Ricoh af500 Service Manual

A217 COPIER

Service Manual

– Insert Version –

The A217 machine is based on the A133 copier. Only the differences from the base copier are described in the following

pages. Therefore, this documentation should be treated as an insert version of the base copier's service manual. It should always be utilized together with the base copier's service manual.

TS Dept. IPP Business Division RICOH Co., LTD.

August 14th 199

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged.

2. The wall outlet should be near the copier and easily accessible.

3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.

4. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components.

5. If the Start key is pressed before the copier completes the warming-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and electrical components as the copier starts making copies as soon as the warming-up period is completed.

6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands.

HEALTH SAFETY CONDITIONS

1. Never operate the copier without the ozone filters installed.

2. Always replace the ozone filters with the specified ones at the specified intervals.

3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, use eye drops or flush with water as first aid. If unsuccessful, get medical attention.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models.

2. The NVRAM on the system control board has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn the battery. Used batteries must be handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTICE FOR DISPOSAL

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame.

2. Dispose of used toner, developer, and organic photoconductors according to local regulations. (These are non-toxic supplies.)

3. Dispose of replaced parts in accordance with local regulations

LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer Engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.

WARNING



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

WARNING FOR LASER UNIT



WARNING:

CAUTION MARKINGS:

Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes.

For the 115 V version

For the 230 V version

14 August 1997 SPECIFICATIONS

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS

NOTE:

Only items marked with ✽ are different from the A133 copier.

Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Copy Paper Size: Maximum

A3/11" x 17" (Paper tray and By-pass tray) A5/81/2” x 51/2” sideways Paper tray)

Minimum

A6/5

1/2

" x 8

1/2

" lengthwise (By-pass)

LCT

A4/11" x 8

1/2

" sideways only

Duplex Copying: Maximum A3/11" x 17"

Minimum A5/8

Copy Paper Weight: Paper tray:

60 ~ 105 g/m

By-pass:

60 ~ 157 g/m

LCT:

60 ~ 128 g/m

Duplex copying:

64 ~ 105 g/m

1/2

" x 5

, 16 ~ 24 lb

, 16 ~ 42 lb

, 16 ~ 34 lb

, 17 ~ 24 lb

" sideways

A217 Copier

✽

Reproduction Ratios:

5 Enlargement and 7 Reduction

A4/A3 Version LT/DLT Version

Enlargement 400%

200% 141% 122% 115%

Full size 100% 100%

Reduction 93%

87% 82% 71% 65% 50% 35%

400% 200% 155% 129% 121%

93% 85% 77% 74% 65% 50% 35%

SPECIFICATIONS 14 August 1997

✽

Zoom:

32% to 400% in 1% steps

Power Source: 120V/60Hz:

More than 12 A (for North America)

220V ~ 240V/50Hz:

More than 7 A (for Europe)

220V ~ 240V/60Hz:

More than 7 A (for Asia)

✽

Power Consumption:

115 V Machine

Maximum Less than 1.44 kW Less than 1.44 kW Copying Less than 1.30 kW Less than 1.35 kW Warm-up Less than 1.05 kW Less than 1.07 kW Stand-by Less than 0.22 kW Less than 0.24 kW

230 V Machine

Maximum Less than 1.50 kW Less than 1.50 kW Copying Less than 1.30 kW Less than 1.35 kW Warm-up Less than 1.10 kW Less than 1.12 kW Stand-by Less than 0.27 kW Less than 0.29 kW

Copier Only Full System

NOTE:

✽

Noise Emission:

NOTE:

Full System: Copier + ADF + Paper Tray Unit + Finisher

Copier Only Full System

1. Sound Power Level

Copying 67 dB(A) 69 dB(A) Stand-by 40 dB(A) 41 dB(A)

2. Sound Pressure Level at the Operator Position

Copying 53 dB(A) 59 dB(A) Stand-by 28 dB(A) 28 dB(A)

The above measurements are to be made in accordance with ISO 7779. Full System: Copier + ADF + Paper Tray Unit + Finisher.

Dimensions (W x D x H): 880 x 655 x 602 mm (34.7" x 25.8" x 23.8")

Measurement Conditions

1) With by-pass feed table closed

2) With copy tray attached

3) With LCT cover closed

4) Without the 500-sheet copy tray

✽

Weight:

97 kg (214 lb)

14 August 1997 SPECIFICATIONS

✽

Copying Speed (copies/minute):

1/2

" x 14"

Warm-Up Time ✽First Copy Time:

A4 sideways/

1/2

11" x 8

50 (US, France) 51 (EU, ASIA)

Less than 140 seconds (20 Less than 4.5 s (from LCT)

A3/11" x 17" B4/8

22 32

C, 68qF)

Copy Number Input: Ten-key pad, 1 to 999 (count up or count down) Manual Image Density

7 steps

Selection: Automatic Reset: 30 s is the standard setting; it can be changed with

a UP mode.

Copy Paper Capacity:

Paper Tray By-pass Feed LCT

About 500 sheets x1 About 40 sheets About 1000 sheets

Hard Disk: More than 1.0 GB, Fast SCSI-2

1/2

Duplex Tray Capacity A4/11" x 8

A3/11" x 17": 50 sheets (80 g/m 30 sheets (81 ~ 105 g/m

": 50 sheets

, 20 lb paper)

21.5 ~ 27.9 lb paper)

A217 Copier

Toner Replenishment: Cartridge exchange (700 g/cartridge) Toner Yield: 20K copies (A4, 6% full black, ID Level 4)

Optional Equipment:

Copy Tray Capacity B4/8

Platen cover

Document feeder

Paper tray unit with two paper trays

Paper tray unit with three paper trays

Finisher

Key counter

Tray heater

Optical anti-condensation heater

Drum heater

500-sheet receiving tray

1/2

" x 14" ~ A4/8

1/2

" x 11" 500 sheets A3/11" x 17" 200 sheets Less than B5/5

1/2

" x 8

1/2

": 200 sheets

MACHINE CONFIGURATION 14 August 1997

1.2 MACHINE CONFIGURATION

5 4

A217V500.vsd

NOTE:

Only items marked ✽ are new items.

Item Machine Code No.

Copier A217 3 ✽ADF (Option)

A663 1

Paper Feed Unit (Option) A549 5

A550 4

✽Finisher (Option)

A612 6

500-sheet Receiving Tray (Option) A615 7 Platen Cover (Option) A381 2

14 August 1997 ELECTRICAL COMPONENT DESCRIPTIONS

1.3 ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout and the point-to-point diagram on the waterproof paper in the pocket for the locations of these components.

✽

: New or modified components.

Symbol Index

No.

Printed Circuit Boards

PCB1 90 SCU Controls all copier functions both directly or PCB2 89 AC Drive Provides ac power to the exposure lamp and PCB3 92 DC Power Supply Provides dc power.

PCB4 93 BCU Controls the mechanical parts of the printer. PCB5 80 Charge High

PCB6 85 High Voltage PCB7 87 Operation Panel Controls the touch panel display and LED PCB8 95 Scanner Drive Drives the scanner motor.

PCB9 81 EX-IPU Processes the video signal from the SBU and PCB10 84 SBU Contains the CCD, and outputs a video PCB11 94 Lamp Stabilizer Provides dc power for the exposure lamp.

PCB12 86 Main Scan

PCB13 83 Main Scan

PCB14 31 Transfer High PCB15 33 Development PCB16 40 Duplex Control Controls the operation of the duplex tray.

PCB17 N/A Liquid Crystal PCB18 51 LCT Interface Interfaces the LCT control signal between the PCB19 91 Relay Board Switches ac power to either the dc drive

PCB20 7 Laser Diode Drive Controls the laser diode.

Description Note

through other control boards. fusing lamps.

Supplies high voltage to the charge corona

Voltage Supply Control

Synchronization Detector - 1

Synchronization Detector - 2

Voltage Bias Power Pack

Display

unit. Controls the high voltage boards and the

quenching lamp. matrix, and monitors the key matrix.

sends the video signal to the LD unit. signal to the EX-IPU board.

Detects the laser beam at the start of the main scan.

Detects the laser beam at the end of the main scan.

Supplies high voltage to the transfer belt. Supplies high voltage to the development

roller.

Controls the guidance display and displays guidance for machine operation.

main board and the LCT. board (if the main switch is on) or to the

heaters (if the main switch is off).

A217 Copier

Motors

M1 57 Main Drives the main body components.

ELECTRICAL COMPONENT DESCRIPTIONS 14 August 1997

Symbol Index

No.

M2 66 Toner Bottle Drive Rotates the toner bottle to supply toner to the M3 73 Tray Lift Raises the bottom plate in the paper tray.

M4 56 Polygonal Mirror Turns the polygonal mirror. M5 48 LCT Lift Lifts up and lowers the LCT bottom plate. M6 74 Optics Exhaust

M7 65 IPU Fan Removes heat from the IPU board. M8 78 Exhaust Fan Removes heat from around the fusing unit.

M9 60 Ozone Fan Removes ozone-laden air from inside the M10 55 Scanner Drive Drives the 1st and 2nd scanners (dc stepper M11 36 Duplex Feed Drives the feed roller and moves the bottom M12 39 End Fence M13 38 Side Fence M14 75 DC Drive Board M15 68 Charge Inlet Fan Provides air flow around the charge corona

✽ M16

59 Development

Description Note

toner supply unit.

Removes heat from the optics unit.

Fan

machine. motor). plate up and down.

Drives the end fence jogger to square the

Jogger Jogger Fan

Drive

paper stack. Drives the side fence jogger to square the

paper stack. Removes heat from around the DC drive

board. unit section.

Drives the development unit.

Sensors

S1 13 By-pass Feed

Paper Width

S2 15 By-pass Feed

Paper End

S3 18 Tray Paper End Informs the CPU when the paper tray runs S4 46 Upper Relay Detects the leading edge of paper from the

S5 16 Tray Upper Limit Detects the height of the paper stack in the S6 47 Lower Relay Detects misfeeds.

S7 49 LCT Lower Limit Sends a signal to the CPU to stop lowering S8 50 LCT Paper End Informs the CPU when the LCT runs out of S9 12 LCT Upper Limit Signals the CPU to stop lifting the LCT

Informs the CPU what width paper is in the by-pass feed table.

Informs the CPU that there is no paper in the by-pass tray.

out of paper. paper tray and duplex unit to determine the

stop timing of the paper feed clutch and duplex feed motor. Also detects misfeeds.

paper tray to stop the upper tray lift motor.

the LCT bottom plate. paper. bottom plate.

14 August 1997 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Index

No.

S10 19 Registration Detects the leading edge of the copy paper to

S11 29 Image Density S12 30 Toner Density S13 1 Scanner HP Informs the CPU when the 1st and 2nd S14 8 Original Length-1 Detects the length of the original. This is one S15 9 Original Length-2 Detects the length of the original. This is one S16 24 Fusing Exit Detects misfeeds.

S17 6 Platen Cover Informs the CPU whether the platen cover is

S18 32 Toner End Instructs the CPU to add toner to the toner S19 28 Auto Response Returns the operation panel display and exits S20 10 Transfer Belt S21 2 Original Width Detects the width of the original. This is one S22 34 Duplex Paper End Detects paper in the duplex tray.

S23 35 Duplex Turn Detects the trailing edge of the copy paper to

S24 42 Duplex Entrance Detects misfeeds. S25 37 Side Fence

S26 41 End Fence S27 23 Toner Overflow Detects when the used toner collection bottle S28 14 By-pass Relay Detects misfeeds.

Switches

SW1 11 By-pass Feed SW2 53 Tray Down Sends a signal to the CPU to lower the LCT SW3 20 Tray Paper Size Determines what size of paper is in the paper SW4 54 LCT Cuts the dc power line and detects whether SW5 52 LCT Cover Cuts the dc power line of the LCT lift motor.

Description Note

determine the stop timing of the paper feed clutch, and detects misfeeds.

Detects the density of various patterns on the

(ID) (TD)

Position

Jogger HP Jogger HP

Table

drum during process control. Detects the amount of toner inside the

development unit. scanners are at the home position. of the APS (Auto Paper Select) sensors. of the APS (Auto Paper Select) sensors.

up or down (related to APS/ARE functions). ARE: Auto Reduce and Enlarge

supply unit, and detects toner end conditions. from the energy saver mode.

Informs the CPU of the current position of the transfer belt unit.

of the APS (Auto Paper Select) sensors.

determine the jogging timing, and detects misfeeds.

Detects the home position of the duplex side fence jogger.

Detects the home position of the duplex end fence jogger.

is full.

Detects whether the by-pass feed table is open or closed.

bottom plate. tray. the LCT is open or not.

A217 Copier

ELECTRICAL COMPONENT DESCRIPTIONS 14 August 1997

Symbol Index

No.

SW6 27 Main Supplies power to the copier. SW7 26 Front Cover

Magnetic Clutches

CL1 61 Toner Supply Turns the toner supply roller to supply toner

✽ CL2

CL3 76 Transfer Belt Lift Controls the touch and release movement of CL4 58 Registration Drives the registration rollers.

CL5 63 By-pass Feed Starts paper feed from the by-pass feed table CL6 71 Relay Drives the relay rollers.

CL7 72 Paper Feed Starts paper feed from the paper tray. CL8 62 By-pass Relay Drives the by-pass relay rollers.

Solenoids

SOL1 67 By-pass Pick-up Drops the pick-up roller to the by-pass paper

SOL2 77 Junction Gate Moves the junction gate to direct copies to SOL3 64 LCT Pick-up Drops the pick-up roller all the way down to

SOL4 69 Pick-up Controls the up/down movement of the pickSOL5 70 Separation Controls the up/down movement of the

Description Note

Cuts the dc power line and detects whether

Safety

Not used

the front cover is open or not.

to the development unit.

the transfer belt unit.

or LCT.

feed position. When paper is fed from the LCT, this solenoid assists SOL3.

the duplex tray or to the paper exit. the LCT paper feed position from the by-pass

paper feed position. up roller in the paper tray. separation roller at the paper tray feed

station.

Lamps

L1 3 Exposure Applies high intensity light to the original for

exposure. L2 43 Fusing Provides heat to the hot roller. L3 88 Quenching Neutralizes any charge remaining on the

drum surface after cleaning.

Heaters

H1 21 Drum (option) Turns on when the main switch is off to

prevent moisture from forming around the

drum. H2 5 Optics Anti-

condensation (option)

Turns on when the main switch is off to

prevent moisture from forming on the optics.

14 August 1997 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Index

No.

H3 22 Tray

Thermistors

TH1 45 Fusing Monitors the temperature at the central area

Thermofuses

TF1 44 Fusing Provides back-up overheat protection in the

Thermoswitch

TS1 4 Exposure Lamp Opens the exposure lamp circuit if the 1st

Counters

CO1 25 Total Keeps track of the total number of copies CO2 N/A Key

Others

CB1 17 Circuit Breaker

HDD 82 Hard Disk Drive Scanned image data is compressed and held

Description Note

Turns on when the main switch is off to keep

(option)

(220 ~ 240V machines only)

paper dry in the paper tray.

of the hot roller.

fusing unit.

scanner overheats.

made.

Used for control of authorized use. The

copier will not operate until it is installed.

Provides back-up high current protection for

electrical components.

here temporarily during copying; also holds

user stamp data.

A217 Copier

DRIVE LAYOUT 14 August 1997

1.4 DRIVE LAYOUT

A217v501.cdr

1011

The development drive mechanism has been changed. (See Drive Mechanism for more information.)

✽

: New or modified components.

1. Toner Supply Clutch

2. Development Gear

3. Drum Drive Pulley

4. Main Motor

5. Scanner Drive Gear

6. Fusing Drive Gear

7. Exit Drive Gear

8. Toner Collection Bottle Drive Gear

9. Transfer Belt Drive Gear

10. Cleaning Blade Drive Gear

11. Registration Clutch

12. Paper Feed Clutch

13. Relay Clutch

14. By-pass Feed Clutch

15. By-pass Relay Relay Clutch

16. Development Drive Motor

14 August 1997 DRIVE LAYOUT

2. DIFFERENCES FROM THE A133 MACHINE

Unit Item Details Main

Reasons

A133 A217

Scanner Scanner speed 200 mm/s 250 mm/s Increased

CPM

Scanner lamp 75V 200W 75V 140W High

sensitivity CCD

Image Processing

Laser Exposure

Toner Supply

Paper Tray Side fence --- Secured with

Fusing Unit Material of the

Analog ProcessIC1 pc 2 pcs Faster image

processing

Laser power on the OPC surface

Polygon motor rotation speed

Operation --- When opening

Housing --- A pawl has been

housing Fusing lamp 790W 930W Increased

1.3 mW 1.66 mW Increased CPM

31,496 rpm 39,370 rpm Increased

CPM To facilitate

the toner supply unit over 60 degrees, the toner supply unit automatically opens out to 90 degrees.

screws added

Plastic Metal Increased

toner bottle replacement.

To prevent image skew

To remove jammed paper in the machine when the tray is drawn out.

fusing pressure

CPM

A217 Copier

EX-IPU 14 August 1997

3. IMAGE PROCESSING

3.1 EX-IPU

3.1.1 OVERVIEW

GA1

(GARD1S)

A217D505.vsd

SBU

Even

Odd

Analog

Process IC 1

Analog

Process IC 2

A/D

Analog signals for odd and even pixels from the SBU undergo analog processing and A/D conversion individually, then these signals go to GA1. This is to speed up the image processing.

14 August 1997 EX-IPU

3.1.2 ANALOG PROCESSING

rom SBU

EVEN

rom SBU

ODD

Z/C

Analog Process IC 1

1. Signal Composition Analog signals for odd and even pixels are merged by a switching device in

the GA1, not in the Analog Process ICs.

2. Signal Amplification This function is the same as in the A133 machine.

AGC

Multi-

plexer

P/H SEL

Analog Process IC 2

Z/C

Vin

A/D

Vref

Vin

A/D

Vref

D/A

GA1

(GARD1S)

CPU

A217 Copier

NVRAM

A217D504.vsd

3. A/D conversion Converts individual pixels to 8-bit digital signals.

4. Feedback - D/A Conversion There are no D/A converters in the Analog Process ICs. Instead of this,

there is a D/A converter outside the IC, and the CPU controls the feedback signal for the Analog Process ICs via the D/A converter.

The CPU ignores the Z/C which is before the multiplexer.

EX-IPU 14 August 1997

3.1.3 AUTO IMAGE DENSITY (ADS)

[A]

D/A

from SBU

EVEN

from SBU

ODD

Z/C

Analog Process IC 1

Z/C

Analog Process IC 2

Multi-

plexer

Multi-

plexer

AGC

P/H SEL

AGC

Z/C

SEL

Z/C

Vin

A/D

Vref

A/D

Vin

from D/A Converter

GA1

(GARD1S)

A217D506.vsd

This function is the same as in the A133 machine. However, in this machine, the CPU detects the peak white level only for even pixels using the P/H (Peak Hold) circuit [A]. This data will be used for the odd pixels.

CPU

NVRAM

14 August 1997 DEVELOPMENT DRIVE MECHANISM

4. DEVELOPMENT

4.1 DEVELOPMENT DRIVE MECHANISM

A217 Copier

[D]

In the A133 machine, the main motor drives the development roller and the toner supply roller. However, in this machine, the development drive motor [A] drives the development drive gear [B], which drives the gears in the development unit and the toner supply roller, which is driven by the gear [C] when the toner supply clutch [D] activates.

This reduces the main motor torque.

[C]

[A]

[B]

A217D508.cdr

FUSING TEMPERATURE CONTROL 14 August 1997

5. IMAGE FUSING

5.1 FUSING TEMPERATURE CONTROL

5.1.1 OVERVIEW

A217D507.cdr

5.1.2 ON/OFF CONTROL

NOTE:

To prevent the power supply from the inlet from fluctuating when the fusing lamp turns on, this machine controls the fusing temperature as follows.

1. When the fusing lamp turns on, 35% of the ac power is applied to the lamp for

2. When not copying, the BCU keeps the fusing temperature at the appropriate

The following explanation is for the 230V machine only.

500 ms, then full ac power is applied. In the fusing lamp off condition, ac power is reduced to 35% for 500 ms, then cut.

fusing temperature This reduces the number of times the fusing lamp switches on/off.

10qC.

14 August 1997 FUSING TEMPERATURE CONTROL

6. ENERGY SAVER AND ENERGY STAR

The energy star and energy saver functions are the same as for the A133 machine. The programming modes for these energy saver functions are as follows.

- 115V machine -

Mode Method Selectable values Default Unit/Step

Auto off timer UP mode 10 ~ 240 min 60 min 10 min Low power timer UP mode 1 ~ 240 min 15 min 1 min Recovery time from

the low power mode

Duplex priority UP mode 1 sided to 1 sided

Auto off mode SP mode Enabled

SP mode 10 s (175ºC)

20 s (162ºC) 30 s (150ºC)

1 sided to 2 sided 2 sided to 2 sided

Disabled

20 s (162ºC)

1 sided to 2 sided

Enabled

A217 Copier

- 230V machine -

Mode Method Selectable values Default Unit/Step

Auto off timer This function only works in 115V machines. Low power timer UP mode 1 ~ 15 min 10 min 1 min Recovery time from

the low power mode

Duplex priority UP mode 1 sided to 1 sided

Auto off mode This function only works in 115V machines.

SP mode 10 s (175ºC)

20 s (162ºC) 30 s (150ºC)

1 sided to 2 sided 2 sided to 2 sided

20 s (162ºC)

1 sided to 1 sided

+ 45 hidden pages

Ricoh af500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

A217 COPIER

IMPORTANT SAFETY NOTICES

14 August 1997 SPECIFICATIONS

1. OVERALL MACHINE INFORMATION

MACHINE CONFIGURATION 14 August 1997

14 August 1997 ELECTRICAL COMPONENT DESCRIPTIONS

DRIVE LAYOUT 14 August 1997

2. DIFFERENCES FROM THE A133 MACHINE

EX-IPU 14 August 1997

14 August 1997 DEVELOPMENT DRIVE MECHANISM

FUSING TEMPERATURE CONTROL 14 August 1997

5. IMAGE FUSING

6. ENERGY SAVER AND ENERGY STAR