Ricoh pearl SPECIFICATIONS

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SERVICE MANUAL

(Machine code: C229)

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

HEALTH SAFETY CONDITIONS

1. If you get ink in your eyes by accident, try to remove it with eye drops or flush with water as first aid. If unsuccessful, get medical attention.

2. If you ingest ink by accident, induce vomiting by sticking a finger down your throat or by giving soapy or strong salty water to drink.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

CAUTION

The RAM has a lithium battery which can explode if handled incorrectly. Replace only with the same type of RAM. Do not recharge or burn this battery. Used RAM's must be handled in accordance with local regulations.

ATTENTION

La carte RAM comporte une pile au lithium qui présente un risque d'explosion en cas de mauvaise manipulation. Remplacer la pile uniquement par une carte RAM identique. Ne pas recharger ni brûler cette pile. Les cartes RAM usagées doivent être éliminées conformément aux réglementations locales.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

2. Used ink and masters should be disposed of in an environmentally safe manner and in accordance with local regulations.

3. When keeping used lithium batteries (from the main processing units) in order to dispose of them later, do not store more than 100 batteries (from the main processing units) per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

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

HEALTH SAFETY CONDITIONS

1. If you get ink in your eyes by accident, try to remove it with eye drops or flush with water as first aid. If unsuccessful, get medical attention.

2. If you ingest ink by accident, induce vomiting by sticking a finger down your throat or by giving soapy or strong salty water to drink.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

CAUTION

ATTENTION

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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

2. Used ink and masters should be disposed of in an environmentally safe manner and in accordance with local regulations.

1 July, 1998 SPECIFICATIONS

1. OVERALL INFORMATION

1.1 SPECIFICATIONS

Configuration: Desktop

Master Processing: Digital with 400 dpi thermal head

Scanning (Pixel Density): 400 dpi CCD

Printing Process: Fully automatic stencil system, with one drum and

pressure cylinder system

Original Type: Sheet/Book

In Platen Mode: Document size:

Maximum 304.8 x 432 mm [12.0" x 17.0"] Thickness: Less than 30 mm Weight: Less than 10 kg

In ADF Mode: Document size:

Maximum 297 x 864 mm [11.6" x 33.8"]

Minimum 105 x 128 mm [4.2" x 5.1"]

Document weight:

52.3 - 104.7 g/m2[14 - 28 lb]

Overall

Information

ADF capacity:

30 sheets (using 20 lb or 80 g/m2 paper)

Reproduction Ratios: Inch versions Others

Full Size: 100% 100%

Reduction: 65% 71%

74% 82% 77% 87% 93% 93%

Enlargement: 121% 115%

129% 122% 155% 141%

Zoom: 50 - 200% (by 1%) in Platen mode

50 - 155% (by 1%) in ADF mode

Directional Magnification:

50 - 200% (by 1%)

Image Modes: Letter, Photo, Letter/Photo, Pencil, Tint

1-1

SPECIFICATIONS 1 July, 1998

Printing Area:

(At 20 °C/ 65 % RH)

Metric size version models:

290 mm x 409 mm

Inch size version models:

290 mm x 419 mm [11.4" x 16.4"]

With optional A4 drum:

290 mm x 204 mm [11.4" x 8.0"]

Edge Margins: Leading edge:

10 mm (At the "0" position of Image Shift mode)

Trailing edge: 2 mm

Print Paper Size: Minimum: 70 mm x 148 mm [2.8" x 5.9"]

Maximum: 325 mm x 447 mm [12.7" x 17.6"]

Print Paper Weight: 47.1 g/m2 to 209.3 g/m2 [12.5 lb to 55.6 lb]

Printing Speed: 60, 75, 90, 105, 120 sheets/minute (5 steps)

Master Process Time: Platen mode:

Less than 15.5 seconds (A3 paper)

Less than 12 seconds (A4 paper)

ADF mode:

Less than 19.5 seconds (A3 paper)

Less than 16 seconds (A4 paper)

Master Eject Box Capacity: 60 masters / A3 size (Normal conditions)

Side Registration Adjustable

± 10 mm

Range:

Vertical Registration Adjustable Range:

Inch size version models:

± 10 mm

Metric size version models:

± 15 mm

Paper Feed Table Capacity: 1000 sheets (80 g/m2 / 20 lb)

Paper Delivery Table Capacity: 1000 sheets (80 g/m2 / 20 lb)

Power Source: 110/120 V, 50/60 Hz: 2.7 A

220 - 240 V, 50/60 Hz: 1.5 A

Maximum Power Consumption: 110/120 V version: 285 W

220 - 240 V version: 280 W

1-2

1 July, 1998 SPECIFICATIONS

Noise Emission:

(At operation position)

At 60 rpm printing speed: 57 dB At 90 rpm printing speed: 60 dB At 120 rpm printing speed: 64 dB

Weight: 94 kg [207 lb]

101 kg [222.7 lb] with ADF

Dimensions: (Width x Depth x Height)

Trays closed: 625 mm x 650 mm x 574 mm

With ADF: 625 mm x 650 mm x 684 mm

Trays open: 1405 mm x 650 mm x 574 mm

With ADF: 1405 mm x 650 mm x 684 mm

Master Type: Thermal master roll type:

420 mm width, 110 m / roll

Yield:

200 masters/roll (at A3 size)

Max run length per master:

2,000 prints

Master Storage Conditions: Temperature:

-10 °C to 40 °C

Overall

Information

Humidity:

10% to 95% RH

Recommended maximum storage period:

One year after production date

* Avoid locations exposed to direct sunlight.

Ink Type 1000 ml cartridge type

Available colors:

Black, Red, Blue, Green, Brown

Ink Storage Conditions: Temperature:

-5 °C to 40 °C

(Optimum conditions: 15 °C to 25 °C)

Humidity:

10% to 95% RH

(Optimum conditions: 20% to 70% RH)

Recommended maximum storage period:

One year after production date

* Avoid locations exposed to direct sunlight.

1-3

SPECIFICATIONS 1 July, 1998

Available Options

· A3 Drum

· A4 Drum

· Document Feeder

· Key Counter

· Memory Board (Editing Function)

· PC Controller

· Interface Board (Standard for the U.S.A and

European versions)

1-4

1 July, 1998 GUIDE TO COMPONENTS AND THEIR FUNCTION

1.2 GUIDE TO COMPONENTS AND THEIR FUNCTION

1.2.1 MACHINE EXTERIOR

Overall

Information

1. Front Door

2. Flip-up Cover

3. Operation Panel

4. Master Feed Unit

5. Paper Feed Tray Down key

6. Paper Feed Side/End Plates

7. Paper Feed Tray

8. Paper Feed Side/End Plate Knob

C229V500.WMF

Open for access to the inside of the machine.

Open to access the Image Density key and so on.

Operator controls and indicators are located here.

Open the master feed unit when installing the master.

Press to lower the paper feed tray.

Use to prevent paper skew.

Set paper on this tray for printing.

Use to move the side/end plates.

1-5

MACHINE INTERIOR 1 July, 1998

1.3 MACHINE INTERIOR

1-6

C229V501.WMF

1 July, 1998 MACHINE INTERIOR

1. Main Switch

2. Paper Alignment Wing Knobs

3. Paper Alignment Wings

4. Paper Delivery End Plate

5. Paper Delivery End Plate Knob

6. Paper Delivery Tray

7. Paper Delivery Side Plates

8. Paper Delivery Side Plate Knobs

9. Master Eject Unit Front Handle E1

10. Ink Holder

11. Drum Unit Lock Lever B1

Use to turn the power on or off.

Use to lift or lower the paper alignment wings.

Lift or lower the wings depending on the paper type you use.

This plate aligns the leading edge of prints.

Use to move the end plate.

Completed prints are delivered here.

These plates align the prints on the paper delivery tray.

Use to move the side plates.

Use to pull out the master eject unit.

Set the ink cartridge in this holder.

Lower to unlock and pull out the drum unit.

Overall

Information

12. Drum Unit

13. Exposure Glass (Contact Glass)

14. Platen Cover

15. Trailing Edge Guides

The master is wrapped around this unit.

Position originals here face down for printing.

Lower this cover over an original before printing.

Swing out these guides when you use A4, 8

1/2

" x 11" sideways, or B5 lengthwise

paper.

1-7

MACHINE INTERIOR 1 July, 1998

1.3.1 OPERATION PANEL

1. Quality Start key

2. Security key

3. Skip Feed key

4. User Tools key

Press to change the default settings and conditions to meet your requirements.

5. Stamp key

6. Make-up key

7. Overlay key

8. Edge Erase key

9. Image Density key

Press to make prints darker or lighter.

C229V502.WMF

11. Economy Mode key

12. On Line key

13. Job Separator key

14. Combine key

Press to combine originals onto one print.

15. Class key

Press to select All Class, Auto Class, Manual Class, or Class mode.

16. Speed keys

17. Scroll keys

Press to shift the image forward, backward, right, or left.

10. Tint key

1-8

1 July, 1998 MACHINE INTERIOR

Overall

Information

18. Program key

Press to input or recall user programs.

19. Number keys

20. Clear/Stop key

While printing, press to stop the machine.

21. Enter key

Use to enter data in selected modes.

22. Clear Modes key

Press to clear the previously entered job settings.

C229V502.WMF

23. Start key

Press to make a master.

24. Auto Cycle key

Use to process the master and make prints at one stroke.

25. Proof key

Press to make a proof print.

26. Print key

Press to start printing.

1-9

MACHINE INTERIOR 1 July, 1998

1.3.2 INDICATORS

1. Special Feature indicator

This indicator is lit when you press keys under the flip-up cover.

2. Monitors

The monitors light up when a non-standard condition occurs within the machine.

3. A3/11" x 17" Drum indicator

This indicator is lit when the A3, 11" x 17" drum unit is installed.

4. A4/81/2" x 11" Drum indicator

This indicator is lit when the A4, 81/2" x 11" drum unit is installed.

C229V503.WMF

5. Color Drum indicator

This indicator is lit when the color drum unit is installed.

6. Counter

Displays the number of prints entered. While printing, it shows the number of prints remaining.

7. Panel Display

1-10

1 July, 1998 PRINTING PROCESS OVERVIEW

1.4 PRINTING PROCESS OVERVIEW

Overall

Information

C229V008.WMF

1. Master Ejecting: Ejects the used master wrapped around the drum

into the master eject box.

2. Scanning: Scans the original image with the CCD through the

mirrors and the lens.

3. Master Feeding: Converts the image signal read by the CCD into

digital signals and sends them to the thermal head to develop the image on the master. The master then wraps around the drum.

4. Paper Feeding: Sends paper to the drum section.

5. Printing: Presses the paper fed from the paper feed section

against the drum. This transfers ink to the paper through the drum screen and the master.

6. Paper Delivering: Peels off the printed paper with the exit pawls and air

knife, and ejects the paper onto the paper delivery table.

NOTE:

Some parts of the master eject, scanning, and master feeding processes are carried out at the same time. Paper feeding also starts before the master feeding process has finished.

1-11

MECHANICAL COMPONENT LAYOUT 1 July, 1998

1.5 MECHANICAL COMPONENT LAYOUT

31 32 33

121314151617181920

1. Master Feed Control Roller

2. Lens

3. CCD

4. SBU

5. Tension Roller

6. Platen Roller

7. Master Set Roller

8. Master Roll

9. Thermal Head

10. Master Buffer Duct

11. Paper Table

12. Paper Feed Roller

13. Paper Separation Roller

14. Registration Rollers

15. Doctor Roller

16. Pressure Cylinder

17. Ink Roller

C229V008.WMF

18. Idling Roller

19. Transport Belts

20. Job Separator Unit

21. Paper Delivery Table

22. Master Eject Rollers

23. Master Eject Box

24. Master Pick-up Roller

25. 2nd Scanner

26. 1st Scanner

27. DF Exposure Glass

28. 1st Transport Roller

29. 2nd Transport Roller

30. Original Feed Belt

31. Separation Roller

32. Pick-up Roller

33. Original Exit Roller

1-12

1 July, 1998 ELECTRICAL COMPONENT LAYOUT

1.6 ELECTRICAL COMPONENT LAYOUT

1.6.1 PRINTED CIRCUIT BOARD LAYOUT

Overall

Information

C229V007.WMF

1-13

ELECTRICAL COMPONENT LAYOUT 1 July, 1998

1.6.2 SCANNER SECTION

1.6.3 PAPER FEED SECTION

C229V001.WMF

1-14

C229V002.WMF

1 July, 1998 ELECTRICAL COMPONENT LAYOUT

1.6.4 MASTER EJECT, PRESSURE CYLINDER, AND OTHER

SECTIONS

Overall

Information

C229V003.WMF

1-15

ELECTRICAL COMPONENT LAYOUT 1 July, 1998

1.6.5 PAPER DELIVERY SECTION

1.6.6 MASTER MAKING UNIT

C229V010.WMF

6869

C229V005.WMF

1-16

1 July, 1998 ELECTRICAL COMPONENT LAYOUT

1.6.7 DRUM UNIT

Overall

Information

C229V006.WMF

1-17

ELECTRICAL COMPONENT LAYOUT 1 July, 1998

1.6.8 TABLES OF ELECTRICAL COMPONENTS

Boards

Index No. Name Function

1 Operation Panel Board Controls the operation panel. 2 Lamp Stabilizer Provides dc power for the xenon lamp. 3 Job Separator Board Controls the job separator. 4 Main Motor Control

Board

6 Main Processing Unit

7 I/O Board Controls the mechanical components. 8 Memory Board Enables the image editing function and data

9 Interface Board Enables the connection with the PC controller.

10 Thermal Head Power

26 Paper Width Detection

51 Separation Pressure

97 Ink Detection Board Checks if there is ink in the drum.

Power Supply Unit (PSU)

(MPU)

Supply Board Sensor Board Unit

(SBU) Feed Pressure

Detection Board

Board

Detection Board

Controls the main motor.

Provides dc power to the system.

Controls all machine functions both directly and through other boards.

printout via SP mode. This is an option.

This is an option for the China and Ricoh Asia versions.

Provides dc power to the thermal head.

Contains the CCD, and outputs a video signal to the MPU.

Sends data about the paper feed pressure to the CPU.

Sends data about the paper width on the paper table to the CPU.

Sends data about the paper separation pressure to the CPU.

Solenoids

Index No. Name Function

86 Duct Entrance Solenoid Opens or closes the plate at the entrance of the

Printing Pressure Release Solenoid

There are two solenoids: one at the front and one at the rear. They pull the release arms to apply the printing pressure against the drum.

master buffer duct.

Switches

Index No. Name Function

35 Main Switch Turns the power on or off. 56 Cover Safety Switches Checks if the front door is set correctly.

Paper Table Lowering Switch

Lowers the paper table.

1-18

1 July, 1998 ELECTRICAL COMPONENT LAYOUT

Motors

Index No. Name Function

17 Scanner Drive Motor Drives the scanner. 21 Feed Pressure Motor Drives the paper feed pressure adjustment

mechanism.

22 Registration Motor

Feeds the paper to align it with the image on the

master on the drum. 23 Paper Feed Motor Feeds the paper from the paper table. 25 Paper Table Motor Raises and lowers the paper table. 36 Pressure Plate Motor

Raises and lowers the pressure plate in the

master eject box. 37 Master Eject Motor Sends used masters into the master eject box. 40 Image Shift Motor Makes a phase difference between the positions

of the drum and pressure cylinder for the

up/down image shifting mode. 47 Clamper Motor Opens or closes the drum master clamper. 50

Separation Pressure Motor

Drives the paper separation pressure

adjustment mechanism. 58 Main Motor Drives the drum, pressure cylinder, and paper

delivery unit components. 60 Transport Vacuum Fan Provides suction so that paper is held firmly on

the transport belts. 61 Air Knife Fan

Provides air to separate the paper leading edge

from the drum. 63 Wing Guide Motor Changes the position of the paper wing guides

in the paper delivery unit. 66 Pressure Cam Shift

Motor

Switches the cams for the small master and full

size master to apply the appropriate printing

pressure. 69 Slider Lift Motor Moves the sliding arm in the job separator unit

up or down. 72 Job Separator Motor Drives the sliding arm in the job separator unit. 78 Cutter Motor Cuts the master after completing the master

making. 82 Platen Release Motor Applies or releases the pressure between the

platen roller and the thermal head. 83 Master Feed Motor Feeds the master to the drum. 84 Master Vacuum Fan

Provides suction to guide the master into the

buffer duct. 87 Ink Pump Motor Drives the ink pump to supply ink. 89 Idling Roller Motor Presses or releases the idling roller against the

drum screen. 91 Drum Shift Motor Slides the drum screen position to the front or

rear for the side-to-side image shifting mode.

Overall

Information

1-19

ELECTRICAL COMPONENT LAYOUT 1 July, 1998

Sensors

Index No. Name Function

12 Original Width Sensor Detects the width of the original on the exposure

glass. 13 Scanner HP Sensor Detects when the scanner is at home position. 15 Platen Cover Sensor Detects if the platen cover is open or closed. 16 Original Length Sensor

18 Master Making Unit Set

Sensor

24 Paper Table Lower

Limit Sensor 27 Paper Length Sensor Detects when long paper is on the paper table. 28 Paper Table Set Sensor Detects if the paper table is closed. 29 Paper End Sensor Detects if paper is present on the paper table. 30 Paper Height Sensor Detects if the top of the paper stack on the

32 Paper Feed Timing

38 Pressure Plate HP

39 Pressure Plate Limit

41 Image Shift HP Sensor

42 Image Position Encoder Sends the image position data to the CPU for

43 2nd Drum Position

45 Clamper Close Position

46 Clamper Open Position

49 1st Drum Master

52 Feed Encoder Detects fluctuations in the pressure cylinder

53 Feed Start Sensor

55 Lower Wrapping Jam

58 Master Eject Sensor Detects master eject misfeeds. 59 Eject Box Set Sensor Checks if the master eject box is installed.

Paper Registration

Sensor

Position Sensor

Sensor

1st Drum Position

Sensor

2nd Drum Master

Sensor

Detects the length of the original on the exposure glass.

Checks if the master making unit is set.

Detects when the paper table is at its lower limit position.

paper table is at the paper feed height. Detects paper approaching the registration

roller. Detects paper approaching the paper clamper in

the pressure cylinder. Detects when the pressure plate is at the home

position. Detects when the pressure plate is at the lowest

position. Detects if the pressure cylinder is at the home

position. (The up/down image shift is 0.)

display on the operation panel. Checks the drum position.

Checks the drum position.

Detects when the clamper is in the closed position.

Detects when the clamper is in the open position.

Detects if there is a master on the drum, to detect master clamping errors.

Detects if there is a master on the drum when the Start key is pressed.

rotation. Checks the pressure cylinder position for the

paper feed start timing. Detects paper wrapping jams on the pressure

cylinder.

1-20

1 July, 1998 ELECTRICAL COMPONENT LAYOUT

Index No. Name Function

62 Paper Exit Sensor Detects paper misfeeds at the exit. 64 A3 Cam Sensor

Detects when the A3 printing pressure cam is used.

65 A4 Cam Sensor Detects when the A4 printing pressure cam is

used.

67 Slider Position Sensor Detects when the job separator slider is fully

moved toward the paper on the delivery table.

68 Slider HP Sensor

Detects when the job separator slider is at the home position.

70 Paper Sensor

Detects when the job separator slider touches the paper on the delivery table.

71 Slider Upper Limit

Sensor 73 Wing Upper Position

Sensor 74

Wing Lower Position

Sensor

Detects when the job separator slider is at the uppermost position.

Detects when the paper wing guides are in the upper position.

Detects when the paper wing guides are in the lower position.

75 Master Edge Sensor Detects the leading edge of the master when a

new master roll is installed. 77 Cutter HP Sensor Detects when the cutter is at the home position. 80 Master Set Sensor Detects whether a master roll is present. 81 Platen Release Sensor Detects when the platen pressure is applied

against the thermal head. 85 Master End Sensor Detects when the master runs out. 88 Drum Shift HP Sensor Detects when the drum screen is at the home

position. (The side-to-side image shift is 0.) 90 Drum Shift Sensor

Sends the image position data to the CPU for

display on the operation panel. 92 Ink Pump Sensor Monitors the operation of the ink pump to count

how many cycles it has moved. 95 Ink Cartridge Set

Detects if the ink cartridge is in place.

Sensor

96 Idling Roller HP Sensor

Detects when the idling roller is at the home

position.

Overall

Information

Others

Index No. Name Function

14 Xenon Lamp Applies light to the original for exposure. 20 Interface Connector Connects the machine to the PC controller. 34 Print and Master

Counters

76 Master Feed Clutch Controls the master feed control roller operation

79 Thermal Head Burns the image of the original onto the master. 93 Thermistor Detects the temperature inside the drum to

94 Ink Detecting Pin Detects if ink is present in the drum.

Keeps track of the total number of prints and

masters.

to feed the master.

adjust various process.

1-21

DRIVE LAYOUT 1 July, 1998

1.7 DRIVE LAYOUT

1.7.1 OVERVIEW

1. Clamper Opening Arm Sector Gear (for the master eject position)

2. Master Pick-up Roller Sector Gear

3. Master Eject Motor

4. Image Shift Motor

5. Pressure Plate Motor

6. Exit Pawl Drive Cam Gear

7. Paper Delivery Unit Drive Gear/Pulley

8. Main Motor

C229V504.WMF

9. Pressure Cylinder Drive Gear (Including the Scissors Gear)

10. Registration Roller Lifting Cam Drive Gear

11. Registration Motor

12. Paper Feed Motor

13. Paper Table Motor

14. Clamper Motor

15. Drum Guide

16. Master Feed Motor

17. Master Feed Clutch

1-22

1 July, 1998 DRIVE LAYOUT

1.7.2 MAIN DRIVE

Overall

Information

C229V505.WMF

18. Drum

19. Pressure Cylinder

20. Printing Pressure Cam

21. Exit Pawl Drive Cam Gear

22. Main Motor

23. Printing Pressure Cam Drive Gear

24. Idler Gear/Pulley

25. Pressure Cylinder Drive Gear (including the Scissors Gear)

26. Primary Gear/Pulley

27. Drum Drive Gear/Pulley

28. Image Shift Gear

1-23

1 July, 1998 SCANNER AND OPTICS

2. DETAILED SECTION DESCRIPTIONS

2.1 SCANNER AND OPTICS

2.1.1 OVERVIEW

[E]

[F]

The exposure lamp, a xenon lamp [A], illuminates the original. The 1st, 2nd, and 3rd mirrors, and a lens [B] reflect the image onto a CCD (Charge Coupled Device) [C].

The 1st scanner [D] consists of the exposure lamp, a reflector [E], and the 1st mirror [F].

A DC power supply energizes the exposure lamp to avoid uneven light intensity when the 1st scanner moves in the sub-scan direction. The entire exposure lamp surface is frosted to ensure even exposure in the main scan direction.

The reflector reflects light with almost equal intensity, to reduce shadows on pasted originals.

[A]

[D]

[C]

C229D094.WMF

[B]

Detailed

Descriptions

2-1

SCANNER AND OPTICS 1 July, 1998

2.1.2 SCANNER DRIVE

[H]

Rear

[G]

[C]

[B]

[E]

[D]

[G]

[A]

Front

[E]

[F]

C229D095.WMF

A stepper motor drives the scanner. The scanner drive motor [A] drives the 1st and 2nd scanners [B, C] through the timing belt [D], scanner drive pulley [E], scanner drive shaft [F], and two scanner wires [G].

- Book mode -

The scanner drive board controls and operates the scanner drive motor. In full size mode, the 1st scanner speed is 42.33 mm/s during scanning. The 2nd scanner speed is half that of the 1st scanner.

In reduction or enlargement mode, the scanning speed depends on the magnification ratio (M: 0.50 to 2.00). The returning speed is always the same, in both full size and magnification modes. Changing the scanner drive motor speed changes the image length in the sub-scan direction. Image processing on the MPU board accomplishes reduction and enlargement in the main scan direction.

SP6-011-1 changes the motor speed and therefore adjusts the magnification ratio in the sub-scan direction.

- ADF mode -

During scanning, the scanners are always in their home positions (when the scanner H.P sensor [H] detects the 1st scanner). The ADF motor feeds the original through the ADF. In reduction/enlargement mode, changing the ADF motor speed changes the image length in the sub-scan direction. Magnification in the main scan direction is done on the MPU board, in the same manner as book mode.

SP6-011-2 changes the ADF motor speed and therefore adjusts the magnification ratio in the sub-scan direction.

2-2

1 July, 1998 SCANNER AND OPTICS

2.1.3 ORIGINAL SIZE DETECTION IN PLATEN MODE

[B]

Detailed

Descriptions

[A]

[C]

C229D096.WMF

C229D120.WMF

[C]

C229D116.WMF

In Platen mode, the size of paper on the paper table usually determines the image reading area for the original. If Reduction or Enlargement mode is used, the magnification ratio affects the image reading area.

However, for Auto Magnification, Image Rotation, or Image Repeat modes combined with Platen mode, the original width [A] and length [B] sensors detect the original size.

The sensors for original size detection are in the optics cavity. There are four reflective sensors in the 115V machines, and six reflective sensors in the 220/240V machines.

2-3

SCANNER AND OPTICS 1 July, 1998

The platen cover sensor [C] or the DF position sensor [D] informs the main CPU of the original size when the platen is about 15 cm above the exposure glass. At this time, only the sensors located underneath the original receive the reflected light and switch on. The other sensors remain off. The main CPU can recognize the original size from the number of activated sensors.

Original Size Length Sensors Width Sensors

A4/A3 version LT/DLT version L1 L2 L3 L4 S1 S2

A3 11" x 17" O O O O O O B4 10" x 14" O O O O O X F4 8 A4L 8 B5L - O X X X X X A4S 11" x 8 B5S - X X X X O X

1/2

" x 14" (8" x 13") O O O X X X

1/2

" x 11" O O X X X X

1/2

"XXXXOO

NOTE:

1) O: On (Paper Present), X: Off

2) The length sensors L3 and L4 are only used in the 220/240V machines.

The above table shows the sensor output for each original size. A message will appear in the operation panel display for other combinations.

2-4

1 July, 1998 IMAGE-PROCESSING

2.2 IMAGE-PROCESSING

2.2.1 OVERVIEW

SBU

CCD

Detailed

Descriptions

Thermal

Head

IPU

Memory

Board

(Option)

MPU

C229D501.WMF

The CCD converts the light reflected from the original into an analog signal. The CCD line has 5,000 pixels and the resolution is 400 dpi (15.7 lines/mm).

After the above process, the A/D converter built into the SBU transforms the analog signals into 8-bit signals. This assigns a value to each pixel from a scale of 256 grades. Then, the digitized image data goes to the MPU board.

The image data then goes to the IPU (Image-processing Unit) IC on the MPU board, which carries out the following processes on the image data:

1. Auto shading

2. Filtering (MTF and smoothing)

3. Magnification

4. Binary processing

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IMAGE-PROCESSING 1 July, 1998

2.2.2 AUTO BACKGROUND CORRECTION

[A]

C229D097.WMF

Auto background correction mode can be used in Photo/Letter, Photo, and Tint modes. The default setting does not allow the user to select auto background correction mode. (Use SP 2-31 to enable this mode.)

Auto background correction prevents the background of an original from appearing on copies.

While scanning the original, the background density detection area [A] is also scanned. This area [A] is a narrow strip at the start of the main scan line, as shown. As the scanner scans down the page, the IPU on the MPU detects the peak white level for each scan line, within this narrow strip only. From this peak white level, the IPU determines the reference value for the A/D conversion for the scan line. The IPU then sends the reference value to the reference controller on the SBU.

When an original with a gray background is scanned, the density of the gray area is the peak white level density. Therefore, the original background will not appear on copies. This feature corrects any changes in background density down the page, because peak level data is taken for each line scanned.

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1 July, 1998 IMAGE-PROCESSING

2.2.3 AUTO SHADING

C229D504.WMF

There are two auto shading methods: black level and white level correction. Auto shading corrects errors in the signal level for each pixel.

Detailed

Descriptions

- Black Level Correction -

The CPU reads the black dummy data from one end of the CCD signal (64 pixels are blackened at the end) and takes an average of the black dummy data. Then, the CPU deletes the black level value of each image pixel.

- White Level Correction -

The machine reads a reference waveform from the white plate, before scanning the original. The average of the white video level for each pixel is stored as the white shading data in the IPU.

The IPU chip corrects the video signal information for each pixel obtained during image scanning.

2-7

IMAGE-PROCESSING 1 July, 1998

2.2.4 FILTERING AND MAIN SCAN MAGNIFICATION/REDUCTION

Overview

Filtering and main scan magnification process the image data after auto shading. However, to reduce moire in the image, the processing order depends on the reproduction ratio, as follows:

1) Reduction and Full size Main Scan Reduction ® Filtering

2) Enlargement

Filtering ® Main Scan Magnification

Filtering

The MTF and smoothing filters are software filters that enhance the desired image qualities of the selected original mode.

The MTF filter, used in all modes except Tint mode (which uses the smoothing filter), sharpens the image.

SP6-082 adjusts the filter strengths for MTF mode.

The diagram below shows how the number stored in the SP mode afects the strength of the filter.

NOTE:

1) Do not set the filter strength number to 1. Abnormal images may result.

2) The smoothing filter strength is not adjustable.

11 8 2

2-8

C229D505.WMF

1 July, 1998 IMAGE-PROCESSING

Main Scan Magnification/Reduction

Detailed

Descriptions

C229D506.WMF

The IPU chip handles reduction and enlargement in the main scan direction.

NOTE:

Changing the scanner speed accomplishes reduction and enlargement in the sub-scan direction.

When making a copy using the ADF, the magnification circuit creates a mirror image. This is because the scanning starting position in the main scan direction is at the other end of the scan line in ADF mode (as compared with platen mode). In platen mode, the original is placed face down on the exposure glass, and the corner at [A] is at the start of the main scan. The scanner moves down the page. In ADF mode, the ADF feeds the leading edge of the original to the DF exposure glass, and the opposite top corner of the original is at the main scan start position.

To create the mirror image, the CPU stores the main scan line data in the LIFO (Last In First Out) memory on the MPU, from the last pixel. When loading the main scan line data from the LIFO memory, the CPU loads the first pixel of the main scan line.

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IMAGE-PROCESSING 1 July, 1998

2.2.5 BINARY PROCESSING

In the IPU chip, the 8-bit data is converted into 1-bit data for black or white pixels. The binary processing for the letter mode is different from that for the photo mode and the letter/photo mode as follows:

1) Letter mode: Binary processing

2) Letter/Photo mode: Binary processing

3) Photo mode: Binary processing + error diffusion + dithering

These processes are used as follows.

- Binary Processing with Gamma Curve Compensation -

This process converts each video signal level from 8-bit to 1-bit (black and white image data) in accordance with a threshold value.

The threshold value changes based on a compensation curve (Gamma curve) which corresponds to selected image settings. For example, if a darker image is selected, a compensation curve, which converts each pixel value to a higher number, is selected. This ensures accurate generation of the gray scale from black to white.

- Error Diffusion - (Photo mode only)

The error diffusion process reduces the difference in contrast between light and dark areas of a halftone image. This process corrects each pixel using the difference between it and surrounding pixels. It then compares the corrected pixels with the error diffusion matrix.

- Dithering - (Photo mode only)

Dithering compares each pixel with a pixel in the dither matrix. Several matrixes are available, to increase or decrease the detail on the copy.

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1 July, 1998 IMAGE-PROCESSING

2.2.6 OPTIONAL MEMORY BOARD

The optional memory board, or editing function board, has 4-Mbyte RAM, which corresponds to the amount of memory required for an A3 original. This enables the following image editing functions.

- Memory Combine Mode -

Combined images of 4, 8, or 16 originals are printed on the same sheet of paper.

- Overlay -

Overlay merges two different originals onto the same sheet of paper.

- Stamp Printing Mode -

This mode enables stamping modes such as, the date, page number, preset message, and user custom stamps.

Detailed

Descriptions

- Make-up Printing Mode -

The user makes command sheets to specify how various areas of the original will be processed. The user must be sure to scan the command sheets before the original. The image-processing chip in the MPU modulates the image data for the command sheet and then stores the modulated command data on the memory board.

The image data for the original is also converted and modulated. The MPU edits the modulated image data, the stored command area data, and the background pattern.

Positive/Negative can be used with this mode.

- Report Print Mode -

This mode prints the following data:

· User reports

· Jam and error counter data

· The number of people in each class set by the user

· Number of prints and masters for each user code account

· SP mode data for service

- Image Rotation Mode -

When the orientation for the original differs from the paper selected, the machine automatically rotates the original image 90 degrees to match the paper orientation.

SP 2-150 can disable this mode.

2-11

IMAGE-PROCESSING 1 July, 1998

2.2.7 THERMAL HEAD

Specifications

· Length 292.6 mm

· Number of thermal head elements 4608

· Density of thermal head elements 400 dpi

Thermal Head Control

The thermal head contains heating elements at a density of 400 dpi. The thermal heating elements melt the over-coating and polyester film layers of the master, in accordance with the image signal for each pixel.

This model has an independent power supply unit for the thermal head. It applies power (VHD) to the thermal heating elements. The power source varies from one head to another since the average resistance of each element varies. Therefore, when replacing the thermal head or power supply unit, it is necessary to readjust the applied voltage to the specific value for the thermal head.

Thermal Head Protection

The thermistor on the thermal head provides thermal head protection, preventing the thermal head from overheating when processing a solid image. The CPU checks for any abnormal condition when the Start key is pressed; it displays an SC code on the operation panel as follows:

SC Code Conditions

SC03-03 SC03-02

SC03-01

SC03-00

Over 54°C Under - 20°C (Normally in this case, the thermistor

is open, or a related connector is disconnected.) When the pulse width that controls the thermal

head energy becomes abnormal, master making stops and generates this SC code.

The CPU monitors the ID signal from the thermal head, which identifies the thermal head type. If an abnormal ID signal is detected just after installing the master making unit in the machine, it generates this SC code.

Detecting

Component

Thermistor Thermistor

MPU

2-12

1 July, 1998 IMAGE-PROCESSING

Remarks for Handling the Thermal Head

Pay careful attention to the following remarks when servicing:

Do not touch the surface with bare hands. If this occurs, clean the surface with alcohol.

Do not damage the heating elements.

Platen

Master

Remove any foreign materials from the platen roller.

Remove foreign materials.

Do not touch the master film surface with bare hands.

There are some ICs inside the metal cover. Do not push the cover down.

Do not touch the connector terminals with bare hands, to prevent damage from static electricity.

Detailed

Descriptions

MPU

Thermal Head

Connect and disconnect the connectors carefully. Keep them horizontal and firmly reconnect them.

Adjust the voltage supplied to match the specified value for the thermal head.

Connector

PSU

- Other Remarks -

Avoid using the machine under humid conditions. Moisture tends to condense on the thermal head, damaging the elements.

2-13

MASTER EJECT 1 July, 1998

2.3 MASTER EJECT

2.3.1 OVERVIEW

[A]

[B]

[C]

[E]

[D]

C229D106.WMF

The master remains wrapped around the drum to prevent the ink from drying. Therefore, making a new master begins from the master ejecting process.

When the Start key is pressed to scan the original, the drum rotates from the home position to the master eject position. As soon as the drum reaches the master eject position, the drum master clamper [C] opens. The drum position lock mechanism locks the drum at this position to prevent the drum from moving during master ejection.

At the same time, the master pick-up roller [A] touches the drum, picking up the leading edge of the master on the drum. Then, the master is caught by the upper and lower master eject rollers [B] and is transported into the master eject box [E].

When the trailing edge of the master passes the roller, the pressure plate [D] begins to compress the master into the box.

Before this process is complete, the original scanning and master making has already started, and the drum will then rotate to the master making position.

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1 July, 1998 MASTER EJECT

2.3.2 MASTER EJECT MECHANISM

Overview

[A]

[B]

[C]

Rear

Detailed

Descriptions

[F]

Front

[E]

[D]

C229D112.WMF

Two photosensors (the 1st and 2nd drum position sensors) and the feeler on the rear drum flange determine the drum position. The drum is at the home position when the feeler actuates the 1st drum position sensor. At this position, the drum master clamper, which clamps the leading edge of the master onto the drum, is located at the bottom of the drum. (For details, refer to Drum Drive Mechanism in the Drum section.)

The drum turns 114.5 degrees from the home position to reach the master eject position (there is no sensor for master eject position detection  main motor encoder pulses only). As soon as the drum stops, the clamper motor [B] starts to open the drum master clamper [F]. The master pick-up roller [D] moves against the drum at the same time, because it is connected through an idle gear.

A link plate connects the drum guide [E] to the clamper opening arm [A]. So, when the arm moves, the drum guide also moves, and this locks the drum position.

NOTE:

1) To lock the drum, the drum guide catches one of two studs at different positions on the drum. The drum guide catches one stud at the master eject position [C], and the other stud at the master making position.

2) The drum master clamper also opens when the drum is at the master making position. However, it uses a different clamper-opening arm. For details, refer to the Master Making section.

3) Do not clean the inside of the master clamper with alcohol or other strong solvents. Use a cloth dampened with water. This prevents the magnetic force from weakening. This part requires periodic cleaning.

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MASTER EJECT 1 July, 1998

Drum Lock Mechanism

The clamper motor drives the drum guide [C]. The clamper closed position

Rear

[A]

sensor [A] and clamper open position sensor [B] monitor the position of the

[B]

drum guide.

When the drum reaches the master eject position, the drum guide moves until the clamper open position sensor [B] is actuated then deactuated (the actuator must go through the sensor). This engages the stud on the rear drum flange.

Before the drum starts rotating to the master

Front

[C]

making position, the drum guide returns to the home position. The clamper closed position sensor [A] determines this position.

NOTE:

The same drum guide also moves when the drum is at the master making position. (There is another stud on the rear drum flange, which is used to secure the drum at the master making position.)

A link plate at the master eject position synchronizes the master clamper with the drum guide movement.

To open the clamper, the drum guide (with the clamper opening arm) must move a greater distance than at the master making position. Therefore, at the master eject position, the drum guide moves (to open the master clamper) until the clamper open position sensor [B] turns on (interrupted by the feeler) and then turns off again, as shown in the diagram. Refer to the Master Feed section to compare the two mechanisms.

C229D107.WMF

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1 July, 1998 MASTER EJECT

Master Pick-up Roller Drive and Master Clamper Open

Rear

[D]

[C]

Front

[B]

[A]

C229D081.WMF

When the clamper motor opens the drum master clamper [B], the master pick-up roller [A] contacts the leading edge of the master on the drum. The clamper motor moves the master pick-up roller against the drum through the idle gear [D], while driving the clamper opening arm [C].

Detailed

Descriptions

At the same time as the drum master clamper [B] closes after the master is picked up, the master pick-up roller [A] also moves back to the original position.

The drum guide is also released at the same time. The drum continues turning towards the master making position while the used master is removed from the drum.

2-17

MASTER EJECT 1 July, 1998

Master Eject and Transportation

[A]

Rear

[B]

Front

C229D082.WMF

The master pick-up roller [A] and the upper and lower master eject rollers [B] all turn together. They start turning as soon as the drum reaches the master eject position.

The rollers stop once the leading area of the master is picked up from the drum. (The master eject sensor detects this.) Then, when the drum starts turning, they turn on again to feed the ejected master to the eject box while the drum turns towards the master making position.

The master eject sensor (not shown) is located just under the lower master eject roller, and it monitors the master feeding. If the master is not properly picked up, i.e. it does not activate the sensor; the operation panel displays a master eject jam message.

2-18

1 July, 1998 MASTER EJECT

Master Eject Roller Unit Drive

The master eject motor [A] turns

[A]

the master pick-up roller [B] with the upper and lower master eject rollers [C].

[B]

When the unit is slid out (explained below), the joint [D] disengages.

[D]

[C]

C229d513.WMF

Detailed

Descriptions

Master Eject Roller Unit Slide-out Mechanism

The master eject roller unit [E] can be slid out of the machine as shown for easy master jam removal.

The unit contains the master pick-up roller, upper and lower master eject rollers, and the master eject sensor.

C229D083.WMF

[E]

2-19

MASTER EJECT 1 July, 1998

[B]

[C]

Master Eject Box Mechanism

[A]

C229D092.WMF

C229D085.WMF

[D]

The user can slide the master eject box out from the operation side of the machine. The front handle of the box [A] has a lock mechanism as shown above.

The master eject box contains a pressure plate [B], which compresses the ejected masters in the box. The pressure plate also works as a guide plate feeding the ejected master into the box.

An independent dc motor, the pressure plate motor, drives the pressure plate. The motor is in the pressure plate drive unit, on the rear frame of the machine separate from the master eject box.

When the master eject box is slid out, the joint [D] for the pressure plate drive disengages. At the same time, the lock lever [C] turns, due to tension from a spring, to hold the pressure plate [B] in the home position.

When the master eject box is re-installed, the drive joint [D] is connected and the pressure plate lock lever [C] is released as shown above.

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1 July, 1998 MASTER EJECT

The ejected masters in the box can be taken out by sliding the eject lever [A]. The

[A]

inner bottom case [C] moves towards the rear of the box.

Masters are ejected from an open door at the rear of the box. The side opposite the eject lever side [A] of the inner bottom case is connected to a belt [B]. This helps the inner bottom case move smoothly.

Detailed

Descriptions

When the master eject box is removed, a push switch (the eject box set sensor) turns off, and the operation panel displays a message.

[C]

[B]

C229D084.WMF

2-21

MASTER EJECT 1 July, 1998

2.3.3 PRESSURE PLATE DRIVE MECHANISM

Overview

There are three phases.

· Homing At power on or when recovering from an error or jam, the machine makes sure that the pressure plate is at home position. This is because, if certain errors occur, the pressure plate may not be in the home position at the start of a job

· Master ejection The pressure plate rotated into a position where it can act as a feed guide for the used master on its way to the eject box.

· Compression The pressure plate compresses the master into the box.

Drive

[D]

[E]

[C]

[A]

[B]

C229D514.WMF

The pressure plate motor [A] drives the pressure plate [B] through the pressure plate gear [C]. This gear contains actuators for the home position sensor [D] and the limit position sensor [E]. These two sensors monitor the pressure plate position.

The diagram shows a front view of the mechanism. The actuators are on the rear of the pressure plate gear, which is shown as see-through for ease of viewing.

2-22

1 July, 1998 MASTER EJECT

Homing Operation

At power on or when recovering from an error or jam condition, the machine carries out the pressure plate homing operation.

If certain errors occur, the pressure plate may not be in the home position. The homing operation starts by turning the pressure plate toward the drum and then it returns to the home position.

The homing operation is as follows:

1. The pressure plate turns

clockwise (as seen from the operation side) until both the pressure plate HP sensor [A] and the limit position sensor [B] are actuated.

C229D089.WMF

Master Eject Ready Position

[A]

[B]

Detailed

Descriptions

Passed the home position slightly

2. As shown in the upper right

diagram, the pressure plate turns counterclockwise until the home position sensor [A] is actuated twice then de-activated. The status of the sensor [A] changes: on Þ off Þ on Þ off.

3. The pressure plate has just

slightly passed the home position. Then, as shown in the lower right diagram, the pressure plate again turns clockwise to return to the exact home position. The home position sensor status changes now from: off Þ on Þ off.

C229D114.WMF

Passed the home position slightly

[A]

[B]

Home Position

2-23

MASTER EJECT 1 July, 1998

[A]

Shift to the Master Eject Position

[B]

When the Start key is pressed to make a new master, the drum turns to the master eject position. During this period, the pressure plate travels to the master eject ready position.

The pressure plate turns clockwise (as seen from the operation side) until both the pressure plate HP sensor [A] and the limit position sensor [B] are actuated.

Home Position

Master Eject Ready Position

C229D086.WMF

Ejected Master Compression

When the ejected master has been fed to the master eject box, the pressure plate compresses the master. During this operation, the machine can recognize how full the eject box is by monitoring the lower limit and home position sensors.

When there are no or very few masters in the box

If there are no or only a few masters

[A]

in the box, the pressure plate can move to its lowest position. The pressure plate limit position sensor detects this position.

The pressure plate turns counterclockwise from the master eject ready position until the limit position sensor [B] has been actuated twice. The sensor status changes: on Þ off Þ on.

The pressure plate stays at the lower limit position for 2 seconds, then returns to the home position.

Lower Limit Position

C229D087.WMF

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1 July, 1998 MASTER EJECT

When there are a lot of masters

If there are a lot of used masters in the box, the pressure plate cannot move to the lower limit position.

If the lower limit position sensor [B] is not actuated within 7 seconds after the pressure plate starts traveling from the master eject ready position, the pressure plate motor stops.

The pressure plate stays in the same position for 2 seconds to compress the masters. Then, it returns to the home position.

There is a torque limiter [C] built into the gear. When the built-up masters in the box block pressure plate movement, the torque limiter allows this gear to slip.

C229D108.WMF

[C]

[A]

[B]

Detailed

Descriptions

Master Compression Position

Master Box Full Detection Mechanism

As explained above, the pressure plate motion range narrows as the ejected masters build up in the box. The stopping position of the pressure plate therefore gets closer to the home position.

When the pressure plate cannot travel past the master box full position from the master eject ready position, this means that the master box is full.

In this case, the home position sensor [A] remains actuated as shown on the right.

The home position sensor status changes (from the master eject ready position): on Þ off Þ on Þ off Þ on, and stays on. This means the master box is full and the operation panel displays a message.

C229D088.WMF

[A]

Master Box Full Position

2-25

MASTER EJECT 1 July, 1998

(

)

Pressure Plate Operation Timing Chart

Does not reach here after 6 seconds

Motor locked

HP Sensor

Limit Position Sensor

Pressure Plate Motor

Drum

Master Box Direction

Eject Position

Drum Direction

Compressing Position

Stays for 2 seconds

HP Returned

Check when rotating in the master box direction

Number of HP Sensor On or Off Edges

(The first on edge is just after the motor starts.)

- Check Timing - When one of the following

occurs:

1. When the Limit Position Sensor turns on.

5 timesÞNormal

4 timesÞMaster box full

Less than 4ÞPressure plate locked

(SC06-00 lights)

2. 6 seconds after the moto turns on.

This timing chart shows how the machine counts the number of home position sensor on and off edges to check if the eject box is full or if the mechanism is jammed.

The signal is checked when:

· The limit position sensor turns on  this is when the pressure plate has turned all the way to the lower limit position inside the box, which is only possible if the box is fairly empty.

· At 6 s after the motor turns on

2-26

1 July, 1998 MASTER FEED

[E]

[A]

2.4 MASTER FEED

2.4.1 OVERVIEW

[B]

[C]

[D]

[L]

[F]

[K]

[G]

[J]

[H]

[I]

C229D115.WMF

A: Master Edge Sensor G: Master Roll B: Tension Roller H: Master End Sensor C: Platen Roller I: Master Vacuum Fans D: Thermal Head J: Master Buffer Duct E: Master Set Roller K: Cutter F: Master Set Sensor L: Master Feed Control Roller

Original scanning starts when an original is set and the Start key is pressed. Master making begins at the same time. Although master ejecting is done first, scanning starts very soon after.

Detailed

Descriptions

The master is a low fiber content paper coated with a thin heat-sensitive film. The heating elements of the thermal head [D] burn the film to copy the scanned image.

The master is fed while the thermal head develops the image on it. The master vacuum fans [I] temporarily suck the fed master into the master buffer duct [J]. This is done because the used master is still being ejected from the drum. When the drum comes to the master making position, the master is fed to the drum and the drum master clamper on the drum clamps the master.

The drum then turns to wrap the master around the drum. When the master has been pulled out of the duct and is pulled tight at the cutter, the cutter [K] cuts the master.

At the same time as the master is wrapping, a sheet of paper, called the trial print, is fed. This ensures that ink transfers to the master on the drum, and that there is a sufficient density of ink for the print run to start. The drum then returns to the home position and is ready for printing.

2-27

MASTER FEED 1 July, 1998

2.4.2 MASTER SET MECHANISM

Master Roll Set

The master set sensor [A] checks to see if the master roll was installed properly. After inserting the master making unit, the sensor detects the leading edge of the master. The master is fed in until the leading edge reaches the master feed control roller.

[A]

C229D102.WMF

Master Feed and Stop Control (Edge Detection)

While the master is being fed after a roll is put in the machine, the master edge sensor [B]

[B]

[C]

checks the leading edge of the master.

The master is fed 18 mm more after the master edge sensor [B] is activated. It has now been caught by the master feed control roller [C] and it stops. This is the stand-by position for master making.

While the master is fed, the

C229D103.WMF

platen roller pressure, which is used to press the master against the thermal head, is repeatedly applied and released using the platen pressure release mechanism. This prevents master skew or creasing after a roll has been put in the machine. A later section will describe this process in more detail.

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1 July, 1998 MASTER FEED

Master Buffer Duct Entrance Control

While the master is being transported to the master feed control roller [A], the duct entrance solenoid [C]

[B]

[A]

Rear

closes the master buffer duct entrance plate [B]. This prevents the duct entrance from catching the leading edge of the master.

After the master feed control roller [A] catches the master leading edge, the entrance plate is opened. (The normal position of the entrance plate is open.)

Front

Detailed

Descriptions

Master End Detection

There is a solid-fill black area at the end of the master roll. When the master end sensor [D] detects this area, the operation panel displays the master end message.

As the master is semitransparent, the sensor can detect the black area at the end of the roll when there are still a few layers of clear master on the roll. When this happens, master roll near-end is detected.

C229D004.WMF

[C]

2-29

[D]

C229D104.WMF

MASTER FEED 1 July, 1998

2.4.3 MASTER MAKING AND FEED MECHANISM

Master Feed Mechanism

[A]

[B]

[C]

[D]

Rear View

[F]

C229D003.WMF

[E]

The master feed motor [F], a stepper motor, drives the master feed control [A], tension [B], platen [C] and master set [D] rollers.

The tension roller feeds the master slightly faster than the platen roller, to prevent the master from creasing. Therefore, the master between the platen roller and thermal head is always under tension.

There is a torque limiter [E] built into the tension roller drive gear. This allows the tension roller to become free from the master feed motor drive when the master is under excessive tension, to prevent damage to the master.

NOTE:

Strips of mylar under each master feed roller prevent the master from being wrapped around the rollers. Be careful not to damage or set the mylars in the incorrect position because they damage easily. For details, refer to the Replacement and Adjustment section.

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1 July, 1998 MASTER FEED

Platen Roller Pressure Release

[C]

Rear View

Detailed

Descriptions

[B]

[D]

[A]

C229D002.WMF

The platen release motor [A] gives half a turn to the platen release cam [B] to apply or release the platen roller [C] pressure. As the motor turns, the actuator on the gear interrupts the platen release sensor [D]. When the pressure is released, the actuator interrupts the sensor.

NOTE:

When installing the gear with the actuator, remember that the setting position depends on the platen release cam position. For details, refer to the Replacement and Adjustment section.

Just before master making, the platen release motor starts turning until the sensor is inactive; this indicates that the platen pressure is now applied to prepare for master making.

When master making is complete, the motor turns again until the sensor is activated, releasing the platen pressure. This allows the user to remove a jammed master. Also, in standby mode, there is no pressure between platen roller and thermal head, so that the user can take out the master.

As explained in Master Feed and Stop Control, the platen roller pressure is repeatedly applied and released to prevent master skew or creasing after a roll has been put in the machine. To do this, the motor continues turning for 3 seconds.

2-31

MASTER FEED 1 July, 1998

Master Buffer Mechanism

Rear

[A]

Front

C229D000.WMF

[B]

To minimize master processing time, the master is stored in the master buffer duct [A] after the thermal head transfers the image to it. The stored master is fed out from the duct when the drum reaches the master making position after master ejecting.

The master buffer duct is located under the master feed path. A two-level chamber inside the duct can hold a sufficient length of the master for A3 printing.

As soon as master making starts, the three master vacuum fans [B] start turning, creating suction to guide the master into the duct [A]. At this time, the master feed control roller has already caught the leading edge of the master. This roller does not start turning until the drum reaches the master making position and the master clamper opens (because the master feed clutch disconnects the master feed motor drive).

The master is fed while the thermal head writes the image on it. As the leading edge of the master stops, the suction guides the fed master into the master buffer duct and stores it as shown in the above diagram.

When the drum comes to the master making position, the master feed control roller starts turning and feeds out the master that is stored in the duct.

2-32

1 July, 1998 MASTER FEED

2.4.4 WRAPPING THE MASTER AROUND DRUM

[F]

Front

[A]

C229D091.WMF

Rear

[G]

[D]

Detailed

Descriptions

[C]

[E]

[B]

Drum Lock and Master Clamper Open

As explained in the Master Eject section, the drum guide [A] holds the drum at the master eject and master making positions.

When the drum reaches the master making position, the drum guide moves to engage the stud [B] on the rear drum flange until the clamper open position sensor [C] is actuated. (The other stud was used for the master eject position.)

The master clamper opening arm [D] is just above the drum guide. The arm is different from the one used for opening the master clamper at the master eject position. The clamper motor [E] drives the arm and opens the master clamper [F], in synchronization with the drum guide movement.

The drum guide moves (to open the master clamper) until the clamper open position sensor is interrupted by the feeler. Then it stops immediately (unlike at the master eject position of the drum) as shown in the diagram.

Before the drum starts turning to start wrapping the master on the drum, the drum guide returns to the home position until the clamper close position sensor [G] is activated. The master clamper opening arm also returns, closing the master clamper.

2-33

MASTER FEED 1 July, 1998

Master Feed Control Roller Mechanism

Front

[B]

[A]

Rear

C229D090.WMF

The master feed clutch [A] connects and disconnects the drive from the master feed motor to the master feed control roller [B]. The master feed control roller only turns in the following cases:

· When a master roll is put in the machine, the master is fed until the master feed control roller catches the leading edge of the master.

· During master clamping, the master feed control roller turns and sends the leading edge to the clamper position.

· While the master is being wrapped around the drum, the master feed control roller turns to feed the master, in synchronization with the drum rotation.

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1 July, 1998 MASTER FEED

Master Clamping and Wrapping around the Drum

Rear

Detailed

Descriptions

Front

[A]

C229D006.WMF

The master feed clutch turns on to feed out the master from the master buffer duct. The master is fed out 31 mm and reaches the drum master clamper [A]. The master feed clutch turns off temporarily.

The master clamper is closed and the drum starts turning to wrap the master around the drum. At the same time, the master feed clutch turns on again to feed the master, synchronizing it with the drum rotation.

When master making is complete and the master is stored in the master buffer duct, the drum turns continuously to wrap the master. The cutter cuts the master when there is no master left in the duct, and the master at the cutter is stretched tightly; this ensures a clean cut.

A sheet of paper, called the trial print, is fed at the same time as the master wrapping. To ensure that ink transfers to the master on the drum, the drum rotates at its lowest speed (16 rpm). This ensures that the print run starts up with a sufficient ink density.

The drum then returns to the home position, ready for printing.

2-35

MASTER FEED 1 July, 1998

Master Cut and Buffer Duct Entrance Control

When the thermal head has finished making the master and the master has been fed

[A]

out of the duct, the cutter [A] will cut the master.

In preparation for making the next master, the leading edge of the next master is continuously fed to the master feed control roller [B].

The new master is fed 32 mm past the cut position and stopped.

[B]

NOTE:

As explained in Master Feed and Stop Control in 2.5.2 Master Set Mechanism, the master edge sensor only controls the master stop position at the master feed control roller after a roll is put into the machine.

The duct entrance plate stays open, except in the following two cases. To close off the duct, the duct entrance solenoid closes the master buffer duct entrance plate [C].

· While the leading edge of the next master is being fed to the master feed control roller [B]

· After a roll is put in the machine (as explained in "2.5.2 Master Set Mechanism").

Front

[B]

C229D105.WMF

Rear

C229D005.WMF

[C]

2-36

1 July, 1998 MASTER FEED

Cutter Mechanism

Detailed

Descriptions

[E]

[A]

[B]

[C]

C231D573.WMF

Rear View

[D]

The cutter motor [D] drives the screw shaft [A], moving the cutter holder [C] forward and backward.

There are two cutter blades [B] in the holder. While the cutter holder [C] travels to the front (the operation side of the machine), the blades cut the master. The cutter motor keeps turning in one direction. However, the cutter holder returns to the home position when it reaches the front end of the cutter unit because of the two different spirals threaded on the screw shaft [A].

When the cutter holder reaches the home position, the cutter home position sensor [E] is activated by the holder and the motor stops.

2-37

MASTER FEED 1 July, 1998

2.4.5 MASTER MAKING UNIT SLIDE-OUT MECHANISM

The master making unit can be slid out along the guide rails.

There are three connectors, which enable electrical contact for the installed unit.

The master making unit set sensor [A] (a push switch) detects when the unit is out. The operation panel displays a message in this case.

[A]

C229D100.WMF

2.4.6 OPENING DOOR FOR MISFED MASTER REMOVAL

There is a jam removal dial to manually rotate the master feed rollers. If pieces of the master remain in the master buffer duct, open the door [B] to remove them. Normally, pieces of master do not remain in the duct. Therefore, the door is only for emergency cases.

[B]

C229D101.WMF

2-38

1 July, 1998 DRUM

2.5 DRUM

2.5.1 OVERVIEW

[C]

[A]

[G]

[D]

[E]

C229D109.WMF

[B]

[F]

Detailed

Descriptions

The drum surface is composed of a stainless-steel screen (metal screen [A]) and two layers of polyester screens (cloth screen [B]). In addition, a drum master clamper [C] clamps the leading edge of the master wrapped around the drum.

Inside the drum are the ink roller [D] and doctor roller [E], which create a precisely maintained gap, known as the doctor gap, to supply a thin layer of ink on the screens and master [F].

This machine uses the drum idling roller [G] to supply ink onto the screens and master before printing. The length of time the machine was not in use determines the idling supply time. This ensures that the first print will have sufficient ink density even after the machine was not used for a long time.

2-39

DRUM 1 July, 1998

2.5.2 INK SUPPLY AND KNEADING MECHANISM

[C]

[F]

[G]

[D]

[E]

C229D010.WMF

Ink Cartridge Installation

The ink cartridge [A] is in the drum. The ink cartridge set sensor [B] (a push switch) detects the presence of the ink cartridge.

[A]

[B]

Ink Supply Mechanism

The whole ink supply mechanism is inside the drum. The ink pump motor [C] drives the ink pump [D], supplying ink from the ink cartridge to the ink roller [E] via the ink distributor [F].

C229D009.WMF

Ink Pump Operation Monitoring

The ink pump sensor [G] monitors the number of pumps the ink pump piston lever makes. The feeler on the piston lever activates the sensor at each complete turn of the piston.

SP1-5 can be used to check the number of ink pump revolutions.

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1 July, 1998 DRUM

Ink Detection Board

C229D110.WMF

[B]

[C]

[A]

Detailed

Descriptions

[D]

C229D011.WMF

Ink Detection Mechanism

The ink detecting pins [A] function as a capacitor electrode and detect the capacitance between the ink [B] and doctor [C] rollers. The capacitance level changes with the ink level. When the ink level is high the pins touch ink, and the capacitance increases. When the ink level is low the pins do not touch the ink and the capacitance therefore decreases. Consequently, by detecting the capacitance between the pins, the ink supply motor maintains the ink level.

If the pins detect an insufficient amount of ink after activating the ink pump motor for 40 seconds, a "no ink condition" is detected. Guidance is displayed on the operation panel.

NOTE:

The ink supply mode is useful when installing a new drum. When the Economy Mode key is pressed while holding down the 0 key, the drum turns 40 rotations, to supply ink inside the drum.

The ink detection board [D], which includes the ink detection circuit, is also inside the drum. There are test pins (TP's) and a potentiometer (VR901) for ink detection adjustment.

2-41

DRUM 1 July, 1998

Drum Type Detection

There are also dip switches on the ink detection board. The settings depend on the drum type in the following manner:

DPS901 -1 -2

Standard Drum ON ON

Optional Color

Drum

Optional A4

Drum

Not Used OFF OFF

Note: If the CPU detects that all dip switches are off, it assumes that there is no drum in the machine.

OFF ON

ON OFF

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1 July, 1998 DRUM

Ink Kneading Mechanism

Rear

C229D007.WMF

[D]

[C]

[B]

[A]

Detailed

Descriptions

Front

[F]

C229D012.WMF

[E]

A gear [C] on the drum shaft drives the ink [A] and doctor [B] rollers. The doctor roller spreads the ink evenly on the ink roller. The ink roller drive gear [D] has a one-way clutch to prevent the ink roller from being manually turned in the reverse direction.

The ink roller only touches the screen during the printing process. During the printing process, ink passes to the paper through holes in the screens and the master. This is because the pressure cylinder below the drum holds the drum screen and the master against the ink roller during printing.

The ink roller blade [E] and separation plate [F] scrape off ink build-up on both ends of the ink and doctor rollers.

2-43

DRUM 1 July, 1998

Drum Idling Mechanism

[B]

Rear

[C]

[D]

[F]

[E]

[A]

C229D013.WMF

Front

Quality Start Mode

In Quality Start mode; the machine enters the drum idling mode before printing. This ensures that the first print has sufficient ink density even if the machine was not used for a long time.

The user selects Quality Start mode by pressing a key on the operation panel. The number of idling rotations is fixed at 45. However, SP3-90 can change this number.

NOTE:

In Quality Start mode; the drum idling motion starts, before printing, when the Start key is pressed. However, if there is no master on the drum, drum idling is not performed. Even if the Quality Start mode is active, and there is no master on the drum, drum idling is skipped although the LED on the operation panel turns on. When printing for the next original starts, the machine enters drum idling mode if a large enough master is wrapped around the drum (it will not be done for an A4 master on an A3 drum).

The drum idling roller [A] puts the ink onto the screens and master before printing. The idling roller motor [B] turns to press the drum idling roller against the inner surface of the drum screen [C]. The spring tension supplies additional force for this.

The cam [D] is turned by the motor, moving the drum idling roller towards the drum screen. The actuator disk [F] interrupts the idling roller HP sensor [E] when the drum idling roller is being used.

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1 July, 1998 DRUM

Auto Quality Start Mode

Auto Quality Start is done if the user does not select Quality Start mode. (It can be disabled with a user tool.)

In Auto Quality Start mode, the idling motion depends on how long the machine was not in use and on the temperature detected by the thermistor [A] in the drum.

The CPU detects a low temperature condition if the thermistor [A] reports approximately 15 °C or lower. If the detected temperature is 28 °C or higher, it is a high temperature condition.

[A]

The number of drum idling rotations depends on temperature and period of machine inactivity, as shown in the following table.

NOTE:

SP3-91 to 3-93 can change

C229D111.WMF

the number of rotations for each of these conditions.

Detailed

Descriptions

Period/

Temperature

High (28°C

or higher)

Normal (15 to

28°C)

Low (15°Cor

lower)

NOTE:

The drum rotation speed during idling is fixed at 90 rpm.

Less than 4

hours

00015

0 0 15 15

0154545

4 to 24 hours 24 to 72 hours Over 72 hours

2-45

DRUM 1 July, 1998

Drum Rotation Speed during Idling

Whether the machine is in Quality Start mode or not, the drum idling roller is always used for the trial print (the print to complete the master making), and for the first and second prints. If a low temperature condition is detected, the drum idling roller is also used for the third print.

The drum rotation speed varies during this mode as shown in the table below. In all cases, the drum idling roller returns to home position when drum rotation speed reaches 75 rpm.

- Change of drum rotation speed (rpm) with temperature -

Temperature

Normal or

High

(above 15

Low

(below 15

NOTE:

These figures apply to the highest printing speed (speed 5, which is at 120 rpm).

Trial

16 Idling Roller On

1st Print

30 Idling Roller On

16 Idling Roller On

2nd

60 Idling Roller On

30 Idling Roller On

3rd Print 4th Print

75 Idling Roller Returned

60 Idling Roller On

90 105 120 120

75 Idling Roller Returned

5th

90 105 120

6th

7th

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1 July, 1998 DRUM

2.5.3 DRUM SHIFT MECHANISM FOR IMAGE SIDE-TO-SIDE SHIFT

[C]

[B]

Rear

[A]

[D]

Detailed

Descriptions

Front

C229D014.WMF

The image side-to-side shift function shifts the outer drum sleeve (with master) from front to back.

The shifting mechanism is inside the drum. It consists of the drum shift motor [A] and a rack and pinion mechanism.

The motor can turn in either direction by the image shift amount set at the operation panel. The motor moves the rear drum flange [B] via the rack and pinion, as shown. At the same time, it rotates the pulse disk. This allows the drum shift sensor [C] to generate pulse signals for sending to the CPU. The CPU detects the amount of shift with these signals and controls motor on/off time.

The maximum shift range, in both directions, is 10 mm from home position. The drum shift HP sensor [D] ensures that the outer drum sleeve returns to the home position.

When the outer sleeve returns to the home position, it activates the sensor, stopping the drum shift motor.

2-47

DRUM 1 July, 1998

2.5.4 DRUM SET MECHANISM

[A]

Upper Handle and Lock

There are two grips [A, and B] to hold the drum.

When the upper grip [A] is pulled up, it releases the drum locking mechanism.

[B]

C229D015.WMF

Front Lock Lever

When the drum is set correctly and the front lever [C] is raised, the drum is locked into position. The connector [D] allows electrical contact for the drum components.

Drum Rotation Lock Mechanism

The rotation stopper [E] prevents the drum from turning when it is removed from the machine.

When the drum is replaced, contact with the rear frame disengages the stopper [E] and releases the lock.

[C]

[D]

C229D016.WMF

[E]

Rear View

C229D017.WMF

2-48

1 July, 1998 DRUM

2.5.5 DRUM DRIVE MECHANISM

[C]

[D]

[B]

[A]

Rear View

C229D018.WMF

[E]

C229D020.WMF

The main motor [A] drives the drum via the timing belt. When the drum is set in the machine, the stud [B] on the joint disk engages the drum drive gear [C]. This transmits the main motor drive to the drum unit.

Detailed

Descriptions

The main motor [C] has an encoder to send pulses to the main motor control board. The CPU monitors the pulses and controls the drum speed and stop positions. The 1st and 2nd drum position sensors [D, E] check the position of the drum. The actuator on the rear drum flange activates these sensors as the drum turns.

There are three drum stop positions: home, master eject, and master making. The CPU starts counting the main motor encoder pulses when these sensors are activated. Certain pulse counts are assigned to each drum stop position. The CPU can stop the drum at the desired positions.

At the home and master making positions, the drum de-actuates the relevant sensor. This ensures that the drum stops in the exact position, even after highspeed rotation. The 1st drum position sensor corresponds to the home position and the 2nd drum position sensor corresponds to the master making position.

2-49

DRUM 1 July, 1998

[C]

2.5.6 MASTER DETECTION

The 1st drum master sensor

[B]

[A] detects a master on the drum.

If a master is on the drum, the black patch [B] is covered and the sensor detects the light reflected from the master. Printing starts when the start key is pressed. If an original has been set, the master is ejected before making a new master.

If no master is on the drum, the

[A]

black patch is exposed. The black patch does not reflect light back to the sensor. The

[D]

C229D019.WMF

machine will skip the master eject process and immediately begin making a new master.

A similar sensor, the 2nd drum master sensor [C], is located just above the 1st drum master sensor. This sensor determines if the master making process correctly wrapped the master around the drum.

The drum starts turning soon after the drum master clamper clamps the leading edge of the master. The 2nd drum master sensor checks for the presence of the master (master clamping error check). If a master is not detected, a clamping error occurred. The master feed stops, the drum returns to the home position, and the machine displays a master feed jam message.

The 1st drum master sensor cannot check for master clamping errors, because the black patch has moved.

Both sensors use the same black patch [A] to detect the master.

NOTE:

There are two black patches on the drum screen. Patch [D] does not face the drum master sensors and is not used for master detection.

The surface of the patches is slightly higher than the surface of the rest of the drum screen. The extra patch ensures that the master pick-up roller contacts the drum surface evenly at this part of the drum, resulting in even pressure from the roller all across the drum.

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1 July, 1998 PAPER FEED

2.6 PAPER FEED

2.6.1 OVERVIEW

Rear

[A]

Front

[C]

[B]

[F]

[E]

[D]

C229D053.WMF

Detailed

Descriptions

Pick-up and Feed

The top sheet of paper on the paper table is first fed by the pick-up roller [D]. Then, it is separated by the paper feed roller [F] and the friction pad [E], and fed to the registration rollers [A]. The upper and lower registration rollers feed the sheet to the drum.

An independent stepper motor (the paper feed motor [C]) drives the pick-up roller and paper feed roller. This allows more precise control than the usual main motor/magnetic clutch system.

Feed/Separation Pressure

The strength of the paper feed roller and the friction pad pressure against the paper depend on the paper type selected at the operation panel. Each component has a separate dc motor to adjust the pressure. The operator is free from complicated adjustments for paper feed and paper separation pressures.

Registration

Also, an independent stepper motor (the registration motor [B]) controls the registration roller. The registration roller synchronizes paper feed timing with the image on the drum. The registration roller starts rotating after the paper has come in contact with the rollers and has been aligned.

Paper feed timing around the registration roller is monitored by two different photosensors. One is located before the registration roller, and the other is after the registration roller. These sensors are also essential for paper feed control.

2-51

PAPER FEED 1 July, 1998

2.6.2 PAPER FEED MECHANISM

Rear

[A]

[B]

[C]

Front

C229D054.WMF

[A]

[D]

[E]

C229D056.WMF

The pick-up roller [C] and paper feed roller [A] are driven by the paper feed motor [B] as shown.

The top sheet of the paper is separated from the paper stack by the friction between the roller and the friction pad [D], and fed to the registration roller.

The friction pad [D] is mounted on a block [E], and spring pressure is applied to this block. As explained later, the spring pressure is changed by a dc motor to adjust the paper separation pressure.

There is a one-way clutch in the paper feed roller. When the roller stops and paper is fed by the registration rollers, the one-way clutch ensures that the paper feed roller does not resist the paper feed.

2-52

1 July, 1998 PAPER FEED

Rear View

[B]

[D]

[A]

C229D118.WMF

[C]

Since paper feed timing must be synchronized with pressure cylinder rotation (so that the paper clamper on the pressure cylinder can catch papers leading edge accurately), the paper feed motor on timing is maintained by the feed start sensor [C].

A short time after the pressure cylinder [D] starts rotating, the actuator [A] on the rear of the pressure cylinder activates the sensor. After a pre-determined duration, the paper feed process begins (this time will vary with the printing speed).

Detailed

Descriptions

NOTE:

There are two actuators: [A] and [B]. The actuator [B] is used to maintain the registration motor start timing.

2-53

PAPER FEED 1 July, 1998

2.6.3 PAPER FEED/SEPARATION PRESSURE ADJUSTMENT

MECHANISM

Overview

The paper separation pressure and the paper feed pressure depend on the paper type selected at the operation panel. When the paper type is changed, two dc motors automatically turn to change the pressure settings.

Paper Separation Pressure

[B]

[A]

[C]

[D]

[E]

C229D057.WMF

The paper separation pressure is applied from the bottom of the friction pad block [A] by a spring on the friction pad base [E].

The direction of the paper separation pressure motor [B] turn depends on the signal from the CPU. The rack [D] moves from side to side, moving the friction pad base up or down. This changes the spring pressure against the friction pad block.

The position of the rack [D] is detected by the separation pressure detection board [C].

2-54

1 July, 1998 PAPER FEED

Paper Feed Pressure

[E]

[D]

[C]

Front

[F]

C229D055.WMF

The mechanism is similar to the separation pressure control mechanism.

Detailed

Descriptions

Rear

The feed pressure motor [E] rotates, pulling or releasing the spring [C] through the rack [D]. The lever [F] moves up or down depending on the tension of the spring. If the spring is pulled, the lever moves upwards, reducing the paper feed pressure.

The position of the rack [D] is detected by the feed pressure detection board (not shown), in a similar way as in the paper separation pressure control mechanism.

2-55

PAPER FEED 1 July, 1998

Paper Types

The user can select the paper type before starting the job. The feed and separation pressures used for the job will depend on the selected paper type (the machine automatically adjusts these pressures to suit the selected paper type.

The possible paper type settings are standard, thick, and special. Two additional settings for paper types can be customized as 'user 1' and 'user 2'.

For the 'user 1' and 'user 2' paper types, the user can choose from 5 settings using a user tool. The user tool settings give the machine a rough idea of what type of paper the user is using as types User 1 and User 2. The five user tool settings are as follows.

· Standard, no feed (Standard paper type, non feed likely)

· Standard, double feed (Standard paper type, double feed likely)

· Thick, no feed (Thick paper type, non feed likely)

· Thick, double feed (Thick paper type, double feed likely)

· Thick, medium (Thick paper type, with intermediate chances of double and non-

feed)

Pressure Settings for Each Paper Type

For each of these paper types (standard, thick, special, user 1, user 2), the user has two settings: Misfeed and Double Feed. Each of these two settings has three possible values: Standard, Frequent, Very Frequent (the user selects one of these depending on how the machine is performing).

The pressures for each setting can be adjusted with SP mode (SP 6-90 to -99). The feed pressure SP modes adjust the feed pressures applied for each of the users three possible misfeed settings, and the separation pressure SP modes adjust the separation pressures applied for each of the users three possible double feed settings. For how to use these SP modes, refer to the Replacement and Adjustment section.

· SP6-90: Feed pressure, special paper

· SP6-91: Feed pressure, normal paper

· SP6-92: Feed pressure, thick paper

· SP6-93: Feed pressure, user 1 paper

· SP6-94: Feed pressure, user 2 paper

· SP6-95: Feed pressure, special paper

· SP6-96: Feed pressure, normal paper

· SP6-97: Feed pressure, thick paper

· SP6-98: Feed pressure, user 1 paper

· SP6-99: Feed pressure, user 2 paper

2-56

1 July, 1998 PAPER FEED

Other Factors affected by the selected Paper Type

The paper type selected for a job also affects the paper delivery wing position, and whether the paper clamper on the pressure cylinder is used or not.

· SP6-100: Paper delivery wing position for standard, special, thick, user 1, and user 2 type paper

· SP6-101: Paper clamp enable/disable for standard, special, thick, user 1, and user 2 type paper

Default Settings

The following table shows the default settings for each paper type. For the pressure, the higher the SP mode value, the higher the pressure.

For details about the paper clamper, see Pressure Cylinder. For details about the wing guides, see Paper Delivery.

Detailed

Descriptions

Feed pressure Separation pressure

Paper Type Std. Freq.

Standard 3 5 6 2 4 6 Up Yes Thick 5 6 6 2 3 4 Down No Special 3 5 6 1 3 4 Down No User1or2:

Standard, no feed User1or2:

Standard, double feed

User1or2: Thick, no feed

User1or2: Thick, double feed

User1or2: Thick, medium

566246UpYes

246456UpYes

566123DownNo

356356DownNo

345246DownYes

Freq.

Std. Freq.

Freq.

Wing

Guides

Paper

Clamp

2-57

PAPER FEED 1 July, 1998

2.6.4 PAPER REGISTRATION MECHANSM

Rear

[B]

[A]

C229D058.WMF

Front

Registration Roller Drive

The lower registration roller [A] is driven by a stepper motor [B] (the registration motor).

2-58

1 July, 1998 PAPER FEED

[B]

Rear View

[D]

[A]

C229D119.WMF

[C]

Paper feed timing must be synchronized with the pressure cylinder rotation, so the registration motor on timing is maintained by the feed start sensor [C].

A short time after the pressure cylinder [D] starts rotating, the actuator [A] on the rear of the pressure cylinder activates the sensor. A pre-determined duration later (see Note 1 below), the registration motor starts turning to feed paper to the drum and pressure cylinder. After the printing paper is caught between the drum and the pressure cylinder, the registration motor stops.

NOTE:

1) The registration motor rotation speed is constant. However, when the operator selects a higher or lower printing speed (to change the copy image density), the drum and pressure cylinder rotation speed changes. The registration motor must feed the paper at the correct time for the leading edge to be caught by the paper clamper on the pressure cylinder. Therefore, the registration motor start timing after the paper feed start sensor is activated depends on the printing speed selected.

2) There are two actuators: [A] and [B]. The actuator [B] is used to maintain the paper feed motor start timing. (This was mentioned earlier, in Paper Feed Mechanism.)

Detailed

Descriptions

Image Up/Down Shift Mode

In addition, the registration motor start timing is changed by pressing the image position keys on the operation panel (this is the image up/down shifting mode). If the paper feed timing is delayed, the image is shifted forward.

NOTE:

The leading edge of the paper must be precisely caught by the paper clamper on the pressure cylinder after leaving the registration rollers. When the image up/down shifting mode is used, the position of the pressure cylinder changes through the image up/down mechanism, so the registration motor start timing must change. (The drum stays at home position.) For details of the mechanism, refer to "2.10 Image Up/Down Shifting" section.

2-59

PAPER FEED 1 July, 1998

[A]

[B]

Rear

[C]

Front

[D]

C229D059.WMF

Registration Roller Up/Down Mechanism

After the paper is caught between the drum and the pressure cylinder, the upper registration roller is released from the lower registration roller. This is to prevent interference from the registration rollers while the paper is being fed by the drum and the pressure cylinder.

When the high point of the cam [A] on the drum drive gear reaches the cam follower [B] (a bearing), the shaft [C] rotates clockwise (as seen from the operation side) to release the upper registration roller [D] from the lower registration roller.

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1 July, 1998 PAPER FEED

2.6.5 PAPER FEED CONTROL MECHANISM

[B]

Rear

[C]

[A]

Front

Detailed

Descriptions

C229D060.WMF

The paper feed timing around the registration roller [A] is monitored by two different photo-sensors. The first is the paper registration sensor [C], which is located before the registration roller. The second sensor is the paper feed timing sensor [B], which is located after the registration roller.

The paper registration sensor [C] detects the paper arriving at the registration roller. The paper feed motor start timing is determined by this sensor. When the paper comes into contact with the rollers, the motor remains stopped to create a buckle in the paper to obtain precise paper registration and to prevent paper skew. The motor starts turning a pre-determined period after the sensor is activated by the paper. The sensor is also used to detect jams.

The paper feed timing sensor [B] is also used to detect paper jams. It is also used to compensate for delays in paper feed caused by slippage at the registration roller, as described below.

The CPU monitors the paper feed timing sensor after the registration motor starts turning. If the sensor turns on late, the CPU determines that there has been slippage at the registration roller. Depending on the size of the delay, the registration motor speeds up to recover the delay.

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PAPER FEED 1 July, 1998

2.6.6 PAPER TABLE ANGLE ADJUSTMENT MECHANISM

There are two paper table open positions: level, and 15 degrees upward slant. Normally the paper table is set at the level position.

The 15 degrees upward slant position is used to feed special types of paper, such as envelopes, which are difficult to feed at the level position. In the slanted position, the tray capacity is reduced.

As the paper table [A] is lowered from the closed position, the pin on the lever [C] engages the cutout in the lock bracket [B]. Then, the paper table stops at the level position.

[A]

[B]

C229D511.WMF

When the paper table is slightly raised from the level position, the spring plate [D] pushes the lock bracket [B], and the pin on the lever [C] disengages. This stops the table at the 15 degrees upward slant position.

C229D061.WMF

[C]

[B]

[C]

[D]

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1 July, 1998 PAPER FEED

2.6.7 PAPER TABLE OPEN DETECTION

[B]

[A]

Detailed

Descriptions

C229D510.WMF

When the paper table is open, the lever [A] activates the paper table set sensor [B]. If the paper table remains closed and the sensor is not activated, guidance will be displayed on the operation panel.

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PAPER FEED 1 July, 1998

2.6.8 PAPER TABLE UP/DOWN MECHANISM

Rear

[C]

[B]

[A]

Front

C229D062.WMF

[D]

C229D063.WMF

Paper Table Drive Mechanism

An independent dc motor, the paper table motor [A], drives the paper table. When the motor turns, the pinion [B] turns along the rack [C], moving the paper table up or down.

To reduce noise, there is a shutter cover below the table, which is a combination of 5 plates. The shutter closes the opening beneath the paper table when the table is lifted up.

NOTE:

Although each plate of the shutter looks similar, only the second and fourth plates [D] from the top are the same in shape. The other plates are all different from each other. Be sure to re-assemble in the correct sequence.

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1 July, 1998 PAPER FEED

Table Upper/Lower Limit Detection and Paper Height Control

[A]

[B]

Detailed

Descriptions

C229D066.WMF

When the paper table moves up, the top of the paper stack contacts the pick-up roller [B], lifting it up. Then, when the paper height sensor [A] is actuated, the paper table stops.

During a printing run, sheets are fed from the stack, and the pick-up roller lowers. When the paper height sensor is de-actuated, the paper table motor starts turning and lifts the paper table until the sensor is actuated again. In this way, the top of the paper stack remains at the same position during printing.

When the tray lowers, the lower limit position is detected by the paper table lower limit sensor (not shown), which is located beside the paper table motor.

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PAPER FEED 1 July, 1998

2.6.9 PAPER SIDE FENCE MECHANISM

[A]

C229D064.WMF

[B]

C229D117.WMF

The left and right side fences move together due to a rack and pinion mechanism.

The actuator plate [A] is attached to the rack. This actuates the paper width detection board, to detect the position of the side fences (see Paper Size and Paper End Detection).

The side plate friction pads on the front and rear paper side fences prevent multiple feed. These are especially useful when thin paper is used.

There are two spring plates [B] applying pressure against the racks (one spring plate each for the right and left racks). Normally, there is no pressure applied to the racks. However, during long copy runs, the side plates may move away from the sides of the stack. By adjusting the position of the spring plates, the side fence pressure can be increased.

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1 July, 1998 PAPER FEED

2.6.10 PAPER SIZE AND PAPER END DETECTIONS

[A]

[B]

C229D040.WMF

Detailed

Descriptions

[C]

C229D065.WMF

When paper is placed on the paper table, the paper end sensor [A], which is a reflective photosensor, is activated.

If B4 sized (or 8 1/2" x 14") paper or larger is set on the paper table, the paper length sensor [B] is activated.

The actuator plate [C] is attached to the rack for the paper side fences. The paper width detection board detects the position of the side fences. The paper size data is sent to the CPU in combination with the status of the paper length sensor.

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PRINTING AND PRESSURE CYLINDER 1 July, 1998

2.7 PRINTING AND PRESSURE CYLINDER

2.7.1 OVERVIEW

[A]

[B]

Rear

[E]

[C]

[A]

[B]

[D]

[C]

Front

This model uses a pressure cylinder, instead of a press roller.

Two printing pressure springs [A] (one each at front and rear) pull the pressure cylinder up against the drum through the front and rear printing pressure arms [C]. (The arms rotate around the shaft [D].) Normally, the arms are engaged and the printing pressure is not applied. When the paper reaches the image transfer area, the arms are released by the printing pressure release solenoid [E].

The printing pressure cams [B] control the printing pressure application area to avoid the master clamper on the drum.

In this model, there are two possible master sizes. Printing on a large master (A3 sized cut) or small master (A4 sideways sized cut) is selected automatically (only if the optional ADF is used). The printing pressure cams include two shapes, one for A3 printing and one for A4 printing, so that the machine can switch to the appropriate printing area.

The paper clamper catches the leading edge of the paper after it has passed the registration roller section.

NOTE:

If the paper is still wrapped around the pressure cylinder after it has passed the image transfer area, the lower wrapping jam sensor detects it. (The upper wrapping jam, which is paper wrapping around the drum, is detected by the paper exit sensor in the paper delivery unit.)

When the Thick Paper mode is selected on the operation panel, the paper is not clamped, because thick paper does not cause paper wrapping jams (around the drum).

C229D067.WMF

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1 July, 1998 PRINTING AND PRESSURE CYLINDER

2.7.2 PAPER CLAMPING

[A]

Rear

[B]

Detailed

Descriptions

Front

C229D041.WMF

Clamping the Paper

The paper clamper catches the leading edge of the paper after it has passed the registration roller.

As the pressure cylinder rotates, the high point of the cam [B] reaches the bearing [A] on the lever at the front end of the paper clamper, and the clamper opens. When the clamper is open, the leading edge of the paper just reaches the clamper and enters it. After the high point of the cam passes the bearing, the clamper closes and holds the paper using magnets.

When Thick Paper mode is selected on the operation panel, the paper is not clamped. (The clamping is not needed since thick paper does not cause paper wrapping jams around the drum.)

So, for Thick Paper mode, the paper feed start timing at the registration roller is delayed to prevent the paper from being caught by the clamper. Then, the motor speeds up the paper feed to ensure the that the image transfers from the drum at the same timing as for normal paper. The clamper will open and close without clamping the thick paper.

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PRINTING AND PRESSURE CYLINDER 1 July, 1998

[A]

Rear

Front

[B]

C229D071.WMF

Releasing the Paper

The paper is released shortly after the leading edge passes through the nip between the drum and pressure cylinder where the image is transferred to the paper, and it is fed towards the paper delivery unit.

As the pressure cylinder rotates, the other high point of the cam [B] reaches the bearing at the front end of the clamper. The clamper is again opened and the paper is released.

The opening angle of the clamper for releasing is larger than for clamping, and this causes the paper release pawls [A] to rise to push the clamped edge of the paper, which helps the release mechanism.

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1 July, 1998 PRINTING AND PRESSURE CYLINDER

2.7.3 PRINTING PRESSURE MECHANISM

[A]

[B]

[C]

Rear

[D]

[G]

Detailed

Descriptions

[F]

Front

[E]

C229D069.WMF

There are two printing pressure springs [D] and two printing pressure arms [B], one each at front and rear. The pressure cylinder rests on the printing pressure arms. Normally, the arms are engaged and the printing pressure is not applied.

The printing pressure cam [G] always rotates because of drive from the main motor. When the high point of the cam reaches the bearing [F] on the printing pressure arm, it pushes down the arm slightly. At this moment, a small gap is created between the hook on the arm and the printing pressure release lever [A]. Then, the printing pressure release solenoid [E] can release the arms. This occurs when the paper reaches the image transfer area.

When the arms are released, the two printing pressure springs pull the pressure cylinder up against the drum through the front and rear printing pressure arms, which turn around the release arm shaft [C].

The printing pressure cam controls the printing pressure application area to prevent printing pressure from being applied to the master clamper area on the drum. After the printing pressure arms are released, the printing pressure is applied while the bearing on the printing pressure arm is riding on the low point of the cam. When it rides on the high point of the cam, the printing pressure is released to avoid the master clamper.

NOTE:

Do not clean the pressure cylinder surface with alcohol or other strong solvents. Use a cloth dampened with water. Periodic cleaning is required for this part.

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PRINTING AND PRESSURE CYLINDER 1 July, 1998

2.7.4 PRINTING PRESSURE CAM SHIFTING FOR A3/A4 SIZE MASTERS

[A]

Rear

[B]

[E]

[B]

[C]

Front

[D]

C229D070.WMF

In this model, printing on a large master (A3 sized cut) or a small master (A4 sideways sized cut) is selected automatically (only if the optional ADF is used).

When the CPU detects that A4 sized paper (or 8 1/2" x 11") or smaller has been set in the sideways feed direction on the paper table, and two or more originals have been placed in the ADF, the machine automatically makes the smaller master.

NOTE:

The master sizes are as follows: Large Master: 320 x 530 mm (320 x 540 mm for U.S.A. models) Small Master: 320 x 355 mm

Since the small master does not cover all the printing area of the drum screen, the last original's image is always made on a large master. This is to prevent the drum screen from drying if the next printing job is not done for a long time.

Therefore, a small master is not made when there is only one original in the ADF, even when printing on small paper. (In the Platen mode, the small master is never made because the machine cannot detect the number of originals.)

Based on the master size, the correct printing area is applied automatically. The printing pressure cam [B] includes two shapes (for A3 printing and for A4 sideways printing) in one part.

When switching the printing area, the pressure cam shift motor [A] turns. The switching plate [E] moves the cam shaft from side to side through some gears, which moves the printing pressure cam at each end of the shaft from side to side. The rack moves until either the A4 cam sensor [D] or A3 cam sensor [C] is activated.

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Ricoh pearl SPECIFICATIONS

Specifications and Main Features

Frequently Asked Questions

User Manual

1. OVERALL INFORMATION

1.1 SPECIFICATIONS

1.2 GUIDE TO COMPONENTS AND THEIR FUNCTION

1.2.1 MACHINE EXTERIOR

1.3 MACHINE INTERIOR

1.3.1 OPERATION PANEL

1.3.2 INDICATORS

1.4 PRINTING PROCESS OVERVIEW

1.5 MECHANICAL COMPONENT LAYOUT

1.6 ELECTRICAL COMPONENT LAYOUT

1.6.1 PRINTED CIRCUIT BOARD LAYOUT

1.6.2 SCANNER SECTION

1.6.3 PAPER FEED SECTION

1.6.5 PAPER DELIVERY SECTION

1.6.6 MASTER MAKING UNIT

1.6.7 DRUM UNIT

1.6.8 TABLES OF ELECTRICAL COMPONENTS

1.7 DRIVE LAYOUT

1.7.1 OVERVIEW

1.7.2 MAIN DRIVE

2. DETAILED SECTION DESCRIPTIONS

2.1 SCANNER AND OPTICS

2.1.1 OVERVIEW

2.1.2 SCANNER DRIVE

2.1.3 ORIGINAL SIZE DETECTION IN PLATEN MODE

2.2 IMAGE-PROCESSING

2.2.1 OVERVIEW

2.2.2 AUTO BACKGROUND CORRECTION

2.2.3 AUTO SHADING

2.2.4 FILTERING AND MAIN SCAN MAGNIFICATION/REDUCTION

2.2.5 BINARY PROCESSING

2.2.6 OPTIONAL MEMORY BOARD

2.2.7 THERMAL HEAD

2.3 MASTER EJECT

2.3.1 OVERVIEW

2.3.2 MASTER EJECT MECHANISM

2.3.3 PRESSURE PLATE DRIVE MECHANISM

2.4 MASTER FEED

2.4.1 OVERVIEW

2.4.2 MASTER SET MECHANISM

2.4.3 MASTER MAKING AND FEED MECHANISM

2.4.4 WRAPPING THE MASTER AROUND DRUM

2.4.5 MASTER MAKING UNIT SLIDE-OUT MECHANISM

2.4.6 OPENING DOOR FOR MISFED MASTER REMOVAL

2.5 DRUM

2.5.1 OVERVIEW

2.5.2 INK SUPPLY AND KNEADING MECHANISM

2.5.3 DRUM SHIFT MECHANISM FOR IMAGE SIDE-TO-SIDE SHIFT

2.5.4 DRUM SET MECHANISM

2.5.5 DRUM DRIVE MECHANISM

2.5.6 MASTER DETECTION

2.6 PAPER FEED

2.6.1 OVERVIEW

2.6.2 PAPER FEED MECHANISM

2.6.4 PAPER REGISTRATION MECHANSM

2.6.5 PAPER FEED CONTROL MECHANISM

2.6.6 PAPER TABLE ANGLE ADJUSTMENT MECHANISM

2.6.7 PAPER TABLE OPEN DETECTION

2.6.8 PAPER TABLE UP/DOWN MECHANISM

2.6.9 PAPER SIDE FENCE MECHANISM

2.6.10 PAPER SIZE AND PAPER END DETECTIONS

2.7 PRINTING AND PRESSURE CYLINDER

2.7.1 OVERVIEW

2.7.2 PAPER CLAMPING

2.7.3 PRINTING PRESSURE MECHANISM

2.7.4 PRINTING PRESSURE CAM SHIFTING FOR A3/A4 SIZE MASTERS