Phaser 7700 Laser Error 1

[richdude]

I have several 7700s and started getting a "Laser Failure" error on start-up on one of the machines. Sometimes it boots up OK, sometimes it gives the error and won't start. Turning it off for a while and trying again usually works, even if I have to do it a few times. Can anyone explain what's happening and any handling other than just buying a new laser for over $1,000? Thanks...

 

[Michael52x]

ROS errors are a faulty laser moter. Try using RegiCon to re-calibrate the laser.Ensure the MOB {mark on belt, the image transfer unit}is in it's correct position before running. let us know if you cant do this, and it can be done step by step.

 

[richdude]

Michael- Thanks very much- I really appreciate your info. It's an 'Error 10'. Unfortunately I don't know what "Regicon" is, nor what the correct position for the mark on the belt is. You've obviously got access to way more tech specs than I do. I'd be greatful for step by step instructions, or any details on how to do this, or links to where I can get that info. Thanks again and I look forward to your response. Rich

 

[Michael52x]

Howdy Rich, this is a five step procedure, and you really need to have the technical wherewithal to do it.
I dont know if the user manual gets into it, but if you have the full driver installed, it might have a help file you can access. It's too much to put here. I will try to get it on my partner site, and paste it here.

 

[Michael52x]

Here ya go! Good luck!
Service Quick Reference Guide - Adjustments & Calibration 4-113
Adjustments and
Calibration
The engine firmware has several built-in diagnostic routines that perform various
alignment and calibration procedures. The RegiCon 685 Adjustment procedures
should be used whenever the technician removes or replaces the Laser Unit, the
Print Cartridge Plate Assembly, the Mark-on-Belt Assembly, Developer Housing
Assembly or where color registration is bad.
The printer is shipped aligned, registered and calibrated. The major disruption
that can affect registration is when the NVRAM that contains the registration
parameters is cleared, requiring that registration be redone. For information on
resetting NVRAM see “Resetting NVRAM” on page 6-131
Internal Hard Drive
The Phaser 7700 Printer has a standard hard drive installed in every printer. The
hard drive bootsmost of the firmware. There is a special file on the hard drive that
stores the specific calibration values for various sensors and for the unique
positioning of the laser in the printer.

During manufacturing, the calibration values from the engine NVRAM
have been written to the hard drive. The stored values can be written
back to the engine NVRAM by performing a front panel “Reset Engine
NVRAM Now” reset procedure.

If "resetting" engine NVRAM does not restore correct color registration,
the laser geometry has probably moved in the printer, and the
registration procedure must be performed. After completing the
registration process, performthe engine NVRAM"store" function to store
the new engine NVRAM values to the hard drive.

If the hard drive needs to be replaced, there is an engine NVRAM "store"
function in the service diagnostics that enables the current engine
NVRAM values to be written to the new hard drive.

If the engine control board is replaced, the NVRAM values on the hard
drive need to be restored to the new board with the engine NVRAM
"reset" function.
4-114 Phaser 7700 Color Laser Printer
Registration Control (RegiCon) Adjustment Overview
The DC685 RegiCon tests are the means by which registration is accomplished.
Registration means establishing the alignment of the four primary colors with
regard to horizontal and vertical positioning, tilt or skew, length of lines and
linearity. When the registration process is completed, all color planes are
positioned properly.
Note For any registration procedure to succeed, the printer
must print with no image defects. Verify by printing
color solid fill pages, see “Print Color Test Prints” on
page 9-267. To resolve a print image problem, see
“Print Image Quality Problems” on page 3-101.
The printer registration process consists of the Belt Edge Learn, Coarse Skew
Adjustment, Fine Skew Adjustment, In/Out Skew Adjustment, and Center Skew
Adjustment, with each test reporting success. On failure of any of Skew
Adjustment, the Coarse RegiCon Initialization must be performed.
Coarse RegiCon Initialization
Coarse RegiCon Initialization is the procedure by which the printer aligns the
magenta, yellow and black vertical and horizontal scan lines to the cyan reference
scan line. Horizontal and vertical alignment ensures that the magenta, yellow
and black lines are superimposed on Cyan.
Note Cyan is the reference color to which all other colors are aligned.
Figure 4-1 Coarse RegiCon Initialization
Figure 1: Horizontal and Vertical
Margins
S7700-460
M, Y, K
Cyan
Service Quick Reference Guide - Adjustments & Calibration 4-115
Coarse and Fine Skew Adjustments
Skew error is the mislevel of one or more of the four scan lines (C, M, Y & K).
During the RegiCon #4 (Coarse) and RegiCon #1 (Fine) adjustments, the left side
of each line is adjusted to be level with the right end.
In/Out Skew Adjustment
The In/Out Skew Adjustment (Magnification) ensures that all four scan lines are
the same length. During RegiCon #2, the printer measures, then adjusts the four
scan lines to the proper length.
Figure 4-2 Coarse and Fine Skew Adjustments
Figure 4-3 In/Out Skew Adjustment
Figure 2: Skew Adjustment
S7700-461
Reference Line
Figure 3: Magnification
S7700-462
4-116 Phaser 7700 Color Laser Printer
Center Skew Adjustment
The Center Skew Adjustment (Magnification Balance) adjusts the linearity of the
scan lines. During RegiCon #3, the printer measures a specific midpoint of each
scan line and adjusts it to a horizontal reference midpoint.
Figure 4-4 Center Skew Adjustment
Figure 4: Magnification Balance
S7700-463
Center Reference
Service Quick Reference Guide - Adjustments & Calibration 4-117
Processes of the RegiCon adjustment
The test procedures should be performed in the following order. Each test must
be successful before proceeding to the next. Refer to the RegiCon Flowchart on
page 4-118.
Check print-quality - this process checks the printer’s ability to print with no image
defects. Run the Print-Quality Test Print (page 9-267). If simple primary or
secondary color solid fill sheets do not appear satisfactory, solve those problems
before performing RegiCon adjustment.
Set DIP switch #2 to Service Mode (down) - this disables the Startup Page and enables
the printer to write test results to the print engine NVRAM.
# 4 is a Coarse Skew adjustment procedure - this process examines the rough
RegiCon image on the belt and reports the skew adjustments that need to be
made.
#1 Fine Skew adjustment procedure - this process examines the fine RegiCon image
on the belt and reports the skew adjustments needed to be made.
#2 is an IN/OUT Skew procedure - this process calibrates the end points of the scan
line for magnification adjustment. There may be manual skew screw adjustments
recommended by this test.
#3 is a CENTER Skew procedure - this process requires moving the Mark-On-Belt
(MOB) sensor from the edge of the Accumulator Belt to an inner position of the
belt (at approximately 1/3 the distance from the edge) to calibrate the CENTER
components of the scan line for the magnification-balance adjustment.
Registration Control Procedures
Note For the following procedures you must perform certain steps prior
to, during and after the tests are run. The following information
is vital to the process and must be followed in order for each
procedure to function properly.

You must enter Service DiagnosticsMode through the front panel by
switching off the printer and pressing the Back and Info keys
simultaneously, and switching on the printer. You must re-enter
diagnostics after each test has concluded.

If the optional Finisher is installed, it must be electrically disconnected
from the printer before performing the RegiCon Adjustments.

After performing a manual adjustment of the skew screws, gently tap
the screw with a screwdriver. This ensures that the adjustment stays
secure.

After performing a RegiCon test, wait for 10 seconds for the results to be
stored after the motor has stopped. You can hear a faint click from the
print engine when the results are complete. To view the results, youmust
re-enter Diagnostics.

The procedures are listed in the order they need to be performed for
optimal adjustments.
4-118 Phaser 7700 Color Laser Printer
RegiCon Flowchart
Figure 4-5 RegiCon Flowchart
Phaser 7700 Registration Control Adjustment
(DC685 RegiCon Adjustment)
Are all
primary fill
test prints
OK?
No
Run Belt Edge
Learn
Pass?
Correct Fault
(Replace
Accumulator Belt)
No
Yes
Yes
Run RegiCon #4
Pass?
Yes
Record results and
run RegiCon #1
Pass?
Yes
Check Print
Quality
Correct print
quality problem
and reset.
Run Coarse RegiCon
Initialization
and Adjust YMK < 1mm
from Cyan
No
Rerun RegiCon #4 and
Adjust mirrors for
values greater than -5
to +5
No
Pass?
No
Troubleshoot,
repair and start
over
Yes All results
-5 to +5?
Run RegiCon #2
Pass?
Move MOB
Sensor to
Center position
No
No
Yes
Yes
Run RegiCon #3
No Pass?
Yes
? Restore MOB Sensor
? Set DIP Switch 2 UP
? Store NVRAM to HD
Note 1: Do not make
adjustments of 5 or
fewer clicks. Any
adjustment of 5 or
less is considered
"noise".
Note 2: Always record
the results of each
RegiCon procedure.
This provides a path
by which the printer
can be restored.
Note 3: After running
a RegiCon test, always
wait 10 seconds after
the printer reboots
and comes to ready
before interrupting
power.
Set DIP switch
2 down
Run RegiCon
#1
Adjust mirrors for
values greater than
-5 or +5
Service Quick Reference Guide - Adjustments & Calibration 4-119
Step 1: Belt Edge Learn
Before doing skew adjustments, it is necessary to align the Accumulator Belt
positioning system. A belt steering cam engages an arm on the Accumulator Belt
cleaner to steer the belt. A belt edge sensor provides the real time feedback to
steer the belt.
Caution The Accumulator Belt must NOT be run without the
Belt Cleaner in place. The belt WILL walk off the
rollers and be permanently damaged.
1. From the Service Diagnostics Menu, highlight the Adjustments/Calibrations
menu and press OK.
2. Highlight Belt Edge Learn and press OK.
The display now reads:
The following result must be displayed after the test completes. Any other result
means that the procedure failed.
Press Back to return to the menu.
If the Belt Edge Learn procedure fails: The Accumulator Belt must be replaced.
<Belt Edge Learn>
<Press back or cancel to abort>
<Belt Edge Learn>
Belt Edge Learn Result: OK
Belt Edge Learn Walk Control
<Press back or cancel to abort>
4-120 Phaser 7700 Color Laser Printer
Step 2: RegiCon #4 Coarse Skew Adjustment
1. From the Service Diagnostics menu, highlight the Adjustments/Calibration
menu and press OK.
2. HighlightRegi Con 685 Setup Cycle and press OK.
3. At the prompt:Which DC685 procedure?, select #4 Coarse Skew Setup and
press OK.
4. At the prompt: Do DC685-4 Coarse Cycle?, highlight Yes and press OK.
The front panel now displays: <PostScript will do 685-4>
5. The printer now reboots and runs the test. When the test is complete, wait for
approximately 10 seconds after the motors turn off and the display indicates
“Ready To Print”, then cycle power and enter Service Diagnostics. (To display
the results, you must re-enter Service Diagnostics Mode.)
6. Enter Adjustments/Calibration --> Regi Con 685 Results Display and press
OK.
7. Wait until the test results are displayed as follows:
Note If the block counts are not the same number as presented here, the
printer has a print-quality problem. Please refer to section
“Streaks in direction of paper travel” on page 3-104 to resolve the
print-quality problems before proceeding further with RegiCon.
8. Press OK to see the second panel of data. If an adjustment is needed, perform
the adjustments displayed on the front panel. Be sure to tap the screw that was
adjusted with a heavy screwdriver to ensure that the adjustment remains true.
Note If the test procedure passes, no adjustments need be made.
Continue directly to RegiCon #1 (Fine Skew Adjustments).
DC685-4 Passed
A Out Blocks: 0
B Out Blocks: 4
<Press Ok for more Data>
Skew Corr. Y: -7 clicks CCW
SkewCorr. M: 7 clicksCW
Skew Corr. C: -5 clicks CCW
SkewCorr. K: -12 clicksCCW
Service Quick Reference Guide - Adjustments & Calibration 4-121
If RegiCon Coarse Skew Fails
This indicates that the horizontal alignment is so far out of adjustment that a
manual adjustment is required before the diagnostics test routines for fine skew
can pass. Other possible problems; a Mark-On-Belt Sensor failure, Developer,
Developer Bias Voltage, Print Cartridge, or Engine Control Board Failure.

Performthe Coarse RegiCon Initialization procedure on page 4-125. This
adjusts the horizontal alignment closer and allows RegiCon #4 to pass.

After Coarse RegiCon Initialization is complete, perform RegiCon #4
(Coarse Skew Adjustment) again. Make the required adjustments.
Note Adjustments should be made only if the skew correction indicated
is greater than +/- five clicks. A positive number indicates
clockwise (CW) adjustment is needed. A negative number
indicates a counter-clockwise (CCW) adjustment is needed.
Adjustment screws are located behind theWaste Cartridge, which
must be removed for access. From left to right, the adjustment
screws are: K, C, M, and Y.
4-122 Phaser 7700 Color Laser Printer
Step 3: RegiCon #1 Fine Skew Adjustment
This process uses sensors to examine the RegiCon image on the belt and report
what skew adjustments need to be made. A side effect of this test is that
horizontal and vertical alignments are automatically done (if the test passed).
The data output presents the skew screw adjustment values (some number of
"clicks" of the screw, either CW or CCW direction). Values less than 5 or so are
"noise" and should not need adjusted.
1. From the Service Diagnostics menu, highlight the Adjustments/Calibration
menu and press OK.
2. HighlightRegi Con 685 Setup Cycle and press OK.
3. At the prompt:Which DC685 procedure?, highlight #1 Fine Skew Setup and
press OK. The front panel now displays: <PostScript will do 685-1>
4. The printer now reboots and runs the test. Wait for approximately 10 seconds
after the motors turn off and the display indicates “Ready To Print”, then cycle
power and enter Service Diagnostics.
5. Enter Adjustments/Calibration --> Regi Con 685 Results and press OK.
6. Wait until the test results are displayed as follows:
Note If the block counts are not the same number as presented here, the
printer has a print-quality problem. Please refer to section
“Streaks in direction of paper travel” on page 3-104 to resolve the
print-quality problems before proceeding further with RegiCon.
7. Press OK to see the second panel data. If an adjustment is needed, adjust by
the smounts displayed on the front panel. Be sure to tap the screwthatwas
adjusted with a heavy screwdriver to ensure that the adjustment remains true.
If RegiCon #1 Fine Skew test fails, see “If RegiCon Coarse Skew Fails” on
page 4-121
DC685-1 Passed
A Out Blocks: 24
B Out Blocks: 4
<Press Ok for more Data>
SkewCorr. Y: -7 clicksCCW
SkewCorr. M: 7 clicksCW
Skew Corr. C: -5 clicks CCW
SkewCorr. K: -12 clicksCCW
Service Quick Reference Guide - Adjustments & Calibration 4-123
Step 4: RegiCon #2 In/Out Skew Adjustment
This test makes "magnification" adjustments for registration. Magnification is the
length of the scan line for the four colors, so that each scan line for each color is
the same length.
The data output can indicate PASSED, or READJUST (PASSED), or FAILED. If the
result is READJUST, the indicated adjustment values for the skew adjustment
should be done. It should not be necessary to rerun the test after making this
adjustment.
1. From the Service Diagnostics menu, highlight Adjustments/Calibration menu
and press OK.
2. Select Regi Con 685 Setup Cycle and press OK.
3. At the prompt:Which DC685 procedure?, select #2 In/Out Skew Setup, select
YES and press OK. The front panel now displays: <PostScript will do 685-2>.
4. The printer now reboots and runs the test. Wait for approximately 10 seconds
after the motors turn off and the display indicates “Ready To Print”, then cycle
power and enter ServiceDiagnostics.
5. Enter Adjustments/Calibration --> Regi Con 685 Results and press OK.
6. Wait until the test results are displayed as follows:
Note If the block counts are not the same number as presented here, the
printer has a print-quality problem. Please refer to section
“Streaks in direction of paper travel” on page 3-104 to resolve the
print-quality problems before proceeding further with RegiCon.
7. If the display indicates <DC685-2 READJUST (Passed)>, press OK to see the
second panel data. If an adjustment is needed, adjust by the amounts
displayed on the front panel. Be sure to tap the screw that was adjusted with a
heavy screwdriver to ensure the adjustment remains true.
When DC685-1 or DC685-2 Fails
The horizontal alignment error is excessive and a manual adjustment is required
before the diagnostics test routines for fine skew can pass. For details of the
Coarse RegiCon Init procedure, see “Coarse RegiCon Initialization” on page 4-125
DC685-2 Passed
A Out Blocks: 24
B Out Blocks: 0
<Press Ok for more Data>
Skew Corr. Y: -7 clicks CCW
SkewCorr. M: 7 clicksCW
Skew Corr. C: -5 clicks CCW
SkewCorr. K: -12 clicksCCW
4-124 Phaser 7700 Color Laser Printer
Step 5: RegiCon #3 Center Skew Adjustment
This test adjusts magnification balance. There are no manual adjustments
required after completing the test.
Note To perform this test, move the Mark-On-Belt sensor to the
CENTER position. After the test has been run, theMark-On-Belt
must be moved back to the home position.
1. Remove the Waste Cartridge.
2. Remove the screw that holds the Mark-On-Belt (MOB) sensor to the front of
the printer.
3. Using the laser mirror cleaning tool backward, push the sensor all the way to
the CENTER position (until it hits the stop).
4. Reinstall theWaste Cartridge.
5. Close the door and run the test.
6. From the Service Diagnostics menu, highlight Adjustments/Calibration menu
and press OK.
7. Select Regi Con 685 Setup Cycle and press OK.
8. At the prompt:Which DC685 procedure?, select RegiCon #3 Center Skew
Setup and press OK. The front panel now displays: <PostScript will do 685-3>.
9. The printer now reboots and runs the test. Wait for approximately 10 seconds
after the motors turn off then cycle power and enter Service Diagnostics. (To
display the results or continue you must re-enter Service Diagnostics Mode).
10.Enter Adjustments/Calibration --> Regi Con 685 Results and press OK.
11.Wait until the test results are displayed as follows:
Note If the block counts are not the same number as presented here, the
printer has a print-quality problem. Please refer to section
“Streaks in direction of paper travel” on page 3-104 to resolve the
print-quality problems before proceeding further with RegiCon.
12.Using the back of the Laser Cleaning Tool, hook the loop of the MOB Sensor
(just pushed back in step 3 above) and pull it all the way to the front. Continue
holding the MOB Sensor in position while reinserting the securing screw
(removed in step 2 above) and tightening.
When DC685-3 Fails
This is probably due to the Mark-On-Belt sensor not being positioned properly
(assuming that RegiCon 1 and 2 tests have already passed). The sensor has a
"wedge-fit" when in position for the number 3 "center" position. If the
Mark-On-Belt sensor not correctly positiond, it can cause the test to fail. Recheck
the MOB sensor position and run the test again.
DC685-3 Passed
A Center Blocks: 24
B Center Blocks: 4
<Press Ok for more Data>
Service Quick Reference Guide - Adjustments & Calibration 4-125
Coarse RegiCon Initialization
The Coarse RegiCon Initialization procedure is needed when either RegiCon 1 or
4 fail.
If any one of the above conditions exist, perform a manual adjustment of the
horizontal alignment.
1. Run the Belt Edge Learn Test (page 4-119).
2. From the Adjustments/Calibrations menu, select Coarse RegiCon Init test.
After some NVRAMvalues are read, the test asks Set Factory Defaults?
Yes/No, then select Yes. This sets the horizontal and vertical alignment to
centered values. At this time, it should not be necessary to reset the
magnification or magnification balance values, so select No to Reset Mag/Bal
Values? Yes/No.
Note In all the following steps, Cyan is the reference line and cannot be
adjusted, so you need to adjust all the other lines towards the
Cyan line.
3. From the Built-in Test Prints menu, select Print Grid 1-Dot. This print shows
the relative error between the CMYK scan lines. Always indicate which edge of
the print comes out of the printer first to be certain which way is Left/Right or
Up/Down (see Figure 4-6 “Grid 1-Dot pattern orientation for A-size paper”).
Measure the distance (in millimeters) between the vertical lines, with the Cyan
line being the reference line.

It is best if the default paper tray contains A-size paper.
Figure 4-6 Grid 1-Dot pattern orientation for A-size paper
Top
S7700-464-b
4-126 Phaser 7700 Color Laser Printer

Note the leading edge of the paper when removing the test print from the
tray. Use a pen or pencil to note the leading edge as the “TOP” of the
print “Grid 1-Dot pattern annotations” on page 4-126. With “TOP” up,
note the direction of scan from left to right as the “FAST ” direction. The
direction from the bottom of the print to the top is referred to as the
“SLOW” direction.

Notice which vertical line color(s) on the print needs to be moved right or
left to line up as closely as possible with the cyan color line.

Measure how much each line needs to move (in millimeters) and
whether it must be moved left or right.
Note Cyan is the reference color and does not move. Make
the adjustments of M, Y, and K toward Cyan.
4. From the Adjustment/Calibrations menu, select Coarse RegiCon Init test.
This time answer No to the Set Factory Defaults? Yes/No, but answer Yes to
the Do you want to adjust NVRAM? Yes/No question. Answer No to Set
Skew Error threshold? Yes/No. Answer Fast to the Which scan direction?
Fast/Slow.
5. Select which color (of YMK) to adjust. Select how many millimeters (1-5) to
adjust. Select which direction (Left/Right). The next screen asks for
confirmation: {Adjust <color> by <n> mm? Yes/No}, select Yes.
6. Repeat steps 4 and 5 for the other colors. You reprint the Grid 1-Dot pattern, as
outlined in step 3, or go to the Adjustments/Calibrations menu: RegiCon 685
Setup Cycle test. If the #1 test fails, print the Grid 1-Dot page to see if the
vertical lines are all clustered within 1 mm of the Cyan line. If not, repeat. It
may be necessary to closely inspect the Color Solid Fill Prints to determine if
the image quality is acceptable.
Figure 4-7 Grid 1-Dot pattern annotations
Top
Left Fast Right
Slow
Down
Up
(Leading edge into
output tray)
Left Fast Right
Slow
Down
Up
S7700-465
(Leading edge into
output tray)
Service Quick Reference Guide - Adjustments & Calibration 4-127
ATC Sensor Setup
The Automatic Toner Calibration (ATC) sensor measures the amount of toner in
each developer. These sensors have an intrinsic gain and output value are stored
in printer NVRAM. New valuesmust be entered when a new Developer Housing
Housing is installed. Incorrect values have color balance effects.
On the side of each new Developer Housing Assembly is a small white tag with a
bold-faced three-digit number printed near the bottom. The first digit is always
"0." The other digits range between 0 and 99. There is a tear off section of the tag
that should be placed on the chassis somewhere in plain view when the front door
is open.
To set the new values:
1. Enter Service Diagnostics.
2. Highlight Adjustments/Calibrations menu and press OK.
3. Highlight ATC Sensor Setup Test and press OK.
4. Note the current values for the tag numbers on the front panel display. They
should correspond to the tag numbers of the developers actually installed.
5. Select the color of the developer you installed.
6. Enter the tag number. You can only modify the lower two digits. Use the Back
and Info keys to select which digit you want to change. Use the Up and Down
keys to actually modify the digit.
7. Press OK to enter the data in engine NVRAM.
8. Press any button to abort the test.
Additional Information
For information on the following topics, see “Service Diagnostics Test Menu
Functions” on page 3-36

TRC Adjust - For Engineering Use Only

ADC Output Check - Check ADC Sensor Fail = 0

Tone Up/Down - Check ATC Sensor Fail = None

Laser Power Check

PWM Mapping - For Engineering Use Only
4-128 Phaser 7700 Color Laser Printer

 

[richdude]

Michael - WOW! That's the biggest TIP I've ever seen. No question that you have resolved my problem. The biggest problem that I usually have is knowing what truthfully can be handled by a savvy user, and what really requires a trained tech. I hate to have a tech come out and then find out that if I'd only done some relatively simple thing it would have handled it in 30 seconds.

Maybe you can answer this - why does it start up fine sometimes and then not start and give the error message? Seems it would either work or not...

If you can answer that, great. If not,thanks very much for the info.
Rich