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

Overall

Information

- 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).

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

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

A4, A5 11" x 8

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

1/2

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

" 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

" x 11" (LT),

1/2

8" x 10

1/2

", 8" x 10"

1/2

" (LT),

1/2

" x 5

" (HLT)

1/4

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

1/2

" x 8

" (HLT)

1/2

" x 11" (LT),

" (HLT)

8" x 13" (F),

1/2

x 8

1/2

" x 11" (LT),

1/2

" x 8

1/2

" (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

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

2 3

3534

6 7

Units different from A109

Bold Italic

Bold

: Additional units : Modified units

1-10

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

2 3

6 7 8

Units different from A109

Bold Italic

Bold

: Additional units : Modified units

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.

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).

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

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.

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.

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

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

board.

Sensors

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

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

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.

101

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.

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.

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

Heaters

H3/H4

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

Detection

Latent Image

Control Toner Density

Control

Around The Drum

OPC Drum The OPC drum layer material

Drum Charge

Wire

Drum Charge

Wire/Grid Cleaning

Drum Cleaning Drum lubrication has been newly

The toner end detection software has been eliminated.

The process control for latent image control has been modified.

CNT

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.

Detailed

Descriptions

Optics

Exposure Lamp The number of exposure la mp’s

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

2nd/3rd Mirrors A heavier stabilizer has been

Exposure Glass A more high- conductivity gl ass is

Reflectors Reflectivity has increased

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

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

each copy mode (l et t er /photo)

To improve gradation and reproduction quality.

has been changed.

Color Correction New matrixes and masking

coefficients have been added to

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

match the new copy modes.

Image

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

installed on the Drum mirrors.

To reduce the occur r ence of banding on copies.

Development

Development Sleeve Roller

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.

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

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

Transfer Belt Cleaning

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 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

Heater

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

Transfer Roller Bias

Paper Discharge Plate

Paper

Discharge Plate Output

Transfer Roller

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.

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

Pressure Roller The material of the pressure

Pressure Roller

Cleaning

Paper Feed

2nd Paper

Feed Station

Operation Panel

LCD (Liquid Crystal Display)

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.

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

Operation Panel Self

Diagnostic Mode

Others

Drum Dri ve Th e drum drive me chanism has

Copier Rear

Frame

Fusing exhaust

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

(A322) Holder

(A702-18) Film Projector

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

)

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

(Development bias) during the process control self check.

2-5

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