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
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
2008 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
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Entering Diagnostics
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dC924 TRC Adjust TRC Adjust LOW
MEDIUM
HIGH
Y
0
0
0
M
0
0
0
C
0
0
0
K
0
0
0
• If the machine is functioning correctly, and the customer 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 should always be returned to 0 when baselining the machine (performing max setup and/or calibration)
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dC950 ATC Sensor Set Up ATC Sensor Set up Y
M
C
K
Bar Code Number
65
67
54
55
Correction Coefficient
1024
914
1089
1024
Correction Offset
-6
69
-44
0
• The ATC sensor calibration value (sensor gain) is printed on each sensor, and must be entered whenever a Developer Housing or ATC sensor 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.
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dC950 ATC Sensor Set Up ATC Sensor Set up Y
M
C
K
Bar Code Number
55
55
55
55
Correction Coefficient
1024
1024
1024
1024
Correction Offset
0
0
0
0
• 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.
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dC 937 ProCon Table
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ProCon dC 937 ProCon 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
2008 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
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ADC Target H / Measure ADC H ProCon On Y
M
C
K
ADC Target H
320
270
260
220
Measure ADC H
317
259
263
219
• 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.
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ADC Target L / Measure ADC L ProCon On Y
M
C
K
ADC Target L
957
941
946
888
Measure ADC L
954
944
940
894
• 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.
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Grid, LD, Bias Settings ProCon On Y
M
C
K
Grid Voltage Settings
613
518
522
730
LD Power
353
360
350
500
Bias Settings
499
409
407
608
• These are the three parameters the machine use/adjusts to achieve the ADC H Target. They are adjusted by process control, there are no manual adjustment 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
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ADC Min 1 ADC Min 2 ProCon On Y
M
C
K
Measurement of ADC Min 1
269
103
106
201
Measurement of ADC Min 2
328
289
268
326
• 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)
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Process Control Setup MINISETUP RADC value
Electric potential (VH, BIAS, VL)
ADC_Mini2 Patch
ADC_Mini1 Patch Grid volt. Grid BC (large)
Grid BC (small)
Bias Large
Bias volt. Bias (small)
RADC_Mini2 RADC_Target
RADC
RADC_Mini1
LD (small) LD
LD_Mini_Limit
LD
LD_OUT _Mini2
LD_OUT _PCON
LD_OUT_ Mini1
LD value
LD_ _ Max_Limit
LD (large)
(small)
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ATC ProCon On Y
M
C
K
ATC Target
682
662
662
675
Measured ATC Ave
668
657
662
687
Measured ATC Amp
151
124
115
105
• 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
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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.
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Procon On Judgments Y
M
C
K
ADC Patch Fail
OK
OK
OK
OK
ADC Minisetup Fail
OK
OK
OK
OK
ATC Average Fail
OK
OK
OK
OK
ATC Amplitude Fail
OK
OK
OK
OK
• 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), 92658 (M), 92-659 (C), or the 92-660 (K) in your service documentation
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Procon Status ProCon Status ADC Shutter Open
OK
• ADC Shutter Open - The MOB ADC Shutter remains open due to Shutter failure If NG go the 92-649 RAP
ADC Shutter Closed
OK
• ADC Shutter Closed - The MOB ADC Shutter remains closed due to shutter failure. If NG go the 92-650 RAP
ADC Sensor Fail
OK
Temperature
26
Humidity
12
Temperature Fail
OK
Humidity Fail
OK
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•
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.
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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)
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Procon Off Procon “On” Print
Procon “Off” Print
(Y)
(M)
(C)
(K)
(Y)
(M)
(C)
(K)
ADC Target H
350
300
310
270
350
300
310
270
Measured ADC H
354
300
299
277
292
266
272
310
Measured ADC Min1
224
205
216
258
227
214
206
260
Measured ADC Min 2
356
339
356
364
364
347
344
363
ADC Target L
957
941
946
888
957
941
946
888
Measured ADC Target L
964
941
942
894
955
933
940
920
ADC Patch Fail
OK
OK
OK
OK
OK
OK
OK
OK
ADC Shutter Open Fail
OK
-
-
-
OK
-
-
-
ADC shutter close Fail
OK
-
-
-
OK
-
-
-
ADC sensor Fail
OK
-
-
-
OK
-
-
-
ADC MiniSetup Fail
OK
OK
OK
OK
OK
OK
OK
OK
Charge Voltage Settings
557
585
590
703
610
610
610
660
LD Power
440
472
477
532
499
499
499
480
Bias Setting
442
463
467
587
482
482
482
555
ATC Target
643
623
623
668
643
623
623
668
Measured ATC Average
650
629
631
686
650
629
634
688
Measured ATC Amplitude
102
92
93
126
104
92
89
129
ATC Average Fail
OK
OK
OK
OK
OK
OK
OK
OK
ATC Amplitude Fail
OK
OK
OK
OK
OK
OK
OK
OK
Temperature
28
-
-
-
28
-
-
-
Humidity
15
-
-
-
15
-
-
-
Temperature Fail
OK
-
-
-
OK
-
-
-
Humidity Fail
OK
-
-
-
OK
-
-
-
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dC991 Tone Up Tone Down Tone Up/Down Y
M
C
K
No. of Cycles
0
0
0
0
ATC Target
682
662
662
675
ATC Measure
668
657
662
687
• 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
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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.
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dC919 Copy Mode Color Balance Adjustment Color Adjustment Y
M
C
K
Low Density
0
0
0
0
Medium Density
0
0
0
0
High Density
0
0
0
0
• Changes made in the dC919 Adjustment will effect the copy mode only. • This is a fine adjustment for very hard to please customers. • 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.
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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
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dC945 CCD Calibration White Reference Value Red
137
Green
137
Blue
136
B&W - X
138
B&W -Y
138
White Reference values should be 135 + 5 bits Things 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
b* Calibration Coefficients PCON
SCAN
3
3
b* Patch Measurement
222
219
b* Standard Value
225
225
b* Judgment
OK
OK
b* Factor Set No.
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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 Assy If the standard value is 0 and the judgment fails go to NVM locations 715-260 and 715-266 and set them both to 225
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dC945 CCD Calibration Reflection Ratio
•
• • • •
• • • • • •
R
G
B
Y
46
96
214
M
119
223
195
C
239
170
99
K
237
239
240
CCD Calibration – Uses the standard test pattern 82E13120 to calibrate the sensitivity of the CCD. It looks at the 5 squares in the upper center of the test pattern as a reference to do the calibration. Highlighted squares in the above table should be 200 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
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dC945 CCD Calibration Optical Axis Set Values Degree
Marks
Judge
3
3
Front
222
219
Rear
225
225
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
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