Ricoh FT 5640 Service Manual

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

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

5.If the start key is pressed before the copier completes the warm-up period, keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed.

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

HEALTH SAFETY CONDITIONS

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

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

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

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

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

4.When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

A204/A206/A207/A208/A210/A211

COPIER

SERVICE MANUAL

The A204 copier is based on the A153 copier.

The A206 copier is based on the A155 copier.

The A207 copier is based on the A156 copier.

The A208 copier is based on the A157 copier.

The A210 copier is based on the A159 copier.

The A211 copier is based on the A160 copier.

Only the differences from the base copiers are described in the following pages. Therefore, this documentation should be treated as an insert version of the base copier’s service manual, although it has a separate binder. It should always be utilized together with the base copier’s service manual.

31 March 1997

SPECIFICATIONS

1. SPECIFICATIONS

NOTE: Only items marked with are different from A153, A155, A156, A157, A159, and A160 copiers.

Configuration:	Desktop
Copy Process:	Dry electrostatic transfer system
Originals:	Sheet/Book
Original Size:	Maximum: A3/11" x 17"
Copy Paper Size:	Maximum: A3/11" x17" (Paper trays)
	Minimum: A5/81/2" x 51/2" sideways (Paper trays)
		A4/11" x 81/2" sideways (LCT)
		A6/51/2" x 81/2" lengthwise (By-pass)
Duplex Copying:	Maximum: A3/11" x 17"
	Minimum: A5/81/2" x 51/2" (sideways)
Copy Paper Weight:	Paper tray: 52 ~ 128 g/m2, 14 ~ 34 lb
	By-pass:	52 ~ 157 g/m2, 14 ~ 42 lb
	LCT:	52 ~ 128 g/m2, 14 ~ 34 lb
	Duplex copying: 64 ~ 105 g/m2, 17 ~ 24 lb
Reproduction Ratios:	4 Enlargement and 6 Reduction
			A4/A3 Version	LT/DLT Version
			200%	200%
	Enlargement		141%	155%
			122%	129%
			115%	121%
	Full size		100%	100%
			93%	93%
			82%	85%
	Reduction		75%	77%
			71%	74%
			65%	65%
			50%	50%

Copier

1

SPECIFICATIONS						31 March 1997
Power Source:	120 V/60 Hz:
	More than 12 A (for North America)
	220 V ~ 240 V/50 Hz:
	More than 7 A (for Europe)
	220 V/50 Hz:
	More than 7 A (for Asia)
	110 V/60 Hz:
	More than 13 A (for Taiwan)
	220 V/60 Hz:
	More than 7 A (for Saudi Arabia, Philippines)
Power Consumption:
	A204, A206, and A207 copiers			A208, A210, and A211 copiers
	Copier Only	Full System		Copier Only		Full System
Maximum	1.35 kW	1.40 kW		1.35 kW		1.40 kW
Copying	1.15 kW	1.21 kW		0.90 kW		1.00 kW
Warm-up	1.21 kW	1.23 kW		0.98 kW		1.00 kW
Stand-by	0.18 kW	0.20 kW		0.16 kW		0.18 kW

NOTE: – Full System –

Copier + ARDF (A663) + Paper Tray Unit (A549) + 20 Bin S/S (A664)

Noise Emission:

		A204, A206, and A207 copiers		A208, A210, and A211 copiers
			Copier Only	Copier Only
1.	Sound Pressure Level
Operator position			64 dB (A)	63 dB (A)
Standard position			59 dB (A)	58 dB (A)
2.	Sound Power Level
	Copying		70 dB (A)	69 dB (A)
	Stand-by		42 dB (A)	43 dB (A)

NOTE: The above measurements were made in accordance with ISO 7779.

2

31 March 1997 SPECIFICATIONS

Dimensions:

		Width			Depth		Height	Copier
A204 copier	1,030 mm (40.6")			655 mm (25.8")			606 mm (23.9")
A208 copier	900 mm (35.5")			655 mm (25.8")			606 mm (23.9")
A206 and A207 copiers	1,258 mm (49.6")			655 mm (25.8")			606 mm (23.9")
A210 and A211 copiers	1,128 mm (44.5")			655 mm (25.8")			606 mm (23.9")
Measurement Conditions
1) With by-pass feed table closed
2) With platen cover and copy tray attached
3) With LCT cover closed
Weight:
					Weight
					NA		EU
		A204 copier			70 kg (154.3 lb)		73 kg (160.9 lb)
		A206 copier			78 kg (172.0 lb)		81 kg (178.5 lb)
		A207 copier			81 kg (178.6 lb)		84 kg (185.2 lb)
		A208 copier			69 kg (152.1 lb)		72 kg (158.7 lb)
		A210 copier			77 kg (169.8 lb)		80 kg (176.4 lb)
		A211 copier			79 kg (174.2 lb)		82 kg (180.7 lb)

	Zoom:		From 50% to 200% in 1% steps
	Copying Speed (copies/minute):
				A4 sideways/	A3/11" x 17"		B4/81/2" x 14"
				11" x 81/2"
	A204, A206, and A207 copiers			40		22/21	25
	A208, A210, and A211 copiers			32		17/16	19
	Warm-up Time:		A204, A206, and A207 copiers:
				Less than 250 seconds (20°C)
			A208, A210, and A211 copiers:
				Less than 110 seconds (20°C)
	First Copy Time:
	Paper Feed Station			A4/11" x 81/2" (sideways)
		A204, A206, and A207 copiers				A208, A210, and A211 copiers
	1st Tray	4.4 s (except for A207)				4.9 s (except for A211)
	2nd Tray			4.9 s			5.4 s
	By-pass			4.4 s			4.7 s
	LCT			4.4 s			4.9 s

NOTE: In A207 and A211 copiers, the 2nd tray in the above table is called the 1st tray.

3

SPECIFICATIONS	31 March 1997
Copy Number Input:	Ten-key pad, 1 to 999 (count up or count down)
Manual Image Density	7 steps
Selection:
Automatic Reset:	1 minute is the standard setting; it can be changed
	to a maximum of 999 seconds or no auto reset by
	SP mode.

Copy Paper Capacity:

	Paper Tray	By-pass Feed	LCT
A204 copier	About 500 sheets x 2	About 40 sheets	—
A206 copier	About 500 sheets x 2	About 40 sheets	About 1,000 sheets
A207 copier	About 500 sheets x 1	About 40 sheets	About 1,000 sheets
A208 copier	About 500 sheets x 2	About 40 sheets	—
A210 copier	About 500 sheets x 2	About 40 sheets	About 1,000 sheets
A211 copier	About 500 sheets x 1	About 40 sheets	About 1,000 sheets

NOTE: Paper tray	- 500 sheets or less than 53 mm stack height
By-pass feed -		40 sheets or less than 4 mm stack height
LCT	- 1,000 sheets or less than 120 mm stack height
Duplex Tray Capacity		50 sheets (30 sheets for A3/11"x17"
[A207/A211]:		81 ~ 105g/m2, 21.5 ~ 27.9 lb paper)
Toner Replenishment:		Cartridge exchange (415 g/cartridge)

Optional Equipment: ∙ Platen cover

∙Document feeder

∙Paper tray unit with two paper trays

∙Paper tray unit with three paper trays

∙10 bin micro sorter (for A208, A210, and A211 copiers)

∙20 bin mini sorter

∙10 bin sorter stapler

∙20 bin sorter stapler

∙20 bin multi-position sorter stapler

∙Sorter adapter (required when installing 20 bin mini sorter, 10 bin sorter stapler, 20 bin sorter stapler, or 20 bin multi-position sorter stapler for A208, A210, and A211 copiers)

∙Key counter

∙Tray heater

4

31 March 1997 SPECIFICATIONS

∙	Optical anti-condensation heater
∙	Original length sensor for 11" x 15" size paper	Copier

(only for LT/DLT version)

∙ ADS sensor for particular types of red original

∙ Specifications are subject to change without notice.

5

MACHINE CONFIGURATION

31 March 1997

2. MACHINE CONFIGURATION

2.1 COPIER

A204V500.wmf

6

31 March 1997

MACHINE CONFIGURATION

2.2 OPTIONAL EQUIPMENT

Copier

A204V501.wmf

7

MECHANICAL COMPONENT LAYOUT

31 March 1997

3. MECHANICAL COMPONENT LAYOUT

– A207 copier –			5	6	7	8	9	10	11
									12
4									13
3									14
2									15
1
									16
38
									17
37									18
36									19
35									20
34
33
32
31
30
									21
									22
29	28	27	26	25			24	23
									A204V502.wmf

The fusing unit has been changed. (See Detailed Descriptions for more information.)

NOTE: 1) The A204 copier is the same as the A207 copier except that the A204 does not have a duplex tray or an LCT.

2)The A206 copier is the same as the A207 copier except that the A206 does not have a duplex tray.

8

31 March 1997

MECHANICAL COMPONENT LAYOUT

– A211 copier –	6	7	8	9	10	11	Copier
5
							12
4							13
3							14
2							15
1
							16
38
							17
37							18
							19
36							20
35
34
33
32
31
							21
30							22

29 28 27 26 25

24

23

A204V503.wmf

The paper tray unit has been changed from the corner separation system to the FRR feed system.

NOTE: 1) The A208 copier is the same as the A211 copier except that the A208 does not have a duplex tray or an LCT.

2)The A210 copier is the same as the A211 copier except that the A210 does not have a duplex tray.

9

MECHANICAL COMPONENT LAYOUT

31 March 1997

1.	3rd Mirror	20.	Separation Roller
2.	2nd Mirror	21.	Large Capacity Tray
3.	1st Mirror	22.	Vertical Transport Rollers
4.	Exposure Lamp	23.	Paper Feed Roller
5.	Lens	24.	Friction Pad
6.	Quenching Lamp	25.	Duplex Friction Roller
7.	Drum Cleaning Blade	26.	Duplex Feed Roller
8.	Drum Charge Roller	27.	Jogger Fence
9.	6th Mirror	28.	Transfer Belt
10.	OPC Drum	29.	Transfer Belt Cleaning Blade
11.	Erase Lamp	30.	Lower Paper Tray
12.	4th Mirror	31.	End Fence
13.	5th Mirror	32.	Entrance Rollers
14.	Toner Supply Unit	33.	Pick-off Pawls
15.	Pre-transfer Lamp	34.	Pressure Roller
16.	Development Unit	35.	Hot Roller
17.	Registration Rollers	36.	Junction Gate
18.	Feed Roller	37.	Hot Roller Strippers
19.	Pick-up Roller	38.	Exhaust Fan

10

31 March 1997

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.

: New or modified components

	Symbol	Name	Function	Index No.
	Printed Circuit Boards
	PCB1	Main Control	Controls all copier functions both directly or	13
			through other control boards.
	PCB2	AC Drive	Provides ac power to the exposure lamp	11
			and fusing lamps.
	PCB3	DC Power Supply	Provides dc power.	10
	PCB4	Main Motor Control	Controls the rotation of the main motor.	94
	PCB5	CB High Voltage Supply	Supplies high voltage to the drum charge	1
			roller and development roller.
	PCB6	T High Voltage Supply	Supplies high voltage to the transfer belt.	52
	PCB7	Operation Panel	Controls the LED matrix, and monitors the	3
			key matrix.
	PCB8	Noise Filter (220 ~ 240	Removes electrical noise.	8
		V machines only)
	PCB9	Duplex Control	Controls the operation of the duplex tray.	60
		(Duplex machines only)
	PCB10	Liquid Crystal Display	Controls the guidance display and displays	6
		(A207 machines only)	guidance for machine operation.
	PCB11	LCT Interface	Interfaces the LCT control signal between	100
		(LCT machines only)	the main board and the LCT.
	Motors
	M1	Main	Drives the main unit components.	85
	M2	Toner Bottle Drive	Rotates the toner bottle to supply toner to	76
			the toner supply unit.
		Upper Tray Lift	Raises the bottom plate in the upper paper
	M3	(Non-duplex machines	tray.	95
		only)	A204/206/208/210: M3 and M4 are
			combined into one unit
	M4	Lower Tray Lift	Raises the bottom plate in the lower paper	83
			tray.
	M5	LCT Lift	Lifts up and lowers the LCT bottom plate.	97
		(LCT machines only)
	M6	Optics Cooling Fan 1	Removes heat from the optics unit.	92
	M7	Optics Cooling Fan 2	Removes heat from the optics unit.	93
			A208/210/211 now have two fans.
	M8	Exhaust Fan 1	Removes the heat from around the fusing	87
			unit.

Copier

11

ELECTRICAL COMPONENT DESCRIPTIONS			31 March 1997
Symbol	Name	Function		Index No.
	Exhaust Fan 2	Removes the heat from around the fusing
M9	(A204/A206/A207	unit.		88
	machines only)
M10	Scanner Drive	Drives the 1st and 2nd scanners (dc		90
		stepper motor).
M11	3rd Scanner Drive	Drives the 3rd scanner (dc stepper motor).		75
M12	Lens Vertical Drive	Shifts the lens vertical position.		84
M13	Lens Horizontal Drive	Shifts the lens horizontal position.		74
M14	Duplex Feed	Drives the feed roller and moves the		55
	(Duplex machines only)	bottom plate up and down.
M15	End Fence Jogger	Drives the end fence jogger to square the		58
	(Duplex machines only)	paper stack.
M16	Side Fence Jogger	Drives the side fence jogger to square the		57
	(Duplex machines only)	paper stack.
	DC Board Cooling Fan	Removes heat from the dc power supply
M17	Motor (A204/A206/A207	board.		86
	N. American models)
Sensors
S1	By-pass Feed Paper	Informs the CPU what width paper is in the		26
	Width	by-pass feed table.
S2	By-pass Feed Paper End	Informs the CPU that there is no paper in		30
		the by-pass tray.
	Upper Tray Paper End	Informs the CPU when the upper paper
S3	(Non-duplex machines	tray runs out of paper.		48
	only)
	Upper Relay	Detects the leading edge of paper from the
S4		upper tray to determine the stop timing of		105
		the upper paper feed clutch, and detects
		misfeeds.
	Upper Tray Upper Limit	Detects the height of the paper stack in the
	(Non-duplex machines	upper paper tray to stop the upper tray lift
S5	only)	motor.		28
		A208/210/211 have the components
		needed for an FRR mechanism.
S6	Lower Tray Paper End	Informs the CPU when the lower paper tray		49
		runs out of paper.
	Lower Relay	Detects the leading edge of paper from the
S7		lower paper tray to determine the stop		104
		timing of the lower paper feed clutch, and
		detects misfeeds.
	Lower Tray Upper Limit	Detects the height of the paper stack in the
		lower paper tray to stop the lower tray lift
S8		motor.		29
		A208/210/211 have the components
		needed for an FRR mechanism.

12

31 March 1997		ELECTRICAL COMPONENT DESCRIPTIONS
Symbol	Name	Function	Index No.
S9	LCT Lower Limit	Sends a signal to the CPU to stop lowering	98		Copier
	LCT Paper End	Informs the CPU when the LCT runs out of
	(LCT machines only)	the LCT bottom plate.
S10	(LCT machines only)	paper.	99
S11	LCT Upper Limit	Sends a signal to the CPU to stop lifting	25
	(LCT machines only)	the LCT bottom plate.
	Registration	Detects the leading edge of the copy paper
S12		to determine the stop timing of the paper	27
		feed clutch, and detects misfeeds.
S13	Image Density (ID)	Detects the density of various patterns on	47
		the drum during process control.
S14	Toner Density (TD)	Detects the toner concentration inside the	50
		development unit.
S15	Lens Horizontal HP	Informs the CPU that the lens is at the	36
		horizontal home position.
S16	Lens Vertical HP	Informs the CPU that the lens is at the	19
		full-size position.
S17	Scanner HP	Informs the CPU when the 1st and 2nd	14
		scanners are at the home position.
S18	3rd Scanner HP	Informs the CPU when the 3rd scanner is	23
		at the home position.
	Original Length-2	Detects the length of the original. This is
S19		one of the APS (Auto Paper Select)	20
		sensors.
S20	Fusing Exit	Detects misfeeds.	42
	Platen Cover	Informs the CPU whether the platen cover
S21		is up or down (related to APS/ARE	15
		functions). ARE: Auto Reduce and Enlarge
	Toner End	Instructs the CPU to add toner to the toner
S22		supply unit, and detects toner end	51
		conditions.
S23	Auto Response	Returns the operation panel display and	40
		exits from the energy saver mode.
	Transfer Belt Contact HP	Informs the CPU of the current position of
S24		both the transfer belt unit and the drum	22
		charge roller unit.
S25	Auto Image Density	Detects the background density of each	12
	(ADS Sensor)	original in ADS mode.
	Original Width	Detects the width of the original. This is
S26		one of the APS (Auto Paper Select)	41
		sensors.
	Original Length-1	Detects the length of the original. This is
S27		one of the APS (Auto Paper Select)	18
		sensors.
S28	Duplex Paper End	Detects paper in the duplex tray.	53
	(Duplex machines only)

13

ELECTRICAL COMPONENT DESCRIPTIONS			31 March 1997
Symbol	Name	Function		Index No.
	Duplex Turn	Detects the trailing edge of the copy paper
S29	(Duplex machines only)	to determine the jogging timing, and		54
		detects misfeeds.
S30	Duplex Entrance	Detects misfeeds.		59
	(Duplex machines only)
S31	Side Fence Jogger HP	Detects the home position of the duplex		56
	(Duplex machines only)	side fence jogger.
S32	End Fence Jogger HP	Detects the home position of the duplex		61
	(Duplex machines only)	end fence jogger.
	Original Length	Detects original length for 11" x 15" paper.
S33	(Option for N. American			21
	models)
Switches
SW1	By-pass Feed Table	Detects whether the by-pass feed table is		32
		open or closed.
SW2	Tray Down	Sends a signal to the CPU to lower the		102
	(LCT machines only)	LCT bottom plate.
	Upper Tray Paper Size	Determines what size of paper is in the
	(Non-duplex machines	upper paper tray, and detects when the
SW3	only)	tray has been closed.		24
		The upper tray switch has been
		eliminated.
	Lower Tray Paper Size	Determines what size of paper is in the
		lower paper tray, and detects when the tray
SW4		has been closed.		33
		The lower tray switch has been
		eliminated.
	Vertical Guide Set	Detects whether the vertical guide is open
SW5	(Non-LCT machines	or not.		31
	only)
SW6	LCT Cover-1	Detects whether the LCT cover is open or		103
	(LCT machines only)	not.
SW7	LCT Cover-2	Cuts the dc power line of the LCT lift motor.		101
	(LCT machines only)
SW8	Main	Supplies power to the copier.		39
SW9	Front Cover Safety	Cuts the ac power line and detects whether		38
		the front door is open or not.
SW10	Exit Cover Safety	Cuts the ac power line and detects whether		45
	(A211 machines only)	the exit cover is open or not.
Magnetic Clutches
CL1	Toner Supply	Turns the toner supply roller to supply		69
		toner to the development unit.
CL2	Development	Drives the development roller.		68

14

31 March 1997		ELECTRICAL COMPONENT DESCRIPTIONS
Symbol	Name	Function	Index No.
	Transfer Belt Contact	Controls the touch and release movement			Copier
CL3		of both the transfer belt unit and the drum	91
		charge roller unit.
CL4	Registration	Drives the registration rollers.	70
CL5	By-pass Feed	Starts paper feed from the by-pass feed	71
		table or LCT.
CL6	Relay	Drives the relay rollers.	73
	Upper Paper Feed	Starts paper feed from the upper paper
CL7	(Non-duplex machines	tray.	81
	only)
CL8	Lower Paper Feed	Starts paper feed from the lower paper tray.	82
Solenoids
	LCT machines:	Picks paper up from the by-pass feed
	LCT/By-Pass Pick-up	table. When paper is fed from the LCT, this
SOL1	Solenoid	solenoid assists SOL3.	72
	Non-LCT machines:
	By-pass Pick-up
	Solenoid
SOL2	Junction Gate	Moves the junction gate to direct copies to	89
	(Duplex machines only)	the duplex tray or to the paper exit.
SOL3	LCT Pick-up	Picks up paper from the LCT.	96
	(LCT machines only)
	Upper Tray Pick-up	Controls the up/down movement of the
SOL4	(Non-duplex machines	pick-up roller in the upper paper tray.	77
	only)	A208/210/211 have the components
		needed for an FRR mechanism.
	Lower Tray Pick-up	Controls the up/down movement of the
SOL5		pick-up roller in the lower paper tray.	79
		A208/210/211 have the components
		needed for an FRR mechanism.
	Upper Tray Separation	Controls the up-down movement of the
	(Non-duplex machines	separation roller in the upper paper tray
SOL6	only)	feed station.	78
		A208/210/211 have the components
		needed for an FRR mechanism.
	Lower Tray Separation	Controls the up-down movement of the
		separation roller in the lower paper tray
SOL7		feed station.	80
		A208/210/211 have the components
		needed for an FRR mechanism.
Lamps
	Exposure	Applies high intensity light to the original for
L1		exposure.	16
		Modified - see the "Optics" section for
		details.

15

ELECTRICAL COMPONENT DESCRIPTIONS			31 March 1997
Symbol	Name	Function		Index No.
	Main Fusing	Provides heat to the central area of the hot
L2		roller.		62
		Modified - see the "Fusing" section for
		details.
	Secondary Fusing	Provides heat to both ends of the hot roller.
L3		Modified - see the "Fusing" section for		63
		details.
	Pre-transfer	Reduces the charge remaining on the
L4		drum surface before transfer.		4
	Quenching	Neutralizes any charge remaining on the
L5		drum surface after cleaning.		5
	Erase	After exposure, this eliminates the charge
L6		on areas of the drum that will not be used		2
		for the image.
Heaters
	Drum	Turns on when the main switch is off to
		keep the temperature around the drum
H1		charge roller at a certain level. Also		35
		prevents moisture from forming around the
		drum.
	Optics Anti-condensation	Turns on when the main switch is off to
H2	(option)	prevent moisture from forming on the		43
		optics.
H3	Lower Tray (option)	Turns on when the main switch is off to		34
		keep paper dry in the lower paper tray.
Thermistors
TH1	Main Fusing	Monitors the temperature at the central		66
		area of the hot roller.
	Secondary Fusing	Monitors the temperature at the ends of the
TH2	(A208/A210/A211	hot roller.		67
	machines only)	A204/206/207 have only one thermistor.
TH3	Optics	Monitors the temperature of the optics		44
		cavity.
TH4	Drum Charge	Monitors the temperature of the drum		46
		charge roller.
Thermofuses
TF1	Main Fusing	Provides back-up overheat protection in		65
		the fusing unit.
	Secondary Fusing	Provides back-up overheat protection in
TF2	(A208/A210/A211	the fusing unit.		64
	machines only)	A204/206/207 have only one thermofuse.

16

31 March 1997		ELECTRICAL COMPONENT DESCRIPTIONS
Symbol	Name	Function	Index No.
TF3	Exposure Lamp	Opens the exposure lamp circuit if the 1st	17		Copier
		scanner overheats.
Counters
CO1	Total	Keeps track of the total number of copies	37
		made.
CO2	Key (option)	Used for control of authorized use. The	N/A
		copier will not operate until it is installed.
Others
CB1	Circuit Breaker (220 ~	Provides back-up high current protection	9
	240 V machines only)	for electrical components.
TR1	Transformer (220 ~ 240	Steps down the wall voltage to 100 Vac.	7
	V machines only)
CC1		This has been eliminated from all models.

17

PAPER FEED DRIVE LAYOUT

31 March 1997

5. PAPER FEED DRIVE LAYOUT

5.1 A204/A206/A207/A208/A210/A211

1

3

2

A204V504.wmf

Since A208, A210, and A211 have been changed to the FRR feed system, all models carry the same type of drive layout.

1.Upper Paper Feed Clutch Gear (A207/A211 only)

2.Lower Paper Feed Clutch Gear

3.Relay Clutch Gear

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31 March 1997

PROCESS CONTROL

6. PROCESS CONTROL

6.1 HALFTONE MODE

This mode is newly added.

If the user selects the halftone mode function on the operation panel, the machine reduces the size of the exposure lamp voltage, development bias, and the drum charge voltage by the changes shown below.

∙Exposure Lamp Voltage: –1.0 V

∙Development Bias: +80 V

∙Drum Charge Voltage: +300 V

Copier

6.2 ADS CORRECTION

Five possible corrections can be selected from, where the base copier has only three.

ADS correction

	ADS Density SP5-106		Development Bias Correction Voltage
	Setting	Copy Density
	0	Darkest	816 x (AR – 0.85) + 60
	1	Darker	816 x (AR – 0.75)
	2	Normal	816 x (AR – 0.85)
	3	Lighter	816 x (AR – 0.95)
	4	Lightest	816 x (AR – 0.85) – 60

Where AR (ADS Ratio) = VADS (original)/VADS (pattern)

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PROCESS CONTROL

31 March 1997

6.3 TONER SUPPLY CONTROL DURING COPYING

The amount of toner supplied per unit of time (TS) has been changed from the base copier.

Toner clutch on time is calculated by the following formula.

	Toner CL on time [ms] =			S x AT x TSC ¤ 100		(Formula 1)
				TS
	where: S	=	Copy paper size [cm2]
	AT	=	Amount of toner developed on the latent image per unit area
		=	0.7 [mg/cm2] (constant)
	TSC =		Toner supply coefficient [%]
	TS =		Amount of toner supplied per unit of time
		=	0.217	[mg/ms] (for A204, A206, and A207 copiers)
		=	0.183	[mg/ms] (for A208, A210, and A211 copiers)

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31 March 1997

PROCESS CONTROL

6.4 VR PATTERN CORRECTION

The values in the ID correction column of the table have been changed.

VR correction

			ID Correction						Drum Charge Roller	Development Bias
	±0 V			–40 V			–80 V		Correction Voltage	Correction Voltage
	74 ~ 100			68 ~ 100			62 ~ 100		±0 V	±0 V
VRP/VRG	53	~ 73		50	~ 67		43	~ 61	–40 V	–40 V
	41	~ 52		37	~ 49		26	~ 42	–80 V	–80 V
x 100 (%)
	31	~ 40		26	~ 36		19	~ 25	–120 V	–120 V
	0	~ 30		0	~ 25		0	~ 18	–160 V	–160 V

For example, taking the ID correction to be zero for now, if VRP/VRG is 45%, the drum charge and development bias corrections will both be –80 V.

VR correction also depends on the current VSP pattern ID correction that is being used. If development bias has been increased by ID correction, the VR correction may be smaller in some cases to take this into account. This is shown by both the table above and the following diagram.

Copier

–160 V

ID correction

0 V

Voltage

–120 V

–40 V

Correction

–80 V

–80 V

V R

–40 V

–0 V

10

20

30

40

50

60

70

80

90

100

Drum residual

Drum residual

V RP /VR G (%)

voltage largel

voltage small

A204D505.wmf

Using the same example to illustrate this, but with an ID correction of –80 V, the corrections will both be –40 V this time.

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PROCESS CONTROL

31 March 1997

6.5 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS

If any sensor errors occur under detect supply mode, toner supply mode is changed automatically as shown below.

	Error	Abnormal Condition	Fallback Toner	Display on
			Supply Mode	Operation Panel
	ID Sensor	When ID sensor output	Fixed Supply Mode	None
	Adjustment Error	cannot be adjusted to
		4.0 ± 0.2 V
	Abnormal ID Sensor	If VSP > 2.5 V during	Fixed Supply Mode	None
	(VSP)	VSP detection.
	Abnormal ID Sensor	If VSG < 2.5 V during	Fixed Supply Mode
	(VSG)	VSG detection
	TD Sensor	When TD sensor	Fixed Supply Mode	Manual ID level or
	Adjustment Error	output cannot be		ADS indicator blinks
		adjusted to 2.5 ± 0.1 V
	TD Sensor (VT)	If VT > 4.0 V or VT <	Fixed Supply Mode	Manual ID level or
	Measurement Error	0.3 V during VT		ADS indicator blinks
		detection.
	Drum Charge	Temperature detected	Fixed Supply Mode	None
	Thermistor Error	by the drum charge
		thermistor is below 0°C
		or above 60°C
	Abnormal Drum	Temperature detected	TD Sensor Supply	None
	Charge Thermistor	by the drum charge	Mode
	Output	thermistor is between
		0°C and 14°C

NOTE: No indication is displayed under the "abnormal drum charge thermistor output" condition, because the machine soon recovers due to the heat inside the machine.

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PROCESS CONTROL

6.6 TEMPERATURE CORRECTION

Copier

[A]

A204D506.wmf

The temperature correction has changed as explained below. Also, the machine no longer does the drum rotation time correction.

The temperature correction difference between the A204, A206, and A207 copiers and the A208, A210, and A211 copiers is a result of the difference in copy processing speed (240 mm/s for the A204, A206, and A207 copiers, compared with 200 mm/s for the A208, A210, and A211 copiers).

The new drum charge roller needs only about half the correction voltage used for the base copier. Also, the level of correction needed for the lowest temperature point (5°C) is about the same as the normal room temperature point for the base copier [A].

In the base machine, rotation time correction was only needed for low temperatures where the temperature correction was large. In the new machines, the temperature correction is never greater than –300 V, so the rotation time correction has been eliminated.

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PROCESS CONTROL

31 March 1997

The temperature corrections are as shown below.

∙Temperature Correction (Copying) - Base drum charge voltage = –1,500 V

∙Temperature Correction (VSP Pattern) - Base drum charge = –1,370 V

–A204, A206, and A207 –

Drum Charge Roller		Temperature Correction
Temperature (°C)		VSP Pattern	Copying
35.0	≤ T	+53	–57.0
28.0	≤ T < 35.0	–83.5 + 3.9T	–211.0 + 4.4T
10.0	≤ T < 28.0	–217.6 + 8.7T	–410.0 + 11.5T
	T < 10.0	–130.0	–295.0

– A208, A210, and A211 –

Drum Charge Roller		Temperature Correction
Temperature (°C)		VSP Pattern	Copying
35.0	≤ T	+47	–61.0
29.0	≤ T < 35.0	–51.0 + 2.8T	–173.0 + 3.2T
10.0	≤ T < 29.0	–199.1 + 7.9T	–355.5 + 9.5T
	T < 10.0	–120.0	–260.0

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31 March 1997

PROCESS CONTROL

6.7 TONER END RECOVERY

If the front cover switch or the main switch is turned off and on during a toner near-end/end condition, the machine will perform the toner end recovery procedure as shown on the flow chart on the next page.

For the base copier, the toner end sensor checked for toner for a total of 10 seconds. The check stops when the toner supply clutch stops transporting toner.

For the A204 series, the toner sensor checks for toner for a total of 14 seconds, stopping 2 seconds after the toner supply clutch stops. When the toner supply clutch stops, any toner present is likely to drop into the development unit, which will be detected during the final 2 seconds of detection time. This will decrease the chances of a mis-detection when a new toner bottle has been installed by the customer.

Copier

Toner Supply

O N

1 0

Clutch

O F F

A153/A155/A156/

A157/A159/A160

Toner End

O N

2

Sensor

O F F

Toner Supply

O N

5

2

5

2

Clutch

O F F

A204/A206/A207/

A208/A210/A211

Toner End

O N

2

Sensor

O F F

A204D516.wmf

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PROCESS CONTROL

31 March 1997

Toner End Condition
	Yes
Front
Cover Switch or Main
Switch Turned OFF/
ON?
	Yes
Drum Drive, Development
Clutch, Toner Supply Clutch,
Toner Bottle Drive Motor
Turn On.	t = 0s.
	No
t ³ 2s
	Yes
			No	Drum Drive, Development
Toner End		No	t ³ 5s	Clutch, Toner Supply Clutch,
Detection. Is Toner				Toner Bottle Drive Motor
Present?				Turn Off.
	Yes		Yes
						Yes
Components Turn Off. Toner			Toner Supply Clutch, Toner	No	t	³ 14s
End/Near End Condition is
			Bottle Drive Turn Off.
Canceled.
				Toner End
	No			Detection. Is Toner	No
			Toner End	Present?
t ³ 7s
		No	Detection. Is Toner
			Present?	Yes
	Yes
			Yes
Toner Supply Clutch, Toner		Components Turn Off. Toner		Components Turn Off. Toner
			End/Near End Condition is	End/Near End Condition is
Bottle Drive Turn On.
			Canceled.	Canceled.
			No
Toner End			t ³ 12s
Detection. Is Toner		No
Present?			Yes
	Yes
Components Turn Off. Toner
End/Near End Condition is
Canceled.

A204D515.wmf

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31 March 1997

PROCESS CONTROL

6.8 SUMMARY

NOTE: Only items marked with are different or reviewed from A153, A155, A156, A157, A159, and A160 copiers.

A summary of process control and correction timing is shown below.

		Electrical	Sensor Output	Correction Timing
	Correction				Automatic	Corrected Value
		Component	Used	Forced Correction
					Correction
	Manual ID	Operation	—	—	Every copy in	∙ Lamp voltage
	correction	panel			manual ID mode	∙ Dev. bias
	Reproduction	Operation			Every copy in	Development bias
	ratio		—	—	reduce/enlarge
		panel
	correction				mode
					Every copy in	∙ Lamp voltage
		Operation	—	—	halftone mode	∙ Dev. bias
	Halftone mode	panel				∙ Drum charge
						roller voltage
					∙ ADS Mode:	Development bias
					Once per original
					(ARDF mode), or
				—	once when the
					key is
	ADS				pressed (Platen
		ADS sensor	VADS (pattern)		mode)
	correction		VADS (original)	New exposure	Every 1,000 copies	∙ VADS
				lamp, ADS sensor,		(pattern)
				after SP4-001		is stored
				(Exposure lamp
				voltage
				adjustment) or
				optics cleaning
			VSG	New drum, ID	At the start of	∙ Dev. bias
	ID			sensor or ID	each copy job	∙ Toner supply
		ID sensor
	correction		VSP	sensor cleaning	About every 10	clutch ON
	and				copies	time
	Toner density
				When the	Every copy
	control
		TD sensor	VT	developer is
				changed
				New drum or ID	After every 1,000	∙ Drum charge
	VR correction	ID sensor	VRP, VRG	sensor replacement	copies	roller voltage
						∙ Dev. bias
				New drum,		Lamp voltage
				exposure lamp or
	VL correction	ID sensor	VLP, VLG	after SP4-001
				(Exposure lamp
				voltage adjustment)
		Drum charge			Every copy	Drum charge roller
	Temperature	roller	T: (temperature)	—		voltage
	correction	thermistor

Copier

27