Océ Operating Manual Océ - files.oceusa.com · 85581 Poing Germany Edition 2005/11 ... Operating...

OcéOcé | Operating Manual

Océ VarioStream 7000 SINGLEPinfed

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Océ Printing Systems GmbHITCPostfach 126085581 PoingGermany

Edition 2005/11Order no. A29246-X20-X-4-7680

Copyright © Océ Printing Systems GmbH 2004, 2005The product names Océ VarioStream®, Océ Web Buffer 9000®, Océ VarioPrint® and Océ CustomTone®

are subject to trademark.

All rights reserved, including rights of translation, reprinting, reproduction by copying or any other method. Offenders will be liable for damages.All rights, including rights created by patent grant or registration of a utility model or design, are reserved.Delivery subject to availability; right of technical modifications reserved.

1Notes on the printing system documentation

5Operating the printing system

2Safety

3Description of the printing system

4Operator panel

6Cleaning the printing system

8Correcting faults

7Replacing consumables and expendables

Index

Appendix

Table of contents

Table of contents1 Notes on the printing system documentation ................................................... 111.1 Overview.................................................................................................................. 111.2 Signposts ................................................................................................................ 121.3 Using "Help" ............................................................................................................ 13

1.3.1 Contents .................................................................................................... 141.3.2 Index ......................................................................................................... 151.3.3 Search ...................................................................................................... 161.3.4 Direct help ................................................................................................ 17

1.4 Symbols in the text ................................................................................................. 191.5 Symbols in diagrams and illustrations .................................................................... 201.6 Other documents .................................................................................................... 221.7 Manufacturer of the printing system ....................................................................... 221.8 Statutory requirements ........................................................................................... 23

2 Safety...................................................................................................................... 252.1 Overview.................................................................................................................. 252.2 Intended Purpose ................................................................................................... 262.3 Operating and service clearance areas .................................................................. 272.4 Flagging of safety directives ................................................................................... 282.5 Warning and Information signs ............................................................................... 292.6 Accident and damage prevention ............................................................................ 31

2.6.1 Personal Representations ......................................................................... 312.6.2 Operation ................................................................................................. 32

2.6.2.1 Operator..................................................................................... 322.6.2.2 Safety covers ............................................................................ 332.6.2.3 Cleaning .................................................................................... 332.6.2.4 Foreign bodies, noises .............................................................. 332.6.2.5 Cooling, heat, emissions ........................................................... 342.6.2.6 Consumables and expendables................................................. 342.6.2.7 Optical wave guide .................................................................... 342.6.2.8 Laser .......................................................................................... 352.6.2.9 Remote control via LAN ............................................................. 35

2.6.3 Assembly and installation ......................................................................... 35

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2.6.4 Transport .................................................................................................. 362.6.5 Repairs ..................................................................................................... 362.6.6 Fire ........................................................................................................... 362.6.7 Disposal .................................................................................................... 36

2.7 Safety regulations and standards ........................................................................... 372.7.1 CE Mark ................................................................................................... 382.7.2 Accident prevention regulations for the replacement cart for developer

stations (optional) ...................................................................................... 38

3 Description of the printing system ..................................................................... 413.1 Overview ................................................................................................................. 413.2 Device overview ..................................................................................................... 41

3.2.1 Doors and covers ..................................................................................... 423.2.2 Internal view ............................................................................................. 453.2.3 Toner bottle identification ......................................................................... 48

3.3 Operating elements ................................................................................................ 503.3.1 Operator panel on paper transporter ........................................................ 503.3.2 Stacker operator panel ............................................................................. 51

3.4 Paper specifications ............................................................................................... 553.4.1 General information................................................................................... 553.4.2 Paper types .............................................................................................. 553.4.3 Paper handling ......................................................................................... 56

3.5 Paper feed options ................................................................................................. 57

4 Operator panel ....................................................................................................... 594.1 Overview.................................................................................................................. 594.2 Operator panel description ..................................................................................... 60

4.2.1 Toolbar ..................................................................................................... 614.2.1.1 Buttons and displays in the left-hand area................................. 624.2.1.2 Center area buttons and displays ............................................. 644.2.1.3 Frame toolbar............................................................................. 69

4.2.2 Menu tree ................................................................................................. 714.2.2.1 Menus <General> ..................................................................... 734.2.2.2 Menus<VarioStream> ............................................................... 744.2.2.3 Menus <Paper Path Manager> ................................................. 78

4.2.3 Menu display ............................................................................................ 794.3 Using the operator panel ........................................................................................ 80

4.3.1 Managing user settings (key operator) ..................................................... 814.3.1.1 Adding users ............................................................................. 81

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4.3.1.2 Deleting users ........................................................................... 824.3.1.3 Editing users ............................................................................. 82

4.3.2 Managing user settings (operator) ........................................................... 844.3.2.1 Logging on as user and requesting the access ticket ............... 854.3.2.2 Changing password .................................................................. 864.3.2.3 Changing language ................................................................... 86

4.3.3 Setting parameters ................................................................................... 874.3.3.1 Selecting settings and entering values ..................................... 884.3.3.2 Apply or reset parameters.......................................................... 89

4.3.4 Starting and completing the replacement of consumables and expendables 90

5 Operating the printing system ............................................................................ 955.1 Overview.................................................................................................................. 955.2 Powering on the printing system ............................................................................ 965.3 After print stop, switch the printing system back to "Ready" .................................. 995.4 Inserting paper (pinfed) ........................................................................................ 100

5.4.1 Semi-automatic paper insertion .............................................................. 1065.4.2 Manual paper insertion after a paper jam ............................................... 112

5.5 Setting the external paper feed lever..................................................................... 1205.6 Settings when changing paper (pinfed) ................................................................ 121

5.6.1 Settings on paper transporter ................................................................. 1215.6.1.1 Setting the calibration gap ...................................................... 1215.6.1.2 Setting loop puller force .......................................................... 121

5.6.2 Settings on the tension roller unit or on the stacker ............................... 1225.6.2.1 Settings on the tension roller unit............................................. 1225.6.2.2 Settings on the stacker ............................................................ 122

5.6.3 Input at the operator panel ...................................................................... 1255.7 Removing the paper stack .................................................................................... 1315.8 Working with setups .............................................................................................. 133

5.8.1 Creating a new setup or changing a setup ............................................. 1345.8.2 Importing a setup ................................................................................... 1365.8.3 Exporting a setup ................................................................................... 137

5.9 Printing with another color .................................................................................... 1385.9.1 Replacing the toner feed ........................................................................ 138

5.9.1.1 Removing toner feed................................................................ 1385.9.1.2 Installing toner feed.................................................................. 142

5.9.2 Replacing the developer station ............................................................. 1455.9.2.1 Removing the developer station .............................................. 1455.9.2.2 Installing the developer station ................................................ 154

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5.10 Converting the printing system ............................................................................. 1625.10.1 Selecting a configuration ........................................................................ 1645.10.2 Converting the printing system ............................................................... 165

5.10.2.1 Start conversion ...................................................................... 1655.10.2.2 Replacing the toner feed ......................................................... 1665.10.2.3 Replacing the developer station .............................................. 1685.10.2.4 Replacing the photoconductor drum ....................................... 1695.10.2.5 Replacing the fuser roller ........................................................ 170

5.10.3 Completing the conversion...................................................................... 1715.11 Emptying condensation water when using the High Temperature Kit (optional) .. 1725.12 Powering off the printing system .......................................................................... 173

6 Cleaning the printing system ............................................................................. 1756.1 Overview................................................................................................................ 1756.2 Cleaning intervals ................................................................................................. 1776.3 Cleaning the paper path ....................................................................................... 1796.4 Cleaning plastic strips ........................................................................................... 1886.5 Cleaning the fuser station ..................................................................................... 1916.6 Cleaning the soft fuser roller ................................................................................. 1996.7 Cleaning the developer station ............................................................................. 2036.8 Cleaning sensors................................................................................................... 207

6.8.1 Cleaning the toner mark sensor .............................................................. 2076.9 Cleaning the paper motion sensor and mirror ...................................................... 209

6.9.1 Cleaning the paper edge sensor in the fuser station .............................. 2116.10 Cleaning the toner suction system ....................................................................... 2136.11 Cleaning the corotrons ........................................................................................ 2186.12 Cleaning the LED print head ................................................................................ 2196.13 Cleaning the filter .................................................................................................. 2206.14 Cleaning the operator panel ................................................................................. 2236.15 General cleaning .................................................................................................. 224

7 Replacing consumables and expendables ....................................................... 2257.1 Overview................................................................................................................ 2257.2 Replacing consumables ....................................................................................... 226

7.2.1 Replacing the toner bottle ..................................................................... 2267.2.2 Filling the toner box ................................................................................ 2327.2.3 Replacing the waste toner bottle ........................................................... 2337.2.4 Replacing the developer ........................................................................ 2387.2.5 Replacing the fuser oil bottle .................................................................. 252

7.3 Replacing expendables ........................................................................................ 256

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7.3.1 Replacing the photoconductor drum ..................................................... 2577.3.2 Run in photoconductor drum .................................................................. 2637.3.3 Replacing the cleaning brush ................................................................ 2637.3.4 Replacing corotrons ............................................................................... 269

7.3.4.1 Preparing corotron replacement .............................................. 2707.3.4.2 Replacing the transfer corotron (1 cartridge) (pinfed) ............. 2717.3.4.3 Replacing the transfer corotron (torn wire) (pinfed) ................ 2757.3.4.4 Replacing charge corotrons (5 cartridges) .............................. 2787.3.4.5 Replacing charge corotrons (torn wire) ................................... 2817.3.4.6 Replacing discharge corotrons (2 cartridges) ......................... 2847.3.4.7 Replacing the discharge corotron (torn wire) .......................... 2877.3.4.8 Complete corotron replacement............................................... 290

7.3.5 Replacing the active filter ....................................................................... 2917.3.6 Replacing the cleaning belt ................................................................... 2977.3.7 Replacing the heater ............................................................................. 3027.3.8 Replacing the fuser roller ...................................................................... 3127.3.9 Replacing the pressure roller ................................................................ 3207.3.10 Replacing the waste collector ................................................................. 3267.3.11 Replacing the fine filter ........................................................................... 330

8 Correcting faults.................................................................................................. 3378.1 Overview................................................................................................................ 3378.2 Processing messages on the operator panel ....................................................... 338

8.2.1 Locating a message ............................................................................... 3388.2.2 Continuing printing after errors have been corrected ............................. 341

8.3 Clogged toner suction ........................................................................................... 3438.4 Poor print quality ................................................................................................... 348

8.4.1 Poor printing ........................................................................................... 3488.4.2 Poor printing, cause and correction ........................................................ 349

8.5 Poor fusing quality ................................................................................................ 3518.6 Permitting or blocking remote access ................................................................... 352

Appendix ...................................................................................................................... 355Overview......................................................................................................................... 355Consumables ................................................................................................................. 356

Consumables for VarioStream 7200, VarioStream 7300, VarioStream 7400 ...... 356Consumables for VarioStream 7450, VarioStream 7550, VarioStream 7650 ...... 357Consumables for VarioStream 7450 CX, VarioStream 7550 CX,

VarioStream 7650 CX ............................................................................. 359Expendables .................................................................................................................. 361

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Expendables for VarioStream 7200, VarioStream 7300, VarioStream 7400........ 361Expendables for VarioStream 7450, VarioStream 7550, VarioStream 7650........ 362Expendables for VarioStream 7450 CX, VarioStream 7550 CX,

VarioStream 7650 CX ............................................................................. 364Cleaning materials and equipment ................................................................................. 365Technical data ................................................................................................................ 367

Print speed ........................................................................................................... 367Paper ................................................................................................................ 368Electrical values ................................................................................................... 370Emissions ............................................................................................................ 371Mechanical conditions ......................................................................................... 371Environmental conditions .................................................................................... 372Dimensions and weight ....................................................................................... 372

Index .............................................................................................................................. 375

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1 Notes on the printing system documentation

1 Notes on the printing system documentation

1.1 Overview

The purpose of this documentation is to ensure that all printing system-related work is car-ried out safely and correctly. It contains safety directives that must be strictly observed.

Each section is divided into small, easy-to-understand subject areas. The beginning of each section contains an overview to help you quickly find the precise information you are looking for.

This section contains information on the following topics:

1.2 Signposts >>> page 12

1.3 Using "Help" >>> page 13

1.4 Symbols in the text >>> page 19

1.5 Symbols in diagrams and illustrations >>> page 20

1.6 Other documents >>> page 22

1.7 Manufacturer of the printing system >>> page 22

1.8 Statutory requirements >>> page 23

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1.2 Signposts

1.2 Signposts

This section 2 Safety gives you all necessary information on how to safely and efficiently operate the printing system.

Section 3 Description of the printing system explains the structure of the printing system. The operational controls are also described.

The section 4 Operator panel describes the individual areas of the operator panel with the most important icons and buttons. You will also learn how to navigate in the menus, set pa-rameters and start and complete the replacement of consumables and expendables.

The section 5 Operating the printing system explains how to power the printing system on and off and the procedure for inserting, removing and changing the paper web.

Section 6 Cleaning the printing system explains the intervals to be followed for cleaning the different assemblies.

Section 7 Replacing consumables and expendables describes in detail all steps required to replace consumables or expendables.

Section 8 Correcting faults will help you eliminate paper jams or distortions of the print im-age. The context-sensitive direct help on the operator panel provides information on the cause and correction of specific error or warning messages.

Appendix will provide you with detailed information on all consumables and expendables. In addition, the required cleaning agents and equipment are described along with the most important technical data.

Specific subjects can be found more quickly by looking at the detailed index at the end of the operating manual.

NoteAlong with the operating manual, Help is also available in the operator panel of the printing system. This Help is updated with every new version of the operator panel.

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1.3 Using "Help"

1.3 Using "Help"

Help on the operator panel of the printing system is operated using the following buttons:

Button Function

opens Help.

hides or displays the navigation area with the following tabs:• Contents(see section 1.3.1 Contents, page 14)• Index(see section 1.3.2 Index, page 15)• Search(see section 1.3.3 Search, page 16)

When the navigation area is hidden, there is more space available to view the help topics.

switches between the last help topics (backwards or forwards).

switches from any help topic directly to the Help start page.

closes Help.

NoteYou can also open context-sensitive direct help for each operational element by se-lecting the respective element and then pressing the F1 key (see section 1.3.4 Direct help, page 17).

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1.3.1 Contents

1.3.1 Contents

The Help is divided into different main groups:

• General

• VarioPrint 5000 orVarioStream 9000 orVarioStream 7000

• Paper Path Manager

• Paper post processing devices, if available

In the "Contents" tab, you can show or hide individual Help levels and select the desired Help topic, e. g.:

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1.3.2 Index

1.3.2 Index

The "Index" tab provides quick access to the required information.

You can also search directly for a specific word within index entries.

Example:

Proceed as follows:

1. Enter the text into the "Search" input field.

2. Press Enter key.

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1.3.3 Search

1.3.3 Search

Via the "Search" tab you can launch the full text search. The full text search is used to find one or more specific words in the entire Help. Uppercase or lowercase is not relevant for the search.

The search results are listed with the title of the corresponding help topic, and are sorted by level of matches and the frequency in which the word appears in the help topic, e. g.:

The circle in the first column indicates the degree of matching. The more filled the circle is, the better the result matches the text that was searched for.

The number in the second column of the search result indicates how often it occurs in the Help topic.

Proceed as follows:

1. Enter the text into the "Search" input field.

2. Press Enter key.

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1.3.4 Direct help

1.3.4 Direct help

Context-sensitive Direct Help provides detailed information on all:

• Menus

• Operating elements in menus

• Error messages and warnings

If necessary, all the requirements for a setting are also listed in the context-sensitive help system. Specified standard settings and values are denoted in bold.

Starting direct help

Proceed as follows:

1. Select menu

or

select operating element

or

select message.

1 of 2

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1.3.4 Direct help

2. Press the F1 key.

The Direct Help is opened, e. g.:

Proceed as follows:

2 of 2

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1.4 Symbols in the text

1.4 Symbols in the text

Different symbols help you to find your way around the text:

For safety directives, different symbols and alert words are used depending on the degree of danger:

Symbol Meaning

Menu <Sample> The name of a button or menu on the operator panel is enclosed in angle brackets.

SAMPLE button Mechanical buttons are denoted in uppercase letters.

This symbol indicates tips for operating the printing system.

CautionWarns against dangers that could lead to injuries.

ImportantWarns against situations that could lead to damage to the printing system or disrup-tions to operation.

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1.5 Symbols in diagrams and illustrations


If not otherwise indicated, diagrams and illustrations of actions depict the starting position of the respective component for the described step.

For easier understanding, the diagrams only depict the components that are directly rele-vant to the immediate context.

Arrows denote the positions where you have to perform an action or observe something in particular. The color of the arrows denotes the type of actions and the sequence in which they are performed:

Symbol Meaning

Black arrow: Direction arrowPerform this action first

Grey arrow: Direction arrowPerform this action next

If additional actions are depicted in a dia-gram, the numbers on the arrows indicate the sequence in which they are to be car-ried out, e. g.:

2

3

2

3

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White arrow: Note arrow An action should be performed in this area, e. g.:

Symbol Meaning

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1.6 Other documents

1.6 Other documents

If not otherwise indicated, the following documents are supplied with each printing system in addition to the operating manual:

1.7 Manufacturer of the printing system

The printing system was manufactured by:

Océ Printing Systems GmbHPostfach 126085581 Poing

Germany

Title Order number

Safety Information on Océ Printing Systems A29246-X23-X-1-79

Papierspezifikation Endlos-DrucksystemePaper Specification Continuous Feed Printing Systems (English)

Deutsch: A29249-X2-X-10-59English: A29249-X2-X-10-7659

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1.8 Statutory requirements


The information, data and instructions in this documentation were up-to-date at the time of going to press. The right of technical modifications due to further development of the print-ing system is reserved. For this reason, the information, illustrations and descriptions in this documentation cannot give rise to any claims for modifications or additions to printing sys-tems that have already been shipped and accepted.

No liability is accepted for damages resulting from:

• Failure to comply with the documentation

• 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 agent’s personnel.

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2 Safety

2 Safety

2.1 Overview

This section gives you all necessary information on how to safely and efficiently operate the printing system.

You will find information on the following topics:

2.2 Intended Purpose >>> page 26

2.3 Operating and service clearance areas >>> page 27

2.4 Flagging of safety directives >>> page 28

2.5 Warning and Information signs >>> page 29

2.6 Accident and damage prevention >>> page 31

2.7 Safety regulations and standards >>> page 37

CautionPlease also observe the safety directives in the documentation for any pre-processing and post-processing devices that may be connected.

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2.2 Intended Purpose

2.2 Intended Purpose

The printing system shall only be considered as being used for its intended purpose if the notices and instructions in this documentation are strictly observed.

The printing system is intended solely for printing materials that comply with the paper specifications (see section 1.6 Other documents, page 22). The printing system may only be used with the recommended consumables (see section Consumables, page 356) and under the prescribed operating conditions (see section Technical data, page 367).

Any use of the printing system that does not comply with the above requirements can cause damage to the printing system or property and moreover injury to persons.

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2.3 Operating and service clearance areas

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2.3 Operating and service clearance areas

The operating and service clearance areas for the printing system depicted in the following diagram should not be obstructed in any way.

Dotted lines: additional area required for replacing the developer stationDimensions in millimeters (inches)

2.4 Flagging of safety directives

2.4 Flagging of safety directives

In addition to the safety directives in section 2.6 Accident and damage prevention, you must also observe the safety directives outlined elsewhere in this documentation .

The following notational conventions are used for the safety directives in the text of the manual:

Different icons and alert words are used depending on the degree of danger:

Example of a safety directive

Alert wordType and/or source of danger, and consequences if the safety guideline is not observedInstructions on avoiding danger

CautionWarns against dangers that could lead to injuries.

Important Warns against situations that could lead to damage to the printing system or disrup-tions to operation.

ImportantFluid can seep inside the machine. This could cause irreparable damage to the elec-trical and mechanical components.Do not place cleaning fluids on top of or in the immediate vicinity of the printing system. Take care to prevent fluids from seeping into the printing system.

Icon

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2.5 Warning and Information signs


The following signs are affixed inside the printing system at potential danger points:

Sign Meaning

Warning: Live electric partsThere are live electric parts behind protective covers bearing this sign. These protective covers may only be removed by authorized Océ ser-vice personnel.

Warning: Rotating partsParts of the body (particularly fingers), unprotected long hair or loosely hanging items of clothing and jewelry (e. g. ties, necklaces, belt ends...) can be crushed, trapped or pulled into the printing system by the rotat-ing mechanism in these areas.

Warning: Hot componentsIn order to prevent burns, you must observe the cooling periods and other directives specified in the documentation for all work in these ar-eas.

Observe documentationFor all work in this area, you must observe the relevant instructions in the documentation.

The PC drum is light-sensitiveStore the PC drum away from direct exposure to light and sunlight.

Wear glovesAlways wear the provided gloves when working with the photoconduc-tor drum.

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Do not touch the photoconductor drum surface.When working with the photoconductor drum, never touch its surface.

Only touch the PC drum on the inside.When working with the photoconductor drum, only hold it on the inside.

DisposalThe symbol "the crossed-out wheeled bin" indicates that at the end of life of the equipment separate collection is required in the EU Member States. The black bar specifies that the appliance is put on the market after 13 August 2005.Reference: Directive/2002/96/EC.

Sign Meaning

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2.6 Accident and damage prevention

2.6 Accident and damage prevention


2.6.1 Personal Representations >>> page 31

2.6.2 Operation >>> page 32

2.6.3 Assembly and installation >>> page 35

2.6.4 Transport >>> page 36

2.6.5 Repairs >>> page 36

2.6.6 Fire >>> page 36

2.6.7 Disposal >>> page 36

2.6.1 Personal Representations

Agent

An agent is any individual or legal entity (corporate body) that uses or commissions the use of the printing system.

Operator

An operator is a person who has been instructed or commissioned by the agent to operate the printing system.

• The requirements for operators are: They are familiar with the contents of the documen-tation.

• They are aware of the potential dangers of improper handling of the printing system.

• They have been informed about necessary safety installations, safety precautions and operating conditions.

• They have been instructed or commissioned by the agent to operate the printing system.

Key operator

The Key Operator is an operator to whom the agent has assigned the additional duty of user management (e. g. allocation of user rights and passwords). The Key Operator can also display or hide menus for the different operators and accordingly adapt the menu structure to the respective requirements.

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2.6.2 Operation

Service

Service staff are specialized Océ personnel who carry out all work that operators do not have the permission to, on and with the printing system. (e. g., any work on the power cir-cuits in the printing system).

2.6.2 Operation

Observe the following instructions when operating the printing system:

2.6.2.1 Operator >>> page 32

2.6.2.2 Safety covers >>> page 33

2.6.2.3 Cleaning >>> page 33

2.6.2.4 Foreign bodies, noises >>> page 33

2.6.2.5 Cooling, heat, emissions >>> page 34

2.6.2.6 Consumables and expendables >>> page 34

2.6.2.7 Optical wave guide >>> page 34

2.6.2.8 Laser >>> page 35

2.6.2.9 Remote control via LAN >>> page 35

2.6.2.1 Operator

• Only operators, key operators and service personnel may operate the printing system.

• The printing system must not be operated by persons under the influence of alcohol or drugs, or by persons taking certain types of medication, such as psychotropic drugs.

• Before operating the printing system, carefully read through the documentation. If you do not understand something in the documentation, please ask (e.g. ask service).

• Observe all warning and information signs both on and in the printing system (see section 2.5 Warning and Information signs, page 29).

• In case of emergency, immediately power off the printing system by the main circuit breaker (location of the main circuit breaker ). In the event of damage to the housing, pow-er cable or operating elements, or penetration of fluids or foreign bodies, call the appro-priate service representative.

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2.6.2.2 Safety covers

• Do not work with unprotected long hair or wear loosely hanging items of clothing (e. g. ties, sleeves, scarves et. c.), or jewelry such as necklaces, bracelets and rings, since these can catch in the drive mechanisms or moving parts of the printing system and cause injury.

2.6.2.2 Safety covers

• Do not attempt to remove safety covers yourself; do not manipulate safety equipment such as the switches monitoring the safety covers, fuses etc., and do not perform any work not intended to be performed by operators. Such action can cause accidents and may also damage the printing system.

• Safe operation of the printing system is guaranteed only when the outer paneling is fully mounted. Only properly and fully affixed housing ensures:

– Protection from electrical shocks

– Protection against injury from mechanical parts, e. g. cuts, drawing in, crushing

– Protection against the spread of fire

– Sufficient cooling of the printing system.

• Keep all doors, trims, flaps and covers closed while the printing system is in operation. This ensures that limit values for radio interference suppression are not exceeded. Noise emission is also minimized.

2.6.2.3 Cleaning

• Observe the instructions in section 6 Cleaning the printing system for cleaning the printing system.

• For vacuuming, an industrial vacuum cleaner with grounded suction device, rubber noz-zle and a filter insert for fine dustmust be used. When vacuuming large quantities of toner spill (e. g. 1 bottle), an explosion-proof industrial vacuum cleaner must be used because there can be a high build-up of static charge when draining toner spill.

• Only use the recommended cleaning agents and equipment (see section Cleaning ma-terials and equipment, page 365).

2.6.2.4 Foreign bodies, noises

• Make sure that no objects (e. g. jewelry chains, paper clips, coins etc.) or liquids get into the interior of the printing system, since this may result in electric shocks or short circuits. Do not place objects on the printing system, and especially do not place containers with fluid, such as drinking bottles, glasses, cups or vases on top of or in the immediate vicinity of the printing system.

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2.6.2.5 Cooling, heat, emissions

• Should the printing system emit any unusual or noticeable noises or smells, power down the printing system and contact your service engineer.

2.6.2.5 Cooling, heat, emissions

• Do not obstruct the cooling ducts, since this may result in overheating or combustion while the device is in operation.

• Make sure there is an adequate supply of fresh air and cooling air to the room in which the printing system is located (see section Technical data, page 367).

• Do not obstruct the operating and service clearance areas in any way (see section 2.3 Operating and service clearance areas, page 27).

• During print operation the fuser station in the printing system is very hot (up to approx. 230° C / 446° F).Always observe the cooling off periods before beginning work in the area of the fuser station and observe the relevant safety directives in this documentation to avoid burns.

2.6.2.6 Consumables and expendables

• Observe the safety directives given in the manual for:

– toner

– Developer

– Fine filter

– Fuser oil

– PC drum

– Cleaning agents

• Keep all consumables for the printing system out of the reach of children. Store consum-ables away from containers used for food and drink.

2.6.2.7 Optical wave guide

• If the printing system has a connection for optical wave guides: Never look directly into a glass fiber cable or glass fiber cable connection. The laser beams in fiber optic devices can injure your eyes.

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2.6.2.8 Laser

2.6.2.8 Laser

• If the printing system contains a laser:Never look directly into a laser beam or laser optics. Never move a tool near the laser beam so that you do not unintentionally divert the laser beam.The laser beams in fiber optic devices can injure your eyes.

2.6.2.9 Remote control via LAN

• If you operate the printing system from a remote operator panel:The access ticket ensures that only one user at a time can access the printing system (see section 4.3.2.1 Logging on as user and requesting the access ticket, page 85).

2.6.3 Assembly and installation

Observe the following instructions when assembling and installing the printing system:

• The printing system may only be assembled and installed by service personnel.

• The printing system must have a dedicated electrical connection or type B plug connec-tion (complying with VDE directives, EN 60950).

• Do not route the lines and cables in such a way that they can be stepped on or tripped over.

• A ventilating flue without a smoke detector should be installed above the fuser module.In very rare cases, paper jammed in the fuser module could be damaged by the infrared fusing to the extent that smoke escapes. However, even in this case there is no danger of fire because the affected component is immediately isolated from the remaining print system by sealed bulkheads. This bulkhead shielding is part of a proven safety concept and does not effect the availability of the print system after the jammed paper has been removed.

• All printing system accessories and options must comply with statutory regulations and directives for safety, radio interference suppression, telecommunications terminal devic-es, as well as with the specifications published by Océ Printing Systems GmbH.

• The installation of other accessories may constitute a violation of these requirements and directives, and may also damage the printing system.

• Consult service personnel for details on which accessories and options are permitted for the printing system.

• With the exception of optical wave guide connections, all data, signaling, process and control lines and holding wires mapping the printing system with other devices must be properly grounded.

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2.6.4 Transport

• Data transmission lines should neither be connected nor disconnected during electrical storms.

2.6.4 Transport

The printing system may only be transported by service personnel or authorized transport companies.

2.6.5 Repairs

Repairs to the device must only be carried out by service personnel. Access to locked areas and areas which can only be opened with special tools is reserved for service personnel. Opening the device without authorization and improperly effected repairs may put operators at considerable risk.

The access ticket used by the service technician ensures that the printing system cannot be used via a LAN from a remote operator panel during repair work.

2.6.6 Fire

Observe the following instructions:

• Fire in the printing system can cause toxic gaseous emissions.

• Selfcontained breathing apparatus must be worn when fighting the fire. Instructions to this effect should be deposited at the fire alarm center and with the local fire-fighting force.

• Fire can cause toxic arsenic gas to develop on the photoconductor drum.

• Exercise special caution if a fire breaks out where a number of photoconductor drums are stored.

2.6.7 Disposal

Océ operates a system by which used parts and consumables can be returned for environ-mentally sound disposal.

• Collect all parts and consumables that are to be returned for disposal. These will be picked up by Océ Printing Systems GmbH or a commissioned shipping company or a contracted disposal company and then recycled or disposed of appropriately.

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2.7 Safety regulations and standards

• Points to observe when disposing of a photoconductor drum:

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

– Should the photosensitive coating on the drum flake off, carefully collect the flakes or fragments of coating.

– Store the photoconductor drum and any flakes of coating in the original drum packag-ing.

– The drums and coating are hazardous waste and require special disposal. Keep the original carton with the photoconductor drum and flakes of coating for collection by ser-vice or the contracted shipping company. Keep the carton out of the reach of children.

– Wash your hands afterwards

2.7 Safety regulations and standards

The printing system complies with the relevant safety requirements for information technol-ogy equipment. It meets the following national and international product standards and reg-ulations:

• VDE 0805/11.93 / VDE GS mark

• TRGS 402/ TRGS 100

• IEC 60950

• EN 60950

• UL 60950

• CSA Standard C22.2 No. 60950

• EN 55022 / class A (Europe)

• EN 55024

• FCC Part 15 Subpart B Class A (USA)

• C108.8 M1983 Class A (Canada)

Further information:

2.7.1 CE Mark >>> page 38

2.7.2 Accident prevention regulations for the replacement cart for developer stations (opti-onal) >>> page 38

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2.7.1 CE Mark

2.7.1 CE Mark

The printing system fulfills the requirements of the EC directives 89/336/EWG, "Electro-magnetic Compatibility" and 73/23/EWG "Low Voltage Directive".

The CE Mark indicates that the printing system complies with these EC directives.

The replacement cart for developer stations (optional) is also CE certified. All other devices that are connected to the printing system must also comply with the requirements set forth in the relevant EC directives.

The printing system is a Class A product (EN 55022). This product may cause radio inter-ference in a domestic environment. In this case, the agent may be required to take appro-priate measures to correct the interference at his or her own expense.

The printing system can cause the power supply to fluctuate if the power network is not in order. According to EN 61000-3-11, the printing system should only be used on premises that have a network with a continuous current-carrying capacity of 100 A per phase or are supplied by a distribution network of 400/230 V.

The agent must ensure that the printing system is operated in a power supply network that meets these requirements. If necessary, consult the power company to ensure that the con-tinuous current-carrying capacity of the power system at the connection point to the public power grid is sufficient to connect the device.

2.7.2 Accident prevention regulations for the replacement cart for developer stations (optional)

The replacement cart must be inspected annually by a technical expert as per BGV D8 "Winches, Lifting and Pulling Devices". The technical inspection includes the following ser-vices:

• Completeness, suitability and effectivity of the security mechanisms (e.g. rebound guards, holdbacks, braking mechanisms, auxiliary brakes, winders, equipment for locking the load shaft, overloading guards, emergency stopping equipment).

• Condition of device, supports, castors, equipment and frame.

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Records must be kept of the results of device inspections as per §23. Proof of these inspec-tions as per § 23 par. 1 and 2 can be provided e. g. by entering the inspection results in an inspection log, by maintaining a file index or by affixing a test badge (giving inspection date and inspection office).Requirement for affixing the test badge: The device has no safety defects.

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3 Description of the printing system

3 Description of the printing system

3.1 Overview

This section presents the printing system structure graphically. The operating elements are also described. You will also find information on paper types, paper handling and toner bottle identification.


3.2 Device overview >>> page 41

3.3 Operating elements >>> page 50

3.4 Paper specifications >>> page 55

3.5 Paper feed options >>> page 57

3.2 Device overview

This section describes all the assemblies that are relevant to the operator.


3.2.1 Doors and covers >>> page 42

3.2.2 Internal view >>> page 45

3.2.3 Toner bottle identification >>> page 48

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3.2.1 Doors and covers


Front view

Side door of fuser station Front door of fuser station

Left door Right door

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Front door of fuser station Cover hood


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Rear view


Center door

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3.2.2 Internal view

3.2.2 Internal view

Front side

1 2 3 4 6 7 9 10 11 125 8

1316 141517181920

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3.2.2 Internal view

1 side door of fuser station2 Stacker operator panel3 Fuser station4 Front door of fuser station5 Paper transporter6 Cover hood7 Transfer corotron cartridge8 Photoconductor drum9 Discharge corotron cartridge10 Cleaning brush

11 Operator panel on paper transporter12 Touchscreen operator panel13 Floppy disk drive14 Charge corotron cartridges15 Front right door16 Developer station17 Front left door18 Rocker19 Stacker top20 Stacker tray

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3.2.2 Internal view

Rear

1 Back left door2 Fuser oil container3 Back center door4 Fuser station5 Back right door6 Container for toner supply bottle7 Container for fine filter8 Toner dust indicator9 Container for waste toner bottle10 Main circuit breaker

1 2 3 4 5

68910 7

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3.2.3 Toner bottle identification


Toner bottle identification ensures that the toner bottle and toner box are assigned correctly and unambiguously to the developer station. A plausibility check also prevents incorrect settings on the developer station.

For this purpose, each toner bottle is equipped with a transponder for toner identification. Transponder data is read by a reader and this information is analyzed by the printing system.

1 Toner bottle2 Transponder3 Reader4 Toner bottle holder

When a toner bottle with the correct toner type is identified, toner is sucked from the toner bottle into the developer station toner boxes.

To prevent soiling of the developer stations and damage to the printing system, the printing process is paused at print start, if:

• a toner bottle with an incorrect toner type is identified, or

• the toner bottle cannot be identified at all (because either no toner bottle is inserted or the transponder on the toner bottle is faulty or not missing, or the reader is faulty).

ImportantIn both cases, a query is displayed on the operator panel asking whether printing should continue regardless. If this query is confirmed, toner continues to be sucked from the toner bottle into the developer station toner box. Soiling of the developer stations and damage to the printing system cannot be ruled out however.

1

2

3

4

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The most important toner data and the current fill level can be found in the operator panel in menu <Replace consumables> <Toner bottle identification>, e. g.:

Display Description

Toner Displays the ID of the toner used.The message "unknown" indicates that the toner bottle is not equipped with a transponder.

Fill level Displays whether there is still toner in the toner bottle.

Feed counter Displays the current number of feed cycles from the toner bottle.

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3.3 Operating elements

3.3 Operating elements


3.3.1 Operator panel on paper transporter >>> page 50

3.3.2 Stacker operator panel >>> page 51

3.3.1 Operator panel on paper transporter

This operator panel can be accessed by opening the printing system cover hood. It has three keys for moving the paper web.

Key Function

EJECT moves the paper web at print speed while the key is pressed. The paper web is not printed.

Requirement:• This function can only be executed in "Stop" status.

ADVF (ADVance Forward) moves the paper slowly forwards while the key is being pressed. The paper speed increases the longer you press the button.


ADVR (ADVance Reverse) moves the paper slowly backwards while the key is being pressed. The paper speed increases the longer you press the button. The backwards movement is restricted to a maximum of five steps.


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3.3.2 Stacker operator panel


The stacker is only available as an option for the printing system.

1 Stacker operator panel2 Stacker

2

1

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a301.fm 51


Stacker operator panel

Pos. Key Function

1 READY Switches the printing system from "Stop" or "Error" modes to ready mode. If no error condition is present, the green indicator lamp lights up.

Requirements:• No errors present• Controller and system control are ready

2 EJECT moves the paper web at print speed while the key is pressed. Depending on how long this key is pressed, single or several pages can be advanced.The yellow NPRO key light and the red STOP key light come on during this time. The paper path always stops at the beginning of the paper depending on the selected form length.The paper web is not printed. Pages already printed are fused.


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1 2 3 4 5 6 7 8

9 10 11 12

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3 switches on the tension rollers in the stacker top. Pressing the key again deactivates them. After a period of 10 seconds, the tension rollers are automatically powered down (not while paper is being inserted).This key has no function during the preparation phase of the printing system.


4 completely lowers the stacker tray slide and deactivates it. This is necessary when stacking very short forms.The indicator light above lights up.Pressing the key again - and every new paper insertion - reactivates the stacker tray slide, which improves stacker behavior even for large stack heights. The associated indicator lamp goes out.

56

Raises and/or lowers the stacker top.Pressing the key again before the end position is reached stops the movement.

7 C-EJECT Pressing this key will carry out an EJECT operation for twin and/or triplex operation.

8 STOP switches the printing system to the "Stop" statusorcancels current functionThe orange indicator light above the key lights up and the green READY indicator light goes out. "Not ready" is displayed in the basic menu.Before the printing system stops, the pages prepared on the PC drum are transferred to the paper. The paper stops at the start of a page.Characters on the paper between paper transporter and fuser station are not yet fused.The printing system is made operational again by pressing the READY key.

Pos. Key Function

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LED display

Pos. Indicator lamp Function

9 READY This green indicator lamp lights up if no error condition is present when the READY key is pressed.

10 EJECT The yellow indicator lamp lights up while the paper is being advanced after pressing the EJECT or NPRO keys.

11 The indicator lamp under this icon lights up after the key for lowering or raising the stacker tray slide in the stacker tray is pressed.

12 STOP The orange indicator lamp lights up after pressing the STOP key.

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3.4 Paper specifications

3.4 Paper specifications


3.4.1 General information >>> page 55

3.4.2 Paper types >>> page 55

3.4.3 Paper handling >>> page 56

3.4.1 General information

To ensure maximum system availability, the paper must comply with the paper specifications and be stored in an environment with suitable ambient conditions.

Non-compliance with the paper specifications can cause damage to the printing system and may also result in the release of substances from the paper which can contaminate the environment or have a detrimental effect on health. Océ Printing Systems GmbH accepts no liability for such damages.

The printing system is designed to process a wide range of paper types. However, the operational properties of the printing system and the print quality also depend on factors such as:

• Paper quality

• Grammage

• Moisture content

• Dimensional stability

• Smoothness, etc.

3.4.2 Paper types

All media that comply with the requirements of the electrophotographic printing method can be used in all specified formats and paper weights. Using other paper qualities may result in reduced operational results, lower availability and possibly also higher usage of consumables and expendables.

NoteWhen using continuous rollpaper, observe the operating instructions for the paper pre- and post-processing devices.

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3.4.3 Paper handling

3.4.3 Paper handling

The climate (temperature and relative humidity) in the storeroom or processing room is of major importance in ensuring optimum paper processing. Unsuitable conditions can, for example, give the paper an excessive curl, make it bumpy, or alter its electrical resistance. The paper should be transported and stored in a suitable manner.

In order not to impair the quality of the supplied paper, observe the following:

• Store the paper in the supplied packaging until use.

• Do not store paper on the floor or next to walls, or in the vicinity of water pipes, radiators, ventilators, windows (sunlight) etc.

• Do not store paper in rooms in which the ambient conditions are subject to constant change.

• Before you use the paper, store it (in its packaging) near the printing system for a few days if possible, or at least for 24 hours.

• Do not unpack more paper than you need.

• Always store open packs on the top of your supply stacks, and use open packs first. If you have to store open packs over a longer period of time, cover the paper with protective film.

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3.5 Paper feed options


1 Photoconductor drum2 LED print head3 External paper feed4 Paper feed from behind5 Internal input tray6 Paper feed from the front

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4 Operator panel

4 Operator panel

4.1 Overview

This section describes the individual areas of the operator panel with the most important icons and buttons. You will also find out how to navigate through the menus, set parameters, and start and end the replacement of consumables and expendables.


4.2 Operator panel description >>> page 60

4.3 Using the operator panel >>> page 80

NoteDetailed information on all menus and operating elements is also available directly in the operator panel via the context-sensitive Direct Help. The context-sensitive Direct Help can be called up by selecting the relevant menu or operating element and then pressing the F1 key.If necessary, all the requirements for setting the respective parameters are also listed in the context-sensitive Direct Help. Specified standard settings and values are denoted in bold.

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4.2 Operator panel description

4.2 Operator panel description

The operator panel is divided into the following areas:

1 see section 4.2.1 Toolbar, page 612 see section 4.2.2 Menu tree, page 713 see section 4.2.3 Menu display, page 79

1

23

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4.2.1 Toolbar

4.2.1 Toolbar

The toolbar can be used to access important functions in the printing system quickly and to switch directly to frequently used menus.

1 see section 4.2.1.1 Buttons and displays in the left-hand area, page 622 see section 4.2.1.2 Center area buttons and displays, page 643 see section 4.2.1.3 Frame toolbar, page 69

1 2 3

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4.2.1.1 Buttons and displays in the left-hand area


NoteThe following buttons can be operated both with the mouse and from the touchscreen.

Button Function

switches the printing system back from "Stop" or "Error" status to operational status.

Requirements:• No errors present• Controller and system control are ready

• switches the printing system to the "Stop" statusorcancels current function

Non Process Run Outtransports the last printed pages out of the printing system.The printed pages are fused.


Display Function

Indicates that print data has been transferred from the host to a printing system.

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Standard display (no current print data from the host).

Indicates that the controller is performing a restart.

If this message is displayed, print data transfer from the host must be repeated as it cannot be guaranteed that the last pages were correctly transferred and fused before the error occurred.

Standard display (no controller restart).

Display Function

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4.2.1.2 Center area buttons and displays


The current printer status is displayed in the center area of the toolbar. The individual displays have different background colors depending on the printer status:

• Green: the printer is printing or is ready to print

• Red: error

• Gray: all other printer states

The most important status displays are described below:

Display Function

The printing system is ready to print, there are no error messages.

Normal print operation.

The printing system is switching from "Stop" status to “Ready” status.

An error message is displayed. The error must be corrected, otherwise printing cannot continue.

All current messages are also displayed in the <Errors and warnings> menu (see section 8.2 Processing messages on the operator panel, page 338).

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The printing system is switching to "Stop" status.

The printing system is being initialized and is not yet ready for printing.

The printing system is stopping to clean the corotrons.

The printing system is being prepared for power off. A shut-down setup is being written, all components are being exited.

A setup is being loaded or saved.

Consumable replacement is being carried out.

Display Function

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The printing system is in "Stop" status.

The following icon is displayed when a message from the data stream has also been transferred:

The complete message is displayed on the "Job Preparation" tab in the <Setup> menu.

The printing system is being prepared for restart and will then be rebooted.

The twin printing system is in the "Stop" status.

Printing is interrupted because pre/post processing has stopped. The printing process will continue when pre/post processing is ready.

Display Function

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Button Function

Switches to the <Emulations> menu.The following buttons are available here under "Job control":

Cancels the current print job. The data in the page buffer is erased.Requirement: The printing system is in "Stop" status.

Only in PCL mode and only if the printing system is in "Not ready" status: Cancels the current print job. The data in the page buffer is still printed out.

Only in I-Mode:deletes the existing data in the printing system.

Performs a test print with the entered number of pages.

Switches to the <Channels> menu.The following buttons are available here:

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Activates the channel.The clutch icon is closed.

Deactivates the channel.The clutch icon is opened.

During the time needed to activate/deactivate a channel, the clutch icon is shown in yellow.

Flashes when there is an error message.

Flashes when there is a warning.

Flashes when there is information.

When there is no error message, warning or information, this button is hidden.

Clicking this button switches to the <Errors and warnings> menu (see section 8.2 Processing messages on the operator panel, page 338).

Indicates that remote access is activated. This allows the service center to perform a remote diagnosis during printer operation.

The button appears only when a remote diagnosis has been arranged. Clicking the button deactivates remote access directly without having to go through the menu.

Also indicates that remote access is activated.

Button Function

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4.2.1.3 Frame toolbar


On the right is the higher-level frame toolbar for the complete printing system. You can use these buttons to quickly access higher-level functions in the printing system and to switch directly to frequently-used menus.

Indicates that remote access is not activated.

Clicking the button activates remote access directly without having to go through the menu.

Switches to the <Consumables counter> menu.

This menu displays the current counter values and the respective limit values for all consumables and expendables in the printing system.

Switches to the <Service ticket> menu.

This menu displays all the data required to notify the relevant service center.

Button Function

Switches to the <User profile> menu. The language of the operator panel can be changed in this menu.

Indicates that the presently logged-on user possesses the access ticket.

Clicking releases the access ticket directly without going through the menu.

Indicates that the access ticket is released for other other users.

Clicking requests the access ticket directly without going through the menu.

Opens Help.

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Button Function

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Switches to the <Change user> menu. Users can be logged on and off in this menu.

Displays the user currently logged on.

Powers down the printing system if the print is confirmed.

This button can be operated both with the mouse and from the touchscreen.

Switches from any sub-menu directly to the main menu of the printing system or the UP3I manager.

Button Function

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4.2.2 Menu tree

4.2.2 Menu tree

All the menus can be accessed via the menu tree.

The menus are structured into main groups, e. g.:

• [00] <General>You can define the user settings valid for the entire printing system in these menus.

• [02] <VarioStream> You can set the relevant parameters for the "VarioStream" printing system in these menus.

• [FF] <Paper Path Manager>In these menus you can get an overview of all UP3I-capable devices of the printing system.

• Devices for post-print processing

The numbers before the main groups are required to identify the devices in the printing system.

Clicking the switches in the menu tree lets you show or hide other menu levels, e. g.:

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4.2.2 Menu tree

You can switch directly to the main menu from any menu. Click the following button in the toolbar for this purpose:


4.2.2.1 Menus <General> >>> page 73

4.2.2.2 Menus<VarioStream> >>> page 74

4.2.2.3 Menus <Paper Path Manager> >>> page 78

NoteThe menus displayed in the menu tree depend on the respective authorizations for the individual user categories.This documentation describes all menu options set up as default for the user categories "Operator" and "Key Operator".

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4.2.2.1 Menus <General>

4.2.2.1 Menus <General>

NoteMenus that can only be opened by the user "Key operator" as standard are shown in italics in the table.

Menu Description

General The sub-menus contain global settings for users, access tickets and screen cleaning for the entire printing system

User management The sub-menus contain the user settings relating to the Key Operator

Add user Add new users or user templates

Delete user Delete users or user templates

Edit user Settings for:Password / authorization levelUser rights (for menus / for elements)User profile (language)

User The sub-menus contain the user settings relating to the operator

Change user Log a user on or off

User profile Select the operator panel language

Access ticket Request or release the access ticket

Network management Overview of all computers with access to the printing system

Tools Enable screen cleaning during printing

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4.2.2.2 Menus<VarioStream>


Menu Description

<VarioStream> Displays basic information on the printing system: • Number of all 12" pages previously printed in

user operation.• Setup currently loaded• Current print job• Name and serial number of the printing system• Available emulations

The sub-menus contain all settings and displays relating to the "VarioStream 7000" printing system.

<Displays> The sub-menus contain displays on current error and warning messages and various counters on the printing system

<Errors and warnings> Displays the current error and warning messages and information

<General counters> Displays page counter, warm-up time, user counters and toner types

<Consumables counter> Displays the current counter values and the relevant limit values for all consumables and expendables of the printing system

<Consumables history> Displays all replacement procedures for all replaced consumables/expendables, each with time and counter reading

<Configuration> The sub-menus contain the parameters for setting the printing system

<Paper> The sub-menus contain the parameters for the paper webs to be printed

<Dimensions> Enter and display paper parameters

<Properties> Enter and display paper properties

<Shift> Enter and display offset parameters

<Marks> Enter and display mark parameters

<Calibrate mark sensor> Procedure for setting up mark sensors

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<Printing system> The sub-menus contain specific parameters for the printing system

<Speed> Select printer speed

<Paper path> Settings for paper brakes, automatic paper ejection and paper end

<Stacker> Settings for stacker properties

<Operating mode> Select operating mode

<System functions> Settings for system functions

<Conversion> Select configuration for the printing system

<Print parameters> The sub-menus contain specific parameters for the printing system

<Fusing quality> Settings for wrapping, fusing temperature and oiling

<Print quality> Contrast setting

<Color management> Settings for colors in the printing system

<Emulations> Displays emulations, buttons for job control, restarting, and PCL settings

<General> Select and enter general cross-emulation settings

<Color>(optional)

Settings for background printing for color printing

<Cut sheet Emulation> Set and display parameters for printing single sheets

<SNMP configuration> SNMP (= Simple Network Management Protocol) is a network protocol that is used to manage TCP/IP networks. External programs can access the PrinterMIB via SNMP

<I-Mode> The sub-menus contain the parameters for I-Mode

<Properties> Settings for font capture, data resolution and logical page extension

<Continuous feed> Settings for specific parameters for continuous printing in I-Mode

Menu Description

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<Standard resources> Select and display standard resources for I-Mode

<Resource management> Install new resources or delete existing resources

<PCL mode> The sub-menus contain the parameters for PCL mode

<Properties> Settings for job separation, alignment, print mode, number of copies and lines per forms overlay

<Continuous feed> Settings for specific parameters for continuous printing in PCL mode

<Standard resources> Select and enter standard resources for PCL mode

<Resource management> Install new resources or delete existing resources

<C/E mode> The sub-menus contain the parameters for C/E mode

<Properties> Set general properties for C/E mode, specific parameters for the EFO values, for 2-up and print orientation

<Channel extensions> Settings for specific parameters for channel extensions

<Channels> Displays the current channel settings and settings for channel control

<Channel A / B / C> Select and enter parameters for channel A

<Channel A / B / C> Select and enter parameters for channel B

<Channel A / B / C> Select and enter parameters for channel C

<Special functions> The sub-menus contain special parameters for the printing system

<Clean corotrons> Cleans all corotrons in the printing system

<Clean LED print head> Cleans the LED print head

<Operator trace> Write an error log

<Service ticket> Display all data required to notify the service center

Menu Description

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<Remote diagnostics> Activate or deactivate remote access by the service

<Setup> Display and edit the globally valid print job setups

<Setup channel A / B / C> Display and edit setups for channel A

<Setup channel A / B / C> Display and edit setups for channel B

<Setup channel A / B / C> Display and edit setups for channel C

<Replace consumables> The sub-menus contain the procedures for replacing consumables and expendables

<Replace active filter> Procedure for replacing the active filter

<Replace pressure roller> Procedure for replacing the pressure roller.

<Replace corotrons> Procedure for replacing the transfer, charge and discharge corotrons

<Replace developer> Procedure for draining or filling the developer in the developer station

<Fill developer> Procedure for filling the developer in the developer station

<Replace heater> Procedure for replacing the heater

<Replace fine filter> Procedure for replacing the fine filter

<Replace fuser oil bottle> Procedure for replacing the fuser oil bottle.

<Replace fuser roller> Procedure for replacing the fuser roller

<Replace photoconductor drum> Procedure for replacing the photoconductor drum

<Run in photoconductor drum> Procedure for inserting the photoconductor drum

<Replace cleaning brush> Procedure for replacing the cleaning brush

<Replace cleaning belt> Procedure for replacing the cleaning belt

<Replace toner bottle> Procedure for replacing the toner bottle

<Fill toner box> Procedure for filling the toner box

<Replace waste toner bottle> Procedure for replacing the waste toner bottle

<Toner bottle identification> Displays information on the toner used

<Replace transfer roller> Procedure for replacing the transfer roller

<Replace transfer foil> Procedure for replacing the transfer foil

Menu Description

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4.2.2.3 Menus <Paper Path Manager>

4.2.2.3 Menus <Paper Path Manager>

NoteYou can find information on the Paper Path Manager in the printing system operator panel in Help.

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4.2.3 Menu display

4.2.3 Menu display

This area shows the menu selected in the menu tree. You can select or set all parameters required to operate the printing system here.

NoteDetailed information on all menus and operating elements is also available directly in the operator panel via the context-sensitive Direct Help.

The context-sensitive Direct Help can be called up by selecting the relevant menu or operating element and then pressing the F1 key.

If necessary, all the requirements for setting the respective parameters are also listed in the context-sensitive Direct Help. Specified standard settings and values are denoted in bold.

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4.3 Using the operator panel

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4.3 Using the operator panel


4.3.1 Managing user settings (key operator) >>> page 81

4.3.2 Managing user settings (operator) >>> page 84

4.3.3 Setting parameters >>> page 87

4.3.4 Starting and completing the replacement of consumables and expendables >>> page 90

4.3.1 Managing user settings (key operator)

4.3.1 Managing user settings (key operator)

As a key operator, you can normally make the following user settings:

4.3.1.1 Adding users >>> page 81

4.3.1.2 Deleting users >>> page 82

4.3.1.3 Editing users >>> page 82

4.3.1.1 Adding users

NoteA logged-on user can only create, delete or edit users who have a lower authorization level. Users with the same or a higher authorization level are not listed in the selection lists.

Proceed as follows:

1. Click the <General> <User management> <Add user> menu.

2. Select user:• If an entire user group is to be added:

select the entry "Template" under "Type"enter a name for the new user group under "Name."

• If a specific user is to be added:select the entry "User" under "Type"enter a name for the new user under "Name."

3. Click on the following button:

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4.3.1.2 Deleting users

4.3.1.2 Deleting users

4.3.1.3 Editing users

Proceed as follows:

1. Click the <General> <User management> <Delete user> menu.

2. Select user:• If a whole user group is to be deleted:

select the entry "Template" under "Type"select the desired template under "Name."

• If a specific user is to be deleted:select the entry "User" under "Type"select the desired user under "Name."


NoteAs standard, three user groups are predefined: Operator, Key Operator and Service. Any changes made to their associated user profiles will be reset when a new opera-tor panel version is installed. However, changes to profiles of individually created us-ers will be unaffected by the installation.

Proceed as follows:

1. Click the <General> <User management> <Edit user> menu.

2. Select user:• If the settings for an entire User group are to be edited:

select the entry "Template" under "Type"select the desired template under "Name."

• If the settings for a specific user are to be edited:select the entry "User" under "Type"select the desired user under "Name."

3. Setting passwords and authorization levels for users >>> page 83 Releasing menus and elements for users >>> page 83 Presetting language for users >>> page 84

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4.3.1.3 Editing users

Setting passwords and authorization levels for users

Releasing menus and elements for users

Proceed as follows:

1. Click on the "General" tab.

2. Enter the password and re-enter it identically under "Password confirmation".The password may consist of any characters.

3. Set authorization level.Authorization levels can only be changed to one level below that of the person editing the level.

Proceed as follows:

1. Click on the "User Rights" tab.

2. Under "Menus" activate the checkboxes for the menus which are to be displayed for the user in the menu tree.

If a menu is not to be displayed, deactivate the respective checkbox. This also pre-vents the user from accessing all subordinate menus.

3. Under "Elements" click the checkboxes in front of the control elements that are to be editable for this user.

If an element is not to be editable:deactivate the respective checkbox.


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4.3.2 Managing user settings (operator)

Presetting language for users

4.3.2 Managing user settings (operator)

As an operator, you can normally make the following user settings:

4.3.2.1 Logging on as user and requesting the access ticket >>> page 85

4.3.2.2 Changing password >>> page 86

4.3.2.3 Changing language >>> page 86

Proceed as follows:

1. Click on the "User Profile" tab.

2. Select the desired language in the selection list.


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4.3.2.1 Logging on as user and requesting the access ticket

4.3.2.1 Logging on as user and requesting the access ticket

To be able to set parameters on the operator panel, you must first log on as a user and then request the access ticket.

The access ticket ensures that parameters are not set by different users at parallel operator panels.

NoteIf a user with a higher authorization level has already requested the access ticket, a message will be displayed. From users with the same authorization level the access ticket can be requested directly.

Proceed as follows:

1. Click the <General> <User> <Change user> menu.

2. Select the desired user in the selection list.

3. Enter password.


Only if several operator panels are connected to the printing system:

5. Click on the <General> <Access ticket> menu.


If the access ticket has already been requested, the button is deactivated.

NoteThe access ticket can also be requested and released directly using the following but-tons in the frame toolbar without going through the menu.

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4.3.2.2 Changing password

4.3.2.2 Changing password

4.3.2.3 Changing language

Proceed as follows:

1. Click the <General> <User> <User profile> menu.

2. Click on the "Password" tab.

3. Enter the old password and then enter the new password twice.The password may consist of any characters.


Proceed as follows:

1. Click the <General> <User> <User profile> menu.

2. Click on the "User Profile" tab.

3. Select the desired language in the “Language” selection list.


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4.3.3 Setting parameters

4.3.3 Setting parameters

All parameters of the printing system can be set at the operator panel. The following prerequisites must be given:

• The necessary rights are available. These rights are allocated by the respective "Key Operator" in the <Edit user> menu (see section 4.3.1.3 Editing users, page 82).

• The access ticket for this operator panel is requested (see section 4.3.2.1 Logging on as user and requesting the access ticket, page 85).

• The printing system is in "Stop" or "Error" status. When the printing system is running, the parameters can only be checked but not reset.

The following steps must be carried out to set parameters:

4.3.3.1 Selecting settings and entering values >>> page 88

4.3.3.2 Apply or reset parameters >>> page 89

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4.3.3.1 Selecting settings and entering values

4.3.3.1 Selecting settings and entering values

You can select predefined settings and values through various operating elements, such as selection lists, option fields, checkboxes, slide controls, etc.

You can also enter new values in input fields via the keyboard.

Example: Entering the paper length

Proceed as follows:

1. Select unit for paper length

The first click opens the selection list, the second click selects the unit.

2. Select the number via the slide control, or enter it into the input field with the keyboard.

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4.3.3.2 Apply or reset parameters

4.3.3.2 Apply or reset parameters

If you change parameters in a menu, you have to confirm these changes before switching to another menu.

If you change to another menu without applying the changed parameters, the following query is displayed:

Button Function

The parameters are applied.

The parameters are not applied; instead the previous parameters are restored.

Button Function

The parameters are applied and the new menu opens.

The parameters are not applied; instead the previous parameters are restored.Then the new menu is opened.

The parameters are not applied.The menu remains open.

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4.3.4 Starting and completing the replacement of consumables and expendables


The operator panel informs you about the current status of the printing system. Warning and error messages indicate when consumables or expendables (= consumables/expendables) have to be refilled or replaced.

You can also check the current counter status at any time in the <Consumables counter> menu, e. g.:

Every time a consumable or expendable part is replaced, individual working steps must be carried out on the operator panel.

Column Description

Status The usage period for this consumable/expendable is below the warning value.No action required.

The warning value for this consumable/expendable has been exceeded.The consumable/expendable part should be replaced soon.

The accumulated value for this consumable/expendable has been exceeded.The consumable/expendable part must be replaced soon.

Counter Abbreviation for the relevant consumable/expendable.

Counter value Number of pages printed since the last replacement.

Unit The values displayed refer to A4 pages or to 12" pages.

Warning value A warning message appears if this value is reached.

End value An error message appears if this value is reached.

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Requirements:

• the user rights for replacing the developer are available

• the access ticket for this operator field is requested

• the printing system is in "Stop" or "Error" status, i.e. does not print

• no other change function is executed.

The following explains the procedure for starting and confirming the individual steps using "Replace cleaning brush" as an example.

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Proceed as follows:

1. Click on the <Replace consumables> <Replace cleaning brush> menu.

2. A menu window is opened, which displays all the necessary steps, e. g.:

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3. Perform all the displayed steps in the given order.

Icons

The icons on the left-hand side show the type of the current step:

Answer a query at the operator panel.

Perform a mechanical adjustment of the printing system.

This step is carried out by the printing system without the operator's involvement.

The icons on the right side indicate the progress:

This step is currently being executed.

The progress display is automatically moved forward for step types and

.

The progress display is not automatically moved forward for step type . To display the details of the next step, you must switch to the next step by clicking the mouse.

This step has not been performed yet and is still to be carried out.

This step was successfully completed.

This step was not completed successfully.

The steps are described in more depth under "Details".

Additional Help for the individual replacement procedures: see section 7 Replacing consumables and expendables, page 225.

Proceed as follows:

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4. Complete replacement procedure.As a result, the following will occur automatically:• the message on the operator panel is deleted• the replacement of the consumable/expendable is documented in the

<Consumables history> menu• the consumable counter is reset.

Proceed as follows:

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5 Operating the printing system

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5 Operating the printing system

5.1 Overview

This section explains how to power the printing system on and off and the procedure for inserting, removing and replacing the paper web.


5.2 Powering on the printing system >>> page 96

5.3 After print stop, switch the printing system back to "Ready" >>> page 99

5.4 Inserting paper (pinfed) >>> page 100

5.5 Setting the external paper feed lever >>> page 120

5.6 Settings when changing paper (pinfed) >>> page 121

5.7 Removing the paper stack >>> page 131

5.8 Working with setups >>> page 133

5.10 Converting the printing system >>> page 162

5.12 Powering off the printing system >>> page 173

5.2 Powering on the printing system


NoteIf the optional High Temperature Kit is used, the external recooling system must be powered on before powering on the printing system:

Proceed as follows:

1. Turn the main circuit breaker on the right narrow side upwards to Position I.

2. Press the POWER ON button.After pressing the POWER ON button, wait until the booting information appears on the operator panel.During the boot phase, different messages appear on the operator panel in the basic menu.

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3. Only if an SRA boot error appears in the operator panel or when rebooting is required.

4. The printing system is initialized (takes approx. 6 minutes). The printing system's current status information is displayed on the operator panel.

5. Activate the desired channel on the operator panel. To do this, click the following button:

The <Channels> menu is displayed.To activate the channel, click on the following button:

During the time needed for activation, the clutch icon is shown in yellow. An activated channel is represented by the following icon:

6. Insert paper web.

7. Set up a print job.

Proceed as follows:

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The printing system is in "Ready" status.

Proceed as follows:

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5.3 After print stop, switch the printing system back to "Ready"

5.3 After print stop, switch the printing system back to "Ready"

A print stop may have the following causes:

• The controller has run out of data.The printing system is in "Ready" status and continues printing automatically as soon as print data is available again.

• The STOP key was pressed on the operator panel.The printing system is in "Stop" status.To switch the printing system back to "Ready":

• The printing system was stopped by an error message.Information on switching to ready after a stop caused by an error: see section 8.2.2 Continuing printing after errors have been corrected, page 341.

Proceed as follows:


Print operation continues without any impairment to print or fusing quality. The temperature of the fuser station decreases in stages with longer standby times. For this reason, the fuser station may first have to be reheated to its operating temperature. Depending on the type of paper, this may take up to 30 seconds.

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5.4 Inserting paper (pinfed)


To insert paper, the printing system must be powered on, i.e. the main circuit breaker is in position I and the POWER ON key is activated. The paper can be fed either via the internal input tray or via the external central paper feed.

Proceed as follows:

1. Lift up cover hood.

2. Open the left and right door at the front of the printing system.

3. Only if replacing the paper stack before paper end click on the following button:

4. Cut the paper in the input tray in the paper stack area.

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The cut paper web is placed in the stacker.

6. Remove paper stack from the input tray.

7. If the paper changes, perform the corresponding actions (see section 5.6 Settings when changing paper (pinfed), page 121).

8. Only if changing the paper width:Loosen the slide for setting the paper width and set to the width of the paper being used.

Proceed as follows:

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9. Only for paper feed via the internal input tray:Insert the new paper stack in the input tray so that the paper points to the right, i.e. the first paper fold is to the left.

10. Push the paper stack and the carton tightly to the front feed edge.

11. Tear off any damaged first pages from the paper stack in such a way that the paper start points to the right.

Proceed as follows:

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12. Only for external paper feed:Pull out the external paper feed lever and turn to the right to the stop point.

13. Position the start of the paper web with the fold line to the front between the guide washers.

Proceed as follows:

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14. Only if the paper width has changed:Move the right guide washer so that the paper has some space to run between the two guide washers.

15. Guide the paper between the tension rollers and push into the printing system by hand.

Proceed as follows:

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16. Continue to push in paper by hand until a few pages are in the printing system.If the paper jams, open the front left door and pull the paper into the printing system by hand.

Proceed as follows:

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5.4.1 Semi-automatic paper insertion


With some printing systems, the preheating saddle is not heated and does not have a cover. The following diagrams illustrate the printing systems with heated preheating saddles and covers.

Proceed as follows:

1. Turn the handle to the left and push the rocker downwards.

2. Open the two upper tractor doors.

3. Swivel the lever to the left.

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4. Open the two lower tractor doors.

5. Only for external paper feed:Guide the paper through the swing as shown.

Proceed as follows:

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6. Hold the left of the paper web by the first fold and with the first and second page folded up (i.e. with the first fold to the right, the first page lies underneath) push it into the paper transporter until the fold lies in the area of the upper tractors.

7. Pull the paper web until the fold reaches the mark above the front tractor. At the same time, place the paper web in the upper tractors so that the pins protrude from the paper tractor holes. Close the front tractor door.

Proceed as follows:

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8. Only if changing the paper width:Adjust the rear tractors with the turning knob so that the pins are in the tractor holes. The paper should not be tightly tensioned.

9. Close the rear tractor door.

10. Swivel the rocker upwards. The paper is now automatically advanced.

Proceed as follows:

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11. Only for printing systems with heated preheating saddle:When the front edge of the paper has disappeared under the cover of the preheating saddle, swivel the lever to the right. The lower tractor doors are now closed.

Only for printing systems without heated preheating saddle:When the front edge of the paper is in front of the fuser station, swivel the lever to the right. The lower tractor doors are now closed.

12. Only for external paper feed:Pull out the paper feed lever by 40o (= 4 stages), turn to the left and release.

13. Check whether the lever has engaged in the gearing.

ImportantThe precise position of the lever can only be determined during printing (see section 5.5 Setting the external paper feed lever, page 120).

Proceed as follows:

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14. Press the EJECT key briefly. The paper is now automatically transported through the fuser station to the stacker and placed there in the correct order.An automatic cleaning phase is now performed. The message "Cleaning cycle underway" is displayed in the operator panel.


The "Check paper position" message is displayed in the P mode in the operator panel.

ImportantIn P mode, in order for printing to begin on the upper page at every job start, there must be a positive fold (^) at the adjustment ruler marking.

16. Adjust a fold perforation so that it lies at the adjustment ruler marking that corresponds to the paper format length (fold length).

17. Click on the following button again:

When the message "Cleaning cycle underway" disappears, the printing system is ready to print.

18. Close the doors on the front of the printing system.

19. Close cover hood.

Proceed as follows:

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5.4.2 Manual paper insertion after a paper jam


Proceed as follows:

1. Turn the knob to the left and push the rocker downwards.

2. Open the two upper tractor doors.

3. Swivel the lever to the left.

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4. Open the two lower tractor doors.

5. Lower the stacker top by pressing the key.

6. Only for printing systems with heated preheating saddle:Open cover above the preheating saddle.

Proceed as follows:

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7. Cut paper in the input tray in the paper stack area or at a negative (>) fold for an external paper feed.

8. Remove paper from the entire paper path, including jammed paper, from the stacker and the fuser station.

9. Only for external paper feed:Guide the paper through the swing as shown.

Proceed as follows:

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10. Hold the paper to the left at the first fold and with the first and second page folded up (i.e. with the first fold to the right, first page underneath) push it into the paper transporter.

11. Push the paper web through the paper transporter until the paper web has left the fuser station and the paper length reaches the stacker floor.

Proceed as follows:

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12. Insert the paper web in the upper tractors in such a way that the pins protrude from the paper tractor holes. Close both tractor doors.

13. Swivel the rocker upwards. The paper is now automatically advanced.

14. Swivel the lever to the right. The lower tractor doors are now closed.

Proceed as follows:

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15. Place the lever for the distance of the tension rollers in the OFF position.

16. Push the paper web through the stacker top and place in stacker.

Proceed as follows:

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17. Return the lever for the distance of the tension rollers to the NORMAL position.

18. Only for printing systems with heated preheating saddle:Close cover above the preheating saddle.

19. An automatic cleaning phase is now performed. The message "Cleaning cycle underway" is displayed in the operator panel.

20. When the message "Cleaning cycle underway" disappears, adjust a fold perforation with the ADVF and ADVR keys so that it lies at the adjustment ruler marking that corresponds to the paper format length (fold length).

ImportantIn P mode, in order for printing to begin on the upper page at every job start, there must be a positive fold (^) at the adjustment ruler marking.

Proceed as follows:

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The "Check paper position" message is displayed in the P mode in the operator panel.

22. Click on the following button again:

23. Close the doors on the front of the printing system.


Proceed as follows:

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5.5 Setting the external paper feed lever

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5.5 Setting the external paper feed lever

The optimum position of the external feed lever can only be determined during printing. The deflection of the swing in the printing system indicates whether and how far the lever needs to be turned to the left. The farther the swing is deflected, the farther the lever must be turned to the left. The position of the lever is optimal when the swing is deflected at an angle of 10o to 20o during printing.In general, the following applies: For heavy papers, the lever must be turned farther to the left than for light papers.

The following diagrams illustrate the relationship between the deflection of the swing and the position of the lever:

Swing deflection Lever position

The swing is deflected more than 20o. The external paper feed lever must be turned farther to the left.Always only adjust the lever by one stage (= 10o) and then observe the deflection of the swing. You may need to continue turning the lever in stages until the swing is deflected at an angle of 10o to 20o.

The swing is deflected by 10o to 20o. The external paper feed lever is now optimally positioned.

⇔

> 20o

OK10o – 20o

5.6 Settings when changing paper (pinfed)

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5.6 Settings when changing paper (pinfed)

5.6.1 Settings on paper transporter

5.6.1.1 Setting the calibration gap

5.6.1.2 Setting loop puller force

Proceed as follows:

1. Set GAP lever to the appropriate position for the paper or printing media used.• Position NORMAL:

Normal position for paper weight

< 140 g/m2.• Position OFF:

Paper weight >140 g/m2, labelpaper, plastic cards.

Proceed as follows:

1. Use the turning knob to position the indicator in the black area of the setting scale which corresponds to the width of the inserted paper.For paper widths not listed, position the indicator in the corresponding intermediate position.

5.6.2 Settings on the tension roller unit or on the stacker

5.6.2 Settings on the tension roller unit or on the stacker

5.6.2.1 Settings on the tension roller unit

5.6.2.2 Settings on the stacker

Proceed as follows:

1. Set the lever for the contact force of the tension rollers to NORMAL.• The MAX position can be better for

very heavy special papers.• The MIN position can be better for

lighter papers.• The OFF position can be used to

remedy a paper jam.

Proceed as follows:

1. Use the turning knob to position the format marking to the value of the inserted paper format length (fold length).

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2. Position the lever for setting the air nozzles (right=air volume, left=direction) to the value of the inserted paper format length (fold length).Depending on the paper, different settings can provide a better stacking result.

3. Position the lever for the distance of the tension rollers to NORMAL.• The MAX position can be better for

very heavy special papers, e.g. label papers.

• The MIN position can be better for lighter papers.

• The OFF position can be used to remedy a paper jam.

ImportantWhen using 19" paper in the stacker• Set the slide for the paper width setting all the way to the left.• Remove the paper guide on the left side.

Proceed as follows:

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4. Loosen the slide for setting the paper width and set to the width of the paper being used.

Proceed as follows:

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5.6.3 Input at the operator panel


When starting a new job or changing the paper, new printer settings at the operator panel may be necessary.

Selecting a job or form-specific printer setting:

Job and form-specific printer settings can be saved under a name in the <Setup> menu. When you load a predefined setup, the printing system is automatically configured with the corresponding parameters for the print job.

Select various settings for paper change:

• Enter the paper format length

Proceed as follows:

1. If the printing system has not yet stopped, click the following button:

2. On the operator panel select:• For universally valid print job setups:

<VarioStream> <Setup> menu• For channel-specific setups:

<VarioStream> <Setup channel A / B / C> menu

3. Select setup in the "Setup List" tab.


5. Click "Setup Contents" tab and check settings.

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• Entering the logical page length on a physical page:

Proceed as follows:


2. On the operator panel select:• Menu <VarioStream> <Configuration> <Paper> <Dimensions>

3. Under "Paper length":• Set paper format length (fold length) with slide control.or• Enter paper format length (fold length) in the text field.


Proceed as follows:



3. Under "Page length":• Set the logical page length with the slide control.or• Enter the logical page length in the text field.

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• Entering the paper width:

• Setting the calibration gap:


Proceed as follows:



3. Under "Paper width":• Set the paper width with the slide control.or• Enter the paper width in the text field.


Proceed as follows:


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Proceed as follows:

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The values for the following settings must be determined by test runs with the paper being used.

• Changing the fusing temperature:

2. On the operator panel select:• Menu <VarioStream> <Configuration> <Printing system> <Paper path>

3.• If using light or normal paper:

select the "Calibrator" checkbox with a mouse click.• If using light or normal paper:

deactivate the "Calibrator" checkbox with a mouse click.


ImportantThe printing system needs a certain amount of time to reach the new temperature.

Proceed as follows:


2. On the operator panel select:• Menu <VarioStream> <Configuration> <Print parameters> <Fusing quality>

3. Select the desired temperature under "Fusing temperature".


Proceed as follows:

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• Increasing the fusing temperature:A waiting period follows automatically during which printing is not possible.

• Lowering the fuser temperature

– by one stage: Printing can begin immediately.

– by more than one stage: A waiting period of five minutes is necessary. If this waiting period is too long, you can instead press the EJECT key, to advance blank pages for one minute.

• Selecting fuser oil quantity:

• Setting the paper brake:

Proceed as follows:


2. On the operator panel select:• Menu <VarioStream> <Configuration> <Print parameters> <Fusing quality>

3. Select the desired fuser oil quantity under "Oiling".


Proceed as follows:


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2. On the operator panel select:• Menu <VarioStream> <Configuration> <Printing system> <Paper path>

3. Select the desired brake force under "Paper brake".


Proceed as follows:

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5.7 Removing the paper stack


The stacker should always be cleared before paper is inserted, even when reinserting paper due to paper problems.

Removing a partial stack

Proceed as follows:


2. Press the EJECT until the last printed page has been placed in the stacker.

3. Raise the stacker top by pressing the left key under this icon .

4. Cut the paper web with the paper cutter.

5. Remove the paper stack.

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6. Position the rest of the paper stack in line with the fold and move the stack to the marking for the corresponding format length.

7. Lower the stacker top by pressing the right key under this icon .


Proceed as follows:

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5.8 Working with setups

5.8 Working with setups

You can collect and save specific settings for frequently recurring print jobs in Setups.

By loading a setup of this type you can then set up the printing system for a print job with the corresponding parameters. Then all the required paper adjustments for inserting the paper are performed automatically.


5.8.1 Creating a new setup or changing a setup >>> page 134

5.8.2 Importing a setup >>> page 136

5.8.3 Exporting a setup >>> page 137

NoteWhen working with setups, the printing system must be in the "Stop" status.

Detailed information on the <Setup> and <Setup channel A / B / C> menus and the respective operating elements is also available directly in the operator panel via the context-sensitive Direct Help.The context-sensitive Direct Help can be called up by selecting the relevant menu or operating element and then pressing the F1 key.

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5.8.1 Creating a new setup or changing a setup


Requirements for saving setups:

• The "key operator" or an operator authorized by the key operator must be logged in.

• There can be no error message present.

Proceed as follows:






4. If this setup is not yet loaded, click the following button:

5. Click "Setup Contents" tab and check settings.

6. Adjust settings as required in the menus under <VarioStream> <Configuration>.

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7. Either:• overwrite setup under the same name (not for "default" setup). To do this:

– Click on the following button:

• or save setup under a new name. To do this:– Click on the following button:

– Enter the new name in the dialog window.– Click on the following button:

Proceed as follows:

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5.8.2 Importing a setup

5.8.2 Importing a setup

You can apply setups created on another printing system VarioStream 7000 SINGLE.

Proceed as follows:






4. Select from where the setup is to be imported:• Floppy disk• Transfer area (a directory on the <D: drive> of the SRA-controller hard disk, used

for the remote data transmission of setups)

5. If importing from a floppy disk, insert the floppy disk with the setups into the floppy disk drive of the SRA controller.

6. Select one or more setups in the dialog window.


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5.8.3 Exporting a setup

5.8.3 Exporting a setup

You can also export setups for other printing systems VarioStream 7000 SINGLE.

Requirements:

• The "key operator" or an operator authorized by the key operator must be logged in.

• A setup must be loaded. The loaded setup cannot be the "default" setup.

Proceed as follows:




<VarioStream> <VarioStream> menu



5. Select where the setup is to be exported:• Floppy disk• Transfer area (a directory on the <D: drive> of the SRA-controller hard disk, used

for the remote data transmission of setups)

6. If exporting to a floppy disk, insert a formatted floppy disk into the floppy disk drive of the SRA controller.


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5.9 Printing with another color

5.9 Printing with another color

To print with another color, you must replace:

• Toner feed

• Developer station


5.9.1 Replacing the toner feed >>> page 138

5.9.1.1 Removing toner feed >>> page 138

5.9.1.2 Installing toner feed >>> page 142

5.9.2 Replacing the developer station >>> page 145

5.9.2.1 Removing the developer station >>> page 145

5.9.2.2 Installing the developer station >>> page 154

5.9.1 Replacing the toner feed

You will find detailed information here on the following topics:

5.9.1.1 Removing toner feed >>> page 138

5.9.1.2 Installing toner feed >>> page 142

5.9.1.1 Removing toner feed

Proceed as follows:


2. Open the center door at the back of the printing system.

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3. Swivel toner bottle holder outwards using the handle.

4. Pull locking lever upwards. The drain head is swiveled off.

CautionThere can be a high build-up of static charge when vacuuming the toner spill.Always use an industrial vacuum cleaner with a grounded suction tube, rubber nozzle and filter set for fine dust. For larger quantities of toner spill (e. g. full bottle), the industrial vacuum cleaner must be explosion-proof.

Proceed as follows:

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5. Remove the toner bottle from the container.If toner is still present in and around the container, remove with a vacuum cleaner.

6. Open cover.

ImportantHoses can fall into the printing system.Make sure that the hoses do not fall into the printing system after you have pulled them out.

Proceed as follows:

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7. Remove the hose from the developer station and the air intake.

8. Remove the pin-and-socket connector between the drain head and the toner bottle holder.

9. Press back on the drain head mounting release and remove the drain head from the mounting.

10. 5.9.1.2 Installing toner feed >>> page 142

Proceed as follows:

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5.9.1.2 Installing toner feed


Proceed as follows:

1. Insert drain head into the mounting and press down until the you hear it engage.

2. Reattach the pin-and-socket connector between the drain head and the toner bottle holder.

3. Attach the hose to the developer station and the air intake.

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4. Close cover.

5. Make sure you use the correct toner type.Shake the new, closed toner bottle well to loosen the toner.

ImportantPossibility of mistaking fresh toner bottle for waste toner bottle.Only refill with original, sealed toner bottles secured by an intact banderole.

6. Place new toner bottle in the toner bottle holder.

7. Wait a few seconds until the toner has settled in the toner bottle.

8. Remove the lid of the toner bottle.

Proceed as follows:

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9. Press locking lever of drain head down, thus closing the toner bottle.

10. Slowly swivel the toner bottle back into position by the handle.

11. 5.9.2 Replacing the developer station >>> page 145

Proceed as follows:

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5.9.2 Replacing the developer station

5.9.2 Replacing the developer station

The developer station is removed using a replacement cart.

The replacement cart consists of the following main parts:


5.9.2.1 Removing the developer station >>> page 145

5.9.2.2 Installing the developer station >>> page 154

5.9.2.1 Removing the developer station


Preparations for removing the developer station >>> page 146

Removing the developer station >>> page 148

Final tasks for removing the developer station >>> page 152

Support Setscrews Pins

Handle Unlocking rod Roller brakes Locking bolts

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Preparations for removing the developer station

Proceed as follows:

1. Open the left and right doors at the front of the printing system.

2. Open the door in front of the photoconductor drum:• Pull lever forward.

3. Push safety lever to the right and open door by lever.

4. Put toner suction hose down.

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5. Hold developer station by the handle and pull out approx. 30 cm.

6. Remove vacuum hose.

7. Remove toner suction hose from toner box.

8. Mount the toner suction hose and vacuum hose in the rubber mounting above the fine filter.

Proceed as follows:

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Removing the developer station

9. Hold the developer station by the handle and push into the printing system to the stop point.

10. Removing the developer station >>> page 148

Proceed as follows:

1. Push the replacement cart towards the printing system and set the height of the support precisely:Turn the setscrews so that the two pins are directly opposite the corresponding holes on the printing system.

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Proceed as follows:

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2. Push the replacement cart forwards into the holes to the stop point.

3. Check whether the replacement cart has engaged in the printing system:Hold the replacement cart by the handle and pull backwards. The replacement cart must not come away from the printing system now.

CautionPossibility of damage to the replacement cart.Make absolutely sure that the replacement cart has engaged in the printing system. Otherwise, the replacement cart could be damaged at the horizontal guide rails when the developer station is pulled from the printing system in the next step.

4. Push the lever on both roller brakes downwards.

Proceed as follows:

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5. Hold the developer station by the handle and pull out to the stop point.

6. Press in handle.

7. Hold the developer station at the black connection box and pull out to the next stop point.

CautionDanger of pinching!Do not hold the developer station by the gear motor housing when you are removing the developer station from the printing system. Otherwise, you could crush your hand in the replacement cart's locking bolts.

Proceed as follows:

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8. Pull out the locking bolt on the printing system (to the left of the developer station) and at the same time hold the developerstation by the black contact box and pull out of the printing system until the replacement cart's locking bolt engages with the housing of the gear motor.

9. Check whether the replacement cart's locking bolt has engaged with the housing of the gearmotor.

10. Final tasks for removing the developer station >>> page 152

Proceed as follows:

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Final tasks for removing the developer station

Proceed as follows:

1. Push the lever on both roller brakes upwards.

2. Pull the replacement cart's unlocking rod and then pull the replacement cart backwards.

ImportantDeveloper can become lumpy.The developer station should not be subjected to strong heat!For this reason, do not put the replacement cart with the developer station in the direct vicinity of heat sources, such as heaters or hot air fans, nor in places where it could be exposed to direct sunlight.

3. Push the replacement cart to one side and leave in a location protected from direct heat.

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4. Push the lever on both roller brakes downwards. The replacement cart can now no longer roll unintentionally.

5. Cover developer station with the protective hood.The protective hood prevents objects entering the developer station and protects the developer mixture from contamination and soiling.

6. 5.9.2.2 Installing the developer station >>> page 154

Proceed as follows:

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5.9.2.2 Installing the developer station



Preparations for installing the developer station >>> page 154

Installing the developer station >>> page 156

Final tasks for installing the developer station >>> page 160

Preparations for installing the developer station

Proceed as follows:

1. Remove the protective hood above the developer station and put in a safe place.

2. Check whether the developer station is at the backmost position on the replacement cart. The locking bolt on the replacement cart must be engaged in the housing of the gear motor.

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4. Push the replacement cart with the developer station towards the printing system and set the height of the supports precisely:Turn the setscrews so that the two pins are directly opposite the corresponding holes on the printing system.

5. Installing the developer station >>> page 156

Proceed as follows:

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Installing the developer station

Proceed as follows:

1. Push the replacement cart forwards into the holes to the stop point.

2. Check whether the replacement cart has engaged in the printing system:Hold the replacement cart by the handle and pull backwards. The replacement cart must not come away from the printing system now.

CautionDanger of damage to the replacement cart.Make absolutely sure that the replacement cart has engaged in the printing system. Otherwise, the replacement cart could be damaged at the horizontal guide rails when the developer station is pushed into the printing system in the next step.

3. Push the lever on both roller brakes downwards.

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4. Remove locking bolts from the trolley and at the same time push the developer station forwards to the stop point.

Proceed as follows:

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5. Remove the retention bolts from the printing system and, at the same time, hold the developer station by the handle and push into the printing system to the stop point.


Proceed as follows:

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7. Pull the replacement cart's unlocking rod and remove the replacement cart from the printing system.

8. Push the replacement cart to one side.

9. Push the lever on both roller brakes downwards. The replacement cart can now no longer roll unintentionally.

10. Hold developer station by the handle and pull out approx. 30 cm

Proceed as follows:

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Final tasks for installing the developer station

11. Final tasks for installing the developer station >>> page 160

Proceed as follows:

1. Remove the toner suction hose and vacuum hose from the rubber mounting.

2. Insert the toner suction hose to the stop point in the developer station.

3. Push vacuum hose to the stop point on the developer station connecting pipe.

4. Take the toner hose from the mounting on the toner feed unit and push to the stop point on the developer station connecting pipe.

5. Check whether all hoses are pushed onto the connecting pipes up to the stop point.

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Proceed as follows:

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6. Hold the developer station by the handle and push into the printing system to the stop point.

7. Push in handle all the way.

8. Move toner suction hose up.

ImportantThe door of the photoconductor drum should close easily. If not, the developer station has not been pushed fully into the printing system. In this case, open the back door of the printing system and push the developer station into the printing system up to the stop point.

Proceed as follows:

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5.10 Converting the printing system


The printing system can be converted to a different configuration. The following configuration options are available:

• High quality - toner: black (600 dpi, 350 pages / minute)

• Normal quality - toner: CustomTone® (300 dpi, 350 - 550 pages / minute)

• Normal quality - toner: MICR (300 dpi, 350 - 550 pages / minute)

9. Close the photoconductor drum door.

ImportantPrint problems possible.Clean the toner mark sensor before you begin to print.

10. Clean the toner mark sensor (see section 6.8.1 Cleaning the toner mark sensor, page 207).

11. Close the center door at the back of the printing system.

12. Close the left and right door at the front of the printing system.


Proceed as follows:

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• Normal quality - toner: black (300 dpi, 350 - 600 pages / minute)

The following combination options result for the configuration of the printing system (depending on the installed SRA key):

• Normal quality - toner: Black

• Normal quality - toner: CustomTone®



• Normal quality - toner: MICR

• High quality - toner: Black










Requirements for printing system conversion:

• the printing system must be convertible

• the corresponding SRA key is installed

• user rights are available for this menu

• the access ticket for this operator field is requested

• the printing system is in the "Stop" or "Operator intervention necessary" state.

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5.10.1 Selecting a configuration

5.10.1 Selecting a configuration

Proceed as follows:

1. Click on the <VarioStream> <Configuration> <Printing system> <Conversion> menu.

2. The "Conversion" menu page opens, e. g.:

Select the desired entry under "Configuration", e. g.:

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5.10.2 Converting the printing system

5.10.2 Converting the printing system

The following worksteps must be carried out in sequence in order to convert the printing system to the desired configuration:

• 5.10.2.1 Start conversion >>> page 165

• 5.10.2.2 Replacing the toner feed >>> page 166

• 5.10.2.3 Replacing the developer station >>> page 168

• 5.10.2.4 Replacing the photoconductor drum >>> page 169

• 5.10.2.5 Replacing the fuser roller >>> page 170

5.10.2.1 Start conversion

Proceed as follows:

1. The first step is preselected under "Worksteps":

Information on the icons displayed on the operator panel under "Worksteps":see section Icons, page 93

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5.10.2.2 Replacing the toner feed


2. Click on the the following button to start the printing system conversion to the selected configuration:

Proceed as follows:

NoteDepending on the selected configuration, only toner bottles permitted for this configuration are listed for installation.

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Proceed as follows:

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1. The list with the worksteps for replacing the toner feed is displayed in the right half of the window:

The worksteps in the list must be followed in order.Detailed information on replacing the toner bottle:see section 7.2.1 Replacing the toner bottle, page 226


2. Click on the following button to complete the toner feed replacement:

Proceed as follows:

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5.10.2.3 Replacing the developer station

5.10.2.3 Replacing the developer station

Proceed as follows:

NoteDepending on the selected configuration, only developer stations permitted for this configuration are listed for installation.

1. The list with the worksteps for replacing the developer station is displayed in the right half of the window:

The worksteps in the list must be followed in order.Detailed information on replacing the developer station:see section 5.9.2 Replacing the developer station, page 145


2. Click on the following button to complete the developer station replacement:

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5.10.2.4 Replacing the photoconductor drum

5.10.2.4 Replacing the photoconductor drum

Proceed as follows:

NoteDepending on the selected configuration, only PC drums permitted for this configuration are listed for installation.

1. The list with the worksteps for replacing the PC drum is displayed in the right half of the window:

The worksteps in the list must be followed in order.Detailed information on replacing the PC drum:see section 7.3.1 Replacing the photoconductor drum, page 257


2. Click on the following button to complete the PC drum replacement:

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5.10.2.5 Replacing the fuser roller

5.10.2.5 Replacing the fuser roller

Proceed as follows:

NoteDepending on the selected configuration, only fuser rollers permitted for this configuration are listed for installation.

1. The list with the worksteps for replacing the fuser roller is displayed in the right half of the window:

The worksteps in the list must be followed in order.Detailed information on replacing the fuser roller:see section 7.3.8 Replacing the fuser roller, page 312


2. Click on the following button to complete the fuser roller replacement:

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5.10.3 Completing the conversion

5.10.3 Completing the conversion

Proceed as follows:

1. After replacing the fuser roller, the values entered during conversion of the printing system are applied and checked for validity. This takes approx. 2 minutes and cannot be cancelled.


2. To complete the printing system conversion, click on the following button:

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5.11 Emptying condensation water when using the High Temperature Kit (optional)

5.11 Emptying condensation water when using the High Temperature Kit (optional)

The condensation water that accumulates when using the High Temperature Kit must be collected in a suitable container.

Proceed as follows:

1. Open the slide-in unit with the condensation water container.

2. Remove the condensation water container and empty it.

3. Place the empty container into the slide-in unit.

4. Close the slide-in unit with the condensation water container.

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5.12 Powering off the printing system


Proceed as follows:

1. "Drain printer", i.e. switch the printing system software offline .

2. Click the following button:

The printing system is switched to the "Stop" status.

3. Deactivate the active channel links on the operator panel. To do this, click the following button:

The <Channels> menu is displayed.

To deactivate the channel, click the following button:

and confirm:

During the time needed for deactivation, the clutch icon is shown in yellow. A deactivated channel is represented by the following icon:

4. Eject paper from the paper transporter and the fuser station.If all the paper in the stack was printed on, the paper is automatically ejected.

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5. If you want to deactivate the printing system after the job is finished, but no paper end is present, an artificial paper end must be generated beforehand:Cut paper web.

6. Press the EJECT key until the paper is placed in the stacker.

7. On the operator panel, click the following button:

and confirm:

ImportantObserve waiting periodThe controller requires this time to back up the data. Powering off prematurely via the main circuit breaker can lead to data loss.

8. Only if the printing system is also to be detached from the line power supply:Turn the main circuit breaker on the right side of the printing system to the "O" position.

NoteIf the optional High Temperature Kit is used, the external recooling system must also be powered off again.

Proceed as follows:

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6 Cleaning the printing system

6 Cleaning the printing system

6.1 Overview

This section shows you the intervals for cleaning the different assemblies.

Strictly observe the following safety information when cleaning:

CautionThe printer system could start unexpectedly if it is not in "Stop" status.Ensure that the printing system is in the "Stop" status before you begin cleaning.

There can be a high build-up of static charge when vacuuming the toner spill.Always use an industrial vacuum cleaner with a grounded suction tube, rubber nozzle and filter set for fine dust. For draining large quantities of toner spill (such as a full bottle), the industrial vacuum cleaner must be explosion-proof.

There is a danger of slipping on toner or developer spill.Clean up toner and developer spill immediately.

The printing system can be damaged if incorrect cleaning materials or equipment are used.Only use specified cleaning materials and equipment (see section Cleaning materials and equipment, page 365).

ImportantSpilled toner is soiled.Re-using spilt toner causes printing problems.Never use spilled toner for printing.

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6.1 Overview


6.2 Cleaning intervals >>> page 177

6.3 Cleaning the paper path >>> page 189

6.4 Cleaning plastic strips >>> page 188

6.5 Cleaning the fuser station >>> page 191

6.6 Cleaning the soft fuser roller >>> page 199

6.7 Cleaning the developer station >>> page 203

6.8 Cleaning sensors >>> page 207

6.10 Cleaning the toner suction system >>> page 213

6.11 Cleaning the corotrons >>> page 218

6.12 Cleaning the LED print head >>> page 219

6.13 Cleaning the filter >>> page 220

6.14 Cleaning the operator panel >>> page 223

6.15 General cleaning >>> page 224

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6.2 Cleaning intervals


The table shows the cleaning activities required for reliable and stable print operation:

Time and display on operator panel Cleaning location See section

After every change of shiftor every 8 hours

Paper path 6.3 Cleaning the paper path >>> page 189

Plastic strips and particle bin

6.4 Cleaning plastic strips >>> page 188

Fuser station 6.5 Cleaning the fuser station >>> page 191

Weekly or after 500,000 pages Developer station 6.7 Cleaning the developer station >>> page 203

When replacing consumables Oiling unit in the fuser station

6.5 Cleaning the fuser station >>> page 191

Toner dust indicator 7.3.11 Replacing the fine filter >>> page 330

Toner supply bin surrounding area

7.2.1 Replacing the toner bottle >>> page 226

Container for waste toner bottle

7.2.3 Replacing the waste toner bottle >>> page 233

After paper has wrapped itself around the fuser roller.

Soft fuser roller 6.6 Cleaning the soft fuser roller >>> page 199

Toner concentration too lowToner mark not detectedBackground too high

Toner mark sensor 6.8.1 Cleaning the toner mark sensor >>> page 207

No paper movement Paper motion sensor and mirror

Edge control error Paper edge sensor in the fuser station

6.9.2 Cleaning the paper edge sensor in the fuser station >>> page 219

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As required Cleaning the corotrons 6.11 Cleaning the corotrons >>> page 218

Cleaning the LED print head

6.12 Cleaning the LED print head >>> page 219

Cleaning the operator panel

6.14 Cleaning the operator panel >>> page 223

General cleaning 6.15 General cleaning >>> page 224

Time and display on operator panel Cleaning location See section

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6.3 Cleaning the paper path


Cleaning the paper path


Proceed as follows:


2. Open the cover hood.

3. Open the left door at the front of the printing system.

4. Remove paper from the paper path.

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5. Remove the paper stack and vacuum the stacker if it is accessible.

Proceed as follows:

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6. Turn the knob to the left and open the rocker.

7. Vacuum the paper dust and paper particles in the input tray and along the paper path.

8. Swivel up the locking lever and release.

Proceed as follows:

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9. Swivel down the paper transporter by the handle to the stop point.

10. When doing so, ensure that the locking lever is engaged on the conveyor.

11. With the vacuum cleaner, vacuum the toner, dust and paper particles from the paper transporter and environment.

Proceed as follows:

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12. Swivel down the paper transporter by the handle to the stop point and hold firmly. At the same time, raise the locking lever with your thumb to the point where it jumps back to its exit position.

CautionDanger of pinching when swiveling up the paper transporter.In the next step, swivel the paper transporter upwards slowly and mind your fingers.

13. Swivel the paper transporter up again.

14. Close the rocker.

15. Clean the area between the paper transporter and developer station with the vacuum cleaner.

Proceed as follows:

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16. Press the two pressure pins inwards.

17. Turn the knob to the left and open the rocker.

18. Remove the paper insertion plate.

Proceed as follows:

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19. Affix vacuum cleaner nozzle as shown in the diagram, and vacuum paper dust and confetti in the entire area.

20. Reinsert the paper insertion plate.

21. Close the rocker.

Proceed as follows:

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22. Press pressure pins inwards to lock.


CautionDanger of burning when touching the hot preheating saddle.Do not touch the hot preheating saddle.

24. Clean the suction slots of the preheating saddle with a brush and a vacuum cleaner.

Proceed as follows:

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25. Only for printing systems with heated preheating saddle:Close cover above the preheating saddle again.

26. Clean the two fold sensors and the associated reflectors on the stacker with a soft cloth.


28. Close the left door at the front of the printing system.

29. Click the following button to switch the printing system to the "Ready" status:

Proceed as follows:

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6.4 Cleaning plastic strips


Remove plastic strips

Proceed as follows:


2. Open the right door at the front of the printing system.

3. Pull the lever forwards to open the door in front of the photoconductor drum.

4. Push locking lever to the right and open door by lever.

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5. Pull plastic strips out of the mounting.

6. Clean plastic strips with a soft paper towel.

Proceed as follows:

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Insert plastic strips

Proceed as follows:

7. Push plastic strips back into the mounting.

8. Close the door in front of the photoconductor drum.

9. Close the right door at the front of the printing system.


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6.5 Cleaning the fuser station


Cleaning the fuser station


Proceed as follows:


2. Open the front and side door of the fuser station.

CautionThe components in the fuser station reach a surface temperature of approximately

230 oC in operation.If you touch them, you may burn yourself.

Do not touch any parts behind the safety covers identified with the icon .

3. Turn the knob on the oiling unit to the left.

4. Swivel on oiling unit.

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5. Lift up the active filter unit on the right side using the handle and swivel out by the rotary axle.


230 oC.If you touch them, you may burn yourself.Allow the printing system to cool down for at least 30 minutes with an open fuser station and put on heat protection gloves.

6. Allow the printing system to cool down in this state for at least 30 minutes.

7. Put on heat protection gloves.


8. Clean the suction slots with a brush and a vacuum cleaner.

Proceed as follows:

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9. Swing the active filter unit back by the handle until it reaches the stop point.


10. Vacuum the cleaning belt of dirt below the contact surface with the fuser roller.

11. Put on heat protection gloves (if you are not already wearing them).

Proceed as follows:

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12. Press against pressure pin and swivel out the waste collector.

13. Check the waste collector.

ImportantDo not damage the cleaning plate.

14. Remove dirt from the cleaning plate with the paper cutter.

15. If it is over half filled with dirt, insert a new waste collector (see section 7.3.10 Replacing the waste collector, page 326).

Proceed as follows:

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16. Turn fuser roller by hand and check visually whether visible damage, such as scratches, loosened coating or blistering is present on the surface. Replace the fuser roller if damaged (see section 7.3.8 Replacing the fuser roller, page 312).

17. Only if a soft fuser roller is installed: Also check whether the fuser roller is soiled with toner.If so, clean the fuser roller (see section (see section 6.6 Cleaning the soft fuser roller, page 199)).

18. Press the lock and swivel off the lower cover.

19. Push the lock below the fuser station to the left and swivel off the roller saddle.

Proceed as follows:

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20. Turn pressure roller by hand and check visually whether visible damage, such as scratches, loosened coating or blistering is present on the surface. Replace the pressure roller if damaged (see section 7.3.9 Replacing the pressure roller, page 320).

21. Swivel on roller saddle.

22. Swivel on lower cover and lock.

Proceed as follows:

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23. Swivel back waste collector and lock by pressing knob.

24. Wipe off traces of oil in and around the waste collector and around the stacker cover area with a paper towel or cloth.

25. Swivel on oiling unit and tighten knob.

26. Close the front and side door of the fuser station.


Proceed as follows:

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Proceed as follows:

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6.6 Cleaning the soft fuser roller


Strictly observe the following safety directives when cleaning the fuser roller:

If there is toner residue on the fuser roller, the fuser roller must be cleaned. Especially if paper has wrapped itself around the fuser roller, toner may be stuck on the fuser roller.

Caution• Clean soft fuser rollers only when they have cooled off, otherwise there is a danger

of burning. For this reason, allow the open fuser station to cool down for at least 30 minutes before cleaning the fuser roller.

• The cleaning agent is very flammable. Danger of fire!• Do not allow developer to get into eyes. In the event of contact with eyes, rinse eyes

out with plenty of water and seek medical help.• Do not breathe in the cleaning agent vapors. If you experience unpleasant

symptoms after inhaling, immediately go into the fresh air and, if necessary, call a doctor.

• Keep cleaning materials out of the reach of children and store away from containers used for food and drink.

Important• Do not use hard objects for cleaning, as they may damage the fuser roller.• Clean the soft fuser roller only with the prescribed cleaning agent (roller cleaner 6-

1508/W1/H).

Proceed as follows:

1. Power off printing system.




Do not touch any parts behind the safety covers identified with the icon.

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3. Turn the knob on the cleaning station to the left.

4. Swivel on cleaning station.


230 oC.If you touch them, you may burn yourself.Allow the printing system to cool down for at least 30 minutes with an open fuser station and put on heat protection gloves.

5. Allow the printing system to cool down for approximately 30 minutes.


7. Press against pressure pin and swivel out waste collector.

8. Soak a fluff-free towel (e.g. paper towel) with cleaning agent 6-1508/W1/H.

Proceed as follows:

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9. Press the cloth lightly on to the fuser roller and remove all toner residue with circular movements.

10. Swivel the waste collector back into position and lock with the knob.

11. Swivel on cleaning station again and tighten knob.



Proceed as follows:

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Proceed as follows:

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6.7 Cleaning the developer station


Proceed as follows:


2. Open the right door at the front of the printing system.

3. Pull the lever forwards to open the door in front of the photoconductor door.

4. Push the locking lever to the right. Pull the door by the lever and open it to the stop point.

5. Open the center and left door at the back of the printing system.

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6. Turn the knob to the left to open the door in front of the developer station.

7. Open the door in front of the developer station.

8. Pull the vacuum hose from the toner box and hang in the rubber clip above the fine filter.

Proceed as follows:

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9. Pull the developer station outwards by the handle to the stop point.


ImportantDo not vacuum around the developer roller, as you might vacuum up developer mix.When performing the following cleaning, only vacuum the specified parts.

10. Using a vacuum cleaner, vacuum toner, developer and paper residue from the front suction bar, on the felt and on the upper cover of the developer station.

11. Push in the developer station by the handle until it reaches the stop point.

Proceed as follows:

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12. Remove vacuum hose from the rubber clip and insert into the toner box until it reaches the stop point.

13. Close the center and left door at the back of the printing system.

14. Close the door in front of the photoconductor drum.

15. Close the right door at the front of the printing system.


Proceed as follows:

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6.8 Cleaning sensors

6.8 Cleaning sensors

An error message in the operator panel notifies you that it is time for cleaning.

6.8.1 Cleaning the toner mark sensor

Proceed as follows:


2. Remove the photoconductor drum(see section 7.3.1 Replacing the photoconductor drum, page 257).

3. Clean the toner mark sensor with a soft cloth.

4. Reinsert the photoconductor drum(see section 7.3.1 Replacing the photoconductor drum, page 257).


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6.8.1 Cleaning the toner mark sensor

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6.9 Cleaning the paper motion sensor and mirror


Proceed as follows:



3. Open front upper tractor door.

4. Clean mirror and paper motion sensor with a soft cloth.

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5. Close the tractor door again.



Proceed as follows:

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6.9.1 Cleaning the paper edge sensor in the fuser station


Proceed as follows:




CautionThe preheating saddle can be very hot. Danger of burning if touched.Do not touch the hot preheating saddle when you are cleaning the paper edge sensor.

4. Clean paper edge sensor at the fuser station infeed with the cleaning equipment (A) supplied.

A

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5. Only for printing systems with heated preheating saddle:Close cover above the preheating saddle again.



Proceed as follows:

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6.10 Cleaning the toner suction system



There is a danger of slipping on toner or developer spill.Clean up toner and developer spill immediately.

Proceed as follows:



3. Pull the container downwards with the handle.

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4. Move the lever upwards to swivel off the drain head.

5. Remove the toner bottle from the container.

6. Open cover.

Proceed as follows:

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7. Pull the hose off the developer station and vacuum with an explosion-proof industrial vacuum cleaner.

8. Vacuum the surface of the drain head.

Also quickly vacuum out the toner suction hose through the drain head.

Proceed as follows:

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9. Stick the hose back on.

10. Reinsert toner bottle in the container.


Proceed as follows:

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12. Use the handle to turn the container upwards slowly.



Proceed as follows:

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6.11 Cleaning the corotrons

6.11 Cleaning the corotrons

Proceed as follows:

Important

Corotrons can only be cleaned when printing is stopped.


2. Select the <Special functions> <Clean corotrons> menu on the operator panel.

3. Click on the following button to start corotron cleaning:

Corotron cleaning is started. The corotrons are run in and then lowered again.The process takes approx. 1 minute.

Information on the icons displayed on the operator panel under "Worksteps":

see section Icons, page 93

4. Click the following button on the operator panel to complete corotron cleaning:

The printing system remains in the "Stop" status.


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6.12 Cleaning the LED print head

6.12 Cleaning the LED print head

Note

The cleaning process for the LED print head is usually carried out automatically after a certain number of pages has been printed. The number of pages is set by service.In rare cases LED print head cleaning may have to be started manually.

CautionWhen cleaning the LED print head, please also observe the other safety directives in section 6 Cleaning the printing system >>> page 175.

Proceed as follows:

Important

You can only carry out LED print head cleaning when in the "Stop" or "Operator intervention necessary" status.


2. Select the <Special functions> <Clean LED print head> menu on the operator panel.

3. Click the following button to start LED print head cleaning:

LED print head cleaning is started.

Information on the icons displayed on the operator panel under "Worksteps":

see section Icons, page 93

4. Click the following button on the operator panel to complete LED print head cleaning:

The printing system remains in the "Stop" status.

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6.13 Cleaning the filter




Before cleaning the filter, please observe the other safety directives in section 6 Cleaning the printing system >>> page 175.

Proceed as follows:

Important

You can only carry out filter cleaning when in the "Stop" or "Operator intervention necessary" status.


2. Open the cover and both doors at the front of the printing system.

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Proceed as follows:

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3. Open the quick lock on the filter cover.

4. Remove the filter cover.


5. Clean filter with vacuum.

Proceed as follows:

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6. Reattach the filter cover.

7. Close the quick lock on the filter cover.

8. Close the cover and both doors at the front of the printing system.


Proceed as follows:

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6.14 Cleaning the operator panel

6.14 Cleaning the operator panel

Cleaning when the printing system is shut off

Cleaning during printing

Proceed as follows:

1. Clean screen with a moist cloth.

Proceed as follows:

1. Click on the <General> <Tools> menu.


3. Clean screen with a moist cloth.


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6.15 General cleaning

6.15 General cleaning


Proceed as follows:

1. Vacuum clean the floor around the printing system.

CautionFluid can get inside the printing system. This could cause irreparable damage to the electrical and mechanical components.Do not place cleaning fluids on top of or in the immediate vicinity of the printing system and ensure that no fluids enter the printing system.

2. Cleaning the surface of the housing:• Add some mild household detergent to water and dip a soft cloth into the solution.• Wring the cloth out well. Wipe down the surfaces of the housing with the cloth.

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7 Replacing consumables and expendables

7 Replacing consumables and expendables

7.1 Overview

This section describes in detail all the steps required to replace consumables or expendables.


7.2 Replacing consumables >>> page 226

7.3 Replacing expendables >>> page 256

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7.2 Replacing consumables

7.2 Replacing consumables

A warning on the operator panel indicates when the consumables should be refilled or replaced. If the consumables are not replaced before a particular number of pages are printed, the printing system stops and displays an error message. The relevant consumable or expendable must be replaced at that point.

7.2.1 Replacing the toner bottle

Strictly observe the following safety directives when replacing the toner bottle:

Consumable See section

Toner bottle 7.2.1 Replacing the toner bottle >>> page 226

Toner box 7.2.2 Filling the toner box >>> page 232

Waste toner bottle 7.2.3 Replacing the waste toner bottle >>> page 233

Developer 7.2.4 Replacing the developer >>> page 238

Fuser oil bottle 7.2.5 Replacing the fuser oil bottle >>> page 252

Caution• Do not allow toner to get into eyes. In the event of contact with eyes, rinse eyes out

with plenty of water and seek medical help.• Avoid contact with skin; wear gloves. In the event of contact with the skin, wash toner

off with plenty of water.• Do not inhale toner. Avoid accumulation of dust. If, after inhaling toner, you

experience symptoms such as nausea, headaches or dizziness, immediately go out into the fresh air.

• Do not spill toner. You can slip on spilled toner. Clean up toner spill immediately.

• Always use an industrial vacuum cleaner with a grounded suction tube, rubber nozzle and filter set for fine dust. For larger quantities of toner spill (e. g. full bottle), the industrial vacuum cleaner must be explosion-proof.

• Keep toner out of the reach of children and store it away from containers used for food and drink.

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The printing system detects the end of the toner supply automatically and displays a warning on the operator panel in good time. The following procedure is for replacing the toner bottle:

- Removing the toner bottle >>> page 227

- Installing the toner bottle >>> page 229

Removing the toner bottle

Important• Only use toner that is suitable for the developer being used (see section

Consumables, page 356).• Only refill with original, sealed toner bottles secured by an intact seal.• Do not re-use toner.

• Always store toner in a cool (< 35 oC), dry and well ventilated room.• Never expose toner to direct heat (sunlight, heaters, etc.)


Proceed as follows:


2. On the operator panel select:• Menu <Replace consumables> <Replace toner bottle>

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3. Click the following button to start toner bottle replacement:



5. Swivel toner bottle holder outwards using the handle.

6. Pull locking lever upwards. The drain head is swiveled off.

Proceed as follows:

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Installing the toner bottle


7. Remove the toner bottle from the container.If toner is still present in and around the container, remove with a vacuum cleaner.

ImportantKeep the empty toner bottle. This is used as the replacement for a full waste toner bottle.

CautionObserve the safety directives before installing the toner bottle (see section 7.2.1 Replacing the toner bottle, page 226).

Proceed as follows:

1. Make sure you use the correct toner type.Shake the new, closed toner bottle well to loosen the toner.

ImportantPossibility of mistaking fresh toner bottle for waste toner bottle.Only refill with original, sealed toner bottles secured by an intact banderole.

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Proceed as follows:

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2. Place new toner bottle in the toner bottle holder.

3. Wait a few seconds until the toner has settled in the toner bottle.

4. Remove the lid of the toner bottle.


Proceed as follows:

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6. Slowly swivel the toner bottle back into position by the handle.


8. On the operator panel, enter whether a new toner bottle has been fitted:

•The message on the operator panel is deleted automatically, the replacement of the toner bottle is recorded in the <Consumables history> menu and the consumable counter is reset.

•The consumable counter is not reset.

9. Click the following button on the operator panel to complete toner bottle replacement:

All printing system assemblies are checked (duration approx. 2-3 minutes) before the printing system is switched to the "Ready" status.

In both cases, the message on the operator panel is automatically deleted, the replacement of the toner bottle is recorded in the <Consumables history> menu and the consumable counter is reset.

Proceed as follows:

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7.2.2 Filling the toner box

7.2.2 Filling the toner box

Proceed as follows:


2. On the operator panel select:• Menu <Replace consumables> <Fill toner box>

3. Click the following button to start filling the toner box:

The toner is fed into the toner box.


4. Click the following button on the operator panel to complete the filling of the toner box:


In both cases, the filling of the toner box is documented in the <Consumables history> menu.

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7.2.3 Replacing the waste toner bottle


Strictly observe the following safety directives when replacing the waste toner bottle:

The printing system detects when the waste toner bottle is full automatically and displays a warning on the operator panel in good time. The following procedure is for replacing the waste toner bottle:

- Removing the waste toner bottle >>> page 233

- Installing the waste toner bottle >>> page 236

Removing the waste toner bottle


with plenty of water and seek medical help.• Avoid contact with skin; wear gloves. In the event of contact with the skin, wash toner

off with plenty of water.• Do not inhale toner. Avoid accumulation of dust. If, after inhaling toner, you


• Do not spill toner. You can slip on spilled toner. Clean up toner spill immediately.

• Keep waste toner bottle out of the reach of children and store it away from containers used for food and drink.


ImportantKeep used toner ready for collection by service or the contracted shipping company .


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Proceed as follows:


2. On the operator panel select:• Menu <Replace consumables> <Replace waste toner bottle>

3. Click on the following button to start the waste toner bottle replacement:


4. Open the left and center door at the back of the printing system.

5. Pull the locking lever of the waste toner bottle holder forwards. The waste toner bottle holder will move to its lower position.

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6. Remove waste toner bottle holder by the locking lever.

7. Place interlock lid on the full waste toner bottle.


8. Remove bottle from holder by the handle.If toner has gathered in the holder, remove with a vacuum cleaner.

Proceed as follows:

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Installing the waste toner bottle

CautionObserve the safety directives before inserting the waste toner bottle (see section 7.2.3 Replacing the waste toner bottle, page 233).

Proceed as follows:

1. Take an empty toner bottle and insert into the waste toner bottle holder so that its handle is to the right.

2. Remove the lid of the empty toner bottle.

3. Push in the waste toner bottle holder and lock with the locking lever.

4. Close the left and center door at the back of the printing system.

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5. Click the following button on the operator panel to complete waste toner bottle replacement:


In both cases, the message on the operator panel is automatically deleted, the replacement of the waste toner bottle is recorded in the <Consumables history> menu and the consumable counter is reset.

Proceed as follows:

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7.2.4 Replacing the developer


Observe the following safety directives when replacing the developer:

The printer detects the end of the developer's service life automatically and displays a warning on the operator panel in good time.

The following procedure is for developer replacement:

- Empty developer station >>> page 239

- Filling new developer >>> page 244

Caution• Do not allow developer to get into eyes. In the event of contact with eyes, rinse eyes

out with plenty of water and seek medical help.• Avoid contact with the skin; wear gloves. In the event of contact with skin, wash

developer off with plenty of water.• Do not inhale developer. Avoid accumulation of dust. If, after inhaling developer, you


• Do not spill developer. There is a danger of slipping on spilled developer. Clean up developer spill immediately.

• Always use an industrial vacuum cleaner with a grounded suction tube, rubber nozzle and filter set for fine dust. For larger quantities, the industrial vacuum cleaner must be explosion-proof.

• Keep developer out of the reach of children and store it away from containers used for food and drink.

Important• Use only permitted developer (see section Consumables, page 356).• Only use original, sealed developer bottles for refilling.• Do not re-use used developer.

• Always store developer in a cool (< 35 oC), dry and well ventilated room.• Never expose developer to direct heat (sunlight, heaters, etc.)• Keep used developer ready for collection by service or the contracted shipping

company .

NoteThe printing system will continue to print even when the end of the developer's service life has been reached.This means that the developer counter in the <Consumables counter> menu can also register negative.

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Empty developer station

Proceed as follows:


2. On the operator panel select:• Menu <Replace consumables> <Replace developer>

3. Click on the following button to start the developer replacement:



5. Replace waste toner bottle with an empty one(see section 7.2.3 Replacing the waste toner bottle, page 233).

6. Set rotary switch to the "SERVICE" position.

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7. Turn the turning knob to the left and swivel off the fan from the developer station.

8. Pull out the lid from the developer station vacuum opening.

9. Remove vacuum hose from the toner box and insert in developer station vacuum opening. Ensure that the noses on the handle lie in the vacuum opening guides.

Proceed as follows:

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10. Move the lever to the right.

11. Click on the following button to start the developer replacement:

The developer is automatically extracted.

12. Repeat as needed. Click the following button on the operator panel:

If the developer has already been completely removed, click the following button:.

13. Move the lever to the left.

Proceed as follows:

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14. Remove the vacuum hose from the vacuum opening and place in the toner box.

15. Close the vacuum opening of the developer station with the lid.

16. Set rotary switch to the "PRINT" position.

Proceed as follows:

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17. On the operator panel, select whether the new developer is to be filled now:• To fill the developer directly afterward, click the following button:

The printing system remains in "Stop" status..

In this case, continue with step 7. >>> page 245.

• To fill the developer later, click the following button:


18. Swivel on the fan to the developer station and turn the turning knob to the right.


20. Click the following button on the operator panel to complete developer replacement:


In both cases, the message on the operator panel is automatically deleted, the replacement of the developer is recorded in the <Consumables history> menu and the consumable counter is reset.

Proceed as follows:

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Filling new developer

CautionObserve the safety directives before filling the developer (see section 7.2.4 Replacing the developer, page 238).

NoteIf the first worksteps for replacing the developer have already been carried out, then continue with step 7. >>> page 245.

Proceed as follows:


2. On the operator panel select:• Menu <Replace consumables> <Fill developer>

3. Click on the following button to start refilling the developer:



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5. Set rotary switch to PRINT.

6. Turn the turning knob to the left and swivel off the fan from the developer station.

ImportantOnly use an original, sealed developer bottle for filling.

7. Remove lid from full developer bottle.

Proceed as follows:

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8. Place developer bottle in the cage.

9. Insert the cast-in hook of the funnel into the horizontal gap of the cage.

10. Place funnel together with the hose on the developer bottle.

Proceed as follows:

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11. Use the metal clamp on the opposite side to fasten the funnel to the cage.

12. Open lid on the developer station refill pipe and insert the hose.

13. Ensure that the hose is affixed properly.

Proceed as follows:

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14. Hang the cage with the developer bottle upside down into the upper recess on the printing system frame.Make sure that there is no bend in the hose.

15. Shake bottle carefully.

16. In the dialog window of the operator panel still displayed, confirm the filling process by pressing the <Refill> button.

17. Click on the following button to start the filling process:

The developer runs into the developer station without shaking.

Proceed as follows:

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18. Check hose to see if the developer bottle is completely empty:• If the developer bottle was not completely emptied, restart process. Do this by

clicking on the following button in the operator panel:

• If the developer bottle has already been completely emptied, click the following button:

19. Detach the cage with the developer bottle and turn.

Proceed as follows:

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20. Remove the tube end from the developer opening and remove the funnel from the developer bottle.

21. Swivel on the fan to the developer station and turn the turning knob to the right.


23. Click the following button on the operator panel to complete refilling the developer:


In both cases, the message on the operator panel is automatically deleted, the replacement of the developer is recorded in the <Consumables history> menu and the consumable counter is reset.

Proceed as follows:

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ImportantOnly when using (CustomTone®):After a print job is started, a procedure for mixing the developer begins automatically. This procedure takes approx. 5 minutes. The print job will then continue automatically.

Proceed as follows:

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7.2.5 Replacing the fuser oil bottle


Strictly observe the following safety directives when replacing the fuser oil bottle:

The printer detects the end of the fuser oil supply automatically and displays a warning on the operator panel. The following procedure is for replacing the fuser oil bottle:

- Remove fuser oil bottle >>> page 252

- Install the fuser oil bottle >>> page 254

Remove fuser oil bottle

Caution• Do not allow fuser oil to get into eyes. In the event of contact with eyes, rinse eyes

out with plenty of water and seek medical help.• Avoid contact with the skin. In the event of contact with the skin, wash fuser oil off

with plenty of water.• Do not spill fuser oil. There is a danger of slipping on spilled fuser oil.• If you do spill fuser oil, immediately apply an agent such as siliceous earth

(kieselguhr) to bind the fluid, and dispose of in a suitable manner.• Keep fuser oil out of the reach of children and store it away from containers used for

food and drink.

Proceed as follows:


2. On the operator panel select:• Menu <Replace consumables> <Replace fuser oil bottle>

3. Click on the following button to start the fuser oil bottle replacement:


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5. Open packaging with the new fuser oil bottle. Use a knife to make a cross-cut in the seal and ready the fuser oil bottle.

6. Swivel out fuser oil bottle holder with the empty fuser oil bottle.

7. Open flap and remove oil suction tube from the fuser oil bottle. Wipe away any residual oil from the tube end at the bottle opening.

8. Immediately place the end of the oil suction tube into the new fuser oil bottle and engage flap.

9. Remove empty fuser oil bottle from the fuser oil bottle holder.

Proceed as follows:

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Install the fuser oil bottle

CautionObserve the safety directives before installing the fuser oil bottle (see section 7.2.5 Replacing the fuser oil bottle, page 252).

Proceed as follows:

1. Insert the new fuser oil container so that the handle points outwards.

2. Wipe away any spilled oil with a paper towel.

ImportantThe hose can bend. The fuser oil cannot be filled in this case.Ensure that the hose is not bent when you tip back the vacuum container.

3. Swivel back the fuser oil bottle holder with the full fuser oil bottle. Make sure that there is no bend in the hose.

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5. Click the following button to complete filling the developer at the operator panel:


In both cases, the message on the operator panel is automatically deleted, and the replacement of the fuser oil bottle is recorded in the <Consumables history> menu.

Proceed as follows:

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7.3 Replacing expendables

7.3 Replacing expendables

NoteA warning will be displayed on the operator panel before the service life of an expendable ends.

In the <Displays> <Consumables counter> menu you can check the current counter status and the respective limit values for each expendable.

Expendable See section

Photoconductor drum 7.3.1 Replacing the photoconductor drum >>> page 257

Cleaning brush 7.3.3 Replacing the cleaning brush >>> page 263

Replacing corotrons 7.3.4 Replacing corotrons >>> page 269

Replace transfer corotron 7.3.4.2 Replacing the transfer corotron (1 cartridge) (pinfed) >>> page 271

Transfer corotron wire is torn 7.3.4.2 Replacing the transfer corotron (1 cartridge) (pinfed) >>> page 271

Replace charge corotrons 7.3.4.4 Replacing charge corotrons (5 cartridges) >>> page 278

Charge corotron wire is torn 7.3.4.5 Replacing charge corotrons (torn wire) >>> page 281

Replace discharge corotrons 7.3.4.6 Replacing discharge corotrons (2 cartridges) >>> page 284

Discharge corotron wire is torn 7.3.4.7 Replacing the discharge corotron (torn wire) >>> page 287

Active filter 7.3.5 Replacing the active filter >>> page 291

Cleaning belt 7.3.6 Replacing the cleaning belt >>> page 297

Heater 7.3.7 Replacing the heater >>> page 302

Fuser roller 7.3.8 Replacing the fuser roller >>> page 312

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7.3.1 Replacing the photoconductor drum


Strictly observe the following safety directives when replacing the photoconductor drum:

The following procedure is for replacing the PC drum:

- Remove photoconductor drum >>> page 258

- Install the the photoconductor drum >>> page 260

Pressure roller 7.3.9 Replacing the pressure roller >>> page 320

Waste collector 7.3.10 Replacing the waste collector >>> page 326

Fine filter 7.3.11 Replacing the fine filter >>> page 330

Caution• The photoconductor drum may only be replaced by operators after training or

instructions from service personnel.• When replacing the photoconductor drum, always wear the gloves provided.

Skin ailments can result from touching the photoconductor drum.If you touch the drum, wash skin thoroughly with soap and water.

• Keep photoconductor drums out of the reach of children.

Important• If pieces of the photoconductor drum coating flake off, you must collect all these

pieces.Store old photoconductor drums with protective covers and any flakes of coating in the original drum cartons, and keep ready for collection by service or the contracted shipping company.Photoconductor drums and collected flakes of coating require special disposal.

• If the photoconductor drum had only a short service life, the cause of the problem must be identified in order to prevent further damage.

• Use only permitted photoconductor drums (see section Consumables, page 356).• Store new photoconductor drums in appropriate conditions:

– Do not store together with flammable substances.

– Store in the closed original carton in a dry environment at 15 to 25 oC .


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Remove photoconductor drum

Proceed as follows:


2. On the operator panel select:• Menu <Replace consumables> <Replace photoconductor drum>

3. Click on the following button to start the PC drum replacement:



5. Open door to photoconductor drum.Pull lever forward.

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6. Push safety lever to the right and pull up door by lever.

7. Loosen the clamping screw and remove the flange.

CautionContact between skin and the photoconductor drum surface may result in skin ailments.Wear the gloves provided with the photoconductor drum.

8. Wear the protective gloves provided with the photoconductor drum.

CautionThe surface of the PC drum can be damaged during removal.Always pull the PC drum quickly and horizontally out of the printing system to avoid touching the PC drum to the printing system housing.

Proceed as follows:

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Install the the photoconductor drum

9. Grasp the photoconductor drum by the handle frame and quickly pull out of the printing system in a horizontal direction.

10. Put down photoconductor drum.

11.• Clean the toner mark sensor (left)

with a soft cloth.• Clean the (lower) charge sensor with

a clean soft brush.

CautionObserve the safety directives before installing the photoconductor drum(see section 7.3.1 Replacing the photoconductor drum, page 257).

Proceed as follows:

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Proceed as follows:

CautionThe surface of the photoconductor drum is extremely sensitive and can be easily damaged.Avoid direct exposure to the sun and do not touch.

1. Grasp the new PC drum by the handle frame and carefully remove from the packaging.

2. Note the "DRUM TYPE:" number specified on the photoconductor drum packaging.

CautionDanger of damage to the cleaning blade.When inserting the photoconductor drum, ensure that the cleaning blade on the charge corotron is not damaged.

3. Push in photoconductor drum to the stop point via the guide rails.

4. Push the flange back onto the guide rails.Align the flange mark to its associated mark on the guide rail.

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5. Attach clamping screw and secure tightly.

6. Swivel on the door in front of the photoconductor drum and close the lever.

7. Close both doors and the cover at the front of the printing system.

8. Select the type of the inserted photoconductor drum ("DRUM TYPE:") .

9. Select inserted photoconductor drum ("DRUM").

10. Enter on the operator panel whether a new photoconductor drum has been inserted:

•The message on the operator panel is deleted automatically, the replacement of the photoconductor drum is recorded in the <Consumables history> menu and the consumable counter is reset.

•If the PC drum is not replaced but only cleaned, for example,the process is documented in the <Consumables history> menu. Status display in the Consumables history:

11. Click the following button on the operator panel to complete PC drum replacement:


In both cases, the message on the operator panel is automatically deleted, and the replacement of the photoconductor drum is recorded in the <Consumables history> menu.

CautionThe old photoconductor drum must be disposed of as hazardous waste.Store the old drum and any flakes of coating in the original carton, and keep ready for collection by service or the contracted shipping company.

12. Have the old photoconductor drum ready for collection by the service center or the contracted shipping company(see section 2.6.7 Disposal, page 36).

Proceed as follows:

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7.3.2 Run in photoconductor drum

7.3.2 Run in photoconductor drum

Only if the photoconductor drum is not to be run in directly after replacement:

7.3.3 Replacing the cleaning brush

Observe the following safety directives when replacing the cleaning brush:

Proceed as follows:

Important

A photoconductor drum can only be run in when printing is stopped.


2. Select the <Replace consumables> <Run in photoconductor drum> menu on the operator panel.

3. Click the following button to run in the PC drum:

The photoconductor drum is run in after a preparation period.


4. Click the following button on the operator panel to complete PC drum run-in:

All printing system assemblies are checked (duration approx. 2-3 minutes) before the printing system is switched to the "Ready" status.•

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The printing system detects the end of the cleaning brush's service life automatically and displays a warning on the operator panel in good time. The following procedure is for replacing the cleaning brush:

- Remove cleaning brush >>> page 264

- Install cleaning brush >>> page 267

Remove cleaning brush


with plenty of water and seek medical help.• Avoid contact between the skin and the toner; wear gloves. In the event of contact

with the skin, wash toner off with plenty of water.• Do not inhale toner. Avoid accumulation of dust. If, after inhaling toner, you



• Keep cleaning brush out of the reach of children.

ImportantKeep used cleaning brush ready for collection by service or the contracted shipping company .

Proceed as follows:


2. Select the <Replace consumables> <Replace cleaning brush> menu on the operator panel.

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3. Click on the following button to start cleaning brush replacement:



ImportantPut on the protective gloves provided in the packaging.Do not touch the exterior of the cleaning brush; hold exclusively by the interior.Place the cleaning brush down vertically only, with the brush hairs facing upwards.

5. Put on protective gloves.

6. Open door to photoconductor drum.Pull lever forward.

7. Push safety lever to the right and open door by lever.

Proceed as follows:

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8. Loosen both knurled screws of the brush cover cap.

9. Slowly remove cover cap with the cleaning brush sitting on the insert taper and put to the side.

10. If the insert taper is not secured, remove the cleaning brush by hand.

Proceed as follows:

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Install cleaning brush


11. Clean the front outside insertion area with the vacuum cleaner.

CautionObserve the safety directives before installing the cleaning brush(see section 7.3.3 Replacing the cleaning brush, page 263).

Proceed as follows:

1. Hold the new brush at the end that has no slit.

2. Insert the new cleaning brush into the opening, push to the back of the casing and turn slightly to click the woodruff key on the rear axis into the slot on the cleaning brush (verify that the cleaning brush rotates).

3. Check that the cleaning brush turns with its drive. If the cleaning brush is correctly inserted, and is turned slightly, you will feel the flywheel mass of the drive.

4. Hold cleaning brush in this position.

5. Insert the cover cap insert taper into the front brush opening and push as far as the system casing. The cover cap must be flush everywhere.

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Proceed as follows:

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6. Press the cover cap with the cleaning brush against the opening and tighten the two knurled screws of the brush cover cap.

7. Swivel on the door to the photoconductor drum and close the lever.

8. Close both doors and the cover at the front of the printing system.

9. Enter on the operator panel whether a new cleaning brush was fitted:

•The message on the operator panel is deleted automatically, the replacement of the cleaning brush is recorded in the <Consumables history> menu and the consumable counter is reset.


10. Click the following button on the operator panel to complete cleaning brush replacement:


In both cases, the message on the operator panel is automatically deleted, the replacement of the cleaning brush is recorded in the <Consumables history> menu and the consumable counter is reset.

Proceed as follows:

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7.3.4 Replacing corotrons

7.3.4 Replacing corotrons

The printer detects the end of the corotron's service life automatically and displays a warning on the operator panel.

7.3.4.1 Preparing corotron replacement >>> page 270

ImportantWhen replacing the corotrons, observe the following safety directives:• Corotrons can only be replaced when printing is stopped.• Corotrons may only be used for the purpose for which they were originally intended.• If the corotron had only a short service life, the cause of the problem must be

identified in order to prevent further damage.• When replacing a corotron, always wear the gloves provided.

Ensure that you do not touch or damage the corotron wires.


Prepare corotron replacement 7.3.4.1 Preparing corotron replacement >>> page 270

Replace transfer corotron 7.3.4.2 Replacing the transfer corotron (1 cartridge) (pinfed) >>> page 271

Transfer corotron wire is torn7.3.4.2 Replacing the transfer corotron (1 cartridge) (pinfed) >>> page 271

Replace charge corotrons 7.3.4.4 Replacing charge corotrons (5 cartridges) >>> page 278

Charge corotron wire is torn 7.3.4.5 Replacing charge corotrons (torn wire) >>> page 281

Replace discharge corotrons 7.3.4.6 Replacing discharge corotrons (2 cartridges) >>> page 284

Discharge corotron wire is torn 7.3.4.7 Replacing the discharge corotron (torn wire) >>> page 287

Complete corotron replacement 7.3.4.8 Complete corotron replacement >>> page 290

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7.3.4.1 Preparing corotron replacement

7.3.4.1 Preparing corotron replacement

7.3.4.2 Replacing the transfer corotron (1 cartridge) (pinfed) >>> page 271

7.3.4.3 Replacing the transfer corotron (torn wire) (pinfed) >>> page 275

ImportantObserve the safety directives before replacing the corotron(see section 7.3.4 Replacing corotrons, page 269).

Proceed as follows:

ImportantThis section only applies if the message "Replace corotrons" is displayed. All corotrons must now be replaced.When a corotron wire has torn, the replacement is carried out according to Abschnitt 7.3.5.3, Abschnitt 7.3.4.7 or Abschnitt 7.3.4.5.


2. Select the <Replace consumables> <Replace corotrons> menu on the operator panel.

3. Click the following button to start corotron replacement:


4. Click the following button to move corotrons to the test position:


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7.3.4.2 Replacing the transfer corotron (1 cartridge) (pinfed)


The printer detects the end of the corotrons' service life automatically and displays a warning on the operator panel. The following procedure is for replacing the transfer corotron:

• Remove transfer corotron >>> page 271

• Install transfer corotron >>> page 273

Remove transfer corotron

ImportantObserve the safety directives before replacing corotrons (see section 7.3.4 Replacing corotrons, page 269).

Proceed as follows:

1. Click the following button to move corotrons to the replacement position:

2. Turn the knob to the left and swivel the rocker downwards.

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Proceed as follows:

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Install transfer corotron

6. Lift spring and simultaneously push it slightly to the right. Pull out corotron cartridge only a few millimeters so that the spring is held.

7. Carefully pull out the corotron cartridge.


Proceed as follows:

1. Push in new corotron cartridge until the spring engages.

Proceed as follows:

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7.3.4.4 Replacing charge corotrons (5 cartridges) >>> page 278


CautionDanger of pinching when swiveling the paper transporter back.Always swivel the paper transporter back slowly and carefully.

3. Swivel the paper transporter back again.

Proceed as follows:

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7.3.4.3 Replacing the transfer corotron (torn wire) (pinfed)


The following procedure is for replacing the torn transfer corotron:

• Remove torn transfer corotron >>> page 275

• Install new transfer corotron >>> page 277

Remove torn transfer corotron


Proceed as follows:

1. Click the following button to move corotrons to the replacement position:

2. Turn the knob to the left and swivel the rocker downwards.


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6. Lift spring and simultaneously push it slightly to the right. Pull out corotron cartridge only a few millimeters so that the spring is held.

7. Carefully pull out the corotron cartridge.

Proceed as follows:

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Install new transfer corotron

7.3.4.8 Complete corotron replacement >>> page 290


Proceed as follows:

1. Push in new corotron cartridge until the spring engages.


CautionDanger of pinching when swiveling the paper transporter back.Always swivel the paper transporter back slowly and carefully.

3. Swivel the paper transporter back again.

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7.3.4.4 Replacing charge corotrons (5 cartridges)


The printer detects the end of the corotrons' service life automatically and displays a warning on the operator panel. The following procedure is for replacing the charge corotron:

• Remove charge corotrons >>> page 278

• Install charge corotrons >>> page 279

Remove charge corotrons


Proceed as follows:

ImportantThis section does not apply to the error message "HV error charge corotron".See Abschnitt 7.3.4.5.

1. Pull out the handle of the corotron mounting and push away from the PC drum.

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Install charge corotrons

2. Remove corotron cartridges individually.


Proceed as follows:

1. Individually insert the new corotron cartridges into the opening until they engage.

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Proceed as follows:

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7.3.4.6 Replacing discharge corotrons (2 cartridges) >>> page 284

2. Pull out handle of corotron mounting and push towards PC drum until it engages.

Proceed as follows:

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7.3.4.5 Replacing charge corotrons (torn wire)


The printer detects the end of the corotrons' service life automatically and displays a warning on the operator panel. The following procedure is for replacing the charge corotron:

• Remove torn charge corotron >>> page 281

• Install new charge corotron >>> page 282

Remove torn charge corotron


Proceed as follows:

ImportantThis section does not apply to the error message "HV error charge corotron".See Abschnitt 7.3.4.5.


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Install new charge corotron

2. Remove corotron cartridges individually.

CautionWhen removing the charge corotron cartridge, the nipple on the corotron wire may fall into the developer station without you noticing. If printing then continues, the developer station can be irreparably damaged.When changing the faulty charge corotron cartridge, always check if the nipple is still on the corotron wire. If the nipple is missing, search for and find it.

3. Check whether the nipple is still in on the corotron wire. If the nipple is missing, search for it. To do this, pull out the developer station (see section 6.7 Cleaning the developer station, page 203) and search the developer station and the entire area around it. If no nipple is found, remove the photoconductor drum and search this area.


Proceed as follows:

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Proceed as follows:

1. Individually insert the new corotron cartridges into the opening until they engage.


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7.3.4.6 Replacing discharge corotrons (2 cartridges)


The printer detects the end of the corotrons' service life automatically and displays a warning on the operator panel. The following procedure is for replacing the discharge corotron:

• Remove discharge corotrons >>> page 284

• Install discharge corotrons >>> page 285

Remove discharge corotrons


Proceed as follows:

ImportantThis section does not apply to the error message "HV error discharge corotron". See Abschnitt 7.3.4.7.


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Install discharge corotrons

2. Remove corotron cartridges.


Proceed as follows:

1. Push new corotron cartridge into the opening to the stop point.

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Proceed as follows:

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Proceed as follows:

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7.3.4.7 Replacing the discharge corotron (torn wire)


The following procedure is for replacing the discharge corotron:

• Remove torn discharge corotron >>> page 287

• Install new discharge corotron >>> page 288

Remove torn discharge corotron


Proceed as follows:

ImportantThis section does not apply to the error message "HV error discharge corotron". See Abschnitt 7.3.4.7.


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Install new discharge corotron

2. Remove corotron cartridges.

CautionWhen removing the discharge corotron cartridge, the nipple on the corotron wire may fall into the developer station without you noticing. If printing then continues, the developer station can be irreparably damaged.When changing the faulty discharge corotron cartridge, always check if the nipple is still on the corotron wire. If the nipple is missing, search for and find it.

3. Check whether the nipple is still in on the corotron wire. If the nipple is missing, search for it. To do this, pull out the developer station (see section 6.7 Cleaning the developer station, page 203) and search the developer station and the entire area around it. If no nipple is found, remove the photoconductor drum and search this area.


Proceed as follows:

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Proceed as follows:

1. Push new corotron cartridge into the opening to the stop point.


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7.3.4.8 Complete corotron replacement

7.3.4.8 Complete corotron replacement

Proceed as follows:

1. Corotron locks are checked.If this step cannot be completed, re-open and close the locking mechanism of the corotron mountings.

2. Close both front doors and the cover of the printing system.

3. Click the following button to lower corotrons:

4. Enter on the operator panel whether a new corotron was fitted:

•The message on the operator panel is deleted automatically, the replacement of the corotrons is recorded in the <Consumables history> menu and the consumable counter is reset.


5. Click the following button on the operator panel to complete corotron replacement:


In both cases, the message on the operator panel is automatically deleted, the replacement of the corotrons is recorded in the <Consumables history> menu and the consumable counter is reset.

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7.3.5 Replacing the active filter


Observe the following safety directives when replacing the active filter:

The printing system detects the end of the active filter's service life automatically and displays a warning on the operator panel. The following procedure is for replacing the active filter:

- Remove active filter >>> page 291

- Install active filter >>> page 294

Remove active filter

Caution• The components in the fuser station reach a surface temperature of approximately

230 oC during operation.• Danger of burning if touched.

• Do not touch any parts behind the safety covers identified with the icon .• Wear heat protection gloves when working with fuser station components.

ImportantKeep used active filter ready for collection by service or the contracted shipping company .

Proceed as follows:


2. Select the <Replace consumables> <Replace active filter> menu on the operator panel.

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3. Click the following button to start the active filter replacement:





4. Open side door of fuser station.

5. Turn the knob of the oiling unit to the left and swivel on oiling unit.


230 oC in operation.If you touch them, you may burn yourself.Put on heat protection gloves before you continue.


Proceed as follows:

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8. Turn the two knobs to the left and swivel down filter frame.

9. Remove both old active filters.

Proceed as follows:

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Install active filter

CautionObserve the safety directives before installing the active filter (see section 7.3.5 Replacing the active filter, page 291).

Proceed as follows:

1. Insert the two new active filters so that the slanted surfaces meet in the middle and the gray sides are visible.

2. Swivel filter frame upwards and turn the two knobs to the right.

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3. Swivel on active filter unit by the handle to the stop point.

4. Swivel on oiling unit and turn the oiling unit turning knob to the right.

5. Close side door of fuser station.

6. Enter on the operator panel whether a new active filter has been fitted:

•The message on the operator panel is deleted automatically, the replacement of the active filter is recorded in the <Consumables history> menu and the consumable counter is reset.


Proceed as follows:

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7. Click the following button on the operator panel to complete active filter replacement:


In both cases, the message on the operator panel is automatically deleted, the replacement of the active filter is recorded in the <Consumables history> menu and the consumable counter is reset.

Proceed as follows:

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7.3.6 Replacing the cleaning belt


The printing system detects the end of the cleaning belt's service life automatically and displays a warning on the operator panel. The following procedure is for replacing the cleaning belt:

- Remove cleaning belt >>> page 297

- Install cleaning belt >>> page 299

Remove cleaning belt

Proceed as follows:


2. Select the <Replace consumables> <Replace cleaning belt> menu on the operator panel.

3. Click the following button to start cleaning belt replacement:






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230 oC in operation.If you touch them, you may burn yourself.Put on heat protection gloves before you continue.


7. Press the empty and the used cleaning belt roller against the right spring support and remove. Place cleaning belt in old packaging.

Proceed as follows:

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Install cleaning belt

Proceed as follows:

NoteHolding pins, bearings and rolls are shaped so that there is only one way to fit them.The upper roll (new, full roll) is longer than the lower roll.

1. Place the new full roll on the spring bearing at top right, press to the right and slide onto the left bearing with the holding pins.

Turn the new full roll so that it engages with the holding pins.

2. Insert the new empty roll into the lower bearings.

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3. Turn the new roll in the opposite direction to that in which it pays out to tighten the cleaning belt until there are no creases.



6. Enter on the operator panel whether a new cleaning belt was fitted:

•The message is automatically deleted on the operator panel and the replacement of the cleaning belt is documented in the <Consumables history> menu.

•If the cleaning belt was not replaced.The process is documented in the <Consumables history> menu. Status display in the Consumables history:

Proceed as follows:

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7. Click the following button on the operator panel to complete cleaning belt replacement:


In both cases, the message on the operator panel is automatically deleted, and the replacement of the cleaning belt is recorded in the <Consumables history> menu.

Proceed as follows:

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7.3.7 Replacing the heater


The printing system detects when the heater is faulty and displays a warning on the operator panel. The following procedure is for replacing the heater:

- Remove heater >>> page 302

- Install heater >>> page 307

Remove heater

CautionObserve the following safety directives when replacing the heater:The heater may only be replaced by operators after training or instructions from service personnel.

Proceed as follows:


2. Select the <Replace consumables> <Replace heater> menu on the operator panel.

3. Click the following button to start heater replacement:






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230 oC in operation.If you touch them, you may burn yourself.Allow the printing system to cool down for at least 30 minutes.

6. Allow printing system to cool down for at least 30 minutes.


Proceed as follows:

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8. Move the temperature sensor to the left.

The temperature sensor bar is now swiveled up.

9. Loosen the heater connector plug on the front side of the printing system and straighten the cable .

10. Open the right door at the back of the printing system.

Proceed as follows:

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11. Disconnect the heater connector plug at the back of the printing system.

12. Remove cable from the cable clamp.


230 oC in operation.If you touch them, you may burn yourself.Put on heat protection gloves to continue working.

Proceed as follows:

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CautionThe heater glass may be damaged.Only grasp the heater by the handle and, if necessary, support it at the other end.

14. Carefully remove the heater from the roller opening.If the front heater connector plug begins to catch, slightly turn the heater back and forth on its own axis during removal.

15. Push heater into the storage opening and allow it to cool down for at least 30 minutes.

Proceed as follows:

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Install heater

CautionObserve the safety directives before installing the heater (see section 7.3.7 Replacing the heater, page 302).

Proceed as follows:

CautionThe heater glass may be damaged.Grasp the heater by the handle only.

1. Open packaging of the new heater.Only grasp the heater by the handle and carefully remove from the packaging.If required, hold the new heater by the cable on the other end with your other hand.

2.Hold the heater by the handle part.Straighten the front end of the cable.Carefully insert the heater into the fuser roller opening at the rear.

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3. Reinsert the heater connector plug on the rear side.

4. Hang cable in the cable clamp.

Proceed as follows:

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6. Carefully remove the faulty heater from the storage opening.

7. Place the faulty heater in the empty packaging, close and make ready for collection by service.

8. Close the right door at the back of the printing system.

Proceed as follows:

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9. Connect the heater connector plug on the front side of the printing system again.Lay the cable so that the cover on the handle does not rub against the cable when subsequently swiveling off the temperature sensor bar.

10. Move the temperature sensor lever to the right. The temperature sensor bar is swiveled on again.


Proceed as follows:

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14. Enter on the operator panel whether a new heater has been fitted:

•The message on the operator panel is deleted automatically, the replacement of the heater is recorded in the <Consumables history> menu.

•If the heater was not replaced, but only removed and then re-inserted for control purposes, for example,the process is documented in the <Consumables history> menu. Status display in the Consumables history:

15. Click the following button on the operator panel to complete heater replacement:


In both cases, the message on the operator panel is automatically deleted, and the replacement of the heater is recorded in the <Consumables history> menu.

Proceed as follows:

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7.3.8 Replacing the fuser roller


The following procedure is for replacing the fuser roller:

- Remove fuser roller >>> page 312

- Install new fuser roller >>> page 315

Remove fuser roller

CautionObserve the following safety directives when replacing the fuser roller:The fuser roller may only be replaced by operators after training or instructions from service personnel.

Proceed as follows:


2. Select the <Replace consumables> <Replace fuser roller> menu on the operator panel.

3. Click on the following button to start the fuser roller replacement:



230 oC in operation.If you touch them, you may burn yourself.Allow the printing system to cool down for at least 30 minutes.

4. Allow the printing system to cool down for at least 30 minutes.

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5. Remove heater (see section Remove heater, page 302).




7. Press against the pressure pin and swivel the waste collector outwards.

8. Open the packaging of the new fuser roller at the end.

9. Remove the new fuser roller with the plastic cover and place vertically on a surface (the notch around the end must be on top).

Proceed as follows:

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ImportantFuser roller models may be mistaken for each other.Ensure that the new fuser roller has the same part number as the old one.

10. Ready carton for old fuser roller.



11. Put on heat protection gloves again if you have removed them.

12. Evenly loosen the three wing screws that secure the fuser roller insert (only one turn for each wing screw).

13. Support the fuser roller by placing your left hand under the center area and at the same time pull on the handle.Carefully remove the fuser roller from the opening (right hand on the handle, left hand supporting the fuser roller).

Carefully put the fuser roller down in an upright position.

Proceed as follows:

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Install new fuser roller

14. Loosen the two knurled screws for the holder claws on the fuser roller insert.Remove the fuser roller insert from the old fuser roller.

15. Insert the cooled fuser roller in the carton and make ready for collection.

CautionObserve the safety directives before installing the fuser roller (see section 7.3.8 Replacing the fuser roller, page 312).

Proceed as follows:

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Proceed as follows:

1. Place the fuser roller insert on the new fuser roller.

NoteIf you encounter a lot of resistance when placing the new fuser roller on the fuser roller insert, allow the fuser roller insert to cool down for approx. 5 minutes and then try again.

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2. Tighten the two knurled screws for the holder claws on the fuser roller insert.

Remove the plastic cover from the new fuser roller.

3. Insert the new fuser roller into the opening and push towards the fuser roller drive.

NoteIf you encounter a lot of resistance when pushing the new fuser roller towards the fuser roller drive, allow the printing system to cool down for approx. 5 more minutes and then try again.

Proceed as follows:

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4. Tighten the three wing screws for attach the fuser roller insert one after the other step by step. Only use a max. of three turns for each screw.Proceed from one wing screw to the next until the flange of the fuser roller insert is secure against the side plate.

5. Swivel on the waste collector and lock with the pressure pin.

6. Installing the heater (see section Install heater, page 307).


Proceed as follows:

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10. Select the installed fuser roller type.

11. Select installed fuser roller.The fuser roller designation is printed on the packaging.

12. Enter on the operator panel whether a new fuser roller has been fitted:

•The message on the operator panel is automatically deleted, and the replacement of the fuser roller is recorded in the <Consumables history> menu.

•If the fuser roller has not been replaced but only cleaned, for example,the process is documented in the <Consumables history> menu. Status display in the Consumables history:

13. Click the following button on the operator panel to complete fuser roller replacement:


In both cases, the message on the operator panel is automatically deleted, and the replacement of the fuser roller is recorded in the <Consumables history> menu.

Proceed as follows:

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7.3.9 Replacing the pressure roller


The following procedure is for replacing the pressure roller:

- Remove pressure roller >>> page 320

- Install pressure roller >>> page 323

Remove pressure roller

CautionObserve the following safety directives when replacing the pressure roller:The pressure roller may only be replaced by operators after training or instructions from service personnel.

Proceed as follows:


2. Select the <Replace consumables> <Replace pressure roller> menu on the operator panel.

3. Click on the following button to start pressure roller replacement:


NoteOnly if paper post-processing is connected:Remove any deflection rollers that may be mounted on the stacker platform.

4. Cut inserted paper in the paper input at a right angle to the transport direction and remove it from the printing system by continuously pressing the EJECT key.

5. Lower the stacker top by pressing the right key under this icon .

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9. Press against the pressure pin and swivel the waste collector outwards.

Proceed as follows:

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10. Swivel off the cover underneath the fuser station.

11. Press opening lever to the left and carefully swivel down roller saddle.

NoteAllow the printing system to cool down in this state for approximately 30 minutes.

12. Grasp pressure roller from below and hold in the center.Open the locking pins on the right and left sides.

13. Carefully remove the pressure roller and place on paper surface.

Proceed as follows:

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Install pressure roller

CautionObserve the safety directives before installing the pressure roller(see section 7.3.9 Replacing the pressure roller, page 320).

Proceed as follows:

1. Remove new pressure roller from the packaging.




3. Insert pressure roller carefully into the fuser station from below and place in the receptacles and hold there.

Close the locking pins on the right and left sides.

4. Swivel on the roller saddle until the lock engages.

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5. Close the cover underneath the fuser station.

6. Swivel in waste collector and lock with the pressure pin.



9. Raise the stacker top by pressing the left key under this icon .

Proceed as follows:

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NoteOnly if paper post-processing is connected: Remount deflection rollers on the stacker platform.

10. Enter on the operator panel whether a new pressure roller has been fitted:

•The message on the operator panel is deleted automatically, the replacement of the pressure roller is recorded in the <Consumables history> menu.

•If the pressure roller was not replaced but only cleaned, for example,the process is documented in the <Consumables history> menu. Status display in the Consumables history:

11. Click the following button on the operator panel to complete pressure roller replacement:


In both cases, the message on the operator panel is automatically deleted, and the replacement of the pressure roller is recorded in the <Consumables history> menu.

Proceed as follows:

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7.3.10 Replacing the waste collector


The following procedure is for replacing the waste collector:

- Remove waste collector >>> page 326

- Install waste collector >>> page 328

Remove waste collector

Proceed as follows:







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4. Press in pressure pin and swivel out the waste collector.

5. Open the packaging of the new waste collector, taking care not to damage it.

6. Remove new waste collector from the packaging and place on surface.




CautionSpilled oil can cause danger of slipping.Wipe away any spilled oil with a paper towel.

Proceed as follows:

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Install waste collector

8.• Remove the old waste collector

(filled with oil and dirt), insert into the packaging, close and make ready for collection.

• Remove soaked felt strip.

9. Remove visible oil traces on the swiveled oiling unit with a paper towel.

Proceed as follows:

1. Insert new waste collector and new felt strips.

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Proceed as follows:

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2. Swivel in waste collector and lock with the pressure pin.




Proceed as follows:

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7.3.11 Replacing the fine filter


Observe the following safety directives when replacing the fine filter:

The printing system detects the end of the fine filter's service life automatically and displays a warning on the operator panel. The following procedure is for replacing the fine filter:

- Remove fine filter >>> page 330

- Install fine filter >>> page 332

- Clean toner dust indicator >>> page 334

Remove fine filter


with plenty of water and seek medical help.• Avoid contact between skin and toner. In the event of contact with the skin, wash

toner off with plenty of water.• Do not inhale toner. Avoid accumulation of dust. If, after inhaling toner, you


• If toner falls on the floor, clean it up immediately, otherwise there is a danger of slipping.

• Keep fine filter out of the reach of children.

ImportantKeep used fine filter for collection by service or the contracted shipping company .

Proceed as follows:


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2. Select the <Replace consumables> <Replace fine filter> menu on the operator panel.

3. Click the following button to start fine filter replacement:



5. Push lever to the left of the fine filter container down to unlock the filter housing.

6. Remove fine filter container with both hands.

Proceed as follows:

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Install fine filter

ImportantToner may fall out.Do not tilt fine filter to ensure that no toner falls out.

7. Grasp fine filter by both handles, remove from the fine filter housing and place to the side.Do not tilt fine filter to ensure that no toner falls out.

CautionObserve the safety directives before installing the fine filter(see section 7.3.11 Replacing the fine filter, page 330).

Proceed as follows:

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Proceed as follows:

1. Take new fine filter from the packaging and fit into the fine filter housing.

2. Reinsert fine filter housing with both hands.

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Clean toner dust indicator

3. Push lever to the left of the fine filter housing up to lock the filter housing.

NoteWhen replacing the fine filter, toner can enter the toner dust indicator.

Proceed as follows:

1. Loosen plastic screw.

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Proceed as follows:

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2. Clean opening with a round brush(see section Cleaning materials and equipment, page 365). Before use, sharply angle round brush and insert into the opening.For function control, the LED must light up when the round brush is being inserted and go off when it is removed.

3. Tighten the plastic screw again.


5. Enter on the operator panel whether a new fine filter has been fitted:

•The message on the operator panel is automatically deleted, and the replacement of the fine filter is recorded in the <Consumables history> menu.

•If the fine filter was not replaced,the process is documented in the <Consumables history> menu. Status display in the Consumables history:

Proceed as follows:

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6. Click the following button on the operator panel to complete fine filter replacement:


In both cases, the message on the operator panel is automatically deleted, and the replacement of the fine filter is recorded in the <Consumables history> menu.

Proceed as follows:

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8 Correcting faults

8 Correcting faults

8.1 Overview

This section will help you to correct print image and fusing problems. In addition, you can also find information on how to locate messages and continue printing after troubleshooting, and how to enable remote access for remote diagnosis by service during printing.


8.2 Processing messages on the operator panel >>> page 338

8.3 Clogged toner suction >>> page 343

8.4 Poor print quality >>> page 348

8.5 Poor fusing quality >>> page 351

8.6 Permitting or blocking remote access >>> page 352

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8.2 Processing messages on the operator panel

8.2 Processing messages on the operator panel


8.2.1 Locating a message >>> page 338

8.2.2 Continuing printing after errors have been corrected >>> page 341

8.2.1 Locating a message

Error messages, warnings and information are displayed on the operator panel:

NoteDetailed information on each message can be found in the operator panel through the context-sensitive Help. You can call up this context-sensitive Help by clicking the message and then pressing the F1 key.

Icon Meaning

Error message When an error occurs, the printer stops and the button on the toolbar flashes.

Warning When there is a warning, the printing system continues to print, and the button flashes in the toolbar.

If an error message is also present, the error message icon flashes too.

Information When there is information, the printing system also continues to print, and the button flashes in the toolbar.

If there is also a warning, the warning message symbol flashes.If an error message is also present, the error message icon flashes too.

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Proceed as follows:

1.Click on the or or button in the toolbar.The <Errors and warnings> menu is displayed.

All error messages, warnings and information messages that have occurred are listed in the upper area, sorted by priority and time.

2. Click message in the "Errors and warnings" list.

In the printer view, the assembly concerned is displayed in color.

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3. The printer view can be controlled with the following buttons:

Switches back to the preset standard view after modifications.

Zooms in on the current printer view.

Zooms out from the current printer view.

Shifts the visible cutout in the direction of the arrow.

Resets a message.

Changes from the printer view to the service ticket.The service ticket displays all the data required to notify the service center.

Returns to the printing system view.

Switches to the previous/next message.

Changes the view between:• only list of "Errors and warnings", without printer view• list of "Errors and warnings" and printer view• only printer view without list of "Errors and warnings"

Proceed as follows:

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8.2.2 Continuing printing after errors have been corrected


Print stop without loss of information

The printing system remains at the start of a page.

Print stop with loss of information

If a cover is opened during printing, or if an error that can damage the printing system occurs during printing, the printing system stops with loss of information.

Proceed as follows:

1. Eliminate the reason why printing stopped as indicated by the information in the error message.


Printing operation is restarted smoothly and without any impairment of the print and fusing quality.

Proceed as follows:

1. Eliminate the reason why printing stopped as indicated by the information in the error message.


The print image on the damaged print pages is fused to ensure that the tension roller and post-processing are not soiled.

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NoteAlternatively, you can remove the damaged pages from the printing system by pressing the EJECT button.

3. Restart print job.

NoteNotify service in accordance with the information in the <Special functions> <Service ticket> menu if:• the error cannot be eliminated,• the same error recurs repeatedly,• the printing system cannot be rendered operational after the error has been

eliminated.

Proceed as follows:

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8.3 Clogged toner suction


If there is sufficient toner supply, the display "Toner supply out" can indicate that the toner suction is clogged.

a) Vacuuming out the toner feed


Proceed as follows:

1. Open the left door at the back of the printing system.

ImportantIn the next step, the rotaryswitch must not be set to SERVICE (up to the stop point).

2. During printing, set the rotary switch to the middle position between PRINT and SERVICE and then back to the PRINT position several times.

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b) Remove clogged toner from the toner feed hose

Proceed as follows:



3. Pull the container downwards with the handle.

4. Move the lever upwards to swivel off the drain head.

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5. Turn the knob to the left to open the door in front of the developer station.

Open the door in front of the developer station.

6. Remove the toner feed hose (small cross section) from the toner box which is connected to the developer station.


Proceed as follows:

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7. Use a vacuum cleaner to vacuum the clogged toner from the hose you have just removed.

Also carefully vacuum accumulated toner from the underside of the drain head (above the toner bottle).

8. Re-affix the toner feed hose to the toner box.

9. Close the door in front of the developer station.Turn the turning knob to the left.

Proceed as follows:

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10. Move the lever downwards to swivel on the drain head.

11. Use the handle to turn the container upwards slowly.



Proceed as follows:

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8.4 Poor print quality

8.4 Poor print quality

8.4.1 Poor printing

The main reasons for poor print quality are listed in section 8.4.2 Poor printing, cause and correction >>> page 349. If this information is not sufficient to correct the error, call the service center.

Dropouts and spots due to faulty photoconductor drum

Dropouts are places that lie within the minimum permissible character contours and are as bright as the unprinted areas.

Spots are printed areas found outside the character contours. They are as dark as normal print characters.

The photoconductor drum is usually at fault if dropouts and spots regularly recur after one drum rotation, in other words, after approx. 760 mm (corresponds to 2.5 pages, 12" in length).

The following number of spots and dropouts is permitted for new photoconductor drums per 12"form:

Size Number per 12" form

Spots <0.25 mm 5

0.25 mm to 1.5 mm 2

Dropouts <0.5 mm 2

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8.4.2 Poor printing, cause and correction


Error source Type of error and correction

Print contrast < nominal value

Gray background Background with dark streaks

Streaked coloring

Charge corotron - Soiled wires, clean, replace.

Transfer corotron - - - Soiled wire, paper fragments in corotron, clean, replace.

Discharge corotron - Soiled wire, clean, replace.

Discharge strip - - - Soiled plastic strips, clean

Brush cleaning - - Cleaning brush soiled or faulty, replace cleaning brush.

Photoconductor drum

Photoconductor drum exposed to light for too long. It recovers after several hundred pages. Possibly replace.

With grooves, possibly replace.

Photoconductor drum soiled, replace

Paper transport - - Paper transport soiled, clean.

-

Fuser station - - Cleaning belt soiled. Advance cleaning belt, replace.

Loop puller force set too strong. Set the loop puller force correctly.

LED print head - - - Load error. Press STOP.


Bright spots / streaks in printed image

Dark spots Smudged print image

Memory effectsghost image

Charge corotron Wires soiled - - -

Transfer corotron Wire soiled. Paper fragments in corotron, clean, replace

- - -

Discharge corotron - - - Soiled wire, clean, replace.

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Discharge strip - - - Soiled plastic strips, clean

Cleaning brush - - - Cleaning brush soiled or faulty, replace cleaning brush.

Photoconductor drum

Photoconductor drum soiled, replace

Soiled, damaged (a few spots are ok), possibly replace

- Damaged, possibly replace.

Developer station Developer out, soiled: replace.

- - -

Paper transport Creases or bumps in the paper. Set, correct, other paper.

- Paper sticks in the carton or to deviations. Open up carton, correct error.

-

Fuser station - (Possible offset if there is not enough oil, check oil level)

Printing not fused (possible operator error), call service. Optimize: Fuser temperature, fuser oil quantity, brake force of the paper brake.

(Possible offset effect if there is not enough oil, check oil level) Optimize: Fuser temperature, fuser oil quantity.Possibly clean fuser roller.

Printhead Only for printingsystems with LPH2: Clean LED print head: In the <User>sub-menu, activate <LPH cleaning>.

- - -


Bright spots / streaks in printed image

Dark spots Smudged print image

Memory effectsghost image

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8.5 Poor fusing quality

8.5 Poor fusing quality

If the fusing quality of the print image is poor, check the following points before notifying Service according to the information in the <Configuration> <Special functions> <Service ticket> menu:

• Does the paper meet the paper specification regulations?(see section 1.6 Other documents, page 22)

• Was the paper stored correctly?

Was the printing system operated incorrectly (e. g. the ADVF button was pressed too long, or the fusing temperature was lowered)?

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8.6 Permitting or blocking remote access


The Service can make a remote diagnosis during printing using remote access if this has been agreed beforehand.

Permitting remote access

Proceed as follows:

1. Click on the following button in the icon bar:

or

click on the following button in the <Configuration> <Special functions> <Remote diagnostics> menu:

The status display shows that remote access is enabled:

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Blocking remote access

Proceed as follows:

1. Click on the following button in the icon bar:

or

click on the following button in the <Configuration> <Special functions> <Remote diagnostics> menu:

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Appendix

Appendix

Overview


Consumables >>> page 356

Expendables >>> page 361

Cleaning materials and equipment >>> page 365

Technical data >>> page 367

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Consumables

Consumables

We recommend that you only use toner and developer from Océ Printing Systems GmbH to ensure the highest printing and fusing quality and to maintain high standards of availability for the printing system.

Consumables for VarioStream 7200, VarioStream 7300, VarioStream 7400

The consumable requirements listed in the table are based on the following conditions:• Printer output per month (12" length/375 mm width):

– 500,000 pages for VarioStream 7200– 1,000,000 pages for VarioStream 7300– 2,000,000 pages for VarioStream 7400

Consumable Order number Packaging unit

Monthly requirement

VarioStream 7200

VarioStream 7300

VarioStream 7400

Toner for VarioStream 7000Standard

OCP:KK01-D25-M10 3 x 4kg 6 bottles24 kg

12 bottles48 kg

24 bottles96 kg

Toner for VarioStream 7000Premium


12 bottles48 kg

24 bottles96 kg

Toner for VarioStream 7000MICR

OCP:KM01-D23-M10 3 x 4kg 24 bottles96 kg

Developerfor VarioStream 7000Standard

OCP:KK01-D15-A10 1 x 8kg 0.25 bottles2 kg

0.5 bottles4 kg

1.0 bottles8 kg

Developerfor VarioStream 7000Premium


1.0 bottles8 kg

2.0 bottles16 kg

Developerfor VarioStream 7000MICR

OCP:KM01-D13-A10 1 x 8kg 1.0 bottles8 kg

Fuser oil S26312-F646 1 x 3 liters 0,17 bottles 0,33 bottles 0,67 bottles

356 A29246-X20-X-4-7680 / faA01.fm

Consumables

• Toner consumption depends on ink coverage. If 100% of the possible characters are printed on a form of 12“ length/375 mm width, then the toner consumption increases from 48 g per 1000 pages to approximately 240 g per 1000 pages. With the contrast setting = extra light, toner consumption can be reduced by up to 50%.

• Average power-on per month: 600 hours• Average printing time per month: 200 hours• Maximum stop rate per 200 forms 1 stop of 10 s duration• Coverage is 16 % of the maximum printable characters at 1/10" column spacing and 1/6" line spacing• Degree of printing surface coverage: 4 %• Different operating conditions can lead to shorter life cycles, i.e. higher usage (roughly 20 - 30%).

• Toner and developer storage: Always store in a cool (< 35 oC), dry and well ventilated room. Never expose toner to direct heat (sunlight, heaters, etc.)

Consumables for VarioStream 7450, VarioStream 7550, VarioStream 7650

Consumable Order number Packaging unit Monthly requirement

VarioStream 7450

VarioStream 7550

VarioStream 7650



36 bottles144 kg

42 bottles168 kg



36 bottles144 kg



42 bottles168 kg



1.5 bottles12 kg

1.75 bottles14 kg

A29246-X20-X-4-7680 / faA01.fm 357

Consumables


– 2,500,000 pages for VarioStream 7450– 3,000,000 pages for VarioStream 7550– 3,500,000 pages for VarioStream 7650


• Average power-on per month: 600 hours• Average printing time per month: 200 hours• Maximum stop rate per 200 forms 1 stop of 10 s duration• Coverage is 16 % of the maximum printable characters at 1/10" column spacing and 1/6" line spacing• Degree of printing surface coverage: 4 %• Different operating conditions can lead to shorter life cycles, i.e. higher usage (roughly 20 - 30%).




1.5 bottles12 kg



1.75 bottles14 kg

Fuser oil S26312-F646 1 x 3 liters

0,83 bottles 1 bottles 1,17 bottles


VarioStream 7450

VarioStream 7550

VarioStream 7650

358 A29246-X20-X-4-7680 / faA01.fm

Consumables

Consumables for VarioStream 7450 CX, VarioStream 7550 CX, VarioStream 7650 CX


– 2,500,000 pages for VarioStream 7450 CX– 3,000,000 pages for VarioStream 7550 CX– 3,500,000 pages for VarioStream 7650 CX


• Average power-on per month: 600 hours


VarioStream 7450 CX

VarioStream 7550 CX

VarioStream 7650 CX



36 bottles144 kg

42 bottles168 kg



36 bottles144 kg



42 bottles168 kg



1.5 bottles12 kg

1.75 bottles14 kg



1.5 bottles12 kg



1.75 bottles14 kg

Fuser oil S26312-F646 1 x 3 liters

0,83 bottles 1 bottles 1,17 bottles

A29246-X20-X-4-7680 / faA01.fm 359

Consumables

• Average printing time per month: 200 hours• Maximum stop rate per 200 forms 1 stop of 10 s duration• Coverage is 16 % of the maximum printable characters at 1/10" column spacing and 1/6" line spacing• Degree of printing surface coverage: 4 %• Different operating conditions can lead to shorter life cycles, i.e. higher usage (roughly 20 - 30%).


360 A29246-X20-X-4-7680 / faA01.fm

Expendables

Expendables

Expendables for VarioStream 7200, VarioStream 7300, VarioStream 7400

The expendable requirements listed in the tables are based on the following conditions:• Printer output per month (12" length/375 mm width):

– 500,000 pages for VarioStream 7200– 1,000,000 pages for VarioStream 7300– 2,000,000 pages for VarioStream 7400


• Average power-on per month: 600 hours• Average printing time per month: 200 hours

Expendable Order number Packaging unit

Monthly requirement

VarioStream 7200

VarioStream 7300

VarioStream 7400

Photoconductor drum S26312-F190-V110(240/300 dpi)

1 unit 0,25 0,5 1,0

S26312-F190-V120(600 dpi)

1 unit 0,25 0,5 1,0

Wide cleaning brush (gloves provided)

S26312-F1042 1 unit 0,25 0,5 1,0

Fine filter S26312-F1071 1 unit 0,13 0,25 0,5

Active filter S26312-F346 3 sets 0,25 0,5 1,0

Cleaning belt S26312-F1116 1 x 13.5m 0,18 0,37 0,74

Corotron cartridge S26312-F645 8 units 2 4 8

Heater S26312-F241 1 unit 0,05 0,1 0,2

Filter mat C26312-H116-C35 1 unit 0,25 0,5 1,0

Fuser roller (hard) S26312-F857 orS29312-F1130

1 unit1 unit

0,10,1

0,20,2

0,40,4

Fuser roller (soft) S26312-F853 orS26312-F1055

1 unit1 unit

0,50,5

11

22

Pressure roller S29312-F1270 1 unit 0,05 0,1 0,2

Waste collector S26312-F648 1 unit 0,25 0,5 1,0

Felt strips S29312-F1352 5 units

A29246-X20-X-4-7680 / faA01.fm 361

Expendables

• Maximum stop rate per 200 forms 1 stop of 10 s duration• Coverage is 16% of the maximum printable characters at 1/10" column spacing and 1/6" line spacing• Different operating conditions can lead to shorter life cycles, i.e. higher usage (roughly 20 - 30%).


Expendables for VarioStream 7450, VarioStream 7550, VarioStream 7650


– 2,500,000 pages for VarioStream 7450– 3,000,000 pages for VarioStream 7550– 3,500,000 pages for VarioStream 7650


Monthly requirement

VarioStream 7450

VarioStream 7550

VarioStream 7650


1 unit 1,25 1,5 1,75

S26312-F190-V120(600 dpi)

1 unit 1,25 1,5


S26312-F1042 1 unit 1,25 1,5 1,75





Heater S26312-F241 1 unit 0,25 0,3 0,35



1 unit1 unit

0,50,5

0,60,6

0,70,7


1 unit1 unit

XX

xx

--




362 A29246-X20-X-4-7680 / faA01.fm

Expendables


• Average power-on per month: 600 hours• Average printing time per month: 200 hours• Maximum stop rate per 200 forms 1 stop of 10 s duration• Coverage is 16% of the maximum printable characters at 1/10" column spacing and 1/6" line spacing• Different operating conditions can lead to shorter life cycles, i.e. higher usage (roughly 20 - 30%).


A29246-X20-X-4-7680 / faA01.fm 363

Expendables

Expendables for VarioStream 7450 CX, VarioStream 7550 CX, VarioStream 7650 CX


– 2,500,000 pages for VarioStream 7450 CX– 3,000,000 pages for VarioStream 7550 CX– 3,500,000 pages for VarioStream 7650 CX


• Average power-on per month: 600 hours• Average printing time per month: 200 hours• Maximum stop rate per 200 forms 1 stop of 10 s duration


Monthly requirement

VarioStream 7450 CX

VarioStream 7550 CX

VarioStream 7650 CX


1 unit 1,25 1,5 1,75

S26312-F190-V120(600 dpi)

1 unit 1,25 1,5


S26312-F1042 1 unit 1,25 1,5 1,75





Heater S26312-F241 1 unit 0,25 0,3 0,35



1 unit1 unit

0,50,5

0,60,6

0,70,7


1 unit1 unit

XX

xx

--




364 A29246-X20-X-4-7680 / faA01.fm

Cleaning materials and equipment

• Coverage is 16% of the maximum printable characters at 1/10" column spacing and 1/6" line spacing• Different operating conditions can lead to shorter life cycles, i.e. higher usage (roughly 20 - 30%).



CautionPlease observe the following safety directives:• Please follow the manufacturer's safety instructions.• Do not use chemical solvents or other aggressive cleaning materials.• Always use an industrial vacuum cleaner with a grounded suction tube, rubber

nozzle and filter set for fine dust. For vacuuming large quantities of toner spill (e. g. full bottle), the industrial vacuum cleaner must be explosion-proof.

Cleaning materials/equipment

Purpose Remarks

Methylated spirits (denatured ethyl alcohol)

To remove traces of adhesive

CautionFlammable!Observe the manufacturer’s safety directives on the container.

Standard store-bought quality

Cleaning materials6-1508/W1/H

Cleaning toner residue from soft fuser rollers

CautionFlammable!Observe the manufacturer’s safety directives on the container.

From manufacturer only:TGW Technische Gummi Walzen GmbHAm Elzdamm 38D-79312 Emmendingen

Glass cleaning agent Cleaning the vision panels


Household detergent Cleaning varnished surfaces


Paper tissues To clean areas soiled with toner, developer and dust

Standard store-bought quality (e.g. KLEENEX)

1 of 2

A29246-X20-X-4-7680 / faA01.fm 365


Round brush Cleaning the toner dust indicator

Standard store-bought qualitye.g. pipe cleaners EGRA-bunt, OLDENKOTT, etc.

Soft cloth Cleaning surfaces MOLTOPREN or similar

Soft brush To clean areas that are not easily accessible

1 cm (1/2") round brushes and 2" flat brushes, standard store-bought quality with NYLON or hair bristles.Do not use brushes with metal casings.

Vacuum cleaner To remove paper dust and residue, toner and developer residue/spill

CautionAlways use an industrial vacuum cleaner with a grounded suction tube, rubber nozzle and filter set for fine dust. For larger quantities of toner spill (e. g. 1 bottle), the industrial vacuum cleaner must be explosion-proof.

Cleaning foil To clean the paper width sensor

supplied; available only from Océ Printing Systems

Cleaning felt with handle To clean the paper edge sensor


Cleaning felt with angled handle

To clean the paper width sensor


Cleaning materials/equipment

Purpose Remarks

2 of 2

366 A29246-X20-X-4-7680 / faA01.fm

Technical data

Technical data

Print speed

Printing method Electrophotographic with LED-PLUS technology

Fusing method Heat pressure fusing

Printing system Print speed

for 2-up(2 x 11 2/3"x8 1/3")

Print speed

for DIN A4 landscape

Océ VarioStream 7200Pinfed / Pinless

180 pages per minute 126 pages per minute







Océ VarioStream 7550Pinless


Océ VarioStream 7650Pinless


Océ VarioStream 7650 CXPinfed / Pinless


A29246-X20-X-4-7680 / faA01.fm 367

Technical data

Paper

Océ VarioStream 7650 CX TWINPinfed / Pinless


Paper feed Stack, deep-pile, roll

Stacker approx. 3300 sheets with 70 g/m2 (19 lbs.)

NoteMore detailed information about the types of paper that can be used is available in the paper specification (see section 1.6 Other documents, page 22). The most important paper requirements are listed below.

Paper dimensions and weight

Format width 165 mm to 457,2 mm (6,5" to 18")

Form height I mode for 300dpi: 76.2 mm to 711.2 mm (3" to 28")I mode for 600dpi (from SRA2 controller):76.2 mm to 508 mm (3" to 20")PCL mode: 76.2 mm to 406.4 mm (3" to 16")(form heights >17" only with external paper feed)

Fold length 152.4 mm to 406.4 mm (6" to 16")

Weight VarioStream 7200/7300/7400/745050 g/m2 to 160 g/m2

(heavier and lighter weights possible after positive test runs)

Volume 1.3 cm3/g ± 0.2 cm3/g

Preprinted forms

368 A29246-X20-X-4-7680 / faA01.fm

Technical data

• Preprinted forms must not contain metal pigmented printing ink on the front or reverse side.

• The printing ink must be heat resistant (approx. 240° C for printing 7.5 x 105 N/m2) and non-abrasive. Thermoplastic particles must not be released.

• The printing ink must be completely dried through.

• If a preprinted surface is to be used for printing:

– the surface must be rastered

– the coverage must be less than 50%

Coated papers Coated papers must not contain components that could be released when heated (240° C and higher).

Self-adhesive labels Continuous forms for labels:

– Weight: 90 g/m2 to 180 g/m2

– Cut edges must be clean– Minimal abrasion– Minimal dustLabel paper:

– Weight: ≥ 65 g/m2

– Volumes: 1.3 cm3/g ± 0.2 cm3/gCarrier paper:– Coated reinforced paper

– Weight: 85 g/m2 ± 4%

– Volumes: 1.3 cm3/g ± 0.2 cm3/gCompound:– Adhesives must be heat-stable at the fuser

temperature.Adhesiveness of labels on the carrier paper: 0.1 per 15 mm

Storage conditions Temperature: 18°C to 24°C

Relative humidity: 35% to 55%

A29246-X20-X-4-7680 / faA01.fm 369

Technical data

Electrical values

Power input at 50 Hz (standby values in brackets)

Average performance characteristics for a paper width of 375 mm (14.8") and a paper weight of 70 g/m2

When idle, the printing system automatically switches to standby.

Power input at 60 Hz (standby values in brackets)

Unit Power frequency

50 Hz ± 1 Hz 60 Hz ± 1 Hz

Supply voltage V 400/230 +6 % / -10 % 208 ± 10 %

Chamfers 3 PH + N + SE 3 chamfers, PE

Device fuse A 4 x 50 3 x 80

Power fuse A 4 x 63 3 x 100

VarioStream

Unit 7200 7300 7400 7450 7550 7650

Effective power PE

KW 7,3(1,9)

8,4(1,9)

10,0(2,0)

11,4(2,0)

12,5(2,1)

14,1(2,1)

Apparent power PA

kVA 8,8(2,6)

9,7(2,6)

11,1(2,6)

12,5(2,6)

13,9(2,9)

15,6(2,9)

Performance factor λ

1 0,83(0,74)

0,87(0,74)

0,89(0,76)

0,91(0,76)

0,90(0,73)

0,90(0,73)

Heat emission Q KJ/h 26.280(6.840)

30.240(6.840)

36.000(7.200)

41.040(7.200)

45.000(7.560)

50.760(7.560)

Kcal/h 6.277(1.634)

7.222(1.634)

8.600(1,720)

9.802(1.720)

10.748(1.805)

12.124(1.805)

VarioStream

Unit 7200 7300 7400 7450 7550 7650

Effective power PE

KW 7,3(1,95)

8,2(1,95)

9,7(1,95)

11,4(2,0)

12,2(2,1)

13,3(2,3)

Apparent power PA

kVA 7,8(2,2)

8,6(2,2)

10,2(2,2)

11,9(2,3)

12,7(2,4)

13,7(2,7)

370 A29246-X20-X-4-7680 / faA01.fm

Technical data

Average performance characteristics for a paper width of 375 mm (14.8") and a paper weight of 70 g/m2

When idle, the printing system automatically switches to standby.

Emissions

Operating noise (standby values in brackets)

max. 70 dB(A)

(max. 61 dB(A))

Printers switch automatically from operating to standby mode when idle

Ozone concentration

0.01ppm

The maximum work place concentration (MAK) defined by the German Research Council is 0.1 ppm.

Mechanical conditions

Performance factor λ

1 0,94(0,88)

0,95(0,88)

0,95(0,88)

0,96(0,89)

0,96(0,88)

0,97(0,87)

Heat emission Q KJ/h 26.280(7.020)

30.240(7.020)

34.920(7.020)

41.040(7.200)

43.920(7.560)

47.880(8.280)

Kcal/h 6.277(1.677)

7.050(1.677)

8.340(1,677)

9.802(1.720)

10.834(1.806)

11.436(1.977)

Vibrations in accordance with EN 60721, intensity class 3M2

Tilt maximum tilt angle of the printing system: 1°

VarioStream

Unit 7200 7300 7400 7450 7550 7650

A29246-X20-X-4-7680 / faA01.fm 371

Technical data

Environmental conditions

Operating ranges

Cooling and fresh air, air cleanliness

To maintain the thermal equilibrium for climatic class 3K2 (general office climate) in the printing system location, a combination of sufficient cool and fresh air is required.

Dimensions and weight

Dimensions

Recommended optimumoperating range

Limit of operation

Limit value with High Temperature Kit (optional)

Temperature 18°C to 24°C 10°C to 32°C up to 35° C (95° F) max.

Relative humidity 38 % to 60 %

(Paper: 45 ± 7,5 %)

10% to 80 % up to 45% max.

Lowest absolute humidity

2 g/m3 1 g/m3 -

Highest absolute humidity

22 g/m3 25 g/m3 18 g/m3

Simplex printing system for 50 Hz power frequency

Simplex printing system for 60 Hz power frequency

Cooling air 7,200 m3/h 8,300 m3/h

Fresh air 10% - 20% of the cooling air must be fresh air

Air cleanliness

according to air cleanliness class 2

Height 1,549 mm (60.3 ")

Length 2,316 mm (90 ")

Depth 1,060 mm (37 ")

372 A29246-X20-X-4-7680 / faA01.fm

Technical data

Weight

Approx 1,260 kg (simplex printing system)

A29246-X20-X-4-7680 / faA01.fm 373

Technical data

374 A29246-X20-X-4-7680 / faA01.fm

Index

IndexAAccess ticket- Button 69- requesting 85Active filter- installing 294- remove 291- replacing 291ADVF- Key 50ADVR- Key 50Agent 31Air nozzle settings 123Alert word- in the safety directives 28Appendix 355Assembly and installation- Safety directives 35Authorization level- presetting for user 82

BBasic information 74Button- Access ticket 69- Cancel print job 67- Change user 70- Channel control 67- Clear buffer 67- Clear printer 67- Consumable counter 69- Display errors 68- Display information 68- Display warnings 68- Help 69

A29246-X20-X-4-7680 / fa_20_baSIX.fm

- Job control 67- Left Right 67- NPRO 62- Océ 70- Off 70- Print one page 67- Ready 62- Remote diagnosis 68- Service ticket 69- Stop 62- Test print 67- User profile 69

CCalibration gap- Preselect setting 127- Setting 121Cancel print job- Button 67Caution- Alert word 28CE Mark 38Channel control- Button 67Charge corotron (torn wire)- replacing 281Charge corotrons- replacing 278Cleaning- Corotrons 218- Developer station 203- Filter 220- Fuser roller 199- Fuser station 191- General 224- LED print head 219

375

Index

- Operator panel 223- Paper path 179- Plastic strips in front of the discharge blade

188- Safety directives 33- Sensors 207- the printing system 175- Time 177- Toner dust indicator 334- Toner mark sensor 207- Toner suction system 213Cleaning belt- installing 299- removing 297Cleaning brush- installing 267- removing 264Cleaning equipment- Overview 365Cleaning intervals 177Cleaning materials- Overview 365Cleaning steps 177Cleaning stop- Status display 65Cleaning the paper path 179Cleaning the plastic strips in front of the discharge blade 188Clear buffer- Button 67Clear printer- Button 67Climate and paper 56Clogged toner suction 343Color- Printing with other colors 138Condensation water 172Consumable- replacing 226Consumable counter- Button 69Consumables- Overview 356Consumables and expendables 90

Context-sensitive help 17Continuing printing after errors have been corrected 341Converting- Converting the printing system 165- Printing system 162- Selecting a configuration 164Converting the printing system 165- Replacing the developer station 168- Replacing the fuser roller 170- Replacing the photoconductor drum 169- Replacing the toner feed 166- Start conversion 165Cooling 34Corotrons- cleaning 218- replacing 269Correcting- Faults 337Correcting errors 337Covers 42CustomTone 251

DDanger points 29Description of the printing system 41Developer- Filling 244- replacing 238Developer station- cleaning 203- Emptying 239- replacing 145Device overview 41Dimensions 372Direct help 17Discharge corotron (torn wire)- replacing 287Discharge corotrons- replacing 284Disposal- Océ disposal concept 36Disposal concept- Disposal 36

376 fa_20_baSIX.fm / A29246-X20-X-4-7680

Index

Documentation signposts 12Doors 42

EEJECT- Key 50, 52Electrical values 370Emissions 371Empty- Developer station 239Enter- fold length 126Entering values 88Environmental conditions 372Error messages- Locating 338- on the operator panel 338Errors- Display (button) 68Expendables- Overview 361- replacing 256

FFaults- correcting 337Filling- Developer 244Filter- cleaning 220Fine filter- installing 332- removing 330Fire- Safety directives 36Fold length- Setting 122Front view of the printing system 42Full text search 16Fuser oil- Replacing bottle 252Fuser oil bottle- installing 254- removing 252

Fuser oil quantity- changing, menu 129Fuser roller- Checking 195- cleaning 199- installing 315- removing 312- replacing 312Fuser station- cleaning 191Fusing quality- poor 351Fusing temperature- changing, menu 128

GGeneral- Menus 73General cleaning 224

HHeater- installing 307- removing 302- replacing 302Help- Button 69High Temperature Kit 372- Emptying condensation water 172- Powering off 174- Powering on 96

IImportant- Alert word 28Indicator lamps- EJECT 54- READY 54- STOP 54Information- Display (button) 68- Locating 338Information signs 29Initialization

A29246-X20-X-4-7680 / fa_20_baSIX.fm 377

Index

- Status display 65Installing- Active filter 294- Cleaning belt 299- Cleaning brush 267- Fine filter 332- Fuser oil bottle 254- Fuser roller 315- Heater 307- Photoconductor drum 260- Pressure roller 323- Toner bottle 229- Waste collector 328- Waste toner bottle 236Intended Purpose 26Internal view 45- Front side of the printing system 45- Rear side of printing system 47

JJob control- Button 67

KKey- ADVF 50- ADVR 50- EJECT 50, 52- READY 52- STOP 53Key operator 31

LLanguage- changing 86- presetting for user 82LED print head- cleaning 219Left Right- Button 67Lever for tension roller distance 123Lever for tension rollers 122Logging on- as user 85

Logical page length- entering 126Lower- Stacker top 53Lower stacker tray slide- Stacker tray 53

MMain circuit breaker 47, 96Manufacturer 22Mechanical conditions 371Menu display- VarioStream 7000 79Menu tree- VarioStream 7000 71Menus- General 73- Open 71- Paper Path Manager 78- releasing for user 82- VarioStream 74

NNavigation tree- VarioStream 7000 71Noises 33Notes on this documentation 11NPRO- Button 62

OOcé- Button 70Off- Button 70Online Help- Button 69Operating and service clearance areas 27Operating elements 50Operation- Safety directives 32Operator 31Operator intervention necessary- Status display 64

378 fa_20_baSIX.fm / A29246-X20-X-4-7680

Index

Operator panel- cleaning 223- Description 60- on stacker 51- Operate 80- Paper transporter 50Optical wave guide 34Overview 41- Cleaning equipment 365- Cleaning materials 365- Consumables 356- Expendables 361

PPaper- Handling 56- inserting 100- insertion after paper jam 112- positioning fold-matching 118- Semi-automatic insertion 106- Specifications 55- Technical data 368- Types 55Paper brake- Setting brake force 129Paper change- Settings 121- Settings in the menu 125Paper edge sensor in the fuser station- cleaning 211Paper feed 57Paper format length- Entering 125- Setting 122Paper handling 56Paper motion sensor and mirror- cleaning 209Paper Path Manager- Menus 78Paper specification 22Paper stack replacement before paper end 100Paper types 55Paper width- entering 127

- setting with slide 101, 124Paper width setting slide 101, 124Parameters- Applying 89- Resetting 89- Setting 87Password- changing 86- presetting for user 82Photoconductor drum- installing 260- removing 258- replacing 257- running in 263Poor fusing quality 351Poor print quality 348Poor printing 348Poor printing, cause, correction 349Positioning fold-matching 118Power off tension rollers- Stacker top 53Power on tension rollers- Stacker top 53Powering down- Status display 65Powering off- High Temperature Kit 174Powering off the printing system 173Powering on- High Temperature Kit 96Powering on the printing system 96Pre-/post-processing not ready- Status display 66Pressure roller- Checking 196- installing 323- removing 320- replacing 320Print one page- Button 67Print quality- poor 348Printer setting- Selecting 125

A29246-X20-X-4-7680 / fa_20_baSIX.fm 379

Index

Printing- Status display 64Printing system- cleaning 175- converting 162- Covers 42- Description 41- Device overview 41- Doors 42- Front view 42- Internal view 45- operating 95- Overview 41- Powering off 173- Powering on 96- Rear view 44- Switching to ready after print stop 99Printing system stopping- Status display 65

RRaise- Stacker top 53READY- Indicator lamp 54- Key 52Ready- Button 62- Status display 64Readying- Status display 64Rear view of printing system 44Releasing elements for user 82Remote access- blocking 352- permitting 352Remote diagnosis- Button 68Remote diagnosis by Service 352Remove- Active filter 291Removing- Cleaning belt 297- Cleaning brush 264

- Fine filter 330- Fuser oil bottle 252- Fuser roller 312- Heater 302- Photoconductor drum 258- Pressure roller 320- Toner bottle 227- Waste collector 326- Waste toner bottle 233Removing the paper stack 131Repairs- Safety directives 36Replacing- Active filter 291- Charge corotron (torn wire) 281- Charge corotrons 278- Cleaning belt 297- Cleaning brush 263- Consumable 226- Corotrons 269- Developer 238- Discharge corotron (torn wire) 287- Discharge corotrons 284- Expendables 256- Filling toner box 232- Fine filter 330- Fuser oil bottle 252- Fuser roller 312- Heater 302- Paper stack before paper end 100- Photoconductor drum 257- Pressure roller 320- Toner bottle 226- Transfer corotron 271- Transfer corotron (torn wire) 275- Waste collector 326- Waste toner bottle 233Replacing consumables- Completing 90- Starting 90Replacing expendables- Completing 90- Starting 90Replacing the cleaning belt 297

380 fa_20_baSIX.fm / A29246-X20-X-4-7680

Index

Replacing the cleaning brush 263Replacing the developer station 168Replacing the fine filter 330Replacing the fuser roller 170Replacing the photoconductor drum 169Replacing the toner feed 166Requesting- Access ticket 85Running in- Photoconductor drum 263

SSafety covers 33Safety directives- Assembly and installation 35- Fire 36- Flagging 28- Operation 32- Repairs 36- Transport 36Safety information- General 22Search 16Selecting a configuration 164Selecting settings 88Sensors- cleaning 207Service 32Service ticket- Button 69Setting- the paper width 101Setting loop puller force 121Setting tension roller distance 123Setting the tension rollers 122Settings- for the paper width 124- of air nozzles 123- of tension rollers 122- of the tension roller distance 123- on paper transporter 121- when changing paper 121Setup- changing 134

- creating new 134- exporting 137- importing 136- Status display 65Signs 29Special functions- Status display 65Spots- in the print image 348- on the paper 348Stacker- Settings 122Stacker top- Lower 53- Power off tension rollers 53- Power on tension rollers 53- Raise 53Stacker tray- Lower stacker tray slide 53Standards 37Start conversion 165Status display 64- Cleaning stop 65- Initialization 65- Operator intervention necessary 64- Powering down 65- Pre-/post-processing not ready 66- Printing 64- Printing system stopping 65- Ready 64- Readying 64- Setup 65- Special functions 65- Stop 66- System loading 66- Twin stop 66Statutory requirements 23STOP- Indicator lamp 54- Key 53Stop- Button 62- Status display 66- With loss of information 341

A29246-X20-X-4-7680 / fa_20_baSIX.fm 381

Index

- Without loss of information 341Switching to ready- Printing system after print stop 99Symbol- in diagrams and illustrations 20Symbols- in the text 19System loading- Status display 66

TTable- Cleaning steps 177Technical data 367- Dimensions 372- Electrical values 370- Emissions 371- Environmental conditions 372- Mechanical conditions 371- Paper 368- Weight 372Test print- Button 67Time- to clean 177Toner- CustomTone 251- Replacing waste bottle 233- Suction clogged 343- Vacuuming out feed 343Toner bottle- installing 229- removing 227- replacing 226Toner bottle identification 48Toner box- filling 232Toner dust indicator- cleaning 334Toner feed- replacing 138Toner mark sensor- cleaning 207Toner suction system

- cleaning 213Toolbar- VarioStream 7000 61Transfer corotron- replacing 271Transfer corotron (torn wire)- replacing 275Transponder 48Transport- Safety directives 36Twin stop- Status display 66

UUser- adding 81- Change (button) 70- deleting 82- editing 82- logging on 85User profile- Button 69User settings- Key operator 81- Operator 84

VVarioStream- Menus 74

WWarning signs 29Warnings- Display (button) 68- Locating 338- on the operator panel 338Waste collector- installing 328- removing 326- replacing 326Waste toner bottle- installing 236- removing 233Weight 372

382 fa_20_baSIX.fm / A29246-X20-X-4-7680

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Name: _____________________________

Tel.: _____________________________

Company: ___________________________

Date: _____________________________

Mail or fax to:

Océ Printing Systems GmbHITC DD&D PoingPostfach 126085581 PoingGermany

Fax: +49-8121-72-3420

Order No.: A29246-X20-X-4-7680

Océ Operating Manual Océ - files.oceusa.com · 85581 Poing Germany Edition 2005/11 ... Operating...

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Transcript of Océ Operating Manual Océ - files.oceusa.com · 85581 Poing Germany Edition 2005/11 ... Operating...