Canon iRC2570, iR5570, iRC3170, iRC3100, iR6570 puncher unit-n1 Service Manual
Service Manual
Finisher, Sorter, DeliveryTray
Puncher Unit-N1
Feb 21 2005
Application
This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and
repair of products. This manual covers all localities where the products are sold. For this reason, there may be
information in this manual that does not apply to your locality.
Corrections
This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products.
When changes occur in applicable products or in the contents of this manual, Canon will release technical information
as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will
issue a new edition of this manual.
The following paragraph does not apply to any countries where such provisions are inconsistent with local law.
Trademarks
The product names and company names used in this manual are the registered trademarks of the individual companies.
Copyright
This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied,
reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc.
COPYRIGHT © 2001 CANON INC.
Printed in Japan
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.
Symbols Used
This documentation uses the following symbols to indicate special information:
Symbol Description
Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.
Indicates an item requiring care to avoid electric shocks.
Indicates an item requiring care to avoid combustion (fire).
Indicates an item prohibiting disassembly to avoid electric shocks or problems.
Introduction
Memo
REF.
Indicates an item requiring disconnection of the power plug from the electric outlet.
Indicates an item intended to provide notes assisting the understanding of the topic in question.
Indicates an item of reference assisting the understanding of the topic in question.
Provides a description of a service mode.
Provides a description of the nature of an error indication.
Introduction
The following rules apply throughout this Service Manual:
1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical
and mechanical systems with reference to the timing of operation.
In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol ,
the arrow indicates the direction of the electric signal.
The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the
delivery unit door, which results in supplying the machine with power.
2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to
indicate "Low".(The voltage value, however, differs from circuit to circuit.) In addition, the asterisk (*) as in
"DRMD*" indicates that the DRMD signal goes on when '0'.
In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the
operations of the microprocessors used in the machines are not discussed: they are explained in terms of from
sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads.
The descriptions in this Service Manual are subject to change without notice for product improvement or other
purposes, and major changes will be communicated in the form of Service Information bulletins.
All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant
Service Information bulletins and be able to identify and isolate faults in the machine."
Contents
Contents
Chapter 1 Specifications
1.1 Product Specifications....................................................................................................................................... 1- 1
1.1.1Specifications .............................................................................................................................................. 1- 1
1.2 Names of Parts................................................................................................................................................... 1- 3
1.2.1External View.............................................................................................................................................. 1- 3
1.2.2Cross Section............................................................................................................................................... 1- 4
Chapter 2 Functions
2.1 Basic Construction ............................................................................................................................................ 2- 1
2.1.1Functional Construction .............................................................................................................................. 2- 1
2.2 Feed Drive System ............................................................................................................................................ 2- 2
2.2.1Overview ..................................................................................................................................................... 2- 2
2.2.2Constraction of the Control System ............................................................................................................ 2- 2
2.2.3Punch Operation .......................................................................................................................................... 2- 4
2.2.4Horizontal Registration Operation .............................................................................................................. 2- 7
2.3 Detecting Jams ................................................................................................................................................ 2- 10
2.3.1Detecting Jams .......................................................................................................................................... 2- 10
2.4 Power Supply .................................................................................................................................................. 2- 11
2.4.1Power Supply Route ................................................................................................................................. 2- 11
2.4.2Protection Function ................................................................................................................................... 2- 11
Chapter 3 Parts Replacement Procedure
3.1 External Covers ................................................................................................................................................. 3- 1
3.1.1 Rear Cover .................................................................................................................................................. 3- 1
3.1.1.1 Removing the Rear Cover ................................................................................................................... 3- 1
3.1.2 Upper Cover................................................................................................................................................ 3- 1
3.1.2.1 Removing the Rear Cover ................................................................................................................... 3- 1
3.1.2.2 Removing the Upper Cover................................................................................................................. 3- 1
3.1.3 Right Guide Unit......................................................................................................................................... 3- 1
3.1.3.1 Removing the Right Guide Unit.......................................................................................................... 3- 1
3.2 Drive System ..................................................................................................................................................... 3- 2
3.2.1 Punch Motor................................................................................................................................................ 3- 2
3.2.1.1 Removing the Rear Cover ................................................................................................................... 3- 2
3.2.1.2 Removing the Upper Cover................................................................................................................. 3- 2
3.2.1.3 Removing the Punch Motor................................................................................................................. 3- 2
3.2.2 Horizontal Registration Motor.................................................................................................................... 3- 2
3.2.2.1 Removing the Rear Cover ................................................................................................................... 3- 2
3.2.2.2 Removing the Right Guide Unit.......................................................................................................... 3- 3
3.2.2.3 Removing the Horizontal Registration Motor..................................................................................... 3- 3
3.2.3 Punch Unit .................................................................................................................................................. 3- 3
3.2.3.1 Notification when dismounting the Punch Unit .................................................................................. 3- 3
Contents
3.2.3.2 Removing the Rear Cover....................................................................................................................3- 3
3.2.3.3 Removing the Right Guide Unit ..........................................................................................................3- 4
3.2.3.4 Removing the Upper Cover .................................................................................................................3- 4
3.2.3.5 Removing the Punch Unit....................................................................................................................3- 4
3.3 Electrical System ...............................................................................................................................................3- 7
3.3.1 Punch Unit Harness.....................................................................................................................................3- 7
3.3.1.1 Notification when dismounting the Punch Unit Harness ....................................................................3- 7
3.3.1.2 Removing the Rear Cover....................................................................................................................3- 7
3.3.1.3 Removing the Right Guide Unit ..........................................................................................................3- 7
3.3.1.4 Removing the Upper Cover .................................................................................................................3- 7
3.3.1.5 Removing the Punch Unit Harness......................................................................................................3- 7
3.3.1.6 Installing the Punch Unit Harness .......................................................................................................3- 9
3.3.2 LED PCB.....................................................................................................................................................3- 9
3.3.2.1 Removing the Rear Cover....................................................................................................................3- 9
3.3.2.2 Removing the Right Guide Unit ........................................................................................................3- 10
3.3.2.3 Removing the Upper Cover ...............................................................................................................3- 10
3.3.2.4 Removing the Punch Unit..................................................................................................................3- 10
3.3.2.5 Removing the LED PCB....................................................................................................................3- 12
3.3.3 Photosensor PCB.......................................................................................................................................3- 12
3.3.3.1 Removing the Rear Cover..................................................................................................................3- 12
3.3.3.2 Removing the Upper Cover ...............................................................................................................3- 13
3.3.3.3 Removing the Photosensor PCB........................................................................................................3- 13
3.3.4 Scrap Full Detector PCB ...........................................................................................................................3- 13
3.3.4.1 Removing the Right Guide Unit ........................................................................................................3- 13
3.3.4.2 Removing the Scrap Full Detector PCB ............................................................................................3- 13
3.3.5 Punch Controller PCB...............................................................................................................................3- 14
3.3.5.1 Removing the Rear Cover..................................................................................................................3- 14
3.3.5.2 Removing the Punch Controller PCB................................................................................................3- 14
Chapter 4 Maintenance
4.1 User Maintenance ..............................................................................................................................................4- 1
4.1.1User Maintenance ........................................................................................................................................4- 1
4.2 Maintenance and Inspection ..............................................................................................................................4- 2
4.2.1 Periodically Replaced Parts.........................................................................................................................4- 2
4.2.1.1 Periodically Replaced Parts .................................................................................................................4- 2
4.2.2 Durables ......................................................................................................................................................4- 2
4.2.2.1 Durables ...............................................................................................................................................4- 2
4.2.3 Periodical Servicing ....................................................................................................................................4- 2
4.2.3.1 Periodical Servicing ............................................................................................................................4- 2
4.3 Adjustment.........................................................................................................................................................4- 3
4.3.1 Adjustment at Time of Parts Replacement..................................................................................................4- 3
4.3.1.1 Adjusting the Punch Hole Position (feed direction) ............................................................................4- 3
4.3.1.2 Sensor Output Adjustment...................................................................................................................4- 3
4.3.1.3 Registering the Number of Punch Holes .............................................................................................4- 3
4.4 Troubleshooting.................................................................................................................................................4- 5
4.4.1 Error Code ...................................................................................................................................................4- 5
4.4.1.1 E503; Puncher unit communication error............................................................................................4- 5
4.4.1.2 E505; Backup RAM error....................................................................................................................4- 5
Contents
4.4.1.3 E590; Punch motor error ..................................................................................................................... 4- 5
4.4.1.4 E591; Scrap full detector sensor error ................................................................................................. 4- 6
4.4.1.5 E592; Trailing edge/Horizontal registration sensor error.................................................................... 4- 6
4.4.1.6 E593; Horizontal registration motor error ........................................................................................... 4- 6
4.5 Outline of Electrical Components ..................................................................................................................... 4- 7
4.5.1Sensors......................................................................................................................................................... 4- 7
4.5.2Microswitches ............................................................................................................................................. 4- 8
4.5.3Motors ......................................................................................................................................................... 4- 9
4.5.4PCBs.......................................................................................................................................................... 4- 10
4.6 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB ........................................ 4- 12
4.6.1Overview ................................................................................................................................................... 4- 12
4.6.2Punch Controller PCB ............................................................................................................................... 4- 12
4.7 Upgrading........................................................................................................................................................ 4- 13
4.7.1Upgrading.................................................................................................................................................. 4- 13
4.8 Service Tools................................................................................................................................................... 4- 21
4.8.1Solvents and Oils....................................................................................................................................... 4- 21
Chapter 5 Error Code
5.1 Overview ........................................................................................................................................................... 5- 1
5.1.1Overview ..................................................................................................................................................... 5- 1
5.2 User Error Code................................................................................................................................................. 5- 2
5.2.1Punch scrap full ........................................................................................................................................... 5- 2
5.2.2Punch scrap overflow .................................................................................................................................. 5- 2
5.3 Service Error Code ............................................................................................................................................ 5- 3
5.3.1E503............................................................................................................................................................. 5- 3
5.3.2E505............................................................................................................................................................. 5- 3
5.3.3E590............................................................................................................................................................. 5- 3
5.3.4E591............................................................................................................................................................. 5- 4
5.3.5E592............................................................................................................................................................. 5- 5
5.3.6E593............................................................................................................................................................. 5- 8
Chapter 1 Specifications
Contents
Contents
1.1 Product Specifications........................................................................................................................................ 1-1
1.1.1 Specifications .............................................................................................................................................. 1-1
1.2 Names of Parts.................................................................................................................................................... 1-3
1.2.1 External View.............................................................................................................................................. 1-3
1.2.2 Cross Section............................................................................................................................................... 1-4
1.1 Product Specifications
Chapter 1
1.1.1 Specifications
Item Specifications Remarks
Punching
method
Paper size 2 holes (Puncher Unit-L1):
0003-4694
T-1-1
Reciprocating punching (Sequential punch-ing)
A3, A4, A4R, B4, B5, B5R
2 or 3 holes (Puncher Unit-M1):
2 holes/LGL, LTRR
3 holes/279mm x 432mm (11 x 17), LTR
4 holes (FRA)(Puncher Unit-N1):
A3, A4
4 holes (SWD)(Puncher Unit-P1):
A3, A4
Hole position
Paper weight
Punched hole
diameter
Punched scrap
capacity
Dimensions
Weight
Power
supply
64g/m2 to 250g/m2
2 holes : 6.5mm
2 or 3 holes : 8mm
4 holes : 6.5mm
2 holes: 10,000 sheets or more
2 or 3 holes: 3,000 sheets or more
4 holes: 5,000 sheets or more
107 x 615 x 378mm (W x D x H)
Approx. 7.2 kg
From finisher unit (24 VDC / 5 VDC)
Transparenie
s not allowed
80 g/m2 or
equivalent
1-1
[1] Puncher unit-L1 (2-Hole)
40±3 mm
80±1 mm / 3.15±0.04 in
[2] Puncher unit-M1 (2-/3-Hole)
35±3 mm
70±1 mm / 2.76±0.04 in
108±3 mm
108±1 mm /
4.25±0.04 in
108±1 mm /
4.25±0.04 in
[3] Puncher unit-N1 (4-Hole (FRA))
40±3 mm
80±1 mm /
80±1 mm /
3.15±0.04 in
80±1 mm /
3.15±0.04 in
3.15±0.04 in
12±3 mm /
0.47±0.12 in
12±3 mm /
0.47±0.12 in
12±3 mm /
0.47±0.12 in
12±3 mm /
0.47±0.12 in
[4] Puncher unit-P1 (4-Hole (SWD))
35±3 mm
21±1 mm /
70±1 mm /
2.76±0.04 in
21±1 mm /
0.83±0.04 in
0.83±0.04 in
F-1-1
12±3 mm /
0.47±0.12 in
1.2 Names of Parts
Chapter 1
1.2.1 External View
0003-4695
F-1-2
T-1-2
[1] Upper cover
[2] Upper cover 2
[3] Front door
[4] Right guide assembly
[5] Rear cover
1-3
Chapter 1
1.2.2 Cross Section
0003-4696
[1]
[2]
[3]
[4]
F-1-3
T-1-3
[1] Cam [3] Punch feed roller
[2] Hole puncher (Punch blade) [4] Punch waste case
1-4
Chapter 2 Functions
Contents
Contents
2.1 Basic Construction ............................................................................................................................................. 2-1
2.1.1 Functional Construction .............................................................................................................................. 2-1
2.2 Feed Drive System ............................................................................................................................................. 2-2
2.2.1 Overview ..................................................................................................................................................... 2-2
2.2.2 Constraction of the Control System ............................................................................................................ 2-2
2.2.3 Punch Operation .......................................................................................................................................... 2-4
2.2.4 Horizontal Registration Operation .............................................................................................................. 2-7
2.3 Detecting Jams ................................................................................................................................................. 2-10
2.3.1 Detecting Jams .......................................................................................................................................... 2-10
2.4 Power Supply ................................................................................................................................................... 2-11
2.4.1 Power Supply Route ................................................................................................................................. 2-11
2.4.2 Protection Function ................................................................................................................................... 2-11
2.1 Basic Construction
Chapter 2
2.1.1 Functional Construction
0003-8735
The puncher unit is optionally installed in the delivery path between the host machine and the finisher.
When the paper delivered from the host machine reaches the puncher unit, it is fed by the punch feed roller. Then
when the trailing edge of the paper is detected, the paper is tempo-rarily stopped and the punch axis rotates to punch
holes in the trailing edge of the paper. These operations are controlled by the finisher controller PCB and the punch
controller PCB drives each puncher component.
Punch
drive
Feed
system
drive
system
Horizontal
registration
drive
system
Finisher unit
control system
Punch
controller
PCB
F-2-1
2-1
Chapter 2
2.2 Feed Drive System
2.2.1 Overview
0003-9479
The puncher unit is located on the feed path between the host machine and the finisher, and successively punches
holes when the paper stops temporarily.
The paper delivered from the host machine is fed by the punch feed roller. The punch feed roller is driven by the
punch feed motor. When the trailing edge of the paper reaches the puncher unit, the inlet roller of the finisher unit
temporarily stops the paper and holes are punched on the trailing edge of the paper.
The following shows the names and functions of the motors and sensors used in punching operation:
T-2-1
Motor Function
Punch motor (M61) Drives the punch unit.
Horizontal registration motor (M62) Drives the punch slide unit.
Punch feed motor(M63) Drives the punch feed roller.
T-2-2
Sensor Function
Horizontal registration home
position sensor (PI61)
Punch motor clock sensor (PI62) Detects the punch motor clock.
Punch home position sensor (PI63) Detects the punch shaft home position.
Horizontal registration sensor
(LED1 to LED4,PTR1 to PTR4)
Trailing edge sensor (LED5,PTR5) Detects the trailing edge of paper.
Scrap full detector sensor
(LED6,PTR6)
2.2.2 Constraction of the Control System
Detects the punch slide unit home position.
Detects the position of the rear edge of paper.
Detects the state of the punch waste case (full).
0003-4698
The puncher unit consists of a die and hole puncher (punch blade).
The hole puncher is driven by the punch motor (M61). The hole puncher is attached to the
eccentric cam of the punch shaft, and rotary action of the punch shaft is converted to reciprocal motion to perform
punching.
Punch motor (M61) is a DC motor. The home position of the punch shaft is detected by punch home position sensor
2-2
(PI63). To stop the DC punch motor accurately at its home po-sition, the punch motor clock sensor (PI62) counts a
predetermined number of clock pulses to stop the punch motor. A single punch operation is performed by rotating
the punch shaft 180° from its home position.
Five light sensors (photosensor PCB) are located at the upper side of the inlet paper feed path of the puncher unit and
a set of five LEDs (LED PCB) are located at the lower side. These sensors and LEDs function as five sensors. The
frontmost sensor (LED5, PTR5) are the trailing edge sensor and are used for detecting the trailing edge of the paper.
The remaining sensors (LED1 to LED4, PTR1 to PTR4) are horizontal registration sensors, and are used for detecting
the inner position of the paper for determining the hole punching position.
The punch motor, puncher unit and above sensors comprise the punch slide unit. This unit moves backwards and
forwards according to the size of the paper. Backward and forward movement is driven by the horizontal registration
motor (M62). The home position of the punch slide unit is detected by the horizontal registration home position
sensor (PI61). The horizontal registration motor (M62) is a 2-phase stepping motor.
The punch motor and horizontal registration motor is driven by the punch controller PCB
according to control signals from the finisher controller PCB.
Punch scraps caused by punching are stored in the punched scrap container. Scrap full detection is performed by a
reflective sensor (LED6 and PTR6 on the scrap full detector PCB unit).
Chapter 2
Punch controller PCB (1/2)
PAEND
Trailing edge detection signal
Horizontal registration detection signal
(LED1 to 4, PTR1 to 4) SREG1 to 4
5
5
Punch motor clock (PI62)
Punch motor (M61) drive signal
detection signal PUNCHCLK
PTR1
2
3
4
LED1
2
3
4
PUNCHHP
Punch home position (PI63)
detection signal
SREGHP
(LED6,PTR6) DFULL
Scrap full detection signal
Horizontal registration home position (PI61) detection signal
Punch feed motor (M63) drive signal
Horizontal registration motor (M62) drive signal
Punch controller PCB (2/2)
F-2-2
2.2.3 Punch Operation
0003-4699
The hole puncher is driven by the punch motor (M61), and its position is monitored by the punch home position
sensor (PI63).
The hole puncher makes a single round-trip movement (punching) as the punch shaft rotates 180° from home
position.
In the case of a 2-or-3 hole type, the half sector of the punch shaft is used when punching 2 holes while the half sector
on the opposite side is used when punching 3 holes as instructed by the host machine.
<2-/4-hole Type>
2-4
Chapter 2
At the home position, the punch home position sensor is ON. Punching of the first sheet ends when the punch shaft
has rotated in the forward direction 180°, and the state of the punch home position sensor has changed from OFF to
ON. Punching of the second sheet ends when the punch shaft has rotated in the reverse direction 180° , and the state
of the punch home position sensor has changed from OFF to ON.
The following illustrates punching when two sheets are punched.
1) A hole is punched in the trailing edge of the first sheet.
Sensor flag
Punch home
position sensor
(PI63)
Punch shaft
Eccentric
cam
Die
Die
[punch shaft stopped/
home position]
Hole
puncher
Sheet
[punch shaft rotated 90˚
in the forward direction /
hole punched]
F-2-3
2) A hole is punched in the trailing edge of the second sheet.
[punch shaft stopped/
home position]
[punch shaft rotated 90˚
in the reverse direction/
hole punched]
Punched scrap
[punch shaft rotated 180˚
in the forward direction /
punch operation completed]
[punch shaft rotated 180˚
in the reverse direction/
punch operation completed]
F-2-4
<2-/3-hole Dual Use Type>
At the home position, the punch home position sensor is ON. To punch two holes, punching of the first sheet ends
when the punch shaft half peripheral area has rotated in the forward direction 180°, and the state of the punch home
position sensor has changed from OFF to ON. At this time, the 3-hole puncher is moved reciprocally in the escape
direction (hole puncher rise direction) on the remaining half peripheral area on the punch shaft. Punching of the
second sheet ends when the punch shaft half peripheral area has rotated in the reverse direction 180°, and the state
of the punch home position sensor has changed from OFF to ON. Also at this time, the 3-hole puncher is moved
2-5
Chapter 2
reciprocally in the escape direction (hole puncher rise direction) on the remaining half peripheral area on the punch
shaft. To punch three holes, the 2-hole puncher is moved reciprocally in the escape direction (hole puncher rise
direction).
The following illustrates punching when two sheets are punched with two holes.
1) A hole is punched in the trailing edge of the first sheet.
Punch home
position
sensor (PI63)
Eccentric
cam
Sensor flag
Punch shaft
Hole
puncher
Die
Die
[punch shaft stopped/
home position]
Sheet
[punch shaft is rotated 90˚
in the forward direction/
hole punched]
Punched scrap
[punch shaft is rotated 180˚
in the forward direction/
punch operation completed]
F-2-5
When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction (hole puncher rise
direction) as shown below.
[punch shaft stopped/
home position]
[punch shaft is rotated 90˚
in the forward direction/
hole puncher rises to
topmost position]
F-2-6
2) A hole is punched in the trailing edge of the second sheet.
2-6
[punch shaft is rotated 180˚
in the forward direction/
hole puncher returns to
original position]
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