HP Color Laserjet CP5220 service manual
HP COLOR LASERJET CP5220
SERIES PRINTER
Service Manual
HP Color LaserJet CP5220 Series Printer
Service Manual
Copyright and License
© 2009 Copyright Hewlett-Packard
Development Company, L.P.
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warranty. HP shall not be liable for technical
or editorial errors or omissions contained
herein.
Part number: CE710-90910
Edition 1, 9/2009
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trademark of Corel Corporation or Corel
Corporation Limited.
Microsoft®, Windows®, Windows® XP, and
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®
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Table of contents
1 Theory of operation
Basic operation ..................................................................................................................................... 2
Major product systems ......................................................................................................... 2
Product block diagram ......................................................................................................... 2
Sequence of operation ......................................................................................................... 3
Normal sequence of operation ............................................................................ 3
Formatter-control system ..................................................................................................................... 5
Sleep mode .......................................................................................................................... 5
Input/output .......................................................................................................................... 5
CPU ..................................................................................................................................... 6
Memory ................................................................................................................................ 6
Firmware ............................................................................................................. 6
Nonvolatile memory ............................................................................................ 6
PJL overview ....................................................................................................................... 6
PML ..................................................................................................................................... 6
Control panel ....................................................................................................................... 6
Engine-control system .......................................................................................................................... 7
DC controller ........................................................................................................................ 8
Motors ............................................................................................................... 11
Fans .................................................................................................................. 13
Fuser-control circuit ........................................................................................... 14
Fuser temperature control ................................................................ 15
Fuser protective function .................................................................. 16
Fuser failure detection ...................................................................... 17
Low-voltage power supply ................................................................................. 18
Overcurrent/overvoltage protection .................................................. 20
High-voltage power supply ................................................................................ 21
Laser scanner system ........................................................................................................ 23
Laser failure detection ....................................................................................... 24
Image-formation system ..................................................................................................................... 25
Electrophotographic process ............................................................................................. 25
Image formation process ................................................................................................... 27
Latent-image formation block ............................................................................ 28
Pre-exposure .................................................................................... 28
ENWW iii
Primary charging .............................................................................. 28
Laser beam exposure ....................................................................... 29
Developing block ............................................................................................... 30
Transfer block ................................................................................................... 31
Primary transfer ................................................................................ 31
Secondary transfer ........................................................................... 31
Separation ........................................................................................ 32
Fusing block ...................................................................................................... 32
ITB cleaning block ............................................................................................. 33
Drum cleaning block .......................................................................................... 33
Print cartridges ................................................................................................................... 34
Memory tag ....................................................................................................... 35
Cartridge presence detection ............................................................................ 35
Toner level detection ......................................................................................... 35
Cartridge life detection ...................................................................................... 35
Developing unit engagement and disengagement control ................................ 35
ITB unit .............................................................................................................................. 37
Primary transfer roller engagement and disengagement control ...................... 38
ITB unit presence detection .............................................................................. 39
ITB cleaning mechanism ................................................................................... 39
Calibration .......................................................................................................................... 40
Color-misregistration control ............................................................................. 40
Environment change control ............................................................................. 41
Image stabilization control ................................................................................. 41
Image density control (DMAX) .......................................................... 42
Image halftone control (DHALF) ....................................................... 42
Pickup, feed, and delivery system ...................................................................................................... 43
Photo sensors .................................................................................................................... 44
Motors and solenoids ......................................................................................................... 45
Pickup and feed block ........................................................................................................ 45
Cassette pickup ................................................................................................. 45
Cassette multiple-feed prevention ..................................................................... 46
Tray 1 (MP tray) paper pickup ........................................................................................... 47
Tray 1 (MP tray) last-paper detection ................................................................................ 48
Paper feed ......................................................................................................................... 49
Skew-feed prevention ....................................................................................... 50
Feed-speed control ........................................................................................... 51
Fusing and delivery block .................................................................................................. 52
Loop control ...................................................................................................... 52
Pressure roller pressurization and depressurization control ............................. 53
Output bin full detection .................................................................................... 55
Duplex block (duplex models only) .................................................................................... 56
Jam detection .................................................................................................................... 57
Paper feeder ....................................................................................................................................... 59
iv ENWW
Paper-feeder motors .......................................................................................................... 60
Paper-feeder paper pickup and feed ................................................................................. 61
Paper-feeder cassette lift operation ................................................................................... 61
Paper-feeder jam detection ............................................................................................... 62
2 Removal and replacement
Introduction ......................................................................................................................................... 64
Removal and replacement strategy ................................................................................................... 65
Electrostatic discharge ....................................................................................................................... 66
Required tools ................................................................................................................................... 67
Service approach ............................................................................................................................... 68
Before performing service .................................................................................................. 68
After performing service ..................................................................................................... 68
Post-service test ................................................................................................................ 68
Removal and replacement procedures .............................................................................................. 69
Customer self repair (CSR) components ........................................................................... 69
External panels, covers, and doors ................................................................................... 89
Print-quality test ................................................................................................ 68
Print cartridges .................................................................................................. 69
Toner-collection unit .......................................................................................... 72
Memory DIMM ................................................................................................... 74
Product memory ............................................................................... 74
Install memory and font DIMMs ........................................................ 74
Enable memory ................................................................................ 78
Check DIMM installation ................................................................... 78
Fuser ................................................................................................................ 79
Pickup roller (Tray 1) ......................................................................................... 80
Separation pad (Tray 1) .................................................................................... 81
Separation roller assembly (Tray 2) .................................................................. 82
Pickup roller (Tray 2) ......................................................................................... 84
Pickup roller, separation roller, and feed roller (Tray 3) .................................... 85
Secondary transfer roller ................................................................................... 86
Intermediate transfer belt (ITB) ......................................................................... 87
Identification and location .................................................................................. 89
Right-front cover and control-panel assembly ................................................... 90
Left cover .......................................................................................................... 92
Rear cover ......................................................................................................... 93
Remove the rear cover ..................................................................... 93
Toner collection unit access door ...................................................................... 93
Right-rear cover ................................................................................................ 95
Top cover .......................................................................................................... 96
Remove the top cover ...................................................................... 96
Front-door assembly ......................................................................................... 98
ENWW v
Right-door assembly ....................................................................................... 102
Internal assemblies .......................................................................................................... 104
Laser scanner assembly ................................................................................. 105
Remove the laser scanner assembly ............................................. 105
Cassette pickup drive assembly ...................................................................... 108
Remove the cassette pickup drive assembly ................................. 108
Registration sensor assembly ......................................................................... 112
Remove the registration sensor assembly ..................................... 112
Lifter-drive assembly ....................................................................................... 115
Remove the lifter-drive assembly ................................................... 115
ITB front guide assembly ................................................................................ 117
ITB rear guide assembly ................................................................................. 119
Residual toner full sensor ............................................................................... 120
Remove the residual toner full sensor ............................................ 121
Formatter case ................................................................................................ 123
Delivery assembly ........................................................................................... 124
Remove the delivery assembly ....................................................... 124
Duplex drive assembly (duplex models) ......................................................... 127
Remove the duplex-drive assembly ............................................... 127
Delivery drive assembly (simplex models) ...................................................... 129
Remove the delivery drive assembly .............................................. 129
Residual-toner-feed assembly ........................................................................ 130
Remove the residual-toner-feed assembly ..................................... 130
ITB motor ........................................................................................................ 132
Remove the ITB motor ................................................................... 132
Drum motor ..................................................................................................... 134
Remove the drum motor ................................................................. 134
Developing motor ............................................................................................ 135
Remove the developing motor ........................................................ 135
Fuser motor ..................................................................................................... 136
Remove the fuser motor ................................................................. 136
Developing-disengagement motor .................................................................. 137
Remove the developing-disengagement motor .............................. 137
Power-supply fan ............................................................................................ 139
Remove the power-supply fan ........................................................ 139
Fuser fan ......................................................................................................... 142
Remove the fuser fan ..................................................................... 142
Formatter PCA ................................................................................................ 144
Formatter resets ............................................................................. 144
DC controller PCA ........................................................................................... 146
Remove the DC controller PCA ...................................................... 146
Low-voltage power supply ............................................................................... 148
Remove the low-voltage power supply ........................................... 148
Imaging (developing) high-voltage power supply ............................................ 152
vi ENWW
Remove the imaging (developing) high-voltage power supply ....... 152
First transfer high-voltage power supply ......................................................... 153
Remove the first transfer high-voltage power supply .................... 153
Second transfer high-voltage power supply .................................................... 155
Remove the second transfer high-voltage power supply ................ 155
Driver PCA ...................................................................................................... 157
Remove the driver PCA .................................................................. 157
Power switch PCA ........................................................................................... 159
Remove the power switch PCA ...................................................... 159
Environmental sensor ..................................................................................... 160
Remove the environmental sensor ................................................. 160
Optional paper feeder assembly (Tray 3) ........................................................................ 161
Tray 3 rear cover ............................................................................................. 161
Tray 3 left cover .............................................................................................. 161
Tray 3 right-front cover .................................................................................... 163
Tray 3 front-upper cover .................................................................................. 164
Tray 3 right door .............................................................................................. 164
Tray 3 right-lower cover .................................................................................. 166
Tray 3 pickup assembly .................................................................................. 167
Tray 3 lifter drive assembly ............................................................................. 168
Tray 3 pickup motor ........................................................................................ 169
Tray 3 driver PCA ............................................................................................ 170
3 Solve problems
Solve problems checklist .................................................................................................................. 172
Menu map ........................................................................................................................................ 173
Troubleshooting process .................................................................................................................. 174
Tools for troubleshooting .................................................................................................................. 177
Pretroubleshooting checklist ........................................................................................... 174
Power-on checks ............................................................................................................. 176
Diagrams ......................................................................................................................... 177
Block diagrams ................................................................................................ 177
Plug/jack locations .......................................................................................... 179
Location of connectors .................................................................................... 180
DC controller connections .............................................................. 180
Product connections ....................................................................... 182
Locations of major components ...................................................................... 189
General timing charts ...................................................................................... 196
General circuit diagram ................................................................................... 197
HP ToolboxFX ................................................................................................................. 200
Open HP ToolboxFX ....................................................................................... 200
Status .............................................................................................................. 201
Event log ......................................................................................... 201
ENWW vii
Alerts ............................................................................................................... 202
Set up Status Alerts ........................................................................ 202
Set up E-mail Alerts ........................................................................ 202
Product information ......................................................................................... 202
Set password .................................................................................................. 202
Help ................................................................................................................. 203
System Settings .............................................................................................. 204
Device Information .......................................................................... 204
Paper Setup .................................................................................... 205
Print Quality .................................................................................... 206
Print Density ................................................................................... 206
Paper Types ................................................................................... 206
Extended Print Modes .................................................................... 206
System Setup ................................................................................. 206
Save/Restore Settings .................................................................... 206
Product Security ............................................................................. 207
Print Settings ................................................................................................... 207
Printing ........................................................................................... 207
PCL5 ............................................................................................... 207
PostScript ....................................................................................... 207
Network Settings ............................................................................................. 207
Shop for Supplies ............................................................................................ 207
Other Links ...................................................................................................... 207
Internal print quality test pages ........................................................................................ 208
Use HP ToolboxFX to troubleshoot print-quality problems ............................ 208
Configuration page .......................................................................................... 209
Print quality troubleshooting tools .................................................................................... 209
Repetitive image-defect ruler .......................................................................... 209
Calibrate the product ....................................................................................... 210
Control-panel menus ....................................................................................................... 211
Use the menus ................................................................................................ 211
Reports menu .................................................................................................. 211
System Setup menu ........................................................................................ 213
Service menu .................................................................................................. 216
Network Configuration menu ........................................................................... 217
Interpret control-panel and status-alert messages .......................................................... 218
Event-log messages ........................................................................................................ 229
Print an event log ............................................................................................ 229
Event-log messages ........................................................................................ 229
Clear jams ........................................................................................................................................ 230
Common causes of jams ................................................................................................. 230
Jam locations ................................................................................................................... 231
Change Jam Recovery setting ......................................................................................... 231
Clear jams in the right door .............................................................................................. 232
viii ENWW
Clear jams in the output bin area ..................................................................................... 235
Clear jams in Tray 1 ......................................................................................................... 235
Clear jams in Tray 2 ......................................................................................................... 237
Clear jams in the optional 500-sheet paper and heavy media tray (Tray 3) .................... 238
Clear jams in the lower right door (Tray 3) ...................................................................... 239
Solve image-quality problems .......................................................................................................... 240
Image defects table ......................................................................................................... 240
Clean the product ............................................................................................................................. 246
Solve performance problems ........................................................................................................... 247
Solve connectivity problems ............................................................................................................. 248
Solve direct-connect problems ........................................................................................ 248
Solve network problems .................................................................................................. 248
Service mode functions .................................................................................................................... 249
Secondary service menu ................................................................................................. 249
Open the secondary service menu ................................................................. 249
Secondary service menu structure .................................................................. 249
Product resets .................................................................................................................. 250
Restore the factory-set defaults ...................................................................... 250
Engine test page ............................................................................................. 250
Cold reset ........................................................................................................ 250
NVRAM initialization ........................................................................................ 251
Super NVRAM initialization ............................................................................. 251
Product updates ............................................................................................................................... 252
4 Parts and diagrams
Order parts by authorized service providers .................................................................................... 254
Order parts, accessories, and supplies ........................................................................... 254
Related documentation and software .............................................................................. 254
Supplies part numbers ..................................................................................................... 255
Customer self repair parts ............................................................................................... 255
Accessories part numbers ............................................................................................... 257
How to use the parts lists and diagrams .......................................................................................... 258
Assembly locations ........................................................................................................................... 259
External covers, panels, and doors .................................................................................................. 260
Right door assembly ......................................................................................................................... 262
Internal components (1 of 6) ............................................................................................................ 264
Internal components (2 of 6) ............................................................................................................ 266
Internal components (3 of 6) ............................................................................................................ 268
Internal components (4 of 6) ............................................................................................................ 270
Internal components (5 of 6) ............................................................................................................ 272
Internal components (6 of 6) ............................................................................................................ 274
Cassette ........................................................................................................................................... 276
Paper pickup assembly .................................................................................................................... 278
ENWW ix
Paper delivery assembly .................................................................................................................. 280
Printed circuit assemblies ................................................................................................................. 282
Paper feeder external components .................................................................................................. 284
Paper feeder internal components ................................................................................................... 286
Paper feeder PCA ............................................................................................................................ 288
Alphabetical parts list ....................................................................................................................... 290
Numerical parts list ........................................................................................................................... 297
Appendix A Service and support
Hewlett-Packard limited warranty statement .................................................................................... 306
HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ................ 307
HP Color LaserJet Fuser Kit Limited Warranty Statement ............................................................... 308
End User License Agreement .......................................................................................................... 309
Customer self-repair warranty service .............................................................................................. 311
Customer support ............................................................................................................................. 312
Appendix B Product specifications
Physical specifications ..................................................................................................................... 314
Performance specifications .............................................................................................................. 314
Electrical specifications .................................................................................................................... 314
Acoustic specifications ..................................................................................................................... 314
Environmental specifications ............................................................................................................ 315
Skew specifications .......................................................................................................................... 316
Appendix C Regulatory information
FCC regulations ............................................................................................................................... 318
Declaration of conformity .................................................................................................................. 319
Safety statements ............................................................................................................................. 320
Laser safety ..................................................................................................................... 320
Canadian DOC regulations .............................................................................................. 320
VCCI statement (Japan) .................................................................................................. 320
Power cord statement (Japan) ......................................................................................... 320
EMC statement (Korea) ................................................................................................... 320
Laser statement for Finland ............................................................................................. 320
Substances Table (China) ............................................................................................... 321
Index ................................................................................................................................................................. 323
x ENWW
1 Theory of operation
Basic operation
●
Formatter-control system
●
Engine-control system
●
Image-formation system
●
Pickup, feed, and delivery system
●
Paper feeder
●
ENWW 1
Basic operation
Major product systems
The product contains the following five systems:
Engine-control system
●
Laser scanner system
●
Image-formation system
●
Media feed system
●
Optional paper feeder system
●
Product block diagram
Figure 1-1 Product block diagram
LASER SCANNER SYSTEM
ENGINE CONTROL SYSTEM
IMAGE-FORMATION SYSTEM
MEDIA FEED SYSTEM
OPTION
2 Chapter 1 Theory of operation ENWW
Sequence of operation
The DC controller in the engine-control system controls the operational sequences of the product. The
following table describes durations and operations for each period of a print operation from when the
product is turned on until the motor stops rotating.
Normal sequence of operation
Table 1-1 Sequence of operation
Name Timing Purpose
WAIT From the time the power switch is turned on, the door
STBY (standby) From the end of the WAIT or LSTR period until either
INTR (initial
rotation)
is closed, or the product exits Sleep mode until the
product is ready for a print operation.
a print command is sent or the power switch is turned
off.
From the time the print command is received until the
product picks up a piece of paper.
Brings the product to printable condition:
Detects and heats the fuser
●
Detects the print cartridge and any cartridge
●
changes
Detects the ITB, and moves the ITB and the
●
developing unit to the home position
Cleans residual toner from the ITB and the
●
secondary transfer roller
Maintains the product in printable condition:
Enters Sleep mode if the sleep command is
●
received
Performs a calibration if the calibration
●
command is received
Prepares for the print job
Activates the high-voltage power supply
●
Activates the laser scanner
●
Opens the laser shutter
●
Cleans the protective laser glass
●
Engages the print cartridges
●
Warms the fuser
●
ENWW Basic operation 3
Table 1-1 Sequence of operation (continued)
Name Timing Purpose
PRINT From the end of the INTR period until the last sheet
completes the fusing operation.
LSTR (last
rotation)
From the end of the PRINT period until the main motor
stops rotating.
Prints
Forms the image on the photosensitive drum
●
Transfers the toner image to the paper
●
Fuses the toner image to the paper
●
Moves the last printed sheet to the output bin.
Stops the high-voltage power supply
●
Stops the laser scanner
●
Closes the laser shutter
●
Cleans the protective laser glass
●
Disengages the print cartridges
●
Stops the fuser
●
The product enters the INTR period as the LSTR
period is completed, if the formatter sends another
print command.
4 Chapter 1 Theory of operation ENWW
Formatter-control system
The formatter is responsible for the following procedures:
Controlling sleep mode
●
Receiving and processing print data from the various product interfaces
●
Monitoring control-panel functions and relaying product-status information (through the control
●
panel and the network or bidirectional interface)
Developing and coordinating data placement and timing with the DC controller PCA
●
Storing font information
●
Communicating with the host computer through the network or the bidirectional interface
●
The formatter receives a print job from the network or bidirectional interface and separates it into image
information and instructions that control the printing process. The DC controller PCA synchronizes the
image-formation system with the paper-input and -output systems, and then signals the formatter to
send the print-image data.
The formatter also provides the electrical interface and mounting locations for an additional DIMM.
Sleep mode
NOTE: In the System Setup menu, this item is termed Sleep Delay.
This feature conserves power after the product has been idle for an adjustable period of time. When the
product is in Sleep Delay, the control-panel backlight is turned off, but the product retains all settings,
downloaded fonts, and macros. The default setting is for Sleep Delay to be enabled, and the product
enters Sleep Delay after a 30-minute idle time.
The product exits Sleep Delay and enters the warm-up cycle when any of the following events occur:
A print job, valid data, or a PML or PJL command is received
●
A control-panel button is pressed
●
A cover is opened
●
A paper tray is opened
●
The engine-test switch is pressed
●
NOTE: Product error messages override the Sleep message. The product enters Sleep Delay at the
appropriate time, but the error message continues to appear.
Input/output
The product has two I/O interfaces:
A USB 2.0 port for connecting directly to a computer
●
An internal 10/100Base-T network port.
●
ENWW Formatter-control system 5
CPU
The formatter incorporates a 540 MHz Coldfire processor.
Memory
The random access memory (RAM) on the formatter PCA contains the page, I/O buffers, and the font
storage area. It stores printing and font information received from the host system, and can also serve
to temporarily store a full page of print-image data before the data is sent to the print engine. Memory
capacity can be increased by adding a DIMM to the formatter. Note that adding memory might also
increase the print speed for complex graphics.
NOTE: If the product encounters a problem when managing available memory, a clearable warning
message appears on the control-panel display.
Firmware
The firmware is contained on NAND flash memory soldered on the formatter board. A remote firmware
upgrade process is available, which overwrites the firmware in the NAND flash.
Nonvolatile memory
The product uses nonvolatile memory (NVRAM) to store device and user configuration settings. The
contents of NVRAM are retained when the product is turned off or disconnected.
PJL overview
The printer job language (PJL) is an integral part of configuration, in addition to the standard printer
command language (PCL). With standard cabling, the product can use PJL to perform a variety of
functions such as these:
Two-way communication with the host computer through a network connection or a USB
●
connection. The product can inform the host about such things as the control-panel settings, and
the control-panel settings can be changed from the host.
Dynamic I/O switching. The product uses this switching to be configured with a host on each I/O.
●
The product can receive data from more than one I/O simultaneously, until the I/O buffer is full.
This can occur even when the product is offline.
Context-sensitive switching. The product can automatically recognize the personality (PS or PCL)
●
of each job and configure itself to serve that personality.
Isolation of print environment settings from one print job to the next. For example, if a print job is
●
sent to the product in landscape mode, the subsequent print jobs print in landscape mode only if
they are formatted for landscape printing.
PML
The printer management language (PML) allows remote configuration and status read-back through the
I/O ports.
Control panel
The formatter sends and receives product status and command data to and from the control-panel PCA.
6 Chapter 1 Theory of operation ENWW
Engine-control system
The engine-control system coordinates all product functions, according to commands that the formatter
sends. The engine-control system drives the laser/scanner system, the image formation system, and
the pickup/feed/delivery system.
The engine control system contains the following major components:
DC controller
●
Low-voltage power supply
●
High-voltage power supply
●
Figure 1-2 Engine-control system
Formatter
ENGINE CONTROL SYSTEM
LASER SCANNER SYSTEM
DC controller
IMAGE-FORMATION SYSTEM
Low-voltage power supply
MEDIA FEED SYSTEM
High-voltage power supply
OPTION
ENWW Engine-control system 7
DC controller
The DC controller controls the operational sequence of the product.
Figure 1-3 DC controller diagram
Cartridge
(x4)
ITB unit
Secondary
transfer roller
AC input
Fan
DEV high-voltage
power supply
TR1 high-voltage
power supply
TR2 high-voltage
power supply
Fuser
Low-voltage
power supply
Motor
Fan
Solenoid
Switch
Photointerrupter
DC controller
LED
Sensor
Option
Switch
Formatter
Control
panel
Laser scanner unit
The DC controller controls the product's electrical components, listed in the following table.
8 Chapter 1 Theory of operation ENWW
Table 1-2 Electrical components
Component type Abbreviation Name
Switch SW1 Power switch
SW2 24V interlock switch
SW3 5V interlock switch 1
SW4 5V interlock switch 2
SW5 Primary transfer disengagement switch
SW6 Toner collection unit switch
SW7 Cassette media end guide position switch
SW8 Cassette media width guide position switch
Solenoid SL1 Cassette pickup solenoid
SL2 Tray 1 pickup solenoid
SL3 Duplex reverse solenoid 1 (duplex models only)
SL5 Primary transfer disengagement solenoid
SL7 Duplex reverse solenoid 2 (duplex models only)
Fan FM1 Power supply fan
FM2 Fuser fan
Photointerrupter (sensor) PS1 Cassette paper-presence sensor
PS2 Tray 1 paper-presence sensor
PS3 Last-paper sensor
PS4 Cassette paper-stack surface sensor
PS5 Top-of-page (TOP) sensor
PS6 Fuser delivery sensor
PS7 Loop sensor 1
PS8 Loop sensor 2
PS9 Fuser pressure-release sensor
PS10 Output bin full sensor
PS11 Developing disengagement sensor
PS12 Black drum home-position sensor
PS13 YMC drum home-position sensor
PS14 Front door sensor
PS15 Right door sensor
ENWW Engine-control system 9
Table 1-2 Electrical components (continued)
Component type Abbreviation Name
Motor M1 ITB Motor
M2 Drum motor
M3 Developing motor
M4 Fuser motor
M5 Pickup motor
M6 Developing disengagement motor
M9 Cassette lifter motor
M10 Scanner motor
10 Chapter 1 Theory of operation ENWW
Motors
The product has eight motors for paper feed and image formation. The DC controller determines a motor
failure if a motor does not reach a specified speed within a specified period after motor startup or if the
rotational speed is outside a specified range for a specified period.`
Figure 1-4 Motors
Drum motor (M2)
Developing motor (M3)
Fuser motor (M4)
ITB motor (M1)
Scanner motor (M10)
Developing disengagement motor (M6)
Pickup motor (M5)
Cassette lifter motor (M9)
ENWW Engine-control system 11
Table 1-3 Motors
Description Components driven Failure
ITB motor (M1) ITB
Black photosensitive drum
Developing roller
Drum motor (M2) Yellow, magenta, and cyan photosensitive drums Yes
Developing motor (M3) Yellow, magenta, and cyan developing rollers Yes
Fuser motor (M4) Fuser pressure and delivery rollers
Pressurizes and depressurizes the pressure roller
Engages and disengages the primary transfer roller
Pickup motor (M5) Tray 1 pickup roller
Cassette pickup roller
Feed roller
Duplex feed roller (duplex models only)
Developing
disengagement motor
(M6)
Engages and disengages the developing unit No
detection
Yes
Yes
No
Cassette lifter motor
(M9)
Scanner motor (M10) Scanner mirror No
Lifter for the cassette No
12 Chapter 1 Theory of operation ENWW
Fans
The product uses to fans to maintain the correct internal temperature. The DC controller determines a
fan failure when a fan locks for a specified period after it starts driving.
Figure 1-5 Fans
Power supply fan
(FM1)
Fuser fan
(FM2)
Table 1-4 Fans
Description Area cooled Type Speed
Power supply fan
(FM1)
Fuser (FM2) Duplex feed unit
Low-voltage power supply
Output bin
Delivery unit
Laser scanner unit
ITB area
Intake Full/Half
Intake Full
ENWW Engine-control system 13
Fuser-control circuit
The fuser-control circuit monitors and controls the temperature in the fuser. The product uses ondemand fusing. The fuser-control circuit consists of the following major components:
Fuser main heater (H1): heats the center of the fuser sleeve
●
Fuser sub heater (H2): heats the ends of the fuser sleeve
●
Thermistors; detects the fuser temperature (contact type)
●
Sleeve thermistor (TH1): Detects the temperature at the center of the fuser sleeve
◦
Main thermistor (TH2): Detects the temperature at the center of the fuser heater
◦
Sub thermistor 1 (TH3): Detects the temperature at the end of the fuser heater nearest the
◦
front of the product
Sub thermistor 2 (TH4): Detects the temperature at the end of the fuser heater nearest the
◦
rear of the product
Thermal fuse (FU1): prevents abnormal temperature rise in the fuser heater (non-contact type)
●
Figure 1-6 Fuser-control circuit
TH3
Pressure roller
Front of engine
H2
TH4
Fuser sleeve
H1
TH2
FU1
TH1
FUSER TEMPERATURE signal
FUSER HEATER
CONTROL signal
Low-voltage power supply
Fuser heater
control circuit
DC controller
Fuser heater
safety circuit
14 Chapter 1 Theory of operation ENWW
Fuser temperature control
The fuser temperature control maintains the fuser heater at its targeted temperature.
The fuser main heater and sub heater control the temperature of the fuser sleeve.
The DC controller monitors the main thermistor and the sleeve thermistor. The DC controller controls
the FUSER MAIN HEATER CONTROL (FSRD1) and the FUSER SUB-HEATER CONTROL (FSRD2)
signals according to the detected temperature. The fuser-heater control circuit controls the fuser heater
depending on the signal so that the heater remains at the targeted temperature.
Figure 1-7 Fuser-heater control circuit
AC input
Low-voltage power supply
Noise filter
Fuser heater
control circuit
Zerocross
circuit
Improper fuser installation prevention circuit
H2
TH3 TH4
RL102
FU102
RL103
Fuser
Fuser presence circuit
Fuser sleeve
H1
TH2
TH1
FU1
RLD1
RLD2
FSRD1
FSRD2
ZEROX
FUSEROPEN
FUHL
THERM4
THERM2
THERM1
THERM3
DC controller
Fuser heater
safety circuit
ENWW Engine-control system 15
Fuser protective function
The protective function detects an abnormal temperature rise of the fuser unit and interrupts power
supply to the fuser heater.
The following three protective components prevent an abnormal temperature rise of the fuser heater:
DC controller
●
The DC controller interrupts power supply to the fuser heater when it detects an abnormal
◦
temperature of the fuser heater.
Fuser-heater safety circuit
●
The fuser heater safety circuit interrupts power supply to the fuser heater when the detected
◦
temperature of the main and sub thermistors is abnormal.
Thermal fuse
●
The thermal fuse is broken to interrupt power supply to the fuser heater when the thermoswitch
◦
detects an abnormal temperature of the fuser heater.
16 Chapter 1 Theory of operation ENWW
Fuser failure detection
The DC controller determines a fuser unit failure, deactivates the FUSER HEATER CONTROL signal,
releases the relay to interrupt power supply to the fuser heater and notifies the formatter of a failure
state when it encounters the following conditions:
Abnormal temperature rise: The sleeve thermistor does not rise at a specified temperature within
●
a specified period after the fuser heater control starts.
Abnormally low temperature: The thermistors are at a specified temperature or lower during a print
●
operation or other fuser heating cycle.
Abnormally high temperature: The thermistors are at a specified temperature or higher, regardless
●
of the fuser control status.
Drive circuit abnormality: The frequency in the zerocross circuit is out of a specified range when
●
the product is turned on or is in the standby period.
ENWW Engine-control system 17
Low-voltage power supply
The low-voltage power supply (LVPS) converts AC input voltage to DC voltage.
Figure 1-8 Low-voltage power supply
Low-voltage power supply
Power switch
SW1
Formatter
FU101
FU102
RL102
RL103
Noise filter
Fuser heater
control circuit
Fuser
Noise filter
Rectifying circuit
RL101
RLD1
RLD2
REMOTEON
Zerocross
circuit
ZEROX
+3.3V generation
circuit
Protection
circuit
+24V generation
circuit
+24V
Remote switch
control circuit
+5V generation
circuit
+5V
+3.3V
PWRON
+3.3V
SWON/OFF
DC controller
SW2
+24R
+24V
Interlock switch
SW4
SW3
+5V
Interlock switch
+5R
The product uses three DC voltages: 24V, 5V, and 3.3V. The voltages are subdivided as follows:
+24V Supplied constantly
Stopped during Sleep mode
+24R Interrupted when the front or right door is opened
18 Chapter 1 Theory of operation ENWW
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