DC+240+-DC250+MAX+SET+UP

2008 Seminar

Max Setup Routines DC 250F

2008 Seminar

Max Setup Routines DC 250• IOT Baseline

�dC924 TRC Adjust

�dC950 ATC Sensor Setup

�dC937 ProCon

• IOT Situational

�dC991 Tone Up / Tone Down

�dC931 Manual In/Out Setup

�dC924 TRC Adjust

• IIT Situational

�dC919 Copy Mode Color Balance Adjustment

�dC945 CCD Calibration

�dC 924 TRC Adjustment

10/9/2008 32008 Seminar

Max Set Up

• Max Set Up should only be performed when directed to do so in the Service Manual

• Process Control adjusts Bias voltage, Laser Diode Power, and Grid/BCR Voltage automatically to maintain density.

• Process Control maintains Toner Concentration automatically, to maintain density. It uses the ATC Sensor and Pixel count to the determine dispense time needed to attain the target TC.

• Most of the procedures, in Max Set Up, only measure parameters of process control but do nothing to effect it. They can be used as a troubleshooting tool but not as a adjustment to correct Image Quality

10/9/2008 42008 Seminar

Entering Diagnostics

10/9/2008 52008 Seminar

10/9/2008 62008 Seminar

10/9/2008 72008 Seminar

dC924 TRC Adjust

000K

000C

000M

000Y

HIGHMEDIUMLOW

TRC Adjust

• If the machine is functioning correctly, and the cu stomer does not like the way Process Control sets up density, you can use dC924 to adjust density levels to satisfy the customer.

• TRC (Tone Reproduction Curve) Adjust is used to adjust image density as desired by adjusting the center value of tone correction in the range of low/mid/high density for each Y, M, C and K.

• The Default value (Mid Range) is 0. By adjusting TRC you will affect both prints and copies.

• This should only be used, as a last resort, if the customer is complaining of color densities of both prints and copies. These values s hould always be returned to 0 when baselining the machine (performing max setup a nd/or calibration)

10/9/2008 82008 Seminar

10/9/2008 92008 Seminar

dC950 ATC Sensor Set Up

0

1024

55

K

-4469-6Correction Offset

10899141024Correction Coefficient

546765Bar Code Number

CMY

ATC Sensor Set up

• The ATC sensor calibration value (sensor gain) is p rinted on each sensor, and must be entered whenever a Developer Housing or ATC sens or is replaced This is accomplished by doing adjustment 9.2 ATC Sensor Set Up (DC 950).

• Locate the ATC Sensor calibration code on the ATC Sensor. This is the 3-digit number in the 3rd line of text on the label (it will always start with a zero).

• Enter the last 2 digits of this code into the appropriate column of the first row.

• After the routine is completed the Correction Coefficient, and Correction Offset will be calculated and displayed in the appropriate boxes.

• This procedure must be performed in order for the ATC Sensor to function accurately.

• When Performing this adjustment using the UI make sure you press the Green Start button on the UI to execute the routine.

10/9/2008 102008 Seminar

dC950 ATC Sensor Set Up

0

1024

55

K

000Correction Offset

102410241024Correction Coefficient

555555Bar Code Number

CMY

ATC Sensor Set up

• If all the bar code numbers are at 55, they are at default. You must input in the ATC Sensor Calibration Value (sensor gain) that is printed on each sensor

• This could occur if the CSE did an IOT initialization without doing a save and restore.

• With this set up the sensors would not function accurately.• If the original ATC sensors are in the machine use the ATC Sensor Bar Codes

listed on the factory sheets located in tray 1.

10/9/2008 112008 Seminar

dC 937 ProCon Table

2008 Seminar

ProCon dC 937ProCon Values• ADC

• Grid Voltage Setting

• LD Power

• Bias Setting

• ATC

Procon Judgments• ADC Patch Fail

• ADC Minisetup Fail

• ATC Average Fail

• AYC Amplitude Fail

Procon Status• ADC Shutter Open

• ADC Shutter Closed

• ADC Sensor Fail

• Temperature Fail

• Humidity Fail

10/9/2008 132008 Seminar

Procon

• There are no adjustments in ProCon, it is a measurement tool only

• It should be used to evaluate how the machine thinks it is performing

• It will also monitor different functions of Process Control and render judgments if they functioning correctly or not.

• Running this procedure will have the same effect on Image Quality as the when the machine runs a Mini Set up.

• Again you have no input it is strictly a measurement tool

10/9/2008 142008 Seminar

ADC Target H / Measure ADC H ProCon On

219263259317Measure ADC H

220260270320ADC Target H

KCMY

• ADC H is used to measure the densities of high area coverage patches (50% for K 75% for CMY).

• ADC Target H is the adjusted target at which the machine should run to maintain correct Image Density for “High Area” coverage. These Targets are effected by HFSI life and other factors like Temperature and Humidity.

• Measure ADC H for all colors is the calculated density measurement for High Area patches (2) for that color. The lower the value the darker the patch the higher the value the lighter the patch .

• The result of ADC H Measure should be within +25 bits of the target value CMY and +50 bits for K

• Things to look for if the ADC H Measure value is not within + 25 Bits CMY or + 50 bits K of the ADC Target H value

• If Mid/Hi density of copies/prints is acceptable do nothing

• If Mid/Hi density of copies/prints is not acceptable check how ATC is functioning. If ATC is good go to next step. If ATC is out troubleshoot the Dispense and Development system

• If Mid/Hi density of copies/prints is not acceptable and ATC is good suspect the Xero CRU, MOB Sensor Assembly, IBT Belt, contacts of the flat cables on the MCU to IOT PWB’s, ROS LD, MCU PWB, HVPS.

10/9/2008 152008 Seminar

ADC Target L / Measure ADC L ProCon On

894940944954Measure ADC L

888946941957ADC Target L

KCMY

• ADC L is used to measure the densities of Low Area coverage patches (18% CMYK).• ADC Target L is the adjusted target at which the machine should run to maintain correct Image

Density for “Low Area” coverage. These targets are effected by HFSI life and other factors like Temperature and Humidity.

• Measure ADC L for all colors is the calculated density measurement for the Light Area patch for that color. The lower the value the darker the patch the higher the value the lighter the patch.

• The result of ADC L Measure should be within +25 bits of the target value CMY and +50 bits for K• Things to look for if the ADC L Measure value is not within + 25 Bits CMY or + 50 bits K of the

ADC Target L value• If Low Density of copies/prints is acceptable do nothing• If Low density of copies/prints is not acceptable check how ATC is functioning. If ATC is

good go to next step. If ATC is out troubleshoot Dispense and Development system• If Low density of copies/prints is not acceptable and ATC is good suspect the Xero CRU,

MOB Sensor Assembly, IBT Belt, contacts of the flat cables on the MCU to IOT PWB’s, ROS LD, MCU PWB, HVPS.

10/9/2008 162008 Seminar

Grid, LD, Bias Settings ProCon On

608407409499Bias Settings

500350360353LD Power

730522518613Grid Voltage Settings

KCMY

• These are the three parameters the machine use/adju sts to achieve the ADC H Target. They are adjusted by process control, there are no manual ad justment procedures. They are used to control image density.

• Grid Voltage

• Grid Voltage Setting is the Bias setting the machine is using to achieve the ADC H target value

• Grid voltage will change as needed to develop a good ADC H patch.

• For K, Grid Voltage is scorotron voltage, for CMY Grid Voltage is Bias Roll Voltage.

• LD Power

• LD Power is the Laser Diode setting the machine is using to achieve the ADC H target value

• LD will change as needed to develop a good ADC H patch.

• Bias Settings

• Bias Setting is the Developer Bias voltage the machine is using to achieve the ADC H target value

• Bias Setting will change as needed to develop a good ADC H patch.

10/9/2008 172008 Seminar

ADC Min 1 ADC Min 2 ProCon On

326268289328Measurement of ADC Min 2

201106103269Measurement of ADC Min 1

KCMY

• Used to extrapolate the value for ADC H by measuring two patches Min 1 and Min 2

• ADC Min 1 must be at least 10 bits lower (darker) then Min 2 (normally lower by 50 bits or more). If the difference is less then 10 bits the setup will fail (ADC Minisetup Fail)

• ADC H will normally fall between Min 1 and Min 2 on a new machine with new IBT, Drum, and Developer. If it does not and Mid/Hi density is acceptable there is no problem.

• Min 1 and Min 2 are also used to calculate LD Power, Grid Voltage, and Bias voltage (See diagram next slide)

10/9/2008 182008 Seminar

Process Control Setup

RADC value Electric potential (VH, BIAS, VL)

RADC_Target

LD_OUT_Mini2

LD

LD_OUT_Mini1

LD__ Max_Limit

LD value

RADC

LD_OUT_PCON

RADC_Mini2

RADC_Mini1

ADC_Mini1 PatchADC_Mini2 Patch

LD (large)�LD (small)

Grid BC (large)Grid BC (small)

Bias (small)

Bias Large

LD (small)

LD-_Mini_Limit

MINISETUP

Bias volt.

Grid volt.

10/9/2008 192008 Seminar

ATC ProCon On

105115124151Measured ATC Amp

687662657668Measured ATC Ave

675662662682ATC Target

KCMY

• ATC Target is the adjusted target. It is determined by adjusting the standard ATC Target in NVM, using a sampling of the following: Temperature, Humidity, Developer Life.

• Measured ATC Ave is the actual measured average of several samplings of the ATC sensor. The lower the value the higher the Toner Concentration. ATC measure should be within + 25 bits of the ATC Target

• If the difference between the ATC Target and the Measured ATC Ave is greater then + 25 bits run 50 to 100 copies of your standard test pattern. This should stabilize your system and bring the numbers to within the 25 bit range.

• Things to check if your ATC values continue to drift off and result in CQ problems: Dispenser assy, Toner Cartridge, Low Toner Sensor, ATC Sensor Set Up not performed, ATC Sensor, Developer housing

10/9/2008 202008 Seminar

ATC ProCon On continued• Measured ATC Amp is the difference between the High point and the low point

of the toner/developer wave created by the developer auger. The auger moves the developer in a wave pattern. The ATC sensor measures the high point and the low point of the wave and calculates the width. The readings represent a direct reading of the waves of developer material produced by the augers.

� The readings should be between 80 and 300 but typically average 80 to 150.

� A new developer installed may result in a value in the range of 50 ~ 100. As the amount of material diminishes over time, the number will increase (i.e. possible range 150 ~300). This is based on the reading of the developer material augured within the housing. As the developer material depletes, the readings will drop back to a lower number (i.e. 0- 50), which indicates the developer material needs to be replaced.

10/9/2008 212008 Seminar

Procon On Judgments

OKOKOKOKATC Amplitude Fail

OKOKOKOKATC Average Fail

OKOKOKOKADC Minisetup Fail

OKOKOKOKADC Patch Fail

KCMY

• ADC Patch Fail - The measured ADC Patch density is light (Over 75% of Vclean). Vclean is the bear IBT belt reading by the ADC Sensor. If this is NG go to the 92-652 RAP in your service documentation

• ADC Minisetup Fail - The two levels of ADC Patch density created in Mini-Setup: high (LD_OUT+60) and low (LD_OUT-60) are reversed. If this is NG go to the 92-663 RAP in your service documentation

• ATC Average Fail – The output from the ATC sensor was not detected. If NG go to RAP’s 92-653 (Y), 92-654 (M), 92-655 (C), or 92-656 (K) in your service documentation

• ATC Amplitude Fail – the amplitude value is smaller then 10 bits. If NG go to RAP’s 92-657 (Y), 92-658 (M), 92-659 (C), or the 92-660 (K) in your service documentation

10/9/2008 222008 Seminar

Procon Status

OKHumidity Fail

OKTemperature Fail

12Humidity

26Temperature

OKADC Sensor Fail

OKADC Shutter Closed

OKADC Shutter Open

ProCon Status• ADC Shutter Open - The MOB ADC Shutter remains open

due to Shutter failure If NG go the 92-649 RAP

• ADC Shutter Closed - The MOB ADC Shutter remains closed due to shutter failure. If NG go the 92-650 RAP

• ADC Sensor Fail - The output read by ADC Sensor from the clean Photoreceptor surface is out of range (100~1000) (in Mini-Setup). If NG go to the 92-651 RAP

• Temperature Fail- The temperature output of the Humidity/Temperature Sensor was not in the appropriate range. If NG go to the 92-661 RAP

• Humidity Fail - The humidity output of the Humidity/Temperature Sensor was not in the appropriate range. If NG go to the 92-662 RAP

• Temperature / Humidity – measurement value of temperature and measurement value of humidity taken by the Temperature/Humidity sensor.

10/9/2008 232008 Seminar

Procon Off• Procon “Off” Print performs a mini setup similar to Procon “On” Print, but

does not use the output of the ADC H patch to determine Charge Voltage Settings, LD Power, and Bias Setting.

� These values are chosen in a Look Up Table (LUT) based on drum and developer

life.

� Note: In this case, Y, M, C drum life are equal so LUT values are equal. Measured

ADC H is not as close to the ADC H Target when LUT values are used.

• Key Point. If troubleshooting a density problem, Visually inspect output of Procon “On” and Procon “Off” Print.

� If the Procon “On” Print has a density problem, but Procon “Off” Print does not, then it is best to troubleshoot the process control system (ADC sensor/harnessing, IOT

software, MCU PWBA).

� If the Procon “On” Print and the Procon “Off” Print have a density problem, then it is best to troubleshoot the image path (transfer, developers, ROS, MCU PWBA,

harnessing, DFE)

10/9/2008 242008 Seminar

Procon Off

---OK---OKHumidity Fail

---OK---OKTemperature Fail

---15---15Humidity

---28---28Temperature

OKOKOKOKOKOKOKOKATC Amplitude Fail

OKOKOKOKOKOKOKOKATC Average Fail

12989921041269392102Measured ATC Amplitude

688634629650686631629650Measured ATC Average

668623623643668623623643ATC Target

555482482482587467463442Bias Setting

480499499499532477472440LD Power

660610610610703590585557Charge Voltage Settings

OKOKOKOKOKOKOKOKADC MiniSetup Fail

---OK---OKADC sensor Fail

---OK---OKADC shutter close Fail

---OK---OKADC Shutter Open Fail

OKOKOKOKOKOKOKOKADC Patch Fail

920940933955894942941964Measured ADC Target L

888946941957888946941957ADC Target L

363344347364364356339356Measured ADC Min 2

260206214227258216205224Measured ADC Min1

310272266292277299300354Measured ADC H

270310300350270310300350ADC Target H

(K)(C)(M)(Y)(K)(C)(M)(Y)

Procon “Off” PrintProcon “On” Print

10/9/2008 252008 Seminar

10/9/2008 262008 Seminar

dC991 Tone Up Tone Down

687

675

0

K

662657668ATC Measure

662662682ATC Target

000No. of Cycles

CMY

Tone Up/Down

• This procedure compares measured toner concentration against a target, and allows manual adjustment of TC.

• ATC Target is the adjusted target. It is determined by adjusting the standard ATC Target in NVM using Temperature/Humidity values, and Developer Life.

• Measured ATC Ave is the actual measured average of several samplings of the ATC sensor. The lower the value the higher the Toner Concentration, the higher the number the lower the toner concentration. ATC measure should be within + 25 bits of the ATC Target

• For each color that is above or below target, enter a value between -99 and 99 into the top row. This value is the number of tone up or tone down cycles to be performed. Negative values increase the ATC Measured Value (less toner concentration) ; positive values decrease ATC Measured Value (more Toner Concentration) .

• Repeat as required until ATC Measured Value matches ATC Target . • A more preferred way to stabilize TC would be to run 50 to 100 copies of your standard test pattern

82E13120.• Things to check if your ATC values continue to drift off and cause CQ problems: Dispenser assy, Toner

Cartridge, Low Toner Sensor, ATC Sensor Set Up not performed, ATC Sensor, Developer housing

10/9/2008 272008 Seminar

10/9/2008 282008 Seminar

Manual In/Out Set up

• This routine is not very useful on the DC250 Family of products

• The ROS Driver PWB does not have the range to adjust the laser to compensate for machine shortfalls or component aging

• Performing these adjustments from -256 to +256 will result in about .02 dU change.

• If In/Out density is a problem suspect the 2nd BTR, 1st BTR’s, XCRU’s, IBT Belt or Assembly, Developer assemblies, ROS assemblies, MCU PWB.

10/9/2008 292008 Seminar

10/9/2008 302008 Seminar

dC919 Copy Mode Color Balance Adjustment

0

0

0

K

000High Density

000Medium Density

000Low Density

CMY

Color Adjustment

• Changes made in the dC919 Adjustment will effect t he copy mode only. • This is a fine adjustment for very hard to please c ustomers.• You can adjust the center set point + 4 steps with 0 being the default number. If you increase the value

you will cause that color to be darker. If you decrease the value you will cause that color to be lighter.• The customer has a coarse adjustment for Color Balance on the image quality tab. There are + 3 steps

in the course adjustment.• dC919 should be used as follows: The customer complains that his output is too light for a certain color.

The customer then selects the Image Quality tab and adjusts color balance for that color. He selects +2 and The color is too light. He then selects +3 and that is too dark. DC919 will allow the CSE to fine adjust this color by changing the fine adjust center point until the customer is satisfied.

• So, Image Quality Color Balance on the UI is a Coarse Adjustment, CSE Diagnostic Color Balance is a Fine Adjustment. Again, this would only be used for very hard to please customers.

10/9/2008 312008 Seminar

10/9/2008 322008 Seminar

dC945 CCD Calibration

• dC945 is three separate routines

� White Reference

� CCD Calibration – Reflection Ratio and B* Calibration Coefficients

� Optical Axis Calibration

• This routine should only be run after replacing a CCD PWB, Lens Pan Assy, IIT IPS PWB, or if directed by the service documentation

• RUNNING THIS ROUTINE WITH INCORRECT PAPER, OR AN INCORRECT OR DIRTY/DAMAGED TEST PATTERM CAN ADVERSLY AFFECT IMAGE QUALITY

10/9/2008 332008 Seminar

dC945 CCD Calibration

138B&W -Y

138B&W - X

136Blue

137Green

137Red

Value

White Reference

White Reference values should be 135 + 5 bitsThings to do, check if these readings are off• Make sure NVM location 715-106 (paper code) is set to 5 for XC (Digital Color

Xpressions+) or 6 for XE (Color Tech+).• Make sure you use 10 sheets of 11X17 Color Expressions + 98 brightness paper to

perform the setup• Clean both sides of the Document Glass, Document Cover, White Reference Strip,

Reflector, and Mirror.• Clean the Exposure Lamp with a clean cloth and Film Remover.• Clean the Lens with Lens and Mirror Cleaner and lint free cloth.• Replace the exposure lamp. Lamp ballast PWB, IIT PWB, and CCD Assy• Note if White reference numbers are off and you do not have color expressions 98 media

input the values on the manufacturing sheets in tray 1 for 715-92 through 715-96

OKOKb* Judgment

225225b* Standard Value

219222b* Patch Measurement

33b* Factor Set No.

SCANPCON

b* Calibration Coefficients

b* Calibration Coefficients – the Patch Measurement should be within + 10 bits of the Standard Value

Things to do, check if judgment fails• Make sure you have the correct test pattern (82E13120)

and it is clean and free of defects. • Make sure the test pattern is positioned with the L.E.

toward the left of the platen glass.• Clean both sides of the Document Glass, Document Cover,

White Reference Strip, Reflector, and Mirror.• Clean the Exposure Lamp with a clean cloth and Film

Remover.• Clean the Lens with Lens and Mirror Cleaner and lint free

cloth.• Replace the exposure lamp. Lamp ballast PWB, IIT PWB,

and CCD AssyIf the standard value is 0 and the judgment fails g o to NVM

locations 715-260 and 715-266 and set them both to 225

10/9/2008 342008 Seminar

dC945 CCD Calibration

240239237K

99170239C

195223119M

2149646Y

BGR

Reflection Ratio

• CCD Calibration – Uses the standard test pattern 82E13120 to calibrate the sensitivity of the CCD. I t looks at the 5 squares in the upper center of the test pa ttern as a reference to do the calibration.

• Highlighted squares in the above table should be 20 0 or higher

• Yellow subtracts Blue (blue 200 or higher)• Magenta subtracts green (green 200 or higher)• Cyan subtracts red (red 200 or higher)

Things to do, check if these readings are off• Make sure you have the correct test pattern (82E13120) and it is clean and free of defects. • Make sure the test pattern is positioned with the L.E. toward the left of the platen glass.• Clean both sides of the Document Glass, Document Cover, White Reference Strip, Reflector, and Mirror.• Clean the Exposure Lamp with a clean cloth and Film Remover.• Clean the Lens with Lens and Mirror Cleaner and lint free cloth.• If problem remains try replacing the exposure lamp. Lamp ballast PWB, IIT PWB, and CCD Assy

10/9/2008 352008 Seminar

dC945 CCD Calibration

225225Rear

219222Front

33Judge

MarksDegree

Optical Axis Set Values

The purpose of this adjustment is to align the CCD with the Lens. This procedure should only be performed if the Lens or CCD is replaced, or if the documentation specifically directs.

Follow your Service Documentation Adj 5.12 to complete this adjustment

10/9/2008 362008 Seminar

Max Setup Routines DC 250F

Presented by:

Katie Lazarus-Born

Norm Srodawa

Jim Strollo