Vacuum TC Measurement Kit Instructions

600T02310

Table of Contents
1. Overview 2
2. Setting up the digital scale 4
3. Taring the scale 5
4. Collecting a developer sample 6
5. Placing the developer sample in the vacuum cage 7
6. Removing the toner 8
7. Weigh the carrier 9
8. Round-off Convention 9
9. Determining the toner concentration 10
10. Clean out the vacuum cage 11
11. Clean out the sample bottles 13
12. Recovery Actions for High or Low TC 13
13. Troubleshooting the kit 15
14. Helpful Tips 19
15. Cage Tare Record 20

TOP Upper funnel

Throat

Vacuum TC
Cage
Detone Chamber

Bottom – Screens
insert in hose

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TC Field Measurement Kit Instructions
Version 3.1 Feb 12, 2009
1. Overview
This kit is used to measure the toner concentration in the highlight
color CCU in the Docutech 180 HLC family and the magenta,
yellow, cyan, and black stations in the iGen3 and iGen4 family of
products. It is meant to replace the Optical Tool used to take tc
measurements called out in the RAPs for the two product families
and to calibrate the Packer and TDK toner concentration sensors.

The kit comes with the following parts:

a. Digital scale (GemPro 250) with AC adapter (18E01780)
b. Anti-vibration rubber pad (19E81740)
c. Magnetic Extraction Device (121K39260)
d. Four developer sample bottles (93E03860)
e. Two (2) Vacuum tc cages (18K01400)
f. Vacuum hose / manometer checkout adapter (52K10190)
g. Plastic funnel (052E35180)
h. TC look up tables (80P11193)
i. Carrying case (101E23060)
j. Instructions (80P11192)

Also available on GSN library 9897

Getting Started information sheet
Instructions for forming a wire holder for the vacuum hose
Training video
PC program to replace TC LUT
BlackBerry program to replace TC LUT

The dry ink (toner) concentration in the developer housing is

controlled to maintain solid area density performance while
preventing image quality problems like background, reload, and
mottle. A sensor in the developer housing measures the tc every
few seconds to enable the machine software to make toner

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Version 3.1 Feb 12, 2009
dispense decisions. The sensor requires an independent
measurement of the toner concentration for calibration.

This kit provides that measurement for setting the tc sensor

intercept value in NVM.

Toner, used to print customer images, consists of colored plastic

particles ranging from 5 to 20 microns in diameter. They are
electrically charged by magnetic carrier beads ranging from 25 to
85 microns in diameter. The amount of charge on the toner
particles and its performance in the xerographic process are
determined by the toner concentration.

By definition, the toner concentration is 100 times the weight of

toner in the developer housing divided by the weight of carrier.
The toner and carrier are well mixed inside the developer housing.
To determine the toner concentration the amount of toner and
carrier must be independently measured. Therefore, the toner must
be removed from a sample of developer taken from the housing.

The vacuum tc cage has a 500 mesh woven metal screen with 25
micron openings that keeps the carrier beads contained inside
while allowing the smaller toner particles to pass through.

The empty cage is placed on the scale and tared out. A 3.0 gram
sample of developer is placed inside the cage and weighed on the
scale. The cage is removed from the scale and placed inside the
end of the CSE vacuum cleaner hose. Holding the cage near
vertical, the vacuum is turned on for a total of 30 seconds (three 10
second intervals) to remove the toner from the carrier beads. Then,
using the vacuum cleaner, toner is cleaned off the bottom of the
cage and the cage is weighed again.

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The second weighing provides the weight of the carrier beads. The
first weighing (developer) minus the second weighing (carrier)
provides the weight of the removed toner. This calculation,
however, is not needed. A set of look-up tables is used to perform
the toner concentration calculation needed to calibrate the sensor.

NOTE: Before using the kit, review the video training on GSN
Library 9897.

2. Setting up the digital scale

The GemPro 250 digital scale comes with an instruction manual
which is summarized here.

Caution: The scale has a maximum capacity of 50 grams. Do not

overload the scale.

Powering the scale: The scale operates with either AC power or 4

AAA batteries. Batteries are optional and are not provided in the
kit. If batteries are installed in the scale, use the AC power adapter
whenever possible to extend battery life.

Keeping the scale clean: Install the round metal cover on the
weighing platform to allow easy clean-up of any spilled toner. The
wind cover should be installed to help keep the scale clean but it
will remain open during use. The black plastic weighing tray is
not used in this application.

Setting the Auto-off time: The scale has an Auto-off feature to

save battery life. If you use the AC adapter to power the scale,
turn this feature off. Follow the directions in section 3.6 (page 4)
of the scale user manual. If you are using batteries to power the
scale, set this timer to at least 5 minutes. If the scale turns off

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during the readings, the tare will be lost and the entire
measurement will have to be repeated.

Setting the units and resolution: Set the units and resolution of the
scale to grams (g) and 0.001. This sets the resolution of the scale
to 1 milligram. To set the units, follow the instructions in section
3.3 of the scale user manual on page 3. Be careful to set it to
grams (g) and not grains (gn). To set the resolution, follow the
scale instructions in section 3.7 on page 4. Use the 0001 setting.

Positioning the scale: Whenever in use, the digital scale should be

placed on the black rubber pad to prevent outside vibrations from
disturbing the readings. The scale should also be leveled using the
circular bubble level on the top of the scale. The four legs are
adjustable by screwing them in or out, as needed.

Once the scale is positioned for measurements, do not move it

between the three measurements (cage tare, cage + developer, cage
+ carrier). Moving the scale can change a reading by a few
milligrams, which is enough to affect the tc measurement.

3. Taring the scale

Turn the scale on and wait for the display to count down to zero
and for the red indicator light to turn off. Press the tare button to
zero the scale. Place the empty vacuum cage on the pan funnel
side up. The red indicator light will appear and stay on. Once the
readings stabilize, compare the cage tare weight to the record on
the last page of this book. If the weight is more than 30 mg higher
than the recorded weight, clean the cage following the procedure in
section 10. When done, press the tare button to zero out the weight
of the cage. The display will reset to zero and the red indicator
light will go off. If the scale does not read zero, press the tare
button again.
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4. Collecting a developer sample
Using a clean sample bottle and the magnetic extraction tool,
follow the instructions for obtaining a developer sample for the
product family you are calibrating.

A. Docutech 180 HLC

i. Prepare the developer housing for obtaining a sample.

a. Enter Diagnostics - dC330 Component Control - 9A

HCN Xerographics.
b. Left click on Mag Auger Motor to highlight, then right
click to turn on.
c. Run the Auger for 30 seconds to get a uniform sample.
d. Left click on Mag Auger Motor to highlight, then right
click to turn off and exit dC330 - Component Control.

ii. Remove the developer housing access port cap.

iii. Use the magnetic extraction device to collect the developer

sample.

NOTE: Hold the sleeve steady and pull up on the magnet wand
of the Magnetic Sampling Device to release the pulled material
from the device.

a. Remove two pulls of material from the Developer

Housing access port with the Magnetic Extracton
Device and set each pull aside on a sheet of paper. This
material can be put back into the developer housing
when you are finished collecting the sample.
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 b. Take a third pull of material and place in the sample
bottle. Take additional pulls to collect about 4 grams of
developer in the sample bottle.

B. iGen3 and iGen4

i. Remove the front Fill Cap on the Developer Housing.

ii. Extract a sample of material from the Developer Housing

using the magnetic wand.

iii. If the auger is positioned such that a sample cannot be

obtained:
a. Remove the plug from the Sample Port
b. Pull two (2) samples and discard (or drop in Fill
Port)
c. Keep the third sample

iv. Place the end of the magnetic wand into the sample bottle.
Pull up on the wand so the material hits the rubber
grommet on the sleeve and falls into the bottle.

v. Take additional pulls to collect about 4 grams of developer

in the sample bottle.

5. Placing the developer sample in the vacuum cage.

With the empty vacuum cage placed on the digital scale and the
weight of the cage tared out, slowly add 3.0 ± 0.2 grams of
developer to the cage. Record the developer weight on a scrap
sheet of paper. Remove the vacuum cage from the digital scale.

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6. Removing the toner
Set up the CSE vacuum cleaner. Place the manometer checkout
adapter on the end of the hose and use a portable manometer (not
included in this kit) to verify that the vacuum is drawing at least 3
inches of water. If not, replace the vacuum cleaner filter.

NOTE: A new filter should draw about 6-7 inches of water.

Remove the manometer checkout adapter before inserting the

vacuum cage on the end of the hose.

Hold the end of the hose vertically.

Gently insert the vacuum cage assembly into the end of the
vacuum hose so it rests on the grounding pin..

Turn on the vacuum cleaner and run for 10 seconds. Turn off the
vacuum cleaner.

When the vacuum cleaner has shut completely off, remove the
vacuum cage from the hose carefully. The bottom of the cage will
be covered in toner. Turn the vacuum back on and hold the bottom
of the cage at a 45 degree angle to the opening of the hose. Hold
the cage in position and rotate the cage in a full circle (360 deg) to
clean off the toner on the bottom of the cage.

Alternately, you can roll the bottom of the cage around the lip of
the hose to clean off the toner on the outside of the cage (see
pictures in Adj 9.40 or video training).

Repeat this process a second time. Return the cage to the

vacuum hose and turn on the vacuum cleaner for an additional 10
seconds. Clean off the bottom of the cage as before.
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Repeat this process a third time. Return the cage to the vacuum
hose and turn on the vacuum cleaner for an additional 10 seconds.
Clean off the bottom of the cage as before.

NOTE: Running the cleaner for three 10 second intervals is

necessary to get accurate readings. The first interval will only
remove about 90% of the toner. The second interval brings this up
to about 97% and the third interval completes the toner removal
process.
NOTE: Leave the cage in the hose as the vacuum motor dies
down. Forcibly removing the cage with the vacuum motor turned
on can cause carrier beads to jump out of the cage through the top
funnel. This can result in higher than expected measurements.

A little loose toner on the top or bottom of the cage will not affect
the measurement. The bottom can be wiped down with a clean
rag.

7. Weigh the carrier

Place the vacuum cage back on the digital scale and wait for the
reading to settle down. Record the carrier weight reading on a
scrap piece of paper.

8. Round-off Convention
The developer weight must be rounded to the nearest 0.005 g. To
do this, the convention is to round down if the weight is within
0.001 g or 0.002 g or round up if the weight is 0.003 g or 0.004 g.

For example,
Actual Weight Rounded weight
x.yz0 x.yz0
x.yz1 x.yz0
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Version 3.1 Feb 12, 2009
 x.yz2 x.yz0
x.yz3 x.yz5
x.yz4 x.yz5
x.yz5 x.yz5
x.yz6 x.yz5
x.yz7 x.yz5
x.yz8 x.y(z+1)0
x.yz9 x.y(z+1)0

9. Determining the toner concentration

Refer to the set of look up tables. The tables are the same for all
colors, toner age, carrier age, etc.

Each table covers a range of 0.1 grams of developer weight. Find

the right table: (1) 2.8 – 2.9 grams, (2) 2.9 – 3.0 grams, (3) 3.0 –
3.1 grams, or (4) 3.1 – 3.2 grams.

Step 1: Find the developer weight (weight before vacuuming found

in Section 5) on the left hand side of the table.

Step 2: Move along the row to find the carrier weight (weight after
vacuuming found in section 7).

NOTE: If the carrier weight is not found on the upper table on the
sheet, move down to the lower table and try again.

NOTE: The tables are set up to give tc readings between 2 and 9%.
If the carrier weight is too high (tc below 2%) or it the carrier
weight is too low (tc above 9%) some recovery action is necessary.
Go to section 11 for recovery actions.

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Step 3: Move up to the top of the column and find the percent
toner concentration. Use this value to calibrate the TC sensor
using the procedure for the product family you are servicing.

10. Clean out the vacuum cage

The carrier beads should be poured out of the vacuum cage onto a
folded sheet of clean paper and examined for residual toner. If the
carrier does not appear gray and detoned, refer to section 13 for
troubleshooting the cage and/or vacuum cleaner filter.

NOTE: Folding the paper before pouring out the detoned carrier
will make it easier to transfer the beads to the sample bottle.

NOTE: Do not put the remaining developer sample or detoned

carrier beads in an open trash container.

Refer to section 11 on how to clean the sample bottle and dispose

of the carrier beads.

Some beads will be caught in the 400 mesh screen. The beads are
rough and can easily get caught in the mesh. To thoroughly clean
the cage, perform the following:
1. Put the cage upside down inside the vacuum hose.
2. Turn on the vacuum cleaner.
3. Strike the side of the cage at the screens with the handle
of a screwdriver or a nutdriver multiple times (~20-30).
Turn off the vacuum cleaner.

NOTE: Support the opposite side of the cage with your hand to
keep the cage from moving sideways with the blow.

4. Put the cage back on the scale and see if the tare has

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 returned to near zero.
5. Repeat as necessary (but see notes, below.)

This will dislodge many of the beads stuck in the wire screens.

Caution: Do not run the vacuum for more than 60 seconds.

Otherwise the motor of the vacuum cleaner may overheat and
become damaged.

NOTE: Check the tare weight of the cage to determine if it is

cleaned of beads. Initially, the tare may increase 20 mg.
Afterwards, an increase of 10 mg -15 mg is okay. If you have
more than this left in the cage, try the cleaning procedure again.

After the beads have been removed, there may be some toner left
in the screens. Place the cage back in the end of the vacuum hose
with the funnel end down and the screens exposed. Turn on the
vacuum cleaner.

Push the funnel into the screen end of the cage with the spout
against the screens. Make a tight seal between the funnel and the
sides of the cage. The vacuum cleaner will collect air through the
funnel and create a jet of air onto the screens. Rock the funnel
around to bathe the screens with compressed air. This will
dislodge any toner in the screens. Turn off the vacuum cleaner
when done.

The blown out toner will coat the inside of the tail section of the
cage. Remove the cage from the vacuum cleaner hose and use the
45 degree method described in section 6 (page 8) to clean off this
toner.

The cage can now be put away or used for another measurement.
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11. Clean out the sample bottle
Pour any unused developer material in the sample bottle back into
the developer housing or safely dispose of it by pouting the
contents into the vacuum cleaner hose with the vacuum turned on.

Take the detoned beads on the folded sheet of paper and carefully
pour them back into the sample bottle.

Put the cap back on the bottle and shake the bottle vigorously for
about 10 seconds. The detoned beads will pick up all the residual
toner coating the inside of the bottle.

Safely dispose of the contents of the sample bottle by pouring them

into the vacuum cleaner hose with the vacuum turned on. These
beads should not be returned to the developer housing. They may
have picked up paper fibers.

12. Recovery Actions for High or Low TC

A. TC too high

If the tc is too high (greater than 9%) it is outside the machine

operating space and beyond the range of the tc look up table. The
developer housing must be detoned to proceed.

Check the tc target and tc reading on the printer. If the reading is

well above the target then simply running prints will detone the
developer housing. Choose a high area coverage test pattern to
quickly detone the housing. 100 prints may be enough.

If the reading is near the target then running prints will not help
lower the housing tc. The problem here is that the calibration of
the tc sensor is off and the process controls are toning up the

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developer housing too far. In this case the target must be lowered
before running prints.

In iGen3 or iGen4, drop the TCTargetNominalX by 1% and run

100 prints of a high area coverage document. Then check the tc
again and calibrate the tc sensor as per the RAP that led you to this
procedure.

In Sorrento, do not adjust the TC target. Instead move the Packer

sensor tc intercept up by 44 bits in dC901. This will raise the tc
reading in by 1%. Now go to dC909 and run HLC prints to lower
the tc. When done, make sure the tc read is within 1% of the
target. If not, run more prints. When it is within 1% of target,
repeat the tc measurement and finish the Packer calibration.

If the tc remains above 9%, follow the RAPs for TC Too High.
This may involve changing the tc sensor or the developer material.

B. TC too low

If the tc is too low, the developer housing must be retoned to

proceed.

In iGen3 or iGen 4 raise the TCTargetNominalX by 1% and run a

100 print job of very low area coverage. This will enable the
machine controls to tone up the developer housing. Check the tc
again and calibrate the tc sensor as per the RAP that led you to this
procedure.

In Sorrento, do not adjust the TC target. Instead move the Packer

sensor tc intercept down by 44 bits in dC901. This will lower the
tc reading by 1%. Now go to dC909 and run HLC prints to
increase the tc. When done, make sure the tc read is within 1% of
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the tc target. If not, run more prints. When it is within 1% of
target, repeat the tc measurement and finish the Packer calibration.

If the developer housing does not tone up, check the dispenser for
toner in the bottle and/or proper function of the dispense system.
Follow the product’s RAPs for TC Too Low.

13. Troubleshooting the kit.

A. The vacuum cage.

Inspection Procedure
The screens in the vacuum cage assembly can be examined by
holding the assembly to your eye and looking through the funnel
end toward the screens with a strong light behind it. Some bead
trapping between the stainless steel screens is normal.

Warning – Do not use a ceiling light fixture to backlight the

screens and hold the cage up without wearing safety glasses.
Loose beads may fall into your eye.

Failure Modes
The vacuum cage has two failure modes – clogged screens and
damaged screens.

i. Clogged screens

NOTE: The problem described here is not the same as beads

caught in the 400 mesh screen and cleaned using the method
described in Section 9.

The wire mesh sandwich at the bottom of the vacuum cage consists
of three stainless steel wire meshes. The coarse 20 mesh screen
provides overall strength to the screen assembly from the vacuum
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pressure. The 500 mesh screen holds back most of the carrier
beads. A 400 mesh screen on top of the 500 mesh screen protects
the fine wires of the 500 mesh screen from breaking under the
impact of the carrier beads as the toner is removed.

The 400 mesh screen has 38 micron openings so carrier beads

between 25 and 38 microns can get trapped between the two
screens. The cleaning method in section 9 may not be able to
remove these beads and some increase in cage tare is unavoidable.

Holding the cage horizontally while tapping it against a hard

surface may move the trapped beads between the screens to one
side and also extend the life of the cage. Eventually, enough beads
will collect between the screens and cut off the air flow. When this
happens, the developer sample will not detone. The only remedy
is to replace the vacuum cage assembly.

For this reason, two vacuum cages are supplied with the kit. Keep
one cage relatively unused and use the other cage to failure.
Discard the failed cage and order a new assembly from spares.
Use the second cage and run this one to failure while keeping the
replacement cage as the new reference cage after it arrives.
Periodically take tc measurements with both cages to check the
accuracy of the used cage. When the readings vary by more than
0.5% its time to discard the failed cage and order a replacement.

ii. Broken screens

The 400 mesh screen is in place to protect the fragile wires of the
500 mesh screen from becoming broken. During the detoning
process, the carrier beads are accelerated in the air flow and strike
the 400 mesh screen. Eventually they may damage the 400 mesh

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screen and create holes in it. This, in turn, can expose sections of
the 500 mesh screen to damage.

If a hole develops in the 500 mesh screen, excess bead leakage can
occur. This will result in higher than expected tc readings, since
the lost beads will be treated as removed toner in the tc calculation.

If you suspect the screens of having a hole, obtain a known sample

of developer. For the Docutech 180 HLC family, fresh developer
packages of standard colors are shipped at 6.5 ± 0.5 % tc. Check
the operation of the tool by measuring a sample. If the tool is says
that the tc is above 7.4 %, replace the vacuum cage assembly.

B. The vacuum filter

As mentioned in section 6, the vacuum cleaner filter may be too

clogged to get an accurate reading. Use the manometer checkout
adapter and the service manometer (not included) to make sure the
vacuum cleaner is drawing at least 3 inches of water. If not,
replace the filter. A new filter should draw between 5 and 6 inches
of water.

Caution – the vacuum will still work at less than 3 inches of water
and may be fine for cleaning up dirt and spills around the machine
but will not give an accurate reading.

The state of the filter has a small but measurable effect on the tc
readings. Each inch of water drop in the vacuum pressure changes
the reading by 0.12. The Packer calibration is only to the nearest
0.5% so correcting for this effect is not necessary. The TDK
sensor in iGen4 is quite accurate so make the following
corrections, if needed

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 Vacuum Pressure
< 3 inches H2O
3 to 3.8 inches H2O
3.8 – 4.8 inches H2O
4.8 – 6 inches H2O
Above 6 inches H2O
Adjustment to TC readings
Replace the vacuum filter
Add 0.10 to the reading
No adjustment to the reading
Subtract 0.10 from the reading
Subtract 0.20 from the reading

Always make this correction when checking the cage against a

known tc sample to determine if the cage should be discarded.
Otherwise you may discard a properly operating cage.

C. The digital scale

The digital scale is fully warranted for 30 years by the supplier. If

it fails, return it to HBI for replacement. A warrantee card
accompanies the instructions with each scale.

A 20 gram reference weight is supplied with the scale but it is

probably not accurate to within 0.001 grams. You may want to
record the actual weight of the 20 g reference in your instruction
manual. The tare weight of the cage, approximately 30 grams, can
also be recorded but this will grow slightly as beads become
trapped between the screens.

Scale drift – when placed on the anti-vibration pad and properly

leveled, the digital scale should not drift more than 0.003 g over a
5 minute period. Test the scale using the 20g calibration weight or
a tc cage. The weight can be tared at the start of the check. Scales
with excessive drift should be replaced.

(We have seen 1 scale failure due to excessive drift. Some thermal
drift is possible but we have not seen any in Rochester, NY.)

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14. Helpful Tips
As a reminder, be sure to following these important steps:

1. Clean the cage thoroughly after each use. Use the scale to check
the cage tare. Keep the bead buildup in the screens as low as
possible.

2. Detone the developer material using three (3) 10 second

intervals and clean the bottom of the cage each time. Do not
simply run one 30 second interval to save time. This will lead to a
bad measurement and miscalibration of the tc sensor.

3. Remember to disable the auto-off feature of the scale to prevent

it from shutting off during a measurement.

4. Do not use canned air to clean the cage and sample bottles. The
use of canned air is not permitted due to a potential fire hazard.

5. Do not use a calculator to figure out the toner concentration.

Some extra corrections are built into the Look Up Tables. The
Look Up Table will give you the proper value.

6. Check the beads for residual toner after completing the detone
process and final weighing. If any visible toner is on the beads, the
vacuum filter may need replacing or the screens may be clogged
with beads.

7. You may wish to keep a spare vacuum filter at the account to

use solely with this kit. Mark the filter clearly. The manometer
readings can be skipped unless the detoned carrier beads have
excess toner after detoning. Then you need to check the filter
before replacing the cage.

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15. Cage Tare Record
Use the cage at least once before recording the tare weight. A new
cage will collect ~ 20 mg of carrier and toner in the internal seams
around the screens. This material cannot be cleaned out.

Record the tare weight of the cage for reference. Check this
reference to make sure the cage is thoroughly cleaned after each
use.

Cage # Date: Tare:

Cage # Date: Tare:

Cage # Date: Tare:

Cage # Date: Tare:

Cage # Date: Tare:

Cage # Date: Tare:

NOTE: Use a bit of masking tape to number each cage. The

weight of the tape is minimal and will be included in the tare.

All documentation for this kit, including the video training, can be
found in GSN, library # 9897 as "Vacuum TC Tool - Helpful
information for Non-optical Vacuum TC Tool"

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