Ricoh lily Service Manual

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

2. 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.

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. If the hot roller temperature is low when the main switch is turned on, the
copier starts process control self check automatically. Keep hands away
from the mechanical and the electrical components to avoid any injury.

5. If the start key is pressed before the copier completes the warm-up period
(Start key starts blinking red and green alternatively), 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. Never operate the copier without the ozone filters installed.

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

3. Toner and developer are non-toxic, but if you get either of them in your
eyes by accident, 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.

1996 By Ricoh Com pany Ltd. All rights r eserved



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.

LASER SAFETY

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

DANGER



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

WARNING FOR LASER UNIT



DANGER: Turn off the main switch before attempting any of the

procedures in the Laser Unit section. Laser beams can
seriously damage your eyes.

CAUTION MARKING:

INTRODUCTION

The A172/A199 copier (product name: LILY) is based on

the base copier.

(DFC-ALPHA)

This documentation gathers the A172/A199 differing points from the base
copier that service personnel will need to maintain this copier. Therefore, this
documentation should be treated as a 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.

,

the A109 copier

SECTION 1

OVERALL

MACHINE INFORMATION

10 May 1996 MACHINE CONFIGURATION

1. MACHINE CONFIGURATION

2

1

4

Overall

Information

3

5

- Copier -

A172V500.wmf

- Full System -

A172V501.wmf

Item Machine Code Note No.

Copier

Dual Job Feeder

Sorter (15-bin)

Film Projector Unit
Holder

Language RO M
board
(for operation panel)

A172
A199

A610

A322
A718

A702-18

A654

A172 is the edit version with a full color

•

operationpanel.
A199 is the non-e di t version with a bla ck &

•

white operati on panel.
An English language ROM board is installed

•

in -17/29/10/22/15 machines.
No language ROM board is installed in

•

-27/26 machines.
Common with A1 75/ A176/A177/A191/A192

•

copiers.
A sorter adapter ( A527) is require d fo r

•

installation.
A holder (A702- 18) i s required for inst all ation.

•

The holder can be installed independently as

•

an original table.
The following languages are available:

•

English (A4), Ger man, French, Ital ian,
Spanish, (Universal).

1

2

3
4
5

—

1-1

SPECIFICATIONS 10 May 1996

2. SPECIFICATIONS

2.1 SPECIFICATIONS

Specifications are subject to change without notice.
Configuration: Console
Copy Process: Dry electrostatic transfer system
Resolutions: 400 dpi
Gradations: 256 gradations
Original Type: Sheet/book, object
Original Size: Maximum: A3 (lengthwise), 11" x 17" (lengthwise)
Original Alignment: Rear-left corner

Paper Tray: 64 - 104.7 g/m2 or 17 - 28 lb

Copy Paper Weight:

•

Bypass Feed Tray: 64 - 157 g/m2 or 17 - 42 lb

•

Available Copy Paper Size:

Tray Paper Directi on A4/A3 version LT/DLT version

1st /2nd

Tray

3rd Tray

Bypass

Feed

Tray

Lengthwise

Sideways

Lengthwise

Sideways A4, B5, A5, 11" x 8

Lengthwise

Sideways

Non-standard

paper size

2

NOTE:

With paper heavier than 104.7 g/m

or
28 lb, use the bypass feed tray and
select Thick Paper mode.

A3, A4, 8

1/4

8

A4, A5 11" x 8

A3, B4, A4, B5, A5, 11" x 17" (DLT ), 11" x 15", 10" x 14",

1/2

8

1/2

8

A3, B4, A4, B5, A5, B6, A6 11" x 17" (DLT), 10" x 14",

A4, B5, A5, B6, 8

Horizontal di rection: 148 - 432 mm or 5.8" - 17.0"
Vertical directi on: 100 - 297 mm or 3.9" - 11.7"

1/2

" x 13" (F4),

" x 13"

" x 14" (LG), 8

1/2

" x 13" (F4), 8

" x 11" (LT), 8" x 10

1/2

1/2

" x 11" 8

1/2

", 8" x 10", 5

" (LT), 8

11" x 17" (DLT), 11" x 15",
10" x 14", 8

1/2

" x 14" (LG),

8" x 13" (F),

1/2

8

" x 11" (LT),

1/2

8" x 10

1/2

8

1/2

1/2

8

", 8" x 10"

1/2

" (LT),

1/2

" x 5

" x 5

" (HLT)

1/4

" x 13", 8" x 13" (F ),

1/2

1/2

" x 8

" (HLT)

1/2

" x 11" (LT),

" (HLT)

8" x 13" (F),

1/2

5

5

1/2

x 8

1/2

" x 11" (LT),

1/2

" x 8

1/2

" (HLT)

" (HLT)

1-2

10 May 1996 SPECIFICATIONS

Warm-up Time:
First Copy Time:

1/2

(A4 or 8

" x 11" sideways)

Copying Speed:
(Standard modes)

About 8 minutes (at 20°C or 68°F)

Full Color (4 scans): 15.5 seconds

•

Single Color:

•

Black, Yellow, Magenta, Cyan: 8.8 seconds
Red, Green, Blue, Orange, Light Green:

11.5 seconds.

NOTE:

1) When selecting OHP/Thick Paper

modes, copying speed is reduced.

2) After changing some modes, the first

copy time will take longer than usual.
Full Color (4 scans):

•

1/2

A4 or 8

" x 11" sideways: 6 copies/minute

A3 or 11" x 17": 3 copies/minute

Single Color (Black, Yellow, Magenta, Cyan):

•

A4 or 8

1/2

" x 11" sideways: 31 copies/minute

A3 or 11" x 17": 15 copies/minute

Single Color

•

(Red, Green, Blue, Orange, Light Green):
A4 or 8

1/2

" x 11" sideways: 10 copies/minute

A3 or 11" x 17": 5 copies/minute

Overall

Information

NOTE:

When selecting OHP/Thick Paper

modes, copying speed is reduced.

Non-reproduction Area:

Leading edge: 5 ± 2 mm or 0.2" ± 0.08"

•

Side: 2 ± 2 mm or 0.08" ± 0.08", Total less than

•

4 mm or 0.16"
Trailing edge: 2 ± 2 mm or 0.08" ± 0.08"

•

Copy Number Input: Number keys, 1 to 99
Automatic Reset: 1-minute standard setting; can also be set to 10

to 900 seconds in 1-second steps, or to no auto
reset.

Paper Feed: Paper Tray x 3

(500 sheets of paper each)

Bypass Feed Tray

(50 sheets of paper with paper lighter than

2

104.7 g/m

or 28 lb)

1-3

SPECIFICATIONS 10 May 1996

Copy Tray Capacity: 100 sheets of paper
Toner Replenishment: Bottle type (340g/bottle)

A4/A3 version: 25%, 50%, 65%, 71%, 75%,

Reproduction Ratio:

•

82%, 93%, 100%, (Full Size),
115%, 122%, 141%, 200%,
400% + User ratio x 2

LT/DLT version: 25%, 50%, 65%, 74%, 77%,

•

85%, 93%, 100%, (Full Size),
121%, 129%, 155%, 200%,

400%, + User ratio x 2
Zoom: From 25% to 400% in 1% steps
Power Source: 115 V 60 Hz, more than 12 A (for NA)

220 ~ 240 V 50/60 Hz, more than 7 A (for EU
and AA)

Power Consumption:
(Copier only)

Maximum: less than 1.5 kW

•

Warm-up: 1.40 kW

•

Stand-by: 0.93 k W

•

Copy Cycle: 1.20 kW

•

Noise Emission Sound pressure level (The measurements are

made in accordance with ISO 7779 at the
operator position.)

Copier only

Stand-by Less than 42 dB (A)

Copying Less than 56 dB (A)

Sound power level (The measurements are
made in accordance with ISO 7779.)

Copier only

Stand-by Less than 59 dB (A)

Copying Less than 69 dB (A)

Dimensions (W x D x H):

Copier Only:

•

692 x 713 x 1026 mm or 27.3" x 28.1" x 40.4"
Full System*:

•

1499 x 713 x 1099 mm or 59.1" x 28.1" x 43.2"

= Copier + Dual Job Feeder + Sorter + Ho l der

(*

)

1-4

10 May 1996 SPECIFICATIONS

Weight:
Optional Equipment

Copier Only: 200 kg or 440.8 lb

•

Dual Job Feeder

•

Sorter

•

Sorter Adapter

•

Projector Unit

•

Holder for Projector Unit

•

Key Counter

•

Interface Kit for Controller

•

Overall

Information

1-5

SPECIFICATIONS 10 May 1996

2.2 FUNCTIONS: BASIC MODEL VS EDIT MODEL

This machine comes in two versions. Refer to the following table for features
available on your machine.

Functions Edit type Basic type

Copy Image Density Adjustm ent (Auto/Manual )
Auto Color Selection
Full Color
Back
Single Color
Twin Color
Original Image Type Select io n
Paper Selection (Auto/Manual)

Preset R/E

Reducing/

Enlarging

Shift/Book

Color

Creation

Image

Creation

Color

Adjustment/

Memory

Area Editing
Interrupt Copying
Recall
Auto Reduce/Enlarge
Bypass Feed Copy i ng
Duplex Copying
Default Setting
User Tools
Display Color Full color Black & white

Zoom
Size Magnification
Directional Size Magnification
Poster Mode
Centering/Co rnering
Margin Adjustment
Erase
Single Copies
Color Conversi on
Color Erase
Color Backgroun d
Outline
Positive/Negat i ve
Shadow
Mirror
Slanted
Image Repeat
Image Overla y
User Color Memory
Single Color Adjustment
Color Balance Adjustment
Color Balance Sample
Image Adjustm ent

✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓
✓✓

—

1-6

10 May 1996 SPECIFICATIONS

2.3 NEWLY-ADDED OPERATING FEATURES

: Available



No. Features LILY (A172/A199) DFC-ALPHA (A109 )

1 Auto Image Density Full Color & Black Copy Black Copy only
2 Auto Color Calibration
3 Duplex Copying
4 Twin Color
5 Single Color 80 (+1) colors 8 colors
6 User Color 48 colors 3 colors
7 Color Back ground 84 (+1) colors 13 colors
8 Paint 84 (+1) colors 13 colors

9 Color Line
10 Frame Line
11 Image Overlay
12 Area Editing See the next page









(Edit type only)
(Edit type only)
(Edit type only)

: Not Available

✗

✗
✗
✗

✗
✗
✗

1. Auto Image Density mode can be selected when in Full Color mode.

2. Auto Color Calibration can be performed by the user.

3. Using the by-pass feed tray, rear side copying is available.

Overall

Information

4. Twin Color mode copies black parts in black and other parts in the
selected colo r .

5. Single Color
(8 colors x 4 density levels) + (12 user colors x 4 density levels) + 1 scan
color = 81 colors
* scan color = Edit type only

6. User Color
12 colors x 4 density levels = 48 possible colors
The total percentages of the mixed colors must be 255% or less.

7. Color Background
(9 colors x 4 density levels) + (12 user colors x 4 density levels) + 1 scan
color = 85 colors
* scan color = Edit type only

8. Paint (Edit type only)
(9 colors x 4 density levels) + (12 user colors x 4 density levels) + 1 scan
color = 85 colors
* Scan color = Edit type only

9. Color Line (Edit type only)
In the Area Editing mode, designated lines can be colored.
Available colors: 85 colors = 81 Single colors + (Bk x 4 density levels)

1-7

SPECIFICATIONS 10 May 1996

10. Frame Line
In the Area Editing mode, the outlines of the designated areas can be
colored.

11. Image Overlay
This function makes a copy merging images of two originals.

12. Area Editing mode

LILY (A172) DFC-ALPHA (A109)

Area Shape Rectangle, Polyg on, R ight Angle

Polygon, Close d Loop, Line

Number of Areas Maximum: 500 points

However, 1 area or li ne must be of
30 or fewer points.

Method of
Designati ng
Areas

Canceling Ar eas Not only single point s but al r eady

Maximum
Number of
Groups/Areas

Storin g the Area
Editing job
settings in
Program Mode

Canceling
Groups

Editor Pen and Cursor Cursor only

closed areas can b e cl eared.
15 Groups

Up to 3 job patterns can be applied .
Changing the color of one job
pattern will not affect the original
settings of the job pattern.

Always available. Not available in Creative Editing

Available. However, canceli ng a
group will remove it from the total
number of grou ps.

Rectangle, Polygon, Right Angle
Polygon, Closed Loop

Creative Editi ng: 6 Are as
1 area must be of 10 orfewer points
Color Editing: 6 Groups
Maximum 500 points

Only single points before closing
the area can be cleared.

Creative Editi ng: 3 Are as
Color Editing: 6 Groups
When in Color Editing mode, up to
3 job patterns can be applied,
Changing the color of one job
pattern will not affect the original
settings of the j ob pattern.

mode.
Available in Color Editing mode.

Not available.

1-8

10 May 1996 SPECIFICATIONS

MEMO

Overall

Information

1-9

MECHANICAL COMPONENT LAYOUT 10 May 1996

3. MECHANICAL COMPONENT LAYOUT

37

38

1

2
3

26

25

24

23

27

28

29

30

31

32

33

3534

36

22

21

20

19

18

17

4

5

6
7

8

9

10

11

12

13

16

Units different from A109

Bold Italic

Bold

: Additional units
: Modified units

15

1-10

14

A172V502.wmf

10 May 1996 MECHANICAL COMPONENT LAYOUT

1. Pre-cleaning Corona Unit

20. Pressure Roller

Overall

Information

2. By-pass Feed Table

3. Transfer Belt

4. ID Sensor

5. Belt Lubricant Bar

6. Belt Cleaning Blade

7. Registration Rollers

8. Roller Lubricant Bar

9. Transfer Roller Blade

10. Relay Roller

11. Transfer Roller

12. Toner Catch Pan

13. Toner Collection Bottle

14. Paper Discharge Plate

21. Hot Roller

22. Development Ozone Filter

23. Black/Cyan Development Unit

24. Drum Potential Sensor

25. OPC Drum

26. 2nd Scanner

27. 1st Scanner

28. Drum Mirror

29. Toner Shield Glass

30. Charge Corona Unit

31. Quenching Lamp

32. Drum Cleaning Blade

33. Drum Lubricant Bar

15. Transport Belt

16. Magenta/Yellow Development
Unit

17. 3rd Paper Tray

18. 2nd Paper Tray

19. 1st Paper Tray

Deleted units from A109

Lubricant brush

•

34. Cleaning Brush

35. Lens

36. f-theta Lenses

37. CCD Board

38. Polygon Mirror

1-11

DRIVE LAYOUT 10 May 1996

4. DRIVE LAYOUT

27
26

25
24

23
22
21

20
19

18
17

1

2 3

4

5

6
7
8

9

10

16

Units different from A109

Bold Italic

Bold

: Additional units
: Modified units

11

12

13

14

15

A172V503.wmf

1-12

10 May 1996 DRIVE LAYOUT

1. Transfer Belt Position Clutch

15. Paper Feed Motor

Overall

Information

2. Scanner Motor

3. Scanner Drive Pulley

4. Drum Timing Belt

5. Drum Motor

6. Bk-Sleeve Motor

7. Color-Development Drive Motor

8. Bk-Development Drive Gear

9. Bk-Development Drive Motor

10. Color-Development Drive Gear

11. Transport Unit Drive Gear

12. Fusing Unit Drive Gear

13. Transport Motor

14. Tray Lift Motors

16. 3rd Paper Feed Drive Pulley

17. Toner Collection Tank Drive Gear

18. 2nd Paper Feed Drive Pulley

19. 1st Paper Feed Drive Pulley

20. Transfer Roller Position Clutch

21. Registration Clutch

22. Relay Roller Drive Gear

23. By-pass Feed Drive Gear

24. Transfer Belt Drive Pully

25. Transfer Belt Motor

26. Lubricant Brush Clutch

27. Cleaning Motor

1-13

ELECTRICAL COMPONENT DESCRIPTIONS 10 May 1996

5. ELECTRICAL COMPONENT DESCRIPTIONS

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

Symbol Name Function Index No.

Printed Circuit Boards

PCB1 DC power supply Provides dc power. 20
PCB2 Lamp regulato r Provides d c power for the exposure l am p. 1

PCB3

PCB4

PCB5

PCB6

PCB7

AC drive Provides ac power for the hot roller and

pressure rol ler fusing lam ps.

High voltage supply ­C/G

High voltage supply -BSupplies high vol t age to the Y/M/C/Bk sleeve

High voltage supply ­T1/PCC/BR

High voltage supply -T2Supplies high voltage to the tra nsf er roller.

Supplies high voltage to the ch ar ge corona
and grid plate.

rollers as development bias or to the OPC
drum for drum potential sensor calibration.

Supplies high voltage to the be l t bias roller,
pre-clean i ng corona, and cleaning bias roll er.

11

12

26

13

17

PCB8

PCB9

PCB10

PCB11

PCB12

PCB13

PCB14 Noise filter Removes electrical noise. 23
PCB15 ID sensor Detects the density of the ID sensor pattern. 127

PCB16
PCB17 Polygon motor drive Controls the polygon motor speed. 8

PCB18

PCB19

PCB20

PCB21 Image Discriminate Used for anticou nt erfeiting. 6
PCB22

High voltage supply -DSupplies high voltage to the pa per di scharge

plate.

Main control Controls all copier functions both directly or

through othe r co ntrol boards.

Interface 1 Interfaces th e i nput/output of ele ct rical

components with the main control board.

Interface 2 Interfaces th e i nput/output of ele ct rical

components with the main control board.

Transfer belt motor
drive

Paper feed inter face Interfaces the inpu t/ output of electrical

Operation panel Cont rols the touch panel display and

CCD Converts the li ght reflected fr om th e original

Scanner contro l Processes R/G/B video signals fr om th e

Scanner drive Interfaces the input/output electrical

Display Editor
interface

Controls the speed and directi on of the
transfer bel t mot or.

components in the paper supply unit with the
main control board.

monitors the key matrix.

into analog electrical signals for the three
basic colors (R/G/B).

CCD board to be sent to the IPU board.

components in the optics cavity with the
scanner contr ol board.

Interfaces th e operation panel board with the
IPU board (A17 2 copier only).

22

15

21

18

14

19

25

9

7

3

10

1-14

10 May 1996 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Name Function Index No.

PCB23

PCB24

PCB25

PCB26

PCB27
PCB28 Paper width detecting Detects paper width in the by-pass feed table. 128

PCB29 Wire cleaner drive Controls ths corona wire cleaner operation. 16

Motors

M1
M2 C - Sleeve Turns the C sleeve roller in both di r ections. 31

M3 M - Sleeve Turns the M sleeve rol l er in both directions. 35
M4 Y - Sleeve Turns the Y sleeve roller in both direc tions. 34
M5 Drum Turns the drum. 28
M6 Bk - Sleeve Turns the Bk - sleeve roller in both directions. 30

M7

M8

M9

M10 Scanner Drives the 1st and 2nd scanners. 29
M11

M12
M13 Polygon Turns the polygon mirror . 47
M14

M15

M16

M17
M18 1st tray lift Lifts the 1st tray bottom plat e. 36

M19 2nd tray lift Lifts the 2nd tray bottom p l at e. 37
M20 3rd tray lift Lifts the 3rd tray bottom pl at e. 38

Operation Pane l
Control

IPU Processes R/G/B video si gnals from the

IPU interface Changes the clock frequency of R/G/B video

LD drive Generates the laser beam for printing the

Laser synchronizing
detector

Bk - Development
drive

Transport Drives the transport uni t , fusing unit, transf er

Color - Development
drive

Cleaning Drives th e dr um cleaning bru sh, the lubricant

Transfer belt Turns the transfer belt drive rol l er i n both

Paper feed Drives the pap er feed sections and the cam

Bk - Toner supply Dri ves the Bk toner tran sport and agitati on

C - Toner supply Dri ves the C toner transport and agita tion

M - Toner supply Drives the M toner transport a nd agitation

Y - Toner supply Drives the Y toner transpor t and agitation

Controls the operation pan el .

scanner control board and sends Y/M/C / Bk
video signals to the LD unit.

signals and al so sends the synchr oni zing
signal for the polygon motor.

latent image on the drum.
Detects the laser beam to control the start

timing of main scan writing.

Drives the Bk dual mixing roller.

roller, and transfer belt cleani ng unit.
Drives the Y/M/C dual mixing rollers

simultaneously.

brush, and the tr ansfer belt relea se
mechanism.

directions .

gear for the tone r collection bot tle.

mechanism.

mechanism.

mechanism.

mechanism.

24

2

4

5

66

46

45

27

32

33

39

43

42

41

40

Overall

Information

1-15

ELECTRICAL COMPONENT DESCRIPTIONS 10 May 1996

Symbol Name Function Index No.

M21 Wire cleaner Drives the wire/grid cleaner 44

Fan Motors

FM1 Fusing exhaust Removes heat from around the fusing unit. 49
FM2

FM3

Charge inlet Provides air flow around th e drum charge

section.

Inner cooling Provides ai r f low around the toner ta nk and

development uni t s.

48

57

FM4 IPU cooling Provides air flow around the IPU board. 52
FM5 Polygon motor cooling Provides air flow around the polygon motor. 53

FM6/7

FM8/9

FM10

Transport Sucks in air to attract co py paper to the

transport belts.

Development exhaust Removes air and heat from aroun d th e drum

and development units.

Optics exhaust Exhausts air from under the le ns housing

cover.

55/54

58/59

51

FM11 LD cooling Provides air fl ow to the LD unit. 50

FM12/13 Optics cooling Blows air into the optics cavity. 60/61

FM14

DC power supply
cooling

Provides air flow to transformers and
radiation plates on the dc power supply

56

board.

Sensors

S1

S2

By-pass feed tab l e Detects whether the by-pass feed table is

open or cl osed.

Oil end Detects whether the silicone oil tank is nearly

empty or not.

S3 Exit Detects misfeeds. 100
S4

S5

Transfer belt posi t i on Detects whether the transfer belt is i n contact

with the drum or not .

Humidity Detects humidity and temperature to

calculate th e absolute humidi t y.

S6 Drum potential Detects the drum surface potential . 125
S7

S8

S9

S10

M - Toner densit y Detects the toner density in the M

development uni t .

Y - Toner density Detects the toner density in the Y

development uni t .

Bk - Toner density Detects the toner density in th e Bk

development uni t .

C - Toner density Detects the toner density in the C

development uni t .

S11 Transport Detects misfeeds. 95

Registration Detects the leading edge or trailing edge of

S12

the copy pape r to control the rotat ion of the
paper feed and r egi stration rollers.

S13

Registratio n guide set De te ct s w het her the registrati on guide plate

is set or not.

73

91

67

88

97

96

101

98

74

70

1-16

10 May 1996 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Name Function Index No.

S14 Bk - Toner End Detects the toner end condition of Bk toner. 94
S15 C - Toner End Detects th e to ner end conditio n of C toner. 93
S16 M - Toner End D etects the toner end condition of M t oner. 92
S17 Y - Toner End Detects the toner end condi tion of Y toner. 90

S18

S19

S20

S21

S22

S23

S24

S25

S26

S27

S28

S29

S30
S31 Ori gi nal length - 1 D etects original length. 65

S32 Ori gi nal length - 2 D etects original length. 63
S33 Original width Detects original width. 106

S34

S35

S36

Transfer roller position Detects whether the t ra nsfer roller is in

contact with the transfer belt or not.

By-pass paper end Detects whether there is paper on the

by-pass feed table or not.

By-pass lengt h Detect s w het her paper on the by-pass feed

table is long er than A4 (Letter) side w ays or
not.

Toner overflow Dete ct s w het her the toner coll ect i on bottle is

full or not.

1st lift Detects the height of the paper st ack in the

1st paper tray to stop the 1st tray lift motor.

2nd lift Detects the height of the paper st ack in the

2nd paper tray to stop the 2nd tray li ft m ot or.

3rd lift Dete ct s the height of the pa per st ack in the

3rd paper tray to stop the 3rd tray lift motor.

1st paper end Detects whethe r there is paper in the 1st

paper tray or n ot .

2nd paper end Detects whether there is paper i n th e 2nd

paper tray or n ot .

3rd paper end Detects whether there is paper i n th e 3rd

paper tray or n ot .

1st paper feed Controls the 1st paper feed cl ut ch off/on

timing and the 1st pick-up sol enoid off timing.

2nd paper feed Cont ro l s the 2nd paper feed cl ut ch of f /on

timing and the 2nd pick-up solenoid off
timing.

3rd paper feed Controls the 3rd paper feed clutch off / on

timing and the 3rd pick-up sol enoid off timing.

Scanner unit lif t Detect s whether the scanner unit is lifted or

not.

Platen cover po si t i on Informs the CP U w het her the platen cov er is

up or down (related to APS/ARE function).

Scanner HP Informs the CPU whether the 1s t an d 2nd

scanners are at th e hom e position or not.

72

71

69

86

76

77

80

89

87

84

82

85

83

64

62

107

Overall

Information

Switches

SW1/2/3/4

Front door safet y Cuts the ac power line throu gh R A 1 and

detects whether the front door i s open or not.

1-17

102/103/

104/105

ELECTRICAL COMPONENT DESCRIPTIONS 10 May 1996

Symbol Name Function Index No.

Vertical transport set Cuts the ac power line through RA1 and

SW5/6

detects whether the vertical transport guide

78/79

is open or not.

Main Provides power to the copier.

When it is at the st andby position, the

SW7

electrical power is suppli ed only to the

99
heaters (drum, optics anti-condensation,
tray, transfer belt/roller).

SW8

SW9

SW10

2nd paper size Detects the paper size for the 2nd paper tray

and whether the tr ay i s set or not.

3rd tray set Detects whether the 3r d paper tray is set o r

not.

1st paper size Detects the paper size for the 1st paper tray

and whether the tr ay i s set or not.

75

81

68

Magnetic Clutches

Transfer belt position Controls the touch and release operation of

MC2

the transfer be l t by u si ng drive from the

108

cleaning mot or.

MC3

By-pass feed Starts pap er feed from the by-p ass feed

table.

111

MC4 Registration Drives the registration r ol l ers. 110

Transfer roller position Controls the touch and release oper at i on of

MC5

the transfer ro ll er unit by using dri ve from the

109

transport motor.

MC6 1st feed Starts pap er feed from the 1st paper tr ay. 1 13
MC7 2nd feed Starts paper fee d from the 2nd paper tray. 114
MC8 3rd feed Starts paper feed from t he 3r d paper tray. 115

Solenoids

SOL1

SOL2

SOL3

SOL4

SOL5

SOL6

SOL7

SOL8

Cleani ng entran ce
seal

Controls the touch and relea se operation of
the cleaning entrance seal on t he t ransfer
belt cleaning unit.

Lubricant ba r Control s the touch and release operation of

the lubricant bar.

Cleaning blade Controls the touch and release operation of

the belt cleaning blade.

By-pass pick-u p Controls th e up/ down movement of the

pick-up roller in the by-pass feed station.

1st pick-up Controls the up/down movement of the

pick-up roller in the 1st feed station.

2nd pick-up Controls the up/down movement of the

pick-up roller in the 2nd feed st at i on.

3rd pick-up Controls the up/down movement of the

pick-up roller in the 3rd feed sta tion.

1st separation roller Controls th e up/ down movement of the

separation roller in the 1st feed station.

1-18

122

124

123

112

121

119

117

120

10 May 1996 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Name Function Index No.

SOL9

SOL10

Lamps

L1 Fusing Provides heat to the hot roller. 144
L2 Pressure Provides heat to the pressure roller. 143

L3

L4

Heaters

H1

H2

H3/H4

H5

H6

2nd separati on r ol l er Controls the up/down movement of the

separation roller in the 2nd feed station.

3rd separation roller Contro l s the up/down move ment of the

separation roller in the 3rd feed station.

Exposure Applies high intensity light to the original for

exposure.

Quenching Neutralizes any char ge remaining on the

drum surfa ce af t er cl eaning.

Lower tray (opti on) Turns on when t he m ai n switch is off to keep

paper dry in the 3r d paper tray.

Upper tray (opti on) Turns on when t he m ai n switch is off to keep

paper dry in the 1st and 2nd paper trays.

Transfer belt /rol l er Turns on when t he t ransfer roller

thermoswi t ch detects 20C° or less to keep
the resistance of the transfer ro ll er at a
constant level.

Optics
anti-condensation

Drum Turns on when t he main switch is off to

Turns on when t he main switch is off to
prevent moisture from forming on the optics.

prevent moisture from forming around the
drum.

118

116

129

126

138

134

136/137

148

131

Overall

Information

Thermistors

TH1 Fusing Monitors the temperature of th e hot roller. 133
TH2

Thermofuses

TF1

TF2

Thermoswit ches

TS1

TS2

Pressure roll er Monitors the tem per at ure of the pressur e

roller.

Fusing Opens the fus i ng l amp circuit if th e fusing

unit overheats.

Pressure roller Opens the pressure roller lamp circuit if the

fusing unit ov er heats.

Optics Opens the exposure lamp circuit if the 1st

scanner overheats.

Transfer belt /rol l er Detects the te m per ature around the transfer

roller in order to keep the resist ance of the
transfer roller at a constant level.

1-19

142

132

141

130

135

ELECTRICAL COMPONENT DESCRIPTIONS 10 May 1996

Symbol Name Function Index No.

Counters

Black total Keeps track of the total number of scans for

CO1

Full color total Keeps track of the total numb er of scans for

CO2

Others

CB1

NF1 Noise filter Removes electrical noise. 140

CC1 Choke coil Removes high frequency cur r ent . 147

Circuit break er Provides back-up hi gh current protection for

black devel opment in both bl ack and color
copy modes.

Yellow, Magenta, and Cyan development in
both single and full color copy modes.

the electrical components.

145

146

139

1-20

SECTION 2

DETAILED DESCRIPTIONS

10 May 1996 MAJOR DIFFERENCES FROM THE DFC-ALPHA (A109)

1. MAJOR DIFFERENCES FROM THE
DFC-ALPHA (A109)

No. Item Contents Details

Process Control

Toner End

1

Detection

Latent Image

2

Control
Toner Density

3

Control

Around The Drum

OPC Drum The OPC drum layer material

1

Drum Charge

2

Wire

Drum Charge

3

Wire/Grid
Cleaning

Drum Cleaning Drum lubrication has been newly

4

The toner end detection software
has been eliminated.

The process control for latent
image control has been modified.

CNT

V

Correction has been

modified.

(Charge Transf er L ayer: CTL)
has changed.

The system has been changed
from a double-wi r e t o a
single-wire scorotron.

Drum charge wire/grid cleaning
has been newly added.

added.
The cleaning brush has been

changed from a looped-bristle
type to a straight- br i st l e ty pe.

A toner end sensor has been
added for each color. See 6.2 in
section 2 for deta i l s.

See 2.1 in section 2 for d et ai l s.

See 2.2 in section 2 for d et ai l s.

To reduce ozone a nd N O
reaction with the drum (to
prolong the life time of the drum).

See 3.1 in section 2 for d et ai l s.

See 3.2 in section 2 for d et ai l s.

See 3.4 in section 2 for d et ai l s.

To apply the lubricant evenly on
the drum. See 3.4 in section 2 for
details.

X

Detailed

Descriptions

Optics

Exposure Lamp The number of exposure la mp’s

1

Infra-red Filter The thickness of the inf ra-red

2

2nd/3rd Mirrors A heavier stabilizer has been

3

Exposure Glass A more high- conductivity gl ass is

4

Reflectors Reflectivity has increased

5

lighting points has increased
from 7 to 9.

filter has increased from 0.8 mm
to 1.0 mm.

installed on the 2nd/3rd mirrors.

used.

because of surface
improvements.

To decrease whit e bands on
copies caused by t he exposure
lamp’s lighting points.

To achieve better copy quality for
originals containing infra-red
radiance.
(prevents black areas from
becomi ng reddish)

To decrease scanner banding to
achieve better results for auto
letter/photo separation.

To decrease the possibility of the
exposure glass becoming dirty
with dust particl es.

To decrease the te m perature
around the optics c avi t y due to
less power to the exposure lamp.

2-1

MAJOR DIFFERENCES FROM THE DFC-ALPHA (A109) 10 May 1996

No. Item Contents Details

Optics Cooling
Fan Filter

6

The filter material has changed. It
is easier to repla ce the filter.

The air flow has improved to
reduce temperature rises in the
optics cavity. For replacement,
see sec t i on 5 for det ails.

Image Processing

RGB Filter The RGB filter coefficient for

1

each copy mode (l et t er /photo)

To improve gradation and
reproduction quality.

has been changed.

Color Correction New matrixes and masking

2

coefficients have been added to

See 4.4 in section 2 for d et ai l s.

match the new copy modes.

Image

3

Separation IC

The image separ at i on IC has
been changed.

To reduce photo/ le t te r image
separation err or s i n auto detect
mode.

Laser Exposure

Drum Mirror A heavier stabilizer has been

1

installed on the Drum mirrors.

To reduce the occur r ence of
banding on copies.

Development

Development
Sleeve Roller

1

The sleeve roll ers have been
changed to a sand-blast type.

Toner Tank

Toner Tank A toner end sensor has been

added for each col or.
The gree n lever has been

eliminated.

1

A toner tank detection
mechanism has been added.
When the tank is pul l ed out, it is
disconnected e lectrically from th e
main body.

Transfer B el t

Transfer Belt
Bias

1

The number of threshold levels
that de cide transfer bel t bi as
depending on environmental
conditions has changed from 2 to

4.

Transfer Belt
Cleaning

2

The belt lubricant mechanism
has changed to ap pl y l ubricant
directly to the transfer belt.

To eliminate th e 1. 25 mm
horizontal lines in halftone image
areas caused by the grooves on
the sleeve roller.

See 6.2 in section 2 for d et ai l s.

See 6.2 in section 2 for d et ai l s.

See 6.2 in section 2 for d et ai l s.

See 7.1 in section 2 for d et ai l s.

To prevent partial bl anking of
lines (due to incomplete toner
transfer) from appearing on
copies.
See 7.2 in section 2 for d et ai l s.

2-2

10 May 1996 MAJOR DIFFERENCES FROM THE DFC-ALPHA (A109)

No. Item Contents Details

Transfer R ol ler

Transfer
Belt/Roller

1

Heater

Transfer Rolle r The material of the transfer ro l le r

2

Transfer Roller
Bias

3

Paper
Discharge Plate

4

Paper

5

Discharge Plate
Output

Transfer Roller

6

Cleaning

The transfer roller heater has
been newly added to keep the
temperature around the transfer
roller unit at 20°C.

has been changed.
The number of threshold levels

that decide transfer roller bias
depending on environmental
conditions has been changed
from 2 to 4.

Transfer roller bi as settings for
duplex copyin g have been newly
added.

The installed a ngle of the paper
discharge plate has changed.

The output of the paper
discharge plate changes
depending on the copy paper.

The roller lubricant mechanism
has been newly added.

See 8.1 in section 2 for d et ai l s.

To improve tran sf er e ffi ciency.

See 8.2 in section 2 for d et ai l s.

See 8.2 in section 2 for d et ai l s.

To prevent toner scatter from
appearing around solid areas in
duplex mode. See 8. 4 i n section
2 for details.

See 8.4 in section 2 for d et ai l s.

See 8.3 in section 2 for d et ai l s.

Detailed

Descriptions

Fusing Unit

Hot Roller The material of the hot roller has

1

Pressure Roller The material of the pressure

2

Pressure Roller

3

Cleaning

Paper Feed

2nd Paper

1

Feed Station

Operation Panel

LCD (Liquid
Crystal Display)

1

been changed.

roller has been changed.
The pres sure rol l er cleani ng

mechanism has been newly
added.

The 2nd paper feed st at i on has
been changed to the universal
tray type.

The LCD has been changed to a
640 x 480 dot type.

A172: Full Color Display
A199: B/W Display

To make it suitable for duplex
copying.

To make it suitable for duplex
copying.

See 9.1 in section 2 for d et ai l s.

To meet customer s’ requests.

For easier operation and editing.

2-3

MAJOR DIFFERENCES FROM THE DFC-ALPHA (A109) 10 May 1996

No. Item Contents Details

Operation
Panel Control

2

Operation
Panel Self

3

Diagnostic
Mode

Others

Drum Dri ve Th e drum drive me chanism has

1

Copier Rear

2

Frame

Fusing exhaust

3

ozone filter

The operation panel control
board has been ne w l y added.
The main control board no longer
contr ols the operation panel.

The operation panel self
diagnostics mode has been
newly added.

been changed from a series of
gears to a timing belt system.

The thickness of the rear frame
has changed from 1. 6 mm to 2.0
mm

This filter has been eliminated. Because the ozone amount has

For easier servi cing of the
machine.

Banding on copie s are reduced.
See 3.3 in section 2 for d et ai l s.

Banding on copie s are reduced.

been decrease d due to the new
charge corona unit.

—

Options

1 DJF (A610) See the DJF section for details. —

15-Bin Sorter

2

(A322)
Holder

3

(A702-18)
Film Projector

4

Unit (A718)

See the Sorter section for details.

The colo r of t he exterior covers
has been changed.

See the Film Projecto r Uni t
section for details.

—

—

—

2-4

10 May 1996 PROCESS CONTROL

2. PROCESS CONTROL

2.1 LATENT IMAGE CONTROL

2.1.1 DRUM POTENTIAL SENSOR CALIBRATION

[A]

Main Board

[C]

RA #1

RA #2

RA#1 and RA #2 are packed in RL1 on
the High Voltage Supp l y Boar d – B.

–300 V
–600 V

A172D507.wmf

Sensor Output

V600 (V

V300 (V

)

2

1

)

Detailed

Descriptions

[B]

–300 –600

Actual Voltage

A172D508.wmf

The drum potential sensor [A] output is calibrated during the process control
self check.

The High Voltage Supply Board - B [B] has two relay contacts. Usually RA #1
grounds the drum. However, during the self check, the main CPU turns RA
#2 on and RA #1 off and applies the test voltage to the drum shaft [C]. In this
condition, the drum is isolated from the ground (floating).

By measuring the output of the drum potential sensor when –300 V (V
–600 V (V

) are applied to the drum, the sensor output is calibrated

600

300

) or

automatically. (The machine can now determine the actual drum potential
from the potential sensor output.) Using -300 and -600 V results in a more
accurate calibration of the sensor, since the voltage applied to the supply
board is much closer to the actual value, which is –450 V for V

B

(Development bias) during the process control self check.

2-5

PROCESS CONTROL 10 May 1996

2.1.2 GRADATION PATTERN DETECTION

LD Power Level

40 mm

1st

40 mm

2nd

3rd

13th

A172D510.img

14th

A172D509.wmf

A latent image of a 14-grade gradation pattern is created for each color (Bk,
C, M, Y) by changing the LD input current.

By creating 14 grades, the machine can achieve a more precise development
gamma factor, resulting in a more reliable pointer control.

2-6

10 May 1996 PROCESS CONTROL

2.2 TONER DENSITY CONTROL

2.2.1 V

T

V

2.5

CNT

CORRECTION

Copies

A172D511.wmf

Average ≥ 3.8

Average ≤ 2.3

2

Pattern Density (mg/cm

Gain Value = –1

Gain Value = ±0

)

Drum Potential

[A]
[C]

[B]

Detailed

Descriptions

A172D512.wmf

Gain value = +1

A172D513.wmf

Even if the toner concentration is constant, the toner density sensor output
gradually increases after new developer is installed because of developer
characteristics. Because of this, the machine believes that the amount of
toner in the developer has reduced. This causes the machine to increase the
toner concentration because the machine controls the toner concentration so
that V

To compensate for this, the V

T

stays constant.

CNT

gain is corrected by using the development
gamma curve made from the 14-grade pattern during process control self
check.

The present gamma curve [A] and the previous gamma curve [B] are
compared, and the average [C] is calculated. As shown in the diagram, the
gain is decreased by 1 when the average gradient is 3.8 or more. The
maximum compensation value is –16.

Because of this new V

CNT

correction system, the V

CNT

correction previously
performed every 200 copies is no longer necessary. Also, due to the use of
the average value, over-reduction of the gain is avoided.

2-7

PROCESS CONTROL 10 May 1996

2.2.2 FORCED TONER CONSUMPTION MECHANISM

For customers that mainly make copies other than full color copies, the
toners other than the selected colors are not used. For these toners, the
amount of toner inside the development unit will gradually increase every 50
copies, since toner agitation is performed at this interval, and some toner is
added at this time (see section 6.1). If this condition continues, toner
scattering and toner density control failure may occur.

To compensate for this, along with the transport screw gear modification, the
machine checks the output of each TD sensor during the process control self
check. If the machine detects V

REF-VT

≥ 0.3 V, it determines that there is too
much toner inside the development unit and makes a pattern across the
whole width of the drum to forcibly consume some toner.

2.2.3 FORCED TONER SUPPLY MECHANISM

When the machine makes consecutive copies that have a large portion of
solid image areas, toner supply and agitation from the toner tank cannot keep
up with the toner consumption speed, causing lighter copies, toner scatter,
and related SC codes to appear.

To compensate for this, the output of each TD sensor is checked every copy.
When the machine detects V

T-VREF

≥ 0.5 V five times consecutively, it
determines that the amount of toner in the development unit is low. At this
moment, the copy job is interrupted, and toner is fed into the development
unit forcibly. After forced supply, the machine resumes the copy job.

2-8

10 May 1996 DRUM UNIT

3. DRUM UNIT

3.1 DRUM CHARGE

This copier uses a single corona wire scorotron system to charge the drum.
The corona wire applies a negative charge to the drum surface. The striped

stainless steel grid plate makes the corona charge uniform and controls the
negative charge on the drum surface to -650 V (standard) by applying a
negative grid bias voltage.

The high voltage supply board –C/G gives a constant corona current (–450

A) to the corona wire, and controls the grid voltage (based on the results of

µ

process control) to maintain proper image density. Grid voltage is controlled
to match changing factors such as a dirty grid plate, dirty charge corona
casing, and OPC chargeability.

The use of the single wire scorotron system has the following advantages.

The amount of corrosive gas (O3, NOX) is reduced due to the decrease in

•

total current.

Detailed

Descriptions

The life time of the drum is increased due to the decrease in the amount

•

of corosive gas.
Uneven charge problems are alleviated due to the increase of the amount

•

of current per meter of the corona wire.

2-9

DRUM UNIT 10 May 1996

3.2 DRUM CHARGE CORONA WIRE/GRID CLEANING

[E]

[B]

[A]

[F]

[D]

[C]

A172D524.wmf

[G]

A172D525.wmf

The flow of air around the charge corona unit may deposit toner particles and
paper dust on the corona wire or corona grid plate. These particles may
interfere with charging and cause uneven charge on the drum.

The wire cleaner [A], which consists of the wire cleaner pads [B] and the grid
plate sponge [C], automatically cleans the wire and the inside of the grid plate
to prevent such problems from appearing.

The wire cleaner is driven by a dc motor. Normally the cleaner is located at
the front end (this is home position). Whenever the main switch is turned on
while the hot roller temperature is below 80°C (before process control), the
wire cleaner motor [D] turns on to bring the wire cleaner to the rear end of the
corona unit and back to the home position. The corona wire and the inside of
the grid plate are cleaned at the same time. This procedure can be manually
performed with an SP mode as well (<2> SP Test, page 4).

When the cleaner moves from the home position to the rear position (the
white arrow in the illustration), only the grid plate is cleaned since the grid
plate sponge is always in contact. When coming back, the rib [E] on the
cleaner is forced by the opening in the corona casing, and the wire cleaner
pads contact the corona wire.

There are no home position or return position sensors. The wire cleaner drive
board at the back of the machine monitors the current applied to the motor.
When the wire cleaner reaches the end, it is stopped and the motor is locked.
At this time, the current of the motor slightly increases and the drive board
detects that it is time to rotate the motor in reverse.

Also, a grounding plate [F] is installed on the back side of the drum stay [G]
to reduce the electrical noise generated from the cleaner motor.

2-10

10 May 1996 DRUM UNIT

3.3 DRIVE MECHANISM

[A]

[B]

A172D500.wmf

The drum is driven by the drum motor [A] through a timing belt [B].
By the use of a timing belt system, banding on copies are reduced due to the

lower mechanical load.

Detailed

Descriptions

2-11

DRUM UNIT 10 May 1996

3.4 DRUM LUBRICATION MECHANISM

[A]

[B]

[B]

A172D501.wmf

[A]

A172D502.wmf

While the drum rotates, the cleaning brush [A] distributes lubricant from the
drum lubricant bar [B] to the surface of the drum.

This mechanism improves the copy quality, especially for letter areas in full
color mode, since it helps the toner transfer to the transfer belt. It also
improves the efficiency of drum cleaning.

To apply the lubricant to the surface of the drum evenly, a straight-bristle type
is used for the drum cleaning brush.

2-12

10 May 1996 IMAGE PROCESSING

4. IMAGE PROCESSING

4.1 IPU SECTION BLOCK DIAGRAM

LD

Unit

Video

Controller

Bk, C, M, Y

Filter

Printer

Gradation

•

•

• Image

Creation

Detailed

Descriptions

I/F

Color ControllerDisplay Editor I/F Board

Magnification•

•

RGB

γ

Scanner

Picture

•

• Color

Correction

I/F

Filter

Element

Correction

ACS

Area

CPU

Auto L/P

Image Separation

Memory

Main Control Board

Board

IPU I/F

Board

Control

Scanner

IDU

A172D535.wmf

2-13

IMAGE PROCESSING 10 May 1996

4.2 ACS (AUTO COLOR SELECTION)

Signal

Level

RBG

*MIN: Also known as "RGB Common D ata"

In Auto Color Selection mode, the Black Copy mode or Full Color mode is
automatically selected to match the original image. During the 1st scanning
cycle, the latent image is developed with amount of black toner according to
the corrected R/G/B video signals. If the original does not have any color
area, the 2nd scanning is aborted, and the developed image is transferred
from the transfer belt to copy paper. Then the black and white copy comes
out. If the original has a color area, copying resumes in the full color copy
mode (4 scans).

MAX

MIN

A172D526.wmf

To recognize if the original has a color area or not, the R/G/B video signals
are compared. If the maximum difference among R/G/B signal levels
(MAX-MIN in the above diagram.) is within a certain range, the original is
considered to be black and white.

This range can be changed by the user.

Black: The range is wider
Color: The range is narrower

Also, the user can select either B/W Priority or Color Priority, to reproduce the
B/W areas or Color areas well, when the ACS mode is selected.

*Factory Setting = Color Priority

2-14

10 May 1996 IMAGE PROCESSING

When Color Priority is selected

Bk Conversion Data

255 : Letter areas

UCR
setting 1

0 255

<ACS: Color Priority>

UCR ratio: 100%

4

3

2

5

: Photo areas

8

7

6

9

RGB Common Data

Detailed

Descriptions

A172D527.wmf

a) Letter areas
The UCR ratio is set to 100% to reproduce the letter areas well. Black toner
is always used if RGB Common Data is greater than zero.

b) Photo areas
In photo areas, black toner is not used until RGB Common Data reaches a
certain value, which depends on the UCR adjustment setting (see below).
This can be one of 9 settings as shown in the above illustration.

Also, the UCR ratio changes with image density. The steeper the gradient in
the above graph, the faster the UCR ratio increases with image density (as
RGB Common Data increases).

The UCR range for the photo areas can be changed over 9 levels by the user
(Image Adjustment: UCR Adjustment) to get the best color reproduction.

2-15

IMAGE PROCESSING 10 May 1996

When B/W Priority is selected

Bk Conversion Data

255 : Letter areas

0 255

<ACS: B/W Priority>

: Photo areas

UCR ratio: 100%

RGB Common Data

A172D528.wmf

a) Letter areas
The UCR (Under Color Removal) ratio is set to 100% to reproduce the letter
areas well.

b) Photo area
The UCR ratio is set to a higher value than for the Color Priority default
setting (level 5), so that low image density areas of B/W originals can be
reproduced well.

2-16

10 May 1996 IMAGE PROCESSING

4.3 RGB FILTER

RGB Filter

RGB Input

Filtering

ADS (Full Color)

RGB Output

(to Color Correction)

A172D529.wmf

4.3.1 Filtering

To improve the image reproduction, the appropriate filter coefficients are
applied to the R/B/G video signals, depending on the selected image modes
(letter/photo) or the result of Auto Letter/Photo separation.

4.3.2 Auto Image Density Control (Full Color)

This mode prevents the background of an original from appearing on copies.
The Auto Image Density Level can be changed using the User Tools. (There
are 5 levels.)

Detailed

Descriptions

When Full Color mode and Auto Image Density mode are selected, video
signals corresponding to the background are detected and their output level
is set to zero. The threshold for detecting the background can be changed
over 5 levels using the User Tools.

RGB
Output Data

RGB Input Data

Threshold

A172D533.wmf

2-17

IMAGE PROCESSING 10 May 1996

4.4 COLOR CORRECTION

(from RGB Filter)

RGB Input

Color
Correction

Positive/Negative

Background Density Control

YMCBk

CPU

Memory

Contrast

ADS

(B/W, Twin Color, Single Color)

ACC

Scan
Color

YMCBk

Color Conversion

YMCBk Output

A172D541.wmf

2-18

10 May 1996 IMAGE PROCESSING

4.4.1 Image Modes

RGB video signals are converted to YMCBk video signals using a color
conversion table.

A172D530.wmf

a) Printed Photo/Glossy Photo mode
A suitable color conversion table for Printed Photo or Glossy Photo mode is
applied to improve the reproduction of such originals.

b) Copied Photo/Map mode
A suitable color conversion table for Copied Photo or Map mode is applied to
improve the reproduction of such originals.

c) Auto Letter/Photo mode
At the factory setting, Printed Photo mode is applied for the photo areas
detected by the Auto Letter/Photo mode.
The user can change this setting so that either of the following modes will be
applied for photo areas.

Printed Photo mode

•

Glossy Photo mode

•

Copied Photo mode

•

Detailed

Descriptions

2-19

IMAGE PROCESSING 10 May 1996

4.4.2 Backgr ound Density Control

RGB
Output Data

Darker
Setting

Lighter
Setting

RGB Input Data

A172D531.wmf

There a 9 levels of background density controls.

a) Lighter setting
Small effect on the high image density areas, but the low image density areas
are reproduced lighter or erased.

b) Darker setting
Small effect on the high image density areas, but the low image density areas
are reproduced darker.

When combining the Full Color mode and Auto Image Density mode, the
background density may be reproduced lighter or erased. To reproduce the
color background well, it is necessary not to use Auto Image Density mode
but to adjust the background density control to a darker setting.

2-20

10 May 1996 IMAGE PROCESSING

4.4.3 Con trast

RGB
Output Data

Weaker

Stronger

RGB Input Data

A172D532.wmf

Contrast between light and dark areas of the image can be adjusted. There
are over 9 levels.

a) Strong setting
The density of the dark image areas is increased and the density of the light
image areas is decreased.

b) Weaker setting
The density of the dark image areas is decreased and the density of the light
image areas is increased.

Detailed

Descriptions

2-21

IMAGE PROCESSING 10 May 1996

4.4.4 Auto Image Density Control (B/W, Twin Color, Single Color)

This mode prevents the background of an original from appearing on copies.
The Auto Image Density Level can be changed using the User Tools. (There
are 5 levels.)

When B/W, Single Color, or Twin Color and Auto Image Density mode are
selected, this function combines the Background Density Control and
Contrast as shown in the following table.

ADS Level

↑

Dark +1

Standard 0

Light –1

↓

+2

–2

Backgro und

Density Control

–1 0
–1 +1
–1 +2
–2 +2
–2 +3

Contrast

2-22

10 May 1996 IMAGE PROCESSING

4.5 ACC (AUTO COLOR CALIBRATION)

Test Pattern

Bk

Target

Actual

C
M

Bk

C
M

γ

γ

Photo mode

Y

Letter mode

Y

(4 scan)

A172D534.wmf

Detailed

Descriptions

Image Density

LM H

A172D540.wmf

Auto Color Calibration can be performed using the User Tools.
A test pattern, including the patterns for Letter mode and Photo mode, will be

printed first. The user then scans the test pattern. The resulting printer
gamma curve depends on the results of scanning the test pattern.

There are adjustment tables for L, M, H, and ID MAX values stored in the
machine. The machine applies these to approximate the actual curve to the
target curve as closely as possible.

If needed, the printer gamma curve can be adjusted further manually in the
SP mode. (See section 5, Color Balance Adjustment)

Also, a printer gamma setting can be stored in memory (temporarily or
permanently) and curve can be recalled. When the ACC is performed, the
current printer gamma setting will be automatically stored in the temporary
memory, which can be recalled after the ACC is performed. (See Section 4,

Service Tables, SP Table

.)

2-23

IMAGE PROCESSING 10 May 1996

4.6 YMCBk FILTER

In addition to the RGB filter, the most suitable software filter is applied to
YMCBk video signals to improve the image reproduction.

High Contrast filter (emphasizing edges)

•

Smoothing filter

•

Soft

(Smoothing)

Setting 1234567

Applied

Filter Table

Letter
mode

Photo

mode

1234567

0123456

Standard

(Emphasizing Edges)

Sharp

The filter can be selected by the user by adjusting the Sharp/Soft level
(Image Adjustment).

2-24

10 May 1996 DEVELOPMENT

5. DEVELOPMENT

5.1 DEVELOPMENT SL EEVE CLEANING

Detailed

Descriptions

A172D506.wmf

To achieve a faster CPM for black and white originals when copying 1 to 1 or
using Auto Color Select (ACS) mode, the development sleeve cleaning mode
previously performed for every original is now performed periodically.

For A4 or smaller size originals, a maximum of 40 black and white copies can
be made without the machine stopping to perform development sleeve
cleaning (20 copies for originals larger than A4 size). If a color original is
detected in between when using ACS mode, the cleaning mode is executed,
and the original counter will be reset. This setting can be changed with SP
mode.

2-25

TONER TANK 10 May 1996

6. TONER TANK

6.1 TONER AGITATION

[B]

[A]

A172D503.wmf

Clockwise

Stop

Counter
Clockwise

Clockwise
Stop
Counter

Clockwise

One Cycle

1.0S 0.3 0.30.5S

A172D504.wmf

Cycle12345

Toner End Detection is done here

A172D505.wmf

Under the following conditions, the toner agitator [A] inside each toner tank
rotates to agitate the toner inside the toner tank.

Whenever the main switch is turned on while the hot roller temperature is

•

below 110°C.
After a multi-copy job is completed and more than 50 copies have been

•

made since the last toner agitation.
When the optional ARDF is used, the machine stops the copy cycle after

•

150 copies have been made since the last toner agitation.
When the toner tank is pushed in during a near toner end or toner end

•

condition.

As shown above, one cycle of this agitation consists of rotating in both
directions, and is performed for five consecutive cycles.
In order to prevent unnecessary toner from entering the development unit
during agitation, the transport screw gear [B] has some play before rotation is
transmitted to the transport screw.

2-26

10 May 1996 TONER TANK

6.2 TONER END DETECTION

[A]

A172D503.wmf

Four toner end sensors [A] (which are piezoelectric) are installed on the toner
tank to monitor the near end condition for each color toner. Toner end
detection is performed during toner agitation, and the detection sequence is
as follows.

Detailed

Descriptions

1. Near Toner End Condition

The machine starts sampling the output of the toner end sensor every 0.1
second during the last three cycles of the toner agitation process (see the
previous page). If a no toner condition is detected for 90% of the
samples, the machine enters the near toner end condition.

2. Toner End Condition

When a near toner end condition is detected, a total of 30 copies can be
made using the toner for which the near end condition was detected.
After this, the machine enters the toner end condition and copying using
that toner is disabled.

3. Toner End Recovery

When the front door is opened and the toner tank rails are pulled out and
in, the machine starts to perform the toner end recovery procedure. The
sequence and the recovery condition is the same as for the near toner
end condition detection.

If the toner end condition is not cleared, copying using that particular color
toner is disabled. This prevents the customer from clearing the near end or
toner end condition by simply opening and closing the front cover or turning
the main switch off and on.

The green lever which was previously installed to prevent toner from flowing
into the development unit has been eliminated, due to the change in the toner
end detection mechanism.

2-27

TRANSFER BELT UNIT 10 May 1996

7. TRANSFER BELT UNIT

7.1 TRANSFER BELT BIAS

Transfer B el t Bi as (Face Side: No rm al H u m idity)

Copy Mode

1C 2C 3C 4C

1st

Dev.

Cycle

2nd
3rd

4th

Transfer Belt Bias Dependi ng on Humidity Range (1C Mode: Face Side)

Bias

1410 1410 1410 1410

1490 1490 1490

1575 1575

1660

2075
1740

1410

Low1 Low2 Low3 Normal High

0 4.3 8.5 11.3 21.5

Humidity (g/m3)

A172D514.wmf

This machine changes the transfer belt bias voltage for every mode and
every copy cycle.

For 1C copy mode, which is more influenced by environmental conditions,
the transfer belt bias output is divided into five ranges by four threshold
values (as mentioned in the table above) and is determined by the output of
the humidity sensor. Only three different bias settings are present as the
factory setting for each environment.

The transfer belt bias voltage data can be monitored in the SP Adjustment
Mode P-5 and 6. These data should not be changed. For more details, see
the SP Mode Section.

2-28

10 May 1996 TRANSFER BELT UNIT

7.2 TRANSFER BELT LUBRICATION

[C]

[C]

[E]

[A]

[B]

[E]

[A]

[D]

A172D515.wmf

ON OFF

A172D516.wmf

Detailed

Descriptions

A172/A199
A109

Amount

0 50 100 150

Copy Count

A172D517.wmf

The transfer belt lubricant bar [A] on the transfer belt cleaning unit [B] applies
lubricant directly to the transfer belt [C] after every copy.

The on/off movement of the transfer belt lubricant bar solenoid [D] which is
synchronized with the belt cleaning mechanism, pushes the lubricant bar
against the support roller [E] in the transfer belt unit.

Compared with the previous model, the amount of lubricant applied to the
transfer belt will stay at a constant level for every copy cycle. Because of this,
copy quality problems such as partial blanking of lines (due to incomplete
toner transfer) can be reduced.

2-29

TRANSFER ROLLER UNIT 10 May 1996

8. TRANSFER ROLLER UNIT

8.1 TRANSFER BELT/ROLLER HEATER CONTROL

[A]

[B]

[C]

A172D518.wmf

HEATER THERMOSWITCH

A172D519.wmf

The resistance of the transfer roller [A] changes with the environment. It is
especially at low temperatures.

The transfer roller thermoswitch [B] detects the temperature around the
transfer roller. To keep the resistance of the transfer roller at a constant level,
when the detected temperature is 20°C or less, the transfer belt/roller heaters
[C] turn on until the temperature rises above 20°C.

The heaters are not turned on/off by the main switch. The heaters operate
whenever the copier power cord is plugged in.

2-30

10 May 1996 TRANSFER ROLLER UNIT

8.2 TRANSFER ROLLER BIAS

<Transfer Roller Bias Coefficient by Humidity Range (1C Mode: Face Side; Normal Paper)>

Bias

1729

1573

Dev.

Cycle

1st

2nd

3rd
4th

(Photo)

4th

(Letter)

1404

1300
1001

Low1 Low2 Low3 Normal High

0 4.3 8.5 11.3 21.5

Transfer R ol ler Bias (Norma l Humidity)

Paper Mode

Normal

Paper

1300 1200 2150 2150 1300 1450
1600 1450 2200 2200 1800 1750
1900 1750 2500 2500 2100 2050

1600 1450 2200 2200 1800 1750
1600 1450 2200 2200 1800 1750

Thick

Paper

OHP:

Sideways

OHP:

Lengthwise

Humidity (g/m3)

A172D520.wmf

Normal:

Back

Thick:

Back

Detailed

Descriptions

The transfer roller bias is determined by the output of the humidity sensor. It
is divided into five humidity ranges by four thresholds, to compensate for
changes in the humidity of surrounding areas to maintain constant copy
quality.

The threshold is divided more towards the low humidity side, resulting in
more sensitivity at the low humidity end. This enables more accurate shift of
the transfer bias with small changes in the environment.

Also, the transfer roller bias is changed for each copy mode and the kind of
copy paper currently used.

NOTE:

All values shown on this page are in volts D.C..
Values shown using SP Mode <1> SP Adjustment, page 7, are in a
data format.

2-31

TRANSFER ROLLER UNIT 10 May 1996

8.3 TRANSFER ROLLER LUBRICATION

[A]

[E]

[D]

[B]

[A]

[C]

[D]

A172D539.wmf

The transfer roller lubricant bar [A] above the cleaning blade [B] continuously
applies lubricant directly to the transfer roller [C].

Four spring plates [D] under the transfer roller guide [E] press the lubricant
bar against the transfer roller.

By applying lubricant, the cleaning efficiency of the transfer roller cleaning
blade is increased, which prevents the back side of copies from becoming
dirty with toner and paper dust.

2-32

10 May 1996 TRANSFER ROLLER UNIT

8.4 PAPER DISCHARGE

[A]

Detailed

Descriptions

[B]

A172D521.wmf

[C]

[B]

A172D522.wmf

Discharge Plate O utput

Normal Paper Thick Paper Duplex: Fa ce Duplex: Back

4000 V 3500 V 4000 V 4000 V

The high voltage supply board -D [A] applies ac voltage to the discharge
plate [B]. The discharge plate removes any charge remaining on the paper
[C] to separate the paper from the transfer belt.

To perform an accurate discharge, the output of the discharge plate differs
with the copy mode or paper being used. For OHP mode, discharge is not
performed because the OHP sheet separates from the transfer belt as a
result of its stiffness.

2-33

FUSING UNIT 10 May 1996

9. FUSING UNIT

9.1 ROLLER CLEANING MECHANISM

[A]

[C]

[B]

[D]

[E]

A172D523.wmf

The cleaning roller [A], which is always in contact with the hot roller [B],
collects the toner and paper dust adhering to the surface of the hot roller. The
collected matter is scraped off by a stainless steel blade [C].

The pressure roller cleaning roller [D], which is always in contact with the
pressure roller [E], collects the toner and paper dust adhering to the surface
of the pressure roller. The pressure roller cleaning roller is driven by physical
contact with the pressure roller.

The pressure roller cleaning roller prevents poor copy quality in duplex mode
(face side) and dirt on the back side of copies in normal mode. It also
prevents horizontal lines from appearing on the back side when making OHP
sheets.

2-34

10 May 1996 FUSING UNIT

9.2 FUSING TEMPERATURE CONTROL

Each rollers are controlled at the temperature shown in the table below.

During Copying

Manual Duplex

(Back Side)

Normal:160 Normal:170

Thick

Paper: 170

Thick

Paper: 170

Hot

Roller

Temp.

Pressure

Roller

Temp.

Stand-by

180 160 170 170 170

120 Hot Roll er T em p . - 20 120 120

Normal OHP/Thick Paper

1C 2C, 3C, 4C 1C 2C, 3C, 4C 1C 2C, 3C, 4C

Detailed

Descriptions

2-35

OPERATION PANEL 10 May 1996

10. OPERATION PANEL

This operation panel has an LCD (640 x 480 dots). Most of the keys for
functions are displayed on the LCD (Touch panel).

There are two versions of the LCD.

Basic Model (A199): Black/White LCD

•

Edit Model (A172): Full Color LCD + Editor Function

•

*The scanned image will be displayed on the LCD
in full color (256 colors in total).

10.1 OPERATION PANEL CONTROL BLOCK DIAGRAM

Image Scanning Section Image Processing Unit Image Printing Section

Main Control Board

Mechanisms/Sensors

Image Data

Command

Control

•

Operation Panel

LCD Touch Panel

VGA Controller

Operation Control Board

Keyboard Controller

OP-PORT1 OP-PORT2

2-36

A172D536.wmf

10 May 1996 OPERATION PANEL

10.2 OPERATION CONTROL BOARD

R

8 bit

GB

8 bit 8 bit

3 bit + 3 bit + 2 bit = 8 bit

A172D537.wmf

Resolution Enlargement Ratio

Full Size
Enlarge 1
Enlarge 2
Enlarge 3
Enlarge 4

25 dpi 100%
50 dpi 200%

67 dpi 264%
100 dpi 400%
132 dpi 528%

The Operation Control Board monitors the commands input by the user, and
sends them to the Main Control Board. Also, the Operation Control Board
controls the operation panel itself (Display Switching, and Display Control).

Detailed

Descriptions

The data is sent as serial data through the optical fiber between the
Operation Control Board and Main Control Board.

When in area editing mode, the Operation Control Board receives the area
image data (RGB data: 8 bit) from the IPU and displays it in 256 colors on the
large LCD.
As the Operation Control Board has a CPU, an Operation Panel
Self-diagnostic Mode is available. (See Section 6, 3. Operation Panel
Self-diagnostic Mode.)

2-37

OPERATION PANEL 10 May 1996

10.3 OP-PORT

Operation
Control
Board

+5 V
+12 V
–12 V

LED DATA

SPEAKER

DRIVER

OP-PORT 2

DECODER

BUZZER

LED MATRIX

OP-PORT 1

LED MATRIX

LCD

KEY DATA

MACHINE ID

CONTRAST

VFF

CFL

ADRFF

SWITCH

CONTROL 1

SWITCH

CONTROL 2

INT2

X DATA

Y DATA

SW MATRIX

DIODE MATRIX

+12 V

INVERTER

+12 V

REF VOLTAGE

GENERATION CIRCUIT

ANALOG

SW

COMPARATOR

AMPLIFIER: X

AMPLIFIER: Y

CONVERTER

X BIAS

Y BIAS
Y ANALOG
X ANALOG

SW MATRIX

DC/DC

HV

+5 V

VR

TOUCH

PANEL

LCD I/F

The OP-PORT 1 & 2 control the following:

1. Switches and LED Buzzer

2. Touch detection and Touch Point detection

3. Power Supply to the LCD

4. Contrast Adjustment

5. CFL (Cold Fluorescent Lamp) Power Supply inverter function

2-38

A172D538.wmf

SECTION 3

INSTALLATION

10 May 1996 INSTALLATION REQUIREMENTS

1. INSTALLATION REQUIREMENTS

1.1 ENVIRONMENT

1. Temperature Range: 10°C to 32°C (50°F to 89°F)

2. Humidity Range: 15% to 90% RH

3. Ambient Illumination: Less than 2,000 lux (Do not expose to direct
sunlight.)

3

4. Ventilation: Minimum space 20 m
Room air should turn over at least

3

30 m

/hr/person

5. Ambient Dust: Less than 0.15 mg/m

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,

.

3

(4 x 10-6, 4 x 10-6, Oz/yd3)

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 5 mm (0.2") of level

2. Right to left: Within 5 mm (0.2") of level

NOTE:

The machine legs may be screwed up or down in order to level
the machine. Set a carpenter’s level on the exposure glass when
you do this.

3-1

INSTALLATION REQUIREMENTS 10 May 1996

1.3 MINIMUM SPACE REQUIREMENTS

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

Copier only

Full system

NOTE:

A172I505.wmf

A172I506.wmf

A space of at least 10 cm (3.9") at the rear of the machine is
necessary for smooth air flow into the machine.

3-2

10 May 1996 INSTALLATION REQUIREMENTS

1.4 POWER REQUIREMENTS

1. Input voltage level: 115 V/60 Hz: More than 12 A
220 ∼ 240 V, 50/60 Hz: More than 7 A

2. Permissible voltage fluctuation: 10%

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.

Installation

3-3

COPIER (A172/A199) 10 May 1996

2. COPIER (A172/A199)

2.1 ACCESSORY CHECK

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

2.1.1 Copier

1. Operating Instructions (except -27 machines)........................... 1

2. NECR (-17, -27, and -29 machines only) ................................. 1

3. Editor Pen.................................................................................. 1

4. Copy Tray.................................................................................. 1

5. Operating Instructions Holder ................................................... 1

6. Total Counter Resetting Tool..................................................... 1

7. Leveling Shoe............................................................................ 4

8. Instructions Procedure Sheet ................................................... 1

9. Philips Truss Head Screws M4 x 8............................................ 2

10. Caution Decal - 4 Languages (-22, -26, -27 only) ..................... 1

2.1.2 Optional Holder (A702-18)

1. Base Bracket ............................................................................ 1

2. Holder Cover ............................................................................ 1

3. Front Cover................................................................................ 1

4. Lower Cover .............................................................................. 1

5. Philips Pan Head Screws M4 X 6.............................................. 8

6. Philips Truss Head Screws M4 X 8 .......................................... 3

3-4

10 May 1996 COPIER (A172/A199)

2.2 COPIER SEPARATION

[A]

A172I509.img

[C]

[B]

[C]

A172I510.img

The machine can be separated into two units (the main frame and the paper
supply unit). Separation of the machine will help the transportation to the
customer’s site.

1. Open the front door and remove the front securing brackets [A] (4 screws

each).

2. Remove both upper and lower rear covers (4 screws each).

3. Remove the rear securing brackets [B] (4 screws each).

4. Disconnect the connectors running between both units, and free them

from the harness clamps.

Installation

5. Lift up the machine by using the handles.

NOTE:

a) When lifting the machine, lift straight up.
b) Positioning pins [C] are located at the rear. When attaching, make

sure to clear the harnesses out of the way.

3-5

COPIER (A172/A199) 10 May 1996

2.3 COPIER INSTALLATION PROCEDURE

NOTE:

Since the installation procedure is not packed with the copier as an
accessory, always bring this manual with you.

[B]
[A]

A172I511.img

NOTE:

a) Before performing the following installation procedure, be sure to

plug in the copier power cord due to the change of material of the
transfer roller. However, don’t switch on yet.
For detailed information about the new roller, see the Detailed
Description section.

b) Insert the leveling shoes [A] under the leveling feet [B], and level

the machine if necessary. (The leveling feet can be screwed up or
down.)

c) Keep the factory setting data sheet under the operation panel for

future use. We recommend making a copy to be kept at your office
also.

d) Before removing the drum protective sheet, always remove all the

development units out of the copier.

3-6

10 May 1996 COPIER (A172/A199)

[A]

[A]

A172I512.img

Installation

[B]

A172I500.wmf

1. Remove the tape strips.

2. Open the front doors then remove the tape strips [A] around the toner

tank and the tapes [B] securing the registration guide plates (knobs B
and B3).

1

3-7

COPIER (A172/A199) 10 May 1996

[B]

[C]

[E]

[A]

A172I513.img

A172I514.img

[D]

A172I515.img

3. Remove the right inner cover [A] (3 screws) and the bracket [B] securing

the toner tank to the front side plate (1 screw).

4. Remove the bracket [C] securing the transfer roller unit (1 screw).

5. Install the operating instruction holder [D] (2 truss screws [M4 x 8]).

6. Push and slide out the toner tank [E]. Then remove the toner tank (2

screws).

3-8

10 May 1996 COPIER (A172/A199)

[C]

[D]

[B]

[A]

A172I504.img

[F]

[E]

A172I501.wmf

A172I503.img

7. Lower the toner collection duct [A] (1 hook [B]).

8. Remove the yellow toner supply receptacle [C] (1 screw).

9. Disconnect the four connectors [D] and free them from the three harness

clamps.

Installation

10. Remove the transfer belt stay [E] (5 screws).

11. Pull out and remove the transfer belt cleaning unit [F].

NOTE:

To prevent the lubricant bar from being scratched, pull the handle
of the transfer belt unit slightly to the right while you pull the
transfer belt cleaning unit out.

3-9

COPIER (A172/A199) 10 May 1996

[C]

[B]

[A]

A172I516.img

[I]

[H]

[H]

A172I517.img

[D]

[G]

[E]

[F]

A172I518.wmf

12. Carefully pull and remove the transfer belt unit [A]. (While holding the

handle [B], release the lever [C])

NOTE:

There are stands at the rear side of the transfer belt unit. After
pulling out the unit out of the machine, stand the transfer belt unit
as shown.
Do not touch the transfer belt surface with bare hands.

13. Remove the charge corona unit [D] (1 screw, 1 connector), PCC [E] (1

screw) and ID sensor board [F] (1 screw).

14. Remove the knob [G] and the two screws [H] and pull out all the

development units slightly (2 ∼ 3 cm) then remove the drum stay [I].

3-10

10 May 1996 COPIER (A172/A199)

[B]

[D]

[C]

[A]

A172I519.img

[E]

[G]

[F]

A172I520.img

A172I521.img

15. Remove the magenta/yellow development unit [A] (1 release lever [B])

and remove the black/cyan development unit [C] (1 release lever [D]).

16. Disconnect the drum’s toner collection pipe [E] as shown.

Installation

17. Remove the knob screw [F] (counterclockwise) and pull out the

quenching lamp.

18. Remove the drum unit [G] (2 screws).

3-11

COPIER (A172/A199) 10 May 1996

[A]

A172I522.img

[B]

[C]

[D]

19. Turn the drum unit over.

NOTE:

Let the unit rest on it’s casing.

20. Remove the drum protective sheet [A].

21. Loosen then move the knob [B]. (Move the knob from [C] to [D].)

•

[C] position = No pressure applied

•

[D] position = Pressure being applied

22. Tighten the knob [B] at the lower position [D].

[E]

A172I523.img

23. While pressing up the latch [E] to apply the cleaning blade pressure,

rotate the drum counterclockwise 3 times to ensure that setting powder is
evenly applied, as shown.

NOTE:

Hold only the edge of the drum to rotate it (within 1 cm from the
end).

3-12

10 May 1996 COPIER (A172/A199)

[E]

[D]

[C]

[A]

[C]

[F]

A172I518.wmf

[G]

Installation

[B]

24. Reinstall the following units or parts in the machine as follows.

1) Slide in the drum unit and secure it to the shaft with the knob screw.

2) Set the drum stay [A] in position and secure the drum unit (2 screws).

3) Remove the drum stay [A] and reinstall the quenching lamp, toner
collection tube and development units.

NOTE:

When reinstalling the magenta/yellow development unit [B],
make sure that the bottom plate fits the rails as shown.

4) Set the drum stay by securing the 2 screws [C] then the knob [D].

5) Reinstall the charge corona unit [E] (1 screw, 1 connector), PCC [F] (1
screw), and the ID sensor board [G] (1 screw).

3-13

A172I524.img

COPIER (A172/A199) 10 May 1996

[A]

[B]

A172I525.img

25. Confirm the belt bias roller [A] is in the release position (innermost
position) as shown. If not, turn the shaft [B] with a flat head screwdriver
until the belt bias roller comes to the release position.

NOTE:

If the belt bias roller is not in the release position, it will touch the
drum and damage it.

26. Re-install the following units or parts in the following order.

1) Transfer belt unit.

2) Transfer belt cleaning unit

NOTE:

To prevent the lubricant bar from being scratched, pull the
handle of the transfer belt unit slightly to the right while you
re-install the transfer belt cleaning unit.

3) Transfer belt stay (5 screws)

4) Four connectors (6P white, 3P red, 3P white, 3P blue)

NOTE:

The 2P white connector is not used.

5) Toner collection duct (1 hook)

3-14

10 May 1996 COPIER (A172/A199)

CAUTION



1. Be careful when handling the fusing unit. It is hot.

2. Take care not to spill silicone oil on the floor. If silicone oil spills on
the floor, immediately clean it with a silicone oil remover. Silicone
oil is very slippery and can cause someone to fall.

[A]

Installation

[B]

A172I526.img

[D]

[C]

A172I527.img

27. While releasing the lever [A], pull out the fusing unit [B].

28. Open the exit unit [C] (2 "D4" release levers).

29. Loosen the 2 black screws [D] until they moves freely so that the fusing
pressure is being applied.

NOTE:

Do not turn the pressure adjustment screws which are located
just beside the screws [D].

3-15

COPIER (A172/A199) 10 May 1996

[E]

[A]

[H]

[D]

[L]

[F]

[B]

[C]

[G]

A172I528.img

[K]

[I]

[J]

A172I507.wmf

A172I508.wmf

30. Remove the fusing handle cover [A] (2 screws) and the fusing top cover
[B] (1 screw).

31. Prime the oil supply pad with silicone oil [C].

32. Remove the oil cap [D] and fill the tank with silicone oil to its max level [E].

33. Manually operate the oil pump lever [F] and confirm the proper operation
of the silicon oil supply system [G].

34. Reset the covers, the exit unit, oil cap and the fusing unit.

35. For

-26 and -27

installation procedures. For

machines, perform the following language ROM

machines, perform if replacement to a

-22

language other than English is needed.

1) Detach the operation panel [H] (2 screws). (Do not remove any

connectors.) Gently place it face down on the platen cover.

2) Remove the securing bracket [I] (2 screws).

3) Install the requested language rom board [J] using the securing

bracket and the accessory screw [K] as shown.

4) Reinstall the operation panel, making sure that the panel is properly

hooked in [L].

3-16

10 May 1996 COPIER (A172/A199)

36. Locate the switch actuator [A] inside
the right door and actuate the front
safety switch.

[A]

A172I529.img

37. Plug in the power cord and turn on the main switch.

38. Enter SP mode as follows.

1) Press the clear modes key.

2) Wait for 2 or 3 seconds while the display returns to the initial screen.

3) Enter "107" with the number keys.

4) Hold down the clear/stop key for more than 3 seconds.

39. Touch the SP Test Mode key [B].

NOTE:

Make sure to use the editor pen when touching the touch panel
display.

[B]

40. Touch the Next key [C] to open page 4.

NOTE:

Wait until the development unit drive stops, then start step 41.

Installation

3-17

[C]

COPIER (A172/A199) 10 May 1996

[F]

[C]

[A]

[B]

[B]

A172I530.img

A172I531.img

41. Remove the black toner supply receptacle [A] (1 screw).

NOTE:

Refer to the toner tank lid for the color of the development unit.

42. Remove the developer supply funnel [B] from the bracket [C] and clean
the inner surface.

43. Set the developer supply funnel on the black development section as
shown.

44. Touch the key [D], to enter the output mode.

45. Enter "68" with the number keys, then touch the key [D] again to select
test mode #68 "black development drive motor ON".

46. Touch the Start key [E].

47. Shake a pack of black developer [F] 20 times then pour it in.

48. 1 minute after pouring the developer, touch the stop key [G].

NOTE:

Do not touch the stop key within 1 minute, otherwise, the
developer will not be distributed evenly in the development unit.

[D]

[E]

49. Remove the developer supply funnel, then install the toner supply
receptacle.

3-18

[G]

10 May 1996 COPIER (A172/A199)

50. Install the cyan, magenta and yellow developer in the same manner as
black developer installation (step #40 to #49).

NOTE:

To select the "color development drive motor ON" mode, enter
"69" for color instead of 68 for black (refer to step #45).

51. Return the developer supply funnel to the original position.

52. Touch the Previous key [A] to open page 3.

[A]

53. Perform developer initial setting as follows.

1) Confirm that the main charge corona, PCC, ID sensor boards are set

correctly (1 screw each).

2) Confirm that the toner tank is not installed.

NOTE:

If the toner tank is installed, toner is supplied during developer
initial setting and the machine cannot figure out the proper toner
concentration of the new developer.

Installation

3) Touch the All Start key [B] to start the developer initial setting. After the

adjustment is completed, the machine stops automatically.

54. Touch the Index key [C].

[B]

[C]

3-19

COPIER (A172/A199) 10 May 1996

55. Touch the SP Data Output key [A].

[A]

56. Check whether V

T

has the same values as V

REF

for all colors (Bk, Y, M,
C). If not, touch the Index key [B] then return to the test mode page 3 to
perform developer initial setting (step 53) again.

[B]

3-20

10 May 1996 COPIER (A172/A199)

[B]

[A]

A172I532.img

A172I502.wmf

57. Put the toner tank [A] on the Accuride rails (2 screws).

58. Add toner [B] for all colors.

•

NOTE:

Read the instructions on the box for how to add toner.

•

Before reinstalling the toner tank, wait at least 30 seconds to
let the toner settle.

59. Slowly push the toner tank [A] in.

60. Close the front doors and install the copy tray.

61. Load A3 or 11" x 17" paper in the 3rd paper tray.

62. Place a C-4 test chart on the exposure glass.

63. Touch the Copy In SP key [C] and make 20 full color copies using A3 or

1/2

11" x 17" size paper. (40 full color copies using A4 or 11" x 8

" is also

acceptable.)

[C]

Installation

3-21

COPIER (A172/A199) 10 May 1996

64.

Wait 5 minutes
NOTE:

The process control self check (step 67) must be performed

to ensure that no residual voltage remains on the drum.

when there is no residual voltage on the drum.

65. Touch the SP Mode key [A] to enter the SP mode.
[A]

66. Touch the Index key.

67. Touch the SP Special Feature key [B].

[B]

68. Confirm that the PID key [C] is selected for the Process Control Mode

Selection. If not, touch the PID key [C].

69. Touch the Index key [D].

[C]

[D]

3-22

10 May 1996 COPIER (A172/A199)

70. Touch the SP Test Mode key [A].

[A]

71. Touch the Next key [B] to open page 4.

Installation

72. Touch the Process Control Self Check Start key [C]. After the self check

is completed, the machine stops automatically.

CAUTION



While process control is taking place, do not touch the knob, drum
stay, or drum shaft. These parts and the fly wheel carry a high
electrical voltage during process control.

73. Touch the Index key [D].

[B]

[D]

[C]

3-23

COPIER (A172/A199) 10 May 1996

74. Touch the SP Data Output key [A].

[A]

75. Touch the Next key [B] and open page 3.

76. Check the V

D

and VL [C] for each color. If the difference between ’Target’
and ’Actual’ for any color exceeds 5, wait 5 minutes and go back to step
72 and perform the process control self check again.

77. Touch the Index key [D].

[B]

[D]

[C]

3-24

10 May 1996 COPIER (A172/A199)

78. Touch the Exit key [A].

[A]

79. Turn off the main switch and place the accessory switch actuator in its
original position.

80. Reinstall the right inner cover (3 screws) and turn on the main switch.

81. Copy the C-4 test chart in letter mode and printed photo mode.

82. Perform the ACC procedure. (See chapter 5.)

Installation

3-25

COPIER (A172/A199) 10 May 1996

2.4 PAPER SIZE CHANGE

[C]

[B]

[B]

[A]

A172I533.wmf

At the customer’s request, change the paper size for the 3rd feed tray as
follows.

1. Draw out the paper feed tray [A].

2. Change the position of the front and the rear side fences [B] (1 screw
each) and the end fence [C] (1 screw) to match the paper size.

3-26

10 May 1996 COPIER (A172/A199)

3. Enter SP Mode as follows:

1) Press the clear modes key.

2) Wait for 2 or 3 seconds while the display returns to the initial screen.

3) Enter "107".

4) Hold down the clear/stop key for more than 3 seconds.

4. Touch the SP special feature key [A].

[A]

5. Touch the Previous key [B] to select the paper tray size setting mode
(page 12).

[B]

6. Touch the appropriate paper size key and direction key for the 3rd feed
station. Then touch the Index key [C].

Installation

[C]

3-27

COPIER (A172/A199) 10 May 1996

7. Touch the Exit key [A] to exit SP mode.

[A]

8. Check machine operation and copy quality.

3-28

10 May 1996 COPIER (A172/A199)

2.5 OPTIONAL HOLDER (A702-18)

[B]

[A]

Installation

A172I534.img

[C]

1. Remove the right upper cover [A] (2 screws).

2. Install the holder base bracket [B] (6 screws).

3. Install the holder cover [C] (2 screws).

A172I535.img

3-29

COPIER (A172/A199) 10 May 1996

[A]

A172I536.img

4. Install the lower cover [A] (2 truss screws).

5. Install the front cover [B] (1 truss screw).

[B]

A172I537.img

3-30

10 May 1996 COPIER (A172/A199)

2.6 KEY COUNTER INSTALLATION

[D]

[E]

[F]

[C]

[B]

[A]

Installation

[G]

A172I538.img

1. Remove the following parts. (Refer to Exterior And Inner Covers.)

•

Upper rear cover

•

Right inner cover

•

Upper right cover

2. Remove the key counter cover [A] (2 screws) from the key counter holder
bracket [B].

3. Disconnect the short-circuit connector [C] from the key counter connector
[D].

4. Couple the connector [D] with the key counter connector [E].

5. Hold the securing plate [F] on the inside of the key counter holder bracket
and insert the key counter holder [G].

6. Align the screw holes in the securing plate with the mounting holes in the
key counter holder and secure the key counter holder (2 screws).

NOTE:

The securing plate has three different hole sizes. Use the holes
that match those on the key counter holder that you are installing.

7. Reinstall all the covers and check the key counter operation.

3-31

COPIER (A172/A199) 10 May 1996

2.7 UPPER AND LOWER TRAY HEATERS (OPTIONS)

[A]

A172I539.img

[E]

[C]

[D]

A172I541.img

NOTE:

Both heaters are available as service parts.

1. Attach the heater to the bracket (2 M4 x 10 screws).

2. Pull out and remove all the paper feed trays [A] (4 screws each).

3. Install the upper tray heater assembly [B] (2 M4 x 8 screws).

[B]

A172I540.img

4. Mount the harness in the clamp [C] and connect as shown.

5. Install the lower tray heater assembly [D] (2 M4 x 8 screws).

6. Mount the harness in the clamp [E] and connect as shown.

7. Reinstall the paper feed trays [A].

3-32

10 May 1996 DUAL JOB FEEDER (A610)

3. DUAL JOB FEEDER (A610)

3.1 ACCESSORY CHECK

Check the accessories against the following list:
Description Q’ty

1. Installation Procedure....................................................... 1

2. NECR (-17, -27 only)........................................................ 1

3. Stepped Screw ................................................................. 2

4. Sponge Retainer............................................................... 1

5. Philips Pan Head Screw with Washer - M5 x 10.............. 2

6. Hinge Stopper Bracket ..................................................... 2

7. Philips Pan Head Screw - M4 x 6..................................... 2

Installation

8. Feed-out Guide Mylar....................................................... 1

9. Decal................................................................................. 1

3-33

DUAL JOB FEEDER (A610 ) 10 M ay 1996

3.2 INSTALLATION PROCEDURE

A610I500.wmf

[A]

A610I501.wmf

[C]

[B]

[D]

[D]

[A]

A610I502.wmf

A610I503.img

1. Remove the tape strips and the cushions [A] as shown.

2. While raising the lock plate [B], slide the platen cover [C] to the right and
remove it.

3. Remove the platen cover mounting screws [D].

3-34

10 May 1996 DUAL JOB FEEDER (A610)

[B]

[C]

[A]

A610I505.wmf

A610I504.wmf

[D]

[E]

[F]

A610I506.wmf

4. Install two stepped screws [A].

5. Attach the sponge retainer [B] to the top cover of the copier as shown.

6. Mount the DF on the copier by inserting the two stepped screws into the
holes in the DF hinge [C], then slide the DF to the front, as shown.

Installation

7. Secure the DF to the copier by using the screw holes as shown
(2 screws - M5 x 10 [D]).

8. Remove the small cap on the upper rear cover then connect the main
connector [E] and the fiber optic cable connector [F].

3-35

DUAL JOB FEEDER (A610 ) 10 M ay 1996

Face up

Mit der Schriftseite

nach oben

Face imprimée

deuuus

Faccia in su

[F]

A610I507.wmf

[A]

[E]

Boca arriba

[B]

A610I515.wmf

[D]

[C]

A610D508.wmf

A610I509.wmf

9. Secure the hinge stopper bracket [A] as shown (2 screws - M4 x 6).

10. Attach the feed-out guide mylar [B] under the original table. Attach it
between the 3rd [C] and 4th [D] ribs (counting from the rear).

11. Apply the appropriate decal at [E].

12. Remove the small cover [F] at the rear of the DF upper cover (1 screw),
and turn on DIP SW101-1.

13. Plug in the copier and turn on the main switch.

NOTE:

The copier automatically recognizes that the DF has been
installed.

14. Make copies using the DF and confirm the machine functions properly.

15. Explain to the customer that settings may now be changed, depending on
the characteristics of each original.

3-36