Ricoh FT2212, FT2012 Service Manual

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A183/A184

SERVICE MANUAL

RICOH GROUP COMPANIES

PN: RCSM2012

SERVICE MANUAL

A183/A184

RICOH GROUP COMPANIES

A183/A184

SERVICE MANUAL

PN: RCSM2012

WARNING

The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.

Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection.

Ricoh Corporation

LEGEND

PRODUCT CODE COMPANY

GESTETNER RICOH SAVIN

A183 FT2012 A184 FT2212

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

9/97 Original Printing

OVERALL INFORMATION

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. COPY PROCESS AROUND THE DRUM. . . . . . . . . . . . . . . . . . . . . 1-4

3. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-6

4. ELECTRICAL COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . . 1-7

DETAILED DESCRIPTIONS

1. DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 OPC DRUM CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2. CHARGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2 CHARGE CORONA CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3. OPTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

3.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

3.2 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3.3 LENS AND 4TH/5TH MIRROR DRIVE (A184 copier only). . . . . . . . . . . . . . . . 2-7

3.4 AUTOMATIC IMAGE DENSITY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3.5 EXPOSURE LAMP VOLTAGE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

4. ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

4.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

4.2 LEAD EDGE ERASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

4.3 SIDE ERASE (A184 copier only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

4.4 TRAILING EDGE ERASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

5. DEVELOPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

5.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

5.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

SM i A183/A184

5.3 CROSS-MIXING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL. . . . . . . . . . . . . . 2-17

5.4.1 Base Bias Voltage Factor In Manual Image Density Mode. . . . . . . . . . . 2-17

5.4.2 Base Bias Voltage Factor In Automatic Image Density (ADS) Mode . . . 2-18

5.4.3 Image Bias Voltage Adjustment Factor. . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

5.4.4 Drum Residual Voltage (V

5.5 DEVELOPMENT BIAS CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

) Correction Factor. . . . . . . . . . . . . . . . . . . . 2-19

6. TONER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

6.1 TONER SUPPLY MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

6.2 TONER DENSITY DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

6.3 TONER SUPPLY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

6.3.1 Detect Supply Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

6.3.2 Fixed Supply Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

6.3.3 TD Sensor Check and Toner Supply Timing. . . . . . . . . . . . . . . . . . . . . . 2-26

6.3.4 Abnormal Condition in Toner Density Detection . . . . . . . . . . . . . . . . . . . 2-26

6.4 TONER END CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

6.4.1 Toner Near End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

6.4.2 Toner End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

6.4.3 Toner End Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

7. IMAGE TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

7.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

7.2 TRANSFER CORONA CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

8. DRUM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

8.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

8.2 TONER RECYCLING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

9. QUENCHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

10. PAPER FEED AND REGISTRATION . . . . . . . . . . . . . . . . . . . . . 2-33

10.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

10.2 PAPER FEED MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

10.3 REGISTRATION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

10.4 BY-PASS FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

A183/A184 ii SM

10.5 PAPER FEED AND MISFEED DETECTION TIMING . . . . . . . . . . . . . . . . . 2-37

11. IMAGE FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

11.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

11.2 FUSING DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

11.3 FUSING LAMP CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

11.4 FUSING LAMP CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

11.4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

11.4.2 On/Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

11.4.3 Phase Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

11.4.4 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

INSTALLATION

1. INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 MACHINE LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.3 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.4 POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

SERVICE TABLES

1. SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.1 GENERAL CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.2 IMAGING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.3 OPTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.4 TRANSFER CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.5 FUSING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.6 PAPER FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.7 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

SM iii A183/A184

2. PROGRAM MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

2.1 BASIC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

2.2 SP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2.3 SP MODE QUICK REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

2.4 UP MODE AND SP MODE CROSS REFERENCE TABLE . . . . . . . . . . . . . . . 4-9

2.5 SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

2.6 CLEAR ALL MEMORY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

3. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

3.1 TEST POINTS (Main Control Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

3.2 VARIABLE RESISTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

PREVENTIVE MAINTENANCE

1. PREVENTIVE MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . 5-1

1.1 PM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.2 REGULAR PM PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

2. SPECIAL TOOLS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . 5-5

REPLACEMENT ADJUSTMENT

1. EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.1 OPERATION PANEL POSITION CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.2 PLATEN COVER POSITION CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

1.3 EXTERIOR COVER/EXPOSURE GLASS REMOVAL. . . . . . . . . . . . . . . . . . . 6-3

1.4 UPPER UNIT STOPPER RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

2. OPTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

2.1 1ST SCANNER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

2.2 2ND MIRROR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

2.3 3RD MIRROR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

2.4 LENS AND 4TH/5TH MIRROR POSITION ADJUSTMENT

(A184 model only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

2.5 4TH MIRROR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

A183/A184 iv SM

2.6 5TH MIRROR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

2.7 LENS AND MIRROR MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

3. IMAGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

3.1 IMAGING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

3.2 CHARGE CORONA UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

3.3 CLEANING BLADE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

4. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

4.1 PAPER FEED CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

4.2 PAPER FEED ROLLER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

4.3 REGISTRAION SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 6-17

5. FUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

5.1 FUSING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

5.2 PRESSURE ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

5.3 FUSING LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

5.4 FUSING EXIT PAWL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

5.5 HOT ROLLER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

5.6 FUSING THERMISTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

5.7 FUSING THERMOFUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6.1 TRANSFER CORONA UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6.2 MAIN DRIVE UNIT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6.3 MAIN MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6.4 TONER SUPPLY CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6.5 ERASE LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6.6 QUENCHING LAMP REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.7 OZONE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6.8 AC DRIVE/DC POWER SUPPLY BOARD/TRANSFORMER

REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6.9 MAIN CONTROL BOARD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

7. COPY QUALITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

7.1 LIGHT INTENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

7.1.1 Base Exposure Lamp Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . 6-34

SM v A183/A184

7.1.2 SP Image Density Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

7.2 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 6-36

7.2.1 Base Bias Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

7.2.2 SP Bias Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

7.3 TONER DENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

7.4 GRID VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

7.5 DRUM CURRENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

7.6 ADS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

7.7 VERTICAL MAGNIFICATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 6-41

7.8 HORIZONTAL MAGNIFICATION ADJUSTMENT (A184 only). . . . . . . . . . . . 6-41

7.9 REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

7.10 ERASE MARGIN ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

7.11 FOCUS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

TROUBLESHOOTING

1. COPY QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

1.1 BLANK COPY (WHITE COPY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

1.2 DIRTY BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

1.3 UNEVEN IMAGE DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

1.4 VERTICAL BLACK BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

1.5 VERTICAL BLACK LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

1.6 VERTICAL WHITE LINES OR BANDS-1 (DULL OR BLURRED) . . . . . . . . . . 7-8

1.7 VERTICAL WHITE LINES OR BANDS-2 (THIN, DISTINCT). . . . . . . . . . . . . . 7-9

1.8 HORIZONTAL BLACK/WHITE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

1.9 JITTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

1.10 BLACK SPOTS ON THE COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

1.11 SKEWED (OPTICAL) COPY IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

1.12 TONER DENSITY TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

1.13 TONER DENSITY TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

1.14 UNFUSED COPY IMAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

1.15 CREASING PAPER AFTER FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

A183/A184 vi SM

1.16 PAPER MISFEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

1.17 ABNORMAL CONDITION IN TONER DENSITY DETECTION . . . . . . . . . . 7-20

1.18 OPTICS OVERHEAT PROTECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

2. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

3. ELECTRICAL COMPONENT DEFECTS . . . . . . . . . . . . . . . . . . . . 7-28

3.1 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

3.2 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

4. BLOWN FUSE CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

5. USER CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

SM vii A183/A184

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

3. 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.

4. 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. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

1. The copier must be maintained by a customer service representative who has completed the training course on the model.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

2. Dispose of imaging units in accordance with local regulations. (These are non-toxic supplies.)

3. Dispose of replaced parts in accordance with local regulations.

TAB INDEX FOR A183/A184

OVERALL MACHINE INFORMATION

DETAILED DESCRIPTIONS

INSTALLATION

TAB POSITION 1

TAB POSITION 2TAB POSITION 3TAB POSITION 4

SERVICE TABLES

PREVENTIVE MAINTENANCE

REPLACEMENT AND ADJUSTMENT

TROUBLESHOOTING

TAB POSITION 5TAB POSITION 6

TAB POSITION 7TAB POSITION 8

OVERALL

MACHINE INFORMATION

SPECIFICATIONS

1. SPECIFICATIONS

Configuration: Desk Top Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum: A4/8.5" x 14" (A183 copier)

B4/10" x 14" (A184 copier)

Copy Paper Size: Paper tray feed:

A4, 8.5" x 11", 8.5" x 13", 8.5" x 14"

Bypass feed:

Maximum: A4/8.5" x 14" Minimum: A5/5.5" x 8.5"

Copy Paper Weight: Paper tray feed: 64 to 86 g/m2, 17 to 23 lb

Bypass feed: 60 to 105 g/m2, 16 to 27 lb

Overall

Information

Reproduction Ratios (A184 model only):

Enlargement

Full Size 100% 100%

Reduction

Metric Version Inch Version

141% 122%

93% 82% 71%

129%

93% 85% 78%

Zoom (A184 model only): From 70% to 141% in 1% steps Copying Speed: 12 copies/minute (A4/8.5" x 11") Warm-up Time:

Less than 30 seconds (at 23°C) First Copy Time: Less than 9 seconds (A4/8.5" x 11") Copy Number Input: Up/Down key, 1 to 50 Manual Image Density

4 steps; can also be set to 5 steps Selection:

Automatic Reset: 1 minute standard setting; can also be set to

3 minutes or no auto reset Paper Capacity: Paper Tray:

250 sheets (A4/8.5" x 11", 80 g/m2/20 lb) 100 sheets (8.5" x 14", 80 g/m2/20 lb)

Bypass feed entrance: 1 sheet Toner Replenishment: Bottle exchange (91 g/bottle)

SM 1-1 A183/A184

SPECIFICATIONS

Copy Tray Capacity:

A4/8.5" x 11" 20 sheets 50 sheets

8.5" x 14" 10 sheets 50 sheets OHP — 1 sheet

Power Source: 120 V/60 Hz:

More than 10 A (for North America)

220 ~ 240 V/50 Hz:

More than 6 A (for Europe)

220 V/50 Hz:

More than 6 A (for Asia)

220 V/60 Hz:

More than 6 A (for Middle East/Asia)

110 V/60 Hz:

More than 10 A (for Taiwan)

127 V/60 Hz:

More than 10 A (for Middle East)

Power Consumption:

Maximum Copy cycle condition Warm-up condiiton Stand-by condition

Copy tray in the

closed position

Copy tray in the

open position

0.9 kW

0.5 kW

0.6 kW

0.1 kW

Dimensions:

Copier

Width Depth Height

400 mm

(15.8")

550 mm

(21.7")

220 mm

(8.7")

Noise Emissions: Sound pressure level (the measurements are

made according to ISO 7779 at the operator position.)

Less than 55 dB Sound power level (the measurements are made

according to ISO 7779)

Stand-by condition Less than 40 dB Copy cycle condition Less than 63 dB

Weight: Less than 18 kg, 39.7 Ib

A183/A184 1-2 SM

MEMO

SPECIFICATIONS

Overall

Information

SM 1-3 A183/A184

COPY PROCESS AROUND THE DRUM

2. COPY PROCESS AROUND THE DRUM

A184V501.wmf

A183/A184 1-4 SM

COPY PROCESS AROUND THE DRUM

1. DRUM CHARGE

In the dark, the charge corona unit gives a uniform negative charge to the organic photoconductive (OPC) drum. The charge remains on the surface of the drum because the OPC drum has a high electrical resistance in the dark.

2. EXPOSURE

An image of the original is reflected to the drum surface via the optics assembly. The charge on the drum surface is dissipated in direct proportion to the intensity of the reflected light, thus producing an electrical latent image on the drum surface.

3. ERASE

The erase lamp illuminates the area of the charged drum surface that will not be used for the copy image. The resistance of the drum in the illuminated areas drops and the charge on those areas dissipates.

4. DEVELOPMENT

Positively charged toner is attached to the negatively charged areas of the drum, thus developing the latent image. (The positive triboelectric charge is caused by friction between the carrier and toner particles.)

Overall

Information

5. IMAGE TRANSFER

Paper is fed to the drum surface at the proper time so as to align the copy paper and the developed image on the drum surface. Then, a strong negative charge is applied to the back side of the copy paper, producing an electrical force which pulls the toner particles from the drum surface to the copy paper. At the same time, the copy paper is electrically attracted to the drum surface.

6. CLEANING

The cleaning blade scrapes the toner off the drum. The collected toner is recycled.

7. QUENCHING

Light from the quenching lamp electrically neutralizes the drum surface.

SM 1-5 A183/A184

MECHANICAL COMPONENT LAYOUT

3. MECHANICAL COMPONENT LAYOUT

1 1098765432

21 20 16171819 1415

1. 2nd Mirror

2. 1st Mirror

3. Exposure Lamp

A184V500.wmf

13. Relay Rollers

14. Paper Feed Roller

15. Toner Bottle Holder

4. Quenching Lamp

5. Charge Corona Unit

6. 6th Mirror

7. Lens

8. Erase Lamp

9. Development Roller

10. 4th Mirror

11. 5th Mirror

12. By-pass Feed Table

A183/A184 1-6 SM

16. Registration Rollers

17. Transfer Corona Unit

18. Drum

19. Cleaning Blade

20. Pressure Roller

21. Hot Roller

22. Exit Rollers

23. Copy Tray

24. 3rd Mirror

ELECTRICAL COMPONENT DESCRIPTIONS

4. ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout and the point-to-point diagram on the waterproof paper in the pocket for symbols and index numbers.

Symbol Name Function Index No.

Motors

M3 Scanner Drive Motor Drives the scanners (1st and 2nd). 10

Main Motor Drives all the main unit components except

for the optics unit and fans.

Exhaust Fan Motor Removes heat from around the fusing unit

and blows the ozone built up around the charge corona unit to the ozone filter.

Lens and Mirror Motor (A184 machines only)

Optics Cooling Fan Motor (220 ~ 240 V machines only)

Moves the lens and 4th/5th mirror positions in accordance with the selected magnification.

Prevents build-up of hot air in the optics cavity.

Overall

Information

Clutches

CL1

CL2

Switches

SW1 Main Switch Supplies power to the copier. 28 SW2 Interlock Switch Cuts all power when the upper unit is opened. 29

Sensors

S5 S6 Exit Sensor Detects misfeeds. 30

Toner Supply Clutch Transfers main motor drive to the toner bottle

gear.

Paper Feed Clutch Transfers main motor drive to the paper feed

roller.

ADS Sensor Detects the background density of the

original.

Registration Sensor Detects paper end conditions. Checks if

paper is set on the by-pass feed table.

Lens and Mirror H. P. Sensor (A184 machines only)

Scanner H. P. Sensor Informs the CPU when the 1st scanner is at

Toner Density (TD) Sensor

Informs the CPU when the lens and 4th/5th mirror assembly are at the home position (full size position).

the home position. Detects the ratio of toner to carrier in the

developer.

Solenoid

SOL 1

SM 1-7 A183/A184

Registration Solenoid Releases the stopper, synchronizing the

paper-feed timing with the original scan.

ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Name Function Index No.

Printed Circuit Boards

PCB1 Main Control Board Controls all copier functions. 5 PCB2 Scanner Drive Board Controls the scanner drive motor. 9

PCB3

PCB4

High Voltage Supply Board - CT/B/G

AC Drive / DC Power Supply Board

Provides high voltage for the charge corona, transfer corona and development bias.

Drives the exposure lamp, fusing lamp and main motor. Rectifies 30 Vac and 8 Vac input

and outputs 5 Vdc and 24 Vdc.

PCB5

Operation Panel Board

Informs the CPU of the selected modes and displays the situation on the panel.

Lamps

Exposure Lamp Applies high intensity light to the original for

exposure.

L2 Fusing Lamp Provides heat to the hot roller. 22 L3

Quenching Lamp (QL) Neutralizes any charge remaining on the

drum surface after cleaning.

Erase Lamp Discharges the drum outside of the image

area. (Provides leading/trailing edge and

side erases.)

Others

TH1

Total Counter (except for -17 machines)

Optics Thermistor Monitors the temperature around the

Keeps track of the total number of copies made.

exposure lamp for overheat protection.

TH2 Fusing Thermistor Monitors the fusing temperature. 21 TF1

TF2

Exposure Lamp Thermofuse

Fusing Thermofuse Provide back-up overheat protection in the

Transformer Steps down the wall voltage to 30 Vac and 8

Provide back-up overheat protection around the exposure lamp.

fusing unit.

Vac.

A183/A184 1-8 SM

DETAILED DESCRIPTIONS

DRUM

1. DRUM

1.1 OPC DRUM CHARACTERISTICS

The OPC (Organic Photoconductor) Drum used in this copier is small in diameter (30 mm), ensuring good paper separation. An OPC drum has the characteristics of:

1. Being able to accept a high negative electrical charge in the dark. (The electrical resistance of a photoconductor is high in the absence of light.)

2. Dissipating the electrical charge when exposed to light. (Exposure to light greatly increases the conductivity of a photoconductor.)

3. Dissipating an amount of charge in direct proportion to the intensity of the light. That is, where stronger light is directed to the photoconductor surface, a smaller voltage remains on the drum.

4. Being less sensitive to changes in temperature (when compared to selenium F type drums).

Detailed

Descriptions

5. During the drums’ life, drum residual voltage gradually increases and the photoconductive surface becomes worn. Therefore, some compensation for these characteristics is required.

SM 2-1 A183/A184

DRUM

1.2 DRIVE MECHANISM

[A]

[B]

A184D500.wmf

The drum [A] is driven by the main motor [B] through idle gears.

A183/A184 2-2 SM

2. CHARGE

2.1 OVERVIEW

CHARGE

[A]

[C]

Detailed

Descriptions

[D]

[B]

A184D501.wmf

A184D502.wmf

This copier uses a single wire scorotron to charge the drum. The corona wire [A] generates a corona of negative ions when the high voltage supply unit applies a negative voltage. The stainless steel grid plate [B] ensures that the drum coating receives a uniform negative charge as it rotates past the corona unit.

The exhaust fan [C] causes a flow of air through the charge corona section. This prevents an uneven build-up of negative ions that can cause uneven image density.

An ozone filter [D], which adsorbs ozone (O3) generated by the charge corona, is located beside the exhaust fan. The ozone filter decreases in efficiency over time as it adsorbs ozone. The ozone filter should be replaced every 30 k copies.

SM 2-3 A183/A184

CHARGE

2.2 CHARGE CORONA CIRCUIT

24 V

GND

CT Trigger

B PWM

CN123-4

CN123-3

CN123-2

CN123-1

CN1-1

CN1-2

CN1-3

CN1-4

DC/DC

Inverter

DC/DC

Inverter

Zener Diode

High Voltage Supply Board-CT/B/G

Ω

3 M

620 V

Drum

To Drum GND

A184D503.wmf

The main board supplies +24 V to the high voltage supply board at CN123-4 as the power source. After the Start key is pressed, the CPU drops CN123-2 from +24 V to 0 V. This activates the charge corona circuit which applies a high negative voltage of approximately –5 k volts to the charge corona wire. The corona wire then generates a negative corona charge.

The grid plate limits the charge voltage to ensure that the charge does not fluctuate and that an even charge is applied to the entire drum surface. The grid plate is connected to ground through a zener diode in the high voltage supply unit. The grid plate drains any charge in excess of –850 V, which is discharged to the ground through the zener diode.

A183/A184 2-4 SM

3. OPTICS

3.1 OVERVIEW

OPTICS

[C]

[B]

[J]

[A]

[H]

[E]

[D]

[G]

[I]

A184D504.wmf

During the copy cycle, an image of the original is reflected onto the drum surface through the optics assembly as follows:

Light path: Exposure Lamp [A] → Original → First Mirror [B] → Second Mirror [C]

→

Third Mirror [D] → Lens [E] → Fourth Mirror [F] → Fifth Mirror [G] → Sixth Mirror [H] → Drum [I]

[F]

Detailed

Descriptions

This copier has five (metric version) or four (inch version) standard reproduction ratios (A184 copier only) and a zoom function. The operator can also change the reproduction ratio in one-percent steps from 70% to 141%. One stepper motor is used to change the positions of the lens and 4th/5th mirrors to enlarge/reduce the image across the page. Changes in reproduction ratio down the page are achieved by changing the scanner speed (A184 copier only).

The CPU monitors the temperature around the optics through a thermistor which is located on the scanner frame. When the temperature reaches 35°C, the optics cooling fan [J] (230 V machines only) starts rotating to draw cool air into the optics cavity. The fan operates until the temperature drops below 32°C. (However, 120 V machines are not equipped with a cooling fan.) For all models, the machine will stop if the optics cavity overheats to a certain temperature. (See Troubleshooting for details.) In this case, the Start key turns red.

Additionally, a thermofuse on the 1st scanner provides back-up overheat protection. It opens when the temperature reaches 128°C and cuts ac power to the exposure lamp.

SM 2-5 A183/A184

OPTICS

3.2 SCANNER DRIVE

[H]

[F]

[D]

[C]

[A]

[E]

[B]

A184D505.wmf

[G]

A stepper motor [A] is used to drive the scanners. The first scanner [B], which consists of the exposure lamp and the first mirror,

is connected to the first scanner belt [C]. The second scanner [D], which consists of the second and third mirrors, is connected to the second scanner belt [E]. Both the scanners move along the guide rail [F].

The pulley [G] drives both the first and second scanner belts. The 2nd scanner moves at half the speed of the first scanner. This maintains the focal distance between the original and the lens during scanning.

The scanner home position is detected by the home position sensor [H]. The scanner return position is determined by counting the scanner motor drive pulses.

A183/A184 2-6 SM

OPTICS

3.3 LENS AND 4TH/5TH MIRROR DRIVE (A184 copier only)

[B]

[D]

[C]

[A]

[E]

Detailed

Descriptions

[F]

A184D506.wmf

Drive from the lens & mirror motor [A] is transmitted to the timing belt [B] on which the lens unit [C] is clamped. The lens position is changed to provide the proper optical distance between the lens and the drum surface corresponding to the selected reproduction ratio. The home position of the lens is detected by the home position sensor [D]. The main board keeps track of the lens position based on the number of pulses sent to the lens motor.

Drive from the lens & mirror motor is also transmitted to the 4th/5th mirror drive cam [E]. As the lens unit position is changed, the cam rotates to change the 4th/5th mirror [F] position to provide proper the focal distance between the lens and the drum.

SM 2-7 A183/A184

OPTICS

3.4 AUTOMATIC IMAGE DENSITY SENSOR

A184D525.wmf

[A]

sampled area

A184D529.wmf

The auto ID sensor [A], a photodiode, is mounted on the upper front frame. The sensor cover has a hole in it to allow light to fall directly onto the sensor.

Sampling starts 6 millimeters from the leading edge of the original and continues for 11.5 millimeters from the leading edge of original in full size mode. These lengths "a" and "b" will vary depending on the selected reproduction ratio (A184 copier only). The lengths "a" and "b" for each reproduction ratio are calculated as follows:

The photosensor circuit converts the light intensity to a voltage. The detected voltage is amplified and sent to the main board. If less light is reflected from the original (the image is darker), the sensor outputs a lower voltage. The CPU compares the maximum detected voltage with the standard voltage and compensates the copy image density by changing the development bias voltage.

A183/A184 2-8 SM

Rev. 05/99

OPTICS

3.5 EXPOSURE LAMP VOLTAGE CONTROL

The main board controls the exposure lamp voltage through the ac drive/dc power supply board.

The exposure lamp voltage is determined by the following factors:

Lamp Voltage =Base Lamp Voltage Setting (SP48)

Image Density Adjustment Factor (SP34)

Manual Image Density Setting Factor (SP35)

VL Correction Factor (SP62)

Reproduction Ratio Correction Factor

1) Base Lamp Voltage Setting

Detailed

Descriptions

The lamp voltage is determined by the SP48 setting. Base Lamp Voltage = SP48 setting x 0.5 (120 V machines)

SP48 setting x 1.0 (230 V machines)

The default setting is: 137 = 68.5 V (120 V machines)

128 = 128 V (230 V machines)

The current lamp voltage can be viewed with SP 51.

2) Image Density Adjustment Factor (SP34)

Depending on the SP34 setting, the exposure lamp data is increased or

⇒

decreased for both ADS and manual ID modes.

SP34 Setting Setting Exposure Lamp

0Normal 0 1 Light +3 steps 2 Dark –3 steps 3 Lighter +6 steps 4 Darker –6 steps 5 Lightest +10 steps 6 Darkest –10 steps

SM 2-9 A183/A184

OPTICS

3) Manual Image Density Setting Factor

Depending on the manual image density setting on the operation panel, the exposure lamp voltage is changed as shown in the table below:

Manual ID Level 1 2 ADS (3) 4 5

Base Development Bias Voltage (Volts)

Manual Image Setting Factor (Volts)

–200 –200 (–200) –200

– 6 steps

(SP35)

– 3 steps V

V0: Base lamp voltage setting (SP48)

V0 + 3 steps V0 + 7 steps

LighterDarker

–240

(SP36)

1 step = 0.5 V (120 V machines) or 1.0 V (230 V machines) The manual setting factor for ID level 1 can be changed using SP35.

SP35 Setting Image Adjustment at ID Level 1

0 –6 steps 1 –8 steps 2 –10 steps

4) VL Correction Factor

The light intensity may decrease because of dust accumulated on the optics parts. Additionally, the drum sensitivity gradually decreases during the drum’s life. This may cause dirty background on copies. To compensate this, V

correction is done. The exposure lamp voltage is increased by +1.0 V (230 V machines), or

+0.5 V (120 V machines) at the set copy count interval. The table below shows the relationship between the SP setting and the interval.

SP62 Setting VL Correction Interval

0 1 step/1500 copies 1 1 step/1000 copies 2 1 step/2000 copies 3 1 step/500 copies 4 1 step/2500 copies 5 1 step/250 copies 6 1 step/3000 copies 7 1 step/4000 copies 8 No Correction

(Default setting: 0)

A183/A184 2-10 SM

OPTICS

5) Reproduction Ratio Correction Factor

The exposure lamp voltage is increased depending on the selected magnification ratio in order to compensate for the change in concentration of light on the drum.

Magnification Ratio Reproduction Ratio Correction Factor

70% to 72% +4 steps 73% to 78% +2 steps 79% to 119% 0 120% to 129% +4 steps 130% to 141% +8 steps

Detailed

Descriptions

SM 2-11 A183/A184

ERASE

4. ERASE

4.1 OVERVIEW

abcdefg abcdefgh

[A]

A184D507.wmf

A184D508.wmf

The erase lamp [A], which is installed in the upper unit, consists of a single row of LEDs extended across the full width of the drum. The erase lamp has the following functions: leading edge erase, side erase (A184 copier only), and trail edge erase.

A183/A184 2-12 SM

ERASE

4.2 LEAD EDGE ERASE

The entire line of LEDs turn on when the main motor turns on. They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum (Lead Edge Erase Margin). This prevents the shadow of the original edge from being developed on the copy. At this point, side erase starts (A184 copier only). The width of the leading erase margin can be adjusted using SP41.

4.3 SIDE ERASE (A184 COPIER ONLY)

Based on the reproduction ratio, the LEDs turn on in blocks (labeled "a" - "h" on the previous page). This reduces toner consumption and drum cleaning load.

The CPU determines which blocks to turn on based on the selected reproduction ratio as follows:

Reproduction Ratio (%) Blocks ON

70 to 72 a - g

73 and 74 a - f

75 to 77 a - e 78 and 79 a - d 80 and 81 a - c

82 to 84 a - b

85 to 141 a

Detailed

Descriptions

4.4 TRAILING EDGE ERASE

This minimizes toner consumption. The entire line of LEDs turns on after the trailing edge of the latent image has

passed 10 mm from the erase lamp. The length of the latent image is determined by the paper length which is checked by the registration sensor. The LEDs stay on to erase the leading edge of the latent image in the next copy cycle. After the final copy, the erase lamps turn off at the same time as the main motor.

SM 2-13 A183/A184

DEVELOPMENT

5. DEVELOPMENT

5.1 OVERVIEW

[D]

[C]

[A]

[E]

When the main motor turns on, the development roller [A] and two agitators [B] and [C] start turning.

There are permanent magnets in the development roller which attract the developer (which is about 50 µm in diameter) to the roller. The turning sleeve of the development roller carries the developer past the doctor blade [D] which trims the developer to the desired thickness.

The development roller sleeve continues to turn, carrying the developer to the drum [E]. When the developer brush contacts the drum surface, the negatively charged areas of the drum surface attract and hold the positively charged toner. In this way, the latent image is developed.

The development roller is given a suitable negative bias for preventing toner from being attracted to the non-image areas on the drum which may have a residual negative charge. The bias also controls image density.

[B]

A184D509.wmf

A183/A184 2-14 SM

5.2 DRIVE MECHANISM

DEVELOPMENT

[B]

[C]

Detailed

Descriptions

[A]

A184D510.wmf

When the main motor [A] turns on, the drive is transmitted to the development roller gear [B] through idle gears. The rotation of the development roller gear is transmitted to the agitator gears [C] through idle gears.

SM 2-15 A183/A184

DEVELOPMENT

5.3 CROSS-MIXING

[C]

[B]

[D]

[A]

A184D511.wmf

A cross-mixing mechanism is used to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent developer clumps from forming and helps create the triboelectric charge.

Two agitators (helical coils) [A] and [B] are used for the cross-mixing. The 1st agitator [A] moves the developer from left to right. The toner supplied from the cutout in the toner cartridge holder is mixed with the developer by the 1st agitator. The 2nd agitator [B] rotates in the opposite direction and moves the developer back from right to left. In this way, the developer is evenly distributed in the development unit.

The magnets in the development roller [C] attract the developer, and the development roller sleeve rotates to carry the developer to the drum. The doctor blade [D] trims the developer on the development roller to the desired thickness.

A183/A184 2-16 SM

DEVELOPMENT

5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL

The image density is controlled by changing two items: the amount of bias voltage applied to the development roller sleeve, and the amount of voltage applied to the exposure lamp.

Applying a bias voltage to the development sleeve reduces the potential between the development roller and the drum, thereby reducing the amount of toner transferred. As the bias voltage becomes greater, the copy becomes lighter.

The method of control depends on whether the image density is manually selected or auto image density is used.

The development bias voltage applied to the development roller sleeve has the following factors:

Development bias voltage = Base bias voltage factor

(Manual ID level 5: SP 36)

+ Image density adjustment factor (SP34)

+ Drum residual voltage (VR) correction factor

Detailed

Descriptions

The base bias voltage for non-image areas (between copies) is –200 volts. The above correction factors are also applied.

NOTE:

SP34 (Image Density Adjustment) is applied for both ADS and manual ID modes. SP36 is for manual ID level 5 only.

5.4.1 Base Bias Voltage Factor In Manual Image Density Mode

Manual ID Level 1 2 ADS (3) 4 5

Base Bias Voltage (Volts)

Base Exposure Lamp Voltage (Volts)

–200 –200 (–200) –200

– 6 steps

(SP35)

– 6 steps V

V0 + 3 steps V0 + 7 steps

: Depends on the setting of SP48

–240

(SP36)

The base voltage applied at each ID level is shown in the above table. Normally, notch 3 is used for the ADS mode. If SP mode 19 is changed from 0 to 1, ADS mode is disabled and notch 3 is used for the center setting of the manual ID level. The base exposure lamp voltage also varies depending on the manual ID level as shown.

SM 2-17 A183/A184

DEVELOPMENT

Adjustment factor for manual ID level 5 (SP36)

The base bias voltage at manual ID level 5 can be changed using SP36 as follows:

Image Density SP36 Setting

Normal 0 –40

Lighter 1 –80

Lightest 2 –120

Base Bias Voltage Change for Level 5

(Volts)

(Default setting: 0)

5.4.2 Base Bias Voltage Factor In Automatic Image Density (ADS) Mode

In ADS mode, the base exposure lamp voltage is fixed at V0 (this value is determined by SP48). Image density is controlled by changing only the base bias voltage.

The base bias voltage for ADS mode depends on the background image density of the original which is measured by the ADS sensor. (See page 2-8 for more information about the ADS sensor).

The CPU checks the voltage output from the automatic ID circuit. This circuit has a peak hold function. The peak hold voltage corresponds to the maximum reflectivity of the original. The CPU then determines the proper base bias level with reference to the peak hold voltage.

The table below shows the relationship between the original background density (ADS voltage ratio) and the base bias voltage.

Base Bias Voltage

α =

ADS0

ADS Voltage Ratio [α] (%)

80 to 100 (light) –200 V

75 to 79 –240 V 70 to 74 –280 V 60 to 69 –320 V 29 to 59 –360 V

0 to 28 (dark) –380 V

ADS0

+ (Total VL Correction Steps so far + Reproduction Correction Steps) x 0.5

: ADS Reference Voltage

ADS Output Voltage

A183/A184 2-18 SM

Rev. 05/99

DEVELOPMENT

5.4.3 Image Density Adjustment Factor

Using SP 34, the the exposure lamp data can be increased or decreased for

⇒

both ADS mode and all manual ID levels as follows:

SP34 Setting Setting Exposure Lamp

0Normal0 1 Light +3 steps 2 Dark –3 steps 3 Lighter +6 steps 4 Darker –6 steps 5 Lightest +10 steps 6 Darkest –10 steps

(Default setting: 0)

5.4.4 Drum Residual Voltage (VR) Correction Factor

During the drum’s life, drum residual voltage (VR) will gradually increase. To compensate for this, the bias voltage is increased by –10 V every 5 k copies.

Detailed

Descriptions

The VR correction is done up to 20 k copies. The VR correction will not change after 20 k copies.

SM 2-19 A183/A184

DEVELOPMENT

5.5 DEVELOPMENT BIAS CIRCUIT

24 V

GND

CT Trigger

B PWM

CN123-4

CN123-3

CN123-2

CN123-1

CN1-1

CN1-2

CN1-3

CN1-4

DC/DC

Inverter

DC/DC

Inverter

Zener Diode

High Voltage Supply Board-CT/B/G

Ω

3 M

620 V

Drum

To Drum GND

A184D503-2.wmf

The main board supplies +24 volts to the high voltage supply board at CN1-1. When the Start key is pressed, the CPU starts sending the bias trigger pulses to CN1-4. This energizes the development bias circuit within the high voltage supply board which applies a high negative voltage to the development roller. The development bias is applied whenever the drum is rotating.

A183/A184 2-20 SM

6. TONER SUPPLY

6.1 TONER SUPPLY MECHANISM

[D]

[C]

TONER SUPPLY

[B]

[H]

Detailed

Descriptions

[G]

[J]

[I]

[A]

[F]

[K]

[E]

A184D512.wmf

When the toner bottle [A] is set and the lever [B] is pushed down, the chuck [C] pulls out the cap [D], and the toner bottle is opened.

While the TD (toner density) sensor detects enough toner in the developer, the toner supply clutch [E] is off, and the main motor drive is not transmitted to the gear [F]. When the TD sensor detects a low toner condition, the toner supply clutch is energized and the drive is transmitted to the gear [G] through idle gears. The gear [G] drives the toner bottle gear [H], and the toner bottle rotates in the direction of the arrow.

The toner bottle has a spiral groove that helps move toner to the toner bottle opening [I]. Then the toner is carried up to the opening [J] of the toner bottle holder by the rotating fins [K], to be supplied into the development unit.

SM 2-21 A183/A184

TONER SUPPLY

6.2 TONER DENSITY DETECTION

[A]

[B]

A184D511-2.wmf

A toner density sensor (TD sensor) [A] is used for toner density control. The TD sensor is located under the 1st agitator [B]. The developer being

conveyed by the 1st agitator passes over the top of the sensor. As the toner in the developer is consumed during development, the toner to carrier ratio changes resulting in a change in the magnetic permeability of the developer. This in turn is converted to a corresponding voltage. The CPU monitors the voltage to control the toner supply mechanism.

When a new imaging unit is installed, the machine starts idling for developer initialization. During the developer initialization, the CPU adjusts the TD sensor control voltage so that the TD sensor outputs 1.9 ± 0.1 volts for the toner to carrier ratio of new developer (4.0% by weight). This voltage is used as the standard TD sensor voltage.

A183/A184 2-22 SM

6.3 TONER SUPPLY CONTROL

6.3.1 Modes Available

TONER SUPPLY

SP30

Setting

3 4

Toner Supply

Mode

Detect Supply Mode

Fixed Supply Mode None Fixed

Target Toner

Sensor Voltage

Depends on the initial TD sensor setting.

Depends on SP53. Depends on the

Depends on the initial TD sensor setting.

Depends on SP53. Fixed

Toner Supply

Depends on the TD sensor output.

TD sensor output. Fixed

Toner Near/End

Amount

Detection

❍

✗ ✗

✗

Default setting: 0

Depending on the SP30 setting, Detect Supply mode or Fixed Supply mode is selected. If 0, 1, 2, or 3 is selected in SP30, Detect Supply mode is used. If 4 is selected, Fixed Supply mode is used. Note that when 2, 3, or 4 is selected, the machine will not perform the toner near/end detection. Normally, SP30 should always be kept at the default setting. The following pages describe in detail each toner supply mode setting.

Detailed

Descriptions

6.3.2 Detect Supply Mode

In Detect Supply mode, the CPU monitors the TD sensor voltage, which depends on the toner to carrier ratio in the developer. As the toner in the developer is consumed, the TD sensor output voltage increases.

The TD sensor voltage is compared with the standard voltage (known as the Target Toner Sensor Voltage), and toner is supplied when the TD sensor output is higher than this target voltage.

The machine has two ways of calculating the target toner sensor voltage; the method used depends on SP30. The toner supply amount can also be changed using SP31 or 32.

SM 2-23 A183/A184

TONER SUPPLY

1) Target Toner Sensor Voltage – Method 1 –

Normally (if 0 or 2 is selected in SP30) the voltage is determined by the following factors:

Target Toner Sensor Voltage (VTS) = Initial Developer Setting Voltage (VT0)

Toner Density Adjustment Factor a) Initial Developer Setting Voltage (VT0) This voltage is adjusted to 1.9 ± 0.1 V during the developer initialization (refer

to section 6.2). b) Toner Density Adjustment Factor The target toner density can be changed by customers or service engineers

using SP mode 38 or user tool No. 4.

SP 38 Setting

00 Normal 0 1 1 Higher –S x 1/2 2 2 Lower +S x 1/2 3 Highest –S 4 Lowest +S

User Tool 4

Setting

Toner Density

S: TD Sensor Sensitivity (SP24) Default: Normal

Toner Density

Adjustment Factor (β)

The sensor sensitivity is stored in SP24. TD Sensor Sensitivity (S) [V/wt%] = Change of TD sensor output [V]/Change of toner density [wt%] = SP24 setting x 0.05 [V] (Default: SP24 = 8)

– Method 2 –

If 1 or 3 is selected in SP30, the setting of SP53 is used as the target toner sensor voltage. In this case, the target toner sensor voltage is determined by the following formula:

Target Toner Sensor Voltage = SP53 setting x 0.02 [V] (Default: 97 = 1.94 V)

A183/A184 2-24 SM

TONER SUPPLY

2) Toner Supply Amount – Method 1 –

Normally (if 0 or 1 is selected in SP30), the toner supply amount is determined by the difference between the TD sensor voltage (VT) and the target toner sensor voltage (VTS). The following table shows the relationship between the sensor output and the toner supply clutch on time for each copy.

Toner Supply Level TD Sensor Voltage Level [VT] Toner Supply Clutch On Time

1 2 3 4 5 6 (Near End Level) 7 (Toner End Level)

< VT ≤ VTS + S/16

+ S/16 < VT ≤ VTS + S/8

+ S/8 < VT ≤ VTS + S/4

+ S/4 < VT ≤ VTS + S/2

+ S/2 < VT ≤ VTS + 4S/5

≥ VTS + 4S/5

≥ VTS + S

The toner supply time step "t" can be changed using SP31. t = SP31 setting x 0.1 [second] (Default: 1 = 0.1 second) S: TD Sensor Sensitivity (SP24)

t 2 x t 4 x t 8 x t

13 x t 16 x t 16 x t

Detailed

Descriptions

In the toner supply level 6 and 7, after a copy job is finished, the main motor continuously rotates, and the toner supply clutch is energized intermittently for T seconds (repeatedly 2 seconds on and 2 seconds off during this T-second interval).

The interval "T " can be changed using SP23.

– Method 2 –

If 2 or 3 is selected in SP30, a fixed amount of toner is supplied when the TD sensor voltage becomes higher than the target toner sensor voltage. The amount of toner can be selected using SP32.

SP32 Setting

00.3 3.5

10.6 7

21.2 15

32.4 30

43.6 45

54.8 60

7 0 (No toner supply) 0

Example: Set SP32 to 2 if the customer’s originals are typically 15% black.

Toner Supply Clutch On Time

(seconds)

Stays on until the TD sensor voltage becomes lower than the target voltage.

Corresponding image area ratio

(%)

SM 2-25 A183/A184

TONER SUPPLY

6.3.3 Fixed Supply Mode

If 4 is selected in SP30, the TD sensor is not used for toner supply control. A fixed amount of toner is supplied at every copy cycle. The toner supply amount is determined by the SP32 setting.

6.3.4 TD Sensor Check and Toner Supply Timing

During every copy cycle, the TD sensor voltage is monitored for three seconds after the machine starts developing the image on the drum. The CPU checks the voltage every 40 ms and stores the second highest voltage of every 250 ms period. Then the stored voltages during the three seconds are averaged, and the average is used as the TD sensor value for the copy. The toner supply clutch on time for detect supply mode using TD sensor output depends on this value.

If the machine determines that toner needs to be added, the toner supply clutch turns on just after the trailing edge of the copy paper passes the transfer corona unit. If the copy paper is shorter than A4/LT size, the clutch is energized for 3 seconds after the machine starts developing the latent image.

6.3.5 Abnormal Condition in Toner Density Detection

If the calculated value of the TD sensor goes below 0.2 volts, the CPU determines that the toner density detection is abnormal. The CPU changes from the detect supply mode to the fixed supply mode. At the same time, either the Auto ID indicator or the selected manual ID level starts blinking, and the machine can be operated. Under this condition, the machine will not perform the toner end detection.

If the value recovers above 0.2 volts, or the main switch is turned off and on, this condition is canceled and the toner density detection will recover to the previous settings.

A183/A184 2-26 SM

TONER SUPPLY

6.4 TONER END CONDITION

6.4.1 Toner Near End

If the CPU detects toner supply level 6 (VT ≥ VTS + 4S/5) five times consecutively, the toner end indicator blinks and the machine goes to the toner near end condition. In this condition, the toner supply clutch is energized for 16t seconds for every copy. If a toner sensor voltage lower than VTS + 4S/5 is detected twice consecutively during the copy cycle, the machine recovers from the toner near end condition. (As explained before, t depends on SP31.)

If the toner sensor voltage does not recover from level 6 during the copy cycle, the main motor continuously rotates after the copy job is finished, and the toner supply clutch is energized intermittently for T seconds (T can be changed using SP23). The CPU monitors the TD sensor voltage during this T seconds. If the toner sensor voltage returns to level 5 or less in this period, the machine recovers from the toner near end condition and the main motor stops.

Detailed

Descriptions

6.4.2 Toner End

If TD sensor level 6 is detected, the machine supplies toner for T seconds after the copy job is finished. During this T seconds, if the CPU detects TD sensor level 7 (VT ≥ VTS + S) three times consecutively, a toner end condition is detected and copier operation is disabled.

If the toner sensor voltage stays in level 6 during the T seconds, the machine keeps the toner near end condition and 50 more copies can be made. After 50 copies, the toner end indicator lights and copying is disabled.

6.4.3 Toner End Recovery

If the main switch is turned off and on, or the upper unit is opened and closed during a toner end condition, the main motor turns on and the toner supply clutch is intermittently energized. If the TD sensor voltage does not recover from level 7 within 40 seconds, the machine stops, keeping the toner end condition. If the TD sensor voltage level recovers to level 6 or less in this period, the toner supply clutch on time is reduced and the main motor continuously rotates for 40 seconds to evenly distribute toner inside the development unit. The on/off timing of the clutch is set using SP25 and 26. (These settings should not be changed.)

SM 2-27 A183/A184

IMAGE TRANSFER

7. IMAGE TRANSFER

7.1 OVERALL

[A]

A184D513.wmf

A high negative voltage (approximately –6 kV) is applied to the transfer corona wire [A], and the corona wire generates negative ions. These negative ions are applied to the back side of the copy paper. This negative charge forces the paper against the drum and attracts the positively charged toner onto the paper.

A183/A184 2-28 SM

7.2 TRANSFER CORONA CIRCUIT

IMAGE TRANSFER

24 V

GND

CT Trigger

B PWM

CN123-4

CN123-3

CN123-2

CN123-1

CN1-1

CN1-2

CN1-3

CN1-4

DC/DC

Inverter

DC/DC

Inverter

Zener Diode

High Voltage Supply Board-CT/B/G

Ω

3 M

620 V

Drum

To Drum GND

Detailed

Descriptions

A184D503-3.wmf]

The terminal which applies high negative voltage to the transfer corona is the same as the terminal for the charge corona. So when the CPU drops CN123-2 from +24 V to 0 V, both the transfer corona and charge corona are applied to the drum at the same time. To apply the proper transfer current to the drum, the transfer corona casing is connected to ground through a varistor. This keeps the potential of the casing at –620 volts to prevent excess corona current from flowing into the casing.

SM 2-29 A183/A184

DRUM CLEANING

8. DRUM CLEANING

8.1 OVERVIEW

[A]

A184D514.wmf

A counter blade system is used for drum cleaning. The cleaning blade [A] scrapes off any toner remaining on the drum after the image is transferred to the paper.

The removed toner is transported into the developer to be recycled.

A183/A184 2-30 SM

8.2 TONER RECYCLING MECHANISM

[A]

[B]

DRUM CLEANING

Detailed

Descriptions

A184D515.wmf

The toner removed from the drum falls onto the toner collection coil [A]. The drum gear rotation is directly transmitted to the gear of the toner collection coil.

As the coil rotates, the toner moves from left to right to be transported to the toner recycling belt [B]. The paddles of the belt, which is driven by the toner collection coil shaft, transports the toner into the developer, and the toner is recycled.

SM 2-31 A183/A184

QUENCHING

9. QUENCHING

[A]

A184D507-2.wmf

In preparation for the next copy cycle, light from the quenching lamp (QL) [A], which is installed in the upper unit, neutralizes any charge remaining on the drum.

LEDs are used for quenching and the lamp is turned on whenever the main motor rotates.

A183/A184 2-32 SM

PAPER FEED AND REGISTRATION

10. PAPER FEED AND REGISTRATION

10.1 OVERVIEW

[C]

[D]

[E]

[B]

Detailed

Descriptions

[A]

A184D516.wmf

This copier has one paper feed station and a by-pass feed table. The paper feed station uses a paper tray [A] which can hold 250 sheets. The

by-pass feed table [B] can hold 1 sheet. The paper tray uses two semicircular feed rollers [C] and a corner separator.

The semicircular feed rollers make one rotation to drive the top sheet of the paper stack to the relay rollers [D].

The paper tray has two corner separators, which allow only one sheet to feed. They also serve to hold the paper stack.

If a sheet of paper is set on the by-pass feed table, the registration sensor [E] is actuated and the machine goes to by-pass feed mode.

SM 2-33 A183/A184

PAPER FEED AND REGISTRATION

10.2 PAPER FEED MECHANISM

[D]

[C]

[E]

[A]

A184D517.wmf

[B]

[F]

A184D518.wmf

Through several gears, main motor rotation is transmitted to the paper feed clutch gear [A]. The rotation of the paper feed clutch gear is transmitted to the relay roller gear [B] through an idle gear.

After the Start key is pressed, the solenoid [C] of the paper feed clutch is energized to release the stopper [D], and the rotation of the relay roller gear is transmitted to the feed roller shaft [E]. The solenoid stays on for 250 milliseconds and then turns off. The feed rollers stop when they complete one rotation.

Before the feed rollers stop, the leading edge of the paper is caught by the relay rollers [F].

A183/A184 2-34 SM

10.3 REGISTRATION MECHANISM

PAPER FEED AND REGISTRATION

[A]

[B]

[C]

A184D524.wmf

The relay rollers always rotate while the main motor rotates. They transport the paper to the registration roller [A]. The registration roller is also driven by the main motor through idle gears.

Detailed

Descriptions

There is a paper stopper [B] between the relay roller and the registration roller. After the leading edge of the paper reaches the stopper, a small buckle is made between the relay roller and the registration roller. 2.7 seconds after the paper feed clutch is turned on, the registration solenoid [C] is energized to release the stopper, synchronizing the paper feeding with the image on the drum.

After 0.5 second, the registration solenoid is de-energized. The registration sensor detects paper length and paper end.

SM 2-35 A183/A184

PAPER FEED AND REGISTRATION

10.4 BY-PASS FEED

[D]

[C]

[B]

[A]

A184D522.wmf

If a sheet of paper is inserted in the by-pass feed table [A], the registration sensor [B] is actuated and the machine goes to by-pass feed mode. 500 milliseconds after the registration sensor is actuated, the main motor turns on for 222 milliseconds to drive the relay roller [C] to catch the leading edge of the paper. After the Start key is pressed, the main motor starts again to transport the paper to the registration roller [D]. The registration solenoid is energized 1912 milliseconds after the main motor started rotating.

A183/A184 2-36 SM

PAPER FEED AND REGISTRATION

10.5 PAPER FEED AND MISFEED DETECTION TIMING

0.1

Start Key

Main Motor

Paper Feed Clutch

Registration Sensor

Registration Solenoid

Exit Sensor

1.5

Paper Length Detection

ON Check

2.7 3.2

5.7

OFF Check

(1)



5.7

ON Check

(2)



(second)

10.3



A184D527.wmf

Detailed

Descriptions

(3)

The registration sensor and the exit sensor are used for misfeed detection. If the CPU detects a misfeed, the Check Paper Path or the Add Paper indicator turns on.

When the main switch is turned on, the CPU checks these sensors for initial misfeed.

During the copy cycle, the CPU performs four kinds of misfeed detection: PE : Checks whether the registration sensor is actuated within 1.5 seconds

after the Start key is pressed. Since this machine has no indicator or sensor to detect paper end, the PE indicator is lit in the paper end condition as well.

(1): Checks whether the copy paper has passed through the registration



sensor 5.7 seconds after the Start key is pressed.

(2): Checks whether the exit sensor is actuated within 5.7 seconds after



the Start key is pressed.

(3): Checks whether the copy paper has passed through the exit sensor



10.3 seconds after the Start key is pressed.

SM 2-37 A183/A184

IMAGE FUSING

11. IMAGE FUSING

11.1 OVERVIEW

[A]

[E]

[B]

[C]

[E]

[D]

[F]

A184D520.wmf

After the image is transferred, the copy paper enters the fusing unit. The image is fused to the copy paper by the process of heat and pressure through the use of a hot roller [A] and pressure roller [B].

The CPU monitors the hot roller temperature through a thermistor [C] which is in contact with the hot roller surface. A thermofuse [D] protects the fusing unit from overheating.

The hot roller strippers [E] separate the copy paper from the hot roller and direct it to the exit rollers. The exit sensor [F] monitors the progress of the copy paper through the fusing unit and acts as a misfeed detector. The exit rollers drive the copy paper to the copy tray.

A183/A184 2-38 SM

11.2 FUSING DRIVE MECHANISM

[B]

[C]

IMAGE FUSING

[A]

Detailed

Descriptions

A184D521.wmf

[C]

[E]

[D]

A184D523.wmf

The main motor [A] drive is transmitted to the hot roller [B] through idle gears. The hot roller always rotates while the main motor rotates. While the upper unit is open, the pressure roller [C] is not in contact with the hot roller. This enables easy misfed paper removal at the fusing area.

When the upper unit is closed, the pressure roller is pushed up by the arms [D]. The two springs [E] apply the proper fusing pressure between the hot roller and the pressure roller.

SM 2-39 A183/A184

IMAGE FUSING

11.3 FUSING LAMP CONTROL

The CPU monitors the temperature of the hot roller surface using a thermistor. The fusing lamp is turned on and off to keep the hot roller surface at the target temperature. The target temperature depends on the machine condition as follows:

A184D528.wmf

Machine Condition

After the main switch is turned on, until one minute has past after the fusing temperature reaches 170°C.

After the above time period

During copying After copying is finished

A183/A184 2-40 SM

Fusing Lamp

ON/OFF Threshold

185°C

150°C

185°C 150°C

Remarks

After the fusing temperature reaches 170°C (ready temperature), the fusing lamp is kept on until it reaches 185°C.

When the Start key is pressed, the red indicator blinks and copying starts after the fusing temperature reaches 170°C.

IMAGE FUSING

When the main switch is turned on, the CPU turns on the fusing lamp. When the fusing thermistor detects 170°C, the machine enters the ready condition. After the ready temperature is detected, the CPU keeps the fusing temperature at 185°C for one minute, then the target temperature is changed to 150°C.

When the Start key is pressed, if the fusing temperature is higher than 170°C, the machine starts copying immediately. If the temperature is lower, the fusing lamp is turned on and the red start indicator blinks. Copying starts after the fusing temperature reaches 170°C, and the fusing temperature is controlled at 185°C during copying.

After copying is finished, the fusing temperature is controlled at 150°C. To prevent any copy quality problem caused by exposure lamp intensity

fluctuation, the fusing lamp does not turn on while the exposure lamp is on, even if the fusing temperature drops below 185°C.

Detailed

Descriptions

SM 2-41 A183/A184

IMAGE FUSING

11.4 FUSING LAMP CONTROL CIRCUIT

11.4.1 Overview

CN121-10

Trigger Pulse

24 V

0 V

Main Board

CN121-11 5 V

CN121-8

24 V

CN121-7

CN404-2

PC2

CN404-3

FU1

T402 T401

AC Power Source

T408

T407

T405

T406

T404

T403

AC Drive/DC Power

Supply Board

Fusing

Thermistor

Fusing Lamp

Main Switch

Interlock Switch

A184D519.wmf

The main board monitors the fusing temperature through a thermistor. It uses the zero cross signal generated by the ac drive/dc power supply board to control the applied power accurately.

Normally, the voltage applied to the lamp is the full duty cycle of the ac waveform. However, through SP29, fusing power can be set to phase control mode. (Phase control is used only if the customer has a problem with electrical noise or interference.)

A183/A184 2-42 SM

IMAGE FUSING

11.4.2 On/Off Control

When the main switch is turned on, the main board starts to output a trigger pulse, which has the same timing as the zero cross signal, to the ac drive/dc power supply board. This trigger pulse allows maximum ac power to be applied to the fusing lamp. When the operating temperature is reached, the CPU stops outputting the trigger pulse (the trigger stays HIGH) and the fusing lamp turns off.

11.4.3 Phase Control Mode

Detailed

Descriptions

A184D526.wmf

The main board sends the fusing lamp trigger pulse (LOW active) to the ac drive/dc power supply board, which provides ac power to the fusing lamp at the falling edge of each trigger pulse. The trigger pulse goes HIGH when the main board receives the zero cross signal.

The amount of time that power is applied to the fusing lamp depends on the temperature of the hot roller.

The trigger pulse (LOW part) is wider [C1] and power is supplied for longer [D1] when the hot roller temperature is lower. It is narrower [C2] and power is supplied for a shorter time [D2] when the hot roller is near the operating temperature.

SM 2-43 A183/A184

IMAGE FUSING

11.4.4 Overheat Protection

There is an overheat protection circuit in the main board. If the hot roller temperature reaches 230°C, the resistance of the thermistor (between CN121-10 and CN121-11) becomes too low. If the main board detects this condition, "E-53" lights on the operation panel and power to the fusing lamp is cut.

Even if the thermistor overheat protection fails, the thermofuse opens when it reaches 169°C, removing power from the fusing lamp.

A183/A184 2-44 SM

INSTALLATION

INSTALLATION REQUIREMENTS

1. INSTALLATION REQUIREMENTS

1.1 ENVIRONMENT

1. Temperature Range: 10°C to 30°C (50°F to 87°F)

2. Humidity Range: 15% to 90% RH

3. Ambient Illumination: Less than 1,500 lux (Do not exposure to direct sunlight.)

4. Ventilation: Minimum space 20 m3. Room air should turn over at least 3 times per hour

5. Ambient Dust: Less than 0.15 mg/m3 (4 x 10-3 oz/yd3)

6. If the place of installation is air-conditioned or heated, do not place the

machine: a) Where it will be subjected to sudden temperature changes.

Installation

b) Where it will be directly exposed to cool air from an air-conditioner. c) Where it will be directly exposed to heat from a heater.

7. Do not place the machine where it will be exposed to corrosive gasses.

8. Do not install the machine at any location over 2,000 m (6,500 feet)

above sea level.

9. Place the copier on a strong and level base.

10. Do not place the machine where it may be subjected to strong vibrations.

1.2 MACHINE LEVEL

1. Front to back: Within 3 mm (0.12") of level

2. Right to left: Within 3 mm (0.12") of level

SM 3-1 A183/A184

INSTALLATION REQUIREMENTS

1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing clearance as shown:

20 cm [7.8"]

40 cm [15.6"]

A184I516.wmf

1.4 POWER REQUIREMENTS

1. Input voltage level: 120 V/60 Hz: More than 10 A 220 ~ 240 V, 50/60 Hz: More than 6 A

2. Permissible voltage

fluctuation:

3. Do not set anything on the power cord.

NOTE:

a) Make sure the plug is firmly inserted in the outlet. b) Avoid multi-wiring.

10%

A183/A184 3-2 SM

INSTALLATION

2. INSTALLATION

2.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following list:

1. Imaging Unit

2. Paper Feed Tray

3. Error Code Decal - English

4. Error Code Decal - Multi-language (-10, -22, -26, -27 machines)

5. Operating Instructions - English (-10, -17, -22, -26, -29, -57 machines)

6. Operating Instructions - Spanish (-17, -22, -26, -57 machines)

7. Operating Instructions - German (-26 machines)

8. Operating Instructions - French (-26 machines)

9. Operating Instructions - Italian (-26 machines)

10. Operating Instructions - Portuguese (-57 machines)

11. Model Name Decal (-10, -22, machines)

12. NECR - English (-57 machines)

13. NECR - Multi-language (-27, -29 machines)

14. Warranty Card (-17 machines)

15. User Registration Card (-17 machines)

Installation

SM 3-3 A183/A184

INSTALLATION

2.2 INSTALLATION PROCEDURE

[B]

[C]

A184I500.wmf

[A]

A184I503.wmf

[D]

A184I501.wmf

A184I506.wmf

1. Remove the tape securing the platen cover, copy tray and power cord.

2. Open the platen cover and remove the two scanner locking pins [A] from

both sides of the exposure glass.

NOTE:

Save the lock pins for future shipping use.

3. Take off the tape covering the screw and remove the knob screw [B] and

red tag [C] as shown.

NOTE:

Save the knob screw for future shipping use.

4. Open the top unit and remove the 4th/5th mirror lock tool [D].

NOTE:

A183/A184 3-4 SM

Save the shipping retainer for future shipping use.

INSTALLATION

[A]

[C]

A184I508.wmf

A184I510.wmf

[B]

Installation

A184I509.wmf

5. Take out the imaging unit from the cardboard box. Then remove the

protective sheet and the tape fixing the lever.

NOTE:

1) Do not touch the drum surface with bare hands.

2) Do not expose the drum to direct sunlight.

6. Remove the paper [A] from the inside of the copier (this paper contains

the installation procedure for the imaging unit).

7. Fit the imaging unit onto both hinges [B], as shown. Then, set the unit on

the guide plate, as shown.

8. Pull out horizontally and remove the tape [C] inside the imaging unit, as

shown.

SM 3-5 A183/A184

INSTALLATION

[A]

A184I512.wmf

[C]

[B]

A184I513.wmf

A184I514.wmf

9. Shake the toner bottle [A] well 5 or 6 times.

10. Remove the black cap [B] from the toner bottle.

NOTE:

Remove the black cap carefully so as not to spill any toner.

11. Open the lever [C] and put the cap side of the toner bottle under the lever.

12. Push the other side of the toner bottle in until it locks in position.

13. Close the lever [C].

14. Close the top unit.

A183/A184 3-6 SM

INSTALLATION

[A]

[B]

A184I502.wmf

Installation

[C]

A184I511.wmf

A184I507.wmf

15. Take out the paper cassette from the clear wrapper and remove the tape

stuck on the center of the cassette. Then remove the two pieces of cardboard beside the side guides.

16. Change the end plate [A] for the paper size the customer requests.

17. Load paper and set the paper cassette in the machine.

18. Paste the Error Code decal [B] next to the exposure glass if needed.

19. Put the cord clamp [C] in the hole that is opposite side of the entrance of

the cord, if necessary.

20. Insert the power plug and turn the main switch on.

NOTE:

When the main switch is turned on, the machine automatically starts developer initialization.

SM 3-7 A183/A184

SERVICE TABLES

SERVICE REMARKS

1. SERVICE REMARKS

1.1 GENERAL CAUTIONS

1. To prevent physical injury, keep hands away from the mechanical drive

components when the main switch is on (especially during the warm-up cycle). If the Start key is pressed before the copier finishes the warm-up cycle, the Start indicator starts blinking and the copier starts making copies as soon as the warm-up cycle is completed.

2. Before disassembling or assembling any parts of the copier, make sure

that the power cord is unplugged.

3. To avoid possible injury or machine damage, always hold the upper unit

firmly with your other hand when opening the upper unit.

4. Keep all the shipping retainers for future shipping use.

1.2 IMAGING UNIT

1. Always make sure of the following when removing the imaging unit from

the copier.

• Do not touch the drum surface with bare hands. When the drum

surface is touched with fingers or becomes dirty, wipe it with a dry cloth.

• Place the imaging unit on a clean and level place. Take care not to

scratch the drum from under the unit as there is no cover to protect it.

• Cover the imaging unit with sheets of paper to prevent the drum from

being exposed to light.

• Do not turn the imaging unit upside down. Toner and developer may

fall out from the unit.

2. Always cover the imaging unit with sheets of paper when the upper unit is

opened.

3. Never use alcohol to clean the drum; alcohol dissolves the drum surface.

4. Take care not to scratch the drum as the photoconductive layer is thin

and is easily damaged.

Tables

Service

5. Never expose the drum to corrosive gases such as ammonia gas.

6. When placing the imaging unit onto the copier, do not push it down

forcibely. This unit is set only to put it on the guide plate. (The imaging unit is shaky if you push it — this is not a problem.)

SM 4-1 A183/A184

SERVICE REMARKS

7. Do not touch the charge corona wire and the grid plate with bare hands.

Oil stains may cause uneven image density on copies.

8. Clean the charge corona wire by sliding the wire cleaning tool from right

to left.

9. Clean the charge grid with a blower brush (not with a cloth).

10. Be careful not to damage the edge of the cleaning blade.

11. After installing a new cleaning blade, be sure to apply setting powder

evenly on the surface and edge of the blade.

1.3 OPTICS

1. Clean the exposure glass with glass cleaner and a dry cloth to reduce the

amount of static electricity on the glass surface.

2. Only use a clean soft cloth to clean the mirrors and reflectors.

3. Only use a blower brush to clean the 6th mirror and the lens.

4. Do not touch the following parts with bare hands:

a) Reflectors b) Exposure Lamp c) Mirrors and Lens

5. Do not change the cutout position of the reflectors as they are adjusted at

the factory.

6. Always replace the 1st scanner unit as an assembly, as the matching of

each set of exposure lamp and reflectors is performed at the factory.

7. Whenever cleaning the optics, all the following actions must be done in

order. a) Optics cleaning b) SP95 (VL Correction Reset) c) SP48 (Light Intensity Adjustment) – see the SP mode table for details d) SP56 (ADS Reference Voltage Adjustment) – see the SP mode table

for details

A183/A184 4-2 SM

SERVICE REMARKS

1.4 TRANSFER CORONA

1. Clean the corona wire by sliding the wire cleaning tool from right to left.

1.5 FUSING UNIT

1. Be careful not to damage the edges of the hot roller strippers or their

tension springs.

2. Do not touch the fusing lamp with bare hands.

3. Make sure that both fusing lamp insulators are properly set in the holders.

4. The two C-rings securing the hot roller are not interchangeable. Make

sure to place them properly when reinstalling. For more details, see section 6 (Replacements and Adjustments).

1.6 PAPER FEED

1. Do not touch the feed rollers with bare hands.

2. The side fences and the end fence of the paper tray should be positioned

correctly so that they securely hold the paper. Otherwise, paper misfeeds may occur. Also when using 8

" x 14" paper, make sure that the trailing

1/2

edges of the paper are under the two guides of the cassette.

3. Avoid storing paper for a long time.

At high temperature and high humidity, or at low temperature and low humidity, store paper in a plastic bag. This is especially important to decrease the amount of curls or waves that would lead to paper misfeeds.

Tables

Service

SM 4-3 A183/A184

SERVICE REMARKS

1.7 OTHERS

1. When replacing the main board, remove the EEPROM (IC106) from the

old main board and place it on the new main board. Then install the new main board in the copier.

2. After installing a new main board with a new EEPROM (IC106), the Clear

All Memory (SP99) procedure must be performed. (Do not perform SP99 if you have placed the old EEPROM on the new main board.)

3. Never perform SP99 (Clear All Memory) except for the following two

cases: a) When the copier malfunctions due to a damaged EEPROM. b) When replacing the EEPROM.

4. Whenever SP99 (Clear All Memory) is performed, the imaging unit must

be replaced with a new one. Otherwise, copy quality might be seriously affected.

5. Tighten securely the screws used for grounding the following PCBs when

reinstalling them.

• Main Control Board

• Scanner Drive Board

• AC Drive/DC Power Supply Board

• High Voltage Supply Board-CT/B/G

A183/A184 4-4 SM

PROGRAM MODES

2. PROGRAM MODES

2.1 BASIC OPERATION

1. Component

This copier is equipped with two program modes. One is the Service Program (SP) Mode for factory and field technician usage, and the other is the User Program (UP) mode for user usage. Both program modes have a different access procedure, but all the UP mode functions can be accessed from the SP mode.

To be able to reset a service call (E5) condition using SP mode, the SP mode can be accessed while the error condition exists. The error code will not be displayed in the copy counter during these conditions.

2. Operation

To access these program modes, a certain key must be held down while turning on the main switch. After accessing, select the required mode number and perform the necessary procedures needed for that function. It is possible to move on to the next required mode without exiting each time.

Tables

Service

To leave from these modes, turn the main switch off/on.

3. Display

To achieve the same operation for the two models (A183 and A184), the Magnification Ratio display, the +Zoom key and the –Zoom key are not used. To display and to distinguish various conditions using the copy counter, the appearance of the copy counter and the dot (•) which appears in the top left corner of the Copy Counter is different.

When the to

accept a program mode number

displayed when you input it.) When the

machine is ready to the current adjustment value.

Copy Counter is blinking

Copy Counter stops blinking

accept an adjustment value

, and the . (The program mode number is

dot is lit

, and the

, the machine is ready

dot starts blinking

, and it may be displaying

, the

SM 4-5 A183/A184

PROGRAM MODES

4. Notes

With the exception of SP57, all copies made inside the program modes are made with ID level 3 (center value).

2. Since the Darker/Lighter keys are used during the program modes, image

density cannot be changed using the Darker/Lighter keys while in the program modes.

3. Since the Copy Counter is used to display the adjustment values and

data, the copy counter can not be displayed.

2.2 SP MODE

1. Service Program Mode Access Procedure

1. Turn off the main switch.

2. While pressing the Darker key and the Clear/Stop key together, turn on

the main switch.

3. A dot (•) will appear in the top left corner of the Copy Counter.

4. Release the Darker key and the Clear/Stop key, and within 5 seconds,

press the Lighter key (if not pressed within 5 seconds, the machine will return to the copy mode). The copier is ready to accept the program number.

NOTE:

To access the UP mode, turn on the main switch while pressing the Clear/Stop key.

2. How to Select the Program Number

1. By using the Increase or Decrease Quantity ("+" or "–") keys, enter the

required program number. At this point, the Copy Counter will be blinking, and the dot (•) will be lit.

2. When the Lighter key is pressed, the number which is currently blinking in

the Copy Counter will be entered as the selected program number.

A183/A184 4-6 SM

PROGRAM MODES

3. Changing the Value of an SP Mode

1. Enter the desired value or setting using the Increase or Decrease

Quantity ("+" or "–") key. For some modes, since the Copy Counter has only 2 digits, the first digit is displayed in the Manual Image Density indicator as shown below.

: "1"

For example:

: "2"

Copy Counter

: "252"

: "3"

A184M500.wmf

NOTE:

After changing the value (setting), the previous value (setting) can be recalled again if the Clear/Stop key is pressed at this point.

2. When the Lighter key is pressed, the number which is currently displayed

in the Copy Counter will be entered as the new value or setting, and will be stored in memory.

3. The copier is ready to accept the new program number. Repeat from step

1 or leave SP mode by turning the main switch off/on.

Tables

Service

SM 4-7 A183/A184

PROGRAM MODES

2.3 SP MODE QUICK REFERENCE TABLE

SP Mode

No.

Function

SP Mode

No.

Function

3 Destination Setting *48 Light Intensity Adjustment 4 Forced Start 49 Fusing Temperature Adjustment

Free Run with Exposure Lamp Off

Exposure Lamp Voltage Display

6 Misfeed Detection Off 52 Fusing Temperature Display 7

Free Run

TD Sensor Target Control

Voltage Adjustment 8 Input Check 54 TD Sensor Gain Adjustment 9 Output Check 55 TD Sensor Output Display

Scanner Free Run

ADS Reference Voltage

Adjustment

11 All Indicators On 57 ADS Output Voltage Display 14 Auto Shut Off Time Setting 59 Optics Temperature Display

Auto Reset Time Setting

Count Up/Down Selection

19 Function of Manual ID Level 3 62 V

Drum Potential Measurement

(With Paper)

Drum Potential Measurement

(Without Paper)

Correction Interval

21 A4 Lengthwise Erase Selection 63 Forced Toner Supply 23

Total Toner Supply On Time During Toner Near/End Condition

Correction Value

24 TD Sensor Sensitivity Setting 66 Imaging Unit Check Mode 25

Toner Supply ON Time During Toner Near/End Recovery

Toner Supply OFF Time During Toner Near/End Recovery

Fusing Temperature Control Selection

TD Sensor Initial Output Display

Imaging Unit Counter Display

Auto Shut Off (Energy Star)

Selection

30 Toner Supply Mode Selection 81 Factory Initialization 31

Toner Supply Amount (TD Sensor Mode)

Toner Supply Amount (Fixed Supply Mode)

Data Communication

Total Copy Counter Display

34 Image Density Adjustment 90 Factory Data and Counter Clear 35

Image Adjustment at ID Level 1

Image Bias Adjustment at ID Level 5

38 Toner Density Adjustment 95 V

*41

Lead Edge Erase Margin Adjustment

Optics Cooling Fan Operation

(120 V (NA) machines only)

Imaging Unit Initialization

Selection

Correction Reset

Toner End Force Cancel

*42 Registration Adjustment 97 Service Call (E5) Reset *43 Vertical Magnification Adjustment 98 Total Counter Clear

*44

Horizontal Magnification Adjustment

Clear All Memory

* Items Listed On The Factory Setting Data Sheet

A183/A184 4-8 SM

PROGRAM MODES

2.4 UP MODE AND SP MODE CROSS REFERENCE TABLE

UP Mode No. SP Mode No. Function

1 34 Image Density Adjustment 2 35 Image Adjustment at ID Level 1 3 36 Image Bias Adjustment at ID Level 5 4 38 Toner Density Adjustment 5 14 Auto Shut Off Time Setting 6 15 Auto Reset Time Setting 7 16 Count Up/Down Selection 8 88 Total Copy Counter Display

9 69 Imaging Unit Counter Display 10 62 V 11 77 Enable / Disable Auto Shut-Off

Correction Interval

Tables

Service

SM 4-9 A183/A184

PROGRAM MODES

2.5 SERVICE PROGRAM MODE TABLE

1. In the

2. In the

Function

Settings

column, comments (extra information) are in italics.

column, the default value is printed in bold letters.

3. If there is a ✝ mark in the Mode No. column, copies can be made within this SP Mode.

Mode No. Function Settings

Destination Setting

The setting can be changed depending on the paper size being used.

No. Measurement

0— — — 1Inch UP

2Metric UP

Copy Count

(SP16 Setting)

This mode does not have any relationship to the electrical power supply. The erase and magnification ratio mechanism is changed. For example, by changing this mode, North American (inch size) machines can use metric size paper for normal usage.

Forced Start Selects whether forced start is on or off.

Copy quality and paper transport are not guaranteed.

If forced start is switched on, the copier enters the ready condition even if the fusing temperature has not reached the required value yet.

using blank originals only.

Free Run with Exposure Lamp Off

A free run is performed without exposure. This mode can be performed before the fusing unit reaches the

✝

ready temperature. Press the Start key to start the free run. Press the C/S key to stop the free run.

This mode is performed with the normal copy process for LG paper size without the paper feed clutch, exposure lamp, and total counter increment. Normally, use SP7 to save toner.

Misfeed Detection Off

Copies are made without misfeed detection by the

✝

registration and exit sensors. Press the Start key to make a copy. It stops when reaching the set count, or when the C/S key is pressed.

Use this mode to check whether the paper misfeed was caused by a sensor malfunction.

The total counter increments when copies are made in this mode.

Note

Factory setting for 120 V copiers

Factory setting for 230 V copiers

Perform this mode

Default = 0

A183/A184 4-10 SM

PROGRAM MODES

Mode No. Function Settings

Free Run Performs a free run with the exposure lamp on. Press

the Start key to start the free run. Press the C/S key to stop the free run.

This mode is performed with the normal copy process for LG paper size without the paper feed clutch and total counter increment.

Before starting, close the platen cover to minimize toner consumption.

Input Check ✝The Manual Image Density indicator is used to

display the input data from the sensors while making a normal copy. Press the Start key to perform this mode.

Sensor Manual ID Level Indication Display: Condition

Registration ID Level 1 ON: Paper Present

Exit ID Level 2 ON: Paper Present

— ID Level 3 — Scanner HP ID Level 4 ON: Home Position *Lens/Mirror

*A184 copier only

ID Level 5

ON: Actuator inside sensor

Output Check Use to turn on individual electrical components.

Enter the desired number given in the following table. Press the Start key to turn on the electrical component. Press the C/S key to turn off the electrical component.

Tables

Service

Component

No.

3 Erase Lamp All LEDs on 4 Toner Supply Clutch 5 Registration Solenoid 6 Paper Feed Clutch

7 8 Optics Cooling Fan

Electrical Component Note

Main Motor + Quenching Lamp + Exhaust Fan Motor (High Speed)

Charge Corona + Transfer Corona + Development Bias Voltage

Main Switch Main switch will turn

Exposure Lamp + Optics Cooling Fan

Exhaust Fan Motor (High Speed)

Dev. bias is the standard voltage for manual ID level 3 without corrections.

off when performed.

Standard voltage for manual ID level 3 without corrections.

SM 4-11 A183/A184

PROGRAM MODES

Mode No. Function Settings

Scanner Free Run

Starts a scanner free run.

Press the Start key to start the free run. Press the C/S key to stop the free run.

All IndicatorsONTurns on all the indicators on the operation panel for

30 seconds. It will turn off automatically after 30 seconds.

To turn off the indicators, press the Lighter key.

Auto Shut Off Time Setting

Selects the auto shut off time in 5 minute steps. 0: 5 min.

The copier main switch is shut off automatically after the selected auto shut off time if SP77 is at "0".

1: 10 min.

2: 15 min. 3: 20 min. 4: 25 min. 5: 30 min.

Auto Reset

Time Setting

Count Up/Down Selection

Function of Manual ID Level 3

A4 Lengthwise Erase Selection

Total Toner Supply On Time During

Toner Near/End Condition

Selects an auto reset time of 1 or 3 minutes, or cancels this mode.

Selects count up or count down.

The default setting depends on the setting of SP3. The setting can be changed after SP3 is set, but if the setting of SP3 is changed again, the SP16 setting will also change accordingly.

Specifies whether the center notch of the manual density indicator is used as the ADS function, or as the manual ID level 3.

This mode is used to perform the light intensity adjustment of the copy quality adjustment. Always change the setting to 1 at this time, in order to achieve the center of the manual image density level to adjust the standard copy quality. Do not forget to change it back to 0 after adjustment.

Selects the trailing edge erase timing to A4 lengthwise on a machine in which the setting of SP3 (Destination Setting) is set to 1 (inch).

Set this to 1 for customers that takes copies of A4 paper occasionally without changing the magnification ratio.

Selects the toner supply clutch on time performed after every copy job under the toner near/end condition.

0: 1 min.

1: 3 min. 2: None

0: Up

1: Down

0: ADS

1: Manual ID Level 3

0: LT

1: A4

0: 5 s.

1: 10 s.

2: 15 s. 3: 20 s. 4: 25 s. 5: 30 s.

A183/A184 4-12 SM

Ricoh FT2212, FT2012 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

SPECIFICATIONS

COPY PROCESS AROUND THE DRUM

MECHANICAL COMPONENT LAYOUT

ELECTRICAL COMPONENT DESCRIPTIONS

DETAILED DESCRIPTIONS

DRUM

CHARGE

OPTICS

ERASE

DEVELOPMENT

TONER SUPPLY

IMAGE TRANSFER

DRUM CLEANING

QUENCHING

PAPER FEED AND REGISTRATION

IMAGE FUSING

INSTALLATION

INSTALLATION REQUIREMENTS

INSTALLATION

SERVICE TABLES

SERVICE REMARKS

PROGRAM MODES