160
950
99600
190
2114
3998 5593007
19600
Galvo voltage error STEP 180 PROCEDURE Replace the galvanometer, and adjust per T&A. Rerun the test. Does the problem still exist? 190 Replace the main harness assembly (part 2493 1412). Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 YES
PC 15 0051
NO
950
950
3998 5593007
2115
19610
MFC Galvo POSACK active during SCAN. STEP 100 PROCEDURE The problem could be cable Distribution A J1. Verify that the cable is correct. Make the necessary adjustments. (Replace it if necessary.) Rerun the test. Does the problem still exist? 105 110 Use a DVM. Is TP1 on the Galvo Amplifier PCBA a logic 0 (< 0.8 V)? Replace the Galvo Amplifier PCBA, and retest. Does the problem still exist? 120 Check the continuity of signal POSACKN from P1-73 on the Galvo Amplifier PCBA back to the Microfilm Controller PCBA. Repair if a problem is found. Does the problem still exist? 130 Run the galvo MTR test, and isolate the fault using manual procedures. Repair as required. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 105 110 YES
PC 15 0052
NO
950 120
950
950
950
2116
3998 5593007
19620
POSACK never goes active. STEP 100 PROCEDURE Check connector J5 on the Microfilm Controller PCBA and P4 on the motherboard. Reseat the Galvo Amplifier PCBA. Rerun the test. Does the problem still exist? 105 Check F1 on the Galvo PCBA. Make the necessary corrections. Does problem still exist? 110 Using an oscilloscope, monitor the POSACK/ signal at pin 73, slot 1 on the motherboard. Does the signal toggle from 5 V to 0 V during POC? 120 Replace the Microfilm Controller PCBA. Rerun the test. Does the problem still exist? 130 Replace the controller jumper cable (part24931354). Rerun the test. Does the problem still exist? 140 Using an oscilloscope, monitor the SCAN signal at pin 75, slot 1 on the motherboard. Does the signal toggle from 0 V to +5 V? 150 Replace the Galvo PCBA, and adjust per T&A. Rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 99600 130 120 110 105 YES
PC 15 0053
NO
950
950
140
950
950
120
950
3998 5593007
2117
Note: 19630
Microfilm Controller Status register 5 failed to clear.
STEP 100
YES
NO
99600
950
950
19640
MFC shutter test failed. STEP 100 PROCEDURE Check connector P13 on the motherboard, and reseat the Reel/Sol. Driver PCBA. Does the problem still exist? 110 Remove connector P13, and perform a POC while monitoring the signal with an oscilloscope at pin 22, slot 8 on the motherboard. Does the signal switch from 24 V to + 5 V to 0 V? 120 Replace the Reel/Sol. Driver PCBA. Does the problem still exist? 130 Remove the cassette, if installed. Check connectors P4 and J1 on the Distribution B PCBA, J1 and P12 on the Distribution A PCBA, and all associated cables. Does the problem still exist? 140 Replace the Capping Shutter Solenoid Assembly, and align per T & A. Does the problem still exist? 150 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 140 130 130 110 YES
PC 15 0056
NO
950
120
950
950
950
950
2118
3998 5593007
Note: 19650
Shutter sensor failed.
STEP 100
PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution A/Distribution B J1.) Make the necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Using the MTR disk, go to the Microfilm Tests Menu. Select CAPPING SHUTTER. Does the test pass? 130 120
120 130
Follow the new fault code. Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 99600 950
950
End of procedure.
19660
MFC Reel/Solenoid control port failed. STEP 100 PROCEDURE Check that the Reel/Sol. PCBA is present and seated correctly. Install or reseat the PCBA as required. Does the problem still exist? 110 Replace the Reel/Sol. PCBA, and retest. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 130 Using the schematics, check the continuity of signals RSDSELN, REN, and WEN on the motherboard and P4-J4. Repair and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
PC 15 0058
NO
950
950
950
950
3998 5593007
2119
Note: 19670
ID display current error.
STEP 100
PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution A J2.) Make the necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Using the MTR disk, go to the Microfilm Tests Menu. Select ID DISPLAY. End of procedure.
19680
ID display read-back error. STEP 100 PROCEDURE Replace the Microfilmer ID Display cable assembly and rerun the POC test. Does the problem still exist? 110 Replace the Microfilmer Distribution A/Distribution B cable and rerun the POC test. Does the problem still exist? 120 Replace the Microfilmer ID Display PCBA and rerun the POC test. Does the problem still exist? 130 Replace the Microfilmer Controller PCBA and rerun the POC test. Does the problem still exist? 140 Replace the Distribution A PCBA and rerun the POC test. Does the problem still exist? 150 Replace the Distribution B PCBA and rerun the POC test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 140 130 120 110 YES
PC 15 0060
NO
950
950
950
950
950
950
2120
3998 5593007
19690
Human readable header error. STEP 100 PROCEDURE Using the MTR disk, go to the Microfilm Tests Menu. Execute the Human Readable Headers test. End of procedure. YES
PC 15 0061
NO
19700
ICM 1 current error. STEP 100 PROCEDURE Using the MTR disk, go to the Microfilm Tests Menu. Execute the ICM Test. End of procedure. YES
PC 15 0062
NO
Note: 19710
Height detect error.
STEP 100
PROCEDURE Using the MTR disk, go to the Microfilm Tests Menu. Select BASIC MICROFILM TEST. Then execute the Height BOL test. End of procedure.
YES
NO
3998 5593007
2121
19720
ALM blocked. STEP 100 PROCEDURE Remove any documents or debris from the optical gate, and rerun the POC. Does the problem still exist? 110 Using the MTR disk, go to the Microfilm Tests Menu. Select LAMPS/ALMS. If the test passes, paint the optical gate walls, and run the Lamp Intensity Density and ALM Adjustment hardware parameter routines. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
PC 15 0064
NO
950
950
19730
False ALM interrupt. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA. Does the problem still exist? 110 Replace the OSM PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
PC 15 0065
NO
950
950
2122
3998 5593007
19740
Front ALM A/D out of range. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check motherboard P11, Distribution A J4, and Distribution B J3.) Make the necessary corrections. Does the problem still exist? 110 Remove any documents or debris from the optical gate, and rerun the POC. Does the problem still exist? 120 Using the MTR disk, go to Microfilm Tests Menu. Select LAMPS/ALMS. If the test passes, paint the optical gate walls, and run the Lamp Intensity Density and ALM Adjustment hardware parameter routines. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
PC 15 0066
NO
950
950
950
19750
Rear ALM A/D out of range. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution A J5.) Make the necessary corrections. Does the problem still exist? 105 Remove any documents or debris from the optical gate, and rerun the POC. Does the problem still exist? 110 Using the MTR disk, go to Microfilm Tests Menu. Select LAMPS/ALMS. If the test passes, paint the optical gate walls, and run the Lamp Intensity Density and ALM Adjustment hardware parameter routines. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 105 YES
PC 15 0067
NO
950
950
950
3998 5593007
2123
19760
MFC front lamp failure. Note: Lamps must be off at the start of this test. Bring the motors down, and ensure that the lamps are off.
PC 15 0068
STEP 100
PROCEDURE Rerun the POC. Does the front lamp illuminate?
YES
NO
130
110
110
Check fuse F2 on the motherboard; replace it if required. Rerun the test. Does the problem still exist? 115 950
115
Use the lamp MTR to power on the front lamp. Check the voltage at slot 6, pin 46 on the motherboard. Is the voltage more negative than - 0.5 V? 120 160
120
Replace the front lamp. Rerun the POC. Does the problem still exist? 170 950
130
Reseat the Lamp PCBA. Rerun the test. Does the problem still exist? 140 950
140
Replace the Lamp PCBA. Rerun the test. Does the problem still exist? 150 950
150
Check connector P8 on the motherboard and J2 on the Lamp Heatsink Assembly and associated cables. Repair as required. Does the problem still exist? 160 950
160
Replace the Lamp Heatsink Assembly. Rerun the test. Does the problem still exist? 99600 950
2124
3998 5593007
19760
PC 15 0068
MFC front lamp failure Note: Lamps must be off at the start of this test. Bring the motors down, and ensure that the lamps are off. STEP 170 PROCEDURE Check connectors J2 and J1 on the Lamp Heatsink Assembly, P6 and P8 on the backplane, and associated cables. Repair as required. Does the problem still exist? 180 Use the lamp MTR to power on the front lamp. Check the Lamp PCBA backplane pin 46 with an oscilloscope or DVM. Is the voltage more negative than - 0.5 V? 190 Replace Lamp Heatsink Assembly. Does the problem still exist? 200 Replace the Lamp Driver PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 99600 950 190 200 180 950 YES NO
3998 5593007
2125
19770
MFC rear lamp failure. Note: Lamps must be off at the start of this test. Bring the motors down, and ensure that the lamps are off. STEP 100 PROCEDURE Rerun the POC. Does the rear lamp illuminate? 110 Check fuse F1 on the motherboard; replace it if required. Rerun the test. Does the problem still exist? 115 Use the lamp MTR to power on the rear lamp. Check the voltage at slot 6, pin 45 on the motherboard. Is the voltage more negative than - 0.5 V? 120 Replace the rear lamp. Rerun the POC. Does the problem still exist? 130 Reseat the Lamp PCBA. Rerun the POC. Does the problem still exist? 140 Replace the Lamp PCBA. Rerun the test. Does the problem still exist? 150 Check connectors P8 on the motherboard, J2 on the Lamp Heatsink Assembly, and associated cables. Repair as required. Does the problem still exist? 160 Replace the Lamp Heatsink Assembly. Rerun the test. Does the problem still exist? 210 160 150 140 170 120 115 130 YES
PC 15 0069
NO
110
950
160
950
950
950
950
950
2126
3998 5593007
19770
MFC rear lamp failure Note: Lamps must be off at the start of this test. Bring the motors down, and ensure that the lamps are off. STEP 170 PROCEDURE Check connectors J2 and J1 on the Lamp Heatsink Assembly, P6 and P8 on the backplane, and associated cables. Repair as required. Does the problem still exist? 180 Use the Lamp MTR to power on the rear lamp. Check the Lamp PCBA signal RQDR on backplane pin 45 with an oscilloscope or DVM. Is the voltage more negative than - 0.5 V? 190 Replace the Lamp Heatsink Assembly. Does the problem still exist? 200 Replace the Lamp Driver PCBA. Does the problem still exist? 210 Replace the Microfilm Controller PCBA. Rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 210 210 190 180 YES
PC 15 0069
NO
950
200
950
950
950
3998 5593007
2127
19780
Lamp error detection circuitry failure. STEP 100 PROCEDURE Reseat the Lamp Driver PCBA slot 6. Does the problem still exist? 120 Replace the Lamp Driver PCBA. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Check the continuity of signals RLCURON (pin 65), FLCURON (pin 66), and LSNSTST (pin 76) on the motherboard. Repair them if faulty. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 120 YES
PC 15 0070
NO
950
950
950
950
2128
3998 5593007
19790
Front and rear lamp failure. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check motherboard connectors P6 and P8 and Lamp Heatsink connectors J1.) Make the necessary corrections. Does the problem still exist? 105 Verify that F1 and F2 on the motherboard are correct. Make the necessary corrections. Does the problem still exist? 110 120 Do the lamps illuminate during POC? Reseat the Lamp Driver PCBA. Does the problem still exist? 130 Replace the Lamp Driver PCBA. Does the problem still exist? 140 Check connector P8 on the motherboard, J2 on the Lamp Heatsink Assembly, and associated cables. Repair as required. Does the problem still exist? 150 Replace the Lamp Heatsink Assembly. Does the problem still exist? 160 Check connector P8 on the motherboard, J1 and J2 on the Lamp Heatsink Assembly, and associated cables. Repair as necessary. Does the problem still exist? 170 Replace the front and rear lamps. Does the problem still exist? 180 170 99600 150 140 130 110 120 105 YES
PC 15 0071
NO
950
950 160
950
950
950
950
950
950
3998 5593007
2129
19790
Front and rear lamp failure STEP 180 PROCEDURE Replace the Lamp Driver PCBA. Does the problem still exist? 190 Replace the Lamp Heatsink PCBA. Does the problem still exist? 200 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 200 190 YES
PC 15 0071
NO
950
950
950
2130
3998 5593007
19800
Jumper configuration error. AA17 indicates DP 1825; microfilm controller indicates NDP 1150. STEP 100 PROCEDURE Check the jumper configuration per SH.09.01.01 for board that does not match the machine configuration. Make the necessary corrections. Rerun the POC. Does the problem still exist? 110 120 Is the sorter a NDP 1150? Replace AA17, and rerun the test. Does the problem still exist? 130 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 110 120 YES
PC 15 0072
NO
950 130
950
950
3998 5593007
2131
19810
Jumper configuration error. AA17 indicates NDP 1150; microfilm controller indicates DP 1825. STEP 100 PROCEDURE Check the jumper configuration per SH.09.01.01 for a board that does not match the machine configuration. Make the necessary corrections. Rerun the POC. Does the problem still exist? 110 120 Is the sorter a NDP 1150? Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 130 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 110 120 YES
PC 15 0073
NO
950 130
950
950
2132
3998 5593007
19820
Watchdog timer test failed. STEP 100 PROCEDURE Remove jumper W1 at 69BB70 on the Microfilm Controller PCBA. Place a volt meter on pin 78 of slot 8. Does it measure between 0 and 1 V? 110 Replace the Microfilm Controller PCBA. Rerun the test. Does the problem still exist? 120 Check the voltages coming into the microfilm gate. Are they all within +/5%? Replace card 8 in the microfilm gate, and rerun the test. Does the problem still exist? 140 Replace the cable at J5 of the Microfilm Controller PCBA. Does the problem still exist? 145 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 150 Replace the DC distribution harness for the microfilm module. Does the problem still exist? 160 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 160 99600 145 140 130 130 120 YES
PC 15 0075
NO
110
950 150
130
950
950
950
950
950
3998 5593007
2133
19830
Controller Supply Encoder register failed. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 110 950 Using the MTR disk, execute the supply encoder routine. End of procedure. Verify proper operation. End of procedure. 110 YES
PC 15 0076
NO
950
2134
3998 5593007
19840
NVRAM parameter out of range Note: Indicates some parameter value in NVRAM is either corrupted or incorrect.
PC 15 0077
STEP
PROCEDURE Acceptable NVRAM values (NDP 1150) LED 7D00 - 9470 (32.0 - 38.0 msec) TED A410 - BB80 (42.0 - 48.0 msec) 80 -FE
YES
NO
Lamps
Galvo 10 - 70 (See T&A 3304 5352 for recovery) ID delay 4E20 - 9C40 (20.0 - 40.0 msec) 00 - 30
ALM
For medium-speed film (NDP 1150) ICM 0F90 - 0FB0 (3.98 - 4.02 msec) AFB8 - AFD8 (44.98 - 45.02 msec)
HR HEADER
For high-speed film (NDP 1150) ICM 03D8 - 03F8 (0.98 - 1.02 msec) 3A88 - 3AA8 (14.98 - 15.02 msec)
HR HEADER
Acceptable NVRAM values (DP 1825): LED 38A4 - 5014 (14.5 - 20.5 msec)
3998 5593007
2135
19840
PC 15 0077 (continued)
NVRAM parameter out of range Note: Indicates some parameter value in NVRAM is either corrupted or incorrect.
STEP
PROCEDURE TED 4C90 - 6400 (19.6 - 25.6 msec) 80 -EF 10 - 70 4E20 - 9C40 (20.0 - 40.0 msec) 00 - 30 03D8 - 03F8 (.98 - 1.02 msec) 3A88 -- 3AA8 (14.98 - 15.02 msec)
YES
NO
Lamps Galvo ID delay
ALM ICM
HR HEADER
100
Select the hardware parameters adjustment routine. Verify all parameters. If any are not in acceptable range, make necessary corrections and rerun POC. Does the problem still exist? 110 950
110
Replace he Microfilm Controller PCBA, an d rerun the test. Does the problem still exist? 120 950
120
Replace the MIIB PCBA (AA03), and rerun the test. Does the problem still exist? 130 950
130
Replace AA17, and rerun the test. Does the problem still exist? 99600
950
2136
3998 5593007
Note: 19850
POC failed during NVRAM test. Could not verify values stored in RAM against NVRAM.
19860
NVRAM failed. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 110 Replace the MIIB PCBA (AA03), and rerun the test. Does the problem still exist? 120 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
PC 15 0079
NO
950
950
950
19870
BOL N is not generating correct IPLN signal. STEP 100 PROCEDURE Replace the MIIB PCBA (AA03), and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure 99600 YES
PC 15 0081
NO
950
3998 5593007
2137
19880
Capstan displacement profile is out of range. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check the cable on the Servo Heatsink PCBA J1, J2, and J7 and on the motherboard P7.) Make the necessary corrections. Does the problem still exist? 104 Rerun the POC with the film removed if not done already. Follow the appropriate fault code. Did PC 15 0082 occur again? 107 Using T&A 3304 4488, check the adjustment of the capstan velocity. Readjust it if required. Does the problem still exist? 110 Replace the Servo Amplifier PCBA, and adjust it to T&A 3304 4488. Rerun the POC. Does the problem still exist? 115 Replace the Microfilm Controller PCBA, and rerun the POC. Does the problem still exist? 120 Run the Film Transport MTR, and select CAPSTAN MOTOR TEST. Remove any film, and keep the film plate in a raised position. Select LARGE FAST MOVES and nonlooping mode. Did the capstan rotate when you pressed the Xmit key? 130 Press the F10 key to exit the routine, and deselect the capstan motor. Visually verify that the capstan has stopped moving. Has the capstan stopped rotating? 135 130 120 115 110 107 104 YES
PC 15 0082
NO
950
950
950
950
950
350
133
2138
3998 5593007
19880
Capstan displacement profile is out of range STEP 133 PROCEDURE Replace the Servo Heatsink Assembly, and retest. Rerun the Film Transport MTR, and select CAPSTAN MOTOR TEST. Select LARGE FAST MOVES and nonlooping mode. Wait 5 seconds, and then press the F10 key. Visually verify that the capstan has stopped moving. Has the capstan stopped rotating? 135 Rotate the capstan motor by hand. Is it free to rotate? 140 On the microfilm backplane slot 7, connect an oscilloscope probe to J1 pin 44 and ground it to J1 pin 29. Set the time base to 20 msec/cm, autotrigger. Using a fast twisting action, rotate the capstan roller in a clockwise direction. Is the waveform triangular with a peak of approximately 2 V? 150 Check the continuity of the connections from J1 pins 29 and 44 on slot 7 of the motherboard to the capstan motor. Repair as required. Does the problem still exist? 155 157 Has the Servo Heatsink Assembly been replaced in a previous step? Replace the Servo Heatsink Assembly, and retest. Does the problem still exist? 160 Replace the capstan motor, and adjust to T&A 3304 4488. Does the problem still exist? 99600 160 155 160 170 140 135 YES
PC 15 0082
NO
160
250
150
950 157
950
950
3998 5593007
2139
19880
Capstan displacement profile is out of range STEP 170 PROCEDURE On the motherboard slot 7, connect the oscilloscope probe 1 to pin 48 and probe 2 to pin 50. Set the time base to 20 msec/cm, autotrigger. Rotate the capstan roller slowly and uniformly. Do both channels show square waves in phase quadrature with switching levels < 0.8 V to > 2.4 V? 190 Check the continuity of the connections from J1 pins 48 and 50 on slot 7 of the motherboard to the capstan motor. Repair as required. Does the problem still exist? 195 197 Has the Servo Heatsink Assembly been replaced in a previous step? Replace the Servo Heatsink Assembly, and retest. Does the problem still exist? 200 Replace the capstan motor, and adjust to T&A 3304 4488. Does the problem still exist? 250 255 260 Monitor pin 25 of the backplane slot 7, signal MOTEN. Is pin 25 < 0.8 V? Has the Servo Heatsink Assembly been replaced in a previous step? Replace the Servo Heatsink Assembly, and retest. Does the problem still exist? 270 200 99600 99600 255 270 195 200 99600 YES
PC 15 0082
NO
190
950 197
950 950 950 280 260
950
2140
3998 5593007
19880
Capstan displacement profile is out of range STEP 270 PROCEDURE Check the continuity of the harness between slot 7 and the Servo Heatsink Assembly. Repair and retest. Does the problem still exist? 280 Unplug connector P1 from the Servo Heatsink Assembly, and retest. Select the Capstan Motor MTR test; do not execute moves at this point. Monitor pin 25 of the backplane slot 7, signal MOTEN. Is pin 25 < 0.8 V? 285 290 Has the Servo Heatsink Assembly been replaced in a previous step? Replace the Servo Heatsink Assembly, and retest. Does the problem still exist? 300 Check the continuity of the harness between slot 7 and the Servo Heatsink Assembly. Repair and retest. Does the problem still exist? 350 370 380 390 400 410 Is the Capstan Motor Roller free to rotate? On the motherboard slot 7, is pin 43 (CAPDR) > 0.8 V? On the motherboard slot 7, is pin 25 (MOTEN) > 2.4 V? On the motherboard slot 7, is pin 26 (CAMPWR) > 2.4 V? On the Servo Heatsink PCBA, is J2 pin 2 (CAPMOTHI) > 15 V? On the Servo Heatsink PCBA, is J2 pin 4 (CAPMOTLO) < 0.8 V? 99600 99600 380 390 400 410 420 300 285 300 99600 YES
PC 15 0082
NO
950
99600 290
950
950 370 500 500 500 440 440
3998 5593007
2141
19880
Capstan displacement profile is out of range STEP 420 PROCEDURE Replace the Servo Heatsink PCBA, and retest. Does the problem still exist? 430 Check on the Servo Heatsink Assembly that J2 pin 5 is > 23 V and that J2 pin 3 is more negative than - 23 V. If not, find the power supply or harness problem, and retest. Does the problem still exist? 440 Check the continuity of the connections from J2 pins 2 and 4 on the Servo Heatsink PCBA to the capstan motor. Repair as required. Does the problem still exist? 450 Replace the capstan motor, and adjust it to T&A 3304 4488. Does the problem still exist? 500 Unplug P1 from the Servo Heatsink Assembly. Run the Film Transport MTR, and select CAPSTAN MOTOR TEST. Remove any film, and keep the film plate in a raised position. Select LARGE FAST MOVES and looping mode. Monitor slot 7 pin 83 of the motherboard (CAMPWR). Is pin 83 > 2.4 V? 510 Trace signal CAMPWR from slot 7 pin 83 back to slot 8 pin 83. Repair and retest. Does the problem still exist? 520 530 On the motherboard slot 7, is pin 43 (CAPDR) < 0.8 V? On the motherboard slot 7, is pin 25 (MOTEN) > 2.4 V? 99600 530 540 510 99600 450 99600 430 YES
PC 15 0082
NO
950
950
950
950
520
950 99600 99600
2142
3998 5593007
19880
Capstan displacement profile is out of range STEP 540 PROCEDURE Replace the Servo Heatsink Assembly, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
PC 15 0082
NO
950
3998 5593007
2143
Note: 19890
Microfilmer dual-port RAM failure. Test data corrupted.
STEP 100
YES
NO
110
950
110
120
130
Check the serial interface cable for proper operation. Make the necessary corrections. Does the problem still exist? 99600 950
950
19900
LED NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0090
NO
19901
TED NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0091
NO
2144
3998 5593007
19902
Front Lamp NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0092
NO
19903
Rear Lamp NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0093
NO
19904
Galvo Home NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0094
NO
19905
ID Display Intensity NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0095
NO
19906
Automatic Light Meter NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0096
NO
3998 5593007
2145
19907
Image Capture Mark NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0097
NO
19908
Human Readable Header NVRAM parameter out of range. STEP 10 PROCEDURE Follow manual procedure for PC 15 0077. End of procedure. YES
PC 15 0098
NO
19910
POC status not being returned by MIIB. STEP 100 PROCEDURE Replace the MIIB PCBA (AA03), and rerun the test. Does the problem still exist? 110 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
PC 15 0100
NO
950
950
2146
3998 5593007
Section 3 Transport Basic Tests: Tracking Logic and AA Backplane Types

50000 TB 0 xxxx
This section deals with faults that occur anytime while running subtests 01-06 and that are not specifically included in any one subtest. 50000
Unexpected bus exception occurred. STEP 100 PROCEDURE Replace board indicated on terminal. Rerun transport basic subtest that failed. Does the problem still exist? 110 Replace AA17 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 950 110 950 YES NO
TB 00 0100
3998 5593007
31
50100
Unexpected bus exception occurred when address on terminal was accessed. STEP 100 PROCEDURE Rerun transport basic test that was running when exception occurred. Does the problem still exist? 110 120 Find address on screen in table below, if listed. Is address listed? Replace suspect board(s) associated with listed address, one at a time. Rerun transport basic test that caused error after replacing each board. Does problem still exist? 130 Replace AA17 and rerun test. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 130 110 120 YES
TB 00 0110
NO
950 130
950
950
3 2
3998 5593007
Table 31. Troubleshooting Chart for Unexpected Bus Exceptions (TB 00 0010) with the NDP 1150 68030-Based Main CPU Board
Address $0 - $00FF FFFF $0100 0000 - $0101 FFFF $0140 0000 - $015F FFFF $0180 0000 - $0180 003F $01FF FF01 - $01FF FFFF $0300 0000 - $0300 1FFF $03FF F100 - $03FF F200 $03FF F900 - $03FF FA00 $03FF E000 - $03FF E7FF $03FF FC00 - $03FF FC0B $03FF FC0C - $03FF FC15 $03FF FC16 - $03FF FC1A $03FF FC1B $03FF FC1C - $03FF FC1D $03FF FC30 $03FF FC32 - $03FF FC3B $03FF FC63 - $03FF FC69 $03FF FC6A - $03FF FC6C $03FF FC6D - $03FF FC6F $03FF FC70 - $03FF FC72 $03FF FC73 - $03FF FC75 $03FF FC76 - $03FF FC79 $03FF FC7A - $03FF FC7B $03FF FCC0 - $03FF FCFF $03FF FD00 - $03FF FD3F $03FF FD40 - $03FF FD7F $03FF FD80 - $03FF FDBF
Suspect Board AA17 AA17 AA17 AA17 AA17 AA17 AA03 (DP 1000-65 camera) AA09 (PEP/Stamp) AA09 (MJE) AA08 AA10 AA08 AA02 AA08 AA08 AA02 AA10 AA05 AA05 AA02 AA02 AA11, AA12 AA11 AA02 AA02 AA05 AA05
3998 5593007
33
Table 32. Troubleshooting Chart for Unexpected Bus Exceptions (TB 00 0010) with the NDP 18xx 68030-Based Main CPU Board
Address $0 - $00FF FFFF $0100 0000 - $0101 FFFF $0140 0000 - $015F FFFF $0180 0000 - $0180 003F $01FF FF01 - $01FF FFFF $0300 0000 - $0300 1FFF $03FF F100 - $03FF F200 $03FF E000 - $03FF E7FF $03FF FC00 - $03FF FC0B $03FF FC0C - $03FF FC15 $03FF FC16 - $03FF FC1A $03FF FC1B $03FF FC1C - $03FF FC1D $03FF FC30 $03FF FC32 - $03FF FC3B $03FF FC63 - $03FF FC69 $03FF FC6A - $03FF FC6C $03FF FC6D - $03FF FC6F $03FF FC70 - $03FF FC72 $03FF FC73 - $03FF FC75 $03FF FC76 - $03FF FC79 $03FF FC7A - $03FF FC7B $03FF FCC0 - $03FF FCFF $03FF FD00 - $03FF FD3F $03FF FD40 - $03FF FD7F $03FF FD80 - $03FF FDBF $03FF FDC0 - $03FF FDFF
Suspect Board AA17 AA17 AA17 AA17 AA17 AA17 AA03 (DP 1800-65 camera) AA09 (MJE) AA08 AA10 AA08 AA02 AA08 AA08 AA02 AA10 AA05 AA05 AA02 AA02 AA11, AA12 AA11 AA02 AA02 AA05 AA05 AA05
3 4
3998 5593007
Section 4 Transport Basic Subtest 1: Tracking Logic and AA Backplane Types

60025
"Area 3 presence" status in the main diagnostic control register (address $03FF FC30, card AA08) does not agree with "Area 3 presence" status in BOL 14 status register (address $03FF F07E, card AA05). STEP 100 110 120 PROCEDURE Are there more than 16 pockets present? Using schematics, trace signal A3PLN (SH.01.23.05). Is it a constant low? Trace signal A3PLN to determine why it is not low. Make necessary corrections. Does the problem still exist? 130 140 Using schematics, trace signal A3PLN (SH.01.23.05). Is it constant high? Trace signal A3PLN to determine why it is not high. Make necessary corrections. Does the problem still exist? 150 Replace AA08 and rerun test. Does the problem still exist? 160 Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 950 160 950 99000 950 99000 150 950 140 YES 110 130 NO 130 120
TB 01 0001
3998 5593007
41
Note: 60050
Different procedures are used to resolve each of the failure codes on this page. TB 01 0002
Area 3 present reporting not consistent.
STEP 100
PROCEDURE Replace AA05 and rerun test. Does the problem still exist?
YES
NO
99000
950
950
60075
Area 3 reported not present, but card can be accessed. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 110 YES
TB 01 0003
NO
950
60100
BOL 30 status register (address $03FF FDBE, card AA05) indicates Area 4 is not present. However, no bus traps occur when Area 4specific addresses are accessed. Area 4 addresses are from $03FF FDC0 - $03FF FDFF. STEP 100 PROCEDURE Verify jumper W10 on card AA05 (SH.09.01.01) is configured correctly. If more than 32 pockets exist, a jumper should be present. If a configuration problem exists, make necessary modifications and rerun test. Does the problem still exist? 150 Replace card AA05. Does the problem still exist? 950 Verify proper operation. End of procedure. 92000 150 YES
TB 01 0004
NO
950
950
4 2
3998 5593007
Note:
60125 (NDP 1150)

Configuration register 2 (address $03FF FC13, card AA10) reports PEP/stamp not present, but card can be accessed. STEP 100 110 PROCEDURE Is Impact Endorser present jumper installed? Install Impact Endorser jumper and rerun test. Does the problem still exist? 120 Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 YES 120
NO 110
950
950
60125 (NDP 18xx)

Configuration register 2 (address $03FF FC13, card AA10) reports rear MJE not present, but card can be accessed. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 110 Replace AA10 and rerun test. Does the problem still exist? 120 Problem is backplane signal NIEPLN open. Use schematics (SH.01.23.06) to trace and make necessary corrections. Rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0005
NO
950
950
950
3998 5593007
43
Note: 60150
Main clock card reports card in test mode.
STEP 100
YES
NO
99000
950
950
60200
Tracking card reports card in test mode. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0008
NO
950
60250
Tracking card reports card in test mode. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0010
NO
950
60275
MICR/CONFIG reports card in a test mode. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0011
NO
950
4 4
3998 5593007
Note: 60300
Microfilm reports card in test mode.
STEP 100
YES
NO
99000
950
950
60375
All cards have independently indicated that they are not in test mode. However, the main diagnostic control register (address $03FF FC30, card AA08) is reporting a card in test mode. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA10 and rerun test. Does the problem still exist? 120 Trace signal INTESTN starting at AA08 - J161. Make necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0015
NO
950
950
950
3998 5593007
45
60400
All cards have independently indicated that they are not in test mode. However, the miscellaneous diagnostic register (address $03FF FC69, card AA10) is reporting a card in test mode. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 110 Problem is with signal INTESTN. Trace signal INTESTN starting at AA08 - J161. Make necessary corrections and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0016
NO
950
950
4 6
3998 5593007
Note: 60425
The same procedure is used to resolve each of the failure codes on this page. TB 01 0017
Command result register does not report gate fault reset.
60450
Command result register did not clear after reading.
TB 01 0018
60475
Command result register does not report. BOL reset.
TB 01 0019
60500
Command result register did not clear after read.
TB 01 0020
60525
Interrupt source register not clear. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0021
NO
950
3998 5593007
47
Note: 60550
Clock register not correct.
60575
Disposition status shows SOKL or STLP. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0023
NO
950
4 8
3998 5593007
60600
All interlocks should be closed but Transport Status Register 2 (address $03FF FC19, card AA08) is reporting an open interlock. STEP 100 PROCEDURE Visually verify that all interlocks are closed. Rerun the test. Does the problem still exist? 105 Replace AA08 and rerun the test. Does the problem still exist? 110 Replace AA02 and rerun the test. Does the problem still exist? 120 Replace AA05 and rerun the test. Does the problem still exist? 130 Run the "Display Scans: Interlock Reports" MTR to determine which interlocks are being reported as open. Use schematic SH.04.03.01 for Area 1 and Area 1B interlocks. Use schematic SH.04.02.01 for pocket module interlocks. Make necessary corrections and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 120 110 105 YES
TB 01 0024
NO
950
950
950
950
950
3998 5593007
49
Note: 60700
Transport Status Register 2 (address $03FF FC19, card AA08) reports an open interlock, but no location can be found.
STEP 100
YES
NO
110
950
110
120
950
60750
User has closed all interlocks, but the interlock(s) listed are still reporting an open condition. STEP 100 PROCEDURE Start the troubleshooting switch and wiring associated with the interlock listed. Make the necessary corrections. Does the problem still exist? 110 Replace the 4 pocket driver card associated with the failed baseplate assembly. Rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0030
NO
950
410
3998 5593007
Note: 60800
Area 1 cover has been opened, but Transport Register 2 (address $03FF FC19, card AA08) is reporting all interlocks closed.
STEP 100 110
PROCEDURE Is Area 1 cover open? Rerun test, following instructions to open area one cover. Does problem still exist?
YES 120
NO 110
120
950
120
Replace AA02 and rerun test. Does the problem still exist? 130 950 950 99000
130
Replace AA08, and rerun test. Does the problem still exist?
950
60825
Area 1 cover has been opened, but BOLE Status Register 1 reports its interlock closed. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0033
NO
950
60850
Area 1B cover has been opened, but BOL PE4 Status Register 1 (address $03FF FD1E) reports its interlock is closed. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0034
NO
950
3998 5593007
411
Note: 60875
Area 1 cover has been opened, but BOLs other than BOL E are reporting an open interlock.
STEP 100
YES
NO
99000
950
950
60900
Area 1B cover has been opened, but BOLs other than BOL PE4 are reporting an open interlock. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0036
NO
950
60925
Interlock(s) other than Area one cover reported open in Area 2 (3, 4). STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA05 and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0037
NO
950
950
412
3998 5593007
Note: 60950
Command result register not reporting BOL reset.
STEP 100
YES
NO
99000
950
950
60975
Not all Area 1 bias values equal zero at power up. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0039
NO
950
61000
Not all Area 1B bias values equal zero at power up. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0040
NO
950
61025
TB 01 0041
NO
950
3998 5593007
413
Note: 61050
Not all Area 3 bias values equal zero at power up.
STEP 100
YES
NO
99000
950
950
61075
TB 01 0043
NO
950
61100
An Area 1 status register not zero at power up. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0044
NO
950
61125
An Area 1B status register not zero at power up. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0045
NO
950
414
3998 5593007
Note: 61150
Area 2 status register not correct.
STEP 100
YES
NO
110
950
110
Problem may be in BOL circuitry. Run subtest 02 and follow appropriate fault code. End of procedure. Verify proper operation. End of procedure.
950
61175
Full pocket reported in Area 2/3/4. STEP 100 PROCEDURE Check switch and wiring for pocket. Make necessary corrections. Does the problem still exist? 110 Replace AA05 and rerun test. Does the problem still exist? 120 Replace 4-pocket driver associated with pocket. Rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0047
NO
950
950
950
61200
More than one full pocket in Area 2/3/4. STEP 100 PROCEDURE Replace AA05, and rerun the test. Does the problem still exist? 110 Disconnect the 4 pocket drivers, one at a time, until the problem disappears. The last baseplate assembly disconnected is the problem area. The problem could be the card or the wiring. Make the necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0048
NO
950
950
3998 5593007
415
Note: 61225
Transport status reports missort or jam in the primary/secondary feeders.
STEP 100
YES
NO
110
950
110
950
61250
Transport status reports jam. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA05 and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0050
NO
950
950
61275
Jam reported, but no jam can be located. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0051
NO
950
416
3998 5593007
Note: 61300
Secondary hopper empty, but documents still sensed or secondary hopper reporting not present and hopper empty.
STEP 100
PROCEDURE Check jumpers per SH.09.01.01. Make necessary corrections. Rerun test. Does problem still exist?
YES
NO
105
950
105
Replace BOL in secondary hopper and rerun test. Does the problem still exist? 110 950
110
120
130
950
61325
Primary hopper empty, but documents still sensed. STEP 100 PROCEDURE Replace BOL in primary hopper and rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0053
NO
950
950
950
3998 5593007
417
Note: 61350
Illegal transport configuration.
61375
Illegal transport configuration. Note: STEP 100 Transport status 2 YES
TB 01 0055
NO
99000
950
950
418
3998 5593007
Note: 61400
Transport Status Register 2 (address $03FF FC19, card AA08) reports Impact Endorser ready. However, Configuration Register 2 (address $03FF FC13, card AA10) indicates the Impact Endorser is not present.
STEP 100
PROCEDURE Verify "Impact Endorser Present" jumper on AA10 is in place if an Impact Endorser is present. Make necessary corrections to ensure jumper configuration matches actual configuration. Rerun test. Does the problem still exist?
YES
NO
105
950
105
110
950
61425
Z-80 overload reported STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 110 Problem is character recognition inputs. Start troubleshooting at character recognition inputs. Make necessary corrections and rerun test. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0057
NO
950
950
61450
Low vacuum is sensed in Transport Status Register 3. STEP 100 PROCEDURE Follow manual procedure for TB 04 0084. End of procedure. YES
TB 01 0058
NO
3998 5593007
419
Note: 61475
Microfilm reported not ready or film skip. (Microfilm present)
STEP 100
YES
NO
99000
950
950
61500
Microfilm not present, but reported not ready, or film skip. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0060
NO
950
61525 (NDP 1150)

PEP/Stamp report not ready. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES NO
TB 01 0061
950
61525 (NDP 18xx)

Endorser report not ready. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES NO
TB 01 0061
950
420
3998 5593007
Note:
61550 (NDP 1150)

PEP/Stamp not present but reported not ready. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES NO
950
61550 (NDP 18xx)

Endorser not present but reported not ready. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES NO
TB 01 0062
950
61575
Blackband reported in transport status. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA10 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0063
NO
950
950
950
3998 5593007
421
Note: 61600
Illegal transport status. Transport Register 4 (address $03FF FC1B, card AA02) is reporting one or more of the following conditions: "A1/2 INT ERR" "BUFFER OVERFLOW" "MISSORT ALL"
STEP 100
YES
NO
99000
950
950
61625
Microfilm missort bit set in transport status 5. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0065
NO
950
950
61650
A circuit breaker has been detected open. STEP 100 PROCEDURE Using schematics start troubleshooting with signal LAMPOFF (SH.03.01.02). Expected high for no circuit breaker open. (Suspect cards are AA08 and CABB1.) Make necessary corrections and rerun test. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0066
NO
950
422
3998 5593007
61675
Dirty BOL A reported. STEP 100 PROCEDURE Replace AA02, and rerun the test. Does the problem still exist? 110 Replace AA10, and rerun the test. Does the problem still exist? 120 Replace AA08, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0067
NO
950
950
950
3998 5593007
423
Note: 61700
A motor error has been detected. Triac card or motor itself could be cause of this failure. Note: Do not open an interlock as this will clear error. YES NO
STEP 100
PROCEDURE Replace CABB1 and rerun test. Does the problem still exist?
110
950
110
950
61725
Illegal status reported in transport status 6. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0069
NO
950
424
3998 5593007
Note: 61750
Reading document data A did not cause expected bus trap.
61775
Reading document data B did not cause expected bus trap.
TB 01 0071
61800
Document Data Status reported, but should be zero. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure 99000 YES
TB 01 0072
NO
950
3998 5593007
425
Note: 61825
Microfilm status not cleared.
STEP 100
YES
NO
99000
950
950
61850
Motor status error detected. STEP 100 PROCEDURE Replace CABB1 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 120 130 Is the control module present? Replace DABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 130 110 YES
TB 01 0074
NO
950
950 99000
950
61875
Area 4 not present, but motor 4 bit not set. STEP 100 PROCEDURE Replace DABB1 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0075
NO
950
950
950
426
3998 5593007
Note: 61900
Area 4 motor reported up.
STEP 100
PROCEDURE Replace DABB1 and rerun test. Does the problem still exist?
YES
NO
110
950
110
Replace CABB1 and rerun test. Does the problem still exist? 120 950
120
950
61925
Motors reporting ready. STEP 100 PROCEDURE Replace CABB1 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0077
NO
950
950
61950
C/M Power error reported. STEP 100 PROCEDURE Replace DABB1 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 01 0078
NO
950
950
950
3998 5593007
427
Note: 61975
Area One cover IEC magnetic switch is sensed closed.
STEP 100
PROCEDURE Using schematics, start troubleshooting switch and wiring signal A1SINT (SH.03.01.03) expected constant high for open switch. Make necessary corrections and rerun test. Does the problem still exist?
YES
NO
99000
950
950
62000
Main power switch is sensed off. STEP 100 PROCEDURE Using schematics, start troubleshooting switch and wiring signal PWRSWNC (SH.02.01.01) expected constant high with power on. Make necessary corrections and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 01 0080
NO
950
62025
Driver status one not reporting correctly. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0081
NO
950
950
428
3998 5593007
Note: 62050
Driver status not reporting open interlock.
STEP 100
YES
NO
110
950
110
120
950
62075
Driver status two not reporting correctly. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA09 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 01 0083
NO
950
950
62100
Driver status two not reporting correctly. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 110 YES
TB 01 0084
NO
950
3998 5593007
429
Note: 62125
Double document switch sensed closed.
STEP 100
PROCEDURE Check double document switch adjustment per T&A 2974 3069. Make corrections and rerun test. Does the problem still exist?
YES
NO
110
950
110
Using schematics, start troubleshooting with signal PIEZON (SH.04.04.01) expected high. Make corrections and rerun test. Does the problem still exist? 120 950
120
950
62150
Configuration Register 2 indicates card AA09 is present. However, addresses on card AA09 are not accessible to the main CPU. STEP 100 PROCEDURE Visually verify the presence of card AA09 in the AA gate. Is the card present? 110 Replace card AA09 and rerun test. Does the test pass? 120 130 140 Does the same error code occur? Follow manual procedure for new error code. End of procedure Replace card AA17 and rerun test. Does the test pass? 150 160 Does the same error code occur? Replace card AA10 and rerun test. Does the test pass? 170 950 Does the same error code occur? Verify proper operation. End of procedure. 950 140 950 99999 950 140 110 YES
TB 01 0086
NO
160
120 130
150 130
170 130
430
3998 5593007
Note: 62160
Configuration Register 2 indicates card AA03 is present. However, addresses on card AA03 are not accessible to the main CPU.
STEP 100
PROCEDURE Visually verify the presence of card AA03 in the AA gate. Is the card present?
YES
NO
110
160
110
Replace card AA03 and rerun test. Does the test pass? 950 140 120 130
120 130 140
Does the same error code occur? Follow manual procedure for new error code. End of procedure Replace card AA17 and rerun test. Does the test pass?
950 99999
150 130
150 160
Does the same error code occur? Replace card AA10 and rerun test. Does the test pass?
950 140
170 130
170 950
Does the same error code occur? Verify proper operation. End of procedure.
62170
Configuration Register 2 indicates card AA09 is present. The main CPU can access the MJE dual port RAM. However, the presence of BOLs J, K, L, and M cannot be verified. This indicates no MJE is installed. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA17 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure 99999 110 YES
TB 01 0088
NO
950
950
3998 5593007
431
432
3998 5593007

Note: 63000
An open interlock has been reported in Transport Register 2, but the open interlock cannot be located in the BOL status register. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 120 Replace AA03 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure.. 99000 950 120 950 YES NO
63050
Area one bad BOL bit did not set. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0002
NO
950
3998 5593007
51
Note: 63100
BOL S (secondary feeder) bad. BOL did not set.
STEP 100
YES
NO
110
950
110
950
63150
Rear MJE present, but BOL J & K not reporting correctly. Note: STEP 100 Should be reporting bad BOL. YES
TB 02 0004
NO
110
950
110
950
63200
Rear MJE not present, but BOL J and BOL K reporting bad BOL. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0005
NO
950
5 2
3998 5593007
Note: 63250
BOLs status reporting bad, but transport status does not agree.
STEP 100
YES
NO
110
950
110
950
63300
"Dirty/Bad BOL" did not reset in area one after a BOL reset. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 120 Replace AA05 and rerun test Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 02 0007
NO
950
950
950
3998 5593007
53
Note: 63350
Bad BOL reported at BOL N, P, Q, but microfilm not present.
63400
Area 1B reports an unexpected/incorrect BOL signal.
TB 02 0009
63450
"Bad/Dirty BOL" did not reset in area 1B after a BOL reset. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0010
NO
950
5 4
3998 5593007
Note: 63500
Area two reports an unexpected/incorrect BOL signal.
STEP 100
YES
NO
99000
950
950
63550
No last pocket found in area two. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. Note: Make sure jumpers are set correctly on 4-pocket driver cards. 99000 YES
TB 02 0012
NO
950
63600
Area two reports more than one last pocket. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0013
NO
950
3998 5593007
55
Note: 63650
Area two BOL reporting Bad/Dirty BOL status, but transport status does not agree.
STEP 100
YES
NO
99000
950
950
63700
"Bad/Dirty BOL" did not reset in area two after BOL reset. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0015
NO
950
63750
Area three reports an unexpected/incorrect BOL signal. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0016
NO
950
5 6
3998 5593007
Note: 63800
No last pocket found in area 3.
STEP 100
YES
NO
99000
950
950
63850
More than one last pocket found in area three. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0018
NO
950
3998 5593007
57
Note: 63900
Area 4 reports incorrect BOL status or last pocket error.
STEP 100
YES
NO
99000
950
950
63950
BOL count incorrect in area 1. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0020
NO
950
950
5 8
3998 5593007
Note: 64000
BOL count check incorrect in area 1B.
STEP 100
YES
NO
99000
950
950
64050
BOL count check incorrect in area 2. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0022
NO
950
64100
TB 02 0023
NO
950
64150
TB 02 0024
NO
950
3998 5593007
59
Note: 64200
"Jam" bit did not set in transport status when forced in area one.
STEP 100
YES
NO
110
950
110
950
64250
"Jam" bit did not set when forced in area one. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0026
NO
950
950
64300
"Jam 1" bit did not set in driver status when forced in area 1. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0027
NO
950
950
510
3998 5593007
Note: 64350
"Jam" did not clear in driver status when BOL/GF/TE reset.
STEP 100
YES
NO
99000
950
950
64400
"Jam" did not clear with BOL/GF/TE reset. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0029
NO
950
950
64450
"Jam" bit did not set in transport status when forced in area 1B. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0030
NO
950
3998 5593007
511
Note: 64500
"Jam" bit did not set in when forced in area 1B.
STEP 100
YES
NO
110
950
110
120
950
64550
"Jam 2" bit did not set in driver status when forced in area 1B. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0032
NO
950
950
64600
"Jam" did not clear after GF/TE/BOL reset. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0033
NO
950
512
3998 5593007
Note: 64650
"Jam" bit did not set in transport status when forced in area 2.
STEP 100
YES
NO
99000
950
950
64700
"Jam" bit did not set when forced in area two. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 02 0035
NO
950
950
950
64750
"Jam 2" bit did not set in driver status when forced in area 2. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0036
NO
950
950
3998 5593007
513
Note: 64800
"Jam" bit did not clear after GF/TE/BOL reset.
STEP 100
YES
NO
99000
950
950
64850
"Jam" bit did not set in transport status when forced in area 3. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0038
NO
950
64900
"Jam" bit did not set when forced in area 3. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0039
NO
950
950
514
3998 5593007
Note: 64950
"Jam 3" bit did not set in driver status when forced in area 3.
STEP 100
YES
NO
110
950
110
950
65000
"Jam" bit did not clear after GF/TE/BOL reset. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0041
NO
950
65050
"Jam" bit did not set in transport status when forced in area 4. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0042
NO
950
3998 5593007
515
Note: 65100
"Jam" bit did not set when forced in area 4.
STEP 100
YES
NO
110
950
110
950
65150
"Jam 3" bit did not set in driver status when forced in area 4. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 120 Replace DABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 02 0044
NO
950
950
950
516
3998 5593007
Note: 65200
"Jam" bit did not clear after GF/TE/BOL reset.
STEP 100
YES
NO
99000
950
950
65250
BOL status incorrect in area 1. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0046
NO
950
65300
The motors are not down is being reported. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0047
NO
950
950
3998 5593007
517
Note: 65350
Feed error being reported.
STEP 100
YES
NO
110
950
110
120
950
65400
Transport status 4 incorrect. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0049
NO
950
65450
Unexpected value in transport status 5. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0050
NO
950
950
518
3998 5593007
Note: 65500
Unexpected value in driver status 1.
STEP 100
YES
NO
110
950
110
950
65550
Microfilm BOLs (BOLN, BOLP, BOLQ) are detected but the microfilm is not declared as an installed option. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0052
NO
950
65600
Area 1B reports an unexpected/in correct BOL status. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0053
NO
950
3998 5593007
519
Note: 65650
The motors are not down is being reported.
STEP 100
YES
NO
110
950
110
950
65700
Feed error being reported. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0055
NO
950
65750
Transport status 04 incorrect. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 02 0056
NO
950
65800
Unexpected value in transport status five. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 02 0057
NO
950
950
520
3998 5593007
Note: 65850
Unexpected status in driver status 1.
STEP 100
YES
NO
110
950
110
950
65900
BOL bias value out-of-range. Note: BOLs in reverse video on screen are out-of-range. YES
TB 02 0059
STEP 100
PROCEDURE Clean/adjust/or replace indicated BOLs. Rerun test. Does the problem still exist?
NO
99000
950
950
3998 5593007
521
65950
Bad BOL reported. STEP 100 105 PROCEDURE Run BAD BOL routine under SCANS. Does SCANS report only one bad BOL? Replace or adjust bad BOL. Rerun basic subtest 02. Does the problem still exist? 106 107 108 Are any bad BOLs reported? Are all BOLs for an area reported bad? (such as, Area 1, Microfilm, Area 2, Area 3, Area 4) A short probably exists on the common LED line or phototransistor line for the problem area. This can be due to a single shorted LED or phototransistor, a harness short, a backplane short, a 4-pocket driver card (if the problem is in the pockets), or the tracking logic card for that area. For corrections check the CCC table in section 15 under BOLs. If a circuit malfunction is determined to be the cause, resume this procedure at step 110. Is the bad BOL in area 1 or area 1B? Replace AA02 and rerun basic subtest 02. Does the problem still exist? 150 160 Is bad BOL(s) in area 2, area 3, or area 4? Replace AA05 and rerun basic subtest. Does the problem still exist? 210 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 210 210 160 120 110 107 108 YES 105
TB 02 0060
NO 106
950 210 110
110 120
150
950 210
950
950
522
3998 5593007

68000
This section deals with diagnosis of problems in the transport (tests pocket lights, BOLs, and motors). If the sorter Power On Confidence (POC) test did not pass, proceed to Section 2 on POC diagnosis. This section provides diagnostic information based on the assumption that the POC test was passed.
TB 03 xxxx
3998 5593007
61
Note: 68000
Area 2 (reject - 14) reports more than one last pocket in the machine.
68010
Area 2 (Reject - 14) reports a last pocket that is invalid, or a valid last pocket is reported in Area 2 with Area 3 (15 - 30) present. STEP 110 PROCEDURE Check for proper jumper configurations on the 4 Pocket Driver cards and AA05 per SH.09.01.01. Make necessary corrections and rerun test. Does the problem still exist? Check voltages of +5V and +24V on all 4 Pocket Driver cards. Repair as needed and rerun test. Does the problem still exist? 130 Temporarily configure the machine as a shorter unit to isolate a faulty 4 Pocket Driver card or a Ribbon Cable connected to them. Caution: Exercise caution if you perform the following steps while power is applied: 1. Disconnect the Ribbon Cable between sections. The last section still connected becomes the last pocket in the machine. Add "Last in machine" jumper to this section. Remove AA05 jumpers "More than 16 Pockets" or "More than 32 Pockets" as needed. 130 YES 120
TB 03 0002
NO 950
120
950
2.
Rerun test as needed on the shortened machine. Power down to replace components as indicated. If unit still fails as a 4 pocket configuration, replace AA05 and rerun the test. Does the problem still exist? 140 150 Replace the first 4 Pocket Driver card and rerun the test. Does the problem still exist? Replace the signal cable to the first 4 Pocket Driver card and rerun the test. Does the problem still exist? Verify proper operation. End of procedure. 140 150 99000 950 950 950
950
6 2
3998 5593007
68020
Not all bias values after last pocket equal zero. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0003
NO
950
3998 5593007
63
Note: 68030
No last pocket found in Area 2 (Reject - 14)and Area 3 (15 - 30) does not exist.
68030
Area 3 (15 - 30) reports more than one last pocket in the machine.
TB 03 0005
68050
Area 3 (15 - 30) reports a last pocket that is invalid or a valid last pocket is reported in Area 3 with Area 4 (31 - 46) present. STEP 100 PROCEDURE Follow manual procedure for TB 03 0001. End of procedure. YES
TB 03 0006
NO
6 4
3998 5593007
68060
Not all bias values after last pocket in Area 3 equal zero. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0007
NO
950
3998 5593007
65
Note: 68070
No last pocket found in the machine.
68080
No last pocket found in the machine.
TB 03 0009
68090
Area 4 (31 - 46) reports more than one last pocket or a last pocket that is invalid. STEP 100 PROCEDURE Follow manual procedure for TB 03 0001. End of procedure. YES
TB 03 0010
NO
6 6
3998 5593007
Note: 68100
Not all bias values past last pocket in Area 4 equal zero.
STEP 100
YES
NO
99000
950
950
68110
STOP/START bar is stuck. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Using schematics, measure signals SSBARN (SH.01.23.09) and SWSTPNO (SH.04.04.01) Are all signals a constant high? 120 Use schematics to trace signal that is not high to determine why it is not high. Make necessary corrections. Is signal a constant high now? 130 Using schematics measure SWSTSPNC (SH.04.04.01). Is signal constant low? 140 Use schematics to trace signal that is not high to determine why it is not high. Make necessary corrections. Is signal a constant low now? 950 Verify proper operation. End of procedure. 950 99000 950 130 110 YES
TB 03 0012
NO
950
120
99000
140
99000
3998 5593007
67
Note: 68120
Transport status not correct. Note: Indicates JAM, or motors up, path no clear, status indicating sorter ready. YES NO
STEP 100
99000
950
950
68150
Microfilm Not Ready or film skip reported, but microfilm not present. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0016
NO
950
68160
Microfilm Not Ready or film skip reported, but microfilm not on. STEP 100 PROCEDURE Replace AA03 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0017
NO
950
950
6 8
3998 5593007
Note: 68170
Microfilm Not Ready or film skip being reported, but microfilm not powered on.
STEP 100
YES
NO
110
950
110
950
68180
Low double is sensed in Transport Status Register 3. STEP 100 PROCEDURE Follow manual procedure for TB 04 0084. End of procedure. YES
TB 03 0019
NO
68190
No "Z-80 OK" bit set in transport status, but MICR board reports "Z-80 OK". STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0020
NO
950
3998 5593007
69
Note: 68200
"Z-80 OK" not being reported.
STEP 100
YES
NO
110
950
110
950
68210
Z-80 Overload. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0022
NO
950
950
68220
BOL A reported dirty. (Black band not enabled.) STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA10 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 03 0023
NO
950
950
950
610
3998 5593007
Note: 68230
Configuration register number 1 read differs from write.
STEP 100
YES
NO
99000
950
950
68240
BOL A reports dirty. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0025
NO
950
950
68250
Circuit breaker reporting open. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 120 Replace DABB1 and rerun test. Does the problem still exist? 130 Using schematics, measure signal LAMPOFF (SH.03.01.02). Is signal a constant high? 140 Using schematics, trace why signal LAMPOFF is not constant high. Make necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 99000 130 120 110 YES
TB 03 0026
NO
950
950
950
140
950
3998 5593007
611
Note: 68270
Microfilm incorrectly reports "ON".
STEP 100
YES
NO
110
950
110
Microfilm switch bad. Make necessary corrections. Does the problem still exist? 99000 950
950
68280
Incorrect Not Ready status being reported. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0029
NO
950
68290
Motor error sensed. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0030
NO
950
950
612
3998 5593007
Note: 68300
Power switch reporting not "ON".
STEP 100
YES
NO
110
950
110
Problem is with power switch. Make necessary corrections. Does the problem still exist? 99000 950
950
68310
IEC switch for Area 1 or microfilm sensed open. STEP 100 110 PROCEDURE Does the machine have IEC switches? Make sure IEC switches work correctly. Make necessary corrections and rerun test. Does the problem still exist? 120 130 Are IEC bypass plugs in? Insert plugs and rerun test. Does the problem still exist? 140 Replace AA08 and rerun test. Does the problem still exist? 150 Replace CABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 150 140 140 140 YES 110
TB 03 0032
NO 120
950 130
950
950
950
3998 5593007
613
Note: 68320
Control module power error sensed.
STEP 100
YES
NO
110
950
110
Replace DABB1 and rerun test. Does the problem still exist? 120 950
120
130
Using schematics, trace signal CMPERR/ starting on SH.01.23.02 to determine why signal is not a constant high. Make necessary corrections. Does the problem still exist? 140 950
140
Problem could be +24 V missing from CM AC controls. Trouble shoot per power supply manual procedures. End of procedure. Verify proper operation. End of procedure.
950
68321
Control module power error sensed. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0034
NO
950
950
614
3998 5593007
Note: 68322
STOP/START bar not sensed.
STEP 100
PROCEDURE Follow procedure for error code TB 03 0128. End of procedure.
YES
NO
68323
Motors did not come up in allotted time. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 120 Replace CABB1 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 YES
TB 03 0036
NO
950
950
68324
"Motor 3 Up" bit not set, but Area 3 not present. STEP 100 PROCEDURE Replace CABB1, and rerun the test. Does the problem still exist? 110 Replace AA08, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0037
NO
950
950
3998 5593007
615
Note: 68325
Motor up bits not correct.
STEP 100
PROCEDURE Replace DABB1, and rerun the test. Does the problem still exist?
YES
NO
110
950
110
Replace CABB1, and rerun the test. Does the problem still exist? 120 950
110
950
68326
Motor 4 bit not set as expected. STEP 100 PROCEDURE Replace CABB1 and rerun test. Does the problem still exist? 110 Replace DABB1 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 03 0039
NO
950
950
950
616
3998 5593007
Note: 68327
Area 4 motor failed to turn on.
STEP 100
PROCEDURE Replace DABC1 and rerun test. Does the problem still exist?
YES
NO
110
950
110
120
130
950
68328
Area 3 motor failed to turn on. STEP 100 PROCEDURE Replace DABG1 and rerun test. Does the problem still exist? 110 Replace DABB1 and rerun test. Does the problem still exist? 120 Replace CABB1 and rerun test. Does the problem still exist? 130 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 120 110 YES
TB 03 0041
NO
950
950
950
950
3998 5593007
617
Note: 68330
Area 2 motor failed to turn on.
STEP 100
PROCEDURE Replace CABC1 and rerun test. Does the problem still exist?
YES
NO
110
950
110
120
950
68340
Area 1 motor failed to turn on. STEP 100 PROCEDURE Replace CABG1 and rerun test. Does the problem still exist? 110 Replace CABB1 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 03 0043
NO
950
950
950
68350
Motors reporting Not Ready and motor still down. STEP 100 PROCEDURE Replace CABB1 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0044
NO
950
950
618
3998 5593007
Note: 68360
Motors reporting Not Ready.
STEP 100
YES
NO
99000
950
950
68370
Motors Ready, but still reporting down. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0046
NO
950
68380
Primary hopper is sensed as not being empty. STEP 100 PROCEDURE Replace BOL in primary hopper. Rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 03 0047
NO
950
950
950
3998 5593007
619
Note: 68390
Secondary hopper is being sensed as not empty.
STEP 100
PROCEDURE Replace BOL in secondary hopper and rerun test. Does the problem still exist?
YES
NO
110
950
110
120
950
68400
JAM or bad BOL reporting in Area 1. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0049
NO
950
950
68410
JAM or bad BOL reporting in Area 1B. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0050
NO
950
950
620
3998 5593007
Note: 68420
An error has been detected from transport interface in Area 2.
STEP 100
YES
NO
110
950
110
950
68430
An error has been detected from transport interface in Area 3. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0052
NO
950
950
3998 5593007
621
Note: 68440
An error has been detected from transport interface in Area 4.
STEP 100
YES
NO
110
950
110
950
68450
Sorter reporting Not Ready, but no cause can be found. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0054
NO
950
950
622
3998 5593007
Note: 68460
Motor JAM test failed.
STEP 100
PROCEDURE Replace CABB1 and rerun test. Does the problem still exist?
YES
NO
110
950
110
130
140
950
68470
Motors did not jam during Jam test. STEP 100 PROCEDURE Replace CABB1 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0056
NO
950
950
68480
Not all motors jammed during Jam test. STEP 100 PROCEDURE Replace TRIAC board for motor that did not jam and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0057
NO
950
3998 5593007
623
68490
Endorser reporting not ready. However, Configuration Register 2 indicates card AA09 (NIE/MJE interface) is not present. STEP 100 PROCEDURE Visually verify the presence of the Front MJE or Rear MJE. Are any of these modules present in the sorter? 120 Replace AA09 and rerun test. Does the test pass? 130 135 140 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Replace AA10 and rerun test. Does the test pass? 150 160 Does the same error code occur? Troubleshoot starting with signal NIEPLN on SH.01.23.06. Does problem still exist? 200 Replace AA08 and rerun test. Does the test pass? 210 220 Does the same error code occur? Troubleshoot starting with signal NIENRDYN on SH.01.23.10. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 950 220 99000 950 160 950 140 120 YES
TB 03 0058
NO
200
130 135
150 135
950
210 135
950
624
3998 5593007
68500
Endorser reporting not ready. Configuration Register 2 indicates card AA09 (MJE interface) is present. Diagnostics are unable to verify presence of MJE(s). STEP 100 PROCEDURE Visually verify the presence of the Front MJE or Rear MJE. Are any of these modules present in the sorter? 120 Replace AA09 and rerun test. Does the test pass? 130 140 170 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Replace AA02 and rerun test. Does the test pass? 180 220 Does the same error code occur? Troubleshoot starting with signal NIEPLN on SH.01.23.06. Does problem still exist? 300 310 Is card AA09 present? Remove card AA09 and rerun test. Does the test pass? 320 330 Does the same error code occur? Replace AA10 and rerun test. Does the test pass? 340 950 Does the same error code occur? Verify proper operation. End of procedure. 950 99000 950 330 99000 310 950 220 950 170 120 YES
TB 03 0059
NO
300
130 140
180 140
950 330
320 140
340 140
3998 5593007
625
68510
Endorser reporting not ready. Configuration Register 2 indicates card AA09 (MJE interface) is present. Rear MJE reported present and turned off. Front MJE reported not present. STEP 100 110 PROCEDURE Is the front MJE present in the sorter? Replace AA02 and rerun test. Does the test pass? 120 130 140 160 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Is the Rear MJE switch on the sorters front control panel on? Replace AA08 and rerun test. Does the test pass? 170 180 Does the same error code occur? Troubleshoot signal EPWRSWN on SH.01.23.10 back to the Rear MJE switch on the front control panel of the sorter. Check switch functionality and make necessary adjustments. Does problem still exist? 300 Replace card AA09 and rerun test. Does the test pass? 310 320 Does the same error code occur? Replace card AA08 and rerun test. Does the test pass? 330 350 Does the same error code occur? Troubleshoot starting with signal NIENRDYN on SH.01.23.10. Does problem still exist? 950 Verify proper operation. End of procedure. 160 950 340 950 320 99000 950 180 160 950 99000 YES 110
TB 03 0060
NO 140
120 130
300
170 130
950
310 130
330 130
950
626
3998 5593007
68520
Rear MJE switch reported on after user has turned switch off. STEP 100 PROCEDURE Replace card AA08 and rerun test. Does the test pass? 110 120 130 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Troubleshoot signal EPWRSWN on SH.01.23.10 back to the Rear MJE switch on the front control panel of the sorter. Check switch functionality and make necessary adjustments. Does the problem still exist? 99000 950 130 YES
TB 03 0061
NO
110 120
950
950
3998 5593007
627
68530
Endorser reporting not ready. Configuration Register 2 indicates card AA09 (MJE interface) is present. Rear MJE reported not present or turned off. Front MJE reported turned off. STEP 100 PROCEDURE Troubleshoot signal FMJEONN on SH.01.23.06 back to the Front MJE switch on the front control panel of the sorter. Check switch functionality and make necessary adjustments. Rerun test. Does the test pass? 110 120 130 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Replace AA08 and rerun test. Does the test pass? 140 150 Does the same error code occur? Replace AA09 and rerun test. Does the test pass? 160 170 180 Does the same error code occur? Is a Rear MJE present in the sorter? Troubleshoot signal EPWRSWN on SH.01.23.10 back to the Rear MJE switch on the front control panel of the sorter. Check switch functionality and make necessary adjustments. Rerun test. Does the test pass? 190 200 Does the same error code occur? Replace AA08 and rerun test. Does the test pass? 210 950 Does the same error code occur? Verify proper operation. End of procedure. 950 99000 950 200 950 170 180 950 150 950 130 YES
TB 03 0062
NO
110 120
140 120
160 120 99000
190 120
210 120
628
3998 5593007
68540
Front MJE switch reported on after user has turned switch off. STEP 100 PROCEDURE Replace card AA08 and rerun test. Does the test pass? 110 120 130 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Troubleshoot signal FMJEONN on SH.01.23.06 back to the Front MJE switch on the front control panel of the sorter. Check switch functionality and make necessary adjustments. Does the problem still exist? 99000 950 130 YES
TB 03 0063
NO
110 120
950
950
3998 5593007
629
68545
Endorser reporting not ready. Configuration Register 2 indicates card AA09 (MJE interface) is present. Rear MJE reported not present or turned off. Front MJE reported turned off. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the test pass? 110 120 130 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Replace AA08 and rerun test. Does the test pass? 135 140 Does the same error code occur? Troubleshoot signal FMJEONN on SH.01.23.06 back to the Front MJE switch on the front control panel of the sorter. Check switch functionality and make necessary adjustments. Rerun test. Does the test pass? 150 160 170 Does the same error code occur? Is a Rear MJE present in the sorter? Troubleshoot signal EPWRSWN on SH.01.23.10 back to the Rear MJE switch on the front control panel of the sorter. Check switch functionality and make necessary adjustments. Rerun test. Does the test pass? 180 950 Does the same error code occur? Verify proper operation. End of procedure. Sorter did not go Not Ready. 950 99000 950 160 170 950 140 950 130 YES
TB 03 0064
NO
110 120
135 120
150 120 99000
180 120
630
3998 5593007
Note: 68550
Sorter did not go Not Ready.
68560
Sorter Not Ready. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0102
NO
950
3998 5593007
631
Note: 68570
Sorter did not go "Not Ready" after lighting reject pocket light.
STEP 100
YES
NO
99000
950
950
68580
Reject pocket "Lite" bit not set. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0104
NO
950
950
68590
Incorrect pocket light on in Area 2. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0105
NO
950
950
632
3998 5593007
Note: 68600
Pocket light(s) indicated on in Area 3 or 4.
STEP 100
YES
NO
99000
950
950
68610
BOL signal detected in Area 2 that should not be illuminated. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0107
NO
950
950
68620
Pocket light(s) indicated on in Area 3 or 4. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0108
NO
950
3998 5593007
633
Note: 68630
BOL signal detected in Area 2 that should not be illuminated.
STEP 100
YES
NO
110
950
110
950
68640
TB 03 0110
NO
950
68650
BOL signal detected in Area 2 that should not be illuminated. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0111
NO
950
950
634
3998 5593007
Note: 68660
Pocket light(s) indicated on in Area 3 or 4.
STEP 100
YES
NO
99000
950
950
68670
BOL pocket signal detected in Area 2 that should not be illuminated. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0113
NO
950
950
68680
TB 03 0114
NO
950
3998 5593007
635
Note: 68690
BOL lite signal detected in Area 2 that should not be illuminated.
STEP 100
YES
NO
110
950
110
950
68700
TB 03 0116
NO
950
68710
BOL lite signal detected in Area 2 pocket that should not be illuminated. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0117
NO
950
636
3998 5593007
Note: 68720
BOL lite signal detected in Area 3 pockets that should not be illuminated.
STEP 100
YES
NO
110
950
110
950
68730
Status register indicates lights on in Area 4. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0119
NO
950
68740
Area 2 or 3 reports incorrect pocket lights. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 03 0120
NO
950
3998 5593007
637
Note: 68750
Status register reports extra lights on in Area 4.
STEP 100
YES
NO
110
950
110
950
68755
Sorter did not go ready after a BOL/Track Error/Gate Fault Reset STEP 100 PROCEDURE Run MACHINE READY STATUS MTR (Menu selection 10 from the DISPLAY SCANS submenu) to determine cause(s) of not ready condition. Make necessary adjustments and rerun Subtest 03. Does the test pass? 110 Replace AA08 and rerun test. Does the test pass? 120 130 950 Does the same error code occur? Follow manual procedure for new error code. End of procedure. Verify proper operation. End of procedure. 950 99000 950 YES
TB 03 0122
NO
110
120 130
638
3998 5593007
Note: 68760
All pocket lights did not light in Area 2.
STEP 100
YES
NO
110
950
110
950
68770
All pocket lights did not light in Area 3. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0124
NO
950
950
68780
All pocket lights did not illuminate in area 4. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 03 0125
NO
950
950
3998 5593007
639
Note: 68790
All pocket lights did not illuminate in sequence.
STEP 100
PROCEDURE Check for obvious bad LEDs. Replace as needed and rerun test. Does the problem still exist? Follow manual procedure for TB 03 0001. Verify proper operation. End of procedure.
YES 110
NO 950
110 950
68800
No last pocket can be found. STEP 100 PROCEDURE Follow manual procedure for TB 03 0001. YES
TB 03 0127
NO
68900
Start / Stop switch or bar broken. STEP 100 PROCEDURE Replace AA08 Does the problem still exist? 120 Replace AA05. Does the problem still exist? 130 140 Did the problem occur when testing the control panel start/stop switch? Troubleshoot starting with signals SWSTPNO and SWSTPNC on SH.04.04.01. Does the problem still exist? 150 Troubleshoot starting with 4 pocket driver card you were testing with signal SSBAR234N on SH.04.01.02. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 99000 130 140 120 YES
TB 03 0128
NO
950
950 150
950
950
640
3998 5593007

71000 TB 04 xxxx
This section deals with problems in the transport (tests document flow). If the sorter power-on confidence (POC) test did not pass, proceed to the section for POC diagnosis. This section provides diagnostic information based on the assumption that the system passed the POC tests.
3998 5593007
71
Note: 71000
Interrupt source register did not clear.
STEP 100
YES
NO
110 130 140
950 130 150
110 130 140
Is AA08 J2-62 constant low? Is AA08 J2-31 constant low? Replace AA10 and rerun test. Does the problem still exist?
150 160 170
950 99000 99000
150 160 170
Is the microfilm option installed? Is AA08 J2-80 constant low? Replace AA03 and rerun test. Does the problem still exist?
99000
950
950
71010
Illegal system configuration. STEP 100 PROCEDURE Check all jumpers per SH.09.01.01. Verify that all jumpers are correct. Make necessary corrections. Does the problem still exist? 110 Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 04 0002
NO
950
950
7 2
3998 5593007
Note: 71020
Feeder 1 clutch engaged.
STEP 100
YES
NO
99000
950
950
71030
Separator 1 is reported on. STEP 100 PROCEDURE Replace AA08, and rerun the test. Does the problem still exist? 110 Replace CABB1, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 04 0004
NO
950
950
71040
Feeder 2 clutch/brake error. STEP 100 PROCEDURE Check all associated fuses. Make the necessary corrections. Does the problem still exist? 110 Replace AA08, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 04 0005
NO
950
950
3998 5593007
73
71050
The microfilm reports Not Ready. STEP 100 150 200 250 300 350 PROCEDURE Is the microfilm option installed? Is the microfilm power on? Power the microfilm off. Did it power off? Rerun test. Does the problem still exist? Is AA03 J2-61 a constant high? Replace AA08 and rerun test. Does the problem still exist? 400 Replace AA03 and rerun test. Does the problem still exist? 500 Replace AA08 and rerun test. Does the problem still exist? 600 Camera On switch circuit is defective. Using schematics, trace signals CAMSWNC and CAMSWNO starting on sheet 02.01.01 and make necessary correction. Rerun test. Does the problem still exist? 900 A second failure exists which reports the same failure code. Rerun MTR and follow failure code displayed. Verify proper operation. End of procedure. 900 600 500 99000 YES 150 200 250 300 350
TB 04 0006
NO 350 300 300 950 400
950
950
950
950
950
7 4
3998 5593007
71060 (NDP 1150)

The PEP/Stamp reports Not Ready. STEP 100 150 PROCEDURE Is the PEP/Stamp option installed? Replace AA09 and rerun test. Does the problem still exist? 160 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 160 YES 150 NO
TB 04 0007
160
950
950
3998 5593007
75
71060 (NDP 1800)

The Endorser reports Not Ready. STEP 100 110 120 PROCEDURE Is the Endorser option installed? Is the Endorser power on? Power the Endorser off. Did the Endorser power off? 130 Rerun test. Does the problem still exist? 140 150 Is AA09 J2-60 a constant high? Replace AA08 and rerun test. Does the problem still exist? 160 Replace AA09 and rerun test. Does the problem still exist? 180 Replace AA08 and rerun test. Does the problem still exist? 200 Endorser switch circuit is defective. Using schematics, trace signals SWRMJENC, SWFMJENC, SWRMJENO, and SWFMJENO starting on sheet 02.01.01 and make necessary corrections. Rerun test. Does the problem still exist? 900 A second failure exists which reports the same failure code. Rerun MTR and follow failure code displayed. Verify proper operation. End of procedure. 900 200 180 99000 140 150 130 YES 110 120 NO
TB 04 0007
150 140
140
950 160
950
950
950
950
950
7 6
3998 5593007
71070
The sorter is Not Ready for no apparent reason. Note: This condition can be caused by pressing the START/STOP bar more than once. YES 110
TB 04 0008
STEP 100 110
PROCEDURE Are the motors up and running? Stop motors, reset sorter and rerun test. Does the problem still exist?
NO 120
120
950
120
Run MTR routine to display Not Ready condition. Correct any Not Ready conditions and rerun test. Does the problem still exist? 130 950
130
Replace AA08 and rerun test. Does the problem still exist? 150 160 950 170
150 160
Is the microfilm module installed? Replace AA03 and rerun test. Does the problem still exist?
170
950
170
950
3998 5593007
77
Note: 71080
Sorter Ready did not cause a transport interrupt.
STEP 100
YES
NO
120
950
120
950
71090
Separator 2 is reported on. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0010
NO
950
71100 UNASSIGNED FAULT CODES TB 04 0011 through TB 04 0015
TB 04 0011
7 8
3998 5593007
71160
Sorter did not respond with a feeding signal. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? Does the problem still exist? 130 Replace AA02 and rerun test. Does the problem still exist? 140 150 Is the microfilm option installed? Replace AA03 and rerun test. Does the problem still exist? 160 Replace AA05 and rerun test. Does the problem still exist? 200 Replace AA09 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 200 99000 140 150 120 130 YES
TB 04 0016
NO
950 950
950 160
950
950
950
3998 5593007
79
Note: 71170
Feeding did not cause a command result interrupt.
STEP 100
YES
NO
99000
950
950
71180
A document was fed from the secondary feeder instead of the primary feeder. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0018
NO
950
71190
A feeder jam was not declared. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 04 0019
NO
950
950
710
3998 5593007
71200
A secondary feeder jam is sensed. Notes: 1. 2. 3. 4. 5. 6. STEP 100 This condition is caused by: Belt off the feeder pulley. A secondary feeder jam. Feeder too slow. Feeder clutch/brake problem. Fuse blown or missing for feeder clutch/brake. Document slippage. YES
TB 04 0020
PROCEDURE Inspect the secondary feeder area for obvious reasons. Make necessary corrections and rerun test. Does the problem still exist?
NO
120
950
120
140
150
Troubleshoot the problem by tracing FD2CTHD starting on schematic sheet 01.23.05 (J1 - P13). Determine why clutch it not engaging and make necessary correction and rerun test. Does the problem still exist? 99000 950
950
3998 5593007
711
71210
A primary feeder jam is sensed. Notes: 1. 2. 3. 4. 5. 6. STEP 100 This condition is caused by:
TB 04 0021
Belt off the feeder pulley. A primary feeder jam. Feeder too slow. Feeder clutch/brake problem. Fuse blown or missing for primary clutch/brake. Document slippage. YES NO
PROCEDURE Inspect the primary feeder area for obvious problems. Make necessary corrections and rerun test. Does the problem still exist?
110
950
110
125
Replace AA02 and retest. Does the problem still exist? 130 950
130
Troubleshoot the problem by tracing FDCTH starting on schematic sheet SH.01.23.05 (J1 P9). Determine why clutch is not engaging and make necessary correction and rerun test. Does the problem still exist? 99000 950
950
712
3998 5593007
Note: 71220
It took too long to declare a valid document at BOL B.
STEP 100
PROCEDURE Verify proper jumper configuration on all cards per SH.09.01.01. Rerun subtest 04. Does the problem still exist?
YES
NO
105 110
950 120
105 110
Does the document just fed have a damaged leading edge? Rerun test with new document. Does the problem still exist?
120
950
120
Rerun test to see if failure is reported again. Does the problem still exist? 130 950
130
140
950
71230
Feeder did not shut off as expected. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 YES
TB 04 0023
NO
950
950
3998 5593007
713
71240
Too much time for document to get from BOL B to BOL C (upper). Note: It took too long for a document to get from the BOL B to BOL C (upper). This can occur because of poor transport control of the document. YES
TB 04 0024
STEP 100
PROCEDURE Check this area of transport for possible causes. Make necessary corrections and run the test several times to determine if the problem is an electronic failure. Is it a probable electronic failure?
NO
110
120
110
120
Problem is mechanical. Make necessary corrections and rerun test several times. Does the problem still exist? 120 950
950
714
3998 5593007
71250
Too much time for document to get from BOL C (lower) to BOL D. Note: It took too long for a document to get from the BOL C (lower) to BOL D. This can occur because of poor transport control of the document. YES
TB 04 0025
STEP 100
NO
110
120
110
120
950
3998 5593007
715
71260
Too much time for document to get from BOL D to BOL E. Note: It took too long for a document to get from the BOL D to BOL E. This can occur because of poor transport control of the document. YES
TB 04 0026
STEP 100
PROCEDURE Check all jumpers per SH.09.01.01. Make necessary corrections. Does the problem still exist?
NO
105
950
105
Check this area of transport for possible causes. Make necessary corrections and run the test several times to determine if the problem is an electrical failure. Is it a probable electronic failure? 110 120
110
120
950
716
3998 5593007
71270
Too much time for document to get from BOL E to BOL F. Note: It took too long for a document to get from the BOL E to BOL F. This can occur because of poor transport control of the document. YES
TB 04 0027
STEP 100
PROCEDURE Check this area of transport for possible causes. Make necessary corrections and run the test several times to determine if the problem is an electrical failure. Is it a probable electronic failure?
NO
110
120
110
120
950
3998 5593007
717
71280
Too much time for document to get from BOL F to BOL G. Note: It took too long for a document to get from the BOL F to BOL G. This can occur because of poor transport control of the document. YES
TB 04 0028
STEP 100
NO
110
120
110
120
950
718
3998 5593007
Note: 71290
STLP occurred too early.
STEP 100
YES
NO
110
950
110
950
71300
No document available signal was detected. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 04 0030
NO
950
950
71310
Cannot reset the batch ticket enable bit. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 04 0031
NO
950
950
3998 5593007
719
Note: 71320
More than 127 characters were received from a document.
STEP 100
YES
NO
99000
950
950
71330
Too much time for document to get from BOL G to BOL H. Note: It took too long for a document to get from the BOL G to BOL H. This can occur because of poor transport control of the document. YES
TB 04 0033
STEP 100
NO
110
120
110
120
950
720
3998 5593007
Note: 71340
No STLP was received.
STEP 100
YES
NO
110
950
110
950
71350
Too much time for document to get from BOL H to BOL J. Note: It took too long for a document to get from the BOL H to BOL J. This can occur because of poor transport control of the document. YES
TB 04 0035
STEP 100
NO
110
120
110
120
950
3998 5593007
721
71360
Too much time for document to get from BOL J to BOL K. Note: It took too long for a document to get from the BOL J to BOL K. This can occur because of poor transport control of the document. YES
TB 04 0036
STEP 100
NO
110
120
110
120
950
722
3998 5593007
71370
Too much time for document to get from BOL K to BOL N. Note: It took too long for a document to get from the BOL K to BOL N. This can occur because of poor transport control of the document. YES
TB 04 0037
STEP 100
NO
110
130
110
130
950
3998 5593007
723
71380
Too much time for document to get from BOL H to BOL N. Note: It took too long for a document to get from the BOL H to BOL N. This can occur because of poor transport control of the document. YES
TB 04 0038
STEP 100
NO
110
130
110
130
950
724
3998 5593007
71390
Too much time for document to get from BOL N to BOL P. Note: It took too long for a document to get from the BOL N to BOL P. This can occur because of poor transport control of the document. YES
TB 04 0039
STEP 100
NO
110
120
110
120
950
3998 5593007
725
Note: 71400
Too much time for document to get from BOL P to BOL Q. Note: It took too long for a document to get from the BOL P to BOL Q. This can occur because of poor transport control of the document. YES NO
STEP 100
PROCEDURE Verify proper jumper configuration on all cards per SH.09.01.01. Run subtest 04. Does the problem still exist?
105
950
105
Check this area of transport for possible causes. Make necessary corrections and run the test several times to determine if the problem is an electrical failure. Is it a probable electronic failure? 110 120
110
120
950
71410
Area 1 or Area 1B window circuit failure. STEP 140 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0041
NO
950
726
3998 5593007
71420
An almost feed error occurred. Notes: 1. 2. STEP 100 This condition can be caused by the following:
TB 04 0042
Damaged document. Poor mechanical control of document prior to the read station, including the feeder. YES NO
PROCEDURE Using undamaged documents rerun the test. Does the problem still exist?
110
950
110
Check the mechanical portion of the transport from the feeder to the read station. Make any necessary corrections and rerun test. Does the problem still exist? 120 950
120
140
150
Recheck all mechanics from the feeder to the read station. Make necessary corrections and rerun test. Does the problem still exist? 99000 950
950
3998 5593007
727
Note: 71425
UNASSIGNED FAULT CODE 71430

The reject pocket gate did not open on an override. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 950 110 950 YES NO
TB 04 0044
71440
Speedup not correct. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0045
NO
950
728
3998 5593007
71450
An underspaced feed occurred. Notes: 1. 2. STEP 100 This condition can be caused by the following:
TB 04 0046
Damaged document. Poor mechanical control of document prior to the read station, including the feeder. YES NO
PROCEDURE Using undamaged documents rerun the test. Does the problem still exist?
110
950
110
Check the mechanical portion of the transport from the feeder to the read station. Make any necessary corrections and rerun test. Does the problem still exist? 120 950
120
140
150
950
3998 5593007
729
71460
Too much time for document to get from BOL Q to BOL R. Note: It took too long for a document to get from the BOL Q to BOL R. This can occur because of poor transport control of the document. YES
TB 04 0047
STEP 100
NO
110
130
110
120
130
Problem is mechanical. Make the necessary corrections and rerun test several times. Does the problem still exist? 130 950
950
730
3998 5593007
71470
Too much time for document to get from BOL K to BOL R. Note: It took too long for a document to get from BOL K to BOL R. This can occur because of poor transport control of the document. YES
TB 04 0048
STEP 100
NO
110
140
110
120
140
The problem is mechanical. Make the necessary corrections, and rerun the test several times. Does the problem still exist? 140 950
950
3998 5593007
731
71480
Too much time for document to get from BOL H to BOL R. Note: It took too long for a document to get from BOL H to BOL R. This can occur because of poor transport control of the document. YES
TB 04 0049
STEP 100
NO
105
140
105
If the microfilmer is present, verify that board AA03 is in place. Make the necessary corrections. Does the problem still exist? 110 950
110
120
135
140
The problem is mechanical. Make the necessary corrections, and rerun the test several times. Does the problem still exist? 140 950
950
732
3998 5593007
71490
An overlength feed error occurred. Notes: This condition can be caused by the following: 1. 2. STEP 100 Damaged document. Poor mechanical control of document prior to the read station, including the feeder. YES
TB 04 0050
PROCEDURE Using undamaged documents, rerun the test. Does the problem still exist?
NO
110
950
110
Check the mechanical portion of the transport feeder to the read station. Make any necessary corrections and rerun test. Does the problem still exist? 120 950
120
130
150
950
3998 5593007
733
71500
Two documents were reported on a single item feed command. Note: This condition may occur due to poor document quality or poor document alignment in the hopper. YES
TB 04 0051
STEP 100
PROCEDURE Rerun test. Does the problem still exist?
NO
110
950
110
130
Troubleshoot FDBRK starting on schematic sheet 04.04.01.Determine why the brake is not holding the primary feeder wheel. Make necessary corrections and rerun test. Does the problem still exist? 99000 950
950
734
3998 5593007
Note: 71510
A document was able to go beyond the reject pocket even though the reject gate was selected.
STEP 100
PROCEDURE Check all pocket driver fuses. Are all fuses OK?
YES
NO
110
105
105
Replace the bad fuse, and rerun the test. Does the problem still exist? 110 950
110
Refer to the T&A gate adjustment. Make the necessary mechanical corrections, and rerun the test. Does the problem still exist? 120 950
120
130
Replace the 4 Pocket Driver/Interface board on the first 4-pocket baseplate assembly (pocket R through 2), and rerun the test. Does the problem still exist? 99000 950
950
71520
Path clear delay time was too short. STEP 100 PROCEDURE Replace AA08, and rerun the test. Does the problem still exist? 110 Replace AA02, and rerun the test. Does the problem still exist? 130 Replace AA05, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 110 YES
TB 04 0053
NO
950
950
950
3998 5593007
735
Note: 71530
Flow stop occurred too early.
STEP 100
YES
NO
99000
950
950
71540
Path clear time is too long. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 120 Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 04 0055
NO
950
950
950
71550
A flow stop was not indicated at path clear. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0056
NO
950
736
3998 5593007
Note: 71560
A transport status interrupt was not set at flow stop.
STEP 100
YES
NO
99000
950
950
71570
Document data interrupt did not occur. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 04 0058
NO
950
950
950
71580
Fault code not used. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0059
NO
950
3998 5593007
737
Note: 71590
No SOKL was detected in response to a disposition.
STEP 100
YES
NO
99000
950
950
71600
No disposition status interrupt was received with SOKL response to a disposition. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0061
NO
950
71610
An unexpected STLP occurred. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 04 0062
NO
950
950
738
3998 5593007
Note: 71620
An override was detected at the reject pocket, but no feed error was reported.
STEP 100
YES
NO
120
950
120
140
950
71630
The reject pocket closed on an item assigned to it. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 130 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 120 YES
TB 04 0064
NO
950
950
950
3998 5593007
739
Note: 71640
No feeding response has detected on a demand feed from the secondary feeder.
STEP 100
YES
NO
99000
950
950
71650
A document was fed from the primary feeder instead of the secondary feeder. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0066
NO
950
740
3998 5593007
71660
A false double document feed was reported. STEP 100 PROCEDURE Rerun test several times to establish that double document feeds are not actually occurring. Are double document feeds occurring? 110 Make necessary corrections and rerun test. Does the problem still exist? 120 Perform double document T&As and check hoses, filters and sensor. Make necessary corrections and rerun test. Does the problem still exist? 130 Run switch test DDD. Is DDD switch test bad? 140 Replace the double document switch and rerun test. Does the problem still exist? 150 Replace AA08 and rerun test. Does the problem still exist? 160 Replace AA02 and rerun test. Does the problem still exist? 170 Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 170 160 150 140 130 120 110 YES
TB 04 0067
NO
120
950
950
150
950
950
950
950
3998 5593007
741
Note: 71670
A MICR overflow is detected.
STEP 100
YES
NO
110
950
110
120
950
71680
The pocket information register reports missort all. STEP 110 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 130 Replace AA08 and rerun test. Does the problem still exist? 140 Replace AA05 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 140 130 YES
TB 04 0069
NO
950
950
950
742
3998 5593007
71690
The primary hopper is sensed as empty. STEP 100 110 PROCEDURE Is the primary hopper empty? Load primary hopper and rerun test. Does the problem still exist? 120 Clean the primary hopper BOL, check its adjustment and rerun test. Does the problem still exist? 130 Replace AA02 and rerun test. Does the problem still exist? 140 Replace primary hopper BOL and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 140 130 120 YES 110
TB 04 0070
NO 120
950
950
950
950
3998 5593007
743
Note: 71700
The secondary hopper is reporting empty.
STEP 100 110
PROCEDURE Is the secondary hopper empty? Load secondary hopper and rerun test. Does the problem still exist?
YES 110
NO 120
120
950
120
Clean the secondary hopper BOL, check its adjustment and rerun test. Does the problem still exist? 130 950
130
140
Replace BOL and rerun test. Does the problem still exist? 99000 950
950
71710
A buffer overflow EWTE is reported. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 120 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 YES
TB 04 0072
NO
950
950
71720
Feed error occurred. 100 See Section 16, "Condition, Cause, Correction Tables", line 100000 for diagnosis of the problem. End of procedure.
TB 04 0073
744
3998 5593007
71730
A jam is detected. Note: The screen indicates the first jam/missort location. Suspect a mechanical problem. YES 110
TB 04 0074
STEP 100 110
PROCEDURE Was there a real document jam? Check the involved area for mechanical problems. Make the necessary correction, and rerun the test. Does the problem still exist?
NO 120
120 130
950 210
120 130
Is the reported jam in Area 2 or the MJE? Replace AA02, and rerun the test. Does the problem still exist?
140
950
140
150
Replace CABB1, and rerun the test. Does the problem still exist? 160 950
160
Clean and inspect the BOL reporting the jam, and rerun the test. Does the problem still exist? 170 950
170
Replace the BOL reporting the jam, and rerun the test. Does the problem still exist? 99000 950
210
220
Clean and inspect the BOL reporting the jam, and rerun the test. Does the problem still exist? 230 950
230
Replace the BOL reporting the jam, and rerun the test. Does the problem still exist? 240 99000 950 950
240
Replace the 4-Pocket Driver/Interface board for the 4-pocket baseplate assembly reporting the jam, and rerun the test.
3998 5593007
745
TB 04 0074
A jam is detected. Note: The screen indicates the first jam/missort location. Suspect a mechanical problem. YES 260 NO 270
STEP 250 260
PROCEDURE Is the problem in Area 3? Replace AA05 and rerun the test. Does the problem still exist?
270 280
950 290
270 280
Is the problem in Area 4? Replace AA05 and rerun the test. Does the problem still exist?
220
950
290
310
Replace CABB1 and rerun the test. Does the problem still exist? 99000 950
950
746
3998 5593007
71740
A missort is detected. Note: The screen indicates the first jam/missort location. YES 110
TB 04 0075
STEP 100 110
PROCEDURE Is the report missort location BOL N, BOL P, or BOL Q? Probable cause is poor drive in the microfilm. Check the transport, drive belts, and vacuum. Rerun the test. Replace AA02 and rerun the test. Does the problem still exist?
NO 130
120
160 140
950 190
130 140
Is the reported missort in Area 2? Replace AA05, and rerun the test. Does the problem still exist?
160
950
160
Clean and inspect the BOL reporting the missort, and rerun the test. Does the problem still exist? 170 950
170
Replace the BOL reporting the missort, and rerun the test. Does the problem still exist? 180 950
180
Replace the 4-Pocket Drive board for the 4pocket baseplate assembly reporting the missort. Rerun the test. Does the problem still exist? 99000 200 950 210
190
Is the problem in Area 3?
3998 5593007
747
TB 04 0075
A missort is detected. Note: The screen indicates the first jam/missort location. YES NO
STEP 200
PROCEDURE Replace AA05 and rerun the test. Does the problem still exist?
200 220
950 230
210 220
Is the problem in Area 4? Replace AA05 and rerun the test. Does the problem still exist?
160
950
230
240
250
950
748
3998 5593007
71750
A full pocket was detected. Note: The location of the full pockets are listed on the screen. YES 110 120
TB 04 0076
STEP 100 110 120
PROCEDURE Are any full pockets listed on the screen? Are the pockets actually full? Empty the full pockets and rerun test. Does the problem still exist?
NO 150 130
130 140
950 950
130 140
Replace full pocket switches indicated on the screen and rerun test. Replace 4 Pocket Driver/Interface board associated with the full pocket condition and rerun test. Does the problem still exist?
160
950
150
160
950
3998 5593007
749
71760
A gate fault is detected. Note: The gate fault location is displayed on the screen. YES
TB 04 0077
STEP 100
PROCEDURE Check the gate adjustment for the gate reporting the gate fault, make necessary corrections and rerun test. Does the problem still exist?
NO
110 120
950 130
110 120
Is the reported gate fault in Area 2, Area 3, or Area 4? Replace AA05 and rerun test. Does the problem still exist?
130
950
130
Replace the 4 Pocket Driver/Interface board associated with the reported gate fault and rerun test. Does the problem still exist? 140 950
140
Replace the gate assembly associated with the reported gate fault and rerun test. Does the problem still exist? 150 950
150
950
750
3998 5593007
71770
An Area 2/3/4 track error occurred. Note: The track error locations are displayed on the screen. YES 110 120 190 99000
TB 04 0078
STEP 100 110 120 190 950
PROCEDURE A location in Area 2, Area 3, or Area 4 reported on the screen? Replace AA05 and rerun test. Does the problem still exist? Replace AA02 and rerun test. Does the problem still exist? Replace AA08 and rerun test. Does the problem still exist? Verify proper operation. End of procedure.
NO 120 950 950 950
3998 5593007
751
71780
A dead BOL was detected. Note: The dead BOL locations are displayed on the screen. YES 110
TB 04 0079
STEP 100 110
PROCEDURE Is only one dead BOL being reported on the screen? Clean the BOL reported as dead and rerun test. Does the problem still exist?
NO 130
120
950
120
Replace the BOL reported as dead and rerun test. Does the problem still exist? 270 140 950 150
130 140
Are the reported dead BOLs in Area 1? Replace AA02 and rerun test. Does the problem still exist?
99000 160
950 180
150
Are dead BOLs in Front MJE (L and M), Microfilmer (N, P, and Q), or Image module (I1, I2, and I3) Replace AA02 and rerun test. Does the problem still exist?
160
99000
950
180
200
Replace the 4 Pocket Driver/Interface board associated with the reported dead BOLs and rerun test. Does the problem still exist? 270 950
270
950
752
3998 5593007
71800
The motors were not ready without the cause being detected. STEP 100 PROCEDURE Rerun test to determine if this failure code or a different failure code will be reported. Was a different failure code reported? 120 150 Follow the new failure code - end of procedure. Replace CABB1 and rerun test. Does the problem still exist? 160 Replace CABC1 and rerun test. Does the problem still exist? 170 Replace CABG1 and rerun test. Does the problem still exist? 180 190 Does unit have more than 16 pockets? Replace DABB1 and rerun test. Does the problem still exist? 200 Replace DABG1 and rerun test. Does the problem still exist? 205 Replace DABC1 and if present rerun test. Does the problem still exist? 210 Replace AA08 and rerun test. Does the problem still exist? 230 Replace AA02 and rerun test. Does the problem still exist? 250 Replace AA05 and rerun test. Does the problem still exist? 260 Replace AA03, if present, and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 260 250 230 210 205 200 180 190 170 160 120 YES
TB 04 0081
NO
150
950
950
950 210
950
950
950
950
950
950
950
3998 5593007
753
Note: 71810
An Area 1/2 track error occurred. Note: This condition can result if an item flies out of the track just prior to the reject pocket or the area prior to the reject pocket has poor drive. YES NO
STEP 100
PROCEDURE Inspect the area prior to the reject pocket for mechanical problems, make necessary corrections and rerun test. Does the problem still exist?
110
950
110
120
950
71820
No normal feed error can be located. STEP 100 110 PROCEDURE Rerun test. Does the problem still exist? Replace AA10 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 130 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 120 YES 110
TB 04 0083
NO 950
950
950
950
754
3998 5593007
71830
Low vacuum is sensed in Transport Status Register 3. Note: In this procedure, the labels LVSW1, OCRVSW1, and OCRVSW2 are vacuum transport switches on SH.04.04.01. LVSW1 = vacuum transport switch connected to AAJ8 - 12 OCRVSW1 = OCR vacuum transport switch connected to AAJ8 - 5 OCRVSW2 = OCR vacuum transport switch connected to pole 2 of LVSW1 STEP 100 PROCEDURE Inspect the double document vacuum system, make necessary corrections, and rerun test. Does the problem still exist? 110 120 Is an OCR unit present in the sorter? Inspect the OCR vacuum system. Make sure that the transport belts have not cut either of the OCR vacuum hoses. Vacuum should be measured. It should be approximately 3 inches on one port and 4.5 inches on the other port. Make necessary adjustments. Does the problem still exist? 130 Remove connector J8 (SH 01.23.02) from AA gate slot 8. Measure the voltage on pin 5 of the cable. Is the pin consistently at ground potential without any intermittent voltage fluctuations? Remove card AA08 from the AA gate and verify that the signal LOVACSW (J2 - 8/P79) on SH.01.23.09 is not shorted to any other backplane signals. Make the necessary adjustments. Re-insert card AA08 and connector J8. Rerun test. Does the problem still exist? 150 Replace AA08, and rerun the test. Does the problem still exist? 160 Replace AA17, and rerun the test. Does the problem still exist? 99000 160 150 130 140 110 120 YES
TB 04 0084
NO
950 130
950 200
140
950
950
950
3998 5593007
755
71830
STEP 200 PROCEDURE Replace connector J8, and rerun the test. Does the problem still exist? 210 Short vacuum transport switch LVSW1. If an OCR unit is present, short OCR vacuum transport switches OCRVSW1 and OCRVSW2 (SH 04.04.01). Rerun test. Does the problem still exist? 220 Verify that the ground for the switches is good. Make necessary adjustments, remove switch jumpers, and rerun test. Does the problem still exist? 230 Remove all vacuum switch shorts except for vacuum transport switch LVSW1. Rerun test. Does the problem still exist? 240 Replace the low vacuum switch LVSW1, and rerun the test. Does the problem still exist? 250 260 Is an OCR unit present in the sorter? Remove the short for LVSW1 and short the OCR vacuum switch OCRVSW1. Rerun the test. Does the problem still exist? 270 Replace the OCR vacuum switch OCRVSW1 and rerun the test. Does the problem still exist? 290 Remove the short for OCRVSW1 and short the OCR vacuum switch OCRVSW2. Rerun the test Does the problem still exist? 300 Replace the OCR vacuum switch OCRVSW2 and rerun the test. Does the problem still exist? 400 Remove the short for OCR vacuum switch OCRVSW2. Short vacuum transport switch LVSW1 and OCR vacuum transport switch OCRVSW1. Rerun the test. Does the problem still exist? 410 Replace the low vacuum switch LVSW1, and the OCR vacuum transport switch OCRVSW1. Rerun the test. Does the problem still exist? 99000 420 99000 400 99000 290 99000 260 250 99000 220 210 YES
TB 04 0084
NO
950
230
950
240
950 99000
270
950
300
950
410
950
756
3998 5593007
71830
STEP 420 PROCEDURE Remove the short for switch OCRVSW1. Short OCR vacuum transport switch OCRVSW2. Rerun the test. Does the problem still exist? 430 Replace the low vacuum switch LVSW1, and the OCR vacuum transport switch OCRVSW2. Rerun the test. Does the problem still exist? 440 Remove the short for switch LVSW1. Short OCR vacuum transport switches OCRVSW1 and OCRVSW2. Rerun the test. Does the problem still exist? 450 Replace the OCR vacuum transport switches OCRVSW1 and OCRVSW2. Rerun the test. Does the problem still exist? 460 Replace all vacuum transport switches: LVSW1, OCRVSW1, and OCRVSW2. Rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 99000 460 99000 440 YES
TB 04 0084
NO
430
950
450
950
950
3998 5593007
757
71840
Sorter went Not Ready for no apparent reason. STEP 100 120 130 150 160 170 200 210 950 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? Replace AA02 and rerun test. Does the problem still exist? Replace AA03 and rerun test. Does the problem still exist? Replace AA05 and rerun test. Does the problem still exist? Replace AA09 and rerun test. Does the problem still exist? Replace AA10 and rerun test. Does the problem still exist? Replace CABB1 and rerun test. Does the problem still exist? Replace DABB1 and rerun test. Does the problem still exist? Verify proper operation. End of procedure. YES 120 130 150 160 170 200 210 99000
TB 04 0085
NO 950 950 950 950 950 950 950 950
758
3998 5593007
Note: 71850
Bit 0 was erroneously set in the end of document flag word from the MICR read interface.
STEP 100
YES
NO
99000
950
950
71860
A mechanical window track error (MWTE) occurred. Note: The location of the MWTE is displayed on the screen. YES 110
TB 04 0087
STEP 100 110
PROCEDURE Is the MWTE location displayed on the screen? Inspect the area of the reported MWTE for poor mechanical document control, make necessary adjustments and rerun test. Does the problem still exist?
NO 950
120
950
120
950
3998 5593007
759
Note: 71870
The reject pocket opened for no apparent reason.
STEP 100
YES
NO
110
950
110
950
71880
An item took too long to be detected by the pocket prior to its assigned pocket and no other errors were detected. STEP 110 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 130 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 120 YES
TB 04 0089
NO
950
950
950
760
3998 5593007
Note: 71890
The pocket gate prior to the assigned pocket did not close.
STEP 110
YES
NO
120
950
120
130
950
71900
The assigned pocket gate did not open. STEP 110 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 130 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 120 YES
TB 04 0091
NO
950
950
950
71910
The Make Not Ready command failed to make the sorter Not Ready. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 04 0092
NO
950
3998 5593007
761
71920
No MICR detected on first document fed. Note: This failure code is reported if (1) the read system is inoperative, (2) a blank document was the first document in the primary feeder or (3) the required 2730 5192 test document was fed upside down. YES 110 130
TB 04 0093
STEP 100 110 120
PROCEDURE Was the first document in the primary feeder a 2730 5192 test document? Was the document correctly positioned in the primary feeder to be read? Rerun subtest 4 with a 2730 5192 test document correctly positioned for read as the first document. Does the problem still exist?
NO 120 120
130 140
950 170
130 140
Have the MICR READ SYSTEM adjustments been verified since the problem occurred? Replace AA10 and rerun test. Does the problem still exist?
150
950
150
160
The problem is in the character recognition logic. Troubleshoot using T&A 2974 4901 and character recognition MTRs. Start with subtest 01. End of procedure. Rerun subtest 4 but answer "YES" to first question (first document feed right side up?) and "NO" to all other questions on the screen concerning the read system. Does the test pass? 160 180
170
180 950
Follow the new failure code. End of procedure. Verify proper operation. End of procedure.
762
3998 5593007
Note: 71930
Document data mismatch.
STEP 100 110
PROCEDURE Was the first document in the primary feeder the 2730 5192 test document? Rerun test using the 2730 5192 test document. Does the problem still exist?
YES 120
NO 110
120
950
120
160
The problem is in the character recognition logic. Troubleshoot using T&A 2974 4901. End of procedure. Verify proper operation. End of procedure.
950
71940
Too much time for document to get from BOL Q to BOL I1. Note: It took too long for a document to get from the BOL Q to BOL I1. This can occur because of poor transport control of the document. YES
TB 04 0095
STEP 105
NO
110
120
110
120
950
3998 5593007
763
Note: 71950
Too much time for document to get from BOL K to BOL I1.Note: It took too long for a document to get from the BOL K to BOL I1. This can occur because of poor transport control of the document.
STEP 100
YES
NO
110
130
110
130
950
71960
Too much time for document to get from BOL H to BOL I1. Note: It took too long for a document to get from the BOL H to BOL I1. This can occur because of poor transport control of the document. YES
TB 04 0097
STEP 100
NO
110
130
110
130
950
764
3998 5593007
Note: 71970
Too much time for document to get from BOL I1 to BOL I2. Note: It took too long for a document to get from the BOL I1 to BOL I2. This can occur because of poor transport control of the document. YES NO
STEP 100
110
120
110
120
950
71980
Too much time for document to get from BOL I2 to BOL I3. Note: It took too long for a document to get from the BOL I2 to BOL I3. This can occur because of poor transport control of the document. YES
TB 04 0099
STEP 105
NO
110
120
110
120
950
3998 5593007
765
71990
Too much time for document to get from BOL I3 to BOL R. Note: It took too long for a document to get from the BOL I3 to BOL R. This can occur because of poor transport control of the document. YES
TB 04 0100
STEP 100
NO
110
130
110
120
130
Problem is mechanical. Make the necessary corrections and rerun test several times. Does the problem still exist? 130 950
950
766
3998 5593007
Note: 72000
Too much time for document to get from BOL H to BOL L. Note: It took too long for a document to get from the BOL H to BOL L. This can occur because of poor transport control of the document. YES NO
STEP 100
110
130
110
130
950
72010
Too much time for document to get from BOL K to BOL L. Note: It took too long for a document to get from the BOL K to BOL L. This can occur because of poor transport control of the document. YES
TB 04 0102
STEP 100
NO
110
130
110
130
950
3998 5593007
767
Note: 72020
Too much time for document to get from BOL L to BOL M. Note: It took too long for a document to get from the BOL L to BOL M. This can occur because of poor transport control of the document. YES NO
STEP 105
110
120
110
120
950
72030
Too much time for document to get from BOL M to BOL N. Note: It took too long for a document to get from the BOL M to BOL N. This can occur because of poor transport control of the document. YES
TB 04 0104
STEP 105
NO
110
120
110
120
950
768
3998 5593007
Note: 72040
Too much time for document to get from BOL K to BOL N. Note: It took too long for a document to get from the BOL K to BOL N. This can occur because of poor transport control of the document. YES NO
STEP 100
110
130
110
130
950
72050
Too much time for document to get from BOL M to BOL I1. Note: It took too long for a document to get from the BOL M to BOL I1. This can occur because of poor transport control of the document. YES
TB 04 0106
STEP 105
NO
110
120
110
120
950
3998 5593007
769
72060
Too much time for document to get from BOL M to BOL R. Note: It took too long for a document to get from the BOL M to BOL R. This can occur because of poor transport control of the document. YES
TB 04 0107
STEP 100
NO
110
130
110
120
130
950
770
3998 5593007
72070
Rear MJE not ready. STEP 100 PROCEDURE Run MJE MTRs for the rear MJE to determine the cause of the not ready condition. Make any adjustments specified by the MJE MTRs and rerun Subtest 04. Does the test pass? Does the same error code occur? Follow manual procedure for new error code. End of procedure. Has AA09 been replaced in a previous manual procedure? Replace AA09 and rerun test. Does the test pass? Does the same error code occur? Replace AA08 and rerun test. Does the test pass? Does the same error code occur? Troubleshoot starting with signal NIENRDYN (J2 - 9/P60) on SH.01.23.10. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 160 950 160 950 180 YES 950
TB 04 0108
NO 110
110 120 130 140 150 160 170 180
130
120
140 150 120 170 120
950
3998 5593007
771
72080
Front MJE not ready. STEP 100 PROCEDURE Run MJE MTRs for the front MJE to determine the cause of the not ready condition. Make any adjustments specified by the MJE MTRs and rerun Subtest 04. Does the test pass? Does the same error code occur? Follow manual procedure for new error code. End of procedure. Has AA09 been replaced in a previous manual procedure? Replace AA09 and rerun test. Does the test pass? Does the same error code occur? Replace AA08 and rerun test. Does the test pass? Does the same error code occur? Troubleshoot starting with signal NIENRDYN (J2 - 9/P60) on SH.01.23.10. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 160 950 160 950 180 YES 950
TB 04 0109
NO 110
110 120 130 140 150 160 170 180
130
120
140 150 120 170 120
950
772
3998 5593007
72090
Front or Rear MJE not ready. STEP 100 PROCEDURE Run MJE MTRs to determine the cause of the not ready condition. Make any adjustments specified by the MJE MTRs and rerun Subtest 04. Does the test pass? Does the same error code occur? Follow manual procedure for new error code. End of procedure. Has AA09 been replaced in a previous manual procedure? Replace AA09 and rerun test. Does the test pass? Does the same error code occur? Replace AA08 and rerun test. Does the test pass? Does the same error code occur? Troubleshoot starting with signal NIENRDYN (J2 - 9/P60) on SH.01.23.10. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 160 950 160 950 180 YES 950
TB 04 0110
NO 110
110 120 130 140 150 160 170 180
130
120
140 150 120 170 120
950
3998 5593007
773
72100
NIE/MJE not present but reporting not ready. STEP 100 PROCEDURE Visually verify the presence of the NIE, Front MJE, or Rear MJE. Are any of these modules present in the sorter? Replace AA09 and rerun test. Does the test pass? Does the same error code occur? Follow manual procedure for new error code. End of procedure. Replace AA10 and rerun test. Does the test pass? Does the same error code occur? Replace AA02 and rerun test. Does the test pass? Does the same error code occur? Replace AA08 and rerun test. Does the test pass? Does the same error code occur? Troubleshoot starting with signal NIEPLN (J1 - 9/P58) on SH.01.23.06. Does problem still exist? 200 210 220 Replace AA08 and rerun test. Does the test pass? Does the same error code occur? Troubleshoot starting with signal NIENRDYN (J2 - 9/P60) on SH.01.23.10. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 99000 950 220 950 150 950 180 950 190 YES 110
TB 04 0111
NO 200
110 115 120 130 135 150 155 180 185 190
950 130
115 120
135 120 155 120 185 120
950 210 120
950
774
3998 5593007
72110
Too much time for document to get from BOL M to BOL PE1. Note: It took too long for a document to get from BOL M to BOL PE1. This can occur because of poor transport control of the document. YES
TB 04 0112
STEP 100
NO
110
130
110
130
950
72120
Too much time for document to get from BOL K to BOL PE1. Note: It took too long for a document to get from BOL K to BOL PE1. This can occur because of poor transport control of the document. YES
TB 04 0113
STEP 100
NO
110
130
110
130
950
3998 5593007
775
72130
Too much time for document to get from BOL H to BOL PE1. Note: It took too long for a document to get from BOL H to BOL PE1. This can occur because of poor transport control of the document. YES
TB 04 0114
STEP 100
NO
110
130
110
130
950
72140
Too much time for document to get from BOL PE1 to BOL PE2. Note: It took too long for a document to get from BOL PE1 to BOL PE2. This can occur because of poor transport control of the document. YES
TB 04 0115
STEP 100
NO
110
130
110
130
950
776
3998 5593007
72150
TB 04 0116
STEP 100
NO
110
130
110
130
950
72160
TB 04 0117
STEP 100
NO
110
130
110
130
950
3998 5593007
777
72170
Too much time for document to get from BOL PE4 to BOL N. Note: It took too long for a document to get from BOL PE4 to BOL N. This can occur because of poor transport control of the document. YES
TB 04 0118
STEP 100
NO
110
130
110
130
950
72180
Too much time for document to get from BOL PE4 to BOL l1. Note: It took too long for a document to get from BOL PE4 to BOL l1. This can occur because of poor transport control of the document. YES
TB 04 0119
STEP 100
NO
110
130
110
130
950
778
3998 5593007
72190
Too much time for document to get from BOL PE4 to BOL R. Note: It took too long for a document to get from BOL PE4 to BOL R. This can occur because of poor transport control of the document. YES
TB 04 0120
STEP 100
NO
110
130
110
130
950
3998 5593007
779
780
3998 5593007

73000 TB 05 xxxx
This section deals with diagnosis of problems in the transport (tests Beam of Light [BOL] timing). If the sorter Power-On Confidence (POC) test did not pass, proceed to the POC section for diagnosis. This section provides diagnostic information based on the assumption that the POC tests passed. Note: Errors in this area can be caused by improper feed rate or poorly adjusted first accelerator roller. If faults continue, execute speed test in system exerciser to verify feed rate.
3998 5593007
81
Note: 73000
No val signal at test BOL.
STEP 100 110 130 150 950
PROCEDURE Run subtest 04. Does subtest 04 pass? Follow fault code for subtest 04. End of procedure. Replace AA02 and rerun the test. Does the problem still exist? Replace AA08 and rerun the test. Does the problem still exist? Verify proper operation. End of procedure.
YES 130
NO 110
150 99000
950 950
73050
Val stuck on at test BOL. STEP 100 110 120 150 950 PROCEDURE Run subtest 04. Does subtest 04 pass? Follow fault code for subtest 04. End of procedure. Replace AA02 and rerun the test. Does the problem still exist? Replace AA08 and rerun the test. Does the problem still exist? Verify proper operation. End of procedure. 150 99000 YES 120
TB 05 0020
NO 110
950 950
8 2
3998 5593007
Note: 73100
No track error at test BOL.
STEP 110 950
PROCEDURE Replace AA02 and rerun the test. Does the problem still exist? Verify proper operation. End of procedure.
YES 99000
NO 950
73150
No flow stopped interrupt in allotted time. STEP 100 110 120 PROCEDURE Rerun subtest 04. Does test pass? Follow fault codes for subtest 04. End of procedure. Replace AA08 and rerun test. Does the problem still exist? 130 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 YES 120
TB 05 0040
NO 110
950
950
73200
Missort did not occur. STEP 100 PROCEDURE Replace AA05 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 05 0050
NO
950
950
3998 5593007
83
Note: 73250
Document did not missort to reject pocket.
STEP 120 140 150 950
PROCEDURE Replace AA02 and rerun test. Does the problem still exist? Replace AA05 and rerun the test. Does the problem still exist? Replace AA08 and rerun the test. Does the problem still exist? Verify proper operation. End of procedure.
YES 140 150 99000
NO 950 950 950
73300
No feed error occurred. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 110 Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 05 0070
NO
950
950
73350
Wrong MTWE location. STEP PROCEDURE Does the problem still exist? 100 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES 110
TB 05 0080
NO 950
950
8 4
3998 5593007
Note: 73400
Wrong number of documents sorted to pocket 0.
STEP 100 140 950
PROCEDURE Replace AA02 and rerun the test. Does the problem still exist? Replace AA05 and rerun the test. Verify proper operation. End of procedure.
YES 140 150
NO 950 950
73450
Too many documents sorted before flow stopped. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 05 0100
NO
950
73500
No MTWE error on document data. STEP 100 PROCEDURE Replace AA10 and rerun test. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 YES
TB 05 0110
NO
950
950
3998 5593007
85
Note: 73550
Timing error on first document.
STEP 100
PROCEDURE Rerun subtest 05. Does the problem still exist?
YES
NO
110
950
110
120
950
73600
No document data available. STEP 100 950 PROCEDURE Rerun subtest 04 of basic tests. Follow fault codes for subtest 04. End of procedure. Verify proper operation. End of procedure. YES
TB 05 0130
NO
73650
Sorter too late to pocket. STEP 100 120 PROCEDURE Rerun subtest 04. Does subtest 04 pass? Replace AA08 and rerun test. Does the problem still exist? 130 Replace AA02 and rerun test. Does the problem still exist? 140 950 Follow subtest 04 fault codes. End of procedure. Verify proper operation. End of procedure. 99000 130 YES 120
TB 05 0140
NO 140
950
950
8 6
3998 5593007
73700
Wrong number of documents sorted to reject pocket. STEP 100 PROCEDURE Replace AA08 and rerun test. Does the problem still exist? 110 Run the feed rate utility from the exerciser and verify that the feed rate is within tolerance for the primary feeder. The feed rate window for the NDP 1150 is: 970 - 1020 dpm The feed rate window for the NDP 1825 is: 1746 - 1836 dpm. If the feed rate is out of tolerance, make the necessary adjustments and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 05 0150
NO
950
950
3998 5593007
87
73750
BOLs time out of tolerance. Note: STEP 100 105 110 BOLs listed on screen YES 110 110
TB 05 0160
PROCEDURE Fault can be caused by using wrong documents. Are documents 6 inches long? Rerun test with 6 inch documents. Does the problem still exist? Check T&A for the transport area indicated by BOLs. (Refer to FT&R Document for T&A packages.) If BOL out of tolerance is pair B to C, check primary feeder and separator T&A. If out of tolerance pair is S to B, check secondary feeder and separator T&A. Does the problem still exist?
NO 105 950
120 130 99000 150 160 99000
950 140 950 160 950 950
120 130 140 150 160 950
Are both BOLs pocket BOLs? Replace AA05 and rerun test. Does the problem still exist? Is one of the BOLs a pocket BOL? Replace AA05 and rerun test. Does the problem still exist? Replace AA02 and rerun test. Does the problem still exist? Verify proper operation. End of procedure.
8 8
3998 5593007
Note: 73800
No last pocket can be found.
STEP 100
PROCEDURE Follow manual procedure for TB 03 0009. End of procedure.
YES
NO
73850
Unused fault code. STEP 100 110 120 140 950 PROCEDURE Rerun subtest 03. Does test pass? Follow fault codes for subtest 03. End of procedure. Rerun subtest 04. Does subtest 04 pass? Follow subtest 04 fault codes. End of procedure. Verify proper operation. End of procedure. YES 120 130 99000
TB 05 0180
NO 110 950 130
73900
Timeout waiting for sorter to go ready. STEP 100 110 120 140 950 PROCEDURE Rerun subtest 03. Does test pass? Follow fault codes for subtest 03. End of procedure. Rerun subtest 04. Does subtest 04 pass? Follow subtest 04 fault codes. End of procedure. Verify proper operation. End of procedure. YES 120 130 99000
TB 05 0190
NO 110 950 130
3998 5593007
89
Note: 73950
Invalid reader configuration.
STEP 100
PROCEDURE Check jumpers on AA10 per card jumper instructions on schematic SH.09.01.01. Does the problem still exist?
YES
NO
110
950
110
Replace AA10 and rerun. Does the problem still exist? 99000 950
950
74000
BOL B to C timing error. STEP 100 PROCEDURE Check T & A for aligner stations accelerator rollers, aligner disks, feeder, and separators. Does the problem still exist? 110 Replace AA02 and rerun. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 05 0210
NO
950
950
74050
Double document error in BOL test. STEP 100 PROCEDURE Check double doc vacuum & feeders per T & A and rerun test. Does the problem still exist? 110 Replace AA08 and rerun. Does the problem still exist? 120 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 05 0220
NO
950
950
950
810
3998 5593007
Note: 74100
Overlength document error in BOL test.
STEP 100
PROCEDURE Check feeders per T & A and rerun test. Does the problem still exist?
YES
NO
110
950
110
Replace AA02 and rerun. Does the problem still exist? 99000 950
950
74150
Underspace document error in BOL test. STEP 100 PROCEDURE Check feeders per T & A and rerun test. Does the problem still exist? 110 Replace AA02 and rerun. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 05 0240
NO
950
950
74200
Mechanical timing window error in BOL test. STEP 100 110 PROCEDURE Is MTWE location in Microfilm area? Check transport vacuum for area in error. Make necessary corrections. Does the problem still exist? 120 Refer to FTR 1 package for mechanical adjustments in area indicated. End of procedure. Verify proper operation. End of procedure. 99000 YES 110
TB 05 0250
NO 120
950
950
3998 5593007
811
Note: 74250
Electrical timing window error in BOL test.
STEP 100
YES
NO
110
950
110
950
74300
Almost feed error in BOL test. STEP 100 PROCEDURE Indicates possible worn or misadjusted feeders or transport rollers. Refer to T & A. End of procedure. YES
TB 05 0270
NO
74350
Timeout sorter did not go ready. STEP 100 950 PROCEDURE Replace AA08 and rerun test. Does problem still exist? Verify proper operation. End of procedure. YES 99000
TB 05 0280
NO 950
74400
Timeout before sampling complete. STEP 100 110 130 950 PROCEDURE Is hopper empty? Load hopper with more document and rerun test. Does the problem still exist? Rerun subtests 03 & 04. Follow appropriate fault codes. End of procedure. Verify proper operation. End of procedure. YES 110 130
TB 05 0290
NO 120 950
812
3998 5593007
74450
No track error at test BOL. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 YES
TB 05 0300
NO
950
3998 5593007
813
814
3998 5593007

77000 TB 06 xxxx
This section deals with diagnosis of problems in the transport (test error detection and document flow.) If the sorter POC test did not pass, proceed to Section 2 for POC diagnosis. This section provides diagnostic information based on the assumption that the POC tests have passed. Note: 77000
Invalid reader configuration. STEP 100 PROCEDURE Check jumpers on AA10 per card jumper instruction, schematic SH.09.01.01. Are all jumpers correct? 110 Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 950 110 950 YES NO
77050
Timeout waiting for sorter to go ready. STEP 100 PROCEDURE Rerun subtest 03. Does test pass? 110 120 Follow fault codes for subtest 03. End of procedure. Rerun subtest 04. Does test pass? 130 Follow fault codes for subtest 04. End of procedure. 99000 120 YES
TB 06 0110
NO
110
130
3998 5593007
91
Note: 77100
No document data available.
STEP 100
PROCEDURE Rerun subtest 04 and follow fault codes. End of procedure.
YES
NO
77150
Sorter too late to pocket. STEP 100 PROCEDURE Rerun subtest 04. Does test pass? 110 120 Follow fault codes for subtest 04. End of procedure. Replace AA08 and rerun test. Does the problem still exist? 130 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 130 120 YES
TB 06 0130
NO
110
950
950
9 2
3998 5593007
Note: 77200
Error in Double Document (DD) count.
STEP 100
PROCEDURE Check DD vacuum for obstructions in hoses, rerun test. Does the problem still exist?
YES
NO
110 120
950 150
110 120
Is the double document count 0? Replace AA08 and rerun test. Does the problem still exist?
130
950
130
Replace DD vacuum switch and rerun test. Does the problem still exist? 140 950
140
150
Recheck T & A and feed error test deck per SEI# 3125 6332 in FT&R package. End of procedure. Verify proper operation. End of procedure.
950
77250
Error in overlength document count. STEP 100 PROCEDURE Refer to SEI 3125 6332, rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 06 0150
NO
950
950
3998 5593007
93
Note: 77300
Error in underspaced document count.
STEP 100
PROCEDURE Refer to SEI 3125 6332, rerun test. Does the problem still exist?
YES
NO
110
950
110
950
77350
Error in mechanical timing window count. STEP 100 PROCEDURE Refer to SEI 3125 6332, rerun test. Does the problem still exist? 110 Replace AA02 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 06 0170
NO
950
950
77400
Error in almost feed error count. STEP 100 PROCEDURE Replace AA02 and rerun test. Does the problem still exist? 110 Replace AA10 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99000 110 YES
TB 06 0180
NO
950
950
9 4
3998 5593007
Note: 77450
Error in batch ticket count.
STEP 100
PROCEDURE Check adjustments of black bands per T & A 3304 2631 and rerun test. Does the problem still exist?
YES
NO
110
950
110
120
130
950
77550
Counter Failure. Test failed to drive resettable item counter. STEP 100 PROCEDURE Replace AA08 and rerun test. Does problem still exist? 110 Replace AA10 and rerun test. Does problem still exist? 120 Replace Resettable Item Counter. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 120 110 YES
TB 06 0210
NO
950
950
950
3998 5593007
95
77700
Item counter count does not agree with number of documents feed. STEP 110 120 PROCEDURE Replace counter in error and rerun test. Does the problem still occur? Replace AA08 and rerun test. Does problem still exist? 130 Replace AA10 and rerun test. Does problem still exist? 950 Verify proper operation. End of procedure. 99000 130 YES 120
TB 06 0240
NO 950
950
950
9 6
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Section 10 E13B Double Read Character Recognition Test

This section includes failure codes for the E13B Double Read Character Recognition Test. Note: 90000 0 0010
Processor test failed.
The same procedure is used to resolve each of the failure codes on this page. CR 0
90050
Result PROM test failed.
CR 00 0020
90100
Maintenance register test failed.
CR 00 0030
90150
Quantizer test failed.
CR 00 0040
90200
Segmentation test failed.
CR 00 0050
90250
MICR test failed.
CR 00 0060
90300
FIFO test failed.
CR 00 0070
90350
Maintenance RAM test. STEP 100 PROCEDURE Replace AA11 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99500 YES
CR 00 0080
NO
950
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101
E13B Double Read Character Recognition Test
Note: 90350
Different procedures are used to resolve each of the failure codes on this page. CR 00 0090
Analog test failed.
STEP 100
PROCEDURE Analog test can fail if write head cable is disconnected or faulty. Check write head cable and verify that it is connected properly and no visible problems exist. Make necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Verify proper jumper positions on AA11 and AA12 per SH.09.01.02. Make necessary corrections. Does the problem still exist? 120 950
120
130
950
102
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90400
Test failure reported but no fault code received. STEP 100 PROCEDURE This error may occur if the write head cable is disconnected or faulty. Check write head cable and verify that it is connected properly and no visible problems exist. Make necessary corrections. Does the problem still exist? 110 Verify proper jumper positions on AA11 and AA12 per SH.09.01.02. Make necessary corrections Does the problem still exist? 120 Replace AA11 and rerun test. Does the problem still exist? 130 140 Is the sorter in the CAPI configuration? Replace AA17 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99500 130 99500 120 110 YES
CR 00 0100
NO
950
950
950 140
950
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103
Note: 90450
Cable connecting analog board to read head report disconnected.
STEP 100
PROCEDURE Check cable to assure proper connection. Is cable properly connected?
YES
NO
120
110
110
Make necessary corrections and rerun test. Does the problem still exist? 120 950
120
950
90500
Character Recognition POC did not complete. STEP 100 PROCEDURE Verify proper jumper locations per SH.09.01.01 and SH.09.01.02. Make necessary corrections. Does the problem still exist? 110 Replace AA11 and rerun test. Does the problem still exist? 120 Replace AA12 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99500 120 110 YES
CR 00 0120
NO
950
950
950
104
3998 5593007
Note: 90550
Unexpected bus exception occurred during character recognition POC test.
STEP 100
PROCEDURE Verify proper jumper locations per SH.09.01.01 and SH.09.01.02. Make necessary corrections. Does the problem still exist?
YES
NO
110
950
110
120
950
90600
Character Recognition failed I-Test. STEP 100 PROCEDURE Replace suspect board and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99500 YES
CR 01 0010
NO
950
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105
TEST A FAILURE 90700 CR 02 0010
The primary board fails to drive its outputs low, or An open line exists between the primary board and the secondary board, or The secondary board fails to detect inputs properly driven by the primary board.
Use the following table to find the destination of the outputs of the primary board. Table 101. Card AA12 TEST A/TEST B Outputs
SIGNAL TI0 TI1 TI2 TI3 TI4 TI5 TI6 TI7 TI8 TI9
AA12 J2-9 J2-10 J2-11 J2-12 J2-13 J2-14 J2-15 J2-16 J2-17 J2-18
OUTPUTS TO AA11-J2-9 AA11-J2-10 AA11-J2-11 AA11-J2-12 AA11-J2-13 AA11-J2-14 AA11-J2-15 AA11-J2-16 AA11-J2-17 AA11-J2-18
106
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90700
STEP 100 PROCEDURE Using a BDM or a Fluke Model 77 Digital Voltage Meter (DVM) grounded to a ground post on the AA gate backplane measure the logic levels of the lines going from the primary board to the secondary board at the secondary board. Do any of the lines measure greater than 0.8 VDC? 110 Remove the secondary suspect. Using the BDM or DVM as an ohmmeter, check continuity of the lines measured in step 100 from the card side of the socket to the backplane side of the socket. Did all of the lines show proper continuity? 130 Make appropriate corrections, insert the board removed in step 110, restore power, and rerun the test. Does this portion of TEST A now pass? 140 Replace the board removed in step 110, restore power and rerun the test. Does TEST A now pass? 150 160 Do any of the lines measure greater than .8 VDC but less than 2.4 VDC? Replace the primary board, restore power and rerun the test. Does TEST A now pass? 165 Measure the logic level of the line which measured between 0.8 V and 2.4 V in step 100 at the primary card socket. Does the line measure between 0.8 V and 2.4 V? 170 950 950 165 950 140 150 YES
CR 02 0010
NO
110
130
100
100 160
100
175
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107
CR 02 0010
STEP 170 PROCEDURE Remove the primary suspect card. Using the BDM or DVM as an ohmmeter, check continuity of the line measured in step 165 from the board side of the socket to the backplane side of the socket. Did all of the lines show proper continuity? 175 An open exists between the line connecting the primary and secondary boards. Make appropriate corrections, restore power, and rerun test. Does TEST A now pass? 180 Make appropriate corrections, insert the primary board, restore power and rerun the test. Does this portion of TEST A now pass? 950 Verify proper operation. End of procedure. 950 100 950 100 160 180 YES NO
108
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TEST B FAILURE 90800 CR 02 0020
The primary board fails to drive its outputs high, or A short to ground or to another line exists on a line between the primary board and the secondary board, or The secondary board fails to detect inputs properly driven by the primary board.
Use Table 10-1 (located after line 90700) to find the outputs of the primary board. Then use the procedure. 90800
STEP 100 PROCEDURE Using a BDM or a Fluke Model 77 DVM grounded to a ground post on the AA gate backplane measure the logic levels of the lines going from the primary board to the secondary board at the secondary board. Do any of the lines measure less than 2.4 VDC? 110 Remove power. Replace the secondary board. Restore power and rerun the test. Does TEST B now pass? 120 Remove power. Remove the secondary board and the primary board. Refer to the destination table. Do any of the lines from the primary board to the secondary board go to other boards? 130 Remove all other boards which are connected to lines which go from the primary board to the secondary board. Using the BDM or DVM as an ohmmeter, check for continuity between the failed line and adjacent lines and/or between the failed line and ground. Does the ohmmeter read less than 100 K ohms on any line? 150 160 130 140 950 100 120 110 YES
CR 02 0020
NO
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109
CR 02 0020
STEP 140 PROCEDURE Using the BDM or DVM as an ohmmeter, check for continuity between the failed line and adjacent lines and/or between the failed line and ground. Does the ohmmeter read less than 100 K ohms on any line? 150 Locate the short and make corrections as required. Insert all boards which were removed in previous steps, restore power and rerun the test. Does TEST B now pass? 160 Replace the primary board and insert all boards which were removed in previous steps. Restore power and rerun the test. Does TEST B now pass? 950 Verify proper operation. End of procedure. 950 100 950 100 150 160 YES NO
1010
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Note: 90850
Too many bytes of data received from the reader.
STEP 100
YES
NO
110
950
110
950
90900
No "IMAGE AVAILABLE" signal received; no data available. STEP 100 PROCEDURE Verify that both write head cable (J11) and read head cable (J10) are connected. Make necessary corrections. Does the problem still exist? 110 Verify proper jumper positions on AA11 and AA12 per SH.09.01.02. Make necessary corrections. Does the problem still exist? 120 Replace AA11 and rerun test. Does the problem still exist? 130 Replace AA12 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99500 130 120 110 YES
CR 03 0020
NO
950
950
950
950
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1011
90905
DC Reader option reported not present. STEP 100 PROCEDURE Check for the jumper installed on card AA10 "DCMICR." Is the jumper present? 110 Install the jumper. Does the problem still exist? 120 Replace card AA10. Does the problem still exist? 950 Verify proper operation. End of procedure. 99570 120 120 YES
CR 04 0010
NO
110
950
950
1012
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90910
Code line mismatch. STEP 100 110 PROCEDURE Is the only difference in code lines one or more rejected characters? Check the jumpers and switches on card AA13 per SH.09.01.02. Are the jumpers correct? 115 120 Correct the jumpers, and rerun the test. Check the mechanical and electrical adjustments per T&A 3304 4660. Does the problem still exist? 130 Replace card AA13, and perform T&A 3304 4660. Does the problem still exist? 135 Replace the Delay Line assembly. Does the problem still exist? 140 Replace head/preamp, and perform T&A 3304 4660. Does the problem still exist? 170 Replace card AA13, and perform T&A 3304 4660. Does the problem still exist? 900 Verify proper operation. End of procedure. 135 99570 140 135 130 120 --YES 110
CR 04 0020
NO 170
115 ---
900
900
900
900
900
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1013
Note: 90915
Scan detected reject. Note: This test is primarily used by the CSE to diagnose read problems most likely caused by poor document encoding or condition. Before making any adjustments or replacing parts, carefully inspect the document for encoding quality. YES NO
STEP 100
PROCEDURE Verify the jumpers and switches on card AA13 and the adjustments per T&A 3304 4660, and continue testing. Does the problem still exist?
110
900
110
Check the mechanical T&As for the read station drive, entrance, and DYNAVAR. Does the problem still exist? 120 900
120
Replace card AA13, and perform T&A 3304 4660. Does the problem still exist? 125 900
125
Replace the Delay Line assembly. Does the problem still exist? 130 900
130
Replace the read head, and perform T&A 3304 4660. Does the problem still exist? 99570 900
900
90920
Illegal character detected. A character code other than reject, a symbol, or 0 through 9 is reported. STEP 100 PROCEDURE Replace card AA13, and perform T&A 3304 4660. Does the problem still exist? 110 Replace card AA10. Does the problem still exist? 900 Verify proper operation. End of procedure. 99570 110 YES
CR 04 0040
NO
900
900
1014
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90925
Code line mismatch. Note: Poor document encoding can cause characters to misread or reject. Poor mechanical presentation (skew or buckling) can also cause misreads or rejects. YES
CR 04 0050
STEP 100
PROCEDURE Verify the jumpers and switches on card AA13 and the gain setting per T&A 3304 4660, and continue testing. Does the problem still exist?
NO
110
900
110
Check the mechanical T&As for the read station drive, entrance, and DYNAVAR. Does the problem still exist? 120 900
120
125
Replace the Delay Line assembly. Does the problem still exist? 130 900
130
Replace card AA10. Does the problem still exist? 140 900
140
900
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1015
Note: 90930
No MICR data. No document.
STEP 100 110
PROCEDURE Did the documents feed and go to pocket 0? Replace card AA10. Does the problem still exist?
YES 110
NO 140
120
900
120
130
140
Go to the Main MTR Menu, and run the transport tests.
90935
All rejects detected. STEP 100 PROCEDURE Check the jumpers and switches on card AA13. Does the problem still exist? 120 Check the mechanical and electrical adjustments per T&A 3304 4660. Does the problem still exist? 130 Replace card AA13, and perform T&A 3304 4660. Does the problem still exist? 140 Replace card AA10. Does the problem still exist? 145 Replace the Delay Line assembly. Does the problem still exist? 150 Replace the read head, and perform T&A 3304 4660. Does the problem still exist? 900 Verify proper operation. End of procedure. 99570 150 145 140 130 120 YES
CR 04 0070
NO
900
900
900
900
900
900
1016
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90945
No characters detected. STEP 100 PROCEDURE Check the jumpers, switches, card edge connector, and backplane connector on card AA13. Does the problem still exist? 120 Check the mechanical and electrical adjustments per T&A 3304 4660. Does the problem still exist? 130 Replace the card AA13, and perform T&A 3304 4660. Does the problem still exist? 140 Replace card AA10. Does the problem still exist? 150 Replace the read head, and perform T&A 3304 4660. Does the problem still exist? 900 Verify proper operation. End of procedure. 99570 150 140 130 120 YES
CR 04 0080
NO
900
900
900
900
900
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1017
90950
Character Recognition PCBA did not respond to a message sent to it by the CAPI PC. STEP 100 PROCEDURE Replace AA11 and rerun the test? Does the problem still exist 110 Replace AA10 and rerun test. Does the problem still exist? 120 Replace PCI PCBA-AA 10 interface cable and rerun test. Does the problem still exist? 130 Replace the PCI PCBA, internal to the CAPI PC, and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99570 130 120 110 YES
CR 05 0010
NO
950
950
950
950
1018
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Section 11 General Assistance Aids

This section provides troubleshooting suggestions that help to isolate the causes of specific diagnostic failures, some causes and effects of problems, and general troubleshooting suggestions. Each procedure is preceded by its corresponding Error Code Line Number.
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111
General Assistance Aids
92000 Entry to this line indicates the failure of the POC diagnostic procedure to correct a POC failure. Review the following troubleshooting suggestions to help isolate the problem: 1. 2. 3. 4. 5. 6. Review or rerun the diagnostic procedure to make sure the proper test points and stepby-step procedure were followed correctly. Check all cards and AA backplane for proper jumper and switch positions per SH.09.01.01 and SH.09.01.02 in the schematic package. Inspect backplane for bent pins and shorting objects such as staples. Check that all boards are properly seated in connectors. Check the +5V, +5VB, -12V, +12V, and +24V indicators on card AA08. Do the following if the problem still exists: a. b. c. d. Restore all cards and cables. Place a jumper at location W1/W2-0 of card AA17 to bypass the POC test. Power on, and wait for the "NDPBUG" prompt. Enable the CSE mode on the NDP PC and then change the default sorter boot program to the MTR file, INITM030.LO. This procedure is outlined in "Maintenance Test Routines" in Section 1. Load the MTRs from the debugger by entering "G 10000DA" and pressing the Xmit key. Run the MTR Transport Tests and follow the appropriate failure codes to isolate the problem.
e. f. 7.
Review the troubleshooting suggestions at line 99999 listed under General Troubleshooting Suggestions.
112
3998 5593007
93000 Entry to this line indicates the failure of failure code PC 05 xxxx diagnostic procedure to correct a Z-80/Character Recognition Interface problem. Review the following troubleshooting suggestions to help isolate the problem: 1. 2. Review or rerun the diagnostic procedure to make sure the proper test points and step by step procedure were followed correctly. Remove card AA13 and rerun the POC. If the POC now passes, constant interrupts are being generated by the DC Read system. Troubleshoot the DC Read system by using T&A #3304 4660 as a guide. Replace the MICR/Configurator card, AA10. Replace the Recognition Control card, AA11. Replace the Analog Interface card, AA12. Replace the DC Recognition Card AA13. Look over the AA backplane for shorting objects such as staples. Check the card connector block AA10 for bent pins and proper card seating. Check the +5V, +5VB, +12V, -12V and +24V indicators on card AA08.
3. 4. 5. 6. 7. 8. 9.
10. Review the troubleshooting suggestions at line 99999 listed under general suggestions.
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113
97200 Entry to this line indicates the failure of PEP/stamp MTRs to correct a fault. review the following suggestions to help isolate the problem. 1. 2. 3. 4. 5. Review or rerun the diagnostic procedure to make sure the proper test points and stepby-step procedure were followed correctly. Measure all voltages on the endorser boards. Inspect all electrical connections for tightness. Ensure all stamp components are free of excessive wear and rotate freely. This includes the printhead, legend, transfer roll, and ink roll. Ensure that the PEP printhead is properly adjusted for print gap to T&A 3304 3647 and, if required, stoned to SEI 1076 3896. Poor quality printing is generally due to ad incorrectly adjusted print gap, or dirt on the platen or drive rollers. Ensure that faulty ribbon cassettes are replaced. Excessive jams could be due to the use of faulty ribbon cassettes. If not already done, replace the PEP/Stamp controller card (AA09). Rerun tests. Follow appropriate fault codes. Problems in hole detect circuitry can show up as print problems. If this occurs, run hold detect MTR and follow appropriate fault codes. See suggestions under 99999. Stamp POC errors are not reported if the Stamp Error Bypass jumper is installed on the Main CPU Board (AA17). The location of this jumper is W4/W3-B on card AA17 (SH.09.01.02).
6. 7. 8. 9.
Note:
114
3998 5593007
99000 Entry to this line indicates the failure of the MTR Transport Tests diagnostic procedures to correct a Transport Test failure. Review the following troubleshooting suggestions to help isolate the problem. 1. 2. 3. 4. 5. 6. 7. 8. Review or rerun the diagnostic procedure to make sure the proper test points and step by step procedure were followed correctly. Shorting objects such as staples can cause constant or intermittent shorts. Verify and adjust, if necessary, the voltages per T&A #2493 6239 including the check for allowable power supply ripple. Check logic to frame ground short per SEI #2493 6221. Check card connector blocks for bent pins and proper card seating. If the problem is in the Area 1 Tracking logic, replace AA02 if it has not already been replaced. If the problem is in the Area 2/3/4 Tracking logic, replace the following cards one at a time if they have not already been replaced: AA05 and the 4 pocket driver cards. Review the troubleshooting suggestions at line 99999 listed under General Suggestions.
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115
99500 Entry to this line indicates the failure of the magnetic ink character recognition POC/MTR diagnostic procedures to correct a POC/MTR failure. Review the following troubleshooting suggestions to help isolate the problem. 1. 2. 3. 4. 5. 6. 7. 8. Review or rerun the diagnostic procedures to make sure the proper test points and step by step procedures were followed correctly. Check for shorting objects (i.e. staples, paper clips) that can cause constant or intermittent shorts, especially on the back plane. Check all onboard jumper locations for all cards (start with AA11, AA12, and AA17) per SH.09.01.02. If not done already, run Capture Image modes (subtest 11 and 12) on MTR disk. Check logic to frame ground shorts per SEI 2493 6221. Check card connector blocks for bent pins and proper card seating. Replace the following cards one at a time if they have not already been replaced: AA11, AA12, AA17. Review the troubleshooting suggestions at line 99999 listed under general suggestions.
116
3998 5593007
99550 Entry to this line indicates the failure of the MTR CM Tests diagnostic procedures to correct a CMC7 Reader problem. The CMC7 Reader logic resides on one PCBA. If the MTR fails to detect a problem but the system is malfunctioning, one or more of the following should be considered as the probable cause. The causes are listed in order, most probable cause first. 1. 2. 3. 4. 5. 6. 7. 8. Documents encoding out of specification. Worn DYNAVAR strap, poor adjustment of DYNAVAR pressure, or DYNAVAR ground missing/intermittent. Read station mechanical T&As improper. CM Recognition gain adjustment incorrect (T&A 3304 3662). CM Recognition PCBA bad (AA13). CM Read head bad. MICR/Configuration PCBA bad (AA10). Review the suggestions at line 99999 listed under "General Troubleshooting Suggestions."
3998 5593007
117
99570 Entry to this line indicates the failure of the magnetic ink character recognition POC/MTR diagnostic procedures to correct a POC/MTR failure. Review the following troubleshooting suggestions to help isolate the problem. 1. 2. Review or rerun the diagnostic procedures to make sure the proper test points and step-by-step procedures were followed correctly. For E13B MICR, refer to T&A 2494 4901 or 3304 4660 for the single-board reader for troubleshooting suggestions used in conjunction with the character recognition stress check. Check for shorting objects (such as staples and paper clips) that can cause constant or intermittent shorts, especially on the back plane. Check all onboard jumper locations for all cards (start with AA11, AA12, AA13, and AA17) per SH.09.01.02. For multitrack E13B (if present), if not done already, run Capture Image modes (subtests 11 and 12) on the MTR disk. Check the logic to frame ground shorts per SEI 2493 6221. Check the card connector blocks for bent pins and proper card seating. Replace the following cards one at a time if they have not already been replaced: AA10, AA12, AA13, and AA17. Review the suggestions at line 99999 listed under "General Troubleshooting Suggestions."
3. 4. 5. 6. 7. 8. 9.
118
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99600 Entry to this line indicates the failure of the microfilmer POC/MTR diagnostic procedures to correct a problem. Review the following troubleshooting suggestions to help isolate the problem. 1. 2. 3. 4. 5. 6. 7. 8. 9. Review or rerun the diagnostic procedures to make sure the proper test points and step-by-step procedures were followed correctly. Check for shorting objects (such as staples and paper clips) that can cause constant or intermittent shorts, especially on the back plane. Check all onboard jumper locations for all cards (start with the Microfilmer Controller PCBA, AA03, and AA17) per SH.09.01.01 and SH.09.01.02. If not done already, run the appropriate microfilmer MTR on the MTR disk. Follow the new fault code. Check the logic to frame ground shorts per SEI 2493 6221. Check the card connector blocks for bent pins and proper card seating. Check the microprocessors on the following cards for proper seating: Microfilmer Controller PCBA, AA03, AA17. Use the CCC table, if not done already, to help isolate the problem. Replace the following cards, one at a time, if they have not already been replaced: AA03, Microfilmer Controller PCBA, AA17, Reel/Solenoid Driver PCBA, Galvo PCBA, Lamp PCBA, OSM PCBA, and Servo PCBA.
10. Review the suggestions at line 99999 listed under "General Troubleshooting Suggestions."
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119
99700 Entry to this line indicates the failure of the imaging POC/MTR diagnostic procedures to correct a problem. Review the following troubleshooting suggestions to help isolate the problem. 1. 2. 3. 4. 5. 6. 7. 8. 9. Review or rerun the diagnostic procedures to make sure the proper test points and step-by-step procedures were followed correctly. Check for shorting objects (such as staples and paper clips) that can cause constant or intermittent shorts, especially on the back plane. Check all onboard jumper locations for all cards (start with the AA15 and AA17) per SH.09.01.01 and SH.09.01.02. If not done already, run the appropriate imaging MTR on the MTR disk. Follow the new fault code. Check the logic to frame ground shorts per SEI 2493 6221. Check the card connector blocks for bent pins and proper card seating. Check the microprocessors on the following cards for proper seating: image interface AA15, AA17. Use the CCC table, if not done already, to help isolate the problem. Replace the following cards, one at a time, if they have not already been replaced: AA17 and AA15.
10. Review the suggestions at line 99999 listed under "General Troubleshooting Suggestions."
1110
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99999
General Troubleshooting Suggestions

1. 2. 3. Do you really have a problem? Performing tests out of order or failure to explicitly follow test procedures can give false failures. Looping on a test that detects the failure will allow an easier signal and symptom tracing. The MTR diagnostic procedures generally assume only one fault exists in a previously good working machine. Multiple faults might exist which can cause the same failure code or a second failure code in a subsequent test. Follow the second failure code diagnostic procedure if you are unable to correct the first problem. If an FCN or new software/firmware has recently been installed, verify that it was installed correctly and all operating instructions, if any, have been followed. Is the card you replaced the same part number, FCN level, as your spare card? Stand back a moment. Observe what the machine statistics, operator and/or failure code are telling you about the machine operation. Is the problem mechanical? Is it electrical? Is it software? Is it the operator? Is it the environment (voltage, heat, improper grounding, etc.)? Is it the media (document condition or bad disk)? Review any TIBs; they may give some insight to your problem. Check all connections on terminal strips, power supplies, and others for tightness. Check for all proper voltages. Check CCC table. There may be a description that fits the problem.
4. 5. 6.
7. 8. 9.
10. Check all cables for rubbing on belts, cut insulation, loose fit in their connectors, etc. 11. If you suspect that the failure may be related to the optional Courtesy Amount Read (CAR) module, refer to the IR 9210/IR 9220 Courtesy Amount Read (CAR) Module Servicing Guide: Installation and Maintenance.
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1111
1112
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Section 12 Condition, Cause, Correction Tables

100000 The CCC tables are used to define the problem condition, the probable cause(s) in descending probability, and the means of isolation and correction.
General Maintenance Hints

1. 2. 3. Mechanical problems often exhibit the same symptoms as electrical malfunctions. Be sure to check for obvious mechanical problems before replacing logic cards. Careful observation of the problem symptoms can usually narrow the fault down to one of several cards without running any diagnostics. Intermittent problems generally fall into one of the following four categories:

4.
Voltage and ground noise problems Intermittent connection or shorts Heat sensitive components Operator or media peculiarities
Certain failures on the IIB may cause an error code to be displayed for which no procedure is provided in this manual (for example, PC 16 0000). Whenever this kind of invalid error code occurs, refer to error code line 20000 for error code PC 16 XXXX.
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121
Condition, Cause, Correction Tables
Reference Documentation
The CCC Table includes summary information about conditions that may occur in Areas 1 through 4, the endorsers, the high speed encode module (HSEM), and the microfilmers. For more detailed information, refer to the following documents:
Network Document Processor (NDP) Field Test and Reference Document DP 1000/DP 1800 Cinemode Microfilmer Field Test and Reference Document
The CCC Table does not include conditions involving the OCR readers, imaging module, courtesy amount read (CAR) module, or Multi-Jet Endorser (MJE). Refer to the following documents for information regarding errors that involve these components.
DP 1800 OCR Reader Installation and Servicing Guide IC 1800/IC 1825 Imaging Module Installation and Servicing Guide IR 9210/IR 9220 Courtesy Amount Read (CAR) Module Servicing Guide: Diagnostic Procedures
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General Conditions, Causes, and Corrections

Table 121. General Conditions, Causes, and Corrections
Condition Machine checks 3101-3108
Causes Memory corruption
Corrections Run Power On Confidence (POC) test. Follow error code, if any. Replace CPU card AA17.
Machine hangs. (STATUS LED on CPU board lights.) Frequent parity errors reported by operating firmware
CPU failure Memory operations
Replace CPU card AA17. Replace AA08. Inspect for and correct any intermittent power connections. Replace CPU card AA17.
POC fails to complete, HALT Condition (STATUS LED on). BUS TRAP ERROR messages are continually displayed on the sorter screen. OPCO TRAP ERROR messages are continually displayed on the sorter screen. POC fails to complete. (No fault displayed.)
CPU, Memory corruption Multibus address corruption Multibus address corruption Circuit malfunction
Go to line 10950. Go to line 10975.
Go to line 10975.
Go to line 10000 of MTR and follow diagnostic procedure directed by symptom table. Go to line 10000 of MTR and follow diagnostic procedure directed by symptom table. Go to line 10000 of MTR and follow diagnostic procedures. Check terminal cable. Go to line 10000 of MTRs and follow diagnostic procedures.
Blank screen after approximately 2 minutes
Terminal problem. Circuit malfunction
POC fails to complete. ****** on screen
CPU failure
Terminal problem
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123
Condition Machine hangs. (RST LED on CPU board lights or DEBUG prompt is displayed without error code.)
Causes CPU Failure.
Corrections Replace CPU card AA17.
Reset circuitry failure. POC bypass fails to complete. POC fails, but manual procedure fails to resolve Cannot power on CPU failure Machine incorrectly configured as DP 1150 Circuit breaker tripped or bad. FCPS fuses +24V supply fuse or AC control card fuses blown. No AC input power. Power on/off switch or harness bad AC control logic bad
Replace AA08. Replace CPU card AA17. Check jumpers on AA17, per SH.09.01.01. Run MTRs on disk. Set/Replace circuit breaker. Replace fuses.
Connect proper AC input power. Check/replace switch or harness. Replace AC control card or trouble shoot starting with SW-OFF & SEQDWN1 signals on SH.03.01.04. Troubleshoot starting with SWOFF signal on AA backplane SH.01.23.02 Check/replace harness.
Cannot power off
Power on switch or harness bad. Harness bad or not hooked up from control panel to AC control card. Circuit malfunction. PCBA left in test mode.
1. Replace CABB1. 2. Replace CABC1. Run POC tests and MTR to isolate.
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Missorts
Table 122. Missorts CCC
Condition Missort to R pocket
Causes Area-1 tracking error Pocket info register error (REGFAIL) Piece of paper or tumbling document Dead BOL Gate fault or track error Circuit malfunction Slippage or slowdown in HSEM aligner.
Corrections See "MTWE" in this table. See "REGFAIL" in this table. Check transport. Replace dead BOL. See "Gate Fault" or "TRACKERR" in this table. Run MTR basic tests. Adjust HSEM aligners per T&A. Aligner track needs cleaning. Roller needs cleaning.
Slippage in encoder. Missort to pocket other than reject Gate fault Area 2/3 document underspacing or slowdown Track error Dead BOL Circuit malfunction False missorts Track error Piece of paper on tumbling document Circuit malfunction Missorts to microfilm / image Document slow down in microfilm / image Jams at optical gate/mirror
Servo rollers need cleaning. See "Gate Fault" in this table. Check area 2/3 belt and roller tension. See "TRACKERR" in this table. Replace BOL. Run MTR basic MTR tests. See "TRACKERR" in this table. Check transport. Run basic MTR tests. Check microfilm / image transport belts and rollers. Check walls per T&A.
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Table 122. Missorts CCC
Condition
Causes Dead BOLs
Corrections Check BOL bias values. Replace faulty BOLs. Run all transport MTRs.
Undetected missorts
Circuit malfunction or sort program execution Pocket information register malfunction. Dead BOLs
Replace card AA02, replace card AA05. Check BOL bias values. Replace faulty BOLs. Run tracking logic MTR.
No missort detection
Circuit malfunction
126
3998 5593007
Jams
Table 123. Jams CCC
Condition Feeder jams
Causes Worn belts or tires Feed shield worn or misadjusted Feeder separator mechanism misadjusted Media or operator handling
Corrections Replace worn belt/tires. Adjust/replace shield. Check T&A for feeder and separator. Instruct operator. Replace card AA08, AA02. Replace or adjust. Flag should have one or two small weights bolted on. Check/replace bad BOL. Instruct operator. Run MTR basic tests. Clear obstruction. Adjust/replace disks.
No feeder jam detection False feeder jams
Logic malfunction Feed belt or shield worn or misadjusted Inadequate hopper flag pressure Bad BOL B or BOL S New Media or operator Circuit malfunction
Aligner station jams
Obstruction in track Acceleration or aligner discs are worn. Wall gap is too narrow. Feeder/separator is misadjusted. Track is worn or misadjusted.
Check walls per T&A. Check T&A for feeder and separator. Check track per T&A. Clear obstruction. Check wall per T&A. Check track per T&A. Clear obstruction. Replace rollers.
Double document detector jams
Obstruction in track Walls misadjusted Track misadjusted
Read station jams
Obstruction in track No-buckle drive rollers
3998 5593007
127
Table 123. Jams CCC
Condition
Causes Read drum belt worn or misadjusted
Corrections Adjust/clean/replace belts. Check them per T&A. Adjust it per T&A. Replace DYNAVAR. Clear obstruction. Clean/replace rollers or belts. Adjust them per T&A. Clear obstruction Clean transport walls, rollers and track Adjust them per T&A Adjust it per T&A Repair or replace clutch or drive Clear paper/staple obstruction. Clean servo roller. Adjust per T&A. Clean rollers/track/walls. Replace leaf spring. Adjust per T&A. Adjust per T&A. Adjust/replace belts. Adjust/replace front printer wall.
Read station jams
Walls or track misadjusted DYNAVAR pressure too high Torn or kinked DYNAVAR
Standby station jams
Obstruction in track Worn rollers or belt Misadjusted walls or track
PEP/Stamp endorser jam
Obstruction in path Dirty transport Misadjusted walls or track Platen misadjusted Endorser drive/clutch malfunction
HSEM Jams
Obstruction in path Dirty servo roller HSEM aligner misadjusted Dirty rollers/track/walls Damaged leaf spring on front printer wall Aligner flexure roller misadjusted Walls misadjusted Belts worn/misadjusted Front printer wall broken/misadjusted
128
3998 5593007
Table 123. Jams CCC
Condition Note:
Causes
Corrections
For other HSEM jams refer to the HSEM CCC table later in this section. Obstruction in path Dirty track/walls Walls misadjusted Belts worn/misadjusted Clear obstruction. Clean track walls. Check walls per T&A. Adjust/replace belts. Clean track/BOLs. See "MTWE" in this table. Run MTR basic tests Clear obstruction. Check pocket entrance roller drive. See "Improper Stacking" in this table. See "Gate Faults" later in this section. Clear obstruction. Check roller and belt tension. Replace bad parts. Check item per T&A.
Microfilm jams
False area-1 through image jams
Pieces of paper or ink smear Document slowdown Circuit malfunction
Area 2/3/4 gate jams
Obstruction in gate/track Improper pocket entrance drive Improper stacking Gate Faults
Area 2/3/4 transport jams
Obstruction in track Document slippage. Worn roller/belt Wall, track, prow, or filler plate misadjusted.
Area 2/3/4 false jam
Pieces of paper or ink smear Improper document drive Circuit malfunction
Clean track/BOLs. Check roller/belt tension. Run basic MTR tests. See "BOLs" in this table. Run basic MTR tests. Remove blockage. Initiate "BOL reset". Check BOL bias values. Clean or replace BOLs.
No area 2/3/4 jam
BOLs not adjusted Circuit malfunction
Constant jam (cannot clear jam)
BOL blockage Locked up or dead BOL
3998 5593007
129
Table 123. Jams CCC
Condition
Causes Circuit malfunction
Corrections Run basic MTR tests. Carefully recheck the level of the entire unit using alignment posts on both sides of each baseplate. Be sure to tighten the locknuts on all leveling feet. Check the poly-vee belts in the standby track and all pocket modules to make sure they are not up or down a groove. Check the timing belts below the baseplates and the drive belts above the baseplates to make sure they are tracking properly. Check the rollers in the standby area and pocket module to make sure they are level and springloaded. Pay special attention to the first gray roller in each 4-pocket section and all Area 2 poly-vee roller springs. Check the OCR vacuum transport, if present, to ensure proper vacuum. If Image and/or Microfilm is installed, check the front transport belt tension; it may be too loose or the transport wall handle(s) may not be fully closed. Adjust as required.
Document skew or riding high
Unit is not level
Belt has jumped a groove
Belt is riding on a flange
Skewed roller or spring off
Slippage in Transport
1210
3998 5593007
Table 123. Jams CCC
Condition
Causes Document catching in track (edge damage)
Corrections Run new documents to all pockets and carefully inspect the bottom and leading edges for damage. If damage is observed, isolate it to the module in which the damage begins. Use the document as a template to locate the track problem. If documents appear to be rising the farther they go down the transport, and none of the possible causes listed above (under Document skew) seem to apply, shims should be installed. The shims (0.020") should be installed under the first poly-vee roller in each 8pocket module. If the documents are still rising, install 0.020" shims under the first poly-vee roller on the 4-pocket baseplate that does not already have shims. Shims 0.010" are already installed beneath the first poly-vee roller. Never use more than 0.030" in shims under a roller.
Gradual climbing
3998 5593007
1211
Table 123. Jams CCC
Condition
Causes Read station rollers are dirty or worn
Corrections If character recognition subtest shows more than 2 channels of skew, check read station entrance swing arm rollers for dirt build-up or excessive wear. Dirty rollers should be cleaned; worn rollers should be replaced. Loose read drum belt should be given proper tension according to the T&As; dirty or damaged Dynavar tape should be cleaned or replaced. Both Conditions may cause some skew. Check rubber rollers in the suspected problem area for flat spots, conical or other wear and replace if necessary. Look for the reason for the uneven wear and correct the problem. Ink or dirt on rollers can also cause document transport problems; clean as necessary. Adjust HSEM aligners per T&A. Perform skew sensor calibration.
Uneven rubber roller wear or dirt build-up
HSEM document too high or skewed.
HSEM aligners misadjusted
1212
3998 5593007
BOLs
Table 124. BOLs CCC
Condition Frequent dirty BOL or dirty & dead BOL
Causes Bad BOL alignment
Corrections Align BOL and check BOL bias value. Check front/back wall alignment. Replace BOL. Inspect for shorted or broken cable shield Run MTR basic tests. Remove document. Replace BOL. Check repair/cable. Run MTR basic tests. Run interlocks scan in loop mode to locate bad interlock. Adjust/replace interlock. Run MTR basic tests.
Marginal BOL BOL shield broken No dirty or dead BOL detection Unresettable dead BOL at one BOL Circuit malfunction Document in front of BOL Dead BOL Cabling open or short Circuit malfunction No BOLs work (BOLs not adjusted) Open or intermittent interlocks
Circuit malfunction
3998 5593007
1213
Track ERR (Areas 2, 3, or 4)

Table 125. Track ERR (Areas 2, 3, or 4) CCC
Condition Dead BOL for whole area - 1, 2, 3, or 4
Causes One shorted LED or photo transistor in area Cabling short or open Circuit malfunction
Corrections Unplug one at a time until bad BOL is found. Check/repair cable. Run MTR basic tests.
All pocket lights on One pocket light on
Circuit malfunction Data overlap in area 2 or 3 due to tumbling document or pieces of paper Circuit malfunction
Run MTR basic tests. Check belt/roller tension
Run MTR basic tests. Run MTR basic tests. Clean/fix bind
Cannot reset gate fault or tracking error Gate faults
No gate fault/track error command Mechanical bind in gate mechanism or pocket entrance Blown fuse Cable problem Gate misadjusted Circuit malfunction
Replace fuse on 4-pocket driver card. Fix/hook up cable. Adjust or replace gate. Run MTR basic tests. Replace the Tracking Logic PCBA for the affected area.
1214
3998 5593007
Feed Errors
Table 126. Feed Errors CCC
Condition High feed error rate or false feed errors
Causes
Corrections Run feed error test deck to isolate excess feed errors to type of error.
Obstruction in Double Doc (DD) detector or hoses Improperly prepared/dog-eared items
Clean out obstruction (for DD feed errors). Poor feeder adjustments, hopper weight, or hopper vibrator. Jog and inspect items per NDP Operations Guide. Replace/adjust as required. Replace/adjust worn part per T&A. Clean/replace parts.
Worn feeder components Aligner or accelerator disc worn/ misadjusted No-buckle drive rollers or read drum belt dirty or worn out Document slippage Circuit malfunction Failure to detect feed errors
See "MTWE" in this table. Run MTR basic tests. Isolate which type of feed error is not detected by running the feed error test deck. Check for mechanical causes.
Double doc detector is not working
Check cyclone filter, hoses, and ports for dirt build up. Set vacuum per T&A. Run MTR basic tests. Run MTR basic tests. Reset sorter. System contention or program problem. Run MTR basic tests.
Circuit malfunction Failure to stop flow on a feed error Burp to reject pocket with no feed errors Circuit malfunction Z-80 CPU hung Too late to pocket select Circuit malfunction
3998 5593007
1215
Condition MTWE (Area-1 tracking error)
Causes Document slippage due to dirty transport, worn parts, or lack of driver Pieces of paper due to bad media/dogeared items Dead BOL Circuit malfunction
Corrections Examine statistics to determine which transport area to address. Refer to the NDP Field Test and Reference Document for the T&A. Use more care when putting documents into hoppers. Replace BOL. Run MTR basic tests. Adjust HSEM aligners per T&A. Aligner track needs cleaning. Servo roller needs cleaning.
MTWE at PE2 or PE3
Slowdown in HSEM aligner.
Feeder allowing clumps of documents to feed. REGFAIL or Electrical Window Error (ETWE) No pocket lights Circuit malfunction or tracking number error 4-pocket driver card fuse, harness, logic card Hopper vibrator open Circuit malfunction
Adjust feeder per T&As and replace feeder components if necessary. Run MTR basic tests. Replace AA02. Run MTR basic tests.
Primary separator motor runs without document feed
Correct open/replace hopper vibrator replace 1) aux. TRIAC card CABGI, or 2) AC control CABB1 Adjust hopper vibrator gap per T&A Correct open/replace hopper vibrator Replace 1) aux. TRIAC card CABGI, or 2) AC control CABB1 Clean hopper BOL and hopper flag.
Hopper vibrator fails to run
Misadjustment Circuit open Circuit malfunction
Constant or false empty hopper
Hopper BOL is dirty
1216
3998 5593007
Condition
Causes Misadjusted hopper BOL Bad hopper BOL Harness problem Circuit malfunction
Corrections Adjust it per T&A. Replace BOL. Check/repair harness. Run MTR basic tests.
3998 5593007
1217
Batch Ticket
Table 127. Batch Ticket CCC
Condition Constant/false batch tickets
Causes BOLA dirty or opposite wall is dirty BOLA misadjusted Bad BOLA BOL harness problem Circuit problem
Corrections Clean them. Adjust per T&A. Replace BOL. Check/repair harness. Run MTR basic tests. Check configuration. Adjust per T&A. Replace card AA02/AA08.
No batch ticket
Detection not active BOLA misadjusted Circuit malfunction
1218
3998 5593007
Interlocks
Table 128. Interlocks CCC
Condition Constant open interlock (cannot turn on motors)
Causes Bad or misadjusted interlock switch Harness problem Circuit malfunction
Corrections Replace/adjust switch. Check/repair harness or connection. Run MTR basic tests. Run MTR basic tests.
No interlock works
Logic malfunctions or interlock switch shorted to ground Intermittent interlock switch
Isolate switch and adjust or replace Check jumpering and harnessing on BOL distribution cards.
Open interlock (with no location reported)
IEC cover interlock(s) open
Repair or adjust IEC interlock switch; check BOL distribution card jumpers. Isolate switch and adjust or replace Check jumpering and harnessing on BOL distribution cards.
Intermittent interlock switch
Control panel lights
LED bad Cable problem Circuit problem Bad switch
Replace LED. Check/repair cable. Replace AA08. Replace switch. Locate which Condition causes Not Ready by running MTR basic test
Sorter Not Ready
Endorser Not Ready Microfilm Not Ready HSEM Not Ready Microprocessor/Char Rec stop Open interlock Jam Feeder jam Empty hoppers
3998 5593007
1219
Condition
Causes Motors down Pocket light on
Corrections
Sorter Not Ready (continued)
Track err, full pocket, gate fault, dead BOL, jam missort, or pocket light Power on reset Program "Not Ready" command Low double doc vacuum START/STOP bar or switch not working or stuck on fascia
START/STOP bar fails to bring up motors Cannot feed with motor up and sorter Ready
START/STOP bar stuck (Batch ticket stop) Constant batch ticket Constant feed error Constant too late to pocket Circuit malfunction
Bar physically stuck. See SH.04.04.01 to isolate fault to specific area. Run MTR basic tests
Cannot start motors or soft motor shutdown
Jam or feeder jam Intermittent or misadjusted interlock switch
See "Jam" in this table. Troubleshoot to interlock causing the problem starting on SH.01.23.05: 8J1-40, LOCK234N for pocket area interlocks, or 8J1-85, INTLCK1N for Area 1/1B interlocks. Use PPC-ON to sync the scope (8J1-81) and cycle motors up and down to locate the faulty interlock. Adjust or replace switch. Close interlock.
Open interlock
1220
3998 5593007
Condition
Causes IEC interlock on Area1 cover, front MJE, Image, or microfilmer cover is open C4MHz clock not running AC control motor error or circuit breaker tripped Circuit malfunction
Corrections Trouble shoot starting with signal "BUPERR" on sheet 03.01.03. Run MTR basic tests. Reset motor error or circuit breaker. Run MTR basic tests. Run MTRs for the appropriate endorser. Run microfilmer MTRs. Run microfilmer MTRs. Correct program. Run MJE MTRs. Work with bank to correct or minimize. Clean/reposition or change. See DYNAVAR per T&A. See DYNAVAR per T&A.
Improper endorsement data Improper microfilm ID number Improper microfilm operation Missing line of endorsement
Circuit problem Circuit problem Circuit problem Program problem Circuit problem
High rejects
Bad media encoding Worn/dirty DYNAVAR or heads Improper DYNAVAR pressure Improper grounding on read drum or DYNAVAR Logic to frame ground short Document misalignment
Check short per SEI. Check track alignment and roller adjustment from feeder exit to read station. Adjust per T&A. Run MTR basic tests.
Read system misadjusted Logic malfunction or Z-80 malfunction Note:
Use of the MTR disk character recognition tests (especially subtests 11 and 12) and the character rec stress deck program can help isolate MICR read problems. See T&A 3304 4660 for NDP Ready or 4344 6541 for CAPI. Logic malfunction Run MTR CMC7 tests.
CMC7 read problems
3998 5593007
1221
Condition
Causes
Corrections See line number 99550.
Z-80 Overload reported
Document fed backward or upside down with MICR ink on document border. (Garbage MICR) Misadjusted Character Rec Documents too close together
Feed documents right side up.
See "High rejects" in this table. Check feeder adjustments. Clean ink off rollers, replace rollers, and check for proper spring and spring tension on turn in rollers. Fix/replace string.
Bad stacking
Improper drive on turn in rollers or worn rollers
Pocket weight string off pulley or string broken Turn in flexure rollers not parallel Flexure spring broken or misadjusted Pocket snubber damaged or packed with paper Pocket entrance guides misadjusted/broken
Adjust/replace rollers per T&A. Adjust/replace spring per T&A. Clean/replace snubber.
Adjust/replace them per T&A.
1222
3998 5593007
Condition Stacking Problems
Causes Pocket hardware problems
Corrections If documents appear to be entering pocket(s) high, the problem may be upstream; see the "Documents catching on track" Condition. If the problem appears to get more or less worse farther down the track, see the "Gradual climbing" Condition. If the stacking problem is isolated (i.e., a good stack on either side of the bad pocket), check for problems in that pocket. These problems may include dirty or worn rubber turn-in roller, throat roller, or dirty steel pinch rollers. If the documents are "curling" or having tail-end collisions check the kicker spring adjustment T&A and the gap between the left and right column forming wall T&A. If the documents are "backing up" in the pocket, check to see if the flag is moving freely. Another possibility is that the flag weight is off the pulley or is caught on something.
Auger noise
Dirt buildup at bearing block Improper lubrication Worn parts
Clean and lubricate per SEI 2974 4356.
3998 5593007
1223
Endorsers
This subsection lists fault conditions for the PEP/Stamp endorsers on the NDP 1150. Fault condition information for the multi-jet endorser used on the NDP 1825 appears in Section 19. Table 129. Endorsers CCC
Condition Print position incorrect (all endorsers)
Cause Wrong print position specified by program Transport drive problem before or at endorser
Correction Select proper print position Check vacuum drive, belts and rollers
1224
3998 5593007
PEP
Table 1210. PEP CCC
Condition Print position incorrect
Cause Wrong print position specified by program Transport drive problem
Correction Select proper print position. Check belts and rollers Clean platter and drive roller Readjust printhead gap per T&A 3304 3647 Stone printhead per SEI 1076 3894 Replace printhead. Run endorser MTR Replace ribbon cartridge
Poor PEP print quality
Dirt buildup on platten or drive roller Printhead gap not correct Print needles require to be stoned flat Bad printhead or end of life Harness, circuit problems
No PEP print
Damaged ribbon or ribbon beyond end of life Ribbon drive malfunction or ribbon jam not detected Printhead gap misadjusted Hole detect sensor malfunction
Run endorser print MTRs
Adjust per T&A 3304 3647 Replace lamp if burnt out. Clean hole detect sensor. Run endorser MTR.
Ribbon cartridge presence not detected
Ribbon cartridge incorrectly loaded Ribbon cartridge presence switch malfunction Harness/circuit problem
Load ribbon cartridge correctly Replace switch
Run endorser MTR Clean hole detect sensor Run endorser hole detect MTR
PEP prints in holes in documents
Hole detect sensor malfunction
3998 5593007
1225
Table 1210. PEP CCC
Condition
Cause
Correction Replace lamp if burnt out
Jams caused by ribbon pulled out of cartridge
Ribbon cartridge malfunction Staples in documents
Replace ribbon cartridge Removes staples in documents Check jumpers J2-3 to J22 Replace controller card AA09 If operation without PEP is OK, deselect PEP and remove ribbon cartridge
PEP not present reported
Selection jumpers on controller PCBA incorrectly set Fault on controller PCBA
PEP POC failed, but manual procedures do not resolve problem Circuit, cable, printhead problem No Transport Interrupts Disposes without document interrupts Documents without dispose interrupts Circuit fault Circuit fault Too late to endorse or circuit fault
Run endorser MTR Run MTR. Run MTR Most probable cause is late dispositions to endorser due to excessive host load
1226
3998 5593007
Stamp
Table 1211. Stamp CCC
Condition Poor stamp print quality
Causes Stamp legend worn or dirty Ink transfer roll worn
Corrections Clean or replace legend Replace ink transfer roll Adjust ink force Replace ink supply roll Adjust to T&As 1076 3126, 1076 3092, 1076 3100, and 1076 3118
Light stamp printing
Ink force setting too low Ink supply roll empty Stamp gap misadjusted Stamp legend worn or dirty
Stamp overshoot (Operator Attention screen)
Stamp printhead or legend not installed Ink transfer roll not installed Home position misadjusted Circuit or cable problem
Install printhead or legend Install ink transfer roll Adjust per T&A 3304 3654 Run endorser MTR Remount stamp legend
Stamp undershoot (from Operator Attention screen)
Stamp legend incorrectly mounted on printhead Debris buildup on mechanism Home position misadjusted Circuit or cable problem
Clean mechanism Adjust per T&A 3304 6554 Run endorser MTR
CSE ATTENTION REQUIRED Screen Messages Home sensor failed Home sensor misadjusted Home sensor failed Circuit/harness problem Replace controller PCBA Internal fault on controller PCBA Readjust home sensor per T&A 3304 3654 Run endorser MTR; replace motor Run endorser MTR Replace controller card AA09
3998 5593007
1227
Table 1211. Stamp CCC
Condition
Causes
Corrections Run endorser MTR
Replace Stamp driver PCBA
Fault detected on Stamp driver PCBA Circuit, harness, or motor problem
Replace Stamp driver PCBA Run endorser MTR Check jumpers J1-1 to J1-2 Front Stamp J1-3 to J1-2 Rear Stamp Replace controller card AA09 If operation without Stamp is OK, deselect Stamp and remove Stamp printhead
Stamp not present reported
Selection jumpers on controller card incorrect Fault on Controller PCBA
Stamp POC failed
Note:
Stamp POC errors are not reported if the Stamp Error Bypass jumper is installed on the Main CPU board (AA17). The location of this jumper is W4/W3-13 on card AA17 (SH.09.01.02). Circuit, harness, or motor problem Run endorser MTR Run MTR Remount Stamp legend
Disposes without document interrupts Stamp acceleration timeout (from statistics)
Circuit problem Stamp legend incorrectly mounted on printhead Debris buildup in mechanism Home position misadjusted
Clean mechanism Adjust to T&A 3304 6554
1228
3998 5593007
HSEM
Table 1212. HSEM CCC
Condition Encoding in wrong left-to-right position
Cause Flat pinch roller spring in servo track wall installed backwards Ribbon takeup motor stalled. Ribbon failed to advance properly.
Correction Remove, flip over, reinstall.
RibbonTakeupFailure, Ribbon Motion Fault, RibbonSkewLeftFailure, RibbonSkewRightFailure
Remove ribbon. Reload ribbon. Clean ribbon skew sensors. Run MTRs. Replace ribbon when used up. If repeats, do hammer adjustment T&A. Remove staple/clean. Clean sensors/run MTR. Run MTRs. Run MTRs. Run MTRs. Fix/reseat cable between CAPRI and Common Controller PCBAs Replace CAPRI/Common Controller PCBAs. Run Bus Test MTR and other MTRs.
RibbonLow, Ribbon Skew Left/Right Warning HammerFlightFault
Operator warning Hammer movement error detected Staple/dirt in hammer bank
RibbonSkewSensorFailure NoDrumIndex/DrumSpeedError Missing/ExtraCharacterClocks InvalidPrintData ParallelInterfaceGone or ParallelInterfaceError
Dirty/bad sensors Drum motor or circuit problem Circuit problem Circuit problem Cable bad/disconnected Circuit problem Communication failure between Common Controller and Printer Controller
SkewedDocument > +1.50 degrees/DocumentTooHigh
Document condition alignment
Take proper care in document preparation. Check aligner adjustment.
DocumentSlip or Leading Edge Problems
Large dog-ear on lower leading edge of document Slip Tables incorrect
Check documents.
Run Slip Calibration MTR. Run MTRs
DocumentNotInStopPosition
Servo System Failure
3998 5593007
1229
Unisys NDP 1xxx Cinemode Microfilmer

Table 1213. NDP 1xxx Cinemode Microfilmer CCC
Condition Microfilmer fails POC
Causes Various
Corrections Go to manual procedure identified by POC error message. Clean transport walls.
Optical path blocked (front or rear)
Too much reflection from the transport wall ALM base value not correct in NVRAM Document or debris in optical gate Light not reaching optical gate or optics system ALM sensor problem Misadjusted leading/ trailing edge delay
Use hardware parameter routine (Section 17) to adjust ALM value. Clear optical gate area of documents or debris. Clear documents or debris obstructing optical path; clean optical path. Run ALM MTR routine. Use hardware parameter routine (Section 17) to adjust delay values. (Remember to add 0.5 milliseconds to the selected value.) Clean transport walls.
Front or rear ALM failure
Too much reflection from the transport wall Incorrect lamp and/or ALM base values in NVRAM Lamp intensity has changed
Use hardware parameter routine and verify that initial base parameters are still in NVRAM. Check lamp and light transmitting surface of fiber optics for discoloration or dirt. Replace lamps if discolored. Perform density step test, and verify basic lamp values.
ALM sensor problem
Run ALM MTR routine.
1230
3998 5593007
Condition Film load failure (continuous)
Causes Film not loaded at power on, but cover closed Film cassette loaded incorrectly in film transport Film loaded incorrectly in cassettes Film track rollers dirty Film transport problem
Corrections Load film and continue.
Reload film cassette in film transport. Reload film in cassettes.
Clean film track rollers as per PM procedure. Run film transport MTR. Clean supply sensor.
End of film message with greater than 15 feet or less than 5 feet of film remaining
Supply sensor dirty
Incorrect film core diameter on supply film Supply sensor problem Film not loaded message with film plate in down position Camera cover open message with cover closed and locked Film load switch problem Cover switch T&A adjustment incorrect Cover switch problem Camera cover will not lock or unlock correctly Lock mechanism T&A adjustment incorrect Cover lock problem Upper height detector warning Upper height BOL is dirty Faulty BOL BOL alignment bad Faulty BOL circuit Lower height detector warning Lower height BOL is dirty Faulty BOL
Check supply film core; replace if incorrect. Run film transport MTR. Run film transport MTR routine. Adjust cover switch to T&A. Run MTR routine. Adjust lock mechanism to T&A. Run MTR routine. Clean BOL and test. Replace BOL. Align BOL per T&A. Run microfilm MTR. Clean BOL and test. Replace BOL.
3998 5593007
1231
Condition
Causes BOL alignment bad Faulty BOL circuit
Corrections Align BOL per T&A. Run microfilm MTR. Clean capstan roller, slip detection roller, and film track rollers using a lintfree cloth moistened in a 50/50 solution of isopropyl alcohol per T&A 3304 3837. If Condition persists, check for roller wear. Replace worn or damaged components. If Condition persists, check capstan screw for tightness. Check capstan electrical adjustment T&A; readjust as required. Run microfilm MTR. Clean sensor, and retest.
Film slip warning
Cumulative film slip has been detected
Takeup loop too small or large (takeup loop too small or large sensor still covered after automatic loop recovery is attempted)
Dirty sensor
Film not properly threaded in cassette Excessive binding of recovery film in cassette Cassette spline not properly engaging with reel motor spline Loop arms binding Faulty sensor or reel motor Supply loop too small or large (supply loop too small or large sensor still covered after automatic loop is attempted) Dirty sensor
Check film loading in cassette, and correct if wrong. Check for binding. Replace film cassette as necessary. Reload film cassette in film transport. Replace worn cassette or worn splines. Ensure that loop arms move freely. Run film transport MTR. Clean sensor, and retest.
Film not properly threaded in cassette
Check film loading in cassette, and correct if wrong.
1232
3998 5593007
Condition
Causes Excessive binding of recovery film in cassette Cassette spline not properly engaging with reel motor spline Loop arms binding Faulty sensor or reel motor
Corrections Check for binding. Replace film cassette as necessary. Reload film cassette in film transport. Replace worn cassette or worn splines. Ensure that loop arms move freely. Run film transport MTR. Clean sensor, and retest.
Idler encoder failure (zero encoder count after a film move is made)
Dirty sensor
Faulty sensor Film movement problem Encoder disk loose Supply encoder failure (less than 500 supply encoder counts after 12 inches of film movement) Dirty sensor
Run film transport MTR. Run film transport MTR. Check encoder disk. Clean sensor, and retest.
Loose encoder disk
If Condition persists, check if encoder disk is loose. Tighten if required. If Condition persists, run MTR routine. Clean or align BOL and retest. If Condition persists, check for intermittent contact on MIIB or in harness. If Condition persists, replace MIIB PCBA. If Condition persists, replace Controller PCBA, MIIB PCBA. Check cable J1, J3.
Faulty sensor or other problem Missing IPL (dispositions were received by the Controller PCBA without an IPL) Dirty BOL sensor
Intermittent contact
Faulty MIIB PCBA Serial Interface failed
3998 5593007
1233
Condition
Causes Faulty Controller PCBA
Corrections If Condition persists, replace Controller PCBA. Clean or align BOL and retest. If Condition persists, check for intermittent contact on MIIB or in harness. If Condition persists, replace MIIB PCBA. Execute POC. If ID display failure reported, replace ID display PCBA. If Condition persists, run ID display MTR routine. Execute POC with film removed. If failure reported, replace Human Readable Header PCBA. If Condition persists, run HRH MTR routine. Clean film track rollers. Check that qualified film is being used. Check for roller wear. Replace worn or damaged components. Ensure that rollers rotate freely. Check and tighten if required. Check and replace if necessary. Check for cause of drag. Ensure that loop arms move freely. Adjust to T&A. Run film transport MTR.
Missing disposition (IPL received without a disposition)
Dirty BOL sensor Intermittent contact
Faulty MIIB PCBA ID display failure (minimum current not obtained while display is turned on or read after write mismatch) Human readable header failure (minimum current not obtained with display turned on) Faulty ID display PCBA or bad contact in harness
Faulty HRH PCBA or bad contact in harness
Film slip detected (insufficient idler encoder counts for three consecutive moves)
Capstan, idler or film track rollers dirty Worn rollers or not free to rotate
Loose capstan roller Loose idler encoder disk Excessive film drag at platen Loop arms binding Capstan velocity incorrect Faulty motor or drive electronics
1234
3998 5593007
Condition Film Advance error
Causes Film Advance light out Film advance did not occur.
Corrections Run MTR system check routine. Run MTR system check routine. Run film transport MTR routine. Check capstan electrical T&A 3304 4488.
Capstan failure
Failure of the film movement control register to have the correct reading before or after a film move is attempted Scan signal not present after LED timeout or is present after TED timeout Galvo posack signal not set after 5 consecutive documents Galvo home sensor not adjusted correctly Galvo/mirror position not correct Galvo home sensor faulty
Galvo scan signal failure
Replace Controller PCBA.
Galvo posack failure
Run galvo MTR routines.
Galvo home too low or too high (home position outside allowed range)
Run hardware parameter to adjust galvo home position. Adjust to T&A 3304 4439. Run galvo home MTR routine. Replace Galvo PCBA. Run galvo MTR routine. Replace Galvo PCBA. Run galvo MTR routine. Replace Lamp PCBA. If Condition persists, check for intermittent contact on analog motherboard. Run capping shutter MTR routine, and check T&A 3304 4363. Run capping shutter MTR routine, and check T&A 3304 4363.
Galvo voltage failure
Loss of one or more voltages on galvo PCBA Current limit detected while sweeping the galvo Failure of front or rear lamp control register to hold a value Sensor not covered after closing the capping shutter Sensor not covered after opening the capping shutter
Galvo current failure
Lamp control read after write mismatch
Capping shutter close failure
Capping shutter open failure
3998 5593007
1235
Condition Channel 1 ICM failure (ICM current not in range while active)
Causes Faulty ICM LED or bad contact in harness
Corrections Run POC with film removed. If error detected, run ICM MTR routine. If error not detected, check for intermittent contact in cabling. Run POC with film removed. If error detected, run ICM MTR routine. If error not detected, check for intermittent contact in cabling. If lamp does not illuminate after pressing start/stop If replacing lamp does not cure problem, run Lamp MTR. Replace MIIB PCBA. Replace Controller PCBA.
Channel 2 ICM failure (ICM current not in range while active)
Faulty ICM LED or bad contact in harness
Front or rear lamp failure (lamp current < than 80 percent of expected value)
Faulty lamp
Faulty drive electronics Interface board internal failure (failure detected on MIIB PCBA) Controller board internal failure (failure detected on Controller PCBA) MTR POC failure (failure detected during POC) Serial interface failure (failure of the serial interface detected by the MIIB PCBA) Power-on failure (loss of a supply voltage detected) Faulty PCBA Faulty PCBA
Various
Run POC, and use manual procedures to identify fault. Run serial interface MTR routine. Check supply voltages. Replace Controller PCBA. Replace Controller PCBA. Have processor check calibration strips against master and correct process. Clean optics as per PM procedures.
Problem on MIIB PCBA, on Controller PCBA, or in harness Faulty power supply or harness Watchdog timer failed
Input capture register failure (internal PCBA failure detected) Image density too light or too dark on film
Faulty Controller PCBA Commercial processor speed/temperature control incorrect Dust buildup on optics
1236
3998 5593007
Condition
Causes Lamp intensity setting incorrect
Corrections Run lamp intensity hardware parameter routine to select correct lamp operation point. Replace lamp, and run hardware parameter routine to select correct lamp operation point. Clean optics as per PM procedures. Replace lamp. Replace fiber bundle. Clean optical gates and/or mirrors. Repair scratches on optical gates or track walls by painting flat black. Replace Galvo PCBA. Replace galvo/mirror assembly. Check the interconnections and repair. Run lamp adjustment hardware parameter routine to select correct operating density. Clean optics per PM procedure. Focus lens per T&A 3304 4330. Replace galvo/mirror assembly. Run hardware parameter routine to adjust LED delay.
Lamp faulty or at end of life
Vertical streaks on document images
Dust buildup on optics Faulty lamp Damaged fiber bundle
Vertical lines on front or rear image from optical gate though galvo scan
Dirt buildup in optical gates/mirrors Damage to optical gates or track walls
Horizontal density variations (bands) on document images
Faulty Galvo PCBA Faulty galvo/mirror assembly Intermittent contact
Poor image resolution
Density on film not between 1.0 and 1.5
Dust buildup on optics Document lens not focused correctly Defective or scratched galvo mirror surface Leading edge of front image and ID number overlap LED delay not set correctly
3998 5593007
1237
Condition
Causes Galvo home position not adjusted correctly ID display position not adjusted correctly
Corrections Run hardware parameter routine to adjust galvo home position. Adjust ID display position per T&A 3304 4348. Run hardware parameter routine to adjust ID display on time. Clean ID display optics per PM procedure. Run hardware parameter routine to adjust TED delay. Adjust galvo scan per T&A. Adjust platen rollers per T&A 3304 4314. Check feeder operation. Adjust electrical T&A. Run film transport MTR. See under loop too large or too small problems. Adjust electrical T&A. Run film transport MTR. See under loop too large or too small problems. Clean microfilmer BOLs. Clean belt and track per PM procedure. Adjust BOL alignment to T&A. Adjust track wall to T&As 3304 4108 and 3304 4132.
ID numbers faint
Incorrect ID display on time selected Dirt buildup on ID optics
Document image too short but resolution good Document image too short or long and poor resolution ICM not correctly located at edge of film Forward leading edge image curl Reverse image curl
TED delay value not correctly set Galvo scan not correctly adjusted Platen roller location not correct Underspaced items Capstan velocity control incorrect Capstan drive faulty Loop arm operation incorrect
Forward trailing edge curl
Capstan velocity control incorrect Capstan drive faulty Loop arm operation incorrect
Missorts in microfilm transport
Dirty BOL Debris in track or dirt on belt drive BOL alignment bad Track wall adjustment bad
1238
3998 5593007
Condition
Causes Transport belt drive adjustment bad
Corrections Adjust belt drive to T&A 3304 4124. Clean track and belts per PM procedure. Adjust belt drive to T&A 3304 4124. Adjust track wall gap to T&As 3304 4090 and 3304 4132. Replace drive belt. Replace AA03 (MIIB), Microfilm Controller PCBA.
Jams in microfilm transport
Debris in track or dirt on belt drive Transport belt drive adjustment bad Track wall gap adjustment bad Broken drive belt
Microfilmer reporting Not Ready. No reason can be found.
Serial interface failed
3998 5593007
1239
1240
3998 5593007
Section 13 Power Supply

150000 To troubleshoot problems with the NDP power supply systems, refer to the "Power Supply Adjustment" T&A (Part #2493 6239) in the NDP Field Test and Reference Document.
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131
Power Supply
132
3998 5593007
Section 14 Machine Checks

This section describes machine checks, which are part of the diagnostic tools for the NDP 1150 and NDP 1825 Document Processors. Machine checks are declared by sorter system software whenever certain error conditions occur that need to be brought to the attention of the customer service engineer and/or sorter programmers. The diagnostic flowchart in Figure 14-1 shows how machine checks work with other diagnostic tools.
Diagnostic Flow
POC/MTR Error Code Displayed
Machine Check Displayed
Go to appropriate section and follow diagnostic procedure under Error Code
Review Machine Check probable causes in this section
Read introduction and refer to CCC chart in Section 12 for diagnostic procedures
Figure 141. Diagnostic Flow Chart
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141
Machine Checks
Machine Check Screen

Whenever a machine check is declared, a screen is displayed that contains important information relating to the particular error. This is shown in Figure 14-2.
MACHINE CHECK <MACHINE CHECK TYPE> ERROR NUMBER: <DESCRIPTION LINE 1> <DESCRIPTION LINE 2> <MACHINE CHECK CAUSE> <xmit> TO RECOVER ------------------------------------------------------------------FOR FIELD ENGINEER/PROGRAMMER USE ONLY: TASK: xx xxxx xxxx PC: xxxxxxxx EEW: xxxx xxxx
Figure 142. Machine Check Screen
142
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Machine Checks
Table 14-1 explains the screen field terms used in Figure 14-2. Table 141. Field Descriptions for Machine Check Screen
MACHINE CHECK TYPE ERROR NUMBER DESCRIPTION LINES MACHINE CHECK CAUSE TASK PC EEW Describes the particular type of error (such as SYSTEM SOFTWARE or PROGRAM). Is the number assigned to the particular error. Describes the error being declared. Is the probable cause of the error (such as SOFTWARE, HARDWARE, ELECTRICAL, MECHANICAL, or DATA COMM). Represents the number of the task declaring the error. Represents the program counter where the error was detected. Represents extended error words - status information that helps define the error condition.
Values for each of these fields are listed in later subsections. The machine check error numbers are followed immediately by the Extended Error Words.
3998 5593007
143
Machine Checks
Diagnosis of Machine Check Conditions

When a machine check condition occurs, follow this procedure: 1. Find the 4-digit machine check error number in a subsection under the "Error Number" subsection. Entries for error numbers can include the Extended Error Word (EEW); the possible hardware cause (PHC) of the condition;, or other diagnostic reference information. Follow the instructions under the error number. The EEW should be decoded by looking up the non-zero, alphabetic digits found in the EEW subsection. EEW information immediately follows the error number listings.
2.
General Causes
Machine checks can have many causes: hardware, software, and environmental. Single occurrences of machine checks can be caused by electrical power line disturbances or electrostatic discharges (ESDs). A single occurrence of a machine check should be fully logged for future reference. If a machine check repeats, it is symptomatic of a hardware or software problem. In general, machine checks can be caused by the following:
A noisy or out-of-adjustment + 5 volt logic supply Dirty or not fully seated card contacts Improper initiation of online programs or mode changes Improperly written customer sort programs
Any hardware-specific machine check (for conditions such as low vacuum; circuit breaker open; or related to the feeder, read station, microfilmer, or imaging module) indicates a possible hardware fault in the respective hardware area. You should run the MTRs for that area to help identify the cause of the machine check.
144
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Machine Checks
EEW Definitions
The following table (Table 14-2) defines abbreviations that appear in the machine check EEWs found in this section. Table 142. Machine Check General Definitions
CC CM CR CS CT DS EF ES FI FM HIT KS LET MB PS RB SRT ST TF TS UA SVC Opcode issued by task CAR Unit message opcodes CAR Unit message response status CAR driver SVC result status CAR Unit operating state Bisync - data comm PIO SVC result status Emulation - 4A Driver SVC Function code Emulation - 4A Driver PIO SVC result status File Manager error codes Forms Manager error codes Host Interface Task Kludge 4A - data comm PIO SVC result status Local Environment Task Modify Configuration buffer Poll-Select Driver (CRT) PIO SVC result status Read Configuration buffer Sort Task CAR Unit operating state Transport Driver SVC Function Code Transport Driver PIO SVC result status User buffer address
3998 5593007
145
Machine Checks
Machine Check Type

The MACHINE CHECK TYPE field on the machine check screen has short descriptions of the area or operation affected by the machine check, including SYSTEM SOFTWARE, PROGRAM, or FIRMWARE CHECK. More machine check type information appears in the following "Error Number" subsection.
Description Lines
These lines on the machine check screen describe the error being declared. "CIRCUIT BREAKER OPEN" is an example of a description line.
Machine Check Cause

The MACHINE CHECK CAUSE field on the machine check screen shows the probable cause of the error, such as SOFTWARE, HARDWARE, ELECTRICAL, MECHANICAL, or DATA COMM.
Task
The TASK field on the machine check screen represents the number of the task declaring the error. The following subsections list the task codes for different operations.
NDP 1150/NDP 1825 Task Number

Table 14-3 lists task numbers for different parts of system software. Table 143. NDP 1150/NDP 1825 Task Number
1 2 3 5 6 $A $C Local Environment Task Firmware Screen Task Status Monitor Task Host Interface Task Sort Task Initialization Task Forms Manager
146
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Machine Checks
SVC Message Opcodes

SVC message opcodes are listed in the following subsections for:
Local Environment Task (Table 14-4) Firmware Screen Task (Table 14-5) Host Interface Task (Table 14-6) Sort Task (Table 14-7)
3998 5593007
147
Machine Checks
Local Environment Task

Table 14-4 lists SVC message opcodes for the Local Environment Task. Table 144. SVC Message Opcodes - Local Environment Task
Opcode 01 02 03 04 07 08 09 0A 0D 0E 0F 10 11 12 13 20 21 22 23 24 25 30 31 51
Definition Enter No_Mode Terminate task Enter Offline mode Enter Online mode Machine check has been declared Recover from machine check Unsolicited input Solicited input Enter Snapshot Exit Snapshot Sorter is ready User display done Execute user sort program Disk operation failed Disk operation successful Display user sort program screen Get input from operator Start screen processing Stop screen processing User sort program halted Host screen write Start monitoring Stop monitoring User sort program is loading
148
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Machine Checks
Firmware Screen Task

Table 14-5 lists SVC message opcodes for the Firmware Screen Task. Table 145. SVC Message Opcodes - Firmware Screen Task
Opcode 21 22 23 24 25 26 27 28 29 2A 2B 2C 2D 2F
Definition Start offload Start emulation Enter no mode Enter online Enter offline Execute user sort program Load and execute user sort program Load and execute utility as PT1TSK Load and execute utility as PT2TSK Display done Solicited operator input Unsolicited operator input Microfilmer header Enter snapshot
3998 5593007
149
Machine Checks
Host Interface Task

Table 14-6 lists SVC message opcodes for the Host Interface Task. Table 146. SVC Message Opcodes -Host Interface Task
Opcode 51 53 54 55 56 57 58 59 5B
Definition User sort program downloaded Enter idle mode Enter sort mode Enter recall mode Enter transfer mode Enter echo mode Host reset started Host reset completed Host screen write
1410
3998 5593007
Machine Checks
Sort Task
Table 14-7 lists SVC message opcodes for the Sort Task. Table 147. SVC Message Opcodes -Sort Task
Code 61 62 64 65 66 67 68 69 6A 6B 6C 6D 6E 6F 70 Start flow Stop flow
Definition
Display user sort program screen Accept operator input Ready failed User sort program halted Open disk file Close disk file Read file (single sector) Write file (single sector) Write file (multiple sectors) Read file (multiple sectors) Initialize disk Format disk Allocate disk file
PC (Program Counter)
The PC field on the machine check screen represents the program counter where the error was detected. An example is 00050FAA.
3998 5593007
1411
Machine Checks
Machine Check Error Number

The ERROR NUMBER field on the machine check screen is the first step in decoding a machine check condition. This field includes a number (ranging from one to four numbers) that gives the CSE a basic indication of the error causing the machine check. The error number helps lead the CSE to the Extended Error Word (EEW), which gives them a more detailed description of the problem. EEWs are described immediately after this machine check error number subsection.
Offload and Emulation Machine Check Error Numbers

The followings subsections list (in numerical order) the 4-digit error numbers that are the first indication of a machine check condition. All machine checks can be declared in either offload or emulation mode, except for the machine checks specified in Table 14-8. Table 148. Offload and Emulation Machine Check Error Numbers
Machine Check Error Number 5xxx 60Ax 60Cx 62xx 66xx 6800 67xx 6801 6802
Offload only * * * * * *
Emulation only
* * *
1412
3998 5593007
Machine Checks
0001-0092, 00C1 (MTOS SVC)

This subsection lists error numbers for MTOS SVC errors. The Probable Hardware Cause (PHC) for each MTOS SVC error is: PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
Note:
The following errors are generated by the Multitasking Operating System (MTOS) of the NDP 1xxx. These errors should be recorded and reported to a support engineer at the Plymouth (Michigan) Development Center. MTOS SVC FAILED EEW: MSMS MSMS 0000 0000 MS: MTOS defined status of SVC
0001
0003
PAUFIN / PAUSTR TIMEOUT EEW: TNRA CMCL CUCT 0000 TN: number of task being started RA: restart argument CM: coordination mode CL: coordination local event flag CU: coordination units CT: coordination time
0060
PARAMETER ERROR: PAUSEEF EEW: PTPT PTPT FFFF FFFF PT: pause time in milliseconds FF: function flags for event IO
0070
PARAMETER ERROR: RECEIVE EEW: MSMS MSMS 0000 0000 MS: MTOS defined status for SVC
3998 5593007
1413
Machine Checks
0081
TASK NOT PAUSED (RESUME ISSUED TO A TASK NOT PAUSED) EEW: TRTN 0000 0000 0000 TR: Number of task issuing resume TN: Number of task to be resumed
0091
MAILBOX MESSAGE NOT ACKNOWLEDGED EEW: RCOP 0000 0000 0000 RC: Receiving task OP: Message Opcode
0092
MAILBOX BUFFER NOT ALLOCATED EEW: N/A
00C1
MEMORY I/O COPY INCOMPLETE EEW: CCCC CCCC LALA LALA CC: Condition Codes LA: Last "to address" copied correctly
1414
3998 5593007
Machine Checks
0100-0112 (File Manager)

0100 FILE MANAGER ERROR EEW: FIFI FIFI 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 0111 FILE ID CONVERSION ERROR (TXT_TO_FID) EEW: ECEC ECEC 0000 0000 EC: Error code from TXT_TO_FID routine PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 0112 DISK ERROR (F_DIRECT) IN FUNCTION: DSKOK EEW: SCSC SCSC 0000 0000 SC: Status code from F_DIRECT routine PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
0200 (Forms Manager)

0200 FORMS MANAGER ERROR EEW: FMFM FMFM 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
3998 5593007
1415
Machine Checks
0300 (Program/Task Loading Routine)

0300 TCB ROUTINE ERROR EEW: MSMS MSMS 0000 0000 MS: MTOS defined error for SVC PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
0401-0405 (Miscellaneous PIO Routines)

0401 TRANSPORT SCAN FAILED EEW: TSTS TSTS 0000 0000 PHC = Card 8 Card 2, 5, 10 0402 FAILED TO FIND FIRST JAM/MISSORT LOCATION EEW: TSTS TSTS 0000 0000 PHC = Card 8 0403 BOL RESET FAILED EEW: TSTS TSTS 0000 0000 PHC = Card 8 0404 GATE FAULT / TRACK ERROR RESET FAILED EEW: TSTS TSTS 0000 0000 PHC = Card 8 0405 RESET TOO-LATE-TO-PKT FAILED EEW: TSTS TSTS 0000 0000 PHC = Card 8
1416
3998 5593007
Machine Checks
0611-0613 (Literal Handling)

0611 LITERAL HEADER VERSION MISMATCH EEW: DSDS DSDS 0000 0000 DS: Directory starting address PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 0612 LITERAL GROUP MISMATCH EEW: LGLG LGLG LNLN LNLN LG: Literal Group LN: Literal Name PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 0613 LITERAL NOT FOUND EEW: DSDS DSDS DEDE DEDE DS: Directory Starting Address DE: Directory Ending Address PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
3998 5593007
1417
Machine Checks
1001-1353 (Local Environment Task)

1001 TIMEOUT WAITING FOR INITIALIZATION TASK TO FINISH EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 1002 INVALID MAILBOX MESSAGE OPCODE EEW: OPOP OPOP 0000 0000 OP: OpCode PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 1004 READ TRANSPORT STATUS FAILED OR TIMED OUT EEW: TSTS TSTS 0000 0000 PHC = Card 8 Card 17 1005 TIMEOUT WAITING ON STOP TASK REQUEST (FWS/MON) AT START FLOW EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 1006 OPERATOR INITIATED MICROFILM HEADER FAILED EEW: TSTS TSTS 0000 0000 PHC = Card 3 1009 TIMEOUT WAITING FOR FIRMWARE SCREEN TASK TO (RE) START EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1418
3998 5593007
Machine Checks
1110
SORT PROGRAM REQUEST TO OPEN FILE WHEN FILE ALREADY OPEN EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1120
SORT PROGRAM REQUEST TO CLOSE FILE WHEN NO FILE OPEN EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1121
SORT PROGRAM REQUEST TO READ FILE WHEN NO FILE OPEN EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1122
SORT PROGRAM REQUEST TO WRITE FILE WHEN NO FILE OPEN EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1123
SORT PROGRAM REQUEST TO UPDATE DISK WITH OPEN FILE(S) EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1131
SORT PROGRAM REQUEST TO READ FILE WITH BAD BUFFER ADDRESS EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
3998 5593007
1419
Machine Checks
1132
SORT PROGRAM REQUEST TO WRITE FILE WITH BAD BUFFER ADDRESS EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1300
UTILITY TASK ALREADY ACTIVE EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1320
INSUFFICIENT STACK/HEAP SPACE FOR UTILITY EEW: HLHL HLHL HAHA HAHA HL: Location of heap area HA: Heap space available PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1331
PROGRAM LOAD ADDRESS OVERLAPS FIRMWARE EEW: LALA LALA 0000 0000 LA: Load address PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
1350
UNABLE TO ALLOCATE HOST INTERFACE ENDPOINT EEW: RCRC RCRC RLRL RLRL RC: FIT result code RL: FIT result class PHC = ??
1420
3998 5593007
Machine Checks
1351
UNABLE TO CREATE HOST INTERFACE ASSOCIATION TO THE PC EEW: RCRC RCRC RLRL RLRL RC: FIT result code RL: FIT result class PHC = ??
1352
UNABLE TO ALLOCATE NOTICE INTERFACE ENDPOINT EEW: RCRC RCRC RLRL RLRL RC: FIT result code RL: FIT result class PHC = ??
1353
UNABLE TO CREATE NOTICE INTERFACE ENDPOINT TO THE PC EEW: RCRC RCRC RLRL RLRL RC: FIT result code RL: FIT result class PHC = ??
3998 5593007
1421
Machine Checks
2001-2401 (Firmware Screen Task)

2001 INVALID SVC MESSAGE OPCODE ("START" EXPECTED) EEW: OP00 0000 0000 0000 OP: Opcode PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 2002 INVALID SVC MESSAGE OPCODE (IN MAIN LOOP) EEW: OP00 0000 0000 0000 OP: Opcode PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 2004 EMULATION DATACOMM CHECK FAILED EEW: 0000 0000 ESES ESES PHC = Card 16/18 Card 17 2100 READ FROM CRT FAILED EEW: 0000 0000 PSPS PSPS PHC = CRT cable connection CRT bad/configured wrong Card 17 2101 READ FROM CRT DURING TERMINAL RECONFIGURE FAILED EEW: RSRS RSRS 0000 0000 RS: BPS/Screen Read result status PHC = ??
1422
3998 5593007
Machine Checks
2103
NOT READING FROM CRT EEW: 0000 0000 PSPS PSPS PHC = CRT cable connection CRT bad/configured wrong Card 17
2104
ALREADY READING FROM CRT EEW: 0000 0000 PSPS PSPS PHC = CRT cable connection CRT bad/configured wrong Card 17
2105
NON-MENU DISPLAY STATE IN MENU HANDLER EEW: 0000 00DS 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
2201
GET DOCUMENT DATA QUEUE INDEX FAILED EEW: FPFP FPFP CPCP CPCP FP: Pointer to the first Data Queue element CP: Pointer to the current Data Queue element PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
2202
NON-EXCEPTION DISPLAY STATE IN EXCEPTION HANDLER EEW: 0000 00DS 0000 0000 DS: Display state (0-43) PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
3998 5593007
1423
Machine Checks
2204
AREA 1 INTERLOCK SHORTED (COMMON INTERLOCK LINE IS SHORTED TO GROUND) EEW: 0000 0000 0000 0000 PHC = Short on Intmux line in Area 1, NIE, microfilmer, or imaging module Card 8
2205
LAST-GOOD-DISPOSE NOT FOUND IN DATA QUEUE EEW: 00LN XXXX XXXX XXXX
Note:
LN represents the LastGoodDispose document ID length, and XXXX XXXX XXXX represents the least significant 6 bytes of the LastGoodDispose document ID PHC = Card 15 Card 17 System disk
2206
TIMEOUT WAITING FOR LAST-GOOD-DISPOSE SEMAPHORE EEW: 0000 0000 0000 0000 PHC = Card 17 System disk
2207
UNEXPECTED STATE OF CAR UNIT EEW: CSCS CSCS CMCM STCR CM (left byte) = CAR Unit Message code received by CAR Unit. CM (right byte) = CAR Unit Message code sent by DP. PHC = Card 17 Card 19 System disk
2208
NON-TIMEOUT ERROR ON CAR INTERFACE EEW: CSCS CSCS CMCM STCR CM (left byte) = CAR Unit Message code received by CAR Unit. CM (right byte) = CAR Unit Message code sent by DP. PHC = Card 19 Card 17 CAR cable connection
1424
3998 5593007
Machine Checks
2209
REQUEST TO CAR UNIT FAILED EEW: CSCS CSCS CMCM STCR CM (left byte) = CAR Unit Message code received by CAR Unit. CM (right byte) = CAR Unit Message code sent by DP. PHC = Card 19 Card 17 CAR cable connection
220A
TIMEOUT WAITING FOR IMAGE-QUALITY-LIST SEMAPHORE EEW: 0000 0000 0000 0000 PHC = ??
220B
SCSI LINK TO CAR UNIT IS HUNG EEW: RSRS RSRS 0000 0000 RS: CAR I/O request result status PHC = ??
2401
IMAGE QUALITY ERROR DOCID NOT FOUND IN DATA QUEUE EEW: NFLN IDID IDID IDID NF: number of items not found in data queue LN: docid length of last (most recent) item not found ID: docid of last (most recent) item not found PHC = ??
3998 5593007
1425
Machine Checks
3001-3500 (Status Monitor Task)

3001 INVALID SVC MESSAGE OPCODE ("START" EXPECTED) EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 3002 INVALID SVC MESSAGE OPCODE ("STOP" EXPECTED) EEW: 0000 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17 3100 GLOBAL MEMORY TEST AREA CORRUPTED EEW: 0000 000X 2324 2526 X: Memory test number (1 - E) 23242526 = Memory test pattern PHC = Card 17 3201 CIRCUIT BREAKER OPEN EEW: 0000 0000 0000 0000 PHC = Circuit breaker tripped Fuse in AC control blown Card CABB1 Circuit breaker auxiliary contacts open/wiring error 3202 LOW VACUUM EEW: 0000 0000 0000 0000 PHC = Low double-document or OCR reader vacuum Vacuum switch Card CABB1 Hose leaking or disconnected
1426
3998 5593007
Machine Checks
3300
NONIMPACT ENDORSER: INK TRAP EEW: 0000 0000 0000 0000 PHC = Ink trap switch/wiring Card 9
3301
NONIMPACT ENDORSER: NO INK EEW: 0000 0000 0000 0000 PHC = NIE needs ink Ink leak No ink switch Card 9
3302
NONIMPACT ENDORSER: JETS OFF WHILE READY EEW: 0000 0000 0000 0000 PHC = Card 9
3303
NONIMPACT ENDORSER: PUMP OFF WHILE READY EEW: 0000 0000 0000 0000 PHC = Card 9
3401
MICROFILMER: POWER FAILED EEW: 0000 0000 0000 0000 PHC = Card 3
3402
MICROFILMER: INVALID ERROR REPORTED EEW: TSTS TSTS 0000 0000 PHC = Card 3
3500
NIE FIRMWARE DETECTED DATA ERROR EEW: TSTS TSTS 0000 0000 PHC = Card 9
3998 5593007
1427
Machine Checks
4001-4002 (Snapshot Task)

4001 ERROR IN SNAPSHOT TASK MENU HANDLER EEW: 0000 0000 0000 0000 PHC = ?? 4002 DATA COMM INITIALIZATION ERROR WITH SNAPSHOT TASK EEW: RCRC RCRC 0000 0000 RC: FIT result code PHC: ??
1428
3998 5593007
Machine Checks
5000-5901, 5AF8-5C02 (Host Interface)

5001 DATA COMM INITIALIZATION ERROR WITH HOST INTERFACE TASK EEW: RCRC RCRC 0000 0000 RC: FIT result code PHC: ?? 5100 INVALID MESSAGE RECEIVED FROM LOCAL ENVIRONMENT TASK EEW: OPTS 0000 0000 0000 OP: Invalid SVC Opcode TS: Sending Task# PHC = Card 17 System disk Card 16/18 51F1 TIMEOUT WAITING LET RESPONSE TO ENTER IDLE EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18 51F2 TIMEOUT WAITING LET RESPONSE TO ENTER SORT EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18 51F3 TIMEOUT WAITING LET RESPONSE TO ENTER ECHO EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
3998 5593007
1429
Machine Checks
51F4
TIMEOUT WAITING LET RESPONSE TO ENTER RECALL EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
51F5
TIMEOUT WAITING LET RESPONSE TO ENTER TRANSFER EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
5200
INVALID MESSAGE RECEIVED FROM SORT TASK EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
52F1
TIMEOUT WAITING SRT RESPONSE TO STOP FLOW REQUEST EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
52F2
TIMEOUT WAITING SRT RESPONSE TO USER SORT
PROGRAM LOADED EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18 5300 INVALID SCAN MESSAGE EEW: OPTS 0000 0000 0000 OP: Invalid SVC Opcode TS: Sending Task# PHC = Card 17 System disk Card 16/18
1430
3998 5593007
Machine Checks
53F1
LET DID NOT RESPOND TO HOST WRITE SCREEN EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
5400
INVALID SENDER TO HIT MBX EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
5500
INVALID STATUS RETURNED FROM DATA COMM DRIVER EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 System disk Card 17
5700
HIT SDB REQUEST WAS IMPROPER EEW: 0000 0000 0000 0000 PHC = Card 16/18 System disk Card 17
5800
DATA COMM DRIVER DID NOT RECEIVE REQUEST EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 System disk Card 17
3998 5593007
1431
Machine Checks
5810 ERROR RETURNED FROM CSL_RECEIVE WHILE WAITING FOR HOST COMMAND EEW: RCRC RCRC DBDB DBDB RC: FIT result code or event code DB: miscellaneous debug info (for systems programmers) PHC: ?? 5811 ERROR RETURNED FROM CSL_SEND WHILE WAITING FOR HOST COMMAND EEW: RCRC RCRC DBDB DBDB RC: FIT result code or event code DB: miscellaneous debug info (for systems programmers) PHC: ?? 5812 HOST ERROR RETURNED FROM CSL_RECEIVE WHILE SENDING RESPONSE TO
EEW: RCRC RCRC DBDB DBDB RC: FIT result code or event code DB: miscellaneous debug info (for systems programmers) PHC: ?? 5813 ERROR RETURNED FROM CSL_SEND WHILE SENDING RESPONSE TO HOST EEW: RCRC RCRC DBDB DBDB RC: FIT result code or event code DB: miscellaneous debug info (for systems programmers) PHC: ?? 5901 LET DID NOT RECEIVE MESSAGE EEW: XXOP 0000 0000 0000 XX: Undefined OP: SVC Opcode sent to let PHC = Card 16/18 System disk Card 17
1432
3998 5593007
Machine Checks
5AF8
DATA COMM DRIVER TRANSMIT RESPONSE EXCEPTION EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 System disk Card 17
5AF9
DATA COMM DRIVER NO LINE ACTIVITY EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 System disk Card 17
5AFA
DATA COMM DRIVER ONLINE REQUEST ERROR EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 System disk Card 17
5AFB
DATA COMM DRIVER HARDWARE ERROR, RECOVERY MAY REQUIRE A RESET OF THE SORTER EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 Host connecting cables Improper host software invoked
5AFC
DATA COMM DRIVER TIMEOUT EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 Card 17
5AFD
DATA COMM DRIVER UNIT OFF LINE
3998 5593007
1433
Machine Checks
EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 Card 17 5AFE DATA COMM DRIVER RESERVE OR RELEASE ERROR EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 Card 17 5AFF DATA COMM DRIVER RECEIVED INVALID PARAMETER EEW: 0000 0000 0000 0000 Refer to "DS -- Data Comm EEW" for more EEW information. PHC = Card 16/18 Card 17 5C01 NO MESSAGE, NO COMMAND, BUT HIT WOKE UP EEW: 0000 0000 0000 0000 PHC = Card 16/18 Card 17 5C02 HIT IN INVALID HOST MODE EEW: 0000 0000 0000 0000 PHC = Card 16/18 Card 17
1434
3998 5593007
Machine Checks
6001-6093, 60A0-60F0, 6200-6802 (Sort Task)

6001 TRANSPORT PIO SVC FAILED: BAD PARAMETER EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 10 6002 TRANSPORT PIO SVC FAILED: RESERVE/RELEASE ERROR EEW: TFTF TSTS TSTS 0000 PHC = Card 17 6003 TRANSPORT PIO SVC FAILED: UNIT OFFLINE EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 16/18 6004 TRANSPORT PIO SVC FAILED: TIMED OUT EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 16/18 Card 8 6005 TRANSPORT PIO SVC FAILED: ONLINE ERROR EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 16/18 6006 TRANSPORT DRIVER PIO TIMED OUT (WAITING FOR ACK) EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 16/18 Card 8 600F INVALID INTERRUPT WHEN IDLE (CMD RESULT) EEW: TFTF TSTS TSTS 0000 PHC = Card 8 Card 3
3998 5593007
1435
Machine Checks
6010
INVALID INTERRUPT WHEN IDLE EEW: TFTF TSTS TSTS 0000 PHC = Card 8 Card 3
6011
INVALID INTERRUPT WHEN SORTER READY (CMD RESULT) EEW: TFTF TSTS TSTS 0000 PHC = Card 8 Card 3
6012
INVALID INTERRUPT WHEN SORTER READY EEW: TFTF TSTS TSTS 0000 PHC = Card 8 Card 3
6013
INVALID INTERRUPT WHEN FLOWING EEW: TFTF TSTS TSTS 0000 PHC = Card 8 Card 3
6014
INVALID INTERRUPT WHEN FLOWING (TRANSPORT STATUS) EEW: TFTF TSTS TSTS 0000 PHC = Card 8 Card 3
6015
TRANSPORT DRIVER DOCUMENT QUEUE FULL EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 17 Card 8
6016
DOCUMENT DATA CHANNEL A OVERFLOW EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 11 Card 12 Card 13
1436
3998 5593007
Machine Checks
6017
DOCUMENT DATA CHANNEL B OVERFLOW EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 11 Card 12 Card 13
6018
DOCUMENT DATA CHANNEL A ERROR EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 11 Card 12 Card 13
6019
DOCUMENT DATA CHANNEL B ERROR EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 11 Card 12 Card 13
6021
DOCUMENT TOO LATE TO POCKET EEW: TFTF TSTS TSTS 0000 PHC = Host system response too slow Card 17 Card 16/18 Card 8
6022
INVALID COMMAND RESULT DURING FLOWING EEW: TFTF TSTS TSTS 0000 PHC = Card 8
6023
TIMEOUT WAITING FOR HEADER RESPONSE EEW: TFTF TSTS TSTS 0000 PHC = Card 3
3998 5593007
1437
Machine Checks
6024
TRANSPORT DRIVER COULD NOT ACCESS MICROFILMER DUAL PORT EEWW: TFTF TSTS TSTS 0000 PHC = Card 3
6025
INVALID MICROFILMER FUNCTION COMPLETE INTERRUPT WHEN READY EEW: TFTF TSTS TSTS 0000 PHC = Card 3
6026
INVALID MICROFILMER FUNCTION COMPLETE INTERRUPT WHEN IDLE EEW: TFTF TSTS TSTS 0000 PHC = Card 3
6030
INVALID RESPONSE TO FEED REQUEST EEW: TFTF TSTS TSTS 0000 PHC = Card 8
6031
INVALID FEED REQUEST PARAMETER EEWW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 8 Card 10
6033
ILLEGAL MERGE REQUEST - NOT FLOWING FROM PRIMARY FEED EEW: TFTF TSTS TSTS 0000 PHC = Card 17 System disk
6034
ATTEMPT TO FEED DOCUMENTS WITH NO READER ENABLED EEW: TFTF TSTS TSTS 0000 PHC = None
6040
INVALID IMAGING MODULE MESSAGE LENGTH VALUE - DISPOSE COMMAND EEW: TFTF TSTS TSTS 0000 PHC = Card 17 System disk
1438
3998 5593007
Machine Checks
6041
TIMEOUT WAITING FOR IMAGING MODULE RESPONSE INTERRUPT EEW: TFTF TSTS TSTS 0000 PHC = Card 15 Card 17
6042
INVALID RESPONSE FORMAT FROM IMAGING MODULE EEW: TFTF TSTS TSTS 0000 PHC = Card 15 Card 17
6043
INVALID INTERRUPT RESPONSE - IMAGING MODULE REQUEST RESPONSE EXPECTED EEW: TFTF TSTS TSTS 0000 PHC = Card 15 Card 17
6050
PREVIOUS DISPOSITION INCOMPLETE EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 16/18
3998 5593007
1439
Machine Checks
6051
POCKET SELECT ERROR EEW: TFTF TSTS TSTS 0000 PHC = Card 8 Card 2 Card 17
6052
INVALID RESPONSE TO DISPOSITION EEW: TFTF TSTS TSTS 0000 PHC = Card 8
6053
INVALID ICM COMMAND PARAMETER EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 16/18
6055
FILM FOOTAGE COUNT FAILED TO INCREMENT EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Run microfilmer MTRs
6056
TRANSPORT DRIVER COU NOT ACCESS NIE DUAL-PORT EEW: TFTF TSTS TSTS 0000 PHC = Card 9
6060
INVALID RESPONSE TO SLEW CMD: EXPECTING NOT READY EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 8
6061
INVALID RESPONSE TO SLEW CMD: EXPECTING BEGIN SLEW EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 8
1440
3998 5593007
Machine Checks
6062
INVALID RESPONSE TO SLEW CMD: EXPECTING END SLEW EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 8
6063
TIMEOUT WAITING FOR SORTER TO GO NOT READY EEW: TFTF TSTS TSTS 0000 PHC = Card 8
6064
TIMEOUT WAITING FOR BEGIN SLEW EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 8
6065
TIMEOUT WAITING FOR END SLEW EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 8
6066
USER ISSUED SLEW REQUEST DURING FLOW EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 3 Card 8
6067
USER ISSUED SLEW REQUEST WHEN CAMERA NOT PRESENT/POWERED ON EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 3
6068
BAD STATUS IN HW MICROFILMER REGISTER 2 OR 3 (SLEW) EEW: TFTF TSTS TSTS 0000 PHC = Card 3
3998 5593007
1441
Machine Checks
6080
INVALID HEADER STYLE SELECTION EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 3
6081
INVALID ICM SELECTION ON HEADER COMMAND EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 3
6082
INVALID RESPONSE TO HEADER COMMAND - EXPECTED TIMEOUT EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 17
6083
BAD STATUS IN HW MICROFILMER REGISTER 2 OR 3 (HEADER) EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 17
6090
INVALID ICM SELECTION EEW: TFTF TSTS TSTS 0000 PHC = Card 17 Card 3
6091
TIMEOUT WAITING FOR ICM COMPLETE EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 17
6092
INVALID RESPONSE TO ICM COMMAND - ICM COMPLETE EXPECTED EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 17
1442
3998 5593007
Machine Checks
6093
BAD STATUS IN HW MICROFILMER REGISTER 2 OR 3 (ICM) EEW: TFTF TSTS TSTS 0000 PHC = Card 3
60A0
INVALID BATCH # RESPONSE EEW: TFTF TSTS TSTS 0000 PHC = Card 8
60A1
TIMEOUT WAITING FOR BATCH # ADVANCE EEW: TFTF TSTS TSTS 0000 PHC = Card 8
60B1
INVALID POCKET LIGHT RESPONSE CODE EEW: TFTF TSTS TSTS 0000 PHC = Card 8
60C0
INVALID READ SYSTEM SELECTED: ONLY CM EEW: MBMB TSTS TSTS 0000 PHC = Card 10
60C1
INVALID READ SYSTEM SELECTED: ONLY AC/DC EEW: MBMB TSTS TSTS 0000 PHC = Card 10
60C2
INVALID READ SYSTEM SELECTED: ONLY AC EEW: MBMB TSTS TSTS 0000 PHC = Card 10
60C3
INVALID READ SYSTEM SELECTED: ONLY DC EEW: MBMB TSTS TSTS 0000 PHC = Card 10
3998 5593007
1443
Machine Checks
60C4
INVALID READ SYSTEM OPTIONS EEW: MBMB TSTS TSTS 0000 PHC = Card 10
60C5
INVALID BLACK BAND OPTION EEW: MBMB TSTS TSTS 0000 PHC = Card 10 Card 2
60C6
INVALID COMMAND DURING FLOW EEW: MBMB TSTS TSTS 0000 PHC = Card 8
60C7
INVALID READ SYSTEM PRESENT EEW: RBRB TSTS TSTS 0000 PHC = Card 10 Card 11 Card 12
60C8
INVALID READ SYSTEM SELECTION DISCOVERED EEW: RBRB TSTS TSTS 0000 PHC = Card 10
60D0
READ MICROFILMER STATUS FAILED DURING COMMUNICATE: READ STATUS EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 17
60D1
READ MICROFILMER STATUS FAILED DURING COMMUNICATE: READ ATTRIBUTES EEW: TFTF TSTS TSTS 0000 PHC = Card 3 Card 17
1444
3998 5593007
Machine Checks
60F0
INVALID RESULT STATUS FROM TRANSPORT DRIVER EEW: TFTF TSTS TSTS 0000 PHC = Card 8
6200
SVC MESSAGE NOT ACKNOWLEDGED BY HOST INTERFACE TASK EEW: 0000 0000 0000 0000 PHC = Card 17 System disk
6201
INVALID SVC MESSAGE OPCODE RECEIVED FROM HOST INTERFACE TASK EEW: OPST 0000 0000 0000 OP: SVC Opcode ST: Sending task # PHC = Card 16/18 System disk Card 17
6400
SVC MESSAGE NOT ACKNOWLEDGED BY LOCAL ENVIRONMENT TASK EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
6401
INVALID SVC MESSAGE OPCODE RECEIVED FROM LOCAL ENVIRONMENT TASK EEW: OPST 0000 0000 0000 OP: SVC Opcode ST: Sending task # PHC = Card 17 System disk Card 16/18
3998 5593007
1445
Machine Checks
6601
REQUEST INFORMATION BLOCK (RIB) ADDRESS NOT IN USERS MEMORY EEW: UAUA UAUA 0000 0000 PHC = Card 17 System disk Card 16/18
6602
REQUEST INFORMATION BLOCK (RIB) ADDRESS NOT WORD BOUNDARY EEW: UAUA UAUA 0000 0000 PHC = Card 17 System disk Card 16/18
6603
USER BUFFER ADDRESS NOT IN USER MEMORY EEW: UAUA UAUA RBRB RBRB RB: User sort program Request Information Block ( RIB ) address PHC = Card 17 System disk Card 16/18
6604
USER BUFFER ADDRESS NOT WORD BOUNDARY EEW: UAUA UAUA RBRB RBRB RB: User sort program Request Information Block ( RIB ) address PHC = Card 17 System disk Card 16/18
6605
INVALID COMMUNICATE FROM SORT PROGRAM EEW: OPOP 0000 RBRB RBRB OP: Invalid Opcode RB: User sort program Request Information Block ( RIB ) address PHC = Card 17 System disk Card 16/18
1446
3998 5593007
Machine Checks
6606
SORT PROGRAM INFINITE LOOP EEW: 0000 0000 0000 0000 PHC = Card 17 System disk Card 16/18
6640
ERROR IN PROCESSING IQE LIST FROM THE IMAGING MODULE EEW: DBDB DBDB DBDB DBDB DB: miscellaneous debug info (for systems programmers) PHC: ??
6650
OCR1 DATA OVERFLOW EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 17 System disk
6651
OCR2 DATA OVERFLOW EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 17 System disk
6652
OCR1 INTERRUPT BUT NO DATA IN FIFO EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 8 Card 17
6653
OCR2 INTERRUPT BUT NO DATA IN FIFO EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 8 Card 17
3998 5593007
1447
Machine Checks
6654
INVALID OCR MESSAGE LENGTH EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 17 System disk
6655
INVALID OCR1 MESSAGE FORMAT EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 17 System disk
6656
INVALID OCR2 MESSAGE FORMAT EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 17 System disk
6657
INVALID OCR SELECTION EEW: TFTF TSTS TSTS 0000 PHC = System disk
6660
OCR FRAMING ERROR EEW: TFTF TSTS TSTS 0000 PHC = Card 10 Card 17 System disk
6661
INVALID TRANSPORT DRIVER INTERRUPT WHILE PROCESSING AN OCR REQUEST EEW: TFTF TSTS TSTS 0000 PHC = System disk Card 10
6662
OCR1 OUTPUT FIFO FILLED UP EEW: TFTF TSTS TSTS 0000 PHC = Card 10
1448
3998 5593007
Machine Checks
6663
OCR2 OUTPUT FIFO FILLED UP EEW: TFTF TSTS TSTS 0000 PHC = Card 10
6670
ATTEMPT TO ENABLE OCR READER WITH NO CONTROLWARE LOADED EEW: 0000 0000 0000 0000 PHC = None (invalid keyboard entry)
6680
TIMEOUT ON CAR DRIVER TO SORT TASK PIO ACKNOWLEDGE EEW: 0000 0000 0000 0000 PHC = Card 17 Card 19 System disk
6681
CAR UNIT PARITY ERROR EEW: 0000 0000 0000 0000 PHC = Card 19 CAR cable connection
6682
IMPROPER PARAMETER TO CAR DRIVER EEW: 0000 0000 0000 0000 PHC = Card 17 System disk
6683
CAR QUEUE OVERFLOW EEW: 0000 00SC AAAA AAAA SC: Sync byte in CAR queue global memory record which would be overwritten. AA: Address of the CAR queue global memory record which would be overwritten. PHC = Card 17 System disk
3998 5593007
1449
Machine Checks
6684
UNEXPECTED ERROR CODE FROM CAR TASK EEW: 00 00ST 00E1 00E2 E1: Extended error byte 1 returned from CAR task E2: Extended error byte 1 returned from CAR task PHC = Card 17 Card 19 System disk
6685
UNEXPECTED RESPONSE FROM CAR UNIT EEW: 00CM 00ST 00CR 0000 PHC = Card 17 Card 19 System disk
6686
CAR UNIT APPEARS TO BE HUNG, RESET SORTER AND CAR UNIT TO CONTINUE EEW: 0000 0000 0000 0000 PHC = Card 19 Card 17 CAR cable connection System disk
668F
UNEXPECTED RESPONSE FROM CAR DRIVER EEW: 00CM CSCS CSCS 0000 PHC = Card 17 Card 19 System disk
6701
4A DRIVER PIO SVC FAILED: BAD PARAMETER EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
6702
4A DRIVER PIO SVC FAILED: RESERVE/RELEASE ERROR EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
1450
3998 5593007
Machine Checks
6703
4A DRIVER PIO SVC FAILED: UNIT OFFLINE EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
6704
4A DRIVER PIO SVC FAILED: TIMED OUT EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
6705
4A DRIVER PIO SVC FAILED: FATAL CONTROLLER ERROR EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
6706
4A DRIVER PIO SVC FAILED: INVALID FUNCTION CODE EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
6707
4A DRIVER PIO SVC FAILED: INVALID UNIT NUMBER EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
6708
4A DRIVER PIO SVC FAILED: DRIVER NOT OPEN EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
3998 5593007
1451
Machine Checks
6709
4A DRIVER PIO SVC FAILED: DRIVER RECEIVED INVALID INTERRUPT EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
670A
4A DRIVER PIO SVC FAILED: CONTROLLER FAILED TO GO ONLINE EEW: EFEF ESES ESES 0000 PHC = Card 16/18 System disk Card 17
6720
ILLEGAL COMMAND RECEIVED FROM 4A DRIVER EEW: XX00 0000 0000 0000 XX: Command Byte PHC = Card 16/18 System disk Card 17
6721
INVALID FEEDER COMMAND EEW: XX00 0000 0000 0000 XX: Feed Command Byte PHC = Card 17 IP20.5System disk Card 8
6722
DISPOSITION COMMAND DURING NON-FLOW EEW: XX00 0000 0000 0000 XX: Command Byte PHC = Card 17 IP20.5System disk Card 8
1452
3998 5593007
Machine Checks
6723
INVALID ENDORSER BAND LOAD NUMBER (PRELOAD) EEW: XX00 0000 0000 0000 XX: Endorser band load command byte PHC = Card 17 Card 9 System disk
6724
INVALID ICM COMMAND - NUMBER OF ICMS IS INVALID EEW: XX00 0000 0000 0000 XX: Command byte and ICM count PHC = Card 17 Card 3 System disk
6730
TIMED OUT WAITING FOR DISPOSITION EEW: 0000 0000 0000 0000 PHC = Card 17 Card 16/18 Card 8
6731
UNEXPECTED DISPOSITION RECEIVED EEW: EFEF ESES ESES 0000 PHC = Card 17 Card 16/18 Card 8
6732
ILLEGAL ENDORSER BAND LOAD NUMBER EEW: XX00 0000 0000 0000 XX: Band load command byte PHC = Card 17 Card 9 System disk
3998 5593007
1453
Machine Checks
6733
COMMAND INVALID DURING FLOW: ICM EEW: XX00 0000 0000 0000 XX: ICM command byte PHC = Card 17 Card 3 System disk
6734
COMMAND INVALID DURING FLOW: SLEW EEW: XX00 0000 0000 0000 XX: SLEW command byte PHC = Card 17 Card 3 System disk
6735
COMMAND INVALID DURING FLOW: HEADER EEW: XX00 0000 0000 0000 XX: HEADER command byte PHC = Card 17 Card 3 System disk
6736
COMMAND INVALID DURING FLOW: POCKET LIGHT EEW: XX00 0000 0000 0000 XX: POCKET LIGHT command byte PHC = Card 17 Card 8 System disk
6737
INVALID COMMAND OPCODE RECEIVED FROM 4A DRIVER EEW: XX00 0000 0000 0000 XX: Illegal command byte PHC = Card 16/18 Card 17 System disk
1454
3998 5593007
Machine Checks
6738
COMMAND INVALID DURING FLOW: START FEEDER EEW: EFEF ESES ESES 0000 PHC = Card 17 Card 16/18 System disk
6739
COMMAND INVALID DURING FLOW: STATISTICS EEW: XX00 0000 0000 0000 XX: Special character in byte 23 of endorsement text PHC = Card 17 Card 16/18 System disk
67F0
INVALID 4A DRIVER PIO RESULT EEW: EFEF ESES ESES 0000 PHC = Card 16/18 Card 17 System disk
6800
LOCAL ENVIRONMENT TASK FAILED TO SET OPERATION MODE EEW: XX00 0000 0000 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
6801
INVALID TRANSPORT DRIVER SVC ROUTINE OPCODE EEW: XXXX 0000 0000 0000 XXXX: SVC code sent to transport driver SVC handler routine PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
6802
INVALID READ DOCUMENT SVC ISSUED WHEN NOT FLOWING EEW: EFEF ESES ESES 0000 PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
3998 5593007
1455
Machine Checks
A001-A102 (Utility Task)

A001 OPEN TRANSPORT SVC TO TRANSPORT FAILED (TIMED OUT) EEW: TSTS TSTS 0000 0000 PHC = Card 17 IP20.5 System disk Card 8 A002 MODIFY CONFIG SVC TO TRANSPORT FAILED (TIMED OUT) EEW: TSTS TSTS 0000 0000 PHC = Card 17 System disk Card 10 A006 READ CONFIG SVC TO TRANSPORT FAILED (UNKNOWN) EEW: TSTS TSTS 0000 0000 PHC = Card 17 System disk Card 10 A010 ILLOGICAL NUMBER OF POCKET MODULES REPORTED EEW: PMPM PMPM 0000 0000 PHC = 4-Pocket Driver card/jumpers Card 5
1456
3998 5593007
Machine Checks
A020
ATTEMPT TO SET MTOS TIMER FAILED EEW: MSMS MSMS 0000 0000 MS: MTOS status PHC = System disk bad/corrupted Dirty/bad disk drive Card 17
A101
READ CONFIGURATION FROM TRANSPORT FAILED EEW: TSTS TSTS 0000 0000 PHC = Card 10 Card 17
A102
MODIFY CONFIGURATION TO TRANSPORT FAILED EEW: TSTS TSTS 0000 0000 PHC = Card 10 Card 17
3998 5593007
1457
Machine Checks
CAR Task Error Code

The CAR Task error codes are defined in Table 14-9. Table 149. CAR Task Error Code
Code 01 02 03 04
Definition CAR task has completed its processing loop CAR queue overwritten CAR unit went into an unexpected state CAR task timed out waiting on an acknowledgment from the CAR driver to a SVC CAR task received an unsuccessful SVC response from the CAR driver CAR task received "CAR data available" SVC from Sort task, but no data was found
05
06
1458
3998 5593007
Machine Checks
CAR Unit Message Opcode Definitions (CM)

The CAR Unit Message Opcodes are defined in Table 14-10. Table 1410. CAR Unit Message Opcode Definitions (CM)
Code 01 02 03 04 05 06 07 08 09 0B 0C 0D 0E 0F 10 11 Get POC results
Definition
Read CAR unit configuration Get CAR unit status Load CAR recognition software Flow started Flow stopped CAR unit reset CAR disposition Get CAR amounts Data capture mode Test Show nominal results Back to IDLE state Back to OP state Show CAR recognition software information Change timeout period
3998 5593007
1459
Machine Checks
CAR Unit Message Response Status Definitions (CR)

The CAR unit message response status codes are defined in Table 14-11. Table 1411. CAR Unit Message Response Status Definitions (CR)
Code 02 03 04
Definition Invalid state for message Bad parameter with message Invalid message code
1460
3998 5593007
Machine Checks
EEW (Extended Error Word)

The EEW field on the machine check screen represents extended error words, which include status information that helps define the error condition. The EEW field can contain up to 16 characters. When fewer than 16 characters appear in the EEW lists in the following subsections, the remaining characters appear as zeros on the machine check screen. The following subsections cover the 2-letter codes listed in Table 14-12: Table 1412. EEW (Extended Error Word) Codes
Code CS DS CAR Driver SVC Result Status Data Comm EEW
Definition
Datacomm PIO SVC Result Status - Bisync for Data Comm PROM Part Numbers 2973 2112, 2973 1866, 2973 1403, and 2494 4555 Datacomm PIO SVC Result Status--Bisync for Data Comm PROM Part Numbers 2973 4282, 2973 4316, and 2973 4449 Datacomm PIO SVC Result StatusBisync for All Other Data Comm PROMs
DS EF ES FI FM KS PS ST TF TS
Menu Display State Error Codes 4A Driver SVC Function Definitions - Emulation Datacomm PIO SVC Result Status: Emulation File Manager Error Codes Forms Manager Error Codes Datacomm PIO SVC Result Status: KLUDGE 4A Poll-Select Driver CRT PIO SVC Result Status CAR Unit Operating State Definitions Transport Driver SVC Function Definitions Transport Driver PIO SVC Result Status Routine TXT_TO_FID Error Codes
3998 5593007
1461
Machine Checks
CS -- CAR Driver SVC Result Status

Table 14-13 includes a listing of explanations for EEWs related to the CAR Driver SVC Result Status (CS). Table 1413. CS -- CAR Driver SVC Result Status
EEW F9 01 00 01 F9 01 00 02
Explanation Incorrect length of command descriptor block (CDB); must be 8 bytes. Command code not defined. Defined codes are: 00h TEST UNIT READY 02h REQUEST SENSE 08h RECEIVE 0Ah SEND 12h INQUIRY Initiator ID not defined. One of the following IDs is expected: PC ID = 0 NDP ID = 1 SEND command not expected from PC. Command has not been executed. Expected command = RECEIVE. Data length in CDB with SEND command greater than 2K bytes (PC). Command was executed but only for 2K bytes of data were transferred. RECEIVE command not expected from PC. Command has not been executed. Expected command = SEND. Data length in CDB = 0 with SEND command from PC. Command has not been executed. Data length within M-AU board for RECEIVE command greater than allocation length (PC). Command has been executed but data was limited according to allocation length. Minimal allocation length should be 2K bytes. Allocation length for SENSE command less than 8 bytes. No data has been transferred. Undefined LUN from PC. Command has not been executed. Defined LUN for PC is: LUN = 0 for normal operation LUN = 1 for MTR operation RECEIVE command not expected from NDP. Command has not been executed. Expected command = SEND. Allocation length in CDB with INQUIRY command less than 96 bytes. Data has been transferred according to allocation length.
F9 01 00 03
F9 01 00 04 F9 01 00 05
F9 01 00 06 F9 01 00 07 F9 01 00 08
F9 01 00 09 F9 01 00 0A
F9 01 00 0B F9 01 00 0C
1462
3998 5593007
Machine Checks
Table 1413. CS -- CAR Driver SVC Result Status
EEW F9 01 00 0D
Explanation Data length within the M-AU board for RECEIVE command greater than allocation length (NDP). Command has been executed but data was limited according to allocation length. Minimum allocation length should be 2K bytes. SEND command not expected from NDP. Command has not been executed. Expected command = RECEIVE. Data length in CDB with SEND command greater than 2K bytes (NDP). Command has been executed but only 2K bytes were transferred. Allocation length with INQUIRY command equals zero, No data transferred. Target has been selected without ATN. No identify message from initiator received. Incorrect length of CDB and selected without ATN (see results F9 01 00 01 and F9 01 00 11). Data length in CDB = 0 with SEND command from NDP. Command has not been executed. RECEIVE command from NDP with allocation length = 0. Command has not been executed. RECEIVE command from PC with allocation length = 0. Command has not been executed. Data for RECEIVE command not available (PC). Command has not been executed and must be repeated until data is available. Data for RECEIVE command not available (NDP). Command has not been executed and must be repeated until data is available. Buffer for SEND command not free (PC). Command has not been executed. Buffer for SEND command not free (NDP). Command has not been executed. Hardware error : unexpected ESP status; X = status from CAR driver in CAR Unit.
F9 01 00 0E F9 01 00 0F
F9 01 00 10 F9 01 00 11 F9 01 00 12 F9 01 00 13 F9 01 00 14 F9 01 00 15 F9 01 01 01 F9 01 01 02 F9 01 02 00 F9 01 02 03 F9 03 00 0X
3998 5593007
1463
Machine Checks
EEW
FB XX YY ZZ
Explanation
I/O request terminated by hard error. XX, YY, and ZZ values are defined as follows: (ZZ) 01 02 03 04 05 06 Received 07 08 09 0A 0B 0C 80 81 82 83 84 85 86 87 (YY) 00 01 02 03 04 05 06 09 0A 0B 0C 0D 0E 0F (ZZ) 01 02 03 04 05 06 07 A SCSI recovery happened on last command The SCSI logical unit address cannot be accessed SCSI command terminated with a non-recoverable error A SCSI non-recoverable hardware error An illegal parameter in the CDB or additional parameters Target may have been reset A read or write was attempted on targets protected area. No error Host memory error Select/Reselect timeout CIB bus parity error Message parity error received or message retried Message reject sent Message not sent CIB failure Buffer bounds error Unexpected disconnection Invalid bus phase Initiator detected error CIB received an abort CIB received a bus device reset CIB failure CAR unit communication failure Terminated - Failure logged in Host Adapter Error Status (HAES) Terminated - SCSI Bus Reset Terminated - Command Block Error Open Receive Buffer Terminated - Nonexecutable Command Command Block Error Empty Incoming Mailbox SVC Error No Mailboxes Available No CAR Board Present SCSI target fatal error Unexpected Reselection ID Error Abort Received Bus Device Reset Received Bus Reset Host Adapter Error Unexpected Selection Mail Box Error
FE 00 00 00
I/O request had reserve/release error
1464
3998 5593007
Machine Checks
EEW
FF 00 00 00
Explanation
I/O request had improper parameter
3998 5593007
1465
Machine Checks
DS -- Data Comm EEW

This subsection includes Extended Error Words for different Data Comm PROMs. This subsection includes three lists of EEWs:
Datacomm PIO SVC Result Status - Bisync (DS) for Data Comm PROM Part Numbers 2973 2112, 2973 1866, 2973 1403, and 2494 4555 (Table 14-14) Datacomm PIO SVC Result Status--Bisync (DS) for Data Comm PROM Part Numbers 2973 4282, 2973 4316, and 2973 4449 (Table 14-15) Datacomm PIO SVC Result Status--Bisync (DS) for All Other Data Comm PROMs (Table 14-16)
1466
3998 5593007
Machine Checks
Table 1414. DS -- EEWs for Data Comm (Part Numbers 2973 2112, 2973 1866, 2973 1403, and 2494 4555)
EEW FB 02 XX XX
Explanation System software tried to close the data comm processor board but could not get control of the semaphore used to close the board. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware problem. The sorter data comm processor exceeded the maximum number of retries allowed attempting to transmit a text message to the host after receiving a host abort (EOT) in response to the sorters message. (The abort count, or the number of aborts received from the host, exceeded the retry limit.) The sorter is now waiting for a bid from the host. Perform the data comm MTRs, and check the host DLP for proper operation. The sorter data comm processor experienced a timeout waiting for the data communications driver (NDP system software) to send the data comm processor a response message to a previously received host command message. The data comm processor has exceeded the retry limit for sending temporary text delays (TTDs) to the host (used to retain control over the line while waiting for a response from the driver). The sorter has aborted (sent an EOT to the host) to give up the line. The sorter is now waiting for a bid from the host. Possibly, the User Sort Program is running too slowly to keep up with the data comm compressor board. The data comm driver (NDP system software) passed an invalid response message to the data comm processor manager to transmit to the host. Probably the actual length was too large or did not agree with the length stored within the message. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware failure. One of the following occurred:
FB 03 XX XX
FB 04 XX XX
FB 05 XX XX
FB 06 XX XX
The data comm processor received an invalid operation code from the data comm driver while waiting for an Open command. The data comm processor received an invalid operation code from the data comm driver while receiving data. The data comm processor received an invalid operation code from the data comm driver while transferring data to the data comm driver. The data comm processor received an invalid operation code from the data comm driver while waiting for a response to a host command from the data comm driver. The data comm processor received an invalid operation code from the data comm driver while waiting to transmit data to the host. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware failure.
3998 5593007
1467
Machine Checks
EEW FB 08 XX XX
Explanation The data comm processor exceeded the maximum number of retries allowed waiting for a valid acknowledge (ACK0) from the host to the sorter bid. (The sorter received an EOT, an invalid response, or no response to the bid.)Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor experienced a failure transmitting a character. The byte following FB 09 indicates which state the protocol machine was in when the failure was detected. Listed next are the possible values and the corresponding states when the error occurred: 01 - The sorter was transmitting ACK0. 02 - The sorter was transmitting EOT. 03 - The sorter was transmitting ACK0. 05 - The sorter was transmitting NAK. 06 - The sorter was transmitting ACK1. 07 - The sorter was transmitting a bid (ENQ). 08 - The sorter was transmitting an abort (EOT). 09 - The sorter was transmitting a TTD or forward abort. 0A - The sorter was transmitting text to the host. 0B - The sorter was transmitting ENQ to an invalid or no response from the host (after transmitting text to the host). Perform the data comm MTRs, and check the host DLP for proper operation.
FB 09 XX XX
FB 0B XX XX
One of the following occurred:
The data comm processor exceeded the maximum number of retries allowed while acknowledging a bid from the host. (The host did not recognize the ACK0 from the sorter to its bid.) The data comm processor exceeded the maximum number of retries allowed while transmitting NAKs to the host text. (The sorter is negative in acknowledging a message from the host.)
Perform the data comm MTRs, and check the host DLP for proper operation. FB 0D XX XX FB 41 XX XX The application message length was too large or the length did not agree with the number of digits in the message. System software tried to answer a service request but found that the data comm processor board was closed. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware problem. The data comm driver (system software) experienced failure in attempting to communicate to the data comm processor board. Possibly, the data comm processor could not gain control of the dual-port RAM semaphore. The data comm processor board returned an invalid response to the data comm driver (system software).Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware failure.
FB 51 XX XX
FB 52 XX XX
1468
3998 5593007
Machine Checks
EEW FB 61 XX XX FB C0 XX XX
Explanation The host had aborted the command response protocol. The first CRC byte the data comm processor received from the host was incorrect. Perform the data comm MTRs, and check the host DLP for proper operation. Possibly the sorter is not receiving characters correctly. One of the following occurred:
FF 01 XX XX
The data comm driver reported an invalid SVC parameter (NDP system software failure). The data comm driver reported an invalid unit number (NDP system software failure). The data comm driver reported an invalid SVC request (NDP system software failure). The extended status is the request value (XX XX).
3998 5593007
1469
Machine Checks
Table 1415. DS -- EEWs for Data Comm (Part Numbers 2973 4282, 2973 4316, and 2973 4449)
EEW FB 02 XX XX
Explanation System software tried to close the data comm processor board but could not get control of the semaphore used to close the board. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware problem. The data comm driver (NDP system software) passed an invalid response message to the data comm processor manager to transmit to the host. Probably the actual length was too large or did not agree with the length stored within the message. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware failure. The application message length was too large or the length did not agree with the number of digits in the message. The data comm processor exceeded the maximum number of retries allowed while acknowledging a message from the host. (The host did not recognize the ACK0 or ACK1 from the sorter to its message.)Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor exceeded the maximum number of retries allowed while transmitting NAKs to the host text. (The sorter is negative in acknowledging a message from the host.)Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor exceeded the maximum number of retries allowed waiting for a valid acknowledge (ACK0) from the host to the sorter bid. (The sorter received an EOT, invalid response, or no response to the bid.)Perform the data comm MTRs, and check the host DLP for proper operation. The sorter data comm processor exceeded the maximum number of retries available waiting for an acknowledge (ACK1) from the host to the text message from the sorter. Perform the data comm MTRs, and check the host DLP for proper operation. Possibly the sorter is not receiving characters correctly. The sorter data comm processor exceeded the maximum number of retries allowed attempting to transmit a text message to the host after receiving a host abort (EOT) in response to the sorters message. (The abort count, or the number of aborts received from the host, exceeded the retry limit.) The sorter is now waiting for a bid from the host. Perform the data comm MTRs, and check the host DLP for proper operation. The sorter data comm processor exceeded the maximum number of NAKs allowed attempting to transmit a text message. Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor received an invalid operation code from the data comm driver while waiting for an Open command.
FB 05 XX XX
FB 0D XX XX FB 11 XX XX
FB 12 XX XX
FB 14 XX XX
FB 15 XX XX
FB 16 XX XX
FB 17 XX XX
FB 21 XX XX
1470
3998 5593007
Machine Checks
FB 22 XX XX FB 23 XX XX FB 24 XX XX
The data comm processor received an invalid operation code from the data comm driver while receiving data. The data comm processor received an invalid operation code from the data comm driver while transferring data to the data comm driver. The data comm processor received an invalid operation code from the data comm driver while waiting for a response to a host command from the data comm driver. The data comm processor received an invalid operation code from the data comm driver while waiting to transmit data to the host. The sorter data comm processor experienced a timeout waiting for the data comm driver (NDP system software) to send the data comm processor a response message to a previously received host command message. The data comm processor has exceeded the retry limit for sending temporary text delays (TTDs) to the host (used to retain control over the line while waiting for a response from the driver). The sorter has aborted (sent an EOT to the host) to give up the line. The sorter is now waiting for a bid from the host. Possibly, the User Sort Program is running too slowly to keep up with the data comm processor board. System software tried to answer a service request but found that the data comm processor was closed. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware failure. The data comm driver (system software) experienced failure in attempting to communicate to the data comm processor board. The data comm processor probably could not gain control of the dual-port RAM semaphore. The data comm processor board returned an invalid response to the data comm driver (system software). The data comm processor experienced a failure transmitting a character. The byte following the FB 61 indicates which state the protocol machine was in when the failure was detected. Listed next are the possible values and the corresponding states when the error occurred. 01 - The sorter was transmitting ACK0. 02 - The sorter was transmitting EOT. 03 - The sorter was transmitting ACK0. 05 - The sorter was transmitting NAK. 06 - The sorter was transmitting ACK1. 07 - The sorter was transmitting a bid (ENQ). 08 - The sorter was transmitting an abort (EOT). 09 - The sorter was transmitting a TTD or forward abort. 0A - The sorter was transmitting text to the host. 0B - The sorter was transmitting ENQ to an invalid or no response from the host (after transmitting text to the host).Perform the data comm MTRs, and check the host DLP for proper operation.
FB 25 XX XX FB 32 XX XX
FB 41 XX XX
FB 51 XX XX
FB 62 XX XX
The data comm processor experienced failure transmitting a PAD character (FF).Perform the data comm MTRs, and check the host DLP for proper operation. The first CRC byte the data comm processor received from the host was incorrect. Perform the data comm MTRs, and check the host DLP for proper operation. Possibly the sorter is not receiving characters correctly.
FB C0 XX XX
3998 5593007
1471
Machine Checks
FF 01 XX XX FF 02 XX XX FF 03 XX XX
The data comm driver is reporting an invalid SVC parameter (NDP system software failure). The data comm driver is reporting an invalid unit number (NDP system software failure). The data comm driver is reporting an invalid SVC request (NDP system software failure). The extended status is the request value (XX XX).
1472
3998 5593007
Machine Checks
Table 1416. DS -- EEWs for Data Comm (All Other Data Comm PROMs)
EEW FB 02 XX XX
Explanation System software tried to close the data comm compressor but could not get control of the semaphore used to close the board. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware problem. The data comm driver (NDP system software) passed an invalid response message to the data comm processor manager to transmit to the host. Probably the actual length was too large or did not agree with the length stored within the message. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware failure. The data comm processor received too many ENQs from the host after sending an ACK0 to a host line bid. Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor received more than the maximum allowable number of ENQs to a NAK of host text. Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor exceeded the maximum number of retries allowed while acknowledging a message from the host. (The host did not recognize the ACK0 or ACK1 from the sorter to its message.)Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor exceeded the maximum number of retries allowed while transmitting NAKs to the host text. (The sorter is negative in acknowledging a message from the host.)Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor exceeded the maximum number of retries allowed waiting for a valid acknowledge (ACK0) from the host to the sorter bid. (The sorter received an invalid response or no response to the bid.)Perform the data comm MTRs, and check the host DLP for proper operation. The sorter data comm processor exceeded the maximum number of retries available waiting for an acknowledge from the host to the text message from the sorter. Perform the data comm MTRs, and check the host DLP for proper operation. The sorter data comm processor exceeded the maximum number of retries allowed attempting to transmit a text message to the host after receiving a host abort (EOT) in response to the sorters message. (The abort count, or the number of aborts received from the host, exceeded the retry limit.) The sorter is now waiting for a bid from the host. Perform the data comm MTRs, and check the host DLP for proper operation. The sorter data comm processor exceeded the maximum number of NAKs allowed attempting to transmit a text message. Perform the data comm MTRs, and check the host DLP for proper operation.
FB 05 XX XX
FB 09 XX XX
FB 10 XX XX
FB 11 XX XX
FB 12 XX XX
FB 14 XX XX
FB 15 XX XX
FB 16 XX XX
FB 17 XX XX
3998 5593007
1473
Machine Checks
FB 18 XX XX The host sent text more than the maximum allowable number of times in a row without a DLE STX. Perform the data comm MTRs, and check the host DLP for proper operation. The host sent an EOT to the sorter line bid. Perform the data comm MTRs, and check the host DLP for proper operation. The data comm processor received an invalid operation code from the data comm driver while waiting for an Open command. The data comm processor received an invalid operation code from the data comm driver while receiving data. The data comm processor received an invalid operation code from the data comm driver while transferring data to the data comm driver. The data comm processor received an invalid operation code from the data comm driver while waiting for a response to a host command from the data comm driver. The data comm processor received an invalid operation code from the data comm driver while waiting to transmit data to the host. The sorter data comm processor experienced a timeout waiting for the data comm driver to respond to a previously received host command message. The data comm processor has exceeded the retry limit for sending temporary text delays (TTDs) to the host (used to retain control over the line while waiting for a response from the driver). The sorter has aborted (sent an EOT to the host) to give up the line, and is now waiting for a bid from the host. Possibly, the User Sort Program is running too slowly to keep up with the data comm processor board. System software tried to answer a service request but found that the data comm compressor board was closed. Check the system software or the data comm processor program. They may have failed. The data comm processor board could have a hardware failure. The data comm driver (system software) experienced failure in attempting to communicate to the data comm processor board. The data comm processor probably could not gain control of the dual-port RAM semaphore. The data comm processor board returned an invalid response to the data comm driver (system software).
FB 19 XX XX FB 21 XX XX FB 22 XX XX FB 23 XX XX FB 24 XX XX
FB 41 XX XX
FB 51 XX XX
FB 52 XX XX
1474
3998 5593007
Machine Checks
FB 61 XX XX The data comm processor experienced a failure transmitting a character. The byte following the FB 61 indicates which state the protocol machine was in when the failure was detected. Listed next are the possible values and the corresponding states when the error occurred: 01 - The sorter was transmitting ACK0 to a line bid. 02 - The sorter was transmitting EOT. 03 - The sorter was transmitting ACK0 to text. 05 - The sorter was transmitting NAK. 06 - The sorter was transmitting ACK1 to text. 07 - The sorter was transmitting a bid (ENQ). 09 - The sorter was transmitting a TTD or forward abort. 0A - The sorter was transmitting text to the host. 0B - The sorter was transmitting ENQ to an invalid or no response from the host (after transmitting text to the host).OC - The sorter was transmitting an ACK to an inquiry. Perform the data comm MTRs, and check the host DLP for proper operation. FB 62 XX XX The data comm processor experienced failure transmitting a PAD character (FF).Perform the data comm MTRs, and check the host DLP for proper operation. The data comm driver is reporting an invalid SVC parameter (NDP system software failure). The data comm driver is reporting an invalid unit number (NDP system software failure). The data comm driver is reporting an invalid SVC request (NDP system software failure). The extended status is the request value (XX XX).
FF 01 XX XX FF 02 XX XX FF 03 XX XX
3998 5593007
1475
Machine Checks
DS -- Menu Display State Error Codes

Menu Display State (DS) error codes are listed in Table 14-17. Table 1417. DS -- Menu Display State Error Codes
Error Number 00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A
Definition Main menu Offload Utility Online Offline Execute USP Accept unsolicited input Debug-Aids USP end-of-job Microfilmer Header Pass dial Data queue Start required Primary hopper empty Host USP display USP accept Jam-Missort Jam-Missort Too late to pocket Microfilmer slewing Microfilmer header NIE Host Recall Host Transfer Host Echo Host Reset
1476
3998 5593007
Machine Checks
Table 1417. DS -- Menu Display State Error Codes
Error Number 1B 1C 1D 1E 1F 20 21 22 23 24 25 26 27 28 29 2A 2B Loading
Definition
Disk operation Motor error Gate fault Track error Z-80 overload BOL dead Pocket light Microfilmer Secondary hopper empty Full pocket Interlock Primary feeder jam Secondary feeder jam BOL blocked Microfilmer skip No state
3998 5593007
1477
Machine Checks
EF -- 4A Driver SVC Function Definitions - Emulation

Definition information relating to the 4A Driver SVC Function - Emulation (EF) is listed in Table 14-18. Table 1418. EF -- 4A Driver SVC Function Definitions - Emulation
2 3 4 5 8 $0F Open 4A interface Close 4A interface Send status to host Send document to host Send statistics to host Wait for host command
1478
3998 5593007
Machine Checks
ES -- Datacomm PIO SVC Result Status: Emulation

Table 14-19 includes explanations of EEWs related to Datacomm PIO SVC Result Status: Emulation (ES). Table 1419. ES -- Datacomm PIO SVC Result Status: Emulation
EEW FF 01 00 00 FF 02 00 00 FF 03 XX 00 FB 01 00 00 FB 02 01 00 FB 02 02 00 FB 03 XX XX FB 04 XX XX FB 05 XX YY
Explanation Invalid open parameter specified Invalid unit 1 SVC / Non-emulation unit 1 SVC Invalid SVC requested XX = request value Any SVC request before OPEN Timeout waiting for 4A controller to receive command from driver Timeout waiting to access dual-port via semaphore #1 Invalid unit 0 SVC, XX XX = SVC request value Invalid unit 1 SVC, XX XX = SVC request value Invalid SVC - not unit 0 or 1, XX = unit # YY = SVC request value Invalid ICM request value, XX = ICM count Invalid IPC byte value from controller, XX = IPC byte No buffer returned from GET_BUF routine, XX = buffer number Invalid queue entry Invalid command in queue Invalid send status command Go ready not set Go ready not set Go ready not set Go ready not set Go ready not set Invalid strobe 1 entry, XX = entry Not strobe 1 entry, XX = entry Not slewing
FB 06 XX 00 FB 07 XX 00 FB 10 XX 00 FB 11 00 00 FB 12 00 00 FB 13 00 00 FB 14 00 00 FB 15 00 00 FB 16 00 00 FB 17 00 00 FB 18 00 00 FB 19 XX 00 FB 1A XX 00 FB 1B 00 00
3998 5593007
1479
Machine Checks
Table 1419. ES -- Datacomm PIO SVC Result Status: Emulation
EEW FB 1C XX 00 FB 1D XX 00 FB 1E XX 00 FB 1F XX 00 FB 20 XX 00 FB 21 XX 00 FB 22 XX 00 FB 23 XX 00 FB 24 XX 00 FB 25 XX 00 FB 26 XX 00 FB 27 00 00 FB 28 XX 00 FB 29 XX 00 FB 2A XX 00 FB 2B XX 00 FB 2C XX 00 FB 2D 00 00 FB 2E 00 00 FB 30 00 00 FB F0 XX 00 FB F1 XX 00 Invalid IF3 value, XX = value
Explanation
Value not pocket select entry XX = entry Invalid PSE entry, XX = entry Invalid X value in STB1, XX = value Invalid interrupt, XX = interrupt source register Invalid interrupt, XX = interrupt source register Invalid interrupt, XX = interrupt source register Invalid interrupt, XX = interrupt source register Invalid interrupt, XX = interrupt source register Invalid interrupt, XX = interrupt source register Invalid interrupt, XX = interrupt source register No buffer from memory management Invalid FIFO1 entry, XX = entry No FIFO entry, XX = interrupt source register No FIFO entry, XX = interrupt source register No FIFO entry, XX = interrupt source register Invalid FCP entry, XX = entry Go ready not set Go ready not set 4A failed to go online 4A Kludge mode open failure, XX = value Emulation mode open failure, XX = value
1480
3998 5593007
Machine Checks
FI -- File Manager Error Codes

Table 14-20 includes definitions of File Manager Error Codes (FI). Table 1420. FI -- File Manager Error Codes
Error Number 00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A 1B No error
Definition
End of file in data block PAUFIN timeout occurred Hard error in data block Hard error in FAB block Hard error in directory block Command incompatible with device Device timeout error FPBCMD out of range in command Logical Channel number out of range No file Channels available No logical Channel numbers left Logical Channel number not assigned File reserved against request Device reserved against request Invalid FPBOPT in command Incompatible FPBOPTs in command Invalid file identifier File already exists File not found Device not found Access violation Logical record length > segment size Invalid record format, must be ASCII Invalid key format Key length error No room left on disk Insufficient memory space for operation
3998 5593007
1481
Machine Checks
Table 1420. FI -- File Manager Error Codes
Error Number 1C 1D 1E 1F 20 21 22 23 24 25 26 27 28 29 2A 2B 2C 2D 2E 2F
Definition End of file in directory block Key not found Key already exists Data buffer overflow Mount violation Volume dismount with files open File must be closed All files must be closed Attempt to free a channel with pending Unit reserved to abort open files Internal FMS error File must be reserved unit must be reserved Invalid time unit with PAUFIN Invalid coordination mode in command Size conflict during write Variable length record must be > 0 Lock option inconsistent No file open No queue blocks available
1482
3998 5593007
Machine Checks
FM -- Forms Manager Error Codes

Definitions of Forms Manager Error Codes (FM) are listed in Table 14-21. Table 1421. FM -- Forms Manager Error Codes
Error Number 64 65 66 67 68 69 6A 6B 6C 6D 6E 6F 70 71 72
Definition Mailbox receive error Illegal command byte File could not be found Version-Header mismatch Bad record in forms file Screen name not found Field name not found No more mailboxes available Screen name mismatch SWRITE/SREAD Mailbox number not found Bad status return from PIO call in SREAD Bad status return from PIO call in SWRITE Bad file information in forms (.FM file) Error during compaction (unloading) Not current screen when SREAD from Vscreen
3998 5593007
1483
Machine Checks
KS -- Datacomm PIO SVC Result Status: KLUDGE 4A

Table 14-22 includes explanations of EEWs for Datacomm PIO SVC Result Status: KLUDGE 4A (KS). Table 1422. KS -- Datacomm PIO SVC Result Status: KLUDGE 4A
EEW FF 01 00 00 FF 02 00 00 FF 03 XX 00 FB 01 00 00 FB 02 00 00
Explanation Invalid open parameter specified Invalid unit 1 SVC Invalid SVC #, XX = SVC requested Go ready bit still set - sending SOKL Cant get semaphore register 2 for close SVC-OR-Go ready bit still set - sending stop flow Go ready bit still set - sending Id number Go ready bit not set - sending SOKL Go ready bit not set - sending stop flow Go ready bit not set - sending Id number Invalid interrupt - PSE expected, XX = interrupt Invalid interrupt - PSE expected, XX = interrupt Invalid interrupt - SRUN expected, XX = interrupt Invalid interrupt - DATA_AVL not cleared, XX = interrupt Invalid interrupt - not NIFE interrupt, XX = interrupt Invalid interrupt - PSE expected, XX = interrupt Invalid interrupt - not NIFE interrupt, XX = interrupt Invalid interrupt - XMIT_RDY not set, XX = interrupt Invalid interrupt - timeout expected, XX = interrupt Invalid interrupt - timeout expected, XX = interrupt
FB 03 00 00 FB 04 00 00 FB 05 00 00 FB 06 00 00 FB 07 XX 00 FB 08 XX 00 FB 0A XX 00 FB 0B XX 00 FB 0C XX 00 FB 0D XX 00 FB 0E XX 00 FB 0F XX 00 FB 15 XX 00 FB 16 XX 00
1484
3998 5593007
Machine Checks
Table 1422. KS -- Datacomm PIO SVC Result Status: KLUDGE 4A
EEW FB 17 XX 00 FB 18 XX 00 FB 19 XX 00 FB 1A XX 00 FB 1B XX 00 FB 1C XX 00 FB 1D XX 00 FB 1E XX 00 FB 1F XX 00 FB 20 XX 00 FB 21 XX 00 FB 22 XX 00 FB 23 XX 00
Explanation Invalid interrupt - timeout expected, XX = interrupt Invalid input FIFO entry - strobe 1 and not PSE XX = entry Invalid input FIFO entry - invalid IF2, XX = entry Invalid input FIFO entry - IF1_PSE expected, XX = entry Invalid input FIFO entry - IF3_PSE expected, XX = entry Invalid input FIFO entry - STB1 & bad IF2, XX = entry Invalid input FIFO entry - IF1_PSE expected, XX = entry Invalid input FIFO entry - IF1_BL1H expected, XX = entry Invalid input FIFO entry - IF1_STB1 expected, XX = entry Invalid input FIFO entry - IF3_SRUN expected, XX = entry Invalid input FIFO entry - invalid PSE, XX = entry Invalid input FIFO entry - invalid IF1, XX = entry Invalid input FIFO entry - invalid BL_MASK mismatch XX = entry Invalid input FIFO entry - invalid PSE, XX = entry Invalid input FIFO entry - invalid PSE, XX = entry Invalid input FIFO entry - invalid PSE, XX = entry Invalid input FIFO entry - invalid PSE, XX = entry No PSE response in time Request from handler was not open
FB 24 XX 00 FB 25 XX 00 FB 26 XX 00 FB 27 XX 00 FB 2A 00 00 FB 2B 00 00
3998 5593007
1485
Machine Checks
Table 1422. KS -- Datacomm PIO SVC Result Status: KLUDGE 4A
EEW FB 2E 00 00 FB 2F 00 00 FB 30 00 00 FB 31 00 00 FB 32 00 00 FB 33 00 00 FB 34 00 00 FB 35 00 00 FB 43 00 00 FB 51 XX XX FB 52 XX XX FB F0 XX 00
Explanation SRUN did not go high in time Waiting for data timeout Waiting for host response timeout Waiting for host response timeout Host aborted communication sequence Host aborted communication sequence Sorter did not get RESPONSE in time No input FIFO SOKL entry when expected Datacomm driver already open Timeout waiting for Semaphore register 1 Invalid response from controller Kludge open failure, XX = value
1486
3998 5593007
Machine Checks
PS -- Poll-Select Driver (CRT) PIO SVC Result Status

Explanations of EEWs relating to the Poll-Select Driver (CRT) PIO SVC Result Status (PS) are listed in Table 14-23. Table 1423. PS -- Poll-Select Driver (CRT) PIO SVC Result Status
EEW FB 10 00 00 FB 20 00 00 FB 30 00 00 FB 40 00 00 FB 50 00 00
Explanation Invalid or no response received from the ET Data transfer failed as a result of too many NAKs Select failed because ET did not receive ready Hardware error detected READ canceled so that WRITE can run
3998 5593007
1487
Machine Checks
ST -- CAR Unit Operating State Definitions

CAR Unit Operating State Definitions (ST) are listed in Table 14-24. Table 1424. ST -- CAR Unit Operating State Definitions
Error Number 01 02 03 04 06 08 0A 0B 0C
Definition Initialize POC Idle POC failed FLOW Finish processing Op Test Error Sync Error
1488
3998 5593007
Machine Checks
TF -- Transport Driver SVC Function Definitions

Table 14-25 lists error numbers for the Transport Driver SVC Function (TF). Table 1425. TF -- Transport Driver SVC Function Definitions
Error Number 2 3 4 5 6 7 9 A D E F 10 11 12 13 14 15 16 17 18 19 1A 1E 1E 20 21 Open Close
Definition
Feed Document Read Document Dispose Document Read Transport status Read Microfilmer status Slew Film Microfilm Header Microfilm ICM Reset BOL Reset Gate fault/Track error Read Configuration Modify Configuration Read Last Microfilmer ID # Read Fault ID # Batch # Advance # Light Pocket Light Transport Scan Clear status bit in Driver Read NIE statistics Read microfilmer statistics Imaging module command Imaging module request Read imaging module status Read imaging module statistics
3998 5593007
1489
Machine Checks
Table 1425. TF -- Transport Driver SVC Function Definitions
Error Number 22 23 24 25 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 34
Definition Read imaging module last good dispose Enable/disable imaging module Clear imaging module error Clear forced reject condition Read OCR status Read OCR statistics Clear OCR error Load OCR character set Activate OCR character set Read OCR1 parameters Read OCR2 parameters Select OCR1 parameters Select OCR2 parameters Read OCR1 configuration Read OCR2 configuration Load OCR controlware Read OCR character subsets
1490
3998 5593007
Machine Checks
TS -- Transport Driver PIO SVC Result Status

Explanations for EEWs relating to the Transport Driver PIO SVC Result Status (TS) are listed in Table 14-26. Table 1426. TS -- Transport Driver PIO SVC Result Status
EEW FA 00 00 00 FB 01 00 00 FB 02 00 00 FB 03 00 00 FB 04 00 00 FB 05 00 00 FB 06 00 00 FB 07 00 00 FB 08 XX 00 FB 09 00 00 FB 0A 00 00 FB 0B 00 00 FB 0C 00 00 FB 0E 00 00 FB 0F 00 00 FB 10 00 00 FB 11 XX 00 FB 12 00 00 FB 13 00 00 FB 14 00 00 FB 15 00 00 FB 17 XX 00
Explanation Unit not offline (online request error) SVC code number is invalid for Driver Interface not opened Interface already opened Sorter not idle when close SVC received Sorter not ready Flow not stopped Sorter went not ready when SVC issued Feed request parameter error, XX = parameter value Sorter not flowing when stop flow issued Illegal merge request No document data available Flow stopped Pocket select error Disposition too late Sorter still has document Invalid ICM command on disposition, XX = command byte Function is illegal - no NIE present Function is illegal - no Microfilmer Microfilmer not powered on Microfilmer not ready Invalid microfilmer header style on header command XX = header style Invalid microfilmer ICM on header command XX = ICM command byte
FB 18 XX 00
3998 5593007
1491
Machine Checks
Table 1426. TS -- Transport Driver PIO SVC Result Status
EEW FB 19 XX 00 FB 1A 00 00 FB 1B 00 00 FB 1C 00 00 FB 1D 00 00 FB 1E 00 00 FB 1F 00 00 FB 20 00 00 FB 21 00 00 FB FC 02 01
Explanation Invalid microfilmer ICM command byte for ICM XX = command byte Invalid read system selection Invalid read system present Invalid read system selected, CM only Invalid read system selected, only AC/DC Invalid read system selected, only AC Invalid read system selected, only DC Invalid read system options Invalid blackband option selected OCR2 controlware reported that it could not receive a message because it ran out of MINIOS buffers. OCR2 controlware reported that rcv_len was called before rcv_data had read all the data from the previous message. OCR2 controlware reported that rcv_data was called with too big a length. OCR2 controlware reported that rcv_data was called with a negative length that was not -1. OCR2 controlware reported that start_msg was called while another message was already being transmitted. OCR2 controlware reported that fin_msg was called without a prior call to start_msg. OCR2 controlware reported a document data interrupt, but no data in the OCR2 input FIFO.XX = (OCR) Datacomm Status register OCR2 controlware reported a framing error. The first character is not STX or SUB.XX = first character OCR2 controlware reported a framing error. The input FIFO ran empty. XX = register OCR2 controlware reported a framing error: missing ETX at end. XX = character received instead of ETX
FB FC 02 02
FB FC 02 03 FB FC 02 04 FB FC 02 05
FB FC 02 06 FB FC 15 XX
FB FC 38 XX
FB FC 3A XX
FB FC 40 XX
1492
3998 5593007
Machine Checks
EEW FB FD 01 01
Explanation OCR1 controlware reported that it could not receive a message because it ran out of MINIOS buffers. OCR1 controlware reported that rcv_len was called before rcv_data had read all the data from the previous message. OCR1 controlware reported that rcv_data was called with too big a length. OCR1 controlware reported that rcv_data was called with a negative length that was not -1. OCR1 controlware reported that start_msg was called while another message was already being transmitted. OCR1 controlware reported that fin_msg was called without a prior call to start_msg. OCR1 controlware detected a document data interrupt, but no data in the OCR1 input FIFO. XX =(OCR) Datacomm Status register OCR1 controlware detected a framing error. The first character is not STX or SUB.XX = first character OCR1 controlware detected a framing error. The input FIFO ran empty. XX = OCR FIFO Status register OCR1 controlware detected a framing error: missing ETX at end. XX = character received instead of ETX Controller detected data parity error Transport interface detected address parity error Transport interface detected address data error Transport interface cable is disconnected Maintenance mode has been entered Invalid interrupt in idle loop XX = interrupt source register value Invalid interrupt in ready loop XX = interrupt source register value
FB FD 01 02
FB FD 01 03 FB FD 01 04 FB FD 01 05
FB FD 01 06 FB FD 14 XX
FB FD 37 XX
FB FD 39 XX
FB FD 3F XX
FB FE 01 01 FB FE 01 02 FB FE 01 03 FB FE 02 00 FB FE 03 00 FB FE 04 XX FB FE 05 XX
3998 5593007
1493
Machine Checks
EEW FB FE 06 XX FB FE 07 XX FB FE 08 XX FB FE 09 XX FB FE 0A XX FB FE 0B XX
Explanation Invalid command result when ready XX = command result register value Invalid command result when idle XX = command result register value Invalid interrupt in flow mode XX = interrupt source value Invalid transport status in flow loop XX = transport status register 1 value Bad contents in interface status register XX = register value Invalid interrupt when waiting cable or exiting maintenance mode XX = register value Invalid interrupt when waiting to exit maintenance mode XX = interrupt source register value Transport driver document queue is full Channel "A" document data overflow XX = document data status register value Channel "B" document data overflow XX = document data status register value Transport driver detected an OCR1 overflow-too many characters XX = last character read Transport driver detected an OCR2 overflow-too many characters XX = last character read Channel "A" document data error XX = document "A" data register value Channel "B" document data error XX = document "B" data register value Transport driver detected an OCR1 document data interrupt, but no data in the OCR1 input FIFO XX =(OCR) Interface Status register 3 Transport driver detected an OCR2 document data interrupt, but no data in the OCR2 input FIFO XX = (OCR) Interface Status register 3
FB FE 0C XX
FB FE 0D XX FB FE 0E XX FB FE 0F XX FB FE 10 XX
FB FE 11 XX
FB FE 12 XX FB FE 13 XX FB FE 14 XX
FB FE 15 XX
1494
3998 5593007
Machine Checks
EEW FB FE 16 XX FB FE 17 XX FB FE 18 XX FB FE 19 XX FB FE 1A XX FB FE 1B XX FB FE 1C XX FB FE 1D XX FB FE 1E XX
Explanation Invalid gate fault/track error reset response XX = response code Invalid BOL reset response XX = response code Invalid feed request response XX = feed result Invalid Batch # Advance request response XX = response code Invalid disposition request response XX = response code Invalid Pocket Light request response XX = response code Invalid Header request response XX = response code Invalid ICM request response XX = response code Invalid response after Slew, expecting not ready XX = response code Invalid begin Slew request response XX = response code Invalid image message length value XX = 0, message from system software XX = 1, message from imaging module Invalid end Slew response XX = response code Invalid command result during flow loop XX = command register value Film footage count failed to increment Unexpected Microfilmer status - register 2 XX = register value Unexpected Microfilmer status - register 3 XX = register value NIE hung XX = 00, couldnt access dual port 01, NIE didnt remove last dispose
FB FE 1F XX FB FE 2F XX
FB FE 21 XX FB FE 23 XX FB FE 24 00 FB FE 25 XX FB FE 26 XX FB FE 27 XX
3998 5593007
1495
Machine Checks
EEW FB FE 30 XX
Explanation Invalid response format from the imaging module XX = imaging module opcode Invalid response from E-routine - imaging module code expected XX = response Invalid OCR message length value. The transport driver received from an OCR unit a message with a bad length. XX = length value Invalid OCR1 message format. The transport driver received from an OCR unit a message with a bad format. XX = format Invalid OCR2 message format. The transport driver received from an OCR unit a message with a bad format. XX = format Transport driver detected an OCR1 framing error. The first character is not STX or SUB. XX = first character Transport driver detected an OCR2 framing error. The first character is not STX or SUB. XX = first character Transport driver detected an OCR1 framing error. The input FIFO ran empty. XX = Interface Status register 3 Transport driver detected an OCR2 framing error. The input FIFO ran empty. XX = register Transport driver detected an OCR1 framing error. The character after NDLE is not NDLE or ETB. XX = character after NDLE Transport driver detected an OCR2 framing error. The character after NDLE is not NDLE or ETB. XX = character after NDLE Transport driver detected an OCR1 framing error: length mismatch.
FB FE 32 XX
FB FE 34 XX
FB FE 35 XX
FB FE 36 XX
FB FE 37 XX
FB FE 38 XX
FB FE 39 XX
FB FE 3A XX
FB FE 3B XX
FB FE 3C XX
FB FE 3D XX
1496
3998 5593007
Machine Checks
EEW FB FE 3E XX FB FE 3F XX
Explanation Transport driver detected an OCR2 framing error: length mismatch. Transport driver detected an OCR1 framing error: missing ETX at end. XX = character received instead of ETX Transport driver detected an OCR2 framing error: missing ETX at end. XX = character received instead of ETX Transport driver detected that an OCR1 reply status was not zero and thus indicates a problem. XX = reply status Transport driver detected that an OCR2 reply status was not zero and thus indicates a problem. XX = reply status Transport driver detected an invalid response from E-routine. An OCR code is expected. XX = E response code Transport driver detected an OCR1 output FIFO was filled up. XX = Interface Status register 3 Transport driver detected that an OCR2 output FIFO was filled up. XX = register Transport driver detected a sync error on the interface to OCR1. XX = Interface Status register 2 Transport driver detected a sync error on the interface to OCR2. XX = Interface Status register 2 Transport driver detected a parity lockup error on the interface to OCR1. XX = Interface Status register 2 Transport driver detected a parity lockup error on the interface to OCR2. XX = Interface Status register 2 SVC not implemented in this release I/O request terminated by timeout Waiting for response to Batch # advance
FB FE 40 XX
FB FE 41 XX
FB FE 42 XX
FB FE 43 XX
FB FE 44 XX
FB FE 45 XX
FB FE 46 XX
FB FE 47 XX
FB FE 48 XX
FB FE 49 XX
FB FF 00 00 FC 00 00 00 FC 24 00 00
3998 5593007
1497
Machine Checks
EEW FC 27 00 00 FC 28 00 00 FC 29 00 00 FC 2A 00 00 FC 34 00 00 FC 37 XX YY
Explanation Waiting for response to an ICM Waiting for a not ready response to Slew Waiting for response to begin Slew Waiting for response to Slew complete Timeout waiting for imaging module response interrupt OCR not responding. The transport driver timed out waiting for a response from an OCR unit. XX = unit (1 or 2)YY = SVC Timed out waiting for the FIFOs to clear on the sorter side of the interface XX = unit (1 or 2) YY = Interface Status register 1 Timed out waiting for an OCR unit to clear its FIFOs. XX = unit (1 or 2) YY = OCR Status register Unit offline I/O request had reserve/release error I/O request had improper parameter Feed request parameter error XX = parameter value Invalid Microfilmer ICM command on dispose XX = parameter value Invalid Microfilmer Header style XX = parameter value Invalid Microfilmer ICM command on Header XX = parameter value Invalid Microfilmer ICM command XX = parameter value Invalid read system selected - only CMC7 XX = selection Invalid read system selected - only AC/DC XX = selection Invalid read system selected - only AC XX = selection
FC 38 XX YY
FC 39 XX YY
FD 00 00 00 FE 00 00 00 $FF 00 00 00 FF 08 XX 00 FF 11 XX 00 FF 17 XX 00 FF 18 XX 00 FF 19 XX 00 FF 1C XX 00 FF 1D XX 00 FF 1E XX 00
1498
3998 5593007
Machine Checks
EEW FF 1F XX 00 FF 20 XX 00 FF 21 XX 00
Explanation Invalid read system selected - only DC XX = selection Invalid read system options selected XX = selection Invalid blackband option selected XX = selection
3998 5593007
1499
Machine Checks
Routine TXT_TO_FID Error Codes

Table 14-27 includes definitions of Routine TXT_TO_FID Error Codes. Table 1427. Routine TXT_TO_FID Error Codes
Error Number C8 C9 CA CB CC
Definition Illegal delimiter found Illegal character found Field too long No file name specified Extra input, ignored
14100
3998 5593007
Section 15 CMC7 Tests

160000 CMC7 option reported not present.
STEP 100 PROCEDURE Check for the jumper installed on card AA10 "CMC7." Is the jumper present? 110 Install jumper. Does the problem still exist? 120 Replace card AA10. Does the problem still exist? 950 Verify proper operation. End of procedure. 99550 950 120 950 120 110 YES NO
CM 01 0010
3998 5593007
151
CMC7 Tests
160010
Code line mismatch. STEP 90 100 110 PROCEDURE Does the Reader us PCBA AA11 (4331 8658) Is the only difference in code lines one or more rejected characters? Check the jumpers on card AA13 per jumper sheet 09.01.02. Are the jumpers correct? 115 120 Correct jumpers and rerun test. Check the mechanical and electrical adjustments per T&A 3304 3662. Does the problem still exist? 130 Replace card AA13, and perform T&A 3304 3662. Does the problem still exist? 140 Replace head/preamp, and perform T&A 3304 3662. Does the problem still exist? 150 Referring to SEI 3304 3688, set the switches to mode 0, and rerun test. Does the problem still exist? 155 160 Does maintenance logic work per SEI 3304 3688? Read the characters from the LEDs on card AA13, and compare them with the characters on the display. (Take note of the symbol coding per chart on SEI 3304 3688.) Do all the characters compare? 170 Replace card AA13, and perform T&A 3304 3662. Does the problem still exist? 180 Replace card AA10. Does the problem still exist? 200 Check the jumpers on card AA11 per jumper sheet 09.01.02. Are the jumpers correct? 210 Correct jumpers and rerun test. 220 130 140 170 155 160 99550 140 130 120 --YES 200 110
CM 01 0020
NO 100 150
115 ---
900
900
900
900 170
180
900
900
210
152
3998 5593007
CMC7 Tests
STEP 220
PROCEDURE Check mechanical adjustments and perform T&A 3304 3662. Does the problem still exist?
YES
NO
230
900
230
240
Replace head/preamp, and perform T&A 3304 3662. Does the problem still exist? 99550 900
900
3998 5593007
153
CMC7 Tests
Note: 160020
Different procedures are used to resolve each of the failure codes on this page. CM 01 0030
Scan detected reject. Note: This test is primarily used by the CSE to diagnose read problems most likely caused by poor document encoding or condition. Before making any adjustments or replacing parts, carefully inspect the document for encoding quality. YES 200 NO 100
STEP 90 100
PROCEDURE Does the Reader us PCBA AA111 (4331 8658) Verify jumpers on card AA13 and gain setting per T&A 3304 3662, and continue testing. Does the problem still exist?
110
900
110
Check mechanical T&As for read station drive, entrance, and DYNAVAR. Does the problem still exist? 120 900
120
130
Replace read head, and perform T&A 3304 3662. Does the problem still exist? 99550 900
200
Check the jumpers on card AA11 per jumper sheet 09.01.02. Are the jumpers correct? 220 210
210 220
Correct jumpers and rerun test. Check mechanical adjustments and perform T&A 3304 3662. Does the problem still exist?
230
900
230
240
Replace head/preamp, and perform T&A 3304 3662. Does the problem still exist? 99550 900
900
Verify proper operation. End of procedures.
154
3998 5593007
CMC7 Tests
160030
Illegal character detected. STEP 90 100 PROCEDURE Does the Reader us PCBA AA111 (4331 8658) Replace card AA13, and perform T&A 3304 3662. Does the problem still exist? 110 Replace card AA10. Does the problem still exist? 200 Verify jumpers on card AA11 per jumper sheet 09.01.02 and retest. Does the problem still exist? 210 Replace card AA11. Does the problem still exist? 900 Verify proper operation. End of procedure. 110 210 99550 110 YES 200
CM 01 0040
NO 100
900
900
900
900
3998 5593007
155
CMC7 Tests
Note: 160040
Different procedures are used to resolve each of the failure codes on this page. CM 01 0050
Code line mismatch. Note: Poor document encoding can cause characters to misread or reject. Poor mechanical presentation (skew or buckling) can also cause misreads or rejects. YES 200 NO 100
STEP 90 100
PROCEDURE Does the Reader us PCBA AA111 (4331 8658) Verify jumpers on card AA13 and gain setting per T&A 3304 3662, and continue testing. Does the problem still exist?
110
900
110
Check mechanical T&As for read station drive, entrance, and DYNAVAR. Does the problem still exist? 120 900
120
130
140
200
Check the jumpers on card AA11 per jumper sheet 09.01.02. Are the jumpers correct? 220 210
210 220
Correct jumpers and rerun test. Check mechanical adjustments and perform T&A 3304 3662. Does the problem still exist?
230
900
230
900
156
3998 5593007
CMC7 Tests
160050
No MICR data. No document. STEP 100 110 PROCEDURE Did documents feed and go to pocket 0? Replace card AA10. Does the problem still exist? 120 Replace card AA08. Does the problem still exist? 130 Replace card AA02. Does the problem still exist? 140 Go to the Basic MTR Menu, and run basic tests. 99550 130 120 YES 110
CM 01 0060
NO 140
900
900
900
3998 5593007
157
CMC7 Tests
160060
All rejects detected. STEP 90 100 PROCEDURE Does the Reader us PCBA AA111 (4331 8658) Check the jumpers on card AA13. Does the problem still exist? 110 Referring to SEI 3304 3688, close all switches, and press SW9. Did the LEDs blink 10 times? 120 Check the mechanical and electrical adjustments per T&A 3304 3662. Does the problem still exist? 130 Replace card AA13, and perform T&A 3304 3662. Does the problem still exist? 140 Replace card AA10. Does the problem still exist? 150 Replace read head, and perform T&A 3304 3662. Does the problem still exist? 200 Check the jumpers on card AA11 per jumper sheet 09.01.02. Are the jumpers correct? 210 220 Correct jumpers and rerun test. Check mechanical adjustments and perform T&A 3304 3662. Does the problem still exist? 230 Replace card AA11. Does the problem still exist? 900 Verify proper operation. End of procedure. 140 230 220 99550 150 140 130 120 110 YES 200
CM 01 0070
NO 100
900
130
900
900
900
900
210
900
900
158
3998 5593007
CMC7 Tests
160070
No characters detected. STEP 90 100 PROCEDURE Does the Reader us PCBA AA111 (4331 8658) Check the jumpers on card AA13. Does the problem still exist? 110 Referring to SEI 3304 3688, close all switches, and press SW9. Did the LEDs blink 10 times? 120 Check the mechanical and electrical adjustments per T&A 3304 3662. Does the problem still exist? 130 Replace the card AA13, and perform T&A 3304 3662. Does the problem still exist? 140 Replace card AA10. Does the problem still exist? 150 Replace the read head, and perform T&A 3304 3662. Does the problem still exist? 200 Check the jumpers on card AA11 per jumper sheet 09.01.02. Are the jumpers correct? 210 220 Correct jumpers and rerun test. Check mechanical adjustments and perform T&A 3304 3662. Does the problem still exist? 230 Replace card AA11. Does the problem still exist? 900 Verify proper operation. End of procedure. 140 230 220 99550 150 140 130 120 110 YES 200
CM 01 0080
NO 100
900
130
900
900
900
900
210
900
900
3998 5593007
159
CMC7 Tests
1510
3998 5593007
Section 16 NDP 1xxx-65 Cinemode Microfilmer Test

This section lists MTR procedures for the NDP 1000-65 and NDP 1800-65 Cinemode Microfilmers. Information about adjusting the hardware parameters of these microfilmers is in Section 17, "Microfilmer Hardware Parameters". 161000
Error occurred uploading/downloading NVRAM parameters. Invalid test code received. STEP 100 PROCEDURE Reset sorter, and try parameter routines again. Does the problem still exist? 110 Replace Microfilm Controller PCBA, and rerun test. Does the problem still exist? 120 Replace AA03 (MIIB PCBA), and rerun test. Does the problem still exist? 130 Run MTR Data Comm Test. Does the test pass on both the Microfilm Controller and MIIB PCBAs? 140 150 Follow the new fault code. End of procedure. Replace the data comm cable. Rerun the test. Does the problem still exist? 160 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 160 950 150 140 130 950 120 950 110 950 YES NO
MM 00 0010
3998 5593007
161
NDP 1xxx-65 Cinemode Microfilmer Test
161010
Error occurred uploading/downloading NVRAM parameters. Invalid number of parameters received. STEP 100 PROCEDURE Reset the sorter, and try the parameter routines again. Does the problem still exist? 110 Replace Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 120 Replace AA03 (MIIB PCBA), and rerun the test. Does the problem still exist? 130 Run the MTR Data Comm Test. Does the test pass on both the Microfilm Controller and MIIB PCBAs? 140 150 Follow the new fault code. End of procedure. Replace the data comm cable. Rerun the test. Does the problem still exist? 160 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 160 160 150 130 120 110 YES
MM 00 0020
NO
950
950
950
140
950
950
162
3998 5593007
161020
No response from controller. STEP 100 PROCEDURE Rerun the test. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 130 Replace AA03 (MIIB PCBA), and rerun the test. Does the problem still exist? 140 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 120 YES
MM 00 0030
NO
950
950
950
950
3998 5593007
163
Note: 161030
The same procedure is used to resolve each of the failure codes on this page. MM 00 0040
MTR cannot get control of semaphore #1.
161040
Command byte never recognized by MIIB.
MM 00 0050
161050
MTR cannot get control of semaphore #6.
MM 00 0060
161060
MTR cannot get control of semaphore #2. STEP 100 PROCEDURE Replace AA03 (MIIB PCBA), and rerun the test. Does the problem still exist? 110 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 00 0070
NO
950
950
164
3998 5593007
Note: 161070
CSE replied that the "*" character was not displayed correctly on the human readable header display.
161080
CSE replied that the "#" character was not displayed correctly on the human readable header display.
MM 01 0005
161090
CSE replied that the "H" character was not displayed correctly on the human readable header display. STEP 100 PROCEDURE Replace the Human Readable Header assembly. Does the problem still exist? 110 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 01 0006
NO
950
950
3998 5593007
165
Note: 161100
Different procedures are used to resolve each of the failure codes on this page. MM 01 0007
CSE replied that the character loop A-Z, 0-9 was not displayed correctly on the human readable header display.
STEP 100
PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution A PCBA J3.) Make necessary corrections. Does the problem still exist?
YES
NO
105
950
105
Replace the Human Readable Header assembly. Does the problem still exist? 110 950
110
950
161110
Current in the human readable header display was too low. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution A PCBA J3.) Make necessary corrections. Does the problem still exist? 110 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 01 0008
NO
950
950
166
3998 5593007
Note: 161120
The BOLs were turned off, but the lower BOL is reported on.
161130
The BOLs were turned off, but the upper BOL is reported on.
MM 02 0002
161140
The BOLs were turned off, but the BOL ABC register reports one. STEP 100 PROCEDURE Replace the OSM PCBA, slot 5 of the microfilmer analog gate. Does the problem still exist? 110 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 02 0003
NO
950
950
3998 5593007
167
161150
The BOLs were turned off, but the lower BOL is reported on. STEP 100 PROCEDURE Place a document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 50 of the microfilmer analog gate. Does the signal measure less than 3 VDC? 110 Turn off the power, and swap the connectors of the upper and lower BOLs. Repeat step 100 with the power on. Does the signal measure less than 3 VDC? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate, and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Replace the lower height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 150 Replace the OSM PCBA, and rerun the test Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 99600 130 120 110 YES
MM 02 0004
NO
120
140
950
950
950
950
168
3998 5593007
161160
The BOLs were turned off, but the upper BOL is reported on. STEP 100 PROCEDURE Place a document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 48 of the microfilmer analog gate. Does the signal measure less than 3 VDC? 110 Turn off the power, and swap the connectors of the upper and lower BOLs. Repeat step 100 with the power on. Does the signal measure less than 3 VDC? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate, and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Replace the upper height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 150 Replace the OSM PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 99600 130 120 110 YES
MM 02 0005
NO
120
140
950
950
950
950
3998 5593007
169
161170
The BOLs were turned on, but the lower BOL is reported off. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check motherboard P12.) Make the necessary corrections. Does the problem still exist? 105 Remove any document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 50 of the microfilmer analog gate. Does the signal measure greater than 3 VDC? 110 Turn off the power, and swap the connectors of the upper and lower BOLs. Repeat step 100 with the power on. Does the signal measure greater than 3 VDC? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate, and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Replace the lower height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 150 Replace the OSM PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 99600 130 120 110 105 YES
MM 02 0006
NO
950
120
140
950
950
950
950
1610
3998 5593007
161180
The BOLs were turned on, but the upper BOL is reported off. STEP 100 PROCEDURE Remove any document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 48 of the microfilmer analog gate. Does the signal measure greater than 3 VDC? 110 Turn off the power, and swap the connectors of the upper and lower BOLs. Repeat step 100 with the power on. Does the signal measure greater than 3 VDC? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate, and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Replace the upper height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 150 Replace the OSM PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 99600 130 120 110 YES
MM 02 0007
NO
120
140
950
950
950
950
3998 5593007
1611
Note: 161190
The upper height detector BOL is dirty.
STEP 100
PROCEDURE Clean the upper height detector BOL. Does the problem still exist?
YES
NO
110
950
110
Replace the upper height detector BOL. Does the problem still exist? 120 950
120
Replace the OSM PCBA, slot 5 of the microfilmer analog gate. Does the problem still exist? 99600 950
950
161200
The lower height detector BOL is dirty. STEP 100 PROCEDURE Clean the lower height detector BOL. Does the problem still exist? 110 Replace the lower height detector BOL. Does the problem still exist? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
MM 02 0009
NO
950
950
950
1612
3998 5593007
161210
The BOLs were covered, but the upper BOL is reported uncovered. STEP 100 PROCEDURE Place a document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 48 of the microfilmer analog gate. Does the signal measure less than 3 VDC? 110 Turn off the power and swap the connectors of the upper and lower BOLs. Repeat step 100 with power on. Does the signal measure less than 3 VDC? 120 Replace OSM PCBA, slot 5 of microfilmer analog gate and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace Microfilm Controller PCBA. Does the problem still exist? 140 Replace the upper height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 130 120 110 YES
MM 02 0010
NO
120
140
950
950
950
3998 5593007
1613
161220
The BOLs were uncovered, but the upper BOL is reported covered. STEP 100 PROCEDURE Remove any document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 50 of the microfilmer analog gate. Does the signal measure greater than 3 VDC? 110 Turn off the power, and swap the connectors of the upper and lower BOLs. Repeat step 100 with the power on. Does the signal measure greater than 3 VDC? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate, and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Replace the lower height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 130 120 110 YES
MM 02 0011
NO
120
140
950
950
950
1614
3998 5593007
161230
The BOLs were covered, but the lower BOL is reported uncovered. STEP 100 PROCEDURE Place a document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 50 of the microfilmer analog gate. Does the signal measure greater than 3 VDC? 110 Turn off the power, and swap the connectors of the upper and lower BOLs. Repeat step 100 with the power on. Does the signal measure greater than 3 VDC? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate, and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Replace the lower height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 130 120 110 YES
MM 02 0012
NO
120
140
950
950
950
3998 5593007
1615
161240
The BOLs were uncovered, but the lower BOL is reported covered. STEP 100 PROCEDURE Remove any document in the track blocking both height detector BOLs. Place a meter probe on slot 5 pin 50 of the microfilmer analog gate. Does the signal measure greater than 3 VDC? 110 Turn off the power, and swap the connectors of the upper and lower BOLs. Repeat step 100 with the power on. Does the signal measure greater than 3 VDC? 120 Replace the OSM PCBA, slot 5 of the microfilmer analog gate, and return the connectors for the BOLs to their original positions. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 140 Replace the upper height detector BOL, and return the BOL connectors to their original positions. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 130 120 110 YES
MM 02 0013
NO
120
140
950
950
950
1616
3998 5593007
161250
Shutter Sensor Error The MTR opened (enabled)/closed (not enabled) the shutter which was verified by the CSE; however, the Input port #1 register indicates the shutter is still closed (not enabled)/open (enabled). Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES 110
MM 04 0001
STEP 100 110
PROCEDURE Did the MTR routine fail with the shutter open? Check the adjustment of the shutter open sensor to T&A 3304 4413. Adjust as required. Does the problem still exist?
NO 210
120
950
120
Run shutter MTR routine to point where shutter is activated to the open position. On the Distribution A PCBA, is J8 pin 4 <1.2V? 130 140 150 160
130 140
Is J2 pin 37 on the Microfilm Controller PCBA < 1.2 V? Replace the Microfilm Controller PCBA. Does the problem still exist?
99600
950
150
Using schematics, trace signal DSODETE from the Distribution A PCBA J8 pin 4 to the Microfilm Controller PCBA J2 pin 37. Find the location of the problem, and correct it. Does the problem still exist? 99600 170 950 180
160 170
Is J8 pin 2 on the Distribution A PCBA <0.8V? Replace the Shutter Open sensor, and adjust to T&A 3304 4363. Does the problem still exist?
99600 190
950 200
180
Is J2 pin 38 on the Microfilm Controller PCBA < 0.8 V?
3998 5593007
1617
MM 04 0001
Shutter Sensor Error (continued) The MTR opened (enabled)/closed (not enabled) the shutter which was verified by the CSE; however, the Input port #1 register indicates the shutter is still closed (not enabled)/open (enabled). STEP 190 PROCEDURE Using the schematics, trace the signal DSOLEDC from the Distribution A PCBA J8 pin 2 to the Microfilm Controller PCBA J2 pin 38. Find the location of the problem, and correct it. Does the problem still exist? 200 Replace the Microfilm Controller PCBA. Does the problem still exist? 210 Check the adjustment of the shutter open sensor to T&A 3304 4413. Adjust as required. Does the problem still exist? 220 Run the shutter MTR routine to point the where the shutter is activated to the open position. On the Distribution A PCBA, is J9 pin 4 < 1.2 V? 230 240 Is J2 pin 39 on the Microfilm Controller PCBA <1.2 V? Replace the Microfilm Controller PCBA. Does the problem still exist? 250 Using the schematics, trace the signal DSCDETE from the Distribution A PCBA J9 pin 4 to the Microfilm Controller PCBA J2 pin 39. Find the location of the problem, and correct it. Does the problem still exist? 260 270 Is J9 pin 2 on the Distribution A PCBA < 0.8 V? Replace the Shutter Closed sensor, and adjust it to T&A 3304 4363. Does the problem still exist? 280 290 Is J2 pin 40 on the Microfilm Controller PCBA <0.8 V? Using the schematics, trace the signal DSCLEDC from the Distribution A PCBA J9 pin 2 to the Microfilm Controller PCBA J2 pin 40. Find the location of the problem, and correct it. Does the problem still exist? 99600 950 99600 290 950 200 99600 270 950 280 99600 950 230 240 250 260 220 950 99600 950 99600 950 YES NO
1618
3998 5593007
MM 04 0001
Shutter Sensor Error (continued) The MTR opened (enabled)/closed (not enabled) the shutter, which was verified by the CSE; however, the Input Port #1 register indicates the shutter is still closed (not enabled)/open (enabled). STEP 300 PROCEDURE Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 YES NO
3998 5593007
1619
161260
Shutter Sensor and Solenoid Error The MTR requested the shutter open (enabled)/closed (not enabled). The open (enabled)/closed (not enabled) sensor verified correct operation, but the CSE indicated the shutter position was incorrect. STEP 100 110 PROCEDURE Did the MTR fail with the shutter open? Check connector P13 on motherboard and reseat the Reel/Sol. Driver PCBA. Does the problem still exist? 120 Remove connector P13, and execute the MTR routine to the point where the shutter should be opened while monitoring the signal at motherboard slot 8 pin 22 with an oscilloscope. Does signal switch from approximately 0 V to +24 V to +5 V? 130 Replace the Reel/Sol. Driver PCBA. Does the problem still exist? 140 Check connectors P4/J1 on the Distribution B PCBA and P12/J1 on the Distribution A PCBA and all associated cables. Repair as required. Does the problem still exist? 150 Replace the Capping Shutter assembly, and readjust to T&A 3304 4363. Does the problem still exist? 155 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 99600 155 150 140 140 120 YES 200
MM 04 0002
NO 110
950
130
950
950
950
240
1620
3998 5593007
MM 04 0002
Shutter Sensor and Solenoid Error (continued) The MTR requested the shutter open (enabled)/closed (not enabled). The open (enabled)/closed (not enabled) sensor verified correct operation, but the CSE indicated the shutter position was incorrect. STEP 200 PROCEDURE Remove connector P13, and execute the MTR routine to the point where the shutter should be closed while monitoring the signal at motherboard slot 8 pin 22 with an oscilloscope. Does the signal switch from approximately +5 V to 0 V? 210 220 Is the shutter return spring attached correctly? Attach or replace the return spring, and retest. Does the problem still exist? 240 Replace the Reel/Sol. Driver PCBA, and retest. Does the problem still exist? 250 Check connectors P4/J1 on the Distribution B PCBA and P12/J1 on the Distribution A PCBA and all associated cables. Repair as required. Does the problem still exist? 260 Replace the Capping Shutter assembly, and readjust to T&A 3304 4363. Does the problem still exist? 270 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 270 950 260 950 250 950 240 950 210 240 240 220 YES NO
3998 5593007
1621
161270
Shutter Sensor and Solenoid Error The MTR requested the shutter to open (enabled)/close (not enabled), but both the sensor and CSE indicated the shutter was closed (not enabled)/open (enabled). STEP 100 PROCEDURE Repeat the MTR routine, and verify faulty operation. Does the problem still exist? 110 Check the adjustment of the capping shutter to T&A33044363 and the shutter sensors to 33044413. Readjust as required. Does the problem still exist? 120 130 Is the error code the same as before? Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 140 Execute the manual procedure for error code MM04 002. Execute the procedures for new error codes as applicable. Does the problem still exist? 150 Execute the manual procedures for error codes. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 140 120 130 110 YES
MM 04 0003
NO
950
950 150
950
950
950
1622
3998 5593007
161280
Cover sensor reports open when cover is closed. STEP 100 PROCEDURE Check connectors J2 and J13 on the Distribution B PCBA and their cables. Make any necessary corrections. Does the problem still exist? 110 Place a probe on pin 3 of BS18 on the Microfilm Controller PCBA. With cover open, manually press on the cover switch at the near right corner of the film box. Does the signal switch between 0 V and 4 5 VDC? 120 Repeat step 110 using the cover instead of your fingers. Does the signal switch between 0 V and 4-5 VDC? 130 Check T&A 3304 4058 and T&A 3304 4066 to adjust the cover, cover latch, and cover switch. Repeat the test. Does the problem still exist? 140 Replace the cover switch and check T&A 33044066. Does the problem still exist? 150 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 150 150 120 110 YES
MM 05 0001
NO
950
140
130
950
950
950
3998 5593007
1623
161290
Camera cover did not lock when it should have. STEP 100 PROCEDURE Check connectors J4 and J15 on the Distribution B PCBA and the cables. Make corrections if necessary. Does the problem still exist? 110 Remove connector J13 from the microfilmer motherboard. Rerun the test. Does the problem still exist? 120 Put a probe on slot 8 pin 27. Rerun the test. When asked to verify that the cover is locked, is the signal > 20 VDC? 130 Put a probe on TP-6 of the Reel/Sol. Driver PCBA (slot 8). Is the signal < 1 VDC? 140 Replace the Microfilm Controller PCBA. Does the problem still exist? 150 Replace the Reel/Sol. Driver PCBA. Does the problem still exist? 160 Check T&A 3304 4058. Then check T&A 33044066. Make any necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 99600 99600 140 160 160 110 YES
MM 05 0002
NO
950
120
130
150
950
950
950
1624
3998 5593007
161300
Cover sensor reports closed when cover is open. STEP 100 PROCEDURE Check connectors J2 and J13 on the Distribution B PCBA and their cables. Make any necessary corrections. Does the problem still exist? 110 Place a probe on pin 4 of BS28 on the Microfilm Controller PCBA. With the cover open, manually press on the cover switch at the near right corner of the film box. Does the signal switch between 0 V and 4-5 VDC? 120 Repeat step 110 using the cover instead of your fingers. Does the signal switch between 0 V and 4-5 VDC? 130 Check T&A 3304 4058 and T&A 3304 4066 to adjust the cover, cover latch, and cover switch. Repeat the test. Does the problem still exist? 140 Replace the cover switch, and check T&A 33044066. Does the problem still exist? 150 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 150 150 120 110 YES
MM 05 0003
NO
950
140
130
950
950
950
3998 5593007
1625
161310
Camera did not turn off when instructed. STEP 100 PROCEDURE Attach a scope to AA03 pin P2-71 (CAMSWNO). Press the Camera On switch. Does the signal change from + 5 V to 0 V? 110 Replace AA03 (the MIIB PCBA), and rerun the test. Does the problem still exist? 120 Monitor Control Panel Connector Cable J1-10. Press the Camera On switch on/off. Does the signal change from + 5.0 V to 0 V? 130 Check the Control Panel Connector cable. Make necessary corrections. Rerun the test. Does the problem still exist? 140 Replace Control Panel Assembly, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 120 110 YES
MM 05 0004
NO
120
950
950
950
950
1626
3998 5593007
Note: 161320
Different procedures are used for each failure code on this page. MM 05 0005
Camera did not turn on when instructed.
STEP 100
PROCEDURE Replace the camera power switch. Does the problem still exist?
YES
NO
110
950
110
Replace the AA03 PCBA. Does the problem still exist? 110 950
950
161330
Film not loaded correctly. STEP 100 PROCEDURE With power on, lift the film plate, and wait until the slack in the film is taken up. Then load the film again. Does the problem still exist? 110 Run all the film transport MTR tests. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 05 0006
NO
950
950
161340
Lamps did not come on. STEP 100 PROCEDURE Run the Lamp/ALM MTR. Follow the appropriate fault code. End of procedure. YES
MM 05 0007
NO
161350
Motors did not come up. STEP 100 PROCEDURE Run the Transport Basic MTRs to determine the problem. Follow the appropriate fault code. End of procedure. YES
MM 05 0008
NO
3998 5593007
1627
161360
Camera cover did not unlock when it should have. STEP 100 PROCEDURE Unlock the cover manually, and check connectors J4 and J15 on the Distribution B PCBA and the cables. Make corrections if necessary, and rerun the test. Does the problem still exist? 105 Does the armature of the cover lock solenoid move freely by hand? In other words, does the cover lock solenoid appear to be off? Remove connector J13 from the microfilmer motherboard. Rerun the test. When asked to verify that the cover is unlocked, place a probe on slot 8 pin 28 of the microfilmer motherboard. Is the signal 24 VDC? 120 Place a probe on slot 8 pin 27 of the microfilmer motherboard. Is the signal < 1 VDC? 130 With power off, reconnect J13 on the motherboard, and check the continuity between slot 8 pin 27 of the motherboard and J15 pin 2 of the Distribution B PCBA. Also, check the continuity between slot 8 pin 28 and J15 pin 1. Does the continuity check out OK? 140 Check T&A 3304 4058 and T&A 3304 4066. Make any necessary corrections. Does the problem still exist? 150 Check T&A 3304 4058 and T&A 3304 4066. Make any necessary corrections. Does the problem still exist? 180 210 140 130 120 105 110 YES
MM 05 0009
NO
950 150
110
160
170
200
950
950
1628
3998 5593007
MM 05 0009
Camera cover did not unlock when it should have. STEP 160 PROCEDURE Put a probe on slot 8 pin 78. Does the signal measure < 1 VDC? 170 Put a probe on TP-16 of the Reel/Sol. Driver PCBA (slot 8 of the microfilmer motherboard). Does the signal measure < 1 VDC? 180 Replace the PCBA in slot 8. Does the problem still exist? 190 Replace the Microfilm Controller PCBA. Does the problem still exist? 200 Replace the cable at J13 of the microfilmer motherboard. Does the problem still exist? 210 Replace the cover lock solenoid. Does the problem still exist? 220 Replace the cable to the cover lock solenoid. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 220 950 99600 950 99600 950 99600 950 180 190 170 180 YES NO
3998 5593007
1629
161370
Film did not advance correctly. STEP 100 PROCEDURE Press the film advance switch. Did the film advance light illuminate? 110 Press the film advance switch, and place a probe on pin J2-75 (FASWNO) of slot 3 on the AA gate. Is the signal level < 1.0 VDC? 120 Replace the MIIB PCBA (slot 3 in the AA gate). Does the problem still exist? 130 Check the continuity of the control panel cable on the AA gate. Make the necessary corrections. Does the problem still exist? 140 Check the continuity of the signal cable (from the AA gate to J1 on the Microfilm Controller PCBA). Make the necessary corrections. Does the problem still exist? 145 Check all cables (especially check Distribution B J-14). Make the necessary corrections. Does the problem still exist? 150 Replace the Microfilm Controller PCBA. Does the problem still exist? 160 Replace the Servo Amplifier PCBA. Does the problem still exist? 170 Check the continuity of the controller signal cable. Make the necessary corrections. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 170 160 150 145 140 130 120 140 YES
MM 05 0010
NO
110
130
950
950
950
950
950
950
950
1630
3998 5593007
161380
Film advance light did not light up. STEP 100 PROCEDURE Remove the film advance lens from the switch. Is the bulb present? 110 Remove the bulb from the holders, and check for continuity from the bulb case to the center contact. Is there continuity? 120 Install a new bulb. Does the problem still exist? 130 Replace the lens in the switch, and press the film advance switch. Listen for capstan motor movement. Does the motor sound as if it is turning? 140 Press the film advance switch, and place a probe on pin J2-83 of slot 3 on AA gate. Is the signal < 1.0 VDC? 150 Press the film advance switch with a probe on pin J2-75 of slot 3 (on AA gate). Is the signal < 1.0 VDC? 160 Replace the MIIB PCBA, and retest. Does the problem still exist? 170 Check the continuity of the control panel cable that terminates on the AA Gate. Make the necessary corrections. Does the problem still exist? 180 Replace the film advance switch on the control panel, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 180 170 160 170 140 130 130 110 YES
MM 05 0011
NO
120
120
950
150
160
170
950
950
950
3998 5593007
1631
161390
Microfilm is not ready, but no reason can be found. STEP 100 PROCEDURE Remove the R/S power, and reseat the MIIB PCBA in slot 3 of the AA gate. Does the problem still exist? 110 Remove the R/S power, and reseat the Main Clock Diagnostic Interface PCBA in slot 8. Does the problem still exist? 120 Remove the R/S power, and replace the MIIB PCBA in slot 3. Does the problem still exist? 130 Remove the R/S power, and replace the Main Clock Diagnostic Interface PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
MM 05 0012
NO
950
950
950
950
1632
3998 5593007
161400
Microfilm ready bits are not consistent. STEP 100 PROCEDURE Remove the R/S power, and reseat the MIIB PCBA in slot 3 and the Main Clock Diagnostic Interface PCBA in slot 8 of the AA gate. Apply power. Does the problem still exist? 110 Replace the MIIB PCBA in slot 3. Does the problem still exist? 120 Replace the Main Clock Diagnostic Interface PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
MM 05 0013
NO
950
950
950
3998 5593007
1633
161410
Reel Motor Error CSE indicated that the supply reel did not rotate correctly when the supply loop arm was pressed. Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES 500 160
MM 06 0001
STEP 100 150 160
PROCEDURE Did both reels rotate when one of the supply loop arm was pressed? Did the supply motor rotate? If the supply motor rotated in the wrong direction, check the wiring from pins 17 and 18 on slot 8 of the motherboard to the supply motor. The most likely cause is the wiring being reversed. Repair as required. Does the problem still exist?
NO 150 180
170
950
170
Replace the Reel/Sol. PCBA, and retest. Does the problem still exist? 205 950
180
Remove connector P9 from the motherboard. Using a DVM, measure the voltage between pins 17 and 18 on slot 8 of the motherboard as the loop arm is moved back and forth. Does the voltage vary between 0 V an > 18 V? 290 200 190 210
190
As you are moving the supply loop arm back and forth, does slot 8 pin 80 vary from < 0.8 V to > 4.5 V? Replace the Reel/Sol. PCBA, and retest if not already done. Does the problem still exist?
200
205
950
205
Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 99600 220 950 230
210
While moving the supply loop arm back and forth, does J5 pin 59 on the MF controller vary from < 0.8V to > 4.5V? Check connection from J5 pin 59 on MF Controller to pin 80 on Reel/Sol. PCBA. Repair any problems found. Does the problem still exist?
220
200
950
1634
3998 5593007
MM 06 0001
Reel Motor Error (continued) CSE indicated that the supply reel did not rotate correctly when the supply loop arm was pressed. STEP 230 PROCEDURE While moving the supply loop arm back and forth, measure J2 pin 54 on the Distribution B PCBA. Does the signal switch from < 1.2 V to >1.2V? 240 While moving the supply loop arm back and forth, measure J2 pin 54 on the Microfilm Controller PCBA. Does the signal switch from < 1.2 V to >1.2V? 250 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 260 Check the continuity from J2 pin 54 on the Distribution B PCBA to J2 pin 54 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 270 Check the continuity from J2 pin 54 on the Distribution B PCBA to J2 pin 54 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 280 Replace Supply Sensor 2, and retest. Does the problem still exist? 290 Using the schematics, check the continuity from pins 17 and 18 on slot 8 of the motherboard to the supply motor. Repair as required. Does the problem still exist? 300 950 200 950 280 950 200 950 200 950 250 260 240 270 YES NO
3998 5593007
1635
MM 06 0001
Reel Motor Error (continued) CSE indicated that the supply reel did not rotate correctly when the supply loop arm was pressed. STEP 300 PROCEDURE Replace the supply motor, and retest. Does the problem still exist? 500 Replace the Reel/Sol. PCBA, and retest. Does the problem still exist? 510 Monitor pins 79 and 80 of slot 8 on the motherboard while moving both loop arms back and forth, first the supply and then the takeup. Do both signals switch between < 0.8 V and >4.0 V with only their respective loop arm movements? 520 Replace the Microfilm Controller PCBA, and rerun the test. Does the problem still exist? 530 Check the continuity of the signals back to the Distribution B PCBA, and repair problems as found. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 530 950 205 520 510 950 200 950 YES NO
1636
3998 5593007
161420
Reel Motor Error CSE indicated that the takeup reel motor did not rotate correctly when the takeup loop arm was pressed. Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES 500 160
MM 06 0002
STEP 100 150 160
PROCEDURE Did both reels rotate when the takeup loop arm was pressed? Did the takeup motor rotate? If the takeup motor rotated in the wrong direction, check the wiring from pins 31 and 32 on slot 8 of the motherboard to the takeup motor. The most likely cause is the wiring being reversed. Repair as required. Does the problem still exist?
NO 150 180
170
950
170
180
Remove connector P9 from the motherboard. Using a DVM, measure the voltage between pins 31 and 32 on slot 8 of the motherboard as the loop arm is moved back and forth. Does the voltage vary between 0 V and > 18 V? 290 190
190
Move the takeup loop arm back and forth. Does slot 8 pin 79 vary from < 0.8 V to > 4.5 V? 200 210
200
210
Move the takeup loop arm back and forth. Does J5 pin 60 on the Microfilm Controller PCBA vary from < 0.8 V to > 4.5 V? 220 230
220
Check the connection from J5 pin 60 on the Microfilm Controller PCBA to pin 80 on the Reel/Sol. PCBA. Repair any problems found. Does the problem still exist? 99600 950
3998 5593007
1637
MM 06 0002
Reel Motor Error (continued) CSE indicated that the takeup reel motor did not rotate correctly when the takeup loop arm was pressed. STEP 230 PROCEDURE While moving the takeup loop arm back and forth, measure J2 pin 48 on the Distribution B PCBA. Does the signal switch from < 1.2 V to > 1.2 V? 240 While moving the takeup loop arm back and forth, measure J2 pin 48 on the Microfilm Controller PCBA. Does the signal switch from < 1.2 V to >1.2 V? 250 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 260 Check the continuity from J2 pin 48 on the Distribution B PCBA to J2 pin 48 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 270 Check the continuity from J2 pin 48 on the Distribution B PCBA to J2 pin 48 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 280 Replace Takeup Sensor 2, and retest. Does the problem still exist? 290 Using the schematics, check the continuity from pins 31 and 32 on slot 8 of the motherboard to the supply motor. Repair as required. Does the problem still exist? 295 Replace the takeup motor, and retest. Does the problem still exist? 200 950 295 950 200 950 280 950 200 950 200 950 250 260 240 270 YES NO
1638
3998 5593007
MM 06 0002
Reel Motor Error (continued) CSE indicated that the takeup reel motor did not rotate correctly when the takeup loop arm was pressed. STEP 500 PROCEDURE Replace the Reel/Sol. PCBA, and retest. Does the problem still exist? 510 Monitor pins 79 and 80 of slot 8 on the motherboard while moving both loop arms back and forth, first the supply and then the takeup. Do both signals switch between < 0.8 V and >4.0 V with only their respective loop arm movements? 520 Check the continuity of the signals back to the Distribution B PCBA, and repair problems as found. Does the problem still exist? 900 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 900 950 900 520 510 950 YES NO
3998 5593007
1639
161430
Reel Motor Error CSE indicated that the supply reel motor did not rotate correctly when activated. Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES 500 160
MM 06 0003
STEP 100 150 160
PROCEDURE Did both reels rotate? Did the supply motor rotate? If the supply motor rotated in the wrong direction, check the wiring from pins 17 and 18 on slot 8 of the motherboard to the supply motor. The most likely cause is the wiring being reversed. Repair as required. Does the problem still exist?
NO 150 180
170
950
170
180
Remove connector P9 from the motherboard. Using a DVM, measure the voltage between pins 17 and 18 on slot 8 of the motherboard as the loop arm is moved back and forth. Does the voltage vary between 0 V and > 18 V? 290 200 190 210
190
As you move the supply loop arm back and forth, does slot 8 pin 80 vary from < 0.8 V to > 4.5 V? Replace the Reel/Sol. PCBA, and retest. Does the problem still exist?
200
99600 220
950 230
210
As you move the supply loop arm back and forth, does J5 pin 59 on the Microfilm Controller PCBA vary from < 0.8 V to > 4.5 V? Check the connection from J5 pin 59 on the Microfilm Controller PCBA to pin 80 on the Reel/Sol. PCBA. Repair any problems found. Does the problem still exist?
220
310
950
1640
3998 5593007
MM 06 0003
Reel Motor Error (continued) CSE indicated that the supply reel motor did not rotate correctly when activated. STEP 230 PROCEDURE While moving the supply loop arm back and forth, measure J2 pin 54 on the Distribution B PCBA. Does the signal switch from < 1.2 V to >1.2V? 240 While moving the supply loop arm back and forth, measure J2 pin 54 on the Microfilm Controller PCBA. Does the signal switch from < 1.2 V to >1.2V? 250 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 260 Check the continuity from J2 pin 54 on the Distribution B PCBA to J2 pin 54 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 270 Check the continuity from J2 pin 54 on the Distribution B PCBA to J2 pin 54 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 280 Replace Supply Sensor 2, and retest. Does the problem still exist? 310 950 280 950 310 950 310 950 250 260 240 270 YES NO
3998 5593007
1641
MM 06 0003
Reel Motor Error (continued) CSE indicated that the supply reel motor did not rotate correctly when activated. STEP 290 PROCEDURE Using the schematics, check the continuity from pins 17 and 18 on slot 8 of the motherboard to the supply motor. Repair as required. Does the problem still exist? 300 Replace the supply motor, and retest. Does the problem still exist? 310 If not already done, replace the Reel/Sol. PCBA, and rerun the test. Does the problem still exist? 500 Replace the Reel/Sol. PCBA, and retest. Does the problem still exist? 510 Monitor pins 79 and 80 of slot 8 on the motherboard while moving both loop arms back and forth, first the supply and then the takeup. Do both signals switch between < 0.8 V and >4.0 V with only their respective loop arm movements? 520 Check the continuity of the signals back to the Distribution B PCBA, and repair problems as found. Does the problem still exist? 900 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 900 950 900 520 510 950 99600 950 310 950 300 950 YES NO
1642
3998 5593007
161440
Reel Motor Error CSE indicated that the takeup reel motor did not rotate correctly. Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES 500 160
MM 06 0004
STEP 100 150 160
PROCEDURE Did both reels rotate? Did the takeup motor rotate? If the takeup motor rotated in the wrong direction, check the wiring from pins 31 and 32 on slot 8 of the motherboard to the takeup motor. The most likely cause is the wiring being reversed. Repair as required. Does the problem still exist?
NO 150 180
170
950
170
180
Remove connector P9 from the motherboard. Using a DVM, measure the voltage between pins 32 and 32 on slot 8 of the motherboard as the loop arm is moved back and forth. Does the voltage vary between 0 V and > 18 V? 290 200 190 210
190
When you move the takeup loop arm back and forth, does slot 8 pin 79 vary from < 0.8 V to > 4.5 V? If not already done, replace the Reel/Sol. PCBA, and retest. Does the problem still exist?
200
99600 220
950 230
210
When you move the takeup loop arm back and forth, does J5 pin 60 on the Microfilm Controller PCBA vary from < 0.8 V to > 4.5 V? Check the connection from J5 pin 60 on the Microfilm Controller PCBA to pin 80 on the Reel/Sol. PCBA. Repair any problems found. Does the problem still exist?
220
200
950
3998 5593007
1643
MM 06 0004
Reel Motor Error (continued) CSE indicated that the takeup reel motor did not rotate correctly. STEP 230 PROCEDURE While moving the takeup loop arm back and forth, measure J2 pin 48 on the Distribution B PCBA. Does the signal switch from < 1.2 V to >1.2V? 240 While moving the takeup loop arm back and forth, measure J2 pin 48 on the Microfilm Controller PCBA. Does the signal switch from < 1.2 V to > 1.2 V? Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 260 Check the continuity from J2 pin 48 on the Distribution B PCBA to J2 pin 48 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 270 Check the continuity from J2 pin 48 on the Distribution B PCBA to J2 pin 48 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 280 290 Replace Takeup Sensor 2 and retest. Does the problem still exist? Using the schematics check the continuity from pins 31 and 32 on slot 8 of the motherboard to the supply motor. Repair as required. Does the problem still exist? 295 950 280 200 950 950 200 950 200 950 240 250 270 260 YES NO
250
1644
3998 5593007
MM 06 0004
Reel Motor Error (continued) CSE indicated that the takeup reel motor did not rotate correctly. STEP 295 PROCEDURE Replace the takeup motor, and retest. Does the problem still exist? 500 Replace the Reel/Sol. PCBA, and retest. Does the problem still exist? 510 Monitor pins 79 and 80 of slot 8 on the motherboard while moving both loop arms back and forth, first the supply and then the takeup. Do both signals switch between < 0.8 V and >4.0 V with only their respective loop arm movements? 520 Check the continuity of the signals back to the Distribution B PCBA, and repair problems as found. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 99600 520 510 950 200 950 YES NO
3998 5593007
1645
161450
Front lamp value out of range (NDP 1150) The value for the Front Lamp stored in nonvolatile memory is outside the range 80 Hex - FE Hex. (NDP 18xx) The value for the Front Lamp stored in nonvolatile memory is outside the range 80 Hex - EF Hex. STEP 100 PROCEDURE Using the Lamp Adjustment procedure in the Hardware Parameter Routines, set the front lamp value to A0. Rerun the MTR routine. Does the problem still exist? 120 Using the Lamp Adjustment Hardware Parameter Routine, reset the lamp value to the correct operating point. Does the problem still exist? 130 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 140 Replace AA03, and retest. Does the problem still exist? 150 Replace AA17, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 140 99600 130 YES
MM 07 0010
NO
120
950
950
950
950
1646
3998 5593007
161460
Rear lamp value out of range (NDP 1150) The value for the Rear Lamp stored in nonvolatile memory is outside the range 80 Hex - FE Hex. (NDP 18xx) The value for the Rear Lamp stored in nonvolatile memory is outside the range 80 Hex - EF Hex. STEP 100 PROCEDURE Using the Lamp Adjustment procedure in the Hardware Parameter Routines, set the rear lamp value to A0. Rerun the MTR routine. Does the problem still exist? 120 Using the Lamp Adjustment Hardware Parameter Routine, reset the lamp value to the correct operating point. Does the problem still exist? 130 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 140 Replace AA03, and retest. Does the problem still exist? 150 Replace AA17, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 140 99600 130 YES
MM 07 0020
NO
120
950
950
950
950
3998 5593007
1647
161470
Front lamp did not turn on STEP 100 PROCEDURE Check that the lamp is properly mounted and that there are no obstructions to the light entering or leaving the fiber optic document illuminator. Does the problem still exist? 110 Replace the front lamp, and retest. Does the problem still exist? 120 Reseat the Lamp Driver PCBA, and retest. Does the problem still exist? 130 Replace the Lamp Driver PCBA, and retest. Does the problem still exist? 140 Check connector P8 on the motherboard, J2 on the Lamp Heatsink Assembly, and associated cables for bad or intermittent contacts. Does the problem still exist? 150 Replace the Lamp Heatsink Assembly, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 130 120 110 YES
MM 07 0030
NO
950
950
950
950
950
950
1648
3998 5593007
161480
Rear lamp did not stay off with front enabled. STEP 100 PROCEDURE Replace the Lamp Driver PCBA, and retest. Does the problem still exist? 110 Check the continuity of signals FLCSELN at pin 78 and RLCSELN at pin 77 of the motherboard slot 8 back to the Microfilm Controller PCBA J5 pins 25 and 23. Repair any bad contacts or shorts found. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 130 Check connector P8 on the motherboard, J2 on the Lamp Heatsink Assembly, and associated cables for shorts or intermittent contacts. Does the problem still exist? 140 Replace the Lamp Heatsink Assembly, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 120 110 YES
MM 07 0040
NO
950
950
950
950
950
3998 5593007
1649
161490
Rear lamp did not turn on. STEP 100 PROCEDURE Check that the lamp is properly mounted and that there are no obstructions to the light entering or leaving the fiber optic document illuminator. Does the problem still exist? 110 Replace the rear lamp, and retest. Does the problem still exist? 120 Reseat the Lamp Driver PCBA, and retest. Does the problem still exist? 130 Replace the Lamp Driver PCBA, and retest. Does the problem still exist? 140 Check connector P8 on the motherboard, J2 on the Lamp Heatsink Assembly, and associated cables for bad or intermittent contacts. Does the problem still exist? 150 Replace the Lamp Heatsink Assembly, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 140 130 120 110 YES
MM 07 0050
NO
950
950
950
950
950
950
1650
3998 5593007
161500
Front lamp did not stay off with rear enabled. STEP 100 PROCEDURE Replace the Lamp Driver PCBA, and retest. Does the problem still exist? 110 Check the continuity of signals FLCSELN at pin 78 and RLCSELN at pin 77 of motherboard slot 8 back to the Microfilm Controller PCBA J5 pins 25 and 23. Repair any bad contacts or shorts found. Does the problem still exist? 120 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 130 Check connector P8 on the motherboard, J2 on the Lamp Heatsink Assembly, and associated cables for shorts or intermittent contacts. Does the problem still exist? 140 Replace the Lamp Heatsink Assembly, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 120 110 YES
MM 07 0060
NO
950
950
950
950
950
3998 5593007
1651
161510
Front ALM value out of range. Either unblocked > 30 hex or blocked < 20 hex. STEP 100 110 150 PROCEDURE Does the ALM read > 30 hex when the track is empty (unblocked)? Does the ALM read < 20 hex when the track is full (blocked)? Check for debris or dust buildup in optical gate. Clean the optical gate. Repaint any excessive wear on the optical gate walls. Does the problem still exist? 160 Replace the OSM PCBA, and retest. Does the problem still exist? 170 Swap P4 and P5 on the Distribution A PCBA, and retest. Does problem move from the Front to the Rear ALM? 180 Replace P4 and P5 to the original location. Replace the Front ALM Sensor Assembly, and retest. Does the problem still exist? 190 Replace the Distribution A PCBA, and retest. Does the problem still exist? 200 Check the continuity of signal FALMVL from J1 pin 32 on the Distribution A PCBA to the OSM PCBA. Repair problems as found. Does the problem still exist? 210 Check the continuity of signal ALMSELN from pin 98 of the motherboard slot 5 to the Microfilm Controller PCBA. Repair problems as found. Does the problem still exist? 220 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 300 Ensure that the document is correctly placed to block the optical gate. Ensure that the document does not have a large area of black or dark print. Does the problem still exist? 310 99600 220 210 200 99600 180 170 160 YES 150 300
MM 07 0070
NO 110 950
950
950
190
950
950
950
950
950
950
1652
3998 5593007
MM 07 0070
Front ALM value out of range (continued) Either unblocked > 30 hex or blocked < 20 hex. STEP 310 PROCEDURE Replace the OSM PCBA, and retest. Does the problem still exist? 320 Swap P4 and P5 on the Distribution A PCBA, and retest. Does the problem move from the Front to the Rear ALM? 330 Replace P4 and P5 to the original location. Check the cabling to ensure that the front and rear ALMs were not swapped. Check that there is no dust or debris blocking the optical path to the ALM sensor. Check that the ALM sensor is mounted correctly. If none of the above is found to be bad, replace the Front ALM Sensor Assembly, and retest. Does the problem still exist? 340 Replace the Distribution A PCBA, and retest. Does the problem still exist? 350 Check the continuity of signal FALMVL from J1 pin 32 on the Distribution A PCBA to the OSM PCBA. Repair problems as found. Does the problem still exist? 360 Check the continuity of signal ALMSELN from pin 98 of the motherboard slot 5 to the Microfilm Controller PCBA. Repair problems as found. Does the problem still exist? 370 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 370 950 360 950 350 950 99600 950 330 340 320 950 YES NO
3998 5593007
1653
161515
Rear ALM value out of range. Either unblocked > 30 hex or blocked < 20 hex. STEP 100 110 150 PROCEDURE Does the ALM read > 30 hex when the track is empty (unblocked)? Does the ALM read < 20 hex when the track is full (blocked)? Check for debris or dust buildup in the optical gate. Clean the optical gate. Repaint any excessive wear on the optical gate walls. Does the problem still exist? 160 Replace the OSM PCBA, and retest. Does the problem still exist? 170 Swap P4 and P5 on the Distribution A PCBA, and retest. Does the problem move from the Rear to the Front ALM? 180 Replace P4 and P5 to their original locations. Replace the Rear ALM Sensor Assembly, and retest. Does the problem still exist? 190 Replace the Distribution A PCBA, and retest. Does the problem still exist? 200 Check the continuity of signal RALMVL from J1 pin 33 on the Distribution A PCBA to the OSM PCBA. Repair problems as found. Does the problem still exist? 210 Check the continuity of signal ALMSELN from pin 98 of the motherboard slot 5 to the Microfilm Controller PCBA. Repair problems as found. Does the problem still exist? 220 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 300 Ensure that the document is correctly placed to block the optical gate. Ensure that the document does not have a large area of black or dark print. Does the problem still exist? 310 99600 220 210 200 99600 180 170 160 YES 150 300
MM 07 0080
NO 110 950
950
950
190
950
950
950
950
950
950
1654
3998 5593007
MM 07 0080
Rear ALM value out of range. (continued) Either unblocked > 30 hex or blocked < 20 hex. STEP 310 PROCEDURE Replace the OSM PCBA, and retest. Does the problem still exist? 320 Swap P4 and P5 on the Distribution A PCBA, and retest. Does the problem move from the Rear to the Front ALM? 330 Replace P4 and P5 to their original locations. Check the cabling to ensure that the front and rear ALMs were not swapped. Check that there is no dust or debris blocking the optical path to the ALM sensor. Check that the ALM sensor is mounted correctly. If none of the above is found to be bad, replace the Rear ALM Sensor Assembly, and retest. Does the problem still exist? 340 Replace the Distribution A PCBA, and retest. Does the problem still exist? 350 Check continuity of signal RALMVL from J1 pin 33 on Dist A PCBA to OSM PCBA. Repair problems as found. Does the problem still exist? 360 Check the continuity of signal ALMSELN from pin 98 of the motherboard slot 5 to the Microfilm Controller PCBA. Repair problems as found. Does the problem still exist? 370 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 370 950 360 950 350 950 99600 950 330 340 320 950 YES NO
3998 5593007
1655
Note: 161517
Lamps did not turn on.
STEP 100
PROCEDURE Check that the lamps are properly mounted and that there are no obstructions to the light entering or leaving the fiber optic document illuminator. Does the problem still exist?
YES
NO
110
950
110
Reseat the Lamp Driver PCBA and retest. Does the problem still exist? 120 950
120
Replace the front and rear lamps, and retest. Does the problem still exist? 130 950
130
Replace the Lamp Driver PCBA and retest. Does the problem still exist? 140 950
140
Check connector P8 on the motherboard, J2 on the Lamp Heatsink Assembly, and associated cables for bad or intermittent contacts. Does the problem still exist? 150 950
150
Replace the Lamp Heatsink Assembly and retest. Does the problem still exist? 99600 950
950
161520
MIIB data comm error: Data gets corrupted in a Tx-Rx wraparound loop. STEP 100 PROCEDURE Remove the interface cable from J5 on the AA gate or J1 on the Microfilm Controller PCBA. Rerun the test. Does the problem still exist? 110 Replace the MIIB PCBA, and retest. Does the problem still exist? 120 Check the connector on the AA gate motherboard for problems, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
MM 08 0010
NO
950
950
950
Note:
Different procedures are used to resolve each of the failure codes on this page.
1656
3998 5593007
161530
MIIB data comm error: SCSI interrupt fails on an overrun, or a framing error occurred. STEP 100 PROCEDURE Remove the interface cable from J5 on the AA gate or J1 on the Microfilm Controller PCBA. Rerun the test. Does the problem still exist? 110 Replace the MIIB PCBA, and retest. Does the problem still exist? 120 Check the connector on the AA gate motherboard for problems, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 120 110 YES
MM 08 0020
NO
950
950
950
161540
Microfilm controller data comm error: Cannot communicate with the Microfilm Controller PCBA. STEP 100 PROCEDURE Execute the manual procedure for error code MM 08 0050. Repair, and retest. Does the problem still exist? 110 Replace AA17, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 08 0030
NO
950
950
3998 5593007
1657
161550
Data comm test error. STEP 100 PROCEDURE Rerun the test carefully following the procedures indicated on the screen. Does the problem still exist? 110 120 Was a new error code displayed? Execute a manual procedure for the new error code. Repair, and retest. Does the problem still exist? 130 Replace the AA03 (MIIB ) PCBA, and retest. Does the problem still exist? 140 Replace AA17, and retest. Does the problem still exist? 150 Check the AA backplane connections to AA03 and AA17. Repair as required. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 150 140 130 110 120 YES
MM 08 0040
NO
950 130
950
950
950
950
1658
3998 5593007
161560
Microfilm controller data comm error. STEP 100 PROCEDURE Select DATA COMMUNICATIONS (option 5) from the Basic Microfilm Test Menu. Select the Microfilm Controller Wraparound Test. Execute the test procedure following the instructions displayed on the screen. Did the test complete with all the Microfilm Controller PCBA LEDs off? 110 Did the LEDs show the code below? D7 D6 D5 D4 D3 D2 D1 D0 120 OFF ON OFF OFF ON OFF OFF OFF 140 120 YES
MM 08 0050
NO
110 130
Repeat the test, ensuring that you hold the MTR switch depressed during the test. Is the test result completed with all the LEDs off? 140 130
130
140
Select the Microfilm Interface Wraparound Test, and execute it. Did the test pass? 160 150
150
Check the interface cable between the AA gate and J1 on the Microfilm Controller PCBA. Repair as necessary. Does the problem still exist? 99600 950
160
Execute the manual procedure for the error code reported by the test. Repair as required. Does the problem still exist? 99600 950
950
3998 5593007
1659
Note: 161570
ICM #1 current is too high when it is off.
STEP 100
YES
NO
99600
950
950
161580
ICM #1 path is open. STEP 100 PROCEDURE Check connector J2 on the Microfilm Controller PCBA and the cable. Check both ribbon cables connected to the Distribution B PCBA. Check connector J10 and J11 of the Distribution A PCBA. Make the necessary corrections. Does the problem still exist? 110 Replace ICM #1. Does the problem still exist? 120 Check the continuity between J10 pin 1 on the Distribution A PCBA and chip AT8 pin on the Microfilm controller PCBA. Make the necessary corrections. Does the problem still exist? 130 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 130 120 110 YES
MM 09 0002
NO
950
950
950
950
161590
ICM #1 A/D value is less than the minimum current. STEP 100 PROCEDURE Replace ICM #1. Does the problem still exist? 110 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 09 0003
NO
950
950
1660
3998 5593007
Note: 161600
ICM #1 A/D says it is on when the CSE says it is off.
161610
ICM #1 A/D is giving a bad value.
MM 09 0005
161620
ICM #2 disabled but viewed on. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 09 0006
NO
950
3998 5593007
1661
Note: 161630
ICM #2 path is open.
STEP 100
PROCEDURE Check connector J2 on the Microfilm Controller PCBA and the cable. Check both ribbon cables connected to the Distribution B PCBA. Check connector J10 and J11 of the Distribution A PCBA. Make the necessary corrections. Does the problem still exist?
YES
NO
110
950
110
Replace ICM #2. Does the problem still exist? 120 950
120
Check the continuity between J11 pin 1 on the Distribution A PCBA and chip AT8 pin on the Microfilm Controller PCBA. Make the necessary corrections. Does the problem still exist? 130 950
130
950
161640
ICM #2 A/D value is less than the minimum current. STEP 100 PROCEDURE Replace ICM #2. Does the problem still exist? 110 Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 110 YES
MM 09 0008
NO
950
950
1662
3998 5593007
Note: 161650
ICM #2 A/D says it is on when the CSE says it is off.
161660
ICM #2 A/D is giving a bad value.
MM 09 0010
161670
ICM #1 disabled but viewed on.
MM 09 0011
161680
ICM #2 current is too high when it is off. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 09 0012
NO
950
3998 5593007
1663
161690
One of the loop arm supply sensors was detected to have a failure. This fault code indicates that either sensor 1, 2, or 3 could have a failure. Ignore the message on the screen about sensor 1 failure. Note: Use a DIP CLIP on the chips specified for easier measurements while performing specified tasks. YES
MM 10 0001
STEP 100
PROCEDURE Locate the Microfilm Controller Board on the microfilm gate. This is the last card on the left of the gate. It is external to the gate. Measure the following pins on chip BF18 for a logic 0: PIN 14 PIN 12 PIN 15 Did all the pins measure a logic 0?
NO
120
110
110
Primary suspect: Microfilmer Controller PCBA. Secondary suspect: If Pin 14 was incorrect, then switch LED No. 1. If Pin 12 was incorrect, then switch LED No. 2 If Pin 15 was incorrect, then switch LED No. 3 Replace the primary suspect first and then the respective secondary. After each replacement, rerun the test. Does the problem still exist? 99600 950
120
Monitor pin 13 of chip BL18 while you move the supply loop arm from the up position to the bottom position and back up again. Was there a transition from a logic 0 to 1 and from a logic 1 to a 0? 160 130
130
Perform a continuity check on the cable J2 on the Microfilm Controller to J10 on the Distribution Board B. Is the cable O.K.? 140 150
140
Primary suspect: Loop Arm Supply Sensor No. 1 Secondary suspects: Microfilm Controller Board, Distribution B Board Primary suspect: Replace the cable.
150
1664
3998 5593007
MM 10 0001
STEP 160 PROCEDURE Monitor pin 11 of chip BL18 while you move the supply loop arm from the up position to the bottom position and back up again. Was there a transition from a logic 0 to 1 and from a logic 1 to a 0? 170 Perform a continuity check on the cable J2 on the Microfilm Controller to J11 on the Distribution Board B. Is the cable O.K.? 180 Primary suspect: Loop Arm Supply Sensor No. 2. Secondary suspects: Microfilm Controller Board Distribution B Board Primary suspect: Replace the cable Monitor pin 9 of the chip BL18 while you move the supply loop arm from the up position to the bottom position and back up again. Was there a transition from a logic 1 to 0 and from a logic 0 to 1? 210 Perform a continuity check on the cable J2 on the Microfilm Controller to J12 on the Distribution Board B. Is the cable O.K.? 220 Primary suspect: Loop arm supply sensor No. 3. Secondary suspects: Microfilm Controller Board, Distribution B Board. Primary suspect: Replace the cable. Verify proper operation. End of procedure. 220 230 99600 170 180 190 200 170 YES NO
190 200
230 950
3998 5593007
1665
161700
Loop arm sensor supply switch #2 failed. STEP 100 PROCEDURE Using a DVM, monitor J2 pin 54 on the Microfilm Controller PCBA while moving the supply loop arm though its extremes. Does the signal switch from < 0.7 V to > 4.3 V? 110 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 120 Check the continuity of the line from J2 pin 54 on the Distribution B PCBA to J2 pin 54 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 130 Replace supply sensor 2, and retest. Does the problem still exist? 140 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 99600 110 YES
MM 10 0002
NO
120
950
950
950
950
1666
3998 5593007
161710
Loop arm sensor supply switch #3 failed (Loop Too Small Sensor in error). STEP 100 PROCEDURE Using a DVM, monitor J2 pin 55 on the Microfilm Controller PCBA while moving the supply loop arm though its extremes. Does the signal switch from < 0.7 V to > 4.3 V? 110 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 120 Check the continuity of the line from J2 pin 55 on the Microfilm Controller PCBA to J2 pin 55 on the Distribution B PCBA. Repair as required. Does the problem still exist? 130 140 Use a DVM. Is J12 pin 2 on the Distribution B PCBA < 0.8 V? Replace supply sensor 3, and retest. Does the problem still exist? 150 Check the continuity of J12 pin 2 on the Distribution B PCBA to J2 pin 56 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 160 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 160 99600 130 140 99600 110 YES
MM 10 0003
NO
120
950
950 150
950
950
950
3998 5593007
1667
161720
One of the loop arm takeup sensors was detected to have a failure. This fault code indicates that either sensor 1, 2, or 3 could have a failure. Ignore the message on the screen about sensor 1 failure. Note: Use a DIP CLIP on the chips specified for easier measurements while performing specified tasks. YES
MM 10 0004
STEP 100
PROCEDURE Locate the Microfilm Controller Board on the microfilm gate. This is the last card on the left of the gate. It is external to the gate. Measure the following pins on chip BF18 for a logic 0: PIN 11 PIN 16 PIN 10 Did all the pins measure a logic 0?
NO
120
110
110
Primary suspect: Microfilmer Controller PCBA. Secondary suspect: If Pin 11 was incorrect, then switch LED No. 1. If Pin 16 was incorrect, then switch LED No. 2. If Pin 10 was incorrect, then switch LED No. 3 Replace the primary suspect first and then the respective secondary. After each replacement, rerun the test. Does the problem still exist? 99600 950
120
Monitor pin 5 of chip BL18 while you move the takeup loop arm from the up position to the bottom position and back up again. Was there a transition from a logic 0 to 1 and from a logic 1 to a 0? 160 130
130
Perform a continuity check on the cable J2 on the Microfilm Controller to J7 on the Distribution Board B. Is the cable O.K.? 140 150
140
Primary suspect: Loop Arm Takeup Sensor No. 1. Secondary suspects: Microfilm Controller Board, Distribution B Board Primary suspect: Replace the cable.
150
1668
3998 5593007
MM 10 0004
STEP 160 PROCEDURE Monitor pin 3 of chip BL18 while you move the takeup loop arm from the up position to the bottom position and back up again. Was there a transition from a logic 0 to 1 and from a logic 1 to a 0? 170 Perform a continuity check on the cable J2 on the Microfilm Controller to J8 on the Distribution Board B. Is the cable O.K.? 180 Primary suspect: Loop Arm Takeup Sensor No. 2. Secondary suspects: Microfilm Controller Board Distribution B Board Primary suspect: Replace the cable Monitor pin 1 of the chip BL18 while you move the takeup loop arm from the up position to the bottom position and back up again. Was there a transition from a logic 1 to 0 and from a logic 0 to 1? 210 Perform a continuity check on the cable J2 on the Microfilm Controller to J9 on the Distribution Board B. Is the cable O.K.? 220 Primary suspect: Loop arm takeup sensor No. 3. Secondary suspects: Microfilm Controller Board, Distribution B Board. Primary suspect: Replace the cable. Verify proper operation. End of procedure. 220 230 99600 210 180 190 200 170 YES NO
190 200
230 950
3998 5593007
1669
161730
Loop arm sensor takeup switch #2 failed. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution B PCBA J8.) Make necessary corrections. Does the problem still exist? 105 Using a DVM, monitor J2 pin 48 on the Microfilm Controller PCBA while moving the supply loop arm though its extremes. Does the signal switch from < 0.7 V to > 4.3 V? 110 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 120 Check the continuity of the line from J2 pin 48 on the Distribution B PCBA to J2 pin 48 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 130 Replace takeup sensor 2, and retest. Does the problem still exist? 140 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 99600 110 105 YES
MM 10 0005
NO
950
120
950
950
950
950
1670
3998 5593007
161740
Loop arm sensor takeup switch #3 failed. (Loop Too Small Sensor in error) STEP 100 PROCEDURE Using a DVM, monitor J2 pin 49 on the Microfilm Controller PCBA while moving the takeup loop arm though its extremes. Does the signal switch from < 0.7 V to > 4.3 V? 110 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 120 Check the continuity of the line from J2 pin 49 on the Microfilm Controller PCBA to J2 pin 49 on the Distribution B PCBA. Repair as required. Does the problem still exist? 130 140 Use a DVM. Is J9 pin 2 on the Distribution B PCBA < 0.8 V? Replace takeup sensor 3, and retest. Does the problem still exist? 150 Check the continuity of J9 pin 2 on the Distribution B PCBA to J2 pin 50 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 160 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 160 99600 130 140 99600 110 YES
MM 10 0005
NO
120
950
950 150
950
950
950
3998 5593007
1671
Note: 161750
Servo Amplifier PCBA failed read-back test. Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES NO
STEP 100
PROCEDURE Check that the Servo Amp PCBA is installed and seated correctly. Reseat as required. Does the problem still exist?
110
950
110
Replace the Servo Amp PCBA, and retest. Does the problem still exist? 120 950
120
130
Using the schematics, check the continuity of signals CDSELN, WEN, and REN on the motherboard and P4-J4. Repair and retest. Does the problem still exist? 99600 950
950
161760
Takeup loop sensor error detected. STEP 100 PROCEDURE Execute the Loop Sensor MTR routine, and follow the new fault code. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 11 0002
NO
950
161770
Supply loop sensor error detected. STEP 100 PROCEDURE Execute the Loop Sensor MTR routine, and follow the new fault code. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 11 0003
NO
950
1672
3998 5593007
161780
Loop failure occurred. STEP 100 PROCEDURE Check if film has run out. Reload the film, and retest. Does the problem still exist? 110 Check that the film in the supply and takeup cassettes is loaded correctly. Check for excessive binding of the film in the cassette. Correct and retest. Does the problem still exist? 120 Check that the motor splines engage correctly with the cassette splines. Replace worn or damaged cassettes or splines. Reload the film cassette, and retest. Does the problem still exist? 130 Execute the Reel Motor MTR procedure to verify correct operation of the reel motors and sensors. Execute the manual procedures for the error codes indicated. Does the problem still exist? 140 Execute the MTR procedures for the loop sensors, and verify correct operation. Execute the manual procedures for the error codes indicated. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 120 110 YES
MM 11 0004
NO
950
950
950
950
950
3998 5593007
1673
Note: 161790
Invalid Move command received.
STEP 100
PROCEDURE Replace the AA03 PCBA, and retest. Does the problem still exist?
YES
NO
110
950
110
120
Replace the AA17 PCBA, and retest. Does the problem still exist? 99600 950
950
161800
During Capstan test, CSE requested film present, but no film is detected. STEP 100 PROCEDURE If the film is not loaded, load the film, and rerun the test. Does the problem still exist? 110 120 Follow the new fault code, if any. End of procedure. Run the microfilm basic tests. End of procedure. 120 YES
MM 11 0006
NO
110
1674
3998 5593007
Note: 161810
During Capstan test, CSE requested to run without film, but film is detected as present.
STEP 100
PROCEDURE If the film is loaded, remove the film, and rerun the test. Does the fault code appear again?
YES
NO
120
110
110 120
Follow the new fault code, if any. End of procedure. Run the microfilm basic tests. End of procedure.
161820
Sensor Error Note: This error could result from:
MM 11 0008

STEP 100 PROCEDURE
Loop Too Large Sensor error Cover Closed Sensor error Film Loaded Sensor error YES NO
Rerun the test. Does MM 11 0008 appear again? 120 110
110 120
Follow the new fault code, if any. End of procedure. Run the Basic and Transport Microfilmer Routines. (Start with the Basic System Check.) End of procedure.
3998 5593007
1675
161830
Film loop error. STEP 100 PROCEDURE Check if the film has run out. Reload the film, and retest. Does the problem still exist? 105 Check F1 on the Galvo PCBA. Make the necessary corrections, and rerun the test. Does the problem still exist? 110 Check that the film in the supply and takeup cassettes is loaded correctly. Check for excessive binding of the film in the cassette. Correct and retest. Does the problem still exist? 120 Check that the motor splines engage correctly with the cassette splines. Replace worn or damaged cassettes or splines. Reload the film cassette, and retest. Does the problem still exist? 130 Execute the Reel Motor MTR procedure to verify correct operation of the reel motors and sensors. Execute the manual procedures for the error codes indicated. Does the problem still exist? 140 Execute the MTR procedures for the loop sensors, and verify correct operation. Execute the manual procedures for the error codes indicated. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 140 130 120 110 105 YES
MM 11 0009
NO
950
950
950
950
950
950
1676
3998 5593007
Note: 161840
Takeup loop sensor error.
STEP 100
PROCEDURE Execute the Loop Sensor MTR, and follow the fault code. Does the problem still exist?
YES
NO
99600
950
950
161850
Supply loop sensor error. STEP 100 PROCEDURE Execute the Loop Sensor MTR, and follow the fault code. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 11 0011
NO
950
161860
Idler encoder register failed. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 12 0001
NO
950
3998 5593007
1677
Note: 161870
Idler encoder count too low.
STEP 100
PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution B J5.) Make the necessary corrections. Rerun the test. Does the problem still exist?
YES
NO
110
950
110
While manually rotating the idler encoder shaft, monitor J2 pin 42 on the Microfilm Controller PCBA. Does the voltage switch from < 1.2 V to > 1.2 V? 120 150
120
150
Check the continuity of signal IENDETE from J5 pin 4 on the Distribution B PCBA to J2 pin 42 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 160 950
160
Check that the Idler Encoder Sensor and disk are clean and correctly mounted. Does the problem still exist? 170 950
170
Replace Idler Encoder Sensor Assembly, and retest. Does the problem still exist? 99600 950
950
161880
Supply encoder register failed. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 13 0001
NO
950
1678
3998 5593007
161890
Supply encoder count too low. STEP 100 PROCEDURE Verify that all cables are correctly connected. (Especially check Distribution B J6.) Make the necessary corrections. Does the problem still exist? 110 Execute the MTR procedure to activate the supply motor, and monitor J2 pin 44 on the Microfilm Controller PCBA. Does the voltage switch from < 1.2 V to > 1.2 V? 120 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 150 Check the continuity of signal SENDETE from J6 pin 4 on the Distribution B PCBA to J2 pin 44 on the Microfilm Controller PCBA. Repair as required. Does the problem still exist? 160 Check that the Supply Encoder Sensor and disk are clean and correctly mounted. Does the problem still exist? 170 Replace the Supply Encoder Sensor Assembly, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 170 160 150 120 110 YES
MM 13 0002
NO
950
150
950
950
950
950
3998 5593007
1679
Note: 161900
Supply encoder motor failed to turn on.
STEP 100
PROCEDURE Run the Reel Motor Test. End of procedure.
YES
NO
161910
Galvo scan error occurred. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 14 0001
NO
950
161920
Register 5 did not clear POSAK. STEP 100 PROCEDURE Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 YES
MM 14 0002
NO
950
1680
3998 5593007
161930
Galvo voltage failure. Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES
MM 14 0003
STEP 100
PROCEDURE Reseat the Galvo Amp PCBA, and retest. Does the problem still exist?
NO
110
950
110
Using the schematics, check with a DVM that supplies + 12 V, - 2 V, + 24 V, and + 5 V are within +/- 10%. Are supplies within tolerance at backplane slot 1? 120 130
120
Replace the Galvo Amp PCBA. Adjust to T&A 3304 4470, and retest. Does the problem still exist? 130 950
130
Check the backplane connections. Repair as required, and retest. Does the problem still exist? 140 950
140
950
3998 5593007
1681
161940
Galvo current failure. Note: The Unisys Microfilmer schematic package is required for this procedure (part #2493 2824). YES
MM 14 0004
STEP 100
PROCEDURE Reseat the Galvo Amp PCBA, and retest. Does the problem still exist?
NO
110
950
110
Using schematics, with a DVM check that supplies + 12 V, - 12 V, + 24 V, and + 5 V are within +/- 10%. Are supplies within tolerance at backplane slot 1? 120 130
120
Replace the Galvo Amp PCBA. Adjust to T&A 3304 4470, and retest. Does the problem still exist? 130 950
130
Check the backplane connections. Repair as required, and retest. Does the problem still exist? 140 950
140
150
Check the adjustment of the galvo to T&A 3304 4447 and the PCBA to T&A 3304 4470. Does the problem still exist? 140 950
160
Replace the Galvanometer, and adjust to T&As 3304 4447 and 3304 4470. Does the problem still exist? 99600 950
950
1682
3998 5593007
161950
Galvo POSAK failure. STEP 100 PROCEDURE Reseat the Galvo Amp PCBA, and retest. Does the problem still exist? 105 Check F1 on the Galvo Amp PCBA. Make the necessary corrections, and rerun the test. Does the problem still exist? 110 Select ICM TEST from the Microfilm Tests Menu, and run the Galvo Scan routine using an oscilloscope monitor TP1 on the Galvo Amp PCBA. Sync the oscilloscope on SCAN (TP7). Does TP1 give an approximately 2 msec pulse at the trailing edge of SCAN? 120 Replace the Galvo Amp PCBA. Adjust to T&A 3304 4470, and retest. Does the problem still exist? 130 Check the backplane connections. Repair as required, and retest. Does the problem still exist? 140 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 150 Check the adjustment of the galvo to T&A 3304 4447 and the PCBA to T&A 3304 4470. Does the problem still exist? 160 Replace the Galvanometer, and adjust to T&As 3304 4447 and 3304 4470. Does the problem still exist? 950 Verify proper operation. End of procedure 99600 160 150 140 130 130 110 105 YES
MM 14 0005
NO
950
950
120
950
950
950
950
950
3998 5593007
1683
161960
No Galvo home can be found. STEP 100 PROCEDURE Install the Galvo home bypass jumper on the Microfilm Controller PCBA. Rerun the Galvo Scan routine. Is an error code reported? 110 Execute the manual procedure for the error code. Remove the bypass jumper, and retest. Does the problem still exist? 120 Run the MTR Galvo Home routine, and monitor pin 33 of the microfilmer backplane slot 5 (OSM PCBA) with a DVM or oscilloscope. Does the signal switch between < 1.2 V and > 3 V? 130 Replace the OSM PCBA, and retest. Does the problem still exist? 140 If not already done, adjust the galvo home position using T&A 3304 4447, and retest. Does the problem still exist? 150 Check the backplane connections on slot 5 for problems. Repair as required. Does the problem still exist? 160 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 170 Monitor signal GALVHME on J1 pin 34 on the Distribution A PCBA. Does signal switch between < 1.2 V and > 3 V? 180 Check the continuity of signal GALVHME from J1 pin 34 on the Distribution A PCBA to slot 5 pin 33 on the motherboard. Repair as required. Does the problem still exist? 190 Check cable P6 on the Distribution A PCBA for problems. Repair as required. Does the problem still exist? 200 Replace the Distribution A PCBA, and retest. Does the problem still exist? 210 200 99600 180 99600 160 150 140 130 120 110 YES
MM 14 0007
NO
120
950
170
950
950
950
950
190
950
950
950
1684
3998 5593007
MM 14 0007
No Galvo home can be found. (continued) STEP 210 PROCEDURE Replace the Galvo Home Sensor PCBA, and adjust to T&A 3304 4447. Does the problem still exist? 220 Monitor J2 pin 34 (GHLEDC). Does the signal remain > 3 V during the test? 230 Replace the Microfilm Controller PCBA, and retest. Does the problem still exist? 240 Check the continuity of signal GHLEDC from J2 pin 34 on the Microfilm Controller PCBA to J7 pin 1 on the Distribution A PCBA. Repair as required. Does the problem still exist? 250 Monitor J7 pin 1 on the Distribution A PCBA. Is the signal < 1.2 V at any time during the test? 260 Check the continuity of signal GHLEDC from J2 pin 34 on the Microfilm Controller PCBA to J7 pin 1 on the Distribution A PCBA. Repair as required. Does the problem still exist? 270 Check cable P7 on the Distribution A PCBA for problems. Repair as required. Does the problem still exist? 280 Replace the Galvo Home LED PCBA, and adjust it to T&A 3304 4497. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 950 280 950 99600 950 260 270 99600 950 240 950 230 250 220 950 YES NO
3998 5593007
1685
Note: 161970
Galvo home position out of expected range.
STEP 100
PROCEDURE Adjust the galvo home sensor to T&A 3304 4447. Does the problem still exist?
YES
NO
110
950
110
Execute manual procedure MM 14 0007. Does the problem still exist? 99600 950
950
161980
ID patterns failed.(Set pattern) STEP 100 PROCEDURE Remove the shield at the platen, and check the seating and condition of the flat ribbons at the Distribution A and Distribution B PCBAs. Does the problem still exist? 110 Check/reseat the controller flat ribbon cable at the J2 connector on the Microfilm Controller PCBA. Does the problem still exist? 120 Replace the Microfilm Controller PCBA. Does the problem still exist? 130 Replace the Distribution A PCBA. Does the problem still exist? 140 Replace the Distribution B PCBA. Does the problem still exist? 150 Check/reseat the flat ribbon cable at the ID Display PCBA. Does the problem still exist? 160 Replace the ID Display PCBA. Does the problem still exist? 950 Verify proper operation. End of procedure. 99600 160 150 140 130 120 110 YES
MM 15 0001
NO
950
950
950
950
950
950
950
1686
3998 5593007
Note: 161990
ID patterns failed.(User-specified pattern)
STEP 100
PROCEDURE Remove the shield at the platen, and check the seating and condition of the flat ribbons at the Distribution A and Distribution B PCBAs. Does the problem still exist?
YES
NO
110
950
110
Check/reseat the controller flat ribbon cable at the J2 connector on the Microfilm Controller PCBA. Does the problem still exist? 120 950
120
130
Replace the Distribution A PCBA. Does the problem still exist? 140 950
140
Replace the Distribution B PCBA. Does the problem still exist? 150 950
150
Check/reseat the flat ribbon cable at the ID Display PCBA. Does the problem still exist? 160 950
160
Replace the ID Display PCBA. Does the problem still exist? 99600 950
950
162000
Galvo Error Detection Bypass jumper is in place. Note: The microfilmer can be operated in this state. Galvo errors will be ignored. YES
WR 00 0010
STEP 100
PROCEDURE Remove the Galvo Error Detection Bypass jumper, and execute the Galvo MTR tests. Follow the appropriate fault code. End of procedure.
NO
3998 5593007
1687
Note: 162010
Different procedures are used to resolve each of the failure codes on this page. WR 00 0020
ALM Error Detection Bypass jumper is in place. Note: The microfilmer can be operated in this state. No ALM errors will be declared. YES NO
STEP 100
PROCEDURE Remove the ALM Error Detection Bypass jumper, and execute the Lamps/ALMs MTR. Follow the appropriate fault code. End of procedure.
162020
Height Detectors failed POC. Note: The microfilmer may still be used. Film usage may be greater than normal. YES
WR 00 0030
STEP 100
PROCEDURE Run the Height BOL MTR from the Basic Microfilm Test Menu. Follow the appropriate fault code. End of procedure.
NO
162030
Human Readable Header failed POC. Note: The microfilmer may still be used. Human Readable Headers will not operate properly. YES
WR 00 0040
STEP 100
PROCEDURE Run the Human Readable Headers MTR test. Follow the appropriate fault code. End of procedure.
NO
162040
Channel 2 ICM failed POC. Note: The microfilmer may still be used. The Channel 2 ICM will not operate properly. YES
WR 00 0050
STEP 100
PROCEDURE Run the ICM MTR test. Follow the appropriate fault code. End of procedure.
NO
1688
3998 5593007
Section 17 Microfilmer Hardware Parameters

These MTR routines facilitate the adjustment of the following parameters of the NDP 1000-65 and NDP 1800-65 Cinemode Microfilmers (hereafter called the microfilmer):
Lamp intensity/density Automatic Light Monitor (ALM) adjustment Leading edge delay (LED) and trailing edge delay (TED) ID display intensity Galvanometer adjustment Modifying nonvolatile RAM values
The microfilmer module is delivered fully adjusted. However, it may be necessary after installation to alter some or all of the parameters to adjust for differences in document processors or for specific customer requirements. An initial test run of documents and review of the resultant film with the customer will identify this need. Note: It is recommended that the values stored in nonvolatile memory be recorded and stored in a safe place with the machine whenever a parameter is modified.
3998 5593007
171
Microfilmer Hardware Parameters
General Operation of Parameter Routines

The Hardware Parameter routines are on the MTR disk and are selected using the normal MTR disk loading procedures. After you load the MTR disk, do the following: 1. Select MICROFILM TESTS (option 3) from the MTR Test Main Menu (Figure 1-1) The Microfilm MTR Menu (Figure 1-6) is displayed. 2. Select HARDWARE PARAMETER ADJUSTMENT ROUTINES (option 9). You will then be prompted to select the film speed, medium or high. Once you have made a selection, the screen shown in Figure 17-1 is displayed.
MICROFILM HARDWARE PARAMETER ADJUSTMENT ROUTINES SELECT ONE OF THE FOLLOWING FOLLOWED BY "XMIT" 1 2 3 4 5 6 7 99 = = = = = = = = LAMP INTENSITY/DENSITY ALM ADJUSTMENT LED/TED ID DISPLAY INTENSITY GALVO ADJUSTMENT MODIFY NON-VOLATILE RAM VALUES RETURN TO MICROFILM MENU RETURN TO MAIN MENU
Figure 171. Parameter Routines Screen Format 3. Select the specific parameter to be changed. The first screen displayed describes the routine and presents the following options to be selected:
Continue with the adjustment routine. Do not flow documents. Proceed to a routine to pick new values. Exit the Routine and return to the Main Menu.
172
3998 5593007
Continuing with Adjustment Routine

If you choose to continue with the adjustment routine (option 2), the following sequence is followed. 1. 2. 3. 4. Specify the type and quantity of documents needed for the test. Specify any jumpers that need to be in place for the test. Specify any special instructions for the routine. Turn on the microfilmer, and press the START/STOP bar to bring up the motors. Before flow starts, the document processor and microfilmer are confirmed Ready, or a Not Ready condition is reported. If the document processor is ready, the documents are fed.
If the document processor is Not Ready, correct the condition, or exit to the Main Menu. If at any time during flow the document processor goes Not Ready, the reason is displayed on the screen, and you can select the following options:

5. 6. 7. 8.
Continue. The routine repeats the test value currently being executed, including header identification. Exit to the Main Menu.
Refer to the detailed routine description for specific routine execution instructions. Wait for the completion of flow. Bring down the motors, and develop the film. Select one of the following:
Exit to the Main Menu. Continue to pick a new value.
3998 5593007
173
Picking a New Value

If you choose to pick a new value (option 2), the following sequence is followed: 1. 2. The table of test values is displayed on the screen together with the current selected value(s). Follow the instructions on the screen to enter the new selections. If the new selections are not valid entries, the following is displayed: Reenter selection 3. On successful acceptance of the new selection, you are prompted to remove any jumpers and continue. Note: You must complete each routine to a valid exit. The microfilmer cannot be reset/powered down in the middle of a routine. If this happens, incorrect parameters may be stored in nonvolatile memory, and you must rerun the routine to select a valid operating parameter.
174
3998 5593007
Lamp Intensity/Density Procedure and ALM Adjustment

This routine is used to ensure that the film density and resolution are correct. Density is a means of expressing the tone of an image as a number. The normal range of acceptable density readings (dependent on customer preference) usually falls in the range between 1.0 and 1.5. The number is derived by reading the white density document, part number 3179 6857, with a densitometer, which measures the opacity of the film image. This procedure must be executed when a lamp or major optics component is changed. Requirement Density to be 1.25 +_ 0.05 with a minimum resolution of 125 lp/mm with a 50X magnification. Prerequisite Operator PM. Special Tools Density Documents 3179 6857. Control film developing and Unisys approved film. Transmission Densitometer with 1 mm or less aperture. Procedure 1. 2. 3. 4. Ensure that the endorser is deselected. Ensure that operator PM has been performed. Check that density documents are not smeared, smudged, or creased. Load the MTR disk. The MTR Test Main Menu (Figure 1-1) is displayed. 5. Select MICROFILM TESTS. The Microfilm MTR Menu (Figure 1-6) is displayed. 6. Select HARDWARE PARAMETER ADJUSTMENT ROUTINES. Once the film speed is selected, the Hardware Parameter Adjustment Routines Menu (Figure 1-8) is displayed. 7. 8. A menu appears that asks you to select medium- or high-speed film. Select the film speed. Load live film into the microfilmer, and close the film transport cover. A 4-foot film advance automatically occurs. 9. Load at least 100 density documents (3179 6857) into the primary hopper.
3998 5593007
175
10. Follow the instructions displayed on the screen to execute the Lamp Intensity/Density adjustment procedure. The routine automatically feeds six documents for each of 10 lamp settings. The human readable header identifies each test on film in the following format: LTD CC LL In this format, CC = counter (1-5). LL = test value. 11. Perform a film advance, cut the film, and remove the takeup cassette. 12. Develop the film using a controlled process. 13. Measure the density of the front and rear images at each test point. 14. Calculate the required operating point for each lamp independently using the following method: a. b. c. d. e. Select densities of test values on each side of the required operating point, 1.25. For example, tv1 = A0 density = 1.2, tv2 = A8 density = 1.3). Subtract test values and densities. For example, tv2 - tv1 = 8, density tv2 - density tv1 = 0.1). Divide the difference in test values by the difference in densities. For example, 8/0.1 = 80. Subtract the density of tv1 from 1.25, and multiply by the value from the preceding calculation. For example, (1.25 - 1.2)*80 = 4. Add this value to tv1 to obtain the required operating point. For example, A0 + 4 = A4.
15. Enter the values calculated for the front and rear lamps using the procedure described on the screen. The MTR automatically runs the ALM parameter routine to select the correct ALM operating values. The routine reports these values on the screen, and you should record them to allow monitoring of any degradation with time.
176
3998 5593007
LED/TED Adjustment Procedure

This routine allows the adjustment of the position of the leading edge of the document in the galvo scan and the adjustment of the termination of the scan relative to the trailing edge of the document. It is required to compensate for machine-to-machine tolerance variations. Requirement To achieve proper spacing between the gate mark and the leading edge of the document and to prevent distortion on the trailing edge of the document. Prerequisite None Special Tools 4.5" x 9.0" Documents 3179 7467 Procedure 1. Load the MTR disk. The MTR Test Main Menu (Figure 1-1) is displayed. 2. Select MICROFILM TESTS. The Microfilm MTR Menu (Figure 1-6) is displayed. 3. 4. 5. 6. Select HARDWARE PARAMETER ADJUSTMENT ROUTINES. Once the film speed is selected, the Hardware Parameter Adjustment Routines Menu (Figure 1-8) is displayed. Select LED/TED. Load live film into the microfilmer, and close the film transport cover. A 4-foot film advance automatically occurs. 7. Load at least 1,100 test documents (3179 7467) into the primary hopper.
3998 5593007
177
8.
Follow the instructions displayed on the screen to execute the LED/TED Adjustment procedure. The routine flows 20 documents for each of 24 settings of LED/TED delays. The human readable header and ID number display the test setting with the following format: LXX.X__TXX.X In this format, L = LED value, XX.X = delay in msec. T = TED value, XX.X = delay in msec.
9.
Perform a film advance.
10. Cut and remove the film. 11. Develop the film, ensuring that the scale on the edge of the documents is clearly visible. 12. View the film, and select the correct operating values for the LED and TED, as explained next. a. b. Select the LED value to produce a document leading edge position corresponding to that shown in Figure 17-2. Select the TED value by adding 0.5 msec to the value that just shows the full undistorted 9.0-inch length of the document.
13. Enter the selected LED and TED values following the description on the screen.
178
3998 5593007
Figure 172. Film Format
3998 5593007
179
ID Display Intensity Adjustment Procedure

This routine allows the adjustment of the ID Display intensity by varying the time the display characters are turned on. Requirement To achieve proper intensity of the ID characters on film. Characters should be clear and legible. Prerequisite ID Display focused correctly to T&A 3304 4355. Special Tools None. Non-CAPI Procedure 1. Load the MTR disk. The MTR Test Main Menu (Figure 1-1) is displayed. 2. Select MICROFILM TESTS. The Microfilm MTR Menu (Figure 1-6) is displayed. 3. 4. 5. 6. Select HARDWARE PARAMETER ADJUSTMENT ROUTINES. Once the film speed is selected, the Hardware Parameter Adjustment Routines Menu (Figure 1-8) is displayed. Select ID DISPLAY INTENSITY. Load live film into the microfilmer, and close the film transport cover. A 4-foot film advance automatically occurs. 7. Load at least 200 documents (any type) into the primary hopper.
1710
3998 5593007
8.
Follow the instructions displayed on the screen to execute the ID Display Adjustment procedure. The routine flows four documents for each of 40 settings of ID display. The human readable header displays the test setting with the following format: ID YY XX.X In this format, YY = test counter XX.X = display on time 10.0 - 30.0 msec. The ID Display displays the pattern 000000000000 for two documents and 111111111111 for two documents.
9.
Perform a film advance.
10. Cut the film, and remove the takeup cassette. 11. Develop the film using a controlled process. 12. View the film, and select the correct operating value for the ID Display on time. 13. Enter the selected ID Display value following the description on the screen. You must enter data in the form XX.X (in msec). CAPI Procedure 1. 2. 3. 4. 5. 6. 7. From the Start Up Menu select "CAPI \ CSE Utilities \ CAPI Maintenance Test Routines". Select "Microfilmer Tests" to expand the Microfilm MTR Menu. Select "Hardware Parameter Adjustment Routines" to expand the parameter adjustment menu. Select the "ID Display Intensity Adjustment" utility. Load live film into the microfilmer, and close the film transport cover. A 4-foot film advance automatically occurs. Load at least 36 documents (any type) into the primary hopper. Follow the instructions displayed on the screen to execute the ID Display Adjustment procedure. The routine flows four documents for each of 9 settings of ID display. The format for the human readable header text is "ID XXXXX us" where "XXXXX" is the "on time" in microseconds. The ID display is set so that the pattern "000000000000" is displayed for every two documents. Perform a film advance. Cut the film, and remove the takeup cassette.
8. 9.
10. Develop the film using a controlled process. 11. View the film, and select the correct operating value for the ID Display on time. 12. Enter the selected ID Display value following the description on the screen.
3998 5593007
1711
Galvo Home Adjustment Procedure

This routine allows the fine adjustment of the Galvo Home position on film. It is used to adjust the galvo home position together with the galvo home sensor. Requirement To achieve proper position of the gate marks on film. Refer to Figure 30-2. Prerequisite Galvo home position adjusted to T&A 3304 4439. Special Tools None. Procedure 1. Load the MTR disk. The MTR Test Main Menu (Figure 1-1) is displayed. 2. Select MICROFILM TESTS. The Microfilm MTR Menu (Figure 1-6) is displayed. 3. 4. 5. 6. 7. Select HARDWARE PARAMETER ADJUSTMENT ROUTINES. Once the film speed is selected, the Hardware Parameter Adjustment Routines Menu (Figure 1-8) is displayed. Select GALVO ADJUSTMENT. Install the Galvo Error Bypass jumper on the Microfilm Controller PCBA. Load live film into the microfilmer, and close the film transport cover. A 4-foot film advance automatically occurs. 8. 9. Load at least 80 documents (any type) into the primary hopper. Follow the instructions displayed on the screen to execute the Galvo Home Adjustment procedure. The routine flows 10 documents for each of eight settings of Galvo Home. The human readable header and ID Display display the test setting with the following format: ID CC VV In this format, CC = test counter. VV = galvo home test value 00 - 80. 10. Perform a film advance. 11. Cut the film, and remove the takeup cassette. 12. Develop the film. 13. View the film, and select the correct operating value for the Galvo Home position. Refer to Figure 30-2.
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14. Enter the selected Galvo Home value following the description on the screen. You must enter data in the form VV. 15. Follow the procedures displayed on the screen to execute the Galvo Home sensor adjustment procedure. Follow T&A 3304 4447 to adjust the sensor position physically. As home is found, the document processor terminal prompts you with a beep together with the message "above home" or "below home." 16. Continue to adjust the sensor until home is located. 17. Execute the Galvo Home position check routine following the directions on the screen. You are prompted to repeat the Galvo Home Sensor Adjustment if there is a mismatch between the Galvo Home position and the home sensor position.
Modify Nonvolatile RAM Values

This routine allows you to
Display the current Hardware Parameter values Modify the values stored in nonvolatile RAM Store the modified values into nonvolatile RAM Always record the values stored in nonvolatile RAM before and after modification. Then store them safely for future reference.
Note:
Requirement To allow Hardware Parameters stored in nonvolatile RAM to be viewed and modified. Prerequisite None. Special Tools None. Procedure 1. Load the MTR disk. The MTR Test Main Menu (Figure 1-1) is displayed. 2. Select MICROFILM TESTS. The Microfilm MTR Menu (Figure 1-6) is displayed. 3. 4. 5. Select HARDWARE PARAMETER ADJUSTMENT ROUTINES. Once the film speed is selected, the Hardware Parameter Adjustment Routines Menu (Figure 1-8) is displayed. Select MODIFY NON-VOLATILE RAM VALUES. The current parameter values are displayed on the screen. Figure 17-3 shows the display format.
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6.
Follow the screen instructions to view and/or modify the parameters in nonvolatile memory.
PRESENT PARAMETER VALUES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 "XMIT" = = = = = = = = = = = = = = = = LED MSB - 8E LED MSB - 94 TED MSB - B3 TED LSB - B0 FRONT LAMP - A3 REAR LAMP - A3 GALVO HOME - 34 ID DISPLAY MSB - 61 ID DISPLAY LSB - A8 FRONT ALM - 0F REAR ALM - 04 ICM MSB - 03 ICM LSB - E8 HR HEADER MSB - 3A HR HEADER LSB - 98 IT
ENTER NUMBER (1-16) OF VALUE TO CHANGE FOLLOWED BY
Figure 173. Nonvolatile RAM Screen Format
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Section 18 Imaging Module (U4/JPEG)

This section deals with diagnosis of problems in the U4/JPEG imaging modules in the NDP 1150 and NDP 1825. Both parts of the imaging module are covered:
The camera submodule, located between the microfilmer and the first pocket module, consists of the optics, electronics, and power supplies necessary to capture document images. The gateway submodule, located in the first pocket module, holds the PCBAs and backplane that enable the analog image data from the camera submodule to be digitized and processed into image packets.
This section provides diagnostic information based on the assumption that the POC tests have passed. If the sorter POC test did not pass, go back to Section 2 for POC diagnosis. For diagnostic information for dual image, refer to Section 22, "Dual Image Manual Procedures."
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Imaging Module (U4/JPEG)
Note: 170000
The same procedure is used to resolve each of the failure codes on this page. IM 00 0001
Sorter timed out waiting for the IIB to get control of the Command Area Semaphore.
170010
Sorter timed out waiting for the IIB to send a queued message to the DTI board.
IM 00 0002
170020
Sorter timed out waiting for the IIB to complete transmission of a message to the DTI board.
IM 00 0003
170030
Sorter timed out waiting for the Dual Port Command Area to become idle.
IM 00 0004
170040
Sorter timed out waiting for the Dual Port Command Area Semaphore to become available.
IM 00 0005
170050
Sorter timed out waiting for a response from the imaging module. PROCEDURE Refer to error code line (ECL) 02100 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures for the diagnostic procedure.
IM 00 0006
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Note: 170060
Sorter timed out waiting for the IIB to complete transmission of a message on the parallel interface.
170070
Sorter timed out waiting for the IIB. The IIB was through transmitting to the DTI and was waiting for a Check Complete status.
IM 00 0008
170080
IIB/DTI parallel interface transmission error.
IM 00 0009
170090
Sorter/IIB communications error. Message too big for dual port memory error.
IM 00 0010
170100
Sorter/IIB communications error. The IIB ran out of memory.
IM 00 0011
170110
IIB/DTI communications error. The parallel interface is not ready. PROCEDURE Refer to error code line (ECL) 02100 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures for the diagnostic procedure.
IM 00 0012
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Note: 170120
Different procedures are used to resolve each of the failure codes on this page. IM 01 0010
The data sent does not equal the data received.
STEP 100
PROCEDURE Replace AA15, and rerun the Parallel Interface Loopback test for connector option number 1 (MIIB Parallel #1 Loopback, 2485 1487). Does the test pass?
YES
NO
950 99700
120 130
120 130 950
Does IM 01 0010 occur? Follow the new fault code. Verify proper operation. End of procedure.
170130
The data sent does not equal the data received. STEP 100 PROCEDURE Replace AA15, and rerun the Parallel Interface Loopback test for connector option number 2 (MIIB Parallel #2 Loopback, 2485 1495). Does the test pass? 120 130 950 Does IM 01 0020 occur? Follow the new fault code. Verify proper operation. End of procedure. 950 99700 YES
IM 01 0020
NO
120 130
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170140
The data sent does not equal the data received. STEP 100 PROCEDURE Run the Parallel Interface Loopback test for connector option number 1 (MIIB Parallel #1 Loopback, 2485 1487). Note: Power should always be down when replacing a connector. 110 YES
IM 01 0030
NO
Does the test pass? 110 Replace the DP Interface cable (Ext to Gate) connected from the AA gate to the image gate. Rerun the Parallel Interface Loopback test for connector option number 3 (MIIB Parallel #1 Cable A Loopback, 4140 4336). Note: Power should always be down when replacing a cable or connector.
120
Does the test pass? 120 950 Follow the new fault code. Verify proper operation. End of procedure.
950
99700
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170150
The data sent does not equal the data received. STEP 100 PROCEDURE Run the Parallel Interface Loopback test for connector option number 2 (MIIB Parallel #2 Loopback, 2485 1495). Note: Power should always be down when replacing a connector. 110 YES
IM 01 0040
NO
Does the test pass? 110 Replace the DP Interface cable (Ext to Gate) connected from the AA gate to the image gate. Rerun the Parallel Interface Loopback test for connector option number 4 (MIIB Parallel #2 Cable A Loopback, 4140 4344). Note: Power should always be down when replacing a cable or connector.
120
950
99700
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Note: 170160
Image Interface board did not enter MTR mode.
170170
The command area never went idle.
IM 01 0051
170180
The sorter received an invalid status code from the IIB.
IM 01 0052
170190
The sorter tried three times to send down a test code to the IIB board, and each time the IIB received an invalid test code. STEP 100 PROCEDURE Replace AA15, and rerun the test. Does the problem still exist? 110 Replace AA17, and rerun the test. Does the problem still exist? 950 Verify proper operation. End of procedure. 99700 110 YES
IM 01 0053
NO
950
950
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170200
The IIB was unable to determine the connector type. STEP 100 PROCEDURE Connect a new loopback connector and rerun the loopback test that displayed the fault code. Note: Power should always be down when replacing a connector. 950 130 YES
IM 01 0060
NO
Does the test pass? 110 120 130 140 Did the fault code IM 01 0060 occur? Follow the new fault code. Did this error occur with Parallel Loopback option 5? Run the Parallel Interface Loopback test for option 3. Note: Power should always be down when replacing a connector.
110 120
140
150
Does the test pass? 150 160 Did this error occur with Parallel Loopback option 6? Run the Parallel Interface Loopback test for option 4. Note: Power should always be down when replacing a connector.
220 160
180 170
230 180
200 190
240 200
260 210
Does the test pass?
250
270
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170200
STEP 210 220 PROCEDURE Did this error occur with Parallel Loopback option 1? Replace the DP Interface cable (Gate Int) connected from the AA gate to the image gate. Rerun the Parallel Interface Loopback test for option 5. Note: Power should always be down when replacing a cable or connector. 950 YES 260
IM 01 0060
NO 270
Does the test pass? 230 Replace the DP Interface cable (Gate Int) connected from the AA gate to the image gate. Rerun the Parallel Interface Loopback test for option 6. Note: Power should always be down when replacing a cable or connector.
99700
Does the test pass? 240 Replace the DP Interface cable (Ext to Gate) connected from the AA gate to the image gate. Run the Parallel Interface Loopback test for option 3. Note: Power should always be down when replacing a cable or connector.
950
99700
Does the test pass? 250 Replace the DP Interface cable (Ext to Gate) connected from the AA gate to the image gate. Rerun the Parallel Interface Loopback test for option 4. Note: Power should always be down when replacing a cable or connector.
950
99700
Does the test pass? 260 Replace AA15 and rerun the Parallel Interface Loopback test for option 1. Note: Power should always be down when replacing a connector.
950
99700
Does the test pass? 270 Replace AA15 and rerun the Parallel Interface Loopback test for option 2. Note: Power should always be down when replacing a connector.
950
280
Does the test pass?
950
280
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Note: 170200
STEP 280 290 950
PROCEDURE Does the fault code IM 01 0060 occur? Follow the new fault code. Verify proper operation. End of procedure. YES 99700 NO 290
170210
The data sent does not equal the data received. STEP 100 PROCEDURE Run the Parallel Interface Loopback test for connector option 3 (MIIB Parallel #1 Cable A Loopback, 4140 4336). Note: Power should always be down when replacing a connector. 110 YES
IM 01 0070
NO
Does the test pass? 110 Replace the DP Interface cable (Gate Int) connected from the AA gate to the image gate. Rerun the Parallel Interface Loopback test for connector option number 5 (MIIB Parallel #1 Cable Loopback, 2485 1933). Note: Power should always be down when replacing a cable or connector.
120
950
99700
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Note: 170220
The sorter was unable to get control of the Command Area Semaphore.
STEP 100
PROCEDURE Replace AA15, and rerun the test. Does the test pass?
YES
NO
110
950
110
950
170230
The data sent does not equal the data received. STEP 100 PROCEDURE Run the Parallel Interface Loopback test for connector option number 4 (MIIB Parallel #2 Cable A Loopback, 4140 4344). Note: Power should always be down when replacing a connector. 110 YES
IM 01 0090
NO
Does the test pass? 110 Replace the DP Interface cable (Gate Int) connected from the AA gate to the image gate. Rerun the Parallel Interface Loopback test for connector option number 6 (MIIB Parallel #2 Cable Loopback, 2485 1941). Note: Power should always be down when replacing a cable or connector.
120
950
99700
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1811
Note: 170240
The data sent does not equal the data received.
STEP 100
PROCEDURE Replace AA15 and rerun the Serial Interface Loopback test for connector option number 1 (MIIB Serial Loopback, 2485 1479). Does the test pass?
YES
NO
950 99700
110 120
110 120 950
Does IM 02 0010 occur? Follow the new fault code. Verify proper operation. End of procedure.
170250
The data sent does not equal the data received. STEP 100 PROCEDURE Run the Serial Interface Loopback test for connector option number 1 (MIIB Serial Loopback, 2485 1479). Note: Power should always be down when replacing a connector. 110 YES
IM 02 0020
NO
Does the test pass? 110 Replace the DP Interface cable (Ext to Gate) connected from the AA gate to the image gate. Rerun the Serial Interface Loopback test for connector option number 2 (MIIB Serial Cable A Loopback, 4140 4328). Note: Power should always be down when replacing a cable or connector.
120
950
99700
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17260
The TDC/RDC serial wraparound test failed. STEP 100 PROCEDURE Replace the loopback connector and rerun the same loopback test. Note: Power should always be down when replacing a connector. 950 130 YES
IM 02 0030
NO
Does the test pass? 110 120 130 140 Did fault code IM 02 0030 occur? Follow the new fault code. Did this error occur with Serial Loopback option 3? Run the Serial Interface Loopback test for option 2. Note: Power should always be down when replacing a connector.
110 120
140
150
Does the test pass? 150 160 Did the error occur with Serial Loopback option 2? Run the Serial Interface Loopback test for option 1. Note: Power should be down when replacing a connector.
170 160
160 190
Does the test pass?
180
190
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STEP 170
PROCEDURE Replace the DP Interface cable (Gate Int) connected from the AA gate to the image gate. Rerun the Serial Interface Loopback test for option 3. Note: Power should always be down when replacing a cable or connector.
YES
NO
Does the test pass? 180 Replace the DP Interface cable (Ext to Gate) connected from the AA gate to the image gate. Rerun the Serial Interface Loopback test for option 2. Note: Power should always be down when replacing a cable or connector.
950
99700
Does the test pass? 190 Replace AA15 and rerun the Serial Interface Loopback test for option 1. Note: Power should always be down when replacing a connector.
950
99700
Does the test pass? 200 210 950 Does the fault code IM 02 0030 occur? Follow the new fault code. Verify proper operation. End of procedure.
950 99700
200 210
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170270
The transmit test on the IIB board failed. STEP 100 PROCEDURE Replace the loopback connector and rerun the same Serial Interface Loopback test. Note: Power should always be down when replacing a connector. 950 130 YES
IM 02 0040
NO
Does the test pass? 110 120 130 140 Did fault code IM 02 0040 occur? Follow the new fault code. Did this error occur with the Serial Loopback option 3? Run the Serial Interface Loopback test for option 2. Note: Power should always be down when replacing a connector.
110 120
140
150
Does the test pass? 150 160 Did the error occur with Serial Loopback option 2? Run the Serial Interface Loopback test for option 1. Note: Power should be down when replacing a connector.
170 160
160 190
Does the test pass?
180
190
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1815
STEP 170
YES
NO
950
99700
950
99700
950 99700
200 210
1816
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170280
The receive test on the IIB board failed. STEP 100 PROCEDURE Replace the loopback connector and rerun the same Serial Interface Loopback test. Note: Power should always be down when replacing a connector. 950 130 YES
IM 02 0050
NO
110 120
140
150
Does the test pass? 150 160 Did the error occur with Serial Loopback option 2? Run the Serial Interface Loopback test for option 1. Note: Power should always be down when replacing a connector.
170 160
160 190
Does the test pass?
180
190
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1817
STEP 170
YES
NO
950
99700
950
99700
950 99700
200 210
1818
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170290
When trying to transmit data, the control lines indicated that data was never sent. STEP 100 PROCEDURE Replace the loopback connector and rerun the same Serial Interface Loopback test. Note: Power should always be down when replacing a connector. 950 130 YES
IM 02 0060
NO
110 120
140
150
Does the test pass? 150 160 Did the error occur with Serial Loopback option 2? Run the Serial Interface Loopback test for option 1. Note: Power should always be down when replacing a connector.
170 160
160 190
Does the test pass?
180
190
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1819
STEP 170
YES
NO
950
99700
950
950 99700
200 210
1820
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170300
The data sent does not equal the data received. STEP 100 PROCEDURE Run the Serial Interface Loopback test for connector option number 2 (MIIB Serial Cable A Loopback, 4140 4328). Note: Power should always be down when replacing a connector. 110 YES
IM 02 0070
NO
Does the test pass? 110 Replace the DP Interface cable (Gate Int) connected from the AA gate to the image gate. Rerun the Serial Interface Loopback test for connector option number 3 (MIIB Serial Cable Loopback, 2485 1925). Note: Power should always be down when replacing a cable or connector.
120
950
99700
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1822
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Section 19 Multiline Ink Jet Endorser Manual Procedures

This section provides information on the Multiline Ink Jet Endorser (MJE) fault codes and the maintenance procedure used to eliminate faults. The section is divided into five parts.
Fault Code Definitions, including POC (Power-On Confidence) and MTR (Maintenance Test Routines). Run Time Fault Code Definitions. MJE Maintenance Procedures. Condition, Cause, and Correction Chart. Additional information, including command names and descriptions, and FRU (field replaceable unit) mnemonic names.
A definition is provided for each fault code, and a procedure for eliminating the fault is given. In some fault code step procedures, the MTR tool kit (part number 4141 1521) is required to isolate the FRU. Before reading the fault codes or using the procedures, be aware of the following points:
MTR commands are used to control the MJE for many procedures and assume the MJE control panel switches start in the "OFF" position, unless otherwise noted. This assures no interaction between automatic and manual commands. These commands can only be executed by loading the MTR disk (powering on the document processor with the MTR disk installed, or installing the MTR disk before proceeding past a POC fault display). Select "NON-IMPACT ENDORSER TESTS" from the MTR main menu. The procedures refer to three categories of commands: Run time commands POC commands Extended diagnostic commands
If a dual-endorse option is present, a selection of rear or front will occur. Other menu selections are to be used when called out by this and other procedures (T&As and SEIs). In the Action column of this manual, perform the replace action or follow the procedure listed.
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Multiline Ink Jet Endorser Manual Procedures
When using the procedure, fix one bit failure at a time. When there is a list of word and bits returned, start at the top and read down until you find the one that has failed or multiple if asked for. All levels are TTL unless otherwise noted. After replacing a FRU, perform the tests again to verify the problem was corrected. Check to make sure that on any board FRU that contains fuses, that they are of proper value and in good condition. Unless otherwise prompted, the MJE On/Off switches on the console should not be changed from their initial state while performing the MJE tests. Doing so will cause unexpected errors.
Note:
Extended Error Word Format

MJE POC test error codes are sometimes accompanied with two extended status words that provide additional information that can be used for diagnostic purposes. In the NonCAPI environment, the extended status is displayed in binary format, with each word and its appropriate bit positions clearly labeled. In the CAPI environment, the extended status words are not displayed in binary. They are displayed in hexadecimal format and are included as part of the 8 byte extended data field in the "DP1XXX Common API Exception Handler" dialog box. The extended data field is to the immediate right of the 5 byte error code, which is bracketed by parenthesis, in the exception handler dialog. The extended error words for the MJE are embedded in the extended data field in the following manner: 01 | 15-8 02 | 7-0 03 | 15-8 04 | 7-0 NU NU NU NU 05 06 07 08 Bytes displayed by Exception Handler (Left to Right) Word bit positions
|________| | WORD 1
|_______| | WORD 2
NU = Not Used for MJE extended error status
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Fault Code Definitions

Table 191. Fault Code Definitions
Test Number Fault Code (Hex) MJE 01 XX MJE 02 01 MJE 03 01 MJE 04 01 MJE 04 02 MJE 04 03 MJE 04 04 MJE 04 05 MJE 04 06 MJE 04 07 MJE 04 08 MJE 04 09 MJE 04 0A MJE 04 0B MJE 04 0C MJE 04 0D MJE 04 0E MJE 04 0F MJE 04 F0 MJE 05 01 MJE 05 02 MJE 05 03 MJE 05 04 MJE 05 05 MJE 05 06 MJE 05 07 MJE 05 08 MJE 05 09 LED visual test
Fault Description
Action Go to 40000 Go to 40000 Go to 40000 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100
EPROM check sum failure External RAM failure Rear font 1 flash memory check sum failure Rear font 2 flash memory check sum failure Rear font 3 flash memory check sum failure Rear font 4 flash memory check sum failure Rear font 5 flash memory check sum failure Rear font 6 flash memory check sum failure Rear font 7 flash memory check sum failure Rear font 8 flash memory check sum failure Rear font 9 flash memory check sum failure Rear font 10 flash memory check sum failure Rear font 11 flash memory check sum failure Rear font 12 flash memory check sum failure Rear font 13 flash memory check sum failure Rear font 14 flash memory check sum failure Rear font 15 flash memory check sum failure Rear font 0 flash memory check sum failure Rear graphics 1 flash memory check sum failure Rear graphics 2 flash memory check sum failure Rear graphics 3 flash memory check sum failure Rear graphics 4 flash memory check sum failure Rear graphics 5 flash memory check sum failure Rear graphics 6 flash memory check sum failure Rear graphics 7 flash memory check sum failure Rear graphics 8 flash memory check sum failure Rear graphics 9 flash memory check sum failure
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Test Number Fault Code (Hex) MJE 05 0A MJE 05 0B MJE 05 0C MJE 05 0D MJE 05 0E MJE 05 0F MJE 05 F0 MJE 06 01 MJE 06 02 MJE 06 03 MJE 06 04 MJE 06 05 MJE 06 06 MJE 06 07 MJE 06 08 MJE 06 09 MJE 06 0A MJE 06 0B MJE 06 0C MJE 06 0E MJE 06 0F MJE 06 F0 MJE 06 0F MJE 07 01 MJE 07 02 MJE 07 03 MJE 07 04 MJE 07 05 MJE 07 06 MJE 07 07
Fault Description Rear graphics 10 flash memory check sum failure Rear graphics 11 flash memory check sum failure Rear graphics 12 flash memory check sum failure Rear graphics 13 flash memory check sum failure Rear graphics 14 flash memory check sum failure Rear graphics 15 flash memory check sum failure Rear graphics 0 flash memory check sum failure Front font 1 flash memory check sum failure Front font 2 flash memory check sum failure Front font 3 flash memory check sum failure Front font 4 flash memory check sum failure Front font 5 flash memory check sum failure Front font 6 flash memory check sum failure Front font 7 flash memory check sum failure Front font 8 flash memory check sum failure Front font 9 flash memory check sum failure Front font 10 flash memory check sum failure Front font 11 flash memory check sum failure Front font 12 flash memory check sum failure Front font 13 flash memory check sum failure Front font 14 flash memory check sum failure Front font 15 flash memory check sum failure Front font 0 flash memory check sum failure Front graphics 1 flash memory check sum failure Front graphics 2 flash memory check sum failure Front graphics 3 flash memory check sum failure Front graphics 4 flash memory check sum failure Front graphics 5 flash memory check sum failure Front graphics 6 flash memory check sum failure Front graphics 7 flash memory check sum failure
Action Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100 Go to 41100
194
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Test Number Fault Code (Hex) MJE 07 08 MJE 07 09 MJE 07 0A MJE 07 0B MJE 07 0C MJE 07 0D MJE 07 0E MJE 07 0F MJE 07 F0 MJE 08 01 MJE 09 01 MJE 09 02 MJE 09 03 MJE 09 04 MJE 09 06 MJE 09 07 MJE 09 08 MJE 09 09 MJE 09 0A MJE 09 0B MJE 09 0C MJE 09 0D MJE 09 0E MJE 09 0F MJE 09 10 MJE 0A 01 MJE 0A 02 MJE 0A 03 MJE 0A 04 MJE 0A 06
Fault Description Front graphics 8 flash memory check sum failure Front graphics 9 flash memory check sum failure Front graphics 10 flash memory check sum failure Front graphics 11 flash memory check sum failure Front graphics 12 flash memory check sum failure Front graphics 13 flash memory check sum failure Front graphics 14 flash memory check sum failure Front graphics 15 flash memory check sum failure Front graphics 0 flash memory check sum failure Internal timer failure Rear ACIA. DCD/ not low in loop back mode Rear ACIA CTS/ not low in loop back mode Rear ACIA TDRE not high in loop back mode Rear ACIA TDRE did not go high in given time Rear ACIA RDRF not high with receive data reg full. Rear ACIA did not receive correct data in loop back mode. Rear RDRF not at 0 when data buffer empty. Rear TDRE not a logic 1. Rear TDRE not at a one after transmitting a character. Rear TDRE not zero when data register full. Rear RDRF not set with data in ACIA. Rear DATA not correct. should be a hex CC. Rear RDRF not at a one Rear incorrect data read back from the ACIA. Rear interrupt on the ACIA did not happen. Front ACIA. DCD/ not low in loop back mode Front ACIA CTS/ not low in loop back mode Front ACIA TDRE not high in loop back mode Front ACIA TDRE did not go high in given time Front ACIA RDRF not high with receive data reg full.
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Test Number Fault Code (Hex) MJE 0A 07 MJE 0A 08 MJE 0A 09 MJE 0A 0A MJE 0A 0B MJE 0A 0C MJE 0A 0D MJE 0A 0E MJE 0A 0F MJE 0A 10 MJE 0B 01 MJE 0B 02 MJE 0B 03 MJE 0B 04 MJE 0B 05 MJE 0B 06 MJE 0B 07 MJE 0B 08 MJE 0B 09 MJE 0B 0A MJE 0B 0B MJE 0B 0C MJE 0B 0D MJE 0B 0E MJE 0B 0F MJE 0B 10 MJE 0B 11 MJE 0B 12
Fault Description Front ACIA did not receive correct data in loop back mode. Front RDRF not at 0 when data buffer empty. Front TDRE not a logic 1. Front TDRE not at a one after transmitting a character. Front TDRE not zero when data register full. Front RDRF not set with data in ACIA. Front DATA not correct. should be a hex CC. Front RDRF not at a one Front incorrect data read back from the ACIA. Front interrupt on the ACIA did not happen. Rear printing bit did not initially reset in sim mode. Rear printing bit did not set when simulating printing Rear printing came too soon for Print Position 0. Rear trailing edge time incorrect for Print Position zero. Rear print complete did not get set in specified time or reset when printing went low Rear drop counter was not at zero with no characters or graphics to print Rear printing not set for Print Position 1 in specified time Rear printing time for position 1 not in tolerance Rear printing did not stop after Print Position 1 specified time Rear trailing edge time not in tolerance for Print Position 1. Rear had no data error with no data to print Rear data error did not clear upon a read Rear printing bit for Print Position 2 did not come up in specified time Rear printing bit came up too soon for Print Position 2 Rear did not get print complete within specified time Rear print complete for Print Position 2 came up too soon Rear drop counter did not have correct count for the characters printed Rear drop counter did not clear upon a read of the counter
Action Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000
196
3998 5593007
Test Number Fault Code (Hex) MJE 0B 13 MJE 0B 15 MJE 0B 14 MJE 0B 16 MJE 0B 17 MJE 0B 18 MJE 0C 01 MJE 0C 02 MJE 0C 03 MJE 0C 04 MJE 0C 05 MJE 0C 06 MJE 0C 07 MJE 0C 08 MJE 0C 09 MJE 0C 0A MJE 0C 0B MJE 0C 0C MJE 0C 0D MJE 0C 0E MJE 0C 0F MJE 0C 10 MJE 0C 11 MJE 0C 12 MJE 0C 13 MJE 0C 14
Fault Description Rear printing bit not set in specified time for Print Position 3 Rear print complete did not come up in specified time for Print Position 3 Rear printing bit came up too soon for Print Position 3 Rear print complete came up too soon for Print Position 3 Rear drop counter did have the correct count for the Print Position 3 with graphics enabled and all FFS as characters. Rear drop counter did not clear upon a read of the counter Front printing bit did not initially reset in sim mode. Front printing bit did not set when simulating printing Front printing came too soon for Print Position 0. Front trailing edge time incorrect for Print Position zero. Front print complete did not get set in specified time or reset when printing went low Front drop counter was not at zero with no characters or graphics to print Front printing not set for Print Position 1 in specified time Front printing time for position 1 not in tolerance Front printing did not stop after Print Position 1 specified time Front trailing edge time not in tolerance for Print Position 1. Front had no data error with no data to print Front data error did not clear upon a read Front printing bit for Print Position 2 did not come up in specified time Front printing bit came up too soon for Print Position 2 Front did not get print complete within specified time Front print complete for Print Position 2 came up too soon Front drop counter did not have correct count for the characters printed Front drop counter did not clear upon a read of the counter Front printing bit not set in specified time for Print Position 3 Front printing bit came up too soon for Print Position 3
Action Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 40000
3998 5593007
197
Test Number Fault Code (Hex) MJE 0C 15 MJE 0C 16 MJE 0C 17 MJE 0C 18 MJE 14 01 MJE 14 02 MJE 14 03 MJE 14 04 MJE 15 01 MJE 15 02 MJE 15 03 MJE 15 04 MJE 16 01 MJE 16 02 MJE 16 04 MJE 16 05 MJE 16 06 MJE 16 07 MJE 16 08
Fault Description Front print complete did not come up in specified time for Print Position 3 Front print complete came up too soon for Print Position 3 Front drop counter did have the correct count for the Print Position 3 with graphics enabled and all FFs as characters. Front drop counter did not clear upon a read of the counter RE-SYNC ECHO (A0) command for rear DCD not at zero when command given to module. RE-SYNC ECHO (A0) command for rear did not get RDRF within specified time RE-SYNC ECHO (A0) command for rear received a "F0" instead of the command echoed RE-SYNC ECHO (A0) command for rear did not receive the command echoed or the "F0" code RE-SYNC ECHO (A0) command for front DCD not at zero when command given to module. RE-SYNC ECHO (A0) command for front did not get RDRF within specified time RE-SYNC ECHO (A0) command for front received a "F0" instead of the command echoed RE-SYNC ECHO (A0) command for front did not receive the command echoed or the "F0" code TEST SYSTEM POWER SUPPLIES (B4 01) command for rear did not get DCD status from the ACIA TEST SYSTEM POWER SUPPLIES (B4 01) command for rear never got RDRF for command returned TEST SYSTEM POWER SUPPLIES (B4 01) command for rear time out before first byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for rear timed out before second byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for rear timed out before the third byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for rear timed out before the fourth byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for rear had communication error. Bit 7 was set in the first byte read back from the module
Action Go to 40000 Go to 40000 Go to 40000 Go to 40000 Go to 42100 Go to 42100 Go to 42100 Go to 42100 Go to 42100 Go to 42100 Go to 42100 Go to 42100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 42100
198
3998 5593007
Test Number Fault Code (Hex) MJE 16 09
Fault Description TEST SYSTEM POWER SUPPLIES (B4 01) command for rear had communication error. Bit 7 was set in the third byte read back from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for rear command echoed back was incorrect TEST SYSTEM POWER SUPPLIES (B4 01) command for rear task 01 was echoed incorrectly TEST SYSTEM POWER SUPPLIES (B4 01) command for rear had power supply out of tolerance failure. TEST SYSTEM POWER SUPPLIES (B4 01) command for rear did not get XMIT ready TEST SYSTEM POWER SUPPLIES (B4 01) command for rear did not get TDRE on second byte written to the module TEST SYSTEM POWER SUPPLIES (B4 01) command for rear did not get TDRE on last byte written to the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front did not get DCD status from the ACIA TEST SYSTEM POWER SUPPLIES (B4 01) command for front never got RDRF for command returned TEST SYSTEM POWER SUPPLIES (B4 01) command for front time out before first byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front timed out before second byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front timed out before the third byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front timed out before the fourth byte was read from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front had communication error. Bit 7 was set in the first byte read back from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front had communication error. Bit 7 was set in the third byte read back from the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front command echoed back was incorrect TEST SYSTEM POWER SUPPLIES (B4 01) command for front task 01 was echoed incorrectly
Action Go to 23100
MJE 16 0A MJE 16 0B MJE 16 0C MJE 16 11 MJE 16 12 MJE 16 13 MJE 17 01 MJE 17 02 MJE 17 04 MJE 17 05 MJE 17 06 MJE 17 07 MJE 17 08
Go to 23100 Go to 23100 Go to 19100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 42100
MJE 17 09
Go to 23100
MJE 17 0A MJE 17 0B
Go to 23100 Go to 23100
3998 5593007
199
Test Number Fault Code (Hex) MJE 17 0C MJE 17 11 MJE 17 12 MJE 17 13 MJE 18 01 MJE 18 02 MJE 18 04 MJE 18 05 MJE 18 08
Fault Description TEST SYSTEM POWER SUPPLIES (B4 01) command for front had power supply out of tolerance failure TEST SYSTEM POWER SUPPLIES (B4 01) command for front did not get XMIT ready TEST SYSTEM POWER SUPPLIES (B4 01) command for front did not get TDRE on second byte written to the module TEST SYSTEM POWER SUPPLIES (B4 01) command for front did not get TDRE on last byte written to the module UMBILICAL LOOP TEST (AE) command for rear did not get DCD status from the ACIA UMBILICAL LOOP TEST (AE) command for rear never got RDRF for command returned UMBILICAL LOOP TEST (AE) command for rear time out before first byte was read from the module UMBILICAL LOOP TEST (AE) command for rear timed out before second byte was read from the module UMBILICAL LOOP TEST (AE) command for rear had communication error. Bit 7 was set in the first byte read back from the module UMBILICAL LOOP TEST (AE) command for rear had incorrect command echoed
Action Go to 19100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
MJE 18 0A
Go to 23100
1910
3998 5593007
Fault Description UMBILICAL LOOP TEST (AE) command for rear has failed. This is the same as MTR POC command "TEST UMBILICAL". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 0 returned (SPB write) Word 1 Bit 1 returned (SPB clock) Word 1 Bit 2 returned (SPB read) Word 1 Bit 7 returned (SPB Dclock) Word 1 Bit 9 returned (drop counter) Word 1 Bit 3 returned (Low dpath) Word 1 Bit 4 returned (high dpath) Word 1 bits 5 and 6 returned (both dpath return) Word 1 Bit 5 returned (low dpath return) Word 1 Bit 6 returned (high dpath return) Word 1 Bit 8 returned (stim circuit)
Action
Go to 26120 Go to 26120 Go to 26120 Go to 26120 Go to 26120 Go to 26200 Go to 26200 Go to 26290 Go to 26300 Go to 26300 Go to 04100
MJE 19 01 MJE 19 02 MJE 1A 0A MJE 1A 10
UMBILICAL LOOP TEST (AE) command for front did not get DCD status from the ACIA UMBILICAL LOOP TEST (AE) command for front never got RDRF for command returned TEST INTERRUPT ENABLE (A1) command for rear had incorrect command echoed TEST INTERRUPT ENABLE (A1) command for rear has failed. This is the same as MTR POC command "TEST INTERRUPT ENABLE PORT". Bit map contains detailed information not applicable to this procedure TEST INTERRUPT ENABLE (A1) command for front did not get DCD status from the ACIA TEST INTERRUPT ENABLE (A1) command for front never got RDRF for command returned TEST INTERRUPT ENABLE (A1) command for front time out before first byte was read from the module TEST INTERRUPT ENABLE (A1) command for front timed out before second byte was read from the module
Go to 23100 Go to 23100 Go to 23100 Go to 35100
MJE 1B 01 MJE 1B 02 MJE 1B 04 MJE 1B 05
3998 5593007
1911
Test Number Fault Code (Hex) MJE 1B 08
Fault Description TEST INTERRUPT ENABLE (A1) command for front had communication error. Bit 7 was set in the first byte read back from the module TEST INTERRUPT ENABLE (A1) command for front had incorrect command echoed. TEST INTERRUPT ENABLE (A1) command for front has failed. This is the same as MTR POC command "TEST INTERRUPT ENABLE PORT". Bit map contains detailed information not applicable to this procedure. TEST AC RELAYS (A2) command for rear did not get DCD status from the ACIA TEST AC RELAYS (A2) command for rear never got RDRF for command returned TEST AC RELAYS (A2) command for rear time out before first byte was read from the module UMBILICAL LOOP TEST (AE) command for front time out before first byte was read from the module UMBILICAL LOOP TEST (AE) command for front timed out before second byte was read from the module UMBILICAL LOOP TEST (AE) command for front had communication error. Bit 7 was set in the first byte read back from the module
Action Go to 23100
MJE 1B 0A MJE 1B 10
Go to 23100 Go to 35100
MJE 1C 01 MJE 1C 02 MJE 1C 04 MJE 19 04 MJE 19 05 MJE 19 08
Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
1912
3998 5593007
Fault Description UMBILICAL LOOP TEST (AE) command for front has failed. This is the same as MTR POC command "TEST UMBILICAL". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 0 returned (SPB write) Word 1 Bit 1 returned (SPB clock) Word 1 Bit 2 returned (SPB read) Word 1 Bit 7 returned (SPB Dclock) Word 1 Bit 9 returned (drop counter) Word 1 Bit 3 returned (Low dpath) Word 1 Bit 4 returned (high dpath) Word 1 bits 5 and 6 returned (both dpath return) Word 1 Bit 5 returned (low dpath return) Word 1 Bit 6 returned (high dpath return) Word 1 Bit 8 returned (stim circuit)
Action
Go to 26120 Go to 26120 Go to 26120 Go to 26120 Go to 26120 Go to 26200 Go to 26200 Go to 26290 Go to 26300 Go to 26300 Go to 04100
MJE 19 0A MJE 1A 01 MJE 1A 02 MJE 1A 04 MJE 1A 05 MJE 1A 08
UMBILICAL LOOP TEST (AE) command for front had incorrect command echoed TEST INTERRUPT ENABLE (A1) command for rear did not get DCD status from the ACIA TEST INTERRUPT ENABLE (A1) command for rear never got RDRF for command returned TEST INTERRUPT ENABLE (A1) command for rear time out before first byte was read from the module TEST INTERRUPT ENABLE (A1) command for rear timed out before second byte was read from the module TEST INTERRUPT ENABLE (A1) command for rear had communication error. Bit 7 was set in the first byte read back from the module TEST AC RELAYS (A2) command for rear timed out before second byte was read from the module TEST AC RELAYS (A2) command for rear timed out before third byte was read from the module
Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
MJE 1C 05 MJE 1C 06
Go to 23100 Go to 23100
3998 5593007
1913
Test Number Fault Code (Hex) MJE 1C 07 MJE 1C 08 MJE 1C 09 MJE 1C 0A MJE 1C 10
Fault Description TEST AC RELAYS (A2) command for rear timed out before fourth byte was read from the module TEST AC RELAYS (A2) command for rear had communication error. Bit 7 was set in the first byte read back from the module TEST AC RELAYS (A2) command for rear had communication error. Bit 7 was set in the third byte read back from the module TEST AC RELAYS (A2) command for rear had incorrect command echoed TEST AC RELAYS (A2) command for rear has failed. This is the same as MTR POC command "TEST AC RELAY DRIVER". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Bit 5 in Word 1 or 2 returned (AC board disconnected) Bit 0 in Word 1 or 2 returned (vacuum relay driver) Bit 1 in Word 1 or 2 returned (ink heater driver)
Action Go to 23100 Go to 23100 Go to 23100 Go to 23100
Go to 09300 Go to 09200 Go to 09200
MJE 1D 01 MJE 1D 02 MJE 1D 04 MJE 1D 05 MJE 1D 06 MJE 1D 07 MJE 1D 08 MJE 1D 09 MJE 1D 0A
TEST AC RELAYS (A2) command for front did not get DCD status from the ACIA TEST AC RELAYS (A2) command for front never got RDRF for command returned TEST AC RELAYS (A2) command for front time out before first byte was read from the module TEST AC RELAYS (A2) command for front timed out before second byte was read from the module TEST AC RELAYS (A2) command for front timed out before third byte was read from the module TEST AC RELAYS (A2) command for front timed out before fourth byte was read from the module TEST AC RELAYS (A2) command for front had communication error. Bit 7 was set in the first byte read back from the module TEST AC RELAYS (A2) command for front had communication error. Bit 7 was set in the third byte read back from the module TEST AC RELAYS (A2) command for front had incorrect command echoed
Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
1914
3998 5593007
Test Number Fault Code (Hex) MJE 1D 10
Fault Description TEST AC RELAYS (A2) command for front has failed. This is the same as MTR POC command "TEST AC RELAY DRIVER". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Bit 5 in Word 1 or 2 returned (AC board disconnected) Bit 0 in Word 1 or 2 returned (vacuum relay driver) Bit 1 in Word 1 or 2 returned (ink heater driver)
Action
Go to 09300 Go to 09200 Go to 09200
MJE 1E 01 MJE 1E 02 MJE 1E 04
TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear did not get DCD status from the ACIA TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear never got RDRF for command returned TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear time out before first byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear timed out before second byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear timed out before third byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear timed out before fourth byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear had communication error. Bit 7 was set in the first byte read back from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear had communication error. Bit 7 was set in the third byte read back from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear had incorrect command echoed
Go to 23100 Go to 23100 Go to 23100
MJE 1E 05
Go to 23100
MJE 1E 06
Go to 23100
MJE 1E 07
Go to 23100
MJE 1E 08
Go to 23100
MJE 1E 09
Go to 23100
MJE 1E 0A
Go to 23100
3998 5593007
1915
Test Number Fault Code (Hex) MJE 1E 10
Fault Description TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for rear has failed. This is the same as MTR POC command "TEST SOLENOIDS and CATCHER HEATER DRIVERS". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 0 returned and Word 2 no bits returned (catcher heater) Word 2 Bit 0 returned and Word 1 no bits returned (catcher heater) Bit 1 in Word 1 or 2 returned (eyelid 12V) Bit 2 in Word 1 or 2 returned (eyelid 5V) Bit 3 in Word 1 or 2 returned (antisiphon valve) Bit 4 in Word 1 or 2 returned (crossflush valve) Bit 6 in Word 1 or 2 returned (ink fill) Bit 7 in Word 1 or 2 returned (replenish fill)
Action
Go to 10200 Go to 10250 Go to 10300 Go to 10300 Go to 10400 Go to 10400 Go to 10500 Go to 10600
MJE 1F 01 MJE 1F 02 MJE 1F 04
TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front did not get DCD status from the ACIA TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front never got RDRF for command returned TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front time out before first byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front timed out before second byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front timed out before third byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front timed out before fourth byte was read from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front had communication error. Bit 7 was set in the first byte read back from the module TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front had communication error. Bit 7 was set in the third byte read back from the module
Go to 23100 Go to 23100 Go to 23100
MJE 1F 05
Go to 23100
MJE 1F 06
Go to 23100
MJE 1F 07
Go to 23100
MJE 1F 08
Go to 23100
MJE 1F 09
Go to 23100
1916
3998 5593007
Test Number Fault Code (Hex) MJE 1F 10
Fault Description TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front has failed. This is the same as MTR POC command "TEST SOLENOIDS and CATCHER HEATER DRIVERS". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 0 returned and Word 2 no bits returned (catcher heater) Word 2 Bit 0 returned and Word 1 no bits returned (catcher heater) Bit 1 in Word 1 or 2 returned (eyelid 12V) Bit 2 in Word 1 or 2 returned (eyelid 5V) Bit 3 in Word 1 or 2 returned (antisiphon valve) Bit 4 in Word 1 or 2 returned (crossflush valve) Bit 6 in Word 1 or 2 returned (ink fill) Bit 7 in Word 1 or 2 returned (replenish fill)
Action
MJE 1F 0A MJE 20 01 MJE 20 02 MJE 20 04 MJE 20 05 MJE 20 06 MJE 20 07 MJE 20 08
TEST SOLENOIDS AND CATCHER HEATER OUTPUT (A3) command for front had incorrect command echoed TEST PRINT MODE CONTROL (A4) command for rear did not get DCD status from the ACIA TEST PRINT MODE CONTROL (A4) command for rear never got RDRF for command returned TEST PRINT MODE CONTROL (A4) command for rear time out before first byte was read from the module TEST PRINT MODE CONTROL (A4) command for rear timed out before second byte was read from the module TEST PRINT MODE CONTROL (A4) command for rear timed out before third byte was read from the module TEST PRINT MODE CONTROL (A4) command for rear timed out before fourth byte was read from the module TEST PRINT MODE CONTROL (A4) command for rear had communication error. Bit 7 was set in the first byte read back from the module TEST PRINT MODE CONTROL (A4) command for rear had communication error. Bit 7 was set in the third byte read back from the module
MJE 20 09
Go to 23100
3998 5593007
1917
Test Number Fault Code (Hex) MJE 20 0A MJE 20 10
Fault Description TEST PRINT MODE CONTROL (A4) command for rear had incorrect command echoed TEST PRINT MODE CONTROL (A4) command for rear has failed This is the same as MTR POC command "TEST PRINT MODE CONTROL". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 2 Bit 1 returned (sweep) Word 1 Bit 1 returned (phase line) Word 1 Bit 3 returned (print pulse line) Word 1 Bit 5 returned (latchen line) Word 1 Bit 7 returned (colreq ack line) Word 1 Bit 8 returned (print jet pwr sup ctrl) Word 1 bits 0 and 2 and 4 returned (multiple failure) Word 1 Bits 2 and 4 and 6 returned (multiple failure) Word 1 Bit 0 returned (phase line from printhead) Word 1 Bit 2 returned (print pulse line from printhead) Word 1 Bit 4 returned (latchen line from printhead) Word 1 Bit 6 returned (colreq line) Word 1 Bit 9 returned (dac not controllable) Word 1 Bit 10 returned (curr det or chg volt on signal) Word 1 Bit 11 returned (curr det not on) Word 1 Bit 12 returned ([2] lsbs of dac) Word 1 Bit 13 returned (chg relay stuck on) Word 2 Bit 0 returned (curr fault interrupt)
Action Go to 23100
Go to 25140 Go to 25200 Go to 25200 Go to 25200 Go to 25140 Go to 25200 Go to 25450 Go to 25450 Go to 25250 Go to 25250 Go to 25250 Go to 25400 Go to 25700 Go to 25600 Go to 25600 Go to 25700 Go to 25120 Go to 25140
MJE 21 01 MJE 21 02 MJE 21 04 MJE 21 05
TEST PRINT MODE CONTROL (A4) command for front did not get DCD status from the ACIA TEST PRINT MODE CONTROL (A4) command for front never got RDRF for command returned TEST PRINT MODE CONTROL (A4) command for front time out before first byte was read from the module TEST PRINT MODE CONTROL (A4) command for front timed out before second byte was read from the module
1918
3998 5593007
Test Number Fault Code (Hex) MJE 21 06 MJE 21 07 MJE 21 08
Fault Description TEST PRINT MODE CONTROL (A4) command for front timed out before third byte was read from the module TEST PRINT MODE CONTROL (A4) command for front timed out before fourth byte was read from the module TEST PRINT MODE CONTROL (A4) command for front had communication error. Bit 7 was set in the first byte read back from the module TEST PRINT MODE CONTROL (A4) command for front had communication error. Bit 7 was set in the third byte read back from the module TEST PRINT MODE CONTROL (A4) command for front had incorrect command echoed TEST PRINT MODE CONTROL (A4) command for front has failed This is the same as MTR POC command "TEST PRINT MODE CONTROL". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 2 Bit 1 returned (sweep) Word 1 Bit 1 returned (phase line) Word 1 Bit 3 returned (print pulse line) Word 1 Bit 5 returned (latchen line) Word 1 Bit 7 returned (colreq ack line) Word 1 Bit 8 returned (print jet pwr sup ctrl) Word 1 bits 0 and 2 and 4 (returned multiple failure) Word 1 Bits 2 and 4 and 6 returned (multiple failure) Word 1 Bit 0 returned (phase line from printhead) Word 1 Bit 2 returned (print pulse line from printhead) Word 1 Bit 4 returned (latchen line from printhead) Word 1 Bit 6 returned (colreq line) Word 1 Bit 9 returned (dac not controllable) Word 1 Bit 10 returned (curr det or chg vlt on signal) Word 1 Bit 11 returned (curr det not on) Word 1 Bit 12 returned ([2] lsbs of dac) Word 1 Bit 13 returned (chg relay stuck on) Word 2 Bit 0 returned (curr fault interrupt)
Action Go to 23100 Go to 23100 Go to 23100
MJE 21 09
Go to 23100
MJE 21 0A MJE 21 10
Go to 23100
Go to 25140 Go to 25200 Go to 25200 Go to 25200 Go to 25140 Go to 25200 Go to 25450 Go to 25450 Go to 25250 Go to 25250 Go to 25250 Go to 25400 Go to 25700 Go to 25600 Go to 25600 Go to 25700 Go to 25120 Go to 25140
3998 5593007
1919
Test Number Fault Code (Hex) MJE 22 01 MJE 22 02 MJE 22 04 MJE 22 05 MJE 22 06 MJE 22 07 MJE 22 08
Fault Description SOLENOID MOTION TEST (A9) command for rear did not get DCD status from the ACIA SOLENOID MOTION TEST (A9) command for rear never got RDRF for command returned SOLENOID MOTION TEST (A9) command for rear time out before first byte was read from the module SOLENOID MOTION TEST (A9) command for rear timed out before second byte was read from the module SOLENOID MOTION TEST (A9) command for rear timed out before third byte was read from the module SOLENOID MOTION TEST (A9) command for rear timed out before fourth byte was read from the module SOLENOID MOTION TEST (A9) command for rear had communication error. Bit 7 was set in the first byte read back from the module SOLENOID MOTION TEST (A9) command for rear had communication error. Bit 7 was set in the third byte read back from the module SOLENOID MOTION TEST (A9) command for rear had incorrect command echoed
Action Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
MJE 22 09
Go to 23100
MJE 22 0A
Go to 23100
1920
3998 5593007
Fault Description SOLENOID MOTION TEST (A9) command for rear has failed. This is the same as MTR POC command "TEST SOLENOID MOTION". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 2 returned and Word 2 Bit 0 not returned (eyelid ckt) Word 1 Bit 3 returned and Word 2 Bit 1 not returned (antisiphon ckt) Word 1 Bit 4 returned and Word 2 Bit 2 not returned (crossflush ckt) Word 1 Bit 6 returned and Word 2 Bit 4 not returned (fill ckt) Word 1 Bit 7 returned and Word 2 Bit 3 not returned (replen ckt) Word 1 Bit 1 returned (eyelid drvr) Word 1 Bit 2 returned (eyelid disconn) Word 1 Bit 3 returned (antisiphon disconn) Word 1 Bit 4 returned (crossflush disconn) Word 1 Bit 6 returned (fill disconn) Word 1 Bit 7 returned (replen disconn) Word 2 Bits 0 thru 4, more than 1 returned (motion ckt bad) Word 2 Bit 0 returned (eyelid motion) Word 2 Bit 1 returned (antisiphon motion) Word 2 Bit 2 returned (crossflush motion) Word 2 Bit 3 returned (replen motion) Word 2 Bit 4 returned (fill motion)
Action
Go to 11150 Go to 11150 Go to 11150 Go to 11150 Go to 11150 Go to 11150 Go to 11400 Go to 11500 Go to 11600 Go to 11700 Go to 11800 Go to 11150 Go to 11200 Go to 11240 Go to 11260 Go to 11280 Go to 11300 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
MJE 23 01 MJE 23 02 MJE 23 04 MJE 23 05 MJE 23 06 MJE 23 0A
SOLENOID MOTION TEST (A9) command for front did not get DCD status from the ACIA SOLENOID MOTION TEST (A9) command for front never got RDRF for command returned SOLENOID MOTION TEST (A9) command for front time out before first byte was read from the module SOLENOID MOTION TEST (A9) command for front timed out before second byte was read from the module SOLENOID MOTION TEST (A9) command for front timed out before third byte was read from the module SOLENOID MOTION TEST (A9) command for front had incorrect command echoed
3998 5593007
1921
Fault Description SOLENOID MOTION TEST (A9) command for front has failed. This is the same as MTR POC command "TEST SOLENOID MOTION". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 2 returned and Word 2 Bit 0 not returned (eyelid ckt) Word 1 Bit 3 returned and Word 2 Bit 1 not returned (antisiphon ckt) Word 1 Bit 4 returned and Word 2 Bit 2 not returned (crossflush ckt) Word 1 Bit 6 returned and Word 2 Bit 4 not returned (fill ckt) Word 1 Bit 7 returned and Word 2 Bit 3 not returned (replen ckt) Word 1 Bit 1 returned (eyelid drvr) Word 1 Bit 2 returned (eyelid disconn) Word 1 Bit 3 returned (antisiphon disconn) Word 1 Bit 4 returned (crossflush disconn) Word 1 Bit 6 returned (fill disconn) Word 1 Bit 7 returned (replen disconn) Word 2 Bits 0 thru 4, more than 1 returned (motion ckt bad) Word 2 Bit 0 returned (eyelid motion) Word 2 Bit 1 returned (antisiphon motion) Word 2 Bit 2 returned (crossflush motion) Word 2 Bit 3 returned (replen motion) Word 2 Bit 4 returned (fill motion)
Action
Go to 11150 Go to 11150 Go to 11150 Go to 11150 Go to 11150 Go to 11150 Go to 11400 Go to 11500 Go to 11600 Go to 11700 Go to 11800 Go to 11150 Go to 11200 Go to 11240 Go to 11260 Go to 11280 Go to 11300 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
MJE 24 01 MJE 24 02 MJE 24 04 MJE 24 05 MJE 24 08
INK PUMP/TRANSDUCER TEST (AA) command for rear did not get DCD status from the ACIA INK PUMP/TRANSDUCER TEST (AA) command for rear never got RDRF for command returned INK PUMP/TRANSDUCER TEST (AA) command for rear time out before first byte was read from the module INK PUMP/TRANSDUCER TEST (AA) command for rear timed out before second byte was read from the module INK PUMP/TRANSDUCER TEST (AA) command for rear had communication error. Bit 7 was set in the first byte read back from the module INK PUMP/TRANSDUCER TEST (AA) command for rear had incorrect command echoed
MJE 24 0A
Go to 23100
1922
3998 5593007
Fault Description INK PUMP/TRANSDUCER TEST (AA) command for rear has failed. This is the same as MTR POC command "TEST INK PUMP/TRANSDUCER". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bits 1 and 3 returned (pump volt & curr low) Word 1 Bits 2 and 7 returned (xducer buffer & pump curr high) Word 1 Bit 0 returned (pump volt high) Word 1 Bit 1 returned (pump volt low) Word 1 Bit 2 returned (pump curr high) Word 1 Bit 3 returned (pump curr low) Word 1 Bit 6 returned (xducer buffer offset) Word 1 Bit 7 returned (xducer buffer output) Word 1 Bit 4 returned (xducer offset high) Word 1 Bit 5 returned (xducer offset low)
Action
Go to 20115 Go to 20120 Go to 20115 Go to 20115 Go to 20900 Go to 20900 Go to 20115 Go to 20115 Go to 20200 Go to 20300
MJE 25 01
INK PUMP/TRANSDUCER TEST (AA) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. INK PUMP/TRANSDUCER TEST (AA) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. INK PUMP/TRANSDUCER TEST (AA) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. INK PUMP/TRANSDUCER TEST (AA) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE.
Go to 45000
MJE 25 02
Go to 45000
MJE 25 04
Go to 45000
MJE 25 05
Go to 45000
3998 5593007
1923
Fault Description INK PUMP/TRANSDUCER TEST (AA) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. INK PUMP/TRANSDUCER TEST (AA) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. INK PUMP/TRANSDUCER TEST (AA) command for front has failed. This is the same as MTR POC command "TEST INK PUMP/TRANSDUCER". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bits 1 and 3 returned (pump volt & curr low) Word 1 Bits 2 and 7 returned (xducer buffer & pump curr high) Word 1 Bit 0 returned (pump volt high) Word 1 Bit 1 returned (pump volt low) Word 1 Bit 2 returned (pump curr high) Word 1 Bit 3 returned (pump curr low) Word 1 Bit 6 returned (xducer buffer offset) Word 1 Bit 7 returned (xducer buffer output) Word 1 Bit 4 returned (xducer offset high) Word 1 Bit 5 returned (xducer offset low)
Action Go to 45000
MJE 25 0A
Go to 45000
MJE 25 10
Go to 20115 Go to 20120 Go to 20115 Go to 20115 Go to 20900 Go to 20900 Go to 20115 Go to 20115 Go to 20200 Go to 20300
MJE 26 01 MJE 26 02 MJE 26 04
POSITIVE AIR PUMP TEST (AC) command for rear did not get DCD status from the ACIA POSITIVE AIR PUMP TEST (AC) command for rear never got RDRF for command returned POSITIVE AIR PUMP TEST (AC) command for rear time out before first byte was read from the module
Go to 23100 Go to 23100 Go to 23100
1924
3998 5593007
Multi-Jet Endorser Manual Procedures
Test Number Fault Code (Hex) MJE 26 05 MJE 26 08
Fault Description POSITIVE AIR PUMP TEST (AC) command for rear timed out before second byte was read from the module POSITIVE AIR PUMP TEST (AC) command for rear had communication error. Bit 7 was set in the first byte read back from the module POSITIVE AIR PUMP TEST (AC) command for rear had incorrect command echoed POSITIVE AIR PUMP TEST (AC) command for rear has failed. This is the same as MTR POC command "TEST POSITIVE AIR SYSTEM". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 2 returned (pos air not sensed) Word 1 Bit 3 returned (tank temp out of range) Word 1 Bit 4 returned (p.h. temp out of range) Word 1 Bit 5 returned (a spill sensor) Word 1 Bit 6 returned (tank too full switch) Word 1 Bit 7 returned (catcher heater drvr fail) Word 1 Bit 8 returned (catcher heater open) Word 1 Bit 9 returned (catcher heater stuck on) Word 1 Bit 10 returned (catcher voltage stuck on)
Action Go to 23100 Go to 23100
MJE 26 0A MJE 26 10
Go to 23100
MJE 27 01 MJE 27 02 MJE 27 04 MJE 27 05 MJE 27 08
POSITIVE AIR PUMP TEST (AC) command for front did not get DCD status from the ACIA POSITIVE AIR PUMP TEST (AC) command for front never got RDRF for command returned POSITIVE AIR PUMP TEST (AC) command for front time out before first byte was read from the module POSITIVE AIR PUMP TEST (AC) command for front timed out before second byte was read from the module POSITIVE AIR PUMP TEST (AC) command for front had communication error. Bit 7 was set in the first byte read back from the module POSITIVE AIR PUMP TEST (AC) command for front had incorrect command echoed
Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
MJE 27 0A
Go to 23100
3998 5593007
1925
Fault Description POSITIVE AIR PUMP TEST (AC) command for front has failed. This is the same as MTR POC command "TEST POSITIVE AIR SYSTEM". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 1 Bit 2 returned (pos air not sensed) Word 1 Bit 3 returned (tank temp out of range) Word 1 Bit 4 returned (p.h. temp out of range) Word 1 Bit 5 returned (a spill sensor) Word 1 Bit 6 returned (tank too full switch) Word 1 Bit 7 returned (catcher heater drvr fail) Word 1 Bit 8 returned (catcher heater open) Word 1 Bit 9 returned (catcher heater stuck on) Word 1 Bit 10 returned (catcher voltage stuck on)
Action
MJE 28 01 MJE 28 02 MJE 28 04 MJE 28 05 MJE 28 06 MJE 28 07 MJE 28 08
VACUUM PUMP TEST (AD) command for rear did not get DCD status from the ACIA VACUUM PUMP TEST (AD) command for rear never got RDRF for command returned VACUUM PUMP TEST (AD) command for rear time out before first byte was read from the module VACUUM PUMP TEST (AD) command for rear timed out before second byte was read from the module VACUUM PUMP TEST (AD) command for rear timed out before third byte was read from the module VACUUM PUMP TEST (AD) command for rear timed out before fourth byte was read from the module VACUUM PUMP TEST (AD) command for rear had communication error. Bit 7 was set in the first byte read back from the module VACUUM PUMP TEST (AD) command for rear had communication error. Bit 7 was set in the third byte read back from the module VACUUM PUMP TEST (AD) command for rear had incorrect command echoed
Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100
MJE 28 09
Go to 23100
MJE 28 0A
Go to 23100
1926
3998 5593007
Fault Description VACUUM PUMP TEST (AD) command for rear has failed. This is the same as MTR POC command "TEST VACUUM SYSTEM". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 2 bits 0,1,2,3 returned (multiple stpr drvr failure) Word 2 Bit 0 returned (stpr drvr winding 1) Word 2 Bit 1 returned (stpr drvr winding 2) Word 2 Bit 2 returned (stpr drvr winding 3) Word 2 Bit 3 returned (stpr drvr winding 4) Word 2 Bit 4 returned (stpr winding 1 open) Word 2 Bit 5 returned (stpr winding 2 open) Word 2 Bit 6 returned (stpr winding 3 open) Word 2 Bit 7 returned (stpr winding 4 open) Word 1 Bit 5 returned (vac buf amp) Word 1 Bit 0 returned (xducer offset high) Word 1 Bit 2 returned (xducer offset low) Word 1 Bit 1 returned (vac too high w/valve open) Word 1 Bit 3 returned (vac too low w/valve closed) Word 1 Bit 4 returned (vac too high w/valve closed) No bits returned ( default)
Action
Go to 02700 Go to 02170 Go to 02170 Go to 02170 Go to 02170 Go to 02500 Go to 02500 Go to 02500 Go to 02500 Go to 02170 Go to 02200 Go to 02400 Go to 02800 Go to 02550 Go to 02300 Go to 02950
MJE 29 01
VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE.
Go to 45000
MJE 29 02
Go to 45000
MJE 29 04
Go to 45000
3998 5593007
1927
Fault Description VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE. VACUUM PUMP TEST (AD) This fault is associated with the Front MJE. Critical timings cause the Front MJE to be configured as a Rear MJE in the preceding manual procedures. The POC is then executed again to isolate the problem on the Front MJE.
Action Go to 45000
MJE 29 06
Go to 45000
MJE 29 07
Go to 45000
MJE 29 08
Go to 45000
MJE 29 09
Go to 45000
MJE 29 0A
Go to 45000
1928
3998 5593007
Fault Description VACUUM PUMP TEST (AD) command for front has failed. This is the same as MTR POC command "TEST VACUUM SYSTEM". Bit map contains further information (bit meanings are listed here in abbreviated form; full descriptions are listed in the "Command Names and Descriptions" subsection). Word 2 bits 0,1,2,3 returned (multiple stpr drvr failure) Word 2 Bit 0 returned (stpr drvr winding 1) Word 2 Bit 1 returned (stpr drvr winding 2) Word 2 Bit 2 returned (stpr drvr winding 3) Word 2 Bit 3 returned (stpr drvr winding 4) Word 2 Bit 4 returned (stpr winding 1 open) Word 2 Bit 5 returned (stpr winding 2 open) Word 2 Bit 6 returned (stpr winding 3 open) Word 2 Bit 7 returned (stpr winding 4 open) Word 1 Bit 5 returned (vac buf amp) Word 1 Bit 0 returned (xducer offSet high) Word 1 Bit 2 returned (xducer offset low) Word 1 Bit 1 returned (vac too high w/valve open) Word 1 Bit 3 returned (vac too low w/valve closed) Word 1 Bit 4 returned (vac too high w/valve closed) No bits returned ( default)
Action
Go to 02700 Go to 02170 Go to 02170 Go to 02170 Go to 02170 Go to 02500 Go to 02500 Go to 02500 Go to 02500 Go to 02170 Go to 02200 Go to 02400 Go to 02800 Go to 02550 Go to 02300 Go to 02950
MJE 2A 01 MJE 2B 01 MJE 2B 02 MJE 2B 03 MJE 2C 01 MJE 2C 02 MJE 70 01 MJE 70 02 MJE 70 03
Dual port RAM failed readCLR/motor signal test failed. MJE ready signal test failed. MJE ready signal test failed. Unexpected exception occurred. MJE time out occurred waiting for the MJE interface (AA09) to respond. Streaker hardware is not present MJE interface (AA09) failed to respond to the streaker command Streaker test failed. a streaker has been detected. No streak should be present at this time.
3998 5593007
1929
Test Number Fault Code (Hex) MJE 70 04 MJE 70 05 MJE 70 06 MJE 70 07 MJE 71 01 MJE 71 02 MJE 71 03 MJE 71 04 MJE 71 05 MJE 71 06 MJE 71 07 MJE 71 08 MJE 71 09 MJE 71 0A MJE 71 0B MJE 71 0C MJE 71 0D MJE 71 0E MJE 71 0F MJE 71 10 MJE 71 11 MJE 71 12 MJE 71 13 MJE 71 14 MJE 71 15
Fault Description Streaker test failed. No streak has been detected. a streak should be present at this time. An overflow has been detected. Streaker board reported present and should not be. MJE interface (AA09) failed to respond to the column print command. An invalid response was received from the MJE module after issuing the reset command. The data received from the MJE is not a valid response. MJE failed to bar down after a run time error occurred. Run time error/warning detected but not available. MJE interface (AA09) failed to enter M&D mode. Time out occurred while waiting for the MJE interface (AA09) to respond to an M&D extended command. a serial communications error occurred MJE interface (AA09) timed out waiting for the MJE to respond. The result status received from MJE interface (AA09) is not valid. MJE interface (AA09) failed to block unsolicited runtime error response($EF). The task number returned from the MJE is not the task that was issued. No command/test code was received from the MJE. An invalid command/test code was received from the MJE. Framing error occurred. Receiver overrun occurred. Parity error occurred. time out occurred waiting for bar up to complete. MJE interface (AA09) failed to respond to clear not ready command. MJE interface (AA09) detected a run time error but no errors were available in dual port RAM. MJE interface (AA09) failed to exit M & D mode. MJE interface (AA09) detected an unexpected interrupt.
Action Go to 43100 Go to 43100 Go to 43200 Go to 40000 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 40000 Go to 40000 Go to 23100 Go to 23100 Go to 40000 Go to 40000 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 23100 Go to 40000 Go to 23100 Go to 40000 Go to 40000
1930
3998 5593007
Test Number Fault Code (Hex) MJE 71 16 MJE 71 17 MJE 72 01 MJE 80 00 MJE 80 3F MJE 80 40 MJE 80 41 MJE 80 42 MJE 80 43 MJE 80 44 MJE 80 45 MJE 80 46 MJE 80 47 MJE 80 49 MJE 80 4C MJE 80 4D MJE 80 4F MJE 80 50 MJE 80 51 MJE 80 52 MJE 80 53 MJE 80 54 MJE 80 55 MJE 80 56 MJE 80 57 MJE 80 58 MJE 80 59 MJE 80 5A MJE 80 5B MJE 80 5C
Fault Description MJE interface (AA09) detected an illegal opcode. Serial interface is out of sync. Unexpected bus exception occurred while accessing address $XXXXXXXX. Invalid run time error occurred. Eyelid solenoid failure Positive air pump not working Vacuum system not working Print jet short Stimulation under amplitude Stimulation over amplitude Power failure detected by IJC Vacuum system restricted Ink spill in printer Maximum state time exceeded Catcher heater driver failed Catcher heater open Ink pressure high Ink pressure low Printhead ink temperature high Printhead ink temperature low Ink tank temperature high Ink tank temperature low Anti siphon valve did not open Crossflush valve did not open Print jet power supply failure Ink pump current high Ink pump current low Ink pump volts high Ink pump volts low Ink fill valve did not open
3998 5593007
1931
Test Number Fault Code (Hex) MJE 80 5D MJE 80 5E MJE 80 61 MJE 80 63 MJE 80 64 MJE 80 70 MJE 80 71 MJE 80 72 MJE 80 73 MJE 80 74 MJE 80 75 MJE 80 80 MJE 80 99 MJE 80 EF MJE 80 F0 MJE 90 A1 MJE 90 A2 MJE 90 A3 MJE 90 A4 MJE 90 A7 MJE 90 A9 MJE 90 AA MJE 90 AC MJE 90 AD MJE 90 AE MJE B4 01 MJE B4 0B Ink tank level high Ink fluid low error
Fault Description
Action Go to 16100 Go to 17100 Go to 04100 Go to 22100 Go to 11100 Go to 18100 Go to 11100 Go to 19100 Go to 44000 Go to 24100 Go to 33100 Go to 31100 Go to 34100 Go to 40100 Go to 36100 Go to 35100 Go to 09100 Go to 10100 Go to 25100 Go to 44000. Go to 11100 Go to 20100 Go to 01100 Go to 02100 Go to 26100 Go to 19100 Go to 21100
Printhead control failed Ink will not warm up Eyelid control failed Replenish fluid low error Replenish solenoid failed motion test Brown out occurred Watch dog circuit disabled BRAM failed Multiple solenoid motion failure If after 15 seconds command re-sync echo (A0) issued and no response A to D control failure Unsolicited run time error occurred. Improper data sent to printer or error code (EF) pending Print jet short interrupt failed. AC relay test failed. Solenoid and catcher heater output test failed. Print mode control test failed. 7-segment display test failed. Solenoid motion test failed. Ink pump/transducer test failed. Positive air system test failed. Vacuum system/stepper motor test failed. Umbilical test failed. Extended diagnostic routine 01 failed. Extended diagnostic routine 11 failed.
1932
3998 5593007
Run Time Fault Code Definitions

Table 192. Run Time Fault Code Definitions
Fault Code (hex) 3F 40 41 42 43 44 45 46 47 49 4C 4D 4F 50 51 52 53 54 55 56 57 58 59 5A 5B 5C 5D
FAULT DESCRIPTION Eyelid solenoid failure Positive air pump not working Vacuum system not working Print jet short Stimulation under amplitude Stimulation over amplitude Power failure detected by IJC Vacuum system restricted Ink spill in printer Maximum state time exceeded Catcher heater driver failed Catcher heater open Ink pressure high Ink pressure low Printhead ink temperature high Printhead ink temperature low Ink tank temperature high Ink tank temperature low Anti siphon valve did not open Crossflush valve did not open Print jet power supply failure Ink pump current high Ink pump current low Ink pump volts high Ink pump volts low Ink fill valve did not open Ink tank level high
ACTION Go to 11100 Go to 29100 Go to 02100 Go to 03100 Go to 04100 Go to 04100 Go to 19100 Go to 02900 Go to 06100 Go to 37100 Go to 01100 Go to 01100 Go to 27100 Go to 28100 Go to 12100 Go to 13100 Go to 14100 Go to 15100 Go to 11100 Go to 11100 Go to 05100 Go to 30100 Go to 32100 Go to 20400 Go to 20500 Go to 11100 Go to 16100
3998 5593007
1933
Table 192. Run Time Fault Code Definitions
Fault Code (hex) 5E 61 63 64 70 71 72 73 74 75 99 EF F0 Ink fluid low error
FAULT DESCRIPTION
ACTION Go to 17100 Go to 04100 Go to 22100 Go to 11100 Go to 18100 Go to 11100 Go to 19100 Go to 44000 Go to 24100 Go to 33100 Go to 34100 Go to 40100 Go to 36100
Printhead control failed Ink will not warm up Eyelid control failed Replenish fluid low error Replenish solenoid failed motion test Brown out occurred Watch dog circuit disabled BRAM failed Multiple solenoid motion failure A to D control failure Unsolicited run time error occurred. Improper data sent to printer or error code (EF) pending
1934
3998 5593007
MJE Manual Procedures

Note: Step 66600 indicates the end of the operation. Verify the operation at that step. Table 193. MJE Manual Procedures
STEP 01100
ACTION Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass?
YES
NO
01150
09100
01150
Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. If no Bits returned Word 1 Bit 2 returned (POs air not sensed) Word 1 Bit 3 returned (tank temp out of range) Word 1 Bit 4 returned (p. temp out of range) Word 1 Bit 5 returned (a spill sensor) Word 1 Bit 6 returned (tank too full switch) Word 1 Bit 7 returned (catcher heater driver fail) Word 1 Bit 8 returned (catcher heater open) Word 1 Bit 9 returned (catcher heater stuck on) Word 1 Bit 10 returned (catcher voltage stuck on) Look at NE4 light on AC supply PCBA assembly. Is it on?
66500 01400 01500 01500 06100 16100 07100 08100 01800 01900
01400
01410 01700
19100 01430
01410 01430
Is the positive air pump running? (Feel the port with the filter. Is it pulling a vacuum?) Unplug positive air pump and measure the voltage across pins 1 and 3 on AC cable fluid system assembly Does it measure between 100 and 123?
01440
01450
01440
Replace air pump assembly and rerun test. Does the problem still exist? 66500 66600
01450
Unplug J8 on AC supply PCBA assembly and measure voltage across pins 6 and 12 on AC supply PCBA assembly? Does it measure between 100 and 123? 01460 19410
01460
Reconnect J8 on AC supply PCBA assembly and unplug AC fluid system bulkhead connector. Measure voltage across pins 6 and 12 on disconnected cable. Does it measure between 100 and 123? 01470 01480
01470
Replace AC cable fluid system assembly and rerun test. Does the problem still exist? 66500 66600
3998 5593007
1935
Table 193. MJE Manual Procedures
STEP 01480
ACTION Replace AC cable board to fluid system and rerun test. Does the problem still exist?
YES
NO
66500
66600
01500
Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Did it return MJE 80 51? Did it return MJE 80 52? Did it return MJE 80 53? Did it return MJE 80 54? Did it return any of the above codes? 12100 13100 14100 15100 66600
01600
Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 01620 09100
01620
Primary suspect: AC supply PCBA assembly. Secondary suspect: AC to DC board cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
01700
Install JP1 in place of pressure switch and Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Did it return Word 1 Bit 2? 01730 01720
1936
3998 5593007
STEP 01720
ACTION Unscrew tubing nut that the pressure switch is attached to. Install tube #1 from vacuum transducers open port (this is P2) to port where pressure switch was installed. Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 10) (10) (optional r/f selection) *get results* <specify>. Did it read above 7?
YES
NO
01725 01725 Remove JP1 & tube #1. Replace pressure switch assembly and rerun test. Does the problem still exist? 01730 Remove JP1 and connect pressure switch. Primary suspect: Ink jet controller PCBA assembly. Secondary suspect DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 01740 Unscrew filter on positive air pump. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 10) (10) (optional r/f selection) *get results* <specify>. Did it read above 7? 01760 01760 Remove JP1, tube #1 and connect pressure switch. Replace filter POs air and rerun test. Does the problem still exist? 01780 Remove JP1, tube #1 and connect pressure switch. Replace air pump assembly and rerun test. Does the problem still exist? 66500 66500 66500 66500
01740
66600
66600
01780
66600
66600
3998 5593007
1937
STEP 01800
ACTION Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass?
YES
NO
01820
01840
01820
Primary suspect: AC supply PCBA assembly. Secondary suspect: Ink jet controller PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
01840
Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: AC supply PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
01900
Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <specify>. Did it pass? 01920 01940
01920
Primary suspect: AC supply PCBA assembly. Secondary suspect: Ink jet controller PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
01940
Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: AC supply PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
02100
Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <specify>. Did it pass? 02150 19100
1938
3998 5593007
STEP 02150
ACTION Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Word 2 Bits 0 through 3 (multiple stpr driver failure) Word 2 Bit 0 returned (stpr driver winding 1) Word 2 Bit 1 returned (stpr driver winding 2) Word 2 Bit 2 returned (stpr driver winding 3) Word 2 Bit 3 returned (stpr driver winding 4) Word 2 Bit 4 returned (stpr winding 1 open) Word 2 Bit 5 returned (stpr winding 2 open) Word 2 Bit 6 returned (stpr winding 3 open) Word 2 Bit 7 returned (stpr winding 4 open) Word 1 Bit 5 returned (vac buf amp) Word 1 Bit 0 returned (xducer offset high) Word 1 Bit 2 returned (xducer offset low) Word 1 Bit 1 returned (vac too high w/valve open) Word 1 Bit 3 returned (vac too low w/valve closed) Word 1 Bit 4 returned (vac too high w/valve closed) If no Bits returned (default)
YES
NO
02700 02170 02170 02170 02170 02500 02500 02500 02500 02170 02200 02400 02800 02550 02300 and 02950
02170
Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 66500 02260 66600 02220
02200 02220
Is vacuum pump running? (Is there air blowing out of the pumps open port?) Unplug vacuum transducer. Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 0 occur?
02230 02230 Reconnect vacuum transducer, replace ink jet controller PCBA assembly, and rerun test. Does the problem still exist? 02240 Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <specify>. Did it pass? 02250 02245 02250 Reconnect vacuum transducer and Go to step 19100 Replace vacuum transducer assembly and rerun test. Does the problem still exist? 02260 Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 02280 66500 66500
02240
66600
02245
66600
09100
3998 5593007
1939
STEP 02280
ACTION Replace AC supply PCBA assembly and rerun test. Does the problem still exist?
YES
NO
66500
66600
02300
Look at catcher line connector in printhead. Is it connected ? 02320 02310
02310
Connect catcher line connector and Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Did it pass? 66600 02320
02320
Disconnect catcher line from catcher and Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Did it pass? 02325 02330
02325
Replace printhead assembly and rerun test. Does the problem still exist? 66500 66600
02330
Reconnect catcher line & look for pinched catcher line. Is catcher line pinched? 66600 66500
02400
Primary suspect: Vacuum transducer assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
02500
Primary suspect: Vacuum control assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
02550
Select (RUN TIME COMMANDS) (BAR UP TO STATE 0) (Y) (optional r/f selection) (0) *wait for completion* <specify>. Did it make it? 02570 02560
02560
Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Go fix the run time error
1940
3998 5593007
STEP 02570
ACTION Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Were there any?
YES
NO
02580 02580 02600 Go fix the run time error. Select (RUN TIME COMMANDS) (BAR UP TO STATE 1) (Y) (optional r/f selection) (1) *wait for completion* <specify>. Is the vacuum pump running? (Is there air blowing out of the pumps open port?) 02610 Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Remove mist box filter and replace lid. Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 3 occur? 02620 02615 Replace filter-filter box and rerun test. Does the problem still exist? 02620 Replace mist box filter. Plug fitting at filter box where vacuum control assembly is connected with tube #2. Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 3 occur? 02690 02625 Remove tube #2 & replace vacuum control assembly and rerun test. Does the problem still exist? 02630 Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 02640 02645 Check NE4 light on AC supply PCBA assembly. Is it on? Select (RUN TIME COMMANDS) (BAR UP TO STATE 0) (Y) (optional r/f selection) (0) *wait for completion* <specify>. Did it make it? 02640 02645 66500 66500 02610
02600
02630
02615
66600
02625
66600
09100 19100
02650
02560
3998 5593007
1941
STEP 02650
ACTION Select (RUN TIME COMMANDS) (BAR UP TO STATE 1) (Y) (optional r/f selection) (1) *wait for completion* <specify>. Look at LED DS5 on AC supply PCBA assembly. Is it on?
YES
NO
02660
02680
02660
Look at NE4 light on AC supply PCBA assembly. Is it on? 02670 02663
02663
Replace the AC supply PCBA assembly and rerun test. Does the problem still exist? 66500 66600
02670
Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Primary suspect: Vacuum pump assembly. Secondary suspect: AC cable-board to fluid system or AC cable fluid system assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
02680
Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Primary suspect: AC supply PCBA assembly. Secondary suspect: AC to DC board cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
02690
Remove tube #2. Primary suspect: Vacuum pump assembly. Secondary suspect: Vacuum line loose or cut or vacuum transducer assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
02700
Disconnect J9 on Ink jet controller PCBA assembly. Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Does the same fault Word 2 Bits 0 through 3 occur? 02710 02760
1942
3998 5593007
STEP 02710
ACTION Unplug vacuum control assembly. Check for shorts between pin 1 to pin 3, 4, 5, & 6 and pin 2 to pin 3, 4, 5, & 6 on the connector on the fluid system. Were there any?
YES
NO
02720
02730
02720
Unplug DC cable-board to fluid system at fluid system bulkhead. Check for shorts between pin 1 to pin 3, 4, 5, & 6 and pin 2 to pin 3, 4, 5, & 6 on the vacuum valve connector on the fluid system. Were there any? 02740 02750
02730
Replace Ink jet controller PCBA assembly and vacuum control assembly and rerun test. Does problem still exist? 66500 66600
02740
Replace Ink jet controller PCBA assembly and DC cable-fluid system assembly and rerun test. Does problem still exist? 66500 66600
02750
Connect vacuum control assembly. Replace Ink jet controller PCBA assembly and DC cable-board to fluid system and rerun test. Does problem still exist? 66500 66600
02760
Connect J9 on Ink jet controller PCBA assembly. Primary suspect: Vacuum control assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
02800
Unscrew filter on vacuum control assembly. Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Did the same fault Word 1 Bit 1 occur? 02820 02840
02820
Replace vacuum control assembly and rerun test. Does the problem still exist? 66500 66600
02840
Replace filter vacuum control assembly and rerun test. Does the problem still exist? 66500 66600
3998 5593007
1943
STEP 02900
ACTION Select (POC COMMANDS) (TEST VACUUM SYSTEM/STEPPER motor) (optional r/f selection) *get results* <specify>. Did it pass?
YES
NO
02910 02910 Unscrew filter on vacuum control assembly. Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <specify>. Did the same fault code MJE 80 46 occur? 02920 02920 Replace vacuum control assembly and rerun test. Does the problem still exist? 02940 Replace filter vacuum control assembly and rerun test. Does the problem still exist? 02950 03100 Primary suspect: Filter-filter box. Secondary suspect: Vacuum pump assembly. Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Does it pass? 03120 Disconnect paddle card at printhead. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 11) (11) (optional r/f selection) *get results* <specify>. Word 1 Bit 7 (printhead is connected but should not be connected for this test, cancel test) Word 1 Bit 1 (current detect line active and it should not be) Word 1 Bit 2 (current fault line active and it should not be) Word 1 Bit 3 (current detect line not active and it should be) Word 1 Bit 4 (current fault line active and it should not be) Word 1 Bit 5 (current fault interrupt not active and it should be) Word 1 Bit 0 (charge voltage commanded but failed to detect response) No Bits 03130 Reconnect paddle card. Select POC command "TEST print MODE CONTROL" Did it pass? 03135 03170 21300 03140 03160 03140 03140 03130 03200 03120 66500 66500 66500
02100
02940
66600
66600 66600
09100
25100
1944
3998 5593007
STEP 03135
ACTION Replace AC supply PCBA assembly and rerun test. Does the problem still exist?
YES
NO
66500
66600
03140
Reconnect paddle card. Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: AC supply PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
03160
Reconnect paddle card. Primary suspect: AC supply PCBA assembly. Secondary suspect: Ink jet controller PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
03170
Disconnect printhead paddle card. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 11) (11) (optional r/f selection) *get results* <specify>. Did the same fault Word 1 Bit 7 occur? 03800 03120
03200
Disconnect printhead paddle card & install test board #1 in its place. Connect J1 to J1 & J2 to J2. Select (RUN TIME COMMANDS) (read PHASE/VOLTAGE) (optional r/f selection) *get results* <specify>. Write down phase number. Select (RUN TIME COMMANDS) (set PHASE/VOLTAGE XX/YY) (optional r/f selection) (enter phase value) (enter volts value) *wait for completion* <specify>. Set phase to old number & set volts to 175. Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <specify>. Does the same fault code MJE 80 42 occur again? 03500 03210
03210
Measure DC voltage between TP9 & TP10 on AC supply PCBA assembly. Is it 175 +/- 3? 03220 03215
3998 5593007
1945
STEP 03215
ACTION Remove test board #1 and reconnect paddle card. Replace AC supply PCBA assembly and rerun test. Does the problem still exist?
YES
NO
66500
66600
03220
Measure DC voltage between TP3 & TP1 on printhead CH driver PCB assembly. Is it 175 +/- 3? 03260 03900
03260
Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Reconnect paddle card. Select (RUN TIME COMMANDS) (read PHASE/VOLTAGE) (optional r/f selection) *get results* <specify>. Write down phase number. Select (RUN TIME COMMANDS) (set PHASE/VOLTAGE XX/XX) (optional r/f selection) (enter phase value) (enter volts value) *get results* <specify>. Set phase to old number & set volts to 115. Select (RUN TIME COMMANDS) (BAR CLEAN) (Y) (optional r/f selection) *wait for completion* <specify>. Does the same fault code MJE 80 42 occur again? 03300 03280
03280
Run exerciser program PHASE and VOLTAGE sweep. Does the problem still exist? 03300 66600
03300
Select (RUN TIME COMMANDS) (BAR CLEAN) (Y) (optional r/f selection) *wait for completion* <specify>. Does the same fault code MJE 80 42 occur again? 03700 03320
03320
Run exerciser program PHASE and VOLTAGE sweep. Does the problem still exist? 03700 66600
03500
Replace printhead CH driver PCB assembly and rerun test. Does the problem still exist? 66500 66600
03700
Conduct a thorough examination of the slot, printhead cover, eyelid seal, and surrounding area for fibers or ink mud that could disturb one or more jets. Remove if found. If not, select "SUPER CLEAN" from the Exerciser MJE Cleaning Menu. Does the same fault code MJE 80 42 occur again? 66400 03705
1946
3998 5593007
STEP 03705
YES
NO
03710 03710 03720 Was the fault code MJE 80 42? Run exerciser program PHASE and VOLTAGE sweep. Does the problem still exist? 03800 Disconnect J4 on AC supply PCBA assembly. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 11) (11) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 7 occur? 03820 03820 Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 03840 Primary suspect: AC supply PCBA assembly. Secondary suspect: Ink jet controller PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 03900 Reconnect J4 on AC supply PCBA assembly. Primary suspect: Printhead CH driver PCB assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 04100 Look at DS2 LED on printhead CH driver PCB assembly. Is it on? 04200 Check Connector J5 & J4 on printhead CH driver PCB assembly and J6 & J7 on Ink jet controller PCBA assembly for proper connection. Were they connected properly? 04250 Connect them and select (run time command) (BAR to STANDBY) (optional r/f selection) *get results* <specify>. Did it make it? 04270 04300 04200 66500 66500 03840 66400 66400
03720 03700
66600
03900
10100
66600
66600
04600
04250
04300
3998 5593007
1947
STEP 04270
YES
NO
04300 04300 Install test board #2 at J6 & J7 using supplied b & C cable and stim test cable to Ink jet controller PCBA assembly. Move dip switches on test board #2 to position 1. Disconnect printhead paddle card & install test board #1 in its place; connect J1 to J1 & J2 to J2. Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <specify>. Did it make it? 04330 04330 Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Were there any? 04350 04350 Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <specify>. Did it pass? 04370 04370 Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 04380 Disconnect test board #2. Reconnect J6 & J7 on Ink jet controller PCBA assembly. Reconnect printhead paddle card. Go to step 19100. 04400 Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. When complete, reinstall J6 & J7 on Ink jet controller PCBA assembly and unplug J5 & J4 on printhead CH driver PCB assembly. Install these cables to test board #2 with dip switches on test board #2 in position 1. Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <specify>. Did it make it? 04410 66500
66600
04350
04400
04380
66600
04420
1948
3998 5593007
STEP 04410
YES
NO
04420 04420 Reconnect printhead paddle card. Replace Umbilical assembly and rerun test. Does problem still exist? 04500 Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. When complete. plug in timer board on printhead to test board #2 & move switches to position 2. Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <specify>. Did it make it? 04510 04510 Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Were there any? 04540 04520 Replace printhead CH driver PCB assembly and rerun test. Does the problem still exist? 66500 04540 Reconnect J5 & J4 on printhead CH driver PCB assembly. Replace printhead assembly and rerun test. Does the problem still exist? 04600 Unplug J5 on printhead CH driver PCB assembly and connect to test board #2. Look at DS2 on test board #2. Is it on? 04610 Replace printhead CH driver PCB assembly and rerun test. Does the problem still exist? 66500 04620 Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <specify>. Did it pass? 04640 04610 66500 66500
04500
66600
04540
04520
66600
66600
04620
66600
04630
3998 5593007
1949
STEP 04630
ACTION Reconnect J5 on printhead CH driver PCB assembly.. Go to step 19100.
YES
NO
04640
Plug in test board #2 to J6 on Ink jet controller PCBA assembly using stim test cable. Look at DS2 on test board #2. Is it on? 04660 04680
04660
Replace Umbilical assembly and rerun test. Does the problem still exist? 66500 66600
04680
Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 66500 66600
05100
Disconnect the high speed print cable(15-pin D) at the printer module. Using a convenient method, attempt to bring the printer up for operation. (Do not attempt to print). Connect the high-speed print cable before proceeding. Does the error 57 continue to occur with the cable disconnected? 05110 05115
05115
Primary suspect: MJE Interface (AA09). Secondary suspect: Cable between printer module and the AA gate. Replace each component and rerun test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
05110
Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <specify>. Did it pass? 05120 25100
05120
Select (POC COMMANDS) (TEST UMBILICAL) (optional r/f selection) *get results* <specify>. Did it pass? 05150 26100
05150
Look at F2 on AC supply PCBA assembly. Is fuse bad? 05170 05200
05170
Replace AC supply PCBA assembly and rerun test. Does the problem still exist? 66500 66600
1950
3998 5593007
STEP 05200
ACTION Select (extended DIAGNOSTIC COMMANDS) (LED SEQUENCE TEST) (optional r/f selection) <specify> *get results* (N). Go look at LED DS18 on AC supply PCBA assembly. Did it flash?
YES
NO
05300 05220 Replace AC supply PCBA assembly and rerun test. Does the problem still exist? 05300 Disconnect printhead paddle PCBA and install test PCBA No. 1 in its place. Connect J1 to J1 and J2 to J2. Select (RUN TIME COMMANDS) (BAR to STANDBY) (optional r/f selection) *get results* <specify>. Did it make it without error MJE 8057 occurring? 05350 Replace printhead assembly and rerun test. Does the problem still exist? 05400 Primary suspect: AC supply PCBA assembly. Secondary suspect: Ink jet controller PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 06100 Look for where spill is coming from, if any, and repair. Clean off spill sensors and Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does fault Word 1 Bit 5 occur? 06200 Unplug spill sensor one at a time. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 5 occur? 06300 Clean spill sensors again that causes error. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 5 occur? 06320 Replace spill sensor assembly and rerun test. Does the problem still exist? 66500 06320 06400 06200 66500 66500 05350 66500
05220
66600
05400
66600
66600
66600
06300
66600
66600
3998 5593007
1951
STEP 06400
ACTION Unplug connector J9 on Ink jet controller PCBA assembly.
YES
NO
Does the same fault Word 1 Bit 5 occur? 06420 Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 06500 Reconnect J9 on Ink jet controller PCBA assembly. Unplug DC cable-board to fluid system at fluid system. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 5 occur? 06520 Replace DC cable-board to fluid system and rerun test. Does the problem still exist? 06540 Replace DC cable-fluid system assembly and rerun test. Does the problem still exist? 07100 Disconnect printhead paddle card & install test board #1 in its place. Connect J1 to J1 & J2 to J2. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 7 occur? 07150 Connect printhead paddle card. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 7 occur? 07140 Replace printhead assembly and rerun test. Does the problem still exist? 07200 Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 07250 Reconnect printhead paddle card. Go to step 10100 07300 Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass?
06420
06500
66500
66600
06520
06540
66500
66600
66500
66600
07200
07150
07140
66600
66500
66600
07300
07250
07400
07350
1952
3998 5593007
STEP 07350
ACTION Reconnect printhead paddle card. Go to step 09100
YES
NO
07400
Check fuse F1 & F3 on AC supply PCBA assembly. Are they both O.K.? 07420 07500
07420
Reconnect printhead paddle card. Replace AC supply PCBA assembly and rerun test. Does the problem still exist? 66500 66600
07500
Replace fuse. Select POC command "TEST POSITIVE AIR SYSTEM." Does the same fault Word 1 Bit 7 occur? 07600 07520
07520
Replace printhead assembly and rerun test. Does problem still exist? 66500 66600
07600
Disconnect J4 on AC supply PCBA assembly & replace fuse. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 7 occur? 07620 07700
07620
Reconnect printhead paddle card. Replace AC supply PCBA assembly and rerun test. Does the problem still exist? 66500 66600
07700
Reconnect J4 on AC supply PCBA assembly. Disconnect J3 on printhead CH driver PCB assembly and connect it to test board #2. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 7 occur? 07720 07740
07720
Reconnect printhead paddle card. Replace Umbilical assembly and rerun test. Does the problem still exist? 66500 66600
07740
3998 5593007
1953
STEP 08100
ACTION Disconnect printhead paddle card & install test board #1 in its place. Connect J1 to J1 & J2 to J2 Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 8 occur?
YES
NO
08200
08150
08150
Reinstall printhead paddle card. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Does the same fault Word 1 Bit 8 occur? 08170 66600
08170
08200
Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 08300 10100
08300
Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 08400 09100
08400
Look at DS1 on printhead CH driver PCB assembly. Is it on? 08450 08420
08420
08430
Replace Umbilical assembly, and rerun test. Does the problem still exist? 66500 66600
08450
Install J3 on printhead CH driver PCB assembly onto test board #2. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Did the same fault Word 1 Bit 8 occur? 08500 08470
08470
1954
3998 5593007
STEP 08500
ACTION Select (extended DIAGNOSTIC COMMANDS) (LED SEQUENCE TEST) (optional r/f selection) <specify> *get results* (N). Go look at DS15 on AC supply PCBA assembly. Did it flash?
YES
NO
08520 08520 Reconnect J3 on printhead CH driver PCB assembly. Primary suspect (AC supply PCBA assembly). Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 08600 Reconnect J3 on printhead CH driver PCB assembly. Primary suspect: AC supply PCBA assembly. Secondary suspect: Ink jet controller PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 09100 Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. If no Bits returned Bit 5 in Word 1 or 2 (AC board disconnected) Bit 0 in Word 1 or 2 (vacuum relay driver) Bit 1 in Word 1 or 2 (ink heater driver) Unplug J5 on Ink jet controller PCBA assembly. Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Does previous error occur? 09210 Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 09220 Primary suspect: AC supply PCBA assembly. Secondary suspect: AC to DC board cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66500 09210 66500 66500
08600
66600
66600
66500 09300 09200 09200
09200
09220
66600
66600
3998 5593007
1955
STEP 09300
ACTION Look at cable AC to DC board cable. Is it plugged in?
YES
NO
09320
09325
09320
Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: AC to DC board cable or AC supply PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
09325
Plug cable AC to DC board cable back in and rerun test. Does problem still exist? 66320 66600
10100
Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. If no Bits returned Word 1 Bit 0 & Word 2 no Bits high (catcher heater) Word 1 no Bits high & Word 2 Bit 0 (catcher heater) Bit 1 in Word 1 or 2 (eyelid 12V) Bit 2 in Word 1 or 2 (eyelid 5V) Bit 3 in Word 1 or 2 (antisiphon valve) Bit 4 in Word 1 or 2 (crossflush valve) Bit 6 in Word 1 or 2 (ink fill) Bit 7 in Word 1 or 2 (replenish fill) DS15 on AC supply PCBA assembly. Is it on?
66500 10200 10250 10300 10300 10400 10400 10500 10600
10200
10210
10215
10210
Unplug cable AC to DC board cable at J5 on Ink jet controller PCBA assembly. Is LED DS15 on AC supply PCBA assembly on? 10220 10230
10215
10220
Replace AC supply PCBA assembly and rerun test. Does the problem still exist? 66500 66600
10230
1956
3998 5593007
STEP 10250
ACTION Unplug AC to DC board cable at J5 on Ink jet controller PCBA assembly. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Did it return Bit 0 in Word 1 or 2?
YES
NO
10255
10260
10255
10260
Primary suspect: AC supply PCBA assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
10300
Unplug J1 on Ink jet controller PCBA assembly. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Does the same fault occur? 10320 10340
10320
Replace ink jet controller PCBA assembly and rerun the test. Does the problem still exist? 66500 66600
10340
Reconnect J1 on Ink jet controller PCBA assembly. Unplug printhead assembly component connector in print housing. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Does the same fault occur? 10360 10380
10360
10380
Reconnect printhead assembly component connector. Replace eyelid solenoid and rerun test. Does the problem still exist? 66500 66600
3998 5593007
1957
STEP 10400
ACTION Unplug J1 on Ink jet controller PCBA assembly. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Does the same fault occur?
YES
NO
10420
10440
10420
10440
Reconnect J1 on Ink jet controller PCBA assembly. Unplug printhead assembly component connector in print housing. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Does the same fault occur? 10460 10480
10460
10480
Replace manifold assembly and rerun test. Does the problem still exist? 66500 66600
10500
Unplug J9 on Ink jet controller PCBA assembly. Select POC command "TEST SOLENOIDS and CATCHER HEATER DRIVERS." Does the same fault occur? 10520 10540
10520
10540
Reconnect J9 on Ink jet controller PCBA assembly. Unplug ink fill valve. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Does the same fault occur? 10560 10550
10550
Replace ink fill valve assembly and rerun test. Does the problem still exist? 66500 66600
1958
3998 5593007
STEP 10560 Reconnect ink fill valve.
ACTION
YES
NO
Primary suspect: DC cable-fluid system assembly. Secondary suspect DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 10600 Unplug J9 on Ink jet controller PCBA assembly. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Does the same fault occur? 10620 Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 10640 Reconnect J9 on Ink jet controller PCBA. Unplug replenish valve. Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Does the same fault occur? 10650 Replace replenish fill valve assembly and rerun test. Does the problem still exist? 10660 Reconnect ink replenish valve. Primary suspect: DC cable-fluid system assembly. Secondary suspect: DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 11100 Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 11120 Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <specify>. Did it pass? 11140 19100 11120 10100 66500 66600 66500 66600 10660 10650 66500 66600 10620 10640 66500 66600
3998 5593007
1959
STEP 11140
ACTION Select POC command" TEST SOLENOID MOTION" If no Bits returned Word 1 Bit 2 high & Word 2 Bit 0 not high (eyelid ckt) Word 1 Bit 3 high & Word 2 Bit 1 not high (antisiphon ckt) Word 1 Bit 4 high & Word 2 Bit 2 not high (crossflush ckt) Word 1 Bit 6 high & Word 2 Bit 4 not high (fill ckt) Word 1 Bit 7 high & Word 2 Bit 3 not high (replen ckt) Word 1 Bit 1 returned (eyelid driver) Word 1 Bit 2 returned (eyelid disconn) Word 1 Bit 3 returned (antisiphon disconn) Word 1 Bit 4 returned (crossflush disconn) Word 1 Bit 6 returned (fill disconn) Word 1 Bit 7 returned (replen disconn) Word 2 if more than 1 Bit of 0 through 4 are returned (motion ckt bad) Word 2 Bit 0 returned (eyelid motion) Word 2 Bit 1 returned (antisiphon motion) Word 2 Bit 2 returned (crossflush motion) Word 2 Bit 3 returned (replen motion) Word 2 Bit 4 returned (fill motion) Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist?
YES 66500 11150 11150 11150 11150 11150 11150 11400 11500 11600 11700 11800 11150 11200 11240 11260 11280 11300
NO
11150
66500
66600
11200
Move eyelid to make sure it is free. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Does the same fault code occur? 11220 66600
11220
Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did the eyelid move? 11225 11230
11225
11230
Primary suspect: Eyelid solenoid. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
11240
Tap on antisiphon valve Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it pass? 66600 11250
1960
3998 5593007
STEP 11250
ACTION Disconnect printhead components connector and install jumper JP2 both ends. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it return Word 2 Bit 2?
YES
NO
11253
11256
11253
Remove JP2 & replace manifold assembly and rerun test. Does the problem still exist? 66500 66600
11256
Remove JP2 & reconnect printhead components connector. Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 66500 66600
11260
Tap on crossflush valve. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it pass? 66600 11270
11270
Disconnect printhead components connector and install jumper JP2 both ends. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it return Word 2 Bit 1? 11273 11276
11273
Remove JP2 & replace manifold assembly and rerun test. Does the problem still exist? 66500 66600
11276
Remove JP2 & reconnect printhead components connector. Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 66500 66600
11280
Tap on replenish valve. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it pass? 66600 11290
11290
Unplug replenish valve and plug it in where ink valve is. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it return Word 2 Bit 4? 11293 11296
3998 5593007
1961
STEP 11293 Reconnect ink valve.
ACTION
YES
NO
Replace replenish fill valve assembly and rerun test. Does the problem still exist? 11296 Reconnect ink & replenish valves. Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 11300 Tap on ink fill valve. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it pass? 11310 Unplug replenish valve and plug it in where ink valve is. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it return Word 2 Bit 4? 11330 Reconnect ink & replenish valves. Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 11340 Reconnect replenish valve. Replace ink fill valve assembly and rerun test. Does the problem still exist? 11400 Look at eyelid solenoid. Is it connected? 11405 Connect eyelid solenoid and rerun test. Does the problem still exist? 11410 Primary suspect: Eyelid solenoid. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 11500 Look at antisiphon valve. Is it connected? 11505 Connect the anti siphon valve and rerun test. Does the problem still exist? 11510 66600 11510 11505 66500 66600 11410 66600 11410 11405 66500 66600 66500 66600 11330 11340 66600 11310 66500 66600 66500 66600
1962
3998 5593007
STEP 11510
ACTION Primary suspect: Manifold assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
11600
Look at crossflush valve. Is it connected? 11610 11605
11605
Connect the crossflush valve and rerun test. Does the problem still exist? 11610 66600
11610
Primary suspect: Manifold assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
11700
Look at ink fill valve. Is it connected? 11710 11705
11705
Connect the ink fill valve and rerun test. Does the problem still exist? 11710 66600
11710
Primary suspect: Ink fill valve assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
11800
Look at replenish fill valve. Is it connected? 11810 11805
11805
Connect the replenish fill valve and rerun test. Does the problem still exist? 11810 66600
3998 5593007
1963
STEP 11810
ACTION Primary suspect: Replenish fill valve assembly: Secondary suspect: DC cable-fluid system assembly, DC cableboard to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
12100
Look at NE3 on AC supply PCBA assembly. Is it on? 12150 12200
12150
Unplug ink heater. Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 12160 09100
12160
Replace AC supply PCBA assembly. Reconnect ink heater and rerun test. Does the problem still exist? 66500 66600
12200
Unplug connector printhead component connector in printhead housing. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 4) (4) (optional r/f selection) *get results* <specify>. Is it below 50? 12400 12300
12300
Unplug Umbilical assembly at J1 on Ink jet controller PCBA assembly. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 4) (4) (optional r/f selection) *get results* <specify>. Is it above 125? 12320 12340
12320
Reconnect printhead component connector. Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 66500 66600
12340
1964
3998 5593007
STEP 12400
ACTION Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 5) (5) (optional r/f selection) *get results* <specify>. Is it above 125?
YES
NO
12500 12420 Replace manifold assembly and rerun test. Does problem still exist? 12500 Look at AC fan. Is it running? 12600 Is the ambient temperature above 125 F ? Note: Printer will not run if above 125 F. 12650 Disconnect fan plug and measure AC voltage across the pin on connector. Is it between 100 and 120? 12660 Replace fan and rerun test. Does problem still exist? 12670 Reconnect fan. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <specify>. Did it pass? 12690 12690 Primary suspect: AC cable-board to fluid system. Secondary suspect: AC supply PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 13100 Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 13130 Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Did it pass? 22100 13130 66500 66500 12660 12600 66600 66500
12420
66600
12650 66500
12670
66600
19100
66600
09100
13150
3998 5593007
1965
STEP 13150
ACTION Unplug printhead components connector in print housing and install JP2 both ends. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 4) (4) (optional r/f selection) *get results* <specify>. Did ink temperature go above 125?
YES
NO
13300 13200 Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 13300 Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 5) (5) (optional r/f selection) *get results* <specify>. Is it below 50? 13400 13320 Remove JP2. Replace manifold assembly and rerun test. Does the problem still exist? 13400 Ambient temperature at printhead is below 50 DEG F. Does the problem still exist? 14100 Look at NE3 on AC supply PCBA assembly. Is it on? 14150 Unplug ink heater. Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <specify>.. Did it pass? 14160 Replace AC supply PCBA assembly. Reconnect ink heater and rerun test. Does the problem still exist? 66500 14160 14150 66500 66500 66500
13200
66600
13320
66600
66600
14200
09100
66600
1966
3998 5593007
STEP 14200
ACTION Unplug ink pump connector at the ink pump. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 5) (5) (optional r/f selection) *get results* <specify>. Is it below 50?
YES
NO
14400 14300 Unplug DC cable-board to fluid system at fluid system bulkhead. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 5) (5) (optional r/f selection) *get results* <specify>. Is it below 50? 14320 14320 Replace DC cable-fluid system assembly and rerun test. Does the problem still exist? 14350 Unplug DC cable-board to fluid system at J9 on Ink jet controller PCBA assembly. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 5) (5) (optional r/f selection) *get results* <specify>. Is it below 50? 14360 14360 Connect ink pump connector. Replace DC cable-board to fluid system and rerun test. Does the problem still exist? 14370 Reconnect DC cable-board to fluid system at fluid system bulkhead & ink pump connector. Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 14400 Connect ink pump connector. Look at AC fan. Is it running? 14500 Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 4) (4) (optional r/f selection) *get results* <specify>. Is it above 125? 14600 14500 66500 66500 66500
14300
14350
66600
14370
66600
66600
14550
14520
3998 5593007
1967
STEP 14520
ACTION Primary suspect: Ink pump assembly. Secondary suspect: The ambient is above 125 F. Note: If the ambient is above 125F the printer will not run. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
14550
Disconnect fan plug and measure AC voltage across the pin on connector. Is it between 103 and 127? 14570 14580
14570
14580
Reconnect fan plug. Go to step 19100
14590
Primary suspect: AC cable-board to fluid system. Secondary suspect: AC supply PCBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600 66600 66500
14600
Is the ambient temperature above 125 F? Note: printer will not run if above 125F.
15100
Unplug connector ink pump assembly at the ink pump and install JP4. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 5) (5) (optional r/f selection) *get results* <specify>. Is it above 125? 15300 15200
1968
3998 5593007
STEP 15200
ACTION Remove JP4 & connect connector ink pump assembly. Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
15300
Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 4) (4) (optional r/f selection) *get results* <specify>. Is it below 50? 15400 15320
15320
Replace ink pump assembly and rerun test. Does the problem still exist? 66500 66600
15400
Remove JP4 & connect connector ink pump assembly. Is ambient temperature at printhead below 45 F? Note: Printer will not run below 45F. 66600 66500
16100
Select (POC COMMANDS) (TEST SOLENOIDS and CATCHER HEATER DRIVERS) (optional r/f selection) *get results* <specify>. Did it pass? 16120 10100
16120
Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Did it return Bit 6 high? 16150 16600
16150
Look at ink level. Is the distance from the top of the tank to the ink level less than 4.5 inches? 16300 16200
16200
Install JP3 in place of float connector. Select (POC COMMANDS) (TEST POSITIVE AIR SYSTEM) (optional r/f selection) *get results* <specify>. Did it pass? 16220 16250
16220
Replace float switch assembly and rerun test. Does the problem still exist? 66500 66600
3998 5593007
1969
STEP 16250
ACTION Remove JP3 & connect float connector. Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
16300
Drain the tank to half. Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <specify>. Select (RUN TIME COMMANDS) (BAR UP TO STATE 0) (Y) (optional r/f selection) (0) *wait for completion* <specify>. Did it return MJE 80 5D? 16200 16310
16310
Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Was there error MJE 80 5D? 16200 16320
16320
Unplug ink fill & ink replenish valves. Install jumper JP3 in place of float switch. Disconnect the tube from the ink fill valve elbow. Select (RUN TIME COMMANDS) (BAR UP TO STATE 2) (Y) (optional r/f selection) (2) *wait for completion* <specify>. Did it make it to state 2? 16325 16520
16325
Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <specify>. Were there any? 16520 16330
16330
Watch to see if ink or replenish is flowing in the tubing. Was there any? 16350 16500
16350
Unplug JP3 & connect float switch, fill valve, and replenish valve. Replace tube from ink fill valve elbow. Replace ink or replenish fill valve assembly (whichever one leaked) and rerun test. Did it pass? 66500 66600
1970
3998 5593007
STEP 16500
ACTION Unplug JP3 & connect float switch, fill valve, and replenish valve. Replace tube from ink fill valve elbow. Select (RUN TIME COMMAND) (BAR UP TO STATE 2) (Y) (optional r/f selection) (2) *wait for completion* <specify>. Did it make it to run time state 2?
YES
NO
66600
16510
16510
16520
Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
16600
Look at the ink tray. Is ink leaking? 16610 16620
16610
Repair ink leak and rerun test. Does the problem still exist? 66500 66600
16620
Select (run time command) (BAR UP TO STATE 3) (Y) (optional r/f selection) (3) *wait for completion* <specify>. Is the ink foaming? 16630 66500
16630
Look below the ink level where the air is entering and repair. Rerun test Does the problem still exist? 66500 66600
17100
Look at ink bottle. Is ink bottle empty? 17150 17200
17150
Replace ink bottle. Does the problem still exist? 66500 17300 66600 17250
17200 17250
Is ink bottle connected? Connect ink bottle. Does the problem still exist?
66500
66600
3998 5593007
1971
STEP 17300
ACTION Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it pass?
YES
NO
17400
11100
17400
Install new ink bottle. Select (RUN TIME COMMANDS) (BAR UP TO STATE 3) (Y) (optional r/f selection) (3) *wait for completion* <specify>. Is there ink flowing in the ink fill line? 17500 17600
17500
Replace filter-restrictor assembly and rerun test. Does the problem still exist? 66500 66600
17600
Replace filter inline and rerun test. Does the problem still exist? 66500 66600
18100
Look at replenish bottle. Is replenish bottle empty? 18150 18200
18150
Replace replenish bottle. Does the problem still exist? 66500 18300 66600 18250
18200 18250
Is replenish bottle connected? Connect replenish bottle. Does the problem still exist?
66500
66600
18300
Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <specify>. Select (POC COMMANDS) (TEST SOLENOID MOTION) (optional r/f selection) *get results* <specify>. Did it pass? 18400 11100
18400
Install new replenish bottle. Select (RUN TIME COMMANDS) (BAR UP TO STATE 3) (Y) (optional r/f selection) (3) *wait for completion* <specify>. Is there replenish flowing in the replenish fill line? 18500 18600
18500
Replace filter-restrictor assembly and rerun test. Does the problem still exist? 66500 66600
1972
3998 5593007
STEP 18600
ACTION Replace filter inline and rerun test. Does the problem still exist?
YES
NO
66500
66600
19100
Look at LEDS DS5, DS6, DS7, & DS8 on Ink jet controller PWBA assembly. Are they all on? 19410 19110
19110
Look at LED DS8 on Ink jet controller PWBA assembly. Is it on? 19130 19120
19120
Primary suspect: -12VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T& a 3304 3092. Secondary suspect: DC cable-bulkhead to board or Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
19130
19140
Measure DC voltage between TP8 and the right side of fuse F1. Is there any voltage? 19160 19150
19150
Primary suspect: +12VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T&A 3304 3092. Secondary suspect: DC cable-bulkhead to board or Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 19170 66600 19165
19160 19165
Was the voltage between 11.5-13? +12VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T & a 3304 3092. Rerun test. Does the problem still exist?
66500
66600
19170
Disconnect J5 on Ink jet controller PWBA assembly. Replace FUSE F1 and look at LED DS7 on Ink jet controller PWBA assembly. Is it on? 19180 19175
3998 5593007
1973
STEP 19175
ACTION Replace ink jet controller PWBA assembly and rerun test. Does the problem still exist?
YES
NO
66500
66600
19180
Reconnect J5 on Ink jet controller PWBA assembly. Look at LED DS7 on Ink jet controller PWBA assembly. Is it on? 66600 19190
19190
Replace AC supply PWBA assembly and rerun test. Does the problem still exist? 66500 66600
19210
19220
Measure DC voltage between TP8 and the right side of fuse F2 on Ink jet controller PWBA assembly. Is there any voltage? 19240 19230
19230
Primary suspect: +5VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T&A 3304 3092. Secondary suspect: DC cable-bulkhead to board or Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 19250 66600 19245
19240 19245
Was the voltage between 4.8-5.5? +5VDC problem indicated. Diagnose per schematic 03.05.07 and T&A 3304 3092. Rerun test. Does the problem still exist?
66500
66600
19250
Disconnect J5 on Ink jet controller PWBA assembly and replace FUSE F2. Look at LED DS6 on Ink jet controller PWBA assembly. Is it on? 19260 19255
19255
Replace ink jet controller PWBA assembly and rerun test. Does the problem still exist? 66500 66600
19260
Reconnect J5 on ink jet controller PWBA assembly. Look at LED DS6 on the ink jet controller PWBA assembly. Is it on? 66600 19265
1974
3998 5593007
STEP 19265
ACTION Replace AC supply PWBA assembly and rerun test. Does the problem still exist?
YES
NO
66500
66600
19300
19310
Measure DC voltage between TP8 and the right side of FUSE F3 on Ink jet controller PWBA assembly. Is there any voltage? 19330 19320
19320
Primary suspect: +24 VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T & a 3304 3092. Secondary suspect: DC cable-bulkhead to board or Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 19340 66600 19335
19330 19335
Was the voltage between 22.5 and 28.5? +24 VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T & a 3304 3092. Does the problem still exist?
66500
66600
19340
Disconnect J5 on Ink jet controller PWBA assembly and replace FUSE F3. Look at LED DS5 on Ink jet controller PWBA assembly. Is it on? 19350 19345
19345
19350
Reconnect J5 on Ink jet controller PWBA assembly. Look at LED DS5 on Ink jet controller PWBA assembly. Is it on? 66600 19360
19360
3998 5593007
1975
STEP 19410
ACTION Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <spcfy>. Word 1 Bit 0 returned (+5 volt supply) Word 1 Bit 1 returned (+12 volt supply) Word 1 Bit 2 returned (+24 volt supply) Word 1 Bit 4 returned (-12 volt supply) Word 1 Bit 5 returned (line volt supply) Word 1 Bit 3 returned ("enhance" volt supply) Word 1 Bit 6 returned (pressure transducer supply) Word 1 Bit 7 returned (vacuum transducer supply) Word 1 Bit 8 returned (A to D gnd check) Word 1 Bit 9 returned (printhead hour meter level) If no Bits returned
YES
NO
19420 19460 19440 19700 19800 19900 19415 19415 19415 19500
19415
Replace ink jet controller assembly and rerun test. Does the problem still exist? 66500 66600
19420
Measure DC voltage between TP3 & TP8 on Ink jet controller PWBA assembly. Do you have voltage between 4.8 & 5.5? 19430 19435
19430
19435
+5 VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T & a 3304 3092. Rerun test. Does the problem still exist? 66500 66600
19440
Measure DC voltage between TP4 & TP8 on Ink jet controller PWBA assembly. Do you have voltage between 22.5 & 28.5? 19450 19455
19450
19455
+24 VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T & a 3304 3092. Rerun test. Does the problem still exist? 66500 66600
19460
Measure DC voltage between TP2 & TP8 on Ink jet controller PWBA assembly. Do you have voltage between 11.25 & 13? 19470 19480
19470
1976
3998 5593007
STEP 19480
ACTION +12 VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T & a 3304 3092. Rerun test. Does the problem still exist?
YES
NO
66500
66600
19500
Disconnect J6 on Ink jet controller PWBA assembly and select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <spcfy>. Did it pass? 19520 19510
19510
19520
Reconnect J6 on Ink jet controller PWBA assembly. Disconnect timer board of printhead. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <spcfy>. Did it pass? 19530 19540
19530
19540
Disconnect J5 on printhead CH driver PCB assembly. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <spcfy>. Did it pass? 19550 19560
19550
19560
Replace Umbilical assembly and rerun test. Does it pass? 66500 66600
19700
Measure DC voltage between TP1 & TP8 on Ink jet controller PWBA assembly. Do you have voltage between -11.25 & -13? 19720 19740
19720
3998 5593007
1977
STEP 19740
ACTION -12 VDC problem indicated. Diagnose per schematic sheet 03.05.07 and T&A 3304 3092. Rerun test. Does the problem still exist?
YES
NO
66500
66600
19800
Look at NE4 on AC supply PWBA assembly. Is it on? 19840 19810
19810
Disconnect AC cable and bulkhead connector at J5 on AC supply PWBA assembly. Measure AC voltage from pin 1 to pin 3 on cable. Do you have voltage between 100 & 123? 19815 19820
19815
19820
Measure AC voltage on AC cable and bulkhead connector from pin 1 to pin 3. Was there any voltage? 19825 19830
19825
Connect AC cable and bulkhead. 110 VAC problem indicated. Check circuit breakers. Diagnose per schematic sheet 03.05.03 and tap setting information per SEI 4142 5455. Rerun test. Does the problem still exist? 66500 66600
19830
Connect AC cable and bulkhead. Primary suspect: 110 VAC problem indicated. Check circuit breakers. Diagnose per schematic sheet 03.05.03 and tap setting information per SEI 4142 5455. Secondary suspect: AC cable and bulkhead connector. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
19840
Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <spcfy>. Did it pass? 19850 09100
19850
Look at DS23 on Ink jet controller PWBA assembly. Is it on? 19870 19860
1978
3998 5593007
STEP 19860
ACTION Primary suspect: AC supply PWBA assembly. Secondary suspect: AC to DC board cable or Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
19870
Look at DS17 on AC supply PWBA assembly. Is it on? 19880 19890
19880
Disconnect AC cable and bulkhead connector at J5 on AC supply PWBA assembly. Measure AC voltage from pin 1 to pin 3. Do you have voltage between 103 & 127? 19883 19886
19883
Connect AC cable and bulkhead. Replace ink jet controller PWBA assembly and rerun test. Does the problem still exist? 66500 66600
19886
Connect AC cable and bulkhead. 110 VAC problem indicated. Check circuit. Breakers. Diagnose per schematic sheet 03.05.03 and tap setting information per SEI 4142 5455. Rerun test. Does the problem still exist? 66500 66600
19890
Disconnect J6 on AC supply PWBA assembly. Is NE4 on? 19970 19980
19900
Look at DS1 on AC supply PWBA assembly. Is it on? 19910 19905
19905
19910
Measure DC voltage between TP1 and TP2 on AC supply PWBA assembly. Is it between 8 & 11? 19930 19920
19920
Disconnect J9 on AC supply PWBA assembly. Is it between 8 & 11 volts DC? 19930 19925
19925
3998 5593007
1979
STEP 19930
ACTION Primary suspect: Ink jet controller PWBA assembly. Secondary suspect: AC to DC board cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
19970
Primary suspect: AC supply PWBA assembly. Secondary suspect: AC to DC board cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
19980
Primary suspect: Ink jet controller PWBA assembly. Secondary suspect: AC to DC board cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
20100
Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <spcfy>. Did it pass? 20110 19100
20110
Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Word 1 Bit 1 & 3 (pump volt & curr low) Word 1 Bit 2 & 7 (xducer buffer & pump curr high) Word 1 Bit 0 returned (pump volt high) Word 1 Bit 1 returned (pump volt low) Word 1 Bit 2 returned (pump curr high) Word 1 Bit 3 returned (pump curr low) Word 1 Bit 6 returned (xducer buffer offset) Word 1 Bit 7 returned (xducer buffer output) Word 1 Bit 4 returned (xducer offset high) Word 1 Bit 5 returned (xducer offset low) If no Bits returned 20115 20120 20115 20115 20900 20900 20115 20115 20200 20300
20115
1980
3998 5593007
STEP 20120
ACTION Disconnect J16 on Ink jet controller PWBA assembly. Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it return Word 1 Bit 2 & 7?
YES
NO
20130 20130 Replace ink jet controller PWBA assembly and rerun test. Does the problem still exist? 20200 Select (RUN TIME COMMANDS) (BAR EVACUATE) (optional r/f selection) *wait for completion* <spcfy>. When complete, Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it return Word 1 Bit 4? 20250 Primary suspect: Manifold assembly. Secondary suspect: Ink jet controller PWBA assembly or Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 20300 Select (RUN TIME COMMANDS) (BAR EVACUATE) (optional r/f selection) *wait for completion* <spcfy>. When complete, Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it return Word 1 Bit 5? 20320 Primary suspect: Manifold assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 20400 Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it pass? 20420 20420 Replace ink pump assembly and rerun test. Does the problem still exist? 66500 66500 20320 66500 20250 66500
20900
66600
66600
66600
66600
66600
20100
66600
3998 5593007
1981
STEP 20500
ACTION Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it pass?
YES
NO
20550 20550 Primary suspect: Ink pump assembly. Secondary suspect: Filter bypass. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 20900 Connect J16 Ink jet controller PWBA assembly. Primary suspect: Ink pump assembly. Secondary suspect: DC cable-fluid system assembly or DC cable-board to fluid system. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 21100 Disconnect printhead paddle card. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 11) (11) (optional r/f selection) *get results* <spcfy>. Word 1 Bit 1 returned (current detect line active and it should not be) Word 1 Bit 2 returned (current fault line active and it should not be) Word 1 Bit 3 returned (current detect line not active and it should be) Word 1 Bit 4 returned (current fault line active and it should not be) Word 1 Bit 5 returned (current fault interrupt not active and it should be) Word 1 Bit 0 returned (charge voltage commanded but failed to detect response) Word 1 Bit 7 returned (printhead is connected but should not be connected for this test, cancel test) No bits returned 21150 Disconnect printhead paddle card. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 11) (11) (optional r/f selection) *get results* <spcfy>. Did it pass? 66600 21300 21500 21400 21500 21500 21200 21150 66600 66500 66500
20100
66600
66600
21100
1982
3998 5593007
STEP 21200
ACTION Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <spcfy>. Did it pass?
YES
NO
21220
21210
21210
Connect printhead paddle card. Go to step 25100
21220
Connect printhead paddle card. Replace AC supply PWBA assembly and rerun test. Does the problem still exist? 66500 66600
21300
Disconnect printhead paddle card & install test board #1 in its place. Connect J1 to J1 & J2 to J2. Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <spcfy>. Did it return Word 1 Bit 1? 21350 21320
21320
21350
Reconnect printhead paddle card. Primary suspect: AC supply PWBA assembly. Secondary suspect: Printhead CH driver PCB assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
21400
Connect printhead paddle card. Primary suspect: AC supply PWBA assembly. Secondary suspect: Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
21500
Connect printhead paddle card. Primary suspect: Ink jet controller PWBA assembly. Secondary suspect: AC supply PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
3998 5593007
1983
STEP 22100
ACTION Select (POC COMMANDS) (TEST AC RELAY DRIVERS) (optional r/f selection) *get results* <spcfy>. Did it pass?
YES
NO
22200
09100
22200
Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <spcfy>. Did it pass? 22300 19100
22300
Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <spcfy>. Look at NE3 on AC supply PWBA assembly. Did it come on? 22400 22320
22320
22400
Primary suspect: Ink pump assembly. Secondary suspect: AC cable-board to fluid system or AC cable-fluid system assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
23100
Look at LEDS DS5, DS6, DS7, & DS8 on Ink jet controller PWBA assembly. Are they on? 23200 19100
23200
Look at DS13 & DS20 on Ink jet controller PWBA assembly. Is one of the LEDS on? 23220 23300
23220
23240
1984
3998 5593007
STEP 23300
ACTION Primary suspect: MJE Interface (AA09) or cable between printer module and AA gate. Secondary suspect: Command and control port cable or Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
23400
Look at the dip switch package on the Ink Jet Controller Board. Are they set per schematic sheet 09.01.02? 23500 23420
23420
Set DIP switches per schematic 09.01.02 and hit manual reset button. Select (POC COMMANDS) (RE-SYNC ECHO TEST) (optional r/f selection) *get results* <spcfy>. Did it pass? 66600 23500
23500
Push manual reset button on Ink jet controller PWBA assembly and wait 15 seconds. Does display 015 stay on? 23600 23550
23550
Unplug J11 on Ink jet controller PWBA assembly. Push manual reset button on Ink jet controller PWBA assembly and wait 15 seconds. Does it display 015? 23560 23570
23560
Primary suspect: MJE Interface (AA09). Secondary suspect: High speed print cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
23570
23600
Look at Leeds DS16, DS17, DS18, and DS12 on Ink jet controller PWBA assembly. Are they on? 23620 23700
3998 5593007
1985
STEP 23620
ACTION Select (extended DIAGNOSTIC COMMANDS) (MULTIPLE RESYNC ECHO TEST) (optional r/f selection) <spcfy> *get results* (N). Go look at LED DS21 on Ink jet controller PWBA assembly. Did it flash?
YES
NO
23640
23630
23630
Primary suspect: MJE Interface (AA09). Secondary suspect: Ink jet controller PWBA assembly or command and control port cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
23640
Select (extended DIAGNOSTIC COMMANDS) (MULTIPLE RESYNC ECHO TEST) (optional r/f selection) <spcfy> *get results* (N). Go look at LED DS19 on Ink jet controller PWBA assembly. Did it flash? 23650 23660
23650
Primary suspect: MJE Interface (AA09). Secondary suspect: Ink jet controller PWBA assembly or command and control port cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
23660
23700
Unplug J10 on ink jet controller PWBA assembly. Look at Leeds DS16, DS17, DS18, and DS12. Are they on? 23800 23720
23720
1986
3998 5593007
STEP 23800
ACTION Connect J10 on ink jet controller PWBA assembly. Primary suspect: MJE Interface board. Secondary suspect: Command and control port cable or cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
24100
Turn off power and turn it back on. Does problem still exist? 24200 66600
24200
Look at LEDS DS8, DS7, DS6, and DS5. Are they on? 24300 19100
24300
Measure DC voltage between TP8 & TP11. Is it more than 2.5? 24320 24340
24320
24340
Replace lithium battery and rerun test. Does the problem still exist? 66500 66600
25100
Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <spcfy>. If no Bits returned Word 2 Bit 1 returned (sweep) Word 1 Bit 1 returned (phase line) Word 1 Bit 3 returned (print pulse line) Word 1 Bit 5 returned (latchen line) Word 1 Bit 7 returned (colreq ack line) Word 1 Bit 8 returned (print jet pwr sup ctrl) Word 1 bits 0, 2, & 4 returned (multiple failure) Word 1 Bits 2, 4, & 6 returned (multiple failure) Word 1 Bit 0 returned (phase line from printhead) Word 1 Bit 2 returned (print pulse line from printhead) Word 1 Bit 4 returned (latchen line from printhead) Word 1 Bit 6 returned (colreq line) Word 1 Bit 9 returned (dac not controllable) Word 1 Bit 10 returned (curr det or chg volt on signal) Word 1 Bit 11 returned (curr det not on) Word 1 Bit 12 returned ([2] lsbs of dac) Word 1 Bit 13 returned (chg relay stuck on) Word 2 Bit 0 returned (curr fault interrupt) Replace AC supply PWBA assembly and rerun test. Does the problem still exist?
66500 25140 25200 25200 25200 25140 25200 25450 25450 25250 25250 25250 25400 25700 25600 25600 25700 25120 25140
25120
66500
66600
3998 5593007
1987
STEP 25140
ACTION Replace ink jet controller PWBA assembly and rerun test. Does the problem still exist?
YES
NO
66500
66600
25200
Disconnect AC to DC board cable at J5 on Ink jet controller PWBA assembly. Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <spcfy>. Did the same fault occur? 25220 25230
25220
25230
25250
25300
Primary suspect: Printhead CH driver PCB assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
25400
Disconnect J11 on ink jet controller PWBA assembly. Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <spcfy>. Did it pass? 25420 25410
25410
25420
Primary suspect: MJE Interface (AA09). Secondary suspect: High-speed print cable or cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
1988
3998 5593007
STEP 25450
ACTION Primary suspect: AC supply PWBA assembly. Secondary suspect: Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
25600
Disconnect printhead paddle card & install test board #1 in its place. Connect J1 to J1 & J2 to J2. Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <spcfy>. Did it have the same fault? 25650 25620
25620
25650
Connect printhead paddle card. Primary suspect: AC supply PWBA assembly. Secondary suspect: Printhead CH driver PCB assembly, Ink jet controller PWBA assembly, umbilical assembly, or AC to DC board cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
25700
3998 5593007
1989
STEP 26100
ACTION Select (extended DIAGNOSTIC COMMANDS) (reset) (optional r/f selection) *wait for completion* <spcfy>. and wait ten seconds. Select (POC COMMANDS) (TEST UMBILICAL) (optional r/f selection) *get results* <spcfy>. If no Bits returned Word 1 Bit 0 returned (SPB write) Word 1 Bit 1 returned (SPB clock) Word 1 Bit 2 returned (SPB read) Word 1 Bit 7 returned (SPB Dclock) Word 1 Bit 9 returned (drop counter) Word 1 Bit 3 returned (Low dpath) Word 1 Bit 4 returned (high dpath) Word 1 Bit 5 and 6 returned (both dpath return) Word 1 Bit 5 returned (low dpath return) Word 1 Bit 6 returned (high dpath return) Word 1 Bit 8 returned (stim circuit)
YES
NO
66500 26120 26120 26120 26120 26120 26200 26200 26290 26300 26300 04100
26120
26200
Disconnect J5 on ink jet controller PWBA assembly. Select (POC COMMANDS) (TEST UMBILICAL) (optional r/f selection) *get results* <spcfy>. Did it return Word 1 Bit 3 or 4? 26220 26250
26220
26250
26290
Disconnect the high-speed print cable (15-pin "D") at the printer module. Select (extended DIAGNOSTIC COMMANDS) (reset) (optional r/f selection) *wait for completion* <spcfy> and wait 10 seconds. Select (POC COMMANDS) (TEST UMBILICAL) (optional r/f selection) *get results* <spcfy>. Connect the high-speed print cable before proceeding. Does the test now pass? 26295 26300
1990
3998 5593007
STEP 26295
ACTION Primary suspect: MJE interface (AA09). Secondary suspect: Cable between printer module and AA gate. Replace each component and rerun test or until the test passes. Does the problem still exist?
YES
NO
66500
66600
26300
26310
Select (extended DIAGNOSTIC COMMANDS) (LED SEQUENCE TEST) (optional r/f selection) <spcfy> *get results* (N). Go look at LED DS9, DS10, & DS11 on AC supply PWBA assembly. Did they all flash? 26320 26330
26320
Select (extended DIAGNOSTIC COMMANDS) (LED SEQUENCE TEST) (optional r/f selection) <spcfy> *get results* (N). Go look at LED DS19 & DS20 on AC supply PWBA assembly. Did they both flash? 26400 26500
26330
Disconnect J2 on AC supply PWBA assembly. Select (extended DIAGNOSTIC COMMANDS) (LED SEQUENCE TEST) (optional r/f selection) <spcfy> *get results* (N). Go look at LED DS19 & DS20 on AC supply PWBA assembly Did they both flash? 26600 26340
26340
Primary suspect: AC supply PWBA assembly. Secondary suspect: AC to DC board cable & Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
3998 5593007
1991
STEP 26400
ACTION Primary suspect: AC supply PWBA assembly. Secondary suspects: Ink jet controller PWBA assembly, AC to DC board cable, printhead CH driver PCB assembly, or Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
26500
Primary suspect: Printhead CH driver PCB assembly. Secondary suspect: Umbilical assembly & AC supply PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
26600
Connect J2 on AC supply PWBA assembly. Primary suspect: Printhead CH driver PCB assembly. Secondary suspect: Umbilical assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
27100
Select (RUN TIME COMMANDS) (BAR EVACUATE) (optional r/f selection) *wait for completion* <spcfy>. Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it pass? 27200 27120
27120
Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it fail Bit 5 only? 27150 20100
27150
Disconnect printhead outlet tube. Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it pass? 27200 27180
27180
Reconnect printhead outlet tube & Go to step 20100.
1992
3998 5593007
STEP 27200
ACTION Reconnect printhead outlet tube. Select (RUN TIME COMMANDS) (BAR UP TO STATE 7) (Y) (optional r/f selection) (7) *wait for completion* <spcfy>. Did it make it?
YES
NO
27250
27220
27220
Select (RUN TIME COMMANDS) (BAR EVACUATE) (optional r/f selection) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (BAR UP TO STATE 6) (Y) (optional r/f selection) (6) *wait for completion* <spcfy>. for 15 MINUTES. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (NORMAL TABLE) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (BAR CLEAN) (Y) (optional r/f selection) *wait for completion* <spcfy>. Did the same error occur? 27500 66600
27250
Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <spcfy>. Were there any? 27220 27300
27300
Select (RUN TIME COMMANDS) (BAR UP TO STATE 10) (Y) (optional r/f selection) (10) *wait for completion* <spcfy>. Did it make it? 27310 27320
27310
Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <spcfy>. Were there any? 27320 27400
27320
Replace manifold assembly and rerun test. Does the problem still exist? 66500 66600
27400
Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <spcfy>. Did it make it? 27420 27440
3998 5593007
1993
STEP 27420
ACTION Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <spcfy>. Were there any?
YES
NO
27440 27440 Primary suspect: Filter by bass. Secondary suspect: Ink jet controller PWBA assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 27500 Select (RUN TIME COMMANDS) (BAR EVACUATE) (optional r/f selection) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <spcfy>.. Select (RUN TIME COMMANDS) (BAR UP TO STATE 6) (Y) (optional r/f selection) (6) *wait for completion* <spcfy>. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 10) (10) (optional r/f selection) *get results* <spcfy>. Is the reading less than 75? 27520 27520 Replace printhead assembly and rerun test. Does the problem still exist? 27540 Replace filter by pass and rerun test. Does the problem still exist? 28100 Select (RUN TIME COMMANDS) (BAR EVACUATE) (optional r/f selection) *wait for completion* <spcfy>. Select (POC COMMANDS) (TEST INK PUMP/TRANSDUCER) (optional r/f selection) *get results* <spcfy>. Did it pass? 28150 28150 Look at the tank. Is there ink in the tank? 28200 66500 66500 66500
66600
66600
27540
66600
66600
20100
28400
1994
3998 5593007
STEP 28200
ACTION Select (RUN TIME COMMANDS) (BAR UP TO STATE 11) (Y) (optional r/f selection) (11) *wait for completion* <spcfy>. When reached, pinch off tube on manifold assembly that has the orifice in it. This tube connects to the manifold beneath the printhead. Select (RUN TIME COMMANDS) (BAR UP TO STATE 12) (Y) (optional r/f selection) (12) *wait for completion* <spcfy>. Did it make it?
YES
NO
28210 28210 Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <spcfy>. Were there any? 28300 28214 Unpinch the tube. Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <spcfy>. Were there any? 28220 Replace manifold assembly and rerun test. Does the problem still exist? 28300 Unpinch tube and disconnect the inlet and outlet tubes from printhead. Connect them together and connect the other tubes together. Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (BAR UP TO STATE 6) (Y) (optional r/f selection) (6) *wait for completion* <spcfy>. Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 9) (9) (optional r/f selection) *get results* <spcfy>. Did it read above 5? 28320 28320 Replace printhead assembly and rerun test. Does the problem still exist? 28325 Replace cover, making sure not to pinch tubes and rerun test. Does the problem still exist? 66500 28330 Replace printhead assembly and rerun test. Does the problem still exist? 66500 28325 66500 28220
28300
28214
28300
66600
28340
28330
66600
66600
3998 5593007
1995
STEP 28340
ACTION Primary suspect: Ink pump assembly. Secondary suspect: Manifold assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
28400
Look at the ink bottle. Is it empty? 28410 28420
28410
Replace ink bottle. Does the problem still exist? 66500 66600
28420
Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (BAR UP TO STATE 2) (Y) (optional r/f selection) (2) *wait for completion* <spcfy>. Is ink tank filling? 28430 28440
28430 28440
After tank is filled, Go to 20100 Install JP5 in place of ink float switch. Do not leave jumper in too long. Select (RUN TIME COMMANDS) (BAR UP TO STATE 2) (Y) (optional r/f selection) (2) *wait for completion* <spcfy>. Is ink tank filling? 28445 28450
28445
28450
Connect float switch assembly. Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: DC cable-board to fluid system or DC cable-fluid system assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
29100
Unscrew positive air filter. Select (RUN TIME COMMANDS) (bar down) (optional r/f selection) *wait for completion* <spcfy>. Did the same fault code MJE 80 40 occur? 29110 29120
1996
3998 5593007
STEP 29110 Reinstall positive air filter. Go to step 01100 29120
ACTION
YES
NO
Replace filter pos air and rerun test. Does the problem still exist? 66500 66600
30100
30200
Disconnect the inlet and outlet tubes from printhead. Connect them together and connect the other tubes together. Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (BAR UP TO STATE 6) (Y) (optional r/f selection) (6) *wait for completion* <spcfy>. Did fault code MJE 80 58 or MJE 80 59 occur? 30300 30220
30220
30300
Primary suspect: Ink pump assembly. Secondary suspect: Manifold assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
31100
Push manual reset button on ink jet controller PCBA assembly and wait 15 seconds. Does display 015 stay on? 31200 23100
31200
Select (extended DIAGNOSTIC COMMANDS) (reset) (optional r/f selection) *wait for completion* <spcfy>. Does display O15 stay on after 15 seconds? 66600 31300
3998 5593007
1997
STEP 31300
ACTION Disconnect high speed print cable at J11 on ink jet controller PCBA assembly. Select (extended DIAGNOSTIC COMMANDS) (reset) (optional r/f selection) *wait for completion* <spcfy>. Does display 015 stay on after 15 seconds?
YES
NO
31400
31320
31320
31400
Primary suspect: MJE interface (AA09). Secondary suspect: High speed print cable or cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66600
32100
32150
Look at the ink tank Is there ink in the tank? 32300 32400
32300
Disconnect the inlet and outlet tubes from printhead. Connect them together and connect the other tubes together. Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (BAR UP TO STATE 6) (Y) (optional r/f selection) (6) *wait for completion* <spcfy>. Did fault code MJE 80 59 or MJE 80 58 occur? 32350 32320
32320
1998
3998 5593007
STEP 32350
ACTION Reconnect the tubes from the printhead to the umbilical assembly. Primary suspect: Ink pump assembly. Secondary suspect: Manifold assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
32400
Look at the ink bottle. Is it empty? 32410 32420
32410
Replace ink bottle. Does the problem still exist? 66500 66600
32420
Select (RUN TIME COMMANDS) (SELECT BAR STATE TABLE XX) (optional r/f selection) (CIRCULATE TABLE) *wait for completion* <spcfy>. Select (RUN TIME COMMANDS) (BAR UP TO STATE 2) (Y) (optional r/f selection) (2) *wait for completion* <spcfy>. Is ink tank filling? 32430 32440
32430 32440
After tank is filled, Go to 20100. Install JP5 in place of ink float switch. Do not leave jumper in too long. Is ink tank filling? 32445 32450
32445
32450
Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: DC cable-board to fluid system or DC cable-fluid system assembly. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 33120 66600 66600
33100 33120
Does error come again in the next bar commands? Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist?
66500
66600
3998 5593007
1999
STEP 34100
ACTION Select (extended DIAGNOSTIC COMMANDS) (Run diagnostic routine 1) (1) (optional r/f selection) *get results* <spcfy>. Did it pass?
YES
NO
34120 34120 Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 35100 Select (POC COMMANDS) (TEST PRINT MODE CONTROL) (optional r/f selection) *get results* <spcfy>. Did it pass? 35200 Replace ink jet controller PCBA assembly and rerun test. Does the problem still exist? 36100 Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <spcfy>. Were there any errors? 36200 36200 36300 36310 Go act on the error. Was improper command sent to printer at this time? Refer to Table 195. A command can be performed in a given state if there is an X in the box for that command under that state. 36310 66500 35200 66500
19100
66600
25100
66600
36300
66500
19100
3998 5593007
Table 194. Commands Available in Different States
Command 80 81 82 83 84 85 86 87 88 89 8A 8B 8C 8D 8E 8F 90 91 92 93 94 95 96 97 A0 A1 A2 A3 A4 A7
Power On State X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
Bar Down State X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
In a Bar State
Normal Table X
Circulate Table X X X X X
Flush Table X X X X X
X X X X X
X X X X X X X X
X X X X
X X X X
X X X X X X X X X X X
X X X X X X X X X X X X
X X X X X X X X X X X X X X
X X X X X X X X X X X X X X
X X X X
X X X X X X X X X
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Table 194. Commands Available in Different States
Command A8 A9 AA AB AC AD AE B4,1 B4,2 B4,3 B4,4 B4,5 B4,9 B4,a B4,b CD
Power On State X X X X X X X X X X X X X X X X
Bar Down State X X X X X X X X X X X X X X X X
In a Bar State
Normal Table X X X X X X X X
Circulate Table X X X X X X X X X X X X X X X X
Flush Table X X X X X X X X X X X X X X X X
X X X X X X
X X X X X X X
Table 193. MJE Manual Procedures (cont.)
STEP 37100
ACTION In the state table you have stayed in a state too long. Do not stay there that long. Does the problem still exist?
YES
NO
66500
66600
38100
Primary suspect: Ink jet controller PCBA assembly. Secondary suspect: High speed print cable. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist? 66500 66500 66600 66600
40000
Replace the MJE interface (AA09) and rerun the test. Does the problem still exist?
19102
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STEP 40100
ACTION Inspect fluid system for obvious leaks. Clean leak sensor as needed. Does the problem still exist?
YES
NO
40110
66600
40110
Select (RUN TIME COMMANDS) (SEND ERRORS/WARNINGS) (optional r/f selection) *get results* <spcfy>. Is a run time fault code indicated?
40120
40130
40120
Follow the procedure for the run time fault code. Does the problem still exist? 66500 66600
40130
Replace ink jet controller board. Rerun test. Does the problem still exist? 66500 66600
41100
Perform exerciser Erase Fonts or Erase Graphics as applicable. Be sure font/graphics write protection jumper is not installed on the MJE Interface (AA09). Note: This will erase any customized entries other than the automatically loaded entry at location 0. This means that a Download Fonts or Download Graphics operation is required to restore all customized entries. 41200 66600
Does the problem still exist? 41200 Replace MJE interface (AA09) and rerun test. Does the problem still exist? 42100 Check DIP switch setting on ink jet controller board per schematic sheet 09.01.01. Does the problem still exist? 42110 Disconnect the high-speed print cable (15-Pin D") at the printer module. Rerun test. Does the same test fail? Connect the high-speed print cable before proceeding. 42120 Primary suspect: MJE interface (AA09). Secondary suspects: Ink jet controller board or command and control port cable or cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
66500
66600
42110
66600
42120
42130
66500
66600
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19103
STEP 42130
ACTION Primary suspect: MJE interface (AA09). Secondary suspect: Cable between printer module and AA gate. Replace each component and rerun the test for each component until all components have been replaced or until the test passes. Does the problem still exist?
YES
NO
66500
66600
43100
Clean and dry streaker sensor PCBA and streaker housing. Rerun the streaker test. Did it pass? 66600 43200
43200
Replace streaker sensor PCBA. Rerun the streaker test. Did it pass? 66600 43210
43210
Replace streaker detector PCBA. Rerun the streaker test. Did it pass? 66600 43220
43220
Replace the streaker harness. Rerun the streaker test. Did it pass? 66600 43230
43230
Replace MJE interface (AA09). Rerun the streaker test. Did it pass? 66600 66500
44000
Replace the ink jet controller board and rerun test. Does the problem still exist? 66500 66600
44100
Primary suspect: MJE interface (AA09). Secondary suspect: Main CPU board (AA17). Replace each board and rerun the test for each board until all boards have been replaced or until the test passes. Does the problem still exist? 66500 66600
44200
Rerun the test that was running when the exception occurred. Does the problem still exist? 44210 66600
44210
Find address on the screen in the table below, if listed. Is address listed? 44220 44230
44220
Replace suspect board(s) associated with listed address one at a time. Rerun test. Does problem still exist? 44230 66600
44230
Replace main CPU board (AA17) and rerun test. Does problem still exist? 66500 66600
19104
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STEP 45000
ACTION Turn off the sorter and MJEs. Reverse the following MJE cables:
YES
NO
(DL1) Reverse J6 (front) and J7 (rear) (DL2) Reverse J18 (front) and 17 (rear) These cables are located adjacent to Card AA09.
Note:
Turn on the sorter and MJEs and observe the POC fault code. Follow the procedure for the fault code that is displayed. IMPORTANT : After the fault is corrected, restore the cable to its original location and rerun the POC.
Table 195. Address: Board Correspondence Table
68030 Address $0 - $00FFFFFF $01000000-$0101FFFF $03FFF100-$03FFF200 $03FFE000-$03FFE7FF $03FFFC00-$03FFFC0B $03FFFC0C-$03FFFC15 $03FFFC16-$03FFFC1A $03FFFC1B $03FFFC1C-$03FFFC1D $03FFFC22-$03FFFC2B $03FFFC30 $03FFFC32-$03FFFC3B $03FFFC63-$03FFFC69 $03FFFC6A-$03FFFC6C $03FFFC70-$03FFFC72 $03FFFC76-$03FFFC79 $03FFC7A - $03FFFC7B $03FFFCC0-$03FFFCFF AA17 AA17
Suspect Board
AA03 (NDP 1800-65 camera) AA09 (MJE) AA08 AA10 AA08 AA02 AA08 AA17 AA08 AA02 AA10 AA05 AA02 AA11, AA12 AA11 for MICR AA02
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$03FFFD00-$03FFFD3F $03FFFD40-$03FFFD7F $03FFFD80-$03FFFDBF $03FFFDC0-$03FFFDFF $01FFFF50-$01FFFF55
AA02 AA05 AA05 AA05 AA17
19106
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Print Problems as Seen in Print Samples

Follow these steps to resolve print problems that are seen in print samples. Table 196. Print Problems as Seen in Print Samples
Step 66300
ACTION Remove printhead cover and clean the slot inside and out with a damp lint free cloth. Replace the cover. Select (RUN TIME COMMANDS) (BAR CLEAN) (Y) (optional r/f selection) *wait for completion* <spcfy>. Run Exerciser program PHASE and VOLTAGE sweep to get the right values for these settings and set them to the right values. Do the voltage sweep cards show inconsistency? Do you still have crooked jet? Do you still have irregular gap in the print sample after setting phase properly? Does one half print black or not print at all?.
Yes
No
66350 66400 66340 66390
66340
66350
Disconnect printhead paddle card & install test board #1 in its place. Connect J1 to J1 & J2 to J2. Select (RUN TIME COMMANDS) (read PHASE/VOLTAGE) (optional r/f selection) *get results* <spcfy>. Write down phase number. Select (RUN TIME COMMANDS) (set PHASE/VOLTAGE XX/YY) (optional r/f selection) (enter phase value) (enter volts value) *wait for completion* <spcfy>. Set phase to old number. Set volts to 125. Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <spcfy>. Does the DC voltage measure 125 +/- 3 between TP9 & TP10 on AC supply PCBA assembly? 66360 66380
3998 5593007
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Table 196. Print Problems as Seen in Print Samples
Step 66360
ACTION Select (RUN TIME COMMANDS) (set PHASE/VOLTAGE XX/YY) (optional r/f selection) (enter phase value) (enter volts value) *wait for completion* <spcfy>. Set phase to old number. Set volts to 156. Select (RUN TIME COMMANDS) (BAR UP - EYELID CLOSED) (Y) (optional r/f selection) *wait for completion* <spcfy>. Does the DC voltage measure 156 +/- 3 between TP9 & TP10 on AC supply PCBA assembly?
Yes
No
66500 66380 Replace AC supply PCBA assembly and rerun test. Does the problem still exist? 66390 Replace ink jet controller PCBA assembly. Does the problem still exist? 66400 Perform printhead swabbing procedure, per SEI 4142 5455. Does the problem still exist? 66450 66450 Replace printhead assembly and rerun test. 66500 66500 66500
66380
66600
66600
66600 66600
19108
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Suggestions to Fault Isolation if Procedures Fail to Correct Problem

Table 197. Suggestions to Fault Isolation if Procedures Fail to Correct Problem
Step 66500
ACTION Entry to this line indicates failure of the MJE MTRs to correct a fault. Review the following suggestions to help isolate the problem. 1. Review or rerun the diagnostic procedure to make sure the proper test points and step by step procedure were followed correctly. Remember when there is a list of word and bits returned you start at the top and read down till you find the one that has failed or multiple if asked for. Problems that are intermittent, are usually due to poor electrical connections, fluid (air or ink) leaks, or restrictions. 2. Measure DC voltages. On the ink jet controller assembly they should be 3. 4. 5. 6. 7. TP8 to TP2 TP8 to TP3 TP8 to TP4 TP8 to TP1 11.5 to 13 4.8 to 5.5 22.5 to 28.5 11.5 to -13
Inspect all electrical connection for tightness and lack of ink contamination. (Remember, the MJE ink is conductive.) Recheck mist box gasket to insure proper seating. Check that all vacuum lines are properly connected & lines have no cuts. Review the information at line 66300. The MTR diagnostic procedures assume only one fault exists in a previously good working machine. Multiple faults might exist which can cause the same failure code or a second failure code in a subsequent test. Follow the second failure code diagnostic procedure if you are unable to correct the first problem. If the failure contains a BITMAP, review the bit definitions in the "Command Names and Descriptions" subsection. If you are getting run time errors and cannot diagnose the problem, you can manually access the Normal Bar Up State tables Table 198 and Table 199 to step through each step to see what function causes the problem. The table gives the status of solenoids and pumps during each state. The table also tells how long the printer normally stays in a state, lists what tests (if any) are done during each state, and gives various pressures and voltage settings. An 0 means that the device is off and a 1 means that the device is on. The normal table can be stepped through with select run time command "BAR UP TO STATE XX".
8. 9.
Example: State 13 antisiphon valve, vacuum pump, catcher heater, and positive air on. Servo pressure 9.5 psi, servo vacuum 120 in. H2O, tab servo voltage 11 mv., and state time 7 seconds.
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Table 198. Normal Bar Up State (States 0-11)
STATE EYELID ACTIVATE EYELID HOLD ANTISIPHON VALVE VACUUM PUMP CATCHER HEATER CROSS FLUSH VALVE POSITIVE AIR IP VOLTAGE (x.1) IP VOLTS MIN (x.1) IP VOLTS MAX (x.1) IP CURRENT MIN (mA x10) 0 0 0 0 0 0 1 0 0
0 0 0 0 1 0 0 1 0 0
1 0 0 0 1 0 0 1 0 0
2 0 0 0 1 0 0 1 0 0
3 0 0 0 1 0 0 1
4 0 0 0 1 0 0 1
5 0 0 1 1 0 0 1
6 0 0 1 1 0 0 1
7 0 0 1 1 0 1 1
8 0 0 1 1 0 1 1
10 0 0 1 1 0 1 1
11 0 0 1 1 0 0 1
050 050 050 110 120 120 180 110 035 045 045 085 115 115 155 105
010 010 010 010 055 055 055 115 125 125 185 145 0 0 0 0 002 002 002 002 002 002 005 002
IP CURRENT MAX (mA x10) 002 002 002 002 040 040 040 050 050 050 050 050 SERVO PRESSURE (psi x.1) 0 PRESSURE MIN (psi x.1) PRESSURE MAX (psi x.1) SERVO VACUUM (in. H2O) VACUUM MIN (IN. H2O) VACUUM MAX (IN. H2O) TAB SERVO VOLTS (mV) CHARGE VOLTAGE RUN TESTS/TRIES STATE TIME (SEC X.1) TEST FAIL STATE BAR DOWN STATE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
060 060 060 060 140 140 140 140 140 140 140 140 120 120 120 120 250 120 120 120 120 120 120 120 0 0 0 0 0 0 0 0 0 0 0 0
255 255 255 255 220 220 220 220 220 140 140 255 0 0 16/ 100 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 255 0 0 0 011 0
4/ 2/ 150 255
001 001 001 008 050 001 001 010 035 020 006 010 0 4 4 2 4 3 4 3 3 3 3 3 3 3 3
19110
3998 5593007
Table 199. Normal Bar Up State (States 12-22)

STATE EYELID ACTIVATE EYELID HOLD ANTISIPHON VALVE VACUUM PUMP CATCHER HEATER CROSS FLUSH VALVE POSITIVE AIR IP VOLTAGE (x.1) IP VOLTS MIN (x.1) IP VOLTS MAX (x.1) IP CURRENT MIN (mA x10) IP CURRENT MAX (mA x10) SERVO PRESSURE (psi x.1) PRESSURE MIN (psi x.1) PRESSURE MAX (psi x.1) SERVO VACUUM (in. H2O) VACUUM MIN (in. H2O) VACUUM MAX (in. H2O) TAB SERVO VOLTS (mV) CHARGE VOLTAGE RUN TESTS/TRIES STATE TIME (SEC X.1) TEST FAIL STATE BAR DOWN STATE 3 3 2 010 070 040 0 0 1 1 0 0 1 110 105 115 002 050 0 040 140 120 0 255 011 0
12 0 0 1 1 1 0 1 0 0
13 0 0 1 1 1 0 1 0
14 0 0 1 1 1 0 1 0
15 0 0 1 1 1 0 1 0
16 0 0 1 1 1 0 1 0
17 0 0 1 1 1 0 1 0
18 0 0 1 1 1 0 1 0
19 0 0 1 1 1 0 1 0
20 1 1 1 1 1 0 1 0
21 0 1 1 1 1 0 1 0
22
080 160 002 050 095 085 105 120 0 255 200 0
080 160 002 050 095 085 105 120 100 140 200 0 8/1 900 15 2
080 160 002 050 095 085 105 250 100 140 200 0
080 160 002 050 095 085 105 120 100 140 200 040
080 160 002 050 095 085 105 120 100 140 200 255
080 160 002 050 095 085 105 120 100 140 200 255 64/1
080 160 002 050 095 085 105 050 0 065 200 255
080 160 002 050 095 085 105 050 0 065 200 255
080 160 002 050 095 085 105 050 0 065 200 255
255 0 255 095 040 147 120 0 255 011 0
010
005
010
000 19
005
001
005
BAR UP TESTS TEST NO. 2 -- INK LEVEL TEST --This test looks at the operating float switch one time. The test passes if the float is above the operating level (switch open). The test fails if the float is below the operating level (switch closed). If the test fails the number of tries in the table, then an error, "5E" or "70" (depending on which fill valve was energized), will occur.
3998 5593007
19111
TEST NO. 4 -- VACUUM PUMP TEST -- This test looks at the vacuum level 10 times. The test passes if the vacuum is above 10 in. 5 or more of the 10 times. It fails if the vacuum is below 10 in. 6 or more of the 10 times. If the test fails the number of tries in the table, an error, "41", will occur. TEST NO. 8 -- INK TEMPERATURE TEST -- This test looks at the manifold thermister one time. The test passes if the printhead temperature is over 75 degrees F. If the printhead temperature is below 75 degrees F., then the software compares the temperature after a two-minute delay to the previous reading. If the new temperature is more than 1 degree F. higher than this, the test will loop until the printhead temperature passes the 75 degree F. mark. The test fails if a new temperature reading is less than 1 F. higher than its previous reading (temperature not rising more than .5 degrees F per minute), in which case, if it fails the number of tries specified in table, an error, "63", will occur. TEST NO. 16 -- VACUUM RESTRICTION TEST -- In this test, the vacuum level is checked. The test passes if the vacuum level is below 5 in. The test fails if the vacuum level is above 5 in. If it fails the number of tries in table, an error, "46", will occur. TEST NO. 64 -- SET PHASE -- This test allows the control software to set the printhead phase to an initial value. No errors can occur in this test.
Procedure End
Step 66600
ACTION End of procedure. Verify proper operation.
19112
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Condition, Cause, Correction Chart

Table 1910. Condition, Cause, Correction Chart
Condition Excessive Streakers
Cause Printing is going over the top or through holes in documents. Charge voltage set too low or high. Ink stream striking contamination on the catcher surface.
Correction Adjust printing height as needed. If accompanied by print jet shorts, voltage is probably too high. Perform voltage sweep per SEI 4142 5455. If accompanied by print jet shorts, contamination is closer to the nozzles. 1. Perform printhead extended flush per SEI 4142 5455. 2. Perform printhead swabbing procedure per SEI 4142 5455.
Defective printhead. Excessive print jet shorts Charge voltage set too high. Excessive vibration from the transport. Ink stream striking contamination on the catcher surface near nozzles (charge plates).
Replace printhead as last resort. Delicate catcher surface may be examined for obvious contaminants. Perform voltage sweep per SEI 4142 5455. Locate vibration source (pulley, belt, bearing) as required. Higher charge voltages settings increase sensitivity. Insure proper setting of charge voltage. 1. Perform printhead extended flush per SEI 4142 5455. 2. Perform printhead swabbing procedure per SEI 4142 5455. Replace printhead as last resort. Delicate catcher surface may be examined for obvious contaminants. Perform Phase Sweep per SEI 4142 5455. Inspect for obvious accumulation on areas that may be intercepting printing ink drops (eyelid, cover slot, wall slot). 1. Perform Ink Stream Centering Procedure per SEI 4142 5455. 2. Perform wall adjustment per SEI 3304 6202.
Defective printhead. Loss of printing information Phase setting not correct. Obstruction in ink path.
3998 5593007
19113
Table 1910. Condition, Cause, Correction Chart
Condition
Cause Air in printhead.
Correction This condition only occur as a result of improper use of maintenance modes and tests. No more than 2 OFF/ON cycles via control panel switch should ever be needed to clear condition or... 1. A leak exists on the inlet side of the printhead (with the in-line filter). 2. Printhead is defective - replace.
Configuration/Application incorrect. Excessive Vacuum System Problems (errors 41 and/or 46) Excessive use of Replenish Fluid (light printing) Vacuum pump inlet filter needs service. The mist filter box has probably let too much ink get to the pump, clogging its filter. Improper installation procedure has filled tank with excessive replenish fluid. Replenish algorithm incorrectly assumed evaporation has occurred (excessive ink left system that has not printed, evaporated, or been involved in streakers detected causing an over-replenish condition.
Change configuration to correct settings via Configuration Utilities to match application requirements (e.g. NIE EMULATION). Be sure and install mist filter element properly and replace periodically per SEI 3304 6251. If maintained, the hose between mist filter "box" and vacuum pump should stay clear of ink dye. Review Ink Tank Drain Procedure in SEI 4142 5455. Review Ink Tank Drain Procedure in SEI 4142 5455.
19114
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Command Names and Descriptions

Table 1911. Command Names and Descriptions
Command Code A2
Name TESTS AC RELAYS DRIVERS
Description Bit set in Word 1 indicates driver cannot be turned off Bit set in Word 2 indicates driver cannot be turned on Bit map for either word defined below: Bit 0 = vacuum relay driver Bit 1 = ink heater relay driver Bit 2 = not used Bit 3 = not used Bit 4 = not used Bit 5 = AC supply PCBA assembly not attached Bit 6 = not used Bit 7 = not used
A3
TEST SOLENOIDS and CATCHER HEATER DRIVERS
Bit set in Word 1 indicates driver cannot be turned off. Bit set in Word 2 indicates driver cannot be turned on. Bit map for either word defined below: Bit 0 = catcher heater driver Bit 1 = eyelid 12 volt source driver Bit 2 = eyelid 5 volt source driver Bit 3 = antisiphon valve driver Bit 4 = crossflush valve driver Bit 5 = not used Bit 6 = ink fill valve driver Bit 7 = replenish valve driver
3998 5593007
19115
Command Code A4
Name TEST PRINT MODE CONTROL
Description Bit map for Word 1 defined below: Bit 0 = phase line not correct from Printhead Bit 1 = phase line not correct on ink jet PCBA Bit 2 = print pulse line not correct from Printhead Bit 3 = print pulse line not correct on ink jet PCBA Bit 4 = latchen line not correct from Printhead Bit 5 = latchen line not correct on ink jet PCBA Bit 6 = colreq line not correct on ink jet PCBA Bit 7 = colreq ack line not correct Bit 8 = print jet pwr supply control failed Bit 9 = DAC is not under processor control Bit 10= current detect or charge volt on signal is sensed on in error Bit 11= current detect is not on and should be Bit 12= the 2 lsb to DAC are not working Bit 13= CHG relay is stuck on. Bit map for Word 2 defined below: Bit 0 = current fault interrupt failed Bit 1 = sweep failed
A9
TEST SOLENOID MOTION
Bit set in Word 1 indicates sol not connected Bit set in Word 2 indicates sol motion not detected Bit map for Word 1 defined below: Bit 0 = not used Bit 1 = eyelid driver failed Bit 2 = eyelid sol not connected Bit 3 = antisiphon sol not connected Bit 4 = crossflush sol not connected Bit 5 = not used Bit 6 = fill sol not connected Bit 7 = replenish sol not connected Bit map for Word 2 defined below: Bit 0 = eyelid motion not detected Bit 1 = antisiphon valve motion not detected Bit 2 = crossflush valve motion not detected Bit 3 = replenish valve motion not detected Bit 4 = ink fill valve motion not detected Bit 5 = not used Bit 6 = not used Bit 7 = not used
19116
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Command Code AA
Name TEST INK PUMP/ TRANSDUCER
Description Bit map for Word 1 defined below: Bit 0 = pump voltage too high Bit 1 = pump voltage too low Bit 2 = pump current too high Bit 3 = pump current too low Bit 4 = transducer offset too high Bit 5 = transducer offset too low Bit 6 = transducer buffer amplifier offset fail Bit 7 = transducer buffer amplifier output fail Bit map for Word 1 defined below: Bit 0 = not used Bit 1 = not used Bit 2 = positive air switch not detected Bit 3 = tank temp sensor out of range Bit 4 = printhead temp sensor out of range Bit 5 = spill sensor 1 and/or 2 indicates spill Bit 6 = ink tank level indicates over full Bit 7 = catcher heater driver failed Bit 8 = catcher heater sensed open Bit 9 = catcher heater driver sensed on and should not be Bit 10= catcher voltage sensed on and should not be Bit map for Word 1 defined below: Bit 0 = transducer offset too high Bit 1 = vacuum too high with valve commanded to open Bit 2 = transducer offset too low Bit 3 = vacuum too low with valve commanded to close Bit 4 = vacuum too high with valve commanded to close Bit 5 = vacuum buffer amplifier failed Bit 6 = not used Bit 7 = not used Bit map for Word 2 defined below: Bit 0 = stepper winding1 driver not working Bit 1 = stepper winding2 driver not working Bit 2 = stepper winding3 driver not working Bit 3 = stepper winding4 driver not working Bit 4 = stepper winding1 not connected Bit 5 = stepper winding2 not connected Bit 6 = stepper winding3 not connected Bit 7 = stepper winding4 not connected
AC
TEST POSITIVE AIR SYSTEM
AD
TEST VACUUM SYSTEM
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19117
Command Code AE
Name TEST UMBILICAL Bit map:
Description
Bit 0 = SPB write failure Bit 1 = SPB clock failure Bit 2 = SPB read failure Bit 3 = low Dpath driver failure Bit 4 = high Dpath driver failure Bit 5 = low Dpath return failure Bit 6 = high Dpath return failure Bit 7 = Dclock failure Bit 8 = STIM circuit failed Bit 9 = onboard drop counter failed B1,4 Run diagnostic routine 01 Test system power supplies; returns a bit map of out-oftolerance supplies 0 = passed, 1 = failed. Bit 0 = +5 volt supply Bit 1 = +12 volt supply Bit 2 = +24 volt supply Bit 3 = "enhance" volt supply Bit 4 = -12 volt supply Bit 5 = line volt supply Bit 6 = pressure transducer supply Bit 7 = vacuum transducer supply Bit 8 = AtoD gnd check Bit 9 = printhead hour meter level B4,2 Run diagnostic routine 02 Read ink pump voltage Command echoed, task number, word of data Word of data = pump voltage*10 B4,3 Run diagnostic routine 03 Read ink pump current Command echoed, task number, word of data Word of data = pump current/10 B4,4 Run diagnostic routine 04 Read printhead temperature Command echoed, task number, word of data Word of data = printhead temp in degrees F B4,5 Run diagnostic routine 05 Read ink tank temperature Command echoed, task number, word of data Word of data = ink tank temp in degrees F
19118
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Command Code B4,9
Name Run diagnostic routine 09 Read ink pressure
Description
Command echoed, task number, word of data Word of data = ink pressure in PSI*10 (95 means 9.5 psi)
B4,10
Run diagnostic routine 10
Read vacuum level Command echoed, task number, word of data Word of data = system vacuum in inches of water
B4,11
Run diagnostic routine 11
Test current fault circuits Bit 0 = charge voltage commanded but failed to detect response Bit 1 = current detect line active and it should not be Bit 2 = current fault line active and it should not be Bit 3 = current detect line not active and it should be Bit 4 = current fault line active and it should not be Bit 5 = current fault interrupt not active and it should be Bit 6 = not used Bit 7 = printhead is connected but should not be connected for this test, cancel test.
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19119
FRU Mnemonic Names

Table 1912. FRU Mnemonic Names
Mnemonic B1 B2 B3 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 FAN FL1 FL2 FL3 FL4 FL5 FUSE FUSE LB M1 MJEIB PH P1 P2 S1 Ink Jet Controller PCBA assembly AC supply PCBA assembly Printhead CH driver PCB assembly AC to DC board cable AC cable & bulkhead conn AC cable-board to fluid system Cable-fluid system assembly DC cable-bulkhead to board DC cable-board to fluid system DC cable-fluid system assembly High-speed print cable Command & control port cable Umbilical assembly Fan Filter by pass Filter inline Filter POS air/vacuum control Filter-filter box Filter/restrict or assembly For B2 F1, F2, & F3 For B1 F1, F2, & F3 Lithium battery Manifold assembly MJE interface (AA09) Printhead assembly Vacuum/air pump assembly Ink pump assembly Vacuum transducer assembly
Description
19120
3998 5593007
Table 1912. FRU Mnemonic Names
Mnemonic S2 S3 S4 U1 V1 V2 V3 Spill sensor assembly Float switch assembly Pressure switch assembly Problem outside printer Vacuum control assembly Fill valve assembly Eyelid solenoid
Description
3998 5593007
19121
19122
3998 5593007
Section 20 PEP/Stamp Tests

140000
Endorser test failed Note: Endorser test may fail because of problems in the hole detect circuitry. If procedures failed to resolve problem, try running hole detect test. YES 105 NO 950
PP 01 0010
STEP 100
PROCEDURE Check cables in PEP/stamp unit. Make necessary corrections. Rerun test. Does the problem still exist? Did anything print on the documents? Were there dots missing from print on documents? Was the quality of print poor? Has PEP been cleaned? Clean PEP per procedure in operations guide. Rerun endorsement tests. Does problem still exist? Check PRINT GAP per T & A 3304 3647. Is GAP OK? Reset GAP. Rerun test. Does the problem still exist? Has head been stoned? Stone head per T & A 1076 3894. Rerun endorsement tests. Does the problem still exist?
105 110 120 130 140
110 340 130 150 100
230 120 950 140 950
150 160 170 180
170 100 190
160 950 180
190 200 210
950 950 950
190 200
Replace head. Rerun test. Does the problem still exist? Replace printer driver PCBA and rerun test. Does the problem still exist?
3998 5593007
201
PEP/Stamp Tests
PP 01 0010
Endorser test failed (continued) STEP 210 220 230 PROCEDURE Replace platen and rerun test. Does the problem still exist? Replace spring and rerun test. Does the problem still exist? Power off NDP 1150. With digital multi meter check F1 and F2 on printer driver PCBA. Do they measure 0 ohms? Replace the fuse that is blown. Rerun endorsement test. Does the problem still exist? 240 While running endorsement test (make sure you have enough documents in primary hopper to make measurements), check PSEN (Q3 collector) on printer driver board. Does it switch between logic 0 ( <.8 VDC) and logic 1 ( >2.4 VDC)? While running endorsement subtest, as in 240, check PFEN1 (J323 2) on printer driver PCBA. Does it switch between logic 0 ( <.8 VDC) and logic 1 ( >2.4 VDC)? Replace printer driver PCBA and rerun test. Does the problem still exist? Replace printhead cable and rerun test. Does the problem still exist? Replace Endorser Controller PCBA and rerun test. Does the problem still exist? While running endorsement subtests, check J323-50 on printer driver PCBA. Does it switch from logic 0 ( < .8 VDC) to logic 1 ( > 2.4 VDC)? Replace printer driver PCBA and rerun test. Does the problem still exist? Problem is with printhead cable. Replace and rerun test. Does the problem still exist? Problem is with printhead cable. Replace and rerun test. Does the problem still exist? Replace Endorser controller PCBA. Rerun test. Does the problem still exist? 230 290 950 250 YES 220 97200 240 NO 950 950 235
235
250
260
270
260 270 280 290
97200 280 97200 300
950 950 950 320
300 310 320 330
310 97200 330 340
950 950 950 950
202
3998 5593007
PEP/Stamp Tests
PP 01 0010
Endorser test failed (continued) STEP 340 350 PROCEDURE Has PEP been cleaned? Clean PEP and rerun test. Does the problem still exist? 360 370 Adjust print gap per T & A 3304 3647. Was gap okay? Reset gap per T & A. Rerun test. Does the problem still exist? 380 390 Has printhead been stoned? Stone head and rerun test. Does the problem still exist? 400 While running endorsement tests, use oscilloscope to check collector of following transistors on printer driver board. Q14, Q17, Q20, Q23, Q26, Q29, Q32, Q35, Q38, Q41, Q44, Q47, Q50, Q53, Q56 Q5, Q8, Q11. Do all collectors switch between 0 and +24 V? 410 Remove head and repeat measurements in step 400. Do all collectors switch between 0 and +24 V? 420 Using schematics to trace collector signal(s) that did not switch to edge connector. Are inputs switching from logic 0 ( < .8 VDC) to logic 1 ( > 2.4 VDC)? 430 Replace printer driver PCBA and rerun test. Does the problem still exist? 440 Replace printhead cable and rerun test. Does the problem still exist? 450 950 97200 950 430 440 460 420 490 410 100 950 100 400 450 390 100 380 950 370 YES 360 NO 350
3998 5593007
203
PEP/Stamp Tests
PP 01 0010
Endorser test failed (continued) STEP 450 PROCEDURE Replace Endorser Controller (AA09) and rerun test. Does the problem still exist? 460 Check resistance of the windings in the printhead. Are they all between 2.2 and 2.7 ohms? 470 Replace printer driver PCBA and rerun test. Does the problem still exist? 480 Replace printhead and rerun test. Does the problem still exist? 490 Use scope to check collectors of Q15, Q18, Q21, Q24, Q27, Q30, Q33, Q36, Q39, Q42, Q45, Q48, Q51, Q54, Q57, Q6, Q9, Q12, on printer driver board. Do all collectors switch between 0 and -24 VDC? 500 Check resistance of the windings in printhead. Are they all between 2.2 and 2.7 ohms? 510 Replace printhead and rerun test. Does the problem still exist? 520 Replace printhead cable and rerun test. Does the problem still exist? 530 Replace printer driver PCBA and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 97200 950 530 950 97200 950 520 510 500 410 97200 950 97200 950 470 480 97200 950 YES NO
204
3998 5593007
PEP/Stamp Tests
140050
Stamp Jam: Either the Stamp is unable to move or the home/encoder assembly is not working. STEP 100 PROCEDURE Check connectors (J1, J2, J3, J4) on the stamp driver board and their respective cables. Make necessary corrections. Does the problem still exist? 110 On stamp driver board, remove connector J2 and place DVM probe on U9-4 (HOMEN). Rotate stamp by hand, make measurement, and then put J2 back on the board. Does the signal switch between logic 1 ( >2.4 VDC) and logic 0 ( <0.8 VDC)? 120 Measure U3-10 on stamp driver board while rotating the stamp. Does the signal switch between 0 V and +24 VDC? 130 Measure P1-7 (HOMELED) on stamp driver board. Does signal measure between 0.6 VDC and 1.2 VDC? 140 On Stamp driver board, remove connector J2 and place DVM probe on U9-10 (ENCODER). Rotate stamp by hand, make measurement, and then put J2 back on the board. Does signal switch from logic 1 to logic 0 to logic 1? 150 Measure U3-4 on stamp driver board while rotating the stamp. Does the signal switch between 0 V and +24 VDC? 160 Measure P1-6 (ENCODLED) on stamp driver board. Does the signal measure between 0.6 VDC and 1.2 VDC? 830 830 190 830 830 140 110 YES
PP 01 0020
NO
950
120
130
820
150
160
820
3998 5593007
205
PEP/Stamp Tests
PP 01 0020
Stamp Jam: Either the Stamp is unable to move or the home/encoder assembly is not working. (continued) STEP 190 PROCEDURE Using MTR disk, go to PEP/Stamp Endorser Test menu. Select Stamp Motor Phase Tests. On submenu, select Phase Driver Check. If J4 on the Stamp Driver board is connected, turn power off and remove it. Select PHASE A from the menu and measure Q13 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 200 210 Measure Q11 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-8 (CHOPAC). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-8 (PHAENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 25. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? From the MTR Phase Driver Check submenu, select PHASE B and measure Q15 collector (metal chase of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 250 260 Measure Q12 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-9 (CHOPBD). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-4 (PHBENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 23. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? 250 260 300 270 830 830 200 210 240 220 830 830 YES NO
220
830
230
230
800
810
240
270
830
290
290
800
810
206
3998 5593007
PEP/Stamp Tests
PP 01 0020
Stamp Jam: Either the Stamp is unable to move or the home/encoder assembly is not working. (continued) STEP 300 PROCEDURE From the MTR Phase Driver Check submenu, select PHASE C and measure Q14 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 310 320 Measure Q11 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-8 (CHOPAC). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-6 (PHCENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 21. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? From the MTR Phase Driver Check submenu, select PHASE D and measure Q16 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 360 370 Measure Q12 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-9 (CHOPBD) Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-2 (PHDENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 19. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? If J4 on the stamp driver board is still removed, plug it back in. Using MTR disk, go to PEP/Stamp endorser test. On submenu, select Stamp Motor Phase Test. On submenu, select Phase Current Check. Select Standby Current. On the stamp driver board put a voltmeter between U2-8 and U2-12. Do not use a scope! Does it measure between 0.2 VDC and 0.3 VDC? 450 410 360 370 400 380 830 830 310 320 350 330 830 830 YES NO
330
830
340
340
800
810
350
380
830
390
390
800
810
400
3998 5593007
207
PEP/Stamp Tests
PP 01 0020
Stamp Jam: Either the Stamp is unable to move or the home/encoder assembly is not working. (continued) STEP 410 PROCEDURE On stamp driver board, put a meter or scope probe on U1-13. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 15. Does it measure more than 2.4 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 17. Does it measure more than 2.4 VDC? In the MTR menu choose low current. On the stamp driver board put a voltmeter between U28 and U2-12. Do not use a scope! Does it measure between 0.4 VDC and 0.5 VDC? 460 On stamp driver board, put a meter or scope probe on U1-13. Does it measure less than 0.7 VDC? On AA09 measure P1 pin 15. Does it measure less than 0.7 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 17. Does it measure more than 2.4 VDC? In the MTR menu choose medium current. On the stamp driver board put a voltmeter between U2-8 and U2-12. Do not use a scope! Does it measure between 0.6 VDC and 0.7 VDC? 510 On stamp driver board, put a meter or scope probe on U1-13. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 15. Does it measure more than 2.4 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 0.7 VDC? On AA09 measure P1 pin 17. Does it measure less than 0.7 VDC? 550 530 510 520 500 480 460 470 YES 430 NO 420
420 430
800 830
810 440
440 450
800
810
470 480
800 830
810 490
490 500
800
810
520 530
800 830
810 540
540
800
810
208
3998 5593007
PEP/Stamp Tests
PP 01 0020
Stamp Jam: Either the Stamp is unable to move or the home/encoder assembly is not working. (continued) STEP 550 PROCEDURE In the MTR menu choose high current. On the stamp driver board put a voltmeter between U28 and U2-12. Do not use a scope! Does it measure between 0.8 VDC and 0.9 VDC? On stamp driver board, put a meter or scope probe on U1-13. Does it measure less than 0.7 VDC? On AA09 measure P1 pin 15. Does it measure less than 0.7 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure less than 0.7 VDC? On AA09 measure P1 pin 17. Does it measure less than 0.7 VDC? Replace Stamp Control Cable. Does the problem still exist? Replace AA09. Does the problem still exist? Replace home/encoder sensor assembly. Does the problem still exist? Replace stamp driver PCBA. Does the problem still exist? Replace the stamp motor. Does the problem still exist? Verify proper operation. End of procedure. 97200 97200 950 950 YES 840 NO 560
560
580
570
570 580
800 830
810 590
590 800 810 820 830 840 950
800 97200 97200
810 950 950
3998 5593007
209
PEP/Stamp Tests
140100
No ribbon present or ribbon always reporting present. Note: The PEP/Stamp Endorser Controller schematic package is required for this procedure (part #2493 0091). YES
PP 01 0030
STEP 100
PROCEDURE Depress ribbon presence switch. Using DVM measure RIBOFFN (J323-52) on printer driver PCBA. Does signal change from logic 1 ( > 2.4 VDC) to logic 0 ( < .8 VDC)?
NO
110
150
110
Measure signal RIBOFFN (P2-37) on AA 09. Does it switch between logic 1 ( > 2.4 VDC) and logic 0 ( < .8 VDC)? 120 97200 130 950
120 130
Replace AA09 (endorser controller) and rerun test. Does the problem still exist? Replace printer control cable and rerun test. Does the problem still exist?
140
950
140
Problem is back plane signal. Use schematics to trace signal RIBOFFN (SH.01.09.54). Make necessary correction and rerun test. Does the problem still exist? 97200 160 950 170
150 160
Does RIBSW (J321-55) change from +24 VDC to 0 VDC? Replace printer driver PCBA and rerun tests. Does the problem still exist?
97200
950
170
Replace ribbon switch and rerun POC/MTR tests. Does the problem still exist? 180 950
180
Replace printer drive cable. Does problem still exist? 190 950
190
Replace hole detect harness. Does problem still exist? 97200 950
950
2010
3998 5593007
PEP/Stamp Tests
140200
Ribbon jams not detected. STEP 100 PROCEDURE Turn transport motors on by pressing START/STOP bar. Does ribbon motor rotate? 110 On printer driver board, measure (J323-12) RIBJAMN. Does signal go from logic 1 ( >2.4 VDC) to logic 0 ( < .8 VDC) when motor is stopped by hand? 120 On AA09, measure P2-39 when ribbon motor is stopped by hand. Does signal go from logic 1 ( >2.4 VDC) to logic 0 ( <.8 VDC) when the motor is stopped by hand? 130 Turn transport motors on by pressing the START/STOP bar. On the printer driver board, measure J321-48. Does it measure +24 VDC? 140 With transport motors on, measure J321-47 on the printer driver board. Does it measure +12 VDC? 150 On printer driver board, measure chip U19 pin 1 while transport motors are on. Does it measure less than .8 VDC? 160 On AA09 measure P2-61. Does it measure less than 0.8 VDC? 170 Power off sorter and check fuse F1 on printer driver board. Does it measure 0 ohms? 800 Replace printer drive cable. Does problem still exist? 810 Replace printer drive cable. Does problem still exist? 97200 97200 840 810 800 850 140 820 120 110 YES
PP 01 0040
NO
130
800
810
170
150
160
820
830
950
950
3998 5593007
2011
PEP/Stamp Tests
PP 01 0040
Ribbon jams not detected. (continued) STEP 820 PROCEDURE Replace Endorser Control PCBA (AA09). Does problem still exist? 830 Replace fuse F1 on printer driver board. Does the problem still exist? 840 Check power supply and endorser power cable. Make necessary corrections. Does problem still exist? 950 Verify proper operation. End of procedure. 97200 950 100 950 97200 950 YES NO
2012
3998 5593007
PEP/Stamp Tests
140300
Ribbon motor rotates always. STEP 100 PROCEDURE Make sure transport motors are off. On printer driver PCBA measure J323-8. Is signal logic 0 ( < .8 VDC)? 110 Replace printer driver PCBA. Does the problem still exist? 120 On AA09 (Endorser Controller board), measure RIBMOTN (P2-61). Is it logic 0 ( < .8 VDC)? 130 140 Replace AA09. Does the problem still exist? Replace cable and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 97200 130 97200 97200 120 YES
PP 01 0050
NO
110
950
140 950
950
3998 5593007
2013
PEP/Stamp Tests
Note: 140350
The same procedure is used to resolve each of the failure codes on this page. PP 02 0010
Home sensor test times out waiting for control semaphore to be released.
140360
Home sensor test times out waiting for status semaphore to be released. STEP 100 PROCEDURE Replace card AA09. Does the problem still exist? 110 Replace card AA17. Does the problem still exist? 950 Verify proper operation. End of procedure. 97200 110 YES
PP 02 0020
NO
950
950
2014
3998 5593007
PEP/Stamp Tests
140370
Home sensor test failed. A stamp jam occurred. STEP 100 PROCEDURE Check connectors (J1, J2, J3, J4) on the stamp driver board and their respective cables. Make necessary corrections. Does the problem still exist? 110 On stamp driver board, remove connector J2 and place DVM probe on U9-4 (HOMEN). Rotate stamp by hand, make measurement, and then put J2 back on the board. Does the signal switch between logic 1 (>2.4 VDC) and logic 0 (<0.8 VDC)? 120 Measure U3-10 on stamp driver board while rotating the stamp. Does the signal switch between 0 V and +24 VDC? 130 Measure P1-7 (HOMELED) on stamp driver board. Does signal measure between 0.6 VDC and 1.2 VDC? 140 On Stamp driver board, remove connector J2 and place DVM probe on U9-10 (ENCODER). Rotate stamp by hand, make measurement, and then put J2 back on the board. Does signal switch from logic 1 to logic 0 to logic 1? 150 Measure U3-4 on stamp driver board while rotating the stamp. Does the signal switch between 0 V and +24 VDC? 160 Measure P1-6 (ENCODLED) on stamp driver board. Does the signal measure between 0.6 VDC and 1.2 VDC? 830 830 190 830 830 140 110 YES
PP 02 0030
NO
950
120
130
820
150
160
820
3998 5593007
2015
PEP/Stamp Tests
PP 02 0030
Home sensor test failed. A stamp jam occurred. (continued STEP 190 PROCEDURE Using MTR disk, go to PEP/Stamp Endorser Test menu. Select Stamp Motor Phase Tests. On submenu, select Phase Driver Check. If J4 on the Stamp Driver board is connected, turn power off and remove it. Select PHASE A from the menu and measure Q13 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 200 210 Measure Q11 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-8 (CHOPAC). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-8 (PHAENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 25. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? From the MTR Phase Driver Check submenu, select PHASE B and measure Q15 collector (metal chase of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 250 260 Measure Q12 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-9 (CHOPBD). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-4 (PHBENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 23. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? From the MTR Phase Driver Check submenu, select PHASE C and measure Q14 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 310 330 250 260 300 270 830 830 200 210 240 220 830 830 YES NO
220
830
230
230
800
810
240
270
830
290
290
800
810
300
2016
3998 5593007
PEP/Stamp Tests
PP 02 0030
Home sensor test failed. A stamp jam occurred. (continued) STEP 310 320 PROCEDURE Measure Q11 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-8 (CHOPAC). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-6 (PHCENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 21. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? From the MTR Phase Driver Check submenu, select PHASE D and measure Q16 collector (metal case of transistor) on the stamp driver board. Does it switch from 0 VDC to -24 VDC? 360 370 Measure Q12 collector. Does it switch between +24 VDC and 0 VDC? Measure U8-9 (CHOPBD) Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? Measure U1-2 (PHDENN). Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? On AA09, measure P1 pin 19. Does it switch between logic 0 (<0.8 VDC) and logic 1 (>2.4 VDC)? If J4 on the stamp driver board is still removed, plug it back in. Using MTR disk, go to PEP/Stamp endorser test. On submenu, select Stamp Motor Phase Test. On submenu, select Phase Current Check. Select Standby Current. On the stamp driver board put a voltmeter between U2-8 and U2-12. Do not use a scope! Does it measure between 0.2 VDC and 0.3 VDC? 410 On stamp driver board, put a meter or scope probe on U1-13. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 15. Does it measure more than 2.4 VDC? 450 430 410 420 360 370 400 380 830 830 YES 320 350 NO 830 830
330
830
340
340
800
810
350
380
830
390
390
800
810
400
420
800
810
3998 5593007
2017
PEP/Stamp Tests
PP 02 0030
430 On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 17. Does it measure more than 2.4 VDC? In the MTR menu choose low current. On the stamp driver board put a voltmeter between U28 and U2-12. Do not use a scope! Does it measure between 0.4 VDC and 0.5 VDC? 460 On stamp driver board, put a meter or scope probe on U1-13. Does it measure less than 0.7 VDC? On AA09 measure P1 pin 15. Does it measure less than 0.7 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 17. Does it measure more than 2.4 VDC? In the MTR menu choose medium current. On the stamp driver board put a voltmeter between U2-8 and U2-12. Do not use a scope! Does it measure between 0.6 VDC and 0.7 VDC? 510 On stamp driver board, put a meter or scope probe on U1-13. Does it measure more than 2.4 VDC? On AA09 measure P1 pin 15. Does it measure more than 2.4 VDC? On stamp driver board, put a meter or scope probe on U1-15. Does it measure more than 0.7 VDC? On AA09 measure P1 pin 17. Does it measure less than 0.7 VDC? In the MTR menu choose high current. On the stamp driver board put a voltmeter between U28 and U2-12. Do not use a scope! Does it measure between 0.8 VDC and 0.9 VDC? 560 On stamp driver board, put a meter or scope probe on U1-13. Does it measure less than 0.7 VDC? 580 570 840 560 550 530 510 520 500 480 460 470 830 440
440 450
800
810
470 480
800 830
810 490
490 500
800
810
520 530
800 830
810 540
540 550
800
810
2018
3998 5593007
PEP/Stamp Tests
PP 02 0030
Home sensor test failed. A stamp jam occurred. (continued) STEP 570 PROCEDURE On AA09 measure P1 pin 15. Does it measure less than 0.7 VDC? 580 On stamp driver board, put a meter or scope probe on U1-15. Does it measure less than 0.7 VDC? 590 On AA09 measure P1 pin 17. Does it measure less than 0.7 VDC? 800 Replace Stamp Control Cable. Does the problem still exist? 810 Replace AA09. Does the problem still exist? 820 Replace home/encoder sensor assembly. Does the problem still exist? 830 Replace stamp driver PCBA. Does the problem still exist? 840 Replace the stamp motor. Does the problem still exist? 950 Verify proper operation. End of procedure. 97200 950 97200 950 97200 950 97200 950 800 810 830 590 800 810 YES NO
3998 5593007
2019
PEP/Stamp Tests
140380
Home sensor test failed. Stamp home sensor implicated. STEP 100 PROCEDURE Check connectors (J1, J2, J3, J4) on the stamp driver board and their respective cables. Make necessary corrections. Does the problem still exist? 110 Using MTR disk, go to PEP/Stamp Endorser Tests menu and select Stamp Motor Phase Tests. On submenu, select Hold Stamp. Execute T&A 3304 3654 to home adjust the home sensor. Is T&A setting OK? 120 Reset to correct setting. Does the problem still exist? 130 950 Go to line 19075 step 190. Verify proper operation. End of procedure. 130 120 110 YES
PP 02 0040
NO
950
130
950
2020
3998 5593007
PEP/Stamp Tests
Note: 140390
Different procedures are used to resolve each of the failure codes on this page. PP 02 0050
Home sensor test failed. Bad stamp driver board reported.
STEP 100
YES
NO
110
950
110
On AA09, measure P1-9 (STAMPBADN). Does the signal measure less than 2.4 VDC? 120 130
120
On stamp driver board place DVM probe on chip U6 pin 8 (STAMPBADN). Does the signal measure less than 2.4 VDC? 830 800
130 800
Go to line 19075 step 190. Replace Stamp Control Cable. Does the problem still exist? 97200 950
830
Replace stamp driver PCBA. Does the problem still exist? 97200 950
950
140400
Data communication between PEP and stamp has failed. STEP 100 PROCEDURE Replace AA09 and rerun test. Does the problem still exist? 950 Verify proper operation. End of procedure. 97200 YES
PP 02 0060
NO
950
3998 5593007
2021
PEP/Stamp Tests
Note: 140410
The same procedure is used to resolve each of the failure codes on this page. PP 02 0070
Invalid status code received from PEP processor.
140420
Phase driver check timed out waiting for control semaphore to be released.
PP 02 0080
140430
Phase current check timed out waiting for control semaphore to be released.
PP 02 0090
140440
Phase current check timed out waiting for control semaphore to be released. STEP 100 PROCEDURE Replace card AA09. Does the problem still exist? 110 Replace card AA17. Does the problem still exist? 950 Verify proper operation. End of procedure. 97200 110 YES
PP 02 0100
NO
950
950
2022
3998 5593007
PEP/Stamp Tests
140500
Hole Test Fails. STEP 100 110 120 130 140 PROCEDURE Is lamp lit? On printer driver PCBA measure lamp (J321-49). Is signal equal logic 1 ( > 2.4 VDC)? Replace lamp. Does the problem still exist? Replace printer driver PCBA. Does the problem still exist? Rerun hole detect test. While documents are flowing, measure on printer driver PCBA HOLESENSORN (J321-58). Does the signal switch from +15 V to +12 V. Again while running hole detect test, measure HOLESENSEN (J323-14). Does signal switch from logic 1 ( > 2.4 VDC) to logic 0 ( < .8 VDC)? Replace printer driver PCBA. Rerun test. Does the problem still exist? On AA09, measure HOLESENSEN (P2-45). Does signal switch from logic 1 ( > 2.4 VDC) to logic 0 ( < .8 VDC)? Replace cable and rerun test. Does the problem still exist? Replace AA09 and rerun test. Does the problem still exist? On Matrix Endorser Hole Sensor board (MHSA) measure HOLESENSORN (J325-5). Does signal switch between +15 VDC and +12 VDC? Replace cable and rerun test. Does the problem still exist? Replace matrix hole sensor assembly (#2493 0836). Rerun test. Does the problem still exist? Verify proper operation. End of procedure. YES 140 120 97200 97200 150
PP 03 0010
NO 110 130 950 950 200
150
170
160
160 170
97200 190
950 180
180 190 200
97200 97200 210
950 950 220
210 220 950
97200 97200
950 950
3998 5593007
2023
PEP/Stamp Tests
140600
One or more of the endorser print needles is firing continuously. STEP 100 PROCEDURE Replace the printhead cable and rerun the test Does the problem still exist? 110 Replace the Endorser Controller/Printer Driver PCBA interface cable and rerun test. Does the problem still exist? 120 Replace the printer driver PCBA and rerun test. Does the problem still exist? 130 Replace the Endorser Controller (AA09) and rerun test. Does the problem still exist? 140 Replace the printhead and rerun test. Does the problem still exist? 950 Verify operation. End of procedure 97200 140 130 120 110 YES
PP 04 0010
NO
950
950
950
950
950
2024
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PEP/Stamp Tests
Note: 140700
Different procedures are used to resolve each of the failure codes on this page. PP 04 0020 - PP 04 0190
Matrix Printhead pin XX is not functioning.
STEP 100
PROCEDURE Replace the printhead cable and rerun test. Does the problem still exist?
YES
NO
110
950
110
Replace the Endorser Controller/Printer Driver PCBA interface cable and rerun test. Does the problem still exist? 120 950
120
Replace the Printer Driver PCBA and rerun test. Does the problem still exist? 130 950
130
Replace the Endorser Controller (AA09) and rerun test. Does the problem still exist? 140 950
140
Replace the printhead and rerun test. Does the problem still exist? 97200 950
950
140800
One of the endorser print needles is not firing. STEP 100 PROCEDURE Replace the printhead cable and rerun the test. Does the problem still exist? 110 Replace the Endorser Controller/Printer Driver PCBA interface cable and rerun test. Does the problem still exist? 120 Replace the Printer Driver PCBA and rerun test. Does the problem still exist? 130 Replace the Endorser Controller (AA09) and rerun test. Does the problem still exist? 140 Replace the printhead and rerun test. Does the problem still exist? 950 End of procedure 97200 140 130 120 110 YES
PP 04 0200
NO
950
950
950
950
950
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2025
PEP/Stamp Tests
2026
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Section 21 CAR Diagnostics (U4/JPEG Imaging System)

180000 CAR xx xx
This section contains the manual procedures required to isolate and repair failures related to the IR 9210 Courtesy Amount Read (CAR) System. These procedures are for U4/JPEG imaging systems only. For dual image systems, refer to Section 24, "CAR Diagnostics (Dual Image System)." Both power-on confidence (POC) and MTR error codes for CAR are contained in this section.
183020
CAR 00 10
The CAR PRESENT jumper on board 10 of the AA gate may not be installed. If the following error code/message is reported, follow the procedure below.
Error Code CAR 00 10
Message CAR UNIT REPORTED NOT PRESENT
STEP 100
PROCEDURE This error should never occur unless the wrong Main Processor Board EPROMs are installed or the POC tests have been bypassed AND either the CAR PRESENT jumper hasnt been installed or an error exists which prevents the CAR PRESENT jumper from being detected. Are the correct version EPROMs installed on the Main Processor Board?
YES
NO
120
110
110
Install the correct version of EPROMs. Go to 950.
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211
CAR Diagnostics (U4/JPEG Imaging System)
183020
STEP 120 PROCEDURE Have the POC tests been bypassed? (If so, it will be indicated on the monitor.) Make the necessary change that enables the POC tests to be executed. If the correct EPROMs have been installed and the POC tests are allowed to execute properly, any error associated with detecting the CAR PRESENT jumper will be detected during POC. Reboot the document processor to execute POC. Are an error code and message displayed? 150 Refer to the Error Code Line procedure associated with the error code displayed during POC. Load the MTR disk and attempt to execute one of the CAR test selections. Does the error CAR 00 10 reappear? 170 950 Elevate the problem to the next level of support. Verify proper operation. End of procedure. 170 150 YES 130
CAR 00 10
NO 140
130 140
160
160
950
212
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183050
CAR 01 1x
CAR Interface Test Status errors. If any of the following error codes / messages are reported, follow the procedure below.
Error Code CAR 01 13 CAR 01 14
Message CONTROL INTERFACE TEST STATUS: BUSY CONTROL INTERFACE TEST STATUS: ERROR
STEP 100
PROCEDURE Re-execute the Control Interface test. Does the problem still exist?
YES
NO
120
950
120
Attach the monitor and keyboard to the CAR module. Is an error code displayed after the CAR unit completes its POC? Retrieve the CAR status at the car unit. Is an error code displayed? Refer to the IR 9210 Courtesy Amount Read (CAR) Module Technical Manual, Volume 4 for the error code line procedures referred to by the error code displayed.
140
130
130 140
170
150
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213
STEP 170
PROCEDURE Reseat the CAR module AU Board. Re-execute the Control Interface Test. Does the problem still exist?
YES
NO
190
950
190
Replace the AU Board. Re-execute the Control Interface Test. Does the problem still exist? 210 950
200
Replace each of the two Control Interface cables one at a time. Re-execute the Control Interface Test after each cable replacement. Does the problem still exist? 210 950
210 950
Elevate the problem to the next level of support. Verify proper operation. End of procedure.
214
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183060
CAR 02 1x
CAR Unit POC Results Errors. If any of the following error codes/messages are reported, follow the procedure below.
Error Code CAR 02 15 CAR 02 16 CAR 02 17
Message CAR UNIT POC RESULTS STATUS: BUSY CAR UNIT POC RESULTS STATUS: ERROR THE CAR UNIT POC REPORTED A FAILURE
STEP 100
PROCEDURE Power down the sorter. Verify the control interface cables between the main processor boards are connected and seated properly. Reexecute the "RETRIEVE CAR UNIT POC RESULTS" MTR. Does the problem still exist?
YES
NO
102
950
102
Run the Control Interface test. Does the test pass? 120 115
115 120
Follow the manual procedure for Control Interface MTR Error Code. Attach the monitor and keyboard to the CAR module. Does the CAR Unit complete its POC test successfully. Refer to the IR 9210 Courtesy Amount Read (CAR) Module Technical Manual, Volume 4 for the error code line procedures referred to by the error code displayed or the CCC table if no error code is displayed. 150 140
140
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215
150
Disconnect and then reconnect the Control Interface cables between the CAR module and the document processor I/O box and between the I/O connector box and the CIB. Re-execute the Control Interface Test. Does this test pass? 170 115
216
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183060
CAR 02 1x
STEP 170
PROCEDURE Reseat the CAR module AU Board. Re-execute the "RETRIEVE CAR UNIT POC RESULTS" MTR. Does the problem still exist?
YES 180
NO 950
180
Replace the AU Board. Re-execute the "RETRIEVE CAR UNIT POC RESULTS" MTR. Does the problem still exist?
200
950
200
Replace each of the two Control Interface cables one at a time. Re-execute the "RETRIEVE CAR UNIT POC RESULTS" MTR after each cable replacement. Does the problem still exist? 210 950
210 950
Elevate the problem to the next level of support. Verify proper operation. End of procedure.
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217
183070
CAR 02 18
Upon completion of its POC tests, the CAR unit failed to enter either the POC Failed or OP state.
If the following error code / message is reported, follow the procedure below.
Error Code CAR 02 18
Message CAR UNIT POC RETURNED AN INVALID STATE
STEP 100
PROCEDURE Run test selection 2, RETRIEVE THE CAR UNIT POC TEST RESULTS, from the CAR System MTR Test Menu. Does the error code CAR 02 18 still get reported?
YES 110
NO 950
110
The design specifies that only two states (POC Failed and OP) are valid upon completion of the CAR modules POC. A problem exists with the CAR module. Attach the CAR modules monitor and keyboard. Apply power to the CAR module. Upon completion of the CAR modules POC, is an error code reported on the monitor? 120 130
120 130 950
Refer to the ECLP in the CAR Technical Manual, Vol 4 for additional troubleshooting procedures. Elevate the problem to the next level of support. Verify proper operation. End of procedure.
218
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183120
CAR 08 xx
CAR Interface Test communication status errors. If any of the following error codes / messages are reported, follow the procedure below.
Error Code CAR 08 80 CAR 08 81 CAR 08 82 CAR 08 83 CAR 08 84 CAR 08 85 CAR 08 86 CAR 08 87
Message UNEXPECTED RESELECTION IDENTIFICATION ERROR ABORT RECEIVED BUS DEVICE RESET RECEIVED BUS RESET HOST ADAPTER ERROR UNEXPECTED SELECTION REPORTED BUSY AFTER 3 RETRIES
STEP 100
PROCEDURE Is the Control Interface Cable between the CAR Unit and the Main Processor Board which resides in the AA Gate is properly attached at both ends? Properly reattach the cable and re-execute the CAR Interface Test. Does the problem still exist? Disconnect the Control Interface Cable and verify that no connecting pins are bent or missing then re-connect the cable. Do this at both ends then re-execute the CAR Interface Test. Does the problem still exist?
YES 120
NO 110
110 120
120 950
130
950
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219
183120
CAR 08 xx
STEP 130
PROCEDURE Verify that the CAR Unit is operating properly. See the IR 9210 Courtesy Amount Read (CAR) Module Technical Manual, Volume 4 for the proper procedures. Was a problem detected with the CAR Unit?
YES
NO
140
150
140
Fix the problem with the CAR Unit and re-execute the CAR Interface Test. Does the problem still exist? 150 160 950 950
150
Power down the document processor and CAR Unit and replace the Control Interface Cable. Power the document processor back up and reexecute the Control Interface Test as directed. Does the problem still exist?
160
Refer to the IR 9210 Courtesy Amount Read (CAR) Module Technical Manual, Volume 4 for additional troubleshooting procedures. Verify proper operation. End of procedure.
950
2110
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Section 22 Dual Image Manual Procedures

This section deals with diagnosis of problems in the Dual Image modules in the NDP 1XXX. It covers the camera submodule and the image camera server (ICS). The camera submodule, located next to the first pocket module, consists of the optics, electronics, and power supplies necessary to capture document images.
Additional POC Test Status Information

In the CAPI Configuration, additional status information is displayed by the Exception Handler when POC test errors occur. The top line of the Exception Handler window contains 5 bytes in parenthesis, followed by 8 additional bytes. The 5 byte grouping in parenthesis is the error database ID. This is used by the Exception Handler to reference a table entry in the error database that contains the text for the error description, manual procedure reference, and suspect components list. The 8 bytes to the right of the error database ID are extended status bytes. For most POC test errors, these bytes are not used and are set to zero. For the Dual Imaging Module POC test, they are used to relay additional information that can be used to further diagnose a problem. The extended status information is described below:
XX XX XX XX XX XX XX XX 8th Byte: Not Used 7th Byte: Not Used 6th Byte: Rear Photodiode 1 Intensity 5th Byte: Rear Photodiode 0 Intensity 4th Byte: Front Photodiode 1 Intensity 3rd Byte: Front Photodiode 0 Intensity 2nd Byte: Suspect PCBAs Slot ID 1st Byte: Not Used
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221
Dual Image Manual Procedures
The N/F and N/F/S PCBAs have a bank of eight LEDs (light emitting diodes) that provide visual indication of the state of the board. The LEDs are identified with a legend on the front edge of the PCBA. The following table defines the conditions under which each LED will be turned on.
LED Bank
+5 Volts Present IIB PRES Set if the NF or NFS PCBAs detect the presence of a DMIIB PCBA in the AA logic gate. SW IPL Set if software has set the item present level (IPL) active for diagnostics. IIB IPL Normally set by the DMIIB PCBA if BOL I2 (beam of light I2 in the image module) has sensed an item. V1 DP Set when sending normalized image data to compressors over the V1 bus. (Used by the NF PCBA to feed the primary compressor; the NFS PCBA uses it to feed the odd compressors) V2 DP - Set when sending normalized image data to compressors over the V2 bus. (Used by NF PCBA to feed the AUX compressor; the NFS PCBA uses it to feed the even compressors) IRQ Interrupt request to the PCI Image Interface (PCI3) PCBA in the Image Capture Server (ICS). RESET Set if board is being reset.
The Turbo CCITT has a bank of eight LEDs (light emitting diodes) that provide visual indication of the state of the board. The following table defines the conditions under which each LED will be turned on.
LED Bank RETCDEB Compressed data ready for retrieval from output buffer B CAPCDEB Capture compressed data to output buffer B RETDOCB Retrieve document data from input buffer B CAPDOCB Capture document data to input buffer B RETCDEA Compressed data ready for retrieval from output buffer A CAPCDEA Capture compressed data to output buffer A RETDOCA Retrieve document data from input buffer A CAPDOCA Capture document data to input buffer A
222
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The Turbo JPEG PCBA has a bank of 12 LEDs that provide visual indication of the state of the board. The LEDs are identified with a legend on the front edge of the PCBA. The following table define the conditions under which each LED will be turned on.
LED Bank SPARE not used EXTENDED DP Set while a document enters the document buffer. (This signal extends the length of an incoming document to end on a multiple of eight scaled pixels as required by the block generator and compressor functions on the board). CODE DP Set if the Turbo JPEG PCBA is transmitting JPEG compressed image data to the ICS over the Video Bus. ZR36050 INT indicates that the compressor integrated circuit has interrupted the digital signal processor (DSP) integrated circuit. ZR36050 BUSY Set while the compressor integrated circuit processes a document. Off otherwise. ZR36015 BUSY Set while the Block Generator integrated circuit processes a document. Off otherwise. DOC BUF OVERFLOW Set if the onboard document buffer memory contains its maximum of two images, and a third image tries to enter. This error condition is latched until cleared internally or by or a board reset, which clears the LED. DOC BUF BUSY - Set while either onboard document buffer memory is sending a document to the grayscale remapper and the compression circuits. Off otherwise. BUF2 SENDING Set while the second document buffer is transmitting a document to the grayscale remapper and the compression circuits. Off otherwise. BUF2 RECEIVING Set while the second document buffer is capturing a document from the scaling circuit. Off otherwise. BUF1 SENDING - Set while the first document buffer is transmitting a document to the grayscale remapper and the compression circuits. Off otherwise. BUF1 RECEIVING - Set while the first document buffer is capturing a document from the scaling circuit. Off otherwise.
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223
Dual Image Camera Module Error Codes (DIMG xx xx)

This subsection describes error codes for the following types of failure for the Dual Image Camera Module:
Common failures (DIMG xx xx) Interface MTR (DIMG 01 xx) Analog Interface Test (DIMG 22 xx) Calibrate Front Camera (DIMG 23 xx) Calibrate Rear Camera (DIMG 24 xx) Normalizer and Diagnostics RAM test (DIMG 40 xx) Digitizer Framing Logic test (DIMG 41 xx) Background Suppression test (DIMG 80 xx) CAR Spot/Void Threshold test (DIMG 81 xx) CAR Interface test (DIMG 82 xx) Get CAR POC (DIMG 83 xx) Image Interface Confidence test (DIMG A7 xx) Valid Image Gate Configuration test (DIMG C3 xx) Image Bus test (DIMG C4 xx) JPEG Compressor test (DIMG D0 xx) JPEG Built-In Self-Test (DIMG D1 xx) CCITT Compressor test (DIMG D2 xx) CCITT Built-In Self-Test (DIMG D3 xx)
224
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(DIMG xx xx) Image Camera Module Common Failures
Table 221. (DIMG xx xx) Image Camera Module Common Failures
Error Code (Hex)
Description
M&D Procedures Section Configuration and Parameter File Access Failures Configuration and Parameter File Access Failures
Primary FRU
Secondary FRU
DIMG xx 51 Front ICM Not Fitted
DIMG xx 52 Rear ICM Not Fitted
DIMG xx 53 Front Normalizer Framer "Fitted/Not Fitted Errors Not Fitted Flow" DIMG xx 54 Rear Normalizer Framer Not Fitted DIMG xx 57 CAR Port Not Fitted "Fitted/Not Fitted Errors Flow" "CAR Port Not Found or CAR Port PCBA CAR Port CI Errors Flow" Configuration Conflict
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225
(DIMG 01 xx) Interface MTR

Table 222. (DIMG 01 xx) Interface MTR
Error Code (Hex)
Description
M&D Procedures Section
Primary FRU DMIIB PCBA
Secondary FRU DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable
DIMG 01 01 The reset bit was not reset on the DMIIB PCBA. DIMG 01 02 The reset bit was not reset when the status was read. DIMG 01 03 The loopback bit was not set on register FC47. DIMG 01 04 The FIFO status was not empty after a clear FIFO was given. DIMG 01 05 An incorrect status for half full was given. DIMG 01 06 The half full status was incorrect when the FIFO is half full. DIMG 01 07 An incorrect status for full was given when the FIFO was full. DIMG 01 08 Incorrect data was read from the FIFO. DIMG 01 09 The half full status was incorrect. DIMG 01 0A The status of the FIFO was incorrect when it was half full. DIMG 01 0B Incorrect data was read from the FIFO. DIMG 01 0C The FIFO should be empty, but the status indicates that it is not empty. DIMG 01 0D The FIFO status is incorrect. DIMG 01 0E The FIFO status is incorrect for empty.
DMIIB PCBA
DMIIB PCBA
DMIIB PCBA
DMIIB PCBA DMIIB PCBA
DMIIB PCBA
DMIIB PCBA DMIIB PCBA DMIIB PCBA
DMIIB Interface Cable DMIIB Interface Cable
226
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Error Code (Hex)
Description
Primary FRU DMIIB PCBA DMIIB PCBA
Secondary FRU DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable DMIIB Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable DMIIB PCBA
DIMG 01 0F The loopback bit was not reset. DIMG 01 10 The input FIFO status was incorrect when it was not yet half full. DIMG 01 11 The half full status was not set when the FIFO was half full. DIMG 01 12 The FIFO status was incorrect for not full yet. DIMG 01 13 The full status was not set when the FIFO was full. DIMG 01 15 Not successful on transmit to PCI. DIMG 01 16 Not successful on Poll to PCI. DIMG 01 17 Not successful on Receive from PCI. DIMG 01 18 The OP code was incorrect on the Get Configuration command. DIMG 01 19 Dual Image POC Communication Failure. The results were not good on the configuration.
DMIIB PCBA
DMIIB PCBA DMIIB PCBA DMIIB PCBA ICS PC, Image Interface Cable DMIIB Interface Cable connecting the DMIIB PCBA to the image gate, Image interface cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable
ICS PC, DMIIB PCBA, Image gate power supply and DC power harness
DIMG 01 1A Not successful on the Enter MTR command. DIMG 01 1B Not successful on Enter MTR Poll. DIMG 01 1C Not successful on Receive for the Enter MTR command. DIMG 01 1D The Enter MTR OP code was not returned. DIMG 02 01 Not successful on Transmit.
DMIIB PCBA DMIIB PCBA DMIIB PCBA
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227
Error Code (Hex)
Description
Primary FRU ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable ICS PC, Image Interface Cable
Secondary FRU DMIIB PCBA DMIIB PCBA DMIIB PCBA DMIIB PCBA DMIIB PCBA DMIIB PCBA DMIIB PCBA DMIIB PCBA DMIIB PCBA
DIMG 02 02 Not successful on Poll. DIMG 02 03 Not successful on Receive. DIMG 02 04 Incorrect OP code after multiple tries. DIMG 02 05 Invalid MTR from Perform MTR command. DIMG 02 06 Incorrect Type for POC. DIMG 02 07 Timed out during Poll for Perform MTR command. DIMG 02 08 No good status after Receive. DIMG 02 09 MTR Complete OP code not returned. DIMG 03 01 Not successful on transmit of Exit MTR command. DIMG 03 02 Not successful on Poll for Exit MTR command. DIMG 03 03 Receive error on Exit MTR command. DIMG 03 04 Incorrect OP code for Exit MTR command. DIMG 03 05 Exit MTR not good.
DMIIB PCBA DMIIB PCBA DMIIB PCBA DMIIB PCBA
228
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(DIMG 22 xx) Analog Interface Test

Table 223. (DIMG 22 xx) Analog Interface Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG 22 01 Front Normalizer Framer "Front Normalizer Front Normalizer Image Interface Communication Failure Framer Not Found or Framer PCBA Cable Front Normalizer Framer CI Errors Flow" DIMG 22 02 Rear Normalizer Framer Communication Failure "Front Normalizer Rear Normalizer Framer Not Found or Framer PCBA Front Normalizer Framer CI Errors Flow" NDP 1150: Front Camera NDP 1825: Front High Speed Digitizer PCBA NDP 1150: Rear Camera NDP 1825: Rear High Speed Digitizer "High Speed Digitizer Front High Not Found or High Speed Digitizer Speed Digitizer CI Errors PCBA Flow" Front Normalizer Framer PCBA
DIMG 22 03 Front Black DAC Control Failure
Power Supply Camera Front Normalizer Framer PCBA
DIMG 22 04 Rear Black DAC Control Failure
Power Supply Camera Rear Normalizer Framer PCBA Front Normalizer Framer PCBA
DIMG 22 05 Front High Speed Digitizer Communication Failure DIMG 22 06 Rear High Speed Digitizer Communication Failure DIMG 22 07 Front Lamps Not On
"High Speed Digitizer Rear High Speed Front Normalizer Not Found or High Digitizer PCBA Framer PCBA Speed Digitizer CI Errors Flow" Front Lamps, Lamp Power Supply Rear Lamps, Lamp Power Supply Lamp Control PCBA, Front Normalizer Framer PCBA Lamp Control PCBA, Rear Normalizer Framer PCBA
DIMG 22 08 Rear Lamps Not On
DIMG 22 0B Front Photodiode Value Too High DIMG 22 0C Rear Photodiode Value Too High
Front Lamps, Photo Sensor Front Normalizer Assy. Framer PCBA Rear Lamps, Rear Normalizer Framer PCBA Photo Sensor Assy.
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229
Table 223. (DIMG 22 xx) Analog Interface Test
Error Code (Hex)
Description
Primary FRU Front Lamps, Lamp Power Supply Rear Lamps, Lamp Power Supply
Secondary FRU Front Normalizer Framer PCBA Rear Normalizer Framer PCBA
DIMG 22 0D Front Photodiode Value Too Low DIMG 22 0E Rear Photodiode Value Too Low DIMG 22 53 Front Normalizer Framer "Fitted/Not Fitted Errors Not Fitted Flow" DIMG 22 54 Rear Normalizer Framer Not Fitted DIMG 22 5E Front High Speed Digitizer Not Fitted DIMG 22 5F Rear High Speed Digitizer Not Fitted "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow"
2210
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(DIMG 23 xx) Calibrate Front Camera

Table 224. (DIMG 23 xx) Calibrate Front Camera
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG 23 01 Front Normalizer Framer "Front Normalizer Communication Failure Framer Not Found or Front Normalizer Framer CI Errors Flow" DIMG 23 02 Front Configuration File Access Failure DIMG 23 03 Front Calibration Cannot Converge DIMG 23 04 Front lamps Not On "Configuration and Parameter File Access Failures Flow" "White Digital-to-Analog Converter and Analog Interface Failure Flow" Front Lamps, Lamp Power Supply "White Digital-to-Analog Converter and Analog Interface Failure Flow" NDP 1150: Front Camera NDP 1825: Front High Speed Digitizer PCBA "Configuration and Parameter File Access Failures Flow" Check Target and glass placement or marks. Front Camera Power Supply Camera Photo Sensor Assy. Lamp Control PCBA
DIMG 23 05 Front Calibration Cannot Set White DACs DIMG 23 06 Front Calibration Cannot Set Black DACs
DIMG 23 07 Front Normalization File Access Failure DIMG 23 08 Front Target Failure or Misaligned
DIMG 23 0A Front Report File Access "Configuration and Failure Parameter File Access Failures Flow" DIMG 23 0B Front Parameter File Access Failure "Configuration and Parameter File Access Failures Flow"
DIMG 23 53 Front Normalizer Framer "Fitted/Not Fitted Errors Not Fitted Flow" DIMG 23 5E Front High Speed Digitizer Not Fitted "Fitted/Not Fitted Errors Flow"
3998 5593007
2211
(DIMG 24 xx) Calibrate Rear Camera

Table 225. (DIMG 24 xx) Calibrate Rear Camera
Error Code (Hex)
Description
M&D Procedures Section "Rear Normalizer Framer Not Found or Rear Normalizer Framer CI Errors Flow" "Configuration and Parameter File Access Failures Flow" "White Digital-to-Analog Converter and Analog Interface Failure Flow"
Primary FRU
Secondary FRU
DIMG 24 01 Rear Normalizer Framer Communication Failure
DIMG 24 02 Rear Configuration File Access Failure DIMG 24 03 Rear Calibration Cannot Converge DIMG 24 04 Rear Lamps Not On
Rear Lamps, Lamp Power Supply "White Digital-to-Analog Converter and Analog Interface Failure Flow"
Photo Sensor Assy., Lamp Control PCBA
DIMG 24 05 Rear Calibration Cannot Set White DACs DIMG 24 06 Rear Calibration Cannot Set Black DACs
NDP 1150: Power Supply Rear Camera Camera NDP 1825: Rear High Speed Digitizer PCBA "Configuration and Parameter File Access Failures Flow" Check Target and glass for placement or marks. "Configuration and Parameter File Access Failures Flow" "Configuration and Parameter File Access Failures Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" Rear Camera
DIMG 24 07 Rear Normalization File Access Failure DIMG 24 08 Rear Target Failure or Misaligned
DIMG 24 0A Rear Report File Access Failure DIMG 24 0B Rear Parameter File Access Failure DIMG 24 54 Rear Normalizer Framer Not Fitted DIMG 24 5F Rear High Speed Digitizer Not Fitted
2212
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(DIMG 40 xx) Normalizer and Diagnostics RAM Test

Table 226. (DIMG 40 xx) Normalizer and Diagnostics RAM Test
Error Code (Hex)
Description
Primary FRU Front Normalizer Framer PCBA Rear Normalizer Framer PCBA
Secondary FRU
DIMG 40 01 Norm LUT/Diagnostic RAM Failure Front DIMG 40 02 Norm LUT/Diagnostic RAM Failure Rear DIMG 40 03 Front Normalizer Framer "Front Normalizer Communication Failure Framer Not Found or Front Normalizer Framer CI Errors Flow" DIMG 40 04 Rear Normalizer Framer Communication Failure "Rear Normalizer Framer Not Found or Rear Normalizer Framer CI Errors Flow"
DIMG 40 53 Front Normalizer Framer "Fitted/Not Fitted Errors Not Fitted Flow" DIMG 40 54 Rear Normalizer Framer Not Fitted "Fitted/Not Fitted Errors Flow"
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2213
(DIMG 41 xx) Digitizer Framing Logic Test

Table 227. (DIMG 41 xx) Digitizer Framing Logic Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG 41 01 Front Normalizer Framer "Front Normalizer Communication Failure Framer Not Found or Front Normalizer Framer CI Errors Flow" DIMG 41 02 Rear Normalizer Framer Communication Failure "Rear Normalizer Framer Not Found or Rear Normalizer Framer CI Errors Flow" Front Normalizer Framer PCBA Rear Normalizer Framer PCBA Front Normalizer Backplane Framer PCBA Rear Normalizer Framer PCBA Front Normalizer Framer PCBA Rear Normalizer Framer PCBA Front Normalizer Framer PCBA Rear Normalizer Framer PCBA Backplane
DIMG 41 03 Front Normalizer Framer Did Not Detect Leading Edge DIMG 41 04 Rear Normalizer Framer Did Not Detect Leading Edge DIMG 41 05 Front Normalizer Framer Normalized Video Signature Failure DIMG 41 06 Rear Normalizer Framer Normalized Video Signature Failure DIMG 41 07 Front Normalizer Framer Total Height of Image Failure DIMG 41 08 Rear Normalizer Framer Total Height of Image Failure DIMG 41 09 Front Normalizer Framer Total Length of Image Failure DIMG 41 0A Rear Normalizer Framer Total Length of Image Failure DIMG 41 53 Front Normalizer Framer "Fitted/Not Fitted Errors Not Fitted Flow" DIMG 41 54 Rear Normalizer Framer Not Fitted "Fitted/Not Fitted Errors Flow"
2214
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(DIMG 80 xx) Background Suppression Test

Table 228. (DIMG 80 xx) Background Suppression Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG 80 01 Normalizer Framer Communication Failure
"Front Normalizer Front Normalizer Framer Not Found or Framer PCBA Front Normalizer Framer CI Errors Flow" "CAR Port Not Found or CAR Port PCBA CAR Port CI Errors Flow" Front Normalizer Framer PCBA CAR Port PCBA CAR Port PCBA Front Normalizer Framer PCBA "Image Interface Communication Failure Flow" "CAR Port Not Found or CAR Port CI Errors Flow" PCI Image Interface PCBA Front Normalizer Framer PCBA
DIMG 80 02 CAR Port Communication Failure DIMG 80 03 Normalizer Framer Signature Failure DIMG 80 04 CAR Port Signature Failure DIMG 80 05 CAR Port Signature Failure DIMG 80 06 Normalizer Framer PCBA Signature Failure DIMG 80 07 Image Interface Communication Failure DIMG 80 57 CAR Port Not Fitted
3998 5593007
2215
(DIMG 81 xx) CAR Spot/Void Threshold Test

Table 229. (DIMG 81 xx) CAR Spot/Void Threshold Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG 81 01 Normalizer Framer Communication Failure
"Front Normalizer Front Normalizer Framer Not Found or Framer PCBA Front Normalizer Framer CI Errors Flow" "CAR Port Not Found or CAR Port PCBA CAR Port CI Errors Flow" Front Normalizer Framer PCBA CAR Port PCBA CAR Port PCBA Front Normalizer Framer PCBA "Image Interface Communication Failure Flow" "CAR Port Not Found or CAR Port CI Errors Flow" PCI Image Interface PCBA Front Normalizer Framer PCBA
DIMG 81 02 CAR Port Communication Failure DIMG 81 03 Normalizer Framer Signature Failure DIMG 81 04 CAR Port Signature Failure DIMG 81 05 CAR Port Signature Failure DIMG 81 06 Normalizer Framer Signature Failure DIMG 81 07 Image Interface Communication Failure DIMG 81 57 CAR Port Not Fitted
2216
3998 5593007
(DIMG 82 xx) CAR Interface Test

Table 2210. (DIMG 82 xx) CAR Interface Test
Error Code (Hex)
Description
M&D Procedures Section "CAR SCSI Communication Failure Flow" "CAR SCSI Communication Failure Flow" "CAR SCSI Communication Failure Flow" "CAR SCSI Communication Failure Flow"
Primary FRU
Secondary FRU
DIMG 82 01 CAR Controller in Bad State DIMG 82 02 CAR in unknown State Failure DIMG 82 03 SCSI Communication Failure DIMG 82 04 SCSI Command Echo Communication Failure
DIMG 82 05 SCSI Driver Open Failure "CAR SCSI - CAR not Present or On Communication Failure Flow" DIMG 82 FF Not Fitted "CAR SCSI Communication Failure Flow"
(DIMG 83 xx) Get CAR POC

Table 2211. (DIMG 83 xx) Get CAR POC
Error Code (Hex)
Description
M&D Procedures Section "CAR SCSI Communication Failure Flow" "CAR SCSI Communication Failure Flow" "CAR SCSI Communication Failure Flow" "CAR SCSI Communication Failure Flow"
Primary FRU
Secondary FRU
DIMG 83 01 CAR Controller in Bad State DIMG 83 02 CAR in Unknown State Failure DIMG 83 03 SCSI Driver Failure
DIMG 83 04 SCSI Command Echo Communication Failure
3998 5593007
2217
Table 2211. (DIMG 83 xx) Get CAR POC
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG 83 05 SCSI Driver Open Failure "CAR SCSI - CAR not Present or On Communication Failure Flow" DIMG 83 06 CAR POC Failure DIMG 83 FF Not Fitted "CAR Module POC Failure Flow" "CAR SCSI Communication Failure Flow"
2218
3998 5593007
(DIMG A7 xx) Image Interface Confidence Test

Table 2212. (DIMG A7 xx) Image Interface Confidence Test
Error Code (Hex)
Description
Primary FRU PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA
Secondary FRU ICS PC
DIMG A7 01 PCI Image Interface Communication Failure DIMG A7 03 PCI Image Interface Signature Failure DIMG A7 05 PCI Image Interface Overflow Failure DIMG A7 51 Front ICM Not Fitted DIMG A7 52 Rear ICM Not Fitted
ICS PC ICS PC
3998 5593007
2219
(DIMG C3 xx) Valid Image Gate Configuration Test

Table 2213. (DIMG C3 xx) Valid Image Gate Configuration Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG C3 01 Front Image Enabled/ Front Normalizer Framer PCBA Communication Failure DIMG C3 02 Front Image Enabled/Front High Speed Digitizer PCBA Communication Failure DIMG C3 03 Rear Image Enabled/Rear Normalizer Framer PCBA Communication Failure DIMG C3 04 Rear Image Enabled/ Rear High Speed Digitizer PCBA Communication Failure DIMG C3 05 CAR Enabled/CAR Port PCBA Communication Failure DIMG C3 0F CAR Enabled/ CAR Port Found in Incorrect Slot DIMG C3 10 Front JPEG Enabled/ Front JPEG Communication Failure DIMG C3 11 Rear JPEG Enabled/ Rear JPEG Communication Failure DIMG C3 12 Front JPEG Enabled/ JPEG Found in Incorrect Slot DIMG C3 13 Rear JPEG Enabled/ JPEG Found in Incorrect Slot DIMG C3 14 Front CCITT Enabled/ CCITT Communication Failure DIMG C3 15 Rear CCITT Enabled/ CCITT Communication Failure
"Front Normalizer Front Normalizer PCI Image Framer Not Found or Framer PCBA Interface PCBA Front Normalizer Framer CI Errors Flow" "High Speed Digitizer Front High Not Found or High Speed Digitizer Speed Digitizer CI Errors PCBA Flow" "Rear Normalizer Framer Rear Normalizer Not Found or Rear Framer PCBA Normalizer Framer CI Errors Flow" Front Normalizer Framer PCBA
Front Normalizer Framer PCBA
"High Speed Digitizer Rear High Speed Front Normalizer Not Found or High Digitizer PCBA Framer PCBA Speed Digitizer CI Errors Flow" "CAR Port Not Found or CAR Port PCBA CAR Port CI Errors Flow" "Slot Errors Flow" "Compressor Not Found Front JPEG or Compressor CI Errors Compressor Flow" PCBA "Compressor Not Found Rear JPEG or Compressor CI Errors Compressor Flow" PCBA "Slot Errors Flow" Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA
"Slot Errors Flow"
"Compressor Not Found or Compressor CI Errors Flow" "Compressor Not Found or Compressor CI Errors Flow"
2220
3998 5593007
Table 2213. (DIMG C3 xx) Valid Image Gate Configuration Test
Error Code (Hex)
Description
M&D Procedures Section "Slot Errors Flow" "Camera Resolution Incorrect Flow"
Primary FRU
Secondary FRU
DIMG C3 16 Dual Camera CCITT Found in Incorrect Slot DIMG C3 17 Front Camera 2 Resolution Incorrect
DIMG C3 18 Dual Camera Normalizer "Slot Errors Flow" Framer Enabled/Found in Incorrect Slot DIMG C3 51 Front ICM Not Fitted DIMG C3 52 Rear ICM Not Fitted DIMG C3 53 Front Normalizer Framer "Fitted/Not Fitted Errors Fitted/Not Fitted Flow" DIMG C3 54 Rear Normalizer Framer Fitted/Not Fitted DIMG C3 57 Front CAR Port Fitted/Not Fitted DIMG C3 5A Front CCITT Fitted/Not Fitted DIMG C3 5B Rear CCITT Fitted/Not Fitted DIMG C3 5C Front JPEG Fitted/Not Fitted DIMG C3 5D Rear JPEG Fitted/Not Fitted DIMG C3 06 Front Image Enabled/Rear High Speed Digitizer Found in Incorrect Slot DIMG C3 07 Rear Image Enabled/Rear High Speed Digitizer Found in Incorrect Slot DIMG C3 5E Front High Speed Digitizer Not Fitted DIMG C3 5F Rear High Speed Digitizer Not Fitted "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" PCI Image Interface PCBA PCI Image Interface PCBA ICS PC ICS PC
"Fitted/Not Fitted Errors Flow"
"Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow"
3998 5593007
2221
(DIMG C4 xx) Image Bus Test

Table 2214. (DIMG C4 xx) Image Bus Test
Error Code (Hex)
Description
Primary FRU Rear Normalizer Framer PCBA Rear Normalizer Framer PCBA Rear Normalizer Framer PCBA Rear Normalizer Framer PCBA
Secondary FRU Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA
DIMG C4 01 Rear Normalizer Framer Bus Failure Pattern aa DIMG C4 02 Rear Normalizer Framer Bus Failure Pattern 55 DIMG C4 03 Rear Normalizer Framer Bus Failure Pattern cc DIMG C4 04 Rear Normalizer Framer Bus Failure Pattern 0f DIMG C4 0D Rear Normalizer Framer Communication Failure
"Rear Normalizer Framer Rear Normalizer Not Found or Rear Framer PCBA Normalizer Framer CI Errors Flow"
DIMG C4 11 Front Normalizer Framer "Image Bus Test Failure Bus Failure Pattern aa Flow" DIMG C4 12 Front Normalizer Framer "Image Bus Test Failure Bus Failure Pattern 55 Flow" DIMG C4 13 Front Normalizer Framer "Image Bus Test Failure Bus Failure Pattern cc Flow" DIMG C4 14 Front Normalizer Framer "Image Bus Test Failure Bus Failure Pattern 0f Flow" DIMG C4 19 Front CAR Port Bus Failure Pattern aa DIMG C4 1A Front CAR Port Bus Failure Pattern 55 DIMG C4 1B Front CAR Port Bus Failure Pattern cc DIMG C4 1C Front CAR Port Bus Failure Pattern 0f CAR Port PCBA Front High Speed Digitizer PCBA Front High Speed Digitizer PCBA Front High Speed Digitizer PCBA Front High Speed Digitizer PCBA
CAR Port PCBA
CAR Port PCBA
CAR Port PCBA
DIMG C4 1D Front Normalizer Framer "Front Normalizer Front Normalizer Communication Failure Framer Not Found or Framer PCBA Front Normalizer Framer CI Errors Flow" DIMG C4 1F Front CAR Port Communication Failure "CAR Port Not Found or CAR Port PCBA CAR Port CI Errors Flow" Front Normalizer Framer PCBA
2222
3998 5593007
Error Code (Hex)
Description
Primary FRU
Secondary FRU Front Normalizer Framer PCBA
DIMG C4 20 Rear JPEG Communication Failure DIMG C4 21 Front JPEG Communication Failure DIMG C4 22 Rear JPEG Bus Failure Pattern aa DIMG C4 23 Rear JPEG Bus Failure Pattern 55 DIMG C4 24 Rear JPEG Bus Failure Pattern cc DIMG C4 25 Rear JPEG Bus Failure Pattern 0f DIMG C4 26 Front JPEG Bus Failure Pattern aa DIMG C4 27 Front JPEG Bus Failure Pattern aa DIMG C4 28 Front JPEG Bus Failure Pattern cc DIMG C4 29 Front JPEG Bus Failure Pattern 0f DIMG C4 2A Rear CCITT Communication Failure DIMG C4 2B Front CCITT Communication Failure DIMG C4 2C Rear CCITT Bus Failure Pattern aa
"Compressor Not Found Rear JPEG or Compressor CI Errors Compressor Flow PCBA "Compressor Not Found Front JPEG or Compressor CI Errors Compressor Flow PCBA Rear JPEG Compressor PCBA Rear JPEG Compressor PCBA Rear JPEG Compressor PCBA Rear JPEG Compressor PCBA Front JPEG Compressor PCBA Front JPEG Compressor PCBA Front JPEG Compressor PCBA Front JPEG Compressor PCBA "Compressor Not Found or Compressor CI Errors Flow "Compressor Not Found or Compressor CI Errors Flow Rear CCITT Compressor PCBA
Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA
3998 5593007
2223
Error Code (Hex)
Description
Primary FRU Rear CCITT Compressor PCBA Rear CCITT Compressor PCBA Rear CCITT Compressor PCBA Front CCITT Compressor PCBA Front CCITT Compressor PCBA Front CCITT Compressor PCBA Front CCITT Compressor PCBA
Secondary FRU Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA
DIMG C4 2D Rear CCITT Bus Failure Pattern 55 DIMG C4 2E Rear CCITT Bus Failure Pattern cc DIMG C4 2F Rear CCITT Bus Failure Pattern 0f DIMG C4 30 Front CCITT Bus Failure Pattern aa DIMG C4 31 Front CCITT Bus Failure Pattern 55 DIMG C4 32 Front CCITT Bus Failure Pattern cc DIMG C4 33 Front CCITT Bus Failure Pattern 0f DIMG C4 34 Rear High Speed Digitizer Communication Failure DIMG C4 35 Front High Speed Digitizer Communication Failure DIMG C4 36 Rear High Speed Digitizer Bus Failure Pattern aa DIMG C4 37 Rear High Speed Digitizer Bus Failure Pattern 55 DIMG C4 38 Rear High Speed Digitizer Bus Failure Pattern cc
"High Speed Digitizer Rear High Speed Front Normalizer Not Found or High Digitizer PCBA Framer PCBA Speed Digitizer CI Errors Flow" "High Speed Digitizer Front High Not Found or High Speed Digitizer Speed Digitizer CI Errors PCBA Flow" Front Normalizer Framer PCBA
"High Speed Digitizer Rear High Speed Front Normalizer Not Found or High Digitizer PCBA Framer PCBA Speed Digitizer CI Errors Flow" "High Speed Digitizer Rear High Speed Front Normalizer Not Found or High Digitizer PCBA Framer PCBA Speed Digitizer CI Errors Flow" "High Speed Digitizer Rear High Speed Front Normalizer Not Found or High Digitizer PCBA Framer PCBA Speed Digitizer CI Errors Flow"
2224
3998 5593007
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG C4 39 Rear High Speed Digitizer Bus Failure Pattern 0f DIMG C4 3A Front High Speed Digitizer Bus Failure Pattern aa DIMG C4 3B Front High Speed Digitizer Bus Failure Pattern 55 DIMG C4 3C Front High Speed Digitizer Bus Failure Pattern cc DIMG C4 3D Front High Speed Digitizer Bus Failure Pattern 0f DIMG C4 51 Front ICM Not Fitted DIMG C4 52 Rear ICM Not Fitted
"High Speed Digitizer Rear High Speed Front Normalizer Not Found or High Digitizer PCBA Framer PCBA Speed Digitizer CI Errors Flow" "High Speed Digitizer Front High Not Found or High Speed Digitizer Speed Digitizer CI Errors PCBA Flow" "High Speed Digitizer Front High Not Found or High Speed Digitizer Speed Digitizer CI Errors PCBA Flow" "High Speed Digitizer Front High Not Found or High Speed Digitizer Speed Digitizer CI Errors PCBA Flow" "High Speed Digitizer Front High Not Found or High Speed Digitizer Speed Digitizer CI Errors PCBA Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" PCI Image Interface PCBA PCI Image Interface PCBA Front Normalizer Framer PCBA
ICS PC ICS PC
3998 5593007
2225
(DIMG D0 xx) JPEG Compressor Test

Table 2215. (DIMG D0 xx) JPEG Compressor Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG D0 01 Front JPEG Communication Failure DIMG D0 02 Rear JPEG Communication Failure DIMG D0 03 Front JPEG Messaging Failure DIMG D0 04 Rear JPEG Messaging Failure DIMG D0 05 Front JPEG Compression Failure DIMG D0 06 Rear JPEG Compression Failure DIMG D0 07 Front Normalizer Framer Signature Failure DIMG D0 08 Rear Normalizer Framer Signature Failure DIMG D0 09 Front JPEG Signature Failure DIMG D0 0A Rear JPEG Signature Failure DIMG D0 0B Multiple Signature Failure Front JPEG Primary FRU DIMG D0 0C Multiple Signature Failure Rear JPEG Primary FRU DIMG D0 0D Multiple Signature Failure Front Normalizer Framer Primary FRU
"Compressor Not Found Front JPEG or Compressor CI Errors Compressor Flow" PCBA "Compressor Not Found Rear JPEG or Compressor CI Errors Compressor Flow" PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA
2226
3998 5593007
Error Code (Hex)
Description
Primary FRU Rear Normalizer Framer PCBA ReInstall ICS software and/or NT OS Front JPEG Compressor PCBA Rear JPEG Compressor PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA PCI Image Interface PCBA PCI Image Interface PCBA
Secondary FRU
DIMG D0 0E Multiple Signature Failure Rear Normalizer Framer Primary FRU DIMG D0 0F System/Memory Failure
ICS PC
DIMG D0 10 Front Transfer Not Started Failure DIMG D0 11 Rear Transfer Not Started Failure DIMG D0 12 Front Partial Transfer Failure DIMG D0 13 Rear Partial Transfer Failure DIMG D0 14 Front PCI Signature Failure DIMG D0 15 Rear PCI Signature Failure DIMG D0 16 Front Overflow Failure
PCI Image Interface PCBA PCI Image Interface PCBA Image Interface Cable Image Interface Cable Image Interface Cable Image Interface Cable PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA
DIMG D0 17 Rear Overflow Failure
DIMG D0 18 Front FIFO Not Empty Failure DIMG D0 19 Rear FIFO Not Empty Failure DIMG D0 1A Front Software Checksum Failure DIMG D0 1B Rear Software Checksum Failure DIMG D0 51 Front ICM Not Fitted DIMG D0 52 Rear ICM Not Fitted "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow"
PCI Image Interface PCBA PCI Image Interface PCBA
ICS PC ICS PC
3998 5593007
2227
Error Code (Hex)
Description
M&D Procedures Section "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow"
Primary FRU
Secondary FRU
DIMG D0 5C Front JPEG Not Fitted DIMG D0 5D Rear JPEG Not Fitted DIMG D0 1E File IO Error
ICS PC
2228
3998 5593007
(DIMG D1 xx) JPEG Built-In Self-Test

Table 2216. (DIMG D1 xx) JPEG Built-In Self-Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU Front Normalizer Framer PCBA Front Normalizer Framer PCBA
DIMG D1 01 Front JPEG Communication Failure DIMG D1 02 Rear JPEG Communication Failure DIMG D1 03 Front JPEG Self Test Failed DIMG D1 04 Rear JPEG Self Test Failed DIMG D1 51 Front ICM Not Fitted DIMG D1 52 Rear ICM Not Fitted DIMG D1 5C Front JPEG Not Fitted DIMG D1 5D Rear JPEG Not Fitted
"Compressor Not Found Front JPEG or Compressor CI Errors Compressor Flow" PCBA "Compressor Not Found Rear JPEG or Compressor CI Errors Compressor Flow" PCBA Front JPEG Compressor PCBA Rear JPEG Compressor PCBA "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" PCI Image Interface PCBA PCI Image Interface PCBA
ICS PC ICS PC
3998 5593007
2229
(DIMG D2 xx) CCITT Compressor Test

Table 2217. (DIMG D2 xx) CCITT Compressor Test
Error Code (Hex)
Description
Primary FRU
Secondary FRU
DIMG D2 01 Front CCITT Communication Failure DIMG D2 02 Rear CCITT Communication Failure DIMG D2 03 Front CCITT Messaging Failure DIMG D2 04 Rear CCITT Messaging Failure DIMG D2 05 Front CCITT Compression Failure DIMG D2 06 Rear CCITT Compression Failure DIMG D2 07 Front Normalizer Framer Signature Failure DIMG D2 08 Rear Normalizer Framer Signature Failure DIMG D2 09 Front CCITT Signature Failure DIMG D2 0A Rear CCITT Signature Failure DIMG D2 0B Multiple Signature Failure Front CCITT Primary FRU DIMG D2 0C Multiple Signature Failure Rear CCITT Primary FRU DIMG D2 0D Multiple Signature Failure Front Normalizer Framer Primary FRU
"Compressor Not Found Front CCITT or Compressor CI Errors Compressor Flow PCBA "Compressor Not Found CCITT or Compressor CI Errors Compressor Flow PCBA Front CCITT Compressor PCBA Rear CCITT Compressor PCBA Front CCITT Compressor PCBA Rear CCITT Compressor PCBA Front CCITT Compressor PCBA Rear CCITT Compressor PCBA Front CCITT Compressor PCBA Rear CCITT Compressor PCBA Front CCITT Compressor PCBA Rear CCITT Compressor PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA Front Normalizer Framer PCBA
2230
3998 5593007
Error Code (Hex)
Description
Primary FRU Rear Normalizer Framer PCBA ReInstall ICS Software and/or NT OS Front CCITT Compressor PCBA Rear CCITT Compressor PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA Front CCITT Compressor PCBA Rear CCITT Compressor PCBA Front CCITT Compressor PCBA Rear CCITT Compressor PCBA PCI Image Interface PCBA PCI Image Interface PCBA Front CCITT Compressor PCBA
Secondary FRU
DIMG D2 0E Multiple Signature Failure Rear Normalizer Framer Primary FRU DIMG D2 0F System/Memory Failure
ICS PC
DIMG D2 10 Front Transfer Not Started Failure DIMG D2 11 Rear Transfer Not Started Failure DIMG D2 12 Front Partial Transfer Failure DIMG D2 13 Rear Partial Transfer Failure DIMG D2 14 Front PCI Signature Failure DIMG D2 15 Rear PCI Signature Failure DIMG D2 16 Front Overflow Failure
PCI Image Interface PCBA PCI Image Interface PCBA Image Interface Cable Image Interface Cable Image Interface Cable Image Interface Cable PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA PCI Image Interface PCBA
DIMG D2 17 Rear Overflow Failure
DIMG D2 18 Front FIFO Not Empty Failure DIMG D2 19 Rear FIFO Not Empty Failure DIMG D2 1A Front Software Checksum Failure DIMG D2 1B Rear Software Checksum Failure DIMG D2 1C Front CCITT Table Load Failure
PCI Image Interface PCBA
3998 5593007
2231
Error Code (Hex)
Description
Primary FRU Rear CCITT Compressor PCBA
Secondary FRU PCI Image Interface PCBA ICS PC ICS PC
DIMG D2 1D Rear CCITT Table Load Failure DIMG D2 51 Front ICM Not Fitted DIMG D2 52 Rear ICM Not Fitted DIMG D2 54 Front CCITT Not Fitted DIMG D2 5B Rear CCITT Not Fitted DIMG D2 1E File IO Error "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow"
PCI Image Interface PCBA PCI Image Interface PCBA
ICS PC
2232
3998 5593007
(DIMG D3 xx) CCITT Built-In Self-Test

Table 2218. (DIMG D3 xx) CCITT Built-In Self-Test
Error Code (Hex)
Description
M&D Procedures Section "Compressor Not Found or Compressor CI Errors Flow" "Compressor Not Found or Compressor CI Errors Flow"
Primary FRU
Secondary FRU
DIMG D3 01 Front CCITT Communication Failure DIMG D3 02 Rear CCITT Communication Failure DIMG D3 03 Front CCITT Self Test Failed DIMG D3 04 Rear CCITT Self Test Failed DIMG D3 51 Front ICM Not Fitted DIMG D3 52 Rear ICM Not Fitted DIMG D3 5A Front CCITT Not Fitted DIMG D3 5B Rear CCITT Not Fitted
Front CCITT Compressor PCBA Rear CCITT Compressor PCBA "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" "Fitted/Not Fitted Errors Flow" PCI Image Interface PCBA PCI Image Interface PCBA ICS PC ICS PC
3998 5593007
2233
Dual Image M&D Procedures

Caution
When you service the dual image camera module, be sure that the internal cables do not become partially unseated. Also, be sure that no switches are unintentionally disturbed. The switches on the CAR Interface (BusLogic) PCBA are located along the top edge and are especially vulnerable. Before returning the dual image camera module to operation, you must fully seat and secure any PCBAs that you disturbed during service. In addition, be sure that all external cables are properly secured.
To use this flow, proceed as follows: 1. 2. 3. 4. Execute the NDP Power On Confidence (POC) tests. The POC error code should identify the faulty FRU or direct you to investigate another part of the machine. After replacing a FRU, power the track off and on to ensure correct operation. Run the exerciser to verify performance.
2234
3998 5593007
Front Normalizer Framer Not Found or Front Normalizer Framer CI Errors Flow
Table 2219. Front Normalizer Framer Not Found or Front Normalizer Framer CI Errors Flow
Next Step Step 10 Action Power off the track. Check the image interface cable at both ends for bent pins, pinched cable, or poor connections. 20 Reconnect the image interface cable. Power on the track. 30 Power off the track. Swap the front Normalizer Framer PCBA with the rear PCBA. Power on the track. 40 Power off the track. Replace the image interface cable. Power on the track. 50 Power off the track. Remove all boards except the front Normalizer Framer PCBA. Power on the track. 60 65 Check the power LED on the Normalizer Framer PCBA. Measure +5 V on the backplane between the inboard terminals of any pair of adjacent capacitors around the perimeter of the backplane. Replace the front digital camera cable (JF610). Replace the front camera. Is the power LED on? Is the voltage between 4.90 and 5.10 V? 65 70 100 100 Does the same error code occur? 60 120 Does the same error code occur? 50 Exit the flow. Does the same error code occur? 40 F1 Response Are there any visible signs of damage? Yes F10 20 No
Does the same error code occur?
30
Exit the flow.
70 80
Does the same error code occur? Does the same error code occur?
80 F5
Exit the flow. Exit the flow.
3998 5593007
2235
Next Step Step 100 Action Power down the sorter and turn the image main breaker off to cut power to the image gate. Remove the DC power harness (two connectors) from the backplane. Turn the image main breaker on and power up the sorter. Response Is the voltage between 4 and 5 VDC? F5 Yes 110 No
Caution
This is a high-current connection. Current can exceed 100 amps. Injury or death may result from accidental electrocution. Measure the DC voltage across the bus bars at the power supply
110
Power down the sorter and turn the image main breaker off to cut power to the image gate. Remove the power harnesses from the supply terminals. Turn the image main breaker on and power up the sorter.
Is the voltage between 4 and 5 VDC?
Repair/ Replace F34
F20
Caution
This is a high-current connection. Current can exceed 100 amps. Injury or death may result from accidental electrocution. Measure the +5 V DC voltage on the Logic/lamps supply. 120 Power off the track. Reseat all previously removed PCBAs on the failing side of the image electronics gate, one at a time. Power on the track. Does the same failure occur? 140 130
2236
3998 5593007
Next Step Step 130 Action Does the system have a CAR module? If so, reseat the CAR PCBA. Power off the track. Replace the last PCBA that was reseated in the gate. Response Does the same failure occur? Yes NDP 1150: F3 NDP 1825: F4 Exit the flow. No Exit the flow.
140
Exit the flow.
3998 5593007
2237
Rear Normalizer Framer Not Found or Rear Normalizer Framer CI Errors Flow
Table 2220. Rear Normalizer Framer Not Found or Rear Normalizer Framer CI Errors Flow
Next Step Step 10 Action Power off the track. Check the image interface cable at both ends for bent pins, pinched cable, or poor connections. 20 Reconnect the image interface cable. Power on the track. 30 Power off the track. Swap the front Normalizer Framer PCBA with the rear PCBA. Power on the track. 40 Power off the track. Replace the image interface cable. Power on the track. 50 Power off the track. Remove all boards except the front and rear Normalizer Framer PCBAs. Power on the track. 60 65 Check the power LED on the front Normalizer Framer PCBA. Measure +5 V on the backplane between the inboard terminals of any pair of adjacent capacitors around the perimeter of the backplane. Replace the rear digital camera cable (JB610). Replace the rear camera. Is the power LED on? Is the voltage between 4.90 and 5.10 V? 65 70 100 100 Does the same error code occur? 60 120 Does the same error code occur? 50 Exit the flow. Does the same error code occur? 40 F1 Response Are there any visible signs of damage? Yes F10 20 No
30
Exit the flow.
70 80
Does the same error code occur? Does the same error code occur?
80 F5
Exit the flow. Exit the flow.
2238
3998 5593007
Next Step Step 100 Action Power down the sorter and turn the image main breaker off to cut power to the image gate. Remove the DC power harness (two connectors) from the backplane. Turn the image main breaker on and power up the sorter. Response Is the voltage between 4 and 5 VDC? F5 Yes 110 No
Caution
This is a high-current connection. Current can exceed 100 amps. Injury or death may result from accidental electrocution. Measure the DC voltage across the bus bars at the power supply. 110 Power down the sorter and turn the image main breaker off to cut power to the image gate. Remove the power harnesses from the supply terminals. Turn the image main breaker on and power up the sorter. Is the voltage between 4 and 5 VDC? Power Supply Diagnostic Flow F20
Caution
This is a high-current connection. Current can exceed 100 amps. Injury or death may result from accidental electrocution. Measure the +5 V DC voltage on the Logic/lamps supply. 120 Power off the track. Reseat all previously removed PCBAs on the failing side of the image electronics gate, one at a time. Power on the track. Does the same failure occur? 140 130
3998 5593007
2239
Next Step Step 130 Action Does the system have a CAR module? If so, reseat the CAR PCBA. Power off the track. Replace the last PCBA that was reseated in the gate. Response Does the same failure occur? Yes NDP 1150: F3 NDP 1825: F4 Exit the flow. No Exit the flow.
140
Exit the flow.
Image Bus Test Failure Flow

Table 2221. Image Bus Test Failure Flow
Next Step Step 210 Action Power off the sorter. Remove the all PCBAs except for the front Normalizer Framer PCBA. Power on the sorter. 220 Power off the sorter. Insert one of the PCBAs removed in step 210. Power on the sorter. 230 Have all the PCBAs been reinserted? Exit the flow. 220 Does the original error code occur again? Response Does the original error code occur? Yes F1(primary FRU) F5 (secondary FRU) Replace the last PCBA inserted 230 220 No
2240
3998 5593007
CAR Port Not Found or CAR Port CI Errors Flow

Table 2222. CAR Port Not Found or CAR Port CI Errors Flow
Next Step Step 810 Action Power off the track. Reseat the CAR Port PCBA. Power on the track. 820 Remove the front panel from the image camera module. Check for any shorts or connection problems on the backplane in the area of the failing slot. Are there any visible problems? F5 NDP 1150: F3 NDP 1825: F4 Response Does the same error code occur? Yes 820 No Exit the flow.
3998 5593007
2241
White Digital-to-Analog Converter and Analog Interface Failure Flow

Table 2223. White Digital-to-Analog Converter and Analog Interface Failure Flow
Next Step Step 1610 Action Power up the track. Measure the voltage on the front and rear linear supply. Response Are the +13.5 VDC and -12 VDC voltages within +/- 0.1 volts". For NDP1150-4X are the +13.5 VDC and -12 VDC voltages within +/- 0.1volts. For NDP1825-4X are the +15 VDC and -12 VDC voltages within +/0.1 volts. 1620 Power down the track. Remove the digital camera cable from the camera connector. Power on the track. Carefully measure the voltage between pins 16 and 17 (+13.5 VDC to analog ground). Measure the voltage between pins 13 and 14 (12 VDC to analog ground.) 1630 Power off the track. Check both ends of the digital camera cable for bent pins and for pinched or frayed wire. Reconnect the cable, and power on the track. Does the same error code occur? F6 (primary FRU) F1 (secondary FRU) Exit the flow. Are the voltages within 0.1 V? 1630 F9 Yes 1620 F20 No
2242
3998 5593007
CAR Module POC Failure Flow

Table 2224. CAR Module POC Failure Flow
Next Step Step 2210 Action Press Shift+Ctrl+Esc on the image capture server keyboard to display the Windows NT task manager. Select the Application tab, highlight the Common CAR task, and click on the "Switch To" button. Press the F1 key to view the MTR Routines menu. Press the F2 key to view the POC Results Screen. Press the F1 key to execute the POC Results MTR. Response Follow the CAR diagnostic flow in Section 24. Yes No
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2243
CAR SCSI Communication Failure Flow

Table 2225. CAR SCSI Communication Failure Flow
Next Step Step 2410 Action Power off the sorter to power off the CAR option. Shutdown the ICS. Disconnect and check the CAR SCSI cable at both ends for bent pins, pinched cables, or poor connections. Reconnect the SCSI cable at both ends. Power on the sorter; then power on the ICS. 2420 Power off the sorter to power off the CAR option. Shutdown the ICS. Remove the ICS cover to gain access to the SCSI PCBA for CAR. Disconnect the CAR SCSI cable from the ICS, and reseat the CAR SCSI PCBA. Reconnect the CAR SCSI cable. Power on the sorter; then power on the ICS. 2430 2440 Examine the LED on the CAR SCSI PCBA. Verify that the CAR unit is receiving power. For the NDP 1150, remove the rear cover from the first eightpocket module so that the front side of the CAR unit PCBAs is visible. For the NDP 1825, remove the front cover of the external CAR box so that the front side of the CAR unit PCBAs is visible. Power on the sorter; then power on the ICS. Is the LED blinking? Are at least some of the LEDs along the front edge of the CAR unit PCBAs illuminated? 2440 2450 F19 Follow the CAR diagnostic flows (Section 24) Does the same error code occur? 2430 Exit the flow. Response Does the same error code occur? Yes 2420 No Exit the flow.
2244
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Table 2225. CAR SCSI Communication Failure Flow
Next Step Step 2450 Action Wait approximately 4 minutes after powering on the sorter and the ICS. Response Is the timeout LED on the side of the CAR unit illuminated? Yes F19 No Follow the CAR diagnostic flows (Section 24)
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Image Interface Communication Failure Flow

Table 2226. Image Interface Communication Failure Flow
Next Step Step 2610 Action Power off the ICS. Remove the cover from the image capture server. Reseat the PCI Image Interface board. Power on the ICS. 2620 Power off the ICS. Replace the PCI Image Interface board. Verify the operation. Exit the flow. Response Does the same error code occur? Yes 2620 No Exit the flow.
2246
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Camera Resolution Incorrect Flow

Table 2227. Camera Resolution Incorrect Flow
Next Step Step 3010 Action Power off the track. Use an editor to view the configuration file dpimgcfg.ini on the ICS. The file is in the C:\dpimage directory. Locate "FrontCamera1Resolution", "FrontCamera2Resolution", and "RearCamera1Resolution". 3020 Change the resolution in the configuration file to match the value indicated by the camera. Does the same error code occur? 3025 Exit the flow. F32 Exit the flow. Response Do the resolution values in the configuration file and the cameras compare favorably? Yes 3025 No 3020
3025 3030 Power off the track. Check the digital camera cable on the camera and on the image camera module backplane for bent pins. Reseat the cable. Power on the track. 3040 Power off the track. Replace the digital camera cable. Power on the track. 3050 Power off the track. Replace the affected Camera. Power on the track.
Is this an NDP 1150? Does the same error code occur?
3030 3040
3050
Exit the flow.
F1
Exit the flow.
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2247
Configuration and Parameter File Access Failures Flow

Table 2228. Configuration and Parameter File Access Failures Flow
Next Step Step 3610 Action Start Windows NT Explorer on the Image Capture Server and change the directory to C:\DPIMAGE. Inspect the directory list and verify that each file in Table 2229 is included. 3620 Check the disk drive space on the C: drive of the ICS. Reinstall the ICS system software. Power off the transport, and then power it on. Does the disk have over 500K bytes available? Does the same error code occur? 3640 Call software support. Exit the flow. Response Do all the files exist? Yes 3620 No 3640
3640
Call software support.
Table 2229. Data File List
File Name CAR.IMG AT_LUT.MTR SV_LUT.MTR CAL.INI FRONT1.CFG
File Name FRONT1.TBL REAR1.CFG REAR1.TBL CMPMTR.INI DPIMGCFG.INI
File Name DPIMGPAR.INI FRNT0101.INI FRNT0201.INI REAR0101.INI REAR0201.INI
2248
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Compressor Not Found or Compressor CI Errors Flow

Table 2230. Compressor Not Found or Compressor CI Errors Flow
Next Step Step 4200 4210 Action Make note of the error details. Power off the sorter. Move the CCITT Compressor PCBA to the JPEG slot on the failing side of the gate. Power up the sorter. 4220 Remove the front panel from the image camera module. Check for any shorts or connection problems on the backplane in the area of the failing slot. 4230 Power off the sorter. Move the CCITT Compressor PCBA back to the original slot. Power on the sorter. 4240 Power off the track. Move the JPEG Compressor PCBA to the CCITT slot on the failing side of the gate. Power up the sorter. 4250 Remove the front panel from the image camera module. Check for any shorts or connection problems on the backplane in the area of the failing slot. 4260 Power off the sorter. Move the JPEG Compressor PCBA back to the original slot. Power on the sorter. Does the same error code occur? F5 Exit the flow. Are there any visible problems? F5 4260 Does the same error code occur? F28 4250 Does the same error code occur? F5 Exit the flow. Are there any visible problems? F5 4230 Response Does the error refer to the CCITT Compressor PCBA? Does the same error code occur? Yes 4210 F33 No 4240 4220
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2249
Slot Errors Flow

Table 2231. Slot Errors Flow
Next Step Step 4320 Action Power down the sorter. Verify that all PCBA(s) are in the correct slot using the Image Slot Location Table later in this section. 4330 4340 Insert the PCBA(s) in the correct slot. Check the connectors, and reseat all PCBA(s). Power up the sorter. 4350 Power down the sorter. Replace the PCBA(s) referenced in the error detail. Power up the sorter. Does the same error code occur? F5 Exit the flow. Exit the flow. Does the same error code occur? 4350 Exit the flow. Response Are all PCBA(s) in the correct slot? Yes 4340 No 4330
2250
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Fitted/Not Fitted Errors Flow

Table 2232. Fitted/Not Fitted Errors Flow
Next Step Step 4420 Action Power down the sorter. Verify that all PCBAs are in the correct slot using the Image Slot Location Table next in this section. 4430 4440 Insert the PCBA(s) in the correct slot. Verify that the NDP1150 and image capture server configuration files are correctly showing the image compressor configuration (for example, dual image present, front compressor type, module level). Power up the sorter. 4450 Power down the sorter. Replace the PCBA(s) referenced in the error detail. Power up the sorter. Does the same error code occur? F5 Exit the flow. Exit the flow. Does the same error code occur? 4450 Exit the flow. Response Are all PCBAs in the correct slot? Yes 4440 No 4430
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2251
High Speed Digitizer Not Found or High Speed Digitizer CI Errors Flow
Table 2233. High Speed Digitizer Not Found or High Speed Digitizer CI Errors Flow
Next Step Step 4510 Action Power off the sorter. Check the image interface cable at both ends for bent pins, pinched cables, or poor connections. 4520 Reconnect the image interface cable. Power on the sorter. 4530 Power off the sorter. Swap the front High Speed Digitizer PCBA with the rear High Speed Digitizer PCBA. Power on the sorter. 4540 Power off the sorter. Replace the image interface cable. Power on the sorter. 4550 Power off the sorter. Remove all PCBAs from the gate except the front Normalizer Framer and the High Speed Digitizer in question. Power on the sorter. 4560 Power off the sorter. Replace the High Speed Digitizer in question. 4570 Power off the sorter. Replace the front Normalizer Framer. Power on the sorter. Does the same error code occur? 4580 Does the same error code occur? 4570 Exit the flow. Does the same error code occur? 4560 Exit the flow. Does the same error code occur? 4550 Exit the flow. Does the same error code occur? 4540 F32 Response Are there any visible signs of damage? Yes F10 No 4520
4530
Exit the flow.
Exit the flow.
2252
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Table 2233. High Speed Digitizer Not Found or High Speed Digitizer CI Errors Flow
Next Step Step 4580 Action Power off the sorter. Shutdown the image capture server, and remove its cover. Reseat the PCI Image Interface PCBA. Power on the sorter; then power on the ICS. 4590 Power off the sorter. Shutdown the image capture server, and remove its cover. Replace the PCI Image Interface PCBA. Power on the sorter; then power on the ICS. Does the same error code occur? F5 Exit the flow. Response Does the same error code occur? Yes 4590 No Exit the flow.
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2253
Image Slot Locations
Figure 221. Card Locator - NDP 1150 Dual Image
2254
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Figure 222. Card Locator - NDP 1825 Dual Image
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2255
Dual Image Camera Module Fault Code List

Fault Code F1 F3 F4 F5 F6 F7 F8 F9 F10 F12 F19 F20 F26 F28 F29 F31 F32 F33 F34 Field Replacement Unit Normalizer Framer PCBA Turbo CAR Port PCBA CAR Port PCBA Backplane (image gate) Front Camera Photo Sensor Assembly Lamp Control PCBA Digital camera cable Image Interface cable (ICS to image gate) Lamp Power Supply SCSI PCBA Power Supply - camera SCSI cable (ICS to CAR module) JPEG Compressor PCBA PCI Image Interface PCBA Rear Camera High Speed Digitizer PCBA CCITT Compressor PCBA DC Power Harness (connects logic/lamp power supply to the image gate backplane)
2256
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Section 23 High Speed Encoder Module

Review the following information before using these procedures:
In the Fault Code Definition section of this manual, if a Flow Step number is given for a fault code, follow the Flow Step. Otherwise, refer to the FRU column. All levels are TTL unless otherwise noted. After replacing a FRU, make sure that you perform the respective test and adjustments (T&As) before executing the MTR or exerciser. These T&As are included in the Network Document Processor (NDP) Field Test and Reference Document . You must bypass the cover interlock switches and open the front door to use the keypad. Check to make sure that, on any board FRU that contains fuses, the fuses are of proper value and in good condition.
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231
High Speed Encoder Module
Using the Maintenance Keypad

To aid in diagnostics, a hand-held maintenance keypad and display unit can be connected to the HSEM. The keypad is used to test only the HSEM printer assembly. Other tests must be run through MTRs, which are initiated from the NDP PC. Note: The handheld maintenance keypad and display unit described here is the same unit that is used on the NDP 250/NDP 500 HSEM.
To access the port into which the maintenance keypad must be connected, you must remove the rear module panel. The keypad/display unit is inactive when the HSEM is in operational mode while the module cover is closed. In maintenance mode, the keypad is available for input, and the display presents messages. After use, disconnect the maintenance keypad and restore all interlocks to their normal operating position. At that point, the HSEM is returned to operational mode, and is ready to transport and encode documents.
232
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Figure 23-1 shows the maintenance keypad and display.
Legend
1. 2. 3. Display Keypad Connecting ribbon cable
Figure 231. HSEM Hand-held Maintenance Keypad and Display Unit
Keypad The CSE uses the keypad to perform maintenance operations on the encoder in the off-line maintenance mode. The keypad uses 16 keys to communicate with the printer:

Display
Digits 0 through 9 Up and down arrow keys
1(;7, &/($5, *2, and (17(5 keys
The maintenance display is a 16 character liquid crystal display (LCD) window, and shows the message 81,6<6 6(59,&( in the maintenance mode. The CSE can choose verification procedures to perform on the encoder by pressing the up or down arrow keys when the 81,6<6 6(59,&( message displays. The display shows a menu, one selection at a time, and allows the CSE to scroll through the menu or to select a verification procedure to perform. Displayed messages must be understandable by the Unisys service representative. Messages must give direction or refer to easily retrievable information.
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233
POC/MTR Error Display

"Test Number Fault Codes" for the High Speed Encoder Module are generated by Power On Confidence (POC) tests as well as Maintenance Test Routines (MTR). For POC errors, the "Manual Procedure" field in the exception handler display indexes the "Test Number Fault Code." For an example, see Figure 23-2.
Figure 232. POC Error Display For MTR failures, the "Manual Procedures" column in the "Test Results" grid indexes the Test Number Fault Code." For an example, see Figure 23-3.
234
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Figure 233. MTR Error Display
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235
HSEM Diagnostic Flows

This subsection defines the fault codes, describes the manual procedures, and identifies the field replacement units (FRUs). At the end of this subsection are the HSEM Fault Code List and FRU Description and a list of HSEM tests.
HSEM Fault Code Definitions (HSEM xxxx)

Table 231. HSEM Fault Code Definitions (HSEM xxxx)
Test Number Fault Code (HEX) HSEM 0101 HSEM 0102 HSEM 0201 HSEM 0202 HSEM 0602 HSEM 0603 HSEM 0604 HSEM 0702 HSEM 0703 HSEM 0704 HSEM 0802 HSEM 0803 HSEM 0804 HSEM 0901 HSEM 0902 HSEM 0903 HSEM 0905 HSEM 0906 HSEM 0907 HSEM 0909 HSEM 090A HSEM 090B
Flow Step 01100
Fault Description Common controller NVRAM checksum failure Common controller NVRAM read/write failure B5 B5 B5, B3
FRU
02100 02200
Printer bus failure Skew/height sensor bus failure Servo sensor level failure Dog-ear sensor level failure Stop sensor level failure Servo sensor receive failure Dog-ear sensor receive failure Stop sensor receive failure Servo sensor failure Dog-ear sensor failure Stop sensor failure
B5, B7, B8 B6, B5 B6 B6, B5 B6 B6 B6 S3, (cables J6J27), B12 S2, (cables J6J27), B12 S4, (cables J3J27), B12
09100 09200
AC power bit not set Cover interlock open Return Module MTR switch to RUN position Servo motor control bit set. Ribbon motor control bit clear. Drum motor control bit set. Servo motor control bit clear. Ribbon motor control bit clear. Drum motor control bit clear. B6, B8 B6, B4 B6, P1 B6, B8 B6, B4 B6, B4
236
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Test Number Fault Code (HEX) HSEM 0A01 HSEM 0A02 HSEM 0A03 HSEM 0A04 HSEM 0A05 HSEM 0A06 HSEM 0C01 HSEM 0C02 HSEM 0C03 HSEM 0C04 HSEM 0D01 HSEM 0D02 HSEM 0D03 HSEM 0E01 HSEM 0E02 HSEM 0F01 HSEM 0F02 HSEM 1001 HSEM 1002 HSEM 1101 HSEM 1201 HSEM 1202 HSEM 1203 HSEM 1204 HSEM 1901 HSEM 1902 HSEM 1B03 HSEM 1B04 HSEM 1B05
Flow Step
Fault Description Cannot clear interrupt B5 B5, B6 B5, B7 B3, B5 B3, B5 B5
FRU
0A200 0A300 20100 20200
No servo sensor interrupt. No skew/height sensor interrupt. Printer timeout Printer data transfer error No Printer READY bit
09200 0C200 0C300 0C400
HSEM cover open Skew/height sensor bus failure Skew/height sensor failure Skew/height sensor trigger failure Skew sensor not compensated Skew sensor voltage too large Skew sensor voltage too small
B5, B6, I1, I2 B5, B7, B8 B7, S10 B5, B7 B7, S10 B7, S10 B7, S10 B5, B8, B12, M1, J27, J1 B5, B8
0E100 0E200 0E200 0F100 10100 10200 11100 12100 12200
Servo clock failure Servo adjustment failure Servo velocity error Fewer than 32 documents processed Servo 24 V failure Servo CCAPDR failure Servo power driver failure CTACK failure Gap adjustment failure SPDREF failure Servo profile failure
B5, B8, P1 B5, B8 B5, B9 B5, B8, B12, (J14J27), (J1-M1), M1 B8, B7 B7, B8 B8, B5, B9 B3, B5 B3 B6, S2, B5 B6, S2, B5 B6, S3, B5
19100
Common controller/printer control signal error Common controller/printer data transfer error
1B100 1B100 1B100
Dog-ear sensor stuck covered Dog-ear sensor stuck uncovered Servo sensor stuck covered
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Test Number Fault Code (HEX) HSEM 1B06 HSEM 1B07 HSEM 1B08 HSEM 1C01 HSEM 1D01 HSEM 1D02 HSEM 1E01 HSEM 1E02 HSEM 2001 HSEM 2002 HSEM 2003 HSEM 2101 HSEM 2102 HSEM 2103 HSEM 2104 HSEM 2201 HSEM 2202 HSEM 2203 HSEM 2301 HSEM 2302 HSEM 2303 HSEM 2304 HSEM 2401 HSEM 2402 HSEM 2403 HSEM 2404 HSEM 2501 HSEM 2502
Flow Step 1B100 1B100 1B100 09200 1D100 ID200 09200 1E200 20100 20200
Fault Description Servo sensor stuck uncovered Stop sensor stuck covered Stop sensor stuck uncovered HSEM cover open Skew sensor data error Skew table calibration: gauge readings not complete HSEM cover open Skew table calibration: skew/height not compensated Printer timeout Printer data transfer error Printer microprocessor instruction set failure B3, B5 B3, B5 B3 B3, B5 B3, B5 B3 B3 B3, B5 B3, B5 B3 B3, B5 B3, B5 B3 B3 B3, B5 B3, B5 B3, B5 B3, B5 B3, B5 B3, B5
FRU B6,S3, B5 B6, S4, B5 B6, S4, B5 B5, B6, I1, I2
B5, B6, I1, I2
20100 20200
Printer timeout Printer data transfer error Printer microprocessor firmware PROM checksum failure Printer microprocessor MTR PROM checksum failure
20100 20200
Printer timeout Printer data transfer error Printer microprocessor RAM failure
20100 20200 23100
Printer timeout Printer data transfer error Printer microprocessor NVRAM check sum failure Printer microprocessor NVRAM read/write failure
20100 20200
Printer timeout Printer data transfer error Printer data bus failure Parallel interface control failure
20100 20200
Printer timeout Printer data transfer error
238
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Test Number Fault Code (HEX) HSEM 2503 HSEM 2504 HSEM 2506 HSEM 2507 HSEM 2508 HSEM 2509 HSEM 250A HSEM 250B HSEM 250C HSEM 250D HSEM 250E HSEM 250F HSEM 2510 HSEM 2511 HSEM 2512 HSEM 2513 HSEM 2514 HSEM 2515 HSEM 2801 HSEM 2802 HSEM 2803 HSEM 2804 HSEM 2805 HSEM 2806 HSEM 2807 HSEM 2808 HSEM 2901 HSEM 2902 HSEM 2903 HSEM 2904
Flow Step
Fault Description Ribbon skew sensor signal failure B3
FRU
25040
HMFIREXN failure RIBVMTR or VERDATAX failure B3
25070
Cannot set VERCLKIN Cannot reset VERCLKIN B3
25090 250A0 250B0
X-Y bus failure Port 9002 bus failure RIBBONCLK or RIBBONEN failure Upper nibble of port 9003 failure B3
250D0
Port A000 bus failure Port A000 control failure B3
250F0
Port A001 bus failure Port A001 control failure Upper nibble of Port A003 failure B3 B3
25120 25130
HMRRST signal failure FLTTIME1 failure Ready signal failure B3
25150 20100 20200 28100 28100 28100 28100 28500 28500 20100 20200 29100 29100
FLTTIME2 signal failure Printer timeout Printer data transfer error Failure to turn on HAMMER MON1 Failure to turn off HAMMER MON1 Failure to turn on HAMMER MON2 Failure to turn off HAMMER MON2 CTRLHSUP is not set CTRLHSUP is not clear Printer timeout Printer data transfer error Failure hammer clock "frequency" 1A Failure hammer clock "frequency" 1B B3, B5 B3, B5 B2, B3 B2, B3 B1, B3 B1, B3 B1, B2, B3 B1, B2, B3 B3, B5 B3, B5 B2, B3 B2, B3
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239
Test Number Fault Code (HEX) HSEM 2905 HSEM 2906 HSEM 2A01 HSEM 2A02 HSEM 2A03 HSEM 2A04 HSEM 2A05 HSEM 2A06 HSEM 2A07 HSEM 2A08 HSEM 2A09 HSEM 2A0A HSEM 2A0B HSEM 2A0C HSEM 2A0D HSEM 2A0E HSEM 2A0F HSEM 2A10 HSEM 2A11 HSEM 2A12 HSEM 2A13 HSEM 2A14 HSEM 2A15 HSEM 2A16 HSEM 2A17 HSEM 2A18 HSEM 2A19 HSEM 2B01 HSEM 2B02 HSEM 2B03
Flow Step 29100 29100 20100 20200 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A100 2A120 2A120 2A120 2A120 2A140
Fault Description Failure hammer clock "frequency" 2A Failure hammer clock "frequency" 2B Printer timeout Printer data transfer error Voltage failure hammer 1 Voltage failure hammer 2 Voltage failure hammer 3 Voltage failure hammer 4 Voltage failure hammer 5 Voltage failure hammer 6 Voltage failure hammer 7 Voltage failure hammer 8 Voltage failure hammer 9 Voltage failure hammer 10 Voltage failure hammer 11 Voltage failure hammer 12 Voltage failure hammer 13 Voltage failure hammer 14 Voltage failure hammer 15 Voltage failure hammer 16 Voltage failure bank 1 or banks 1 and 3 Voltage failure bank 2 or banks 2 & 4 Voltage failure in bank 3 Voltage failure in bank 4 Voltage failure in all hammers Voltage failure banks 1 & 2 Voltage failure banks 3 & 4 B1, B3 B1, B3 B3, B5 B3, B5
FRU
B2, B3, B10, H1 B1, B3, B10, H1 B2, B3, B10, H1 B1, B3, B10, H1 B2, B3, B10, H1 B1, B3, B10, H1 B2, B3, B10, H1 B1, B3, B10, H1 B2, B3, B10, H1 B1, B3, B10, H1 B2, B3, B10, H1 B1, B3, B10, H1 B2, B3, B10, H1 B1, B3, B10 , H1 B2, B3, B10, H1 B1, B3, B10, H1 B2, B10, H1 B1, B10, H1 B2, B10, H1 B1. B10, H1 B3, B11, P1 B3 B3 B3, B5 B3, B5 B3, B2
20100 20200 2B100
Printer timeout Printer data transfer error Hammer 1 no movement
2310
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Test Number Fault Code (HEX) HSEM 2B04 HSEM 2B05 HSEM 2B06 HSEM 2B07 HSEM 2B08 HSEM 2B09 HSEM 2B0A HSEM 2B0B HSEM 2B0C HSEM 2B0D HSEM 2B0E HSEM 2B0F HSEM 2B10 HSEM 2B11 HSEM 2B12 HSEM 2B13 HSEM 2B14 HSEM 2B15 HSEM 2C01 HSEM 2C02 HSEM 2C03 HSEM 2C04 HSEM 2C05 HSEM 2C06 HSEM 2C07 HSEM 2C08 HSEM 2C09 HSEM 2C0A HSEM 2C0B HSEM 2C0C
Flow Step 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B100 2B200 2B200
Fault Description Hammer 2 no movement Hammer 3 no movement Hammer 4 no movement Hammer 5 no movement Hammer 6 no movement Hammer 7 no movement Hammer 8 no movement Hammer 9 no movement Hammer 10 no movement Hammer 11 no movement Hammer 12 no movement Hammer 13 no movement Hammer 14 no movement Hammer 15 no movement Hammer 16 no movement Failure in cusp detect of odd hammers Failure in cusp detect of even hammers Failure to maintain 48v during a hammer fire B3, B1 B3, B2 B3, B1 B3, B2
FRU
B3, B1 B3, B2 B3, B1 B3, B2 B3, B1 B3, B2 B3, B1 B3, B2 B3, B1 B3, B2 B3, B1 B3, B2 B3, B1 B1 & B2 B3, B5 B3, B5 B2, B1, B3 B1, B3 B2, B3 B1, B3 B2, B3 B1, B3 B2, B3 B1, B3 B2, B3 B1, B3
20100 20200 2C100 2C100 2C100 2C100 2C100 2C100 2C100 2C100 2C100 2C100
Printer timeout Printer data transfer error Improper VCL hammer #1 Improper VCL hammer #2 Improper VCL hammer #3 Improper VCL hammer #4 Improper VCL hammer #5 Improper VCL hammer #6 Improper VCL hammer #7 Improper VCL hammer #8 Improper VCL hammer #9 Improper VCL hammer #10
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2311
Test Number Fault Code (HEX) HSEM 2C0D HSEM 2C0E HSEM 2C0F HSEM 2C10 HSEM 2C11 HSEM 2C12 HSEM 2D01 HSEM 2D02 HSEM 2D03 HSEM 2D04 HSEM 2E01 HSEM 2E02 HSEM 2F01 HSEM 2F02 HSEM 2F03 HSEM 2F04 HSEM 2F05 HSEM 2F06 HSEM 2F07 HSEM 2F08 HSEM 2F09 HSEM 2F0A HSEM 2F0B HSEM 3201 HSEM 3202 HSEM 3203 HSEM 3204 HSEM 3205
Flow Step 2C100 2C100 2C100 2C100 2C100 2C100 20100 20200 2D100 2D200 20100 20200 20100 20200 2F100 2F200 2F300 2F400 2F500
Fault Description Improper VCL hammer #11 Improper VCL hammer #12 Improper VCL hammer #13 Improper VCL hammer #14 Improper VCL hammer #15 Improper VCL hammer #16 Printer timeout Printer data transfer error Stepper voltage failure Stepper phase failure Printer timeout Printer data transfer error Printer timeout Printer data transfer error No current in ribbon skew sensors LEDs Ribbon skew left warning sensor failure Ribbon skew right warning sensor failure Ribbon skew left fail sensor failure Ribbon skew right fail sensor failure Ribbon skew right warning and left warning sensors failed Ribbon skew right fail and left fail sensors failed Ribbon skew right warning and left fail sensors failure Ribbon skew right fail and left warning sensors failed B2, B3 B1, B3 B2, B3 B1, B3 B2, B3 B1, B3 B3, B5 B3, B5 B4, P1
FRU
B4, M5 B3, B5 B3, B5 B3, B5 B3, B5 S11, B3, B7 B7, B3, S11 B7, B3, S11 B7, B3, S11 B7, B3, S11 B7 B7 B7 B7 B3, B5 B3, B5 B3
20100 20200
Printer timeout Printer data transfer error Ribbon motion counter did not clear.
32400
Ribbon motion not at zero Ribbon motion counter did not count. B3
2312
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Test Number Fault Code (HEX) HSEM 3206 HSEM 3207 HSEM 3208 HSEM 3209 HSEM 320A HSEM 3301 HSEM 3302 HSEM 3303 HSEM 3304 HSEM 3305 HSEM 3306 HSEM 3401 HSEM 3402
Flow Step Not used 32700
Fault Description
FRU
Low ribbon clocks detected. VERDATA1 did not clear. B4, B3, HSEM cover/door open
32900
VERDATA1 did not set by movement of take-up motor with applied current. VERDATA1 was set without current to take-up motor. B4, HSEM cover/door open B3, B5 B3, B5
20100 20200 33300 33400 33500 33600 20100 20200
Printer timeout Printer data transfer error Drum index failure Drum index frequency failure Drum character clock failure Character clock frequency failure Printer timeout Printer data transfer error
B3, B5 B3, B5
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2313
Main Diagnostic Flow

Table 232. Main Diagnostic Flow
Next Step Step 01100 Action Execute the following T&As: Servo Velocity Adjustment Servo Slip Reference Skew Sensor Calibration Power down the sorter. Power up the sorter. Observe the HSEM fault code. 01101 02100 Use the NDP 1XXX diagnostic procedures to diagnose any new faults. Power down the HSEM. Remove FRU B3. Power up the HSEM. Observe the HSEM fault code. Power down the HSEM. Remove FRU B7. Power up the HSEM. Observe the HSEM fault code. Power down the HSEM. Remove FRU B8. Power up the HSEM. Observe the HSEM fault code. Observe PB 48 signal ACOK on the sensor power control (B6). Primary suspect: AC power supply Secondary suspect: (B6) 09200 09210 09220 09230 Observe the HSEM cover. Observe PA 36 signal CVRS-NC on the sensor power control (B6). Close the HSEM cover and rerun the POC. Make sure that the cover interlock switch is adjusted properly when the cover is closed. Primary suspect: (I1) Secondary suspect: Cable J1-AC export harness 09232 Adjust the covers interlock switch. Rerun the POC. Is the switch adjusted properly? 09231 09232 Is the cover closed? Is the signal a logic 0? 09210 B6 09220 09230 Is the HSEM fault code HSEM 0201? Is the HSEM fault code HSEM 0202? Is the HSEM fault code HSEM 0202? Is the signal a logic 1? B5 B3 Response Is the HSEM fault code HSEM 0101? Yes B5 No 01101
02200
02201
B7
02201
B5
B8
09100 09110
B6
09110
09231
2314
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Next Step Step 0A200 Action Observe signal PB 21 of common controller (B5). Loop the HSEM-ServoSkew Interrupt test. Observe signal PA 41 of common controller (B5). Loop the HSEM-ServoSkew Interrupt test. Observe signal PB 15 of skew sensor (B7). Loop the HSEM-Skew Sensors test. Observe signal PA 21 of skew sensor (B7). Observe signal PA 14 of skew sensor (B7). Remove the Servo Amplifier board (B8). Run the HSEM skew sensors-test. Observe signal PA 16 of skew sensor (B7). Loop the HSEM Skew Sensors-test. Observe signal PA 39 of skew sensor (B7). Loop the HSEM Skew Sensors test. Loop the HSEM Servo-Velocity Adjust test. Observe PA 29 &30 on the Servo Amp board (B8). Observe PA 40&41 on the Servo Amp board (B8). Loop the HSEM Servo-Velocity Adjust test. Observe PA 49 on the Common Controller board (B5). Fewer than 32 documents were passed through the HSEM while the servo slip reference was active. Repeat the test. Observe PA 13 on the Servo Amp board (B8). Measure 24 and 5 V to the Servo Amp board (B8) at the backplane. Loop the HSEM Servo-Voltage Monitor test. Observe PA 34 on the Servo Amp board (B8). Observe PA 32 on the Servo Amp board (B8). Is this signal low? Are all voltages present? Does the signal toggle? B5 B8 10201 10101 P1 B8 Response Does the signal toggle? Yes B5 No B6
0A300
Does the signal toggle?
B5
B7
0C200 0C201 0C202 0C203 0C300 0C400
Does the signal toggle? Does the signal toggle? Does the signal toggle? Does the test pass? Does the signal toggle? Does the signal toggle?
0C201 0C202 0C203 B8 B7 B5
B5 B5 B5 B7 B5 B7
0E100
Do the signals toggle?
0E101
J27, J1, B12, M1 B8 B8
0E101 0E200
Do the signals toggle? Does the signal toggle?
B5 B5
0F100
10100 10101 10200
10201
B5
B8
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Next Step Step 11100 Action Loop the HSEM Servo Driver -Voltage Monitor test. Observe PA 46 on the Servo Driver board (B9). Loop the HSEM Servo Normal Mode test. Observe PA 31 on the Servo Amp board (B8). Observe PA 20 on the Servo Amp board (B8). Observe pin 5 of J1 on the Printer Interface board (CHA). Observe pin 1 of J1 on the Printer Interface board (CHB). Observe pin A29 on the Servo Amp board (CHA). Observe pin A30 on the Servo Amp board (CHB). Observe pin 7 of J1 on the Printer Interface board (B12). Loop the HSEM Servo-Normal Mode test. Observe PB 28 on the Servo Amp board (B8). Loop the HSEM - Echo test. Observe signal PA 16 of the Common Controller board (B5). Observe signal PA 13 of the Common Controller board (B5). Observe signal PA 17 of the Common Controller board (B5). Observe signal PA 14 of the Common Controller board (B5). Run the HSEM Track sensors Current Monitor test, the HSEM Track Sensors Input Simulation test, and the HSEM Track Sensors Normal Mode test to diagnose this fault. The data entered conflicts with readings taken. Rerun the T&A. Response Does the signal toggle? Yes B5 No B9
12100
B5
12101
12101 12101A 12101B 12101C 12101D 12102 12200
Does the signal toggle? Does the signal toggle? Does the signal toggle? Does the signal toggle? Does the signal toggle? Does the signal toggle? Does the signal show a sign of life? Does the signal toggle?
B8 12101B 12101 C 12101 D B8 B12, J27 B8
12101A M1, J1 M1, J1 B12 B12 M1, J1 B7
19100
19101
B3
19101 19102 19103 1B100
Does the signal toggle? Does the signal toggle? Does the signal toggle?
19102 19103 B3
B5 B3 B5
1D100
2316
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Next Step Step 1D200 Action Calculate Skew table (1D)(HSEM Skew "Table Calibration") has been executed before the rest of the T&A was completed. Refer to T&A Skew Sensor Calibration for the proper execution order. Skew Table Calibration (1E) has been executed before the rest of the T&As completed. Refer to T&A Skew Sensor Calibration for the proper execution order. Run the HSEM Echo test to diagnose this fault. Run test 7524 (HSEM Printer - Ext. Bus Wrap test) from the HSEM keypad. Execute the following HSEM T&As: Hammer Flight Time adjustment Character Phase Adjustment Power down the HSEM. Power up the HSEM. Observe the HSEM fault code. 23101 25040 Use the NDP 1XXX diagnostic procedures to diagnose any new faults. Turn off the HSEM power, and remove both Analog positive boards (B1 & B2). Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. 25041 Turn off the HSEM power, and install the Analog VE board B1. Turn on the power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove B2. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove B1. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Does the same fault code HSEM 2504 occur again? B1 B2 Does the same fault code HSEM 2504 occur again? B3 25041 Does the display show FAILED 752403? Is the HSEM fault code HSEM 2303? B3 B3 B5 23101 Response Yes No
1E200
20100 20200 23100
25070
Does the same fault code HSEM 2507 occur again?
B3
B2
25090
25091
B1
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Next Step Step 25091 Action Turn off the HSEM power, and remove B1. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove B4 (ribbon control). Turn on the HSEM power, and run the HSEM printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove B2. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove B2. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Observe the fault code. Turn off the HSEM power, and remove B4 (ribbon control). Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove the top frontplane connector between the B3 and B1 boards. Remove the bottom frontplane connector between the B2 and B1 boards. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and install the bottom frontplane connector between the B3 and B1 boards. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove the top frontplane connector between the B3 and B1 boards. Remove the bottom frontplane connector between the B2 and B1 boards. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Response Does the same fault code HSEM 2509 occur again? Yes B3 No B2
250A0
Does the same fault code HSEM 250A occur again?
250A1
B4
250A1
250A2
B2
250A2
B3
250A3
250A3 250B0
Did the same fault code HSEM 2515 occur? Does the same fault code HSEM 250B occur again?
B3 B3
B1 B4
250D0
Does the same fault code HSEM 250D occur again?
B3
250D1
250D1
Does the same fault code HSEM 250D occur again?
B1
B2
250F0
Does the same fault code HSEM 250F occur again?
B3
250F1
2318
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Next Step Step 250F1 Action Turn off the HSEM power, and remove the bottom frontplane connector between the B3 and B1 boards. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove both B1 and B2 boards. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and install B1. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove B2. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Turn off the HSEM power, and remove B1. Turn on the HSEM power, and run the HSEM Printer External Control Signal Wrap-Around test. Loop the HSEM Hammer - Supply Monitor test. Swap the Analog VE boards (B1 and B2), and observe the fault code. Replace the Analog VE board (B2) if the fault code is 3 or 4. Replace the Analog VE Even board (B1) board if the fault code is 5 or 6. 28500 Loop the HSEM Hammer Supply Monitor test. Observe PB 13 on the Printer Microprocessor board (B3). Remove the Analog VE Even board (B1). Loop the HSEM Hammer Clock Verification test. Swap Analog VE boards, and observe the fault code. Loop the HSEM Hammer Voltage Monitor test. Swap Analog VE boards, and observe the fault code. Ensure that both frontplane connectors are on firmly. Does the signal toggle? B3 28501 Response Does the same fault code HSEM 250F occur again? Yes B1 No B2
25120
B3
25121
25121
B1
B2
B25130
B3
B2
25150
B3
B1
28100
Did the fault code follow the Analog board?
28101
B3
28101
28501 29100
Does the signal toggle? Did the fault code follow the Analog board? Did the fault code follow the Analog board?
B1 28101
B2 B3
2A100
2A101
2A102
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Next Step Step 2A101 Action Replace the B2 board if the fault code is odd, or replace the B1 board if the fault code is even. Swap hammer bank connections at the Hammer Interconnect board (B10) with one of the other three hammer banks. Measure the signal at the appropriate frontplane pin (HMMON signals 1-16) on the Printer Microprocessor board (B3). Check the continuity of the appropriate hammer from the hammer interconnect board (B10) to the backplane (coil signals 1-16). Loop the HSEM Hammer Volt Monitor test. Swap Analog VE boards, and observe the fault code. Ensure that both frontplane connectors are on firmly. Replace the Analog VE board odd (B2) if the fault code is 11 or 13. Replace the even board (B1) if the fault code is 12 or 14. Check the connections at the Hammer Interconnect board (B10). Loop the HSEM Hammer - Volt Monitor test. Measure the 48 volts at the hammer interconnect board (B10). Ensure that both frontplane connectors are on firmly. Measure the 48 volts at the power supply (P1). Loop the HSEM Hammer - Impact Monitor test. Swap Analog VE boards and observe fault code. Ensure that both frontplane connectors are on firmly. Replace the odd Analog VE board (B2) if the fault code is odd, or replace the even Analog VE board (B1) if the fault code is even. Is the voltage 48 V at the board? B3 2A141 Did the fault code follow the Analog board? 2A121 2A122 Did the fault code follow the hammer bank? Does the signal toggle? H1 2A103 Response Yes No
2A102
2A103
B3
2A104
2A104
2A120
2A121
2A122 2A140
2A141 2B100
Is the voltage 48 volts at the power supply? Did the fault code follow the Analog board?
B11 2B121
P1 B3
2B121
2320
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Next Step Step 2C100 Action Loop the HSEM Hammer - VCL test. Swap Analog VE boards, and observe the fault code. Ensure that both frontplane connectors are on firmly. Replace the odd Analog VE board (B2) if the fault code is odd, or replace the even Analog VE board (B1) if the fault code is even. Observe signal PB 27 of the ribbon control (B4). Observe signal PA 57 of the ribbon control (B4). Loop the HSEM Ribbon Stepper Motor test. Observe signal PA 39 of the ribbon control (B4). Observe signal PA 57 of the Printer Microprocessor (B3). Loop the HSEM Ribbon - Stepper Motor test. Power down the HSEM. Test the resistance between pins PB 17 and PB 27 of the ribbon control (B4). Test the resistance between pins PB 15 and PB 27 of the ribbon control (B4). Test the resistance between pins PB 21 and PB 27 of the ribbon control (B4). Test the resistance between pins PB 19 and PB 27 of the ribbon control (B4). Observe the signal on PA 20 of the skew sensor (B7). Raise the HSEM printer module. Remove the MICR ribbon. Run test 7534 (HSEM Ribbon - Tracking Adjust test) from the HSEM keypad. Raise the HSEM printer module. Remove the MICR ribbon. Observe the signal on PB 35 of the skew sensor (B7). Observe the signal on PA 29 of the skew sensor (B7). Is the voltage 12 V? Does the signal toggle? 2D101 2D102 P1 B3 Response Did the fault code follow the Analog board? Yes 2C121 No B3, B2, B1
2C121
2D100 2D101
2D102 2D200
Does the signal toggle? Does the signal toggle?
B3 B3
B4 2D201
2D201
Is the resistance approximately 5.5 ohms? Is the resistance approximately 5.5 ohms? Is the resistance approximately 5.5 ohms? Is the resistance approximately 5.5 ohms? Is the signal low? Does the display show FAILED 753400?
2D202
M5
2D202 2D203 2D204 2F100 2F101
2D203 2D204 B4 B3 B7
M5 M5 M5 2F101 S11
2F200
Is the signal low?
2F201
S11
2F201
Is the signal low?
B7
B3
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Next Step Step 2F300 Action Raise the HSEM printer module. Remove the MICR ribbon. Observe the signal on PB 39 of the skew sensor (B7). Observe the signal on PA 30 of the skew sensor (B7). Raise the HSEM printer module. Remove the MICR ribbon. Observe the signal on PB 31 of the skew sensor (B7). Observe the signal on PA 21 of the skew sensor (B7). Raise the HSEM printer module. Remove the MICR ribbon. Observe the signal on PB 27 of the skew sensor (B7). Observe the signal on PB 22 of the skew sensor (B7). Monitor signal DPDCT on PA 25 of the skew sensor (B7). Run the HSEM Ribbon Sensors test in loop mode. Monitor signal RIBMOT on PA 40 of the skew sensor (B7). Primary suspect: B7 Secondary suspect: S6, B12, cables J2, and J27 32700 Monitor signal SPTE on PA 33 of the skew sensor (B7). Run the HSEM Ribbon Sensors test in loop mode. Monitor signal LOWRIB on PA 36 of the skew sensor (B7). Primary suspect: B7 Secondary suspects: S7, B12, cables J5, and J27 32900 Remove the panel covering the HSEM take-up motor pulleys. Observe the takeup motor drive belt to the TU reel. Replace the drive belt, and rerun the HSEM Ribbon Sensor test. Rerun the HSEM Ribbon sensor test (7532), and observe the take-up reel. Did the take-up reel rotate during the test? B4, B3 B4, M6 Is the drive belt broken or worn out? 32910 32920 Is there at least one pulse per test loop? Is there at least one pulse per test loop? 32710 32720 Response Is the signal low? Yes 2F301 No S11
2F301 2F400
Is the signal low? Is the signal low?
B7 2F401
B3 S11
2F401 2F500
Is the signal low? Is the signal low?
B7 2F501
B3 S11
2F501 32400
Is the signal low? Does the signal toggle?
B7 32410
B3 32420
32410 32420
B3
B7, B3
32710 32720
B3
B7,B3
32910 32920
2322
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Next Step Step 33300 Action Lift up the HSEM cover, and cheat the cover interlock switch. Observe the drum. Measure PA 47 signal Index 1 on the skew sensor (B7). Measure PA 48 signal INDCLK on the skew sensor (B7). Adjust the magnetic sensor pickup for the index clock. Verify the Index Clock Freq., and rerun the POC. Measure PA 45 Signal Clock on the skew sensor B7. Measure PA 46 signal Charclk on skew sensor B7. Turn off the HSEM power, and remove skew sensor B7. Turn on the HSEM power, and run the HSEM Drum Sensor test. Measure PA 45 signal clock on the skew sensor. Adjust the magnetic sensor pickup for the clock character. Verify the character clock, and rerun the POC. Is the signal pulsating? Is the signal occurring every 3.3ms. at a width of 1.0 ms.? Is the signal pulsating? 33510 B3 B7 33520 B7,B3 S8, cable (J4-J27) Response Is the drum rotating? Yes 33310 No M4
33310
Is the signal pulsating?
33320
S9, B7, cable (J4-J27) B7, B3
33320
Is the signal occurring every 33.3 milliseconds (ms) with a pulse width of 23.3 ms? Can the sensor be adjusted properly?
B3
33400 33410 33500 33510 33520
33410
S9, M4
33600 33610
Can the sensor be adjusted correctly?
33610
S8, M4
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2323
Print Quality Diagnostic Flow

Table 233. Print Quality Diagnostic Flow
Next Step Step 100 200 300 400 500 600 700 Action Examine the ribbon Replace the ribbon. Rerun the test. Examine the print drum. Replace the print drum. Rerun the test. Examine the hammer bank. Repair or replace the hammer bank. Rerun the test. Make adjustments by performing the following T&As: Magnetic Pickup Gap Character Phase Adjustment Hammer Bank Adjustment Drum Horizontal Adjustment 800 900 1000 1100 No fault or error detected. Rerun the system exerciser. Repair or replace the faulty component. Rerun the system exerciser. Corrections were made. Return to the customer application. Primary suspect: B2 Secondary suspect: B1 After replacing the boards(s), run the Flight Time Adjustment T&A and the Character Phase Adjustment T&A before rerunning the system exerciser. Is the print quality acceptable? 1000 1100 Can the adjustments be performed? 800 900 Are any hammers damaged or dirty? 600 700 Is there any obvious damage, wear, or dirt on the drum? 400 500 Response Are there any voids in the ribbon? Yes 200 No 300
2324
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Maintenance Mode Diagnostic Flow

Table 234. Maintenance Mode Diagnostic Flow
Next Step Step 100 Action Open the HSEM door. Lift the HSEM cover and defeat the magnetic switch and AC interlock. Observe the LCD display on the maintenance keypad. Toggle the override switch on the top of the HSEM logic gate and observe the print drum. Press the Enter key on the keypad. Observe the LCD display. Return the override switch to its original position and observe the LCD display. Perform the HSEM Top Cover and Door Switch Adjustment T&A. No fault was found, or the adjustment was performed. Rerun the test. Response Is UNISYS SERVICE displayed? Yes 200 No 500
200
Is the drum rotating?
300
B6
300 400 500 600
Is STEP RIBBON displayed? Is ON LINE displayed? Can the adjustment be performed?
400 1200 1200
B3, K1 1000 B6, I3
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Track Motors Diagnostic Flow

Table 235. Track Motors Diagnostic Flow
Next Step Step 100 200 210 300 400 500 600 700 800 900 1000 1100 No fault or error detected. Rerun the system exerciser. Observe the exit rollers. Observe the entry AC motor. Replace the drive belt, and rerun the system exerciser. Replace the entrance AC motor, and rerun the system exerciser. Observe the exit AC motor. Replace the drive belt, and rerun the system exerciser. Replace the exit AC motor, and rerun the system exerciser. Primary suspect: solid state relay for AC motor control Secondary suspect: B6, cable P10-P2 Is the exit AC motor cycling on and off? 900 1000 Are the exit rollers cycling on and off? Is the entry AC motor cycling on and off? 500 600 1100 700 Action Select test HSEM Servo -Velocity Adjust in loop mode. Observe the entry rollers. Observe the exit rollers. Response Are the entry rollers cycling on and off? Are the exit rollers cycling on and off? Are there consistent jams in the HSEM module? Yes 200 210 B5 No 400 800 300
2326
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HSEM Outsort MTR Procedures

Table 236. HSEM Outsort MTR Procedures
Next Step Step 100 200 300 310 Action Record the outsort error. Execute the HSEM confidence test. Follow the fault code displayed on the screen to isolate the problem. Observe the recorded outsort error. Clean or replace the servo rollers per Sections 3 and 5 of the NDP Field Test and Reference Manual. Run the system exerciser. Replace the Servo Amp board, B8, and run the system exerciser. Observe the recorded outsort error. Was the outsort error document jam or document not in stop position? Was the outsort error document jam or document not in stop position? Was the outsort error hammer flight? Was anything other than a zero displayed? 360 370 Was the outsort error document slip? Was the outsort error document slip? 310 320 350 900 Response Did the test pass successfully? Yes 300 No 200
320 350
360
Replace the Servo Amp board, B8, and run the system exerciser. Observe the recorded outsort error. Place the HSEM Printer Module into maintenance mode. From the maintenance keypad, select the Flight Fault Item. Press the Enter key four times, and record the display after each Enter key depression. Observe the recordings.
B5
900
370 380
380 390
400 800
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Next Step Step 390 Action From the recorded FLIGHT FAULT, refer to the example and chart below to isolate the failing hammer. This chart gives the hammer number relative to its failure as recorded earlier. {Example: Recorded Flight Fault was H01 H05 H09 H0D 0000 0000 0000 0500 Response Yes No
Referring to the chart below, this would indicate that hammer 14 is failing because the hammer flight fault was something other then zero.} Replace the faulty hammer. and perform the Hammer Flight Time and Phase T&As. Run the system exerciser. Flight Fault Hammer Identification Chart H01 1 2 3 ______________ H05 5 6 7 ______________ 4 8
H09 9 10 11 12 ______________ H0D 13 14 15 16 ______________ 400 Observe the recorded outsort error. Was the outsort error one of the following? SKEWED DOCUMENT >+0.75 DEGREES SKEWED DOCUMENT >+1.50 DEGREES SKEWED DOCUMENT <-0.75 DEGREES SKEWED DOCUMENT <-1.50 DEGREES DOCUMENT TOO HIGH 410 Rerun the Skew Calibration T&A, and rerun the system exerciser. Are there still Skew/Height related outsorts? B7 900 410 500
2328
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Next Step Step 500 Action Observe the recorded outsort error. Response Was the outsort error one of the following? RIBBON SKEW LEFT FAILURE RIBBON SKEW RIGHT FAILURE RIBBON SKEW LEFT WARNING RIBBON SKEW RIGHT WARNING 510 Remove the HSEM ribbon. Use test sensors, nontrack to test the ribbon tracking sensor states. Run the Ribbon Tracking Adjustment test in loop mode. Rerun the system exerciser, and observe the error code. Perform step 100 again. The system experienced a glitch. Run the clients program again. Corrections were made. Return to the clients application. Are the sensors functional? 520 B7, S11 B4, M7 Yes 510 No 600
520
Does the ribbon deskew motor swing back and forth from one limit to the other? Does the error code appear again?
800
600 700 800 900
700
800
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2329
HSEM Fault Code List and FRU Description

Table 237. HSEM Fault Code List and FRU Description
FRU B1 B2 B3 B4 B5
BP Slot 11 10 9 8 6
Description Analog VE (Even) PWBA Analog VE (Odd) PWBA Printer Microprocessor PWBA Ribbon Control PWBA Common Controller PWBA
T&A(s) Flight Time Adjustment Flight Time Adjustment Microprocessor Initialization None Skew Sensor Calibration Servo Slip Reference Skew Sensor Calibration
B6 B7 B8
4 3 2
Sensor Power Control PWBA Skew Sensor PWBA Servo Amplifier PWBA
None Skew Sensor Calibration Servo Velocity Adjustment Servo Slip Reference
B9 B10 B11 B12 P1
Servo Driver PWBA Hammer Interconnect PWBA HVSD PWBA Printer Interface PWBA Power Supply
Servo Velocity Adjustment None None None Servo Velocity Adjustment Flight Time Adjustment
H1 K1 I1 I2 I3 I4 I5 M1
Hammer bank Maintenance keypad Cover interlock switch Cover switch Module position switch Lift switch Lift solenoid Servo motor
Hammer Bank Adjustment None Module Interlock Switch Adjustment Module Interlock Switch Adjustment Module Position Switch Adjustment None Latch Solenoid Adjustment Servo Velocity Adjustment Servo Slip Reference
M4 M5 M6
Drum motor Ribbon stepper motor Ribbon take-up motor
Print Drum Belt and Drive Pulley Adjustment Ribbon Timing Belt Tension Adjustment Ribbon Drive Shaft Endplay and Pulley Location
2330
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Table 237. HSEM Fault Code List and FRU Description
FRU M7 S2 S3 S4 S6 S7 S8 S9 S10 S11
BP Slot
Description Ribbon de-skew motor Dog-ear sensor Servo sensor Stop sensor Ribbon motion encoder Ribbon low encoder Character clock magnetic pick-up Drum index magnetic pick-up Document skew sensor Ribbon skew sensors None None None None
T&A(s)
3142 5762????????? 3142 5739?????? Magnetic Pickup Gap Magnetic Pickup Gap Skew Sensor Calibration None
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HSEM Tests
Table 238. HSEM Tests
Test Number 01 02 06 07 08 09 0A 0C 0D 0E 0F 10 11 12 13 14 18 19 1A 1B 1C 1D 1E 20 21 22 23 24 25 26 HSEM - NVM Test
MTR Kernel Display
HSEM- Ext. Bus Wrap Around Test HSEM Trk Sens-Curr Monitor Test HSEM Trk Sens-Input Simuln Test HSEM Trk Sens-Normal Mode Test HSEM -Power Control Circuitry Test HSEM - Servo Skew Interrupt Test HSEM Skew/Height Sensors -Test HSEM Skew/Height Sensor Compensation HSEM Servo -Velocity Adjust HSEM Servo-Slip Reference HSEM Servo-Volt Mon Test HSEM Servo Driver- Volt Mon Test HSEM Servo-Normal Mode Test HSEM Enter Print on Outsort Mode HSEM Exit Print on Outsort Mode HSEM NDP 1XXX FIFO Interface Test HSEM -Echo Test HSEM Sensor State HSEM Sensor Compensation HSEM Read Skew Results HSEM Skew Sens-Calculate Table HSEM Skew Sens- Set Gauge Heights HSEM Printer - Processor Test HSEM Printer-PROM Checksum Test HSEM Printer- RAM Test HSEM Printer-NVM Test HSEM Printer-Ext. Bus Wrap Test HSEM Printer-External Control Signal Wrap-Around Test HSEM Print Drum Image
2332
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Table 238. HSEM Tests
Test Number 28 29 2A 2B 2C 2D 2F 32 33 34
MTR Kernel Display HSEM Hammer-Supply Mon Test HSEM Hammer- Clock Verification Test HSEM Hammer-Volt Mon Test HSEM Hammer-Impact Mon Test HSEM Hammer -VCL Test HSEM Ribbon-Stepper Motor Test HSEM Ribbon-Ribbon Skew/Height Sens Status HSEM Ribbon Sensors-Test HSEM Drum Sensors-Test HSEM Ribbon-Tracking Sensors Test
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2333
2334
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Section 24 CAR Diagnostic Procedures (Dual Image System)

This section describes the testing methods used for diagnosing the courtesy amount recognition (CAR) unit. It explains how to interpret the POC results to isolate the fault to a field replacement unit (FRU). These procedures pertain to the CAR module designed to operate with the dual image system. For CAR modules designed to operate with U4/JPEG image systems, refer to Section 21, "CAR Diagnostics (U4/JPEG Imaging System)."
Introduction
The following diagnostic tests are available to use for isolating problems:
Power-on confidence (POC) test for each PCBA in the CAR unit Test Slot test
Other information in this section includes the following:
Error code index CAR diagnostic flows
When you see an error code displayed at the image capture server (ICS) PC of the form shown in the "Error Code Format" section, look up the error in the "Error Codes" section to identify the procedure you should use to diagnose the problem. Error codes, error code formats, and diagnostic procedures are found later in this section.
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241
CAR Diagnostic Procedures (Dual Image System)
POC Test
For the NDP1825, the CAR module is external to the sorter and has its own power source. On the right, front side of the module is a CAR Status panel. This panel has three status LEDs: Power, Unit On, and Error. Beneath the Unit On LED is the Unit On switch that is used to power up the external CAR module. When power is applied, the CAR POC test executes automatically. This test is also run if the CAR unit is reset. For the NDP1150, the CAR module is internal to the NDP transport. The CAR gate is located under the first eight pocket module in the transport. When the sorter is powered on, so is the CAR unit. Consequently, the NDP1150 CAR unit executes its POC test whenever the sorter is powered on. The POC test routines for both the external and internal CAR modules are on EPROMs resident on PCBAs in the CAR gate. The POC test verifies that the CAR unit is free of faults before it is used with the document processor. The POC test provides confidence that the following components are functioning properly:
Processors Memories Buses Internal serial links DC voltage Hard-disk controller and drive
Interpreting the Error Indicator LEDs

The error indicator light on the CAR module shows the general result of the CAR POC test. For the external CAR module, the error indicator light is the Error LED on the CAR Status panel. For the internal CAR module, the error indicator light is located on top of the CAR gate.
If the error indicator light remains off after the CAR unit is turned on or reset, the CAR unit has passed its POC test. If the error indicator light is lighted, the POC test has detected an abnormal situation. When this happens, you need to check the result of the POC test on each PCBA, as indicated by a set of error indicator light-emitting diodes (LEDs). The LEDs are located on the front side of each PCBA.
Figure 241 and Figure 242 show the LED displays for the PCBAs.
242
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o o o / o o o
green green red
for 2nd Character Recognition Unit
reset switch for starting test slot function green green red
for 1st Character Recognition Unit
Figure 241. LEDs on Recognition Unit (RU) PCBA
o o o /
green green red reset switch for starting test slot function
Figure 242. LEDs on Adaption Unit (AU) and Pixel Unit (PU) PCBAs During the POC test of a PCBA, the LEDs flash on and off. At the end of a successful POC test, the red LED is off and the two green LEDs are flashing. At the end of an unsuccessful POC test, the red LED is on. The POC test stops when an error is encountered. The state of the green LEDs (whether they are on, off, or flashing) indicates when the error occurred.
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243
Executing the POC Test

Use the following procedure to execute the POC test. 1. Do one of the following:
For the external CAR module: a. b. Turn the power on by pressing the "Unit On" switch on the control panel. Press the reset button inside the cabinet.
For the internal CAR module: c. d. Turn the sorter transport power on. Press the reset button on top of the CAR unit.
The POC test runs. 2. Check the state of the Error indicator on the operator panel after two minutes.
If the Error indicator is off, no errors were encountered. You are done with this procedure. If the Error indicator is on, the test was unsuccessful.
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Card Cage Test Slot

The test slot is located at the far left side of the card cage. You can use the test slot to verify the hardware functions and the input/output circuitry on suspect PCBAs. The test slot can test the AU, PU, and RU PCBAs independently of the current CAR unit state. The test slot test has several steps. As the test runs, the result of each step is indicated by the LEDs. At the end of a successful test, there is a two-second pause. Then the test repeats until you remove the PCBA or an error occurs. If an error occurs, the test stops and the red LED on the PCBA lights. The state of the green LEDs (whether they are on or off) shows when the error occurred. The following procedure includes a table that shows the state of the LEDs during the test. If an error occurs, use the table to see during which step the error occurred. For example, if the red LED is on and both green LEDs are off, the error occurred during the internal self-test. Use the following procedure to test a PCBA in the test slot.
WARNING
Be sure that power to the CAR unit is turned off before removing and replacing FRUs. Otherwise, serious injury or death may result from electrical shock.
Caution
You must wear an antistatic wrist strap during this procedure to reduce the possibility of electrostatic discharge. Failure to wear one could result in equipment damage and/or performance degradation now, or in the future.
1. 2. 3.
Insert the test fixture into the test slot, and then insert the PCBA into the test slot. Press the reset button on the PCBA in the test slot. Watch the LEDs.

4. 5.
If the test repeats, there is no error. Skip to step 5. If all three LEDs become static (light up and stay lighted), there is an error. Go to the next step.
Compare the state of the LEDs to those in Table 24-1 and 24-2 to determine when the error occurred. Remove the PCBA from the test slot.
If an Error Code Line procedure directed you to execute this test, return to that procedure to determine what to do next.
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Table 241. Test Slot Steps and Related LED Displays for RU and AU PCBAs
Test Step 1 Lamp testing
Process green x green x red x green o green o red x green x green o red x green x green x red o green x green x red o
LED
Internal self-test running
Internal self-test successfully finished, interfaces being checked Interfaces all right
Pause of two seconds, then loop to step 1
Legend
x = on o = off
Table 242. Test Slot Steps and Related LED Displays for PU PCBA
Test Step 1 Lamp testing
Process green x green x red x green o green o red x green x green + red x green x green x red o
LED
Internal self-test running
Internal self-test successfully finished, interfaces being checked. Interface OK. Pause of two seconds, then loop to step 1
Legend
x = on o = off + = blinking
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Testing the CAR Unit

Use the Offload Exerciser to test the CAR unit. The Offload Exerciser is described in the NDP Servicing Guide: Analysis and Test Software (2983 9289). The Image View Utility, a PC-based utility for viewing documents captured by the image camera unit, has several commands for analyzing the code line data captured by the CAR unit. Instructions for using the Image View Utility are provided in an online help facility, which is accessed from the utility.
Error Code Format

This section lists the messages that may be generated by the CAR unit. The CAR unit provides messages when the following states occur:
POC Failed Error Sync Error Other information
Not all messages in this list require action. Many are for information only. This list is provided to help isolate a problem. To diagnose an error, refer to the "CAR Diagnostic Flows" subsection later in this section. An error code includes a message qualifier, a source identification, and a unique number. A string of words or numbers may follow the error code.
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Message Qualifiers
The first 2 characters are the message qualifier. The message qualifier indicates the type of error message. The characters that may appear are IN, IW, IE, E followed by a space, F followed by a space, XE, and S followed by a space. They are explained next. IN IN means internal news. An internal news message is displayed only on the ICS PC screen. No action is required. IW IW means internal warning. A warning indicates that a function has not been performed or has been only partially performed. For example, if something is wrong with the message syntax, the CAR unit issues a warning message and sends the document processor a flag in the prefix of the response. IE, E, and F IE means internal error. An internal error message may be generated by the AU software, PU software, or PC standard functions. Generally, an internal error causes the CAR unit to enter the Error or POC Failed state (depending on the previous state). E stands for error state. F stands for POC Failed state. When the transport processor requests the status of the CAR unit, the CAR unit sends internal error messages with E followed by a space or F followed by a space as the message qualifier. For example, the internal error message IEAU081010 000D would be sent to the transport document as E AU081010 000D. An E or F message also is displayed on the CAR unit PC screen if the PC monitor is connected. If the CAR unit is already in the Error, POC Failed, or Sync Error state when an internal error occurs, the error message is displayed only on the PC screen of the CAR unit (if the monitor is connected). If the screen is full, further messages are ignored. XE and S XE means external error. An external error causes the CAR unit to enter the Sync Error state. S stands for sync error. When the transport processor requests the status of the CAR unit, the CAR unit sends external error messages with S followed by a space as the message qualifier. For example, the error message, XEAU012024 0001 would be sent to the transport processor as S AU012024 0001. If an external error occurs when the CAR unit is already in the Sync Error state, the error message is displayed only on the CAR unit PC screen. If the screen is full, further messages are ignored.
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Source Identification
The next 4 characters identify which piece of software generated the message. For example, AU08 identifies a piece of the AU software. This can be used for support, if necessary.
Number
The last 4 characters compose a number that, when combined with the message qualifier and source identification, uniquely identifies the error code.
String
A string may follow the error code. Typically, the string provides more information about the error. For example, an error message concerning a defective RU may identify the RU by its number in a string. In the description of the error messages, the string information is often referred to as a parameter.
Notation Conventions
Error codes listed in the following subsection, "CAR Error Codes," have the following general format: IWAU<id>0105 <nnnn> <ssss> In this format, variables are shown in angle brackets. When an error code is displayed on a monitor, variables are replaced by values, as shown by the following example: IWAU010105 0001 1010 When an RU PCBA reports an error, the beginning of the source identification part of the error code is a variable. For example, IW<ru>020021 When displayed, the variable is replaced by a value. For example, IW04020021
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Because variables are often embedded in the middle of error codes, it may be difficult to find some error codes in this listing. As a general rule, if you cannot find an error code in the listing where you expect to find it, consider the following:
Codes that begin with E AU, F AU, IEAU, INAU, IWAU, S AU, and XEAU are the most likely to have a variable in the fifth and sixth characters. For example, if you do not find IWAU010105 listed between IWAU010104 and IWAU010106 in the Error Code subsection, look for it as IWAU<id>0105. Note: In the Error Codes subsection, the error codes that contain variables in the first 10 characters follow the codes without variables.
If the third and fourth characters are numbers, such as IW03260004, the error concerns an RU. Substitute <ru> for the numbers when looking up the code in the index. For example, look for IW<ru>260004.
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CAR Error Codes

Table 243 provides a list of CAR error codes and descriptions. Table 243. CAR Error Codes
Error Code E AU059200 E AU079000 E AU079002 <pppp>
Description The SCSI Buffer for sending messages to PC is not free. PC did not get the last message correctly. Error input queue overflow. Invalid CRU number. <pppp> = Erroneous CRU number
E AU079003 <pppp>
No more RUs running. <pppp> = Number of last CRU to go defective.
E AU079004 <pppp> <qqqq>
SBUS/MTR command has invalid length. <pppp> = Expected command length <qqqq> = Received command length
E AU079005 <pppp>
SBUS/MTR command name is not known. <pppp> = Name field of command
E AU079006 E AU079007 E AU079008 <pppp> <qqqq>
Index in error input queue is out of Range. Invalid pointer into error message output queue. Invalid CAR unit state for event flag. <pppp> = Event flag bit <qqqq> = CAR unit state
E AU079009 <pppp>
Invalid event bit number. <pppp> = Erroneous event bit number
E AU079010 <pppp>
Timer Interrupt detected error. <pppp> = Value of global variable = 8000: Fan Motion Detection signal detected.
E AU079011 <pppp>
Error returned from dsend_pc(). <pppp> = Error number returned by dsend_pc( );
E AU079012 <pppp>
Bad response from PC. <pppp> = Command name received from PC
E AU079013 <pppp>
Sending response to DP failed. <pppp> = Detailed error code
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Table 243. CAR Error Codes
Error Code E AU079014 <pppp>
Description No more data capture on CRU left. <pppp> = Number of defective CRU.
E AU081010 <qqqq>
Bad nominal results from PC. <qqqq> values: 000B: Result-ID zero or greater than 255 000C: Values of length and number of bytes are inconsistent. 000D: Data length exceeds buffer size NOMRES_BUF_SIZE. 000E: Nominal results records with nonunique result ID.
E AU081011 <qqqq>
Bad message response from PC. <qqqq> = value: 0004: Wrong response code to message PV. Should be AV. 0006: Wrong response code to message PD. Should be AD. 0008: Wrong response code to message PP. Should be AP. 000F: Bad response code to message PX. Should be DN or AX.
Error trying to send message to PC. <pppp> = Error code returned by dsend_pc() <qqqq> = Value of program location identifier err_index in MESSAGE_HANDLER.C
Error on pending BOS flag. <pppp> error cause: 0010: Zero flag bits 0020: Event flag group deleted 0040: Nonexistent event flag group <qqqq> = Value of program location identifier err_index in MESSAGE_HANDLER.C
Error trying to send response to DP. <pppp> = error cause: 0390: Bad SCSI-Status 0360: Excessive response length 0380: Wrong response code <qqqq> = Value of program location identifier err_index in MESSAGE_HANDLER.C
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Error Code E AU0E1001 <pppp> <qqqq> <rrrr>
Description Bad data in reference amount from PC. <pppp> = Byte offset of the bad byte in reference amount data. <qqqq> = Value of program location identifier err_index in TESTTASK.C. <rrrr> = Sync byte value.
E AU0E1003 <qqqq>
Bad RU number (greater than 31) from check handler. AU defective. <qqqq> = Value of program location identifier err_index in TESTTASK.C
E AU0E1004 <qqqq>
Test did not pass because of defective RUs. <qqqq> = Value of program location identifier err_index in TESTTASK.C
E AU0E1006 <qqqq>
No RUs are ready. <qqqq> = Value of program location identifier err_index in TESTTASK.C
E AU0E1007 <qqqq>
Bad message response code from PC. <qqqq> = Value of program location identifier err_index in TESTTASK.C
E AU0E1008 <pppp> <qqqq>
Error trying to send message to PC. <pppp> = Error code returned by dsend_pc() <qqqq> = Value of program location identifier err_index in TESTTASK.C
E AU0E1009 <pppp> <qqqq>
Error on pending BOS flag. <pppp> = error cause: 0010: Zero flag bits 0020: Event flag group deleted 0040: Non-existent event flag group <qqqq> = Value of program location identifier err_index in TESTTASK.C
E AU501105 <rrrr>
Bad success code in amounts. <rrrr> = Bad success code value.
Error trying to send message to PC. <pppp> = Error code returned by dsend_pc(). <qqqq> = Value of program location identifier.
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Error Code E AU501107 <rrrr> <ssss> <qqqq>
Description Unexpected message response from PC. <rrrr> = Command code sent to PC <ssss> = Command code received from PC <qqqq> = Value of program location identifier
Error on pending BOS flag. <pppp> = Error cause 0010 = Zero flag bits 0020 = Event flag group deleted 0040 = Non-existent event flag group <qqqq> = Value of program location identifier
E AU501110 E AU501111 <pppp>
Amount buffer for statistics overflows. Too many statistic IDs in configuration file. <pppp> = Number of statistic IDs allowed
E AU<id>0990 E AU<id>0999 <nnnn>
Parity error in program memory of AU. AU goes into Error state. Internal lists of BOSAU are corrupted. <nnnn> = System error number
E AU<id>2011 E AU<id>2012 <pppp> <rrrr>
Interrupt for serial output when output-state not active. Bad response from PU. <pppp> = Nominal response <rrrr> = Received response
E AU<id>2013 E AU<id>2014 <pppp>
Interrupt for serial input when output-state active. Unknown command from PU. <pppp> = Received command
E AU<id>2015 <pppp>
PU indicates video data received, but AU did not get appropriate dispo message. <pppp> = Sync byte
E AU<id>2016 <pppp> <rrrr>
PU indicates video data received in command where sync byte does not correspond with sync byte in dispo message. <pppp> = Nominal sync byte <rrrr> = Received sync byte
E AU<id>2017
More than 12 Video Received flags are set in control FIFO.
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Error Code E AU<id>2018 <pppp> <rrrr>
Description Interrupt for serial input document sent to CRU. Control FIFO Video received is empty. <pppp> = Sync/field code <rrrr> = CRU number
E AU<id>2019 <pppp> <rrrr> <ssss>
Interrupt for serial input document sent to CRU. Synch byte is wrong. <pppp> = Sync/field code nominal <rrrr> = Sync/field code received <ssss> = CRU number
Control FIFO RU overflow. <pppp> = Sync/field code <rrrr> = CRU number
E AU<id>2021 <pppp>
Interrupt for serial input. Document rejected. Control FIFO video received is empty. <pppp> = Sync/field code
Interrupt for serial input. CRU does not receive document. Control FIFO video is empty. <pppp> = Sync/field code <rrrr> = CRU number
E AU<id>2023 <pppp> <rrrr> <ssss>
Interrupt for serial input. CRU does not receive document. Sync byte is wrong. <pppp> = Nominal sync byte <rrrr> = Received sync byte <ssss> = CRU number
E AU<id>2025 E AU<id>2027 E AU<id>2031 E AU<id>2040 <pppp>
Interrupt for serial input PU video buffer full. All CRUs in Error state or disabled. Call for subroutine that is already busy. No more control blocks free to process a dispo message. BR, BD, BS, or BE command received from CRU, and control block pointer = 0. <pppp> = CRU number
E AU<id>2041 <pppp>
Sync byte or field code in BR command from CRU is wrong. <pppp> = CRU number
E AU<id>2042 <pppp>
Number of fields in BR command from CRU is wrong. <pppp> = CRU number
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Error Code E AU<id>2043 <pppp>
Description Command BR, BD, BS, or BE from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
E AU<id>2044 <pppp>
Command BS from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
E AU<id>2045 <pppp>
Command BR from CRU. Control block pointer equals zero. <pppp> = CRU number
E AU<id>2046 <pppp>
Command BD from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
E AU<id>2047 <pppp>
Command BD from CRU. Control block pointer equals zero. <pppp> = CRU number
E AU<id>2048 <pppp>
Command BE from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
E AU<id>2049 <pppp>
Command BE from CRU. Control block pointer equals zero. <pppp> = CRU number
E AU<id>204A <pppp>
Command BE from DC task. Control FIFO for CRU is empty. <pppp> = CRU number
E AU<id>204B <pppp>
Command BE from DC task. Control block pointer equals zero. <pppp> = CRU number
E AU<id>204C <pppp>
Command BD received from CRU, and command length is wrong. <pppp> = CRU number
E AU<id>2050 E AU<id>2062 <pppp> <rrrr>
Unknown command or command sequence is wrong. Timeout for document in CRU. Control FIFO is empty. <pppp> = Sync byte <rrrr> = Field code
Timeout control block undefined. <pppp> = Sync byte <rrrr> = Field code
E AU<id>5343 0300 0100 E AU<id>5343 0300 0200 E AU<id>5343 0300 0300 E AU<id>5343 0300 0400
AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure.
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Error Code E AU<id>5343 0300 0500 E AU<id>5343 0300 0600 E AU<id>5343 0300 0700 E AU<id>5343 0300 0800 E AU<id>5343 0300 0A00 E AU<id>8100 E AU<id>8103 E AU<id>9006 E PU000021 <pppp> AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure.
Description
SCSI Send buffer not empty. SCSI Receive buffer is empty. Read or Write Index Number to Error Input Queue is out of range. Data may be overwritten. Error Input Queue is cleared. Wrong command list in AU disposition. <pppp> = Actual command list
E PU000022 <eeee> <aaaa>
Wrong receipt from AU on serial interface. <eeee> = Expected value <aaaa> = Actual value
E PU000023 E PU000024 E PU000025 E PU000026 E PU000027 E PU000028 E PU000029 E PU000030 E PU000031 E PU000032 E PU000033 E PU000034 E PU000035 E PU000036 E PU000037 E PU000038
Wrong command from AU on serial interface. More than 30 dispositions received from AU. More than 30 free CRU numbers received from AU. PU mode is missing. Checksum error in RL command. Checksum error in RD command (upload request data). Checksum error in 09 command (disposition from AU). Interrupt sequence on video interface is wrong. Command 09 (disposition from AU) is missing. The field width is exceeded. The field width is too small. The locations defined in disposition are false; field width is less than or equal to 0. Two fields defined in disposition. FIFOs for video interface are not empty. Transmit buffer for serial interface overflowed. PU buffer overflowed.
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Error Code E PU000039 <ssss> <dddd>
Description Document ID number in ID line is not identical to sync number from disposition. <ssss> = sync number from AU dispo <dddd> = doc ID number in ID line
Checksum error in RD command. <eeee> = Expected value <aaaa> = Actual value
Checksum error in RP command. <eeee> = Expected value <aaaa> = Actual value
Checksum error in DD command. <eeee> = Expected value <aaaa> = Actual value
Checksum error in DP command. <eeee> = Expected value <aaaa> = Actual value
E PU000061 E PU000062 E PU000063 E PU000066 <ssss> <dddd>
Video data missing. No test ID line received. No free CRU. Doc ID number is not identical to sync number of dispo message. <ssss> = Sync number from AU dispo <dddd> = Doc ID number from ID line
E PU000067 F AUEP1004 F AUEP1005 F AUEP1014 F AUEP5100 F AUEP5101 F AUEP5102 F AUEP5103 F AUEP5104
Document not in PU buffer. Parity error in program memory. Parity error in data memory. No downloading possible because of timer synchronization problems. Module: AUPROM or SCMOVP. Internal error in module POCFAI. PC command with checksum error. Unknown command received. Expected commands are AP or AX. Unknown command received. Expected commands are DP, DD, SP, or AX. Unknown command received.
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Error Code F AUEP5105 F AUEP5106 F AUEP5107 F AUEP5108 F AUEP5109 F AUEP5110 F AUEP5112 F AUEP5113 F AUEP5114 F AUEP5115 F AUEP5116 F AUEP5117 F AUEP5118 F AUEP5119 F AU079003 <pppp>
Description Buffer not valid when calling message handler. Start address not valid. Expected start address is equal to or less than $0FEFF. PC does not perform download. PC responds with command AX. Last command to perform is not SP. Sender field in command does not contain PC. Receiver field in command does not contain AU. Verification error in performing the command DD. Verfication error in performing the command DP. Error while converting bytes in words. Timeout (60 s) in communication with PC. PP command does not get the response AP. Power-off initiated because of Power Fail signal, but power-off is not performed. Power-off initiated because of Fan Motion Detection signal, but power-off is not performed. Power-off initiated because of Fan Motion Detection signal. No more CRUs running. <pppp> Number of last CRU to go defective.
F AU079010 <pppp>
Timer Interrupt detected error. <pppp> = Value of global variable. = 8000: Fan Motion Detection signal detected.
F AU145055 <ssss>
Error in Communication with PU. <ssss> = Status word of PU
F AU145255 F AU501100 <rrrr> <ssss>
There is no ready RU. Missing byte in PC response to PV/300 message. <rrrr> = Byte position of missing byte <ssss> = Missing byte value
F AU501101 <rrrr> <ssss> <tttt>
Bad byte in PC response to PV/300 message. <rrrr> = Byte position of missing byte <ssss> = Missing byte value <tttt> = Expected byte value
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Error Code F AU501102 <rrrr>
Description Expected digit in PC response to PV/300 message is missing. <rrrr> = Byte position of missing digit
F AU501103 <rrrr> <ssss>
Byte in PC response to PV/300 message is not an expected comma. <rrrr> = Byte position of bad byte <ssss> = Bad byte value
F AU501104 <rrrr> <ssss> <tttt>
Illegal statistics ID in PC response to PV/300 message. <rrrr> = ID position of bad ID <ssss> = First and second byte of bad statistics ID <tttt> = Third and fourth byte of bad statistics ID
F AU501112 F AU501113 F AU501114 F AU<id>3012 <kkkk> <rrrr>
Bad length of "/301 nnnn" parameter string. Missing digit in "/301 nnnn" parameter string. Missing "/301 nnnn" parameter string. Error in communication with PC. <kkkk> = First word of command <rrrr> = Return value
F AU<id>3030 <eeee> <rrrr>
Error in communication with PC. PC sent an unknown return message. <eeee> = Expected message <rrrr> = Returned message
F AU<id>3031 <kkkk>
Error in communication with PC. PC sent an unknown command in return message. <kkkk> = First word of command
F AU<id>3116 <rrrr>
Error in communication with PC. PC sent a command with an unknown receiver field during download. <rrrr> = Receiver field
F PC__0009 F PC__0010 F PC__0011 F PC__0012 F PC__0013 F PUEP0010 F PUEP0011
Download ID not found: [Download-ID]-. No download list in configuration file. Download not running, no loadlist specified. Error in download file: [Filename]. Download file not found: [Filename]. Wrong command name during Download program. Checksum error in command Download Program.
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Error Code F PUEP0012 F PUEP0013 F PUEP0014 F PUEP0015 F PUEP0016 IEAU059200 IEAU079000 IEAU079002 <pppp>
Description Checksum error in command Start Program. Command Download Program is missing. Wrong transmit/receive name in Download Program. Wrong transmit/receive name in Start Program. Wrong receipt from AU on serial interface. The SCSI buffer for sending messages to PC is not free. PC did not get the last message correctly. Error input queue overflow. Received invalid CRU number (out of range). <pppp> = Erroneous CRU number
IEAU079003 <pppp>
No more CRUs running. <pppp> = Number of last CRU to go defective.
IEAU079004 <pppp> <qqqq>
SBUS/MTR command has invalid length. <pppp> = Expected command length <qqqq> = Received command length
IEAU079005 <pppp>
SBUS/MTR command name is unknown. <pppp> = Name field of command
IEAU079006 IEAU079007 IEAU079008 <pppp> <qqqq>
Index in error input queue is out of range. Invalid pointer to error message output queue. Invalid CAR unit state for event flag. <pppp> = Event flag bit <qqqq> = CAR unit state
IEAU079009 <pppp>
Invalid event bit number. <pppp> = Erroneous event bit number
IEAU079010 <pppp>
Timer Interrupt detected wrong functions. <pppp> = Value of global variable = 8000: Fan Motion Detection detected fan defect.
IEAU079011 <pppp>
Error Returned from dsend_pc(). <pppp> = Error number returned by dsend_pc( );
IEAU079012 <pppp>
Bad response command from PC. <pppp> = Command name received from PC.
IEAU079013 <pppp>
Sending response to DP failed. <pppp> = Detailed error code
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Error Code IEAU079014 <pppp>
Description No more data capture on CRU left. <pppp> = Number of defective CRU
IEAU081010 <qqqq>
Bad nominal results from PC. <qqqq> = values: 000B: Result ID zero or greater than 255 000C: Values of length and number of bytes are inconsistent. 000D: Data length exceeds buffer size NOMRES_BUF_SIZE. 000E: Nominal results records with non-unique result ID.
IEAU081011 <qqqq>
Bad message response from PC. <qqqq> = value: 0004: Wrong response code to PV message. Should be AV. 0006: Wrong response code to PD message. Should be AD. 0008: Wrong response code to PP message. Should be AP. 000F: Bad response code to PX message. Should be DN or AX.
Error trying to send message to PC. <pppp> = Error code returned by dsend_pc(). <qqqq> = Value of program location identifier err_index in MESSAGE_HANDLER.C
Error on pending BOS flag. <pppp> = error cause: 0010: Zero flag bits 0020: Event flag group deleted 0040: Nonexistent event flag group <qqqq> = Value of program location identifier err_index in MESSAGE_HANDLER.C
Error trying to send response to DP. <pppp> = error cause: 0390: Bad SCSI-Status 0360: Excessive response length 0380: Wrong response code <qqqq> = Value of program location identifier err_index in MESSAGE_HANDLER.C
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Error Code IEAU0E1000 <rrrr> <ssss> <pppp> <qqqq>
Description Amount field code from RU does not correspond to reference test data field code from PC. <rrrr> = Number of RU with bad amount data <ssss> = Sync byte <pppp> = Byte offset of the bad byte in reference amount data <qqqq> = Value of program location identifier err_index in TESTTASK.C
IEAU0E1001 <pppp> <qqqq> <rrrr>
Bad data in reference amount from PC. <pppp> = Byte offset of the bad byte in reference amount data <qqqq> = Value of program location identifier err_index in TESTTASK.C <rrrr> = Sync byte value
IEAU0E1002 <rrrr> <ssss> <tttt> <uuuu> <aaee>
Amount data from RU is not identical to reference amount data from PC. <rrrr> = Number of RU showing amount compare error <ssss> = Actual sync byte <tttt> = Actual field code <uuuu> = Byte-offset of byte in amount data in which compare error occurs <aaee> = Actual and expected byte values
IEAU0E1003 <qqqq>
Bad RU number (greater than 31) from check handler. <qqqq> = Value of program location identifier err_index in TESTTASK.C
IEAU0E1004 <qqqq>
Test not passed. Defective RUs. <qqqq> = Value of program location identifier err_index in TESTTASK.C
IEAU0E1005 <rrrr> <ssss> <qqqq>
RU time out error. <rrrr> = RU showing time out error <ssss> = Sync byte <qqqq> = Value of program location identifier err_index in TESTTASK.C
IEAU0E1006 <qqqq>
No RUs ready. <qqqq> = Value of program location identifier err_index in TESTTASK.C
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Error Code IEAU0E1007 <qqqq>
Description Bad message response code from PC. <qqqq> = Value of program location identifier err_index in TESTTASK.C
IEAU0E1008 <pppp> <qqqq>
Error trying to send message to PC. <pppp> = Error code returned by dsend_pc() <qqqq> = Value of program location identifier err_index in TESTTASK.C
IEAU0E1009 <pppp> <qqqq>
Error on pending BOS flag. <pppp> = error cause: 0010: Zero flag bits 0020: Event flag group deleted 0040: Non-existent event flag group <qqqq> = Value of program location identifier err_index in TESTTASK.C
IEAU145055 <ssss>
Error in Communication with PU. <ssss> = Status word of PU
IEAU145255 IEAU501105 <rrrr>
There is no ready RU. Bad success code in amounts. <rrrr> = Bad success code value
Error trying to send message to PC. <pppp> = Error code returned by dsend_pc() <qqqq> = Value of program location identifier
IEAU501107 <rrrr> <ssss> <qqqq>
Unexpected message response from PC. <rrrr> = Command code sent to PC <ssss> = Command code received from PC <qqqq> = Value of program location identifier
Error on pending BOS flag. <pppp> = Error cause 0010 = Zero flag bits 0020 = Event flag group deleted 0010 = Nonexistent event flag group <qqqq> = Value of program location identifier
IEAU501110
Amount buffer for statistics overflows.
2424
3998 5593007
Error Code IEAU501111 <pppp>
Description Too many statistic IDs in configuration file. <pppp> = Number of statistic IDs allowed.
IEAU<id>0990 IEAU<id>0999 <nnnn>
Parity error in program memory of AU. AU goes into Error state. Internal lists of BOSAU are corrupted. <nnnn> = System error number
IEAU<id>2011 IEAU<id>2012 <pppp> <rrrr>
Interrupt for serial output when output-state not active. Bad response from PU. <pppp> = Nominal response <rrrr> = Received response
IEAU<id>2013 IEAU<id>2014 <pppp>
Interrupt for serial input when output-state active. Unknown command from PU. <pppp> = Received command
IEAU<id>2015 <pppp>
PU indicates video data received, but AU did not get appropriate dispo message. <pppp> = Sync byte
IEAU<id>2016 <pppp> <rrrr>
PU indicates video data received in command where sync byte does not correspond with sync byte in dispo message. <pppp> = Nominal sync byte <rrrr> = Received sync byte
More than 12 Video Received flags are set in control FIFO. Interrupt for serial input document sent to CRU. Control FIFO Video received is empty. <pppp> = Sync/field code <rrrr> = CRU number
IEAU<id>2019 <pppp> <rrrr> <ssss>
Interrupt for serial input document sent to CRU. Sync byte is wrong. <pppp> = Nominal sync/field code <rrrr> = Received sync/field code <ssss> = CRU number
Interrupt for serial input document sent to CRU. <pppp> = Sync/field code <rrrr> = CRU number
3998 5593007
2425
Error Code IEAU<id>2021 <pppp>
Description Interrupt for serial input. Document rejected. Control FIFO video received is empty. <pppp> = Sync/field code
Interrupt for serial input. CRU does not receive document. Control FIFO video is empty. <pppp> = Sync/field code <rrrr> = CRU number
IEAU<id>2023 <pppp> <rrrr> <ssss>
Interrupt for serial input. CRU does not receive document. Sync byte is wrong. <pppp> = Nominal sync byte <rrrr> = Received sync byte <ssss> = CRU number
IEAU<id>2025 IEAU<id>2026 <pppp>
Interrupt for serial input PU video buffer full. All CRUs in Error state or disabled. Interrupt for serial input. CRU <pppp> does not receive document. State manager disabled CRU. <pppp> = CRU number
IEAU<id>2027 IEAU<id>2031 IEAU<id>2040 <pppp>
Call for subroutine that is already busy. No more control blocks free to process a dispo message. BR, BD, BS, or BE command received from CRU, and control block pointer = 0. <pppp> = CRU number
IEAU<id>2041 <pppp>
Sync byte or field code in BR command from CRU is wrong. <pppp> = CRU number
IEAU<id>2042 <pppp>
Number of fields in BR command from CRU is wrong. <pppp> = CRU number
IEAU<id>2043 <pppp>
Command BR, BD, BS, or BE from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
IEAU<id>2044 <pppp>
Command BS from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
IEAU<id>2045 <pppp>
Command BR from CRU. Control block pointer equals zero. <pppp> = CRU number
IEAU<id>2046 <pppp>
Command BD from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
2426
3998 5593007
Error Code IEAU<id>2047 <pppp>
Description Command BD from CRU. Control block pointer equals zero. <pppp> = CRU number
IEAU<id>2048 <pppp>
Command BE from CRU. Control FIFO for CRU is empty. <pppp> = CRU number
IEAU<id>2049 <pppp>
Command BE from CRU. Control block pointer equals zero. <pppp> = CRU number
IEAU<id>204A <pppp>
Command BE from DC task. Control FIFO for CRU is empty. <pppp> = CRU number
IEAU<id>204B <pppp>
Command BE from DC task. Control block pointer equals zero. <pppp> = CRU number
IEAU<id>204C <pppp>
Command BD received from CRU, and command length is wrong. <pppp> = CRU number
Unknown command, or command sequence is wrong. Timeout for document in CRU. Control FIFO is empty. <pppp> = Sync byte <rrrr> = Field code
Timeout control block undefined. <pppp> = Sync byte <rrrr> = Field code
IEAU<id>2065 <pppp>
Timeout Data Capture RU. State manager disabled RU. <pppp> = CRU number
IEAU<id>3012 <kkkk> <rrrr>
Error in communication with PC. <kkkk> = First word of command <rrrr> = Return value
IEAU<id>3030 <eeee> <rrrr>
Error in communication with PC. PC sent an unknown return message. <eeee> = Expected message <rrrr> = Returned message
IEAU<id>3031 <kkkk>
Error in communication with PC. PC sent an unknown command in return message. <kkkk> = First word of command
3998 5593007
2427
Error Code IEAU<id>3116 <rrrr>
Description Error in communication with PC. PC sent a command with an unknown receiver field during download. <rrrr> = Receiver field
IEAU<id>5343 0300 0100 IEAU<id>5343 0300 0200 IEAU<id>5343 0300 0300 IEAU<id>5343 0300 0400 IEAU<id>5343 0300 0500 IEAU<id>5343 0300 0600 IEAU<id>5343 0300 0700 IEAU<id>5343 0300 0800 IEAU<id>5343 0300 0A00 IEAU<id>8100 IEAU<id>8103 IEAU<id>8106 IEAU<id>9006 IEPCAU0001 IEPCAU0002 IEPCAU0003 IEPCAU0004 IEPCCA0001 IEPCCA0002 IEPCCA0003 IEPCCA0004 IEPCCA0005 IEPCCA0006 IEPCCA0007 IEPCCA0008 IEPCCA0009 IEPCCA0010 IEPCCA0011
AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure. AU board hardware failure. SCSI Send buffer not empty. SCSI Receive buffer is empty. CAR status unknown. Read or Write Index Number to Error Input Queue is out of Range. Data may be overwritten. Error Input Queue is cleared. Invalid state for message. Bad parameter with message. Invalid message code. Unexpected message. Length of CDB wrong. Undefined command code. Unknown initiator ID. SEND unexpected from PC. Data length in CDB for SEND greater than 2 kByte from PC. RECEIVE unexpected from PC. Allocation length for RECEIVE less than 2 kByte from PC. Data length from AU too large (PC). Allocation length for SENSE less than 8 bytes (PC). Wrong logical unit number from PC. RECEIVE unexpected (DP).
2428
3998 5593007
Error Code IEPCCA0012 IEPCCA0013 IEPCCA0014 IEPCCA0015 IEPCCA0016 IEPCCA0017 IEPCCA0018 IEPCCA0019 IEPCCA0020 IEPCCA0021 IEPCCAA022 IEPCCA0023 IEPCCE0001 IEPCCE0002 IEPCCE0003 IEPCCE0004 IEPCCE0005 IEPCCE0008 IEPCCE0009 IEPCCE0010 IEPCCE0011 IEPCCE0012 IEPCCE0013 IEPCCE0014 IEPCCE0015 IEPCCE0016 IEPCCE0018 IEPCCE0019 IEPCCE0100 IEPCCE0101 IEPCCE0102
Description Allocation length for RECEIVE less than 2 kByte (DP). Data length from AU too large (DP). SEND unexpected (DP). Data length in CDB for SEND too large (DP). Allocation length for INQUIRY less than 96 bytes. HARDWARE Error: Unexpected ESP Status [Status] Power on reset. Bus device reset. SEND buffer not empty (PC). RECEIVE buffer empty (PC). RECEIVE buffer empty (DP). SEND buffer not empty (DP). Selection timeout on channel [channel]. Data over/under run on channel [channel]. Unexpected bus free on channel [channel]. Target bus phase sequence failure on channel [channel]. Target check condition on channel [channel]. Invalid CCB operation code on channel [channel]. Linked CCB does not have the same logical unit name on channel. Invalid target direction received from host on channel. Duplicate CCB received in target mode on channel. Invalid CCB or segment list parameter on channel. CCB for canceled task not found on channel [channel]. Task completed with Error on channel [channel]. CCB of target LUN not available on channel [channel]. Invalid host adapter command on channel [channel]. MBO command invalid on channel [channel]. MBI state undefined on channel [channel]. SCSI device driver state [state] unexpected on channel [channel]. SCSI transfer in progress on channel [channel]. SCSI timeout on channel [channel].
3998 5593007
2429
Error Code IEPCCE0103 IEPCCE0104 IEPCCE0105 IEPCCE0107 IEPCCE0108 IEPCCE0109 IEPCCE0110 IEPCCE0115 IEPCCE0116 IEPCCM0001 IEPCCM0002 IEPCCM0004 IEPCHA0001 IEPCHA0002 IEPCHA0003 IEPCHA0004 IEPCHA0005 IEPCHA0006 IEPCHA0007 IEPCHA0008 IEPCHA0009 IEPCHA0010 IEPCHA0011 IEPCHA0012 IEPCHA0013 IEPCHA0014 IEPCHA0015 IEPCHA0016 IEPCHA0017 IEPCHA0018 IEPCHA0019
Description SCSI channel closed on channel [channel]. Invalid SCSI command on channel [channel]. No mailbox free on channel [channel]. SCSI check condition on channel [channel]. SCSI command aborted on channel [channel]. Target status busy on channel [channel]. Unexpected inmail received on channel [channel]. SCSI reset detected on channel [channel]. SCSI device driver Error on channel [channel]. Send data on channel [channel] denied. Receive data on channel [channel] denied. Data length Error on channel: [channel] send [data1] of [data2]. Host adapter not installed at port address [port]. Internal diagnostic failed at port address [port]. DMA channel initialization failed. Interrupt channel initialization failed. Return configuration data failed. Enable target mode failed. No operation test failed. Mailbox initialization failed. Adapter inquiry failed. Board identification reserved. Special options ID reserved. Firmware revision reserved. Return installed devices failed. SCSI ID is [id] expected ID is [id2]. SCSI device driver installation failure. Open SCSI channel [channel] failed. Test unit ready failed on channel [channel]. SCSI inquiry failed on channel [channel]. Request sense failed on channel [channel].
2430
3998 5593007
Error Code IEPCHA0020 IEPCIN0001 IEPCIN0002 IEPCIN0003 IEPCIN0004 IEPCIN0005 IEPCIN0006 IEPCIN0007 IEPCIN0008 IEPCIN0009 IEPCIN0010 IEPCIN0011 IEPCLP0001 IEPCLP0002 IEPCLP0003 IEPCLP0004 IEPCLP0005 IEPCLP0006 IEPCLP0008 IEPCLP0009 IEPCLP0010 IEPCLP0011 IEPCUS0001 IEPCUS0002 IEPCUS0003 IEPCUS0004 IEPC__0001 IEPC__0002 IEPC__0003 IEPC__0004 IEPC__0005
Description Host adapter not idle at port address [port]. Could not allocate memory. Configuration file not found. Too many file specifed. Syntax error in configuration file. Syntax error in configuration file. Syntax error in configuration file. Syntax error in configuration file. Syntax error in configuration file. Syntax error in configuration file. Syntax error in configuration file. Syntax error in configuration file. Prefix not available. Invalid data length. Data integrity error. State of CAR Module: Undefined. State of CAR Module: Unexpected. Invalid message code. Response status undefined. POC result undefined. Invalid error code. Error message expected. Configuration file PCSWCONF.TXT not found. Cannot open PCSWCONF.TXT. No data in configuration file. Upgrade file A:PCBSUPDT.BAT not found. Configuration file PCSWCONF.TXT not found. Error in configuration file PCSWCONF.TXT. Configuration number missing. No configuration data for AU available. No data expected.
3998 5593007
2431
Error Code IEPC__0006 IEPC__0007 IEPC__0008 IEPC__0009 IEPC__0010 IEPC__0011 IEPC__0012 IEPC__0013 IEPC__0014 IEPC__0015 IEPC__0016 IEPC__0017 IEPC__0018 IEPC__0019 IEPC__0020 IEPC__0021 IEPC__0022 IEPC__0023 IEPC__0024 IEPC__0025 IEPUEP0010 IEPUEP0011 IEPUEP0012 IEPUEP0013 IEPUEP0014 IEPUEP0015 IEPUEP0016 IEPU000021 <pppp>
Description LOG file entry denied, error in file handling. Data expected. Download still running. Stop download first. Download ID not found: [Download-ID]-. No download list in configuration file. Download not running, no loadlist specified. Error in download file: [Filename]. Download file not found: [Filename]. Syntax error. Upload medium not writable. Upload not running. Receive command not expected from PC. Upload ID not found: [Upload-ID]. Error in upload list. Upload still running, stop upload first. Message out of range. Bad parameter with message. Upload device not installed. Error in upload file: [Filename]. Upload medium write protected. Wrong command name during download program. Checksum error in Download Program command. Checksum error in Start Program command. Command Download Program is missing. Wrong transmit/receive name in Download Program. Wrong transmit/receive name in Start Program. Wrong receipt from AU on serial interface. Wrong command list in AU disposition. <pppp> = Actual command list.
2432
3998 5593007
Error Code IEPU000022 <eeee> <aaaa>
Description Wrong receipt from AU on serial interface. <eeee> = Expected value <aaaa> = Actual value
IEPU000023 IEPU000024 IEPU000025 IEPU000026 IEPU000027 IEPU000028 IEPU000029 IEPU000030 IEPU000031 IEPU000032 IEPU000033 IEPU000034 IEPU000035 IEPU000036 IEPU000037 IEPU000038 IEPU000039 <ssss> <dddd>
Wrong command from AU on serial interface. More than 30 dispositions received from AU. More than 30 free CRU numbers received from AU. PU mode is missing. Checksum error in RL command. Checksum error in RD command (upload request data). Checksum error in 09 command (disposition from AU). Interrupt sequence on video interface is wrong. Command 09 (disposition from AU) is missing. The field width is exceeded. The field width is too small. The locations defined in disposition are false; field width is less than or equal to 0. Two fields defined in disposition. FIFOs for video interface are not empty. Transmit buffer for serial interface overflowed. PU buffer overflowed. Document ID number in ID line is not identical to sync number from disposition. <ssss> = Sync number from AU dispo <dddd> = Doc ID number in ID line
IEPU000042 <eeee> <aaaa>
Checksum error in RD command. <eeee> = Expected value <aaaa> = Actual value
Checksum error in RP command. <eeee> = Expected value <aaaa> = Actual value
3998 5593007
2433
Error Code IEPU000044 <eeee> <aaaa>
Description Checksum error in DD command. <eeee> = Expected value <aaaa> = Actual value
Checksum error in DP command. <eeee> = Expected value <aaaa> = Actual value
IEPU000061 IEPU000062 IEPU000063 IEPU000066 <ssss> <dddd>
Video data missing. No test ID line received. No free CRU. Doc ID number is not identical to sync number of dispo message. <ssss> = Sync number from AU dispo <dddd> = Doc ID number from ID line
IEPU000067 IE<ru>020012 <kkkk> <llll> <ssss> <rrrr> <cccc>
Document not in PU buffer. CRU <ru> received a command with checksum error on the SBUS. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Right checksum of received command <cccc> = Checksum field of received command
IE<ru>020013 <aaaa>
CRU <ru> received a command with an unknown instruction on the SBUS. <aaaa> = Received instruction
IE<ru>020014 <kkkk> <llll> <ssss> <rrrr> <cccc>
CRU <ru> received a command with an unknown command name on the SBUS. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command <cccc> = Checksum field of received command
2434
3998 5593007
Error Code IE<ru>020015 <kkkk> <llll> <ssss> <rrrr>
Description CRU <ru> received a command with a not allowed length field on the SBUS. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command
IE<ru>020016 <kkkk> <llll> <ssss> <rrrr> <cccc>
CRU <ru> received a command with with an unknown receiver name on the SBUS. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command <cccc> = Checksum field of received command
IE<ru>020017 <kkkk> <llll> <ssss> <rrrr> <wwww>
CRU received a XA command with an unknown receiver in the data field. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command <wwww> = Wrong parameter of received command
IE<ru>020990 IE<ru>020999 <nnnn>
Parity error in program memory of CRU <ru>. Possible hardware error. CRU <ru> becomes disabled. Internal error in BOSRU. CRU <ru> becomes disabled. <nnnn> = System error number
IE<ru>260001<pppp>
Hardware or Character Recognition software error. <pppp> = Error and task that detected error
INAU079040 <pppp> <qqqq>
State of CAR unit changed. <pppp> = Old State of CAR unit <qqqq> = New State of CAR unit
INAU079041 INAU079042 <pppp>
CAR Status manager started. CRU enabled. <pppp> = Number of CRU
INAU079043 <pppp>
CRU disabled. <pppp> = Number of CRU
3998 5593007
2435
Error Code INAU<id>5343 0200 0001 INAU<id>5343 0200 0002 INAU<id>5343 0200 0003 INAU<id>5343 0200 01<xx>
Description Power-on reset reported to PC. Power-on reset reported to DP. Power-on reset reported to PC with logical unit number greater than 0. Power-on reset reported to PC with logical unit number greater than 0. <xx> = SCSI ID of initiator and target
INAU<id>5343 0300 0100 IWAU030330 <kkkk> <llll> <ssss> <rrrr> <cccc>
Unexpected ESP status. Unknown command name on the SBUS. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Right checksum of received command <cccc> = Checksum field of received command
IWAU030332 <kkkk> <llll> <ssss> <rrrr> <cccc>
Unknown sender name on the SBUS. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Right checksum of received command <cccc> = Checksum field of received command
IWAU030711 <ssss> <nnnn> <aaaa> <llll>
Wrong parameter in RD command. <ssss> = Sender field of received command <nnnn> = Number of data page <aaaa> = Address of data page <llll> = Length of requested data
IWAU030712 <ssss> <nnnn> <aaaa> <llll>
Wrong parameter in RP command. <ssss> = Sender field of received command <nnnn> = Number of data page <aaaa> = Address of data page <llll> = Length of requested data
2436
3998 5593007
Error Code IWAU059240 <pppp> <qqqq> <rrrr> <ssss>
Description Format of response message from PC incorrect. <pppp> = Error reason: = 0350 Message too short (less than 6 bytes), or message length field not 0. = 0340 Message code not 0xa0 <qqqq> = Number of bytes sent by PC <rrrr> = Message length field of message, if present <sssss> = Message code, if present
IWAU059241 <pppp> <qqqq> <rrrr> <ssss>
Response command from PC has incorrect length field. <pppp> = Error reason: = 0320 Command Length less field too small (<3) = 0330 Message does not contain full command <qqqq> = Number of bytes sent by PC <rrrr> = Command name field <ssss> = Command length field
IWAU059242 <pppp> <qqqq> <rrrr> <ssss>
User buffer too small for PC response command. <pppp> = Error reason 0300 means the user buffer is too small. <qqqq> = Command name field <rrrr> = Command length field <ssss> = User buffer size
IWAU059243 <pppp> <qqqq> <rrrr> <ssss> <tttt>
Checksum of response command from PC incorrect. <pppp> = Wrong command checksum <qqqq> = Command name field <rrrr> = Command length field <ssss> = Checksum received <tttt> = Checksum evaluated by PC_Stdout
IWAU060390 IWAU079001 IWAU079024 <pppp>
SCSI buffer MTR Send is not free. Error message output buffer (queue) overflow. Enable command given for CRU that is already enabled. Command ignored. <pppp> = Number of CRU
3998 5593007
2437
Error Code IWAU079025 <pppp>
Description Disable command given for CRU that is already disabled. Command ignored. <pppp> = Number of CRU
IWAU079026 <pppp>
Tried to enable a defective CRU. <pppp> = Number of CRU
IWAU079027 <pppp>
Tried to enable or disable nonexistent CRU.

<pppp> = Number of CRU
IWAU079028 <pppp> <qqqq>
Invalid state for received command. <pppp> = State of CAR unit <qqqq> = Name of command not allowed in this CAR state
IWAU079029 <pppp>
Timer Interrupt detected wrong functions. <pppp> = Value of global variable = 0080: Power Fail detected
IWAU079030 <pppp>
Bad parameter received with message from DP. <pppp> = Message code received from DP
IWAU079031 <pppp>
Bad message code received from DP. <pppp> = Message code received from DP
IWAU079032 <pppp>
DP sent a message which is not allowed in current state. <pppp> = Message code received from DP
IWAU0A0710 <aaaa> <nnnn>
Wrong parameter in XA command. <aaaa> = First data word <nnnn> = Second data word
IWAU0A0822 <llll>
Command too long on MTR channel. <llll> = Length field of received command
IWAU0A0826 <kkkk> <llll> <ssss> <rrrr> <cccc>
Checksum error on the MTR channel. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Right checksum of received command <cccc> = Checksum field of received command
2438
3998 5593007
Error Code IWAU0A0828 <kkkk> <llll> <ssss> <rrrr> <cccc>
Description Unknown receiver name on the MTR channel. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Right checksum of received command <cccc> = Checksum field of received command
IWAU0A0830 <kkkk> <llll> <ssss> <rrrr> <cccc>
Unknown command name on the MTR channel. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Right checksum of received command <cccc> = Checksum field of received command
IWAU140103 <nnnn> <ssss>
CRU number <nnnn> is in error status and became disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
IWAU140104 <nnnn> <ssss>
CRU number <nnnn> did not successfully start its BOSRU. The CRU is disabled. <nnnn> = CRU number. <ssss> = Statusword of CRU <nnnn>
IWAU<id>0100 IWAU<id>0101 <nnnn> <ssss>
Spurious interrupt on SBUS. The AU received a SBUS interrupt, but no CRU wanted to send a command. CRU <nnnn>, which is marked not ready, sent a command <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
IWAU<id>0105 <nnnn> <ssss>
CRU number <nnnn> did not successfully respond to the RL command. The CRU is disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
Timeout while sending an RX instruction to CRU <nnnn>. The CRU is disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
3998 5593007
2439
Error Code IWAU<id>0320 <nnnn> <ssss>
Description Timeout while receiving the header of a command from the SBUS. The CRU is disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
IWAU<id>0322 <nnnn> <kkkk> <llll>
Command too long on the SBUS. CRU <nnnn> is disabled. <nnnn> = CRU number <kkkk> = Name field of received command (first word of command) <llll> = Length field of received command (second word of command)
IWAU<id>0324 <nnnn> <kkkk> <llll> <ssss> <rrrr>
Timeout while receiving a command from CRU <nnnn>. The CRU is disabled. <nnnn> = CRU number <kkkk> = Name field of received command (first word of command) <llll> = Length field of received command (second word of command) <ssss> = Sender field of received command (third word of command) <rrrr> = Right checksum of received command
IWAU<id>0326 <kkkk> <llll> <ssss> <rrrr> <cccc>
Checksum error on the SBUS. <kkkk> = Name field of received command (first word of command) <llll> = Length field of received command (second word of command) <ssss> = Sender field of received command (third word of command) <rrrr> = Calculated checksum of received command <cccc> = Checksum field of received command (last word of command)
2440
3998 5593007
Error Code IWAU<id>0328 <kkkk> <llll> <ssss> <rrrr> <cccc>
Description Unknown receiver name on the SBUS. <kkkk> = Name field of received command (first word of command) <llll> = Length field of received command (second word of command) <ssss> = Sender field of received command (third word of command) <rrrr> = Receiver field of received command (fourth word of command) <cccc> = Checksum field of received command (last word of command)
CRU <nnnn> was not ready to receive a command and became disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
Timeout while sending an RY instruction to CRU <nnnn>. The CRU is disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
Timeout while sending a command to CRU <nnnn>. The CRU is disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn>
IWAU<id>0500 <nnnn> <ssss> <aaaa>
Timeout while AU sending an instruction to CRU <nnnn>. The CRU is disabled. <nnnn> = CRU number <ssss> = Statusword of CRU <nnnn> <aaaa> = Instruction to be sent
IWAU<id>0713 <ssss> <nnnn> <aaaa> <llll>
Wrong parameter in DD command. <ssss> = Sender field of received command <nnnn> = Number of data page <aaaa> = Address of data page <llll> = Length of requested data
3998 5593007
2441
Error Code IWAU<id>0714 <ssss> <nnnn> <aaaa> <llll>
Description Wrong parameter in DP command. <ssss> = Sender field of received command <nnnn> = Number of data page <aaaa> = Address of data page <llll> = Length of requested data
IWAU<id>2010 IWAU<id>2026 IWAU<id>2032 IWAU<id>2061 <pppp> <rrrr>
Call for serial output with length 0. Interrupt for serial input. RU does not receive document. Field width or height in disposition is out of range. Warning to PC. Field reject with error code $20. Timeout for document with number of fields = 0. <pppp> = Sync byte <rrrr> = Field code
IWAU<id>2064 <pppp> <rrrr>
More amounts processed than dispo messages received. <pppp> = Sync byte <rrrr> = Field code
IWAU<id>5343 0100 01<xx>
Incorrect length of command descriptor block (CDB). Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 02<xx>
Command code in CDB not defined. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 03<xx>
Initiator ID not defined. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 04<xx>
Send command not expected from PC. Program error in PC software or incorrect command sequence after SCSI reset. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 05<xx>
Data length in CDB with Send command greater than 2K bytes. Program error in PC software. Only 2K bytes data transferred. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 06<xx>
Receive command not expected from PC. Program error in PC software or incorrect command sequence after SCSI reset. Command ignored. <xx> = SCSI ID of initiator and target
2442
3998 5593007
Error Code IWAU<id>5343 0100 07<xx>
Description Data length in CDB = 0 from PC Program error in PC software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 08<xx>
Data length for Receive command greater than allocated length. Program error in PC software or M-AU data length greater than 2K bytes. Data limited according to allocation length. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 09<xx>
Allocation length for SENSE command less than 8 bytes Program error in initiator software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 0A<xx>
Undefined LUN in CDB from PC Program. Error in PC software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 0B<xx>
Receive command not expected from DP. Program error in DP software or incorrect command sequence after SCSI reset. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 0C<xx>
Allocation length in CDB with INQUIRY command less than 96 bytes Program error in initiator software. Data limited according to allocation length. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 0D<xx>
Data length for Receive command greater than allocated length Program error in DP software or M-AU data length greater than 2K bytesData limited according allocation length. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 0E<xx>
Send command not expected from DP. Program error in DP software or incorrect command sequence after SCSI reset. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 0F<xx>
Data length in CDB with SEND command greater than 2K bytes Program error in DP software. Only 2K bytes data transferred. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 10<xx>
Allocation length with INQUIRY command = 0 Program error in initiator software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 11<xx>
Target selected W/O ATN. No identify message received from initiator. <xx> = SCSI ID of initiator and target
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Error Code IWAU<id>5343 0100 12<xx>
Description Target selected W/O ATN and incorrect length of CDB. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 13<xx>
Data length in CDB with SEND command = 0 Program error in DP software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 14<xx>
Allocation length = 0 with Receive command. Program error in DP software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0100 15<xx>
Allocation length = 0 with Receive command Program error in PC software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0101 01<xx>
Data for Receive command issued by PC not available. Occurs in normal operation. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0101 02<xx>
Data for Receive command issued by DP not available. Occurs in normal operation. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0102 00<xx>
Program error in AU software. Command ignored. <xx> = SCSI ID of initiator and target
IWAU<id>5343 0102 03<xx>
Buffer on M-AU for SEND command from DP not free Program error in AU software. Command ignored. <xx> = SCSI ID of initiator and target
Invalid state for message. <pppp> = State of CAR unit <rrrr> = Message code
IWAU<id>8102 <pppp>
Invalid message code. <pppp> = Message code
Message length does not correspond with this message. <pppp> = Message code <rrrr> = Message length
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Error Code IWAU<id>8105 <pppp> <rrrr> <ssss>
Description Received message length is not the same as message length byte transmitted with message. <pppp> = Message code <rrrr> = Message length <ssss> = Message length received
IW<ru>020021 <kkkk> <llll> <ssss> <rrrr>
Timeout on receiving a command on VIBUS. CRU <ru> becomes disabled. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command Note: The reported parameters may be wrong. They could be the parameters of the last right command received before.
IW<ru>020022 <kkkk> <llll> <ssss> <rrrr> <cccc>
Checksum error on VIBUS. CRU <ru> may be disabled. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Right checksum of received command <cccc> = Checksum field of received command
Unknown command name on VIBUS. CRU <ru> may be disabled. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command <cccc> = Checksum field of received command
IW<ru>020025 <kkkk> <llll>
CRU <ru> received a command with disallowed length field on VIBUS. CRU <ru> may be disabled. <kkkk> = Name field of received command <llll> = Length field of received command
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Error Code IW<ru>020026 <kkkk> <llll> <ssss> <rrrr> <cccc>
Description Unknown receiver name on VIBUS. CRU <ru> may be disabled. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command <cccc> = Checksum field of received command
IW<ru>020027 <kkkk> <cccc> <dddd> <ssss> <tttt>
Pixel Image too large to fit in memory. CRU <ru> may be disabled. <kkkk> = Name field of received command <cccc> = Horizontal coordinate of image corner. <dddd> = Vertical coordinate of image corner. <ssss> = Horizontal size of the image <tttt> = Vertical size of the image
IW<ru>020028 <kkkk> <llll> <ssss> <rrrr> <dddd>
CRU <ru> received a command. The number of VI words does not fit in the reserved memory. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command <dddd> = Number of vi-words to be received
CRU <ru> received too many commands without a VE command on the VIBUS. CRU <ru> may be disabled. <kkkk> = Name field of received command <llll> = Length field of received command <ssss> = Sender field of received command <rrrr> = Receiver field of received command <cccc> = Checksum field of received command
IW<ru>020710 <aaaa> <nnnn>
First data word of XA command is an unknown instruction or second data word of XA command is an unknown logical device. <aaaa> = First data word of XA command <nnnn> = Second data word of XA command
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Error Code IW<ru>020711 <ssss> <nnnn> <aaaa> <llll>
Description The length of the requested data is too long. <ssss> = Sender field of received command <nnnn> = Number of data page <aaaa> = Address in data page <llll> = Length of requested data
IW<ru>020712 <ssss> <nnnn> <aaaa> <llll>
The length of the requested program code is too long. <ssss> = Sender field of received command <nnnn> = Number of program page <aaaa> = Address in program page <llll> = Length of requested program code
Unknown data page or address plus length is greater than 0xffff. <ssss> = Sender field of received command <nnnn> = Number of data page <aaaa> = Address in data page <llll> = Length of downloadable data
Unknown program page or address plus length greater than 0xffff. <ssss> = Sender field of received command <nnnn> = Number of program page <aaaa> = Address in program page <llll> = Length of downloadable program code
IW<ru>260001 IW<ru>260002 IW<ru>260003 IW<ru>260004 IW<ru>260005 IW<ru>260006 S AU079015 S AU<id>2024 <pppp>
Error video command input, data are inconsistent. PU error, video bus error, or video bus driver error. Errors in video command input are such that commands cannot be evaluated. Wrong input data from DP. Wrong Unisys input data. Plausibility check detected error in CRS software. Error on system bus input. Erroneous data capture command. No CRU ready with Flow Started. Interrupt for serial input with command video received. Video too late - timeout. CAR unit goes to Sync Error state. <pppp> = Sync
S AU<id>2030
CAR unit receives the 16th disposition before receiving the image belonging to the first one. CAR unit goes to Sync Error state.
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Error Code S AU<id>2060 <pppp> <rrrr>
Description Timeout for document, no video. CAR unit goes to Sync Error state. <pppp> = Sync <rrrr> = Field code
S PU000001 <pppp> <rrrr>
Document ID number in ID line is not identical to sync number from disposition. <pppp> = Sync number from AU dispo <rrrr> = Doc ID number in ID line
S PU000002 S PU000003 <pppp>
Video data received, no disposition message present. Error on video interface. <pppp> Bit0 = 1 parity error Bit1 = 1 Hardware test of video interface (test = 1), the signals at the four video channels are not identical Bit2 = 1 Number of pixels between 2 control signals EOS are not divisible by sixteen.
S PU000004 S PU000005 S PU000006 S PU000007 S PU000008 <pppp> <ssss> <iiii>
Fewer than 128 clock cycles between 2 control signals EOS. More than 128 clock cycles between 2 control signals EOS. FIFO for video interface overflowed. FIFO for video interface is not empty. Number of words in FIFO for ID line is false. <pppp> 0001 = Special situation 0002 = FIFO underflow 0003 = FIFO overflow 0004 = verflow of scanline counter <ssss> = Number of scanlines <iiii> = Number of ID lines
XEAU079015 XEAU<id>2024 <pppp>
No CRU ready with Flow Started. Interrupt for serial input with command video received. Video too late - timeout. CAR unit goes to Sync Error state. <pppp> = Sync
XEAU<id>2030
CAR unit receives the 16th disposition before receiving the image belonging to the first one. CAR unit goes to Sync Error state.
2448
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Error Code XEAU<id>2060 <pppp> <rrrr>
Description Timeout for document, no video. CAR unit goes to Sync Error state. <pppp> = sync <rrrr> = field code
XEPU000001 <pppp> <rrrr>
Document ID number in ID line is not identical to sync number from disposition. <pppp> = Sync number from AU dispo <rrrr> = Doc ID number in ID line
XEPU000002 XEPU000003 <pppp>
Video data received, no disposition message present. Error on video interface. <pppp> Bit0 = 1 parity error Bit1 = 1 Hardware test of video interface (test = 1), the signals at the four video channels are not identical. Bit2 = 1 Number of pixels between 2 control signals EOS are not divisible by sixteen.
XEPU000004 XEPU000005 XEPU000006 XEPU000007 XEPU000008 <pppp> <ssss> <iiii>
Fewer than 128 clock cycles between 2 control signals EOS. More than 128 clock cycles between 2 control signals EOS. FIFO for video interface overflowed. FIFO for video interface is not empty. Number of words in FIFO for ID line is false. <pppp> 0001 = Special situation 0002 = FIFO underflow 0003 = FIFO overflow 0004 = verflow of scanline counter <ssss> = Number of scanlines <iiii> = Number of ID lines
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CAR Diagnostic Flows

Table 244. CAR Diagnostic Flows
Next Step Step 10 Action Verify that there is power to the CAR unit by listening for the fans turning and by checking the LEDs on the PCBAs. Verify that A power is reaching the CAR power supply. Verify that the rest of the NDP 1XXX is getting power. Response Is there power to the CAR unit? 90 Yes 20 No
20 30
Is there a problem with the AC power? Is the rest of the NDP 1XXX getting power?
Correct as needed. 40
30 Go to "General Conditions, Causes, and Corrections" in Section 12, "Condition, Cause, Correction Table." Follow the corrections for the "Cannot Power On" condition. Replace the CAR power supply.
40
Measure the CAR power supply voltages on the backplane of the CAR unit: Remove the cable from connector J53IT. Measure the voltage to pin 1 (5 VDC). Remove the cable from connector J531B. Measure the voltage to pin 1 (5 VDC).
Are all voltages correct?
90
90
Press the reset button on top of the CAR unit, or power the NDP 1XXX off and on to rerun the POC tests. Test the PU PCBA in the CAR test slot. Refer to "Card Cage Test Slot," earlier in this section, for further instructions.
Observe the LEDs on each PCBA using Figure 241 and Figure 242 as a guide. Did the POC test pass on each PCBA? Did the PU PCBA pass the test slot test?
100
Replace the failed PCBAs.
100
110
Replace the PU board.
2450
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Table 244. CAR Diagnostic Flows
Next Step Step 110 Action Test the RU PCBAs in the CAR test slot. Refer to "Card Cage Test Slot," earlier in this section, for further instructions. Test the AU PCBA in the CAR test slot. Refer to Card Cage Test Slot earlier in this section for further instruction. Replace the AU board. Verify that the following cables are properly connected and do not show any sign of failure: Response Did the RU PCBAs pass the test slot test? 115 Yes No Replace any failed RU PCBA. 120
115
Did the AUBA pass the test slot test?
140
120 140
Does the problem still exist? Did any cable have a problem? Note: If the SCSI cable was a problem, power the NDP 1XXX off and on to reestablish communications.
130 Replace the suspect cable.
Exit the flow. 160
AC Power Cable Video Cable SCSI Cable (CAR to ICS) For the NDP 1825 CAR module, there are two SCSI connectors on the CAR backplane, X15 and X16. X15 is a differential SCSI and X16 is a singleended SCSI. The cable connecting the ICS to the CAR box shouldbe attached to the X15 differential connector.
Note:
160
The problem cannot be isolated using the diagnostic procedures. Possible causes include the following:
Incorrect power supply voltage Loose connection in power supply Bad backplane
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Section 25 NDP 1150 MJE Diagnostic Procedures

This section provides information on diagnosing faults in the 1150 MJE.
MJE Operation
The 1150 MJE provides ink-jet endorsement on the rear of documents flowing through the NDP 1150. The 1150 MJE is composed of 5 main hardware components: the Print Cartridges (2 are used), the Print Head Assembly which holds the 2 print cartridges, the LCMJE Driver board, the LCMJE Interface board (Card 9), and the transport mechanism. Transport drive belts and pulleys control movement of the documents past the print head assembly, located at the right end of Area 1. The Common API software provides a track control interface, nearly identical to the NDP 250/500 MJE interface, which controls the 1150 MJE. This track control software interfaces from the NDP PC, through a dual port interface on the LCMJE board. Controlware, residing in FLASH Memory on the LCMJE Interface board takes commands from the track control SSW and provides commands, through a serial interface, to the driver board. The LCMJE Driver board houses the electronics required to drive the droplet generators in each of the print cartridges, producing endorsed characters on documents flowing through the transport. The 1150 MJE utilizes a replaceable print cartridge with its own ink supply and droplet generation electronics. This cartridge is the same one used with the NDP 250/500 MJE, however the 1150 uses two cartridges to assure printing quality at the 150 ips track speed. Both cartridges print the same pattern, resulting in double droplets. This technique creates darker print for better microfilm/image readability and reduced ink usage. However, even with double droplets, a new font shaping was added which actually cuts the total ink use. For Dual systems (Front and Rear endorse), an extra LCMJE driver board, an extra print housing, 2 additional print cartridges and additional drive rollers are provided to allow endorsing on the front of the document, as well. Updates for Common API SSW are delivered on CD-ROM. Updates for Controlware (FLASH) on the LCMJE are downloadable.
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NDP 1150 MJE Diagnostic Procedures
The document processor system software includes online help that provide operational instructions for the MJE. Procedures and videos for changing the print cartridge and adjusting the print height are included. The main problem categories are:
Printing Quality Out-of-Ink Errors Jams Error Codes Displayed
Use the following flow to diagnose problems: Error Code or Error Message? No Run the Exerciser with 4 lines of Text and a Logo.
Main Flow
Yes
Follow on-screen instructions.
Evaluate the Endorsed Print and resolve problems using Table 251 and the FRU list.
Note:
Re-execute the Main Flow after correcting the problems below.
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Table 251. Main Flow
Problem Weak or Bad Print
Possible Cause Bad/dirty cartridge
Procedure Clean cartridges using the operator help file procedures, Replace if necessary (Must replace BOTH cartridges at once). If cartridges are replaced, answer yes when asked if the cartridges are new. Verify that cables are connected from the housing assembly to the driver card and that all cables are connected to the driver card. Use the following procedure: 1. Power down and install a jumper at position 3 on the LCMJE Interface Card (AA Card 9). Using the Exerciser, load the UPDOWN.GF logo, positioned at 3 inches. Print the logo on 8-9" blank documents. The pattern shows two dark rectangles. The upstream head prints the right rectangle and the downstream head prints the left rectangle. Note which head may be printing badly. Leaving the power on with an interlock open, identify the upstream and downstream cables going to the print head from the LCMJE driver board (mounted on the underside of baseplate directly beneath the MJE Track). Swap the upstream and downstream cables at the board. Reprint the UPDOWN.GF logo. The printing in each print position is now switched. The downstream driver is now printing the right rectangle and the upstream driver is now printing the left rectangle. Evaluate the print. If the bad printing changed positions, F3. If the bad printing stayed in the same place, F2. Swap the driver cables back before replacing the FRU.
One printhead not printing
2.
3.
4.
5. Downstream/upstream air hoses transposed
Remove and reinstall hoses, ensuring that the downstream hose is connected to a D port and the upstream hose is connected to a U port on the manifold. Adjust drive belt tension per T&A
Fuzzy Print
Drive belts too loose
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Table 251. Main Flow
Problem
Possible Cause Improper head assembly position Incorrect print head registration
Procedure Adjust print housing assembly per T&A Adjust print registration per T&A Open track wall and verify air flow at air vent holes. If no air flow, check blower and hoses and replace as necessary. Otherwise, F3 or F6, if required. Adjust housing assembly per T&A Adjust wall spacing per T&A Open track wall and verify air flow at air vent holes. If no air flow, check blower and hoses and replace as necessary. Otherwise, F3 or F6, if required. Clean cartridges using the operator help file procedures, Replace if necessary (Must replace BOTH cartridges at once). If cartridges are replaced, answer yes when asked if the cartridges are new. Check cables from driver to printheads and from interface to driver. Reconnect as necessary Measure power to board. Check that interface board is seated in correct slot. If no power, check wiring and appropriate power supply output voltages
Ink Smearing on documents/walls/rollers
Blower driver PCBA or hoses problem
Jams in MJE Area
Housing assembly not positioned correctly Walls not adjusted properly Blower driver PCBA or hoses problem
No Print
Bad/dirty cartridges
Cables disconnected
No power to driver board
Driver/Interface Board Print Cartridge Missing message, even with cartridges installed Print Housing assembly or cables faulty
Check that the interface board is seated in its connector. If so, F5. Replace both cartridges with new ones Verify that the LCMJE driver card to print housing assembly cables are connected. If the cables are ok, F7. Replace F4 Follow the on screen instructions and replace the suspect components one at a time, beginning with "Suspect 1". Replace suspect components indicated by MTR Error Code Index Table (Table 252)
Communications error with LCMJE module POC/Error Codes on screen
LCMJE Interface board bad. Various.
MTR Error Codes on screen module
Various
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Table 252. MTR Error Code Index
Manual Procedure LCMJE 00 01 LCMJE 00 02
Error Description MJE dualport RAM not enabled for multibus access Time out waiting for MJEs dualport RAM semaphore to be released by MJE Invalid test command response received from the MJE MJE Module communications failure. Rear MJE driver board timed out when getting a response. Front MJE driver board timed out when getting a response. MJE Module failure: Non-volatile RAM write/read test error occurred. MJE Module failure: Non-volatile RAM address test error occurred. Rear MJE Module failure: A driver board timeout occurred during the head purge. Front MJE Module failure: A driver board timeout occurred during the head purge. Rear MJE Module failure: A driver board timeout occurred during the print logic test. Front MJE Module failure: A driver board timeout occurred during the print logic test. Rear MJE Module failure: Unable to read the upstream print head thermal sensor. Front MJE Module failure: Unable to read the upstream print head thermal sensor. F4 F4
Primary
Secondary
LCMJE 00 03 LCMJE 00 04 LCMJE 01 01 LCMJE 01 02 LCMJE 04 01
F4 F4 F3 F3 F4 F2 F2 --
LCMJE 04 02
F4
--
LCMJE 05 01
F3
F2
LCMJE 05 02
F3
F2
LCMJE 06 01
F3
F2
LCMJE 06 02
F3
F2
LCMJE 07 01
F8
LCMJE 07 02
F8
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Table 252. MTR Error Code Index (cont.)
Manual Procedure LCMJE 08 01
Error Description Rear MJE Module failure: Unable to read the upstream print head thermal sensor. Front MJE Module failure: Unable to read the upstream print head thermal sensor. MJE Module failure: Bus exception occurred while accessing the MJEs dual port RAM. MJE Module failure: Dual port RAM write/read failure occurred. Rear MJE Ambient Temperature Sensor Error. Front MJE Ambient Temperature Sensor Error. F8
Primary
Secondary
LCMJE 08 02
F8
LCMJE 09 01
F4
--
LCMJE 09 02 LCMJE 11 01 LCMJE 11 02
F4 F2 F2 F3 F3
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Field Replacement Units (FRUs)

The following is a list of FRUs.
FRU F1 F2 F3 F4 F5 F6 F7 F8 Print cartridge(s) Print housing assembly LCMJE driver board LCMJE interface board
Part to Replace
Replace in the following sequence: LCMJE driver board, LCMJE interface board, cables Blower assembly Replace in the following sequence: print housing assembly and then LCMJE driver card Replace in the following sequence: print cartridge indicated driver PCBA print housing assembly cable connected from driver board to print housing assembly
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Section 26 Full-Height OCR Reader Procedures

This section provides procedures for inspecting and verifying FH OCR reader functionality. It includes power-on confidence (POC) tests and the manual procedures for the FH OCR reader.
The FH OCR Reader Diagnostic System

The FH OCR reader contain built-in POC tests which provide the CSE with repair messages on the document processor screen. The OCR manual procedures, a block diagram of the reader system, and a CCC (Condition, Cause, and Correction) table are included. The POC tests, in conjunction with the manual procedures, generally diagnose to the field replaceable unit (FRU). To correct the fault, you must replace the indicated FRU and rerun the tests. At times when the POC tests do not detect a problem, such as reduced operating efficiency of the reader, you can isolate the problem using the CCC table. This table lists various operational symptoms that indicate a particular problem within the reader unit. The table includes a procedure for you to fix the problem or reference to additional information that you can use for further diagnosis.
Error Handling
Messages for faults in the OCR reader diagnosed by the POC tests are displayed on the document processor screen and refer to procedures in this manual. All electronic, electromechanical, and mechanical faults for the OCR reader fall into three categories:
Obvious failures that require no additional direction to be corrected. You correct these failures using procedures based upon your product knowledge. Subtle or difficult to isolate failures that prevent or hamper operations. These failures display a failure message or code on the screen when POC tests are executed. When failures and corrections are not obvious, you must execute the POC tests.
If the POC reports a failure message, you must perform the procedure stated by the message. If the POC fails to complete and does not display a failure message, you should consult the CCC table for an appropriate analysis procedure.
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Full-Height OCR Reader Procedures
Obvious Failures that require additional direction to be corrected. These failures have the following characteristics:
They have hidden causes. They do not have obvious corrections. They do not generate a failure message or fault code when POC tests or MTRs are executed. You need to use the OCR reader Condition, Cause, Correction (CCC) table for direction to perform the necessary corrective action.
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General Repair Guidelines

When a POC test detects an error in the reader system, a fault code is displayed on the document processor screen. Noting the fault code, go to the appropriate fault code in the FH OCR fault recovery procedures below and follow the steps listed. Most of the steps will involve replacing a board or component or by otherwise verifying that it is functioning correctly. It may be possible to verify that certain components are functioning correctly, such as power supplies, switches, and harnesses without actually replacing them. Whenever a test indicates that you should replace a board, you should first verify that the board is not loose in its slot or that connections to the board or backplane are not loose. Also, while a board is removed from its slot or the board has its cabling removed, you should carefully inspect the backplane connector and/or cable connectors for bent, corroded, or otherwise damaged contacts. Some faults could be caused by one of two boards or the interconnecting circuitry between them. To correct the fault, you must go to the manual procedures specified by the message on the screen and carefully follow those procedures. Each reader in the FH OCR reader system will generate its own fault codes. In a dual reader system, a fault code will be displayed on the document processor screen for each of the readers that exhibits a failure. Although the OCR1 and OCR2 recognition boards are identical, the error detection and reporting of error codes are handled in a slightly different manner depending upon which slot the board is in. Since OCR1 provides the interface to and control over the camera and lamp control boards, and OCR2 is essentially a slave, some of the failure codes that apply to OCR1 do not apply to OCR2. In addition, some of the OCR2 tests depend upon OCR1 functioning correctly; OCR1 failures may cause apparent failures in OCR2 and thus OCR1 failures should be repaired before OCR2 failures. Often, repairing the OCR1 problem will in itself correct the OCR2 problem.
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FH OCR Reader System Block Diagram
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FH OCR Fault Recovery Procedures

200000
OCR1 Master processor memory Failure. The OCR1 Recognition Boards master processor detected an internal memory fault. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 950 YES NO
FHO 01 00 01
200010
OCR1 FLSA Processor Loopback Failure. The OCR1 Recognition Boards master processor could not communicate with the FLSA processor. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 00 02
NO
950
200020
OCR1 Framer Processor Loopback Failure. The OCR1 Recognition Boards master processor could not communicate with the framer processor. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 00 03
NO
950
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200030
OCR1 Framer Processor Loopback Failure. The OCR1 Recognition Boards master processor could not communicate with the recognition processor. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 00 04
NO
950
200040
OCR1 Framer Processor Memory Failure. The OCR1 Recognition Boards framer processor detected an external memory error. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 00 05
NO
950
200050
OCR1 Recognition Processor Memory Failure. The OCR1 Recognition Boards recognition processor detected an external memory error. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 00 06
NO
950
200060
OCR1 Interrupt Failure. The OCR1 Recognition Board detected a fault in its interrupt system. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 00 07
NO
950
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200070
FHO 01 00 08
STEP 100
PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist?
YES
NO
99800
950
950
End of procedure
200080
OCR1 Video Processor Failure. The OCR1 Recognition Board detected an error in its video processing logic. STEP 100 PROCEDURE Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 00 09
NO
950
200200
OCR1 Camera Loopback Failure. The OCR1 Recognition Board could not communicate with the camera. STEP 100 PROCEDURE Check the cable connection between the backplane and the camera and rerun POC Does the problem still exist? 200 Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 300 Replace the camera harness and rerun POC Does the problem still exist? 400 Replace the Camera Assembly and rerun POC Does the problem still exist? 950 End of procedure 99800 400 300 200 YES
FHO 01 00 32
NO
950
950
950
950
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267
200210
OCR1 Camera Video Failure. The OCR1 Recognition Board received incorrect video patterns from the camera. STEP 100 PROCEDURE Check the reader lamps Are the lamps stuck in the high intensity mode? 150 Check the lamp control interface harness connections and the lamp control harness connections Are the lamps still in the high intensity mode? 200 Replace the Lamp Control Board and rerun POC Are the lamps still in the high intensity mode? 250 Replace OCR1 Recognition board (AA14) and rerun POC Are the lamps still in the high intensity mode? 300 Replace the lamp control interface harness and rerun POC Are the lamps still in the high intensity mode? 350 Replace the lamp control harness and rerun POC Are the lamps still in the high intensity mode? 500 Check the POC results Does the original failure (camera video incorrect) still exist? 550 Check the camera harness connections and the camera power harness connections and rerun POC Does the problem still exist? 600 Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 650 Replace the Camera Assembly and rerun POC Does the problem still exist? 700 Replace the camera backplane power harness and rerun POC Does the problem still exist? 750 Replace the camera harness and rerun POC Does the problem still exist? 950 End of procedure 99800 750 700 650 600 550 99800 500 300 250 200 150 YES
FHO 01 00 32
NO
500
500
500
500
350
500
950
950
950
950
950
950
268
3998 5593007
200300
OCR1 to OCR2 Communication failure. The OCR1 Recognition board did not receive the required command responses from the OCR2 Recognition Board. STEP 100 PROCEDURE Check the DIP switch settings on OCR1 Recognition board (AA14) and ensure that DIP switch 1 is CLOSED, then rerun POC Does the problem still exist? 200 Replace OCR1 Recognition board (AA14), again making sure that DIP switch 1 is CLOSED, and rerun POC Does the problem still exist? 300 Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 300 200 YES
FHO 01 00 34
NO
950
950
950
3998 5593007
269
200310
Main Cover Open Error. The OCR1 Recognition Board detected that the main cover interlock switch is open and the lamps could not be tested. STEP 100 PROCEDURE Verify that the main cover is properly closed and rerun POC Does the problem still exist? 200 Verify that the main cover switch is not damaged or otherwise misaligned; replace if necessary and rerun POC Does the problem still exist? 300 Check the lamp control interface harness connections and the lamp control harness connections Does the problem still exist? 400 Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 500 Replace the lamp control board and rerun POC Does the problem still exist? 600 Replace the lamp control interface harness rerun POC Does the problem still exist? 700 Replace the lamp control harness rerun POC Does the problem still exist? 800 Verify that the output voltages of the +1 -24V supply are correct. Replace the supply if necessary Does the problem still exist? 950 End of procedure 99800 800 700 600 500 400 300 200 YES
FHO 01 00 35
NO
950
950
950
950
950
950
950
950
2610
3998 5593007
200320
Lamp Cover Open Error. The OCR1 Recognition Board detected that the lamp cover switch is open. STEP 100 PROCEDURE Verify that the lamp cover is properly closed and rerun POC Does the problem still exist? 200 Verify that the lamp cover switch is not damaged or otherwise misaligned or that its magnet is not missing; replace if necessary and rerun POC Does the problem still exist? 300 Check or replace the lamp temperature switch Does the problem still exist? 400 Check the lamp control interface harness connections and the lamp control harness connections Does the problem still exist? 500 Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 600 Replace the lamp control board and rerun POC Does the problem still exist? 700 Replace the lamp control interface harness rerun POC Does the problem still exist? 800 Replace the lamp control harness rerun POC Does the problem still exist? 950 End of procedure 99800 800 700 600 500 400 300 200 YES
FHO 01 00 36
NO
950
950
950
950
950
950
950
950
3998 5593007
2611
200330
Lamp Temperature Sensor Error. The OCR1 Recognition Board detected that the lamp temperature switch is open (reporting a too hot condition). STEP 100 PROCEDURE Check the lamp fan and replace if necessary Does the problem still exist? 150 Check or replace the lamp temperature switch Does the problem still exist? 200 Verify that the lamp cover is properly closed and rerun POC Does the problem still exist? 250 Verify that the lamp cover switch is not damaged or otherwise misaligned or that its magnet is not missing; replace if necessary and rerun POC Does the problem still exist? 300 Check the lamp control interface harness connections and the lamp control harness connections Does the problem still exist? 350 Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 400 Replace the lamp control board and rerun POC Does the problem still exist? 450 Replace the lamp control interface harness rerun POC Does the problem still exist? 500 Replace the lamp control harness rerun POC Does the problem still exist? 950 End of procedure 99800 500 450 400 350 300 250 200 150 YES
FHO 01 00 37
NO
950
950
950
950
950
950
950
950
950
2612
3998 5593007
200340
Lamp Current Error. The OCR1 Recognition Board detected that the lamp current sensor showed either (1) high current condition in the lamp low-power mode or (2) low current condition in the lamp high-power mode STEP 100 PROCEDURE Replace the bulbs Does the problem still exist? 200 Check the lamp control interface harness connections and the lamp control harness connections Does the problem still exist? 300 Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 400 Replace the lamp control board and rerun POC Does the problem still exist? 500 Replace the lamp control interface harness rerun POC Does the problem still exist? 600 Replace the lamp control harness rerun POC Does the problem still exist? 950 End of procedure 99800 600 500 400 300 200 YES
FHO 01 00 38
NO
950
950
950
950
950
950
3998 5593007
2613
200400
OCR2 Master processor memory Failure. The OCR2 Recognition Boards master processor detected an internal memory fault. STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 01
NO
950
200410
OCR2 FLSA Processor Loopback Failure. The OCR2 Recognition Boards master processor could not communicate with the FLSA processor STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 02
NO
950
200420
OCR2 Framer Processor Loopback Failure. The OCR2 Recognition Boards master processor could not communicate with the framer processor STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 03
NO
950
2614
3998 5593007
200430
OCR2 Recognition Processor Loopback Failure. The OCR2 Recognition Boards master processor could not communicate with the recognition processor. STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 04
NO
950
200440
OCR2 Framer Processor Memory Failure. The OCR2 Recognition Boards framer processor detected an external memory error. STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 05
NO
950
3998 5593007
2615
200450
OCR2 Recognition Processor Memory Failure. The OCR2 Recognition Boards recognition processor detected an external memory error. STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 06
NO
950
200460
OCR2 Interrupt Failure. The OCR1 Recognition Board detected a fault in its interrupt system. STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 07
NO
950
200470
OCR2 Video Ram Failure. The OCR2 Recognition Board detected an error in its internal video RAM. STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 08
NO
950
2616
3998 5593007
200480
OCR2 Video Processor Failure. The OCR2 Recognition Board detected an error in its video processing logic. STEP 100 PROCEDURE Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 YES
FHO 02 00 09
NO
950
200600
OCR2 Camera Video Failure. The OCR2 Recognition Board received incorrect video patterns from the camera. STEP 100 PROCEDURE Check the OCR1 POC test results Did the OCR1 fail any of its POC tests? 200 Remedy the OCR1 POC failure first using the FHO Error Recovery Manual Procedures (OCR1 must successfully pass its POC tests in order for the video patterns to be available to OCR2) then rerun POC. Does the problem still exist? 300 Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 400 Replace OCR1 Recognition board (AA14) and rerun POC Does the problem still exist? 950 End of procedure 99800 400 300 200 YES
FHO 02 00 33
NO
950
950
950
950
3998 5593007
2617
200650
OCR1 to OCR2 Communication failure. The OCR2 Recognition board did not receive the required command sequences the OCR2 Recognition Board STEP 100 PROCEDURE Check the OCR1 POC test results Did the OCR1 fail any of its POC tests? 200 Remedy the OCR1 POC failure first using the FHO Error Recovery Manual Procedures (OCR1 must successfully pass its POC tests in order for the video patterns to be available to OCR2) then rerun POC. Does the problem still exist? 300 Check the DIP switch settings on OCR1 Recognition Board (AA14) and ensure that DIP switch 1 is CLOSED, then rerun POC Does the problem still exist? 400 Replace OCR1 Recognition board (AA14), again making sure that DIP switch 1 is CLOSED, and rerun POC Does the problem still exist? 500 Replace OCR2 Recognition board (AA12) and rerun POC Does the problem still exist? 950 End of procedure 99800 500 400 300 200 YES
FHO 02 00 34
NO
950
950
950
950
950
2618
3998 5593007
FH OCR Reader to Track Communication Errors Manual Procedures

200800
OCR1 Communication failure. The Track PC could not communicate with the OCR1 recognition board. STEP 100 PROCEDURE Replace the OCR1 Recognition Board (AA14) Does the problem still exist? 950 End of procedure 99800 950 YES NO
FHO 01 99 00
200810
OCR2 Communication failure. The Track PC could not communicate with the OCR2 recognition board. STEP 100 PROCEDURE Replace the OCR2 Recognition Board (AA12) Does the problem still exist? 950 End of procedure 99800 YES
FHO 01 99 00
NO
950
3998 5593007
2619
FH OCR MTR Failures Manual Procedures

200900
Calibrate Camera MTR Scan Line Hardware Failure. The OCR1 Recognition Board could not capture a video scan line because it detected a hardware failure in its scan capture logic. STEP 100 PROCEDURE Replace the OCR1 Recognition Board (AA14) and rerun the test. Does the problem still exist? 950 End of procedure 99800 950 YES NO
FHO 01 03 30
200910
Calibrate Camera MTR Final Black Level Setting Failure. The OCR1 Recognition Board could not set the camera final black levels properly. STEP 100 PROCEDURE Replace the OCR1 Recognition Board (AA14) and rerun the test. Does the problem still exist? 200 Replace the Camera Assembly and rerun the test. Does the problem still exist? 950 End of procedure 99800 200 YES
FHO 01 03 31
NO
950
950
200920
Calibrate Camera MTR Initial Black Level Setting Failure. The OCR1 Recognition Board could not initialize the camera black levels properly. STEP 100 PROCEDURE Replace the OCR1 Recognition Board (AA14) and rerun the test. Does the problem still exist? 200 Replace the Camera Assembly and rerun the test. Does the problem still exist? 950 End of procedure 99800 200 YES
FHO 01 03 32
NO
950
950
2620
3998 5593007
200930
Calibrate Camera MTR Calibration Failure Error. The OCR1 Recognition Board could not complete the camera calibrate process for some unknown reason. STEP 100 PROCEDURE Make sure the calibration target has been properly inserted and rerun the test. Does the problem still exist? 200 Make sure the calibration target has is not damaged, replace if necessary and rerun the test. Does the problem still exist? 300 Replace the OCR1 Recognition Board (AA14) and rerun the test. Does the problem still exist? 400 Replace the Camera Assembly and rerun the test. Does the problem still exist? 950 End of procedure 99800 400 300 200 YES
FHO 01 03 33
NO
950
950
950
950
3998 5593007
2621
200940
Calibrate Camera MTR White Target Error. The OCR1 Recognition Board could not detect the calibration target. STEP 100 PROCEDURE Make sure the calibration target has been properly inserted and rerun the test. Does the problem still exist? 200 Make sure the calibration target has is not damaged, replace if necessary and rerun the test. Does the problem still exist? 300 Replace the OCR1 Recognition Board (AA14) and rerun the test. Does the problem still exist? 400 Replace the Camera Assembly and rerun the test. Does the problem still exist? 950 End of procedure 99800 400 300 200 YES
FHO 01 03 34
NO
950
950
950
950
200950
Calibrate Camera MTR Lamp Error. The OCR1 Recognition Board could complete calibration because it detected a lamp failure. STEP 100 PROCEDURE Replace the bulbs and rerun the test Does the problem still exist? 200 Rerun POC and check the OCR1 POC results. Does the problem still exist? 300 Using the FH OCR manual procedures, repair the problem and then rerun the test. Does the problem still exist? 950 End of procedure 99800 300 200 YES
FHO 01 03 35
NO
950
950
950
2622
3998 5593007
99800 Entry into this line indicates the failure of the FH OCR POC diagnostic procedures to correct a problem. Review the following troubleshooting suggestions to help isolate the problem. 1. 2. 3. 4. 5. 6. 7. 8. Review or rerun the diagnostic procedures to make sure the proper step-by-step procedures were followed. Check for shorting objects (such as staples or paper clips) that can cause constant or intermittent shorts, especially on the backplane. Check all onboard jumper locations. Check for logic to frame ground shorts. Check the card connector blocks for bent pins and proper card seating. Use the CCC table, if not done already, to help isolate the problem. Check the AA gate power supply voltages, including the +/- 24V supply that supplies the camera, for proper outputs. Replace the following, one at a time, in the following order: AA10 (CAPRI) AA11 (AC/DC MICR) AA Gate Backplane 9. Review the suggestions at line 99999 listed under General Troubleshooting Suggestions.
3998 5593007
2623
FH OCR CCC TABLE

The following text provides information about problem conditions to which normal POC tests do not apply, their probable causes, and possible corrective actions to those conditions. Table 261. FH OCR CCC Table
CONDITION
Transport rejects a large percentage of documents The print quality is good on these rejected documents but cant reads or dont reads appear on the code line, especially near the edge of the document Transport still rejects a large percentage of documents even though the print quality is even though the print quality is good, and the readers codeline height setting seems to be correct
CAUSE
The scan position may be improperly set, causing some or all of the characters on the document to be outside of the readers field of view
CORRECTION
Adjust the codeline position up or down and see if the read rate improves
The camera optics may have become coated with dust, resulting in reduced video signal
Clean and inspect the glass at the front of the camera and both ends of the fiber optic assemblies. It may be necessary to increase the frequency of preventative maintenance to prevent reoccurrence of this problem Perform the Camera Calibration Test and adjustment procedure
Transport still rejects a large percentage of documents even though the print quality is good, the codeline height is set properly, and the camera optics have been cleaned No codelines are detected by the reader even though it passes POC. No codelines are detected by the reader even though it passes POC.
The camera settings may have drifted or the lamps may have been changed without recalibrating the camera or somehow the camera calibration file on the PC may have become corrupted. Scan height set above top of codeline or above top of document Hardware failures listed in order of decreasing likelihood: Faulty Camera Beam Of light
Replace the Camera Assembly Replace
No codelines are detected by the reader even though it passes POC.
OCR reader does not turn on its lamps when reading (motors on signal not detected) Hardware failures listed in order of decreasing likelihood: Faulty Camera Beam of light
Replace the OCR1 recognition board
The code line read is blank even though there are characters on the document and the reader lamps are on while reading
Replace Camera Assembly Replace OCR Recognition board
2624
3998 5593007
*39985593-007*
39985593007

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Unisys e-@ction Network Document Processor 1150/1600/ 1825/2000

Servicing Guide: Maintenance Procedures (DL3)

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Unisys e-@ction Network Document Processor 1150/1600/ 1825/2000

Unisys e-@ction Network Document Processor 1150/1600/ 1825/2000

Unisys e-@ction Network Document Processor 1150/ 1600/1825/2000

3998 5593 007

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Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Power-On Confidence Tests

Transport Basic Tests: Tracking Logic and AA Backplane Types

Transport Basic Subtest 1: Tracking Logic and AA Backplane Types

Transport Basic Subtest 2: Tracking Logic and AA Backplane Types

Unisys Proprietary - Class C

Transport Basic Subtest 3: Tracking Logic and AA Backplane Types

Transport Basic Subtest 4: Tracking Logic and AA Backplane Types

Transport Basic Subtest 5: Tracking Logic and AA Backplane Types

Transport Basic Subtest 6: Tracking Logic and AA Backplane Types

Section 10. E13B Double Read Character Recognition Test

Section 11. General Assistance Aids

Section 12. Condition, Cause, Correction Tables

Section 13. Power Supply

Unisys Proprietary - Class C

Section 14. Machine Checks

Section 15. CMC7 Tests

Section 16. NDP 1xxx-65 Cinemode Microfilmer Test

Section 17. Microfilmer Hardware Parameters

Section 18. Imaging Module (U4/JPEG)

Section 19. Multiline Ink Jet Endorser Manual Procedures

Section 20. PEP/Stamp Tests

Section 21. CAR Diagnostics (U4/JPEG Imaging System)

Section 22. Dual Image Manual Procedures

Unisys Proprietary - Class C

Section 23. High Speed Encoder Module

Unisys Proprietary - Class C

HSEM Tests .............................................................

Section 24. CAR Diagnostic Procedures (Dual Image System)

Section 25. NDP 1150 MJE Diagnostic Procedures

Section 26. Full-Height OCR Reader Procedures

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Unisys Proprietary - Class C

Document Processor 33 Mhz NPD030 CPU PCBA MULTIBUS

Document Processor 25 Mhz 68030 CPU PCBA MULTIBUS

Unisys Proprietary - Class C

POC/MTR error code displayed

Performance or other problem

POC/MTR error code displayed

Machine check displayed

Performance or other problem