Xerox iGen3 Digital

Production Press
iGen3 Digital Production Press
2.6 Service Update Package

701P46172
Initial Issue
November 2006

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 2.6 Service Update Package

Prepared by: Xerox Global Knowledge and Language Services, 780 Phillips
Road, Webster, New York 14580
© 2001, 2002, 2003, 2004, 2005, 2006 by Xerox Corporation. All rights
reserved.
***Xerox Private Data***
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informational purposes only. Xerox service documentation is intended for use
by certified, product-trained service personnel only. Xerox does not warrant or
represent that it will notify or provide to such customer any future change to
this documentation. Customer performed service of equipment, or modules,
components, or parts of such equipment may affect whether Xerox is
responsible to fix machine defects under the warranty offered by Xerox with
respect to such equipment. Non-Xerox users of this documentation should
consult the applicable warranty for its terms regarding customer or third-party
provided service.
While Xerox has tried to make the documentation accurate, Xerox will have
no liability arising out of any inaccuracies or omissions.
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non-Xerox brands and product names are trademarks or registered
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2 iGen3 Digital Production Press

 Table of contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GSN libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Kit instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Image Quality Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Consistent Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Smoother Halftones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Profiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
200 DPI Halftone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Custom Destination Profiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How Profiling is Different Than Calibrating . . . . . . . . . . . . . . . . . . 13
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Color Check Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Customer Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

EDOC / Service Procedures Updates . . . . . . . . . . . . . . . . . . . . . . . 21

1 Ghz Creo DFE Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
x86 Press Interface Upgrade Requires a New License . . . . . . . . . . . . . . 21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Service impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Table of contents 2.6 Service Update Package

Customer impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Release strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuser 500K HFSI Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Configuring EDOC to Match Machine Configuration . . . . . . . . . . . . . . . . 23
New Banding SIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Hardware / Software Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

x86 Based DocuSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DTP 41 ll USB Cable for PDSi DocuSP . . . . . . . . . . . . . . . . . . . . . . . . 29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Xerox Premium Digital Carbonless Paper . . . . . . . . . . . . . . . . . . . . . . . . 30
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Post Fuser Curl and the Decurlers . . . . . . . . . . . . . . . . . . . . . . . . 30
Additional Cleaning Requirements . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuser Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DocuSP Sample Current Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
New Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tag A-33 Decurler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Service Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Customer Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Release Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4 iGen3 Digital Production Press

 Introduction

Purpose

The purpose of this communication package is to familiarize you

with the changes to the iGen3 software and hardware as well as
the new tools and diagnostic procedures included with the
release of C1.2.6.0.0 (Creo configuration) and C2.2.6.0.0
(DocuSP configuration) iGen3 software.

Organization

This document is organized into 4 major sections:

• Introduction
• Image Quality Update
• EDOC / Service Procedures Updates
• Hardware / Software Changes
Each change that is listed in this document contains a detailed
description and also includes information related to the following
if applicable:
• Service impacts
• Customer impacts
• Release strategy

General Information

This section provides some general information about

communications with field personnel, supporting resources for
the 2.6 configuration, and other important information.

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Introduction 2.6 Service Update Package

GSN libraries

GSN Libraries continue to be a major method for communicating

late breaking important information. The libraries in Table 1.
should be checked often for updated software and kit
instructions, and service communications.

Table 1. GSN Libraries

Number Name Description

4254 XDAT & Engineering Files and information regarding

Tools XDAT and other Engineering
Tools

4265 Retrofit Kits Contains the latest updates

and fixes to retrofit kit
instructions

4268 Finishing Contains the DFA Resource

Guide and other documents
used for DFA enablement

4449 Installation Contains the latest Installation

Manual and Resource Guide
used to install extra Feeders,
Stackers, or an Inserter onto
an existing system

4438 2.6 Service Contains the latest updates

Communication and improvements to the 2.6
Package Service Communication
Package

4438 2.6 Software Kit Contains the latest updates to

Instructions the System Software
Installation Instructions

Kit instructions

We take your feedback seriously. Continuous improvements are

made to both hardware retrofit kit and software installation kit
instructions based on your feedback. Remember that any
amendments or improvements to issued retrofit kit instructions
are available at GSN Library #4265. The latest software kit
instructions will also be available at GSN Library #4438.

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Reference Material

Reference Material

In addition to this change description document, the following

individual documents are provided in the Reference Material
folder on this CD:
• Image Quality Suite for the DocuSP Controller
• 2.6 Customer Expectations Document
Links to this reference material are provided above, as well as
within the body of this change description as required.
If you have any questions related to the technical accuracy of
information presented in this communication package, contact
the Technical Support Center for assistance.

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8 iGen3 Digital Production Press

 Image Quality Update

Overview

The iGen3 2.6 configuration software release was designed to

provide customers with more consistent color, smoother
halftones and better machine to machine color. These goals are
achieved by implementing three specific changes to the machine
software and to customer and service tools.

Consistent Color

To achieve more consistent color, a new customer and service

tool is being introduced, the Color Check Tool (CCT). This tool,
which resides on the DFE, provides an objective pass/fail criteria
for processed color (from the DFE). In lieu of “calibrating” the
DFE on a daily basis, the customer will be requested to run the
CCT instead (or run it prior to starting a color critical job).
Likewise, the service team will run the tool at the end of each
service call to insure the color is within spec. The objectiveness
of the tool’s response will insure the color output is within the
machine specification – if the test “passes” the machine is in
spec and if it “fails” the machine is out of spec. Keeping the
machine in a known color space is critical to the following two
topics.

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Smoother Halftones

Smoother halftones are achieved via a new 200 dpi halftone.

This halftone is in addition to the “old” 200 dpi halftones. The
new halftone requires the use of a custom profile (see next topic)
so it can not be used without “profiling” the machine. When the
Analyst trains the customer on the use of 2.6 software, they will
profile the machine for one of the customer’s media. Without a
profile the new 200 dpi halftone should not be used as the output
will be unpredictable. The “old” 200 dpi halftone and the other
halftones will continue to use the generic color tables provided
with the DFE. These other halftones may be profiled also if the
customer desires.

Profiling

To use the new 200 dpi halftone, the machine must be profiled
for this halftone. A Custom Destination Profile improves color
matching between machines, and improves color quality
throughout the gamut. Custom Destination Profiles uses the
specific machine conditions, halftone selections, and the paper
stock of the press to optimize color performance. Custom
Destination Profiles should only be created on machines at
restore level image quality.
Profiling is a customer/Analyst action; the service team enables
this by ensuring all IQ color parameters meet restore criteria at
the end of this upgrade / install. XPE-IQ-P680 Uniformity
Checkout Procedure and the Color Check Tool will be used to
verify the machine is within color specification. Customer should
be aware that before creating a custom profile, the machine
should be in a state where subsequent maintenance actions will
not change the color performance of the machine. (i.e. All Image
Quality related customer maintenance procedures should be
preformed prior to profiling.

By using all three new features: profiling to create a machine and

media-specific color profile, the new 200 dpi halftone to achieve
smoother gradations and the Color Check Tool to keep the day-
to-day color within the machine’s color specification, the
customer will realize better, more consistent color.
The topics below go into more detail on each of these three new
features.

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200 DPI Halftone

Description

The current 200 dpi Halftone dots may create a “Linen Pattern”,
producing objectionable patterns in some images. The iGen3
Config 2.6 software introduces a new 200 dpi halftone. This new
halftone improves high-frequency moire and general image
smoothness. This new dpi halftone improves the overall
appearance of small and medium sized photos & pictorials (see
sample image below).

Figure 1. Comparing New and Old 200 DPI Halftone pattern

Color differences may be seen when reprinting old 200 dpi jobs
with the new 200 dpi halftone. Legacy jobs using the old 200 dpi
halftones should be re-ripped using the new halftone.

Service Impacts

NVM ID 21890 can be one of three possible values:

• 1 - The "1.9 configuration" 200 halftone dot
• 2 - The nominal (2.0 and greater) 200 halftone dot
• 3 - The 200 halftone dot introduced in the 2.6 configuration
software. To use this dot the machine must be profiled by the
Analyst or Customer.
At the conclusion of the 2.6 Software install (and until the Analyst
and the customer profile the machine), the NVM value will be "2."
(Software Default)
Depending on how the customer is running the machine (profiled
or not profiled or legacy dot) the nvm may be any of the three
values.

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The System Install Instructions will have the CSE record the
value in this NVM location before loading SW to re-enter upon
software load completion to maintain continuity of the Halftone
Dot.
There are no other actions the CSE should be taking with this
NVM location.

Customer Impacts

• Customers may choose between the “old” and the “new” 200
dpi halftone.
• Customer Analysts will work with the customer to help them
decide which 200 dpi halftone is the best for their needs.
• The Customer needs to perform a Custom Destination Profile
for the new 200 dpi halftone.

Release Strategy

2.6 Software

Custom Destination Profiling

Description

A Custom Destination Profile (“Profiling”) improves color

matching between machines and colors throughout the color
gamut. Prior to the 2.6 software release, only Default Destination
Profiles were available for the Press. The default profiles are
generic profiles intended to provide the best color performance
for the average machine. Due to variations in machines and the
lack of unique parameters to define the machine’s output, these
generic profiles do not generally enable machines next to each
other to produce output that looks similar.
Listed below are some examples of iGen3 supplied Destination
Profiles
• XEROX iGen3
• XEROX iGen3 Heavy GCR
• XEROX iGen3 Light GCR

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2.6 Service Update Package Image Quality Update

• XEROX iGen3 Maximum GCR

• XEROX iGen3 Medium GCR
To compensate for machine to machine differences, the Custom
Destination Profile incorporates machine-specific conditions
(e.g. tolerance stack-ups, etc.), the halftone selection and the
media running on the press into the profile, making each profile
unique. Although Custom Destination Profiling is only required
for the new 200 halftone, all halftones may be profiled to achieve
optimal color output. Prior to any custom profiling, the customer
must perform those maintenance procedures indicated to insure
the machine baseline IQ is within restore level.
Although Custom Destination Profiling is only required for the
new 200 halftone, the 175 Halftone, used with the Color Check
Tool, should also be profiled to baseline the 175 halftone color
output. When profiling is performed, all halftones requiring a
profile should be profiled at the same time. Prior to custom
profiling, the customer must perform those maintenance
procedures indicated to insure the machine baseline IQ is within
restore level.
Failure to perform the maintenance action prior to profiling could
result in color output changes with subsequent service actions.

How Profiling is Different Than Calibrating

Calibration corrects color output by measuring a 2 page set of

color targets (Figure 2.). These targets are mainly C, M, Y, K
primaries and neutral patches made up of C, M & Y (no black).
This correction methodology is referred to as a “1D correction”
and does not provide correction for the press’s entire color
gamut as does Custom Destination Profiling.

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Image Quality Update 2.6 Service Update Package

Figure 2. Sample Calibration Target

Profiling takes a much more sophisticated approach, using not

only neutral (C, M & Y) color patch data, but also color data from
throughout the press’s color gamut on a 3 page set of color
targets. (Figure 3.) This correction methodology is referred to as
a “3D correction”.

Figure 3. Sample Profiling Target

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2.6 Service Update Package Image Quality Update

The Custom Destination Profile is unique to the Press specific

conditions, Halftone Dot selection and media type, as any of
these change sufficiently, re-profiling may become necessary.
Continued use of the Color Check Tool will minimize the need for
re-profiling. Profiling is not a substitute for calibration, profiling
compliments calibration. Calibration is still a part of the process
needed to maintain the machine color quality. For those
customers using the Color Check Tool on a once per shift basis,
calibrating on a once per shift basis is no longer required.
Instead, the CCT should be used to insure the machine’s output
is within the known good color space and calibration should only
be performed when required.

Service Impacts

• Profiling is a customer/Analyst action; the service team

enables this by ensuring all IQ color parameters meet restore
criteria at the end of this upgrade / install. XPE-IQ-P680
Uniformity Checkout Procedure and the Color Check Tool will
be used to verify the machine is within color specification.
• Service must ensure the machine passes the CCT whenever
leaving the customer site.
• New RAPS and Procedures:
– XPE-IQ-0095 Color Check RAP
– XPE-IQ-P505 Color Check Tool Procedure
– SCP-06 Final Actions

Customer Impacts

• The customer is responsible for creating their own Custom

Destination Profiles. The analyst will train them on this
process after the machine is upgraded or installed.
• If the customer chooses to use Custom Destination Profiles,
they will use the CCT in place of once-a-day or once-a-shift
calibrations.

Release Strategy

2.6 Software

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Image Quality Update 2.6 Service Update Package

Color Check Tool

Description

Customers have been requesting a method to determine the

amount of color variation they should expect from a well-
maintained iGen3. Prior to the 2.6 SW release; customers were
shown the Range of Variation (ROV) collateral to assist setting
customer expectations for “Within Run” and “Worst Case” Range
of Variation (Figure 4.). The feedback received on the ROV
documents was that they were too subjective and did not provide
customers with the confidence that their machine was operating
within specification.

Figure 4. Range of Variation Collateral Document

The 2.6 software release introduces the Color Check Tool (CCT)
to be used for assessing system color (Figure 5.). This new
DFE-resident tool objectively measures system color against the
machine specifications and displays a Pass or Fail result. If a
Color Check indicates that the press has failed, it will direct the
customer to perform a procedure in the Customer Maintenance
Manual. If the CCT indicates the press passes, it enables the
customer to confidently print their jobs, knowing the press is
within color specification.

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2.6 Service Update Package Image Quality Update

The Press color variability is still in the parameters describes by

the Range of Variation Documents. The CCT does not prevent
machine color from drifting over time, it just allows for an
objective measurement to determine that color is within spec. By
using the CCT on a frequent day to day basis, the customer will
be better equipped to assess when press maintenance is
required for consistent color.

Figure 5. Color Check screen

The System Checkout test patterns

11x17_SystemCheckout_1017.pdf and
A3_SystemCheckout_1017.pdf have been modified and contain
the required color targets. Customers and service will be
instructed to use the DFE-resident System Checkout test
patterns when performing the Color Check.

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Image Quality Update 2.6 Service Update Package

Figure 6. New System Checkout Test pattern

• 17x11 XeroxDC Gloss Elite 80 lb. text

• A3 XeroxColotech+ G 120 gsm
The paper listed in table 1 is required for service to perform the
Color Check. The paper is the same as that used by service to
perform the Print Engine Checkout and System Checkout
Procedures.
Customers will be expected to supply their own paper for running
the color check. Customers may use the paper in table 1 or
equivalent paper when performing the measurement. When
service is on site, the Xerox Media will be the media used to
determine if the machine color is within specification.
The required DFE settings are documented in the Color Check
queue setup instructions for customers and in the SCP-06 Final
Actions for Xerox Service. Customer operation instructions and
usage guidelines are documented in The iGen3 Image Quality
Suite and in the online Instructions available via the CCT Help
menu.
Xerox service instructions and usage guidelines have been
integrated into the appropriate service EDOC RAPs and
Procedures and provided in the supplemental material section of
this package and are contained in the November 2006 EDOC.
• XPE-IQ-0095 Color Check RAP
• XPE-IQ-P505 Color Check Tool Procedure

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2.6 Service Update Package Image Quality Update

• SCP 06 Final Actions

Service Impact

This new tool has been incorporated into the Service Call
Procedures Final Actions.

Customer Impact

Enables customers to confidently print their jobs, knowing the

press is within system color specification.

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 EDOC / Service Procedures Updates

1 Ghz Creo DFE Platform

Description

Creo DFE’s that have a 1 Ghz processor cannot take any

software updates after System Configuration 2.4. The Creo
hardware must have a processor that runs 2.8Ghz or higher to
install the 2.5 or higher System Configuration software.

Service Impacts

If System Configuration 2.6 software is loaded on a 1 Ghz Creo,

the DFE will not run. A complete scrape of the system will need
to be performed before the old software can be reloaded.

Customer Impacts

Features that are in System Configuration 2.6 and later will not
be available.

x86 Press Interface Upgrade Requires a New License

Description

The hostid on the x86 Press Interface (PI) running on 6.0.48

software (base 2.4 configuration) was generated by the internal
components of the PI. This means that if any part in the x86 PI
changed, the hostid could conceivably change. This is not the
desired state with all PI licenses being hostid dependent.

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Starting with the 6.0.50 SPAR, and continuing with the

introduction of the 2.5 configuration (6.1.06), the PI software will
generate a unique hostid based on the internal network card
(NIC) of the x86 PI. This will prevent the hostid of the x86 PI
from changing unless the NIC on the motherboard changes
(essentially a motherboard change).

Service impacts

On any software upgrade from 6.0.48 (base 2.4 configuration) to

6.0.50 or greater, the hostid of the x86 will change and new PI
licenses must be procured.

Customer impacts

None

Release strategy

Initially with the 6.0.50 SPAR release and continuing with the 2.5
configuration release (6.1.06)

Fuser 500K HFSI Changes

Description

Additional actions have been added to the 500K Fuser

Maintenance HFSI (XPE-10-8500) in EDOC. These actions
include a new procedure (REP 10.108 Fuser Assembly Paper
Path Cleaning) intended to eliminate surface contamination in
the Fuser Assembly area caused by leakage of oil from the
Fuser Web Cartridge Motor and other contaminants from Fuser
Fluid, moisture, toner and paper. If these contaminants are not
removed they can be transferred from the Fuser Assembly to
other areas of the Print Engine, causing Print Quality problems
and damage to the Photoreceptor Belt.

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Service Impacts

These new maintenance actions will be required at each XPE-

10-8500 Fuser Maintenance (500K) HFSI.

Customer Impacts

None

Release Strategy

Begin following the new Fuser Maintenance actions with the

November 2006 EDOC release.

Configuring EDOC to Match Machine Configuration

With the implementation of the June 2006 EDOC, many

procedures in the EDOC required that the Print Engine product
code be known so that the correct information for that machine
could be displayed. This could be done manually using the book
configuration page if the PWS is not connected to the machine,
or automatically when connected to the machine.
Unfortunately, if not connected and the user did not manually
select the Print Engine product code, it would default to the CC9
product code, and the user would have no feedback to indicate
as such.
Beginning with the November 2006 EDOC, if the PWS is not
connected to the machine, no product code will be set. If a user
is viewing the Parts List under that situation, any parts that are
product code dependant will display the message “Product Code
Configuration not set”(Figure 1.) That message is linked back to
the Book Configuration page where the appropriate Product
Code can be selected. Once the Product Code is set, the proper
parts will be displayed.

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Figure 1. Product Code Not Set

New Banding SIR

Description

The iGen3 Banding SIR has been redesigned. The new SIR
comes in two parts instead of one. Also, the new SIR has two
cutouts for viewing areas instead of one. The UM Threshold
level patches are no longer in use and have been removed. The
method of use remains the same.
Both the “old” and the “new” Banding SIR may be used. There is
no need to discard the previous version unless it becomes worn
or damaged.

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Figure 2. New Banding SIR Part 1

Figure 3. New Banding SIR Part 2

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Figure 4. Old Banding SIR

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 Hardware / Software Changes

x86 Based DocuSP

Description

The Sun DocuSP v890 Digital Front Ends (DFE) have gone end
of life and are being replaced by a new, faster x86 based
DocuSP for the iGen3 110 and iGen3 90.
x86 is the generic name of the microprocessor architecture
manufactured by Intel. The new DocuSP is built by Pinnacle
Data Systems Inc (PDSi) and powered by AMD Four Opteron
2.2 GHz Dual Core Processors (8 processors total). The PDSi
Config 4 DocuSP is equipped with three high performance 73
GB SCSI Hard Drives and an internal DVD R/W drive. Although
the hardware for the DocuSP is new, the Operating System will
remain Solaris 10, so operability to the user will be transparent.
Sun VTS Diagnostics is not supported for the iGen3 x86
platforms; therefore hardware diagnostics will be performed
using PC Check® diagnostic software. This application should
be run whenever any of the computer hardware components
does not run properly.

Figure 1. PDSi DocuSP

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Service Impacts

• Hardware diagnostics will be performed using the PC

Check® diagnostic software.
• DFE Installation of the x86 Config 4 Server (including
unpack) is to be completed by the Rigger (2 people required)
prior to analyst setup. This is a change from the v890 install
that was performed by the CSE(s) in the CSE System
Installation Manual.
• Because of potential ESD Issues with the DFE during install,
this process may change in the near future to become CSE
installable.
• Please note that the x86 DFE is very top heavy when not
affixed to the Dolley and could tip over easily.
• The x86 DocuSP DFE has a 3+1 power supply configuration.
This means that it can run on 3 power supplies should one
fail. The failure tell-tale sign is usually a high pitched noise.
• The Part List for the x86 DocuSP is on Service Disk 2 along
with other x86 DFE technical related information.

Customer Impacts

• Although the hardware for the DocuSP Config 4 Server is

new, the Operating System will remain Solaris 10 making
operability to the user transparent.
• Power requirements have changed with one additional
power cord per the nationalization kit used.
• The new DocuSP PDSi platform will have standard electrical
requirements of four 110VAC or 220VAC power outlets (see
the Sept 2006 Installation Planning Guide for more
information).
• The fiber network connection is no longer available, just two
copper Ethernet cables with R/J45 connections is the sole
option.

Release Strategy

The PDSi DocuSP started shipping with iGen3 Machines in the

October 2006 time frame.

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DTP 41 ll USB Cable for PDSi DocuSP

Description

A USB cable is being shipped with the X-Rite DTP41

Spectrophotometer. The USB cable is in addition to, and does
not replace, the serial cable which is used for all SunFire 880
and 890’s, all Creo DFE’s and the PWS laptop.
The new cable was added to enable communications between
the PDSi DocuSP DFE and the spectrophotometer. The DocuSP
communications port to the DTP41 Spectrophotometer now uses
a USB connection for communication. The serial port on the
PDSi DocuSP does not support communications with the
spectrophotometer.
When installing a PDSi DocuSP DFE, use the USB
communications cable to interface with the DTP41. When
connecting the DTP41 to the Service laptop, the serial
communications cable must be used.

Service Impacts

For PDSi DocuSP machines, the serial communications cable

for the Spectrophotometer should be stored in the service
cabinet for use with XDAT diagnostic tools requiring the
spectrophotometer. Service must use the serial cable shipped
with the DTP41 to connect the Spectrophotometer to the PWS.

Customer Impacts

None.

Release Strategy

Started shipping 2nd Qtr 2006

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Xerox Premium Digital Carbonless Paper

Description

Xerox Premium Digital Carbonless Paper has been approved for

use on the Xerox iGen3 Digital Production Press. There are
some configuration changes that may need to be made in order
to optimize running this media.

Post Fuser Curl and the Decurlers

Xerox Premium Digital Carbonless paper may experience a

higher post fuser curl level than many of the common substrates
typically imaged in this printer. If stacker jams are experienced,
adjustment to the decurlers may be necessary. Adjustments are
made via Customer Accessible NVMs [Refer to Customer
Bulletin #218-C Decurler Settings For Carbonless Paper]. Also
refer to EDOC Adj. 10.24 Output Curl.
It is important to remember that upon completion of any
carbonless jobs where a decurler adjustment was made, it will be
necessary to manually reset the decurler to the default setting to
prevent any potential negative impact on performance of
subsequent jobs being run.

Additional Cleaning Requirements

If a customer runs a significant amount of Xerox Premium Digital

Carbonless paper through the iGen3 the Customer or CSE may
need to perform some paper path cleaning more frequently.

Fuser Fluid

A new blend of fuser oil, Fuser Fluid II [8R13030], is now

available for improved performance when printing with
Carbonless paper – especially in duplex mode.
Although Carbonless paper has been approved for use with
regular Fuser Fluid, there are three significant benefits
associated with Fuser Fluid II when running Carbonless paper:
• A significant reduction of post-fuser idler roll contamination

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• More reliable duplex printing

• Significant reduction in fuser-fluid-related Photoreceptor
contamination
Other considerations:
• If Xerox Premium Digital Carbonless will be run Simplex, use
either Fuser Fluid
• If Xerox Premium Digital Carbonless will be run Duplex, use
Fuser Fluid II
• Further information regarding Fuser Fluid II may be found on
Eureka (search term “Carbonless”) or via escalation. This
includes potential issues the introduction of Fuser Fluid II
may raise and how to work with the customer to resolve
them.

Release Strategy

Xerox Premium Digital Carbonless paper was announced in

September 2006.

DocuSP Sample Current Job

Description

With the 2.6 release, the DocuSP Current Job Sampling feature
delivers a sample print to the Top Output Tray within typically 30
seconds (though it may take somewhat longer depending on the
job parameters). This is a significant improvement over the up-
to-20 minutes required with the 2.4 software.
DocuSP allows you to send to the Top Output Tray an extra copy
of one of the pages of the currently printing job. When the press
running, selecting [Printer: Sample Current Job] (Figure 2.) will
cause the next eligible page in the job will be selected for
sampling. One copy of the page will be delivered to the Stacker
as usual. A second copy will be delivered to the Top Output Tray.

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Figure 2. Sample Current Job

The following pages are not eligible for sampling:

• Pages programmed for delivery to the Top Output Tray
• Pre-cut tabs or ordered stock
• Administration Pages (Attributes Report, Banner Sheets, and
Error Sheets)
• Inserts, slips sheets, and blank covers
When Sample Current Job is selected, DocuSP displays a status
indicating that a sample has been requested. When DocuSP has
chosen a page for sampling, the status “Sample in progress” will
be displayed.

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Figure 3. Sample in Progress

When the sample page has been printed, the status message is
removed. The sampled page increments the billing meters as
two pages. If no remaining sheets in the job are eligible for
sampling when a sample has been requested, DocuSP will
display a fault.

New Drive Rolls

Description

A new drive roll material is being cut-in to all transports. Like the
existing drive rolls the base material is polyurethane ester. The
new drive rolls can easily be distinguished by their black color.
The cleaning interval will be the same throughout the machine
and the cleaning material will be the same as for the old drive
roller. However, because of the black contrasting background of
the roller it may appear to be more susceptible to contamination
although performance is not impacted. The new rolls can be
used in existing machines. Mixing and matching between the
orange and black rolls within transports will not cause any
problems.

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The life of the new black roll will be the same as the orange roll
except for the duplex upper turn transport where the orange roll
has been known to soften prematurely. The new black drive
roller will have a longer life in the duplex upper turn transport
because it is less susceptible to the heat and moisture that
comes from the fused paper.

Figure 4. New and Old Drive Rolls

Service Impacts

The benefit of the new drive roller is lower cost, and longer life
when used in the post fusing area. There is no change to
cleaning frequency or cleaning materials. The new rolls can be
used in existing machines. Mixing and matching between the
orange and black rolls within transports will not cause any
problems.

Customer Impacts

None

Release Strategy

The new drive shafts and transports containing the new drive
shafts will become available in early 2007.

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Tag A-33 Decurler

Description

As part of the iGen3 cost down strategy, starting with Output

Module Serial Numbers CDO-166030 & YWR-805847, the
Decurlers will be built with 9 Drive shaft pressure rolls instead of
18 (Tag A-33). The drive shaft pressure rolls will now have a
specific location in the Decurler. The rolls will be grouped into
three groups of three rolls. The center location of these three roll
groups will be marked with a circular indentation for each
grouping. (Figure 5.)
NOTE: The drive shaft pressure rolls are interchangeable
between the old and new Decurlers.

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Figure 5. Tag A-33 Decurler Rolls

Service Impacts

Instead of populating the entire assembly, the drive shaft

pressure rolls will now have specific locations in the Decurler.

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Customer Impacts

None.

Release Strategy

This will be a rolling cut-in starting with Output Module Serial

Numbers CDO-166030 & YWR-805847

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38 iGen3 Digital Production Press