Product

• Trendsetter 400/800 (TSM)
• Trendsetter Autoloader (TSM)
• Trendsetter NEWS (TSM)
• Trendsetter ContinuousLoad
• Trendsetter/Proofsetter Spectrum (TSM)
• Trendsetter Autoloader Spectrum
• Trendsetter ContinuousLoad Spectrum

Component

• Carriage firmware module (CRG)
• Carriage parameters in MCE NVS
• Carriage system hardware

Symptoms

Error message:
43308 CRG: Carriage travel limit (<xxx>) unexpectedly hit
<xxx> = home, away, none, or both

Cause

• Device CRG firmware module version out-of-date, contains bugs
• Carriage system hardware damaged or out-of-alignment

Solution

1. Record the following information:
   • Full text of error message
   • [If carriage has not moved since error #43308 was reported] Whether the carriage home or away limit sensors detect the carriage. Use command:
     carriage

     Example:
     
     MCE>> carriage
Current carriage status:
------------------------
Hdwr ver = 1.10
State    = 0
Position = invalid (not initialized)
Velocity = 0.000 (mm/sec)
Edge pos = 0.000 (mm)
Home lim = FALSE
Away lim = TRUE
NOT Initialized
No valid carriage plot params
*** Command Complete

     [RC | SE]
     If you wish, you can view more specific information about the carriage home and away limit sensors by using command:
     scan car
 
     Example:
     
     MCE>> scan car
Bit Name              State  Group      Bit Mask
CAR_&SensorAwaySide    1 b DI_Group0    00000400h
CAR_&SensorHomeSide    1 b DI_Group1    00000400h
CAR_SensorAwaySide    ~0   DI_Group3    00000001h
CAR_SensorHomeSide    ~1   DI_Group3    00000010h
*** Command Complete

     In the above example, the first two lines beginning with CAR_& display 1 in the State column, indicating the presence of the cables connected to the sensors. If the sensors had failed or were not connected, 0 would be displayed in the State column.
     The second two lines beginning with CAR_ display 0 under the State column for CAR_SensorAwaySide and 1 under the State column for CAR_SensorHomeSide, indicating that the carriage has blocked the home side limit sensor.
     For more information, see Interpreting Sensor I/O bit states.

2. [RC | SE]
   1. Check device CRG module version. Use commands:
      access dev
list version version
   2. If the version is CRG_V1.68 or greater skip to step 3.
      Otherwise, proceed to step c.
   3. Inspect the carriage table.
      Before entering any other carriage commands, display the carriage table using commands:
      access dev
carriage table
      
      The following is a sample of the output:

      >> carriage table
      Accel Repeat ...[Table 1]
      ---------------
      40 217938
      19 1
      Accel Repeat ...[Table 2]
      ---------------
      -19 1
      -40 217937
      0 1
      -40 4194304
      -18 1
      -22 1

      If the table output cannot be displayed, go to step d.
      If the output contains 4194304, the symptom was caused by a known bug in pre 1.68 carriage modules that occurs with carriage moveto <position>.
      It the output does not contain 4194304, skip to step 3.

   4. Inspect the device log file.
      Determine if the symptom occurred during plot setup or retrace—in other words, not while plotting or carriage initializing. If it did occur during plot setup or retrace, then it is likely the cause is the known bug in pre 1.68 carriage modules.
      Determine if the symptom occurred when the edge detect position was significantly different than for nearby symptom-free loads of the same media.
3. [UC]
   From Service Shell, run Version Checker.
   For Trendsetter NEWS, if CR level is 3.0 or lower then cause of this symptom could be a firmware bug.
4. [RC | SE]
   Inspect event (Statilyzer) logs for other errors that could be due to carriage performance. Specifically look for:
   • 38135 MPC: The media is positioned incorrectly along the drum
   • 38166 MPC: Carriage position is wrong - carriage has probably stalled
5. [RC | SE]
   Inspect the carriage NVS parameters. Correct any that are not set to the product defaults.
   Check to see if the carriage home and away sensors that were blocked (home, away, both) are still blocked. If it is not, the sensor or carriage tab may be damaged.
6. Initialize the carriage with command:
   carriage init
   Repeat the command if it fails the first time.
   If initialization is successful, you may proceed to step 7, but consider performing the actions in step 6 if time allows.
7. [SE | UC]
   Perform the following inspections/tests:
   1. Inspect/test the following:
      • Carriage position
      • Home/away sensors
      • Home/away sensor wiring
      • Carriage tabs
      • Carriage drive belt tension and condition (debris, tooth condition and fit on pulley)
      • Flex track
      • Carriage tracks
   2. If carriage is locked at one end, manually rotate the ball screw to free it.
   3. If parts are out of adjustment, adjust them.
   4. If parts are damaged, replace them.
   5. Initialize the carriage with command:
      carriage init
      Repeat the command if it fails the first time.
8. Test the function of the carriage subsystem.
   1. Run a loop test with command
      carriage moveto <position>
from near home (5) to near away (away-5) and back 100 times.
   2. Check to see if command
      carriage moveto 0
      is successful.
9. [RC | SE]
   If no cause has been found so far and the symptom is recurring, consider performing one of the following actions:
   • If not already done, apply FCO CA00752, carriage driver upgrade.
     OR
   • Initiate escalation process by contacting the Response Center. See the appropriate Escalation page for details.

Technical contact(s)

Doug Jeffery

Submitted by

Remy Dawson

Date submitted

08 Dec 2004