I turned my new Xerox Document Centre 490 STinto a paperweight, help!

[Guest]

I'm a Technology teacher, here in Plainview, and recently was GIVEN a xerox document centre 490 st. Being its way to big to use at home I decided to bring it to my school to use in my class and on my network for network scanning, printing the kids CAD drawings, etc.

Its 7 years old and has only 1,730,000 copies on it (w/ a 500,000 monthly duty cycle it has seen little use).

Here's the issue w/ a long story... when I got it, it copied just fine, but the network controller was not initializing ( I wanted the network abilities) a little research showed that it may be a power supply issue (how accurate this is I cant say).

So I opened it up to look at the power supply in the computer. (i've been in there before to clean toner out when I got the machine). I noticed that the 3vdc/5vdc OK status light was out, see PICTURE 7 and 12.

So I took out the SWMODULE card, PICTURES 4 and 5. You can also see it in place in PIC 7 and 12. As it had a "snaphat" battery I wanted to check it w/ a DMM. After taking it out I removed the battery, tested OK and then I put it back.

Now when I turn the machine on it does not work. It does its warm-up cycling of the trays and in a few minutes posts the message "communications problem encountered" and after that nothing else. PICTURES 1 and 3

I think I turned it into a giant door stop. The snaphat battery is plugged directly into an IC on the SWMODULE card, when I pulled the battery to test I guess I wiped the memory.

Since the machine is mine, not the schools, I'm on my own for the out-of-pocket cost of repair, which I'm hoping is not expensive. I'd rather not wheel it into the dumpster as it's a great resource for my class.

If you think this ailing patient can be fixed for not too much $$, let me know. Does anybody know a tech on Long Island that would pitty this fool.

Can I do the fix myself w/ PWS9.2, Service manual, Diagnostic software for repair copiers and printers, EUREKA bulletins, Firmware? I don't have these but welcome handouts!

Thanks for any help you can provide!

Doug
doug_olitsky@yahoo.com

[TzALbg]

Problem:


The machine will not boot up, and gives "dots of death" on the UI. In Diagnostics, the faults/counters display shows 10-706 faults in the history. If the machine is placed in the manufacturing mode, it will boot up, but as soon as it is placed in install complete, it will fail POST, and give the dots of death.


Cause:


A short or open in the IIOC bus 1 line will keep the machine from booting. The 10-706 fault is generated because the decurler is the first device that the machine looks for during POST. The following parts were replaced to attempt to resolve the problem:
W3A1 IIOC, W3A1 harness, Registration Clutch, Registration Transport, Developer Collector Bottle Sensor, Registration Sensor, Distribution PWB, and the LVPS.




The ROS/Developer cooling fan had a broken wire at the connection point on the fan. The wire was re-soldered to the fan, and the machine would boot up. *NOTE* The BSD did not indicate the fan connection to IIOC W3A1 (It was listed on the IIOC list of input/output connections, but was not shown on the wiring BSD).

[TzALbg]

Problem:


Machine comes on and reboots. When copy is run machine enters system is initialising. After which the machine comes up with dots of death. After half hour machine goes into dots of death. In dots of death machine does not communicate with the PWS. The LED on the Atlanta board beats very slowly. When machine POPO it does not come on normally. After one hour of machine shut down it comes on as before and does the same above process.

In initial condition before dot of death machine communicates with PWS and fault history shows 2-320 codes. During this we tried NVM reloading and initialising. Upgraded the machine to 7.19.5.522 successfully but machine still gives same problem. Altbooting the machine did not resolve the issue.

There is no 24v supply on the distribution when the machine is giving dot of deaths.

Tried replacing power supply, distribution pcb did not resolve the issue.



Cause:


Replacing the Atlanta board resolved the problem but after few days machine gave problem again. This time it was permanent dot of deaths and no communication with PWS.



Replaced a new Atlanta board and checked for PCB Cooling fan PL 9.1 item 3 . Found that the Fan would not start on its own and needed a push. this meant that the fan was working intermittently, due to which the Atlanta failed. Replaced the fan too!! and solved the problem.

[TzALbg]

Problem:


Machine will not come to a "Ready to Copy" state. The UI shows the Dots of Death and will log 03-813 faults. EDOC has you run IIOC test 1 and 2 and troubleshoot the 03-813 faults. The Xero Mod, Distribution Pwba, IIOC W8A3 and the Bus 0 Harness. None fixed the problem. All voltages were present on the LVPS


Cause:


The machine had a foriegn interface pwba attached to an Atlanta Gold Pwba. The Foriegn Interface Pwba appeared to bring down the Atlanta Pwba.


Solution:


Remove and replace the Foriegn Interface PWBA

[TzALbg]

Problem:


Dots of death if the front door is closed at Power On. With the front door open at Power On, I got a hardware configuration change, no HCF/Bypass or Finisher. Faults codes were the following: 14-325, 14-335, 5-331


Cause:


Ground clip came off in the DADF.


Solution:


Following the RAP, I replaced the DADF PWB, the DIST. PWB, IOT LVPS, Scanner Lamp, and Lamp PS PWB. At this point the RAP suggested the placement of the Main PWB, to which I said No!

I unplugged the DADF from the DIST. PWB and PO the machine. Now I had the HCF/Bypass and Finisher return. I reconnected the DADF to DIST. PWB and disconnected all the PJ's off the DADF PWB and plugged them in one at a time until the HCF/Bypass and Finisher disappeared.

The CVT Motor was failed. Replaced the CVT Motor and machine returned to normal function.

[TzALbg]

Problem:


Demo machine ( WCP 90 ) arrived ESS would boot and config sheet would print. Control panel would display dots of death and eventually the UI would display a communication fault. The PWS was able to communicate with the machine and access diagnostics. No faults were logged in diagnostics. After going through the RAPs for communication faults, checking for voltages, continuity checks and on and on. The documentation eventually leads to replacement of the main PWB and possibly The NVM module. At this point stop and check the machine configuration.


Cause:





Solution:


This Particular machine was in manufacturing mode, also in diagnostics in the System, Imaging, and IOT Configuration tab check the System tab to ensure that it indicates Install Complete and that the configuration is accurate. For example the Market Area, Machine Speed, Product Identifier etc. This machine's configuration was not accurate. Then exit diagnostics and reboot the machine. The UI should now come up normally.

[Doug Olitsky]

TzALbg

thanks for the infor on the work you did on your machine, should offer insight to the issues here.

Does anybody know what the SWMODULE board do, and what happens if its battery is removed?

Thanks

Doug

[TzALbg]

SWModule is non voltage memory , If battery is removed mashine forget all. NVM values goes to default position

[Milo Wilson]

490st

That is where the motherboard software is kept. When you upgrade the system board software, it is stored on that module.
When the battery is removed it goes to the default state.

[Milo Wilson]

490st

The problem you are having is when you removed the battery on the SWmodule you reset to initial level of Software.
If the machine had any upgrades to it during it's life then the ESS, Sys. board and UI board and not matched up on the same level of software.
That is the reason you are getting the "dots of death" on the screen.
The problem you initially started with was probably a bad ESS hard drive ( the network controller part of the 490st).
A full software reload and new ESS hard drive will probably fix your problems. If you would like a tech to do that you can call me and maybe work out a trip out to get it going, or just give me a call. 714-292-6912

Milo

[Doug Olitsky]

Hey Milo;

Thanks a bunch for the details on the swmodule and the hard drive.

gonna see what pans out on this end and if it fizzes out I'll drop you a line.


Doug