1

Edition

varioPRINT 135 Series / VarioPrint DP Line – Symptoms and

Solutions Guide
Canon U.S.A., Inc.
 varioPRINT 135 Series
Symptoms and Solutions Guide

Today’s Technical Workbook will focus on actual field

activity and product specialist experiences. In addition
countermeasure procedures and guidelines for
implementation are discussed.

i
Table of Contents
Contents
varioPRINT 135 Series ................................................................................................................ i

Symptoms and Solutions Guide ............................................................................................. i

Avoidable Service Calls .......................................................................................................................... 1
Robin / Porthos....................................................................................................................................... 2
varioPRINT Engine Symptoms and Solutions ..................................................................................... 3
WARNING REGARDING PARTS REPLACEMENT! ............................................................................. 3
NIP PCB (s/n 698002501 and above): TP13 218a ......................................................................................... 3
TM2 controller: TP13 218a ............................................................................................................................ 4
Incompatible Power Supply Assemblies: TP13 218a ................................................................................... 4
Different Warm Process support frames ...................................................................................................... 5
Installing CREATEUSB on 32BIT Vs. 64BIT Windows® systems ............................................................ 5
Create USB Tool - "The USB drive was not created" Message .................................................................. 6
Importance of Creating a System Backup .................................................................................................... 6
Backing up Contents of Users DocBoxes ....................................................................................................... 7
Correcting “Off the Glass” Document Detection Failure ............................................................................ 8
Spots on Prints: TP13 398c ............................................................................................................................. 8
Configuration on Canon branded varioPRINT 135 Series printers and Océ brand VarioPrint DP Line
printers equipped with PE Foils (MOD 18 – TP13 374b) ............................................................................ 9
POC SETTINGS for PE FOILS .................................................................................................................................... 9

Spiral Cleaner contamination on Prints ...................................................................................................... 10

Moulds for varioPRINT Tray “Z” Adjustments (trays 3 & 4) of Main Body ......................................... 11
Blank UI Panel Display: TP14 251a ............................................................................................................ 11
Action to Perform When Replacing PCB in Finishing Accessory: TP13 412 .......................................... 12
QC Reset Function ........................................................................................................................................ 12
Differences between varioPRINT 135 Series and Océ VarioPrint DP Line Accessories ................. 13
Finisher AK1/AK2 Neat Stacking Assembly .............................................................................................. 13
Upper Return Roller Operation.................................................................................................................................... 14
Roller Assist Disengage Control.................................................................................................................................. 14

ii
 Availability of AF+ Enhancement Kit-A1 ................................................................................................... 15
Decoding Finisher 7 Segment Display ......................................................................................................... 15
Finisher-AF1/AK1 / Saddle Finisher-AF2/AK2 Reported Issues ..................................................... 16
Error codes during run and resuming from standby (Fault codes 1850260; 1850292; 1850242;
1850272).......................................................................................................................................................... 16
Complaint of Slow Printing on Tray B of Finisher-AF1/AF2 and Finisher-AK1/AK2 .......................... 17
Saddle Finisher Operation Assembly Slams Shut [AK1/AK2 Finisher] .................................................. 17
Paper Guides misalignment or damaged Mylar can result in curved Line on Prints [AK1/AK2
Finisher] ......................................................................................................................................................... 18
Error 11504;1870217 due to motor M26 unplugged: TP13 457a.............................................................. 20
Professional Puncher-B1: TP13 399a ................................................................................................ 21
Installation ..................................................................................................................................................... 21
Professional Puncher-B1 Reported Issues.......................................................................................... 23
Measure against puncher communication errors 1859965, 1859966: TP15 035 ..................................... 23
Intermittent Jamming 1879996, 1879992, & 1879994 ................................................................................ 24
High Capacity Stacker F1/G1.............................................................................................................. 25
Differences between High Capacity Stacker-F1 and High Capacity Stacker-G1 ................................... 25
High Capacity Stacker F1/G1 Reported Issues .................................................................................. 25
Error Code 2170343 when feeding 80lb Cover Stock ................................................................................ 25
Additional Hardware Options .............................................................................................................. 26
Duo Paper Tray Kit-C1: TP13 155 .............................................................................................................. 26
Bulk Tray Small Format: TP14 399 ............................................................................................................ 27
Decurler Unit-A1: TP14 025......................................................................................................................... 27
Appendix ............................................................................................................................................... 29
Power Flow Chart for New Type Electronics ...................................................................................... 30

iii
 1
Chapter

Model Troubleshooting
This portion of the Technical Connections seminar materials will focus on particular
troubleshooting techniques you can use when diagnosing a problem on the varioPRINT 135
Series / VarioPrint DP Line. As discussed with the Digital Solutions Specialist presenting
this seminar, remember the important elements of a Troubleshooting Game Plan:
1. Product Knowledge
2. Identify Problem Area(s)
3. Have Access To and Use reference materials
4. Have needed tools with proper knowledge of tool use
5. Separate machine into subassemblies (identify which subassemblies could or could not affect the
issue)
6. Test subassemblies to verify fault
7. Correct or Replace verified fault

Avoidable Service Calls

The purpose of this Technical Workbook is to call out specific procedures that Canon USA Inc. feels will
assist dealer technicians to minimize repeat service visits. A reduction in avoidable service visits benefits both
servicing dealers as well as end users by keeping service costs to a minimum.

1
Robin / Porthos
Robin / Porthos is the software suite used to download and receive periodic updates to the HTML based
varioPRINT 135 Series TSM (Technical Service Manual). Information regarding the installation and
configuration of Robin/Porthos is located on e-Support

“Robin” You will use this application to Subscribe, Replicate and Manage TSMs and other content to your
local computer/Laptop.

“Porthos” You will use this application to view the varioPRINT 135 Series TSMs and other content
replicated to your local computer/laptop. Porthos launches a local web server on your computer/laptop and
you browse the content using Internet Explorer.

2
varioPRINT Engine Symptoms and Solutions
WARNING REGARDING PARTS REPLACEMENT!
DO NOT under any circumstances (unless directed by CUSA Hardware Engineering), attempt to
remove the following (3) parts and install them in another varioPRINT engine. These (3) components
adopt the serial number and counter information from their host engine and will copy this information to
the donor engine. Once the serial number and counter information is corrupted it is not possible to
restore it to proper values:
 DRUM UNIT
 CONTROLLER (PRISMAsync - HDD)
 BEAGLE CORE PCB

NIP PCB (s/n 698002501 and above): TP13 218a

The NIP (Network Interface Proxy) PCB allows the varioPRINT PRISMAsync Controller to shut down and
still accept print jobs over the network. The NIP PCB accomplishes this by cloning the MAC address of the
PRISMAsync Controller. When a print job is sent to the varioPRINT engine, the NIP PCB wakes up the
Controller and Print Engine in preparation for printing.

3
PROBLEM: We have discovered in some situations where the varioPRINT is installed in a DHCP configuration,
the printer may not properly “wake” from “Deep Sleep Mode”, resulting in an 11576 or 11577 error code.

SOLUTION: In DHCP network configurations, we recommend that “Deep Sleep” be disabled in the Settings
Editor.

TM2 controller: TP13 218a

The PRISMAsync Controller is changed from TM1 to TM2. The TM2 controller is backwards compatible for
machines with a serial number below 698002501. A separate harness is needed [Additional Bundle
1070012128] to install a TM2 Controller in a machine with serial numbers below 698002501.

When installing the TM2 Controller, verify the Ethernet Cable (TOP), and Touch Screen Interface Cable
(BLACK/USB/MIDDLE) are in the correct ports.

TM2 Controller [A] TM2 Controller

[B] Harness

Incompatible Power Supply Assemblies: TP13 218a

CONCERN: there are two power supplies for the VarioPrint DP line.

 Power supply with part number 1060077775 is incompatible with serial numbers 6980002501 and
later. These machines have the new style electronics (NIP board; TM2 Controller) which require a
different power supply.
 Power supply with part number 1060130792 is compatible with all machines. Both power supplies
look identical so you must pay attention to the part number label on the power supply for proper
identification.

4
  CUSA inventory of discontinued Power Supply 1060077775 is depleted; however local dealer
inventories may still contain legacy part numbers.

Different Warm Process support frames

They are three different Warm Process support frames used on the varioPRINT.
 For serial numbers 69002500 and lower you will need to use part number 1060130299.
 For serial numbers 69002501 and higher you will need to use part number 1070012671.
 For serial numbers 69004621 and higher you will need to use part number 1060099633.
If you should swap any of the warm process support frames for troubleshooting, your HOD lamps will not
turn on and the machine will display “warming in 10 minutes”.

The ONLY warm process harness available for the varioPRINT is 1070013140 which is used with warm
process support frame 1070012671.

Before replacing this harness (22W02) or the warm process support frame, you should also check if the two
small HOD lamps are good. Their resistance when checked with an Ohm Meter should read between 4 to 7
ohms. In addition, check for possible connector pins that may have been pushed out of the rear side of the
connector housing when inserting the Warm Process Unit

Installing CREATEUSB on 32BIT Vs. 64BIT Windows® systems

PROBLEM: The CREATEUSBSETUP.exe on the e-Support system software download page is designed for
64 Bit Windows® systems. If installing this version on 32bit Windows® the technician will receive an error
that the program did not install or did not install correctly.

SOLUTION: The installation of the CREATEUSB utility v3.2.4.0 is now identical for both 64bit and 32bit
Windows® Systems. Using the figure on the next page as a guide, follow the procedure outlined below

Place the CREATEUSB folder in a safe location on your laptop hard drive.
1. Open the folder and locate the file “CREATEUSBINSTALL.EXE”
2. Right click on this file and choose “Send to”
3. Select “Desktop (create shortcut)”
Return to your desktop and launch the utility by clicking on the shortcut you created in step 3

5
 Install Create USB Tool

Create USB Tool - "The USB drive was not created" Message
PROBLEM: When attempting to create a USB Key, the Create USB Tool will display the message "The
USB drive was not created".

SOLUTION: Check the version of Microsoft® .NET Framework installed on the service laptop/PC. The
Create USB Tool requires .NET Framework 4.5.1, and it is possible that .NET Framework 4.5.2 or
higher may have been installed, causing this issue. Uninstall the incorrect version of .NET Framework,
and install .NET Framework 4.5.1.
NOTE: There were some reports of USB Key creation completing successfully with the wrong .NET
Framework version. However, when using that USB key to perform an upgrade, the varioPRINT restarts
with an 11504 error code and software installation would not continue. If you are confronted with this
symptom; remove the non-recommended version of .NET Framework and install the version indicated
above. Once completed, recreate the USB Key and attempt to install the System Software again. If
installation continues to fail, contact the Canon Technical Support Center for further instructions.

Importance of Creating a System Backup

Please create a system backup prior to upgrading any software version. This backup can be used to restore the
current version or newer version in case of an upgrade failure or a system downgrade becomes necessary.
NOTE: It is not advisable, and in many instances will destabilize the system if using a new backup file (ex.
V3.4.x) to restore a downgraded system (v3.4.x → v3.3.x).

6
Backing up Contents of Users DocBoxes
Software version 3.4.0 supports the backup/restore of the customer’s DocBox structure and files. The user’s
files are temporarily backed up to the USB Key during the upgrade from v3.3.x to v3.4.x and automatically
restored during the installation. THIS IS ONLY POSSIBLE WHEN UPGRADING FROM v3.3.x TO
v3.4.x or later!!

To activate this feature, be sure to select “Yes” when creating the USB Key.

Backing up DocBox Contents v3.4

NOTE: Do Not select this option if upgrading from the minimum prerequisite version (v3.2.x). Only select
this option when upgrading from v3.3.x.

While DocBox contents are being backed up, the User Interface will appear suspended with a PRISMAsync
icon on the screen with a blue background. Do Not power down the engine or data corruption may
result.

Backing Up DocBox
Contents

7
Correcting “Off the Glass” Document Detection Failure
PROBLEM: In case of a possible scanner fault, detection of original size from the Platen Glass may fluctuate
between Universal and AB/INCH paper sizes

SOLUTION: Replace Color image Reader Scanner unit FM3-5491-000 (not scanner of DADF).
 As a temporary measure, detection of Universal paper sizes can be deactivated by changing the
following value to “1”:
SDS>Parameters>Scanner>Duplex Color Image Reader-D1>”MODELSZ2: Ppr size dtct
global support in bookmode”.

Disabling Universal Paper Sizes

Spots on Prints: TP13 398c

PROBLEM: How to enable the Start-up / Standby Spot Countermeasure on Océ Branded VarioPrint DP Line
engines not equipped with MOD 20 (TP13 398c).
SOLUTION: The two parameters described below should be set to enabled (1). Together they make up the “Start-
up / Standby Countermeasure:

SDS>Parameters>Printer>Warm Process>”Advanced Stand-by-Mode to Prevent spots at

start of a run (1)”
This setting will enable “Standby Spot Countermeasure”
SDS>Parameters>Printer>Warm Process>”Future release preparation (1)”
This setting will enable “Start-up Countermeasure”.

8
Configuration on Canon branded varioPRINT 135 Series printers and Océ brand
VarioPrint DP Line printers equipped with PE Foils (MOD 18 – TP13 374b)
PROBLEM: My printer is equipped with PE Foils, but my customer is being prompted by the system to change
them. How do I prevent the “Wrench Light” from appearing and prompting my customer to replace the PE Foils?

SOLUTION: Enter SDS and verify the following settings:

SDS>Parameters>Printer>Paper Path>”Heat Exchanger Foil Type Setting *(0,1)”

*Graphite Foils (0) or PE Foils (1)

HEX Foils Setting in Parameters

POC SETTINGS for PE FOILS

1. SDS>POC Configuration>Replace the Heat Exchanger Foils [Uncheck Box]
2. SDS>POC Configuration>Remove Paper from the Heat Exchanger (Old Graphite Foils) [Uncheck Box]
3. SDS>POC Configuration>Remove Paper from the Heat Exchanger (PE Foils) [Select Check Box]

POC Configuration (SDS)

9
Spiral Cleaner contamination on Prints
Image quality contamination resembling spiral roller marks on the printed output may be caused by a setting
in SDS.

Lead Edge

Spiral Roller Marks

PROBLEM: Appearance of Spiral Roller contamination on both the front and backside of prints after several
hundred pages.
SOLUTION: Check the following SDS Parameter and verify setting is set to “0:Absent”.

SDS>Parameters>Printer>Warm Process>”Steel Roller Present”

Steel Roller Present = (0)

10
Moulds for varioPRINT Tray “Z” Adjustments (trays 3 & 4) of Main Body
When performing the Paper Tray Multi Format tray adjustment in the TSM, a "Mould" or template is required
to perform the SDS test.

SDS test: Adjustments/printer/Paper Feed Module/Paper 3 and 4 Z-size calibration.

These Moulds may or may not be shipped with the printer. There is no service part number for the Moulds.
Moulds can be cut from standard size plain paper and utilized to complete the adjustment.
NOTE: Mould size = 290mm x 140mm

Blank UI Panel Display: TP14 251a

PROBLEM:

1. Faulty UI Monitor whereas the display is otherwise functional except for the touch screen
“mouse” portion.

a. When touching the screen on the left side, the right side will respond or vise-versa.

b. Screen does not respond to touch at all.

c. Can occur after software update or software reload.

d. Connect USB mouse and activate in Settings Editor (Preferences>System

Settings>Accessibility) as a workaround
2. Blank User Interface Panel: This issue may occur during power on or when the machine
resumes from Sleep / Deep Sleep Mode.
a. Can occur after software update or software reload.
b. Temporary workaround - Perform a hard shutdown of the engine using the power button.
Wait 15 minutes and turn on engine. If the Engine resumes, immediately disable all Sleep
Modes , Sleep Mode timers and Auto Shut Off features in Settings Editor. Advise
customer to leave machine “ON” and do not turn “OFF” until a permanent solution is
reached.

SOLUTION: Review TP14 251a to see if you are able to request a free of charge replacement UI Panel.
Perform temporary workaround as suggested until UI Panel is replaced.

11
Action to Perform When Replacing PCB in Finishing Accessory: TP13 412
PROBLEM: When replacing the controller or slave PCB of a finishing device, the varioPRINT engine
automatically uploads the required software to the new PCB. Under some circumstances however, it is
possible that the varioPRINT engine does not detect the new controller/slave PCB. In this case, the
required software will not automatically be uploaded from the engine to the newly replaced board of the
finishing device. Without software on the replacement board, the finishing device may malfunction in
different ways (not starting, jams, adjustments are lost, etc). To prevent such problems, it is
recommended to perform the following SDS action after the replacement of the PCB.
SOLUTION: From the Local User Interface, Log in to SDS:

SDS>Special tests>Printer>Finishing>Force software download.

The engine will restart and on startup; software will be uploaded to all finishing accessories.
NOTE: The Professional Puncher B1 software cannot be upgraded via the varioPRINT main engine.
For Professional Puncher software upgrade instructions, please consult Technical Publication TP13
193.pdf.

QC Reset Function
• QC RESET- The purpose of this function is for R & D to be able to reset any software flags that were
activated during factory production of device. QC Reset can be used in the field to attempt to reset any
software anomalies that may occur during software upgrades etc.
• There is a QC RESET for ENGINE and EPIM; both functions can be located in SDS;

SDS>Load/Save Settings>M&L Settings

12
Differences between varioPRINT 135 Series and Océ VarioPrint DP Line
Accessories
Additional Accessories Available on the varioPRINT 135 series:

 SDD Two Knife Trimmer (& Square Fold)

 SDD jr. (Square Fold Only)
 SDD BLM 300C Professional Booklet maker
o Optional Front Trimmer
o Optional Two Knife Trimmer
o Optional Square Fold
o Optional Rotator
o Choice of Two Beltstackers [Long, Short] (Motorized Output Tray)
 Max Ring Binder MB-1000C (Requires pedestals & Ramp Set)
 Decurler Unit-A1
 Professional Puncher-B1 & Integration Unit-A1
 Bulk Tray Small Format
 Duo Paper Tray Kit-C1
 Form Assist Module II
 V3.3 and above will support BLM-300C

Finisher AK1/AK2 Neat Stacking Assembly

An Alignment mechanism aligns the front and rear edges as well as the feed direction of paper by using
the Alignment Plate and the Return Roller when ejecting paper to the tray. The Alignment Plates (arms)
are lifted and lowered by the drive of the Upper Neat Alignment Plate Lifting Motor.

13
Upper Return Roller Operation
This mechanism aligns the paper in the feed direction. The Return Roller is lifted and lowered by the drive of
the Neat Return Roller Lifting Motor. The drive of the Delivery Motor rotates the Return Roller, and the
paddle of the Return Roller pulls paper in the direction opposite of the feed direction.

Roller Assist Disengage Control

 When feeding paper whose feed length is 148mm or smaller (A4R_Half Fold, LTRR_Half Fold,
LTRR_Z-Fold), feed ability is improved by turning ON the Assist Disengagement Solenoids 2 and 3,
engaging the Feed Assist Rollers.

 When papers are 148mm or longer, the Assist Rollers 2 and 3 are lifted (disengaged) to avoid
stretching and buckling of the sheets. This function is performed due to differences in rotational speed
tolerances among the finisher feed rollers.

 The Assist Rollers 1, help feed shorter paper formats into the Side Registration Correction Unit.

14
Availability of AF+ Enhancement Kit-A1
Info Bulletin 03 AF+ Kit

Kit, External Knocker is available as an option for the Finisher-AF1 / Saddle Finisher-AF2. This rudimentary
option allows for better stack quality on the legacy AF Series Finisher which does not feature the “NEAT
STACK” capability on the newer Finisher-AK1 / Saddle Finisher-AK2.

Please review the TSM> Info Bulletin 03 for prerequisite software requirements and limitations

Kit, External Knocker : 1070004831

AF+ Enhancement Kit-A1

Decoding Finisher 7 Segment Display

On new style High Volume finisher AK1/2, Pro Finisher Q1, Finisher AM1/2 (Similar Finishers utilized on
Monochrome and Color Printer models) it is possible for the 7 segment display to indicate an additional
character:

EXAMPLE: 'E' - '6'-'7'-'0'-'2'

This code indicates the last two digits of the main code
and the last 2 digits of the sub code:

15
NOTE: This particular error on varioPRINT 135 series is currently not defined on the operator UI
Panel and makes use of the 7 segment display crucial for troubleshooting.

(Error message obtained from imagePRESS 1135+ Service Manual. Location code "02")

PROBLEM: E567 8002 Title Error in shift roller operation

Description of detection Shift roller unit HP sensor does not go OFF within 5 sec after the side
registration shift motor starts operation.
SOLUTION:

1. Check the connector of the side registration shift motor and the shift roller unit HP sensor, and
replace the motor/the sensor if necessary.
2. Replace the Finisher Controller PCB

Finisher-AF1/AK1 / Saddle Finisher-AF2/AK2 Reported Issues

Error codes during run and resuming from standby (Fault codes 1850260;
1850292; 1850242; 1850272)
SPECIAL NOTE: 7 segment display on finisher will indicate E4201 or E7601
PROBLEM: When front door of Finisher-AK1 is closed, the door plunger misses target (Flag Actuator Arm),
however lateral friction against actuator depresses it just enough to temporarily complete circuit. During operation,
vibration releases friction and interlock circuit opens, resulting in aforementioned error condition.

SOLUTION: Verify Actuator assembly is not bent or loose. Reform or replace deformed components as
necessary (see images below).

Finisher [A]

Flag actuator [A] Finisher Door Plunger misses Actuator but moves
Finisher AK1
arm it just enough to temporarily complete circuit.
Interlock

16
Complaint of Slow Printing on Tray B of Finisher-AF1/AF2 and Finisher-AK1/AK2
Dip Switch settings for Lower Delivery Mode found in the Finisher-AF1/AF2 and Finisher-AK1/AK2
Service Manual have an adverse effect on the print speed and behavior of Tray B. HWE tested and confirmed
a significant drop in speed performance (50%) on the VarioPrint DP when printing to tray B with a Dip
Switch Setting of 3 or 4. Please review chart below for details:

• 0: Normal mode
• 1: Forcible 1 sheet through delivery mode (all)
• 2: Forcible stack delivery (with buffer) mode (alignment is not performed)
• 3: Forcible stack delivery (without buffer) mode (alignment is performed on the process tray)
• 4: Forcible 1 sheet alignment delivery mode (alignment is performed on the process tray with 1 sheet)
• 5: Forcible 1 sheet through delivery mode (plain paper only)

Saddle Finisher Operation Assembly Slams Shut [AK1/AK2 Finisher]

PROBLEM: The Saddle Finisher Operation Assembly Slams Shut. This can result in other parts in the
Operation Assembly becoming damaged.

SOLUTION: Inspect the Tension Spring; Item 18 on Figures L20-1 / L20-3. This Tension Spring breaks. It has
been noticed on new installs where the Finisher was pre-installed. Apparently in shipping the Operation
Assembly bounces around and the Tension Spring breaks, resulting in the erratic operation of the Operation
Assembly.

17
SPRING , TENSION QTY 2 : FS7-2632-000

Operation Assembly (Front) Operation Assembly (Rear)

Figure L20-1 Figure L20-3
Key 18 Key 18

Paper Guides misalignment or damaged Mylar can result in curved Line on Prints
[AK1/AK2 Finisher]
PROBLEM:

If the Finisher AK1/AK2 inlet guide is bowed or the Mylar strips on the paper guide are damaged or
torn, printed sheets may become scratched by the paper guide. This scratch appears as a solid line
running from the lead edge to the trail edge of the print. This line is most visible when printing halftone
images or graphics. The scratch line is very distinctive in that it will curve near the trail edge of the
printed page (large sheets) due to the Shift Assembly performing registration correction.

Feed Direction
Feed Direction

Figure XXX
Scratched Sheets

18
SOLUTION:

Inspect Inlet Paper Guide Area in the 3 Figures below. Check for deformation [A], foreign
substance/Burr [B] or damaged Mylar [C] on paper guide.

[A]

Finisher AK1/AK2 Paper Guide

[B]

Finisher AK1/AK2 Paper Guide

[A] Check for warp or bow in guide
[B] Inspect area for lump or damage of guide

19
 [C]

Finisher AK1/AK2
[C] Damaged Mylar

Error 11504;1870217 due to motor M26 unplugged: TP13 457a

PROBLEM
Fault Code 11504 and/or 1870217 may occur at installation of a new Finisher-AK1/Saddle Finisher-AK2

SOLUTION
Verify connector for Motor M26 is fully inserted. See Figure below.

20
Professional Puncher-B1: TP13 399a
Installation
The Professional Puncher-B1 must be installed in combination with the Integration Unit-A1. The
Professional Puncher-B1 can be attached to the VarioPrint DP Line (serial number below 698006001)
and the varioPRINT 135 Series (serial number 698006001 and above). When attaching the Professional
Puncher-B1 directly to a VarioPrint DP Line engine with s/n below 698006001, it is required to first
replace the engine interface bracket with the New Type (1070033126). If the VarioPrint DP is
configured with another Canon finishing device (e.g. Inserter-F1, Decurler-A1) between the engine and
Professional Puncher-B1, the New Type bracket is not required. This bracket is not supplied with the
Professional Puncher-B1 installation kit and must be ordered separately by the service technician prior
to installation. Please refer to the TSM for correct installation procedures:

SDS> Installation/Install the Professional Puncher-B1 and Professional Puncher Integration Unit-A1

The Professional Puncher-B1 manufactured for use with the varioPRINT 135 Series is mechanically
different than previous versions of the Professional Puncher-B1. It is important that existing Professional

21
Puncher-B1 units in the field are not connected to the varioPRINT 135 Series or issues such as paper
jam and skew feed will result. The updated Professional Puncher-B1 is compatible with current and
legacy imagePRESS Products which also utilize the Professional Puncher-B1. The serial number prefix
and cut-in for the new Professional Puncher-B1 is EFJ02000. Please note the difference as indicated
below:

The Professional Puncher-B1 can cause some pollution on the prints. The amount of pollution depends
on the media used. The use of rough media, such as uncoated or recycled media, can cause more
pollution. The pollution of smooth media, such as coated media, is rare. When you see pollution on the
prints, it is advised to start a cleaning procedure as soon as possible. The cleaning procedure requires
two sheets. One sheet to clean the Puncher, and one sheet to check the result. The cleaning procedure
consists of the following steps:

 Start the cleaning procedure from the [Maintenance] section on the control panel.
 Select a paper tray that contains A4 or LTR (Professional Puncher-B1 only supports A4
and LTR size paper).

22
  The automatic cleaning of the puncher begins. This can take up to two minutes.
 When the cleaning is complete, the printer will print a second sheet. Check this sheet to see if
the cleaning was successful.
 If the cleaning is not yet sufficient, repeat the cleaning procedure.

On the control panel, touch [System] -> [Maintenance] -> [Start maintenance] -> [Clean the puncher] -
> [Start].

Professional Puncher-B1 Reported Issues

Measure against puncher communication errors 1859965, 1859966: TP15 035
When the female connector of the communication cable was assembled at the factory, additional locking
washers were inadvertently installed on the wrong side of the threaded studs (Figure 1). With the additional
washers in place, it is not always possible to secure a good connection when installing the interface cable
between the Professional Puncher-B1/C1 and Puncher Integration Unit-A1/B1, resulting in the
aforementioned symptom.

23
If the Error (1859965) or (1859966) occurs in the field, please check the area indicated in the Figure below for
the presence of additional washers. If additional washers are installed, please remove and discard them.

Intermittent Jamming 1879996, 1879992, & 1879994

Professional Puncher-B1 devices beginning with s/n EFJ02000 were manufactured with six (6) white anti-
static strips in the Aligner, Exit Drive Assembly area. These strips were intended to reduce static related
jamming with coated papers. It was discovered that these HDPE strips had a negative effect on the feed ability
of plain paper. At the time of the writing of this Technical Workbook, we are advising the field to remove
these six (6) white HDPE strips if encountering any of these Jam/Fault Codes. When removing these strips
take care to clean any residual adhesive from the paper path.

NOTE: ONLY REMOVE STRIPS IF THEY ARE COLORED WHITE!

24
High Capacity Stacker F1/G1
Differences between High Capacity Stacker-F1 and High Capacity Stacker-G1
The High Capacity Stacker-G1 is the successor of the High Capacity Stacker-F1. The HCS-G1 can be
connected to the imagePRESS C800 Series, the imagePRESS C701xVP(S) Series and to the
varioPRINT 135 Series. The HCS-F1 can be connected to the imagePRESS C701xVP(S) Series and to
the varioPRINT 135 Series, but cannot be connected to the imagePRESS C800 Series.

The major differences of the High Capacity Stacker-G1 compared to the HCS-F1 are:
• An additional CAN bus interface for communication to Print Engine via CAN bus (for
example the imagePRESS C800 series)
• A changed PBA, Stacker Spider IO [21PBA02] and a new CAN communication PBA
• An additional motor [21M1c] in the input paper path
• When you connect the HCS-G1 to the imagePRESS C800 series you must de-install the Stacker
ON/OFF switch [21S6]
• The serial number of the HCS-G1 starts with 6983, the serial number of the HCS-F1 starts with
6982. The serial number is located behind the right front door at the bottom.

High Capacity Stacker F1/G1 Reported Issues

Error Code 2170343 when feeding 80lb Cover Stock
PROBLEM: CUSA received report of code 2170343 caused by damaged Paper Guide (RIB). Paper may get
caught in tiny paper cuts on diverter guide resulting in paper jam and “dog-ear” of corners.

SOLUTION: Replace Guide Assembly 1070012123

25
 High Capacity Stacker F1/G1
Paper Guide Assembly 1070012123

Additional Hardware Options

Duo Paper Tray Kit-C1: TP13 155
The Duo Paper Tray-A1 accessory for the VarioPrint DP line increases the capacity of tray 3 and/or 4 of
the optional ePIM from 1700 sheets to 3300 sheets of A4/LTR paper. To support this accessory, the
minimum software level on the device should be 2.4.7.0 or greater.

26
Bulk Tray Small Format: TP14 399
With the introduction of Software Version 3.3.0.0., the Bulk Tray Small Format becomes available as an
option for the varioPRINT 135 Series. By installing this option, one or both main body Bulk Trays of
the print engine can be configured as a Bulk Tray Small Format. If a Bulk Tray Small Format is installed,
the operator UI will always allow 6 media sizes to be defined for that tray: A4, 16K, A5, LTR,
Statement (5.5” x 8.5”) and B5

Decurler Unit-A1: TP14 025

The Decurler Unit-A1 enables the VarioPrint DP Line and varioPRINT 135 series to handle a wider
range of media and still meet its curl specification. The Decurler Unit-A1 was designed to be compatible
with the varioPRINT 135 Series. In order to connect it to the 1st generation VarioPrint DP Line, some of
the engine specifications need to be brought up to the level of the 2nd generation varioPRINT 135 Series.
This minimum specification can be met by installing the PE Heat Exchange Foils (MOD 18)
p/n1070036094 according to the instructions in TP13 374a.

PREREQUISITE:

 Software version 3.2 or above must be installed on the Print Engine.

27
 PE Heat Exchange Foils (MOD 18) should be installed on the VarioPrint DP engine to support
the Decurler Unit-A1. Please review Technical Publication TP13 374b for information
regarding MOD 18.

28
Appendix

29
Power Flow Chart for New Type Electronics

30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88