Ricoh Stinger P3, Stinger P4 Service manual

STINGER - P3/P4

SERVICE MANUAL

Subject to change

Ricoh Technical Service

March 12th 1999

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

4. If a print job has started (the Data In LED has started blinking) before the printer completes the warm-up or initializing period, keep hands away from the mechanical and electrical components because the printer starts making prints as soon as the warm-up period is completed.

5. The inside and the metal parts of the fusing unit become extremely hot while the printer is operating. Avoid touching those components with your bare hands.

HEALTH SAFETY CONDITIONS

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

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do not incinerate the toner cassettes. Toner dust may ignite suddenly when exposed to an open flame.

2. Dispose of toner cassettes in accordance with local regulations. (This is a non-toxic unit.)

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

LASER SAFETY

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

WARNING

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

WARNING FOR LASER UNIT

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

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

CAUTION MARKING:

TABLE OF CONTENTS

1. OVERALL MACH INE INFORMATION........................................1-1

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

1.2 MACHINE CONFIGURATION.................................................................. 1-5

1.3 PAPER PATH........................................................................................... 1-6

1.4 MECHANICAL COMPONENT LAYOUT................................................... 1-7

1.5 ELECTRICAL COMPONENT LAYOUT.................................................... 1-8

1.6 ELECTRICAL COMPONENT DESCRIPTIONS...................................... 1-10

1.7 PRINTING PROCESS............................................................................ 1-12

1.8 BOARD STRUCTURE............................................................................ 1-14

1.8.1 OVERVIEW ................................................................................... 1-14

1.8.2 MAJOR COMPONENTS................................................................ 1-15

1.9 COMPARISON....................................................................................... 1-16

2. DETAILED SECTION DESCRIPTIONS.......................................2-1

2.1 PRINTING................................................................................................. 2-1

2.1.1 IMAGE DATA PATH........................................................................ 2-1

2.1.2 PRINTER CONTROL BOARD......................................................... 2-2

2.1.3 IMAGE DATA PROCESSIING......................................................... 2-3

2.1.4 HOST INTERFACE.......................................................................... 2-4

2.2 LASER EXPOSURE................................................................................. 2-5

2.2.1 OVERVIEW ..................................................................................... 2-5

2.2.2 OPTICAL PATH............................................................................... 2-6

2.2.3 AUTO POWER CONTROL (APC)................................................... 2-8

2.2.4 LD SAFETY SWITCH...................................................................... 2-9

2.3 TONER CARTRIDGE............................................................................. 2-10

2.3.1 OVERVIEW ................................................................................... 2-10

2.3.2 DRIVE............................................................................................ 2-11

2.3.3 DRUM CHARGE............................................................................ 2-12

2.3.4 DEVELOPMENT............................................................................ 2-13

2.3.5 DRUM CLEANING......................................................................... 2-15

2.4 IMAGE TRANSFER AND PAPER SEPARATION.................................. 2-16

2.4.1 OVERVIEW ................................................................................... 2-16

2.4.2 TRANSFER ROLLER CLEANING................................................. 2-17

2.5 PAPER FEED......................................................................................... 2-18

2.5.1 OVERVIEW ................................................................................... 2-18

2.5.2 PAPER TRAY................................................................................ 2-20

2.5.3 BY-PASS TRAY............................................................................. 2-25

2.5.4 PAPER REGISTRATION............................................................... 2-27

2.6 IMAGE FUSING...................................................................................... 2-29

2.6.1 OVERVIEW ................................................................................... 2-29

2.6.2 FUSING......................................................................................... 2-30

2.6.3 FUSING UNIT DRIVE.................................................................... 2-30

2.6.4 PRESSURE ROLLER/PAPER EXIT.............................................. 2-31

2.6.5 FUSING UNIT DRIVE RELEASE................................................... 2-31

2.6.6 NEW FUSING UNIT DETECTION (STINGER - P3 ONLY)............ 2-32

2.6.7 FUSING TEMPERATURE CONTROL........................................... 2-33

2.6.8 OVERHEAT PROTECTION........................................................... 2-35

2.6.9 ENERGY SAVER MODE............................................................... 2-36

2.7 COVER OPEN DETECTION.................................................................. 2-37

2.7.1 FRONT COVER LOCK.................................................................. 2-37

2.7.2 FRONT COVER SAFETY SWITCH............................................... 2-37

2.7.3 REMOVING THE FUSING UNIT................................................... 2-38

2.8 ENGINE CONTROL BOARD.................................................................. 2-39

2.8.1 PCB LAYOUT................................................................................ 2-39

2.8.2 DEVICES....................................................................................... 2-40

2.8.3 STRUCTURE................................................................................. 2-41

2.8.4 CONNECTION TO THE ECB........................................................ 2-42

2.9 SIGNAL TABLE...................................................................................... 2-44

2.10 PRINTER CONTROL BOARD.............................................................. 2-47

2.10.1 PCB LAYOUT.............................................................................. 2-47

2.10.2 DEVICES..................................................................................... 2-48

3. INSTALLA TION...........................................................................3-1

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

3.1.1 ENVIRONMENT .............................................................................. 3-1

3.1.2 POWER REQUIREMENTS.............................................................. 3-1

3.2 PRINTER INSTALLATION........................................................................ 3-2

3.3 PAPER FEED UNIT INSTALLATION....................................................... 3-2

3.4 ENVELOPE FEEDER INSTALLATION.....................................................3-2

3.5 HARD DISK INSTALLATION.................................................................... 3-2

3.6 MEMORY UNIT INSTALLATION.............................................................. 3-2

3.7 NETWORK INTERFACE BOARD INSTALLATION.................................. 3-2

3.8 CHECKING THE CONNECTIONS........................................................... 3-3

3.8.1 CONNECTION BETWEEN MAIN PRINTER CONTROL BOARD (AND RELATED OPTIONS: HDD, RAM SIMM, NIC) AND

OPTIONAL HDD & PERIPHERALS................................................. 3-3

3.8.2 CONNECTION BETWEEN PRINTER CONTROL BOARD AND

NETWORK INTERFACE BOARD.................................................... 3-6

3.8.3 PRINTING THE NETWORK INTERFACE BOARD

CONFIGURATION SHEET.............................................................. 3-6

4. SERVICE PROCEDURES AND TABLES................................... 4-1

4.1 OVERVIEW .............................................................................................. 4-1

4.2 SERVICE PROGRAM MODE................................................................... 4-2

4.2.1 ENABLING AND DISABLING SERVICE PROGRAM MODE.......... 4-2

4.2.2 SERVICE PROGRAM MODE MENU TREE.................................... 4-3

4.2.3 SERVICE MODE MENU TABLE...................................................... 4-5

4.2.4 PRINT LOG...................................................................................... 4-9

4.2.5 PRINTER ID................................................................................... 4-13

4.3 IC CARD BOOT SERVICE MODE ......................................................... 4-15

4.3.1 OVERVIEW ................................................................................... 4-15

4.3.2 ENABLING AND DISABLING IC CARD BOOT SERVICE

MODE............................................................................................ 4-15

4.3.3 IC CARD BOOT SERVICE MODE TREE...................................... 4-16

4.3.4 SERVICE MENU TABLE............................................................... 4-17

4.4 EEPROM AND NVRAM RESET PROCEDURES................................... 4-18

4.5 DOWNLOADING NEW CONTROLLER SOFTWARE ............................ 4-19

4.5.1 OVERVIEW ................................................................................... 4-19

4.5.2 DOWNLOADING NEW FIRMWARE FROM AN IC CARD............. 4-20

4.6 USER MENU.......................................................................................... 4-23

4.7 ECB TEST PATTERN............................................................................. 4-24

4.8 DIAGNOSTIC TEST MODES................................................................. 4-25

4.8.1 OVERVIEW ................................................................................... 4-25

4.8.2 POWER-UP DIAGNOSTIC MODE................................................ 4-25

4.8.3 DETAILED DIAGNOSTIC MODE.................................................. 4-26

4.8.4 DIAGNOSTIC TEST DETAILS....................................................... 4-27

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

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

6. REPLACEMENT A N D ADJUSTMENT........................................ 6-1

6.1 COVERS................................................................................................... 6-1

6.1.1 EXTERIOR COVER REMOVAL...................................................... 6-1

6.1.2 FRONT COVER REMOVAL............................................................ 6-2

6.1.3 CONTROL BOARD COVER REMOVAL ......................................... 6-3

6.2 FUSING UNIT........................................................................................... 6-4

6.2.1 FUSING UNIT REPLACEMENT...................................................... 6-4

6.2.2 HOT ROLLER AND FUSING LAMP REPLACEMENT .................... 6-5

6.2.3 PRESSURE ROLLER REPLACEMENT.......................................... 6-7

6.2.4 FUSING THERMOFUSE REPLACEMENT ..................................... 6-8

6.2.5 FUSING DRAWER CONNECTOR REPLACEMENT....................... 6-9

6.3 TRANSFER ROLLER............................................................................. 6-10

6.3.1 TRANSFER ROLLER REPLACEMENT ........................................ 6-10

6.4 PAPER FEED......................................................................................... 6-11

6.4.1 BY-PASS TRAY REMOVAL.......................................................... 6-11

6.4.2 BY-PASS FEED ROLLER REPLACEMENT.................................. 6-12

6.4.3 PAPER FEED ROLLER REPLACEMENT..................................... 6-15

6.4.4 RELAY ROLLER REPLACEMENT (STINGER - P4 ONLY)........... 6-17

6.4.5 FRICTION PAD REPLACEMENT.................................................. 6-18

6.4.6 TRAY PAPER FEED CLUTCH REPLACEMENT.......................... 6-19

6.5 LASER UNIT........................................................................................... 6-20

6.5.1 CAUTION DECAL LOCATIONS.................................................... 6-20

6.5.2 LASER UNIT/SHIELD GLASS REPLACEMENT........................... 6-21

6.5.3 LD UNIT/LASER SYNCHRONIZATION DETECTOR

REPLACEMENT............................................................................ 6-22

6.5.4 POLYGONAL MIRROR MOTOR REPLACEMENT....................... 6-23

6.5.5 LD UNIT/POLYGONAL MIRROR MOTOR REPLACEMENT........ 6-24

iii

6.6 OTHERS................................................................................................. 6-25

6.6.1 TONER NEAR-END SENSOR REPLACEMENT........................... 6-25

6.6.2 MAIN MOTOR/GEAR BOX REMOVAL ......................................... 6-26

6.6.3 ENGINE CONTROL BOARD REPLACEMENT............................. 6-27

6.6.4 PRINTER CONTROL BOARD REPLACEMENT........................... 6-28

6.6.5 HIGH VOLTAGE SUPPLY BOARD............................................... 6-29

6.6.6 POWER SUPPLY UNIT REPLACEMENT..................................... 6-30

6.7 PRINT REGISTRATION ADJUSTMENT................................................ 6-31

7. TROUBLESHOOTING.................................................................7-1

7.1 OPERATOR ERRORS ............................................................................. 7-1

7.2 PRINTER ENGINE SC CODES................................................................ 7-6

7.3 DIAGNOSTIC ERROR CODES................................................................ 7-9

7.3.1 DIAGNOSTIC ERROR CODE TABLE............................................. 7-9

7.4 ELECTRICAL COMPONENT DEFECTS................................................ 7-17

7.4.1 SENSORS..................................................................................... 7-17

7.4.2 SWITCHES.................................................................................... 7-17

7.4.3 FUSES........................................................................................... 7-17

OPTION

ENVELOPE FEEDER (Machine Code: G913)

1. OVERALL INFORMATION................................................... G913-1

1.1 SPECIFICATIONS..............................................................................G913-1

1.2 MECHANICAL COMPONENT LAYOUT.............................................G913-1

2. DETAILED SECTION DESCRIPTIONS................................ G913-2

2.1 PAPER LIFT.......................................................................................G913-2

3. INSTALLA TION.................................................................... G913-3

4. REPLACEMENT AND ADJUSTMENT................................. G913-4

4.1 FRICTION PAD REPLACEMENT.......................................................G913-4

PAPER FEED UNIT (Machine Code: G914)

1. OVERALL MACH INE INFORMATION................................. G914-1

1.1 SPECIFICATIONS..............................................................................G914-1

1.1.1 STINGER - P3...........................................................................G914-1

1.1.2 STINGER - P4...........................................................................G914-1

1.2 MECHANICAL COMPONENT LAYOUT.............................................G914-2

1.3 ELECTRICAL COMPONENT LAYOUT..............................................G914-3

1.4 ELECTRICAL COMPONENT DESCRIPTION....................................G914-4

2. DETAILED SECTION DESCRIPTIONS................................ G914-5

2.1 PAPER SIZE DETECTION.................................................................G914-5

2.2 PAPER LIFT.......................................................................................G914-5

2.3 PAPER END DETECTION .................................................................G914-5

2.4 PAPER NEAR END DETECTION ......................................................G914-5

2.5 PAPER FEED.....................................................................................G914-6

3. INSTALLA TION.................................................................... G914-8

4. REPLACEMENT AND ADJUSTMENT................................. G914-9

4.1 PAPER FEED UNIT (OPTION FOR STINGER - P3)..........................G914-9

4.1.1 PAPER FEED ASSEMBLY REMOVAL .....................................G914-9

4.1.2 DRIVE ROLLER REPLACEMENT...........................................G914-10

4.1.3 PAPER FEED MOTOR REPLACEMENT................................G914-11

4.1.4 PAPER FEED CLUTCH REMOVAL........................................G914-12

4.1.5 PAPER FEED UNIT BOARD/PAPER SIZE SWITCH

REPLACEMENT......................................................................G914-13

4.2 PAPER FEED UNIT (OPTION FOR STINGER - P4)........................ G914-14

4.2.1 PAPER FEED ROLLER/PAPER FEED CLUTCH

REPLACEMENT......................................................................G914-14

4.2.2 PAPER DRIVE ROLLER REPLACEMENT..............................G914-15

4.2.3 DRIVE ROLLER IDLER/FRICTION PAD REPLACEMENT.....G914-16

4.2.4 PAPER FEED MOTOR/PAPER FEED UNIT BOARD

REPLACEMENT......................................................................G914-17

NETWORK INTERFACE BOARD (Machine Code: G919)

1. OVERALL MACH INE INFORMATION................................. G917-1

1.1 SPECIFICATIONS..............................................................................G917-1

2. INSTALLATION PROCEDURE............................................ G917-2

2.1 HARDWARE INSTALLATION ............................................................G917-2

2.1.1 SERIAL NUMBER AND MAC ADDRESS..................................G917-2

2.1.2 STATUS SHEET........................................................................G917-2

2.2 PROGRAMMING NETWORK/PROTOCOL PARAMETERS..............G917-3

2.2.1 IPX NETWORK..........................................................................G917-3

2.2.2 TCP/IP NETWORK....................................................................G917-4

2.2.3 ETHERTALK (APPLETALK) NETWORK...................................G917-5

2.3 SETUP FOR VARIOUS NETWORK TYPES...................................... G917-6

2.3.1 PEER-TO-PEER NETWORK.....................................................G917-6

2.3.2 NOVELL NETWARE NETWORK...............................................G917-7

2.3.3 TCP/IP NETWORK....................................................................G917-7

3. SERVICE TABLES AND PROCEDURES ............................ G917-8

3.1 FACTORY RESET (NVRAM CLEAR).................................................G917-8

3.2 FLASH ROM UPDATE.......................................................................G917-9

3.2.1 INTRODUCTION .......................................................................G917-9

3.2.2 FLASHUP UTILITY (FOR NOVELL IPX NETWORKS)............G917-10

3.2.3 FTPDL UTILITY (FOR TCP/IP NETWORKS)..........................G917-13

4. TROUBLESHOOTIN G........................................................ G917-16

4.1 LED INDICATIONS...........................................................................G917-16

APPENDIX

1. DOWNLOADING CONTROLLER FIRMWARE...........APPENDIX-1

1.1 OVERVIEW .............................................................................. APPENDIX-1

1.1.1 IC CARD (FLASH CARD)................................................APPENDIX-1

1.1.2 PC, VIA PARALLEL PORT.............................................. APPENDIX-2

1.1.3 DIMM............................................................................... APPENDIX-2

1.1.4 RELEASING NEW CONTROLLER FIRMWARE............. APPENDIX-3

1.2 SERVICE TOOLS..................................................................... APPENDIX-4

1.2.1 OPERATION PANEL....................................................... APPENDIX-4

1.2.2 SERVICE TOOL MENUS ................................................ APPENDIX-5

1.2.3 STINGER SERVICE UTILITY (SSU)...............................APPENDIX-7

1.3 USING AN IC CARD................................................................. APPENDIX-8

1.3.1 PREPARING THE IC CARD............................................ APPENDIX-8

1.3.2 DOWNLOADING FROM THE IC CARD TO

THE PRINTER............................................................... APPENDIX-13

1.4 USING A DIMM ...................................................................... APPENDIX-14

1.4.1 PREPARING THE DIMM............................................... APPENDIX-14

1.4.2 DOWNLOADING FROM THE DIMM TO

THE PRINTER............................................................... APPENDIX-19

1.5 COPYING FROM A PC DIRECTLY........................................ APPENDIX-20

1.5.1 PREPARATION............................................................. APPENDIX-20

1.5.2 DOWNLOADING TO THE FLASH MEMORY................ APPENDIX-22

1.6 SSU TROUBLESHOOTING ................................................... APPENDIX-26

vii

12 March 1999 SPECIFICATIONS

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS

Configuration: Desktop Print Process: Laser beam scanning & electrophotographic printing

Monocomponent toner development

Printing Speed (600 dpi):

First Print Speed: Stinger - P3:

Resolution: True 1,200 x 1,200 dpi (available for PCL6 or PostScript)

Printer Language PCL6/PCL5e

Stinger - P3:

Maximum 20 pages per minute (A4/LT LEF)

Stinger - P4:

Maximum 14 pages per minute (A4/LT SEF)

5.5 s or less (A4/LT - LEF, standard tray)

Stinger - P4:

6.5 s or less (A4/LT - SEF, standard tray)

600 x 600 dpi 300 x 300 dpi (simulated by doubling pixel width and

height at 600 dpi resolution)

Compatible with Laser Jet 5N driver and printer. Windows 3.1x/95/98, Windows NT4.0 drivers available.

PostScript Level II

Windows 95/98, Windows NT4.0, and Macintosh (OS

7.5 or later) PPDs are available.

Overall

Information

Printer Fonts: PCL6

35 Intellifonts 10 True Type fonts 1 Bitmap font

PS2

35 Adobe type 1 fonts

Printer Interface: Bi-directional IEEE1284 parallel x 1 (Standard)

Ethernet (100 Base-TX/10 Base-T for TCP/IP, IPX/SPX,

EtherTalk)

RS232C interface (Optional)

1-1

SPECIFICATIONS 12 March 1999

Printing Paper Size: Stinger - P3:

Maximum A3/11" x 17" Minimum A5 LEF - Standard Tray

B6 SEF - By-pass Tray A5 LEF - Optional PFU

Custom paper size (PCL 6/PS): By-pass Tray

11.69" x 17" ~ 3.88" x 5.83" (297 x 431.8 ~ 98.4 x 148 mm)

Envelope: By-pass & Envelope Feeder

Com#10, C6, DL, Monarch

Stinger - P4:

Maximum A4/LG (only A4/LT for Standard Tray) Minimum A4/LT – Standard Tray

B6 SEF - By-pass Tray A5 LEF - Optional PFU

Custom paper size (PCL 6/PS): By-pass Tray

8.5" x 14" ~ 3.88" x 5.83" (216 x 355.6 ~ 98.4 x 148 mm)

Envelope: By-pass & Envelope Feeder

Com#10, C6, DL, Monarch

Printing Paper Weight: Paper tray: 60 ~ 106 g/m2, 16 ~ 28 lb

By-pass: 60 ~ 162 g/m2, 16 ~ 43 lb

Power Source: Stinger - P3:

120 V, 60 Hz: More than 8.0 A (for North America) 220 V ~ 240 V, 50/60 Hz: More than 8.0 A (for Europe)

Stinger - P4:

120 V, 60 Hz: More than 6.0 A (for North America) 220 V ~ 240 V, 50/60 Hz: More than 5.0 A (for Europe)

Power Consumption:

Stinger - P3 Stinger - P4

Maximum 795 W or less 600 W or less

Printing 480 W or less 380 W or less

Energy Saver 30 W or less 30 W or less

Noise Emission (All Options Installed):

Stinger - P3 Stinger - P4

Sound Power Level

Printing 64 dB or less 59 dB or less

Stand-by 48 dB or less 48 dB or less

NOTE:

The above measurements were made in accordance with ISO 9296 at the operator position.

1-2

12 March 1999 SPECIFICATIONS

Dimensions (Printer only):

Width Depth Height

Stinger - P3 450 mm (17.7") 420 mm (16.6") 270 mm (10.6") Stinger - P4 360 mm (14.2") 420 mm (16.6") 270 mm (10.6")

Weight: Stinger - P3: Less than 15 kg (33 Ib.)

Stinger - P4: Less than 12 kg (27 Ib.)

Overall

Information

Warm-up Time

Less than 39 seconds: 23°C

Energy Saver Mode 30 min. is the standard setting; it can be changed with the

Job Control menu

Print Paper Capacity: Standard Tray: 250 sheets

By-pass Tray: 100 sheets

10 envelopes (Stinger - P3) 5 envelopes (Stinger - P4)

Optional Paper Feed Unit: 500 sheets x 2 (Stinger - P3)

500 sheets x 1 (Stinger - P4)

Optional Envelope Feeder: 60 envelopes

Memory:

Standard 8 MB, up to 40 MB with optional SIMM.

Toner Cartridge Information:

Stinger - P3 Stinger - P4

Pre-set

Toner Cartridge

Average

3,000 pages/crtg.;

200g

Measurement Conditions:

Commercial

Toner Cartridge

Average

14,000 pages/crtg.;

750g

1) 5% test pattern

Pre-set

Toner Cartridge

Average

3,000 pages/crtg.;

200g

Commercial

Toner Cartridge

Average

8,000 pages/crtg.;

430g

2) A4 paper

3) LEF for Stinge r - P3, SEF for Stinger - P4

4) Continuous printing

Optional Equipment:

A3/DLT paper feed unit (unique for Stinger - P3)

A4/LT paper feed unit (unique for Stinger - P3)

Paper feed unit (unique for Stinger - P4)

Envelope feeder (unique for Stinger - P3)

Envelope feeder (unique for Stinger - P4)

Network Interface Board

1.6 GB HDD unit (hard disk drive unit)

RS232 board

Output Paper Capacity: 250 sheets

1-3

SPECIFICATIONS 12 March 1999

Utility Software (Main frame CD-ROM):

Utility Software (Optional Network Interface Board):

Maintenance Kit:

Printer Drivers

PS PPD files

Font Manager

Aficio Manager

Operating Instructions (G031/G032 -22, -27, -29)

IP-P2P

IPXP2P

MAP

Bootpl

NW setup

NIB User’s Manual

Acrobat Reader

Fusing Unit x 1

Transfer Unit x 1

Friction Pad x 1

Paper Feed Roller x 3 (Stinger - P3)

Paper Feed Roller x 1 (Stinger - P4)

1-4

12 March 1999 MACHINE CONFIGURATION

1.2 MACHINE CONFIGURATION

Internal Options

[G]

Stinger - P3

Stinger - P4

G031-17, 22, 27, 29 G032-17, 22, 27, 29

[E]

[F]

[H, I]

[A]

[B]

Overall

Information

[D][C]

G031V500.WMF

*NOTE:

No. Item Machine Code

Stinger - P3

A B *Envelope Feeder Type 2000 G913-17

Stinger - P4

C Paper Feed Unit Type 1400 G914-57 D Envelope Feeder Type 1400 G913-57

Internal Option s

E Network Int erface Board Type 2000 G919-17

F RS232C Board Type 2000 G527-17 G Hard Disk Drive Type 2000 G690-17 H Memory Unit Type 204 (16 MB) G 688-04

Paper Feed Unit Type 2000 (A4/LT) Paper Feed Unit Type 2000 (A3/DLT)

I Memory Unit Type 204 (32 MB) G688-05

G915-17, -27 G914-17, -27

The envelope feeder for the Stinger - P3 can only be installed in place of

the optional 2nd paper tray.

1-5

PAPER PATH 12 March 1999

1.3 PAPER PATH

Stinger - P3

Output Tray

By-pass Tray

Stinger - P4

Paper Tray

Output Tray

G031V503.WMF

By-pass Tray

Paper Tray

G031V504.WMF

1-6

12 March 1999 MECHANICAL COMPONENT LAYOUT

1.4 MECHANICAL COMPONENT LAYOUT

Stinger - P3

1312

15 1 2

3 4 5

Overall

Information

Stinger - P4

1. Exit Roller

2. Hot Roller

3. Pressure Roller

4. Transfer Roller

5. By-pass Feed Roller

6. By-pass Tray

7. Registration Rollers (Stinger - P3) Relay Roller (Stinger - P4)

8. Paper Feed Roller

15 1 2

910 8

G031V505.WMF

3 4 5

910 8

G031V506.WMF

9. Toner Cartridge

10. Paper Tray

11. Polygonal Mirror Motor

12. 1st Mirror (Stinger - P3) F-theta Lens (Stinger - P4)

13. Barrel Toroidal Lens (Stinger - P3)

14. F-theta Mirror (Stinger - P3)

15. Shield Glass

1-7

ELECTRICAL COMPONENT LAYOUT 12 March 1999

1.5 ELECTRICAL COMPONENT LAYOUT

Stinger - P3

G031V501.WMF

1. Laser Synchronization Detector

2. Engine Control Board

3. Exhaust Fan Motor

4. High Voltage Supply Board

5. LD Drive Board

6. Main Motor

7. Tray Paper Feed Clutch

8. By-pass Feed Solenoid

9. Tray Paper Size Switch

10. Registration Sensor

11. By-pass Tray Paper Sensor

12. Registration Clutch

13. Toner Near-end Sensor

14. Tray Paper End Sensor

15. Fusing Thermistor

16. Tray Paper Near-end Sensor

17. Control Panel Board

18. Fusing Exit Sensor

19. Fusing Lamp

20. Thermofuse

21. Front Cover Safety Switch

22. Power Supply Unit

23. Main Switch

24. Polygonal Mirror Motor

25. Printer Control Board

1-8

12 March 1999 ELECTRICAL COMPONENT LAYOUT

Stinger - P4

Overall

Information

1. Engine Control Board

2. Exhaust Fan Motor

3. Power Supply Unit

4. High Voltage Supply Board

5. Main Motor

6. Tray Paper Feed Solenoid

7. By-pass Feed Solenoid

8. Toner Near-end Sensor

9. Registration Sensor

10. By-pass Tray Paper Sensor

11. Tray Paper End Sensor

G031V502.WMF

12. Fusing Exit Sensor

13. Fusing Thermistor

14. Control Panel Board

15. Fusing Lamp

16. Thermofuse

17. Front Cover Safety Switch

18. LD Drive Board (with synchronization detector)

19. Main Switch

20. Polygonal Mirror Motor

21. Printer Control Board

1-9

ELECTRICAL COMPONENT DESCRIPTIONS 12 March 1999

1.6 ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout and the point-to-point diagram on the waterproof paper in the pocket for the locations of these components.

Symbol Description Note

Printed Circuit Boards

High Voltage Supply

PCB1

PCB2 PCB3 LD Drive Board Controls the laser diode. 5 18 PCB4

PCB5

PCB6

Motors

M1 Main Drives the main body components. 6 5 M2 Polygonal Mirror Turns the polygonal mirror. 24 2 0 M3 Exhaust Fan Removes heat from the printer. 3 2

Board Power Supply Unit

(PSU)

Control Panel Controls the display panel, LED, and Engine Control Board

(ECB) Printer Control Board

Supplies high voltage to the drum charge roller, development roller, and transfer roller. Provides dc power to the system and ac power to the fusing lamp.

the touch key pad. Controls all base engine functions

either directly or through other control boards. Controls the PC interface, print image processing, operation panel, and other controller options.

Index No. P3 P4

22 3

17 14

25 21

Sensors

S1 Fusing Exit Detects misfeeds. 18 12 S2

S5 S6 Toner Near-end Detects when toner is low. 13 8

Switches

SW1 Main Supplies power to the machine. 23 19 SW2

SW3

Tray Paper End Informs the CPU when the paper tray

runs out of paper. Tray Paper Near-end (Stinger - P3)

By-pass Tray Paper Registration Detects the leading edge of the paper

Front Cover Safety Cuts the +5VLD and +24 V dc power

Tray Paper Size (Stinger - P3)

Informs the CPU when the amount of

paper in the tray becomes low (50±30

sheets).

Informs the CPU when there is paper

on the by-pass tray.

to determine when to stop the paper

feed clutch, and detects misfeeds.

lines and detects whether the front

cover is open or not.

Determines the size of paper in the

paper tray, based on the dial setting.

14 11

16 —

11 10

10 9

21 17

9—

1-10

12 March 1999 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Description Note

Index No. P3 P4

Magnetic Clutches

MC1 MC2

Tray Paper Feed (Stinger - P3) Registration (Stinger - P3)

Starts paper feed from the paper tray.

Drives the registration rollers.

7—

12 —

Solenoids

SOL1 SOL2

By-pass Feed Starts paper feed from the by-pass

tray. Tray Paper Feed

Starts paper feed from the paper tray. (Stinger - P4)

—6

Lamps

L1 Fusing Heats the hot roller. 19 15

Thermistors

TH1

Fusing Monitors the temperature of the hot

roller.

15 13

Thermofuses

TF1

Fusing

Provides back-up overheat protection

in the fusing unit.

20 16

Overall

Information

Others

LSD1

Laser Synchronization Detector (Stinger - P3)

Detects the laser beam at the start of

the main scan.

1—

1-11

PRINTING PROCESS 12 March 1999

1.7 PRINTING PROCESS

OPC

–600 V

–100 V

–400 V

G031V507.WMF

Stinger - P3/4 use an all-in-one type of toner cartridge that includes the drum, toner, development roller, charge roller and other components.

1. DRUM CHARGE

In the dark, the charge roller gives a negative charge of –600 volts to the organic photo-conductive (OPC) drum. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark.

2. LASER EXPOSURE

The processed print image data from the engine control board (ECB) is transferred to the drum by a laser beam, which forms an electrical latent image on the drum surface. The areas exposed by the laser beam drop to about –100 volts.

3. DEVELOPMENT

The magnetic development brush on the development roller approaches the latent image on the drum. The development roller gives a negative bias of –400 volts to the toner. Toner particles jump and electrostatically attach to the areas of the drum surface where the laser reduced the negative charge on the drum.

1-12

12 March 1999 PRINTING PROCESS

4. IMAGE TRANSFER

Paper is fed to the area between the drum surface and the transfer roller at the proper time for aligning the print paper and the developed image on the drum surface. Then, the transfer roller applies a positive current to the reverse side of the paper (the size of the current depends on the resolution and the paper size). This pulls the toner particles from the drum surface to the paper. At the same time, the paper is attracted to the transfer roller.

5. PAPER SEPARATION

Paper separates from the drum as a result of the electrostatic attraction between the paper and the transfer roller. The discharge plate helps separate the paper from the drum.

6. CLEANING

The cleaning blade removes any toner remaining on the drum surface after the image is transferred to the paper.

7. QUENCHING

There is no quenching mechanism.

Overall

Information

1-13

BOARD STRUCTURE 12 March 1999

1.8 BOARD STRUCTURE

1.8.1 OVERVIEW

Motors &

Clutches

Laser Diode

Sensors

High Voltage

Supply Board

Paper Feed

Unit

LD Drive

Board

Engine Control

Board (ECB)

Video I/F

+5 V/+24 V

Printer

Control

Board

Power

Supply

Unit

(PSU)

Control

Panel Board

Fusin

Unit

G031V508.WMF

The engine control firmware controls the components connected to the engine control board (ECB). The printer control board controls the control panel board. The printer control board is also connected to the personal computer.

1-14

12 March 1999 BOARD STRUCTURE

1.8.2 MAJOR COMPONENTS

1. Engine Control Board (ECB)

This is the printer engine control board. It controls the following functions:

Engine sequence

Machine control, printer engine control

Timing control for peripherals

Video control

Drive control for the sensors, motors, solenoids, and high voltage supply

board

PWM control for edge smoothing (PWM is done on the printer control board)

2. Printer Control Board

This is the machine’s main control board. It controls the following functions:

IEEE 1284 parallel port

Edge smoothing and toner saving

Engine control board

Control panel board

Interfacing with the HDD and NIB

3. LD Drive Board

Overall

Information

This is the laser diode drive circuit board.

4. Power Supply Unit (PSU)

Provides dc power to the system and ac power to the fusing lamp.

5. High Voltage Supply Board

Supplies high voltage to the drum charge roller, development roller, and transfer roller.

6. Fusing Unit

Fuses toner to the paper. The fusing lamp is controlled by the ECB.

7. Control Panel Board

Controls the display panel, the LED, and the touch keypad.

1-15

COMPARISON 12 March 1999

1.9 COMPARISON

Stinger - P3 Stinger - P4 V20

Standard Paper Tray Standard Bypass Tray Optional Paper Tray

Envelope Feeder 10 envelopes 5 envelopes 100 envelopes Output Paper

Capacity Input Paper Size

(Std./Opt. Tray) Input Paper Size

(By-pass Tray) First Print Speed

Duplex Printing N/A Option Memory

(Std./Max. with Opt.) HDD (Option) 1.6 GB Fonts

Interface Bi-directional parallel x 1

Warm-up Time Utilities Aficio Manager Dimensions

(mm: W x D x H)

Weight Less than 15 kg (33 lb.) Less than 12 kg (27 lb.) Less than 44.5 kg (99 lb.) Consumable Yield Toner Cartridge: 14 K Toner Cartridge: 8 K PM Kit Maintenance Kit: 80 K Maintenance Kit: 60 K Technology

Resolution True 1,200 x 1,200 dpi (PCL6/PS)

Continuous Print Speed

Power Consumption Max. 795 W Max. 600 W Max. 950 W Drivers PCL6/5e version : Windows 3.1x, 95(98), Windows NT 4.0

Halftoning Electrical Sorting Diagnostic Test Mode Test Print Hex Dump List Smoothing Rotated Sorting N/A N/A N/A Toner Saving Mode PDL Auto Change Overlays (PCL) Auto Cassette Change Energy Saver

250 sheets 100 sheets 500 sheets x 2

250 sheets

A3/11" x 17" ~ A5 (LEF) A4 ~ A5 (LEF) A3/11" x 17" ~ A5/5.5" x 8.5" (LEF)

A3/11" x 17" ~ B6 (SEF) free:

11.69" x 17" ~ 3.88" x 5.83"

5.5 s or less

(A4/LT ~ LEF, Standard Tray)

8 MB/40 MB 8 MB/ 40 MB 8 MB/68 MB

PCL6 (35 Intellifonts, 10 True Type fonts and 1 bitmap font) PS2 (35 Adobe type 1 fonts)

Ethernet (100 Base-Tx/10 Base-T for TCP/IP, IPX/SPX, Ether

Talk)

RS232C (Optional)

Less than 39 seconds: 23°C (73°F) Less than 60 seconds: 23°C (73°F)

450 x 420 x 270 mm (with Std. Tray adjusted for A4) 450 x 555 x 270 mm (with Std. Tray adjusted for A3)

Laser beam scanning & electrophotographic printing Monocomponent development

600 x 600 dpi (PCL6/PCL5e/PS) 300 x 300 dpi (PCL5e/PS)

20 ppm (A4 SEF) 14 ppm (A4 LEF) 25 ppm (A4/LT LEF)

PS PPD: Windows 95 (98), Windows NT 4.0, Macintosh OS 7.5 or later

mm m mm m mm m mm m mm mm m

mm m mm m mm mm m mm m

A4/LG ~ B6 (SEF) free:

8.5" x 14" ~ 3.88" x 5.83"

(A4/LT ~ SEF, Standard Tray)

360 x 420 x 270 mm (with Std. Tray adjusted for A4)

250 sheets 100 sheets 500 sheets

6.5 s or less

500 sheets x 2 + 1,500 sheets

Standard Output Tray: 400 sheets

A3/11"x17" ~ A5/5.5" x 8.5" (SEF)

PCL5e (35 Intellifont, 10 True Type font and 1 bitmap font) PS2 (35 Adobe type 1 fonts)

Bi-directional parallel (Standard) Ethernet (10 Base 2/T for IPX/SPX, TCP/IP, Apple Talk) Token Ring (4 Mbps, 16 Mbps for IPS/SPX, TCP/IP, Apple Talk)

530 x 625 x 472 mm (with by-pass tray closed, without the optional paper tray unit, without options)

Laser beam scanning & electrophotographic printing Dualcomponent development

600 dpi, 400 dpi (available when the PostScript option is installed), 300 dpi (simulated by doubling pixel width and height at 600 dpi resolution)

PCL version : Windows 3.1xx, 95, Windows NT 3.51/4.0 (PCL & PS version: Macintosh)

250 sheets 100 sheets

External Tray: 100 sheets

(N/A from Driver)

N/A

1-16

12 March 1999 PRINTING

2. DETAILED SECTION DESCRIPTIONS

2.1 PRINTING

2.1.1 IMAGE DATA PATH

Drum

LD Unit

LD Drive

Board

ECB

PC AT

Compatible

Parallel

Gate

Array

Printer Control Board

Macintosh

Ethernet

NIB

Optional Bus I/F

CN.

ROCKY W

G031D502.WMF

The printer control board receives the print data from the host computer (AT compatible Windows PC or Macintosh).

For the Stinger - P3, the printer control board has two OBI (Optional Bus

Interface) connectors to connect a network interface board (NIB), RS232C interface, or HDD unit.

For the Stinger - P4, the printer control board has one OBI connector.

Detailed

Descriptions

The printer control board generates the print image data and sends it with commands to the ECB (Engine Control Board).

The printer control board contains the image processing ASIC (ROCKY W). The ROCKY W ASIC controls the image processing, IEEE1284 interface, DRAM, edge smoothing, and toner saving. (ASIC: Application Specific Integrated Circuit)

The ECB contains a gate array. The gate array controls LD print timing control and the serial interface to the printer control board.

Finally, the ECB sends the video data to the LD drive board.

2-1

PRINTING 12 March 1999

2.1.2 PRINTER CONTROL BOARD

CPU

Printer Control Board

Parallel I/F

ROCKY W

Resident

DRAM

32-bit Data

Address/Command

ECB LD Unit

(ASIC)

Option Board

NIB

HDD

RS232C

Code ROM

DIMM

SIMM

G031D503.WMF

The printer control board receives the print data from the computer through the parallel cable or network interface board.

The printer control board contains the CPU (which is a 64-bit RISC processor), the ROCKY W ASIC, 8 MB of resident DRAM for main memory, and a 8 MB code ROM.

A SIMM card can be installed for extra DRAM memory and a DIMM card can be connected for service purposes (firmware upgrade).

The control board controls the following to produce the print image data.

1) IEEE1284 parallel port interface

2) Control panel

3) Edge smoothing and toner saving

4) Engine control board

5) Interfacing with the HDD, NIB, and RS232C board.

2-2

12 March 1999 PRINTING

2.1.3 IMAGE DATA PROCESSIING

Edge smoothing and toner saving are performed by an ASIC (ROCKY W). The edge smoothing and toner saving modes can be switched on/off with the machine’s control panel or the printer driver.

Edge Smoothing

Fig. A

Fig. B

Fig. C

Sub Scan Direction

Main Scan Direction

4/4 3/4 2/4 1/4 0

G031D504.WMF

Detailed

Descriptions

Jagged edges on characters as shown in the above illustration are reduced using edge smoothing. Edge smoothing changes the laser pulse duration and position for certain pixels.

Fig. A shows the four possible pulse durations, and Fig. B shows how the laser pulse can be in one of three positions within the pixel. Fig. C shows an example of how edge smoothing is used.

Edge smoothing is not done for 1,200-dpi printing.

Toner Saving Mode

Toner saving is done by reducing the number of black dots in the printed image. An 8 x 8 matrix filter is used.

As a result, less toner is used to create the latent image on the drum and black areas print as gray.

The printer driver prevents edge smoothing and toner saving mode from being used at the same time.

2-3

PRINTING 12 March 1999

2.1.4 HOST INTERFACE

Bi-directional Parallel Interface

G031D505.WMF

A 36-pin bi-directional parallel interface connector (female) is used. The bi-directional parallel interface on the controller works in three modes;

Compatible, Nibble and ECP modes. These modes are standardized by IEEE

1284.

2-4

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