We for months have been having issues with color streaking due to buildup in the 2nd BTR unit. We had a long stading (several months) service call with Xerox to try and resolve it, that reached the hands of technicians, specialists and management with no solution provided. In fact, despite the fact that these forums are loaded with people having the same problem we were, Xerox continually wanted to blame the paper we were using, when in fac,t we were having problems accross both digital, non digital, coated and uncoated stock. Poor customer service is putting it lightly.
What i did notice is it happened primarily on longer runs and runs with minimal coverage. Those seemed to be the most common factors. What it seeme dlike to me was not that the 2nd BTR unit was failing so much as it being loaded with excess tonor was a SYMPTOM of poor filtration and removal of excess toner. It is no secret that these machines run very dirty.
We tried some work arounds on our own and we found a solution that works every time now. We put a strip of 4 color black on the lead edge and side of our layout and we have no problems now. Same paper, same run sizes. This gives the machine an opportunity to use some of the excess toner it drops that would otherwise be floating around inside the machine. Below there are photos of the problem and the fix. We hope this helps out some other folks that might be having similar issues, with no resolve from Xerox.
Hmmm... not really a solution - more of a workaround, I'd say :-) However, I do generally agree with your findings which are broadly similar to what I'm finding on our V180 (and the V80 before that). Another workaround is to run the machine in "skip pitch" mode, which will avoid the issue, albeit running at under half the rated speed hence I do not call that a solution eithere.
I've not had the chance to check, but I presume these colour strips cannot be added via Impose? We use a 1up PDF -> Impose workflow. Also, obviously this doesn't help with non-bleed printing on A3/A4 for example.
I know Xerox blame the paper and it sounds like a bit of a cop out, but paper stock is a factor. Granted, it can eventually happen on all stocks, but in my experience it triggers on coated stock more quickly to begin with. And, for example, using two different 300gsm silk stocks, we find that one of them will trigger the 2nd BTR issue within 200 sheets (even directly after a new 2nd BTR was fitted!) and the marks are really much worse spanning entire width. Printing the same job on a different brand of paper, the problem takes much longer to appear and when it does it is not as bad. That said, the worst stock was a Xerox certified stock, so they cannot really blame the paper if it happens on their own! I am sure there is no magic paper stock that avoids this issue completely.
We are now having similiar issue. Before I have my manager order the ($600) part can you tell me by the photos that (2nd BTR Assembly) is causing the toner to be left on the unit and dirty edges on everything? We are no longer under a maintenance program so wanted to sure before ordering part.
Thanks Gabi, I will have my Manager order that part and I'll attempt to replace it as it dosen't look to hard to do. I was trying to get some clarification before ordering part (have to purchase, not on maintenance program anymore unfortunately). We paid a tech to come out when it was jamming ( i found it to be a dirty sensor right before the fuser, caused from all the toner reidue) but he was trying to tell us it was the fuser causing that. I didn't think so because after cleaning sensor it was printing fine again minus the dirty edges and fusing perfectly. So thanks again for you reply.
We have been having the same issue for over a year now. SOme times we get 250k impressions before it brakes and sometimes 40k. It really is a pain in the bum.
I will give this a try :-)
I can not thank you enough. As a print shop, the majority of stock we use for color work is glossy / silk. Coated Stock. This streaking has been a bane of mine since we got two Versant 180's in house for our digitial work. We have quite few large run newsletters / periodicals that we do each month that make me want to take a bat to these machines due to the streaking, and the issues with the 2nd BTR. We have had to replace them at like 10-20K on impressions, almost once a month due to build up and the inablity to run jobs that go beyond 2k - 3k impressions. The streaks are a constant.
We just ran two (2) 5000k sheets on the two machines using this method of creating Black Build Boxes around all edges, and I can say it ran the entire run without streaking, maybe a few sheets upon stopping fill paper or change toner.... it worked in the most flawless way we have ever seen.
Much thanks for the heads up! I use to do this on 4 color machines to help with ghosting / ink builds. Don't know why I did not think of this before! Thanks so much!