Xerox
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 1 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
Instruction #: Tag/Mod: Classification Code:
Purpose
The purpose of this instruction is to install DocuColor 240/250 Engine Software Set Version 1.231.16
Required tools and supplies
x PWS Laptop with DC240/250 DiagnosticTool.
x Access to GSN Library 6973 to retrieve the SW file “All_In_One 1_231_16.bin”
x Save/Place file 1 231 16.zip to your desktop. Extract all files to location :
C:\Xerox\PWS Diagnostic Tool\System SW\DC250\DC250-all-modules
x GSN Release 9.0 or Higher PWS Software
x GSN Lock
x USB Cable (p/n 600T02231)
x Color Test Pattern (p/n 82E13120)
Introduction
Read all of the Instructions before beginning the upgrade.
These instructions can be used when upgrading from and to the following software:
Software Table
ROM FROM TO Set
Versions Version
Controller ROM All 1.231.16
IOT ROM All 8.32.0
C Finisher ROM (If Installed) All 17.15.0
IIT ROM All 11.56.1
IIT Option ROM All 12.3.2
ADF (DADF) ROM All 11.8.0
SJFI (This is part of Controller ROM SW) All 3.0.3
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 2 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
Procedure
__ 1. Print a System Settings List for Copier and Network Controller (if present). Section 6 General procedures
in EDOC
__ 2. Make a Copy of the Color Test Pattern. Fix any IQ or other problems before upgrading software.
__ 3. Check Controller ROM Software Version. If it’s 1.231.5, 1.231.6, 1.231.7 or 1.231.11 skip to step 5.
__ 4. Print an Auditron Report (as shown below) if accounts are setup give to customer and inform them this
data will have to be re-entered after upgrade is complete.
Enter UI Diagnostics – Press Log in /Out on UI – Login set up/Auditron Administrator / Reset user Accounts / All
User Accounts / Print the Auditron Report
__ 5. Switch off the Machine. Wait 60 seconds for the machine to completely power down.
__ 6. Power off the DFE
__ 7. Connect the USB Cable to the IOT USB port (On the Control Unit.) and to the PWS
__ 8. Enter Machine into Download Mode. (Press and hold the Power Saver Button while switching on the
machine. Continue holding the power saver button until the UI displays Download Mode. Note: The UI will
display Download Mode for a short time, then go blank and then display Download Mode again.)
__ 9. Start the DC250 PWS Diagnostic Tool
__ 10. Select Enter Software Download.
__ 11. Select “Browse File(s)”, select “All_In_One 1_231_16.bin” (16-743 may occur if wrong file is
used.)
Make sure the 1.231.16 Version file is the only file showing and is
highlighted .
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 3 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
__ 12. Press the Start Download button. The machine UI screen will display the progress. Wait until all files have
been downloaded at which point the machine will reboot to Ready to Copy (this could take up to 16
minutes).. If a 116-331 occurs Reboot IOT and it should then come to Ready to Copy. If a 042-xxx occurs
ignore and continue to next step.
__ 13. Exit PWS.
__ 14. Enter UI diagnostics / NVM Read/Write
Write the NVM in the Table Below
Chain/Link Description Value
740-019 IOT Conditional Initialization 2
__ 15. Exit UI Diagnostics , select Exit (Keep Log) and then Yes. Machines will self Reboot. Wait for the
machine to come up to Ready to Copy
__ 16. Enter UI diagnostics / NVM Read/Write
Read the NVM value in the Table below.
Chain/Link Description Value
740-020 IOT Last Initialization Version
__ 17. If the Value read in step 16 is not 832, return to step 14. If it is 832, continue.
__ 18. Write the NVM in the table below.
Chain/Link Description Value
740-019 IOT Conditional Initialization -2
__ 19. Read the Special Notes on page 10 and confirm that the Developer Bias HVPS NVM’s are correct based on
which part is actually installed (PL11.1, item 16) on the device (the part number is on the PWB, near P588).
Most machines have these values on T1 NVM Sheet.
__ 20. For Machines without Finishers skip to step 22 otherwise continue to step 21.
__ 21. For Advanced or Professional Finisher (C Finisher), Check/Set the NVM in the table on the next page.
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 4 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
A/P Finisher NVM Settings
Chain/Link Description Value Comment
763-015 Punch 0
763-039 MBX-Fin 11
763-040 MBX-Fin 11
763-041 MBX-Fin 71
763-042 MBX-Fin 11
763-043 MBX-Fin Duplex 91
763-044 MBX-Fin Duplex 11
763-046 Maximum Compile 10 Unstapled Eject Set
763-047 Maximum Compile 10
763-172 Top Tray Exit Motor 1
763-174 Top Tray Exit Motor 1
763-180 Top Tray Exit Motor 7
763-181 Top Tray Exit Motor 7
763-182 Top Tray Exit Motor 7
763-183 Top Tray Exit Motor 7
763-189 Simplex Straight 55
763-190 Simplex Straight 11
763-191 Simplex Invert 55
763-192 Simplex Invert 11
763-193 Duplex Eject 55
763-194 Duplex Eject 11
763-195 Punch Mode Select 0
763-196 Eject Clamp Full Up 2
763-198 1
763-950 Set Eject Tray Ctrl 9
763-951 Set Eject Tray Ctrl 2
763-952 Tamper Return 0
763-953 Stapler Move 0
763-956 Debug command enable 0
763-970 Stacker Full 13
763-988 Simp invert 11
763-989 Duplex 11
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 5 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
__ 22. For all machines, Check/Write the following NVM values in the table below.
Chain/Link Description DC240/250 Comment
Values
752-367 Procon value 670
752-368 Procon value 650
752-369 Procon value 650
752-370 Procon value 715
752-381 Procon value -20
753-470 Procon value -4312
753-471 Procon value -4312
753-474 Procon value -3503
753-475 Procon value -3503
753-478 Procon value 80
753-479 Procon value 80
753-482 Procon value 65
753-483 Procon value 65
753-490 Procon value 1
753-491 Procon value 1
753-494 Procon value 20
753-495 Procon value 20
761-091 Toner % dispalyed 10
762-091 Deve Bias Cycle down Y 0
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 6 of 11
Title: Engine Software Set Install Instructions V1.231.16
Machines in the office environment (Non-Graphic arts) run their machines in a low stress manner where extended Fuser
life can be achieved.
This is a mandatory retrofit. Perform the Fuser NVM life extension procedure for the following Target Population:
x Typical office type customers who run low area coverage, 11in or 17in plain paper (20 – 28lb), and who
currently replace fusers at or beyond the replace now message (200,000 HFSI).
x Those customers who have Tag 17 installed.
PROCEDURE
DocuColor 240/250
x Using PWS, set the following NVM locations to the values listed in Table 1.
Table 1
Location Location Name Correct Value
744-354 Fuser Assembly Warning Threshold 340
744-355 Fuser Assembly Life Threshold 350
954-842 Fuser Change Threshold 350000
x From the DC Quick Pull Down, select DC131.
x In Quick ID (located in lower right corner), enter 744-354 (Fuser Assembly Warning Threshold).
x Highlight entry and in New Column enter 340 then Write NVM.
x In Quick ID, enter 744-355 (Fuser Assembly Life Threshold).
x Highlight entry and in New Column enter 350 then Write NVM.
x From DC Quick Pull Down, select DC135.
x Scroll to location 954-842 (Fuser Change Threshold) and highlight location.
x In left column, under DC135, select Change Threshold.
x Enter 350000 into New Threshold.
x Select Set New Machine Threshold.
x Select Refresh.
x Exit Diagnostics.
x Reboot machine.
x Mark off IOT tag 17 on the inside of the machine front door.
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 7 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
__ 23. Exit UI Diagnostics , select Exit (Keep Log) and then Yes. Machines will self Reboot. Wait for the
machine to come up to Ready to Copy
__ 24. Power Off Machine and wait 60sec.
__ 25. Power on the DFE.
__ 26. Power on the IOT and wait for the machine to come up to Ready to Copy
__ 27. Print a System Settings List for Copier and Network Controller (if present). Section 6 General procedures
in EDOC
__ 28. Verify that all the files downloaded successfully. See Table on Page 1 of these instructions.
__ 29. Disconnect the USB Cable from the IOT
__ 30. Make another Copy of the 82E13120 test pattern and Compare it to the copy made in section 1, step 3.
The copy should be of equal quality. If it is not, perform appropriate adjustments per IQ RAPS.
__ 31. Check with the System Administrator to insure that clients can print to the machine.
Hint: Make sure the Network Icons are not grayed out. If they are Reboot the IOT then DFE if necessary. Wait until Icons
come on before having the Customer Print. Some DFE’s take longer then others.
Optional (Recommended)
Connect PWS NVM Tool and Enter DC351 and Save Machine Settings. The tool names the file with Serial Number and
date. The file name can be changed, if desired, when it is saved on Exit of PWS Diagnostic Tool.
This will save many critical NVM including any adjustments made, including the locations on the Tray 1 NVM List. It may
be useful to restore NVM in the future if this machine has PWB replacements, NVM problems, or if NVM is initialized. The
saved file will be sent to C:\Xerox\PWS Diagnostic Tool\Data\DC250, unless directed to another location.
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 8 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
CALL CLOSE REPORTING (US Only):
Close the Primary Activity Code 10
Open a Primary Activity Code 85 with no travel
Show part used - 635K10240 (this is not an orderable part and is for retrofit reporting purposes only)
Show Quantity Used 1
Show Order 0
Show part source code 07
BLR code of 3
Close the Primary Activity Code 85
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 9 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
NOTES
1.) If Upgrading Controller ROM from (1.210.6, 1.230.5, 1.210.9 or 1.230.9), Auditron Data and Administrator
Password will be lost. The Auditron does remain turned on however and the Administrator ID will be reset to
the default setting (11111). Pay special attention to steps 3&4 in the procedure.
Even though the message “Press Log In/Out Button and enter user Details” is not displayed on UI, it does
not indicate that the customers does not have any accounts set-up. Print an Auditron Report for the Customer
before upgrading to this software to enable reprogramming after the upgrade. If Accounts are set-up you must
inform the Customer that this data will be lost. Explain to the Customer that reprogramming will be required after
the upgrade is complete. See Steps 3&4
2.) This IOT release V8.26.0 provides the ability to adjust slow scan (process direction) magnification ( aka “Image
Shrink” problem). Please note that this adjustment is very specific and not all machines are good candidate for
this adjustment. If this adjustment is going to be performed, have a sample of the actual file in question before
upgrading. Also copy a Test pattern on the platen. GP procedure to come in EDOC.
3.) DO NOT interrupt the download or power off the machine during download. If the machine is
powered off and on during download or the download is interrupted, serious problems may result.
4.) Make sure that the USB cable is securely connected. If this cable disconnects during download, the file being
loaded onto the machine will become corrupted and the file will have to be downloaded again.
5.) Newly implemented function of IOT ROM Software 8.26.0. NVM Location 740-019. A value of -2 allows an
Automatic Conditional Initialization of the IOT NVM. When the machine sees a change in IOT ROM Software
Version it Automatically Conditionally Initializes the IOT NVM Data as required. This value will stay at a -2. NVM
Location 740-020 is updated and indicates which Version of IOT SW the last IOT initialization occurred with.
6.) If a Full IOT Initialization is done using UI Diagnostic Routine Manually set NVM location 740-019 to a -2.
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 10 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
Helpful Hints
x All-in-One files are the most time effective method to upgrade software. If RAP directs to reload software; Browse to a single
file must be used.
x When reloading single software Files consult table below. The Single file desired can be selected by Browsing File(s) on the
PWS Software Download Tool, then carefully browsing to the appropriate module file.
x If directed, in EDOC, to Reload Software, Browse File(s) must be selected. A single file downloaded is required, because the
All-in-One download routine will not download software into any module that already has the same version loaded onto it.
x The PWBs in Table below have software pre loaded. When a PWB is replaced, always check what software is pre-loaded and
upgrade to the appropriate version if needed. An All-in-One download will always ensure that the PWB has the proper Engine
Set Version, but it may be shorter to only browse to a single file to upgrade a PWB, but care must be taken to ensure proper
set version. In order to avoid mismatch set version, ensure that the version loaded is part of a valid set version as noted in
Engine Softwre Set Version Table below.
x When Reloading Software, follow instructions in table below.
x When PWB’s are replaced, Browse to single file may be used, but care must be taken to ensure proper set version. All-in-One
download may also be used. All-in-One download will ensure matching set version.
Note: HCF Versions will not be upgraded, listed for reference only.
Reload Module or Required Software Actions to Take when performing Browse File(s) and downloading a single file
PWB Replaced Version
DADF ADF ROM Just upgrade the software on the board and no further action is required
IIT/IPS IIT ROM Just upgrade the software on the board and no further action is required
Extension Memory IIT Option ROM Just upgrade the software on the board and no further action is required
MF ROM Controller ROM Upgrading this software will require attention to the Notes in the Main instructions. It
may also require DC351 Bach File XC or XE to be written if the Country Code is not
correct on the Systems Settings List.
MCU IOT ROM Steps 14-19
Finisher Finisher ROM Load the Software then follow step 20- 24
Engine Software Set Version Table
Engine Firmware ESS IOT (IOT IIT (IIT IIT (IIT ADF SJFI HCF (HCF FIN
Set Version (Controller ROM) ROM) Option (DADF ROM) (Finisher
ROM) ROM) ROM) ROM)
This General Release 1.231.16 8.32.0 11.56.1 12.3.2 11.8.0 3.0.3 Any Version 17.15.0
General Release 1.231.15 8.26.0 11.56.1 12.3.2 11.8.0 3.0.3 Any Version 16.25.0
General Release 1.231.14 8.26.0 11.56.1 12.3.2 11.8.0 3.0.3 Any Version 16.25.0
General Release 1.231.11 7.8.0 11.52.1 12.0.0 11.2.3 3.0.3 5.2.0 6.4.0
Tag 6 3.6.0 or 3.10.0
General Release 1.231.7 7.8.0 11.52.1 12.0.0 11.2.3 3.03 5.2.0 6.4.0
Tag 5 3.6.0 or 3.10.0
SPAR Release 1.231.6 7.8.0 11.52.1 12.0.0 11.2.3 3.03 5.2.0 6.4.0
3.6.0 or 3.10.0
OHCF Enablement 1.231.5 7.8.0 11.52.1 12.0.0 11.2.3 3.0.3 5.2.0 6.4.0
Release 3.6.0 or 3.10.0
Tag 3
SPAR 1.210.9 5.27.0 11.42.2 12.0.0 11.2.3 3.0.2 5.2.0 5.12.0
Release & 1.230.9 NA
Launch Release 1.210.6 5.27.0 11.42.2 12.0.0 11.2.3 3.0.2 5.2.0 5.12.0
& 1.230.5 & 11.42.0 NA
Product(s): DocuColor 240/250 Date: 10/28/08 Page: 11 of 11
Title: Engine Software Set Install Instructions V1.231.16 Set
NVM Setting according to YMC Developer Bias HVPS (PL11.1, item 16)
Modified HVPS (105K20761) was cut in (line) in around July 2005.
After upgrade the following NVM values will not be correct if a older HVPS (105K20760) is installed.
If any doubts please confirm which Developer Bias HVPS is installed in the machine by checking P/N on supply installed
in the machine, and set the following location accordingly.
NVM setting value shown in Table below may need be changed depending on which HVPS is mounted on the device.
“HVPS for YMC” is PL11.1, item 16 (105K20760 Developer Bias HVPS) .
NVM Value NVM Value
Chain Link NVM Name Part # 105K20760 Part # 105K20761
(Old HVPS Value) (New HVPS Value)
761 018 Deve Bias AC YMC High Output Voltage 521 592
Value(220)
761 019 Deve Bias AC YMC High Output Voltage 521 592
Value(110)
761 020 Deve Bias AC YMC High Output Voltage 521 592
Value(73.33)
762 222 Deve Bias AC YMC Low Output Voltage 521 592
Value(220)
762 223 Deve Bias AC YMC Low Output Voltage 521 592
Value(110)
762 224 Deve Bias AC YMC Low Output Voltage 521 592
Value(73.33)
762 253 Deve Bias AC YMC Output Voltage Value 521 592
(ComponentCheck)
Most machines have these values on T1 NVM Sheet
