LPM For Windows: Diagnosis Tool For Pagestream Printer

LPM for Windows
Oc Printing Systems GmbH
Diagnosis Tool for Pagestream Printer

Users Guide PS 210 (ED1) Printer Module
July 2001
Printer Maintenance for OPS Printer

by OPS
Copyright 1996 ... 2001
Oc Printing Systems GmbH
Poing
All Rights reserved
Page 2
Last Change: tt.01.jj
Table of Contents
1. INTRODUCTION.............................................................................................................................. 5
1.1. DOCUMENTATIONS OVERVIEW ................................................................................................... 7
1.1.1. Printed manual Online help.............................................................................................. 7
1.1.2. File name conventions........................................................................................................ 7
1.2. SAFETY REGULATIONS.............................................................................................................. 8
1.2.1. Accident and Damage Prevention.......................................................................................8
1.3. STATUTORY REQUIREMENTS.................................................................................................... 11
2. MAIN MODULE.............................................................................................................................. 13
2.1. REVISION LEVELS.................................................................................................................. 13
2.2. CONFIGURATION.................................................................................................................... 13
2.3. ERROR MESSAGES................................................................................................................ 14
2.3.1. Current Error Messages.................................................................................................... 14
2.3.2. Suppressing Error Messages............................................................................................ 14
2.4. OPERATOR PANEL MENU........................................................................................................ 15
2.4.1. Paper................................................................................................................................. 15
2.4.2. Image................................................................................................................................ 17
2.4.3. Printer................................................................................................................................ 21
2.5. NVRAM............................................................................................................................... 23
2.5.1. Reading / Writing NVRAM.................................................................................................23
2.5.2. Backup NVRAM................................................................................................................ 23
2.5.3. Restore NVRAM................................................................................................................ 23
2.6. PORT SIGNALS...................................................................................................................... 24
2.7. READING / CHANGING COUNTERS........................................................................................... 24
2.8. COUNTER DEFAULTS.............................................................................................................. 24
2.9. COLD START......................................................................................................................... 25
2.10. DE FIRMWARE VERSION....................................................................................................... 25
3. CHECK- AND TEST FUNCTIONS................................................................................................26
3.1. PAPER TRANSPORT................................................................................................................ 27
3.1.1. Revision Levels................................................................................................................. 27
3.1.2. Setting Parameters........................................................................................................... 27
3.1.3. Reading Parameters......................................................................................................... 28
3.1.4. Complex Functions........................................................................................................... 30
3.2. BASIC UNIT........................................................................................................................... 31
3.2.1. Revision Levels................................................................................................................. 31
3.2.2. Configuration of the Developer Station.............................................................................31
3.2.3. Aggregates........................................................................................................................ 32
3.2.4. Call Switches / Values....................................................................................................... 33
3.2.6. Color Verification............................................................................................................... 44
3.2.7. TREK Board...................................................................................................................... 44
3.3. FUSER STATION / STACKER..................................................................................................... 45
3.3.1. Revision Levels................................................................................................................. 45
3.3.2. Reading Fuser / Stacker Signals.......................................................................................45
3.3.3. Set / Reset........................................................................................................................ 48
3.3.4. Reading Analogous Signals..............................................................................................49
3.3.5. Setting Analogous Values.................................................................................................. 50
3.4. CONVEYOR............................................................................................................................ 56
3.4.1. Revision Levels................................................................................................................. 56
3.4.2. Loop Puller........................................................................................................................ 56
3.4.3. Vacuum............................................................................................................................. 57
3.4.4. Paper Width Adjustment................................................................................................... 58
3.4.5. Sensors............................................................................................................................. 59
3.4.6. Fuser Roller Speed........................................................................................................... 59

3.5. CHARACTER GENERATOR CG1............................................................................................... 60
3.5.1. Revision Levels................................................................................................................. 60
3.5.2. Elementary Functions....................................................................................................... 60
3.6. CHARACTER GENERATOR CG2............................................................................................... 65
3.6.1. Revision Levels................................................................................................................. 65
3.6.2. Driver Supply Voltage....................................................................................................... 65
3.6.3. Power Request.................................................................................................................. 65
3.6.4. Temperature...................................................................................................................... 65
3.6.5. Measuring Slide Position................................................................................................... 66
3.6.6. Controller Test................................................................................................................... 66
3.6.7. Cleaning SELFOC Cover.................................................................................................. 66
3.6.8. Measuring Slide -> Garage Position.................................................................................66
3.6.9. Slide -> CG End................................................................................................................ 66
3.6.10. Foreign Light Check........................................................................................................ 67
3.6.11. Starting Measuring Routine............................................................................................. 67
3.6.12. Alignment........................................................................................................................ 69
3.6.13. Reading Data.................................................................................................................. 70
3.6.14. Reset............................................................................................................................... 70
3.6.15. Status.............................................................................................................................. 70
3.7. POST-PRINT PROCESSING TYPE-1........................................................................................... 71
3.7.1. Output Signals................................................................................................................... 71
3.7.2. Input Signals..................................................................................................................... 72
3.8. POST-PRINT PROCESSING TYPE-2........................................................................................... 73
3.8.1. Revision Level................................................................................................................... 73
3.8.2. Memory Test...................................................................................................................... 73
3.8.3. Controller Interface Test.................................................................................................... 73
3.8.4. Type-2 Interface Test......................................................................................................... 73
1. Introduction
Welcome to
LPMW - Printer Maintenance for OPS Printers
LPMW is a diagnosis and maintenance program for OPS high performance printers.
With a revision level 3.00 or higher the program is a true 32 bit application and will run on
any PC with Windows95. It is furnished on CDROM exclusively by the software logistics
of Oc Printing Systems.
L P M W for Pagestream supports
general
diagnosis (all functions) for the

printing systems
PAGESTREAM Single 145/154, PS235/250, PS350/372, PS440/466,
PAGESTREAM-Twin-Systems PS290/308, PS470/500, PS700/744, PS880/1000,
DEMANDSTREAM 8000 DI model 8070, 8000 DI model 8080 and
2240 (NDZ)
and the RDC functions (error log...) and controller functions of all printing systems with
remote capabilities:
2050, 2075 (ND75), 2090, 2140,
PAGESTREAM 55, 75, 88, 158, 200/210 DSC
DEMANDSTREAM 3000 DI Model 3020, 3000 DI Model 3030, 6000 DI.
LPMW is useful for

Printer diagnosis / error recovery on customer site (local) or
Remote Printer diagnosis
Function extent:
RDC Functions:
Retrieve and display error statistics (frequency, chronology)
Silent trace: start, stop and transmit
Retrieve printer parameters, e.g. serial number, controller type,

emulation, release levels of HW/FW/SW, page counters, waste
counters,...
Check and test functions:

Manage NV-RAM of main module (backup, restore, write, read)
Read and display state of sensors and switches (part. dynamically)
Switch motors, drives, heating and other devices
Read out error bytes (detailed error information of pcbs)
Read out revision levels and counters directly out of sub modules
Start complex test functions
ITF basic functions: start, stop, trace param., printer config.
Powerful terminal emulation
and so on.
User interface:
Menu driven, handle with keyboard or mouse
Online help, notebook function
Complete trouble shooting guide
Batch processing
Menus for managing com ports and modems
Customer / Dial data base
GOAL:
REDUCTION OF DOWN TIMES by

SERVICE ASSISTANCE
SUPPORT OF ERROR RECOVERY
PROOF OF SUCCESSFUL REPAIRING
MANAGEMENT OF PRINTER CONFIGURATION
1.1. Documentations overview

This part of the documentation (Users Guide PS 210 (ED1) Printer Module) describes those
functions of LPMW witch are printer-type dependent (for PS200/210, DS 6060 DI).
The functions of the LPMW base programme, identical for all printer types, are explained in the
documentation (Users Guide Base Programme).
This manual and the online help suppose that the user has some knowledge how to
operate a Windows95-programme. Most of the users questions should be satisfied (see
also Chapter online help).
1.1.1. Printed manual Online help

The contents of printed manual and online help are nearly identical.
During development of documentation the online help has a higher priority.
That means the online help is more actual and more detailed. Also the use is more simple. Thats
the reason for the
Hint:
Please use the online help instead of the

printed manual if possible.
1.1.2. File name conventions

The names of the documentation files have following structure:
L P M <t> <l> M A N . D O C
l = language: E = English, D = German
t = type:
P = Pagestream/NDZ, M = PS88, F = PS158,
E = PS200/210, W = LPMW-Base programme
The documents are in the file format of Word for Windows (Office 97).
1.2. Safety Regulations

1.2.1. Accident and Damage Prevention
1.2.1.1. Persons
-
The printing system may only be operated by trained and authorized personnel.
Read the entire operating manual before beginning work on and with the printing system. If there
is anything in the manual that you do not understand, ask service personnel or someone with the
requisite knowledge in your company.
The printing system must not be operated by persons under influence or drugs or alcohol, or by
persons taking medication such as psychotropic drugs.
1.2.1.2. Operating the Printing System

-
In cases of emergency (e.g. damage to the housing, power cable or operating controls, ingress
of fluids or foreign bodies) switch the device off immediately (for the position of the main power
switch, see figure: Operating the printing system, overview on page 23) and inform the
appropriate service point.
Any unauthorized removal of safety covers, manipulated of safety switches such as those
monitoring that the safety covers are closed and improper handling (i.e. work not intended to
be carried out by operators) is strictly prohibited. Such action can cause accidents and may in
addition damage the printing system.
Correct handling (i.e. handling that complies with the intended purpose of the printing system) is
guaranteed only when the outer paneling is fully mounted. Only if paneling is affixed correctly in
position are you assured protection against:
- Electrical shocks
- Injury due to mechanical parts, e.g. cuts, crushing
- The spread of fire
- Inadequate cooling of the printing system
Observe all warning and information signs both on and inside the printing system
The fusing station reaches very high temperatures during print operation. Before you do any
work on or around the fusing station, always let the station cool down for the specified length of
time. Always wear heat-proof safety gloves.
With any drive mechanism, unprotected hair and loosely hanging items of clothing, such as ties,
belt ends, necklaces, bracelets and rings, can cause accidents if caught in the mechanism.
Improper handling of the printing system - in the paper transport areas, for example can cause
injury. Tie back hair and remove ties and jewelry.
Make sure that no objects (jewelry chains, paper clips, coins, etc.) or liquids get into the interior
of the device, since this may result electric shocks or short circuits. Also do not place containers
with fluid (such as drink bottles, glasses, cups or vases) on top of or in the immediate vicinity of
the printing system.
Should the printing system emit any unusual or noticeable noises or smells, power down the
printing system and contact your service engineer.
Observe the instructions for cleaning the printing system. The vacuum cleaner must be an
industrial cleaner with grounded suction tube. For vacuuming large quantities of toner spill (e.g.
one bottle), the cleaner must be explosion-proof. Otherwise, there can be a high buildup of static
charge when vacuuming toner spill. Always use recommended cleaning agents and materials.
Do not obstruct the cooling ducts, since this may result in overheating or combustion while the
device is in operation.
The operating and service clearance areas may not be obstructed in any way.
Keep all doors, flaps and covers closed while the printing system is in operation. this ensures
that optimum levels are maintained for radio interference suppression and operating noise.
Observe the safety instructions given in the manual for:

-
Toner
Developer
Fine filter
Fusing oil
Handling the photoconductor drum
Make sure there is an adequate supply of fresh air and cooling air to the room in which the
printing system is located
Keep all consumables and parts out of reach of children.
If your printing system has a beam waveguide connection:

-
Never look directly down a glass fiber cable or cable connection. The laser beams in fiber
optic devices can damage your eyes.
1.2.1.3. Assembly and Installation of the Printing System

-
The printing system may only be installed by service personnel.
The printing system must have a dedicated electrical connection or type B plug connection
(complying with VDE directives, EN60950).
Do not route the lines and cables in such a way that they can be trodden on or tripped over.
All printing system accessories and options must comply with statutory regulations and
directives for safety, radio interference suppression, telecommunications terminal device, as well
as with the specifications published by Oce Printing Systems GmbH. The installation of other
accessories may constitute a violation of these requirements and directives, and may in addition
damage the printing system. Please consult service personnel for details on which accessories
and options are permitted for the printing system.
With the exception of beam waveguide connections, all data, signalling, process and control
lines and holding wires linking the printing system with other devices must be properly grounded.
Data transmission lines should neither be connected up nor disconnected during electrical
storms.
1.2.1.4. Transport
-
The printing system may only be transported by service personnel or authorized transport
companies.
When the printing system is standing or being moved on its own rollers, all doors must be closed
firmly and secured to prevent unintentional opening. Otherwise the printing system could be
damaged. A printing system designed for printing in two colours can overbalance if the center
rear door holding the toner supply canisters opens while the printing system is being moved on
its rollers.
1.2.1.5. Repairs
-
Repairs to the device must only be carried out by service personnel. Access to locked areas and
areas which can be opened with special tools is reserved for service personnel. Opening the
device without authorization and improperly effected repairs may put operating personnel at
considerable risk.
1.2.1.6. Fire
-
Fire can cause gaseous emissions and toxic arsenic gas to develop on the photoconductor drum
(as is the case with many types of office equipment). There is a particular danger of this
happening if a large stock of photoconductor drums is kept. For this reason, firefighters must
wear special protective suits and use breathing apparatus.
1.2.1.7. Disposal
Oce operates a system by which used parts and consumables can be returned for environmentally
sound disposal.
-
Collect all parts and consumables that are to be returned for disposal. these will be picked up by
service personnel or by a commissioned shipping company. Oce Printing Systems GmbH or a
contracted disposal company the recycles the parts or consumables or disposes of the
appropriately.
Point to observe when disposing of a photoconductor drum:

-
Before touching the drum, always put on the gloves provided.
Should there be flaking of the photosensitive coating on the drum, carefully collect the
flakes or fragments of coating.
Store the photoconductor drum and any flakes of coating in the original drum packaging.
Keep the original carton with the photoconductor drum and flakes of coating for collection by
service personnel or contracted shipping company.
1.3. Statutory Requirements

The information, data and instructions in this operating manual were up-to-date and the time of
going to press. The right of technical modifications due to further development of the printing system
is reserved. For this reason, the information, illustrations and descriptions in this operating manual
cannot give rise to any claims for modifications or additions to printing systems that have already
been shipped and accepted.
No liability is accepted for damages resulting from:
-
Failure to observe the operating manual

Errors due to improper handling
Work performed incorrectly on the printing system
Use of non-original parts and accessories
Use of non-original consumables
Unauthorized modification and retrofitting of the printing system by the agent or the agents
personnel
For further information see the Safety Information for Oce Printing Systems.
No. U27874-J-Z246-1
AT T E N T I O N
Actuation of many functions in the printer, for example various drives, direct access to the
printer controller, sometimes inactivating internal control mechanisms. The application of
this program and the consequences (personal or property damage) are in the responsibility
of the user. Adequate safety measures, e.g. barriers or visual control, are required.
Important: During operation via modem activated test functions might continue running after
the connection breaks down.
Users Guide PS 210 (ED1) Printer Module is an internal diagnosis tool of

Oc Printing Systems GmbH and may not be given to third parties.
We w ish you w ell in you r w o rk w ith L P M W.
Printer ED1
This is the main menu of the printer specific program part for the printer ED1. From here you can
select all controller- and test functions.
Attention:
Depending on the selected printer and its configuration there are grey-coloured menus,
which are not available in the program. Within the help, however, these menus are always
available.
Reading Printer Definitions

The printer definition is usually read out automatically. In Demo-Mode you have to select the printer
type and the modules belonging to it manually.
2. Main Module
2.1. Revision Levels
Here, the revision levels of all boards of an individual sub-module is read out.
2.2. Configuration
At this position the information about the configuration bytes of the printer may be read out from the
NV-RAM or it may be changed. Each modification of these values requires a turning off / on the
printer. The byte marked by the menu bar is decoded in single bits. The description of the individual
bits is automatically given when a certain bit is selected by the return key.
Configuration Byte 1
This byte informs the controller, which options the printer features. '1' is displayed when the
respective option is installed. The control and the error monitoring for the option are activated in this
case. In case of a cold start (with empty NV-RAM), this byte is set automatically to 00h.
This byte serves to define the character generator type of the printer. In case of a cold start (with
empty NV-RAM), this byte is set automatically to 00h.
This byte informs the controller about the options of the fuser station. '1' is displayed when the
corresponding option is installed. The control and the error monitoring for the option are activated in
this case. In case of a cold start (with empty NV-RAM), this byte is set to 00h automatically.
This byte informs the controller which printer type is concerned. In case of a cold start (with empty
NV-RAM), this byte is initialised at 02h (ED1) automatically.
This byte informs the controller, which controller options are installed. In case of a cold start (with
empty NV-RAM), this byte is initialised at 00h automatically.
2.3. Error Messages

2.3.1. Current Error Messages
Here, the current error messages are displayed. Click on an error code to display the trouble
shooting guide.
The Trouble Shooting Guide is closed by the menu File Quit or the
- Button.
2.3.2. Suppressing Error Messages

Here, all error messages available for this printer type are displayed with text, error byte and error
code. With this menu item individual messages can be suppressed at the operator panel screen. For
this reason some error messages are marked with a special sign +, * or #. Error messages
without this sign are not relevant for this printer equipment. The signs mean:
#
+
*
this error message can not be suppressed for reason of security

this error message can occur
this error message will be suppressed
error codes without error bytes can not be suppressed (controller error)
Suppressing an error message is done by the cursor keys and the Space-bar. The Del-key unlocks
all suppressed error messages. The Trouble Shooting Guide to an individual error code is called by
the Enter-key.
The Trouble Shooting Guide is closed by the menu File Quit or the
- Button.
However, even if an error message is suppressed nevertheless it will be written into the errorlog-file.
The total of all suppressed error messages is displayed in the menu head line. All error messages
are unlocked after turning off and on the printer.
Attention!
Suppressing some error messages at the printer may cause unpredictable results or
damages of the printer. Using a printer with suppressed error messages is allowed only a
maintenance technical expert.
2.4. Operator Panel Menu

2.4.1. Paper
2.4.1.1. Paper Length
In this submenu item, the physical paper form length is entered. The value may range between 6
and 16 inches ( 6 and 28 inches, if an external paper feeder is used) in steps graded by 1/6".
2.4.1.2. Page Length

In this submenu item the logical paper form length is entered. The value may range between 3 and
17 inches in steps graded by 1/6 inch.
NOTE: In P-Mode some page lengths are not supported by the host program in several systems.
2.4.1.3. Paper Width

Here, the paper width is entered. The value may be entered in mm, inch or pel.
Mode
inches
mm
pels (240 dpi)
pels (300 dpi)
pels (600 dpi)
one-web
6,49 - 18,25
164,9 - 463,6
1558 - 4380
1948 - 5475
3896 - 10950
two-webs
6,49 - 9,5
164,9 - 241,3
1558 - 2280
1948 - 2850
3896 - 5700
The paper width defined in the operator panel is compared with the current, automatically measured
paper width
- after power-on the printing system ( if paper is inserted)
- after inserting paper
- after entering the changed paper width
2.4.1.4. Fuser Oil

The quantity of fuser oil that should be selected for optimal fusing contact depends on the used
paper and the way of operation. Also here, any special recommendations cannot be given due to the
variety of suitable printing materials.
However, the fuser oil quantity should always be set to "NORMAL" as the standard selection and left
in this setting as long as the fusing result is good.
Only in case of fusing problems (e.g. if excess oil is appearing on the printed media or, in the other
case, if there is print offsetting resulting from a lack of oil), a different setting should be selected. To
distinguish between circumstances that may require a setting other than "NORMAL", only the
following very general recommendations can be given:
If the printer is left in standby operation for longer time, if an extreme woody paper (e.g. recycled
paper) is used, or if the printer is operated in excessive start-stop, the MAXIMUM setting may be
advantageous. If extreme smooth paper is used, a reduction of the oil quantity to LOW or to
MINIMUM may be advantageous. Whatever setting is the best for a certain type of paper need to be
found out in praxis or by special tests.
2.4.1.5. Fuser Temperature

Here, you can control the fuser temperature. It may be set to MINIMUM, LOW, NORMAL, HIGH or
MAXIMUM. These adjustments can be used if the paper tends to curling across the paper path.
Changing these adjustments, however, involves the risk of getting a fusing quality degradation
(under-fusing), especially when using "rough" paper. The fuser temperature and/or the fusing contact
angle should therefore only be reduced if with critical paper the curling is so strong that either print
smudging occurs while the paper is running through the fuser station, or if functional problems occur
with a post-print forms handling equipment.
2.4.1.6. Calibrator
Here, the calibrator adjustment in the menu is pre-selected. If selected
ON: Status message 11.00 CALIBRATOR UNLOCKED is displayed,
OFF: Warning W.0B CALIBRATOR UNLOCKED is displayed.
2.4.1.7. Paper Cooling

This menu item serves for setting the paper cooling fan to NORMAL, HIGH or MAXIMUM.
2.4.1.8. Paper Brake

Here, the power of the paper brake may be entered. Possible values are NORMAL and REDUCED.
2.4.1.9. Decurler
As a result of the thermal-mechanical load of the paper during the run through the fuser station, the
paper may become "curled" more or less, depending on the used paper. The decurler smoothes the
paper by curling it in the opposite paper path direction. The grade of this decurling effect can be
adjusted in five levels: 2 (weak) .. 6 (strong), 0 = off. The adjustment 1 is not available.
The grade of decurling that should be selected depends on how strong the paper that leaves the
stacker is curled. The adjustment must be made by in such a way that the curling is nearly "ironedout" and that the paper does not begin to become curled in the other direction. In any case, it must
be tried which selection gives the best results.
NOTE: The adjustment on the operator panel may differ from the physical adjustment.
2.4.2. Image
2.4.2.1. Horizontal Shift
Here, you may enter the horizontal print image shift depending on the selected operation mode in
the previously selected measuring unit.
Boot-Mode
I
P
E+C
PCL
inches
from - to
-2.0 +2.0
0.0 +0.17
-2.0 +2.0
-5.0 +5.0
mm
from - to
-50.8 +50.8
0.0 +4.2
-50.8 +50.8
-127 +127
PEL (240 dpi)

from - to
-480 +480
0 +40
-480 +480
-
PEL (300 dpi)

from - to
-600 +600
-1500 +1500
PEL (600 dpi)

from - to
-1200 +1200
-3000 +3000
2.4.2.2. Vertical Shift

Here, you may enter the vertical print image shift for the selected operation mode in the previously
selected measuring unit.
Boot-Mode
I
P
E+C
PCL
Inches
from - to
-2.0 +2.0
-0.17 +0.17
-0.17 +0.17
-5.0 +5.0
mm
from - to
-50.8 +50.8
-4.2 +4.2
-4.2 +4.2
-127 +127
PEL (240 dpi)

from - to
-480 +480
-40 +40
-40 +40
-
PEL (300 dpi)

from - to
-600 +600
-1500 +1500
PEL (600 dpi)

from - to
-1200 +1200
-3000 +3000
2.4.2.3. Hor. Shift (Back)

This function is available only in double track printing. Here, you may enter the horizontal print
image shift depending on the selected operation mode in the previously selected measuring unit.
Boot-Mode
I
P
E+C
PCL
inches
from - to
-2.0 +2.0
0.0 +0.17
-2.0 +2.0
-5.0 +5.0
mm
from - to
-50.8 +50.8
0.0 +4.2
-50.8 +50.8
-127 +127
PEL (240 dpi)

from - to
-480 +480
0 +40
-480 +480
-
PEL (300 dpi)

from - to
-600 +600
-1500 +1500
PEL (600 dpi)

from - to
-1200 +1200
-3000 +3000
2.4.2.4. Vert. Shift (Back)

Here, you may enter the vertical print image shift for the selected operation mode in the previously
selected measuring unit.
Boot-Mode
I
P
E+C
PCL
Inches
from - to
-2.0 +2.0
-0.17 +0.17
-0.17 +0.17
-5.0 +5.0
mm
from - to
-50.8 +50.8
-4.2 +4.2
-4.2 +4.2
-127 +127
PEL (240 dpi)

from - to
-480 +480
-40 +40
-40 +40
-
PEL (300 dpi)

from - to
-600 +600
-1500 +1500
PEL (600 dpi)

from - to
-1200 +1200
-3000 +3000
2.4.2.5. Contrast
Here, you can select the toner density of the printout: ECONOMY, LIGHT, NORMAL, DARK. With
color only the adjustment NORMAL is possible.
2.4.2.6. Eject to Front Facing

At the start of a new print job, a blank sheet is inserted via the host channel if necessary to ensure
that the next job begins on a front-facing sheet.
2.4.2.7. Perf to Perf

Only in P-Mode: Printing from perforation to perforation can be adjusted separately for channel A
and B.
2.4.2.8. Horizontal Shift (Two up)

Here, the horizontal printout shift for both logical pages may be entered.
Boot-Mode
inches
mm
PEL:240
PEL:300
PEL:600
P,E+C
-0,5 ... +0,5
-12,7 ... +12,7
-120 ... +120
-
I
-0,5 ... +0,5
-12,7 ... +12,7
-120 ... +120
-150 ... +150
-300 ... +300
2.4.2.9. Overlay Number

Only in P-,E+C-Mode:
Select an electronic form overlay. The value may range between between 1 and 50,000. 0 means:
no overlay.
2.4.2.10. Two Up Printing

Mode
Select option
- NO TWO UP
- NO COPIES
- 1 IDENTICAL COPY
X-Extent
Enter value for start of printing (X-direction) of the right-hand logical page measured in pels ( 0 to
9999 ). 1 pel = 1 / (resolution of character generator).
Order
Sequence of start of printing; first page printed on right or left side.
2.4.2.11. Print Direction

Print direction in
P-Mode:
- 0
- 90
- 180
- 270
Print direction in
E+C-Mode:
- 0
- 90
- 180
- 270
- 90 toggle
- 180 toggle
- software rotated
2.4.2.12. Shift EFO

Horizontal Shift EFO
Enter the horizontal print column shift for the electronic form and select a measuring unit. After
selecting the unit, enter your shift value. Any increment is permitted within the valid range.
inches:
mm:
PEL (240dpi):
0
0
0
to
to
to
+2,0
+50,8
+480
Vertical Shift EFO

Enter the vertical print column shift for the electronic form and select a measuring unit. After
selecting the unit, enter your shift value. Any increment is permitted within the valid range.
inches:
mm:
PEL (240dpi):
0
0
0
to
to
to
+2,0
+50,8
+480
2.4.2.13. Unit
Here, the measuring units mm, inch or pels for the printout shift is selected.
2.4.3. Printer
2.4.3.1. Configuration
Stacker Height
Enter the maximum permitted height of the output stack:
- 105 mm
- 165 mm
- 225 mm
- 285 mm
- 345 mm
When there is a decurler installed on the stacker, the maximum stack height is 225 mm.
Auto Eject
Turn the automatic paper eject function on or off.
2.4.3.2. Page Counters

Here, the following counter levels may be read out:
- User Pager Counter (printed 12-inch pages in USER-Mode)
- Duplex Page Counter
- Clean-stop Counter
- Simplex Page Counter
- Total Page Counter (printed 12-inch pages in User- and Maintenance-Mode in total)
- Operation hours
2.4.3.3. Remaining Pages

This submenu item contains a lot of counter levels which indicate how many pages are still to be
printed until an expendable part must be changed or a consumable is used up.
2.4.3.4. Type 2 Interface Parameters

Identification
The interface is activated by entering the identification

number.
Error Recovery
When a hard error occurred, the lost pages are repeated

automatically, if RETRANSMISSION was adjusted,
The system stops automatically 0..50 pages after a hard error
to allow the operator to check the printed pages.
Automatic Stop after Error

Periodic Stop after Error
The system stops automatically after printing the adjusted

number of pager to allow the operator to check the printed
pages.
Distance Printer to Type
24..72 inches loop length. This is the distance between

stacker upper part and the Troy printer. The corresponding
number of pages for synchronising is calculated by the Type-2
PC assy.
Dist. Printer to Type2-Stacker
Distance between stacker upper part and the end of the postprint processing device.
2.5. NVRAM
The NV-RAM is a not volatile memory in the printer. There, the most important data are stored, for
example the serial number, the configuration bytes, the pages counters and various printer
adjustments. The contents are kept even after turning off the printer.
With the following sub-menus, you can read or write NVRAM contents. Moreover you can store
complete NVRAM contents as files to your PC, or transfer it into the printer memory.
2.5.1. Reading / Writing NVRAM

Starting from a particular address 8 bytes are read out from the operator panel NVRAM and
displayed in hexadecimal notation as well as in ASCII characters. Each byte can be changed and
rewritten to the NVRAM.
2.5.2. Backup NVRAM

All printer specific data is read from main module NV-RAM and is saved in a file in the PC. The file
name consists of "NV" + controller type letter + printer serial number. The controller type letter is "A"
for APA, "L" for LIP and "S" for SRA. The extension consists of the printer id and a sequence
numbers between 1 and 99. The first backup file of the printer 60239 equipped with a APA controller
is therefore called NVA60239.E01". The path to this file is given in the file manager. While the
information is read from the printer a status bar at the bottom of the screen shows the progress of
the backup. The backup process can be stopped anytime by pressing the <ESC> key.
The error message "Backup file cannot be created!" can have the following causes:
the program is not connected online to a printer

the serial number of the printer was not read
there is no space available on the storage medium for the backup file
99 backups have already been made for this printer
2.5.3. Restore NVRAM

The printer data is read from a previously created file (see "NV-RAM backup) and written to the NVRAM of the printer. For this all files listed in the configuration index are sorted in ascending order
according to the printer numbers in a menu with page turning and selection options. Then the
content of the selected file is transferred to the printer. Here you have to state which information
should be written.
The following references are possible:
No NV-RAM backup files found!
No files NV*.* found in NV-RAM configuration index.
WARNING, different serial number! Write data?
You tried to write content of another printer to the NV-RAM.
2.6. Port Signals

Here, an overview about the emergency-stop signals of the individual sub-modules is displayed.
2.7. Reading / Changing Counters

Here, the various page counters can be read out and changed. The user-pager-counter and the totalpage-counter run in ascending order, the other counters run from a maximum value in descending
order to 0. The current, changed and maximum values are displayed.
The page counters count the number of the printed pages. Pages moved by EJECT do not change
the page counters.
2.8. Counter Defaults

Here, you may change the thresholds of the maintenance counters described above. The actual
value, the new value and the valid range are displayed.
2.9. Cold Start

As a result of a cold start the most parameters of the NV-RAM will deleted. Therefore the program
asks you several times if you really want to perform the cold start procedure.
Cold Start Procedure
Cold Start is a process that resets the NVRAM to a default state. This is typically performed when
you install a blank NVRAM IC as would be the case if the existing IC was damaged. In some
extreme cases, this process might need to be performed if the NVRAM was corrupted in some way.
Once the boot process is completed, you must either restore a previous NVRAM file or go to the
configuration and page counter screens to re-enter those fields not correct for your printer. All
printers are shipped with a configuration sheet called "Datenprotokoll". This sheet lists all the special
configuration information that was required when the printer left the factory. Use this information to
rebuild NVRAM if you do not have a valid NVRAM file to restore.
Note: Never use values from another printer unless instructed to do so by your support specialist.
After a cold start the usage counters are set to zero. In order to enter the correct values, you must
answer no to restore page counters when restoring a NVRAM file.
1. Save NV-RAM.
2. Start Cold Start
3. Power down (Enable Switch)
4. Power up.
5. Enter serial number displayed in operator panel. Input OPS serial number by using keyboard of
the printer.
. Printer boots F-Code.
Note: The default dpi is 240 dpi. If error message 76.01 LED HARDWARE ERROR OCCUR set
correct dpi via this program or operator panel. If NV-RAM data are saved, rewrite the NV-RAM data
with this program.
2.10. DE Firmware Version

The firmware version of the Device Electronics is displayed.
3. Check- and Test Functions

Turning on / off the test mode and reading out the revision levels is available in all modules.
Attention:
Depending on the selected printer and its configuration there are grey-colored menus, which
are not selectable in the program. Within the help, however, these menus are always
available.
3.1. Paper Transport

3.1.1. Revision Levels
Reading out the revision levels of the paper transport boards D840, D871, D117.
3.1.2. Setting Parameters

3.1.2.1. LED-Current
The value of the LED current must be set in accordance with sensor soiling and ageing as well as
the degree of paper transparence. This adjustment may be carried out in a range of 12 steps. Step
1 corresponds to min. current (10 mA), step 12 to max. current (37.5 mA).
3.1.2.2. CORTIME
This parameter sets the monitoring time of the transfer corotron movement in steps of 50 ms.
3.1.2.3. LOCHNO
Monitoring of the paper path: the parameter determines the monitoring threshold for the motion
sensor in steps of 1/6 inch (default value: 0Fh = 15 corresponds 2.5 inches, i.e. 5 hole distances).
3.1.2.4. EMITVLOCH
Threshold for the evaluation of the monitor sensor voltage in 256 steps from 2.0 to 4.0V linear
(default value: 99h = 153 corresponds to 3.0 V).
3.1.3. Reading Parameters

3.1.3.1. Saddle
The signal SADDLEOFF15-P indicates the position of the motor: swivelled off 15 degrees before
limit. The signal is "high" if the saddle is swivelled off.
The signal SADDLEON15-P indicates the position of the motor: swivelled on 15 degrees before
limit. The signal is "high" if the saddle is swivelled on.
3.1.3.2. Transfer Corotron

There are 3 signals. TRANSIN-P monitors whether the corotron wire is inside the cassette. (When
changing the cassette, the corotron wire must be inside it.) In this case the signal is "high".
TRANSOUT-P monitors whether the corotron wire was drawn out of the cassette according to the
adjusted paper width. In this case, the signal is "high". PAPWIDTH-P (clock signal) reads the
physical status of the PAPWIDTH-P signal.
3.1.3.3. Calibrator
When the paper is fed into the printer it passes through a calibrator gap which is designed, above all
to prevent a multiple paper feed, in order to protect the PCD from mechanic destruction. When the
calibrator level is switched from on to off, the calibrator gap is widened, and thus allows the use of
special paper types. The micro-switch S49 (closing contact 1-3) sends the calibrator switch position
to sub-module 1. The error display 11.00 CALIBRATOR UNLOCKED depends on the operator panel
adjustment.
Adjustment in menu
Adjustment at switch
Calibrator on
Calibrator off
Calibrator on
no display
no display
Calibrator off 11.00 CALIBRATOR UNLOCKED
W.0B CALIBRATOR UNLOCKED
3.1.3.4. LED-Current A/B

The value of the LED current must be adjusted corresponding to the soiling and ageing of the
sensor, and the degree of the paper transparence. This is carried out via this function stepwise from
10 mA to 37.5 mA.
3.1.3.5. EMITVLT
The sensor monitors whether the tractor pins transport the paper. EMITVLT shows the value of the
motion sensor voltage in linear steps from 0.0 V to 5.0 V. The test result is only sensible when no
paper is inside the printer and the flaps are closed.
3.1.3.6. CORTIME
The monitoring time of the transfer corotron movement is read out.
3.1.3.7. LOCHNO
Monitoring of the paper path: the parameter determines the monitoring threshold for the motion
sensor in steps of 1/6 inch (default value: 0Fh = 15 corresponds to 2.5 inches, i.e. 5 hole distances.)
3.1.3.8. Emitvloch
Threshold for the evaluation of the motion sensor voltage in linear steps from 2.5 to 4.8 V (default
value: 99h = 153 corresponds to 3.0 Volt).
3.1.4. Complex Functions

3.1.4.1. PCB-Test PDM**
This function starts the test of the PCB PDM**. If the test result is 00h, the PCB is ok. If the test
result is FFh, the test is not available at this time. Any other test result indicates a defective PCB.
This test lasts about 30 seconds. After running the test, the error 35.00 PAPER DRIVE CHECK is
displayed. Call the operator to reset this message.
3.1.4.2. Transfer Corotron IN

The transfer corotron is drawn back from the current position to the start position. The test result is
the number of pulses of the PAPWIDTH sensor until the start position is reached. For this reason the
error code 90.02 TRANSFER COROTRON ERROR is set. The error code is reset, when the
corotron is moved via the end position to the paper edge position.
3.1.4.3. Transfer Corotron OUT

The transfer corotron is moved from the current position to the end position. The test result is the
number of pulses of the PAPWIDTH sensor until the end position is reached.
3.1.4.4. Transfer Corotron to Paper Edge

The transfer corotron is moved from the current position to the paper edge (if not detected, back to
the start). The test result is the number of pulses of the PAPWIDTH sensor until the paper flap is
reached (start position).
Note: Before starting this function you have to call the function "Transfer corotron OUT" first.
Otherwise you get an error code 04 due to incorrect pulse count.
3.1.4.5. Swivel
On-Off Evaluation
The swivel flaps are moved to a search run between two limits (sensors). The number of full steps to
the motor is counted. The test result is the number of these steps.
3.1.4.6. Evaluate Motion Sense Statically

The test causes stepping up of the LED current until the motion sensor responds at the pre-set
position. The test must be carried out without paper inserted and with closed flaps. The LED current
is displayed in mA.
3.1.4.7. Paper Transport Motor
The paper transport motor may be driven
slowly forth or back,

fast forth, or
stepwise forth or back.
3.2. Basic Unit

Note: You cannot leave this menu, if any aggregate is still switched on (in sub-menu "Switch on/off
Aggregates"). The menu items:

Here, the revision levels of the Basic Unit boards are read out.
3.2.2. Configuration of the Developer Station

This menu item informs you about the configuration of the developer station.
Serial No.
Type:
State:
Serial number of the developer station

Type of developer station, with or without electronics
- no errors
- Emptying cancelled
- Filling cancelled
Filling Station:
Toner Type:
(Counter:
Number of filling station

as stored in NVRAM, toner name, toner color
Backwards running waste counter for the developer in 100 pages steps)
3.2.3. Aggregates
ATTENTION !!!
The following test commands allow to switch on/off the various basic unit drives. Neither errors nor
time limits are monitored, i.e. the test person must care that no damage is done to persons or the
device. The move commands for the corotron slide motors which are switched off automatically via
hardware make an exception. All switched on devices are marked with a '*'.
NOTE: You can't leave the menu 'Basic Unit: Aggregates' if any device is switched on.
Exhauster motor
Toner box valve(s)*
Vibrator(s)*
Toner feed*
Developer station motor
Green light
Red light
Drum
Charge corotron print position
Charge corotron change position
Discharge corotron print position
Discharge corotron change position
Bias voltage
Charge voltage
Discharge voltage
Transfer voltage
With this function, the fan can be switched on/off.

With this function, the valve(s) can be switched on/off.
With this function, the vibrator(s) solenoid can be
switched on/off.
With this function, the toner feed motor(s) can be
switched on/ off.
With this function the developer station motor can be
switched on/off.
With this function, the green light can be switched on/off.
With this function, the red light can be switched on/off.
With this function, the drum motor can be switched on/off.
With this function the charge corotron can be moved to
print position.
With this function the charge corotron can be moved to
change position.
With this function, the discharge corotron can be moved
to print position.
With this function, the discharge corotron can be moved
to change position.
With this function, the bias voltage can be switched
on/off.
With this function, the charge voltage can be switched
on/off.
With this function, the discharge voltage can be switched
on/off.
With this function, the transfer voltage can be switched
on/ off.
* =The number of some aggregates is depending on the fuser station type.

Note: In Standby-Mode the toner feed motors are not turned off automatically by the firmware.
3.2.4. Call Switches / Values

Here, the individual switches and values of the Basic Unit are read out and displayed.
3.2.4.1. Toner Sensors

Toner Bottle In
This function messages via a micro-switch whether a toner bottle is installed and the toner bottle
container is swivelled on. If the toner bottle is swivelled off during standby (W.05) CHECK TONER
BOTTLE is displayed and the printer cannot be started. If the toner bottle is swivelled off during
printing, at first the same warning is prompted. If the toner bottle is not swivelled on within one
minute, the status display 0B.00 TONER BOTTLE NOT INSTALLED is prompted and the printer
stops.
Toner bottle swivelled on => switch S26 actuated => TBOTTLEIN-N = 0 V
Toner bottle swivelled off => S26 not actuated
=> TBOTTLEIN-N = 5 V
Toner Feed System
This function reports whether the toner feed system is installed.
Fumes
When the main fan is switched on, the air flow at the fine filter exit is monitored by a light barrier of
the fumes sensor for contamination. If the light barrier is interrupted, the printer stops at once and
the error message 6E.00 FUMES is set.
Toner Empty
The capacity sensor in the toner box on the developer station detects that the toner box is full. At
toner empty detection, the toner feed cycles are started until toner empty is inactive again. If toner
empty is not reset after 5 minutes, the warning TONER EMPTY is set. If the signal is not reset within
1000 pages, the status display 04.00 TONER EMPTY is set and the printer stops until a new toner
bottle is installed.
During toner feed, a mixing bow moves in the toner box which would reset the toner empty signal
incorrectly. This measurable signal change is masked out.
No toner or mixing bow in front of sensor => TONEREMPTY-L= 0-1V
Toner or mixing bow in front of sensor => TONEREMPTY-L= 24-29V
Catchbox Full
05.00 TONER COLLECTOR FULL is displayed when the toner bottle in the toner catchbox below the
cyclone filter is full. A capacity sensor equipped additionally with a red LED, detects the full condition
of the toner bottle and messages it to sub-module 2.
Toner bottle not full => TONERFULL-H = 10.8 V, red LED is illuminated
Toner bottle full
=> TONERFULL-H = 0.4 V, red LED is not illuminated
If TONERFULL is detected during printing, at first a warning (W.07) is displayed. If the bottle is not
replaced within the next 3000 12" pages, the printer stops with the error message 05.00 TONER
COLLECTOR FULL. The printer can only be restarted when the toner bottle has been replaced.
When the toner bottle is removed, a metal bow is swivelled in front of the capacity sensor which is
pressed down again when a new toner bottle has been installed. The sensor can be tested by
moving the metal bow manually and observing the red LED when doing so. This LED only becomes
visible through a mirror at a metal part behind the sensor. The sensor signal can be adjusted by a
potentiometer besides the red LED.
Tonermark
Background - Dot Pattern - Filled Area
Measure input only for experts for electro-photography, not useful for standard maintenance.
3.2.4.2. Corotron Sensors

The Discharge-Corotron-In sensor indicates that the discharge corotron slide is in change position
(in the cassette). The Discharge-Corotron-Out sensor indicates that the discharge corotron slide is
in print position. The Discharge-Corotron-Lock sensor indicates that the discharge corotron unit is
snapped and locked.
Cassette locked : CLEANPOS-L = 0 V
Cassette unlocked : CLEANPOS-L = 5 V
The Charge-Corotron-In sensor indicates that the charge corotron slide is in change position (in the
cassette). The Charge-Corotron-Out sensor indicates that the charge corotron slide is in print
position. The Charge-Corotron-Lock sensor indicates that the charge corotron unit is snapped and
locked.
Cassette locked : CHARGEPOS-L = 0 V
Cassette unlocked: CHARGEPOS-L = 5 V
3.2.4.3. Voltage Switches

All messages cause System Restart Required in any case; the printer does not stop with correct
forms position.
Charge Voltage
After command SWON sub-module 2 switches on all units required for printing. After approx. 5 sec.
HV monitoring is activated. If a line breakage or a defective plug occurs, error message
CHARGEOV is set. If a short circuit occurs in the line, error message CHARGEUV is set.
Charge corotron voltage: +10 kV DC.
Bias Voltage
high voltage (HV) monitoring is activated. If a line breakage or a defective plug occurs, error
message BIASOV is set. If a short circuit occurs in the line or in developer station, error message
BIASUV is set.
Bias voltage: +230V DC.
Transfer Voltage
HV monitoring is activated. If a line breakage or a defective plug occur, error message TRANSOV is
set. If a short circuit occurs in the line, error message TRANSUV is set.
Transfer corotron voltage: approx. -4 - 6 kV DC.

Discharge Voltage
HV monitoring is activated. If a line breakage or a defective plug occurs, error message ACOV is
set. If a short circuit occurs in the line, error message ACUV is set.
Discharge corotron voltage: 10kVSS 5 kHz.
3.2.4.4. Various Sensors / Signals

Vacuum System Control
Position of the vacuum system control switch is displayed.
Drum Cover
Switch K10 drops when the door in front of the PCD is opened. The 5V power supply stays switched
on. The error can be reset with CHECK-RESET when the drum cover door is closed. The printer
starts with a power-up phase.
Developer Station Drain Valve
The positions of the switches S20 and S25 are displayed. In order to empty the developer station,
the lever at the developer station must be actuated which changes the position of the magnetic
stator in the uppermost developer roller and which opens the magnetic mixture barrier. This lever
can only be actuated when the vacuum hose is disconnected from the toner box and plugged into
the developer station. The lever is located at the drive side of the device, the witch S25 is positioned
on the operator panel side of the printer. The position of the lever is monitored with micro-switch S25
(relays 1-3). The status message is displayed if the printer is to be started with the lever in position
for changing the developer.
Mode
Position of lever
Micro-switch
S25 pin1 (yellow)
S25 pin 3 (blue)
PRINT
vertical
actuated
CHANGEDEV = 0V
0V
SERVICE
horizontal
not actuated
CHANGEDEV = 5V
0V
Two positions can be set with the alteration switch in the vacuum system:
PRINT => normal position during printing
SERVICE => air flap position for suction of developer mixture
The switch is on the reverse side of the device above the cyclone filter. The micro-switch S 20
(closing contact 1-3) forms the signal VALVEOPEN-L, which is evaluated by sub-module 2.
Switch position
PRINT:
Switch S 20
not actuated
Signal VALVEOPEN-L = 5 V
SERVICE:
actuated
=0V
Internal Paper End

This sensor (reflexion light barrier in paper input tray) reports internal paper end to sub-module 2.
The printer stops with correct forms position if the function 'automatic eject' has not been set on the
operator panel. The printer starts with 'eject' until the remaining paper path is fused and is in the
stacker in case 'automatic eject' has been set. The upper part of the stacker rises to the stacker-end
position. The red LED at the sensor is lit if there is paper between sensor and reflector. The
sensitivity of the sensor can be changed at the sensor.
External Paper End
This sensor (reflexion light barrier in the external paper feed) reports external paper end to submodule 2. The printer stops with correct forms position, if the function 'automatic eject' has not been
set on the operator panel. The printer starts with eject until the remaining paper path is fused and is
in the stacker in case 'automatic eject' has been set. The upper part of the stacker rises to the
stacker end position. The red LED at the sensor is lit if there is paper between sensor and reflector.
The sensitivity of the sensor can be changed at the sensor.
Drum Charge
During preparation (PCD stands still) the voltage on the analogous port of the processor of submodule 2 is measured by the TREK probe via TREK PCB. The measurement is at 0 .. +10 mV. After
5 seconds a second measurement is carried out. The error message 9B.00 CHARGE REGULATION
ERROR is issued if these measurements differ a lot. This function offers the PCD charge / 1000 in a
range from 0 to 1.2 volts.
Drum Temperature
Designed for measuring the drum temperature. There are no exact instruction values. Expected
values:
70H if printer is cold
90H if printer is warm.
Red Light
This function offers the measuring value for the current of the red LED-bar in a range from 0 to 5
volts. In case the red light sensor has not enough light intensity, a too low analogous voltage value is
measured by the REDLIGHT-H signal on the analogous port of processor PCB BUM**. The voltage
value is 1.2 - 1.3 V. The preparation is terminated in case a calibration error is noticed during
preparation. Error message: 97.00 RED LIGHT LED NOT SHINING
Green Light
This function offers the measuring value for the current of the green LED-bar in a range from 0 to 5
volts. In case the green light sensor has not enough light intensity, a too low analogous voltage value
is measured by the GREENLIGHT-H signal on the analogous port of the processor PCB BUM**. The
voltage value is 0.65 - 0.75 V. The preparation is terminated in case a calibration error is noticed
during preparation. Error message: 97.01 GREEN LIGHT LED NOT SHINING.
Pressure
The voltage of the differential pressure sensor (fine filter monitoring) is in a range of 0 to 12 volts.
The PCB BUM** reports a 63.00 PRESSURE ERROR in case the vacuum is beyond the permitted
range.
PLL Control Voltage
Measurement exit for development department / check field informative; irrelevant for printer
maintenance.
Sensor Display
DOORCLOSED-L:
VALVEOPEN-L:
front door closed

manual switch suction valve
Thermal Switch
TONER FEED BLOWER: Turns off in case of over-temperature.
Sense Signals
TONERCYC-L
The signal indicates whether a Toner Recycling Unit is installed.
SENSECLECOR-L and SENSECHACOR-L

These signals indicate whether the Corotron-Motor is live.
SENSESUCKVA-L
The sensor indicates whether the suck valve is live.

Some of the sensors of the basic unit allow very detailed tests. For this, however, partly other
assemblies of the printer beyond the basic unit must be activated. Therefore the following tests are
limited to those which can be executed by the basic unit alone.
3.2.5.1. Red Light Check
This function offers the adjustment values (voltage and current) for the red LED-bar.
3.2.5.2. Green Light Check

This function offers the adjustment values (voltage and current) for the green LED-bar.
3.2.5.3. Toner Mark Sensor Check

This function offers the value set for the print operation and measured in the test for the current
setting of the scan LED. A measured value less than A3h is ok. The toner supply motor is activated
which brings toner into the developer station via a foam roller, in case the toner mark falls below the
determined contrast. The error message 14.00 CHECK TONER DENSITY is issued if 50 toner marks
are recognised as being too bright.
3.2.5.4. Charge Corotron Runtime Check

This function offers the runtimes for moving in and out of the charge corotron. The resolution is in 65
ms steps. If the corotron does not reach the end position, the maximum runtime FAh = 16.25
seconds is displayed (see also trouble shooting guide 90.00 TRANSFER COROTRON ERROR).
3.2.5.5. Discharge Corotron Runtime Check

This function offers the runtimes for moving in and out of the discharge corotron. The resolution is in
65 ms steps. If the corotron does not reach the end position, the maximum runtime FAh = 16.25
seconds is displayed.
3.2.5.6. Filter Check

This function furnishes the difference pressure of the fine filter in rest or during pressing. The test
also returns the filter status when the various control steps are reached. Measured value M and rest
value R are displayed. If the difference between the two values is:
<
>
>
>
<
39h :
39h :
40h :
50h :
01h :
filter ok
filter replacement warning
filter replacement error
vacuum error (max.)
vacuum error (min.)
3.2.5.7. Drum Charge Check

This function offers the control value of the HV-power supply and the resulting drum charge.
Note: This value only makes sense if the printer was in use before and the function 'Charge Voltage
(dyn.)' has been started before.
3.2.5.8. Charge Voltage (dyn.)

This function adjusts the control value of the HV-power supply. The resulting drum charge is
displayed.
Note: This value only makes sense if the printer has printed before.
3.2.5.9. Charge-Sensor Alignment

D760
The PCB D760 works in a special mode and the analogous value of the TREK probe is displayed via
LEDs.
H6 (red) glows: > 15 mV
H5 (yellow) glows: 10 .. 15 mV
H4 (green) glows: 5 .. 10 mV
H3 (yellow) glows: < 5 mV (negative too!)
Find the adjustment point via the potentiometer, when H3 begins to glow and H4 just begins to go
out.
D1008
The PCB D1008 works in a special mode and the analogous value of the TREK probe is displayed
via LEDs.
H1 glows: < 5 mV
H2 glows: 5 .. 10 mV
H3 glows: 10 .. 15 mV
H4 glows: 15 .. 20 mV
H5 glows: > 20 mV
Find the adjustment point via the potentiometer, when H1 is glowing and H2 begins to glow. The
H3 .. H5 must not glow.
Additionally the type of the Trek-Sensor board is displayed. There are 2 different types:
old:
new:
V26898-B489 for BU boards D760 or D1008

V26898-B489-V1 only for BU board D1008
3.2.5.10. D760 / D1008 Test

This function offers the results of the CPU test, the EPROM check sum and the CPU analogous
inputs.
3.2.5.11. Cold-Start Algorithm

The cold start algorithm prevents the consumption of too much toner after a cold start if using the
low fusing toner 2.5. In this menu item the factor, the bias and charge voltage, the nominal and the
actual value are displayed. Additionally a message is displayed whether the cold start algorithm is
running or not.
Factor
The value here declared is fix pretend and depending on the printer type.
Bias Voltage
The hex value, here declared, is significant only as standard value. Determinative is the measured
value at plug X137 of power supply E25 (nominal value: 200 V +/- 3%). This value is only valid if
CONTRAST=NORMAL is adjusted.
Charge Voltage
The hex value, here declared, is significant only as standard value. Determinative is the measured
value at plug X73 pin 22b (nominal value: 520 mV). This value is the average of 5 measurements.
Nominal Value
Nominal value of the controlling.
Actual Value
The actual value is calculated by the first 8 measured toner marks after starting the print. If nominal
and actual value are different, the cold start algorithm is still running and the I-LED is not able to be
changed.
Only for HW BU D1008 and FW BU > 6.015
The cold start algorithm prevents the consumption of too much toner after a cold start. In this menu
item the bias and charge voltage are displayed. Additionally a message is displayed whether the
cold start algorithm is running or not.
Control Type
00 = short TM ; 01 = old LTM-Control (TK-Sensor); 02 = new LTM - RS color; 03 = new LTM - A2.6
black
Control Threshold
Rated value of the control.
TM-Delta
The actual value is calculated by the first 8 measured toner marks after starting the print. If rated
and actual value are different, the cold start algorithm is still running and the I-LED is not able to be
changed.
Offset of TMS
The offset keeps the toner mark signal in the optimum range between 40h ... 60h. The offset is
controlled dynamically during printing and is independent of toner and PCD.
Delta Cold Start
If not 0 -> printer is in cold-start mode.
3.2.5.12. LTM-Control
In this menu item the toner control is displayed.
Requirements
Hardware: BU D1008
Firmware: BU FW 6.016 or higher
Source
For data input you can select either the printer itself or a protocol. A protocol is a file containing data
of a previous regulation. When protocol is selected a file input window is opened. The filenames
have the extension 'LTM'. We recommend to use the same extension when you create further
measurements.
Web
If using 2 webs, you can select either web A or web B. In the other case there is only web B.
Left Diagram
When the LTM control is active a diagram is created by up to 24 toner mark signals. The offset value
is taken into consideration.
Right Diagram
In this diagram the control threshold RS and the last measured actual value LTM-Diff are displayed.
the x-axis is the time axis, the y-axis corresponds to the binary values 00h ... FFh (decimal 0 .. 255).
Lower Diagram
In this diagram you can see two digital signals: the red line corresponds to the READY- / NOT
READY state (high signal = READY) of the printer, the yellow one indicates toner feed cycles.
Signals in Diagram
RS+DK
= control threshold + cold start delta
DE
= actual value TM-Diff
RS
= control threshold (nominal data)
OFFSET
= offset of TM-Sensor
LTM
= (large) toner mark
TF
= toner feed cycle
READY
= printer state READY / NOT READY
3.2.5.13. Discharge Level Control

The Discharge Level Control (DLC) fits the radiant energy of the Character Generator for the
characteristic of the PCD. With it difference in sensitivity of PCDs can be compensated. The test is
available only with Character Generator ZG2, main module D909, Basic Unit D1008 and the
corresponding firmware version. There are 2 modes of operation.
Mode 1 writes a 6 inches bar alternating black/white on the photo conductor and adjusts the CG
radiant energy until the needed discharging has been reached. This mode is not possible while a
normal print job is running and is only executed with following criterion:
- after power-on
- after changing an ELFO parameter
- after 30 min. delay-time
- after a K10 error
- after booting the controller
Mode 2 regulates the CG radiant energy on the basis of the measured PCD temperature. This mode
is available only while a normal print job is running and after at least 1 measurement in mode 1.
The check contains the following functions:

- STATUS:
- LAST RESULT:
- START CONTROL:
requests whether ELTR is available or not

the last measured result is displayed
the measurement is started. The result is evaluated and displayed.
3.2.5.14. Bias Voltage Adjustment

The resulting Bias Voltage with a fixed adjustment value by the Basic Unit is in a dispersion. Since
the Bias Voltage influences greatly the printing quality and the life time of the developer, it is
necessary to adjust the characteristic curve of the HV power pack.
Requirements
- PCB Basic Unit: D1008
- Printer must be in standby mode
- The engineer has to know the password for level 3.
When is the adjustment necessary?
- after the printers initial installation
- after replacement of the HV power pack (E91)
- after replacement of the Basic Unit (D1008)
- after deleting the NVRAM
- after cold-start or replacement of the NVRAM
Procedure
The adjustment is an iterative process between the Basic Unit and the LPM-Program. Use the
following procedure:
1.
2.
3.
4.
5.
6.
The function Bias-Voltage-Adjustment in LPM* is called by the engineer.

The Bias Voltage is measured by the engineer at the plug, not at the measuring sockets.
The measured value is entered into LPM*.
The Basic Unit decides a correction, acceptance or repetition of the procedure.
Repeat 3. and 4.
Check the optical density, improve it if necessary
The procedure has to be performed for 2 Adjustment points (180V and 250V).
3.2.6. Color Verification

Toner Type
corresponding the new term scheme
EFG-Set
In the EFG-Set the electro-photographical parameters for a toner type are stored. These are BiasVoltage, Charge Voltage and the control threshold for LTM-Diff.
Verification ID
a two-byte value, determined by the customer for each color / toner.
Verification Name
can be determined by the customer
3.2.7. TREK Board

The type of the TREK-Sensor-Board is displayed. There are two different kinds:
old
new
V26898-B489 for BU-Boards D760 and D1008

V26898-B489-V1 only for BU-Board D1008
3.3. Fuser Station / Stacker

These tests relate to the controlling of the swivelling saddle, pressure roller, oiling station, paper
brake, heating element, stacker and the board-tests for the processor-, heating- and power-boards.

The revision levels of the fuser station boards can be read out.
3.3.2. Reading Fuser / Stacker Signals

At present only "older" stacker tops are supported.
3.3.2.1. Operator Panel
STARTADD-N
This signal is generated by pressing a key at the stacker operator panel to set the printer 'ready'.
STOPADD-N
This signal is generated by pressing a key at the stacker operator panel to set the printer 'not-ready'.
EJECTADD-N
This signal is generated by pressing a key at the stacker operator panel to start the printer's eject
function.
STACKEROUT-L
This signal is transmitted by pressing a key at the stacker operator panel to swivel out the swivel
stacker bottom. The stacker-outside-sensor controls the end position of the swivel stacker bottom
(end position reached = micro-switch is actuated). The error message STACKER OUT POSITION
NOT FOUND is issued if the stacker-out-side-position has not been reached after xx ms after the
actuation of the stacker-swing-motor; stacker-swing-pos signals, however, are recognised.
STCKRLIFTOFF-L
This signal is generated by pressing a key at the stacker operator panel to move the rocker on the
stacker bottom completely in or out.
STACKUP-N
This signal is generated by pressing a key at the stacker operator panel to rise the stacker.
STACKERDOWN-N
This signal is generated by pressing a key at the stacker operator panel to lower the stacker.
STACKON-N
This signal is generated by pressing a key at the stacker operator panel to start the transport rollers
and paddle shafts.
3.3.2.2. Stacker Tray Slide

LIFTMIN-N, LIFTLOW-N, LIFTMIDDLE-N, LIFTHIGH, LIFTMAX
These 5 signals are transmitted by Hall sensors for all 9 possible positions of the stacker tray slide.
The stacker tray slide is positioned in the stacker bottom to avoid "paper smiling" ).
3.3.2.3. Stacker
STACKERFULL-P, STACKEREND-P, STACKERLOW-P
These 3 sensors (micro-switches) give a code for stacker positions STACKERFULL, STACKERLOW
and STACKEREND. STACKERFULL is a status message displayed if during Print or Eject the
stacker height adjusted on the operator panel is reached or if the Stacker Full Position (= max.
stacker height) is reached. The stacker positions between Stacker Low and Stacker Full are detected
by the Stacker-Pos-Sensor. The printer will be stopped properly aligned and the stacker
automatically moves to the top Stacker End Position. You can only restart after pressing the
STACKER DOWN key.
RIGHTP-N, LEFTP-N
The right-(left-)paddle-sensor (1 Hall switch and 4 magnets) sends alternating pulses as long as the
right paddle shaft rotates. The paper stack gets so high during printing that the paddle shaft is
blocked. The upper part of the stacker rises in small steps until the paddle shaft is able to rotate
again. The error 7D.00 RIGHT PADDLE SENSOR DEFECTIVE is issued if the right paddle sensor
sends no RIGHTPAD-pulses; the signal can always be high or low; after xx-times calling the rise
cycle (upper part of stacker).
RIGHT(LEFT)PAD L-H
RIGHT(LEFT)PAD L-L
1.25 V if magnet is not before Hall switch

2.50 V if magnet is before Hall switch
1.25 V if magnet is before Hall switch
2.50 V if magnet is not before Hall switch
can also be measured in stop-state of printer.
FOLD-N, FOLD2-N
These signals are transmitted by 2 sensors (reflexion light barrier) indicating the paper fold direction
of the paper running into the stacker. If no paper is in the light barrier, the signals are set to LOW. An
error is set and the printer is stopped with correct forms position in case pulses of the light barrier
are missing.
3.3.2.4. Oiling Station

FELTUNITON-N
This signal is transmitted by the Felt Unit Sensor (Hall-Sensor) which specifies the swivel position of
the oiling station (i.e. felt roll).
oiling station swivelled on
oiling station swivelled off
-> switch X42H actuated

-> signal FELTUNITON-L = 0V
-> switch X42H not actuated -> signal FELTUNITON-L = 5V
OILEMPTY-P
This signal is transmitted by a sensor (optical-electronic sensor) to sub-module 3, and indicates an
empty fuser oil container. The operator is informed to insert a new fuser oil container. After paper
end you cannot restart unless a new container is inserted.
Oil Empty recognised : X219

Pin 1 = 0 V
Pin 2 = + 5 V
Pin 3 = + 5 V
Pin 4 = 1,25 V
Oil Empty not recognised : X219

Pin 1 = 0 V
Pin 2 = 0 V
Pin 3 = + 5 V
Pin 4 = 1,25 V
3.3.2.5. Cooling
COOLINGSADDLE-N
This signal is generated by the Hall-Sensor X42W, which is activated by swivelling on the cooling
saddle. The switch position is registered in the signal processor SPUAL and transmitted to the main
module.
3.3.2.6. Heating Errors

BHEATDEF-P
This signal is transmitted by the heating element power assy FUP** and indicates a defective back
heating element.
FHEATDEF-P
This signal is transmitted by the heating element power assy FUP** and indicates a defective front
heating element.
HOT
Indicates whether the fuser roller heating is too hot.
3.3.2.7. Tempguard
PRETEMPGUARD/H-H; PRETEMPGUARD/W-H and TEMPGUARD-H
The over-temperature switches (bimetal switch) of the heating saddle, the preheat saddle or the
fuser roller are actuated in case of over-temperature (>160C at the heating and preheat saddle, >
260C at the fuser roller); this way the main contactor K10 is cut off. The 5V power supply remains
switched on.
3.3.3. Set / Reset

In this submenu you can switch on and off the following assemblies:
- exhauster motor
- paddle wheel motor
- felt winding motor
- oil pump
- paper cooling
Switching on or off these assemblies is performed by selecting the corresponding function. The state
is displayed. Critical assemblies are automatically reset after a determined time.
3.3.4. Reading Analogous Signals

The following analogous signals are read out cyclically:
3.3.4.1. Fuser Station Temperatures
FTEMPFRONT and FTEMPBACK are 2 signals, which are generated by two thermal elements
(FRONT and BACK) to measure the temperature of the fuser roller.
The thermal voltage is proportional to the fuser roller temperature. The value is transmitted and
corresponds to the temperature in a range of 00h until FEh. That corresponds to 0..508C.
3.3.4.2. Correction Values of the Fuser Roller Temperature

The evaluated input and correction values of the front and back fuser roller halves (also see SET
ANALOG VALUES - CORR. FUSER ROLLER TEMPERATURE) are displayed.
3.3.4.3. Fuser Roller Motor Speed

Here, the speed of the fuser roller motor is displayed for standby and print-speed in rotations per
minute and in half-steps per second (clocks for stepper motor). Additionally the lowest and highest
value of the speed is displayed during the measuring period.
Note: Reading the values makes sense only during printing.
3.3.5. Setting Analogous Values

3.3.5.1. Setting Signal PEDGELED
This signal is a power exit which serves for adjusting the LED in the paper edge sensor. This sensor
detects whether and at which point of time paper is in the tension rollers. In order to balance soiling,
this reflective light barrier must be readjusted time and again during printing. This is possible in 256
steps with one step being 0.24 mA.
In this function the current value is read out and displayed (scroll bar). The selected value is taken.
Function not supported by the firmware at the time.
3.3.5.2. User-Defined Temperatures

After initial start the main module writes FFh into the NVRAM address for the fuser roller
temperature. This value determines that no valid temperature value is given. So the menu item
"User Defined" for the fuser temperature is disabled at the operator panel of the printer.
User Defined Temperature
Enter the new temperature for the fuser roller in Celsius degrees. For the valid temperature range
see the input window. Any changing will be stored into the NVRAM and reported to the sub-module
fuser station. At the operator panel of the printer the function "User Defined Temperature" is enabled
now.
Disable
The menu item "User Defined Temperature" at the printer is disabled again.
3.3.5.3. Setting Correction Values

The thermoelements in the temperature sensors have tolerances caused by production which can be
checked by the correction values. In this test the temperature of fuser roller is automatically set to
NORMAL, possible corrections are switched off. The temperature of the fuser roller halves is brought
to a given value depending on the type of the fuser roller ( hard or soft ). The temperatures are
constantly displayed during the test, an overshot during the adjustment phase is normal.
About 10 to 20 seconds after reaching the normal temperature the user is requested to press the
ESC-key and perform the measurement. The measurement is performed manually with the IR
temperature measuring device. The result has to be entered in the mask on the screen. The
correction values are automatically evaluated and displayed.
This measurement cannot be performed during standby-operation with active temperature reduction
of the fuser roller.

3.3.6.1. Drift Control Sensor Test
The test function of the photo-elements serves for detecting a soiled or defective sensor. During the
test the sensor may not be covered with paper. The measurement is permanently repeated and the
result is displayed. The sensor is defective if the value is below 9Ah. In this case the sensor must be
checked for soiling and the test has to be repeated.
3.3.6.2. Drift Control Sensor Adjustment

This function serves for adjusting the drift control sensor. Prior to this the above described drift
control sensor test is performed. The deviation is permanently measured and displayed. The sensor
offset is only valid, if the test result of the photo-elements is 'ok'. The sensor should be adjusted, so
that the deviation is as close as possible to the value 0. The foil gauge must be inserted for this
adjustment.
3.3.6.3. Swivel Saddle

Turning on
If the swivel saddle motor is turned off, the power PC assy D117 can turn on the power again.
Turning off
The power PC assy D117 can turn off the current of the motor in any mode of operation.
Swivelling on
With this command the swivel saddle is moved from its current position 356 steps in the swivel
direction (independent of the swivel sensor activation). The step motor is accelerated and slowed
down via accelerating and slow down ramps.
Swivelling off
The swivel saddle is moved from its present position 366 steps in swivel off position. If the swivel
sensor is actuated (usually the case after 356 steps) the swivel saddle will be stopped at that point.
The step motor is slowed down and accelerated by way of accelerating and slow down ramps, the
ramps being designed for a step frequency of 356. If the swivel process is stopped earlier (in case
the swivel sensor is actuated), the step frequency is simply terminated.
Search Routine
The swivel sensor is searched. The swivel saddle is moved in swivel direction in slow motion
(however not more than 356 steps), until the sensor is actuated. In case the swivel sensor is
actuated at the beginning of the search run, the swivel saddle is moved further in swivel direction,
until the sensor is deactivated.
Measuring Routine
The position of the on and off sensors is determined by the counted step motor clocks.
Half-automatic test procedure:
1. The swivel motor is turned off automatically.
2. Swivel off the heating saddle by hand from stud and swivel it back
3. Press ESC-key; the measuring routine is started; wait until the measuring is finished
4. The number of counted steps is displayed.
If the number of counted steps is not within the threshold, undo the screw "J" (Tx20) and shift the
board support H1 (see Adjustment below); tight the screw and repeat the measuring run.
Nominal Values:
Given in menu.
Adjustment:
If the number of steps is greater, shift the support to the right. If the number of steps is too small,
shift the board support to the left.
3.3.6.4. Pressure Roller

Turning on
If the pressure roller motor current is switched off, the power PC assy D117 can switch on the power
again if this command is transmitted.
Turning off
The power PC assy D117 can switch off the current of the motor in any mode of operation.
Swivelling on
This command moves the pressure roller from its present position 356 steps (independent of swivel
sensor actuation) in swivel on direction. The step motor is accelerated and slowed down via specific
ramps.
Swivelling off
The pressure roller is moved from its current position 366 steps in swivel off direction. If the swivel
sensor is actuated before that position is reached (usually after 356 steps), the swivel saddle will be
stopped at that point. The step motor is accelerated and slowed down via specific ramps, the ramps
being designed for a step frequency of 356; if the swivel off process is stopped at an earlier stage (if
the swivel sensor is actuated), the step frequency output is abruptly terminated.
Search Routine
The swivel sensor is searched. The pressure roller is moved in swivel direction in unramped slow
motion (however not more than 356 steps), until the sensor is actuated. In case the swivel sensor is
actuated at the beginning of the search run, the pressure roller is moved further in swivel direction,
until the sensor is deactivated.
Measuring Routine
The position of the On- and Off-Sensors is determined by the counted step motor clocks.
Half-automatic test procedure:
1. The swivel motor is turned off automatically.

2. Swivel off the pressure roller on magnetic support M2 by hand from stud and swivel it back
3. Press ESC-key; the measuring routine is started; wait until the measuring is finished
4. The number of counted steps is displayed.
If the number of counted steps is not within the threshold, undo the screw "J" (Tx20) and shift the
board support H2 (see Adjustment below); tight the screw and repeat the measuring run.
Nominal Values:
Given in menu.
Adjustment:
If the number of steps is greater, shift the support to the right. If the number of steps is too small,
shift the board support to the left.
3.3.6.5. Fuser Roller

Turning on
If the fuser roller motor current is turned off, the power PC board FUS** can turn on the power again.
Turning off
The power PC board FUS** can turn off the current of the motor in any mode of operation.
Ramp up
With this command the fuser roller can be ramped up from its stop position to standby speed; this
process takes place on the same ramp as the ramp for the print speed.
Stop
The fuser roller is ramped down from any speed until it stops completely.
3.3.6.6. Tension Rollers

Turning on
If the tension roller motor current is turned off, the power PC board FUS** can turn on the power
again.
Turning off
The power PC board FUS** can turn off the current of the motor in any mode of operation.
Ramp up (print speed)
The tension rollers are ramped up to print speed.
Ramp up (advance forward)
The tension rollers are ramped up to the speed of advance operation in forward direction.
Ramp up (advance reverse)
The tension rollers are ramped up to the speed of advance operation in reverse direction.
Stop
The tension roller is ramped down from any speed until it stops completely.
3.3.6.7. Oil Pump

This function serves for switching on / off the constant operation of the oil pump, i.e. with the
command "Oil Pump On", the oil pump will be activated for 2 seconds (loaded with spring force) and
then it will be deactivated for 10 seconds (pumping). This cycle is repeated, until the command "Oil
Pump Off" is transmitted.
3.3.6.8. Drift Control Motor

The drift control motor serves as correcting element for the paper drift control. The motor makes an
adjustment of the pressures of the pressure roller possible and therefore influences the paper path.
The standard size is derived from the paper drift sensor (light sensor). The end position and the
middle position of the correcting element are derived from the signals HALLRIGHT-L, HALLEFT-L
and HALLMID-L. 5 test functions are available:
1. Set KR-motor middle
2. Set KR-motor right
3. Set KR-motor left
4. Step KR-motor right
5. Step KR-motor left
By reason of a better maintenance two new test functions were added.
Detecting / Setting the Motor Position
This function makes the displaying of the current position of the drift control motor possible as well
as driving the motor into one of the 15 possible positions.
Paper Edge / Motor Position
This test is to be performed during operation mode. Following results are displayed cyclically:
- the position signal of the paper edge sensor as voltage between 2.5 .. 7.5 V
- the motor position of the paper edge controlling
- information about sensor adjustment and the corresponding shift value
3.3.6.9. Stacker Tray Slide: Step up / down

The stacker tray slide is moved to the next out of 9 available positions. The result is displayed.
3.3.6.10. Stacker Up / Down

The stacker motor can be operated in both directions. After reaching the end position or when the
timeout period has been exceeded the motor is switched off. The respective control signals are
monitored and displayed.
3.4. Conveyor
Here, the revision levels of the conveyor boards are read out.
3.4.2. Loop Puller

Output of several limits: Limits for HIGHPOS- and LOWPOS ERROR, upper and lower switch point
for synchronous stop, nominal position of the loop pullers as well as the actual loop puller positions
and the pressure adjustment.
3.4.2.1. Position
Here, the actual position of the loop pullers and the pressure force adjustment are displayed
cyclically as well as the limits for HIGHPOS and LOWPOS ERROR.
3.4.2.2. Limits
Here, the several loop puller limits for the control of the speed of the fuser roller are displayed. The
upper position (HIGHPOS) is set to 00h during the preparation of the printer after reading out the
calibration offset. The maximum control range is LOWPOS to HIGHPOS.
Following values are displayed:
the limits for LOWPOS and HIGHPOS ERROR

the upper and lower switching threshold for synchronous-stop
the specified position of the loop pullers
3.4.3. Vacuum
3.4.3.1. Calibration Parameters
For an optimum controlling of the vacuum a calibration search run of the vacuum valves is
necessary. For that purpose the main blower is switched on with covered paper webs (DIN-A4
duplex) und the vacuum valves are turned more than 360 degrees. The result is displayed for both
vacuum valves (REAR and FRONT).
3.4.3.2. Vacuum Valves Test Procedure

1) DUPLEX is adjusted automatically
2) Max. paper width is adjusted
3) Initialisation of the valves
4) Test run valve REAR is started
5) Test run valve FRONT is started
6) Previous adjustment DUPLEX/SIMPLEX is adjusted again
7) Previous paper width is adjusted again
3.4.3.3. Vacuum Values

The current vacuum values for web A and B are displayed cyclically.
3.4.3.4. Vacuum Valve -> REFPOS

This function serves for testing whether the reference position is reached. For that reason the test
procedure moves the vacuum valves to REFPOS.
3.4.3.5. Vacuum Valves -> MAXPOS

The valve is moved to the position with the maximum vacuum during the calibration procedure (Test
of calibration parameters).
3.4.4. Paper Width Adjustment

Slide FRONT to Refpos
Carry the slide of the paper width adjustment FRONT to the reference position. Possible Results:
Reference position has been reached

No clocks
Motor slugish
Reference sensor has not been reached
Punched tape defective
Motor rotation sense wrong
Both motors or clocks exchanged
Slide REAR to Refpos

Carry the slide of the paper width adjustment REAR to the reference position. Possible Results:
Reference position has been reached

No clocks
Motor slugish
Test: Paper Width Adjustment

First both slides are carried to the reference position and then to the actual paper width defined in
the printer. In simplex-mode the rear slide keeps on the reference position. Possible Results:
Defined paper width reached

No clocks
Motor slugish
Timeout Error, REFPOS has been reached before
No clocks, REFPOS has been reached before
3.4.5. Sensors
3.4.5.1. Clutch
Test for the clutch-sensors (Hall sensor between loop pullers). Possible results:
Loop puller coupled

Loop puller not coupled
3.4.5.2. Paper Rocker

Display of the paper rocker. Possible results:
Paper rocker opened

Paper rocker closed
3.4.5.3. Refpos Vacuum Valves

Display of the reference position of the vacuum valves
3.4.5.4. Analogous Values

Display of the analogous signals of the vacuum sensors FRONT and REAR measured in 0..5 V.
3.4.6. Fuser Roller Speed

Stop and go the fuser roller to standby-speed.
3.5. Character Generator CG1

The revision levels of the character generator boards are read out and displayed.
3.5.2. Elementary Functions

The elementary commands base directly on the individual routines of the hardware control firmware
package. They serve to control simple bit-oriented functions such as poser on / off of the power
supply.
Turning on / off the character generator power supply E35 is performed by the board ZGS**. After
turning on (Power On, K10) 220 V are applied to the input of the power supply; at this point the red
control LEDs for 3.14 V and 5 V must be lit. After some seconds 5 V are turned on via the signal
LOGICON and the green control LED is lit. The 5 V power supply of the character generator is
switched on and off in the preparation phase for positioning the measuring slide. The 5 V supply is
switched on again during the power-on phase of the printer; it is only switched off in case of a hard
error or power off from the operator panel. The driver voltage is switched on at start of print (signal
TREIBERON) and switched off at any stop of print with the signal TREIBEROFF (observe red and
green LEDs). In case of a 3.15 V sensor line break it is not possible to turn on the driver voltage.
3.5.2.1. Power On / Off

Power On
This procedure switches on the supply voltage. The following error code appears in addition to other
standard messages:
0BH: power supply cannot be switched on
0DH: driver voltage cannot be switched on
Power Off
This procedure switches off the supply voltage. The following error code appears in addition to other
standard messages:
0CH: power supply cannot be switched off
0EH: driver voltage cannot be switched off
3.5.2.2. Power Request

The character generator power supply is thermally monitored during operation. The power supply is
switched off in case this thermal control is active. In addition these power supply errors (sensor 3.15
V, internal short circuits or on array) generate the signals PFRLOGIC or PFRTREIBER which can
switch off the power supply too. When falling below the under-voltage limit, the red LEDs are lit.
When exceeding the over-voltage limit, the green LEDs go out and after switching off the
corresponding voltage the red LED is blinking. The 3.15 V power supply is blocked if one of the
monitored limits in the 5 V area is exceeded.
This procedure checks whether the driver voltage of the character generator is switched on. Possible
messages are:
00H: supply voltage switched on
0BH: supply voltage not switched on
0DH: driver supply voltage not switched on
3.5.2.3. Temperature
This procedure transmits temperature values of the 3 sensors on the array. The reported parameters
give the sensor temperature at TEMPSENSE1-H, TEMPSENSE2-H and TEMPSENSE3-H. There is
a linear relation between the two limit values.
00H: corresponds to 10 C
FFH: corresponds to 60 C
3.5.2.4. Slide Position

This procedure checks whether the measuring slide of the character generator has reached its
parking position. Possible messages are:
00H: CG measuring slide end position reached
01H: CG measuring slide end position not reached.

3.5.3.1. Open Cover
This procedure moves the measuring slide into its parking position, where the Selfoc cover is open.
The following error codes may appear in addition to the standard messages:
32H : Slide does not find parking position
33H : Slide does not leave parking position
34H : Slide does not find neither parking position nor end position
3.5.3.2. Close Cover

This procedure moves the measuring slide into the end position and closes the Selfoc cover. The
following error code may appear in addition to the standard messages:
35H : Slide does not find end position
3.5.3.3. Memory Test

This command starts a ZGS** memory test on the board D736. The processor memory, NV RAM
and print data memory (memory 1) are tested. The following error code may appear in addition to
the standard messages:
02H : memory error
3.5.3.4. Read Status

This function serves for displaying the results of the previously performed measuring process.
3.5.3.5. Check
The measuring process serves to gather the brightness values of all LEDs of the character
generator. For this measurement, the following prerequisites have to be fulfilled:
1) The new functions are only implemented from a firmware level of the D736 equal or larger than
11. It has to be read out before calling the measuring process by way of the menu item "read
revision level".
2) The new functions are only performed for character generators without movable cover and with
measuring carriage (refer to configuration bytes).
3) Before starting the measuring process, the LED array has to be cleaned by using the SELFOC
cleaning unit.
This function starts all processes necessary for the gathering of the measuring value in the character
generator (e.g. complete initialisation of the character generator). The following analysis of the LED
array produces as result either 'test successful' or an explaining error message (severe errors or
functional disorders). The measuring process may last up to 3 minutes!
Measuring Results
Mean value of brightness in delivery condition (HS)
Current mean value of brightness (HA)
Resolution of character generator:
0 - 600 dpi
1 - 240 dpi
2 - 300 dpi
Number of LED arrays: 72 at 240 dpi, 84 at 300 dpi, 600 dpi
Number of LEDs which exceed the tolerance range of 25% by HA or which are saturated
Number of LEDs with total failure or in saturation range
Number of neighbouring LED pairs which differ by more than 25 % from the HA or are saturated
Severe Errors
If one of the status codes 21H to 24H occurs, the tested character generator has to be replaced. In
case of the error message 25H the correction value EPROM of the LED array has to be exchanged.
Status code
21H: Current mean value of the LED brightness HA differs by more than 25 % from the mean
value at delivery of the character generator HS.
22H: Too many LEDs exceed the tolerance range of 25% by HA or are saturated.
23H: Total failure of one or several LEDs resp. LED arrays or one or several LEDs are saturated.
24H: The brightness of one or several neighbouring LED pairs differs by more than 25 % from HA
or the LED pairs are saturated.
25H: The check sum of correction value EPROM is wrong.
Functional Disorders
These acknowledgements are codes of errors which have occurred due to functional errors during a
measuring process. After a reset of the character generator the printer is still serviceable. In this
case, the character generator has only to be replaced if bad printing quality is caused by the
character generator.
Code
Description
Possible cause
0BH:
ZG power supply (logic) is not switched on
0CH:
ZG power supply (logic) is not switched off
0DH:
ZG power supply (driver) is not switched on
0EH:
ZG power supply (driver) is not switched off
31H:
Hardware error of controller PC assy
32H-34H: carriage does not find garage
33H:
carriage does not leave garage
36H:
No LED on the first two LED arrays lights up
37H:
Sensor finds threshold value before or behind the first
40H:
Sensor finds threshold value in garage

cable
41H:
ZG power supply (logic) has failed
42H:
ZG power supply (driver) has failed
43H:
first LED not found
46H:
foreign light at end of array
73H:
measuring carriage too slow
74H:
foreign light incidence
75H:
measuring carriage too fast
76H:
ZG synchronisation error
78H: mains frequency exceeds tolerance range
B1-B8H: Hardware error PC assy
FFH:
test cannot be carried out
PC assy, power supply, cable

PC assy
D582, sensor, PC assy, cable
two LED array
D582, PC assy, sensor,
foreign light, cable
D582, PC assy, sensor, foreign light,

D582,PC assy, cable
foreign light, D582, sensor
foreign light
PC assy, char. gen.,
main supply, PC assy, power supply,cable,
PC assy
3.5.3.6. Reset
All error messages in the character generator controller are reset, the measuring carriage is moved
form the active range of the character generator into garage position and the logic and driver
voltages are switched off.
After calling this function, the printer can also continue printing if the measuring process was
terminated with an error message. If the measuring carriage does not move any longer due to a
mechanical defect in the measuring carriage drive or due to a failure of a component on the PC assy
or the power supply, error 32H is set. In this case - after unsuccessful repetition of the command one of the following components has to be replaced in the sequence listed below:
1) PC assy.
2) power supply
3) LED array
WARNING: Wait up to 1 minute for the acknowledgement. If no acknowledgement is given due to
disturbances in the communication lines, the printer should be switched on and off again.
3.5.3.7. Reading Data
The number of LED failures per LED-Chip is read out.
3.5.3.8. Alignment
At the time function not supported by the firmware.
3.6. Character Generator CG2

Here, the configuration data, revision levels and the order name for the character generator
controller (PC assy D933) and the LED-PAC-PC assy are read out. The field STATUS gives
information about the process of the test.
The configuration data are
- the serial number of the character generator
- the resolution of the character generator (600 dpi, 300 dpi, 240 dpi)
- the wavelength of the LEDs (665 nm, 740 nm);
- the max. print width (FF/ED1, CS)
The revision levels and the order name (PC assy D933) are
- Hardware revision level (0..255)
- Software revision level (0..255)
- the PC assy name e.g. S26312-D933-V100
The revision levels and the order name (LED-PAC PC assy) are
- Hardware revision level (0..255)
- Software revision level (0..255)
- the PC assy name e.g.S26312-D931-V1
3.6.2. Driver Supply Voltage

Power On
This procedure turns on the driver supply voltage. The following error code may appear:
0DH: driver voltage cannot be switched on
Power Off
This procedure switches off the driver supply voltage. The following error code may appear:
0EH: driver voltage cannot be switched off
3.6.3. Power Request

This procedure checks if the supply voltage of the character generator is switched on. Possible
messages are:
00H: supply voltage switched off
0BH: logic supply voltage is switched on
0DH: LED driver supply voltage is switched on
0FH: power pack without supply voltage (K10 deactivated ?)
3.6.4. Temperature
This procedure transmits temperature values of the 3 sensors on the array.
3.6.5. Measuring Slide Position

This procedure checks whether the measuring slide of the character generator has reached its
parking position. Possible messages are:
00H: CG measuring slide end position reached
01H: CG measuring slide end position not reached.
3.6.6. Controller Test

This command starts the selftest of the PC assy D933. In this process the VILED adjustment and the
temperature measurement are checked. The error return codes will be defined later.
Maximum waiting period: 10 s
3.6.7. Cleaning SELFOC Cover

The measuring slide is moved from the garage position to the character generator end and moved
back. By the movement of the foam fixed to the measuring slide the SELFOC optics are cleaned.
Max. execution period: 130 s. The result of the cleaning process is reported from the cyclical
STATUS request. Possible message from STATUS:
00H : Cleaning process carried out correctly
3.6.8. Measuring Slide -> Garage Position

The measuring slide is moved to the garage position. Max. execution period: 90 s. The result of the
process is reported from the cyclical STATUS request. Possible message from STATUS:
32H : Measuring slide cannot find garage position
33H : Measuring slide cannot leave garage position
3.6.9. Slide -> CG End

The slide is driven to character generator end opposite the plugs. The state of the positioning is
reported by the cyclical STATUS-Request. Max. execution time: 90 sec.
3.6.10. Foreign Light Check

The light is measured at 3 positions:
1) above the first LED of the bar (unit side)
2) in the middle of the bar
3) above the last LED of the bar (user side)
Max. execution period: 120 s. The result of the process is reported from the cyclical STATUS
request. Possible message from STATUS:
00H :
74H :
75H :
76H :
02H :
No incidence of foreign light

Incidence of foreign light on unit side
Incidence of foreign light on user side
Incidence of foreign light on both sides (or in the middle)
no result
3.6.11. Starting Measuring Routine

The character generator is initialised and the measuring process is started. The measuring process
may be stopped by executing the RESET command. Before the measuring process starts the Lvalues are loaded into the character generator from the KL-file again. Max. execution period: 7 min.
The result is reported by the cyclical STATUS command.
Test Results of Measuring Process
- Mean value of brightness in delivery condition (HS)
- Current mean value of brightness (HA)
- Resolution of character generator: 600 dpi, 240 dpi and 300 dpi
- Number of LED arrays: 76 at 240 dpi, 96 at 300 dpi, 600 dpi
- Number of LEDs which exceed the tolerance range of 5% by HA or which are saturated
- Number of LEDs with total failure or in saturation range
- Number of neighbouring LED pairs which differ by more than 25 % from the HA or are saturated
Using the STATUS command the following codes may be reported:
00H:
01H:
21H:
22H:
23H:
24H:
26H:
27H:
Character generator data are already correct. No alignment occurred.

Alignment concluded successfully.
Current mean value of the LED brightness HA differs by more than 5 % from the mean value
at delivery of the character generator HS.
Too many LEDs exceed the tolerance range of 5 % by HA or are saturated.
Total failure of one or several LEDs resp. LED arrays or one or several LEDs are saturated.
The brightness of one or several neighboring LED pairs differs by more than 25 % from HA
or the LED pairs are saturated.
Brightest LED above tolerance limit (warning)
Darkest LED below tolerance limit (warning)
The error messages 21H..24H are arranged in ascending priority. Only the error with the highest
priority is reported.
If one of the status codes 21H to 24H occurs, the technical expert has to start an alignment.
Functional Errors
measuring process. In this case, the character generator has to be reset.
Code
0BH:
0CH:
0DH:
0EH:
31H:
32H,
34H:
33H:
41H:
42H:
43H:
74H:
75H:
76H:
86H:
87H:
88H:
90H:
Description
Possible cause
PC assy
carriage does not find garage

first LED not found
foreign light on unit side
foreign light on user side
foreign light on both sides
L-loading error (LED-PAC error)
LED-PAC init error
measuring process error
measuring process aborted

D582,PC assy, cable
foreign light
3.6.12. Alignment
The character generator is initialised and the alignment is started. Depending on the result of the
first measuring process new correction values are calculated, loaded into the character generator
and the measuring process is started again until all measuring values are inside 3% of the nominal
data or the maximum number of iterations was reached. Max. execution period: 30 min. The result is
reported by the cyclical STATUS command.
Messages:
00H: command executed
FDH: command not practicable, no measuring slide
Using the STATUS command the following codes may be reported:
00H:
01H:
21H:
22H:
23H:
24H:
26H:
27H:
Character generator data are already correct. No alignment occurred.

Alignment concluded successfully.
Current mean value of the LED brightness HA differs by more than 5 % from the mean
value at delivery of the character generator HS.
Too many LEDs exceed the tolerance range of 25% by HA or are saturated.
Total failure of one or several LEDs resp. LED arrays or one or several LEDs are saturated.
The brightness of one or several neighbouring LED pairs differs by more
than 25 % from HA or the LED pairs are saturated.
Brightest LED above tolerance limit (warning)
Darkest LED below tolerance limit (warning)
The error messages 21H..24H are arranged in ascending priority. Only the error with the highest
priority is reported.
If one of the status codes 21H to 24H occurs, the technical expert has to start an alignment.
Functional Errors
measuring process. In this case, the character generator has to be reset.
Code
0BH:
0CH:
0DH:
0EH:
31H:
32H,
34H:
33H:
41H:
42H:
43H:
74H:
75H:
76H:
86H:
87H:
88H:
90H:
Description
Possible cause
PC assy
carriage does not find garage

first LED not found
foreign light on unit side
foreign light on user side
foreign light on both sides
L-loading error (LED-PAC error)
LED-PAC init error
measuring process error
measuring process aborted

D582,PC assy, cable
foreign light
3.6.13. Reading Data

Here the number of total failures of the LEDs in the individual LED array is indicated. Altogether 96
values may be read out (96 with 300/600 dpi, 76 with 240 dpi). Max. waiting period: 8 s
3.6.14. Reset
All error messages in the character generator controller are reset, the measuring carriage is moved
into garage position and the driver voltages are switched off. If RESET is called while a measuring
process or an alignment is running, these processes are stopped. The printer is ready for operation
even if the measuring process was terminated with an error message. The KL-file created before
calling the alignment process is used. Max. execution period: 90 s
The result of the process is reported from the cyclical STATUS request.
Possible message from STATUS:
00H : Character generator is reset
32H : Measuring slide cannot find garage position
3.6.15. Status
This function reports the current test condition as well as the results of the tests for cleaning the
SELFOC, measuring slide -> garage, measuring process, alignment, unexpected light test and
RESET.
3.7. Post-Print Processing Type-1

Here, the output signals (from the printer to the additional device) and the input signals (from the
additional device to the printer) of the PC board assy D909 can be read out. The signals can be set
or reset too.
3.7.1. Output Signals

The output signals (signals from printer) can be set and reset.
ADMOB-P:
HIGH: backward paper movement, with ADVANCE REVERSE or retraction in case of print stop.
LOW: forward paper movement or printer standstill.
BLOWERON-P:
HIGH: vacuum fan is switched on in the printer. Paper advance is started approximately 5 sec.
after the signal is set. After a print stop the signals stays active for approx. 5 sec.
Exception: If the printer requires more than 10 sec. to build a page, the signal is set inactive without
causing a printout.
RELFORM-H:
HIGH:
the printer has released the last page of the stack. The additional device can
be operated as long as paper is available.
FORMSEJECT-H:
HIGH:
paper advance with correct forms position caused by:
actuation of EJECT or NPRO on printer operator panel
low signal from additional device at input ADEJECT.
automatic PAPEREJECT at paper end.
3.7.2. Input Signals

Signals from Additional Device
ADEVPEJECT-N:
LOW:
When this signal is active (low), the printer advances paper in correct forms
position. Signal FEJECT is returned within this period (high)
ADEVRDY-N:
LOW:
additional device is ready for operation.
HIGH: error occurred at additional device. The printer stops with correct forms position and the
error message '42.00 BURSTER INOP' is displayed on the operator panel. To make the
device ready for operation again, first eliminate the error on the additional device and then
press READY at the operator panel.
ADEVCONN-N:
LOW:
an additional device is connected to the printer. The stacker of the printer moves to the top
position; 'FOLD ERROR' detection and paddle wheels are out of order.
Exception: When the printer is turned on with a connected post-print processing interface
(ADCONN-L = low), the stacker moves downwards by approx. 2 cm during the search routine and
then moves back to the top position. During this stacker movement the paddle wheels are actuated
too. If the stacker is moved into the top position manually, the 'FOLD ERROR' detection and the
paddle wheels are active again and work as usual.
ADEVSTOP-N:
LOW:
the printer stops with correct forms position, however it stays ready for operation. The
message 'ADEVSTOP' is displayed and the SEQUENCE LED is lit.
HIGH: the printing process is continued automatically.
3.8. Post-Print Processing Type-2

3.8.1. Revision Level
Here, the revision levels of the Type-II interface PC assy D827 / D889 may be read out.
3.8.2. Memory Test

A test pattern is written into the memory of the PCB. By verifying the memory the test results in a
statement, whether the memory is ok or not. The complete test runs about 2 minutes. During the test
the refresh of the memory and HSCX interface is still working. No inputs from a V24-terminal are
handled.
3.8.3. Controller Interface Test

To execute this test, the connection between controller and Type2 PCB has to be removed and the
connection to the test-board has to be installed. Output signals and input signals (only the control
signals) of the controller interface are connected on the test-board. As an effect of sending data to
the controller, the D827 / D889 writes data into its own FIFO. If the control signals of the FIFO work
correctly the test is passed, otherwise it failed.
3.8.4. Type-2 Interface Test

To execute this test, the connection between Type2 PCB and the additional device has to be
removed and the connection to the test-board has to be installed. The output signals (no data lines)
of the D827 / D889 are connected to the input signals on the test board. Changes on the output lines
will result in a change on the input lines. If all changes result in an equivalent change on the
corresponding input signal, the test passes, otherwise it fails.

LPM For Windows: Diagnosis Tool For Pagestream Printer

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LPM For Windows: Diagnosis Tool For Pagestream Printer

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LPM for Windows

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Diagnosis Tool for Pagestream Printer

Users Guide PS 210 (ED1) Printer Module

Printer Maintenance for OPS Printer

Last Change: tt.01.jj

Users Guide PS 210 (ED1) Printer Module

3.4.6. Fuser Roller Speed........................................................................................................... 59

diagnosis (all functions) for the

LPMW is useful for

Remote Printer diagnosis

Users Guide PS 210 (ED1) Printer Module

Silent trace: start, stop and transmit

Retrieve printer parameters, e.g. serial number, controller type,

Check and test functions:

Read and display state of sensors and switches (part. dynamically)

Switch motors, drives, heating and other devices

Read out error bytes (detailed error information of pcbs)

Start complex test functions

ITF basic functions: start, stop, trace param., printer config.

Powerful terminal emulation

Online help, notebook function

Complete trouble shooting guide

Menus for managing com ports and modems

Customer / Dial data base

REDUCTION OF DOWN TIMES by

MANAGEMENT OF PRINTER CONFIGURATION

1.1. Documentations overview

1.1.1. Printed manual Online help

Please use the online help instead of the

1.1.2. File name conventions

Users Guide PS 210 (ED1) Printer Module

1.2. Safety Regulations

1.2.1.2. Operating the Printing System

Observe the safety instructions given in the manual for:

Handling the photoconductor drum

Keep all consumables and parts out of reach of children.

If your printing system has a beam waveguide connection:

1.2.1.3. Assembly and Installation of the Printing System

The printing system may only be installed by service personnel.

Users Guide PS 210 (ED1) Printer Module

Point to observe when disposing of a photoconductor drum:

Before touching the drum, always put on the gloves provided.

1.3. Statutory Requirements

Failure to observe the operating manual

Users Guide PS 210 (ED1) Printer Module is an internal diagnosis tool of

We w ish you w ell in you r w o rk w ith L P M W.

Users Guide PS 210 (ED1) Printer Module

Reading Printer Definitions

Users Guide PS 210 (ED1) Printer Module

2.3. Error Messages

2.3.2. Suppressing Error Messages

this error message can not be suppressed for reason of security

2.4. Operator Panel Menu

2.4.1.2. Page Length

2.4.1.3. Paper Width

2.4.1.4. Fuser Oil

Users Guide PS 210 (ED1) Printer Module

2.4.1.5. Fuser Temperature

2.4.1.7. Paper Cooling

2.4.1.8. Paper Brake

PEL (240 dpi)

PEL (300 dpi)