More information ... and I know even less than before.
The roll2 media sensor made no difference, and detects paper present/paper absent in diagnostic mode.
The roll2 rewinder is now passing the diagnostic. I have no idea why.
I figured out that I can key the top door and watch the paper passage during the "Unloading". My abbreviated test is to:
Load roll2
Load roll1 (roll2 now parked)
Print an internal print (like Usage Page) from roll2.
So what usually happens is:
Roll1 parks.
Roll2 feeds paper up the vertical path.
Slight hesitation when paper trips the clean-out media sensor.
Pinch rollers raise ~2mm.
Paper advances to ~13mm from the star wheel guide, and pinch rollers lower.
Simultaneously paper advances into the star wheel guide and starts measuring the left edge location x3
Paper advances ~200mm then repeats the left edge measurement
If it doesn't like the measurement, the pinch rollers raise/lower to release any buckle.
Paper backs up ~200mm then repeats the left edge measurement
Carriage moves in ~100mm and the paper advances x3 edging past the line sensor
I think this is where it goes wrong:
When it fails, the paper backs down into the roll2 tray and displays "Unloading Roll".
When it's successful, printing starts.
I am suspecting the Line Sensor-Tetris, or Carriage PWB, or Engine PWB ... except for the fact that roll1 uses exactly the same paper, line sensor, PWB's and always detects left edge and leading edge correctly. We'll see what tech support has to say. =^..^=
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