Xerox DocuPrint 96 IPS Series Installation guide

Xerox DocuPrint 96/4635/180 IPS
System Overview Guide
Version 7.1
August 2000
721P88150

Xerox Corporation
Printing Systems Documentation and Education
701 South Aviation Boulevard, ESM1-058
El Segundo, CA 90245
©1998, 1999, 2000 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms and matters of
copyrightable material and information now allowed by statutory or
judicial law or hereinafter granted, including without limitation,
material generated from the software programs which are displayed
on the screen, such as icons, screen displays, looks, etc.
Printed in the United States of America.
Publication number: 721P88150
Xerox® and all Xerox products mentioned in this publication are
trademarks of Xerox Corporation. Products and trademarks of other
companies are also acknowledged.
Changes are periodically made to this document. Changes, technical
inaccuracies, and typographic errors will be corrected in subsequent
editions.

XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE iii
Laser safety
!Warning: Adjustments, use of controls, or performance of
procedures other than those specified herein may result in
hazardous light exposure.
The Xerox DocuPrint printers are certified to comply with the
performance standards of the U.S. Department of Health, Education,
and Welfare for Class 1 laser products. Class 1 laser products do not
emit hazardous radiation. The DocuPrint printers do not emit
hazardous radiation because the laser beam is completely enclosed
during all modes of customer operation.
The laser danger labels on the system are for Xerox service
representatives and are on or near panels or shields that must be
removed with a tool. DO NOT REMOVE LABELED PANELS OR
PANELS NEAR LABELS. ONLY XEROX SERVICE
REPRESENTATIVES HAVE ACCESS TO THESE PANELS.
Ozone information
This product produces ozone during normal operation. The amount
of ozone produced depends on copy volume. Ozone is heavier than
air. The environmental parameters specified in the Xerox installation
instructions ensure that concentration levels are within safe limits. If
you need additional information concerning ozone, call 1-800-828-
6571 to request the Xerox publication 600P83222, OZONE.
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iv XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE
Operation safety
Your Xerox equipment and supplies have been designed and tested
to meet strict safety requirements. They have been approved by
safety agencies, and they comply with environmental standards.
Please observe the following precautions to ensure your continued
safety.
•Always connect equipment to a properly grounded electrical
outlet. If in doubt, have the outlet checked by a qualified
electrician.
!Warning: Improper connection of the equipment grounding
conductor may result in risk of electrical shock.
•Never use a ground adapter plug to connect equipment to an
electrical outlet that lacks a ground connection terminal.
•Always place equipment on a solid support surface with
adequate strength for its weight.
•Always use materials and supplies specifically designed for
your Xerox equipment. Use of unsuitable materials may result in
poor performance and may create a hazardous situation.
•Never move either the printer or the Printer Controller without
first contacting Xerox for approval.
•Never attempt any maintenance that is not specifically
described in this documentation.
•Never remove any covers or guards that are fastened with
screws. There are no operator-serviceable areas within these
covers.
•Never override electrical or mechanical interlocks.
•Never use supplies or cleaning materials for other than their
intended purposes. Keep all materials out of the reach of
children.
•Never operate the equipment if you notice unusual noises or
odors. Disconnect the power cord from the electrical outlet and
call service to correct the problem.
If you need any additional safety information concerning the
equipment or materials Xerox supplies, call Xerox Product Safety at
the following toll-free number in the United States:
1-800-828-6571
For customers outside the United States contact your local Xerox
representative or operating company.
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XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE v
Table of contents
Laser safety iii
Ozone information iii
Operation safety iv
Introduction ix
About this guide ix
Contents ix
Conventions x
Related publications xi
1. System overview 1-1
Functional overview of the DocuPrint IPS 1-1
Major system components 1-2
Throughput speed 1-3
Host connectivity options 1-4
IPDS data stream 1-5
Dual Mode 1-5
96/4635/180 IPS hardware features 1-6
Multiple input trays 1-6
Roll feeder support 1-7
Advanced paper handling 1-7
600 dpi resolution 1-8
Multiple high-capacity output bins 1-8
Bypass transport option 1-9
User interface 1-10
Software features 1-11
Mixed paper sizes within a job 1-11
Tray selection capabilities 1-11
IOCA Replicate and Trim 1-12
Mixed plex 1-12
Enhanced N-Up 1-13
Trace facility 1-13
Overstrike, underscore, subscript, and superscript 1-13
Background color for OCA colors 1-13
Full-page 600 dpi images 1-14
Document Feeding and Finishing Architecture (DFA) 1-14
Page origin rotation for continuous form jobs 1-14

TABLE OF CONTENTS
vi XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE
Double-byte fonts 1-14
Outline font support 1-15
Printer resident font support 1-15
Processing options 1-15
Message translation 1-15
Configuration file processing 1-15
PCI Bus support 1-16
Access control by privilege mode 1-16
Software license 1-17
Remote service (Sixth Sense Technology) 1-17
2. Printer Controller 2-1
Components of the Printer Controller 2-1
Processor 2-3
Hard disk 2-3
Diskette drive 2-4
CD-ROM drive 2-4
Cartridge tape drive 2-4
Monitor 2-4
Keyboard 2-4
Mouse 2-4
Host Channel Unit (HCU) —channel-attached systems only 2-5
Placement of the processor 2-5
3. User interface 3-1
Graphical user interface screen 3-2
IPS main window 3-4
4. Printers 4-1
Printer components 4-2
Components overview 4-2
Printer control console 4-3
Sample tray 4-6
Attention light 4-6
Purge tray 4-6
Inverter 4-7
Feeder/stacker modules 4-7
Processor feeder trays 4-7
Feeder trays 4-8
High-capacity stackers 4-10
Printer configurations 4-12
Options enabling third-party feeding and finishing 4-14

TABLE OF CONTENTS
XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE vii
Configurations supporting bypass transport and Input
Enablement kit 4-15
Additional IPS printer features 4-15
Printer paper paths 4-16
5. MICR IPS 5-1
96/4635/180 MICR IPS printing features 5-1
MICR output 5-3
Verifying MICR output with the MICR Position and
Dimension Gauge 5-4
Verifying MICR output with the MICR comparator 5-4
A. Paper and other supplies A-1
Paper and other throughput stocks A-1
Selecting paper A-1
Paper width and printer performance A-3
Paper care A-9
Other supplies A-12
Dry ink A-12
Fuser agent A-12
Developer A-12
Diskettes A-13
Cartridge tapes A-13
MICR tools A-14
MICR Positioning and Dimension Gauge A-14
MICR comparator A-14
Consumable supplies tables A-15
Paper and special stocks tables A-15
Complete supplies list—96/4635/180 printers A-22
Ordering supplies A-23
B. Paper performance guidelines B-1
Index INDEX-1

TABLE OF CONTENTS
viii XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE

XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE ix
Introduction
This Xerox DocuPrint 96/4635/180 IPS System Overview Guide
provides an overview of the individual components of the DocuPrint
IPDS Printer System (IPS) and how they work together. This
reference is designed to provide you with background information
that can be used to make informed decisions regarding printer use
and performance.
About this guide
The Xerox DocuPrint 96/4635/180 IPS System Overview Guide
provides information to help you quickly determine hardware,
software, and connectivity requirements for printing from various
clients to DocuPrint IPS.
This reference is useful for workstation users, printer operators, and
system administrators who want to understand the overall DocuPrint
IPS. Managers can use the reference information to assist them in
making planning decisions.
Before using this guide, become familiar with its contents and
conventions.
Contents
This section lists the contents of this guide:
•Chapter 1, “System overview,”identifies and describes the
function of the major components of the DocuPrint 96/4635/180
IPS.
•Chapter 2, “Printer Controller,”provides the information on the
Printer Controller components, software, and fonts.
•Chapter 3, “User interface,”describes the features of the IPS
graphical user interface.
•Chapter 4, “Printer,”details the base printer components and
optional printer components.
•Chapter 5, “MICR IPS,”discusses the special features of the
96, 4635, and 180 MICR IPS systems, and the requirements for
MICR printing on the IPS.
•Appendix A, “Paper and other supplies,”provides information
and specifications on paper and other media used with the IPS
or MICR IPS, as well as instructions for ordering supplies.
•Appendix B, “Paper performance guidelines,”summarizes the
capabilities of the paper trays, duplex printing considerations,
and paper stock considerations.
An index is provided at the back of the guide.

INTRODUCTION
x XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE
Conventions
This guide uses the following conventions:
•All caps and angle brackets —Within procedures, the names of
keys are shown in all caps within angle brackets (for example,
press <RETURN>).
•Italics —Document and library names are shown in italics (for
example, the Xerox DocuPrint 96/4635/180 IPS System
Overview Guide).
•Capitalization of graphical user interface (GUI) window titles
matches the titles as they appear on the screen. In cases where
a window does not have a title, it is referenced using all lower
case. For example:
—At the graphical user interface, use the Output
Configuration window to group the trays.
—The main window displays the current system status.
Note: Notes are hints that help you perform a task or understand
the text.
Caution: Cautions alert you to an action that could damage
hardware or software.
!Warning: Warnings alert you to conditions that could affect the
safety of people.
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INTRODUCTION
XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE xi
Related publications
This document is part of the Xerox DocuPrint IPS publication set.
Xerox documents Following is a list of all Xerox DocuPrint IPS documents. For a
complete list and description of available Xerox documentation, refer
to the Xerox Customer Documentation Catalog (publication number
610P17517), or call your service representative.
Application Programmer/System Administrator Quick Reference
Card
Customer Information Quick Reference Card
Generic MICR Fundamentals Guide
Glossary
Guide to Configuring and Managing the System
Guide to Performing Routine Maintenance
Helpful Facts About Paper
Installation Planning Guide
Master Index
Messages Guide
Solutions Guide
System Overview Guide
Troubleshooting Guide
Xerox Standard Font Library Font User Guide
The documentation set also includes an electronic version, the
DocuPrint IPS Interactive Customer Documentation CD.
IBM documents Following are related IBM documents. Contact your local IBM
representative for ordering instructions for IBM AFP/PSF manuals
that might be useful for your specific installation.
IBM 3825 Page Printer Product Description
IBM Intelligent Printer Data Stream Reference
IBM Advanced Function Presentation Printer Summary
IBM ITSC Distributing AFP Printing from a Host System
IBM Advanced Function Printing Data Stream Reference
IBM Data Stream and Object Architectures: Mixed Object Document
Content Architecture Reference
Guide to Advanced Function Presentation

INTRODUCTION
xii XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE

XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE 1-1
1. 1System overview
This chapter introduces the DocuPrint 96 and 96 MICR IPS, the 4635
and 4635 MICR IPS, and the DocuPrint 180 and 180 MICR IPS
printing systems. It describes the systems’hardware and software
components, features, functions, and modes of operation.
Functional overview of the DocuPrint IPS
The 96 IPS, 96 MICR IPS, 4635 IPS, 4635 MICR IPS, 180 IPS, and
the 180 MICR IPS print high quality documents in simplex or duplex
mode at high speeds.
DocuPrint IPS printers support:
•Duplex printing
•Media handling of multiple weights, sizes, and types
•Optional modules for enhanced finishing and output to third-
party finishing devices
•Optional enabling of third-party roll feeders
•Optional high-capacity feeder which provides additional feeder
trays.
The IPS emulates an IBM AFP Group 3 page printer with the
Advanced Function Image and Graphics (AFIG) option and can print
in all the following PSF environments:
•MVS
•VM (channel-attached only)
•VSE (channel-attached only)
•OS/2
•OS/400 (with TCP/IP only)
•AIX
Note: Although PSF/VSE does not support TCP/IP directly, a
printing system with PSF/2, PSF/6000, or IBM InfoPrint Manager can
attach to a PSF/VSE system and the PSF/2, PSF/6000, or IBM
InfoPrint Manager can furnish the TCP/IP support for the IPS printer.
For information on the minimum PSF levels needed to support the
IPS, refer to your Xerox DocuPrint 96/4635/180 IPS Installation
Planning Guide.

SYSTEM OVERVIEW
1-2 XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE
Major system components
The IPS has the following main components, each of which is
described in greater detail in later chapters of this guide:
Printer Controller The Printer Controller accepts IPDS data from the host, processes
the data, and sends it to the printer using the IPS operating system
for IPDS or the NPS operating system for PostScript or PCL.
The Printer Controller provides the printer with print data and
commands and receives status information from the printer.
Host Channel Unit: On channel-attached systems, the Printer
Controller has an additional component called the Host Channel Unit,
or HCU. The HCU contains the channel communications board, and
handles communication between PSF and the controller when data
is received over a bus and tag connection.
Graphical user interface The full-color graphical user interface (GUI) provides an easy-to-use,
mouse-driven interface to the IPS. Using the windows on the GUI
screen, you can configure your system; perform diagnostic and
administrative tasks; and set up, change, and implement system
options, and run print jobs.
The IPS main window displays the current system status, as well as
the current printer settings, including the current input and output tray
configurations. From the IPS main window you access the various
menus and windows you use to configure and operate the system.
Refer to the chapter “User interface”in this guide, for more detailed
information on the IPS graphical user interface components.
Printer The printer accepts data from the Printer Controller and prints the
document according to the print options specified by the user. The
printer also provides paper stacking, collating, and optional finishing.
The 96, 4635, and 180 IPS are monochrome printers. Print jobs that
contain color commands are printed in black.

SYSTEM OVERVIEW
XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE 1-3
Throughput speed
The 96 IPS, 4635 IPS and 180 IPS can print at the following speeds,
using stocks 8 by 10 inches / 203 by 254 mm or larger:
•96 IPS and 96 MICR IPS: Up to 96 impressions per minute
•4635 IPS and 4635 MICR IPS: Up to 135 impressions per
minute
•180 IPS and 180 MICR IPS: Up to 180 impressions per minute.
With small paper sizes Using the smaller papers, such as 7 by 10-inch / 178 by 254 mm or
B4, with the 7 by 10-inch paper option kit, the throughput rates
increase:
•4635 IPS/4635 MICR IPS: Up to 154 impressions per minute
•180 IPS/180 MICR IPS: Up to 206 impressions per minute.
Note: The 7 by 10-inch kit is not available on the 96 IPS.
Monthly print volume The monthly print volumes for these systems are:
•96 IPS: Up to 3 million impressions
•4635 IPS: Up to 4 million impressions
•180 IPS: Up to 6 million impressions

SYSTEM OVERVIEW
1-4 XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE
Host connectivity options
The IPS can be set up to receive data from a host in one of two ways:
•Over a channel with bus and tag cable connection, via the Host
Channel Unit (HCU)
•Through a Token Ring or Ethernet interface, using TCP/IP
protocol (not available in a VM or VSE host environment)
Note: A transmission rate of at least 16 megabits per second
should be used with a Token Ring interface on the IPS. (Overall
performance depends on network traffic and job density.)
Channel-attached configuration Figure 1-1 illustrates the components of a channel-attached IPS.
This configuration requires a Host Channel Unit (HCU) to interface
between the host channel and the IPS controller.
Figure 1-1. 96/4635/180 IPS: channel-attached configuration
1 Host system (PC or mainframe)
2 96, 4635, or 180 IPS printer
3 Printer interface cable
4 Printer Controller
5 SCSI interface
6 Host Channel Unit (HCU)
7 Bus and tag cables
TCP/IP configuration If you are using Token Ring or Ethernet with TCP/IP, as shown in
figure 1-2, the bus and tag cables and the HCU are not required.
Figure 1-2. 96/4635/180 IPS: TCP/IP configuration
1 Host system (PC or mainframe)
2 Token Ring or Ethernet network connection
3 Printer Controller
4 Printer interface cable
5 96, 4635, or 180 IPS printer
1
7
65
4
3
2

SYSTEM OVERVIEW
XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE 1-5
IPDS data stream
All IPDS resources (print data sets, page definitions, form definitions,
page segments, fonts, and overlays) supported by the IBM 3825 and
3827 printers are supported by the Xerox IPS software. Additionally,
there are several data towers supported within the AFP environment
which are fully supported by the IPS software, to a level supported by
the IBM 3825 and IBM 3827 printer capabilities:
•IM Image IMD1
•FOCA: Font Object Content Architecture
•MO:DCA-P: Mixed Object Document Content Architecture for
Presentation
•PTOCA PT1, PT2, and PT3: Presentation Text Object Content
Architecture
•IOCA: Image Object Content Architecture
•GOCA: Graphics Object Content Architecture
•BCOCA: Bar code Object Content Architecture
•OL1: Overlay One
•PS1: Page Segment One
•Line mode data streams
Each of the data objects follow the same object rule of containing
delimiting fields with structured fields describing each object.
Dual Mode
Xerox DocuPrint Dual Mode option enables both DocuPrint NPS and
IPS systems to coexist on the same Printer Controller (Sun
workstation). This allows the DocuPrint system to receive data
streams supported by NPS and IPS, including IPDS, PostScript
Levels 1 and 2, HP PCL5c, HP PCL5e, and ASCII.
Either of the following types of configurations may be used:
•The same Token Ring or Ethernet connection can be used for
both IPDS (IPS) and Postscript/PCL (NPS).
•Both a Token Ring card and an Ethernet card can reside in the
Sun workstation controller, with one being used for IPDS and
the other for PostScript/PCL.
•Bus and tag attachment through the HCU can be used for
IPDS, and Token Ring or Ethernet connection for the NPS.
When the DocuPrint system is in IPS mode, it can accept PostScript
and PCL data streams in the background; however, it can print these
jobs only after it is switched to NPS mode. However, when the
system is in NPS mode, it cannot accept IPDS data streams in the
background.

SYSTEM OVERVIEW
1-6 XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE
96/4635/180 IPS hardware features
The 96, 4635, and 180 IPS provide numerous features that can be
enabled or configured using the graphical user interface on the
printer controller.
Multiple input trays
Multiple feeder trays can be configured to feed paper for jobs in the
most effective manner. For example, the trays can provide nonstop
printing of a complex job that requires many paper stocks, or only a
few stocks, by using the trays’continuous loading capability. A
different input tray can also be selected for each copy of a specific
page in a print job, for example, to provide different paper colors for
specific pages.
•96 IPS: Three addressable input trays are standard with the
system, and one additional tray is available as an option.
•4635 and 180 IPS: Four addressable input trays are standard
with the system, and two additional trays are available as
options.
Feeder tray capacities, based on 20-pound or 80 gsm (grams per
square meter) bond, are:
•Tray 1: 1100 sheets
•Tray 2: 600 sheets
•Trays 3, 4, 5, and 6: 2600 sheets
Note: The equivalent grams per square meter of 20-pound bond is
actually 75 gsm. However, there is no standard 75 gsm paper —the
available stock that is closest in weight to 20-pound bond is 80
gsm.

SYSTEM OVERVIEW
XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE 1-7
Roll feeder support
The 96, 4635, and 180 IPS can each accommodate a third-party roll
feeder as an optional input tray.
•The 96 and 4635 IPS have an optional configuration in which
the roll feeder interfaces with the last feeder/stacker module.
With this configuration the 4635 IPS may have up to six feeder
trays with the sixth being the roll feeder. The 96 IPS may have
up to five input trays, with the roll feeder as the fifth.
Note: To be able to use this roll feeder option on the 96/4635
IPS, you must have the Input Enablement kit installed. (Refer to
“Options enabling feeding and finishing,”later in this
chapter.)
•The roll feeder option for the 180 IPS is installed in the inverter
feeder/stacker module, replacing the feeder tray. It does not
require the Input Enablement kit or DFA software. The
maximum number of feeder/stacker modules supported for this
configuration is four, including the inverter module with the roll
feeder. With the two processor feeder trays, this makes a total
of six input trays possible.
Advanced paper handling
The 96/4635/180 IPS can handle paper stock ranging in size from 8
by 10 inches / 203 by 254 mm to 14.33 by 17 inches / 364 by 432
mm, including sizes A3 and A4. They process paper weights from 16-
to 110-pound / 60 to 200 gsm.
Note: The 4635 and 180 IPS can also print on paper as small as 7
by 10 inches / 178 by 254 mm, with the optional 7 by 10-inch kit.
Jobs can also be printed on label stock, transparencies, precollated
stock, tab stock, carbonless paper, and other specialized stocks. The
printer engine monitors the print job so that, should a paper jam
occur, the job resumes on the correct page, at the correct tab, using
the same color, and so forth, providing complete document integrity.

SYSTEM OVERVIEW
1-8 XEROX DOCUPRINT 96/4635/180 IPS SYSTEM OVERVIEW GUIDE
600 dpi resolution
The 96, 4635, and 180 IPS all print at high resolution. The printers
can receive data at 240, 300, and 600 dpi (dots per inch). All 240 or
300 dpi data is interpolated to 600 dpi for higher print quality.
Table 1-1 shows how data streams of different resolutions are
interpolated.
For the 96 IPS, the 4635 IPS, and the 96/4635 MICR IPS, it is
recommended that all fonts and other resources that are at 240 dpi
be converted to 300 dpi before printing, rather than leaving the
conversion for the controller to do. This ensures better print quality.
Caution: The 96/4635/180 IPS must have the same font resolution
specified as the host input data stream (refer to your 96/4635/180
IPS Guide to Configuring and Managing the System for instructions
on specifying the input resolution). Conflicts between the input font
resolution and the IPS specification could result in inability to print the
job, or in missing variable data in the output.
Multiple high-capacity output bins
Each output bin has offsetting capability and a capacity of 2500
sheets of 20-pound or 80 gsm bond.
Note: This capacity does not apply to 11 by 17-inch and A3 papers.
Because of the additional weight these large sheets add to the bins,
each bin can hold only up to 1500 sheets of A3 or 11 by 17-inch
papers.
•96 IPS: One output bin is standard for the system, with one
additional bin available as an option (providing up to two bins
total).
•4635 and 180 IPS: Two output bins are standard, with up to two
additional bins available as options (providing up to four bins
total).
Table 1-1.Data stream conversion to 600 dpi
Incoming input resolution of document
Printer 240 dpi data 300 dpi data 600 dpi data
180 IPS Interpolated by printer to
600 x 2400 dpi
(when 240 board is installed
in the printer)
Interpolated by printer to
600 x 2400 dpi
Print at 600 x 2400 dpi
96/4635 IPS Converted by controller to
600 dpi
Interpolated by printer to
600 x 600 dpi
Print at 600 x 600 dpi