Max Setup Routines DC 250F

2008 Seminar
 Max Setup Routines DC 250
• IOT Baseline

dC924 TRC Adjust

dC950 ATC Sensor Setup

dC937 ProCon

• IOT Situational

dC991 Tone Up / Tone Down

dC931 Manual In/Out Setup

dC924 TRC Adjust

• IIT Situational

dC919 Copy Mode Color Balance Adjustment

dC945 CCD Calibration

dC 924 TRC Adjustment

2008 Seminar
 Max Set Up
• Max Set Up should only be performed when directed
to do so in the Service Manual
• Process Control adjusts Bias voltage, Laser Diode
Power, and Grid/BCR Voltage automatically to maintain
density.
• Process Control maintains Toner Concentration
automatically, to maintain density. It uses the ATC
Sensor and Pixel count to the determine dispense time
needed to attain the target TC.
• Most of the procedures, in Max Set Up, only measure
parameters of process control but do nothing to effect
it. They can be used as a troubleshooting tool but not as
a adjustment to correct Image Quality
10/9/2008 2008 Seminar 3
 Entering Diagnostics

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 dC924 TRC Adjust
TRC Adjust

LOW MEDIUM HIGH

Y 0 0 0

M 0 0 0

C 0 0 0

K 0 0 0

• If the machine is functioning correctly, and the customer does not like the way
Process Control sets up density, you can use dC924 to adjust density levels to
satisfy the customer.
• TRC (Tone Reproduction Curve) Adjust is used to adjust image density as desired by
adjusting the center value of tone correction in the range of low/mid/high density for each
Y, M, C and K.
• The Default value (Mid Range) is 0. By adjusting TRC you will affect both prints and
copies.
• This should only be used, as a last resort, if the customer is complaining of color
densities of both prints and copies. These values should always be returned to 0
when baselining the machine (performing max setup and/or calibration)

10/9/2008 2008 Seminar 7

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 dC950 ATC Sensor Set Up
ATC Sensor Set up

Y M C K

Bar Code Number 65 67 54 55

Correction Coefficient 1024 914 1089 1024

Correction Offset -6 69 -44 0

• The ATC sensor calibration value (sensor gain) is printed on each sensor, and must
be entered whenever a Developer Housing or ATC sensor is replaced This is
accomplished by doing adjustment 9.2 ATC Sensor Set Up (DC 950).
• Locate the ATC Sensor calibration code on the ATC Sensor. This is the 3-digit number in
the 3rd line of text on the label (it will always start with a zero).
• Enter the last 2 digits of this code into the appropriate column of the first row.
• After the routine is completed the Correction Coefficient, and Correction Offset will be
calculated and displayed in the appropriate boxes.
• This procedure must be performed in order for the ATC Sensor to function accurately.
• When Performing this adjustment using the UI make sure you press the Green Start
button on the UI to execute the routine.

10/9/2008 2008 Seminar 9

 dC950 ATC Sensor Set Up
ATC Sensor Set up

Y M C K

Bar Code Number 55 55 55 55

Correction Coefficient 1024 1024 1024 1024

Correction Offset 0 0 0 0

• If all the bar code numbers are at 55, they are at default. You must input in the
ATC Sensor Calibration Value (sensor gain) that is printed on each sensor
• This could occur if the CSE did an IOT initialization without doing a save and
restore.
• With this set up the sensors would not function accurately.
• If the original ATC sensors are in the machine use the ATC Sensor Bar Codes
listed on the factory sheets located in tray 1.

10/9/2008 2008 Seminar 10

 dC 937 ProCon Table

10/9/2008 2008 Seminar 11

 ProCon dC 937
ProCon Values
• ADC
• Grid Voltage Setting
• LD Power
• Bias Setting
• ATC
Procon Judgments
• ADC Patch Fail
• ADC Minisetup Fail
• ATC Average Fail
• AYC Amplitude Fail
Procon Status
• ADC Shutter Open
• ADC Shutter Closed
• ADC Sensor Fail
• Temperature Fail
• Humidity Fail

2008 Seminar
 Procon
• There are no adjustments in ProCon, it is a
measurement tool only
• It should be used to evaluate how the machine thinks it is
performing
• It will also monitor different functions of Process Control
and render judgments if they functioning correctly or not.
• Running this procedure will have the same effect on
Image Quality as the when the machine runs a Mini Set
up.
• Again you have no input it is strictly a measurement tool

10/9/2008 2008 Seminar 13

 ADC Target H / Measure ADC H ProCon On
Y M C K
ADC Target H 320 270 260 220

Measure ADC H 317 259 263 219

• ADC H is used to measure the densities of high area coverage patches (50% for K 75% for CMY).
• ADC Target H is the adjusted target at which the machine should run to maintain correct Image
Density for “High Area” coverage. These Targets are effected by HFSI life and other factors like
Temperature and Humidity.
• Measure ADC H for all colors is the calculated density measurement for High Area patches (2) for
that color. The lower the value the darker the patch the higher the value the lighter the patch.
• The result of ADC H Measure should be within +25 bits of the target value CMY and +50 bits for K
• Things to look for if the ADC H Measure value is not within + 25 Bits CMY or + 50 bits K of the ADC
Target H value
• If Mid/Hi density of copies/prints is acceptable do nothing
• If Mid/Hi density of copies/prints is not acceptable check how ATC is functioning. If ATC is good
go to next step. If ATC is out troubleshoot the Dispense and Development system
• If Mid/Hi density of copies/prints is not acceptable and ATC is good suspect the Xero CRU,
MOB Sensor Assembly, IBT Belt, contacts of the flat cables on the MCU to IOT PWB’s, ROS
LD, MCU PWB, HVPS.

10/9/2008 2008 Seminar 14

 ADC Target L / Measure ADC L ProCon On
Y M C K
ADC Target L 957 941 946 888

Measure ADC L 954 944 940 894

• ADC L is used to measure the densities of Low Area coverage patches (18% CMYK).
• ADC Target L is the adjusted target at which the machine should run to maintain correct Image
Density for “Low Area” coverage. These targets are effected by HFSI life and other factors like
Temperature and Humidity.
• Measure ADC L for all colors is the calculated density measurement for the Light Area patch for
that color. The lower the value the darker the patch the higher the value the lighter the patch.
• The result of ADC L Measure should be within +25 bits of the target value CMY and +50 bits for K
• Things to look for if the ADC L Measure value is not within + 25 Bits CMY or + 50 bits K of the
ADC Target L value
• If Low Density of copies/prints is acceptable do nothing
• If Low density of copies/prints is not acceptable check how ATC is functioning. If ATC is
good go to next step. If ATC is out troubleshoot Dispense and Development system
• If Low density of copies/prints is not acceptable and ATC is good suspect the Xero CRU,
MOB Sensor Assembly, IBT Belt, contacts of the flat cables on the MCU to IOT PWB’s, ROS
LD, MCU PWB, HVPS.

10/9/2008 2008 Seminar 15

 Grid, LD, Bias Settings ProCon On
Y M C K
Grid Voltage Settings 613 518 522 730

LD Power 353 360 350 500

Bias Settings 499 409 407 608

• These are the three parameters the machine use/adjusts to achieve the ADC H Target. They are
adjusted by process control, there are no manual adjustment procedures. They are used to
control image density.
• Grid Voltage
• Grid Voltage Setting is the Bias setting the machine is using to achieve the ADC H target value
• Grid voltage will change as needed to develop a good ADC H patch.
• For K, Grid Voltage is scorotron voltage, for CMY Grid Voltage is Bias Roll Voltage.
• LD Power
• LD Power is the Laser Diode setting the machine is using to achieve the ADC H target value
• LD will change as needed to develop a good ADC H patch.
• Bias Settings
• Bias Setting is the Developer Bias voltage the machine is using to achieve the ADC H target value
• Bias Setting will change as needed to develop a good ADC H patch.
10/9/2008 2008 Seminar 16
 ADC Min 1 ADC Min 2 ProCon On
Y M C K
Measurement of ADC 269 103 106 201
Min 1
Measurement of ADC 328 289 268 326
Min 2

• Used to extrapolate the value for ADC H by measuring two patches Min 1 and
Min 2
• ADC Min 1 must be at least 10 bits lower (darker) then Min 2 (normally lower by
50 bits or more). If the difference is less then 10 bits the setup will fail (ADC
Minisetup Fail)
• ADC H will normally fall between Min 1 and Min 2 on a new machine with new
IBT, Drum, and Developer. If it does not and Mid/Hi density is acceptable there
is no problem.
• Min 1 and Min 2 are also used to calculate LD Power, Grid Voltage, and Bias
voltage (See diagram next slide)

10/9/2008 2008 Seminar 17

 Process Control Setup
MINISETUP
RADC value Electric potential (VH, BIAS, VL)

ADC_Mini2 Patch ADC_Mini1 Patch

Grid
volt.
Grid BC (large)
Grid BC (small)

Bias
Bias Large volt.

Bias (small)
RADC_Mini2

RADC_Target RADC

RADC_Mini1 LD (small)

LD

LD- LD_OUT LD_OUT_ LD_

_Mini_Limit _Mini2 LD_OUT Mini1 _ Max_Limit
_PCON
LD LD value LD (large)
(small)

10/9/2008 2008 Seminar 18

 ATC ProCon On
Y M C K
ATC Target 682 662 662 675

Measured ATC Ave 668 657 662 687

Measured ATC Amp 151 124 115 105

• ATC Target is the adjusted target. It is determined by adjusting the standard ATC Target in NVM,
using a sampling of the following: Temperature, Humidity, Developer Life.
• Measured ATC Ave is the actual measured average of several samplings of the ATC sensor. The
lower the value the higher the Toner Concentration. ATC measure should be within + 25 bits of the
ATC Target
• If the difference between the ATC Target and the Measured ATC Ave is greater then + 25 bits run 50
to 100 copies of your standard test pattern. This should stabilize your system and bring the numbers
to within the 25 bit range.
• Things to check if your ATC values continue to drift off and result in CQ problems: Dispenser assy,
Toner Cartridge, Low Toner Sensor, ATC Sensor Set Up not performed, ATC Sensor, Developer
housing

10/9/2008 2008 Seminar 19

 ATC ProCon On continued
• Measured ATC Amp is the difference between the High point and the low point
of the toner/developer wave created by the developer auger. The auger moves
the developer in a wave pattern. The ATC sensor measures the high point and
the low point of the wave and calculates the width. The readings represent a
direct reading of the waves of developer material produced by the augers.
 The readings should be between 80 and 300 but typically average 80 to
150.
 A new developer installed may result in a value in the range of 50 ~ 100.
As the amount of material diminishes over time, the number will increase
(i.e. possible range 150 ~300). This is based on the reading of the
developer material augured within the housing. As the developer material
depletes, the readings will drop back to a lower number (i.e. 0- 50), which
indicates the developer material needs to be replaced.

10/9/2008 2008 Seminar 20

 Procon On Judgments
Y M C K
ADC Patch Fail OK OK OK OK

ADC Minisetup Fail OK OK OK OK

ATC Average Fail OK OK OK OK

ATC Amplitude Fail OK OK OK OK

• ADC Patch Fail - The measured ADC Patch density is light (Over 75% of Vclean). Vclean is the bear
IBT belt reading by the ADC Sensor. If this is NG go to the 92-652 RAP in your service
documentation
• ADC Minisetup Fail - The two levels of ADC Patch density created in Mini-Setup: high (LD_OUT+60)
and low (LD_OUT-60) are reversed. If this is NG go to the 92-663 RAP in your service documentation
• ATC Average Fail – The output from the ATC sensor was not detected. If NG go to RAP’s 92-653 (Y),
92-654 (M), 92-655 (C), or 92-656 (K) in your service documentation
• ATC Amplitude Fail – the amplitude value is smaller then 10 bits. If NG go to RAP’s 92-657 (Y), 92-
658 (M), 92-659 (C), or the 92-660 (K) in your service documentation

10/9/2008 2008 Seminar 21

 Procon Status
ProCon Status
• ADC Shutter Open - The MOB ADC Shutter remains open
ADC Shutter Open OK due to Shutter failure If NG go the 92-649 RAP
• ADC Shutter Closed - The MOB ADC Shutter remains
ADC Shutter Closed OK closed due to shutter failure. If NG go the 92-650 RAP
• ADC Sensor Fail - The output read by ADC Sensor from
ADC Sensor Fail OK
the clean Photoreceptor surface is out of range (100~1000)
(in Mini-Setup). If NG go to the 92-651 RAP
Temperature 26
• Temperature Fail- The temperature output of the
Humidity/Temperature Sensor was not in the appropriate
Humidity 12
range. If NG go to the 92-661 RAP

Temperature Fail OK • Humidity Fail - The humidity output of the

Humidity/Temperature Sensor was not in the appropriate
range. If NG go to the 92-662 RAP
Humidity Fail OK
• Temperature / Humidity – measurement value of
temperature and measurement value of humidity taken by
the Temperature/Humidity sensor.

10/9/2008 2008 Seminar 22

 Procon Off
• Procon “Off” Print performs a mini setup similar to Procon “On” Print, but
does not use the output of the ADC H patch to determine Charge Voltage
Settings, LD Power, and Bias Setting.

These values are chosen in a Look Up Table (LUT) based on drum and developer
life.
Note: In this case, Y, M, C drum life are equal so LUT values are equal. Measured


ADC H is not as close to the ADC H Target when LUT values are used.
• Key Point. If troubleshooting a density problem, Visually inspect output of
Procon “On” and Procon “Off” Print.

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

If the Procon “On” Print and the Procon “Off” Print have a density problem, then it is
best to troubleshoot the image path (transfer, developers, ROS, MCU PWBA,
harnessing, DFE)
10/9/2008 2008 Seminar 23
 Procon Off
Procon “On” Print Procon “Off” Print
(Y) (M) (C) (K) (Y) (M) (C) (K)
ADC Target H 350 300 310 270 350 300 310 270

Measured ADC H 354 300 299 277 292 266 272 310

Measured ADC Min1 224 205 216 258 227 214 206 260

Measured ADC Min 2 356 339 356 364 364 347 344 363

ADC Target L 957 941 946 888 957 941 946 888

Measured ADC Target L 964 941 942 894 955 933 940 920

ADC Patch Fail OK OK OK OK OK OK OK OK

ADC Shutter Open Fail OK - - - OK - - -

ADC shutter close Fail OK - - - OK - - -

ADC sensor Fail OK - - - OK - - -

ADC MiniSetup Fail OK OK OK OK OK OK OK OK

Charge Voltage Settings 557 585 590 703 610 610 610 660

LD Power 440 472 477 532 499 499 499 480

Bias Setting 442 463 467 587 482 482 482 555

ATC Target 643 623 623 668 643 623 623 668

Measured ATC Average 650 629 631 686 650 629 634 688

Measured ATC Amplitude 102 92 93 126 104 92 89 129

ATC Average Fail OK OK OK OK OK OK OK OK

ATC Amplitude Fail OK OK OK OK OK OK OK OK

Temperature 28 - - - 28 - - -

Humidity 15 - - - 15 - - -

Temperature Fail OK - - - OK - - -

Humidity Fail OK - - - OK - - -

10/9/2008 2008 Seminar 24

10/9/2008 2008 Seminar 25
 dC991 Tone Up Tone Down
Tone Up/Down

Y M C K

No. of Cycles 0 0 0 0

ATC Target 682 662 662 675

ATC Measure 668 657 662 687

• This procedure compares measured toner concentration against a target, and allows manual
adjustment of TC.
• ATC Target is the adjusted target. It is determined by adjusting the standard ATC Target in NVM using
Temperature/Humidity values, and Developer Life.
• Measured ATC Ave is the actual measured average of several samplings of the ATC sensor. The lower
the value the higher the Toner Concentration, the higher the number the lower the toner concentration.
ATC measure should be within + 25 bits of the ATC Target
• For each color that is above or below target, enter a value between -99 and 99 into the top row. This
value is the number of tone up or tone down cycles to be performed. Negative values increase the ATC
Measured Value (less toner concentration); positive values decrease ATC Measured Value (more
Toner Concentration).
• Repeat as required until ATC Measured Value matches ATC Target.
• A more preferred way to stabilize TC would be to run 50 to 100 copies of your standard test pattern
82E13120.
• Things to check if your ATC values continue to drift off and cause CQ problems: Dispenser assy, Toner
Cartridge, Low Toner Sensor, ATC Sensor Set Up not performed, ATC Sensor, Developer housing

10/9/2008 2008 Seminar 26

10/9/2008 2008 Seminar 27
 Manual In/Out Set up

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

• The ROS Driver PWB does not have the range to adjust the laser to
compensate for machine shortfalls or component aging
• Performing these adjustments from -256 to +256 will result in about .02
dU change.
• If In/Out density is a problem suspect the 2nd BTR, 1st BTR’s, XCRU’s, IBT
Belt or Assembly, Developer assemblies, ROS assemblies, MCU PWB.

10/9/2008 2008 Seminar 28

10/9/2008 2008 Seminar 29
 dC919 Copy Mode Color Balance Adjustment
Color Adjustment

Y M C K

Low Density 0 0 0 0

Medium Density 0 0 0 0

High Density 0 0 0 0

• Changes made in the dC919 Adjustment will effect the copy mode only.
• This is a fine adjustment for very hard to please customers.
• You can adjust the center set point + 4 steps with 0 being the default number. If you increase the value
you will cause that color to be darker. If you decrease the value you will cause that color to be lighter.
• The customer has a coarse adjustment for Color Balance on the image quality tab. There are + 3 steps
in the course adjustment.
• dC919 should be used as follows: The customer complains that his output is too light for a certain color.
The customer then selects the Image Quality tab and adjusts color balance for that color. He selects +2
and The color is too light. He then selects +3 and that is too dark. DC919 will allow the CSE to fine
adjust this color by changing the fine adjust center point until the customer is satisfied.
• So, Image Quality Color Balance on the UI is a Coarse Adjustment, CSE Diagnostic Color Balance is a
Fine Adjustment. Again, this would only be used for very hard to please customers.

10/9/2008 2008 Seminar 30

10/9/2008 2008 Seminar 31
 dC945 CCD Calibration

• dC945 is three separate routines

 White Reference
 CCD Calibration – Reflection Ratio and B* Calibration
Coefficients
 Optical Axis Calibration
• This routine should only be run after replacing a CCD
PWB, Lens Pan Assy, IIT IPS PWB, or if directed by the
service documentation
• RUNNING THIS ROUTINE WITH INCORRECT PAPER,
OR AN INCORRECT OR DIRTY/DAMAGED TEST
PATTERM CAN ADVERSLY AFFECT IMAGE QUALITY

10/9/2008 2008 Seminar 32

 dC945 CCD Calibration
White Reference values should be 135 + 5 bits
Things to do, check if these readings are off
White Reference • Make sure NVM location 715-106 (paper code) is set to 5 for XC (Digital Color
Xpressions+) or 6 for XE (Color Tech+).
Value • Make sure you use 10 sheets of 11X17 Color Expressions + 98 brightness paper to
perform the setup
Red 137 • Clean both sides of the Document Glass, Document Cover, White Reference Strip,
Reflector, and Mirror.
Green 137
• Clean the Exposure Lamp with a clean cloth and Film Remover.
Blue 136 • Clean the Lens with Lens and Mirror Cleaner and lint free cloth.
• Replace the exposure lamp. Lamp ballast PWB, IIT PWB, and CCD Assy
B&W - X 138 • Note if White reference numbers are off and you do not have color expressions 98 media
input the values on the manufacturing sheets in tray 1 for 715-92 through 715-96
B&W -Y 138
b* Calibration Coefficients – the Patch Measurement
should be within + 10 bits of the Standard Value
Things to do, check if judgment fails
b* Calibration Coefficients • Make sure you have the correct test pattern (82E13120)
and it is clean and free of defects.
PCON SCAN • Make sure the test pattern is positioned with the L.E.
toward the left of the platen glass.
b* Factor Set No. 3 3 • Clean both sides of the Document Glass, Document Cover,
White Reference Strip, Reflector, and Mirror.
b* Patch Measurement 222 219 • Clean the Exposure Lamp with a clean cloth and Film
Remover.
b* Standard Value 225 225 • Clean the Lens with Lens and Mirror Cleaner and lint free
cloth.
b* Judgment OK OK • Replace the exposure lamp. Lamp ballast PWB, IIT PWB,
and CCD Assy
If the standard value is 0 and the judgment fails go to NVM
locations 715-260 and 715-266 and set them both to 225

10/9/2008 2008 Seminar 33

 dC945 CCD Calibration

Reflection Ratio

R G B

Y 46 96 214

M 119 223 195

C 239 170 99

K 237 239 240

• CCD Calibration – Uses the standard test pattern

82E13120 to calibrate the sensitivity of the CCD. It looks
at the 5 squares in the upper center of the test pattern
as a reference to do the calibration.
• Highlighted squares in the above table should be 200 or
higher
• Yellow subtracts Blue (blue 200 or higher)
• Magenta subtracts green (green 200 or higher)
• Cyan subtracts red (red 200 or higher)

Things to do, check if these readings are off

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

10/9/2008 2008 Seminar 34

 dC945 CCD Calibration
Optical Axis Set Values

Degree Marks

Judge 3 3

Front 222 219

Rear 225 225

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

Follow your Service Documentation Adj 5.12 to complete this adjustment

10/9/2008 2008 Seminar 35

 Max Setup Routines DC 250F

Presented by:
Katie Lazarus-Born

Norm Srodawa
Jim Strollo

10/9/2008 2008 Seminar 36