ColorQube 9200, 9300 Family Advanced Technical Training Manual

Jupiter
Advanced Technical Training
Revised: 04/07/2009 Table of Contents Xerox Internal Use Only

Contents
Power – Page 3
User Interface (UI) – Page 12
Run Control – Page 22
DADH – Page 37
Scanner – Page 49
Paper Supply & Paper Feed – Page 66
IME Paper Path – Page 105
Transfix – Page 140
Drum – Page 152
Abatement – Page 174
Ink Loader & Melt Plate Assembly – Page 181
Ink Reservoir and Delivery – Page 197
Print Heads – Page 214
Marking Unit PWBs – Page 243
IOD (Ink On Drum) – Page 255
Cleaning Unit – Page 274
Color & Image Quality – Page 298
Fax – Page 418
Finishers (LCSS (Low Capacity Stacker Stapler and HVF (High Volume Finisher) - Page 517
Machine Software – Page 641
Page 2 Table of Contents Xerox Internal Use Only

Power

Power On
When the power on switch is pushed this sequence starts:
1) The CBC (Common or Combined Board Controller) and the IME

Controller runs POST,
2) Only the IME Controller runs PEST
3) Mechanical Initialization
The IME Controller releases the CBC to initialize Scanner and Output
Devices
The IME Controller initializes it’s subsystems (Drum, Printheads etc.)

Print Engine Self Test also known as PEST
The CBC waits while the IME controller performs the PEST.
Look at the PEST codes in DC 123 to start your troubleshooting.
If the machine is down and never gives a PEST code then look at the POST
test blink code.

Power On Self Test also known as POST
The results of the POST test are a blink code that can be seen at the front
of the machine (IME Controller) or in the rear of the Media Path PWB, It is
not necessary to look at both of them since they have the same
information.

POST Test
If the machine has a short, the power supply will shut down all voltages
except the 3.3 Vdc. This voltage will light the POST test blink leds.
Go to the blink codes in OF 16 to further troubleshoot the machine.
The LEDs are bright when giving a code otherwise they are dim.
If there are no leds lit at all, check the AC power coming into the machine.
If AC is present then replace the LVPS.

Power Supply
The input for the PS can be 115VAC or 230 VAC.
The supply can run on 50 Hz or 60 Hz.
It is Energy Star Compliant
The PS runs at 20 Amps max at 115VAC
The PS runs at 10 amps max at 230 VAC.

Power Supply
The 3.3Vdc is always on when connected to AC.
The PS also generates the following DC voltages:

5, 12, -12v, 17, 24, 48, -48 and 410.

Power Supply Shorts
- Troubleshooting shorts can be done easily by looking at the green LED on
the Power Supply
- Turn off the power and turn on the power.
- Look at the green LED in photo below, it is the left most LED.
- If it turns on then off you have an overload.

Power Supply Shorts (continued)
JDC1, JDC3 and JDC4 can be unplugged one at a time to see where the
overload is.
Do not have more than one of them unplugged at the same time or you will get
a false short reading.
JDC 3
JDC 1
JDC 4

Jupiter
User Interface (UI)

Overview
User Interface (UI)
The User Interface (UI) allows the user to interface to the machine and
access functions such as copy, scan to email, fax…etc.

Overview
User Interface (UI)
The UI relies on the machine Copy Controller PWB for the following inputs:
− Power (12Vdc and 3.3Vdc)
− Initialization of and communication with the UI PWBA to accept

user input and to control UI module outputs.
− Graphics and text data is displayed directly on the UI module LCD

panel.

Overview
User Interface (UI)
The UI, when powered up and initialized will carry out the following tasks:
− Scan the keypad and LCD touch panel for user input.
− Power the LCD backlight.
− Allow the user to put the machine into sleep mode and wake the
machine up from sleep mode.

Power
3.3 Vdc
The UI PWB, LCD Module and LED Backlight are powered by the 3.3Vdc
supply from the CBC tray. In Sleep mode, the UI continues to monitor for
User Input so that the machine can be taken out of sleep mode.
12 Vdc
Supplied by Power Distribution PWB via the Copy Controller

UI Performance
The UI does not perform any processing of Image or Video. The processing,
manipulation and timing of the video signals and application software that
runs the UI resides on the Copy Controller.
The UI’s performance is constantly monitored by the Copy Controller.
The UI PWB performs the following tasks:

− Keyboard scanning
− Touch screen scanning
− Backlight control
− LCD ON/OFF
− Buzzer control
− Status LED control
− UI Wakeup Signal

Video Path to LCD
The Copy Controller generates the LCD video and timing . It transmits 3 data
channels and 1 clock of LVDS logic via a network cable. The UI PWBA converts
the LVDS frames into parallel CMOS data signals. These CMOS data signals
will be transmitted to the LCD module.
CBC module UI PWBA LCD
LVDS pair 1 n
LVDS pair 2 CMOS data lines
LVDS pair 3
LVDS clock

Backlight Control
The UI enables the LED backlight and Cold Cathode Fluorescent Lamp (CCFL)
backlight.
The LCD module CCFL backlight is driven by on the UI PWBA supplied by the
12V supply.
The LCD module LED backlight is driven by a Pulse Width Modulated signal
with a frequency of 100 to 1000Hz. 0% duty cycle on the PWM means the
LED backlight is off. 100% duty cycle means the LED backlight is at full
intensity.

Touch Screen
The display has a touch screen to enable the operator to interact with the
graphics and the soft buttons displayed on the LCD panel.
The UI provides the X,Y coordinate of the users touch point on the
touchpad to the Copy Controller, The X,Y coordinates are then interpreted
by embedded software resident to the UI Controller.
The Copy Controller supplies a soft button identification on the touchpad

providing user feedback.

Sleep Mode
The UI has it’s own sleep mode, in which the backlight is turned off. The
backlight is turned ‘On and ‘Off’ by receiving commands from the Copy
Controller. When the machine is in Sleep Mode, the power button on the UI
becomes illuminated.
In order to wake the rest of the machine up from Sleep mode, the UI needs
to generate a Power Management Event (PME) wake up signal if the
operator interacts with the machine while it is in Sleep mode. The PME
wake up signal is then sent to the Copy Controller.
While in Sleep Mode, we shut down various electronic sub-systems. To

maintain the LVPS’s ability to provide power to the FAX, UI and Network
Controller the UI utilizes a ‘Sleep Converter’ circuit. This is called the UI
Watchdog. The UI Watchdog is Software controlled.

Run Control / CBC (Copy Board
Controller) Tray

CBC Tray Main Components Locator
2 HDDs mounted on underside of tray

CBC Module part
number label
Network
Controller or
Power NC - used to
Distribution enable
Board (PDB) – network
used to distribute
connectivity.
power.
Copy Controller or CC – used to perform image processing and CBC Tray cooling fan
provide image video data to IME.

Power Distribution PWB (PDB)
Main Functions of PDB:
− Generate 3.3VDC from LVPS 24V (17V in Low Power mode)

− Provide remote voltage sensing of the 3.3V at Copy Controller and
compensate for voltage drops.
− Control power to the IIT (3.3V, 5V, 12V and 24V),via the IIT_Enable signal
from Copy Controller.
− Provide current limiting of the IIT power to prevent smoking harnesses in
event of a fault.
− Control power to the CBC cooling fan (controlled from Network Controller)
− Provide power to HDDs
− Provide power to Network Controller CPU cooling fan.

Power Distribution PWB Connectors
IIT comms from Copy Controller
(fed through PDB only) HDD Power x 2
Power &
comms to IIT Power from LVPS
Power to Copy Power to Network Controller

Controller

Copy Controller Low Voltage Generation
Copy Controller Distributions
Besides the 12V, 5V, 3.3V from the PDB, the

Copy Controller PWB has 5 on-board regulators
to provide core and various power required for
the PWBA

Copy Controller LED Locations
CR21
CR13 CR30
CR14 CR31
CR15 CR32
CR37
CR38
CR22
CR35
CR16
CR19
CR36
CR40 CR24
CR23
CR39 CR18
CR17

Copy Controller LEDs
LED Indicator On Off Our Lab Machine
(standby)
CR13 USB Host 2 Power Enable Power Enabled Power Disabled On
CR14 USB Host 1 Power Enable Power Enabled Power Disabled On
CR15 SATA Disk Active Disk Access No Disk Access Off
CR16 1.1V Regulator Status Failure Condition Good Off
CR21 8545 Checkstop Out Failure Condition Good Off
CR22 Turin II Configuration Done Not Configured Configured Off
CR23 3.3V Switched Present Power Present No Power On
CR24 3.3V Main Present Power Present No Power On
CR30 8545 GPIO – UBoot Heartbeat Active During UBoot Flashing (60hz)
CR31 8545 GPIO – Unused On
CR32 8545 GPIO – Unused Off
CR35 Clocks Enabled Clocks Disabled Clocks Enabled Off
CR36 Casper Configuration Done Not Configured Configured Off
CR39 SIM LED On
CR40 SIM LED Off

Copy Controller Connectors
PCI to Network Controller
USB
Ethernet Foreign Interface
PWB Connector
Video from
(PWB mounts on
Scanner
top of CC)
Video/power
To UI Power from PDB
SIMM Comms to IME
IIT Comms PCI to riser Serial SATA Video to

debug HDD IME

Copy Controller Key Components
SATA controller CPU & cooling fan 512MB DDR2 System memory
256Mb Flash
Mercury ASIC module
1GB EPC Battery backed

module NVM module
Aries FPGA Casper FPGA
LEDS CR23 &

24
Galileo ASIC Turin FPGA

Copy Controller
Key Components
MPC8545 – The MPC8545 is the heart of the Copy Controller PWBA running at
800Mhz core speed. It controls all image path ASICs through the PCI and its local
bus. The two PCI buses run at independent speeds. One of the PCI buses runs at
66Mhz while the other runs at 33Mhz. There is an internal logic that links the two
buses together inside the MPC8545. It also has a DDR2 controller designed for
200Mhz clock speed. This is a 64 bit un-buffered, un-registered memory.
Mercury ASIC – is a specialized image processor ASIC. All functions inside Mercury
are controlled via the 32-bit host PCI port. The PCI port is 32 bits wide and operates
at 66 MHz clock, and with 3.3V external signal levels. Mercury also contains the
necessary functions to configure and control up to two external PCI devices on the
VBUS port. Thus it has some features in common with a PCI-to-PCI bridge, however,
it is not intended for use as a general purpose PCI-to-PCI Bridge and does not
identify itself as one in the configuration class code field. The DDR controller inside
the Mercury ASIC is designed to interface to one or two un-buffered, unregistered,
DDR memory. There is one video input port and one video output port. The input
port is also known as the Front End Channel (FECH) which is five channels that can
be configured as C, Y, M, K, and BW color planes. The output port is also known as
the expansion port (EXP). The EXP port has 4 video outputs can be configured as
CYMK format.

Copy Controller
Key Components
Galileo ASIC – is the color Image Processing ASIC. It receives 10-bit or 8-bit
calibrated RGB video from a Scanner Interface device. Orion, which resides in the
Jupiter scanner, provides video and synching control to the Galileo ASIC. Galileo
provide a number of image processing functions such as color space
transformations, test pattern generator, JPEG compressions, and many others.
Odyssey ASIC – is designed to supply data to the Jupiter color IME. It supports up
to 90 pages per minute. There are some limited image processing capabilities such
as scaling, rendering and print jet compensation. Odyssey is able to handle input
CMYK planar or interleaved data. It will output LVDS serialized data to the IME as
specified in the Jupiter IME Specification. It will also support full and half panel,
mono and color LCDs for a UI, as well as Display UI.
SATA Controller – is an Intel 31244 that has four SATA channels running at
1.5Gb/s. It is configured to interface to a standard 32bit 66Mhz PCI bus.
System Memory – The MPC8545 will need 512 MB of memory for it processing
functions. The memory will be fixed on board and its sizes are not configurable.
This is DDR2 memory that runs at 200MHz clock speed.

Copy Controller
Key Components
EPC Memory – There will be one SO-DIMM socket for EPC memory. The
memory module can be obtained in various sizes. The base configuration
will be 256MB and can be configure up to 1GB. This will be DDR memory
with CL 2.5 Non registered, un-buffered memory with clock frequency of
133Mhz clock speed.
NVM – The NVM module will be based on the same design as the Patriot
NVM, which is a low cost design. The current Patriot NVM is designed with
512KB. The 3.3V will always be available to the PWBA, so this 3.3V will
supply power to the NVM and the battery back up is used for RTC.
Flash – The flash memory module is used to provide boot instruction for
the MPC8545. This module will be the same as the Patriot Flash module
that is 256Mb

Copy Controller
Key Components
Turin II FPGA – provide local bus for NVM, flash, Galileo, and FDI. Turin II
also is used to control power sequencing during the system sleep mode, and
IIT/IME UART communication.
USB Host – is an ISP1561 by Phillips, which is a 4 ports controller. There
will be no wakeup support when the system is in sleep mode. Three of the
four ports will bring out connectors. Two ports will connects to standard
USB host connectors (Stacked) and one will be routed to the XUI/DUI
connector to support XUI interface.
USB Target – is by PLX NET2280 that will be used for system SW upgrade
connects to the PWS. There will be no wakeup support when the system is
in sleep mode.
SIM – System Identification Module (SIM) is design to keep track of the
machine configuration (DC/MFD).

Optional PWBs
Optional PWBs in the CBC Tray are:
− Fax PWB – provides either single line or dual line fax capabilities
(monochrome only) – Please see Fax portion of this presentation for more
information.
− Riser PWB – provides mechanical and electrical interface between Fax

PWB and Copy Controller PWB.
− Foreign Interface PWB

CBC Tray Cooling
The CBC Tray is cooled by the CBC Tray Cooling Fan, which is located in the
rear of the tray behind the Network Controller PWB.
The fan receives +17VDC power from the Power Distribution PWB, and is
controlled by the Network Controller PWB.

DADH

DADH
Overview
Feeder
The DADH feed mechanism is a top friction feeder with semi-active retard
(TFRF). The feeder consists of an input gate, nudger roll, feed roll and a retard
roll. The nudger, feed and retard rolls are packaged as a Customer
Replaceable Unit (CRU) for easy replacement:
CRU Part numbers:

PL 5.15 Item # 1 - Approximate 150K yield
DADH Assembly:
PL 5.10 item # 9

DADH
Overview
Document Registration and Skew Control
Document lead edge registration for both simplex and duplex paths are
accomplished by a combination of the following methods:
– Document lead edge buckle at takeaway rolls (TAR) - By driving the
document with the feed roll assembly at a higher speed than the TAR
rolls, a buckle is formed. This allows the document lead edge to help
correct any skew that exists during this first stage of feeding.
– The side guides are the most important factor in the control of skew
within the DADH. They align the stack to the direction of feed and thus
remove skew before any documents are fed.
– There is no active skew control within the DADH unit. The right-hand
DADH hinge unit contains a mechanical adjuster that permits a small
shift in DADH to Scanner alignment for initial set-up.

DADH
Overview
Size Sensing
Document size sensing and selection is achieved by a combination of:
- Width sensing (cross-process direction)
- Static and active length detection (process direction).
- Customer selectable NVM settings.
- Mixed Length Mode selection by operator.

DADH
Overview
Document Width Sensing

Document width sensing is accomplished by means of a variable linear
potentiometer (05-325). The potentiometer slide is directly connected to one
of the two paper width guides.
The output signal from the potentiometer is converted into a physical

dimension of the paper guide from the paper path centerline. This sensing
method is sufficiently accurate to differentiate single width guide positions of
more than 4 mm.

DADH
Overview
Document Length Sensing
Static length detection is used to determine document length for most
document sizes and orientations. This is accomplished with two sensors (05-
315 & 05-320) located in the input tray, which are at appropriate distances
from the lead edge of the paper stack. The state of these two stack length
sensors, when documents are loaded in the input tray at start of a job will
determine the stack length range.
Active length detection is used to distinguish between 8.5 X 11 SEF and A5

(5.5 X 8.5) LEF. Discrimination between these two sizes is accomplished by
checking whether the feed sensor (05-330) is covered as the first document
passes the registration Sensor (05-340). An active “minimum length” check is
also included, and any sheet shorter than 110 mm (corresponding to the
longest distance between two successive nip rolls) will not be allowed to
proceed beyond the upper portion of the paper path.

DADH
Overview
Counterbalances
Two counterbalance (C/B) assemblies secure the document handler to the
scanner frame. They are the primary locators for the DADH to the scanner.
The C/B assemblies allow the DADH to pivot open and provide access for jam
clearance from the underside as well as make document glass copies directly
on the scanner.
In addition, the C/B assemblies are double-hinged to allow a customer to

close the DADH onto books of up to 25 mm in thickness without applying
excessive force to the document glass of the scanner. This feature is called
book-mode operation. The principle of the double hinge operation is further
used to accommodate tolerance build-up between any given DADH and
scanner assembly.

DADH Overview
Simplex Mode
In simplex mode only one side of a set of documents is scanned. The
documents are fed in 1-n order across the scan line and are sent to the catch
tray in the same 1-n order. Documents are placed face up in the input tray
and are delivered face down in the catch tray. Simplex feed is 51 PPM.
Duplex Mode
In duplex mode both sides of a set of documents is scanned. The documents
are fed in 1-n order across the scan line and are sent to the catch tray in the
same 1-n order. Before being sent to the catch tray, however, each document
is inverted in the exit area, and sent across the scan line again, before being
inverted one more time and across the scan line a third time, this time
without being scanned. Documents are placed face up in the input tray and
are delivered face down in the catch tray. Duplex feed is 23 PPM.

DADH Paper Path
S1 to S10
In-tray
Post- Nudger
Feed S5 Feed S4
TAR S6
Up-CVT Width
S10 S3
Length Length
Retard
S1 S2
CVT roll
Exit/Duplex
S8
Registration
S7

DADH Document Tray Capacity
Minimum Maximum Nominal Max Document Tray

Size Size Weight Weight Capacity
5.5x8.5 / A5 11x17 / A3 20lb / 75 gm² 32lb / 160gm² 100 Sheet (20lb)

DADH Top Problems
Problem:
When customers copy hole-punch originals, the copies show the holes
distinctly because the CVT roll is grey (59K58930). Shaded holes were not a
problem with white CVT rolls (59K50780) because the holes blended in.
Cause:
CVT roll color
Solution:
The White CVT Roll is currently spared

DADH Top Problems
Problem:
Skewed image through the DADH, Platen copies and internal prints are fine.
Skews are most noticeable when the customer uses Scan to File or Scan to
Email features
Cause:
− DADH width guide is not adjusted properly or it "walks" out of position
− DADH is not aligned to the scanner assembly
Solution:
− Install the DADH width guide stop PN: 655N243.
− Perform DADH skew adjustment 5.7

Scanner

Overview of Scanner
The scanner uses a full width array with a resolution of 600 dpi at 50 PPM
color.
The full width array is mounted on the scan carriage along with the two
exposure lamps.
In CVT mode, the scanner stays fixed and the document is moved past it.
In document glass mode the scan carriage moves beneath the document.

Document Glass
The document glass can accept documents up to 11 x 17 or A3 paper.
Registration is in right rear corner of the glass.
There is a scale on the right side and rear of the glass.

CVT Glass
The Constant Velocity Transport (CVT) glass is a separate glass to the left
of the document glass.
In DADH mode the scan carriage is under the CVT glass and the originals
are passed over the glass.
CVT Glass

Optical Path
Light from the exposure lamps on the scan carriage, is directed

through the document glass to illuminate the document.
Light from the document passes vertically downwards through the

document glass, through the Selfoc lens to the full width array.

Exposure
Exposure is accomplished by two lamps which consist of 30 banks of 5 LEDS
each.
They are mounted on the scan carriage.
The surface is shaped to diffuse the light from the LEDs and produce an
even intensity. They generate very little heat.
It is supplied with 24vdc via a ribbon cable from the scanner pwb. A second
ribbon cable takes the voltage from one lamp to the other.
Exposure LED Lamps

Exposure (continued)
No warm-up is required.
Calibration takes place at every platen scan and the start of every DADH
job.
Calibration changes when switching between color and mono modes.
Calibration function is contained in the Scanner pwb.
Selfoc lens is similar to Sorcery.

Scan Carriage
The scan carriage assembly is arranged to slide on front and rear
rails being controlled by scan cables driven by the scan motor. The scan
carriage has three upper skids that are held in contact with the lower
surface of the document glass by two spring loaded lower skids. This
arrangement gives a constant length of light path between the document
and the full width array.
Scanner Skids

Scan Carriage (continued)
Scan cables are connected to a capstan and routed around the periphery
of the scanner cavity by scan idler pulleys. The scan carriage is clamped to
these cables so that the rotation of the capstan causes the scan carriage to
translate to the left or right. The capstan is driven by the scan drive belt
which is connected to the scan motor. The scan motor power and control
comes from the scanner pwb.
Capstan

The Selfoc Lens
The Selfoc lens consists of 650 Selfoc rods of 0.5 mm diameter.
Each rod is set in to a resin-type material to form a ~/= 13” wide lens.
The lens sits above the full width array in the scan carriage.
Selfoc Lens

The Full Width Array
The full width array contains an array of twenty silicon detector chips
which are bonded to the full width array PWB.
Each detector chip contains 384 detectors of 43 microns diameter. The

total width of the array being ~/= 13” or 7680 pixels.
The silicon detectors convert the light levels reflected from the document
into analogue voltage levels.

Full Width Array (Continued)
Each silicon detector produces one pixel (picture element) of image

information.
Each pixel represents one spot of white grey black or color

corresponding to the image on the document.

Scanner Cable
A ribbon cable supplies power to the lamp from the scanner pwb.

Scanner Size Sensors
Two document size sensors are located in the base of the scanner.
The output of the sensors together with the edge position data from the
full width array sensors is used by the scanner pwb to send document size
information to the image processing pwb when in scanning mode.
The signal from the input module angle sensor is used to provide
timing information to the scanner pwb before the DADH if closed.

Image Processing
Digital image information from the scanner PWB passes to the Copy Controller
PWB. At the Copy Controller PWB, the image can be modified according to the
selections made by the user, such a reduction/enlargement, copy lighter/darker
or booklet mode.
The image is then sent to the Fax module, the network controller or the IOT for
processing or printing.
The Copy Controller PWB provides scanner control and processing of the
scanned image. Communications with the scanner components use an RS422
asynchronous serial interface in full duplex mode. The link is used to send
commands to the scanner to control actions such as a document glass or
scanner calibration.

Image Processing (continued)
The Copy Controller PWB has two DIMM slots. One slot is used for memory
expansion up to 256Mb and the other is occupied by the software NVM
module.
The Software module contains the operating software for the Scanner. The
Scanner NVM resides on the NVM PWB on the Copy Controller, which is
maintained by an integral battery.
Interfaces for the network controller, foreign devices are also provided

Shielded Cable
A shielded ribbon cable supplies the analog image data from the full width
array to the scanner pwb.

Paper Supply and
Paper Feed Information

Paper Feed Modules
MSI
(Tray 4)
PFP Tray 1 3TM

Tray 3
Tray 5 (Three Tray Module)
Tray 2
PFP slides away from IOT for

jam clearance

IOT Paper Path
Registration RaLPH
Tray 4 7 Array
(MSI) Transfix
Roll
Drum
Marking
Unit
Tray 5 Horizontal Transport
Tray 1
Tray 3
Tray 2

Paper Tray Capacities
Minimum Max Capacity

Tray Minimum Size Maximum Size
Weight Weight With 75gm² media
1 5.5x8.5 (A5) 11x17 (A3) 60gm² 216gm² 550
2 5.5x8.5 (A5) 11x17 (A3) 60gm² 216gm² 550
3 8.5x11 (A4) 8.5x11 (A4) 60gm² 216gm² 2100
4 (MSI) 5.5x8.5 (A5) 11x17 (A3) 60gm² 216 gm² 100
4000 (8.5x11/A4 LEF)

5 (PFP)* 8.5x11 (A4) 11x17 (A3) 60gm² 216gm²
2000 (8.5x14/11x17)
*Note: Optional PFP Kits will allow for 8.5x11 SEF/8.5x14 SEF and 11x17

Equivalent Weights of Paper
Jupiter Weight Range Specification

Paper Feed Basics
Trays 1/2/3 - (3 Tray Module)

3 Tray Module Components
Tray 1 Feed
Tray elevator
Motor
drive coupling
Tray 1
Feeder
Tray 2 Feed Tray size sensing
Motor switches
Tray 2
Feeder
Tray elevator
Tray size sensing
drive coupling
switch actuator
Rear of Tray

3 Tray Module Components
3TM Main PWB
Horizontal and Vertical

Transport Drive Motor
Stack Too High Sensor

Stack Height Sensor
Paper Feed Sensor
Paper Present Sensor Tray 1
Feed Roll
Tray 2
Nudger Roll
*Retard Roll under Feed Roll (not visible) Trays 1 and 2 Feeders

Paper Feed Basics
3 Tray Module
Tray 1 and 2 Elevation
The paper stack is raised to the feed head on a hinged paper lift plate.
When the tray is closed the drive coupling at the rear of the tray
engages with the gear train from the feed motor. The feed motor is
energized and drive is applied to the coupling through a one-way
clutch. The quadrant gear rotates and raises the paper lift plate.
Drive coupling
Quadrant Gear
Note: The feed motor rotates in one direction to feed paper and rotates
in the opposite direction to elevate the tray.

Paper Feed Basics
3 Tray Module
Tray 3 Elevation
Since the load capacity of Tray 3 is 4x that of the PFM tray, a dedicated and
independent elevator motor and gearbox is used. The paper stack is raised to
the feed head on a paper lift plate. When the tray is closed the drive coupling
at the rear of the tray engages with the drive dog on the elevator motor. The
elevator motor is energized and drive is applied to the coupling. The coupling
rotates and raises the paper lift plate via cables.
Tray 3 Home Tray 3 Tray 3 Elevator Elevator Drive Lift Tray 3 Home
Sensor Latch Motor Coupling Cables Sensor Actuator

Paper Feed Basics – 3 Tray Module
Stack Height
For all three trays, the elevator motor will run to lift the tray until the top of the
stack contacts and raises the nudger roll. At this point the Stack Height Sensor
will actuate and the feed/elevator motor will de-energize.
When the stack drops below an acceptable height the flag drops out of the
Stack Height Sensor, and the stack will be raised by a set amount. The distance
raised will be fixed for a given motor and is to be controlled by motor steps for
trays 1 and 2.
Trays 1 and 2 Indexing
Because the elevate and feed functions are shared between 1 stepper motor,
the elevate function MUST happen between feed cycles. A 2 sheet burst feed
mode, in which 2 sheets are fed in quick succession followed by an inter-
document gap is used. An elevate cycle can only happen in this space, since
the Inter Document Gap (IDG) between the 2 sheets in the burst feed is not
sufficient. Therefore, if the stack height sensor becomes made between
successive feeds, the elevate cycle must be delayed until the next full IDG.

Feeding Paper
The Semi Active Retard (SAR) paper feeders in trays 1, 2 and 3 use a
nudger, feed and semi active retard rollers. The feed rollers are driven by a
paper feed motor. Each tray uses it’s own feed motor.
When the control logic calls for paper to be fed from the tray the feed
motor is energized. The nudger rolls advance the top sheet into the nip and
the feed rolls feed paper from the tray.
If feed is not achieved in the expected time, a second feed attempt is

made. If is still not achieved after the second attempt, a 7X-101 fault is
declared.

Tray Empty Detection
A Tray empty condition is detected by a reflective sensor mounted in the
feeder frame which aligns with a hole in the elevate plate. When the last
sheet has left the tray the hole becomes exposed.
In the event of an out of paper condition in the middle of a 2 sheet burst feed,
the signal is raised and acknowledged by the controller as normal or out of
paper.
Paper Present
Sensor
Outboard (front) of feeder

3 Tray Module Size Sensing
Trays 1 and 2 Size Sensing
For trays 1 and 2, the detection of the media size is derived from the positions of the
tray side and end guides, which is determined by the length and width of the media
loaded. Movement of the guides causes movement of the size switch actuator on the
rear of the tray. The position of this actuator will cause the various combinations of
the 5 size switches. The software uses the combination of actuated size switches to
recognize one of 11 standard sizes. For custom media size that does not have a
determined 5 switch combination, the customer will be required to enter the length
and width dimensions as instructed by the UI.
Tray 3 Size Sensing
In tray 3 the detection of the media size will is determined by using an associated
NVM value. The customer is able to set the tray attributes via the UI, but will only be
able to choose between 8.5x11 LEF and A4 LEF. There are no size sensors used in
Tray 3.

3 Tray Module Size Sensing
Moving the rear and side guides in trays 1 and

2 will cause the movement of this size switch
actuator on the back of the tray.
The switch actuator on the back of the tray

actuates a combination of these size
switches on the rear frame of the machine.

Paper Feed Basics
Tray 4 – Multi Sheet Inserter (MSI)

Tray 4 - MSI
Size Sensing
The customer is required to set the media side guides to the edges of the stack to
enable accurate media width sensing. One side guide is also connected to a
potentiometer that provides the IME with a voltage indicating the width of the loaded
media. To give greater accuracy to the width sensing the guide connection will use the
full length of the potentiometer twice with a secondary sensor indicating whether the
slide is moving up or down the potentiometer length. If the customer does not correctly
adjust the guide, there is no alternative mechanism for sensing the media width in the
MSI. The width sensing will not allow for sensing custom sized media, but will allow
custom media width once entered by the user.
When the media present sensor is activated the width indicating sensors are polled.
Once stable readings have been achieved the IME software will indicate to the user via
the UI the most likely media size based on the output of the media width sensors and
the shortest corresponding media length. The user can override this media size
indication at the UI. The IME will continually monitor the width indicating sensors to
check for changes in media size.

Tray 4 - MSI
Size Sensing
Potentiometer
Side Guides
Underside of MSI Tray

Paper Feed Basics
Tray 4 - MSI
Feeding Paper
Once the media present sensor is made and the media size is confirmed
by the user, the feeding of the first sheet can begin. The nudger is
lowered onto the stack by reversing the stepper motor until the nudger
home sensor is made at which point the stepper motor is de-energized.
To feed media the stepper motor is driven forward which rotates the
nudger and the feed rolls. The media at the top of the stack is fed up the
ramp and into the feed nip. The SAR nip then feeds a single sheet to the
feed sensor.
The feed nip then feeds the sheet into nip E in the vertical paper path.
Nip E then feeds the sheet to timing sensor 16.
When the lead edge of the sheet has been seen at timing sensor 16 the
feed motor is de-energized and drive from nip E pulls the remainder of
the sheet through the SAR feed nip.

Tray 4 - MSI
Components
Registration Gate
To ensure that media stacks are correctly positioned in the MSI prior to feeding there is
a mechanism that provides a registration gate and the media present sensing. The
registration gate has an arm that hangs down from the MSI upper housing and
provides the sensor flag for the media present sensor. When no media is present, the
flag breaks the media present sensor indicating an empty tray. When media is pushed
against the arm it rotates about its pivot in the housing. This lifts the media present
flag out of the sensor indicating that media is present. This change in sensor state can
only occur when the stack is under the nudger. As the stack is pushed further into the
feeder a mechanical stop is provided by the reg. gate registering the lead edge of the
stack.
This stop is provided by a pivoting link mounted on the nudger mechanism with its own
hard stop. When the nudger is lowered to feed media the pivoting link is also lowered.
This removes the stop enabling the reg gate to be rotated by media when fed by the
nudger.

Paper Feed Basics
Tray 5 - PFP

Paper Feed Basics
Tray 5 - PFP
Feeding Paper
Tray 5 uses a Semi Active Retard (SAR) paper feeder that is very similar in function to the
feeder used in trays 1 and 2. The Tray 5 feeder uses a nudger, feed and semi active retard
rollers. The feed rollers are driven by a paper feed motor. The rolls used in Tray 5 are larger
in diameter, however, and have a unique part number.
Stack Height
When the PFP door is closed, the
Elevator Motor will energize to drive the
tray up. The Elevator motor continues to
drive up until the Nudger Roll lifts a flag
out of the Stack Height Sensor. When
the Stack Height Sensor actuates, the
Elevator Motor is de-energized and the
paper stack is at the correct height for
feeding. Stack Height Sensor

Paper Feed Basics
Tray 5 - PFP
Stack Height
Toothed track
A sensor mounted on the elevator motor
assembly counts the slots in a toothed track
and measures the amount of travel of the
paper tray. The machine software uses this Sensor
information to display how much paper is in
the tray. As paper is fed from the tray the
Stack Height Sensor will eventually
de-actuate. The Elevator Motor will then be
energized to lift the tray and maintain correct
stack height.
Elevator Motor

Paper Feed Basics
Tray 5 - PFP
Out of Paper
The Out of Paper Sensor is actuated when the last sheet is fed from the
tray. A message will appear on the UI and the tray will be driven to the
down position.
Tray 5 cut out for

Tray Down Sensor Out of Paper Sensor Out of Paper Sensor

Paper Feed Basics
Tray 5 - PFP
Tray Limit Switches

Tray Up and Down Limit Switches are used as a safety precaution in the
event that the Stack Height Sensor or the Tray Down Sensor do not
operate correctly.
Tray Up Limit Switch Tray Down Limit Switch

Actuator
Tray Up Limit Switch

Shown with tray cover removed

Tray 5 – PFP
PWB (Not used)
(Not used)
CR4 (SW Run)
Empty
(No PJ housing)
CR3 (24V)
CR1 (5V)
CR2 (not used)

Semi Active Retard Basics
A magnetic hysteresis type brake is located next to the retard roll. This
brake is loaded as drive from the feed roll is transferred to the retard roll
by the paper. This occurs when only one sheet is in the nip. The force of
drive from the feed roll overcomes the force of the brake, resulting in the
retard roll turning in the feed direction.
When more than one sheet is in the nip, the drive from the feed roll does
not transfer to the retard roll. Instead, the sheets slip and separate from
each other, and the force from the retard brake causes the retard roll to
stall or stop, retarding the excess sheet from feeding.
Nudger Nudger Feed

Feed
Retard Retard
With one sheet in the nip With more than one sheet in the nip

Paper Feed Basics
3 Tray Module Vertical Transport

Paper Feed Basics
Location
The vertical transport runs up the left-hand side of the machine.
Function
The Vertical Transport area has three functions:
− To provide paper transportation from trays 1, 2 and 3 to the IME interface

nip.
− Allow access for jam clearance on that lower side of the machine.
− Provide a Take away roll nip to take the sheet from the feeders in tray 1
and 2.

Paper Feed Basics
Components
The vertical Transport as an assembly consists of these main elements:
− A rear-hinged door with front latch handle
− Spring loaded idler rolls
− Drive rolls
− Paper path sensors
− Interlock sensor
− Harness
− Covers
− Shared drive system (receives drive from the Horizontal / Vertical Drive Motor)
The drive rolls are mounted to the main frame of the 3 Tray Module, while the
spring loaded idlers are mounted within the door. When the door latches shut the
required nip will be made at the correct load. Two reflective sensors are mounted
in the door, 1 above each Takeaway roll shaft. These are used for paper path
timing and also for paper path jam detection.

Paper Feed Basics
Tray 1 takeaway Rolls
Paper Path Sensors
Tray 2 Takeaway Rolls

Paper Feed Basics
3 Tray Module Horizontal Transport

Paper Feed Basics
Location
The 3 Tray Module Horizontal Transport is located just above Tray 1.
Purpose
The purpose of horizontal transport is to transport A4 / 8.5x11” LEF paper from tray 3 (
HCF), across the top of trays 1 and 2 into the vertical transport.
Components
The 3 Tray Module Horizontal Transport consists of:
• Three sets of drive nips
• Lower guide
• Pivoting top guide to allow for jam clearance
• Independent slide features to allow whole sub assembly to be pulled forward
out of the machine for Jam clearance
• Two paper path Sensors
• Home sensor
• Shared drive system (receives drive from the 3 TM Horizontal / 3 TM Vertical
Drive Motor)

Paper Feed Basics
HT Paper Path Sensors
HT Drive
Coupling
HT Drive
Belts
All horizontal transport nips are driven by means of a toothed belt.

Interface to the drive motor is through a drive dog.
In the event of a paper path jam outside of the 3 TM, this section of
paper path is monitored by the controller to ensure that sheets are
not stopped across sub-system interfaces. The park position of sheets
within the HT should not result in torn sheets, when drawers and
trays are pulled out.

General Information
Incorrect media description in the UI can cause jamming in the transfix

area. This is because transfix load timing can vary for different weights of
media.
Heavy or glossy media can affect output PPM during multiple copy runs.
Paper trays will attempt 2 feed cycles to feed a sheet of paper. A delay in
feeding can mean that 1 image is placed on the drum rather than 2.
Tray 1 and Tray 2 harnesses may be swapped to aid in diagnosing feed

head problems.

Paper Feed Basics
Vertical Paper Path

Paper Feed Basics
Vertical Paper Path
Components
The Vertical Paper Path consists of these main elements:
− Upper door with front latch handle and Bypass Tray
− Mid Door
− Spring loaded idler rolls
− Drive rolls
− Paper Path Sensors #5 and #16
− Interlock sensor interaction
− Covers
− Vertical Transport Drive Motor
− Nip D Solenoid
The drive rolls are mounted to the main frame of the Vertical Paper Path, while
the spring loaded idlers are mounted within the doors. When the doors latch shut
the required nip will be made at the correct load.

Paper Feed Basics
Vertical Paper Path Components (inside view)
NIP D Roller
Motor M2
Drive Gears/Belts
Nip E Roller (rear view)
Paper Path
Nip F Roller Sensor 16
Paper Path
Sensor 5
Nip H Roller

Paper Feed Basics
Vertical Paper Path
Nip D Solenoid
When 14” or longer paper is fed, Nip D retracts from the trail edge of the paper,
relieving idler roller pressure. This allows the paper to move freely when the lead
edge enters the RaLPH, and registration movement is done.
The Vertical Transport Drive Motor (M2) and Nip D Solenoid are controlled through
the Media Path PWB. Both operate on 50 V dc.
The motor M2 reverses in duplex operation. Two 8.5 x 11 LEF, or one 8.5 x 11 SEF (or
longer) sheets can enter the Vertical Paper Path from the Horizontal Paper Path
during duplexing.

Useful Diagnostic Routines
dC113 – Fast Time to Ready. This allows blank paper to be run prior to fully
warming ink heaters. Useful to test paper feeding without waiting for full
warm-up and purging. This routine requires a machine reset or power
off/power on to disable it.
dC715 Active Registration Control. This routine allows Active Registration

Control to be disabled. Use to test paper feed or skew problems which occur
before paper enters the RALPH. Disable this routine after done, or power
off/power on to reset (re-enable) Active Registration Control.
See General Procedures section of EDOC for instructions for these routines.

IME Paper Path

IME Paper Path
Horizontal Transport
Registration Pre-Heat
Assembly Exit Paper
Path
Assembly
Transfix Roll
Stripper Area

IME Paper Path Sensors

The Horizontal Transport

contains 2 sensors and
two solenoids. The Duplex
End Sensor and the
Duplex Sensor (see next
slide). It also contains the
Diverter Gate Solenoid
and the Nip C Solenoid.
Nip C Solenoid
Diverter Gate
Solenoid

Duplex Sensor
Duplex End Sensor

The Horizontal Transport drive motor – M6 is a

servo motor. This motor drives Nips C, R and Q
via a 90 tooth gear and two 108 tooth drive
belts.
Duplex End Sensor (reflective sensor)
When a sheet is fed from the vertical transport
this sensor detects the leading edge. Nip C is
now rotating in a forward direction to transport
the sheet for first side marking. When the sheet
returns via Nip C for second side marking this
sensor detects the leading edge (Nip C is now
rotating in reverse) until the sensor detects the
trailing edge when Nip C changes direction to
the forward direction to print the second side.

Nip C:
Driven by M6 can be opened by the Nip C solenoid. To allow the sheet to
be driven by Nip A in the registration/preheat assembly.
Diverter Solenoid:
Actuates to allow sheets to return from the duplex area to Nip C, rotating in
reverse. It deactuates to allow sheets to return to the drum with Nip C
rotating forwards.
Duplex Sensor (Reflective):
Monitors leading and trailing edges of sheets returning along the horizontal
transport.
Nip R and Nip Q:
These Nips provide drive to sheets returning along the horizontal transport.
Heat Shield:
A hinged plate that provides thermal protection to the rollers from the heat
of the registration/preheat assembly and the drum.

Registration/Preheat Assembly (RalPH)
Monitors paper with two sensors. The Registration Scan Sensor which is
made in the same way as the light bar in Ink On Drum Assembly. It is not
possible to check with dC330. The second sensor is the Pre Transfix Sensor
(S20) which can be checked in dC330.
The registration/preheat assembly takes paper from the horizontal
transport and delivers it to the drum/transfix roll.
Depending on the size of the stock being fed it uses one set of three idler
rolls (2) to drive paper.
It is also equipped with a pre-heater to preheat the paper and 2 air pumps
help media go through the Registration/Preheat Assembly.

Post Fix Transport
The next area that paper travels through (after it clears the Drum/Transfix
Nip) is the Post Transfix Transport.
Post transfix transport motor M4 – this is a stepper motor located at the
rear of the post transfix transport. It turns in the forward direction to power
Nips J and L through a chain of gears. In reverse it turns the eccentrics that
slide home the stripper latching mechanism.
Post transfix sensor 11 – is the first sensor to detect the sheet stripped from
the drum.
Nip J – transports the sheet to the pre exit sensor 12 and Nip L.
Pre-exit sensor 12 – this is a reflective sensor located just before Nip L.
Nip L – last Nip in the post fix transport.

Exit Transport
The output transport contains the

following components:
Exit sensor 15 – a reflective sensor
which detects sheets fed from either
Nip P or Nip L to Nip N.
Duplex Sensor 13 – a reflective sensor
for second side marking, also detects
the trailing edge of those sheets being
inverted before being fed to the
finishing device.

Exit Transport
Nip P:
Used to feed sheets back for second side marking also works in conjunction
with the output diverters in performing the final inversion of tabs or duplex
drilled or preprinted sheets.
Nip N:
The exit nip feeding sheets to the finishing device.
The output diverter solenoid.?????
The output transport motor M5. A stepper motor which drives Nip N and Nip
P via two gears and 2 toothed belts.
Jam clearance LED, Two LED boards the provide 4 LEDs to assist in the jam
clearance process.

Exit Transport
Diverter Solenoid

Exit Transport
The last part contained in

the exit transport is the
attachment point for the
ESD Antenna.
ESD hits are recorded in 92-
527 and 92-528
ESD Antenna

IME Paper Path
RaLPH

RalPH
Gears to open RalPH for jam Gears to load idlers and move
clearance – activate via one- CIS (Contact Image Sense) Stance sensor flag. driven
Scan Bar Assembly
way clutch when front drive through one-way clutch when
roll is reversed. Paper Entrance drive roll is reversed
Stance gear and stance sensor (on IF PWBA)
Front
Air Pumps (2)
Throughput exits to Transfix Area

RalPH Function (1 of 2)
The function of the RalPH (Registration and long Pre – Heater) is to:
Monitor the LE of throughput and report its lateral position, print process
direction position and the amount of skew
Drive the throughput by activating specific drive roll stances to properly de-
skew and register the paper (skew and image registration).
Heat the throughput material in preparation for image transfer during

transfix.
Provide paper path sensors for timing functions using Contact Image Sense
(CIS) Scan Bar and S20.

RalPH Function (2 of 2)
Load the proper drive roll idlers based on incoming throughput width to de-
skew and register the throughput
Provides a jam clearance area by opening the RalPH automatically in jam

conditions (LEDs on the Horizontal Paper Path will illuminate as well)
Automatically opens the RalPH @ jam and closes the RalPH after the jam is
cleared and the front door interlock is closed.
Provides Drum Thermal Cutout protection (see figure 2 on next slide)

RalPH Components
The steering shafts are spared (PL 88.11 item 5) and easily replaced.
Air pump motors are also spared (PL 88.10 item 5).
CIS Scan Bar opening at an angle to LE of paper
Steering Shafts Front

Rear Drive
Drive Motor
Motor
Separate drive motors for steering rolls under this plate
DRUM Thermal Cutouts PWBA

Figure 2 – Bottom View

Location and Removal / Electrical Connections
Location and removal:

The RalPH is directly above and to the left of the drum. It is held by one
screw at the front. Removal of the RalPH is accomplished by first removing
the inner front panel, the horizontal transport, 4 electrical connections (1
AC and 3 DC), and then the RalPH.
Electrical Connections:
There are AC (1) and DC (3) electrical connectors that go to the RalPH.
These are accessed from the front of the machine. Ground is provided by
the screw at the front of the RalPH and by a hard wire to the rear frame
which goes to the AC connector. The DC connections are on the RalPH IF
(interface) PWBA. The AC connector is above and to the right of the RalPH
IF PWBA as is the remaining DC connector.

RalPH Principle of Operation (1 of 4)
Registration:
In many center registered products, registration is achieved by forcing the
throughput into stationary rollers, then accelerating the paper to the image. If skew
was removed then the throughput has probably also moved inboard or outboard of
center. So even though Lead Edge registration is good, the top to bottom (inboard
to outboard) may be off.
To help eliminate this problem, the RalPH reads the skew and position of the
throughput by utilizing a scan bar which is the same type scan bar that would be
found in an A size (8.5”) scanner. This is also the identical scan bar to the IOD (Ink
On Drum) scan bar which is covered in the IOD section.
This scan bar information is then used to determine how to get the paper de-skewed
and orientated correctly from inboard to outboard and set the lead edge margin
process position. This is generally accomplished by intentionally skewing the paper
twice. The sum of the two actions causes the throughput to be both aligned
inboard to outboard and the lead edge to be de-skewed. The movement of the
paper through the RalPH is called ‘WAG’ because of these unusual movements.

This intentional ‘skewing’ of the paper is accomplished by the steering rolls.

These shafts align with one another but are separate and are driven by
separate stepper motors.
Depending upon the width of the throughput, various idlers will be engaged
to provide drive to the paper. This is accomplished with the rear drive
motor by running in reverse which actuates a one- way clutch on the rear
gear train.
The knob on the front of the RalPH is marked with dots indicating the
present operating position. If there is no dot in alignment with the
rectangular slot in the sheet metal ground plane – the RalPH is in the ready
to open position.

Position 1 (one dot) = wide stance (loaded outer roller only) –approx media range
273mm to 320mm Roller Spacing (at centerline) = 250mm
Medias at Position 1 = LEF A, LEF A4, Tabloid (11 X17), A3, SRA3, Tabloid Extra, etc.
Position 2 (two dots) = narrow stance (inner/narrow roller loaded) - approx media
range 104mm to 203mm Roller Spacing (at centerline) = 76mm
Medias at Position 2 = Statement, A5, #10 envelope, DL envelope, Executive, B5, C5
Envelope, 6X9 Envelope
Position 3 (three dots) = medium stance (medium roller loaded) - approx media
range 204mm to 272mm Roller Spacing (at centerline) = 181mm
Medias at Position 3 = Legal, Folio, SEF A, SEF A4, B4, 9X12 Envelope, C4 Envelope
Position 4 (zero dots) = hatch unlocked (no rollers in contact) Opened via motor or
manually.

To assist the RalPH in making these rapid movements of paper, there is an

air system which reduces friction on the throughput while helping to hold
the throughput in contact with the heated lower plate. Air from two air
pumps (wired in parallel) is fed to the center of the eight upper platelets.
Four upstream platelets are fed by one air pump and four downstream
platelets are fed via the other pump.
This air helps to force the throughput down while ‘floating’ the platelets,
thereby allowing easy movement of the throughput. Loss of this air system
may cause smearing on duplex, poor lead edge registration, image quality
issues due to poor heating of the throughput and / or skewing of the
throughput.
Air pumps are turned on just before the paper enters the RalPH and turned
off soon after the paper exits the RalPH.

Heating of the Throughput
In order to assure a good transfer of image from the drum to the

throughput and to assure a good bond of the ink with the throughput, the
throughput needs to be pre-heated. This is accomplished by a large surface
heater adhered to the bottom of the lower paper path plate of the RalPH.
Air pressure forces the paper to contact the heated lower metal plate.
A loss of air pressure to the platelets will probably not result in jams but
may contribute to lead edge mis-registration. Often the first indication of
an air pressure failure is missing pixels on side two of two sided throughput.
This is mainly caused by insufficient heat since the paper is not being held
fully against the heated plate.

Jam Clearance
If the machine jams and paper is in the RalPH, the inboard paper path drive motor
will run in reverse activating a one-way clutch to the rear gear train which unloads
the idler rollers and unlocks the jam hatch. The ‘0’ dot position on the round handle
indicates the RaLPH is unlocked and ready for opening.
The outboard motor will then run in reverse for a designated amount of time to
open the RalPH and to position the heat shield (which hangs from the bottom of the
horizontal paper path) in the open position. The jam clear opening of the RaLPH is
assisted by the opening of the heat shield which is powered by the horizontal paper
transport.
The motor then maintains this open position. Once that is done, two LEDs on the
bottom of the heat shield will be illuminated to help in jam clearance. To close the
RalPH – the front motor will run very slowly in the forward direction to lower the
RalPH.
Jams may occur in the RalPH if the Scan Bar senses there is more skew or lateral
movement than the RalPH can remove – which would mean some image might be
left on the drum and / or transfix roller.

Drum Thermal Cutout
AC to the Drum heater runs thru the Thermal Cutouts on the RalPH thermal
cutout PWBA (seen in Figure 2. If the Drum goes into a thermal runaway –
the thermal cutouts on this PWBA would open (@ ~ 108 C) and remove AC
from the Drum heaters.

Cleaning
From time to time throughput that has an image on it from the first side,
may jam in the RalPH and may contaminate the heated RalPH plates or the
RalPH may become contaminated in other ways. To clean the RalPH of
contamination, a cleaning routine may automatically run or may be called
from diagnostics.
First the machine checks for A size LEF paper, then turns the temperature of
the RalPH plates from ~61 degrees C (~140F) to ~ 85 degrees C (~ 180F).
10 sheets of LEF A paper is slowly fed through the RaLPH and wagged back
and forth to remove ink from the platelets. The machine will then run 10 to
20 sheets in burst mode. This is done to more rapidly cool the RALPH to
<65 degrees C and enabling the machine to continue running jobs. An
alternative method may be to run chase sheets until the RalPH plates cool
to less than 65 degrees C.
Ink Melt temperature is ~100C (212F), so ink on the RalPH plates is not
melted but is ‘softened’ to where it will tend to stick to the passing ‘chase’
sheets.

A4 / Letter Size Paper
RalPH Calibration
Media Edge
‘Inked Edge’ detected as a
detected a
light to dark transition
light to dark
during Calibration Scan #1
during
Calibration
Scan #2
Side #1 is
Dark output
registered to
adjustment for the
these edges
‘Inked Edge’ is
determined by
scanning this black
block.
Print
Direction
(1st side)
Cal Scan
Direction
(2nd
Side)

Calibration
RalPH Calibration: (When to calibrate)

1. As necessary, can be called from the UI Diagnostics
2. Whenever RalPH is replaced.
3. Whenever RalPH is removed and reinstalled.
4. Whenever Horizontal Paper Path is removed or replaced
5. Whenever IOD is removed or replaced.
6. Whenever a Print Head is replaced (especially PH # 3)
RaLPH calibration runs 30 A sized prints, 10 for each of the drive roll
stances, in order to calibrate the media position for image placement.
Aborting a calibration sequence due to jam/oop (out of paper) is no big
deal, since it can be re-started right away. However, if a cleaning cycle
is aborted, then no cooling sheets will be run, and you will have to wait
some time to let the preheater drop below 65 C before anything can be
done.

Calibration
RalPH Calibration Steps: (runs 30 A size prints)

Prerequisites:
• IOD calibration and ‘Y’ runout calibration.
• Print heads are aligned (no obvious stitch errors or missing jets)
• No missing black jets (can use jet sub)
• An image is placed on A size throughput Sheet is fed back to the RalPH
via the duplex paper path
Image is read by the CIS Scan Bar
• The large black square is used to ‘calibrate’ the Scan bar to dark output
• The ‘L’ shaped image is used to read the front to rear and lead edge
alignment in relationship to the throughput media edges
Adjustment is made after 30 scans are analyzed
CSE has no input to this process.

Data Line Shielding
The RalPH Scan bar is sensitive to electrical noise. This noise may cause a
misregistered output. To help eliminate this, an electrical noise shield is
placed over the ribbon cable from the CIS Scan Bar. It is important to
ensure this ribbon cable is properly inserted into both Interface PWB and
CIS. Careful attention not to unseat the ribbon cable during removal and
installation is advised.

Potential Field Failures and Symptom (1 of 3)
Failure Result / Symptom
RalPH pump failure This may result in smearing of images, skew and poor
registration (mainly Lead edge). Motors are in parallel.
When running, you can feel the motor vibrate with your
finger but may not be able to tell otherwise in diagnostics.
May cause a buildup of ink at the platelet edges as well.
ESD RalPH may read ESD hits as skew and over compensate.
Shielding is being added to help avoid this failure mode
RalPH removed and / RalPH Calibration routine needs to be run.

or replaced

Contamination (jam In cases of contamination (melted ink) – a routine can be run

on side two in the manually to increase RalPH plate temperature and then run
RalPH or other chase sheets (blanks) – this generally cleans most or all of
contamination) the debris. If not the RalPH will need to be removed and
cleaned or replaced.
Pre-heater temp low PQ dropout and durability – low temperature should not
happen without a fault being called to direct the CSE to the
root cause.
Pre- heater temp high Cohesive failure in simplex or duplex smear or transfix roll
offsetting– high temperature should not happen without a
fault being called to direct the CSE to the root cause
Skew on side 2 Excessive show thru of a solid image on side 1 can
conceivably affect the registration on side 2

Scan bar failure Fault tolerance should hide this until the next service call
Sensor S20 Failure Fault code should lead to root causal.
Steering shaft rolls not May lead to wandering lead edge issues.
round
Clean for Ink Smears Cleaning cycle offsets paper +/- 5MM. That is enough for A
to cover A4 image areas but not enough for SRA3 – but
that cannot be duplexed so shouldn’t be an issue.

Troubleshooting Tips
Air pump motors have a slight vibration when running, feeling the motor as
it starts, stops and runs may be the best way to determine the motor is on
since air pressure is slight. (Use diagnostics Component Control to test)
NOTE: Scan Bar is mounted at approximately twice the maximum

allowable Skew. Large amounts of skew can be removed but there are
limitations.
Black Cal. varies with time and temperature so must be rechecked during
the RalPH Calibration routine.

Transfix

Function and Components
Function:
Force the image onto the throughput material
Maintain correct pressure for throughput selected via Network or UI
Transfix Motors
Compound
Gear
Transfix
Roller
Front Flexure Assembly
Front Flexure Encoder

Transfix Assembly
Components: (PL 10.20)

Transfix Motor (front and rear motors are the same part number)
Transfix Stripper blade assembly
Transfix Encoders (front and rear encoders are the same part number)
Rear Transfix linkage assembly
Front Transfix linkage assembly
Front and Rear linkages are NOT interchangeable.
Compound transfix gear (same part number front and rear)
Transfix roller
Front Transfix encoder cover

Location, Removals and Electrical
Location and Removal:
The transfix mechanisms are located at the front and rear of the engine
block assembly.
Each flexure has a calibration value from the vendor. This value cannot be
determined in the field except by the label on the front engine block frame
or on the label shipped with the new flexure assembly. This value is placed
into NVM and if it is substantially incorrect, Image Quality will be degraded
and a fault may also be declared. Expected values presently range from
2000 to 2600 Newton meters.
A fault or service code may be declared.
Electrical connections to the Transfix motors go to the Drum Driver PWBA
as do the transfix encoders.

Theory of Operation
When transfix is required, both the front and rear transfix stepper motors
are energized and the mechanism is driven at the front and rear until the
appropriate flexure assembly flexes enough to make the appropriate
flexure encoder (either front or rear) read the preset expected value for the
selected throughput. Drive is then held by the motors at ~ 900 lbs. per
square inch, until the trailing edge of the throughput is present. At that
time transfix returns to the unloaded position. This varies somewhat in
some modes of operation.
The transfix roller generally does not contact the drum. The roller lands on
the leading edge of the throughput and is raised just before the trailing
edge of the throughput.
NOTE: One exception to this is transfix in burst mode on the duplex side. In
that case the transfix roller stays in contact with the throughput.

Modes of Operation
Roll-off
Initiated to even out the distribution of release oil on the transfix roller to
prevent stripes from transferring to the back of duplex prints which can
cause ghosting artifacts on the second side printed. The trail edge is rolled
off of simplex pages by a length determined by a firmware variable and
then lift the transfix roller while the drum is still moving.
Stop Edge
Drum and media stop. Transfix loads ~ 4.3 mm past the LE. Drum velocity
ramps up to 40 inches per second (ips). At the end of image, the transfix
force is reduced and the drum velocity ramps up. Roll off is now
implemented. The transfix roller is lifted after the trail edge of the second
sheet. The roll off distance is variable. Now it is 180 mm. The drum velocity
when the transfix roller is disengaged is also a variable.

TOF – Transfix on the Fly
As the rendezvous of paper and drum approaches, the drum is slowed to 30

ips (inches per second). A low initial transfix loading against the drum
occurs just prior to climbing the lead edge of the first sheet. When climbing
the lead edge, the normal transfix load setting is applied. Because of this, if
the media is thicker than anticipated, the drum/transfix may stall. For this
reason it is important that the operator properly identify throughput
material.
Transfix on the fly refers to rolling onto the leading edge of the page. This
is required to ensure that the roller is stopped (since it was still spinning
from the previous sheet's roll-off move) prior to touching the next page
(because a spinning roller would disrupt the margins on a page it touches
down on the throughput).
The transfix roll never touches the oiled drum during duplex printing.

Burst Mode
Copy mode in which two letter or A4 images are on the drum at the same
time – so minimum time to retract / re-engage the Drum stripper and
Transfix roller.
Burst mode is implemented when printing enough sequential pages to

queue them up two pitch (two A/A4 images side by side on the drum) after
measuring the thickness of the first sheet if necessary (after a paper tray is
refilled) and before stopping and lifting the roller at the trailing edge of the
last sheet (or sheets based on a firmware variable). In this mode we roll
onto the leading edge of the first pitch, roll across the gap between pages,
and roll off of the trailing edge of the second pitch (adjusting the transfix
force at each transition).

Transfix Facts
Transfix has a ground at the front bearing retainer. If this ground is not
reattached during removal or replacement you may experience ESD hits to
the communications line. Remember to reinstall all grounds during service
in this or any other area of the machine.
The transfix roll is not driven. It receives its movement from the contact
with the Drum surface or paper.
Transfix pressure is ~ 900 lbs. per square inch (~850lbs / sq. inch is the lower
functional limit whereas ~ 950 lbs / sq. inch is the upper functional limit).

Transfix
Stripper Blade
Transfix Stripper Blade:

The Transfix stripper blade is Mylar and is always in contact with the
transfix roller. Its function is to keep paper from wrapping around the
transfix roller.
Main need for the transfix blade is light weight media and low area
coverage.

Potential Field Problems
Problem: Cause: Solution:

Paper Debris seen on Protective coating for the Remove the protective
output copies Transfix blade was not coating (clear plastic) then
removed in manufacturing reinstall the transfix blade.
prior to install.
Machine Resets May be caused by a Repair the wiring and / or
intermittently frayed wire on the rear replace the transfix
transfix encoder and less encoder. Problem is
commonly the front assumed to be fixed post
transfix encoder. 01/2009

Drum Stripper Blade
Just beyond the transfix point there is a stripper blade, which strips the lead
edge of the sheet from the drum. If a sheet is not successfully stripped, it
can wrap around the drum and collide with the print heads, which are
mounted very close to the drum.
This can cause blocked jets due to the transfer of paper fibers to the print
heads. Damage to the print heads is very undesirable because this would
cause a service call and they are expensive to replace.
!!!CAUTION!!!
Do not clean the drum stripper blade. The drum stripper blade is very
sharp and can cause severe injury. If the drum stripper blade is dirty a
new drum stripper blade must be installed.

Drum

CAD Representation
Drum Cooling Fan
Rear of
Machine
Rear Coils (4)
Front Coils (4)
Drum Encoder
Thermistors
FRONT
Heater Wiring

Functions and Components
The function of the drum is to hold the image prior to image being transfixed
The function of Drum Thermals is to:
− Bring the drum surface to the correct operating temperature
− Warm up from ~22.5C (~70F) to 55.5C (~ 132F) ( +/- 2 degrees C) takes ~ 7
minutes. Drum temperature is critical to Print Quality.
− Maintain the drum surface at the correct operating temperature. Requires
not only heating coils but a fan since the drum can absorb heat from applied
ink. High area coverage jobs may mean heater is off during printing or cycles
less.
Drum Area Components: (PL94.20)

Drum Assembly (includes heating elements which are not field replaceable)
Encoder Assembly , Drum Drive belt, Drum Drive Motor, Front and Rear
Thermistor

Drum Thermal
Theory of Operation (1 of 3)
Drum Thermals Operation:

The drum heater has two independent sections (front & rear), each section
has four heating coils wrapped externally over glass rods. These are
configured either in series (4 in series) or parallel (2 in series) depending on
input voltage. To go from room temperature to operating temperature
takes approximately 7 minutes. Since the ink reservoir takes ~16 minutes,
the drum is not the limiting time to warm-up factor.
If the line voltage is below 180V then the coils are run in parallel (the front
four rods in series as are the rear and these two series of four are then
placed in parallel with each other). If voltage is >180V then all eight coils
are placed in series. The reason is to keep the current through the coils at
about the same level independent of operating voltage.
This configuration of the heaters is accomplished by a relay within the
power supply unit (PSU) based on detected line voltage.

Drum Thermal
110 VAC machines could have one section (front or rear) working but not
the other. The machine may work this way, however, 220VAC machines
would lose all drum heating if any open occurs.
Drum temperature is critical for Print Quality and because of this, the
temperature is closely monitored. Since melted Ink (~115 degrees C / ~235
degrees F) is hotter than the drum surface (~55.5 C / ~ 139 F) when applied,
high area coverage long runs may raise the temperature of the drum to the
point where no drum heating is required and eventually drum cooling
cannot keep up with the excess heat.
Prior to getting to this condition, Software should slow the machine down
or inhibit printing temporarily while the drum cools to the proper range.
This should only happen with jobs of >150% coverage and > ~350 copies.

Drum Thermal
Drum heating AC circuits come thru the thermal cutout board that is part of
the RalPH assembly. This sits directly above the drum and if the drum
overheats, the thermal cutouts will permanently open and remove power
from the drum heater circuits.
If the Thermal Cutouts open then the RalPH Assy will need to be replaced.
Drum Heaters are inhibited unless the Drum is turning.
Drum heaters are broken in with a two minute burn at the vendor site. This
is to reduce start up smells at a Customer site.

Drum Encoder
The drum encoder helps to track run out
variations in the drum surface which
impacts the distance variance to the print
heads. The encoder keeps track of the
home position of the encoder and the IOD
reads the drum distance at 6 degree
intervals. This information is used by the
system to help set print head Y direction
compensation to properly set the jet firing
times.
Drum home position may also be used in
fault tolerance mode if it is known there is
Drum Encoder a defect in the drum surface, the encoder
signal could be used to stop printing in the
defect area whenever possible.

Drum Grounding
Heater pin (steel) contacts steel ball bearing.
Contact insured by spring.
Ground path from drum rear end bell thru the
spring and ball to heater assy extrusion to
encoder on front of drum to front drum frame.
NOTE:
A ground brush is now the primary ground
path but the path described above also still
exists.
Failure of ground to the drum will increase oil

consumption considerably (Static Charge
builds up on Drum and that attracts the oil).
ESD hits to the serial links, may contribute to
link (communication) errors.

Drum Drive
410VAC 5A 3 phase sinusoidal Motor
Belt
tensioner Mounting
Post
Drum Drive Analog hall affect on motor,
Pulley
‘e’
ring Analog optical encoder on drum for
position control.
NOTE: Because of the high voltage

and high current to the Drum Drive
motor – care should be taken.
Discharge PSU (by waiting 10 sec.)

then disconnect power cord per EDOC
Prior to service of Drum Drive motor
wait an additional 2.5 minutes.

Drum Drive
Theory of Operation
Drum Drive can be both CW (most common) or CCW (as seen from the
front).
The Drum operates at varying speeds depending upon the IME model
(speed) and the mode of operation.
During some IOD modes the image is placed on the drum and then the
drum is rotated CCW as seen from the front. This saves some calibration
time.

J 401 (WD 9.1) Transfix
Drum Driver PWBA Motors
P/J Locator
J 701 (WD 9.2) to RalPH

J101 (WD 9.1) to IOD
J 801 (WD 9.3) Transfix Mot. Encoders, Rear Drum Therm.,
Strip latch sol., Front door interlock and strip jam LEDs
J 501 (WD 9.1)
Front Transfix Flex
Encoder, Front
J 802 (WD 9.3) CU and PSU Drum Thermistor,
Drum Fan, Drum
Encoder
J901 (WD 9.4) Top Enclose Fan, MU Fan, Abatement
J 601 (WD 9.2) CU,Strip Sol., Waste Sensor
J 602 (WD 9.2) PSU JDC3
J902 (WD 9.4) (from PSU – PJDC2) J603 (WD 9.2) to IME Cont.

Drum Driver PWBA Functions:
The Drum Driver PWBA receives control signals from the IME Controller PWBA
and generates properly timed output signals to the following components:
- Ralph Interface PWBA
- Stripper Jam LEDs
- Cleaning Unit
- Waste Tray Switch
- Stripper Solenoid & sensor
- Stripper Latch exit sensor (S12)
- Front & Rear Flexure Encoders
- Front and Rear Drum Thermistors
- Front & Rear Transfix Motor & Encoders
- Drum Drive Motor, Encoder (With Drum Home sensor)
- Drum Fan, Abatement Fan, Top Enclosure Fan, MU Fan
- Input from the Front Door Switch

Drum Facts
The Drum is made from Extruded Aluminum.
End Bells and Drum Bearings are structured to handle ~900 lbs. per square
inch placed on the drum by the transfix roller.
Scratches on the drum will initially show as a change of gloss on the output
copies but once scratched, the drum must be replaced. There is no method
to recover a scratched drum.

Drum Stripper Assembly:
Stripper assemby as shipped with Stripper Cams Assembly
installed guard
Cam Latch arm
position sensor
and flag behind
the front arm
M4 Motor Assembly
Stripper Solenoid

Drum Stripper Blade
The Drum Stripper Blade is actuated and placed against the drum just prior
to paper arrival. The stripper is necessary to break the bond of the
throughput with the drum surface. Once the edge is lifted the stripper is
retracted until the next lead edge is almost to the stripper.
The Drum Stripper Blade is grounded via conductive plastic in the assembly.
This provides the path back to the metal paper path plate and back to the
frame via the shaft of the stripper latch baffle. Failure of this ground may
lead to ESD hits on the communications lines and /or electrical arcs from
the stripper blade to the drum surface (which may cause pitting of the
drum).
M4 drive motor is used to lock and unlock the drum stripper assembly. This
is accomplished by running the M4 Motor in reverse. M4 also provides drive
to the ‘J’ and ‘L’ paper path nips (part of the stripper assembly) when run in
the forward direction.

Drum Stripper
During normal machine operation the stripper mechanism should

automatically go to the unlocked position with front door opening.
The stripper cam home sensor sits behind the front stripper cam latch arm.
This is an optical sensor which is blocked by a flag when in the stripper
operational position. However, the stripper assembly can be unlatched and
still have the arm in the home position. This means you cannot inform the
operator they have failed to close the stripper assembly but since you
cannot close the front door without the stripper being latched, this is not
considered an issue.
During normal operation, the stripper assembly is locked in position. When
the front door is opened and you have a jam in the stripper area, the
stripper cam arm should move to the home position which allows the
stripper assembly to be unlatched.

Drum Stripper
Should the stripper fail to home and unlatch, there is a screw slot accessible
through the front engine block frame (to the right and below the transfix
flexure encoder) which will allow the technician to manually turn the M4
motor to home the cams. Screw slot will be approximately horizontal.
Stripper release
screw access hole

Drum Stripper
The stripper blade is coated with Teflon to make the blade less likely to
have a build up of ink. However, debris on the Drum Stripper blade can
contribute to damage on the lead edge of the throughput. DO NOT
ATTEMPT TO CLEAN BLADE! Replace as needed.
Additionally the contamination on the blade may come off the blade when
it is brought off contact with the drum and comes up, striking throughput
approximately 15mm from the leading edge.
The Stripper blade mechanism is ordinarily locked and does not release
until the front door is opened. This is necessary due to the mass of the
stripper transport and blade assembly.

Potential Field Failures (1 of 3)
Failure Result / symptom
Drum Temperature Low PQ Defect
Spotty looking copies; low dot fill – similar to low
transfix pressure failures
Drum Temperature High Above 57.5 degrees C – you may get IOD and cohesive
failures (ink may stop sticking to the drum and may
sling off the drum surface – possibly damaging the
PHs).
If Drum severely overheats – thermal cutouts on the
RalPH will open and remove AC from the drum heater
circuits. Also get LE debris on throughput, Cleaning
Unit slime, and poor pixel transfer and distorted pixels.

Drum Damage PQ defects – the Drum must then be changed. Initial

indication of a scratch may be gloss changes on the output
copies/prints.
Drum Drive Belt Slip This will show as a Y Axis stall fault. This can be caused by
as little as one finger print of oil on the belt and or pulley.
Care should be taken when handling the Drum Drive belt
and / or pulley.
Broken Thermistor Thermistor assembly is frail and may crack, which may
mean insufficient contact with the drum and therefore
excessive heating on that end.

Drum Stripper Ungrounded Probable intermittent electrical noise hits. May jam
on second sheet of a job and may or may not give link
errors. Eventually arcs may pit the drum surface.
Sensor 12 Static jams Jams with no paper present may be due to the plastic
baffle that holds the sensor not being fully or properly
seated in the front or rear drum frames

Troubleshooting tips
Use extreme caution when servicing the drum area. If you have a defective
interlock switch, the Drum may turn even if the front door is open.
WARNING: The Drum is driven by a stepper motor which will apply
more torque if any resistance to movement is detected.
During Drum Replacement:
Be sure to unplug the front and rear thermistors – DO NOT let them hang
during the replacement. If you do, they may get damaged and if you
forget to install one or both of them, one or both ends of the drum may be
damaged by a severe overheat condition.
Take care not to damage the heater element when you insert a screwdriver
handle to keep the drum from turning while loosening the drum pulley
screws.
To reinstall the Drum Drive belt – install tensioner spring and hold some
tension on this by moving the Drum Drive Motor CCW. Loop drum drive
belt over the pulley while maintaining tension. Then fully engage the
tensioner. Be careful NOT to snag any wiring while moving the tensioner.

Abatement

Abatement
IME Fan
NOHAD
Exhaust Assembly
Drum Cooling Fan

Abatement
Blower
Marking Unit
Abatement Plenum
Exhaust Fan

Function
The function of the Abatement is to remove contaminants from the air just
prior to the print head area. By removing these contaminants from the air,
the occurrence of IWMs (Intermittent Weak or Missing jets) and CWMs
(Continuously Weak or Missing jets) are substantially reduced.
Contaminants removed from the air include environmental dust, paper
dust, paper fibers and other small particles.
Abatement tests indicate a 4X reduction in particles. It is assumed at least

a 2X reduction in IWMs (Intermittently Weak or Missing jets) and CWMs
(Continuously Weak or Missing Jets).

Components
Location and Removal
Components: (PL 94.20)

Abatement Blower
Abatement Plenum (sits directly beneath the drum)
NOHAD Exhaust Assembly (holds the Drum fan) and abatement blower is
attached to this assembly.

The abatement plenum is located directly below the drum between the IOD
and the Cleaning Unit (CU). It is removed by removing the CU, then pull
the CU handle while pulling the abatement plenum to the right.

Abatement
Theory of Operation
The abatement blower provides a negative air pressure along the abatement
plenum opening. This slight vacuum captures nearby contaminants just prior
to drum rotating to the print head area.
The abatement Blower has a tachometer to detect stall/failure. Presently it is

not known if this circuit is capable of detecting a clogged abatement exhaust
filter, but if it can, then a secondary fault code (92-621) would be logged.

Potential Field Failures and Symptoms
Failure Symptom
Clogged Abatement filter You would probably see an increase in IWMs and
(there is no filter as of 2/2009) / or CWM jets but this would not be an obvious
problem.

Whenever the abatement plenum is removed, inspect and clean as

necessary.
Whenever rear panel is accessed, inspect, clean or replace the abatement

filter as necessary. Note: As of 02/2009 there is no filter.
Take care when reinstalling a plenum – there have been cases where an
incorrectly installed plenum caused oil spills from the Cleaning Unit during
run.
Page 181 Table ofTable

Contents
of Contents Xerox Internal Use Only
Ink Load and Melt Plate
Assembly

Ink Loader / Melt Plate Assembly
Ink Stick Belt

Drive Motor
Ink Load
area
Melt Plate Assembly – spare

contains all 4 melt plates (thermal
cutouts and Melt Plate assembly)

Functions:
Provide a keyed entry to help assure the proper color ink stick is inserted in the
proper channel of the ink loader. Each color ink stick has a unique shape.
Keyed entry is also used to assure Non-Sold ink sticks cannot be used in SOLD
machines. Also used to help identify non approved ink sticks.
Deliver the installed ink sticks to the melt plate area. This movement is
accomplished by the Ink Stick Drive belt (one for each color), the Ink Stick belt
drive motor (one motors runs all 4 belts) and by gravity.
Monitor ink insertion and ink low signals via sensors.
Monitor the ink insertion area cover door.
Melt the inserted ink upon demand from signals generated by a level sensor in
the ink reservoir and by look ahead software which monitors demand by pixel
count. (Melt occurs at ~ 100C / ~ 212 F)
Detect Ink Out conditions (done via the melt plate thermistor, if the melt plate
warms too quickly – it is assumed there is no contact with an Ink Stick)

Components (Field Replaceable Units)
− Ink Melt plate assembly (all four melt plates on a single assembly)
− Ink loader door switch (door covers the entire ink loading input area).
− SKU Sensor assembly (Stock Keeping Unit – refers to various markets
and sold or metered ink sticks, 3 sets of 4, for a total of 12 different
shape ink sticks). This is the keyed area of the ink loader where ink is
added by operator.
− Ink Stick Belt Drive motor (1 motor drives all 4 belts).
− Ink low sensor (1 / color but spared as all 4 sensors on a common pwba
with a common harness).
− Ink Loader PWBA
− Upper Ink Loader (complete Ink Loader minus the Melt plate assembly).

When a Customer installs an ink stick, the ink loader detects this,
determines if it is an approved shape then feeds the stick past the SKU
sensors (2 per inlet) once the stick is approved. Then the ink stick is moved
past the ink present sensor and then by drive and gravity to the ink low
sensor and eventually to the melt plate. The ink stick drive belts turn long
enough to assure the ink stick will reach the melt plates even if the ink
loader is empty. If the SKU sensor determines this is not an approved ink
stick, the UI will display an appropriate message. The ink belt drive motor
may run in reverse to assist in getting the non-approved ink stick out of the
loader.
The ink stick drive belt motor may run for brief periods of time during the
day to help assure proper contact with the melt plates and proper stick to
stick contact.

The ink low sensor (reflective) is used to estimate when ink will run out.
Once the ink low sensor is no longer actuated an algorithm is started. The
algorithm determines from average usage in copies and area coverage
when it is anticipated to run out of this color ink. This sensor is also ignored
for a period of time after being not made to compensate for the angled
gap between ink sticks.
From this, an appropriate message should be displayed on the UI in time

for the Customer to order ink sticks if necessary. Because of the way this
algorithm works, if you replace an ink loader assembly you should reset the
NVM counters and then fill the new ink reservoir at least to the ink low
sensor while power is on.
True Out of Ink is detected by monitoring the temperature change rate of

the melt plates, when no ink is present the warm up is much quicker and an
ink out message will be declared.

If the Ink Loader believes an ink stick jam has occurred then the Ink Belt
drive motor will run in reverse for ~ 1 second and then forward again to
attempt to clear the jam. As an example, this might happen if the low ink
sensor did not see an ink block after an appropriate amount of time after
insertion of an ink stick
Melt plates are heated by a ceramic PTC disk. PTC stands for Positive
Thermal Coefficient – which means that as the temperature rises, the
resistance rises and the current decreases. The main reason for using this
type heater is safety since it is self regulating.
If an ink stick jam is assumed – the Welcome Center may ask a Customer to
install another ink stick in hopes of clearing the jam.

Ink Loader Facts (1 of 3)
Each ink stick is ~200 grams
~ 4800 grams fully loaded (6 ink blocks of each color)
~ 50,000 prints at 5% avg. area coverage when ink loader is fully loaded
Ink melts at ~ 100 C (212 F) – the boiling point for water
Customer / CSE should never insert partial sticks. Only exception might be
when replacing the melt plate assembly. If the partially melted sticks on
the old melt plate come off easily then they could be used with the new
melt plate but MUST be inserted from the bottom of the loader – they
should not be sent thru the loader since they might jam the ink loader.
CAUTION: Care should also be taken to keep any shards, especially of
the wrong colored ink, from contaminating another color in the ink
reservoir.

Ink sticks should only be loaded with the power on since the sensors need to
see the ink block to keep an accurate inventory of available ink.
When replacing the melt plate assembly, inspect carefully to insure the
plates are all at the correct angle (further explained in the next slide). They
may have been damaged in shipping and can be damaged when inserting
the new plate assembly. The melt plate assembly should go together with
the upper ink loader with very little resistance. If not, you probably aren’t
properly aligned.

There are two distinct versions of melt plates. Magenta and Yellow are
labeled as ‘B’ and are angled at ~45 degrees. Cyan and Black are labeled as
‘A’ and the plate is at ~30 degrees. Since there is no plan to spare the melt
plates separately, this is informational only.
Ink stick present sensors and wiring are identical and could be interchanged
at the PWBA. This should also be a rarely serviced area.
There is a catch tray beneath the ink loader load area which will bypass any
inadvertently spilled liquids to the base of the machine. Without this, the
liquid would more likely find its way to the ink reservoir and cause even
more contamination and damage to the machine. The tube will not
presently pass water and will be redesigned in the next version of the
machine.

Ink Stick Load area (Hardware 1 of 2)
Top View Moving Key plate – motor driven

(position changes to match Sold /
Metered / DMO-EU)
SKU entry sensing
Ink Stick – top surface
Optical entry sensors (8)

– checks for proper Bottom View
‘notch’ on ink sticks

Ink Stick Load area (Hardware 2 of 2)
SKU sensors to
further verify
correct ink stick is
loaded
SKU sensor –
checks for
proper notch
feature at
bottom of ink
stick
In the metered position, the moving slide will align with the permanent locating features of the ink load
assembly.

Ink Stick Family Configurations
NOTE: Ink stick shape is patented by Xerox. Because of this,

competitors should not be making ink sticks that will work within
Jupiter. Remember that in addition to the shapes shown above
there are also features in the bottom sides of the ink sticks as well
which help to verify the ink stick color and service plan.

SKU sensor misreads correct block Customer will get a message that the incorrect
Ink Stick has been installed
Ink stick doesn’t reach melt plate Customer gets an incorrect out of ink message.
Welcome Center may instruct Customer to add
a stick of ink. This may help dislodge the stuck
ink stick.
Customer installs a broken block or May jam the passage to the melt plate and
part of broken block give an incorrect out of ink message. This may
also cause contamination of the ink reservoir.
Ink Stick count not cleared at Machine may display an incorrect ink level.
install of a new Ink Loader Note: Be sure to follow procedure for Ink
Loader replacement in the Edoc.

Arcing in Ink Melt Plate Loud Arcing noise – potentially some smoke.

Warning:
Never use aerosol lubricants on any Xerox copier – but especially on this
product. There are many locations with very hot surfaces and areas where
an aerosol can easily reach 110 VAC or greater.
Warning:
Never use Film Remover / Isopropyl Alcohol on parts while in the machine.
This may lead to fire, especially if used around heat and / or AC voltages.
(i.e. RalPH plates)

Ink Reservoir and Delivery

Ink Reservoir and Ink Melt Delivery
Umbilicals One of two

mounting
screws
Purge lines –
(the four larger
clear tubes) To
capacitive
level sense
sensors
Normal fill level
is slightly above
the ‘rock’ screen

Ink Reservoir and Ink Melt Delivery
Function:
The function of the reservoir and ink delivery system is to:
− Store melted ink (melt occurs at ~100C / 212F)
− Keep the melted ink at the proper temperature (~ 115 C / 239 F)
− Deliver the melted ink to the print heads
Components:
Ink reservoir and delivery system consists of these spares:
- Ink reservoir assembly - (tank, air router, air motor, Solenoid Patch PWB, capacitive
level sense (2 sets of 2), and Mica insulation plates)
- Umbilicals (2) – these also include the purge tubes (2 per umbilical) and the Check
Valve Unit (CVU) –– 1 per umbilical. The umbilicals are identical.
- Air pump motor (includes low pressure assist valve and accumulator)
- Mica Insulation plates – all plates are contained in a kit

Ink Reservoir and melted Ink delivery
Air Delivery Operation
The Ink Reservoir has two main sections for storage of ink. These are the
low pressure side and the high pressure side. Each side has sixteen
reservoirs. One ink storage area for each color (4) and one of each color for
each print head (4) for a total of sixteen.
There are sixteen solenoids which control each of the sixteen high pressure
tanks and one purge solenoid for each of the 4 print heads, for a total of 20
solenoids.
High Pressure side
Umbilical
connection area
– one on each
side of center
Low Pressure side
Router Plate (shown in red) – routes

ink to the two umbilical connections

Reservoir Fill (1 of 2)
Melted ink is received on the low pressure side from the ink loader melt
plates through holes at the top of each color reservoir. Each color reservoir
is divided into four areas (one for each print head). If the air solenoid for a
particular area is not energized, then a mechanical flapper valve between
the low and high pressure side may open and allow the ink level in the low
and high pressure side to be at the same level, up to the fill limit
determined by the capacitive ink level sensor which will be covered in a later
portion of this ATT module.
If the air solenoid for the a particular storage area is enabled then the high
pressure side will go to ~ 4 lbs. of pressure and this pressure will close the
mechanical flapper valve between the high and low pressure sides of the
reservoir. The low pressure side may continue to fill but the high pressure
side cannot fill until the air solenoid for this storage area is de-energized.

Reservoir Fill (2 of 2)
Varying air pressure (purge, fill or low pressure assist) is accomplished by an

electrically operated valve on the air pump motor assembly. When
energized (open) the pressure drops for low pressure assist which places
enough pressure on the jets so that the ink will stick out of the jet and
provide lubrication for the cleaning blade but not drool.
When a solenoid is energized, ink will flow from the high pressure side to
the ink router plates which comprise the lower portion of the ink reservoir,
then to the appropriate umbilical connection and on to the appropriate
Print Head.

Ink Level sense
Ink level sense is provided by one of two capacitive sensor

assemblies. Each assembly has two capacitive sensor probes that
Stop AC Fault ‘sit’ in the ink reservoir and monitor ink level for two colors (1 probe
to melt in each color ink reservoir).
plates Max
One set monitors the black and yellow while the other set monitors
magenta and cyan.
Since black is the most conductive and yellow is the least, one of
the potential problems is level sense once the yellow is
contaminated with black (worst scenario) or the black is
contaminated with yellow. Other varieties of contamination may
occur but contamination of Yellow by Black is the most severe.

Ink Router Plates

Ink Reservoir and melted Ink delivery:
Air Pressure
The Low Pressure Assist (LPA) valve and the air

pump motor are connected to an accumulator (not
shown). When low pressure is required (to lubricate
the Print Head during a wipe cycle), the LPA valve
will open which cuts the stored pressure from ~4lb.
to ~0.05lb.
The accumulator is a small plastic ‘tank’ attached to
the air pump output and the LPA valve. This makes
purge and dose masses more robust to air leakage.
Additional explanation of Low Pressure Assist (LPA)
can be found in the Print Head module

Umbilicals (1 of 2)
Purge line connects

AC connection to the purge filter Tube with the
‘nub’ goes to CVU = Check Valve Unit
the closest PH
PH (3 or 4)
Purge lines
Couples 1 / PH Couples to
air to PH reservoir
Couples ink to PH
Umbilical – Print Head End Umbilical - Ink Reservoir End

Umbilical's (2 of 2)
The Umbilicals are a flexible, mostly silicon material, with 8 ink tubes that are
heated to maintain the ink in a liquid state as it provides the path for the ink to
move from the reservoir to the print heads. Each umbilical attaches to one of the
SFWAs (Staggered Full Width Array). Each SFWA contains two print heads.
Upper = 2 & 4 Lower = 1 & 3
The CVU (Check Valve Unit) contains valves which will allow ink to flow toward the
print head but NOT back toward the reservoir. This valve is mainly needed during a
purge, if it were not there or if it fails open then ink will be forced back into the air
router and replacement of the reservoir and umbilical assembly would be necessary.
For the CVU to work properly it must be primed with ink prior to a purge. The
replacement procedure and training will cover this thoroughly. Failure to prime the
CVU will likely lead to a replacement of the Ink Reservoir when ink and air are forced
back into the reservoir and air router during a purge routine.
Purge lines provide pressure (~ 4lb. for a full purge and ~ 0.05 lb. for a low pressure
assist) to force ink through all jets of the PH being purged.

Ink Reservoir Heater
The ink reservoir is brought to and maintained at temperature by two rod

type AC heaters which are thermally protected from overheat. This heater
is not spared due to a very low failure rate and difficulty of replacement.
Melt temperature of ink is ~100C (~212F)
Mica
Insulation
Plates
Umbilicals
Rear bracket
supports assembly
while fasteners are
installed 1 of 2 heaters

Mica Insulation Plates and Flush Mode
Mica insulation plates surround the ink reservoir and help to maintain the
ink reservoir temperatures. These are not very robust and can be easily
broken but they are spared separately (as a kit) and provide excellent
thermal qualities at a very low cost.
Note: You cannot purge a single color as of this writing. Refill the reservoir
and check for contamination, if no longer present continue with normal
machine operation. If contamination is detected, run purge routine an
additional time or times until contamination cleared (may change in future
SW releases).

Ink Reservoir and melted Ink deliver
Potential Field Failures and symptom (1 of 3)
Flapper valve stuck open PH fill timeout (generally 1 color on only one head).
(flapper is between low & hi When pressure gets to the high side, much of the
pressure tanks) ink will be forced back to the low pressure side
instead of the PH. R/R the Ink reservoir
Flapper valve stuck closed PH fill time out (generally 1 color on only one head).
Since the high pressure side cannot refill, eventually
you will get a PH fill timeout. R/R the Ink Reservoir
Flapper valve – poor seal PH dosing incorrect. You may get intermittent PH fill
time out failures (generally 1 color on only one
head).
R/R the Ink Reservoir

CVU valve fails OPEN Ink will backfill into the ink reservoir during a purge, which
may result in ink being forced into the air router.
Since the air router is clear, this will be easily seen. Repair
would be to replace the Ink reservoir and the affected
umbilical/s if this type failure occurs.
CVU valve fails CLOSED Ink will not be able to flow from the high pressure side to
the PH (generally 1 color on only one head) so you will
end up with a PH fill timeout fault.
R/R umbilical (which includes the CVU)
Clogged Purge Air line This will result in a starved Print Head – all colors in that
Filter or an internal PH PH will have a PH fill timeout. R/R the Purge Air Filter
filter (part of PH) and if problem continues then the affected Print Head.


Purge lines – connected Most likely may occur during service. You might
improperly interchange upper with lower purge line pairs or PH1
with 3 or PH2 with 4. SW tests the Purge line
connections and may correct misrouting via SW for a
misconnected Purge line automatically – this takes
time so pay attention to proper install of purge lines.
Air router solenoid stuck PH fill timeout error – since you have no air pressure
closed to push ink up to the print head from the high
pressure side tank.
Air router solenoid stuck PH will overfill with ink and drool down into the
open waste tray and eventually the IME base pan area.
Clogged internal Print Head Print Head timeout for all colors for that print head,
filter once you are sure the purge line filter is not clogged,
then you should replace the Print Head.

When replacing an umbilical – the CVU must be primed prior to performing

a head purge (which will occur automatically if the heads cooled sufficiently
while the umbilical was being replaced). Closely follow the umbilical repair
procedure or you will destroy the Ink Reservoir and the Umbilical by
pumping ink and air into the air router at purge. (dc976)
Care should be taken if removing the MU or opening/closing the drawer

while ink is HOT. Cross contamination of the reservoirs may occur if there is
any sloshing of ink.
MU Drawer should not be opened until 20 seconds after removing the front
door interlock cheater. This assures the melt plate has stopped melting
prior to the MU drawer being opened.

Print Heads

Print Head
Jetting side of PH Ink connection view
Note: Slight differences may exist – depending on build date / version.

Print Head
Function and Components
Function:
Provide the path to get ink from print head input ports to the ink jets.
On command, jet the appropriate color jet as necessary to produce a print
similar to what would be produced if there were only one print head instead
of four.
Keep the melted ink in a liquid state (heat and maintain heat) ~115
degrees C at the PH face.
Monitor ink reservoir fill level (in either full or not full state)
Components:
Print Head (Individual)
Ribbon connectors (2 to each PH. Two types, data and power)

Print Head
Location / Removal / Electrical
Location and removal:

Each print head is held in place by two captured screws. First you access
the print heads by sliding the Marking Unit (MU) to the fully opened
position. Then remove the screws by loosening each a little bit then going
to the other until both are removed. To reinstall, reverse the process.
Visually assure the jet plate of the just installed PH aligns visually in the
same plane as the remaining PH (as a rough first check). Then assure Head
to Drum alignment via the documentation. (Automatic if a PH has been
replaced or swapped location).
Electrical connections to the print head include two ribbon cables, one from
the Wave Amp PWBA is driver power, and one from the MU Controller
provides digital data to enable jet control, and an AC connector for the
print head heaters.

Print Head – Exploded View

Print Head
General Description (1 of 3)
The print head consists of multiple layers which provide the path for ink to
get from the print head reservoir to the appropriate jets. Also within the PH
is an ink filter.
There are NO serviceable parts within the print head.
A matrix of individual piezo electric crystal driven diaphragms are used to
fire individual jets. Signals to these crystals come from the Quad Wave
amp PWBA and the IME Controller via two ribbon cables located at the top
of each Print Head (PH).
Print heads are numbered from front to rear. One closest the front is # 1
which is on the lower SFWA then #2 is the outboard PH on the top then # 3
is the inboard on the bottom, then # 4 is inboard top. The PH Number is
also stamped in the casting which holds the PHs - so the CSE should not be
confused by PH #.

Print Head
General Description (2 of 3)
The marking technology uses four print heads in order to make an image. Each
print head contains 300 jets per inch arranged in an array, giving a total jet count
per head of 880 (3520 for the complete imaging system). The print heads have a
fire rate of 41 KHz, delivering a drop mass (see drop mass explanation – next slide)
of 23ng onto the imaging drum. Piezo-technology provides the drive to jet ink from
the heads onto the drum. Each print head creates a portion of the image. Pixel
alignment between print heads ensures a seamless ‘meshing’ to deliver a single
image.
The image resolution achievable using a single pass of one feed head is 75dpi.
For cross process direction
In order to increase the image resolution, the image is built up using several passes
of the drum past the feed heads to make the required image resolution, the print
heads being slightly offset for each pass in order to avoid the build-up of ink drops
on top of each other. Therefore, as an example to make up an image of 375dpi the
drum must go through 5 passes. An image of 300dpi must go through 4 passes.
E.g.: 75dpi x 5 passes = 375dpi

Print Head
General Description ( 3 of 3)
For process direction

The resolution of image in the process direction is determined by the speed
of the drum while in the imaging cycle. The expression below shows the
relationship
Y-resolution (in DPI) = 25.4xhead frequency (Hz) / imaging speed (mm/s)
In order to achieve any different resolution in the process direction the
speed of the drum must change, therefore the imaging time will change for
each revolution.
Drop Mass:
Drop mass is how much ink gets to the page for a given image. This can
only be measured in a lab environment with sensitive scales. With time the
drop mass will decrease and compensations occur to help assure the
amount of ink reaching the throughput remains consistent. This variation
in drop mass over time is referred to as ‘drift’ and the ‘drift’ calibration
should maintain the heads in a calibrated state.

Print Head
Purge
First the wiper assembly homes then moves to the initial position in front of
the lower heads. A purge of the lower PHs occurs. This forces ink thru all the
jets at once.
Note: Purge takes place when the proper solenoid or solenoids is/are
energized to send ~4lbs. of air pressure to the head or heads that is being
purged. Then an area on the lower heads (well below the jets) touches the
wiper to liquefy any residual 'ink' on the wiper. The heads back off then
retouch the wiper blade after slight movement of the lower Carriage. Once
the purge is completed then the Low Pressure Assist takes place.

Print Head
Low Pressure Assist (LPA)
This is accomplished by a valve being opened on the ‘accumulator’ on the

Ink Reservoir air system. Now you have ~ 0.05 lbs of pressure on the Print
head and this causes a film of ink to stay on the head for lubrication and to
keep ink on the head from being drawn back into the head by capillary
action.
The Print Head then moves back to the wiper. Wiper starts at the top and
slowly moves down. Once this wipe is complete, the Low Pressure Assist
stops and the wiper re-homes and then goes to the upper heads and
repeats this process if it is a purge of all heads (i.e. purge from a cold
condition – off more than ~ 10 minutes).

Print Head
Basic Jet Fix Operation
• Need to determine
this rate
Jet Substitution may slow the rated

speed slightly on a 50ppm (J3)
• Bad Jet and Chronic
jet treatment
• Customer and Service Most Customers running under 4,000
notification
pages a day would see only a slight
lowering of the print speed (i.e. ~2 PPM).
Yes
Jet Substitution on a 30PPM will have no
impact to speed – so Print Heads with
minor missing jets would not affect the
speed or output quality on a 30PPM IME.
Source: Pieter Ganzer

Print Head
Internal Chambering
The above image (left) illustrates the internal plumbing of the print head assembly.
Complex paths are necessary to get each color ink to the appropriate ink jets.
The above image on the right illustrates the ink reservoirs within the print head. One
of the important features is the top air channel. It is designed such that if the PH is
tipped while hot and then righted, ink that got into the air chamber will flow to the
black reservoir. This is the least problematic solution but tipping of the print head
while hot should be avoided.

Print Head
Cold Purge
Purge from Cold:

Whenever the machine is coming from a cold state to a printing state, a
purge is required.
A purge forces air into the print heads (one or both on a SFWA). This air
forces about 10 grams of ink to be forced through the jets; this along with
Low Pressure Assist (explained next slide) and the wipe cycle will generally
clear any clogged jets. The purge cycle then continues to the remaining
SFWA. Once the purge is completed an IOD cycle is run to determine if
there are any missing jets. If there are, the IME may ‘warm’ purge the
affected Print head one more time and then repeat the IOD cycle.
NOTE: Purge utilizes only air, there is no control or power from MU PWBAs
The drip bib (on the front bottom of the PH) is a tab approximately 3/8th of
an inch long. This tab is to focus the purged ink and keep it from
contaminating nearby areas as the ink falls into the waste tray.

Print Head
Warm Purge and Low Pressure Assist
If the IOD cycle – which is run every 500 copies – detects a missing jet, the IME will
select a time deemed to be the least invasive to the Customer and run a warm
purge. A warm purge generally only involves the Print Head with the weak or
missing jet/s. The actual purge cycle is presently identical whether the purge is a
cold or warm purge.
Low Pressure Assist (LPA):

Low Pressure Assist takes place during a purge cycle. After the purge is completed, a
Low Pressure assist is placed on the PH ink reservoirs by applying ~0.05 lbs. of air
pressure to the purged SFWA. This is accomplished by energizing the LPA valve on
the air pump assembly (within the Ink Reservoir) while also energizing the purge
solenoid / solenoids for the just purged SFWA. This is necessary to keep the ink on
the face plate from being drawn back into the print head through the jets and
contaminating the individual colors. This low pressure is kept on the purged PH or
PHs from the time the purge is completed until the wipe cycle has fully completed.

Print Head
Low Pressure Assist – why we need it
LPA – Why do we need it? LPA too low:

Ink Mixing by ‘waste’ ink being drawn
•Ink level in reservoir is back in the PH jets. Run Cleaning
lower than apertures pages.
Normal Ink Level
•Necessary for jetting
stability
•Small apertures allow
May cause IWM (intermittent Weak
surface tension force to /Missing jets) or CWM (Continuous)
balance pressure
Purged Ink Level gradient LPA too High:
Ink Mixing because of drool after the
wipe process
May cause IWM jets and / or CWM
•Directly after purge (prior to wipe)
apertures are covered with purged ink
•This effectively eliminates surface
The purge cycle is the only
tension force, allowing waste ink to be recommended cleaning procedure for
drawn into apertures and purge vents the print heads, all other methods will
•To minimize this effect, LPA is result in PH jet contamination.
applied to reservoir to offset ink level
difference

Print Head
Level Sense
The following is a simplified explanation of the thermistor level sense system. Assume
that the Print head is at its ready operating temperature. At that temperature, the ink
in the reservoir and the air pocket above the ink will be at ~132 C (current set-point
which is ~270 degrees F). The ink level sense thermistors are self-heated 22 C above
the operating point by running current through them. The thermistor’s tip will either be
submerged in the melted ink (full condition) or suspended in the air pocket (not-full
condition). Power to the thermistor is now turned off and a timer starts.
Because the thermal conductivity of the ink is much greater than that of air, the
thermistor will cool down to 132 C quicker if it is in the full condition. Software
compares the time it took for the thermistor too cool down to a threshold value. Based
on the outcome of the comparison a flag is set to an empty or full state for each ink
channel. If a color reservoir flag is set to not-full or ‘empty’ then other printer software
and circuitry will start filling that Print Head reservoir from a main ink reservoir. At the
same time current to the thermistors is turned on again allowing the thermistors to self-
heat again. The process then starts over.

Print Head
Heat
Print Head Heat:

Each Print Head has two jet stack heaters to maintain the jet stack at the
proper operating temperature and one reservoir heater to maintain the PH
ink reservoir at the proper operating temperature. This is ~132 C (~270 F).
Approximately 27 watts per PH. This being ~7 watts for each jet stack
heater and ~13 Watts for the PH reservoir heater.
The jet stack face will be at ~ 115 C during standby / print.

Print Head
Drooling
Drooling can show up as missing jets, but is easy to identify by watching

the print head after a purge-wipe cycle. As the wiper blade descends down
the face of the jet stack you may see ink starting to form on the faceplate.
If you do, you have a ‘drooling’ print head. A sample of moderate drool is
given below. Note: Similar beading on the PH face may be seen during
warm up and is NOT a problem.

Print Head
Wiper Chatter
Definition:
Wiper chatter is a jerky movement of the wiper blade assembly – which
may be accompanied by noise which could be described as chatter.
Head maintenance wiper chatter alone is not considered a failure. HM
wiper chatter itself is only considered a failure if it causes PQ defects. The
usual defect is discolored jets after a purge.
HM wiper chatter is acceptable if:

− It happens only outside the jet array
− It only leaves ink outside the jet array
HM wiper chatter is NOT acceptable if:

− It leaves ink on the jet array
− It causes PQ artifacts

Print Head
Acceptable Wiper chatter
This HM chatter event left 3

lines of ink at the start of the
wipe. Again, all the ink left by
the HM wiper chatter is
outside the jet array area of
the Print Head

Print Head
Unacceptable Wiper Chatter
In this case, the HM wiper

chatter occurred down the
entire jet stack and left ink on
the jet stack. The wiper
assembly would need to be
replaced.

Print Head
Waste Tray Sensor (1 of 2)
Ferrite Magnet is heat staked in the waste

tray assembly (at right rear corner of tray)
This sensor is part of a safety circuit which
assures that carriage motion will not occur
when the waste tray is not in place (except
while in diagnostics for Head
Maintenance). This is necessary to avoid
severe pinch hazard.
A UI warning will prompt the user to not

Rear of waste tray installed in the machine.
remove the waste tray if a purge is in
progress or if the waste ink has not
sufficiently cooled (~ 2 minutes required
after a purge to sufficiently cool).

Print Head
Waste Tray Sensor (2 of 2)
The waste tray sensor is a magnetic reed switch which is actuated by a

magnet in the rear right corner of the waste tray. If this circuit detects the
waste tray was removed and the power is on, then the print heads will not
be allowed to move since it is possible for someone to place their hand thru
the waste tray cavity and get to moving print heads.
Waste tray must be removed for > 10 seconds for it to be considered
emptied and also must be at a state of almost full for it to count as
emptied. For example if you are at near empty, then the removal for > 10
seconds doesn't count as an empty cycle. Additionally, waste tray full goes
by mass not necessarily by where that mass came from - i.e. all from PH 2.
The Waste Tray lock is used to lock the tray during and for two minutes
after a purge. This is used to avoid handling or dumping a tray while the ink
may still be molten.

Waste Tray
Locking mechanism
The Waste Tray lock is used to lock the tray during and for two minutes
after a purge. This is used to avoid handling or dumping a tray while the
ink may still be molten.
Locking
Mechanism
Latch Solenoid
at front of
waste tray

Print Head
Special case purging (prior to H2H cal.)
Prior to Head to Head Calibration (H2H) a double purge may occur.

Note: H2H may be called via IOD (automatically) or may be called via CSE
by running dC972
The printer monitors the last 24 hr ink flow for cyan and magenta colors for
each head. If the ink flow is less than 2.5 grams on either cyan or magenta,
we perform 2 purges on that head / s. If the ink flow is greater than 2.5
grams but not greater than 5, for either cyan or magenta, we perform 1
purge on that head. If the ink flow is greater than 5 grams for both cyan
and magenta, we do not purge that head.
This process helps to clear cooked and migrated colors.
We also automatically print out 3 sets of cleaning pages before we start

H2H calibration to clear ink mixing. The 3 sets are printed prior to H2H
calibration, irrespective of a purge occurrence.

Print Head
Potential Field Problems (1 of 2)
Clogged PH internal filter (non PH fill timeout (probably all colors in that
replaceable) PH). First verify purge line filter is not
clogged, then R/R Print Head
Clogged external air purge filter PH timeout on all colors in that PH.
R/R the air filter.
IWM or CWM IWM = Intermittent Weak Missing Jet
(worst after a “freeze / thaw” – then CWM = Continuous Weak Missing Jet
improves over the next 1 to 2 K and For either failure, first try a purge and then a
generally remains stable after that) PH. Jet substitution may hide most IWM /
CWM jets. IWMs and CWMs often are worst
when PH is new but improve with multiple
purges and / or time.
IWMs and CWMs may also increase if lots of
purges (PO/POs) occur – especially multiple
purges from cold.

Print Head
Potential Field Problems (2 of 2)
Fault Result / Symptom:
Color shift May be contamination or ink cooking.

Ink cooking may occur if the machine
sits for long periods of time unused (i.e. 3
or more days). SW addresses this by
running auto purge cycles
X stitch is off This can be caused by ‘Y’ stitch also

being off.

Print Head
Troubleshooting tips ( 1 of 2)
If HOT, keep PHs in the approximate orientation they are in the machine.
If you tilt the PH excessively while the ink is still molten – you may ruin the
PH. Set PH down on the lower PWBA – that won’t hurt the PWBA since it
actually sits on the screws. Take care to not touch or brush up against a
print head jet area. It takes very little contamination to permanently clog a
jet.
Print Heads should only be cleaned via a Purge.
Expectation in field is < 1.2 power off cycles per month is best.
PH ribbons can be physically interchanged – but never do this. The power

ribbon has many connections shorted together and if installed in the data
location may damage the IME controller pwba or worse.

Print Head
Troubleshooting tips (2 of 2)
J1 and J2 machines can maintain close to full speed with many missing jets
– so IWMs and CWMs are less critical. This is accomplished by Software
speeding up print speed. See Jet Fix in IQ section
LED on PH PWBAs indicate that you do or don’t have 3.3 VDC (one on each
PH PWBA – upper is referred to as the master and lower is referred to as the
slave).
When warming up from cold – you may see a considerable amount of drool
– this is normal.
Interchanging PH positions for troubleshooting should be avoided since the

machine will see the PH has been changed and force a series of lengthy PH
calibrations and alignments ( ~ 1 hour).

Marking Unit (MU) - PWBAs

Marking Unit (MU) PWBAs
MU Service Loop
Marking Unit Power

Heater Supply
J121 JDC1
Media Path
PWBA J340
IME System
Controller, for
Image Data
J140
MU Drum Driver
Power PWBA J940
2 J190
3
1
Power Supply
J4AC
Media Drum
Path Driver
Driver PWBA J160
J121 Copy Controller RJ-45

IME Controller
P/J locations (1 of 2)
The IME Controller uses a 6-layer PCB. The overall dimensions are 150mm x
390mm. Below is the mechanical outline showing connector, jumper, and
LED locations.
DS302 ENG/OK
DS301 OS/BAD
J101 JX201 JX301
Waveamp Head 4 Head 2
(Back side) (Back side) J304
J401 Ethernet
CBC
DS604 CABLE
J402
DS605 CPU
MPD DS606 +50V
DS602 -50V
DS607 +24V
J403 DS603 -12V
DD DS608 +12V
DS609 -5V
DS610 +3.3V
CPU
J701
J801 J601
Power J902 J903 J904
Serial1 DDR2 SODIMM
J804 J805 J806 Head 3 MUD Head 1
Laser Boot Mode

IME Controller PWBA (2 of 2)
To CBC for Pin 18

Image Data +50V +24V
To Media Path
RJ-45 J 401 (1) Driver Board -12V
+12V
J402 (2) pin 9
+3.3V
To Drum Driver sns +3.3V
Board J403 (3) +5V
Pin IO
- 50V
J 701 Power
RJ 45 Cables 1
Pins 1 - 9 GRD

IME Controller – Function
The main function of the IME Controller is to receive video signals from the
Copy Controller via a one way serial link. The IME Controller takes this
information and disseminates it to the appropriate Print Head and
appropriate jet to recreate the received image on the drum.
The IME Controller sends control information to the Print Head Driver,
Drum Driver, Media Path Driver, and Marking Unit Driver boards, as well as
the Dual Wave Amp The Controller communicates to the Copy Controller
over a multi-master CAN* serial management bus.
*CAN protocol is an international standard serial bus defined in ISO 11898,

which describes a physical medium comprised of a two-wire bus line with
common return terminated at both ends by resistors. Jupiter uses CAN
open, which is a CAN-based higher layer protocol. CAN open provides
standardized communication objects for real-time data, configuration data,
and special functions as well as network management data.

QUAD Wave Amp PWBA
J 110 J 150
PJ Locator (WD9.13) to PH4 (WD 9.13) to PH2
J 590
(WD 9.13)
to the IME
Cont.
PWBA
J 930 (WD 9.13) to PH3 J 970 (WD 9.13) to PH1

Quad Wave Amp PWBA
The Quad Wave Amp is a power amplifier that amplifies waveforms

generated by DACs on the IME controller board. The amplified waveforms
are then used to drive the piezo-electric transducers on the Print Heads in
order to jet ink.
The Quad Wave Amp board consists of 4 independent amplifiers and is

referred to as the Quad Wave Amp; each of the 4 amplifiers is an exact
replica of each other. Each amplifier is further divided into the (+) and (-)
amplifier portions. The (+) amplifier is responsible for amplifying the
positive wave forms which result in waveforms in the 0V to 50V range.
Similarly, the (-) amplifier amplifies the negative waveforms which result in
waveforms in the -50V to 0V range.
The (+) and (-) waveforms come in from the IME controller board. Each one
of the amplifiers drives one of the 4 Print Heads.

Quad Wave Amp PWBA
A 40-pin ribbon cable connects the IME controller to the Quad Wave Amp.
A flex cable connected to 30-pin connectors connects the Quad Wave Amp
to each Print Head. The flex cables carry the (+) and (-) waveforms; the
cable also has a ground conductor in it.
The whole Quad Wave Amp can be enabled and disabled by the IME
controller; in the disabled state the output of the each of the Wave Amps is
held to ground potential.
Being a power amplifier, power dissipation is an important concern in the

operation of the Quad Wave Amp. Heat-sinks, thermistors, and a cooling
fan provide a comprehensive temperature control solution. Temperature
and over-current situations are monitored by the board and reported to the
IME controller for further action.

MU Driver PWBA
J303 (WD 9.10/11)
J202 Lower X-axis Drive Mot.
J102 (WD 9.9) J203 (WD 9.10)
PH1 Stitch & Roll Mots.
PH2 &4 Stitch and Roll To IME Controller J304
PH3 roll Mot.
Mots., PH4 Roll, Up X axis (WD 9.11)
Low Ship restraint Mot.
Mot., Up Ship restraint Up and Lower
J101 Up Umb. Thermistor
Carriage
(WD 9.9) home
Input AC Sensors, HM
from PSU mot. And
sensor, Waste
Sensor
J401
(WD 9.11)
HM Vert. J607 (WD 9.11)
Mot. Carriage drive
Select Mot.
J701 J605 (WD 9.11)

(WD 9.12) to Carriage Dr.
MU Htr. Mot.
J801 (WD 9.12) Controls to Sol. Patch PWBA
PWBA

Marking Unit Driver (MUD) PWBA
The Marking Unit Driver Board (MUD) controls the motors on the Marking
Unit drawer, Ink Delivery and head maintenance motors. This consists of
Carriage motion, Print Head adjustment motors (stitch and roll), and Head
maintenance motors. In addition this board controls ink reservoir level and
temperature readings for ink umbilicals, ink reservoir, and carriages.
The Marking Unit Driver board controls the serial link to the Marking Unit
Heater (MUH) board. The data and clock for the Marking Unit Heater board
originate on the IME controller.

MU Heater PWBA
J201 (WD 9.8) Ink
Reservoir Htrs.
J101 (WD9.8)
AC from PSU
J 401 (WD 9.8)

PH 2 & 4 Htrs,
Up Umb. Htr.
J901
(WD9.8)
to MU
Driver
PWBA
J701 (WD 9.8)
PH 1 & 3 Htrs,
Low Umb. Htr.

MU Heater PWBA
The Marking Unit Heater Board controls the AC heaters for the four Print
Heads, AC heaters for the Ink Delivery Reservoir, and the two Ink umbilicals.
Fuses on this PWBA are soldered on and not field replaceable

IOD

IOD (Ink On Drum)
Components
Mylar dirt shield
Scan bar (under

IOD Drive Motor mylar shield)
(attached to base
pan)
Locating pins
(front and rear)
Ramp that
opens / closes
shield
IOD CIS (IF) PWBA

CIS = Contact Interface Sense
IF = InterFace
Electrical Connection:
Locking Tab From CIS (Contact Image Sense) pre-
amp to Drum Driver PWBA, then IME
Controller then MU Driver PWBA to
motors that move the Print Heads (PHs)

IOD (Ink On Drum)
Components / Function
Components:
There are presently no spared parts on the IOD assembly.
Function:
The function of the IOD (Ink On Drum) is to:
− Detect weak and missing jets- used for jet substitution.
(IOD scan occurs every 500 copies and takes ~ 30 seconds each time)
− Read Drum uniformity (‘Y’ run out = imperfection in diameter of drum)
− Move the scan bar from the center (park) position to both the front and
rear positions to read IOD test images on the drum as necessary.
− Read images on the drum which are used to determine how to move the
Print Heads to achieve proper Head to Head (H2H) alignment (roll and
stitch)
− Read images on the drum and use those measurements to set H2H
intensity
Note: Used to set overall PH intensity – can’t adjust individual jets.

IOD (Ink On Drum)
Location, Removal and Electrical Connections

The IOD is directly beneath the drum. To remove it, you first remove the
Cleaning Unit and the Abatement channel. Release the metal tab clip at
the front to back center of the IOD and pull up on the electrical connector
until the IOD releases. Unplug the electrical connector. Rotate the IOD
assembly fully CCW and pull out on the Cleaning Unit handle while pulling
the IOD to the right. Install in the reverse order.
Electrical connection (1) from the IOD interface (IF) goes to the Drum
Driver PWBA, then to the IME Controller which forwards the instructions to
the Marking Unit Driver which controls the Print Head roll, stitch motors and
x-axis motors.

IOD
Theory of Operation
The IOD is an A size (~8.5” long) scan bar located at the 6 o’clock position
beneath the drum. This is the identical type scan bar used in the RalPH for
skew measurement. It’s primary function is to ‘read’ special images on the
drum and send this information to the IME Controller for interpretation and
eventual movement of the individual print heads (PHs) to align them well
enough that the output images are similar to using a single print head.
Since the scan bar is ~ 8.5 inches long and the drum is ~ 12 inches in width,
the IOD is mounted to a rail system that allows movement of the IOD to
front and rear positions. This assures the IOD can properly see the
transition area between each of the four print heads.
The IOD is located beneath the drum. It is possible to contaminate the IOD
lens. To help avoid this, the IOD lens is covered by a Mylar shield which
remains in place except for those times the IOD is actually reading images
on the drum at either the front or rear read positions.

IOD
Theory of Operation
IOD calibrations occur on a regular basis depending on settings in software, but

checks of the print head alignment are more frequent until the machine is
considered thermally stable. This is to reduce misalignment caused by thermal
shifts to the SFWAs (Staggered Full Width Arrays) and IME (Image Marking Engine).
When the heads are re-docked, the thermal timer restarts and IOD calibrations will
be more frequent until considered thermally stable.
There is no IOD validate – adjustments are made and assumed to be correct or
better than before. They are not validated until the next cycle.
The IOD has three color outputs (RBG) that are used to achieve the best contrast for
the various colors printed on the drum.
The IOD module enables a variety of system functions. Its primary function is to
align the 4 print heads to create a seamless image. This is called Head-to-Head
Alignment, or H2H alignment. A second function is to adjust the jetting intensity of
the heads, again to create a seamless image. This is called Head-to-Head intensity.
Intensity for the whole print head is set to a value. Individual jets cannot be
individually adjusted for intensity. A third function is to detect and mask weak and
missing jets by substitution. This is called Jet Fix.

IOD
Sequence
The IOD sequence is only performed from a Standby state (or if called via
diagnostics).
When an IOD sequence is executed, the following steps are performed:
- DM (Drum Maintenance) - Cleaning via the Cleaning Unit. A DM cycle is
performed to prepare the drum for imaging.
- Calibrate - The scan bar is moved to the rear (or front) position. It reads
the bare drum surface with and without illumination to establish “black”
and “white” calibrations. This is done while the drum is rotating, so an
average is achieved. After calibration, the scan bar is moved to the park
position, which is the approximate center of travel of the IOD.
- Image - The target image is jetted onto the drum.
- Acquire - The scan bar is moved to the rear (or front) position. The image
is acquired by the IOD by rotating the drum with the target image past the
scan bar. After the IOD has acquired the image, the scan bar is protected
and moved to the park position.
Note: The drum sometimes turns CCW since this allows the fastest time to
move the image to the scan position.

IOD
Sequence
Analyze - The acquired target is analyzed by the IME Controller to calculate

head position. Note: Signals first go to the Drum Driver PWBA.
Correct - Appropriate head position corrections are calculated and applied.

There are 4 types of corrections:
Roll - Each PH has a small motor to adjust print head rotation in the radial
axis. IOD correction immediately moves these motors.
Y-Axis Offset (Y offset are all jet timing adjustments) - Each PH has a Y-
axis offset value from the drum home position that controls jet timing for
all jets on that head during imaging. IOD correction step updates these Y-
offset values (every 6 degrees from the drum home position)

IOD
Sequence
X-Axis offset - Each Staggered Full Width Array (SFWA) has an X-Axis
offset value from the SFWA home position that controls the starting
position of the SFWAs during imaging. IOD correction step updates these
X-offset values.
X-Stitch - Each (SFWA) has a head that is fixed, and a second head with a
small motor to adjust X-position relative to the fixed head. IOD correction
step immediately moves these motors.
Cleanup - A cleaning cycle is performed to scrape the target image off the
drum.

IOD
Sequence
IOD Operation Jet Fix

Weak and Missing Jets
Head Alignment
Data sent to
the Drum
Driver PWBA
H2H Intensity
Y-Norm IME
Controller
Drum Rotates
CW and CCW
MU
Print Heads Driver
PWBA
Ink printed on Drum

by Print Heads PH motors
Image scanned by IOD
PHs
IOD Mechanical

IOD
Type of Sequences
Types of IOD Sequences

Manual - Will be called from the UI via diagnostics.
Dock - Performs a Rear then a Front IOD scan every time the print heads
are docked.
Page - When turned on, every 500 pages the printer will stop and do an
IOD Rear scan then wait another 500 pages then do an IOD Front scan.
After that it will continue to alternate between Rear and Front every 500
pages. This will not occur in mid job

IOD
Summary of Sequences
Summary of Jupiter IOD sequences

Sequence Measures Adjusts How often How Long Target removal
X-Stitch Stitch & Roll Motors Automatic: 1 side: 20 seconds Scrape
iodAlign
Y-Stitch. SFWA X home position Every dock 2 side: 40 seconds
Roll Head Y timing offset 10x / day
Badjets
Purge
jetFix
jetSub
pixBorrow
Y-Stitch SFWA Y timing table Manual only: 2 minutes Scrape

iodRunout
runout Mfg
Service
100% Fill Head Voltage Automatic: 20 minutes 4 A4 chase sheets

iodUniformity
Intensity Head color norm clicks 2x / month. (3 iterations) Per iteration + 4
Midtone
Head delta TRC
Intensity
Jet Y-pos Head y-norm Automatic: 20 minutes 6 A4 chase sheets
iodYnorm
with (4 iterations) Per iteration
iodUniformity
Head Head Voltage Automatic: TBD TBD

DropMass
“dropmass” TBD
(IOD? IIT?)

IOD
Differences
Front & Rear sequence differences

Since the IOD can’t see one of the print heads during a scan, it can’t correct
head alignment for all 4 heads in one sequence. It only corrects based on
what it sees during that sequence. Also, it does not pass information
forward to a subsequent sequence—for example, it does not read head
position in a rear scan, then head position in a front scan, then correct all 4
heads.
The IOD has no home sensor. It drives fully in one direction until it stalls
and ‘assumes’ it is fully forward or rearward. Then it counts clock pulses to
the central park position.

IOD
Front and Rear Sequences
Measurement and correction for front & rear sequences

Head Positions Front Rear
Head 1 Roll Measure & move Can’t measure, don’t move
Head 2 Roll Measure, don’t move Measure & move
Head 3 Roll Measure, don’t move Measure & move
Head 4 Roll Can’t measure, don’t move Measure & move
Head 1 Y-offset Measure & move Can’t measure, move as if
stitched to 2.
Head 2 Y-offset Measure, don’t move Measure & move
Head 3 Y-offset Anchor Anchor
Head 4 Y-offset Can’t measure, don’t move Measure & move
Head 1 X-stitch Measure & move Can’t measure, move as if
stitched to 2.
Head 2 X-stitch Measure, don’t move Measure & move
Head 3 X-offset Anchor Anchor
Head 4 X-offset Can’t measure, don’t move Measure & move

IOD
Print Head align (front / rear scans)
Front and Rear Sequences

SWFA Pitch
Stop
Pin Pitch
Stop
0.0
Upper Right Roll

Upper Left Roll
5.8945
Last
+ Move - +
0.3mR Last
o o Move -
0.3mR
Upper SWFA
Upper Stitch
Start
Last Move +40um Last
` Move +40um Lower 9.696
Lower Stitch
SWFA Start
Lower Right Roll

Lower Left Roll
Last Last
+ Move - + Move -
0.3mR 0.3mR
o o
(Anchored)
Front Scan
Rear Scan
X-Stitch Roll
Roll X-Stitch Roll
Y-Stitch
Roll, Set Roll Measure
Y-Stitch Roll Measure
Only, Not
Only
Used
X-Stitch
X-Stitch Y-Stitch
Y-Stitch Measure,
Not Used,

IOD
IQ Calibration (1 of 2)

IOD
IQ Calibration (2 of 2)
IOD Run out measurement - (runout = amount of Drum out of round) IOD
reads drum run out at home (home determined by the drum encoder) and
at every 6 degree interval. These values are stored and used to set Y axis
run out variance of timing of the jets on the print heads. Perform this
calibration whenever the drum encoder is serviced (which may change the
home position) or the drum is changed (which will change the run out).
IOD Calibration - IOD white calibration occurs with the drum turning.
Calibration should be run after an IOD is replaced or removed and
reinstalled. If a Print Head or IOD is replaced – follow the repair procedure.
CBE (Chip Boundary Error) - If a jet lands on the chip boundary within the
IOD scanner (every 54 bits), the IOD has a higher chance to mis-read this.
To resolve this issue we may move the head (if the defect moves then you
have a PH jet failure) or move the IOD and if the defect moves you have an
IOD chip boundary failure.

IOD
Potential Field Failures

Contamination of IOD May cause mis-reads but SW should be
able to catch this since IOD scan bar and
shield don’t move at the same time.
IOD not in proper position IOD has no home sensor, it ‘homes’ by
driving until it stalls, then ‘assumes’ it is
in a given position but if it stalls in an
incorrect position – it has no way of
knowing this.
IOD drive broken Machine should post an error – and CSE
would fix at next service call – this error
should not put the machine down
IOD failure If a cycle cannot complete, the PHs are
left at the last known position and an
error is logged but machine remains
functional. CSE would correct on next
service call.

IOD
In the very rare case of paper being trapped between the IOD and the
drum, remove the IOD first and then remove the paper. This may help to
avoid damaging the shield over the IOD or the IOD itself.
The IOD re-installation should go in easily – do not try to force or you may
jam the IOD between the frames. It is important to keep both ends parallel
during removal and re-installation.
Extreme care should be taken if either of the ribbon cables on the IOD are
reseated – they are fragile.

Cleaning Unit

Cleaning Unit

Cleaning Unit
Function
The function of the CU is to:

− Lubricate the drum with a very thin, uniform layer of Silicone oil before
each print cycle.
− Remove any remaining pixels and debris left on the drum after each
print cycle.
− Provide the Customer with an easy and clean to change CRU.
− Provide a signal to help the Customer know when to order a CU if
necessary
− Provide a signal to let the Customer know it is time to replace the CRU
− Keep a running count of # of prints on the CU

Cleaning Unit
Front Panel
The following information about the CU is provided on the UI.
- Percent life remaining of the CU.
- Number of prints remaining of the CU. (Only during the final 3000 prints.)
The following status messages may be displayed as applicable:

− CU will need replacing soon. Reorder now, DO NOT replace until
requested.
− CU will need replacing soon. Please ensure the replacement is available.
− CU needs to be replaced. Replace Cleaning Unit now.
− CU is not detected. Please insert Cleaning Unit.
− A fault has occurred in the CU, Please Replace.
− Call For Service.

Cleaning Unit
Location & Removal
The CU is located below the transfix / exit area. It is easily accessible via
the Customer. There is a latching mechanism that keeps the CU from being
removed if it is not in the fully disengaged position.
If the CU does not slide out easily the CU cams might not be locked in their
home position. Use a straight slot screw driver to move the cams to their
home position through the cam shaft access hole as shown in next slide.
Once the cams are locked in their home position the CU should slide out
easily.

Cleaning Unit
Removal
Figure 1: Cleaning Unit Cam Shaft Access Hole

Cleaning Unit
Electrical Connections
There is only one electrical connection to the cleaning unit. This connection
includes the following signals:
- Serial link to the Drum Driver PWBA
- Transmit
- Receive
These go to J840 of the Drum Driver PWBA

Cleaning Unit
Components
Metering
Blade
Oil
Applicator
Roller
Peristaltic
Pumps
Oil Reservoir

Cleaning Unit
Components
Note: There are no spare parts for the CU because it is a CRU. The entire
CU is replaced as necessary. This section is only to familiarize yourself with
the internal workings of the CU.
Pressure sensor (may or may

not be there post launch).
Gives the ability to detect an
out of oil condition.
CU IF (Inter Face) PWBA –

distributes signals to the two
peristaltic pumps, CRUM (also
called an I-button) and to the
pressure sensor.
Figure 4

Cleaning Unit
Components
CU electrical connector
CU support rail
CU Latch mechanism:
As CU is inserted this latch will release (move to the rear).
As CU is removed the latch is moved to the front to lock the
mechanism in place – so the cams are locked in the down
position & CU can be reinstalled easily.
NOTE: Care should be taken to not run the cams while in
diagnostics unless this latch is unlatched (in and down).
CRUM corruption may occur if CU is removed while writing. To
avoid this, the CU latch motor waits ~2 seconds after opening
the front door interlock before unlocking the CU.
Redundant ground source to CU

Cleaning Unit
Components
When the CU is removed from the printer, the CU cams are locked in their
home position. It may be necessary in some diagnostics to unlock the
cams as shown below.
Cleaning Unit Cam Lock

Cleaning Unit
System Operation
The CU has a foam applicator roller, which is fully saturated with oil. When
the applicator roller is pressed against the spinning drum surface of the
printer, it floods the drum with oil. That oil is metered to a very thin,
uniform layer with a urethane blade, which is also pressed against the
spinning drum surface.
The urethane blade also removes any pixels which are left on the drum
from the previous print cycle. Consequently, the CU blade and applicator
roller accumulate ink buildup over time. The polypore foam applicator roller
helps to eliminate Gloss Uniformity issues and reduces Drum ghosting
(residual images showing on the following copies).
The applicator roller and urethane metering blade are actuated
independently by the CU cams inside the printer. Both of these components
are driven by the drum turning and have no independent drive

Cleaning Unit
The CU is tested prior to shipment and a small amount of oil will be in the
roller, the CU coats the drum prior to making each print / copy, it is cammed
away from the drum prior to application of the images.
Once an out of oil condition is sensed you have approximately 5,000 prints
before the roller becomes too dry to be effective
CU oil level low sensor actuates at approximately 40% remaining and then
is used to calculate remaining life. This calculation is then used to notify
the Customer as to when they should order a replacement.
A CU cycle places oil on the drum. This occurs just prior to applying ink to
the drum.

Cleaning Unit
Filter is called a slime filter and removes large ink particles from the oil
Internally, the CU has two peristaltic pumps for circulating oil through the
system and a pressure relief solenoid valve. Oil is pumped from an oil bottle
to the roller and re-circulated back into the bottle from a reclaim area. The
oil passes through a filter in the reclaim area before being pumped back
into the oil bottle.
The oil is pumped through flexible PVC blend tubing. Each CU starts with
1359 grams of oil, which should last approximately 220,000 prints.

Cleaning Unit
The CU has an internal circuit board which houses connectors, a pressure

sensor, and an EPROM. The pressure sensor is used for end of life sensing
and internal system diagnostics. The EPROM stores print count,
serialization, and calibration information about its respective CU.

Cleaning Unit
Schematic

Cleaning Unit
Facts
Each CU contains approximately 1359 grams of oil.
220,000 prints (anticipated average life over the product population)
Oil usage goes up with area coverage and throughput size. Therefore, life
goes down as area coverage and throughput size increases.
CU has a minor ‘catch’ to prevent Customer from removing the CU

completely until they pick up slightly on the CU.

Cleaning Unit
Grounding
CU makes a ground connection via feature at the front of the CU. This
mechanical ground makes prior to the rear electrical connector connecting
and remains grounded till after the electrical connector at the rear
disconnects during CU removal.
Loss of this ground may lead to CU circuitry failure because very high
electrical charges can build with the movement of the oil over CU
components.
NOTE: The ground thru the electrical connection is insufficient to fully

handle the current discharge to ground.

Cleaning Unit
Leaks
A drip pan has been added beneath the CU to minimize the affects of an oil
leak. This catch tray may need occasional cleaning. Efforts are still
underway to minimize the possibility of an oil leak.
Diagnostics built into the CU include a level sensor and a pressure sensor
which will be monitored to help avoid oil leakage.

Cleaning Unit
Service via Diagnostic Prints
Test Patterns available
Black Solid Fill
Serial Oil Bar Chase
Explanation of usage:
Black Solid Fill - Field of solid black pixels should be continuous. Large patches of
missing ink or significant amounts of missing individual pixels could indicate too
much or too little oil.
Gloss should be uniform - If the blade is ‘chattering’ the gloss will show a high
frequency artifact which cycles in the process direction (chatter marks will be
perpendicular to the process direction). If oil is being applied non-uniformly the
gloss will be uneven. If the roller is excessively dry there may be a distinct line of
transition between matte and glossy sections of the image.
Serial Oil Bar Chase - Should see a thin line of oil (< 3mm) approximately half way
between the fiducial marks. If line is faint or missing, roller may not be properly
saturated with oil.

Cleaning Unit
Print Quality – There are several potential print quality problems resulting
from a failed Cleaning Unit which include:
− Gloss artifacts – non-uniform gloss on the print.
− Ghosting – a ghost of the image of the previous print is visible on a print.
− Duplex Ghosting – a ghost of the image of the first side is visible on the
second side.
− Oil on paper – oil is visible on either side of a print.
− Cohesive failure – the printed image does not transfer completely to the
paper.

Cleaning Unit
Potential Field Problems (cont’d)
Failure Symptom
CU out of oil SW should catch this in time but if not, you’ll begin to hear a
‘ripping’ noise as paper is ‘peeled’ off the drum. This noise
starts about 8 to 10 pages after last CU cycle and begins to
cause jams at ~ 80 copies or less of A4 size paper.
Excessive oil Loss of image especially on Duplex prints and a dirty
running machine (see above)
Metering Blade void A knick or void in the metering blade may lead to IWM
(intermittent Weak or Missing Jets) or CWM (continuously
weak or missing jets). The root causal being excessive oil on
the drum being ‘slung’ onto the Print Head jets
CU Cams inoperative Drum would not get cleaned and previous images would
mix with throughput.

Cleaning Unit
Potential Field Problems (cont’d)
Failure Symptom
CU CRUM (I button) If you remove the CU during a write to the CRUM – you
corruption may corrupt the CRUM / I button. To avoid this you
shouldn’t remove the CU within 2 seconds of opening the
front door. This may only be of concern with a service
interlock cheater.
Oil on side one of a May be aggravated by running a large duplex job (i.e. 8.5 X
simplex 11 SEF) and then a simplex job (larger size, i.e. 8.5 X 11 LEF)
Blade Chatter May show up as severe dropout – sometimes in the process

direction.
Extraneous Oil May be out of position CU. If it gets pushed forward – may
come off one or more cams and not remove excess from
the drum – then contaminated drum and PHs and base
pan. One cause is incorrectly mounted abatement plenum.

Cleaning Unit
Do NOT run the Cleaning Unit cam motor without first manually unlocking
the CU latch. This is accomplished by pushing in and then down on the CU
latch tab.
High volumes of dithers (halftones) may lead to sludge buildup in the CU

and oil spots on the drum / copy – some cleaning of the CU blade may help
minimize oil spots caused by contamination of the cleaning blade.
The CU is not intended to be serviced internally, but rather treated as a

“Black box”. If a CU fails, the entire unit should be replaced. Most problems
due to a failed CU can be diagnosed by swapping the suspect CU with a
new CU.

Color and Image Quality

What is Color?
Color is our brain’s interpretation of different wavelengths of light. Light is

energy emitted by the sun in the form of electromagnetic radiation waves.
In the middle of the range of wavelengths is a small band that we can see
with our eyes - visible light.

How our Eyes See Color
All objects either emit, reflect, or absorb wavelengths of light. The color
that we perceive an object to be depends on the physical characteristics of
the object and which wavelengths of light it emits, reflects, or absorbs.
For example, an object appears to you as red because the surface of the
object absorbs blue and green light and reflects red. Only red light reaches
your retina.

The perception of color occurs when different wavelengths of visible light
enter the eye and stimulate millions of cells on the lining of the retina. The
retina contains two types of light sensitive cells called rods and cones.
Rods can perceive only light and dark, and work best in dim light.
Cones are sensitive to only
three wavelengths of light:
red, green, and blue (RGB).
When stimulated by light,
cone cells send electrical
signals to the brain.
The brain processes these
RGB signals and interprets
them as colors.

We can see many different colors even though the cones only respond to
red, green and blue light. This is possible because our brain interprets
simultaneous RGB wavelengths as other colors. For example, you perceive
purple because the brain has translated a particular intensity of red and
blue light together as purple.
The Retina
L-cones
Each of the three types of cone-shaped M-cones
cells is sensitive to the long, medium S-cones

Rods
or short wavelengths of light,
transmitting valuable information for
color interpretation by the brain;
Cornea
L-cones capture reds (long wavelengths) Lens
Optic Nerve
M-cones capture greens (medium wavelengths) Retina
The Eye
S-cones capture blues (short wavelengths)

Color Blindness
To some degree, the perception of color is subjective. If you ask any two
people what color something is, they are likely to have different opinions.
Mood, age, capability of the eye, cultural, and psychological factors all
affect how we see or interpret colors.
Color blindness is a deficiency caused by the amount and types of cones
each of us has in our eyes. It can also be caused by other defects of the
eyes as well as the nerve pathways between our eyes and brain.
•There are different degrees of color blindness.
•The most common is the inability to see reds and greens.
•Color blindness affects 8% of men and 0.5% of women.
An individual with normal color vision will see a 5

revealed in the dot pattern.
An individual with Red/Green (the most common) color
blindness will see a 2 revealed in the dots

Color Blindness
Normal Color Vision Red / Green Blue / Yellow

Blindness Blindness

Color Primaries (Additive Primaries)
Additive Primaries
Devices that emit light such as monitors, televisions, and projection systems
use only three colors - red, blue, and green (RGB) - to create all other colors.
These primaries are called additive primaries or display primaries.
Secondary colors: cyan, magenta, and yellow (CMY), are created by adding
two primary colors. Thus, cyan is created from blue and green, magenta
from red and blue, and yellow from red and green.
The secondary colors are all lighter than the

primaries because when one light is added to
another light the result is a brighter light. When
all three display primaries are added together the
result is white light. Thus, white light contains all
colors within it. Black is the absence of light, and
therefore, color.

Color Primaries (Subtractive Primaries)
Subtractive Primaries
Devices such as printers create images from chemical pigments such as
inks, dyes, or toners. These devices use subtractive primaries: cyan,
magenta, and yellow (CMY). The subtractive primaries are also called
process primaries. The secondary colors are red, green, and blue (RGB). Red
is created from magenta and yellow, green is created from cyan and yellow,
and blue is created from cyan and magenta. Notice that the additive
primary colors are the subtractive secondary colors and visa versa
Additive Subtractive
(light) (pigments)
Red Cyan
Primary Green Primary Magenta
Blue Yellow
Cyan = Green + Blue Red = Magenta + Yellow

Secondary Magenta = Red + Blue Secondary Green = Cyan + Yellow
Yellow = Red + Green Blue = Cyan + Magenta

Color Primaries (Subtractive Primaries)
With emitted light, color is created when lights of different color are added
together.
Subtractive color works in a different way. Process colors are created from
light reflected from a surface. Pigments absorb (subtract) some colors and
reflect others. Seeing a color in a pigment, such as red, means that red light
has been reflected and the other RGB colors of light (blue and green) have
been absorbed or subtracted by the surface.
Secondary process colors are all darker than the process primaries, because
when you add inks, dyes, or toners to one another, the result is a darker
pigment. When all of the subtractive primaries are added together the
result is black pigment. Thus, black pigment contains all colors within it (all
light is absorbed, none is reflected). White is the absence of pigment (no
light absorbed, all light reflected).

Color Primaries
The imperfections in inks, dyes, and toners make the combination of CMY
result in a color more like muddy brown. To compensate, black is added to
the three subtractive primaries to yield CMYK, where K stands for black.
CMYK are the colors of the four color process.
M
B
C K R
G
Y

Color Printing
C M Y K
During the
printing process,
color pigment is
laid down on the
surface in
patterns of tiny
dots. Colors other
than the
primaries are
created by
varying the size
and the position
of dots of
primary colors.

Color Mixing
Cyan, Magenta and Yellow can be combined to create almost all of the
colors visible to the human eye by combining any two primary colors in
varying amounts.
The color wheel is a good tool to help remember the relationships between
colors.
Colors directly across from each other subtract. For example, adding
magenta will reduce the amount of green.
Two colors on either side of a color combine to
produce the center color.
For example, magenta and yellow
produce red.

Factors Affecting Color

Characteristics of Color
The name we give to a color, such as green, orange, or purple, is that color’s
hue. Any given hue can be made lighter or darker and that is called a hue’s
value, lightness or brightness.
Sea green and pale green are both values of the hue green. When you add
white to a hue it is called a tint. When you add black to a hue it is called a
shade.
A hue can range from its most colorful,
or most intense, to grey. This range is
the color’s saturation or chroma. Highly
saturated colors are at their most colorful.
Desaturated colors are closer to grey.
Not all colors have hue. White, black
and all shades of grey are called neutral
colors. The color space model shown here depicts three dimensions: hue,
value (lightness), and saturation.

Paper
Manufacturers have many different varieties of whiteness, smoothness and
weights.
Paper has a particular white point which is the level of brightness of the
paper. White point is expressed as a number – with the maximum
brightness of 100. That would mean 100% of the light is reflected off the
paper. Most papers have a white point between 60 and 90.
White paper is not really white. It can be white, beige, yellow, blue or gray.
Here in the United States, paper tends to have a slightly yellow cast. In
Europe, paper tends to have a slightly blue cast.
Obviously, colored paper will change the appearance of printed colors.

Paper
The type of paper stock used has an important effect on the appearance of the
final document. Paper finish, brightness, and surface texture alter the
perception of color and its sharpness. White paper with a smooth surface
provides the best base material for printing high quality output. Use of paper
with color variations, such as parchment, will alter the image quality.

Illumination – Light Source and Color
Because we use Light Source Color Temp (Kelvin°)
reflected light to see Clear Blue Sky 12,000 to 27,000
color, the color we
Overcast Sky 7,000
see will vary based
on the color of the Daylight fluorescent lamp 6,500
light. Blue flash lamp 6,000
Temperature is a White flame carbon arc 5,000
way of measuring Sunlight 4,300 to 6,500
the intensity of light Clear flash lamp 3,600
and a measure of Gas filled Tungsten 2,856 to 3,200
wavelengths in the
Tungsten Lamp 2,400 to 2,700
visible spectrum.
The unit used to measure color temperature is Kelvin.
Notice the colors of the chart. Blue sky adds a blue cast to objects while Tungsten
light adds a reddish cast to objects.
5,000 Kelvin° is the standard color temperature for viewing color prints.

Illumination
Colors do not look the same under different lighting conditions. The effect
of colored light on perception is called Metamerism. A color that looks
bright and vibrant under white light may look dull and washed out under
colored light. It is important to use a consistent light source when proofing
colors. If the final output is to be viewed under colored light, it may
drastically alter the appearance of the document and should therefore be
considered in its design.
Sample viewed under Same sample viewed under

fluorescent light 5000°K light

Background and surrounding colors
Colors are strongly influenced by their surroundings. We perceive a color
differently depending on the background. This is called the adjacency
effect. Note how different the green rectangles below look against
different background colors, but are actually the same green.

Do squares A and B look the same or different?

Squares A and B are actually the same!

This is another example of the adjacency effect.

Device Gamuts
Everything in the physical world that can either perceive or produce color
has limitations in its ability to encompass the entire range of possible
colors. Each device used in a print process has its own range of colors that it
can produce, called a color gamut. The larger the gamut for a device, the
more colors it can produce.
The graphic below represents the gamut of all visible color and the gamuts
of other devices in the printing process. Notice that the gamut of all visible
color is much larger than the gamut for any of the color models. The RGB
color gamut used by monitors is much larger than the CMYK color gamut
used by printers.
Visible
If the machine finds colors in the image
that are outside the gamut of the CMYK (printer)
machine, it converts them to colors that RGB (monitor)
are within the machine’s gamut.

Resolution (Print Process)

Printing Resolution
The machine uses four printheads to create an image on the drum.

Each printhead contains 220 jets of each color (C,M,Y and K) providing a total jet
count per printhead of 880 (3520 jets for the complete 4-head imaging system).
This equates to 300 jets per inch arranged in an array.
Each Printhead creates a portion of the image. Pixel matching, monitored by the
IOD Sensor, ensures a seamless stitching together of Printhead output to deliver a
single image.
The image resolution achievable using a single pass is 75dpi. To increase image
resolution in the cross process direction, the image is built up using several passes
to achieve the required image resolution. At each pass of the image past the
Printheads, the Printheads are slightly offset to avoid the build-up of ink drops on
top of each other.

Printing Resolution
For example, to develop an image of 375dpi on the drum, the image is built up over 5
passes (75dpi x 5 passes = 375dpi). The image resolution in the process direction is
determined by the speed of the Drum while in the imaging cycle.
In order to achieve any different resolution in the process direction the speed of the
drum must change, therefore the imaging time will change for each revolution.
Depending on mode selected and jet sub requirements, it can take up to 10
revolutions of the drum to create a complete image.
2nd pass 4th pass And so on…

1st pass 3rd pass
NOTE: PCL input is typically 600x600. The machine scales this to 450x500 at
normal mode resolution to provide Normal mode performance.

Changing Resolution
For print jobs:

Select Print Quality under
the Paper/Output tab. Select
the desired quality.

Changing Resolution
For copy jobs:
Copy Quality (resolution) is changed on the UI. On the Image Quality Tab
select Image Options. Use the slider for Sharpness to change between
‘Soften’, ‘Normal’ and ‘Sharpen’.

Stitching and Stitch Errors

Stitching
Stitching refers to the alignment of the printheads and timing of jet firing to obtain
one solid image out of the four printheads. This is achieved by using the Stitch
motors, Roll motors and X-axis motors in the Marking Unit. Control of these motors
is provided by the IME Controller PWB using input from the IOD sensor assembly.
Upper X-Axis Drive Motor

Roll Motor
Stitch Motor
Lower X-Axis Drive Motor

Stitch and IOD Sequence
The IOD monitors the image being produced by the printheads and corrects for
misalignment by feeding back information to the IME Controller PWB.
Drum Maintenance
Calibrate
The system performs IOD
sequences on four occasions:
Clean up
At Power On Image
Check initial image quality
Correct
Calibration Routines
Detect test images
Intelligent Ready Idle time Acquire
Check for missing jets and Analyze
purge or substitute as needed.
Normal Operation
Every 500 prints

X-stitch Errors (cross process direction)
X-stitch errors are usually seen as white lines through all colors or text. Primary causes for X-stitch
errors are print heads out of alignment, weak jets, IOD problems or using fast color print mode. In
some cases, X-stitch errors can also be seen as dark lines in the stitch regions if pixels overlap.
X-Stitch errors are easily confused with missing jets. Remember that missing jets only affect
some colors (not all) and can appear anywhere on the page. X-stitch errors will affect all colors,
and only appear in stitch regions. The stitch regions are identified with chevrons on the test prints.
Example of X-stitch error. Example of missing jets.

Note the defect occurs over Note the defects do not occur
the chevrons and affects over the chevrons and affect
more than one primary color. only one primary color.
X-stitch motion of printheads

X-stitch Errors (cross process direction)
There are 2 types of X-stitch errors:
Static X-stitch
Static X-stitch is a stitch error that remains consistent from the lead edge of
the page to the trail edge of the page. Static X is most likely caused by a
failure of the IOD, weak jets, X-stitch or X-axis motors.
Transient X-stitch
Transient X-stitch is a stitch error that varies in intensity from the lead edge
to the trail edge of the page. Transient X is usually the result of slight IB-OB
movement of the drum as it rotates. This may be due to faulty drum end
bells, bearings, debris on the inside surface of the drum drive belt or a
wobbling drum drive pulley.

Y-stitch Errors (process direction)
Y-stitch errors can be seen on horizontal lines or in text. Y-stitch errors are
alignment errors, which are dot placement problems spanning all colors in
one or more of the printhead stitch zones. (chevrons indicate the stitch
zones). Primary causes for Y-stitch errors are drum drive belt slipping or
drum encoder problems.

Y-dot Position
Y-dot position refers to the timing of the firing of the jets in the printheads. Y-dot can also be a
printhead roll problem, since the timing of jet firing can be thrown off by printheads that are not
properly in line with each other. Y-dot can affect all jets or only one jet on a printhead.
This has to do with the spacing between the printhead face and drum surface. Because the
printhead is flat and the drum is round, the jets on the outer edges of the Jetstack are further
from the drum than the jets toward the middle. Therefore, the timing of the firing of each jet is
adjusted to ensure accurate placement.
Flat PH Jetstack
Round Drum
Jet distances from drum

vary from jet to jet
Y-dot position error Y-dot position error Examples of acceptable Y-dot

magenta jet only all jets position

Common IQ Issues

Color Shift when Copying Solid Ink Originals
A color shift can occur when copying originals that have been printed with solid ink.
This is primarily because black solid ink reflects deep red, where toner does not significantly
reflect deep red. In other words, the spectral response of the solid ink versus toner is different.
Black solid ink does not absorb the deep red portion of the spectrum. The most noticeable result
is black reproducing with a reddish hue.
An IR filter in the FWA can significantly minimize this effect. In pre-production machines (like
ICAT, Alpha, ECAT and even some early training machines) the scanners had the IR filter
removed in an attempt to reduce UMC. This decision has been reversed and the IR filter will be
cut-in again beginning with P11 build machines.
To get the best possible result, it is important
to select the correct original type and
production method from the
Image Adjustment Tab on the UI.
Solid Ink Copy of Solid

(K-only) Ink (K) at
Original default

Punched Media Concerns
When printing on punched media, it is important to set the tray attributes to
punched. If the image on the drum overlaps a hole in the media, the ink in the
area of the hole will be left on the drum and may appear on subsequent pages.
By setting the tray attribute to punched, a larger margin (edge erase) will be
applied to the edge of the page with the holes.
If part of the image goes across This ink can then turn up anywhere
a punched hole, the ink gets left on subsequent images
on the drum from the transfer

Edge Erase
The minimum edge erase the machine will print with is 4.3mm. This is
because we do not want to risk having ink overlap the edge of the media
which could result in ink being left on the drum which could then appear on
subsequent pages. This problem is avoided by not allowing print to edge.
As of 036.05 Alpha software, the user can select an minimal edge erase of
0.1”. Even with this setting, the machine will still produce a 4.3mm (~3/16th
or ~.2” of an inch) margin on all edges on the output.

Jetting Issues – Weak, Sputtering or Missing Jets
Weak, sputtering or missing jets are caused by small bits of debris or
contamination in the ink within the print head, print head drool or wiper
blade chatter.
The corrective action for jetting issues is always a purge (dC968). If purging
does not resolve a jetting problem, you must jet sub or replace the print head.
Never touch or attempt to clean the face of a print head!
Sputtering Jet Examples
Missing Jet Examples

Weak Jet Example

Jet Condition
Jet condition is monitored by the IOD.
Jets are classified in 4 ways:
Good – jet is operating normally
Missing – jet is detected as missing. The machine will attempt to recover
this jet during Intelligent Idle Time. The 9201 uses a different process for
this than 9202/9203 machines.
Chronic – jet is still missing after 3 consecutive Intelligent Idle Time
attempts to recover it.
Masked – a chronic jet that is being substituted by a good adjacent jet.
Jets may be masked automatically by the IOD if Jet Substitution is enabled
by the machine Administrator, or manually masked by the CSE. You may
manually mask a jet even if Jet Substitution is disabled.
Jet condition is displayed on both the Customer Jet Test Pages and the
Service Jet Test Pages.

Identifying Bad/Chronic or Masked Jets on Customer
Jet test pages
Jets will be marked
on Customer Jet Test
Pages as follows:
W = Bad (missing)
C = Chronic
M = Masked

Identifying Bad/Chronic or Masked Jets on Service Jet
test pages
The color of the jet number on
the Service Jet Test Page
indicates the status of the jet.
Black = Good
Purple = Missing
Red = Chronic (will be
masked automatically
if Jet Sub is enabled)
Green = Manually Masked

Jet Recovery Strategy
9201 9202 9203
Advertised color speed 38 ppm 45 ppm 50 ppm
Average blended speed with 42 ppm 44 ppm 48 ppm
bad jets (50%color, 50% B&W)
Allowable missing Black jets 1 1 0
(proactive night purge)
Allowable missing Color jets 20 6 1
(proactive night purge)
Freeze/Thaw recovery No Yes Yes
Speed up with bad jets Yes Yes N/A
Color Chronic message 2 consecutive Any 2 chronic Any 1 chronic
Black Chronic message Any 1 chronic Any 1 chronic Any 1 chronic
Service Action when IOD does Mask Mask 1st – Replace PH
not detect missing jet (up to 40 replace PH when
color or 2 2 chronic
black jets)

If Full Fix (Purge setting) feature is set to Eco fix (the default setting),
during the next Automatic Maintenance Cycle (that happens during the
night idle time), the machine attempts to purge and clear missing jets if:
Model 9201 - any 2 black jets are missing, or any two consecutive jets
are missing (black or color). No purges are attempted for non-
consecutive, missing color jets.
Model 9202 - any 6 color jets are missing, any 2 black jets are missing,
or any two consecutive jets are missing (black or color).
Model 9303 - any 2 color jets are missing, any black jet is missing, or
any two consecutive jets are missing (black or color).

Freeze-thaw sequences:
After 3 regular warm purges, 9202/9203 machines perform a 30-minute
freeze-thaw sequence as a final attempt to clear problem jets (during next
Automatic Banding Fix sequence).
9201 machines never perform freeze-thaw sequences. It marks the jet as

chronic if the 3 warm purges fail to clear the jet.
After 3 unsuccessful attempts to clear a missing jet:

• The machine labels the jet as “chronic” and will mask the jet.
• A Service Code with UI message will be triggered as follows:

If the machine successfully detects a previously chronic jet has recovered at a later
time:
• The Service Code and UI message will be cleared.
• Masking will be disabled for the jet.
• The maintenance cycle counters for warm purges and freeze-thaw will be reset.
Full Fix settings control how the machine behaves after detecting a missing jet:
• Eco Fix (default setting) - during the next Automatic Maintenance Cycle (that
happens during the night idle time), the machine attempts to purge and clear
missing jets.
• Immediate – the machine purges frequently because it will not wait for the
missing jet limits expected for purging (example: 6 non-consecutive color jets for
Model 9202).
• Off - purges will not occur.

Impacts of Jet Sub Mode
Jet substitution can slow down the print speed. However, it has an impact
on print speed only when:
•The masked jet is needed for imaging.
•The jet is located within the A4, LEF print zone (4.3 mm margin).
If a missing jet exists in the A4 (with 4.3 mm margin) LEF print zone, a
special speed-up mode increases print speed for all pages that DO NOT use
masked jets.

Speed up mode is enabled if:
• A jet is manually masked.
• The IOD Sensor detects a missing jet within the A4 (with 4.3 mm
margin) LEF print zone.
Speed-up mode causes pages to print at the maximum 9203 speed for the
selected Print Quality Mode, regardless of the machine type.
The machine disables speed up mode if a jet is unmasked manually or by
the IOD Sensor.

Speed Up Mode Example:

The maximum Enhanced mode print speed is 38 ppm for 9201 and 50
ppm for 9203. If a 9201 prints a 6 page document that uses a masked jet
on pages 2 and 5 only, the machine generates the pages at the following
speeds:
– Pages 1 and 2 - 28 ppm
Two images are simultaneously created on the drum for each pair of LEF
pages within the same job. In the above example, extra drum revolutions
will be required to mask the jet for page 2, thus decreasing the Page 1 print
speed. This principle also applies to Pages 5 and 6.

Jetting Issues – Color Mixing
Color mixing is caused by ink of one color mixing with ink of a different color in one
or more jets of a print head. This can occur after a purge as the wipers can push ink
into surrounding jets. Other causes of color mixing are print head drooling, wiper
blade chatter and tilting hot printheads.
Cleaning pages (mud pages) are intended to clean out any color mixing in the jets
after a purge, but may not always be 100% effective.
The corrective action for color mixing is running copies/prints or solid fill test
patterns of the appropriate color (dC612). Continue running solid fills until no color
mixing is seen.
Color Mixing
Wiper
Movement
Examples of Color Mixing

Ink Mixing – Printhead/Umbilical
Ink Mixing can occur in the Printhead Reservoirs, Umbilicals and the Melt
Reservoir.
Printhead/Umbilical Ink mixing will usually affect only one or two
Printheads.
Y
Example of ink mixing in Yellow,
PH1 and 3 only M
K
Because Y is used in the
secondary colors R and G, the R=M+Y
mixing can be seen in the
R and G color bands, but not G=C+Y
as prominently.
B=C+M

Ink Mixing – Melt Reservoir
Ink mixing in the Melt Reservoir will ultimately affect all 4 Printheads, although at the
time of service the mixing may not be seen in all 4 Printheads because the contaminated
ink may not have had time to be delivered to all 4 Printheads.
When dealing with ink mixing issues, the recommended action is to perform 3 Printhead
Purge cycles. This is because 3 purge cycles will cause the umbilical/printhead reservoir
combination to deplete all of the ink contained in the umbilical/printhead reservoir
combination.
If the problem is ink mixing in the Melt Reservoir, you should see the ink mixing appear in
all 4 printheads after 3 Purge Cycles.
If the problem is contained to a Printhead or Umbilical, you should see the problem
resolved after 3 purge cycles, or remain isolated to a specific Printhead(s) after 3 purge
cycles.
Do not confuse color mixing on the Jetstack face after the purge with ink mixing in
the Melt Reservoir appearing in previously unaffected Printheads. If in doubt, run 4
extra sets of Cleaning Pages from dc968 before evaluating more test prints.

Head to Head Uniformity
Head to Head (H2H) uniformity refers to the intensity of the image
produced by each individual print head compared to the other heads.
Ideally, all 4 heads will have the same intensity and create a uniform
image in the cross process direction.
If H2H uniformity issues are seen, run dC972 to correct the problem.
Stitch Stitch Stitch
Head 1 Head 2 Head 3 Head 4
•Sensitive in non 100% fill areas •Artifact should persist if any stitch
•Head areas 1,2,3,4 should be the same color defect is resolved

Secondary Banding
Secondary banding is bands seen in NON primary colors, due to alignment and
jetting between colors being slightly non uniform. This shows as increased
patterning (or banding) in secondary colors.
Primary colors are:

Cyan, Magenta, Yellow, Black
A Secondary color is a mix of two primaries.

Red, Green, Blue
Magenta Cyan Cyan
+ + +
Yellow Yellow Magenta
Tertiary colors are mixes of three primaries

(Refer to IQ 14)

Print Head Ringing
Print head ringing is a low level problem which can be seen as light bands
on either side of a cross process line in a solid fill (usually a dark solid fill).
This is caused by the large number of jets that must turn off and then on
again to create a lighter line in a dark fill area. The liquid ink in the
printhead will ripple, like throwing a rock in a pond. This causes slight
momentary changes in drop mass.
This is an image dependent defect, therefore most customers will not see
ringing.
At this time, there is no resolution for print head ringing.
PH Ringing
Scan of actual print Exaggerated example of ringing

Printed Colors Shift over Time with Exposure to Light
Magenta solid ink fades
considerably when exposed to gy
sunlight. The graph shows a 65
LE Cyan
60
significant increase in DeltaE, LE Magenta
LE Yellow
55
with the Blue and Red following 50
LE Black
the rise in Magenta. Blue and Red 45

LE Red
LE Green
show an increased DeltaE value 40

LE Blue
due to being partly composed of
Delta E
35
Magenta. The fading is clearly 30
visible on the Magenta, Blue and 25
Red colors while the other four 20
colors on the print, Cyan, Yellow, 15
Green and Black, show little or no 10
visible fade. 5
0
It is important to remember that 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Hours Exposed
when exposed to sunlight the
colors on the print will fade, in
varying degrees, over an
extended period of time.

Gloss Variance
Gloss variance is generally caused by an oiling variation

high oil = low gloss
low oil = high gloss
Very low oil causes very high gloss and if it gets low enough, you’ll hear a
ripping noise as paper is stripped from the drum. Soon after that the
machine will jam with a paper stuck to the drum

Drum Ghosting
Drum Ghosting is defined as an outline of a previous image, especially of multiple
copies, showing up in the next image. The defect is caused by a slight difference in
the oiling of the drum caused by non image areas retaining slightly more oil than
those areas which received ink. Ghosting can occur on any color, and the position on
the page can be random. Ghosting normally improves as multiple pages are printed.
For example:
If you run an Followed by an You might see

image like this image like this ghosting like this

Dropout
Dropout is actually missing ink pixels on the printed page (pixels remain on
the drum and do not transfer to the media). It appears as white spots or an
overall grainy appearance. It is most easily visible in halftone regions and
occurs most frequently on the second side of a duplex print. However, it can
also occur on simplex prints as well on particularly rough media.
A common cause of dropout is improper oiling of the drum.
Note: Although the example

shown here illustrates dropout
on the trail edge of the second
side, dropout can occur
anywhere on the page.

Fold / Crease Permanence
When an image is folded (like in the Booklet maker) the ink can crack and flake off
the page in the fold area. This is a solid ink limitation.
Some ideas to improve fold fix:
Slower speed (~9ppm when using the tri-folder in the HVF)
Lighter weight paper
Running in Standard mode (enhanced mode is worst)
Warm throughput (waiting to fold later makes the fix worse)
Color (solid blues and greens are worst)
Outside radius is worse than the inside radius
Specifications is under review as of (08/02/07) and have asked that the
specification be something that can be measured in the field and is clearly stated in
the Expectations Documents.

Embedded Test Prints
Revised: 04/07/2009
Table of Contents
Table of Contents Xerox Internal Use Only
Test Print Chevrons ( )
Most Embedded Test Prints have chevrons on them to identify the stitch
regions between printheads on the prints. This can be very useful especially
when trying to differentiate between missing jets and stitch defects.
Note: On Simplex – the chevrons point to the leading edge.

TP 1 Initial Test Prints Test Pages – run from dc612

These A or A4 pages are a set of diagnostic test prints used to initially diagnose image quality
issues in IQ 1. TP 1 prints the three test pages shown.
Purpose
These test pages are printed as part of an
evaluation of image quality performance
in IQ 1. Examine each print for the following:
•The color bands print is useful for identifying

jetting, stitching, and uniformity defects.
•The horizontal lines print is useful for
Y-dot position, Y-stitch, drum runout and
printhead alignment defects.
•The text print is useful for line separation
and resolution defects.

TP 2 ~ TP 10 Solid Fill Test Pages – run from dc612
Solid fills are used to purge the jets of contamination or correct cross-color contaminated jets.
Solid fills are also used to examine media damage, cleaning unit function, skew, and margins.
Purpose
These are single-sided, solid-fills in eight colors. If colors are uneven or wrong, see IQ 13.
Look for:
•Even uniform fill throughout each print.
•Wrinkles or deformity of the paper.
•Proper ink transfer.
•White striping or banding.
Causes:
•Weak jets or improper drum heating can cause uneven fills.
•To solve wrinkling, try different media. See IQ 24.
•If there is poor transfer on one side, check to see if the transfix
linkages are moving correctly and free of debris. If either transfix
linkage is worn, install a new assembly.
•If there are repeating white stripes, see IQ 9.
For skew and margin defects see IQS 1.

TP 11 - Color Bands and Dithers – run from dc612
These A or A4 pages are a set of diagnostic test prints used to
diagnose image quality issues related to color uniformity.
NOTE:
Defects revealed by the prints may not occur in the course of
ordinary printing. In servicing the system, you should minimize
the defects shown by the prints but not necessarily eliminate
them.
Purpose
These pages are used to evaluate print quality problems caused
by drifting or misadjusted printheads.
Look for: Vertical bars or bands of much lighter color or a
different hue running in-line in one or more of the solid fills.
Causes: A weak jet can cause banding; see the jets test print.
Banding is also caused by incorrect color-to-color registration.
Use Service Diagnostics to ensure that the printhead and drum
thermals are correct. Refer to IQ 13, IQ 14, and IQ 15 for
examples of common color uniformity problems.

TP 12 Chase Page – run from dc612

Chase pages are picked from the selected tray and fed through the media path. No image is
applied.
Purpose
Chase pages are used to clear the drum of any residual image or possible contamination.
Chase pages are also useful for examining jam conditions and media damage. Use chase
pages to clear the media path, clean light contamination from the registration/preheat
assembly, drum, or transfix roller.

TP 13 Text Test Pages – run from dc612
Text test pages are used to diagnose text quality defects.

There are no known imaging problems that affect only text
and allow all other printed objects, such as fills, dithers, lines,
and pictures to be defect-free. Text quality is particularly
sensitive to incorrectly placed dots; thus it is most dependent
on proper printhead operation, mechanical alignment, and
motion. The third page of landscape text repeats the same
characters over and over again across the page to aid in
detecting spatial variations in dot placement. Look for relative
differences between the quality of the characters across the
print.
Most likely causes of poor text quality are:
•Pages printed in low resolution (fast or standard modes)
•Printhead out of adjustment; see IQ 5, IQ 9, IQ 12, IQ 13.
and IQ 14
•Printer out of adjustment; see IQ 6, IQ 11, IQ 20, and IQ 21

TP 14 Drum Stripper Blade Test Page – run from dc612
This print is used to diagnose errors related to the drum stripper blade and stripper drive. The
drum stripper blade test page records stripper blade activity during two typical drum stripper
activation sequences. In addition to blade timing, anomalies in the blade such as warpage,
bounce, or edge damage may be visible in the stripped area of the image.
First, the image is created on the drum. The drum stripper blade is activated to simulate the
stripping of two sheets of media.
The area where the stripper blade contacts the drum is visible
on the print as the wiped off region. The test print is followed
by two chase sheets to clean the drum.
Purpose
Record drum stripper blade action.
During normal operation, the drum stripper blade makes contact in
the 10 – 20 mm window of pitch 1 and 245 – 255 mm window of
pitch 2 (left side scale). The drum stripper blade releases from the
drum in the 35 – 45 mm window of pitch 1 and 270 – 280 mm
window of pitch 2 (left side scale). If the test page indicates the
stripper blade is releasing either earlier (release mark is before the
MLE line), or later (release mark is beyond the MLE line), the stripper
drive assembly (solenoid) is damaged or installed incorrectly.
The drum driver
board may also be defective.
TP 15 Media Path Test Pages – run from dc612
Print the media path test page using the same size media as
the affected print. Reconstruct the media path by aligning the
test pages vertically. Jam zone 1a at the top through 4b at the
bottom.
Compare markings on the affected print to the features on
the test print to determine the jam zone, nip, or ribs affecting
the output. The test image is cropped according to the media
size selected for printing. To see the complete image, use SRA3
or tabloid extra media.
Purpose
The media path test page is used to locate the source of scratches,
marks, or gloss differences on the output due to transport components.
The page is organized according to the media path layout. Each of the
jam areas (1a through 4a) is segregated on the test print with a horizontal
line. Rollers for each nip are identified by letter, and rib locations are
indicated by rectangles or hash marks.
For example, jam zone 1a, located at the top of sheet 1, includes nips H and
F and ribs to guide media up the vertical transport. The roller contact
locations, both drive and idler, are shown along with contact points for the
ribs.

TP 16 Stitch Identification Test Pages – run from dc612
The printheads work together to stitch the image together. The X-stitch and Y-stitch
patterns print when the stitch identification selection is made from dc612.
Purpose
The X-stitch and Y-stitch patterns check the accuracy of printhead alignment.
Example of X-stitch error in PH2

TP 17 Printhead Uniformity Test Page – run from dc972 (option 3)

This A or A4 page has seven solid fill bars of colors yellow, magenta, cyan, black, red, green,
and blue.
Purpose
The printhead uniformity test page is used to
diagnose image quality issues related to color
uniformity in solid fills. This page
(accessible via dc972 --> Option 3 --> Print Test)
is part of the printhead uniformity adjustment
sequence used to correct print quality problems
related to color uniformity and dot position.
Refer to IQ 13, IQ 14, and IQ 15 for examples
of common color uniformity problems.

TP 18 TRC Generation Test Pages – run from dc972 (option 4)
These four A or A4 pages have red, green, blue, or black step dithers.
Purpose
The TRC Generation Test Pages are a test print
suite used by service to diagnose image quality
issues related to color uniformity in dithers. This
page (accessible via dc972 -->Option 4 -->Print Test)
Refer to IQ 13, IQ 14, and IQ 15 for examples
of common color uniformity problems.

TP 19 Y-Dot Position Correction Test Page – run from dc972 (option 5)
This A or A4 print consists of 1 and 5 pixel thick lines in the cross process direction. The colors of
the lines are blue, green, red, black, yellow, magenta, and cyan.
Purpose
The Y-Dot Position Correction test page is a
diagnostic test print used by service to diagnose
image quality issues related to dot position errors
in the process direction. This page
(accessible via dc972 --> Option 5 --> Print Test)
Refer to IQ 5 for examples of common problems
with dot position in the process direction.

TP 20 Oil Bar and Metering Blade Timing Test Pages – run from dc959
There are 3 test prints available from the cleaning unit diagnostics screen. The black solid fill, serial
oil bar chase, and dynamic blade timing (note that 2 and 3 are printed together).
Purpose
These test prints are used to check operation of the cleaning unit.
The oil bar chase print is used to check cleaning

unit roller oil saturation. A thin line (~3mm) located
approximately half way between the fiducial marks
should appear on the page. If line is faint or missing,
the cleaning unit roller may not be properly
saturated or contacting the drum.

The dynamic blade timing page is used to check operation of the cleaning unit blade and roller
contact area. The blade removes residual oil and ink following transfix and prepares the drum for the
next image by spreading the oil evenly across the drum’s surface. The blade engages the drum
150mm past the leading edge and continues wiping through the deadband and lifts at 50mm past
LE. This leaves approximately 100mm of unwiped area in the center of the A/A4 page. The target
points are 50mm and 150mm from the leading edge. The test print should have a uniform field of
pixels between the black target lines labeled blade
engage and blade disengage. Blade timing is within
tolerance if the field is wiping off within 5mm of
target lines and pixel wiping is between the dashed
lines on either side of target line. Outside of the
target zone, the image should be wiped off
uniformly. If part of the image remains, this may
indicate improper roller and/or the blade contact
with the drum. If significant portions of the image
remain, the roller may be dry or improperly engaged
with the drum. If the remaining pixels are not
uniform, the roller may be clogged or improperly
engaged with the drum.

The black solid fill is used to check the application of oil. Gloss should be uniform. If the
cleaning unit blade is chattering against the drum, the gloss will show a high frequency
artifact which cycles in the process direction (chatter marks are perpendicular to the process
direction). If oil is being distributed incorrectly, the gloss appears blotchy. If the cleaning unit
roller is excessively dry there may be a distinct line of transition between matte and glossy
sections of the image. Large patches of missing ink or significant amounts of missing
individual pixels could indicate too much or too little oil.

TP 21 Jet Test Pages – run from dc968 or dc977
Jet test pages (2, 4 or 8 pages dependent on version and media size) are used to check printhead
jet status. Two versions are available, customer and service. The service version consists of a
number of test pattern sheets. Service jet test pages do not use jet substitution, but do indicate
jets the IOD has identified for substitution with Red jet numbers. Jet test prints demonstrate
effective print quality and provide visual feedback on the health of printhead jet stack.
Jet numbers can be one of four colors:

Black = healthy jet
Red = identified chronic missing jet
Purple = identified missing jet, but not yet chronic
Green = jet that has been manually masked
You may also see color variations from jet to jet on

the jet test print. Some variation is normal and usually
self corrects within a few printed pages.
Printheads occasionally get clogged jets that require user

intervention to restore jet function. When a clogged jet
occurs, areas of solid color may show signs of light stripes.

TP 22 Cleaning (Mud) Page – run from dc968
The two-sheet cleaning page, [Figure 1], prints following a purge to clear the jets of any ink
discoloration. The cleaning page must print long-edge feed on A or A4 media. Tray 3 is the default
source. The cleaning page is also available from dc612.
Purpose
The cleaning page flushes the jet nozzles of possible
contamination or color contaminated jets. The first
sheet cleans printheads 2 and 4 on the upper carriage.
The second sheet cleans printheads 1 and 3.
Three sets of prints typically clear any ink
mixing or discoloration associated with
printhead maintenance. If discoloration
persists after three prints, see IQ 14.
NOTE:
Do not use the cleaning pages to evaluate
print quality.

TP 23 Drum Runout and Y-Stitch Test Pages – run from dc977
The two-page drum runout test print provides
visual indication on the success or failure of
drum runout and Y-stitch calibrations. Two
pages of horizontal lines are printed to cover the
entire drum. The print order is marked in the
upper corner (P1 and P2).
The images in the callouts are examples of a
drum runout defect as it would appear on this
test print. Notice that the horizontal lines are
offset with PH1 lines being lower than PH2 at
first, then the lines become aligned, and finally
on P2 the lines produced by PH1 are higher than
lines from PH2.
The prints are arranged vertically and the lines
evaluated for consistency. The drum runout test
print may also be run as a pre-check before
running the drum runout calibration routine
dc977.

TP 25 IME Test Print
This test print isolates the IME from other system issues. The
image is a simple pattern of colored bars as shown. The image
includes primary color bars printed by all four printheads. Image size
is the width and length of the media less the 4.3 mm margins. The
tray selection is from the 3TM and prints on A or A4 media only.
The print is printed simplex with a 600x600 resolution. Print
orientation (LEF vs. SEF) is determined by how the selected tray is
loaded. The tray is selected automatically based upon the same
priority system used to select a chase source. An error is noted if none
of the trays contain valid media. If a finisher is installed, the sheet is
sent to the catch tray on the finisher.
1. Turn the machine off.
2. Open the left mid door.
3. Remove the waste tray.
4. Close the front door or insert an interlock cheater.
5. Power up the machine. Look for three blink pattern on the Marking Unit’s upper Red LED.
6. Close the left mid door, insert the waste tray and close the front door or keep the cheater in
place.
7. An A or A4 sheet will be printed.

Validating and Adjusting IOT
Primary Color Output
Revised: 04/07/2009
Table of Contents
Adjusting IOT Color Output
There are no IOT color adjustments that will affect print jobs. Print job color is only
adjustable in an application (Word, PowerPoint, etc) or in the print drivers.
The user can, however, make several adjustments on the UI to each of the process
primaries. These adjustments will only affect copy jobs.
To do so, select the Image

Adjustment tab on the UI,
then select Color Balance.
The screen to the right will
be displayed.
The selections available on
this screen are explained on
the next few slides…

Color Balance – Basic Color
On the Basic Color Balance screen, you may increase or reduce the amount
of process primaries used in printing. Slide the indicators up or down as
desired, and select save in the upper right corner of the screen. Your
selections will then go into effect until the machine times out or the Clear
All button is pressed.

Color Balance – Advanced Color
On the Advanced Color Balance screen, you can make more specific
adjustments to each of the four process primaries in terms of highlights,
midtones and shadows. This allows for a more precise adjustment of color
than the Basic Color Balance Screen.
Slide the indicators up or down as desired, and select save in the upper right
corner of the screen. Your selections will then go into effect until the
machine times out or the Clear All button is pressed.

Color Balance – To Add or Reduce?
So how do you know which process primaries to adjust – and should you
increase or decrease them?
The table on the following slide provides a guide to adjusting process

primaries.
How much should you adjust? The answer depends on the observer, lighting
conditions and the media being used. In other words, it’s trial and error.
At this time, there does not appear to be a way to set these adjustments as
defaults, so they would need to be adjusted for each job run.

Basic Color Correction Quick Reference
If the image is And the image is Adjust these CMY’s

Too Red Too Dark Reduce M & Y
Too Light Add C
Too Magenta Too Dark Reduce M
Too Light Add C & Y
Too Blue Too Dark Reduce C & M
Too Light Add Y
Too Cyan Too Dark Reduce C
Too Light Add M & Y
Too Green Too Dark Reduce C & Y
Too Light Add M
Too Yellow Too Dark Reduce Y
Too Light Add C & M

Color Sampler Pages
Users have the ability to print Color Sampler Pages from the UI. There are
three types of Color Sampler Pages:
1. CMYK Sampler Pages

2. RGB Sampler Pages
3. Spot Color (Pantone) Sampler Pages
Sampler pages allow customers to specify

colors in documents which will produce the
desired color when printed.

Color Sampler Pages
The Sampler Pages print sample squares of color. The formula for each color
is printed under each square.
To obtain a good color match between Sampler Pages and user created
documents, it is extremely important that the driver settings for Print Quality
and Color Correction match the settings that the Sampler Pages were printed
with.
It is equally
important to use the same
media.

Color Sampler Pages
To match print driver settings

to Sampler Pages settings,
perform the following:
1. Under the Paper/Output

tab, select desired Print
Quality setting.

Color Sampler Pages
Under the Color Options Tab:
2. Select Color Adjustments 4. Select desired Color Correction

stetting.
3. Select Color Adjustments

IQ Troubleshooting Hints &
Tips
Revised: 04/07/2009
Table of Contents
Troubleshooting Concepts/Hints
Techniques and observations for isolating solid ink IOT issues:
• If the defect involves random lines, are they dark or light?
Weak/missing jets are light and affect one primary color, calibration or stitch
issues can be light or dark and affect all colors.
• Does the defect appear in one section of the image or across the drum?
Helps to identify if the problem involves one printhead vs. all four or cross-
process defects caused by blades, carriage motion, etc.
• Does the defect improve after running the purge sequence?
Printhead maintenance or Printhead reservoir ink mixing issues improve after
purging. Remember that ink mixing on the face of the Printhead (such as
after a purge) should be resolved by printing solid fills or cleaning pages – not
by performing more purge cycles. Calibration issues or Melt reservoir ink
mixing issues are not affected by the purge process.
• After running a purge sequence, does each section of the waste tray contain
a normal amount of waste ink?
Air pump, hoses, and solenoids can decrease air pressure during the purge
sequence.

Troubleshooting Concepts/Hints
• Does the defect appear in solid fills or halftones only?

Halftones only equates to TRC and Y Dot Position calibration.
• Does the machine have a Service Code?
Use OF 17 Service Code RAP to determine cause/s of the service code.
• Does the defect involve oil on the media?
Check the Cleaning Unit (IQ 21) or oil build up on parts.
• Does the issue involve smudges/smears or defects to the actual printed
image?
Smudges/smears are resolved by cleaning paper path.
• Is the defect visible primarily in text and fine lines?
Check for calibration, thermal, and carriage/drum drive issues.
• Repeating defects appear at 9 inch intervals or on alternate pages.
Only the Transfix Roller and drum can cause them.

IME (print engine) Only Test Print
To isolate IOT defects to the IME (print engine):
1. Turn the machine off.
2. Open the left mid door.
3. Remove the waste tray.
4. Close the front door or insert an interlock
cheater.
5. Power up the machine. Look for three blink
pattern on the Marking Unit’s upper RED
LED.
6. Close the left mid door, insert the waste tray
and close the front door or keep the cheater
in place.
7. An A or A4 sheet will be printed. Compare
this to your color reference original.

Useful Diagnostic Routines
Revised: 04/07/2009
Table of Contents
Useful Diagnostic Routines for IQ/PQ/CQ
dc612 Print Test Pattern

The dc612 Print Test Pattern routine provides a diagnostic tool to assist service in
identifying image copy / print quality problems. The routine provides common
access to electronic test patterns.
Coverage and Color Mode Selections are not currently functional

(as of 026.02 software)
1. Select Test Pattern from
the list on the left
2. Select Tray (media) to use
3. Select Simplex or Duplex
(only some Solid Fills can be duplexed)
4. Select Quantity
5. Press Start

dc972 Printhead Uniformity

Purpose
To adjust individual printheads for image quality.
Printhead drop mass and Y Dot Position Note: Selecting option 2 here is the same as running
will drift over time at different rates. New DC971 – they both do the same thing.
printheads have a tendency to drift at a

faster rate than used components. Failure
to correct this drift will result in image
density changes across the page and fuzzy
text / jagged lines. The routine consists of
a list of individual routines that perform
specific adjustments.
Never select option 6 unless specifically directed to

do so by EDOC. Selecting option 6 requires performing
option 1 (about 1 hour if no faults are encountered).

dc972 Printhead Uniformity – Media Requirements

Several dc972 options require good quality media as the printed test patterns are scanned to
determine the necessary adjustment. The required media size is A4 or 8.5x11 inch.
Recommended media is Xerox Color Xpressions + 24lb white (3R11540) or Colour Impressions
90 g/m2 white (003R97663) or equivalent high quality, bright white plain paper. Do not use
media less than 20lb (75gsm). Do not use glossy, colored, preprinted or punched media. Do
not mix media types.
Option Required Media Quantity Duration (minutes)
1. Printhead Replacement Uniformity – Manual 34 sheets. 24 - 43
1. Printhead Replacement Uniformity – Automatic 16 sheets. 9 –24
2. Head to Head Alignment Adjust N/A 1 –3
3. Head to Head Uniformity – Manual 26 sheets. 8 –23
3. Head to Head Uniformity – Automatic 16 sheets. 5- 16
4. TRC Generation – Manual 8 sheets. 12
4. TRC Generation – Automatic N/A N/A
5. Y Dot Position Correction N/A 4-8
6. Reset Head Uniformity Data N/A Less than 1

dc972 Printhead Uniformity – Manual or Automatic?
Automatic – this method of running dc972 is the same as the overnight (intelligent
idle time) adjustments. Targets are printed on the drum and the IOD interprets the
targets and appropriate adjustments are made. Targets are then cleaned off the drum
by the Cleaning Unit.
Manual – using this method the

machine will print test targets on paper
which are then fed through the DADH.
The IIT scans the targets and machine
makes necessary adjustments.
Manual is more precise and provides
better results than Automatic, so it is
highly recommended to run dc972 in
Manual mode unless specifically
directed to do otherwise by EDOC.

dc972 Printhead Uniformity – which printheads should I select?

It is recommended to always select all four printheads unless specifically directed to
do otherwise by EDOC.
Order matters!
The order of adjustments is
critical and must be
performed in numerical order
(except option 6) unless
specifically instructed to do
otherwise by a RAP or REP.
When instructed to run dc972
without any options
specified, run Option 1
Printhead Replacement
Uniformity in Manual mode.

dc972 Printhead Uniformity
Two Printhead adjustments require you to manually scan test patterns using the IIT
when run in Manual Mode. The machine selects calibration values based on the
scanned images:
• Printhead to Printhead
Uniformity
• Tonal Response Curve

(TRC) Generation

dc972 Printhead Replacement Uniformity – Option 1 (23 - 43 minutes)
The Printhead Replacement Uniformity routine (option 1) runs options 2 through 5. It is
recommended that all Printheads are selected irrespective of which head(s) are replaced.
The routine provides the following

options:
Manual - Select for best results, this
will deliver test prints that require
technician intervention.
Manual is the recommended
printhead calibration.
Automatic -Automatic is only
recommended to diagnose faults
associated with the dC972
processes that run in the
background.
Start - Select to run the routine,
follow the prompt on the U/I

dc972 Head to Head Alignment Adjust – Option 2 (1-3 minutes)

The routine aligns the printheads with X-stitch, Y-stitch and roll adjustments automatically and
requires no intervention. This the same routine as dc971 Head to Head Alignment Adjustment.
Start - Select to run

the routine.
Note: During the routine the

test image is printed and
scanned on the drum,
then cleaned off.
No pages are printed

dc972 Head to Head Uniformity – Option 3 (8-23 minutes)

The routine balances the color intensity in solid fills across all four printheads.
The routine provides the following options:
Manual - Select for best results – Internal
test patterns are printed and require
technician intervention. Manual is
recommended for printhead calibration.
Automatic - Automatic is only

recommended to diagnose faults
associated with the adjustment
processes that run in the background.
Print Test – Select to print

Test Pattern 17 Printhead Uniformity
Test Page. This test print helps diagnose
print quality defects and is not required
to complete this procedure.
Start - Select to run the routine and

follow the prompts on the U/I.

dc972 TRC Generation – Option 4 (12 minutes)

The routine balances the color intensity in dithers across all four printheads.
Manual - Select for best results.

Internal test patterns are printed.
Manual is recommended for printhead
calibration. This step requires technician
intervention, follow the steps listed on
the UI.
Auto - Not currently enabled.

Print Test button - Select to print
Test Pattern 18 TRC Generation Test
Pages. This test print helps diagnose
print quality defects and is not required
to complete this procedure.
Start - Select to run the routine,

following instructions on the UI.

dc972 Y Dot Position Correction – Option 5 (4-8 minutes)

The routine ensures that all ink drops are printed in the correct location in the process direction.
Select Heads 1, 2, 3 and / or 4

Select all printheads, unless specifically
directed otherwise.
Print test - Select to print TP19 Y-Dot

Position Correction Test Page. This test
print helps diagnose print quality
defects and is not required to complete
this procedure.
Start - Select to run the routine.
The test image is printed and scanned

on the drum, then cleaned off.
No pages are printed

dc972 Reset Head Uniformity Data – Option 6

The routine deletes the current adjustments (non-recoverable) and restores the manufacturing voltages.
Only perform this routine if specifically instructed.
Printheads 1, 2, 3 or 4
Select the required printheads.
Start - Select to run the routine.
After completion of the routine:

Perform the full manual Printhead
Replacement Uniformity routine
(option 1) to re-calibrate the
uniformity data.

dc972 Printhead Uniformity – Fault Recovery

Fault Action
Critical Service Code may indicate issues with dC972

Go to OF 17 Service Code RAP. Perform the relevant procedures.
adjustments.
Status
One or more of the following items may have caused the

Unable to Perform Printhead Replacement Uniformity Close
failure:
An unexpected error has occurred. Check the following items and run the test again:
•If an automatic adjustment was already in progress when you
• Print Quality Maintenance may be in progress. Please check status lines and wait for adjustments
entered the diagnostics menu (check the status lines), it must
to complete.
• Go to “dc122 Last 40 Fault History” and address calibration related device faults.
finish before you can initiate another adjustment.
• Inspect and adjust the DADH guides to prevent document skew. •Check dC122 for calibration related device faults. See Table 3.
• Inspect the previously scanned test prints for damage
• Inspect the test prints for color mixing. Color mixing may be corrected by repeatedly pressing the •See IQ 14 for examples of color mixing (ink mixing), and repair
"Print Test" button until the colors stabilize.
• Ensure the test prints are loaded in correct orientation and in printed order. actions.
• Ensure all interlocks are closed and the marking engine is ready to print.
After fixing an issue, reenter the adjustment procedure with the
step that was interrupted.
Popup window with one of these error messages: Ink needs to

Perform the corrective actions, then retry the adjustment
be added. Load 8.5 x 11" or A4 LEF Paper into a Paper Tray.
procedure.
Head Purge needs to be performed.

dc972 Printhead Uniformity – Fault Recovery
Fault Action
If test prints were misprinted, damaged, loaded in wrong

order, or in wrong orientation, then follow instructions on the
Popup window with this warning message: Step 1 Unable to
UI for scanning with the reprinted set of test prints. If test
Scan Test Prints – Iteration <#>.
prints were normal and loaded correctly, check dC122 for
calibration related device faults.
An internal communications error occurred. Re-run the
incomplete dc972 adjustment. If canceling the adjustment
The progress bar stops at 99% or stops updating. does not work, switch the machine off, then on, GP 14.
Reenter the adjustment procedure with the step that was
interrupted.
The UI reboots during dC972 adjustment and machine goes Login in as administrator, then put machine back online. Re-
offline. run the dC972 adjustment.

dc968 Head Purge

This routine is where the CSE can initiate a Head Purge. You may select to purge only one
printhead, all four print heads or any combination of the four. The routine provides the
following options:
Jet Test Pages – will print Service Jet

Test Pages.
Cleaning Pages - will print Cleaning
Pages
Purge Heads selection – select the
heads you wish to purge here.
Purge button – will initiate the purge
cycle
Reset Waste Counter – will reset the
waste tray counter. Ensure waste tray is
empty before pressing this button.

dc977 Drum Runout Calibration

The Drum Runout Calibration routine is used to adjust the timing of jet firing from the printheads to compensate
for minute inaccuracies in the concentricity of the drum. This routine will print and analyze a target image
printed on the drum. No pages are printed. The routine provides the following options:
Print Runout Test Page - this will
print TP23. For an example of a
Drum Runout defect as seen on the
Test Prints, refer to TP23 in this
document.
Print Jet Test Page – this will print

the service Jet Test Pages. If more
than 10 jets are missing across all 4
heads, a purge is required before
running dc977
dc968 Head Purge button – will

take you to dc968 if required
Calibrate Runout – this will start

the runout routine.

Manually Masking a Missing Jet

Jets are masked in NVM locations 445-9 through 445-48 by entering a 5 digit
number which represents the head, color and number of the jet to be masked.
This 5 digit number uses the format “HCJJJ” where H=head number, C=color
(C=1, M=2, Y=3, K=4) and JJJ=jet. Jet numbers must be 3 digits in length – zero-
fill as necessary (jet 4 would be 004).
Example: to mask yellow jet 44 on head 2 enter: 23044.
Head 2 Yellow Jet 44
When manually masking a jet, the specific NVM location to use is not
important provided the value in the location where you wish to enter a 5 digit
masking value is 0. If a value other than 0 is seen, do not enter a new value.
Keep moving to the next location until a value of 0 is found.

Verifying that a jet has been manually masked:
Print the Service Jet Test Page from dc968. The jet that you have masked should have a green
jet number.
To un-mask a previously manually masked jet:

Locate the NVM location that contains the 5 digit value which corresponds with the jet to be
unmasked. Enter a new value of 0 (zero). Select ‘save’.
Jet Masking Restrictions

• If 3 or more consecutive jets are missing the machine cannot mask the jets
• Do not mask jets adjacent to any masked or chronic jet
• Do not mask more than 40 color (C, M, Y) jets (9201)
• Do not mask more than 2 black jets (9201, 9202) or 1 black jet (9203)
• Do not mask black color jets in the A4 LEF print zone (i.e. the chronic jet is not in Head 1
between jets 1 to 12 or in Head 4 between jets 208 to 220).

Customer Prints and Fixes
Revised: 04/07/2009
Table of Contents
Customer Image Quality Tools
The UI contains tools for customers who experience image quality issues:
• Fix Image Quality
• Paper Tips & Office Demo Pages
• Copying Guide/Scanning Guide

Fix Image Quality
This screen is reached by pressing:

Machine Status Button>Tools>Troubleshooting>Fix Image Quality
Light Lines (formerly known as Banding) (Quick)
Runs an IOD sequence. Any identified missing jets are substituted. The machine
may run slower as a result.
Light Lines (Full)
Performs a full Head Purge and
then runs an IOD sequence after
the purge.
Ink Smears
Sends multiple chase sheets
through the machine to clear ink
and other debris from the paper
Path.

Customer Jet Test Page
Customer Jet Test Pages provide key information:

• Color Bands - General health of all four Printheads
• JSC (On,On) - Jet Substitution Configuration is
enabled for both customer setting and machine
setting.
• PC (On, On) - The Purge Configuration is set to
“purge at night/when idle” for both customer
setting and machine setting.
• All Four Printheads - S/N and the total number of
Intermittent or Chronic weak/missing jets (as
defined by the IOD information):
Example:
H4:<serial number>;W2;C3 means Printhead 4 has two
Intermittent and three Chronic weak/missing jets

Customer Jet Test Pages
The customer is able to print Jet Test Pages from the UI. These pages look different than
service Jet Test Pages, but still contain some useful information. The text at the bottom of the
customer version, provides the following:
Max left/rt: Indicates shift position in relation to the drum. Shifting involves all the jets in the
imaging process.
JSC[On,On]: indicates jet substitution is enabled (On) for both customer and machine settings
(the machine may override the customer setting temporarily if the Quick Light Lines fix has been
selected from the Tools -> Fix Image Quality menu). After the next purge or machine reboot, the
settings revert to customer settings. When jet sub is enabled, print speed slows down only when a
jet is missing and is required for the current print.
PC[On,On]: means the purge configuration is set to 'purge at
night/when idle' for both customer setting and machine
setting. Same override rule applies. The purge here is jet fix
purge that will only occur if the machine needs to auto recover
an intermittent, weak, or missing jet. This info is followed by
each print head head serial number and the total number of
IWM/CWMs for each (as defined by the IOD information).
For instance: H1:<serial number>; W0;C0 means printhead
number 1 has no IWMs or CWMs

Automatic Banding Fix
Automatic banding fix settings are not initiated directly by users. You must
log in as an administrator to change these settings.
The Automatic Banding Fix capabilities use the system’s Intelligent Ready
function:
• Intelligent Ready determines
when machine is idle.
• System attempts to recover
intermittent missing jets
during longest idle time
predicted in the next 24
hours (normally at night).
• Intermittent missing jets -
purged less than three times.
• Chronic missing jets - fail to
recover after three purges.

Fax

Fax
Overview
Embedded Fax - Scan documents and send them to any type of fax machine
that is connected to a telephone network. Users images are sent from their
machine directly to the fax number of their choice. This type of fax travels
over normal telephone lines and will therefore be charged at normal
telephone rates.
Basic Fax - An optional device with Single telephone line connection.
Extended Fax – An optional device with 2 telephone lines. The second line
enables the device to send and receive faxes concurrently.
The BASIC fax module will interface to the Copy Controller. The User
Interface will be implemented on the control panel of the machine. It will
provide a single telephone line connection.

Fax
Overview
The fax module is capable of standard G3 fax operation (maximum data rate
14400 bps) or Super G3 fax (maximum data rate 33600 bps).
It is designed to connect to analogue telephone lines that carry audible
frequencies (ie. speech).
Fax data is converted into audible signals for transmission through the Public
Switched Telephone Network (PSTN) using a modem.

Fax
Data Transmission Digital Phone Line
Sending Machine
Scans the
Document
Receiving Machine
Converts the
image to a Prints the
digital signal Document
Image
Image
Compression
Decompression
Conversion of Telephone line Conversion of
signal from
signal from
Digital to
Analogue to
Analogue PSTN - Public Switched Telephone Network Digital
Takes place on
the Fax PWB
Network
Data Connection
Transmission Unit
(NCU) –
Cable Modem

Fax
Fax Control PWB (Rev 9)
Once we have the converted signal, which represents our original, we need
to transmit it along the telephone line. This is done by using a Fax Control
PWB. The Fax Control PWB connects the machine to the PSTN, which has
several functions.
• Provides electrical safety isolation between the machine and the
telephone network.
• Electrically match the machine to the network.
• Control the signalling with the telephone exchange.
• Monitors the PSTN line for incoming calls.

Fax
Fax Control PWB (Rev9) – PL 20.05 item 4
Line 2
Line 1
Compact Flash
Memory Card

Feature Descriptions

Image Quality
The Embedded Fax Image Quality feature has two functions:
− It enables the user to specify the type of image on the original

document. This ensures that the scanner uses an image compression
process optimized for that particular image type.
− It enables the user to lighten or darken the scanned image of the

document being faxed It allows the user to enable the Background
Suppression feature with certain image quality settings.

Basic Fax
The basic faxing screen allows the user to select a dialing option, change the
resolution or select which sides are scanned of a set of fax originals.
It also allows the user to select different job types by pressing the more fax
features tab and then press the Added Fax Features tab.
The job types can be grouped into two groups, these are: - jobs that need a
destination number before they can start and jobs that need to be stored locally,
which do not need a destination.
Destination Required Job Types
These can be further divided into those that require an image and jobs that do
not.
Image required
This group consists of “Basic Send Fax” and “Send to a Remote Mailbox”. These
jobs require documents to be scanned and destinations to be entered so that
faxes can be transmitted to remote fax machines.

Basic Fax (continued)
No Image Required
These jobs require a destination so those images can be retrieved from remote
fax machines. Jobs of this type are “Poll Remote Fax”, “Poll Remote Mailbox”
No Destination Required Job Types:

This group of jobs requires an image to be stored e.g. “Store for Polling” and
“Store to Local Mailbox”
To send a basic fax the user must select the Fax Service by pressing the Basic
Fax tab and place a document (if job is a basic fax or send to a remote
mailbox) either on the Document Glass or in the DADH. The user must enter
either a telephone number, a Speed Dial or a Group number for the receiving
device. By pressing the Start button the user initiates the fax.

Speed Dial
The Speed Dial feature enables the user to enter a three-digit code for
individual destinations or a ‘#’ (hash) followed by a three-digit code for group
destinations instead of typing the full fax number.
Three-digit codes correspond to directory locations; therefore Speed Dial can

only be used to enter destination numbers already stored in the Dial Directory
(Phone List). The number of directories the fax system shall support will be
dependent on the type of memory (basic or extended) installed on the fax card.
Accessing the speed dial feature may involve the GUI having to update
directory information. An update pop up is provided in this instance.

Starting Rate
The Starting Rate feature enables the user to set the default starting speed on
a per job basis.
All valid starting rates:

V.29 Modem speed – 9600
V.17 Modem speed (G3) – 14400
V.34 Modem speed (Super G3) -33600

Delayed Send
Delayed Send enables the user to control the time of a fax transmission or poll.
Delayed Send can be used to delay transmission of a Fax job for a minimum
period of 15 minutes and a maximum period of 23hrs 59mins, by specifying
the time at which the Embedded Fax is to be sent.
The Fax System supports Delayed Send from the local user interface. The Fax
system supports 23 hours 59 minutes as a maximum timer time. The Fax
System allows the user to specify a time to delay the Job Send on a per job
basis from the local user interface.

Reduce Split
Reduce / Split enables the user to choose how an outgoing document is sent to
the remote fax machine if it contains large images that the remote machine is
not capable of receiving.
The Fax system supports the sending options feature.
The Reduce/Split feature works on a per job basis. , i.e. the Reduce/Split setting
is configured by the user when programming a fax job, these setting are stored
with the job until it is completed.
The Fax System allows the user to set the split original feature on a per job
basis
The Fax System allows the user to set the automatically reduce feature on a
per job basis.

Mail Box
The sending machine will send a DTMF (Dual Tone Multi Frequency) code
or sub address which directs the fax to the recipients’ mailbox. The fax is
received into memory and printed out on the recipients’ request.
This prevents received fax documents from being seen by anyone walking
by the fax machine. Instead of printing the document, it is received into
the Mailbox’s memory.
A password may be required to print the document.

Storing to Mail Box
The Mailboxes feature allows the user to store documents in a mailbox. The mailbox can
be located on the same device the user is using (local mailbox) or sent to a mailbox on a
remote device (remote mailbox). The local mailbox may be password protected.
Local mailboxes contain either stored documents or received documents; it is possible
for a mailbox to contain a mixture of these two document types. Stored documents are
placed in the local mailbox by the user standing at the device; received documents are
placed in the local mailbox by a remote fax device.
Stored documents held within the local mailbox can be accessed by a remote device.
A local user can delete or print the contents of a local mailbox.
The Send to Remote Mailbox feature allows a user to send a fax document directly to a
mailbox on a remote machine. This feature will only work when the remote machine has
mailbox capability and when the user sending the document knows the mailbox number
of the mailbox. A pass code is not required to access the mailbox when a remote fax
device is depositing a document into that mailbox.

Poll Remote Mailbox
The Poll Remote Mailbox feature enables the user to request that the
device calls a remote mailbox, which is set up on a remote fax machine, and
retrieve a stored document. The remote machine then sends the faxes
stored within that mailbox to the requesting machine.
Poll Remote Mailbox can be reached by touching the Added Fax Features
tab in the Basic Fax window; then the Advanced Fax Features round feature
button; then the Polling round feature button, then the Poll Remote
Mailbox round feature button.
Accessing the send list feature may involve the GUI having to update
directory information. An update pop up is provided in this instance
The Fax System allows the user to call a remote fax mailbox and retrieve a
fax, from the local user interface.

Store for Polling
Store for Polling enables users to scan documents and store them in the fax
card memory. When remote machines poll the device, they are able to
retrieve the scanned document or documents. A user may setup passcodes
to control which machines have access to documents stored for polling.
The secure Polling feature allows users to define which remote machines
have access to documents stored for polling. When Secure Polling is
enabled, only remote machines whose numbers are stored either in the
Individual Directory, or in the Secure Polling Pass code list, are able to
access documents stored for polling. When the feature is disabled then any
connecting fax device is able to access the stored document.
The enabling or disabling of the Store for Polling feature applies only to
documents store for polling, and not for documents stored in a mailbox.

Junk Fax
The Junk Fax Prevention feature allows the SA/KO to prevent the receipt of
unwanted ‘junk’ fax documents. This is done by instructing the machine to
only allow the receipt of faxes from numbers held in the Dial Directory.

Batch Send
Batch Send feature allows multiple fax jobs to be sent to the same
destination during the same transmission session. This reduces the
connection time for the customer and provides an economy rate for call
connection charges.
Batch Send jobs are supported when the Batch Send feature is enabled and
two or more separate jobs to the same telephone number destination are
submitted; each job is compressed as a single transmission to the
destination telephone number.

Build Job
When Build Job is enabled, large or multiple fax jobs can be scanned in
separate segments as one job which can be sent to single or multiple
destinations.
All destinations must be entered before the user starts scanning any
documents. The Build Job feature enables a user to overcome the 70-page
limitation of the DADF.

Comment Setup
The Comment Setup feature allows a user to create, modify or delete

comments, which shall appear on Fax Cover letters.
Comment Setup shall be accessed by selecting the Comment Setup button

from the Added Fax Features tab
When the Comment Setup screen is entered, the fax card communicates to
the local user interface all the comments previously saved.
When the user saves a comment on the Comments Setup screen, the
comments are passed to the fax card for storage.

Dial Directory
The Dial Directory setup feature allows users to store fax destination details
so as to avoid them having to repeatedly enter the details of frequently
used destinations.
The device supports two types of directory: Individual directories contain
fax destination information such as phone number and connection settings.
Group directories contain one or more of the Individual directories.
The individual and group directories can be saved via the CAT, which saves
the SAKO having to re-configure each location.
Dial Directory Setup is reached by touching the Added Fax Features tab in
the Basic Fax screen, then the Dial Directory Setup button. Once the Dial
Directory Setup button is pressed the Dial Directory Setup window opens.
A device that has 32, 64, 128 or 192Mb of fax card memory installed is
denoted as a basic memory device; a device that has 256Mb of fax card
memory installed is denoted as a extended memory device.

Automatic Redial:
Automatic Redial Setup enables the SA/KO to specify the time interval
between automatic redials when a receiving fax is busy; and to specify the
number of attempts the system shall make to send a fax, before rejecting
the job.
Audio Line Monitor:

The Audio Line Monitor feature enables the SA/KO to hear the Embedded
Fax transmission taking place across the telephone line.

Line Selection:
Line Selection enables the SA/KO to set the send and receive properties of
Lines 1 and 2.
If the machine is configured with the standard Line 1 then Line 2 will be
grayed out. This is because these features are only applicable to machines
with the optional line 2 installed.
Line Configuration:
The Line Configuration feature enables the SA/KO to configure the lines for
PSTN communications.

Receive Printing Mode
The Receive Printing Mode feature sets whether a received Embedded Fax
is printed onto media selected automatically by the machine or media
specified manually by the SA/KO.

Secure Receive
The Secure Receive feature enables the SA/KO to set the system to hold
received Embedded Faxes in the job queue as ‘Secure Receive’. The held faxes
shall be released from the queue only when the user enters a 'print on pass
code'.
There are two options available to the SA/KO:

Off – The Secure Receive feature is disabled and incoming Embedded Faxes
shall be printed as soon as they are received.
On – When selected the SA/KO sets a four-digit pass code. The user (those
with knowledge of the pass code) has to enter the pass code to release all held
secure faxes from the queue.

Default Document Output
Default Output Options allow the SA/KO to define the finishing options which
will be applied to incoming fax documents.

Fax Receive Page Margin:
The Page Margin feature is designed to overcome scanner slippage and is
located on the Receive Printing Mode.
Fax Receive Paper Type:

Stock Defaults enables the SA/KO to specify the default manual paper type
and color onto which incoming Embedded Faxes will be printed.
Fax Receive Paper Size:

The manual paper size feature allows the SA/KO to specify the size of paper
that an incoming fax is printed on. Using this feature along with Page Margin,
Stock Type and Stock Color allows the SA/KO to specify exactly what paper
incoming faxes should be printed on.

Fax Printing Paper Selection
This document describes how the system selects the media used to print
incoming fax jobs and the scaling and how fax images are scaled to print on the
available media. This document also describes when the system will break up
"unlimited length" fax images, producing continuation sheets.
There are a number of SA/KO settings that affect how incoming fax jobs are
printed:
The SA/KO can select an Automatic or Manual Fax Receive Printing Mode.
When Automatic Receive Printing Mode is selected, the system will select the
media that results in the "best fit" for received fax jobs and will automatically
scale down received fax images to fit the selected media as necessary.
When Manual Receive Printing Mode is selected, the SA/KO can specify the
allowable paper sizes and media type/colour that an incoming fax can be printed
upon. The SA/KO can also choose to enable or disable a Page Margin feature.

Send List
Send List enables the user to send a single Embedded Fax job to one or more
destinations. Recipient details may be added to the Send List using any of the
following fax features: manual fax number entry, Speed Dial, Dial Directory and
Chain Dial. Entries can be deleted individually from the Send List.
Accessing the send list feature may involve the GUI having to update directory
information. An update pop up is provided in this instance.

Chain Dialing
The Chain Dialing feature enables the user to create a single fax destination
number by adding two or more Individual Directory locations together, or by
adding pseudo numbers.
For example, a telephone area code may be stored separately to a telephone

number; or an extension number may need to be added to a separately stored
main number.
When Chain Dialing is enabled the user is able to select these separate numbers
and combine them into a single number, e.g. the telephone area code ‘0208’ is
selected first, followed by the main number ‘3215678’ to give a single number of
‘02083215678’.

Original Size
Original Input enables the user to specify the size of the original document; or
allow the system to sense size automatically or scan mixed size. This makes it
possible to add margins or crop the scanned image.

Bound Originals
The Bound Originals Fax feature enables a user to specify which page (s) of
a bound document are to be scanned and faxed.
The Bound Originals feature requires that a fax destination number be

entered before scanning and faxing can take place. If a user attempts to use
the Bound Originals feature before entering a destination number, the
following message appears in SR3: “Please enter a fax destination number
before using this feature”.

Fax Memory
This Functional Description defines the behaviour of the fax system when the
available memory to send and receive fax jobs is low. There are two main
memory components that influence the behaviour of the Fax jobs; CBC memory
and non-volatile memory (flash or compact disk memory) on the fax card.
The fax system behaviour under low memory conditions defined herein is hard
coded, i.e. No SA settings or user intervention can be applied to change the
behaviour defined below.
When receiving a fax the fax card will store all of the images in compressed form
to non-volatile memory. When the CBC returns a paper size (for printing) the fax
card will rotate the image (if necessary) and transfer the image to the CBC for
marking.

Fax Memory (continued)
If the available CBC memory is low for send jobs the scanner will slow down the
processing and transfer of images to the fax card. For receive jobs the fax card
will hold onto images until the CBC has enough memory to handle them. This
behaviour is transparent to the user and affects all services similarly, i.e. there is
no CBC specific behaviour to consider here. Therefore this specification
concentrates on the fax card behaviour.

The table on lists typical raw files sizes for small medium and large paper sizes at
each resolution. Each image is compressed before storage in the fax card NVM.
The actual memory used by each image is dependent on the complexity of the
image as this impacts the compression ratio, for a typical text only fax the
compression ratio could be up to 10:1, i.e. an 11 x 17 page at standard resolution
may take around 250 Kbytes.
Table 1: Approximate file sizes for typical paper types and scanned resolutions.
Raw size at Standard Raw Size at Fine Raw size at Superfine

Paper Size resolution (200 x 100) resolution (200 x 200) resolution (600 x 600)
8.5 x 14” / A5 ~ 0.13 Mb ~ 0.25 Mb ~ 2.25 Mb
8.5 x 11” / A4 ~ 0.25 Mb ~ 0.5 Mb ~ 4.3 Mb
11 x 17 / A3 ~ 0.5 Mb ~ 1 Mb ~ 8.6 Mb

A complex photographic image may not compress more than 2:1, i.e. the file size
could be around 4-5 Mbytes. For the compression algorithm used it is possible for
a highly complex image to have a compressed stored size greater than its raw
image size, i.e. have a negative compression ratio.
There shall be three non-volatile fax memory states that are associated with
differing behaviour of the fax system. These states are: no free memory, low
memory and normal memory. The low memory threshold level selected is a
trade-off between maintaining full fax services when free memory is running low
and avoiding the sudden, complete termination of all fax services when a new
job is submitted. The low memory mode allows basic send and receives
functionality for the majority of simple jobs and provides some warning that the
free memory is low. A single page high resolution job of sufficient complexity will
however cause the fax to enter a no memory condition.

Transmission Options
The Transmission Options feature allows the user to specify the behavior of the
Transmission Report and the Transmit Header Print. The Transmission Report
option enables the user to choose whether or not a Transmission Report is
printed, following a fax transmission. The Transmit Header Print option enables
the user to choose whether full or partial details of transmission are included in
the header at the top of each page of a fax transmission. If enabled the
Transmit Header Print feature prints a header on each Embedded Fax page
transmitted.
This header includes the following details: The local Line ID of the sending
machine, the Local Line Name of the sending machine, the time and date of
transmission, and fractional page numbers.

Transmission Options (continued)
The time of the transmission shall be in: Hrs: Mins: Secs format and is
configurable to 12 or 24 hours depending upon that selected by the SA/KO in
‘System Settings’.
The Local Line Name is a SA/KO designated name given to each line. The name
is entered at Fax Installation and can be changed in ‘Line Configuration’. The
Date of the transmission can be set in the ‘Systems Settings’.
The time of transmission recorded is the time the call is initiated by the
Embedded Fax System.

Data Transmission
- The telephone call is set up.

- A hand shake takes place between the sending and receiving machines.
- Machine identifications are exchanged.
- Information on each machines capabilities are exchanged.
- The quality of the telephone connection is assessed.
- The mode of operation and transmission speed is determined by the remote
receiving machine.
- Data is transmitted to the receiving machine.
- Post message confirmation.
- Telephone call is terminated.
Note: It is the receiving machine which takes control of the transaction.

Cover Letter
The Cover Letter feature allows the user to create a cover letter for a fax job.
Cover Letter also gives the option to add text to the ‘To’, ‘From’ and ‘Comment’
fields in a fax cover letter.
Cover Letter can be accessed by selecting the Added Fax Features tab from the
Basic Fax window, then by choosing the Fax Sending Features option, then
pressing the Cover Letter button.

Poll Remote Fax
The Poll Remote Fax feature enables the user to request that the Embedded Fax
machine calls a remote fax machine, to locate and receive faxes stored by the
remote machine, Remote Polling may take place instantly, or at a specified time
by using in conjunction with Delayed Send and may involve a single remote
machine or group of remote machines.
The Poll Remote Fax feature works on a per job basis. After a job is completed
the Poll Remote Fax feature is turned off.
Poll Remote Fax can be reached by touching the Added Fax Features tab in the
Basic Fax window; then the Advanced Fax Features round feature button; then
the Polling round feature button, then the Poll Remote Fax round feature
button.

Poll Remote Mailbox
The Poll Remote Mailbox feature enables the user to request that the device
calls a remote mailbox, which is set up on a remote fax machine, and retrieve a
stored document. The remote machine then sends the faxes stored within that
mailbox to the requesting machine.
Poll Remote Mailbox can be reached by touching the Added Fax Features tab in
the Basic Fax window; then the Advanced Fax Features round feature button;
then the Polling round feature button, then the Poll Remote Mailbox round
feature button.
Accessing the send list feature may involve the GUI having to update directory
information. An update pop up is provided in this instance
The Fax System shall allow the user to call a remote fax mailbox and retrieve a
fax, from the local user interface.

Broadcast and Relay Broadcast
Broadcast:
A document is scanned once then transmitted to multiple recipients
sequentially.
Relay Broadcast:
A document is scanned and transmitted to a receiving machine along
with information as to where to forward the document onto. The
receiving machine then re-transmits the document to multiple recipients
sequentially. These recipients must be programmed into the machines
directory as a group.
Useful when documents are transmitted to multiple recipients over a long
distance such as Transatlantic calls.

Advanced Fax Features
Polling and Secure Polling
Polling:
A machine which initiates the telephone call, retrieves a document from the
called machine instead of transmitting to it.
• Use a Fax back service.
• If a number of remote locations fax to a central recipient on a regular
basis, Polling can be used to prevent congestion of the line.
Secure Polling:
There are several methods to prevent the unauthorized retrieval of
documents.
• Documents are stored in a mailbox with password access.
• A machine will only allow itself to be polled by another machine that has
its number programmed into its dial directory.

Reports
The Fax Reports feature enables the Customer Service Engineer, the System
Administrator and the user to gain information about the status of the device.
The Fax Reports feature is accessible to the SA/KO only. It enables the SA/KO to
specify default printing behaviors for the reports available from the fax system.
When the SA/KO modifies a setting the GUI sends the new setting to the fax
system to be stored in the Fax NVM.
Activity Report:
An activity report shows the last x activities whether they are incoming or
outgoing fax jobs, plus any report jobs that have been printed.
Usually splits sent/received transmissions, contains a job number, remote
machine ID, number dialed, transmission start time and possible error code

Reports (continued)
Protocol Report:
The Embedded Fax Protocol Report feature enables the operator to print out
Protocol Reports for both lines 1 and line 2 if fitted. The Protocol Report
contains the protocol information about the last fax transmission whether it
was a send or receive job.
When a request is made to print the report, the report is submitted to the job
queue on the fax card. It is not possible to print the report directly from the fax
card due to technical limitations. Once the user has exited diagnostics the
report job is recovered using existing job recovery behaviours, and printed as
normal. If other jobs are in the queue then this will be printed before the report
is printed.

Reports (continued)
Protocol Monitor:
Printed on demand through service mode, on a job by job basis and usually
contains items found in activity report, machine software revision levels,
error codes and T.30 commands and information fields transmitted by each
Machine. See next slide for details

Reports (continued)
Transmit PBX Receive
Call
Dialing
Ring Detect
Ringing
CED Signal
Monitor Area
DCN Signal
Disconnect
Disconnect
Protocol Monitor
A protocol monitor printout is a report of the protocols that are exchanged
between the sending and the receiving fax machines. This print out can be
useful in analyzing a problem if two fax machines have communication
problems.

Reports (continued)
Broadcast and Multi poll:

A broadcast report is a report on the success or failure of a specific sending fax
job, which includes more than one individual destination. A Multi poll Report is
a report on the success or failure of a specific polling fax job, which includes
more than one individual destination. This feature is setup by pressing the
Broadcast and Multi poll Report button.
Confirmation / Transmission Report:

A Transmission Report is a report on the success or failure of an individual
sending fax job. It informs the user if the sent job either passed or failed.
Sometimes includes a reduced size image of the top page of the job.
Usually includes date, start time, end time, job number, number dialed, number
of pages and whether it was successful or not

SA Feature Defaults
The Feature Defaults feature enables the SA/KO to specify permanent defaults
for features that are accessible to users. The feature is accessible only to the
SA/KO via a password. Defaults specified using this feature may be altered by
users on a per-job basis via the user interface but can be changed permanently
only by the SA/KO via the Feature Defaults feature

Automatic Resend
The Automatic Resend feature automatically resends part or all of a failed Fax
transmission.
The following options are available to the SA/KO with regards to what parts of
the Embedded Fax job are re-sent if transmission fails:
Failed page (s) without a fax generated cover page
Whole job without a fax generated cover page
Failed page (s) with a fax generated cover page
Whole job with a fax generated cover page The Embedded Fax System shall
also print a Transmission Report if the Automatic Resend fails if set to ‘print on
error’ or ‘Always’. An error is defined as ‘when all Resend attempts have failed’

Transmission Header
The Transmission Header Text feature enables the SA/KO to specify a text
string which will then be printed on the remote as part of the Transmission
Header on the top of every fax page.
Placed on the image before transmission commences - part of the image

usually contains, date & time of transmission, sending machine ID, job
number, page number
Required by law in some countries (e.g., Canada & USA)

Fax Country Setting and Ring Volume
Fax Country Settings:

The Fax Country Setting window allows the SA/KO to change the country
the fax card is installed in. This changes the modems setting to the country
selected.
Ring Volume:
The Ring Volume feature enables the user to hear and audible ringing
sound when a Embedded Fax is received

Auto Answer Delay and Retained Documents Policy
Auto Answer Delay:

The Automatic Answer Delay feature enables the SA/KO to set an answer
delay time of between 0 and 15 seconds from the first qualified ring. After
the time period set has elapsed the Fax System picks up the line. This
feature is commonly used where the machine is on a shared telephone line.
Retained Documents Policy:

The Retained Documents Policy feature allows the SA/KO to specify the
period of time for which documents may be held in machine memory. A
different time period may be specified for documents received in
mailboxes, and for documents stored for polling (whether in general
memory or a mailbox location).

Auto Paper Size
Also is known as Auto Reduction.
Auto Reduction reduces an image to a smaller percentage in order to fit it

on the page. The reduction can be as much as 74%; therefore an 8.5 x 14
legal size page can be printed on an 8.5 x 11 paper. When a greater
reduction is needed, the image will print on extended pages.
Enables an A4 document to be printed onto a single 8.5 x 11 paper.

Error Correction Mode - ECM
Re-transmitting entire pages is rather inefficient, Error Correction Mode

(ECM) overcomes this by breaking the page up into blocks, and blocks into
frames (although a simple page may fit into one block).
The receiving machine holds the incoming data in memory and requests
retransmission of any garbled frames before printing. That way, if errors
occur only small portions of the page have to be retransmitted. The page
prints with no visible errors, though total transmission time is longer when
errors occur.
MMR encoding is only effective in transmission error-free communications
environment, as any errors resulting from the modem communication will
appear throughout the fax image, making it unusable. MMR is only used in
conjunction with ECM.

Fax Install
The Fax Install procedure begins automatically when a fax card is installed in a
powered-down machine, which is then powered-up. The fax card install screens
may or may not be presented dependent on whether or not the card has been
previously installed in the machine.
Fax Install enables the SA/KO to install the Fax Card correctly by entering
information relating to the country and setting up the fax line (s).
The Fax Install procedure can be undertaken immediately on first power-up

following installation, or at a later date.

Principles of Operation

Compact Flash
The basic fax system uses 32Mb Compact-Flash memory card to store
Faxes as well as Speed Dial Directory.
The Compact Flash card is expandable to 256Mb when the enhanced fax
module is installed (2-line).
The fax system should be able to store over 1000 letter-size documents
scanned at 200X200dpi using MH compression

Document Scanning
The document is scanned into the IIT using either the DADH or Platen
Glass. The DADH can handle up to 100 pages, but additional pages can be
scanned using the Build Job function.
When completed, all pages are stored as one file. The scanned document is
processed through the machine in basically the same manor as any document
that is scanned or copying. The IIT outputs the image as a 1-bit pixel image.

Document Scan
Scanning the document is done by passing the original over a light source.
The information contained on the original is reflected back into the scanner
via LED Arrays and a Full Width CCD Array
The electronic image from the scanner is converted to a digital signal which
allows for processing.
DADH Platen Glass Platen Glass
Provides the
Light Source
LED ARRAYS
Copy Ri ser Fax PWB

Controller PWB
Full Width CCD ARRAY

Image Rotation
If a document is scanned Long Edge Feed (LEF) then…
The scanned image is stored in Rotation Memory where image rotation is

performed, if required. All fax files are transmitted from the machine as SEF
documents. The image is always automatically rotated to SEF.

EPC Memory
Once rotated (if necessary), the image is stored in raw format in the EPC
memory on the Copy Controller then sent to the Embedded Fax Card where it
will be compressed.

Image Compression
Why compress the image?
Scanning an 8.5” x 11” page at standard resolution (200x100dpi) produces

1188 lines each of 1728 elements (black and white dots) 2 million bits of
data. If this was sent at 9600 bps, it would take at least 4 minutes to send
at a high cost to the sender.
Reduces the amount of memory required to store documents.

Image Compression
After image rotation, the image is sent to the Embedded Fax Card for
compression. The default method is MMR (Modified Modified Read, see next
slide). However, other compression methods can be configured.
The compression ratio is within a range between 5:1 to 10:1. This depends on
image resolution and complexity of the job. The compression function is
significant in reducing file size for faster and less costly transmission.

Image Compression
MMR (Modified Modified Read)
A two dimensional encoding scheme. Unlike MR (Modified Read), MMR does
not require an initial one dimensional encoded line. All scan lines in MMR are
encoded 2 dimensionally.
MH (Modified Huffman)
Various lengths of white and lengths of black are each assigned a code word.
Then, the appropriate code words for each length of white and black in one
scan line are sent, followed by an End of Line code.
Modified Huffman (MH) Coding Method

Image Compression
MR (Modified READ)
The first scan line is sent via MH. The next line uses codes that represent the
changes to the first line. This code not only considers the horizontal line
length, but changes in the vertical direction as well. It is sometimes a called a
2 dimensional code.
JBIG
The newest in compression code, its basic idea is to send codes that 1st
describe the image in very low resolution, then to send codes that describe
how to change pixels to “increase” the resolution and restore the image.
JBIG Compression Scheme (Simplified)

Image Compression
Reformatting the Fax File
If the destination machine does not support MMR format, but supports MH or
MR, the Embedded Fax Card decompresses the MMR file, then re-compresses
the file in the format of the destination machine capability.
Data Errors
One data error can ruin the scan line, or possibly several scan lines if MR
coding is being used. If enough error occur this results in “squashed” looking
fax. Error Correction Mode attempts to repair this.
Effect of Data Errors on Non-ECM Reception

Fax Sending Data Flow
Job Programming
User Interface
DADH
(100 Pages)
Fax Transmission
Original Document Copy
Riser PWB Fax PWB
Controller
Platen

Fax Sending
FAX CONTROLLER
COPY CONTROLLER
IMAGEN S
rotate to SEF REMOTE MACHINE
IMAGE2 C
compress
rotate to SEF A
IMAGE1store in non-volatile N negotiate capabilities
scan IMAGE1 compress
rotate tomemory
SEF receive IMAGE1
send to Fax store in non-volatile
compress S confirm receipt
controller memory
store in non-volatile memory T negotiate capabilities
scan IMAGE2 receive IMAGE2
E
: confirm receipt
dial Remote machine P
: etc
scan IMAGEN
send to Fax IMAGEN
controller negotiate Remote machine
IMAGE2
capabilities
negotiate
IMAGE1read fromRemote machine
non-volatile memory
capabilities
decompress
negotiate Remote machine
read from non-volatile memory S
scale/adjust
capabilities resolution based on
decompress E
Remote
read from machine memory
non-volatile
scale/adjust resolution based on N
add fax heading
decompress
Remote machine D
compress
scale/adjust and send
resolution image
based onstripes
addreceipt
Remote fax heading
confirmed
machine add fax heading
compress S
compress andand send
send image
image stripes
stripes T
receipt confirmed
receipt confirmed E
P
(Disconnect call)
delete from non-volatile memory
Key: tasks in blue are performed
send 'Fax completed' to copy
by the ASIC/FPGA
controller

Reformatting the Fax File
The sending and receiving machine identify their capabilities (resolution,

format, etc.) to each other. This is part of standard fax protocol. If the remote
machine cannot handle the sending machine’s format, it cannot accept the
file. The file must be sent in a different format.
Normally, this causes a small delay in transmission due to the tasks required
by the processor within the sending machine.
If MMR is the compression utilized but is not support by the destination

machine but supports MH or MR, the Fax PWB decompresses the MMR file and
then re-compresses the file in the format of the remote machine.

Receiving Faxes
The incoming fax data is stored in the Fax PWB memory. The Fax PWB as the
Copy Controller what size and orientation the paper trays are configured for.
The Fax PWB then chooses the best fit for the image and will rotate the image
accordingly.
The incoming fax is then sent to the EPC memory on the Copy Controller
where it is input to the Internal Marking Engine, where it is printed and then
sent to it’s appropriate output location (HVF or 2K LCSS)
After the Fax is received and the line is release another Fax can be received on
that line. If the incoming Fax is addressed to a location in the Fax mailbox, it is
held in memory (Compact Flash) until the user retrieves it for printing.

Receiving Faxes
Incoming Fax Copy Printed Document

Fax PWB Riser PWB IME DRUM
Controller

Receiving Faxes
FAX CONTROLLER
answer Remote machine

COPY CONTROLLER
negotiate IMAGEN capabilities
RECEIVE STEP
negotiate IMAGE2 capabilities
REMOTE MACHINE
negotiate IMAGE1 capabilities Ready to mark image
receive IMAGE1 Send paper size
decompress
compress
dial up store in non-volatile memory
copy IMAGE3 to 'memory'
negotiate capabilities confirm receipt
start marking
send IMAGE1
negotiate capabilities disconnect call copy IMAGE2 to 'memory'
:
send IMAGE2 Is Copy Controller ready to mark image? start marking
scan IMAGEN
negotiate capabilities Get Copy Controller's marking paper size
send
copy to Fax controller
IMAGE1 to 'memory'
etc :
MARK STEP
Start marking
end of document .
copy IMAGEN from non-volatile
send image decompress
copy IMAGE2 from non-volatile
rotate to LEF
decompress
copy
scaleIMAGE1 from non-volatile
rotate to LEF
decompress
send
scale to Copy Controller
rotate to LEF
send
scale to
to Copy Controller
CC paper size and resolution*
send IMAGE1 to Copy Controller IMAGEN mark complete
IMAGE1 mark complete
:
delete IMAGEN from non-volatile memory scan IMAGEN
IMAGE1 mark complete
:
send to Fax controller
delete IMAGE2 from non-volatile memory scan IMAGEN
scan IMAGEN
send to Fax controller
delete IMAGE1 from non-volatile memory send to Fax controller
end of receive Fax

Resolution Settings
Super Fine – 600 x 600 dpi, 400 x 400 dpi, 300 x 300 dpi, 200 X 200 dpi
and 200 x 100 dpi.
Fine - 200 X 200 dpi and 200 x 100
Standard – 200 x 100
Note: The actual resolution sent depends on the receiver’s capability.

3 Types of Fax - Embedded Fax
Hardware based (Fax PWB), communicates via the customer’s telephone

service (Analog Line, FoIP...).
Two versions of Embedded Fax modules are available:

• Basic Fax - Single line module interfaces with the Image Processing PWB
and supports a single phone connection.
• Extended Fax - Two line module interfaces with the Basic Fax PWB, to
enable a second telephone connection

3 Types of Fax – Server Fax (Draft)
A Network Controller with an IPA card and extended memory is required,

with Server Fax enabled in Optional Services.
Server Fax uses a dedicated server on the local network, which provides
access to telephone lines. The fax is then sent over the telephone service.

3 Types of Fax – Internet Fax (DRAFT)
Utilizes Network Controller, IPA card and Extended Memory. It must have
access to a Mail Server and enabled in Optional Services.
Internet Fax allows scanned images to be sent as an attachment to any e-

mail address.
This type of fax travels over the Internet or Intranet.
The basic Internet Fax screen allows the entry of SMTP (Simple Mail Transfer
Protocol) e-mail addresses for Fax.
This screen is also used to add and remove recipients and edit the subject line.

3 Types of Fax - Internet Fax (DRAFT)
Utilizes the Network Controller, IPA Card and Extended Memory. It must have
access to a Mail Server and be enabled in Optional Services.
Internet Fax allows scanned images to be sent as an attachment to any e-mail

address. This type of fax travels over the internet or intranet.
Internet Fax is only available on the Work Centre Pro versions of the machine.
The basic Internet Fax screen allows the entry of SMTP (Simple Mail Transfer
Protocol) e-mail addresses for Fax. This screen is also used to add and remove
recipients, and edit the subject line.
All types of Fax service can be resident on the same machine.

Low Memory
The Fax PWB accepts only as many whole pages as memory will allow.
If the incoming file is too large, the connection will be terminated, the
received pages are stored and an error message is displayed on the UI.
If low memory is reached when sending a fax, the user is given the option
to send immediately or delete the job.

Power (DRAFT)
Power provided by Phone Line and the Copy Controller via the Riser PWB
Fax Card never enters Power Saver mode
Fax Card will draw a total of 5.7 Watts

Power
Typical phone lines have 85 to 105VAC ring signal superimposed on a

nominal 48 VDC. The AC current during the ringing cycle is between 20 to
50 milliamps.
The common frequency used in the United States is 20Hz, it can be any
frequency between 15 to 68Hz.
The two phone wires connected to the telephone should be red and green.
The red is negative also is known as “Ring” and the green is positive also is
known as “Tip”.

Glossary of Terms

Glossary of Terms
Activity Report - A list of information about the previous received and
transmitted faxes.
Batch Transmission – If two or more documents stored in memory are going
to the same destination, they can be automatically grouped together to save
costs.
Broadcast Transmission - The ability to scan a document into the fax once
and send it to a large number of destinations sequentially.
Delayed Sending - Allows you to send a document at a pre-determined time;
i.e., late at night to benefit cheaper call charges or if sending to a different
time zone. This can also be done from a machines memory.
Error Correction Mode - If the fax doesn’t recognize an incoming signal due
to line distortion, it requests the sender’s fax to re-transmit, so fax
transmissions with interference or distortion are re-transmitted. This is only
supported on machines with ECM.

Glossary of Terms
CCITT (Consultative Committee on International Telegraph and
Telephone) - A governmental advisory organization of the International
Telecommunication Union which recommends worldwide communication
standards including those for facsimile See Groups 1 2 3 and 4
Group 1 - Analog facsimile equipment per CCITT Recommendation T.2. It

sends an A4 or 8 1/2 x 11-inch page in 6 minutes over a voice grade
telephone line using frequency modulation with 1300 Hz corresponding to
white and 2100 Hz to black of the original. (Note: Because North American
6-minute equipment uses 1500 Hz white and 2400 Hz black, it is not
compatible with Group .1 equipment.)
Group 2 - Analog facsimile equipment per CCITT Recommendation T. 3. It

sends an A4 or 8 1/2 X 11-inch page in 3 minutes over a voice grade
telephone line using 2100-Hz AM-PM-VSB.

Glossary of Terms
Group 3 - Digital facsimile equipment per CCITT Recommendation T.4. It
sends an A4 or 8 1/2 X 11-inch page typically in one-half minute over a
voice grade telephone line.
Group 4 - Digital facsimile equipment per CCITT Recommendations T.5
and T.6, which uses Public Data Networks and their procedures for
essentially error-free reception. It may also be used on the Public Switched
Telephone Network with an appropriate modulation process.
Handshaking - An exchange of signals (called “control procedures”)
between the facsimile transmitter and facsimile receiver to verify that
facsimile transmission can proceed, to determine which specifications will
be used, and to verify reception of the documents sent.
ISDN (Integrated Services Digital Network) - A public network conforming
to internationally agreed standards, fully integrating digital transmission
systems with digital switching systems. ISDN allows the integration of
multiple services -voice, data, fax etc - over a common network interface
and can provide a wide range of network-based supplementary services
such as CLI, Call Park, Call Diversion etc.

Glossary of Terms
PABX or PBX Private (Automatic) Branch Exchange - Customer premises
equipment (switch), which provides for the transmission of calls to and from
the public telephone network.
PSTN (Public Switched Telephone Network) - The complete network of

interconnections between telephone subscribers, operated for public use.
Secure Mode – Incoming faxes can still be received, but only printed upon
re-entering a security code.
Station/Line ID - The stored information that appears on the top of faxed

pages. It includes the sender’s name and fax number.

Glossary of Terms
Transmission Speed - The speed at which the machine is capable of

transmitting a CCITT standard text page No 1, or the “Slerexe” page. This
speed is dependent on the modem and the scanning method used
Transmission Time - The time for sending a single page (i.e., elapsed time
between the start of picture signals and the detection of end-of-message
signal by the facsimile receiver).
Transmission Confirmation Report - A page produced at the end of a

transmission to indicate whether it was successful and its duration.

Glossary of Terms
Modified Huffman - (MH) Coding - A one-dimensional run length digital

scheme of coding white and black runs, where the shortest length code
words represent the most probable run lengths. MH is used by Group 3
facsimile.
Modified Read - (MR) Coding - A two-dimensional optional digital coding
scheme for Group 3 facsimile. (Note: MR provides an improved transmission
speed over modified Huffman coding.)
Modified Modified Read - (MMR) Coding - A two-dimensional coding
scheme for Group 4 facsimile. (Note: MMR provides improved transmission
speed over modified read coding.)

Top Problems

Send and Receive Problems
Test Setup to check DC phone line voltage:
− Remove the FAX PWB from the machine.
− Remove the Plastic Safety cover from the FAX PWB.
− Set up the meter on DC Scale.
− Reinstall FAX PWB and phone cord. With the FAX off line (on hook -
Standby), measure the DC voltage between Tip and Ring (see figure on
the next slide). The voltage should be above 48Vdc for a PSTN (analog)
line, and greater than 20Vdc for a PBX (digital) line. With the FAX on
line (off hook - Dialing), the voltage will normally drop 5V to 10V from
the Standby voltage
− If the voltage is low, check that Telephone Cord to the FAX PWB is not
damaged. Replace the Telephone Cord.

− Disconnect the Phone Cord from the FAX PWB. If the voltage increases,
replace the FAX PWB.
− If the FAX is online and the voltage is high, replace the FAX PWB.
Place the meter probes

between Tip and Ring to
measure the DC voltage.
Tip and Ground, Ring and
Ground (AC) for checking
machine and FAX Ground.
Ground
Ring
Tip

Machine and FAX Ground Check
Test setup to check for AC phone line noise:

− Remove the FAX PWB from the machine.
− Remove the FAX PWB Plastic Safety Cover.
− Set the meter to AC Scale.
− Install FAX PWB and Phone Cord. With the FAX Line off hook, the voltage
between Tip to ground and Ring to ground should be less than 1VAC (see
figure on the previous slide).
− If the voltage is greater than 1VAC, check for correct ground connection to
the machine and FAX PWB.
− Check to see if an ADSL (Digital) Filter is installed on the phone line.
ADSL/Digital Line noise levels are considerably higher than PSTN/Analog
Line noise levels.

FAX Escalation Process
Problem: If the sending or receiving problems are not resolved
by the latest software, they should be escalated to Field
Engineering.
Cause: N/A
Solution: The following Files and Reports are required when escalating
FAX issues to Field Engineering:
1. Protocol Report. (FAX DC TBD).
2. Activity Report. (FAX Added Features screen).
3. Option Report.
4. FAX Trace from the failed Sending or Receiving job.
5. Capture.cap File.
6. An Audio Trace. Please contact Field Engineering to
obtain the recording tools to capture the FAX Audio Trace.

FAX Transaction Audio Recording Procedure
Retell 157-Line Recorder Retell 142- Line Adapter
1. 2m RJ11 Phone Cable (Provided by Field Engineering).

2. 1 Retell 157 Recorder (Provided by Field Engineering).
3. 1 Retell 142 Line Adapter (Provided by Field Engineering).
4. Extended RJ11 Phone Cable.
5. Go to http://audacity.sourceforge.net/ to obtain the Audacity
recording program.

Phone Wall
Outlet
Pin 3 &
4
Line
Splitter
RJ11
Plug RJ12
Plug
Retell 142
Mic. – Line
Socket Adaptor
PWS
Retell 157-
Line Recorder
RJ12 Plug
Not Used

Test Setup:
The Switch on the Retell 157 Line Recorder should be set to REC. Open the
Audacity Utility on the PWS. All settings within Audacity should be at the
installation default.
Procedure:
To record an audio FAX Transaction (.wav File):
1. First ensure that the microphone input on the PWS is enabled.
2. Start Audacity Utility on the PWS.
3. Start either a send or receive FAX transaction and start Audacity recording.
It is important that the microphone recording level is set so that the
recording is loud enough for play back but does not saturate the recording.
To ensure this, enable the Microphone BU meter in the top right hand by
setting it to monitor the input and set the scale to dB. During the recording,
the VU meter should peak at between -6 and 0 but not go above 0.
4. When the FAX Transaction is complete, stop the recording.
5. From the File menu, select the Export command to save the file as a .wav
file. This file should be sent to WGC for further analysis.

Finishers
LCSS (Low Capacity Stacker Stapler and HVF High
Volume Finisher)

LCSS (Low Capacity Stacker Stapler)

Overview
The LCSS contains two selectable destinations bins, a 250 sheet capacity top tray (20
lb.) and a high capacity 2000 sheet stacker tray (20 lb.). When the high capacity
stacker tray is selected the output will be compiled and tamped.
The following finishing options can be used when output is directed to the stacker
tray:
− A 25mm offset.
− Automatic stapling of up to 50 sheet (20lb) sets, with the user able to select one of
the following three positions dependant upon paper size and feed direction:
a) Single front (Front corner)
b) Single rear S ing le Fro nt
(C o rner)
S ing le R ear D ual
c) Dual

Overview
Punching (mechanical optional 2, 3 or 4 hole) 4 Hole punch is not an option

in the US.
2- H o le 3- H o le 4- H o le

Modes of Operation
Collate Modes:
Non - Collate Mode – Delivers & Stacks the paper in the Top Bin.
Collate/Offset Mode – Delivers & Stacks the copies into the Stacker Bin per
set of copies and separation between stacked sets.
Staple Modes:
Non - Staple Mode - No staple operation
Auto Staple Mode - At the end of copying, stapling is automatically

performed on the paper set in the Paper Base in accordance with the staple
position selection made on the IOT control panel.

Modes of Operation
Hole Punch - As sheets are received in the LCSS entrance paper path, sets
of nip rollers transport the sheets through the hole punch unit.
When hole punching is selected, the Punch Sensor, (Q12-078) senses the
trail edge of the sheet. The sheet is held in the correct position by the
Transport Motor, (MOT12-223).
The Hole punch motor, MOT 12-243 is then energized to punch the sheet,
the hole punch motor continues to be driven until the hole punch home
sensor, Q12-194 sends a signal to the LCSS PWB, so that the hole punch
motor is stopped at the home position.
If hole punching is not requested by the operator, sheets pass straight

through the hole punch unit to the vertical transport.

Key Components Stacker Bin Exit
Paper Path Sensor
Top Bin Exit

Paper Path Sensor
Exit Paper Transport Motor
Diverter Gate Solenoid
Entrance Paper Path Sensor
Input Paper Transport Motor
Paddle/Safety Gate Motor

Docking Interlock Switch
Ejector Motor
LCSS Rear
View Stacker Bin Motor

Key Components
Top Cover Interlock Switch
Stacker Bin Paper High Level Sensor
Stacker Bin Paper Low Level Sensor
Stacker Bin Upper Limit

LCSS Side Interlock Switch
View
Front Door Interlock Switch
Stacker Bin Lower Limit

Interlock Switch

Stapler Assembly
Paddle Roll Home Sensor
Paddle/Safety Gate Motor
Stapler Index Motor
Stapler Index Home Sensor
Safety Gate
Safety Gate Interlock Switch

Staple Head
Stapler Index Sensor
Staple Paper Edge Registration Sensor

Safety Gate Interlock Switch
(Receiver)
Staple Paper Present Sensor
Cartridge Present Sensor Staples Ready Sensor
Staples Low Sensor
Staple Jaw Home Sensor
Staple Head Motor

Tamper Assembly
Rear Tamper Home Sensor
Rear Tamper Away Home Sensor
Front Tamper Motor
Rear Tamper Motor
Front Tamper Home Sensor

Hole Punch Unit
Punch Motor
Front Rear
Punch Chad Bin Full Sensor
Punch Position Paper Path Sensor
Punch Head Present Sensor
Punch Head Home Sensor

Ejector Assembly
Ejector Motor Encoder

Ejector Out Sensor
Ejector Motor
Ejector Home Sensor

Stacker Assembly
Stacker Bin Upper Limit Interlock Switch
Stacker Bin Paper High Level Sensor
Stacker Bin Paper Low Level Sensor
Edge Registration Sensor (Emitter)
Stacker Bin Motor Encoder
Stacker Bin Motor

Principle Modes of Operation
The LCSS receives and sends serial input and output data to and from the IOT. The
machine interface comprises of the LCSS PWB, the communication cable, a
bulkhead connector, a harness and the IOT PWB. Communications between the IOT
PWB and the LCSS PWB are provided by the communication cable. If there is an
open or short circuit in any communications data lines, a communication fault will
be declared by the IOT.
Power / Interlock:
The LCSS has its own power cord which is connected to the LCSS power supply
module located inside the LCSS. The power supply module can handle between 90
and 265 volts AC at 50 or 60Hz.
Interlock switches are used to prevent user and machine from getting
injures/damages caused by unexpected operation of each component when users
put their hands inside the machine or the machine faces errors. When an interlock
switch is open, every driving current that operates such parts as motors and solenoid
is blocked so that no operation is available at any circumstances including software
malfunction.

Top Cover Interlock Switch:

When a user opens the Top Cover, no operation is performed. The LCSS,
sends a signal to IOT that Top Cover is open in order to encourage user to
take action.
Front Door Interlock Switch:

In the same manner as Top Cover, when a user opens the Front Door, no
operation is performed. The LCSS, then, sends a signal to IOT that Front
Door is open to encourage user to close it.
Docking Interlock Switch:

In the same manner as Top Cover, when a user un-docks LCSS from IOT, no
operation is performed breaking the driving current. LCSS, then, sends a
signal to IOT that LCSS is undocked in order to encourage user to take next
actions.

Stacker Bin Lower Limit Interlock Switch:

When Stacker Bin descends to the lower limit, Stacker Bin Lower Limit
Interlock Switch blocks driving current of Stacker Bin Motor downwards only
so that any breakage is avoided.
Stacker Bin Upper Limit Interlock Switch:

When Stacker Bin ascends to the upper limit, Stacker Bin Upper Limit
Interlock Switch blocks driving current of Stacker Bin Motor upwards only so
that any breakage is avoided. The Stacker Bin Upper Limit Interlock Switch
will be used also in determining if Stacker Bin is empty by combination with
status of Stacker Bin Paper High Level Sensor.

Sensors
Entrance Paper Path Sensor (Q12-077) – Detects paper that has entered
the LCSS from the IOT.
Stacker Bin Exit Paper Path Sensor (Q12-106) – Detects whether the
Leading and Trailing edges of the paper passes through to the Stacker Bin.
Top Bin Exit Paper Path Sensor (Q12-107) – Detects whether Leading and
Trailing edges of paper passes through to the Top Bin.
Punch Position Paper Path Sensor (Q12-078) – Detects trailing edge of

paper ready for hole punching operation.
Front Tamper Home Sensor (Q12-180) – Detects the Home position of the
Front Tamper.

Sensors
Rear Tamper Home Sensor (Q12-181) – Senses Home Position of the Rear
Tamper.
Rear Tamper Away Home Sensor (Q12-183) – Used to correct Rear Tamper
Position when small sizes papers are fed.
Punch Head Home Sensor (Q12-194) – Detects Punch Mechanism at the

home position.
Punch Head Present Sensor (Q12-193) – Detects Chad Bin Full State
Staple Paper Present Sensor (Q12-196) – Detect paper correctly positioned

to enable stapling.
Stapler Index Home Sensor (Q12-168) – Detects Staple Head is positioned

at home.

Sensors
Stapler Sensor (Q12-135) – Detects stapler transport to the right position when dual and
rear stapling.
Staple Jaw Home Sensor (Within Stapler Head) – Detects Staple Jaw is fully opened
(Home Position)
Staples Low Sensor (Within Staple Head) – Detects Staples are low
Cartridge Present Sensor (Within Staple Head) – Detects whether Staple Cartridge is
installed.
Staples Ready Sensor (Within Staple Head) – Detects staples are transported to the
front end of the staple jaw.
Staple Paper Edge Registration Sensor (a pair of Emitter and Receiver) – Detects paper
registration at manual staple operation.

Sensors
Ejector Out Sensor (Q12-185) – Detects Ejector mechanism in fully forward
position.
Ejector Home Sensor (Q12-184) – Detects Ejector mechanism in fully retracted

position.
Ejector Motor Encoder (Q12-096) – Detects Ejector Motor speed and Ejector
position.
Stacker Bin Paper High (Upper) Level sensor (Q12-188) – Detects stack top and is
used to cause Stacker Bin to lower as substrate is added.
Stacker Bin Motor Encoder (Q12-163) – Detects Stacker Motor movement and
motor stall condition to prevent overload damage.
Paddle Roll Home Sensor (Q12-186) – Detects Paddle roll/safety gate at home
position.

Stepper Motors
Input Paper Transport Motor (MOT 12-233) – Provides drive to the input
nips in the process direction.
Exit Paper Transport Motor (MOT 12-224) – Provides drive to the main
paper path and exit nips of both bins in the process direction.
Front Tamper Motor (P/O Tamper Assembly) – Front Tamper Operation

Motor
Rear Tamper Motor (P/O Tamper Assembly) Rear Tamper operation motor
Stapler Index Motor (Mot 12-238) – Provides drive to the compile

registration paddles.

DC Motors & Solenoids
Punch Motor (Mot 12-243) - Punch operation motor
Ejector Motor (P/O Eject Assembly) - Operating motor for ejection of

compiled paper
Stacker Bin Motor (Mot 12-241) - Moves the main Stacker Bin up and down.
Staple Head Motor (P/O Stapler Assembly) - Operates the Staple Jaw for
stapler operation.
Diverter Gate Solenoid (Sol 12-225) - When energized, moves diverter to

direct the paper entered to the Top Bin. (Off: Paper feed to Compiler, On:
Paper feed to Top Bin)

Initialization
The purpose of the initialization sequence is to check that each functional
component is at its home position. If not in position, the component is moved to
its home position.
Initialization Sequences
There are two different modes separated by whether compiled sheets are
ejected or not. Initializing sequence for each mode is as follows.
Initialization with compiler retained
LCSS initializes its components except ejector and
tamper as below sequence to retain compiled sheets.
Paddle, Stapler, Punch, Stacker, Input/Exit
Paper Transport Motors
Initialization with compiler purged
LCSS initializes by sequence below for all components.
Tamper, Paddle, Stapler, Ejector, Punch,
Stacker, Input/Exit Paper Transport Motors
If a sheet is detected in the paper path, the LCSS sends a signal to IOT to hold
initialization. If not, the LCSS operates paper transport motors for 1 second to check
for possible strayed sheet and the Diverter Gate Solenoid becomes de-energized
when initializing.

Paper Transport
Operation of the Input Paper Transport Motor
− The Transport Motor provides drive to the LCSS input nips in order to
transport paper from the IOT.
Conditions for Start

− When entry sensor detects lead-edge of a paper in normal operation mode.
− In Component control
Conditions for Stop

− When trail-edge of the paper has left the last roller that is driven by Input
Paper Transport Motor.
− When a jam has occurred.
− When a failure has occurred.
− When an interlock is opened.
− In Component Control

Paper Transport
Operation – Exit Paper Transport Motor
− The Exit Motor provides drive to the LCSS paper transport and exit nips in order
to transport the paper from the input nips to the top bin or the high capacity
stacker bin.
Conditions for Start

− When lead-edge of the paper is nearing to the first roller that is driven by exit
paper transport motor.
Conditions for Stop

− When feeding on Top Bin, paper passes Top Bin exit sensor, then becomes off. It
stops after 50 mm movement.
− When feeding on Stacker Bin, paper passes Stacker Bin Exit Paper Path Sensor,
then becomes off. It stops after 40mm movement.
− When a jam has occurred
− When a failure has occurred
− When an interlock is opened

Paper Transport
Operation – Diverter Gate Solenoid
The Diverter Gate diverts sheets either to Top Bin or to Stacker Bin.
Initialization Control
− De-energized at initialization.
Conditions for energizing

− When the lead edge is nearing the Diverter Gate, top bin selected.
Conditions for de-energizing

− After three seconds and after the trail edge of sheet being transported to Top
Bin has left Diverter Gate.
− When the lead edge is nearing the Diverter Gate, top bin selected.
− When a jam has occurred
− When a failure has occurred
− When an interlock is opened

Hole Punch
Overview
− The Hole Punch Motor drives Punch Heads to punch holes in the sheet as it is
temporarily stopped.
− Select a punch mode in IOT.
− The media stops in the punch position whenever hole punch is selected. The
punch motor is driven CCW, then punches holes and releases the punched
media to the Compiler.
Components
− Punch Head Present Sensor
− Punch Head Home Sensor
− Punch Chad Bin Full Sensor
− Punch Position Paper Path Sensor
− Punch Motor
Initialization
The Punch Motor is driven until the Punch Head Home Sensor is made.

Hole Punch
Operation of the Punch Motor
Punching is done to every page fed in punch mode. If the Punch Position Paper
Path Sensor detects the trail edge of paper getting in, the Exit Paper Transport
Motor speed is quickly reduced and the motor stops in order to get ready for
punching. Punching is done to sheets being transported to Stacker Bin only.
Control of the Punch Motor

- The Punch Motor is controlled by following process.
- Once the trail edge of the sheet is sensed by Punch Position Paper Path Sensor,
the Exit Paper Transport Motor is brought to a stop, and is held in this state
while the Punch Motor finishes one cycle. On completion of the punch cycle,
the Exit Paper Transport Motor is accelerated back to speed.
- The Punch Motor performs 9 revolutions per 1 cycle.
- The Punch Motor rotates at average rate of 3,150 rpm (when using 20lb
paper).

Hole Punch
Failure Detection
− It takes approx. 173ms for one cycle of punching. A failure is reported when
it exceeds 250 ms for a margin.
− The Punch does not leave home position within 250 ms.
− The Punch does not return to home position within 250 ms.
When completed, the motor rotates in the opposite direction to normal

punching direction so that Punch Head returns home.

Paddle
Paddle Overview
When the Paddle Motor is driven CCW, the paddle mechanism causes the sheets to
register in the reverse process direction against the rear stops in the Compiler
Bin.
Components:
Paddle Roll Home Sensor
Paddle/Motor
Initialization
The Paddle Motor is driven in the CCW direction until the Paddle Roll Home Sensor is
made.
Operation – Paddle
Sheets being transported to Stacker Bin are first compiled onto Compiler Bin then
stacked by the Ejector. In order to register the compiled sheets in Compiler Bin,
the Paddle rotates as much as 70° to catch each sheet being extracted onto its
rubber surface. The Paddle then performs the rest of the cycle to register the
sheet to the Compiler Bin.
Failure Detection
One revolution of paddle takes 192 steps typically, but a failure is declared
when it exceeds 400 steps.

Tamper
Tamper Unit
Overview
Tamper is used to align sheets within a set in cross process direction and to give an
offset to sets being stacked.
Components
− Front Tamper Home Sensor
− Rear Tamper Home Sensor
− Rear Tamper Away Home Sensor
− Front Tamper Motor
− Rear Tamper Motor
Initialization
Tamper performs two different initializations as follows:
- Initialization with compiler retained
- No position change
- Initialization with compiler purged
- Ensure tampers are in the home position (fully retracted).

Tamper
Operation of the position of the Tamper
LCSS first calculates and stores each distance required for moving as per positions
depending on the paper size data provided by the UI.
Operation on each page

Every sheet being transported to Compiler within a set is aligned by Tamper in cross
process direction.
Operation on each set

− Single Front Staple (Front Corner Staple) Mode
Tamper performs no movement after the last sheet of a set is aligned
since the single front staple position and aligned position are identical.
− Single Rear Staple Mode
Tamper moves to rear staple position after the last sheet of a set is
aligned.
− Dual Staple Mode
Tamper moves to dual staple position after the last sheet of a set is
aligned.

Tamper
− Offset
Depending on whether or not offset is done, tamper either stays at
aligned position or moves to Offset position. 25mm is allowed for offset
amount.
− Release
Tamper arms are spread to drop the offset set onto Stacker Bin.
Control of the Tamper Motor

− Moving speed dependent on distance
− Moving distance of Tamper Arm per one step of Tamper Motor is designed to
be 0.291 mm
Failure Detection
− When Front/Rear Tamper Home Position Sensor is not made against the
maximum moving range at initialization.
− When Front/Rear Tamper Home Position Sensor stays made even if Tamper
Arms have left their home positions.

Stapler Unit
Overview
The LCSS has three staple positions depending on paper types, which are Front Corner,
Dual and Rear. The maximum sheets allowable is 50 (24lb / 80gsm).
Components
− Staples Low Sensor
− Cartridge Present Sensor
− Staple Jaw Home Sensor
− Staples Ready (Primed) Sensor
− Staple Paper Present Sensor
− Safety Gate Interlock Switch
− Stapler Index Sensor
− Staple Paper Edge Registration Sensor
− Stapler Index Home Sensor
− Staple Head Motor
− Stapler Index Motor

Stapler Unit
Initialization
Returns staple jaw to home position
Returns staple head to home position
If staple is not ready, LCSS performs self priming (stapler clinches up to 10 times).
Operation of the Stapler

The LCSS ensures Staple Head is correctly positioned to deliver the required stapling as
instructed by the IOT. When the sheet has been correctly registered in Compiler Bin, the
Staple Head is driven to staple the set. Upon completion of dual or rear stapling, the
Staple Head must be indexed back to its home position to allow the set to be ejected.
Staple Positions
The user may select from up to three possible stapling options for their copy set (s) as
follows:
Single front staple (Corner staple)
Single rear staple
Dual staple

Stapler Unit
Low Staple
The Stapler cartridge contains 72 staple sheets and 1 staple sheet contains 70
staples. When 6 ±2 staples are used from the last staple sheet in the cartridge, low
staple signal is sent to LCSS PWB and approximately 40 staples are clinched from
this point. However, if LCSS is turned on or door /cover is closed at low staple status,
staple cartridge is detected as being empty.
Stapler Indexing Motor

The stapler index motor provides the drive to transport the staple head between
staple positions.
Single front staple

LCSS ensures Staple Head is at the home position.
Single rear staple

LCSS drives Staple Index Motor to transport Staple Head to the rear staple position.
Once the stapling operation is completed, Staple Index Motor is driven to transport
the staple head back to its home position.

Stapler Unit
Dual staple
The LCSS drives the Staple Index Motor to transport the Staple Head to the rear
staple position. Once the first stapling operation is completed the Staple Index
Motor is driven to transport Staple Head (back) to the second staple position. Once
the second stapling operation is completed, Staple Index Motor is driven to the
transport Staple Head back to its home position.
Self Priming
If staple strip is not primed during initialization, Staple Head primes the strip
forward by clinching approximately 5 times (max. 10).
Stapler Index Motor
Single front staple: There is no movement of Stapler Transport Unit.
Single rear staple Mode: Operates by following Speed-Step and rotating direction
Dual staple Mode: Operates in following PPS, Steps and rotating direction.
Home position searching: Stapler Index Motor operates in following Speed-Step to
reposition Staple Head at home.

Stapler Unit
Failure Detection
More than 1000 steps are taken for the Staple Head to:
- Return home position at initialization.
- Move to rear staple position from home position.
- Move to the 1st staple position (rear staple position) of dual staple from
home position.
- Move to the 2nd staple position (front staple position) of dual staple from
the 1st staple position (rear staple position)
- Return home position from the 1st staple position (rear staple position)
after the completion of dual staple mode.
- At initialization and door open/close, in the event that it takes more than
0.8 seconds for Staple Jaw to open, if staple jaw is not opened.
- In the event that the signal of Staple Jaw Home Sensor takes more than
0.8 seconds to perform one cycle of stapling while the Staple is in operation.

Ejector Unit
Overview
Once the set/sheet has been registered correctly in the compiler, Ejector Motor drives
(CCW) to retract Ejector to its home position. Once Ejector achieves its home position
the drive motor is stopped and after a brief pause is driven (CW) to extend Ejector to
its eject position thereby pushing the sheet/set out of the compiler on to the stacker
bin.
Components
Ejector Home Sensor
Ejector Out Sensor
Ejector Motor Encoder
Ejector Motor
Initialization
To avoid interference with Staple Head, LCSS ensures that Staple Head positions at
home prior to initialization of Ejector. Ejector retracts first and pushes sheets that may
remain in Compiler to Stacker Bin then retracts again.

Ejector Unit
Operation – Ejector
Retreat:
When Initialization with compiler purged
When a job has been completed without subsequent job
When manual stapling
When lead edge of the last sheet of a set has entered input nip of LCSS in Non-
staple or Front staple mode
When Staple Head has returned home after Dual or Rear stapling
Eject:
When the first sheet of a set has entered the input nip of LCSS
After retracting in order to get ready for ejecting operation
Failure Detection
Fault is raised under following condition.
When two home sensors are detected at the same time during operation or
initialization
In the event that it takes more than 1 second when moving between home and
eject position in either way.
When two home sensors are detected at the same time during operation or
initialization

Stacker Unit
Overview
Since Stacker directly affects the registration of sheets being stacked/compiled,
it is programmed to position at base position defines by moving frequently,
which can be explained by the fact that Stacker Bin goes up or down until the
highest point of Stacker Bin that has sheets reaches Stacker Bin Paper High
Level Sensor if either user takes stacked sheets out of the Stacker Bin or more
sheets are stacked while in operation.
Components:
Stacker Bin Upper Limit Interlock Switch (Upper Limit Interlock)
Stacker Bin Lower Limit Interlock Switch (Lower Limit Interlock)
Stacker Bin Paper High Level Sensor (Higher Level Sensor)
Stacker Bin Paper Low Level Sensor (Lower Level Sensor)
Stacker Bin Paper 90% Full Sensor (Bottom Sensor)
Stacker Bin Motor Encoder
Stacker Bin Motor

Initialization
The LCSS checks to stacker bin position and ensures that it is placed in the receive
position.
The bin position is controlled by two sensors, two limit switches and a bi-directional
elevator motor.
The limit switches are employed to prevent elevator over-travel (both up and down).
The sensors comprise a Higher Level Sensor and Lower Level Sensor.
If the Upper Limit Interlock is activated then the bin is prevented from elevating and
can only descend.
If the Lower Limit Switch is activated then the bin is prevented from descending and
can only elevate.
When the bin is empty and at the top in its receive position, the Lower Level Sensor will
be made by the bin rear edge and the Higher Level Sensor will be clear.
As paper being delivered to the bin, the stack builds and operates the Higher Level
Sensor, with the Higher Level Sensor made the elevator motor operates to lower the bin
until the Higher Level Sensor is clear.
As the bin is lowered to accommodate the increase in stack height, the Lower Level
Sensor is held in the closed position by the stack rear edge.
When the user unloads the bin the Lower Level Sensor is cleared and the elevator motor
raises the bin until both the Higher Level Sensor and Lower Level Sensor are made, at
which point the elevator motor reverses and lowers the bin into the receive position.

Initialization
Operation – Moving The Stacker Bin to The Base Position

When Lower Level Sensor is Off, Stacker Bin elevates till Higher Level Sensor or
Upper Limit Interlock is made.
When Higher Level Sensor is On, Stacker Bin descends till Higher Level Sensor is
Off or Lower Limit Interlock made.
Operation – Stacker Bin Paper Level Detection
4 steps are specified to indicate the degree of stacked paper as follows:
Empty:
LCSS recognizes that Stacker Bin is empty if it gets simultaneous information
that Higher Level Sensor is not made and Upper Limit Interlock is made.
Not Full/Not Empty:
LCSS recognizes that Stacker Bin is not full/not empty if it gets simultaneous
information that Higher Level Sensor is made and Bottom Sensor is not made.

90% Full:
LCSS recognizes that Stacker Bin is 90% full if it gets simultaneous information that
both Higher Level Sensor and Bottom Sensor are made.
Full:
LCSS recognizes that Stacker Bin is full if it gets simultaneous information that both
Higher Level Sensor and Lower Limit Interlock are made.
Control – Stacker Bin Motor
Bi-directional DC Motor Control
When Stacker Bin ascends or descends, stop the motor by short brake
Stacker Bin Speed is 31.81 mm/s typically. (On condition of no paper on Stacker Bin)
Failure Detection
LCSS senses the motor speed through Stacker Bin Motor Encoder. If an outer load
causes the speed to be reduced significantly, motor stops its rotation to avoid
possible damages.
If the initialization is not completed within the period of time set, LCSS stops the
motor and sends a fault signal to IOT.

Top Problems
Problem: Failure of the LCSS PWB
Cause: If the machine is turned on with the Stapler not home, the
LCSS PWB can fail
Solution: Problem has been identified and a solution is forthcoming

High Volume Finisher - HVF

Overview
There are 2 types of High Volume Finishers (HVF), one with the Booklet Maker and one
without. The Booklet Maker version of the HVF can be fitted with a Tri-Folder.
HVF provides the following functions:
Top Tray output for single sheets from the IOT, with a capacity of 250 sheets of 20lb.
Bin 1 or Main Tray output, providing compiled, multiple sheet sets with a capacity of 3000
sheets of 20lb. This capacity will be less by the addition of stapled sets
A Booklet Maker with a minimum capacity of 10 sets of 15 sheets, stapled booklets at
20lb. This capacity will also be less by the addition of stapled sets
Tri-Folder is capable of producing C or Z folds. This has an output bin with minimum
capacity of 50 single sheet tri-folder jobs @ 20lb. This requires a Booklet Maker to be
fitted.
Main HVF Stapler with a maximum capacity of 100 sheets of 20lb
Main HVF upgradeable Punch Unit
Post Process Inserter (PPI), allows up to 250 20lb sheets of paper to be inserted at any
point into compiled sets.

Modules
Top Tray
PPI
Bin 1 or Main
Tray
Stapler
From the IOT
Hole Punch
HVF LVPS
Booklet Maker
Tri - Folder

Modes of Operation
Stack Mode
The Stacker Tray tray provides a stacking and collating capability to finished
jobs. Up to 3000 sheets of 80gsm paper are stacked face down onto the
Stacker Tray. (Tray capacity will be reduced to 2000 sheets when the Trifolder
unit is fitted) The HVF notifies the host controller when the stacker tray is 90%
and 100%full. The stacker will be capable of stacking mixed length and width
sheets registered to the front of the stacker. Intermixed stacks may be offset
and will be distinguishable between sets.
Top Tray
The Finisher will be able to divert sheets to a separate catch tray, which has a
capacity of 250 sheets. This will also be a selectable destination for unstapled
sample sets and is also utilized for purged sheets following a jam.

Modes of Operation
Staple Mode
A choice of stapled positions are offered and is dependent on paper size and
orientation. There is a single front 450 corner position for LEF sets, a single rear
position for both LEF and SEF papers together with dual and/or multiple
position options.
Staples are driven from the underside of the stack and clinched at the top to
ensure the correct orientation of the staple for the finished set. The stapler
monitors the availability of staples, and reports any malfunction to the IOT.
The staple head has a capacity of 5000 staples and are user replaceable. The
stapler also has a 100 sheet stapling capability.

Modes of Operation
Booklet Maker (Booklet Fold Mode)
Collates and provides a single Booklet Fold up to 5 sheets of 20lb delivered to
the output of the booklet tray. The specification for the fold position is +/- 3mm
to the center line.
Booklet Maker (Booklet Fold Mode and Saddle Stitch )

Will staple and fold up to 10 sets of 15 sheets 20lb or equivalent, parallel to
lead edge with no trimming and deliver output to the booklet tray. One cover of
up to 65lb may be included with the sheet capacity consistent with the
paperweight of the body of the booklet (I.e. 13 sheets of 20lb and 1 cover sheet
of 160 gsm). Staple orientation will be with the clinched legs on the inside of
the fold. The specification for the fold position is +/- 3mm to the center line.

Modes of Operation
Hole Punch Unit
The Hole Punch is an upgradable customer unit. The Hole punch waste is
deposited into a Chad Bin with a capacity that will allow a minimum of 5,000
punches. A notification is sent to customer to empty the Chad Bin. The Hole
Punch Unit is capable of punching sheets fed from the PPI (Post Process
Inserter). The Hole Punch is enabled to operate continuously.
The Hole Punch Unit is capable to perform 3 Hole punch for Letter and 2 Hole
punch for Legal.
Post Process Inserter (PPI)
The Post Process Inserter (PPI) provides the mechanism to include media, such
as cover sheets or separators (but not tabs), at a predefined point into a
printed job supplied by the host controller. Separates and feeds a stack of a
minimum of 250 documents with image in the appropriate orientation to
match the required output.

Modes of Operation
Post Process Inserter (PPI) (continued)
Handles between A4/8.5x11 (LEF & SEF) & A3/11x17 (SEF) sizes within a
weight range of 20 to 60lb.
Handles special stocks such as pre printed, transparencies and coated stock.
Detects and categorizes specific document sizes between A4/8.5x11 (LEF &
SEF) and A3/11x17 (SEF) including A4 and 8.5x11 differentiation.
Delivers documents registered to the HVF.
Feeds at the same speed as the IOT. (i.e. The PPI inserts sheets at the
appropriate process speed to maintain full system productivity).
PPI will be capable of operating continuously.

Modes of Operation
PPI does not support
Tab stock
Can not copy/print onto stock that is fed from the PPI.
Mixed Size Stock.
Tri – Folder
The external free standing module is capable of being fitted to the HVF
Booklet Maker (BM) and provides a capability for transporting all Booklet
Maker output to a standard Booklet Maker catch tray mounted to it’s right side
and for the C or Z folding of SEF A4 / 8.5 x 11 output only.
The Booklet Maker provides the 1st fold and the Tri-folder provides the 2nd fold.
The Tri-Folder has the capability of folding just 1 sheet at a time.

Modes of Operation
Pause and Unload Mode

This is a user selectable button at the top of the HVF with an indicator LED.
When pressed the indicator light will flash and a pause request will be sent
to host controller. This will send a request to pause the copy/print job in its
current state and the output will enter unload mode. In addition, if booklets
are being produced then they too will be processed to exit for unloading.
The output tray will be lowered to indicate ready to unload.
When the pause button is pressed again the system will resume
printing/copying. A timer for one minute will allow the user to empty the
Main Tray and walk away without initiating a restart of the pause button.

Job Capabilities
The following table displays the combinations of finishing functions that may be selected together for a single job.
The HVF is capable of handling these combinations. All of the outputs may be selected individually.
Top Booklet Staple Booklet Booklet Tri-

Stacker Tray Offset Punch Insert
Tray Tray Fold Staple Fold
Single Dual Multiple
Top Tray N/A X X X X X X X X X 3 X
Stacker
X N/A X 3 3 3 3 X X X 3 3
Tray
Booklet
X X N/A X X X X 3 3 3 X 3
Tray
Single
X 3 X N/A X X 3 X X X 3 3
Staple
Dual Staple X 3 X X N/A X 3 X X X 3 3
Multiple
X 3 X X X N/A 3 X X X 3 3
Staple
Offset X 3 X 3 3 3 N/A X X X 3 3
Booklet
X X 3 X X X X N/A 3 X X 3
Fold
Booklet
X X 3 X X X X 3 N/A X X 3
Staple
Tri-Fold X X 3 X X X X X X N/A X X
Punch 3 3 X 3 3 3 3 X X X N/A 3
Insert 3 3 3 3 3 3 3 3 3 X 3 N/A
3 = May be selected. X = Not Available. N/A = Not Applicable.

Media
Module Weight Size (s) Exclusions
Top Tray 60 – 216 gsm SEF - A6, 4.25” x 5.5”, A3, 11” x 17”, Tabs & Envelopes None
Stacker Tray 60 – 216 gsm SEF - B5, A3, 11” x 17”, Tabs
Stapler 60 – 216 gsm 100 Sheets @ 80 gsm or equivalent Transparencies & Labels
A4/8.5” x 11” SEF & LEF, 8.5” x 13”, 8.5” x 14”, 11” x No other paper sizes are
PPI 60 – 216 gsm
17” A3 SEF supported. Tabs & Labels
SEF - 8.5” x 11”, 8.5” x 13”, 8.5” x 14”, 11” x 17”, A3 Transparencies, Labels or Pre-
Punch 60 – 216 gsm
LEF – A4, 8.5” x 11” Punched Tabs
SEF – A4, A3, 8.5” x 11”, 8.5” x 13”, 8.5” x 14” & 11” x
Booklet Maker 60 – 216 gsm Transparencies, Labels or Tabs
17”
A4, 8.5” x 11”

Tri – Folder 60 – 216 gsm Transparencies, Labels or Tabs
SEF Only!
When requested to finish a particular job the HVF shall perform a final compatibility check to ensure that only
valid combinations are selected together.
If the HVF compatibility check identifies an error the HVF will deliver the requested job with as much as the
requested tasks completed as possible.
The HVF will then notify the Host Controller of the error.

Specifications
HVF with Booklet Maker:
Capacity: Top Tray – 250 Sheets
Main/Stacking Tray – 3000 Sheets
Sizes: 4.25” x 5.5” to 11” x 17”
Weights: 16lb to 57lb Bond / 80lb Cover (60 – 216 GSM)
Stapling: 100 Sheets Single (Any corner), Dual, Front, Rear, SEF
and 4 Stitch

Specifications
HVF with NO Booklet Maker:
Capacity: Top Tray – 250 Sheets

Main Tray – 3000 Sheets
Sizes: 4.25” x 5.5” to 11” x 17”
Weights: 16lb to 57lb Bond / 80lb Cover (60 – 216 GSM)
Stapling: 100 Sheets
Single (Any corner), Dual, Front, Rear, SEF and 4 Stitch
Hole Punch: Option 1 – 3 Hole
Option 2 – 2-Hole Legal Punch

Specifications
Booklet Maker:
Capacity: Tray Stop Up – 30 Booklets (1 – 15 sheets per booklet)
Tray Stop Down – Unlimited
Sizes: Letter (8.5” x 11”), Legal (8.5” x 14”) & Ledger (11” x 17”)
Weights: 16 lb to 57lb Bond / 80lb Cover (60 – 216 gsm)
Stapling: Saddle Stitch (2 – 15 sheets) / 8 – 60 page booklet), 12 sheets of
20lb and 1 cover @ 110lb V-Fold
Fold & Saddle-Stitch
2-15 Sheets (8-60 page 1-5 Sheets
Folding: V-Folding ( 1 – 5 sheets / unstapled) booklet) (unstapled)
Hole Punch: Option 1 – 3 Hole

Option 2 – 2-Hole Legal Punch

Specifications
Tri Folder – Z - Fold / C – Fold:
Capacity: 50 Sheets or unlimited capacity with the tray stop in the down position.
Sizes: Letter – 8.5” x 11”
Weights: 16lb to 57lb Bond / 80lb Cover (60 to 216 GSM)
The Tri-Folder will not fold – Transparencies, Card Stock and Labels
Post Process Inserter (PPI, Tray 6):

Side 1 Image
Capacity: 250 Sheets
Sizes: Letter – 8.5” x 11” Side 1 Image (inside)
C Configuration Z Configuration
Legal – 8.5” x 14”
Ledger – 11” x 17”
Weights: 16lb to 57lb bond / 80ln cover (60 – 216 gsm)

HVF Initialization
NOTE: The HVF initialization procedure can be triggered by opening and closing the HVF front door or by raising
and lowering the top tray. When this is done, the tray will not lower completely, but will adjust it’s position.
When an initialization command is received from the IOT, the HVF is initialized in the following sequence:
The Stacker Tray lowers
The Flappers perform 2 revolutions
The Ejector Module travels to the out position
The Stapler Unit travels to the inboard position
The Stapler Unit returns to the home position
The Ejector Module returns to the home position
The Stacker Tray offsets
The 3 Feed Motors start
The Booklet Maker Diverter Solenoid actuates, if applicable.
The Exit Diverter Solenoid actuates
The Booklet Maker Diverter Solenoid de-actuates
The Exit Diverter Solenoid de-actuates
The 3 Feed Motors stop
The Hole Punch Unit operates, if applicable
The Stacker Tray returns to the home position

Electrical Requirements
The AC to the HVF is supplied from the IOT. HVF can support AC supply voltages
ranging from 99 Vac to 254 Vac inclusive at both 50 Hz and 60 Hz.
When power is first applied to the total system, there are certain limitations regarding
the power available to the various modules, including the HVF. The IOT requires the
majority of the power to get key modules ready for printing/copying. As power
becomes available the other modules can now be powered on.
After the IOT applies AC power to the HVF, the HVF initializes it’s software and then
attempts to sync with the IOT. After synchronization takes place the HVF responds to
instructions from the IOT.

Power
HVF is supplied by a dedicated power supply within the base of the HVF, it supplies
+5Vdc and +24Vdc.
A harness from the HVF PWB to the Booklet Maker PWB supplies +5Vdc and +24Vdc.
In turn the Booklet Maker PWB supplies the Tri-folder with +5Vdc and +24Vdc.
The Post Process Inserter is powered from the HVF PWB through a connector at the
base of the PPI.

Power
Tri-folder
Interlocks
Docking
Inserter

Interlock Switches
NOTE: Removal of any interlock will result in all motors and moving parts to shut
down immediately.
Top Cover Interlock (S12-197) –

Triggered when the Top Cover is lifted.
In the HVF there are 3 Interlock Switches wired

in series, +24Vdc passes through them.
When all 3 Interlock switches are closed, this
allows +24Vdc to be distributed to Motors,
Solenoids & Clutches.
Front Door Interlock (S12-303) –

Docking Interlock (S12-177) –
Triggered when the front door is
Triggered when the HVF is undocked
opened.
from the machine.

Machine Interface
The harness between the IOT and the HVF PWB carries the communication between the
2 modules, on serial data lines. The type of output device is identified by the voltages on
the ID lines within this harness.
Communication between the HVF PWB and the Booklet Maker occurs on serial data lines.
The Booklet Maker present link is present within this harness.
The PPI does not have any dedicated communications to the HVF PWB, but the PPI
information is carried within a harness to the HVF PWB
The Tri-folder does not have dedicated communication line to the Booklet Maker PWB,
but the Tri-Folder present link is carried within a harness to the Booklet Maker PWB.

HVF PWB
LED 8 – Steady – Indicates that the HVF

Top cover, Front Door and Docking
Interlocks are all closed and +24Vdc is
available for the Motors, Solenoids and
LED 7 – Flashes @ 1Hz – indicates that
Clutches at the HVF.
the software is operating in normal
mode. When software is downloading it
operates at a faster rate.
LED 9 – Steady – Indicates that the

+5Vdc supply is present at the HVF

Booklet Maker Control PWB
LED Indicators:
LED 1 – (RED) Steady – This indicates a fault or abnormal
status.
LED 2 – (YELLOW) Flashing - @ ~ 1/3 Hz. Indicates that the
software is operating under normal condition.
LED 3 – (ORANGE) Steady – Indicates 2 things:
The Tri-Folder front door and top cover interlocks are closed, and
+24Vdc is available to the Booklet Maker or if the Tri-Folder is
not installed
The interlock cheater is present in PJ553 on the Booklet Maker
control PWB, the logic cheater is present in PJ563 on the Booklet
Maker Control PWB.
LED 19 – (ORANGE) Steady – Indicates that the +24Vdc supply
is within voltage and current limits, and that the power limiting
circuit has not been active for over a set time limit.
LED 5 - (BLUE) Steady – Indicates that the +5Vdc supply is
present at the Booklet Maker.

Paper Path

Paper Path
Top Bin Exit Sensor
Stacker Bin Exit Sensor 2

PPI Exit Sensor
PPI Tab Sensor

Stacker Bin Exit Sensor 1
Entrance Sensor
Booklet Exit Sensor
From the IOT

Booklet Maker Entrance Sensor
Buffer Position Sensor

Paper Path
Entry Feed Motor 1 (MOT12-223) – Provides

drive to the input path from the IOT, drives the
vertical paper path from the PPI and takes paper
through the Hole Punch.
Entry Sensor (Q12-077) – Senses paper at

the HVF input transport, receives paper from
the exit of the IOT.

Paper Path
Booklet Maker Diverter Solenoid (SOL12-258) – Actuates
to pass paper to the Booklet Maker. In the non-actuated
condition. Allows paper to pass to the Buffer transport.
HVF Booklet Exit Sensor (Q12-087) – Senses paper exiting

the HVF for the Booklet Maker.
Buffer Pocket
Buffer Clamp Solenoid (SOL 12-056) – Actuates during multiple-sheet compiled output
Bypass Feed Motor (MOT 12-262) – Takes jobs. When actuated it hold the trail edge of the 1st sheet in the Buffer Pocket until the
the paper from the Hole Punch to the Buffer arrival of the 2nd sheet, at that time both sheets are fed to the Ejector. Works as follows:
Transport or to the Booklet Maker. Depends -1st sheet fed vertically up into buffer transport until it is released by the action of the
on the action of the Booklet Maker Diverter Nip split motor, moves the idler rolls to the left, away from the paper. Then the Buffer
Solenoid. Feed Motor stops.
- Sheet then drops into the buffer pocket, where it is held by the buffer clamp solenoid
until the 2nd sheet arrives. This action maintains the Inter-set gap.

Paper Path
Buffer Path Sensor (Q12-321) – Reflective

sensor, located in the Buffer Transport. Senses
Buffer Feed Motor (MOT12-262*) – Stepper paper being fed to the Top Tray or Stacker
Motor, located at the rear of the HVF. Takes
the paper from the Booklet Maker diverter to
the top tray or stacker

Paper Path Nip Split Motor (MOT12-264)
Opens the nip in the vertical buffer
path by moving the idler rolls to the
left, away from the paper. This
allows the 1st sheets of a multi-
sheet compiled job to drop in the
buffer pocket.
Nip Split Sensor (Q12-091) Flag sensor,

operated by cylindrical flag on the nip
split cam shaft, senses the open
position of the nip.
Nip Home Sensor (Q12-088) Flag sensor, operated cylindrical

flag on the nip spilt cam shaft, senses the closed position of the
nip.

Paper Path
Exit Diverter Solenoid (SOL12-225) – Actuates to divert the

paper from the buffer to the top tray. In the non-actuated
condition, it allows paper to pass to the stacker.
Transport Motor 2 (MOT12-224) – Takes the paper from the

exit diverter and feeds it either to the top tray, via the top exit
sensor, or to the stacker, via the Stacker Exit sensor.

Paper Path
Top Exit Sensor (Q12-107) – Senses paper
passing out to the top tray.
Compiler Exit Sensor (Q12-106) – Senses

paper passing out to the stacker.
Buffer Path Sensor (Q12-321) – Senses

paper being fed to the Top Tray or Stacker
Entry Sensor (Q12-077) – Senses Booklet Exit Sensor (Q12-213) – Senses

paper from the exit of the IOT. paper entering into the Booklet Maker.
Buffer Position Sensor (Q12-086)

Senses paper fed to the Hole Punch
and to the Buffer Transport.

Paper Pusher
Paper Pusher Motor (MOT11 – 083)

Paper Pusher
The final roll at the stacker exit corrugates the paper to
give it stiffness. The Paper Pusher moves down as each
sheet leaves the final roll and pushes the sheet down to
Paper Pusher Upper Sensor (Q11 – 171)
the ejector unit.
Paper Pusher Motor (MOT 12-265) – Drives pinions with Paper Pusher Lower Sensor (Q11 – 173)
racks integral with the pusher.
Paper Pusher Upper Sensor (Q12-092) – Detects the Stapler Safety Gate (S11 – 365)
Pusher in the upper position.
Paper Pusher Lower Sensor (Q12-094) – Detects the

Pusher in the lower position.
Stapler Safety Gate (S12-319) – Disables the +24Vdc

supply to the stapler when the paper pusher is away from
the lower position. This ensures personal safety when it is
possible to reach the stapler jaws, under the paper pusher.

Paddle Unit
Paddle Unit
As the pusher moves down with the 1st sheet, the paddle unit moves to the lower
position. As the paper pusher returns to the upper position, ready for the next sheet, the
paddle rotates to position the 1st sheet correctly in the ejector. The sheet is correctly
positioned when it’s trail edge is in contact with the upright posts in the stapler module.
The number of cycles the paddle rotates depends on the size and orientation of the
paper. The paddle unit remains in the lower position and every sheet in the set is
positioned in this way. When the final sheet in the set has been positioned by the paddle,
the paddle unit returns to the upper position.
Lower Paddle
This is a single paddle, that is integral with the ejector unit, which operates on the 1st
sheet only in each set. The lower paddle turns at the same time as the upper paddle. It
is actuated by the eject roll motor turning in the reverse direction. The action of this
motor in the forward direction is described later.

Paddle Unit
Paddle Unit Lower Sensor (Q12–175) Senses
the paddle unit in the lower position.
Paddle Unit Upper Sensor (Q12–174)

Senses the paddle unit in the upper position.
Paddle Unit Motor (MOT12-239) Drives

the paddle unit down to the working position
and back up at the end of each set.

Paddle Unit
Paddle Roller Home Sensor (Q12-186)

Senses the paddle roller in the home
position.
Paddle Roller Motor (MOT12-238) The

paddle is turned one complete revolution.

Curl Suppression
Curl Suppression
A solenoid operated flap moves down onto the
center of each sheet to counteract any tendency
to curl, therefore to affect the performance of the
compiler. The flap is down during compiling and
is raised during ejection.
Component associated are:

Curl Suppression Solenoid (SOL 12-266) – This
solenoid is located in the center of the paddle
unit. A flap is lowered and raised by this solenoid,
via a quadrant gear.

Paper Ejection, Pressing & Support
When the set is compiled, and the Paper Pusher and Paddle units have returned to the
upper position, and the Curl Suppression Flap has been raised, the Ejector Unit moves
to the out position. The Support Fingers move out, taking the pressing fingers down to
hold the previous set in place on the stacker.
The Ejector Roll Motor turns the belts and the Ejector Fingers push the set out on the
Stacker. The Pressing and Support Fingers then return to the home position. The
ejector fingers are carried round on the belts to their home position as the ejector unit
moves to it’s home position.

*Sorcery Ejector Shown

Eject Unit Motor (MOT12 – 233) Drives the
Ejector Motor Encoder Sensor (12-096) ejector unit to the out and home positions.
Senses the rotation of the Ejector unit
motor.
Ejector Unit Home Sensor (Q12-184) Ejector Unit Out Sensor (Q12 – xxx)
Senses the Ejector unit has reached the Senses the Ejector Unit has reached the out
home position. position.

Support Finger Out Sensor (Q12-173) –

Detects the support fingers in the out
position.
Support Finger Motor – This motor
moves the support fingers to the ‘out’,
Support Finger Home Sensor (Q12–172) ‘init’ & ‘home’ positions.
Detects the support fingers in the home The pressing fingers are mechanically
position. linked to the support fingers so that as
the support fingers leave the home
position, the pressing fingers move down
Support Finger to hold the previous set on the stack.
Support Finger In Sensor (Q12–171)

Detects the support fingers in the init Support Finger Motor Encoder Sensor (Q12-093) –
position. Senses the rotation of the support finger motor.

Ejector Roll Motor (MOT12-233) DC Motor,

located at the rear underside of the ejector
unit. It runs in the reverse direction to rotate
the lower paddle. Located behind the encoder
disc.
Ejector Roll Encoder Sensor (Q12-097)

Flag type encoder sensor, senses the motor
rotation.

Ejector Lower Paddle Home Switch (S12-099) This is a micro switch

located at the front underside of the ejector unit, sensing the home
position of the lower paddle. This switch allows the paddle to rotate for
one complete cycle .
Ejector Lower Paddle

Tamping and Offsetting
Operation of offsetting the compiled sets is performed by the front and rear tampers.
Offsetting is performed immediately before ejection. If stapling is selected, offsetting is
performed after stapling. When a stapling operation is selected, the rear tamper
operates before stapling, to ensure that each set is correctly positioned for stapling at its
outboard end.
After stapling the sets are alternately either left at the outboard end, or offset towards
the inboard end by the front tamper. During A4 and LEF feed operation, the bin 1 offset
function is not performed. The offset function comes into effect, during A4 or letter SEF
operation, or similar. In these cases, the Bin 1 offset moves outboard, to the away
position, before tamping the 1st set. This is done in order to position the ejector in the
center of the paper set. The offset remains in the away position until the last set has
been ejected, then returns to the home position.

Tamping
Front Tamper Home Sensor (Q12-180) – This is a flag sensor,

located under the bracket on the front frame. This sensor detects the
front tamper in the home position
Front Tamper Away Sensor (Q12-182) – This is a flag sensor,

located under the bracket on the front frame. This sensor detects the
front tamper in the away position
Front Tamper Motor (MOT12-266) – This is a DC motor, located

above the bracket on the front frame. This motor moves the front
tamper to the away and home positions

Tamping
Rear Tamper Motor (MOT12-227 )
This is a stepper motor, located
immediately to the rear of the ejector unit.
This motor between the rear and home
positions.
Rear Tamper Away Sensor (Q12-183) This

is a flag sensor, located to the rear of the
rear home sensor. This sensor detects the
rear tamper in the away position .
Rear Tamper Home Sensor (Q12-181)
This is a flag sensor, located to the rear of the
rear home sensor. This sensor detects the rear
tamper in the away position

Stapling
The stapling functions of the HVF, are distinct from those of the booklet maker and are performed on each set
immediately after compiling, but before tamping and offsetting. A single traveling stapler unit is used. When 1
staple is selected, the stapler remains at the outboard end of it’s travel, and the corner of each set is stapled. When
2 or more staples are selected, the stapler travels from outboard to inboard between each staple, then travels to the
mid home position where it remains during the tamping and eject functions. The stapler then returns to the home
position.
Various Stapling Positions

Stapling
Stapler Primed Sensor Q12-134
Stapler Head Motor Q12-247
Stapler Mid Home Sensor Q12-176

Stapler Head
Stapler Home Sensor Q12-135

Stapling
Components associated with the stapling function are:
Cartridge Sensor (Q12-317) – Integral part of the Stapler and cannot be serviced. It detects the presence of a cartridge, ensure it is
correctly fitted.
Stapler Home Sensor (Q12-135) – Integral part of the Stapler and cannot be serviced. Senses that the stapler jaws are correctly
positioned, ready for a stapling cycle.
Stapler Head Motor (MOT12-247) - DC Motor that drives the Stapler inboard and outboard.
Stapler Unit Mid Home Sensor (Q12–176) - Flag sensor, located towards the inboard end of the bed of the Stapler. Detects the
position where stapler head moves to before the first sheet is ejected for Dual/Multi/Rear Stapling
Stapler Head - Staples compiled sets
Stapler Home Sensor (Q12-135) - Flag sensor, located at the outboard end of the Stapler. Detects the Stapler’s home position.
Stapler Primed Sensor (Q12-134) - Integral part of the Stapler and cannot be serviced. It detects the staples are in the correct
position, ready for forming and stapling.
Low Staples Sensor (Q12-133) – Integral part of the Stapler and cannot be serviced. Senses when the staples are running low and
warn the user.
Stapler Safety Gate Switch (S12-319) – Micro switch, located at the inboard left of the Paper Pusher. This switch disables the +24Vdc
supply to the stapler motor drive circuit, when the paper pusher is away from the lower position. This is to ensure personal safety when
it is possible to reach the stapler jaws, under the paper pusher.

Stacker
Bin 1 movement and control - As the bin fills, the tray moves down to
maintain the top of the stack at the correct level. This is controlled by the bin
1 home sensor, which is in 2 parts, the bin 1 rear wall sensor, it senses the top
edge rear wall of the stack of paper. If the paper stack is flat, the rear wall
sensor will control the stack height, if the paper stack is curved, the bin 1 home
sensor will detect the top of the nearly full. There are upper & lower limit
switches, to keep the tray within its allowable range of movement.
Bin 1 Elevator Motor (MOT12-241) – Motor lifts & lowers the paper stack via a gear
chain, driving 2 toothed belts.
Bin 1 Encoder Sensor (Q12-163) – Senses the rotation of the bin 1 elevator motor.
Bin 1 Upper Level Sensor (Q12-188) and Transmitter– The rear sensor is used for
transmitting while the front is used is used for receiving.
Bin 1 Wall Sensor (Q11 – 196) – Sensor detects the top of the rear wall of the paper
stack.
Bin 1 90% Full Sensor (Q11 – 331) – Bracket has 2 possible positions; the lower
position, used when the tri-folder module is not installed, and the upper position,
used when a tri-folder is present. Sensor is actuated by a flag on the bin 1 rear bar
lift bracket.

Stacker
Bin 1 elevator motor, MOT12-241 - This is a DC
motor, located on the rear frame. This motor lifts Bin 1 Encoder Sensor
(Q12-163)
and lowers the paper stack via a gear chain, driving Paper Pressing
Sensor (Q12-322) Bin 1 Elevator Motor
Mot 12-241
two toothed belts. In the forward direction, this
motor drives the stack down, and in the reverse
direction, the stack is driven up.
Bin 1 encoder sensor, Q12-163 - This is a standard Bin 1 Upper Level
Sensor (Receiver)
flag, encoder-disc sensor, sensing the rotation of (Q12-188)
the bin 1 elevator motor. Bin 1 Upper Level Sensor

(Transmitter) (Q12-188)
Bin 1 upper level sensor, Q12-188 - This consist of

two reflective sensors, located in the frames at the
front and the rear of the tray. The rear sensor is
used as the transmitting sensor, while the front
sensor is used as the receiving sensor.
Paper pressing sensor, Q12-322 - This is a
reflective sensor, located beneath the ejector front
cover. This sensor detects the top of the rear wall of
the paper stack.

Stacker
Bin 1 90% full sensor, Q12-187 - This is a flag sensor,
located on the rear frame and mounted on the same
bracket as the lower limit switch. This bracket has two
possible positions; the lower position, used when a tri-
folder module is not installed, and the upper position, used
when a tri-folder is present. This sensor is actuated by a
flag on the bin 1 rear bar lift bracket.
Bin1 upper limit switch, S12-190 - This is a micro switch,

located on the rear frame. This switch is actuated when the
tray is above its normal level of operation. When this
switch is actuated, the reverse, upwards, direction of the
elevator motor is disabled, but the motor is allowed to Bin 1 Upper Limit
Switch (S12-190)
drive the stack down.
Bin 1 lower limit switch, S12-191 - This is a micro switch,

Bin 1 90% Full
located on the rear frame and mounted on the same Sensor (Q12-187)
bracket as the 90% full sensor. This switch is actuated

when the tray is at its lowest allowable limit of operation.
When this switch is actuated, the forwards, downwards,
direction of the elevator motor is disabled, but the motor is
allowed to drive the stack up.
Bin 1 Lower Limit

Switch (S12-191)

Stacker Tray Full Detection
The Stacker Tray provides a stack height detection mechanism and tray height control
that will enable the HVF to comply with the product performance specification.
The tray is a fixed size capable of accepting the range of papers permitted to this tray
and meeting the registration requirements.
It has an offset capability in order to separate individual jobs, either stapled or

unstapled.

The following example details the Stacker Tray operation as it approaches full:
For this example the stacker tray initially contains 2899 sheets. In this condition the HVF will have not reported
100% full as the Stack Height Sensor is broken but the 100% full sensor is not made. Therefore, the HVF can
accept more ejected sets. The next set, of potentially 100 sheets (A), can be compiled ready to eject.
100 sheet set (A)

Ejector
Stack
2899
Height
Stack
100%
Full
Lower Limit Not
Full
The 100 sheet set (A) is ejected onto the existing stack of 2899 sheets, resulting in a total stack of 2999 sheets.
As a result of the ejected set the stacker tray moves down enough to make the Stack Height Sensor beam and
then moves back up to break it.

In this example the stack height is just short of making the full sensor:
Therefore, the HVF does not report Tray Full. As the tray is not full the IOT can continue with the next set for
compiling. Again this could potentially be up to 100 sheets (B).
Next set off 100

sheets compiles. (B) 100 sheet set
(A)
Stack
2899 2999
Height
Stack Stack
100%
Full
Lower Limit Not
Full
The 100 sheet set (B) is ejected onto the existing stack of 2999 sheets, resulting in a total stack of 3099 sheets. The
stacker tray moves down to make the stack height sensor beam. As a result of moving down to clear the beam the
tray has reached the 100% full sensor. This will cause the HVF to report to the IOT that the tray is full. The tray will
then move up to break the stack height sensor beam.

The IOT has already begun scheduling and delivering the next set to the HVF. This set could be another 100 sheets
(C). The IOT will continue to schedule and out put this next set to the HVF compile tray. When the IOT reaches the
set boundary it will stop scheduling any further sheets to the HVF. If the set it greater than 100 sheets the IOT will
stop at 100 sheets.
When the IOT has reached the set boundary the HVF will be expected to collate and eject this final set onto the
existing stacker tray.
This combination of all of these factors indicates that the HVF stacker is capable of accepting a total of
approximately 3199 sheets.
100 sheet set. (B)
Last set off 100
sheets. (C)
Stack 2999 3099

Height Stack Stack
100%
Full
Full
Lower Limit

Hole Punch
Punch Head Home
Sensor (Q12-194)
– Detects if the Punch Unit Motor (Q12-245) –
Paper Edge Detecting Sensor – Chad Bin Level Sensor punch returns to Rotates punch
Detects front edge of paper entering (Q12-193) – Detects when home after 1
into the punch unit chad bin is full rotation
Punch Unit Motor (Q12-245) – Moves

punch unit to detect papers front edge
Punch Unit Home Sensor (Q12-214) –

Detects the punch unit is in the home
position.
Chad Bin Present Sensor (Q12-118)–

Detects if chad bin is installed

Inserter Trail Edge
The Inserter, enables the user to insert a sheet at a pre- Sensor (Q12-084)
defined point in a set. For example it may be used to insert
Inserter Lead Edge
cover sheets or separators. The media inserted can be hole- Sensor (Q12-083)
punched, stapled or folded, as required.

Inserter motor, MOT12-261 - This motor runs forward to
drive the paper tray up and to feed the paper, and the
motor runs in reverse to drive the paper tray down. The
Inserter Pick Up
variable speed is used to synchronize the inserted media Sensor (Q12-315)
with the printed sheets coming from the IOT, and

compensates for any speed mis-match. In the forward
direction, this motor turns the retard roll in the reverse
direction, via a torque limiter. The retard roll thus acts as a Inserter Clutch
(CL12-260)
Inserter Motor
(Q12-261)
retard pad, continually renewing its point of contact with
the paper, thereby increasing its life and effectiveness.
Inserter clutch, CL12-260 - Located at the rear of the
inserter, this clutch passes the drive to the feeder roll and
Nudger roll.
Inserter Pickup sensor, Q12-315 - This is a reflective
sensor, located on the underside of the inserter top cover.
Inserter Standby
The IDG pickup sensor supports the pickup sensor, which Sensor
controls the electric clutch to start feeding.

Inserter TE sensor, Q12-084 - This is a reflective sensor, Inserter Trail Edge
Sensor (Q12-084)
located mid-module, immediately in front of the feeder
roll. The pickup sensor detects the trailing edge of the Inserter Lead Edge
Sensor (Q12-083)
sheet, to control the electric clutch and is part of the
speed compensation system.
Inserter LE sensor, Q12-083 - This is a reflective sensor,
located mid-module, immediately after the feeder roll.
The paper path sensor detects the leading edge of the Inserter Pick Up Sensor
(Q12-315)
sheet, to verify that the sheet was successfully fed.
Inserter acceleration sensor - This is a reflective sensor,
located behind the inserter left hand door. This sensor
detects the leading edge of the sheet and operates Inserter Clutch Inserter Motor
together with the inserter LE sensor, to determine the (CL12-260) (Q12-261)
speed of the paper. When the speed has been measured,

the information is used to control the speed of the
inserter motor.
Inserter standby sensor - This is a reflective sensor,
located on the HVF vertical transport, below the inserter.
It senses the leading edge of the sheet passing into the
HVF from the inserter and provides the final Go / Wait Inserter Standby
Sensor
information, for feeding the sheet into the HVF at the
correct inter-document gap (IDG).

Post Process Inserter (PPI) Inserter Paper Width
Sensor 1 (Q12-081)
Inserter Paper Length

Sensor 2 (Q12-080)
Inserter unit empty sensor, Q12-082 - This is a

reflective sensor, located on the inserter paper
tray. This sensor detects the presence of paper in
the inserter tray. In normal operation, once this
sensor detects no paper in the tray, the tray lowers Sensor 1 (Q12-079)
Inserter Unit Empty
after about two seconds. Sensor 2 (Q12-082)
Inserter Paper Width Sensor 3 (Q12-090)
Inserter paper length sensor 1, Q12-079 - This is Sensor 2 (Q12-169)
a reflective sensor, located on the sensor tray. It
detects paper longer than 203 x 330 mm (8 x 13
inches). Inserter Jam Cover
Inserter paper length sensor 2, Q12-080 - This is Interlock (S12-179)

detects paper longer than 203 x 280 mm (8 x 11
inches).
Inserter paper length sensor 3, Q12-090 - This is
detects paper less than 203 x 280 mm (8 x 11
inches). Inserter Top Cover
Interlock (S12-178)

Inserter Paper Width
Sensor 1 (Q12-081)
Inserter paper width sensor 1, Q12-081 - This Inserter Paper Length
detector incorporates two width sensors. Width Sensor 2 (Q12-080)
sensor 1 is a flag sensor, actuated by the paper

width guide position. The sensor changes state at
285mm, (11 1/4 inches) and 210mm, (8 1/4
inches) paper widths.
Inserter paper width sensor 2, Q12-169. Width Inserter Paper Length
Sensor 1 (Q12-079)
sensor 2 - This is a flag sensor, actuated by the Inserter Unit Empty
Sensor 2 (Q12-082)
paper width guide position. The sensor changes Inserter Paper Width Sensor 3 (Q12-090)
Sensor 2 (Q12-169)
state at 273mm, (10 3/4) inches paper width.
Inserter jam cover interlock, S12-179. This is a
micro switch, located behind the top inside cover. Inserter Jam Cover
Interlock (S12-179)
This switch is wired in series with the inserter top
cover interlock, to supply +24V to the inserter.
When both interlocks are closed, the +24V LED on
the Inserter PWB is lit.
Inserter top cover interlock, S12-178. This is a
micro switch, located behind the front cover. This
switch is wired in series with the inserter left hand
door interlock, to supply +24V to the inserter. Inserter Top Cover
When both interlocks are closed, the +24V LED on Interlock (S12-178)
the Inserter PWB is lit.

Booklet Maker
Crease Roll Gate Crease Roll Gate Motor
When a booklet maker job is requested, but prior to the first

sheet arriving at the booklet maker, the BM backstop motor,
MOT 12-255 is energized to move the backstop assembly to
a preset receiving position based on the paper size value
selected. The positioning of the backstop is measured in
stepper motor pulses from the BM backstop guide home
sensor, Q12-204.
The booklet maker module receives sheets from the lower

diverter gate and through the BM entry roll nips. As each
sheet is fed through the entry nip, it is driven downwards
until it rests against the backstop.
Crease Rolls
Stapler Head Assembly
Booklet Maker Staple

Head Carrier Closed
Sensor

Booklet Maker
The BM entry roll has smaller hard rollers and Crease Roll Gate Crease Roll Gate Motor
larger soft foam rollers. As the lead edge of each

sheet touches the backstop, the trail edge is
released by the hard roller nip, but is still held by
the soft roller, which pushes the sheet under the
roller and against the right side of the booklet
compiler tray. This ensures that the trail edge of
every compiled sheet is always located on the
same side of the following sheet, thus
eliminating both stubbing and sheet order errors.
Cross process registration is maintained by using

two tampers, which move in opposite directions
simultaneously, and are driven by the BM
tamper 1 motor, MOT 12-256. Tamping aligns
Crease Rolls
the centre of the sheets with the centre of the
booklet compiler tray. Stapler Head Assembly
Booklet Maker Staple Head

Carrier Closed Sensor

Booklet Maker
The tamping position is a preset number of motor Booklet Maker

Booklet Maker
steps from the BM tamper 1 home sensor, Q12-205 Crease Roll Compiler Motor
Entry Roll Nips
Gate Home
and is based on the paper size of the compiled Sensor
sheet, provided by the IOT PWB. Booklet Maker Flapper
BM Tamper Assembly
1 Home
The tampers are moved from the home position to Sensor
a ready position stored in NVM, when the lead edge

of the first sheet in the set is detected at the BM Crease Roll Crease Motor Blade
Motor
entry sensor, Q12-089.
As each sheet enters the booklet compiler tray, the Booklet Maker
Backstop Motor
tampers are moved from the ready position to the
tamping position, then returned to the ready
position. For the last sheet of the set, the tamping Backstop Assembly
stroke is repeated once more. After the last sheet in

a set is compiled and tamped, the tampers are Backstop Guide Home
Sensor
moved to the home position.
Booklet Maker PWB
Booklet Maker Stack
Hold Solenoids

Booklet Maker
Booklet Maker
Booklet Maker
The BM flapper is utilized when the tampers start their Crease Roll Compiler Motor
Entry Roll Nips
Gate Home
return stroke from the tamp position to the ready Sensor
position. Booklet Maker Flapper
BM Tamper Assembly
1 Home
Sensor
The BM flapper motor, MOT12-271 provides
mechanical drive to the BM flapper and the position of
the flapper is controlled by the flapper home sensor Crease Roll Crease Motor Blade
Motor
Q12-207. The fingers on the flapper push the sheet
into the booklet tray to aid the registration and de-
skewing process. The flapper rotates after each sheet Booklet Maker
Backstop Motor
is tamped. The flappers are then parked in the home
position, so that the fingers on the flapper do not
impede the next sheet fed into the booklet compiler Backstop Assembly
tray.
Backstop Guide Home
Sensor
The set is then ready to be moved into position for the
next operation of stapling. Booklet Maker PWB
Booklet Maker Stack
Hold Solenoids

Booklet Maker
Backstop Movement
The BM backstop system consists of a backstop assembly, mounted on a near
vertical slide driven by BM backstop motor MOT12-255, via a toothed belt. A flag
mounted on the backstop assembly actuates the BM backstop guide home sensor,
Q12-204 to signal the home position of the backstop.
After the last sheet of the set has been received and compiled, the BM stack hold
solenoids, SOL12-259 are energized to hold the set in place. The BM backstop motor
then moves the backstop to the stapling position. The BM motor now performs a
short up and then down again to jog the set into place. After stapling, the BM
backstop motor moves the backstop to the creasing position.
Booklet Stapling
Two BM staple head assemblies are mounted on a bracket, which can be pivoted
open for staple jam clearance. The BM staple head carrier closed sensor, Q12-217
detects the closed position of the stapler bracket assembly.
When the staplers are actuated, two staples are placed in the centre of the compiled
stack, spaced 120 mm apart. The maximum capacity for the stapling and folding in
the booklet maker is given in Table 1.

Booklet Maker
Table 1. Booklet maker stapling and folding capacity
Media Paper weight Maximum No. of sheets Maximum No. of booklet pages
Plain paper 60 to 80gsm (16 to 21lb bond) 15 60

Heavyweight 90gsm (24lb bond) 13 52
Plain paper with 60 to 80gsm (16 to 21lb bond)
heavyweight Cover with 160gsm (43lb bond) cover 14 including 1 cover 56

Booklet Maker
The stapling sequence operates as follows:
1. The tampers are energized to engage the stack and keep both edges in place.
2. After 50 ms, the front stapler is energized.
3. After a further 80 ms the rear stapler is energized.
4. This sequence prevents wrinkling of the paper and limits the load imposed on the power supply.
5. Once the staplers reach the home position, a dynamic brake is applied to prevent overrun. The
stapler motor will be reversed if the home switch is not made, after the stapling operation, in an
attempt to bring the stapler home and avoid a fault.

Booklet Maker
Folding and Creasing
The booklet creasing system consists of a crease blade, two pairs of crease rolls, a crease roll gate and
the backstop assembly.
The crease roll gate is used to cover the entry nip into the crease rolls. This prevents sheets from
coming into contact with the crease rolls during compiling.The crease roll gate is raised to expose the
crease rolls, or lowered to cover the opening to the crease rolls, by the crease roll gate motor, MOT12-
273. The home position (fully raised) is sensed by the BM crease roll gate home sensor, Q12-222.
After the stapling operation is complete, the backstop raises the stapled set to the fold position, so
that the centre line of the set is directly in line with the crease blade. At the same time, the crease roll
gate motor moves the crease roll gate up until it actuates the crease roll gate home sensor.
The BM crease roll motor, MOT12-253 is energized when the backstop reaches the fold position, and
continues to run until 220 ms after the trail edge of the folded book is detected at the BM exit sensor,
Q12-213. An encoder wheel is mounted on the output shaft of the BM crease roll motor. The encoder
wheel is read by the BM crease roll motor encoder sensor, Q12-216 to control the roll surface speed.

Booklet Maker
A stapled set is folded by the combined function of the crease rolls and the
crease blade. The crease blade pushes the centre of the set into the crease
rolls nip. The crease blade is driven by the BM crease blade motor, MOT12-
252. The BM crease blade home sensor, Q12-214 and the BM crease blade
motor encoder sensor, Q12-215 are used to monitor the location of the
crease blade during the folding process.
During booklet folding, the crease blade moves from home position when the
backstop reaches the fold position. The blade stroke is 36 pulses of the
crease blade motor encoder sensor from the blade home position.
During banner sheet folding, a delay of 700 ms from the trail edge at the BM
entry sensor is used before the crease blade moves from the home position.

Booklet Maker
The crease blade is held at the fold position by a dynamic brake for 250 ms to
allow the banner sheet or stapled set to be drawn into the crease rolls. The BM
crease blade motor is then reversed to drive the crease blade back to its home
position as the crease rolls crease and feed the booklet.
The BM exit sensor, Q12-213, located just after the crease rolls, detects jams.
When the BM eject sensor is clear, the crease roll gate motor moves the crease
roll gate down to cover the crease rolls.
For a booklet consisting of 10 or more sheets, or when handling 8.5 x 11 in

paper, folding is executed four times before ejecting to provide extra creasing.

Booklet Maker
Bin 2
After a booklet is folded, it is ejected onto the bin 2 by the crease roll nip.
The bin 2 is mounted at the lower right side of the booklet maker, below bin 1. Bin 2 has two bail
arms and two parallel conveyor belts over a flat surface. With the tray extension raised, bin 2 has
a capacity of 10 booklets of 11-15 sheets, or 20 booklets of 6-10 sheets, or 30 booklets of 1-5
sheets. With the tray extension lowered, the booklets can be allowed to drop into a suitable box
on the floor.
The BM eject sensor, located at the exit, provides control logic signals and monitors the paper
path for jam detection and timing control for actuation of the BM conveyor belt drive motor.
When a booklet has been compiled, it passes under the BM eject sensor and pushes partially
through the bail arm rollers. 200 ms after the lead edge is detected at BM eject sensor, the BM
conveyor belt drive motor, MOT12-274, is turned on and drives the two conveyor belts for a preset
time dependent on the booklet size.
The BM bin 2 90% full sensor, Q12-206 is an optical sensor located at the right of bin 2 between
the conveyor belts.

Tri Folder
When the job does not require a tri-fold, the tri-folder becomes a straight-through
paper path from the booklet maker to the output tray. When a tri-fold is requested, the
tri-folder clutch, diverter solenoid, and for C-folds only, the assist gate solenoid are
brought into use.
The tri-folder does not have a drive motor, but takes its motive power, via a toothed
belt and drive coupler, from the crease roll motor in the booklet maker. The drive
coupler engages when the booklet maker is pushed into the home position. The belt
turns as each sheet is folded and stops as each sheet leaves the tri-folder.
When the tri-folder is not installed, a shorting link fitted to PJ553 in the booklet maker
PWB, simulates the tri-folder interlocks, to feed +24V to the booklet maker PWB.
The tri-folder works in conjunction with the booklet maker, to produce ‘C’ or ‘Z’ folds.
The booklet maker makes the first fold, and passes the sheet to the tri-folder to make
the second fold. One sheet at a time is folded, and the tri-folder can fold 60-120gsm,
(15-30lb) sheets.

Tri Folder
The figure on the left shows how the C-

folds and the Z-folds are formed. The
difference lies in where the first fold is
made in the sheet, by the booklet maker.
For a C-fold, the backstop is raised to
produce a fold near the leading edge of the
sheet. For a Z-fold, the backstop is lowered
to produce a fold near the trailing edge of
the sheet, effectively inverting the sheet.

Tri Folder
Drive clutch CL12-269 Tri-folder Entry Sensor

Q12-164
Tri-folder assist gate
The active components of the tri-folder are: sensor, Q12-165
Tri-folder entry sensor, Q12-164 - This is a flag sensor,

located in the input paper guide. This sensor detects the
sheet entering the tri-folder from the booklet maker.
Drive clutch, CL12-269 - This clutch is located at the rear

of the tri-folder, and actuates to drive the tri-folder crease
rolls via a toothed belt.
Tri-folder diverter solenoid, SOL12-267 - This solenoid is

located at the rear of the tri-folder, and diverts single, tri-
fold job sheets into the folder mechanism. It is actuated
immediately after the drive belt from the BM starts to
turn, and de-actuates as each sheet leaves the tri-folder.
Tri-folder Diverter
Tri-folder Assist Gate Solenoid SOL 12-267
Solenoid SOL 12-268

Tri Folder
Drive clutch CL12-269 Tri-folder Entry Sensor

Q12-164
Tri-folder assist gate
sensor, Q12-165
Tri-folder assist gate sensor, Q12-165 - This is a flag

sensor, located in the roller assembly, and is mounted on
the adjustable backstop plate. This sensor detects the
sheet entering the roller assembly to be folded.
Tri-folder assist gate solenoid, SOL12-268 - This

solenoid is located at the rear of the tri-folder. The assist
gate solenoid is only actuated during C-folds, to assist the
first folded flap into the crease rolls. It actuates as the
sheet enters the crease rolls and ensures that the trailing
edge of the first fold stays inside the crease of the second
fold.
Tri-folder Diverter
Tri-folder Assist Gate Solenoid SOL 12-267
Solenoid SOL 12-268

Tri Folder
Folder Exit Sensor

Q12-166
Folder exit sensor, Q12-166 - This is a flag sensor,

located in the exit paper guide. This sensor detects
the sheets as they leave the tri-folder.

Tri Folder
Tri-folder top cover interlock switch - This is a single-
pole micro switch, located at the front of the tri-
folder. This switch is connected in series with the front
door interlock switch, S12-209. When both switches
are made, the +24V supply is fed to the tri-folder PWB Top Cover Interlock Switch Top Cover Interlock Sensor S12-220
and the BM PWB. The BM PWB has +24V LED

indication, as described in the Power / Interlocks
section of this document.
Top cover interlock sensor, Q12-210 - This is a flag

sensor, located towards the rear of the tri-folder top
cover. This sensor detects whether the top cover is
open or closed.
Front door interlock switch, S12-209 - This is a

double-pole switch, located behind the top of the tri- Front Door
Interlock
folder front door. One pole of this switch is connected Switch,
in series with the TF top cover interlock switch. When S12-209
both switches are made, the +24V supply is fed to the

tri-folder PWB and the BM PWB. The second pole of
this switch detects whether the tri-folder front door is
open or closed.

Tri Folder
Booklet Maker Bin 2 Output Tray

Bin 2 receives the folded output from
the tri-folder, and the booklets from
the booklet maker and / or the tri-
folder module. The components
associated with this tray are:
BM conveyor drive motor, MOT12-
274 - This is a stepper motor, driving
the conveyer belts.
Bin 2 90% full sensor, Q12-206. This
is a flag sensor, detecting a nearly-full
tray.

Machine Software

Software
Description
Software Sets are compilations of the various software modules (DADH,
Scanner, Finisher, Fax ...) and together with SCD (Software Compatibility
Database) are packaged into a DLM (Down Loadable Module).
There are 2 methods of installing machine software:
Via a USB Jump Drive
or
Customer/CSE upgradable via the Web UI. There are 2 ways to connect to the
machine’s Webui:
- Using a Laptop, connect the Crossover Cable directly into the Network
Controller and by increasing the last digit of the IP address by 1 on your PC.
For example: if the IP address of the machine is 13.140.211.21, then change your PC’s
IP address to 13.140.211.22
- Over the network utilizing the machine’s IP address

Software
Modules
A software module is defined as a programmable piece of software that

may reside on the module PWB. Each platform has a software module that
resides within.
For example… the Scanner Software resides on the Scanner PWB
NOTE: The software for the 3 Tray Module, DADH and Tray 5 (PFP) can only
be upgraded if a newer version of the relevant PWB has been replaced.
These platforms have firmware attached to them and are not eligible for
software upgrade via the regular software upgrade process.

Software
Software Compatibility Database (SCD)
The Software Compatibility Database (SCD) is used to describe the

machine’s software. The SCD comprises of the System Software version, in
the format D (WW) (XXX) (YY) (ZZZ)_00_1.dlm and a list of software
versions for the different modules. It’s primary function is to ensure that all
software on the machine is compatible
Software Level Described, below is an example:
D 60.050.08.329.02_00_1.dlm = Work Centre
Year Day 329 of 2008
WW = is the platform
XXX = is the field for major change
YY = is the field for minor changes
ZZZ = is the field for SPAR Fixes

Software
Common Upgrade Behavior
A software upgrade is requested when a new piece of hardware is installed.
When an upgrade has been initiated the machine will reboot with all modules
in upgrade mode.
Progress and errors are displayed on the UI
When the upgrade is complete, the machine reboots

Software
Common Upgrade Behavior (continued)
When a machine is switched on, the copy controller compares its SCD with the
software within the hardware modules. If necessary, a software upgrade or
downgrade is performed by the copy controller.
If a component is installed that has a later version of software than the

software set on the copy controller PWB, at machine startup the software on
the new component is downgraded.

When do I use the ‘8’ or ‘9’ key to load software?
- ‘8’ Key (Normal AltBoot) used for either upgrading or downgrading the
machine software (all platforms including Fax)
- ‘9’ Key (Forced AltBoot) used if the machine is in an in-operative state, it

will force load all platforms except for Fax

Software
Loading Procedure – Forced AltBoot Load ‘9 Key’
A Forced AltBoot software load should only be performed for the following
reasons:
- As an attempt to recover a corrupt Hard Disk Drive (HDD) for the Copy
Controller and/or HDD Network Controller
- After replacing a HDD for either the Copy Controller and/or Network
Controller
- To upgrade machine software without running individual software
upgrades.
- To recover a non working machine, that a normal AltBoot load will not
cure.
NOTE: The AltBoot software loading procedure (GP4) erases customers
unique network configuration settings… Example: Workflow Scanning
Therefore, you should perform an NVM Save (dC361) and the Network
Clone Procedure (GP17)

Software
Loading Procedure – AltBoot Load
− Need to create a top level folder on the USB Jump Drive and name it
[AltBoot].
− Copy the DLM file into this folder
− Turn the machine’s power off
− Insert the Jump Drive onto the left hand side of the machine
− Turn the machine back on, while the machine is attempting to power up,
continuously depress the number ‘8’. The software upgrade screen should
appear. If the key is not pressed in it’s allocated time, the machine will boot
normally.
NOTE: After switching the machine on, press the ‘8’ or ‘9’ key to initiate the
AltBoot process.

Software
NOTE:
Occasionally the USB flash drive will be incompatible with the machine and
the software upgrade window (see below) will be continually displayed. If
after 10 minutes the screen has not changed, replace the USB flash drive
with a different model. Power off the machine and restart the process.
Figure 1 - Upgrade Start Screen

Software
Note: If there is more than one version of the Jupiter machine’s DLM, the
machine will always utilize the latest version.
Below is the progress screen, note that the files are transferred to the
Network Controller first. They are then transferred to the Copy Controller.
Upgrade Progress

Software
The AltBoot process should complete after approximately 5 minutes and the
AltBoot complete screen will open, Figure 3. Follow the on screen instructions.
Figure 3 - AltBoot complete

Software
If the AltBoot completes successfully, then the machine will reset. When the
machine comes back up it then proceeds to upgrade the remaining
platforms. For Example: Scanner, IME, Finisher, Fax (If installed).
When all platforms are upgraded, the machine will automatically reset
several times prior to returning to a ready state. Upon completion the
machine will print a Software Upgrade Report.

Software
If the AltBoot process fails, the AltBoot failed screen will open. Power off the
machine and restart the procedure.
Refer to Troubleshooting Section in GP4 as necessary.
Figure 4 - AltBoot failed

Software
NOTE:
Do not switch off the machine until told to do so by the UI. During the next
few reboots, the HDD copy controller assembly (HDD1) and HDD Network
controller assembly (HDD2) are being encrypted.
Switching off the machine can cause only partial encryption of the
partitions on the Hard Disk Drives. The AltBoot process may need to be re-
run if power is removed at this step.

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Jupiter

Advanced Technical Training

Revised: 04/07/2009 Table of Contents Xerox Internal Use Only

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When the power on switch is pushed this sequence starts:

1) The CBC (Common or Combined Board Controller) and the IME

2) Only the IME Controller runs PEST

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Look at the PEST codes in DC 123 to start your troubleshooting.

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The input for the PS can be 115VAC or 230 VAC.

The supply can run on 50 Hz or 60 Hz.

It is Energy Star Compliant

The PS runs at 20 Amps max at 115VAC

The PS runs at 10 amps max at 230 VAC.

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The 3.3Vdc is always on when connected to AC.

The PS also generates the following DC voltages:

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Revised: 04/07/2009 Table of Contents Xerox Internal Use Only

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− Power (12Vdc and 3.3Vdc)

− Initialization of and communication with the UI PWBA to accept

− Graphics and text data is displayed directly on the UI module LCD

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− Power the LCD backlight.

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The UI’s performance is constantly monitored by the Copy Controller.

The UI PWB performs the following tasks:

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CBC module UI PWBA LCD

LVDS pair 2 CMOS data lines

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The Copy Controller supplies a soft button identification on the touchpad

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While in Sleep Mode, we shut down various electronic sub-systems. To

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Revised: 04/07/2009 Table of Contents Xerox Internal Use Only

2 HDDs mounted on underside of tray

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− Generate 3.3VDC from LVPS 24V (17V in Low Power mode)

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Power to Copy Power to Network Controller

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Besides the 12V, 5V, 3.3V from the PDB, the

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SIMM Comms to IME

IIT Comms PCI to riser Serial SATA Video to

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1GB EPC Battery backed

Aries FPGA Casper FPGA

LEDS CR23 &

Galileo ASIC Turin FPGA

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