Brother HL-2400C Service Manual

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COLOR LASER PRINTER

SERVICE MANUAL

MODEL:HL-2400C

Jan. ‘98 54S002BE0

COLOR LASER PRINTER

SERVICE MANUAL

MODEL:HL-2400C

© Copyright Brother 1997 All rights reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. Specifications are subject to change without notice.

Trademarks: The brother logo is a registered trademark of Brother Industries, Ltd.

Apple, the Apple Logo, and Macintosh are trademarks, registered in the United States and other countries, and True Type is a trademark of Apple computer, Inc. Epson is a registered trademark and FX-80 and FX-850 are trademarks of Seiko Epson Corporation. Hewlett Packard is a registered trademark and HP Laser Jet is a trademark of Hewlett Packard Company. IBM, IBM PC and Proprinter are registered trademarks of International Business Machines Corporation. Microsoft and MS-DOS are registered trademarks of Microsoft Corporation. Windows is a registered trademark of Microsoft Corporation in the U.S. and other countries.

PREFACE

This service manual contains basic information required for after-sales service of the color laser printer (here-in-after referred to as "this machine" or "the printer"). This information is vital to the service technician to maintain the high printing quality and performance of the printer.

This service manual covers the HL-2400C color laser printer. This manual consists of the following chapters:

CHAPTER I : OUTLINE OF PRODUCT

Features, parts names, internal structure, and description of the control panel.

CHAPTER II : SPECIFICATIONS

Specifications, etc.

CHAPTER III : INSTALLATION

Installation conditions and installation procedures.

CHAPTER IV : STRUCTURE OF SYSTEM COMPONENTS

Basic operation of the mechanical system, the electrical system and the electrical circuits and their timing information.

CHAPTER V : CONTROL PANEL OPERATION

Operation and setting procedures on the control panel.

CHAPTER VI : PERIODIC MAINTENANCE

Description of periodic maintenance parts, and procedures for periodic replacement and cleaning.

CHAPTER VII : DISASSEMBLY

Procedures for replacement of the mechanical system parts.

CHAPTER VIII : TROUBLESHOOTING

Description of error messages on the control panel, troubleshooting image failure, etc.

APPENDICES :SERIAL NO. DESCRIPTIONS, ETC.

Information in this manual is subject to change due to improvement or re-design of the product. All relevant information in such cases will be supplied in service information bulletins (Technical Information).

A thorough understanding of this printer, based on information in this service manual and service information bulletins, is required for maintaining its print quality performance and for improving the practical ability to find the cause of problems.

CONTENTS

CHAPTER I PRODUCT OUTLINE.................................................... I

-1

1. FEATURES......................................................................................................I-1

2. PARTS NAMES & FUNCTIONS......................................................................I-4

3. INTERNAL STRUCTURE................................................................................I-6

4. DESCRIPTION OF CONTROL PANEL...........................................................I-7

4.1 Video Controller Mode...........................................................................................................I-7

4.2 Engine Controller Mode.........................................................................................................I-7

CHAPTER II SPECIFICATIONS......................................................II-1

1. RATING..........................................................................................................II-1

2. GENERAL SPECIFICATIONS........................................................................II-2

2.1. Printing................................................................................................................................II-2

2.2. Functions.............................................................................................................................II-3

2.3. Electrical and Mechanical ...................................................................................................II-3

2.4. Paper Specification .............................................................................................................II-4

3. ENVIRONMENTAL CONDITION.....................................................................II-8

3.1 Ambient Temperature / Humidity / Altitude...........................................................................II-8

CHAPTER III INSTALLATION........................................................III-1

1. CONDITIONS REQUIRED FOR INSTALLATION .........................................III-1

1.1. Environmental Conditions ..................................................................................................III-1

1.2. Basic Layout of Printer Set-up Location.............................................................................III-1

2. UNPACKING .................................................................................................III-2

2.1 Unpacking of Printer............................................................................................................III-2

2.2 Unpack the Starter Kit.........................................................................................................III-4

3. INSTALLATION WORK.................................................................................III-5

3.1 Install the OPC Belt Cartridge.............................................................................................III-5

3.2 Install the Toner Cartridge to the Printer.............................................................................III-6

3.3 Install the Oil Bottle and Fuser Cleaner ..............................................................................III-7

3.4 Test Print.............................................................................................................................III-8

CHAPTER IV STRUCTURE OF SYSTEM COMPONENTS............IV-1

1. BASIC STRUCTURE.....................................................................................IV-1

1.1 Print System and Transfer System .................................................................................... IV-6

1.2 Scanning System............................................................................................................. IV-21

1.3 Paper Transportation System .......................................................................................... IV-23

1.4 Fusing Unit.......................................................................................................................IV-25

2. STRUCTURE OF THE CONTROL SYSTEM ..............................................IV-27

2.1 Basic Structure................................................................................................................. IV-27

2.2 Control System................................................................................................................. IV-36

2.3 Main PCB (Video Controller PCB)....................................................................................IV-46

2.4 Power Supply Unit............................................................................................................ IV-58

2.5 High Voltage Power Supply Unit......................................................................................IV-61

2.6 Wiring Diagram.................................................................................................................IV-64

CHAPTER V CONTROL PANEL OPERATION..............................V-1

1. PANEL LAYOUT.............................................................................................V-1

2. VIDEO CONTROLLER MODE .......................................................................V-2

2.1 Configuration of Operational Mode ..................................................................................... V-2

2.2 Toner Save Mode / Power Save Mode...............................................................................V-3

2.3 Line Test Mode ...................................................................................................................V-4

2.4 DRAM Test Mode................................................................................................................ V-8

2.5 Program Version Display Mode ..........................................................................................V-9

2.6 Test Print Mode................................................................................................................. V-10

2.7 NVRAM Reset Mode......................................................................................................... V-10

3. ENGINE CONTROLLER MODE...................................................................V-11

3.1 Configuration of Operational Mode ................................................................................... V-11

3.2 Operation of Normal Mode................................................................................................ V-13

3.3 Service Mode.................................................................................................................... V-19

3.4 Adjustment Work Procedures ........................................................................................... V-39

CHAPTER VI PERIODIC MAINTENANCE.....................................VI-1

1. GENERAL......................................................................................................VI-1

1.1 Handling Precautions.........................................................................................................VI-1

1.2 Periodic Maintenance Cleaning..........................................................................................VI-4

1.3 Periodic Maintenance Parts and Maintenance Cycle....................................................... VI-15

2. PERIODIC MAINTENANCE PROCEDURES..............................................VI-18

2.1 OPC Belt Cartridge Replacement.................................................................................... VI-18

2.2 Fusing Unit Replacement................................................................................................. VI-20

2.3 Transfer Roller Replacement...........................................................................................VI-22

2.4 Paper Discharger Unit Replacement................................................................................ VI-24

2.5 Drum Cleaner Replacement............................................................................................. VI-26

2.6 Ozone Filter Replacement ...............................................................................................VI-28

2.7 Paper Feed Roller and Separator Pad Replacement....................................................... VI-29

2.8 Transfer Drum Replacement............................................................................................VI-30

CHAPTER VII DISASSEMBLY.....................................................VII-1

1. BEFORE STARTING DISASSEMBLY..........................................................VII-1

1.1 Precautions....................................................................................................................... VII-1

1.2 Preparation of Disassembly..............................................................................................VII-1

2. PARTS NAME ..............................................................................................VII-3

2.1 Cover................................................................................................................................. VII-3

2.2 Circuit Boards (PCBs)....................................................................................................... VII-4

2.3 Motor Units........................................................................................................................ VII-4

2.4 Clutches and Solenoids ....................................................................................................VII-5

2.5 Sensors.............................................................................................................................VII-6

3. DISASSEMBLY FLOW.................................................................................VII-7

4. DISASSEMBLY PROCEDURE.....................................................................VII-8

4.1 Right Side of the Printer....................................................................................................VII-8

4.2 Top of the Printer ............................................................................................................VII-17

4.3 Left Side of the Printer.....................................................................................................VII-26

4.4 Paper Exit Unit ................................................................................................................ VII-33

4.5 Front of the Printer.......................................................................................................... VII-38

4.6 Rear of the Printer........................................................................................................... VII-40

4.7 Fusing Unit......................................................................................................................VII-44

CHAPTER VIII TROUBLESHOOTING .........................................VIII-1

1. OUTLINE OF TROUBLESHOOTING ..........................................................VIII-2

2. OPERATOR CALL.......................................................................................VIII-3

2.1 Video Controller Mode......................................................................................................VIII-3

2.2 Engine Controller Mode....................................................................................................VIII-6

3. PAPER TRANSPORT ERROR....................................................................VIII-8

3.1 Feed Jam......................................................................................................................... VIII-8

3.2 Inner Jam......................................................................................................................... VIII-9

3.3 Outer Jam ........................................................................................................................VIII-9

3.4 Others ..............................................................................................................................VIII-9

4. SERVICE CALL.........................................................................................VIII-10

4.1 Video Controller Mode....................................................................................................VIII-11

4.2 Engine Controller Mode..................................................................................................VIII-13

5. IMAGE FAILURE.......................................................................................VIII-41

APPENDIX A....................................................................................A-1

REGULATIONS

LASER SAFETY (FOR 110-120 V MODEL ONLY)

This printer is certified as a Class I laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation.

Since radiation emitted inside the printer is completely confined within protective housings and external covers, the laser beam cannot escape from the machine during any phase of user operation.

FDA REGULATIONS (FOR 110-120 V MODEL ONLY)

U.S. Food and Drug Administration (FDA) has implemented regulations for laser products manufactured on and after August 2, 1976. Compliance is mandatory for products marketed in the United States. One of the following labels on the back of the printer indicates compliance with the FDA regulations and must be attached to laser products marketed in the United States.

Caution

Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

IEC 825 SPECIFICATION (FOR 220-240 V MODEL ONLY)

This printer is a Class 1 laser product as defined in IEC 825 specifications. The label shown below is attached in countries where required.

CLASS 1LASER PRODUCT APPAREIL Å LASER DE CLASSE 1 LASER KLASSE 1 PRODUKT

This printer has a Class 3B Laser Diode which emits invisible laser radiation in the Scanner Unit. The Scanner Unit should not be opened under any circumstances.

Caution

Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

The following caution label is attached near the scanner unit.

5mW

780nm-800nm

DANGERVORSICHT

DANGERPELIGRO-

INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM.

UNSICHTBARE LASERSTRAHLUNG, WENN ABDECKUNG

GEÖFFNET UND SICHERHEITSVERRIEGELUNG ÜBERBRÜCKT. NICHT DEM STRAHL AUSSETZEN.

RAYON LASER INVISIBLE LORS DE L’OUVER TURE. EVITER L’EXPOSITION DIRECTE.

RADIACION LASER INVISIBLE AL ABRIR. EVITAR LA EXPOSICION DIRECTA AL HAZ.

MAS

For Finland and Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT

Varoitus! Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

Varning – Om apparaten används på annat sätt än i denna Bruksanvisning specificerats, kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass

SAFETY INSTRUCTIONS

SAFETY PRINCIPLE

1) Before starting any operations, read this manual thoroughly. Especially read the safety instructions in this section carefully and ensure that you understand the contents.

2) Perform all the operations by following the procedures described in this manual. Follow all the cautions and warnings set out in the procedures and on safety labels affixed to the machine. Failure to do so may result in human injury or equipment damage.

3) Perform only the procedures explained in this manual. Refrain from opening or touching any portions that are not related to your required operation(s).

4) Repair and replacement of parts should be performed by trained and qualified persons only. Operators should not attempt to do such repair or replacement work.

5) It must be appreciated that the above-mentioned cautions and warnings do not cover everything because it is impossible to evaluate all the circumstances of repair situations.

SPECIAL SAFETY INFORMATION

Introductory Information

Cautions and warnings are made clear by following the ‘Safety Alert Symbols’ or ‘Signal Words’ such as DANGER, WARNING and CAUTION.

<SAFETY ALERT SYMBOL> This is the safety alert. When you find this symbol placed on the equipment or marked in

this manual, be aware of the potential of human injuries. Follow the recommended precautions and safety operation practices.

<Understanding Signal Words> DANGER is used to indicate the presence of a hazard which will cause severe human

injuries or a fatal accident if the warning is ignored. WARNING is used to indicate the presence of a hazard or unsafe practices which may

cause severe human injuries or a fatal accident if the warning is ignored. CAUTION is used to indicate the presence of a hazard or unsafe practices which may

cause minor human injuries if the warning is ignored. CAUTION also calls your attention to safety messages in this manual.

<Follow Safely Instructions> Carefully read all the safety messages set out in this manual and also in the safety warning

signs placed on the equipment. In this manual, the safety instructions (safety alert symbols and signal words) are enclosed in a rectangular enclosure to bring them to your attention. Keep the safety signs on the equipment in good condition and ensure none are missing or damaged. Replace the safety signs if unreadable or damaged. Learn how to operate the equipment and how to use the controls properly. Do not let anyone operate this equipment without following the instructions. Keep the equipment in proper working condition. Unauthorized modification to the equipment may impair the function & safety and affect the life of the equipment.

Listed below are the various kinds of “WARNING” messages contained in this manual.

iii

WARNING

HAZARDOUS VOLTAGE

May cause serious injuries or fatal accidents. Voltage is now applied from the power supply of printer. There is a danger of electrical shock if you touch the active area inside the printer.

Be sure to turn the power supply switch OFF and pull the plug out from the power outlet before starting maintenance work on the printer.

WARNING

HARMFUL OZONE GAS

Inhalation of an excessive amount of ozone gas may adversely affect the respiratory organs.

An Ozone Filter is fitted to this printer to reduce the exhausted ozone. This filter must be replaced with a new filter periodically in accordance with the manual supplied with the printer.

WARNING

HOT SURFACE

The Fusing Unit reaches a temperature of approx.160°C and adjacent parts are also very hot.

When you need to change the cleaning pad or remove jammed paper, wait about 20 minutes after opening the paper exit unit to allow the unit to cool down.

CAUTION

ROTATING PARTS

Be aware of the potential danger of various rollers and take care not to get your fingers or hand caught into the machine, this can cause serious injuries. Note that the exit roller that ejects the printed paper is rotating while printing.

Be careful not to get your hair, fingers, hands, sleeve or necktie caught in the machine while operating the machine.

CAUTION

HAZARDOUS POWDER

Toner is a fine powder which can cause a powder explosion if disposed of into a fire. Under no circumstances dispose of toner into a fire.

CAUTION

HAZARDOUS POWDER

Toner is a fine powder which may cause irritation to the eyes and respiratory organs if inhaled.

Handle the toner cartridge, waste toner pack and developing unit carefully so as not to spill the toner.

CAUTION

POWER CORDS & PLUGS

This printer is equipped with a 3-wire power cord fitted with a 3-pronged plug (bi-polar plug with grounding) for the user’s safety.

Use these power cords in conjunction with a properly grounded electrical outlet to avoid an electrical shock.

CAUTION

SAFETY INTERLOCK

The front cover, paper exit unit and transfer unit of this printer have electrical safety interlocks to turn the power off whenever they are opened. Do not attempt to circumvent these safety interlocks.

1. Hot Caution Label

2. Laser Caution Label

3. Rating Label (For US)

WARNING WARNUNG

Hot surface. Avoid contact.

MODEL HL-C1

SER. NO.

120V ~ 50/60Hz 8.0A BROTHER INDUSTRIES, LTD.

Heiße oberfiäche. Bei beseitigung.

DANGERVORSICHT

DANGERPELIGRO-

U52492L7H111101

BROTHER PRINTER HL SERIES COVERED BY ONE OR MORE FOLLOWING PATENTS:

USP4, 968, 159 USP5, 050, 228 USP5, 068, 805 USP5, 086, 481 USP5, 093, 904 USP5, 126, 788

AVERTISSEMENT

Surface chaude. Eviter tout contact.

5mW 780nm-800nm

INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM.

UNSICHTBARE LASERSTRAHLUNG, WENN ABDECKUNG GEÖFFNET UND SICHERHEITSVERRIEGELUNG ÜBERBRÜCKT. NICHT DEM STRAHL AUSSETZEN.

RAYON LASER INVISIBLE LORS DE L’OUVER TURE. EVITER L’EXPOSITION DIRECTE.

RADIACION LASER INVISIBLE AL ABRIR. EVITAR LA EXPOSICION DIRECTA AL HAZ.

MAS

CLASS 1 LASER PRODUCT APPAREIL Å LASER DE CLASSE 1 LASER KLASSE 1 PRODUKT

MADE IN JAPAN

MANUFACTURED; BROTHER INDUSTRIES, LTD.

15-1, Naeshiro - cho, Mizuho - ku, Nagoya 467, Japan. This product complies with FDA radiation performance standards, 21 CFR Subchapter J.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions : (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

NOVEMBER 1997

FCC ID : B3QHLC1

HTJ

(For Europe)

MODEL HL-C1

SER. NO.

E52619L7H111101

220V-240V~ 50/60Hz 4.0A BROTHER INDUSTRIES, LTD.

ProductSafety

TOV

CLASS 1 LASER PRODUCT APPAREIL Å LASER DE CLASSE 1 LASER KLASSE 1 PRODUKT

ACN 001 393 835

MADE IN JAPAN

SHIPMENT OF THE PRINTER

If for any reason you must ship the printer, carefully package the printer to avoid any damage during transit. It is recommended that you save and use the original packaging. The printer should also be adequately insured with the carrier.

CAUTION

• When shipping the printer, remove the toner cartridges, the OPC belt cartridge and the waste toner pack from the printer to prevent toner spill in the printer or damage of the toner cartridge and the OPC belt cartridge.

• When shipping the printer, remove the oil bottle and the fuser cleaner from the fusing unit. After removing the oil bottle, be sure to remove the oil remaining in the fusing unit with the supplied syringe. Failure to do so will cause severe damage to the printer.

vii

CHAPTER I

PRODUCT OUTLINE

CONTENTS

CHAPTER I PRODUCT OUTLINE................................................... I-1

1. FEATURES.....................................................................................................I-1

2. PARTS NAMES & FUNCTIONS.....................................................................I-4

3. INTERNAL STRUCTURE...............................................................................I-6

4. DESCRIPTION OF CONTROL PANEL..........................................................I-7

4.1 Video Controller Mode...........................................................................................................I-7

4.2 Engine Controller Mode.........................................................................................................I-7

CHAPTER I PRODUCT OUTLINE

1. FEATURES

This printer has the following features:

2400 x 600 dpi Class Resolution

The printer prints pages with a resolution of 600 dots per inch (dpi) as default. It also provides higher quality printout which is the equivalent of 2400 x 600 dpi resolution when using HRC or CAPT.

High Speed Color Laser Printing

The printer allows crisp printing in 24 bit brilliant color. The printer prints at a speed of 16 pages per minute in monochrome mode and 4 pages per minute in full color mode. The controller utilizes a high speed 32-bit RISC microprocessor and special hardware chips, which provides a very fast processing speed.

High Resolution Control (HRC)

The high resolution control (HRC) technology provides clear and crisp printouts and improves even the 600 dpi resolution. This mode is effective when printing text data.

Color Advanced Photoscale Technology (CAPT)

The printer can print graphics in 256 shades for each color in HP color printer PCL5C™ and BR-Script level 2 emulations, producing nearly photographic quality. This mode is effective when printing photographic images.

Maintenance-Free Toner Cartridge

A toner cartridge can print up to 10,000 (Black) and 6,000 (Cyan, Magenta and Yellow) single-sided pages at 5% coverage. The one piece, easy-to-replace toner cartridges do not require difficult maintenance.

Universal Media Cassette

This printer loads paper automatically from the media cassette. Since the media cassette is a universal type, a number of different sizes of paper can be used. Even envelopes can be loaded from the media cassette.

Three Interfaces

This printer has a high speed IEEE 1284 compliant bi-directional parallel interface, an RS-232C serial interface, and a modular input/output (MIO) compatible interface.

If the application software supports the bi-directional parallel interface, you can monitor the printer status. It is fully compatible with the industry-standard IEEE 1284 bi-directional parallel interface.

The RS-232C serial interface is an industry standard so that you can connect it to any computer using a standard serial cable.

The MIO interface allows you to install a commercial MIO-compatible card. If the card is installed, this interface port can be used for features such as networking or printer sharing.

I-1

Automatic Interface Selection

The printer can automatically select the bi-directional parallel, RS232C serial, or MIO interface depending on the interface port through which it receives data. With this feature, the printer can be connected to more than one computer.

Five Emulation Modes

The printer can emulate Hewlett-Packard Color PCL monochrome mode) and PostScript (Brother BR-Script Level 2) printers, the industry-standard HP-GL™ plotter as well as EPSON (in monochrome mode). It is possible to print with all application programs that support one of these printers.

Automatic Emulation Selection

The printer can automatically select the printer emulation mode depending on the print commands it receives from the computer software. With this feature, many users can share the printer on a network.

Data Compression Technology

The printer can internally compress the received graphics and font data in its memory so that it can print larger graphics and more fonts without additional memory.

Various Fonts

The printer has 75 scalable fonts and 12 bitmapped fonts The fonts that can be used vary according to the current emulation mode.

CCITT G3/G4

Since the printer supports the CCITT G3/G4 format in addition to HPcompatible formats, it can quickly receive and print data compressed in this format.

Level 2 language emulation

FX-850™, and IBM® Proprinter XL® printers

5C (PCL6® in

Lock Panel

Power Save Mode

Toner Save Mode

Reprint Function

If the panel button settings have been changed, the printer may not work as expected. It is possible for the administrator of the printer to lock the settings to prevent changes from being made.

The printer has a power saving mode. As laser printers consume power to keep the fixing assembly at a high temperature, this feature can save electricity when the printer is on but not being used. The factory setting of the Power Save mode is ON so that it complies with the EPA Energy Star new specification. Compared with conventional laser printers, this printer consumes less power even when the power saving mode is turned off.

The printer has an economical toner save mode. This mode allows you to reduce the printer running cost substantially in addition to the improved life expectancy of the toner cartridge.

A touch of a panel button allows reprinting of the last print job without sending the data again from the computer. When there is not enough memory to print the last complete job out, the last print page can be reprinted.

I-2

PCMCIA Card Slot

The printer has two PCMCIA card slots (Type II cards: 2 slots available, Type III cards: 1 slot available). The following cards can be installed;

•

Saving User Settings

It is possible to operate the printer differently from other users with the panel button settings. Two sets of user settings can be stored.

PCMCIA-compatible flash memory card HDD card PCMCIA Fax Modem card

I-3

2. PARTS NAMES & FUNCTIONS

2. Control Panel

4. Power Button

3. Front Cover

Media cassette

1. Top Cover

Fig.1-1

7. Controller Box

5. Power Inlet

6. Rear Access Cover

Fig.1-2

I-4

No. Part Name Outline of Functions

1 Top Cover

2 Control Panel To display the status of printer operation.

3 Front Cover

4 Power Button

5 Power Inlet To connect a power supply cable.

6 Rear Access Cover

To act as an upper enclosure and also as a paper tray for printed paper.

To act as a front enclosure, opened when replacing a toner cartridge or waste toner pack.

To operate power-on and off to the printer. (Push for On/Off operation)

To act as a rear enclosure, opened when clearing an internal jam or doing maintenance work.

7 Controller Box

Space where the main (video controller) PCB is installed.

I-5

3. INTERNAL STRUCTURE

4.Fusing Unit

5.Transfer

7.Paper

Discharger

8.Transfer

6.Transfer Drum

12.Register Roller

Roller

10.Paper Pick-

Unit

up Roller

3.Drum Cleaner

2.OPC Belt Cartrid

Fig.1-3

1.Toner Cartridge (K,Y,M,C)

11.Scanner Unit

9.Media Cassette

No. Components Name Outline of Functions

1 Toner Cartridge

Contain the toner (K, Y, M, C) for developing. Each toner cartridge (K, Y, M, C) is independent.

2 OPC Belt Cartridge Forms images and includes the photoconductive belt.

3 Drum Cleaner

Cleans and collects waste toner adhering to the transfer

drum. 4 Fusing Unit Fixes by heat and pressure the toner image onto the paper. 5 Transfer unit Transfers toner images from the transfer drum to the paper.

6 Transfer Drum

7 Paper Discharger

Forms color images, combining the toner images from the

OPC belt on the drum.

Emits a corona charge for separating the paper from the

transfer drum. 8 Transfer Roller Transfer the toner image on the transfer drum to the paper. 9 Media Cassette Feeds paper automatically.

10 Paper Pick-up Roller Feeds paper automatically from the paper cassette. 11 Scanner Unit Generates a laser beam and scans the OPC belt. 12 Register roller Aligns the paper correctly ready for printing

I-6

4. DESCRIPTION OF CONTROL PANEL

The printer control panel provides control of the printer including test printing, maintenance operations performed by the video controller and also the ones which are performed by the engine controller.

The Video Controller Mode and the Engine Controller Mode have some common functions. Under normal circumstances the functions in the Video controller mode will be used. Refer to Chapter V for further information.

4.1 Video Controller Mode

The printer goes into the Video Controller Mode when the power is turned on by pressing the power button.

The Video Controller Mode supplies the general test printing and setting functions and some of the maintenance operations. If further engine settings are required, use the Engine Controller Mode.

4.2 Engine Controller Mode

The printer goes into the Engine Controller Mode when power is turned on by pressing the power button at the same time as holding down the Mode, Set and ▼ buttons. (Refer to Fig.1-4.)

Note: This mode provides unique control panel display and operation functions which are

completely different from the ones described on the actual control panel or in the user’s guide. Refer to Chapter V for detailed information.

I-7

Copy Pages

Orientation

Feeder

Emulation Mode

Ready Data

Alarm

Mode

Emulation Economy

Shift

On Line

Sel

Font

SetContinue

KCMY

Toner

Copy Reset

Form Feed

Feeder

Test

Fig.1-4

No. LED / Button Name

1 LCD: 16 character by 2 lines 2 Ready LED 3 On Line LED 4 Data LED 5 Select button 6 Form Feed / Feeder button 7 Alarm LED 8 Mode / Emulation button 9 Font / Economy button

▲ / Test button

11 Continue / Shift button 12 Set / Copy button 13

▼ / Reset button

I-8

CHAPTER II

SPECIFICATIONS

CONTENTS

CHAPTER II SPECIFICATIONS..................................................... II-1

1. RATING .........................................................................................................II-1

2. GENERAL SPECIFICATIONS.......................................................................II-2

2.1. Printing.................................................................................................................................II-2

2.2. Functions.............................................................................................................................II-3

2.3. Electrical and Mechanical....................................................................................................II-3

2.4. Paper Specification..............................................................................................................II-4

2.4.1 Printable Media & Cassette Capacity ............................................................................II-4

2.4.2 Printed Output................................................................................................................II-5

2.4.3 Recommended Paper Specifications.............................................................................II-5

2.4.4 Effective Printing Area....................................................................................................II-5

2.4.5 Paper Feed Jam Rate....................................................................................................II-7

3. ENVIRONMENTAL CONDITION...................................................................II-8

3.1 Ambient Temperature / Humidity / Altitude...........................................................................II-8

CHAPTER II SPECIFICATIONS

1. RATING

Use the power supply cable supplied with the printer, or a similar cable complying with the following specification (3-wire power cable with ground).

Use of an “out of specification” cable may result in an electric shock.

Destination Voltage (V) Frequency (Hz) Input Current (A) Power Cord (Piece)

US / Canada 120 50/60 8 1

Europe 220 - 240 50/60 4 1 *

* For the model for Europe, the power supply cable depends on the country as

follows;

Figure Rating Approval Agency Applicable Area

WARNING

BBSUK

Figure A: For Europe (Sample)

Figure B: For UK

Note: For details of other power supply cables, refer to the parts reference list.

250VAC, 6A

VDE, DEMKO, SEV Europe (Continent)

2.5m

** For rating labels, refer to the Safety Instruction on Page vi.

II-1

2. GENERAL SPECIFICATIONS

2.1. Printing

Print method: Electrophotography by semiconductor laser beam scanning

Resolution: 300 x 300 dots per inch (Normal)

600 x 600 dots per inch (Fine) The resolution can be enhanced to 2400 dpi class by using the HRC(High Resolution Control) and CAPT (Color Advanced Photoscale Technology) features.

Print speed: Monochrome mode: 16 page/minute (A4/Letter-size)

Full color mode: 4 page/minute (A4/Letter-size)

Warm-up: Max. 3 minute at 20°C (68°F)

First print: Monochrome mode: 19 seconds or less

Full color mode: 30 seconds or less (when loading A4/Letter-size paper by face down print delivery from standard upper cassette feed)

Print media: Toner in a single-color single-component cartridge

Life Expectancy: 10,000 single-sided pages/cartridge (Black)

6,000 single-sided pages/cartridge (Cyan, Magenta, Yellow)

Note: These figures are based on an average of 5% coverage of the printable area for

one color using laser paper. The frequency of replacement will vary, depending on the complexity of the prints, the percentage of coverage, and the type of media. Transparencies, glossy coated paper and other special media will result in shortened consumable life.

Resident Printer Fonts:

<HP PCL, EPSON FX-850, and IBM Proprinter XL modes> 66 scalable fonts and 12 bitmapped fonts <BR-Script Level 2 mode> 66 scalable fonts

II-2

2.2. Functions

CPU: MB86832 (SPARC architecture) Emulation: Automatic emulation selection

Interface: Automatic interface selection between the bi-directional parallel, RS-

RAM: Standard model: 16Mbytes

Card Slots:

HP Color Printer (PCL5C) including HP LaserJet 4+ (PCL5e) and HP LaserJet 5 (PCL6 monochrome)

BR-Script Level 2 (Adobe PostScript Level 2 compatible) HP-GL EPSON FX-850 IBM Proprinter XL

232C serial and MIO interface.

Network model: 32Mbytes (Expandable up to 112Mbytes with SIMMs) The standard memory fitted can vary depending on the printer model and country

2 card slots: PCMCIA Type I, II 1 card slot: PCMCIA Type III

Compatible for Flash Memory or HDD cards Control panel: 8 buttons, 4 LEDs and a 16-column x 2 lines liquid crystal display Diagnostics: Self-diagnostic program

2.3. Electrical and Mechanical

Power source: U.S.A. and Canada: AC 120V, 50/60Hz

Europe and Australia: AC 220 to 240V, 50/60Hz Power consumption:

Printing: 450W or less

Standing by: 150W or less

Sleep: 25W or less Noise: Printing: 55dB A or less

Standing by: 48dB A or less Temperature: Operating: 10 to 32.5°C (50 to 90.5°F)

Non Operating: 5 to 35°C (41 to 95°F)

Storage: 0 to 35°C (38 to 95°F) Humidity: Operating: 20 to 80% (non condensation)

Storage: 20 to 80% (non condensation) Dimensions (W x D x H):

500 x 490 x 388 mm (19.7 x 19.3 x 15.3 inches)

500 x 490 x 493 mm (19.7 x 19.3 x 19.4 inches)

with the optional lower tray unit fitted Weight: Approx. 32kg (70.5lbs.)

Approx. 36kg (79.4lbs.)

with the optional lower tray unit and toner cartridges fitted

II-3

2.4. Paper Specification

2.4.1 Printable Media & Cassette Capacity

The standard media cassette (upper cassette) is supplied with the printer. The optional lower tray unit and the optional Legal cassette can also be installed.

Note: The standard cassettes (including the optional lower tray unit) and the optional Legal

cassette are interchangeable between the upper and the lower feeder.

1) Printable Media: Plain paper / Envelope / Transparency / Label

2) Printable size: (Refer to the list below.)

3) Feedable paper weight: 60 (16lb.) to 160 (43lb.) g/m

4) Maximum load height : 27mm

• Plain paper: 250 sheets of 75g/m

• Envelopes : 15 sheets

• Transparency: 50 sheets

• Label: 80 sheets

5) Setting method: Pull the media cassette out of the printer toward you, insert

the paper into the cassette after aligning the top edge of the sheets, then push the cassette back into its original position.

(20lb) paper

Paper Source Printable Media Size

Plain paper: The Standard Media Cassette Envelope: (Upper/Lower feeder) Other size:

Plain paper: The Optional Legal Cassette Envelope:

Other size:

105 to 216 mm

Feeding direction

(face up)

A4, Letter, B5, Executive COM10, DL width 105-216mm (4.1”-8.5”)

length 220-297mm (8.7”-11.7”) Legal, A4, Letter, B5, Executive

COM10, DL width 105-216mm (4.1”-8.5”)

length 220-355.6mm (8.7”-14”)

220 to 297mm (Standard Cassette) 220 to 355.6 mm (Legal Cassette)

II-4

2.4.2 Printed Output

250 sheets of 75g/m

(20lb) paper / plain paper can be stacked in the output tray.

Face-down print delivery

Note: Face down: Delivers the printed side of the paper downwards

Environment: 17.5 ∼ 27.0°C, 50 ∼ 70%RH

2.4.3 Recommended Paper Specifications

Item Description Basis Weight (g/m2) 82 ± 5 Thickness (µ m) 95 ± 6 Smoothness (Bekk) (seconds) 90 ± 20 Stiffness (Clark) 100 ± 15 Brightness (%) 85 ± 2 Surface Resistance (Ω) Grain Direction Long

Measurement Condition: 17.5 ~ 27.0°C, 50 ~ 70%RH

~ 10

Note: Keep the paper sealed in the bag as supplied and do not open the paper bag

until the paper is required for use.

2.4.4 Effective Printing Area

(1) Printable area

The effective printing area means the area within which the printing of all the data received without any omissions can be guaranteed. (Refer to Table 2-1 for details.)

II-5

Table 2-1: Effective Printing Areas

Size A B C D E F

A 4

Letter

Legal

B 5 (JIS)

B 5 (ISO)

Executive

COM-10

D L

210.0mm

8.27” (2,480 dots)

215.9mm

8.5” (2,550 dots)

215.9mm

8.5” (2,550 dots)

182.0mm

7.16” (2,149 dots)

176.0mm

6.93” (2,078 dots)

184.2mm

7.25” (2,175 dots)

104.8mm

4.125” (1,237 dots)

110.1mm

4.33” (1,299 dots)

297.0mm

11.69” (3,507 dots)

279.4mm

11.0” (3,300 dots)

355.6mm

14.0” (4,200 dots)

257.0mm

10.12” (3,035 dots)

250.0mm

9.84” (2,952 dots)

266.7mm

10.5” (3,150 dots)

241.3mm

9.5” (2,850 dots) 221mm

8.66” (2,598 dots)

203.2mm

8.0” (2,400 dots)

207.44mm

8.16” (2,450 dots)

207.44mm

8.16” (2,450 dots)

173.54mm

6.82” (2,049 dots)

167.54mm

6.59” (1,978 dots)

175.74mm

6.91” (2,075 dots)

96.34mm

3.785” (1,137 dots)

101.64mm

3.99” (1,199 dots)

288.5mm

11.36” (3,407 dots)

271.0mm

10.67” (3,200 dots)

347.1mm

13.67” (4,100 dots)

248.5mm

9.78” (2,935 dots)

241.5mm

9.5” (2,852 dots)

258.3mm

10.17” (3,050 dots)

232.8mm

9.16” (2,750 dots)

211.5mm

8.33” (2,498 dots)

3.4mm

0.13” (40 dots)

4.23mm

0.17” (50 dots)

4.23mm

0.17” (50 dots)





(Note that the paper sizes indicated here should conform to the nominal dimensions specified by JIS.)

A4 paper must accommodate 80 characters printed in pica pitch (203.2 mm). The dot size is based on 300 dpi resolution.

II-6

(2) Print guarantee area

3mm

5mm

guarantee

area

Non printable area

4mm

Non printable area

Non guarantee area

4mm

3mm

5mm

Paper:5mm Other:10mm

Paper:4mm Other:10mm

42mm

16mm

3mm

4mm

2.4.5 Paper Feed Jam Rate

Less than 1 misfeed per 2000 pages under normal environmental conditions. Less than 1 misfeed per 1000 pages outside the normal environmental conditions.

Non guarantee area

COM10:68mm DL:40mm

Print guarantee

area

4mm

COM10:68mm DL:40mm

Note: These figures are based on the paper whose specification is recommended. For the

recommended specifications, refer to Section 2.4.3 of this chapter.

II-7

3. ENVIRONMENTAL CONDITION

3.1 Ambient Temperature / Humidity / Altitude

(1) Under Operational conditions: 10.0 ∼ 32.5°C, 20 ∼ 80%RH (See the figure below.)

80 70

60 50

Ambien Humidity (%RH)

100 17.5 20 27 30 32.5 40

Ambient Temperature ( )

Recommended Condition;

17.5 ∼ 27.0°C 50 ∼ 70%RH

(2) Under Non Operational conditions: 5.0 ∼ 35.0°C, 10 ∼ 80%RH (See the figure

below.)

40 30

Ambient Humidity (%RH)

20 10

10020303540

Ambient Temperature( )

II-8

(3) Storage and Transportation Environment of Printer The following defines the storage and transportation environment of printers that have

been packed according to Brother specification. However, this section does not cover the OPC belt cartridge and toner cartridges.

Normal Conditions

Temperature

Humidity Period of Storage One Year Other No Condensation Atmosphere

The period under the severe conditions should not be continuous, and is assumed as an accumulation of intermittent time. However, an individual period of intermittent time under severe conditions should not be allowed to exceed 48 hours.

Severe Conditions

0°C ∼ 35°C (35°F ∼ 95°F)

High Temperature: 35°C ∼ 40°C (95°F ∼ 104°F) Low Temperature: -10°C ∼ 0°C (14°F ∼ 32°F)

10% ∼ 90%RH

613 ∼ 1,067hpa (460 ∼ 880mmHg)

Note: Normal conditions should occupy more than 90% of total storage period. Severe conditions should be less than 10% of total storage period.

II-9

CHAPTER III

INSTALLATION

CONTENTS

CHAPTER III INSTALLATION....................................................... III-1

1. CONDITIONS REQUIRED FOR INSTALLATION.........................................III-1

1.1. Environmental Conditions...................................................................................................III-1

1.2. Basic Layout of Printer Set-up Location .............................................................................III-1

2. UNPACKING.................................................................................................III-2

2.1 Unpacking of Printer............................................................................................................III-2

2.2 Unpack the Starter Kit..........................................................................................................III-4

3. INSTALLATION WORK................................................................................III-5

3.1 Install the OPC Belt Cartridge..............................................................................................III-5

3.2 Install the Toner Cartridge to the Printer..............................................................................III-6

3.3 Install the Oil Bottle and Fuser Cleaner...............................................................................III-7

3.4 Test Print .............................................................................................................................III-8

3.4.1 Test Print.......................................................................................................................III-8

3.4.2 On-line Printing (Video Controller Mode only).............................................................III-10

CHAPTER III INSTALLATION

1. CONDITIONS REQUIRED FOR INSTALLATION

Any Laser beam printer is likely to be influenced by the environment of the set-up location. If the printer is set-up in an inappropriate location, the printer may not perform as expected. Therefore, the following factors should be taken into consideration before deciding where to set-up the printer.

1.1. Environmental Conditions

The printer should not be set up in the locations referred to in the following items (a) through (d) which specify inappropriate locations for set-up.

(a) Where it is likely to receive direct sunlight or similar light. (For example, next to a

window)

(b) Where it is likely to suffer a big difference in temperature and humidity between the

maximum and minimum levels. (Normal operation environment is within 10°C ∼

32.5°C, 20 ∼ 80%RH and without any condensation.)

heater, or to receive direct radiant heat.

(d) Where it is likely to be excessively dusty or be subject to corrosive gases such as

ammonia.

(e) Users should select a location with good ventilation and set the printer on a flat

surface.

(f) Users should check that the maximum angle of the set-up location is horizontal to

within ±1°.

1.2. Basic Layout of Printer Set-up Location

Fig.3-1 shows the basic layout of the printer set-up location that is suitable for smooth

operation and maintenance of the printer.

40cm(16") 70cm(28")

Paper Exit Side

• The space in front of the printer (70cm) is necessary to open the front cover.

• The space at back of the printer (40cm) is necessary to open / close the rear access

cover.

• The space on both sides of the printer (10cm) is necessary for general access.

10cm(4")

Front Side

10cm(4")

Fig.3-1

III-1

2. UNPACKING

• The package containing a printer weighs approximately 40kg (80lbs), so it is too heavy for one person to carry. It needs two adults to move the printer. Since the printer is a precision machine, make sure that it is carried slowly with care so that no impact occurs to the printer while moving it.

• Do not attempt to lift a printer when it is covered by the vinyl bag because it is slippery and may result in damage and injury if dropped.

2.1 Unpacking the Printer

Refer to Fig.3-2 on the next page.

1) Remove the binding tape from the top of the package.

2) Open the top of the package and take the starter kit out.

3) Remove the upper packing.

4) Take the customize kit** out.

5) Remove the plastic joints (4 locations).

6) Lift the outer box up from around the printer.

7) Take the power cable. (for US / Canada only).

8) Open up the vinyl bag enclosing the printer.

9) Lift up the printer with another person’s help, and move it away from the vinyl bag.

10) Set up the printer in a suitable location.

WARNING

** For USA/Canada, it contains the user’s guide and printer driver disks.

For other countries, it contains the user’s guide, printer driver disks and the power cable.

III-2

Starter Kit Packing (U)

Polyethylene Bag (T)

Polyethylene Bag (CL)

Starter Kit

Packing (L)

Outer Box

Tape

Syringe

Joint

Outer Box

Polyethylene

Bag (OPC)

Bag (ST)

Polyethylene

Bag (OIL)

Silica Gel (ST)

Silica Gel (EN)

Power

Cord

Upper Packing

Brush

Cleaning

Polyethylene

Kit

Fig.3-2

Base

Bag (EN)

III-3

Costomize

2.2 Unpack the Starter Kit

)

(

)

1) Open the vinyl bag and slide off the cardboard sleeve covering the starter kit.

2) Confirm all of the following parts are inside the starter kit packing box.

No. Kit Name Appearance Quantity

Y (Yellow M (Magenta

Toner Cartridge

(Y,M,C,K)

2 OPC Belt Cartridge 1

C (Cyan)

Black

3 Oil Bottle 1

4 Fuser Cleaner 1

5 Syringe 1

PRECAUTION

When shipping the printer, remove the oil bottle and the fuser cleaner from the fusing unit. After removing the oil bottle, be sure to remove the oil remaining in the fusing unit with the supplied syringe. Failure to do so will cause severe damage to the printer.

III-4

3. INSTALLATION WORK

Install the unit parts of the starter kit into the printer according to the following procedures:

3.1 Install the OPC Belt Cartridge

• Do not directly touch the OPC belt surface with bare hands or gloves.

• If the belt is exposed for more than two minutes to a light source of 800 lux, the belt may be damaged.

PRECAUTION

1) Open the front cover and the top cover

by releasing the latches.

CAUTION

When installing or removing the OPC belt,

be sure to open the front cover first. Failure to do so will cause the OPC belt to be damaged due to contact with the toner cartridges.

Front Cover

2) Release the belt cartridge lock levers

(left & right).

3) Pull and remove the tension release

pins on both sides (left & right) of the OPC belt cartridge.

4) Remove the protective sheet from the

new OPC belt cartridge.

Belt cartridge

lock lever

Tension

release pin

Top Cover

Fig.3-3

(Left)

Belt cartridge

lock lever (Right)

Fig.3-4

OPC Belt Cartridge

III-5

Protective sheet

Tension

release pin

Fig.3-5

5) Install the new OPC belt cartridge into

the guides at both sides in the printer.

6) Set the belt cartridge lock lever at both

sides (left and right).

3.2 Install the Toner Cartridges into the Printer

Fig.3-6

Fig.3-7

1) Rock each of the cartridges 3 to 4 times

through 30

to the horizontal.

2) Remove the tape fixing the protective

cover and remove the protective cover from the new toner cartridge.

3) Install the new toner cartridge along the

guide into the printer.



Fig.3-8

Protective cover



Fig.3-9

III-6

Fig.3-10

Note: The installation order of the four toner

cartridges should be from the bottom to the top, in terms of colors this is in the order Cyan (C), Magenta (M), Yellow (Y), and Black (K).

4) Close the front cover.

3.3 Install the Oil Bottle and Fuser Cleaner

Fig.3-11

K Y M C

1) Pull out and remove the orange

protective parts fitted between the rollers of the fusing unit.

2) Install the oil bottle into the fusing unit.

Orange protective

part

Fig.3-12

Oil Bottle

3) Install the fuser cleaner into the fusing

unit.

4) Secure the oil bottle and the fuser

cleaner with the retainer lock levers.

5) Close the top cover.

III-7

Fig.3-13

Fuser Cleaner

Retainer lock lever

Fig.3-14

3.4 Test Print

After completing the installation work, perform a test print. The test print should be done in the Video Controller Mode and checked for correct print output. If there appear to be any print problems then the test print in the Engine Controller Mode should be used if necessary.

Note: The test print pattern differs between these two modes.

3.4.1 Test Print

1) Before connecting a power cable to the

printer, ensure that the power button located on the front of the printer projects from the cover surface. This means that the printer is in the power-off status.

2) Connect the connector of the power

cable to the printer.

Power Button

3) Insert the plug of the power cable into

the power outlet.

4) Press the power button, and confirm

that the SELF TEST LCD panel screen is displayed during printer initialization.

04 SELF TEST

The printer checks the RAM size and then goes into warming-up mode.

RAM SIZE = 16 M

5) The Ready LED lights within 210

seconds maximum, before which the screen shown on the right appears on the control panel display.

LJ WAIT 001P T1 AUTO

6) Press the Select button to set the printer off-line.

7) Hold down the Shift button and press the Test button so that the printer enters the test

mode.

8) The printer has built-in print patterns for test printing. The display shows the first test

mode item.

9) Press the ▲ or ▼ button until the desired test mode appears on the display, then

press the SET button to print the desired test page.

III-8

Note: Refer to the table below for each test mode item.

Display Message Test Mode Description

DEMO PAGE Prints out the demonstration.

TEST PRINT

PRINT CONFIG

PRINT FONTS I

PRINT FONTS C

PRINT FONTS P

exit

10)Push the power button in order to shut off the power supply to the printer.

Note: use the following procedures to identify the problem if the test print is incorrect.

11)Press and hold down the Mode, Set and

▼ buttons and press the power button to go into the Engine Controller Mode. The Ready LED lights within 210 seconds maximum, when the screen (a) on the right appears on the control panel display.

12)Press the Select key, then the screen

(b) on the right appears on the control panel display.

Performs the printer test and prints out the test pattern.

Prints out a list of panel button settings you have configured as user settings for the printer.

Prints out a list of internal or resident fonts.

Prints out a list of optional fonts stored in the font cartridge/card.

Prints out a list of permanent download fonts.

Exits from the test mode. The printer does not perform any test.

(a)

00 READY [ ] U:[ ] L:[ ] [ ]

(b)

SERVICE MODE TEST PRINT/NEXT

13)The printer has two built-in print

patterns for test printing in the Engine Controller Mode as follows. Use the Set or ▼ button to scroll through the menu options and then press the Continue key to perform the selected test print. Press Font to stop the test print.

1. Grid Pattern: Available in mono color print of Y, M, C, K, and two color print of R, G, B.

2. Stripe Pattern: Available in color print of Y, M, C, K, R, G, B.

Grid

Stripe

III-9

14)Press the Font button to stop the test print and then push the power button in order to shut off the power supply to the printer.

(This switch is push-on/push-off type.)

Power Button

15)Unplug the power cable from the outlet.

PRECAUTION

• Before unplugging the power cable, confirm that the main power button located on the front of the printer is set to Off.

• Under no circumstances power off or unplug the printer while it is performing any printing operations.

• Do not turn the printer power back on until at least 5 seconds after powering off.

3.4.2 On-line Printing (Video Controller Mode only)

Upon confirmation of correct printing by the test print modes, proceed with normal OnLine Printing according to the following procedures. Since this service manual does not refer to the interface connection or operation of the host computer, read the printer User’s Guide and any manuals detailing the operation procedure of the host computer before starting normal On-Line Printing.

1) Connect the interface cable to the host computer.

2) Push the power button to turn on the printer.

Power Button

3) Confirm that the printer is set to the OnLine mode. (On Line LED is lit.)

4) Upon completion of the warming-up process, the Ready LED lights.

** Confirm what is indicated on the control panel

LJ WAIT 001P T1 AUTO

This warming-up process takes 210 seconds maximum.

5) The printer starts printing upon receipt of print data transmitted from the host PC.

III-10

CHAPTER IV

STRUCTURE OF

SYSTEM COMPONENTS

CONTENTS

CHAPTER IV STRUCTURE OF SYSTEM COMPONENTS...........IV-1

1. BASIC STRUCTURE.................................................................................IV-1

1.1 Print System and Transfer System.................................................................................IV-6

1.1.1 Structure of the Printer ............................................................................................. IV-7

1.1.2 Basic Structure of the Printing System.....................................................................IV-8

1.1.3 Details of Each Process.........................................................................................IV-10

1.2 Scanning System..........................................................................................................IV-21

1.3 Paper Transportation System.......................................................................................IV-23

1.4 Fusing Unit.................................................................................................................... IV-25

2. STRUCTURE OF THE CONTROL SYSTEM...........................................IV-27

2.1 Basic Structure.............................................................................................................. IV-27

2.1.1 Electrical System and Functions............................................................................IV-27

2.2 Control System..............................................................................................................IV-36

2.2.1 Control of the Print Process ...................................................................................IV-36

2.3 Main PCB (Video Controller PCB).................................................................................IV-46

2.3.1 Outline....................................................................................................................IV-46

2.3.2 Circuit ..................................................................................................................... IV-47

2.4 Power Supply Unit.........................................................................................................IV-58

2.5 High Voltage Power Supply Unit...................................................................................IV-61

2.6 Wiring Diagram............................................................................................................. IV-64

CHAPTER IV STRUCTURE OF SYSTEM COMPONENTS

1. BASIC STRUCTURE

This laser beam color printer (hereinafter called “Printer”) consists of five mechanical systems; Print, Transfer, Scanning, Paper Transport and Control System. The printer produces color printing through the interactive operations of these five systems as shown in Fig.4-1.

(1) Print System

The print system consists of the following 6 (six) functional parts located around the OPC belt which form a toner image on the OPC Belt.

• Charger Part

• Exposure Part

• Development Part

• First Transfer Part

• Discharger Part

• Cleaner Part

(2) Scanning System

The scanning system consists of the following 2 (two) functional parts which form an electrostatic latent image on the OPC Belt by scanning it with a laser beam.

Scanner Unit Scanner Motor (SCM)

(3) Transfer System

The transfer system consists of the following 3 (three) functional parts and transfers the toner image formed on the transfer drum onto the page.

• Transfer Drum

• Second Transfer Part

• Drum Cleaner Unit

(4) Paper Transport System

The paper transport system consists of the following 5 (five) functional parts and picks up paper from the media cassette, separates the paper from the transfer drum and exits it from the printer body after fusing the toner image on the paper.

• Media Cassette

• Transport rollers

• Paper Discharger

• Fusing unit

• Paper Exit

IV-1

I/F Controller

MCTL

I/F Control

Sequence Control

Laser Control

SCM

Develope Motor

Main Motor

OPC Belt

Drum Cleaner Unit

Drum Cleaning

Development

Operation

Transfer Drum

First Transfer

Scanner Unit

Exposure

Discharge

Charge

DC Charger

Paper Feed

Media Cassette

Cleaning

Fig.4-1

Erase Lamp

Fix

Paper Exit

Paper Exit Unit

Fusing Unit

Second Transfer

Paper Discharger

AC Discharger Unit

Transfer Roller

Transfer Unit

IV-2

Registrater Roller

Paper Pick-up Roller

(5) Control System

The control system consists of the following 4 (four) control parts and runs the printer by processing the interface signals transmitted from the Host computer and interfacing to the print, transfer, scanning and transport systems.

• Sequence Control

• Laser Control

• Fusing Temperature Control

• Interface Control

(1) Principle of Color Printing

Color printing is made through the subtractive process by combining the three primary colors, yellow, magenta, and cyan. Fig.4-2 shows the three primary colors and subtractive process:

Y: Yellow M: Magenta C: Cyan R: Red GR: Green BL: Blue BK: Black

Fig.4-2

(2) Basic Color Printing Process

(a) The printer has a Toner Cartridge of each color yellow, magenta, cyan and black

as shown in Fig.4-3.

(b) The toner image developed using the primary colors is transferred to the transfer

drum for the printed color combination as shown in Fig.4-4 a .

paper as shown in Fig.4-4 b .

(d) The toner on the paper is fused by the thermal fixing unit to fix the toner image

onto the paper as shown in Fig.4-4 c .

Summarizing the above processes, a toner color layer is formed on the transported paper, and subsequently, the color image is made through the subtractive process.

IV-3

OPC Belt

Toner Cartrid

Transfer Drum

. First Transfer

. Second Transfer

Fig.4-3

YYY

Y M

Transfer Drum

Paper

YYY

CCC

Toner

. Fusing

Fig.4-4

Red

Cyan

Green

Paper

IV-4

The OPC belt consists of a surface layer having a photoconductor (OPC) of organic material, the inner layer of an insulator material (PET / Mylar) and an aluminum deposit layer in between. The OPC belt is located as shown in Fig.4-5 as the main part of the print system.

OPC Belt

Transfer Drum

OPC Belt Cartridge

Fig.4-5

Toner Cartrid

Scanner Unit

Electrode

Fig.4-6

Photoconductor

(OPC)

Aluminum deposit layer Insulator Material

IV-5

1.1 Print System and Transfer System

Fig.4-7 shows the basic structure of the print system having the OPC belt as the main part and the transfer system having the transfer drum as the main part. Color printing is achieved by actuating in sequence each process in the print system and transfer system.

4 cycles of actions 1 to 6 are required to form a full 24 bit color image on the transfer drum, only one cycle of actions 7, 8 and 9 is required to transfer the image to the paper from the transfer drum ready for fixing by actions 10 and 11.

Print System

Transfer System

Charging

Exposing

OPC Belt

KYMC

Transfer Drum(First Transfer)

Transfer Drum

KYMC

Second Transfer(Paper)

Paper Dischanging

OPC Belt Cleaning

Belt DischargeDeveloping

Transfer Drum Cleaning

Transport System

Fusing

Paper Exit

Fig.4-7

IV-6

1.1.1 Structure of the Printer

No. Component Part Process

1 Charger Charging 2 Scanner Unit Exposing 3 Toner Cartridge Developing 4 OPC Belt Receives the Image 5 Transfer Drum Transfers the Image 6 Belt Discharger Erase Lamp Discharges the Belt 7 Cleaning Blade Cleaning the Belt 8 Transfer Roller Transferring

9 Paper Discharger Discharges the Paper 10 Drum Cleaner Cleans the Drum 11 Fusing Unit Fusing 12 Paper Exit Unit Exits the Paper 13 Register Roller Paper Alignment

11. Fusing Unit

12. Paper Exit

Unit

10. Drum Cleaner 4. OPC Belt Cartridge

3. Toner Cartridge (K,Y,M,C)

Transfer Unit

9. Paper

Discharger

8. Transfer

5. Transfer Drum

13. Register Roller

Roller

Paper Pick-up

Roller

6. Erase Lamp

7. Cleanin

Fig.4-8

g Blade

1. Charger

2. Scanner Unit

Media Cassette

IV-7

1.1.2 Basic Structure of the Printing System

A toner image is formed through the potential of the OPC belt varying in each of the charger, exposure, development, transfer and cleaning processes.

(1) Process of Print System (See Fig.4-9.)

i) The OPC belt is biased to the voltage -CBV(V) by the power supply CBV. ii) A negative high voltage is applied to the charger unit by the power supply CHV,

and a corona is generated as the result.

iii) The developer magnetic roller of the toner cartridges is biased to -DBV(V) by

the power supply DBV.

iv) The frame potential of the transfer drum is GND.

Fuser Unit

Paper Discharger

ACHV

Transfer Roller

THV (+)

THV ( - )

Cleaning

Burush

Transfer Drum

Paper

FCBV

Erase Lamp

Cleaning Unit

OPC Belt

Cleaning

Blade

Toner

Charger

CHV

Toner Cartridge

Develop

DBV

CBV

Scannerl Unit

ZDV

Fig.4-9

No. Function Power Supply (P/S)

P/S Name Approx.Output Voltage

1 Charging CHV(-) 4.6KV

HVRD6190 619V 2 First Transfer CBV(-) 3 Developing Y,M DBV(-A)

Bias C,K DBV(-B)

4 Second Transfer THV(+)

200V ∼ 900V 200V ∼ 400V 200V ∼ 400V

400V ∼ 3,000V 5 Transfer Roller Cleaning THV(-) 600V 6 Paper Discharging

ACV(∼)

4.9KV

DCV(+) 200V

7 Drum Cleaning FCBV

200V ∼ 1,500V

IV-8

(2) Variation of OPC Belt Potential (See Fig.4-10.)

i) The OPC belt is initially biased to -CBV(V). ii) The OPC belt surface is evenly charged to V iii) The potential of the exposure part of the OPC belt is reduced to -VR(V) as it is

exposed to the laser beam in the process of exposing, and an electrostatic latent image is formed on the OPC belt as the result.

iv) Negatively charged toner is moved onto the exposed part of the OPC belt in the

development process due to the difference of potential between -VR(V) (the latent image) and -DBV(V), and a visible toner image is formed as the result.

v) Negatively charged toner on the OPC belt moves to the transfer drum surface

in the transfer process because the GND potential of the transfer drum is greater than -VR(V) of the OPC belt.

vi) The OPC belt is discharged by the erase lamp.

(V) in the charging process.

Process

OPC Belt

CBV

- V

CHV

- CBV

- VR

DBV

Charger

Transfer Drum

Toner

Dev. roller

1 2 3

DBV

CBV CHV

DBV

- VR

GND

Charging Process Exposing Process Developing Process Transfering Process Cleaning (Erase) Power Supply for OPC Belt Bias Power Supply for Charging Power Supply for Mag Roller Bias Remain voltage on the OPC Belt

Fig.4-10

IV-9

1.1.3 Details of Each Process

-V0

(

1 Charging

The charging process ensures that the OPC belt is evenly charged by the charger system.

(1) Structure of the Charger Unit (Refer to Fig.4-8 and Fig.4-11)

i) The charger unit is located as shown in Fig.4-8. ii) The charger unit consists of the case, corona wire and grid. iii) The charger unit charges the OPC belt surface to the potential -V

corona charge.

iv) The charger unit has the grid controlled to the constant voltage ZD(V) for even

charging.

(2) Process of Charging (Refer to Fig.4-12.)

i) The status of the OPC belt surface before charging is -CBV(V). ii) The charger unit charges the OPC belt surface evenly to -V

negative charge.

(V) with the

(V) by generating a

CBV CHV

Grid

Corona wire

Fig.4-11

Case

Cleaning

Blade)

Charging

Fig.4-12

IV-10

2 Exposing

The exposing process means that the OPC belt surface is exposed to the laser beam to form an electrostatic latent image.

(1) Structure of Scanner Unit

i) The scanner unit is located as shown in Fig.4-8. ii) The source of the laser beam is a semiconductor laser. iii) The laser light is scanned onto the OPC belt by converting the laser light to a

beam of light through the lens and reflective mirror to form an electrostatic latent image.

(2) Process of Exposing (Refer to Fig.4-13.)

i) The OPC belt surface has been charged to the potential -Vo(V) in the charging

process.

ii) The laser light is scanned at right angles to the forward direction of the OPC

belt.

iii) High speed switching of the laser is made according to the transmitted image

data.

iv) The charge of the areas radiated by the laser light is reduced to the potential -

VR(V).

v) An invisible electrostatic latent image is formed on the OPC belt as shown in

Fig. 4-13.

Charging

-VR

-VO

Exposing

Fig.4-13

IV-11

3 Developing

The developing process means that an electrostatic latent image on the OPC belt is made visible by depositing toner onto the exposed areas of the OPC belt.

(1) Structure of the Toner Cartridge (Refer to Fig.4-8 & 4.14.)

i) The toner cartridge is located as shown in Fig.4-8. ii) Four toner cartridges are made available from the top to bottom in the order

black, yellow, magenta and cyan.

iii) Each color toner is loaded in the corresponding toner cartridge.

(2) Process of Developing (Refer to Fig.4-8, 4-14, 4-15, and 4-16)

i) Toner adheres to the developer roller of the toner cartridge. Developing is processed by this roller contacting the OPC belt surface. ii) The developer roller has been biased to the potential -DBV(V). Fig.4-15

describes the relationship established between the potential of the toner, the potential -V

(V) at the non-exposed area of OPC belt and the potential -VR(V)

on the exposed area of the OPC belt.

iii) Developing is processed by the toner adhering to the OPC belt due to the

attraction between the potential of the toner and the potential -VR(V) on the exposed area of the OPC belt. A visible Toner image is formed on the OPC belt.

iv) No developing takes place on the non-exposed area because the potential of

the toner and that of the OPC belt is the same polarity and therefore repel each other.

Toner

OPC Belt

Develper roller

Toner

Fig.4-14

IV-12

Developer roller

Toner

OPC Belt

Fig.4-15

CBV

DBV

Exposing

Toner (M)

Developin

Fig.4-16

IV-13

4 First Transfer (Drum)

The first transfer process means that the toner image on the OPC belt is transferred onto the transfer drum.

(1) Structure of the Transfer Drum (Refer to Fig.4-8.)

i) The drum is located as shown in Fig.4-8. ii) Material of the drum is aluminum. iii) Semiconductor rubber is used to provide the drum surface as shown in Fig.4-

17.

iv) The transfer drum rotates by contacting and synchronizing with the OPC belt.

Transfer Drum

Fig.4-17

Aluminum

Rubber

IV-14

(2) First Transfer Process (Refer to Fig.4-18.)

i) The OPC belt has been through the development process and contacts and

synchronizes with the transfer drum.

ii) The OPC belt has been biased to the potential of -CBV(V). The potential of the

transfer drum is nearly GND.

iii) Toner on the OPC belt is moved onto the transfer drum due to the difference of

potential between the OPC belt and the transfer drum.

iv) Toner that has been developed by each color in sequence is moved from the

OPC belt onto the transfer drum and the color toner images overlap on the transfer drum.

v) Upon completion of the drum transfer process, the complete toner image is

transferred onto paper in the paper transfer process.

OPC Belt

Drum transferring

Residual Charge

Residual Toner

Belt cleaning (Blade)

Belt discharging (Erase Lamp)

Fig.4-18

IV-15

5 Belt Discharging (Erase Lamp)

The belt discharging process means that upon completion of the drum transfer process, an LED light is radiated onto the OPC belt prior to mechanically cleaning the belt to discharge the residual charge.

(1) Structure of Erase Lamp

i) The erase lamp is located as shown in Fig.4-8. ii) The light source of the erase lamp is 24 light emitting diodes (LEDs).

(2) Process of Discharging (Refer to Fig.4-19.)

i) Though the toner image was transferred to the transfer drum in the drum

transfer process, there is still a residual charge on the OPC belt.

ii) The residual charge (-VR) on the OPC belt is discharged by the radiation of the

erase lamp light prior to cleaning the belt.

Drum transferring

Fig.4-19

Belt discharging (Erase Lamp)

Belt cleaning (Blade)

IV-16

6 Belt Cleaning

The belt cleaning process means that the residual toner adhering to the OPC belt surface is mechanically scavenged.

(1) Structure of Belt Cleaning

The blade for the belt cleaning is located relative to the OPC belt cartridge as shown in Fig.4-8.

(2) Process of Belt Cleaning (Refer to Fig.4-20.)

There is residual toner on the OPC belt as it has not been completely transferred in the drum transfer process.

Residual toner is mechanically scavenged by the blade edge. The scavenged residual toner is collected in the waste toner pack by the waste

toner feeder.

Drum transferring

Fig.4-20

Belt discharging (Erase Lamp)

Belt cleaning (Blade)

IV-17

7 Second Transfer (Paper)

The second transfer process is where the toner image on the transfer drum is transferred onto the transported paper.

(1) Second Transfer Structure

i) The transfer roller for the paper transfer is located as shown in Fig.4-8. ii) The transfer roller is normally kept out of contact with the transfer drum until the

second transfer process starts. iii) The transfer roller is positively biased by the power supply THV. iv) The transfer roller is in contact with the transfer drum only in the second

transfer process. v) Transported paper passes between the transfer roller and transfer drum.

(2) Second Transfer Process (Refer to Fig.4-21.)

i) Paper is transported and is synchronized with the transfer drum. ii) The transfer roller operates and is synchronized with the transported paper and

is in contact with the transfer drum through the transported paper. iii) The transported paper passes between the transfer roller and transfer drum. At this time the positive high voltage (THV) is fed to the transfer roller. iv) Negatively charged toner on the transfer drum is moved to the positively

charged paper. v) The transported paper with the toner transferred to it is moved to the paper

discharging process.

Paper Discharger

Transfer Roller

VAC

THV

Transfer Drum

Toner image

Paper

Fig.4-21

VAC: Power Supply for Paper discharging THV: Power Supply for Transfer Roller Bias

IV-18

8 Paper Discharging

The paper discharging process is where the transported paper onto which the toner transfer has been completed is separated from the transfer drum by applying an AC charge to the paper.

(1) Structure of Paper Discharger (Refer to Fig.4-22.)

i) The AC charger unit for discharge the paper is located as shown in Fig.4-8. ii) The AC charger unit consists of the case and a charger wire. iii) A high alternating voltage (VAC) is fed to the AC charger unit.

(2) Process of Paper Discharging (Refer to Fig.4-22.)

i) The paper adheres to the transfer drum in the transfer process. ii) The paper is neutralized (discharged) in terms of any electrical charge by the

alternate voltage generated by the discharger. iii) Paper is separated from the transfer drum and subsequently transported to the

fusing (fixing) process.

Paper Discharger

Transfer Roller

VAC

THV

Transfer Drum

Toner

Paper

Fig.4-22

IV-19

9 Drum Cleaning

The drum cleaning process is where the residual toner on the transfer drum is removed.

(1) Structure of Drum Cleaning (Refer to Fig.4-23.)

i) The drum cleaning unit is located as shown in Fig.4-8. ii) The drum cleaning brush is a semiconductor type so that the brush can clean

the surface of the rotating transfer drum. The Drum cleaning brush is kept out

of contact with the transfer drum when the print image on the transfer drum is

being created. iii) The drum cleaning roller is positively biased by the positive voltage FCBV(V). iv) FCBV(V) is fed to the cleaning brush in contact with the roller and the cleaning

brush is self-biased by the resistance of the brush. v) The drum cleaning roller rotates in contact with the drum cleaning brush.

(2) Process of Belt Cleaning (Refer to Fig.4-23.)

i) There is residual toner on the surface of the transfer drum after the paper

transfer process. ii) The Drum cleaning brush is positively self-biased and so the negatively

charged residual toner is removed from the surface of the transfer drum onto

the drum cleaning brush. iii) The Drum cleaning roller has been biased to the positive voltage FCBV(V). As

the cleaning brush rotates, the residual toner absorbed into the brush from the

transfer drum is attracted by the positive FCBV(V) voltage on the roller and

adheres to the surface of the drum cleaning roller. iv) Waste toner adhering to the surface of the drum cleaning roller is scavenged by

the cleaning blade and collected into the waste toner pack by the waste toner

feeder.

FCBV: Cleaning Roller

Power Supply for Fuser Cleaner Bias

Cleaning Brush

Residual

Toner

FCBV

Fuser Cleaner

West Toner Feeder

Drum Cleaning Unit

Transfer Drum

Fig.4-23

IV-20

1.2 Scanning System

This printer employs a semiconductor laser diode as a light source. This laser diode is switched according to the transmitted image data (video signal).

The generated laser light scans over the OPC belt through a polygon mirror and lens, by which method electrostatic latent images will be formed on the OPC belt.

(1) Structure of the Scanning System (Refer to Fig.4-24.)

The scanner unit is located as shown in Fig.4-8. The scanner unit consists of the following parts;

Laser Unit: Light emitting source incorporating a laser diode.



Cylinder Lens: Condenser for the laser beam.



Polygon Mirror: Hexahedral mirror for scanning the laser beam.















F-

Lens:

Scanner Motor: Motor to rotate the polygon mirror. Mirror: Reflecting mirror for the laser beam path. LDC: Laser diode control circuit. PD: Beam detector. BTD Mirror: Beam timing detector mirror to guide the laser beam

Focus lens for the laser beam.

to the PD sensor.

Fig.4-24

IV-21

(2) Specification:

Specification of the Scanner Unit is as follows;

Item Specifications Rated Output of Laser Diode 5mW. Wave Length of Laser Beam Approx.785nm. Scanning Density 600dpi Scanning Width 220mm Scanner Motor speed 23,936rpm Number of Polygon Mirror Faces 6

IV-22

1.3 Paper Transportation System

(1) Outline

This printer employs automatic paper feeding from the media cassette.

When toner images are formed on the transfer drum through the operations of the print system and transfer system, paper is fed by the pick-up roller and transported to the register roller. The transported paper is further transported to the transfer, fuser and exit parts by the register roller synchronizing with the rotation of the transfer drum.

(2) Structure of Paper Transportation System (Refer to Fig.4-25.)

The paper transportation system consists of the following parts;

Media Cassette: Case to accommodate paper to be fed



Paper Pick-up Roller: Roller to feed sheets of paper one by one,





Transfer System: Print processing part consisting of transfer



automatically.

preventing multi-feed.

the transfer drum.

drum and transfer roller to transfer the toner image onto the paper.

Paper Discharger Unit: Corona generator to generate AC corona for



separating paper from the transfer drum.

Fusing Unit: Mechanical part to fuse the toner image with



heat rollers and fix it on the paper.

Paper Exit Unit: Mechanical part to exit the fused paper from



the printer.

Paper Exit Roller: Roller to feed paper from the printer.



IV-23

5 4

Media Cassette



Paper Pick-up Roller





Transfer Part



Fig.4-25

Paper Discharger Unit



Fusing Unit



Paper Exit Unit



Paper Exit Roller



IV-24

1.4 Fusing Unit

The fusing unit employs a thermal fusing system using heater lamps in the rollers. Paper carrying the combined toner image passes between the heat rollers. Heat and pressure is applied to the paper when passing between the heat rollers so that the toner image is melted and fused onto the paper.

(1) Structure

The fusing unit consists of the following component parts; (Refer to Fig.4-26.)















Back-up Roller: is a pressure roller and incorporates a heater

lamp.

Fuser Roller: incorporates a heater lamp. Fusing Heaters: halogen lamps to heat the rollers. Thermal Fuse: prevent the fuser roller from being

excessively heated up.

Thermistor: is a sensor to detect the temperature of the

fuser roller’s surface.

Oil Bottle: contains silicone oil for fusing. Fuser Cleaner: cleans the fuser roller.

Fig.4-26

IV-25

(2) Fusing Process (Refer to Fig.4-27.)

Silicone oil supplied from the oil bottle is applied to the surface of



fuser roller. The toner image has been transferred onto the paper, but not yet



fused. Transported paper passes between the heater roller and back-up



roller. Each roller is heated up to approx.140°C, and receives



approximately 156N pressure from the opposite heat roller. When the paper carrying the toner images passes between the



two heat rollers, the toner images are melted and fused on the transported paper.

The paper carrying the fused image is separated from the heat



rollers, and ejected from the printer.

(a). Before Fusing

(b). After Fusing

M Y

Fig.4-27

Toner Ima

Fixed toner

Paper

IV-26

2. STRUCTURE OF THE CONTROL SYSTEM

2.1 Basic Structure

2.1.1 Electrical System and Functions

Most of the main electrical parts of this printer are controlled by the MCTL (engine controller) PCB.

The basic structure of the sequence control is shown in Fig.4-28.

Print Process Control: To control the print process from the paper feed



through to the paper exit.

Laser Output Control: To automatically control the laser output.



Fuser Temperature Control: To control the fixer heater so that the



temperature of the fuser roller and back-up roller will be correct.

Toner Sensing Control: To control the sensing of the toner empty



status.

Interface Control:



(Video Signal) Control Panel Indicator: To display the printer operational status on the



Error Control: To control the safety stop procedures when



To process the input and output signals to and from the external controller (host).

control panel indicator.

errors occur in the printer.

IV-27

Motor

Scanner

LDU

Laser Control

Main

Motor

Fan

Cooling

Panel

Control

ATC (4 pcs.)

YMCK

Drum

Sensor

Belt

Sensor

CPU

Sequence Control

Temperature Control

Toner Empty Sensing Control

Control Panel Control

MCTL (Engine Controller)

Error Processing Program

Paper Empty Sensor

Toner Empty Sensor

Paper Feeding Sensor

Paper Size Sensor

High Voltage Unit

Interlock Switches

DC Power

Supply Unit

Paper Exit Sensor

Drum Jam Sensor

OHP Sensor

Fig.4-28

Host Computer

I/F

Controller

Control

Video

Controller

IV-28

Oil Sensor

Cleaning Roller

Sensor

Fusing Unit

(1) Print PCB (Refer to Fig. 4-29.)

No. Name Function

To receive the print data from the host computer,

1 Video Controller PCB

convert it into image data and then send the printing image data to the MCTL PCB.

To control the sequence of processes of the

Engine Controller

(MCTL) PCB

printer: Fusing Temperature Control, Laser Output Control, Control Panel Indications, Toner Empty Sensing Control, Error Processing Control, Interface Control.

3 Control Panel PCB

4 LDU PCB

5 PDU PCB

To display the printer’s operation status and support the control panel switches.

To control the drive and output to the laser diode in the scanner unit.

To sense the emission of the laser diode and the beam position in the scanner unit.

6 Erase Lamp To discharge the OPC belt with the LEDs.

To send the signals from the sensors to the MCTL

7 IOD1 PCB

PCB, and to drive the outputs from the MTCL PCB to the motors, clutches and solenoids.

8 IOD2 PCB - Ditto -

DC Power Supply

(LVPS) PCB

High-voltage Power

Supply (HVU) PCB

To provide the printer with the power for printer control.

To provide the printer with the high voltage power supplies necessary for the printing process.

IV-29

3. Control Panel PCB

10. High-voltage Power Supply (HVU) PCB

6. Erase Lamp

8. IOD2 PCB

7. IOD1 PCB

1. Video Controller PCB

9. Power Supply (LVPS) PCB

2. Engine Controller (MCTL) PCB

4. LDU

5. PDU

Fig.4-29

IV-30

(2) Motors (Refer to Fig.4-30.)

No. Name Code Function

1 Main Motor MM

2 Developing Motor DM

To drive the OPC belt and the paper transport system.

To drive the toner cartridge and the developing system.

3 Scanner Motor SCM To scan the laser beam

4 Ozone Fan Motor OZFAN

To exhaust the ozone from the printer (charger unit).

5 Heater Fan Motor HTFAN To exhaust the heat of the fusing unit.

6 Controller Fan Motor CTLFAN

To exhaust the heat of the power supply unit and Interface Controller.

4. Ozone Fan

5. Heater Fan

1. Main Motor

Top cover SW.

6. Controller Fan

Rear access cover SW.

2. Developing Motor

Front cover SW

3. Scanner Motor

Fig.4-30

IV-31

(3) Clutches and Solenoids (Refer to Fig.4-31.)

No. Name Code Function

To feed paper by coupling the feeding

1 Paper Feed Clutch PCLU

roller to the main gear unit at the correct timing for paper feeding.

To transport paper by coupling the

2 Registration Clutch RECL

3 Fuser Clutch FUCL

4 Cleaner Clutch FBCL

5 ∼ 8

Developer Clutch

Developer Solenoid Unit

DVCL

(Y,M,C,K)

DVSOL

10 Transfer Solenoid TRSOL

To drive the fusing rollers by coupling the fusing unit to the main gear unit.

To drive the brush of the drum cleaner by coupling the cleaner clutch to the main gear unit at the correct timing for drum cleaning.

To drive the magnetic roller of the desired color toner cartridge by coupling that toner cartridge to the developer gear unit during developin

To position the desired color toner cartridge in the developing position during developing.

To make the transfer roller contact the transfer drum surface at the time of the second transfer.

Drum Cleaner Solenoid

FBSOL

IV-32

To make the drum cleaner contact the transfer drum surface at the correct timing for drum cleaning.

Layout of Clutches and Solenoids

11. Drum Cleaner Solenoid

3. Fuser Clutch

4. Cleaner Clutch

10. Transfer Solenoid

2. Registration Clutch

1. Paper Feed Clutch

8. Developer Clutch (K)

7. Developer Clutch (Y)

9. Developer Solenoid Unit

6. Developer Clutch (M)

5. Developer Clutch (C)

Fig.4-31

IV-33

(4) Sensors

No. Name Code Function

1 Paper Size Sensor PSU Photo sensor to detect the paper size.

2 Paper Feeding Sensor PT1

3 Paper Exit Sensor PT2

4 Paper Empty Sensor PE

5 Oil Sensor OIL

6 OHP Sensor OHP

7 Drum Jam Sensor DPJ

8 Drum Encoder Sensor EN

9 Belt Sensor PBS

Photo sensor to detect when paper is fed from the media cassette.

Photo sensor to detect that paper is exited from the paper exit unit.

Photo sensor to detect if paper is loaded in the media cassette.

Photo sensor to detect if the fusing unit oil is empty.

Photo sensor to detect if media in the media cassette is an OHP.

Photo sensor to detect if paper is wound around the transfer drum.

Photo sensor to detect rotation of the transfer drum.

Photo sensor to detect the home position of the OPC belt.

10 Toner Empty Sensor TPD/TTR

11 Waste Toner Sensor WTS

Developing Photo Sensor

DHP1,

DHP2

13 Cleaning Roller Sensor CRS

Temperature Sensor

for Fusing Unit

Photo sensor to detect if the toner is empty for each toner cartridge.

Photo sensor to detect if the waste toner bottle is full of toner.

Photo sensor to detect the position of the toner cartridge.

Photo sensor to detect if the fuser cleaner is fitted in the fixing unit.

Thermistor to detect the fuser temperature.

IV-34

14. Temperature Sensor (Thermistor to detect)

3. Paper Exit Sensor

13. Cleaning Roller Sensor

5. Oil Sensor

9. Belt Sensor

8. Drum Encoder Sensor

6. OHP Sensor

2. Paper Feeding Sensor

4. Paper Empty Sensor

1. Paper Size Sensor

7. Drum Jam Sensor

10. Toner Empty Sensor

12. Developing Photo Sensor

11. Waste Toner Sensor

Fig.4-32

IV-35

2.2 Control System

2.2.1 Control of the Print Process

A Micro CPU mounted on the MCTL PCB controls the print processes.

Host Computer

I/F Controller

Video Controller

Cleaning Roller Sensor

Oil Sensor

Fusing Unit

I/F Control

Control Panel

DC Power Supply Unit

Cooling Fan

MCTL (Engine Controller)

Sequence Control Temperature Control

Toner Empty Sensing Control Control Panel Control Error Processing Program

Interlock Switches

Belt

Sensor

High Voltage Unit

Drum Sensor

ATC (4 pcs.)

YMCK

CPU

Paper Empty Sensor

Paper Feeding Sensor

Toner Empty Sensor Paper Size Sensor Paper Exit Sensor

OHP Sensor Drum Paper Jam Sensor

Scanner Motor

LDU

Laser Control

Main Motor

Fig.4-33

IV-36

(1) Control Block Diagram (Refer to Fig.4-33.)

No. Name Function

1 Sequence Control

2 Temperature Control

3 Toner Empty Sensing Control

4 Control Panel Control

5 Error Processing Control

To control the sequence of printer operations.

To control the temperature of the fixing unit.

To detect the toner empty status of each toner cartridge.

To control the control panel indications and the operational signals.

To sense errors occurring in the printer and control the stop procedures.

To control the receipt and transmission of

6 Interface Control

the interface signals from the external controller.

7 Laser Control To control laser scanning and laser power.

IV-37

(2) Laser Drive Control Circuit

Laser Drive Control Circuit (LDC) consists of the video signal input circuit, laser drive circuit, laser diode, output sensing circuit and output control circuit, as shown in Fig.4-34.

(1) When the video signal is received, the laser drive control circuit switches the

laser diode according to the video signal data.

(2) The radiated laser beam is sensed by the photo detector (PD) and the signal is

fed back to the output control circuit.

(3) The output control circuit controls the laser output to make the level constant by

comparing the laser output with the feed-back value transmitted from the output sensing circuit.

(4) The scanning laser beam is sensed by the beam detector (PD), then the beam

detecting timing (BDT) signal is output.

IV-38

OPC Belt

Scaner Motor

Laser

MCTL PCB

Frequency Control

Circuit

BDT

Synchronizie

Control Circuit

Beam Scanning

Control Circuit

LDC PCB

Fig.4-34

PRINT Signal

VIDEO Signal

IV-39

(3) Control of the Fusing Temperature

Each roller of the fusing unit is controlled to maintain the appropriate temperature so that toner will be fixed correctly onto the print paper.

FLS: Thyristor to switch the power supply to the heat lamp. TFU1/TFU2:Temperature fuse to shut down the circuit for safety when the

temperature becomes too hot within the fixing unit.

TH: Temperature sensor to detect the surface temperature of the

heat roller (HR).

RY: Relay to prevent further heating when it becomes hotter than

the set temperature within the fixing unit.

GA/CPU: Process circuit to control the temperature signal (micro

computer). CM1: Sensor circuit for temperature signal (for ACOFF signal). CM2: Sensor circuit for temperature signal (for HON signal). CM3: Sensor circuit for temperature signal (for processing). Q: Sensor circuit for shut-down by the thermistor (for THERR

signal). HR: Heat lamp for the heat roller. BR: Heat lamp for the back-up roller.

< Signal Functions >

HON-N To turn on/off the heater inside the fuser roller. ACOFF To turn off the relay RY1 if overheat occurs. THERR To detect the shut-down by the thermistor. AD To convert the temperature sensing signal to AD.

Temperature

( )

TPS

150 TS

Time

IV-40

RY-1

FLS

Fusing Unit

TFU

ACOFF-P

CM3

HON-N

CM2

CM1

HON

GA/CPU

THERR ACOFF

Fig.4-35

IV-41

TS:

To maintain the temperature for fixing of the toner at 140°C by

turning the thyristor on and off. TA:

Reference temperature ( °C) to identify that it is excessively

hot inside the fusing unit. When it reaches this point ( °C), the

relay RY turns off, the power supply to the heat lamp is shut

down and the printer stops operating. TPS: Limit temperature when the thermal fuse will start to melt and

shut down the power supply to the heat lamp if the temperature

control circuit should break down. When the thermal fuse

melts, the printer will stop operating.

H0: When the THERR signal is input, the control panel indicates

“H0”, and the printer will stop operating. H2: If the temperature of the fixing unit does not reach the required

point “T1” after a certain time, the control panel indicates “H2”

and the printer will stop operating. H3: If the “Heater On” signal still continues after a certain time, the

control panel indicates “H3”, and the printer will stop operating. H4: If the temperature within the fusing unit becomes unusually hot

and when ACOFF signal is input, the control panel indicates

“H4”, and the printer will stop operating.

IV-42

(

4) Interface Control <General> (a)Interface Type The video interface handles laser image data that corresponds to dots for printing

but does not store image data in a buffer. The video data signals of the input image data switches the semiconductor laser diode to form a print image.

(b)Interface Connection

Operator

Panel

Host

System

Main PCB

(Video Controller)

Engine

Controller

DC Power Supply

Fig.4-36

The interface connector of this laser printer is connected to the host system as shown in Fig.4-36.

IV-43

+5V

GND

0.01 F

220

330

GND

Table 4-1: Interface Circuit

No. Interface Circuit Signal Name

VIDEO-N

150

M5M34050

•

VIDEO-P

•

HSYNC-N

•

HSYNC-P

•

PRREQ-N

•

COMMAND-N

•

ID1-N

•

ID2-N

•

+5V

3.3K

SN7406

VSYNC-N

•

IREADY-N

•

STATUS-N

•

KEY-STATUS-N

•

IV-44

(d)Connector Pin Assignment The connector in the printer to connect to the controller board is type 128A-064S2B-:13A(DDK) or the equivalent.

Table 4-2: Connector Pin Assignment

Pin No. Signal Name Pin No. Signal Name

1A PSGND 1B +5V 2A PSGND 2B +5V 3A PSGND 3B +5V 4A PSGND 4B +5V

5 PSGND 5B +5V 6A PSGND 6B +5V 7A PSGND 7B +5V 8A PSGND 8B +5V 9A VIDEO-P 9B VIDEO-N

10A RET(GND) 10B Reserve 11A HSYNC-P 11B HSYNC-N 12A ID2-N 12B Reserve 13A RET(GND) 13B VSYNC-N 14A RET(GND) 14B Reserve 15A RET(GND) 15B STATUS 16A RET(GND) 16B IREADY-N 17A RET(GND) 17B Reserve 18A RET(GND) 18B COMMAND 19A RET(GND) 19B PRREQ-N 20A RET(GND) 20B Reserve 21A ID1-N 21B Reserve 22A RET(GND) 22B KEY_STATUS-N 23A Reserve 23B Reserve 24A Reserve 24B Reserve 25A RET(GND) 25B Reserve 26A RET(GND) 26B Reserve 27A RET(GND) 27B Reserve 28A RET(GND) 28B Reserve 29A RET(GND) 29B Reserve 30A RET(GND) 30B Reserve 31A RET(GND) 31B Reserve 32A RET(GND) 32B Reserve

IV-45

2.3 Main PCB (Video Controller PCB)

2.3.1 Outline

The Main PCB consists of the circuits which perform the following functions;

• Receive the printing data from the computer.

• Convert the received data to the bitmap data such as characters or graphics.

• Control the engine and send the generated bitmap data as a video signal.

The control panel is controlled by communicating with the engine CPU to display LCD messages, light the LEDs and display the button status, etc.

The power for the Main PCB is supplied from the engine through the engine interface connector.

Main PCB

+3.3V

PCMCIA x2

RS-232C I/F

CDCC I/F

MIO

BOARD

LS245

MIO RELAY

(CONNECTOR)

ADM202

Regurator+5V

LS245

PCB

CPU

MB86832

(SPARC lite)

ASIC

MB87F1610

EEPROM

X24C04

4kbit

Address

Data

F245

SN75C1168

MASK ROM

32M mask x2(8MB)

EDO DRAM

16M x8(16MB)

MA,RAS,CAS

LS07

Flash ROM

8M x2(2MB) x2Banks

SIMM(72pin) 3Slots (EDO or Fast Page)

96MB max.

Video HSync

Command, PrReq

VSync, Status,

IReady, KeyStatus

+5V

GND

ENGINE I/F

Fig.4-37

IV-46

2.3.2 Circuit

(1) CPU block

(2) ASIC block

Model name: MB86832-100 (SPARC lite), RISC CPU manufactured by

•

Fujitsu

Clock speed: 33.1776MHz (external) / 99.5328MHz (internal)

•

Cache memory: 8KB (Command cache) / 8KB (Data cache)

•

Appearance: 176-pin QFP

•

Model name: MF87F1610 manufactured by Fujitsu

•

Appearance: 240-pin QFP

•

Functions:

•

Controls CPU

∗

Controls memory

∗

Controls interrupts

∗

Timer

∗

External interfaces (Centronics, RS-232C, PCMCIA, MIO)

∗

Engine interface (Engine control, Video signal control)

∗

Supports Software

∗

(3) ROM block

The ROM stores the CPU control program and font data. ROMs used are an 8Mbytes masked ROM, and a 2 Mbytes flash ROM which can be rewritten on the board.

Access time: less than 120nsec.

•

Appearance: 42-pin DIP

•

Model name: MBM29F800T-120 manufactured Fujitsu

•

Access time: less than 120nsec.

•

Appearance: 48-pin TSOP

•

(4) DRAM block

DRAMs are used for the receiving buffer and the working area of the CPU. The DRAM block contains eight 16Mbit EDO RAM, thus having 16MB memory capacity in total.

Model name: M5M41705CJ-6 manufactured Mitsubishi (or equivalent).

•

Type: 16Mbit EDO DRAM (4x4, 164,304bit)

•

Access time: less than 80nsec.

•

Appearance: 26-pin SOJ

•

IV-47

(5) SIMM block

SIMM (Single-Inline-Memory-Module) allows memory extension by up to 96MB.

3 SIMM sockets are available.

The following type of SIMM can be installed into each slot.

Appearance: 72-pin

•

Memory type: Fast page or EDO (automatic selection)

•

Access time: less than 80nsec.

•

Parity: either Parity or Non-parity can be used

•

Memory capacity: 1MB, 2MB, 4MB, 8MB, 16MB, 32MB

•

1MB: HITACHI HB56D25632B-6A, -7A, -8A

∗

2MB: HITACHI HB56D51232B-6A, -7A, -8A

∗

4MB: HITACHI HB56A132BV-7A, -7AL, -7B, -7BL, -8AL, -8B, -8BL

∗

8MB: HITACHI HB56A232BT-7A, -7AL, -7B, -7BL

∗

16MB: TOSHIBA THM324000BSG-60, -70, -80

∗

32MB: TOSHIBA THM328020BSG-60, -70, -80

∗

MITSUBISHI MH25632BJ-7, -8

MITSUBISHI MH51232BJ-7, 8

MITSUBISHI MH1M32ADJ-7, -8

Any combination of SIMM size can be installed into any slot in any order.

Note: Fast page type and EDO type can be used together although it is not recommended.

(6) External interface block

Centronics Interface

•

RS-232C Interface

•

PCMCIA Interface

•

MIO Interface

•

(7) Engine interface block

The engine interface consists of the following signals;

<IREADY> The signal indicating the engine is ready <PRREQ> Signal requesting printing from the controller <KEY_STATUS> Signal indicating that a key switch status on the control panel has changed. <VSYNC> Vertical synchronization signal for printing

IV-48

<HSYNC> Horizontal synchronization signal for printing <VIDEO> Video data signal <COMMAND> Command signal sent from the controller to the engine <STATUS> Status signal sent from the engine to the controller

Fig.4-38 shows the timing of each signal after the power switch is turned on.

Power On

IREADY-N

PRREQ-N

VSYNC-N

VIDEO-P

VSYNC-N

HSYNC-N

VIDEO-P

210s MAX.

1.0sec. MAX.

0.1sec. MIN. 15sec. MAX.

15us MIN. 10ms MAX.

(K) data

417.781us

1st line 2nd line Last line1dot

(M) data

56.296ns

3.75s

3.0sec. MAX. for Continuous Printing

(Y) data

Fig.4-38

The COMMAND signal and STATUS signal are the signals that are used to transfer the data between the controller and the engine, which perform as a half-duplex asynchronous serial communication. Refer to Fig.4-39.

COMMAND

STATUS

Start bit

LSB

Parity bit

MSB

Fig.4-39

IV-49

Stop bit

8ms (TYP)

Start bit

30ms (MAX)

LSB

MSB

Parity bit

Stop bit

Note:

• Based on “Asynchronous Communication” method.

• Command/Status communication must keep the “Handshake Rule”.

• Baud rate is 9600 bps.

• Frame format: - one (1) start bit,

- eight (8) data bits (Start bit side is LSB, Parity bit is MSB),

- one (1) odd parity bit,

- one (1) stop bit.

• The video controller has to send an “Initialize Command” to the engine controller after power on in order to establish communication.

The power for the Main PCB is supplied through the engine interface connector.

IV-50

B48K299CIR (1/7)

IV - 51

CODE UK391301

NAME

Appendix 1. Main PCB Circuit Diagram, (1/7)

Brother HL-2400C Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual