Ricoh VT3500 S Service Manual vt3500

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1. OVERALL MACHINE INFORMATION

1. SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. GUIDE TO COMPONENTS AND THEIR FUNCTION . . . . . . . . . . . . 1-4

3. OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4. PRINTING PROCESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

5. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . 1-11

6. ELECTRICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . 1-12

7. ELECTRICAL COMPONENT DESCRIPTIONS. . . . . . . . . . . . . . . . 1-16

8. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

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CONTENTS

2. SECTIONAL DESCRIPTION

1. MASTER EJECT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 MASTER EJECT ROLLER ROTATING MECHANISM . . . . . . . . . . . . . . . . . . . . 2-2

1.3 MASTER EJECT ROLLER DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . 2-3

1.4 MASTER EJECT CLAMPER MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

1.5 PRESSURE PLATE UP/DOWN MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

1.6 ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

1.7 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2. SCANNER/OPTICS SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.2 ORIGINAL FEED MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.3 ORIGINAL FEED DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.4 ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5 ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.6 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

3. MASTER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

3.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

3.2 MASTER CLAMPER OPENING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

3.3 MASTER FEEDING MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

3.4 MASTER WRAPPING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

3.5 CUTTER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

3.6 ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

3.7 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

4. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

4.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

4.2 PAPER FEED ROLLER/UPPER SEPARATION ROLLER MECHANISM . . . . . 2-40

4.3 FEED ROLLER PRESSURE MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

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4.4 PAPER SEPARATION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

4.5 SEPARATION ROLLER PRESSURE RELEASE MECHANISM . . . . . . . . . . . . 2-45

4.6 SEPARATION PLATE PRESSURE RELEASE MECHANISM. . . . . . . . . . . . . . 2-46

4.7 PAPER RETURN MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

4.8 SECOND FEED ROLLER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

4.9 PAPER TABLE SIDE ADJUSTMENT MECHANISM . . . . . . . . . . . . . . . . . . . . . 2-51

4.10 PAPER TABLE UP/DOWN MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

4.11 PAPER SIZE DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

4.12 ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

4.13 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

5. PRINTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

5.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

5.2 PAPER DETECTING AND PRINTING PRESSURE ON/OFF MECHANISM. . . 2-60

5.3 PRINTING PRESSURE ON/OFF MECHANISM FOR A4/LT DRUM . . . . . . . . . 2-61

5.4 PRINTING PRESSURE RELEASE MECHANISM. . . . . . . . . . . . . . . . . . . . . . . 2-62

5.5 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

6. DRUM SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

6.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

6.2 DRUM ROTATION MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

6.3 DRUM LOCK MECHANISM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

6.4 DRUM LOCK MECHANISM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

6.5 DRUM LOCK MECHANISM 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

6.6 DRUM LOCK MECHANISM 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

6.7 INK SUPPLY MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

6.8 INK KNEADING MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

6.9 DRUM MASTER DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

6.10 DRUM TYPE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

6.11 INK DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

6.12 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

7. DELIVERY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

7.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

7.2 EXIT PAWL DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

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7.3 VACUUM UNIT DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

7.4 PAPER EXIT PAWL AIR PUMP MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

7.5 WING GUIDE MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

7.6 PAPER DELIVERY TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

7.6.1 Master Eject Unit Lock Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

7.6.2 Paper Delivery Table Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84

7.7 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85

7.8 ELECTRICAL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

8. IMAGE POSITIONING SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

8.1 OVERALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

8.2 IMAGE POSITIONING MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

8.3 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

9. IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

9.1 CCD (CHARGE COUPLED DEVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

9.2 A/D CONVERSION PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

9.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

9.2.2 Inversion and Amplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

9.2.3 A/D Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

9.2.4 Reference Data Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

9.3 IMAGE PROCESSING PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

9.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

9.3.2 MTF Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107

9.3.3 Main Scan Magnification and Ima ge Shi ft Proc essing . . . . . . . . . . . . . . . 2-110

9.3.4 Binary Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112

9.3.5 Photo Data Compensation Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113

9.3.6 Half-tone Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115

9.3.7 Make-up Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120

9.4 PLOTTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133

9.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133

9.4.2 Thermal Head Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135

9.4.3 Thermal Head Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136

9.4.4 Thermal Head Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-139

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10. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141

10.1 INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141

10.2 MONITOR INDICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142

10.2.1 Cover Open Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142

10.2.2 Key Counter Indicator: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142

10.2.3 Master Eject Box Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143

10.2.4 Ink Supply Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143

10.2.5 Master Supply Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144

10.2.6 Paper Supply Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144

10.2.7 Master Eject Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145

10.2.8 Paper Misfeed Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145

10.2.9 Paper Delivery Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145

10.2.10 Paper Wrap Message 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-146

10.2.11 Paper Wrap Message 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-146

10.2.12 Master Clamp Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-146

10.2.13 Original Misfeed Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147

10.2.14 Other Guidance Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-148

10.2.15 Other Monitor Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149

10.3 MASTER PLOTTING AND PRINTING AREA . . . . . . . . . . . . . . . . . . . . . . . . 2-150

10.4 PAPER MISFEED DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154

10.5 PROTECTION FROM OVERCURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-155

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CONTENTS

3. INSTALLATION

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

1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 ACCESS TO THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.3 POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

2. ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3. INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.1 MAIN BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2 PAPER CASSETTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.3 COLOR DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.4 KEY COUNTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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CONTENTS

4. SERVICE TABLES

1. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.1 MAINTENANCE TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.1.1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.1.2 User’s Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

1.1.3 Table of Periodic Inspection (every 6 months) . . . . . . . . . . . . . . . . . . . . . . . 4-4

1.1.4 Table of Periodic Inspection (every 12 months) . . . . . . . . . . . . . . . . . . . . . . 4-4

1.2 TABLE OF SERVICE CALL INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

1.3 TABLE OF DIP SW, LED, VR, TP (ON THE MAIN CONTROL PCB) . . . . . . . . . 4-8

1.3.1 DIP SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

1.3.2 Photodiode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

1.3.3 VR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

1.3.4 TP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

1.4 EXPECTED LIFE of PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

1.5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

2. SERVICE PROGRAM MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

2.1 SERVICE PROGRAM MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

2.1.1 Service Program Mo de Access Procedure (for engineers). . . . . . . . . . . . . 4-11

2.1.2 Service Program Mo de Access Procedure (for user s) . . . . . . . . . . . . . . . . 4-11

2.1.3 Change Adjustment Values or Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

2.2 SERVICE PROGRAM TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

2.3 THERMAL HEAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

2.4 COMMAND SHEET CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

2.5 INPUT/OUTPUT CHECK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

2.5.1 Input Check Mode Access Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

2.5.2 Output Check Mode Access Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

2.5.3 Input Check Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

2.5.4 Output Check Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Page 8

2.6 USER CODE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

2.6.1 User Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

2.6.2 How To Use a User Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Page 9

CONTENTS

5. REPLACEMENT AND ADJUSTMENT

1. EXTERIOR SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1 EXTERIOR COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

2.1 ADJUSTING THE TENSION OF THE ORIGINAL FEED ROLLER DRIVE BELT 5-3

2.2 ADJUSTING THE ORIGINAL PRESSURE SOLENOID. . . . . . . . . . . . . . . . . . . . 5-4

2.3 EXPOSURE GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

2.4 EXPOSURE LAMP/HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

2.5 ORIGINAL REGISTRATION SENSOR/2ND ORIGINAL SENSOR . . . . . . . . . . . 5-7

2.6 ORIGINAL FEED ROLLERS/PULL-OUT ROLLERS . . . . . . . . . . . . . . . . . . . . . . 5-8

3. OPTICS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

3.1 OVER VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

3.2 ADJUSTING THE REDUCTION RATIO (MOIRE ADJUSTMENT) . . . . . . . . . . 5-11

3.3 ADJUSTING THE FOCUS (MTF ADJUSTMENT) . . . . . . . . . . . . . . . . . . . . . . . 5-12

3.4 ADJUSTING THE READING START POSITION IN THE MAIN SCAN

DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

3.5 ADJUSTING THE SCAN LINE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

3.6 ADJUSTING THE SHADING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

3.7 ADJUSTING THE WHITE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

4. MASTER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

4.1 ADJUSTING THE THERMAL HEAD VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . 5-17

4.2 ADJUSTING THE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

4.3 ADJUSTING THE RIGHT AND LEFT CUTTER SWITCHES. . . . . . . . . . . . . . . 5-19

4.4 CUTTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

4.5 THERMAL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

4.6 THERMAL HEAD DRIVE PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5. MASTER EJECT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5.1 ADJUSTING THE MASTER EJECT SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Page 10

5.2 ADJUSTING THE MASTER EJECT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5.3 ADJUSTING THE AIR KNIFE MOTOR SAFETY SWITCH . . . . . . . . . . . . . . . . 5-25

5.4 MASTER EJECT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5.5 MASTER EJECT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5.6 MASTER EJECT BELT/ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

6. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

6.1 ADJUSTING THE PAPER TABLE OPEN SWITCH . . . . . . . . . . . . . . . . . . . . . . 5-29

6.2 ADJUSTING THE PAPER TABLE HEIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

6.3 ADJUSTING THE SEPARATION PLATE RELEASE SOLENOID . . . . . . . . . . . 5-31

6.4 ADJUSTING THE PAPER FEED ROLLER PRESSURE . . . . . . . . . . . . . . . . . . 5-33

6.5 ADJUSTING THE LOWER GUIDE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

6.6 ADJUSTING THE UPPER SECOND FEED ROLLER . . . . . . . . . . . . . . . . . . . . 5-36

6.7 ADJUSTING THE SEPARATION PLATE PRESSURE . . . . . . . . . . . . . . . . . . . 5-37

6.8 ADJUSTING THE FEED-LENGTH OF THE PAPER FEED ROLLER . . . . . . . 5-38

6.9 ADJUSTING THE CLEARANCE OF THE PAPER FEED SECTOR GEAR

STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

6.10 ADJUSTING THE CLEARANCE OF THE SECOND FEED ROLLER SECTOR

STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

6.11 ADJUSTING THE FEED-LENGTH OF THE SECOND FEED ROLLER . . . . . 5-41

6.12 ADJUSTING THE FEED TIMING OF THE SECOND FEED ROLLER . . . . . . 5-42

6.13 PAPER FEED ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

6.14 PAPER FEED ROLLER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

6.15 UPPER SEPARATION ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

6.16 SEPARATION PLATE RELEASE SOLENOID AND PAPER RETURN MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

6.17 SEPARATION PLATE/LOWER SEPARATION ROLLER . . . . . . . . . . . . . . . . 5-48

7. PRINTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

7.1 ADJUSTING THE CLEARANCE OF THE PAPER DETECTING ARM . . . . . . . 5-49

7.2 ADJUSTING THE PRESS ROLLER POSITION 1 . . . . . . . . . . . . . . . . . . . . . . . 5-50

7.3 ADJUSTING THE PRESS ROLLER POSITION 2 (FOR THE A4/LT DRUM) . . 5-51

7.4 ADJUSTING THE PRESSURE TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

7.5 ADJUSTING THE PRINTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

7.6 ADJUSTING THE CLEARANCE OF THE PRINTING PRESSURE SOLENOID 5-54

7.7 PRESS ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Page 11

8. DRUM SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

8.1 ADJUSTING THE MAIN DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . 5-56

8.2 ADJUSTING THE DRUM MASTER DETECTION SENSOR . . . . . . . . . . . . . . . 5-57

8.3 ADJUSTING THE PRINTING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

8.4 ADJUSTING THE DRUM STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

8.5 ADJUSTING THE DRUM LOCK SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

8.6 ADJUSTING THE MASTER FEED CLAMPER CAM . . . . . . . . . . . . . . . . . . . . . 5-61

8.7 ADJUSTING THE MASTER EJECT CLAMPER CAM . . . . . . . . . . . . . . . . . . . . 5-62

8.8 ADJUSTING THE POSITION OF THE INK DETECTING PIN. . . . . . . . . . . . . . 5-63

8.9 ADJUSTING THE CLEARANCE OF THE DOCTOR ROLLER . . . . . . . . . . . . . 5-64

8.10 ADJUSTING THE INK ROLLER WITH THE DRUM UNIT . . . . . . . . . . . . . . . . 5-65

8.11 ADJUSTING THE POSITION OF THE INK SUPPLY SOLENOID. . . . . . . . . . 5-66

8.12 ADJUSTING INK DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

8.13 SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

8.14 DRUM DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

9. DELIVERY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

9.1 ADJUSTING THE FIRST PAPER EXIT SENSOR . . . . . . . . . . . . . . . . . . . . . . 5-73

9.2 ADJUSTING THE SECOND PAPER EXIT SENSOR . . . . . . . . . . . . . . . . . . . . 5-74

9.3 ADJUSTING THE CLEARANCE OF THE EXIT PAWL . . . . . . . . . . . . . . . . . . . 5-75

9.4 ADJUSTING THE EXIT PAWL TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

9.5 ADJUSTING THE PAPER EXIT PAWL AIR PUMP . . . . . . . . . . . . . . . . . . . . . 5-77

9.6 TRANSPORT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

9.7 DELIVERY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

9.8 TRANSPORT VACUUM FAN AND PAPER EXIT SENSORS . . . . . . . . . . . . . . 5-80

10. IMAGE POSITIONING SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 5-81

10.1 ADJUSTING THE IMAGE POSITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81

Page 12

CONTENTS

6. TROUBLESHOOTING

1. ELECTRICAL COMPONENT TROUBLE. . . . . . . . . . . . . . . . . . . . . . 6-1

2. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

2.1 IMAGE TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

2.2 PAPER FEED TROUBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Page 13

CONTENTS

7. ELECTRICAL DATA

1. INK DETECTING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

2. CCD CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

3. TAPE MARKER CIRCUIT (OPTION). . . . . . . . . . . . . . . . . . . . . . . . . 7-3

4. PAPER SIZE DETECTION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

5. AC DRIVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

6. POWER SUPPLY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7. THERMAL HEAD DRIVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

8. A/D CONVERTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

9. MAIN BOARD CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

10. OPERATION PANEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Page 14

CONTENTS

8. TAPE MARKER

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

2. BASIC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

2.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

2.2 DRIVE AND CUTTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

2.3 MANUAL CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

3.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

3.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

4. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 8-10

4.1 CUTTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

4.2 CUTTER HOME POSITION SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . 8-11

4.3 TAPE CUT LENGTH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Page 15

SECTION 1

OVERALL MACHINE INFORMATION

Page 16

1 December 1993

1. SPECIFICATIONS

Configuration: Desk top Master Processing: Digital Printing Process: Fully automatic one drum stencil system Original Type: Sheet Original Size: Maximum 307 mm x 432 mm (12.0" x 17.0")

Minimum 90 mm x 140 mm (3.6" x 5.5")

Reproduction Ratios: LT version 93%, 77%, 74%, 65%

A4 version 93%, 87%, 82%, 71%

Enlargement Ratio: LT version 155%, 129%, 121%

A4 version 141%, 122%, 115% Image Mode: Line/Photo Color Printing: Drum unit replacement system

(red, blue, green and brown) Master Feed/Eject: Roll master automatic feed/eject Leading Edge Margin: 10 mm (0.39") Print Paper Size: Maximum 325 mm x 447 mm (12.7" x 17.5")

Minimum 90 mm x 148 mm (3.6" x 5.8") Printing Area: Maximum 290 mm x 405 mm (11.4" x 15.9") at

20°C/65% RH Print Paper Weight: 50 g/m

to 215 g/m2 (13.3 lb to 57.19 lb) Printing Speed: 40, 60, 80, 100, 120 sheets/minute (5 steps) First Print Time: 39 sec./A3/DLT (with "L" drum)

36 sec./A4/LT (with "L" drum) 29 sec./A4/LT (with "S" drum)

Paper Feed Table Capacity: Table mode: 1,000 sheets (66 g/m

Cassette mode: 500 sheets (66 g/m

Paper Delivery Table

500 sheets (66 g/m

, 17.6 lb)

Capacity: Power Source: 110 V, 60 Hz, 5.5 A (for Taiwan)

120 V, 60 Hz, 4.8 A (for N.A.) 220/240 V, 50/60 Hz, 2.7 A (for Eu., Asia)

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1 December 1993

Power Consumption: 110 V, 60 Hz, 385 W (for Taiwan)

120 V, 60 Hz, 385 W (for N.A.) 220/240 V, 50/60 Hz, 443 W (for Eu., Asia)

Weight: 110 V version: 110 kg (242.5 lb)

120 V version: 110 kg (242.5 lb) 220/240 V version: 116 kg (255.7 lb) Cabinet: 23.5 kg (51.8 lb)

Dimensions (W x D x H): Stored: 735 x 698 x 599 mm

(29.0" x 27.5" x 23.5")

Set up: 1331 x 698 x 616 mm

(52.4" x 27.5" x 24.2")

Cassette mode: 1386 x 698 x 616 mm

(54.6" x 27.5" x 24.2")

Cabinet: 719 x 630 x 426 mm

(28.3" x 24.8" x 16.8")

ADF Original Capacity: 20 sheets (66 g/m

, 17.6 lb) or 1.8 mm height Original Scanning Time: 3 ms/1 line Original Guide Movement

90 mm to 310 mm (3.54" to 12.2")

distance: Original Feed Speed: 21.4 mm/sec (while master processing)

87.8 mm/sec (not master processing) Pixel Density: 400 dpi Master Eject Box Capacity: 50 masters with "L" drum

70 masters with "S" drum Paper Separation: Friction roller/center separation system Feed Table Side Plate

88 mm to 336 mm (3.46" to 13.2") Movement Distance:

Paper Feed Roller Pressure: Normal position 300 g

Thick paper position 600 g Separation Roller Pressure: Normal position 125 g

Weak position 50 g Separation Plate Pressure: Weak 10 g

Normal 20 g

Strong 1 40 g

Strong 2 60 g Side Registration:

Vertical Registration:

±10 mm

±20 mm

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Page 18

1 December 1993

Paper Table Raising/ Lowering speed:

22 mm/sec (50 Hz)

26 mm/sec (60 Hz) Ink Supply: Automatic ink supply system Press Roller Pressure:

13 ± 1 kg Paper Delivery: Air knife/vacuum delivery Delivery Side Plate

80 mm to 327 mm (31.5" to 12.9") Movement distance:

Print Counter: 7 digits Supplies: Master Thermal master 320 mm width

Master roll 225 masters/1 roll Roll diameter

Master length 535 mm/1 master Max run length 2000 prints

Ink 800 cc ink pack (black)

500 cc ink pack (red, blue, green, blown)

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1 December 1993

2. GUIDE TO COMPONENTS AND THEIR FUNCTION

1-5

Page 20

1 December 1993

No. Name Function

1. Wing Guide Release

Use to aid paper stack of large size paper.

Lever

2. Paper Delivery Table

3. Small Size Paper

Delivery End Plate (for smaller than A4)

4. Paper Delivery End

Plate (for larger than A4)

5. Paper Delivery Side

Plate

6. Master Eject Box

Cover

7. Main Switch

8. Master Eject Unit Open

Button

9. Original Table

10. Master Cut Button

Completed prints are delivered here.

Use to align the leading edge of prints that are

A4/LT or smaller.

Use to align the leading edge of prints larger

than A4/LT.

Use to align the prints on the paper delivery

table.

Open when removing the master eject box.

Use to turn the power on or off.

Press to remove misfed paper or a misfed

master.

Place the originals on this table.

Press this button to cut the master paper

leading edge after installing a new master roll.

11. Pressure Release

Lever

12. Operation Panel

13. Drum Rotation Button

14. Drum Unit

15. Ink Holder

Use to install the master roll, or to clean the

thermal head.

Operator controls and indicators are located

here.

Press to rotate the drum manually.

The master paper is wrapped around this unit.

Set the ink cartridge in this holder.

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1 December 1993

1-7

Page 22

1 December 1993

No. Name Function

16. Front Door

Open for access to the inside of the machine.

17. ADF Unit

18. Original Tray

19. ADF On/Off Select

Switch

20. ADF Unit Open Button

21. Original Guides

22. Original Table Release

Lever

23. Feed Roller Pressure

Lever

24. Separation Roller

Pressure Lever

25. Paper Table

Feeds the original to the scanning position

automatically.

Originals used to make master(s) are delivered

to this tray.

When setting originals one sheet at a time, set

this switch to the off position.

Use to open the ADF unit.

Adjust these guides to position the originals

correctly.

Use to open the original table unit to the left for

master installation.

Use to adjust the contact pressure of the paper

feed roller according to paper thickness.

Use to adjust the separation roller pressure to

prevent double feed.

Set paper on this table for printing.

26. Paper Feed Side Plate

27. Paper Table Down

Button

28. Side Registration Fine

Adjusting Dial

Use to prevent paper skew.

Press to lower the paper table.

Use to shift the paper table sideways.

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Page 23

3. OPERATION PANEL

– Keys and Indicators –

1 December 1993

6789

1. Reset key

2. Directional

Magnification key

3. Image Shift key

32 1

10 11 12 13

Press to reset error indicators. Press to enter the horizontal or vertical

magnification for copies, using the number keys. Press to shift the image.

4. Contrast key

5. Screen key

6. Make Up key

7. Combine 2 Originals

key

8. Image Density key

9. Image Mode key

10. Zoom keys

11. Reduce/Enlarge key

12. Full Size key

13. Auto Cycle key

Press to select the desired contrast according to the type and quality of the original.

Press to select the desired grade of screening to be applied to the image according to the type and quality of the original.

Press to use the make-up function. Press to combine two originals onto one print

image. Press to make prints darker or lighter. Press to select line mode, photo mode or sharpen

image mode according to the type and quality of the original.

Press to alter the reproductions ratio in 1% increments from 50% to 200%.

Press to reduce or enlarge the image. Press to make prints the same size as the original. Use to automatically process masters and make

prints.

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1 December 1993

19 20

14. Clear Modes key

15. Program key

16. Enter key

17. Counter

17 16 15 14

Press to cancel all previously entered settings and modes.

Press to input or recall user programs. Press to input information into memory. Displays the number of prints entered. While

printing, it shows the number of copies left to print.

232425

27 28

18. Monitors

19. Speed keys

20. Image Position key

21. Memory/Class

Indicators

22. Number keys

23. Memory/Class key

24. Clear key

25. Stop key

26. Proof key

27. Print Start key

Light or blink when a non-standard condition occurs within the machine.

Press to adjust the rotation speed of the drum according to the type of image and printing paper.

Press to shift the image forwards or backwards on the print paper.

Shows the number entered in memory mode or class mode.

Press to enter the number of prints. Press to select group printing in memory mode or

class mode. Press to change the number set in the counter.

Also use to change make-up mode. This key can be used only after the machine stops operation.

Press to stop the machine operation. The machine will continue operation when the Print Start key or Master Making key is pressed.

Press to make trial prints or extra prints. Press to start printing.

28. Master Making key

Press to make a master.

1-10

Page 25

4. PRINTING PROCESS

1 December 1993

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

drum into the master eject box.

2. Original Feeding: Transports the original to the scanner section.

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

the mirror and the lens while feeding the

original.

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

digital signals and sends them to the thermal

head to plot holes on the master. The master

then wraps dround the drum.

5. Paper Feeding: Sends paper separately to the drum section.

6. Printing: Presses the paper fed from the paper feed

section to the drum. This transfers the ink to the

print through the drum screen and the master.

7. Paper Delivering: Peels the printed paper with the exit pawl and

air knife and ejects the paper onto the paper

delivery table.

1-11

Page 26

1 December 1993

5. MECHANICAL COMPONENT LAYOUT

123456

3433323130

18202122

141516

1. Drum Unit

2. Lens

3. CCD

4. Reverse Roller

5. Master Feed Roller

6. Platen Roller

7. Thermal Head

8. Master Roll

9. Plotter Unit

10. Upper Separation Roller

11. Paper Feed Roller

12. Paper Table

13. Separation Plate

14. Lower Separation Roller

15. 2nd Feed Roller

16. Doctor Roller

17. Press Roller

18. Ink Roller

19. Paper Exit Pawl Air Pump

20. Paper Exit Pawl

21. Transport Unit

22. Paper Delivery Table

23. Master Eject Box

24. 1st Eject Roller

25. 2nd Eject Roller

26. Master Eject Unit

27. Mirror

28. Fluorescent Lamp

29. Original Exit Tray

30. 2nd Original Transport Roller

31. Exposure Glass

32. 1st Original Transport Roller

33. Original Feed Roller

34. Pull-out Roller

1-12

Page 27

6. ELECTRICAL COMPONENT LAYOUT

1 December 1993

33 32 31

1-13

Page 28

1 December 1993

1. Original Registration Sensor

2. 2nd Original Sensor

3. 1st Original Sensor

4. Original Transport Motor

5. Original Pressure Solenoid

6. Fluorescent Lamp Stabilizer

7. Original Width Sensor

8. CCD PCB

9. Scanner Unit Safety Switch

10. A/D Conversion PCB

11. Paper Return Motor

12. Paper Table Down Button

13. Paper End Sensor

14. Paper Width Sensor

22. Transformer

23. Paper Table Lower Limit Sensor

24. Main PCB

25. Printing Pressure Sensor

26. Front Door Safety Switch

27. Power Supply Unit

28. Vacuum Fan Motor

29. 1st Paper Exit Sensor

30. Drum Detection Switch

31. 2nd Paper Exit Sensor

32. Circuit Breaker

33. Delivery Table Open Switch

34. Main Switch

35. Interlock Switch

15. Paper Table Open Switch

16. Paper Table Safety Switch

17. Paper Detection PCB (Paper Length Sensor)

18. Cassette Size Detection PCB

19. Paper Table Height Sensor

20. Image Processing PCB

21. Separation Plate Release Solenoid

36. Air Knife Motor Safety Switch

37. Drum Rotation Switch

38. Drum Rotation LED

39. Total Counter

40. Operation Panel

41. ADF Safety Switch

42. ADF Drive Motor

43. Fluorescent Lamp

1-14

Page 29

1 December 1993

58 57

55 54

44. Ink Supply Solenoid

45. Drum Lock Solenoid

46. Master Eject Unit Safety Switch

47. 2nd Drum Position Sensor

48. Noise Filter

49. Printing Pressure Solenoid

50. Main Motor

51. Drum Rotation Sensor (Pulse Generator)

52. Paper Table Drive Motor

53. Paper Table Drive Motor Capacitor

54. Paper Feed Solenoid

55. AC Drive PCB

56. Master Eject Clamper Solenoid

57. Image Position Sensor

58. Master Feed Clamper Solenoid

59. Ink Detection PCB

60. Master Cut Button

61. Image Positioning Motor

62. Drum Unit Safety Switch

63. 1st Drum Position Sensor

64. Drum Master Detection Sensor

1-15

Page 30

1 December 1993

69 70 71

65. Pressure Plate Motor

66. Lower Pressure Plate Sensor

67. Upper Pressure Plate Sensor

68. Full Master Detection Sensor

69. Master Eject Sensor

70. Master Eject Solenoid

71. Air Knife Motors

72. Master Eject Box Switch

73. Master Eject Motor

74. Thermal Head Drive PCB

75. Reverse Roller Magnetic Clutch

76. Cutter Motor

77. Master End Sensor

78. Right Cutter Switch

79. Thermal Head

80. Master Buckle Sensor

81. Master Feed Motor

82. Left Cutter Switch

1-16

Page 31

1 December 1993

7. ELECTRICAL COMPONENT DESCRIPTIONS

Index No. Name Function

Motors

4 Original Transport

Motor

11 Paper Return Motor Returns paper to the paper table when

28 Vacuum Fan Motor Provides suction so paper is held firmly

42 ADF Drive Motor Feeds the original to the scanner

50 Main Motor Drives paper feed, drum, printing and

Transports the original to the scanner section.

the paper table is lowered.

on the transport belt.

section.

paper delivery unit components.

52 Paper Table Drive

Motor

61 Image Positioning

Motor

65 Pressure Plate Motor Raises and lowers the pressure plate. 71 Air Knife Motors Rotates the fan to separate the paper

73 Master Eject Motor Sends used master into the master

76 Cutter Motor Cuts the master. 81 Master Feed Motor Feeds the master to the drum.

Solenoids

5 Original Pressure

Solenoid

21 Separation Plate

Release Solenoid

44 Ink Supply Solenoid Releases the spring clutch to turn on

Raises and lowers the paper table.

Changes the timing between the paper feed roller and the drum to adjust the vertical image position.

leading edge from the drum.

eject box.

Presses the original pressure plate down on the originals.

Releases the separation plate when the paper table is lowered.

activate the ink supply pump.

45 Drum Lock Solenoid P revents the drum unit from being

removed during the printing run.

49 Printing Pressure

Solenoid

54 Paper Feed Solenoid Releases the sector gears to feed the

Engages the pressure ON/OFF lever when a paper misfeed occurs.

paper.

1-17

Page 32

1 December 1993

Index No. Name Function

56 Master Eject

Clamper Solenoid

58 Master Feed

Clamper Solenoid

Opens the master clamper to eject the master.

Opens the master clamper to clamp the master.

70 Master Eject Solenoid Presses the lower master eject roller

against the drum surface.

Sensors

1 Original Registration

Sensor

Informs the CPU when the original activates the sensor. Also, detects the original misfeed.

2 2nd Original Sensor Informs the CPU when the original

activates the sensor. Also, detects original misfeeds.

3 1st Original Sensor Informs the CPU if the original is set in

the ADF mode. 7 Original Width Sensor Informs the CPU of the original width. 13 Paper End Sensor Informs the CPU if the paper is set on

the paper table. 14 Paper Width Sensor Informs the CPU of the paper width. 19 Paper Table Height

Sensor

23 Paper Table Lower

Limit Sensor

25 Printing Pressure

Sensor

Informs the CPU if the paper table is at

the paper feed position.

Informs the CPU if the paper table is at

the lowest position.

Informs the CPU if printing pressure is

applied. Also, detects paper misfeeds. 29 1st Paper Exit Sensor Detects paper misfeeds. 31 2nd Paper Exit

Detects paper misfeeds.

Sensor

47 2nd Drum Position

Checks the position of the drum.

Sensor

51 Drum Rotation

Sensor

57 Image Position

Supplies timing pulses to the CPU

based on the main motor speed.

Informs the CPU of the image position.

Sensor

63 1st Drum Position

Checks the position of the drum.

Sensor

1-18

Page 33

Index No. Name Function

64 Drum Master

Detection Sensor

66 Lower Pressure

Plate Sensor

67 Upper Pressure

Plate Sensor

Informs the CPU if the master is on the

drum.

Informs the CPU if the pressure plate is

at the lower limit position.

Informs the CPU if the pressure plate is

at the upper limit position.

1 December 1993

68 Full Master Detection

Sensor

Informs the CPU when the master eject

box is full of masters. 69 Master Eject Sensor Detects used master misfeeds. 77 Master End Sensor Informs the CPU if the plotter unit runs

out of master roll. 80 Master Buckle

Sensor

Informs the CPU if the master is

buckling.

Switches

9 Scanner Unit Safety

Switch

Cuts off the power line of the main and

paper table drive motors when the

scanner unit is open. 12 Paper Table Down

Button

Informs the CPU to turn on the paper

table drive motor to lower the paper

table. 15 Paper Table Open

Switch

16 Paper Table Safety

Switch

Checks whether the paper table is

opened correctly or not.

Stops lowering the paper table to

prevent catching fingers under it. Cuts

the AC power line. 26 Front Door Safety

Switch

Cuts off the power line of the paper

table drive motor when the front door is

open. 30 Drum Detection

Switch

Checks whether the drum unit is set

correctly or not. 33 Delivery Table Open

Switch

Checks whether the delivery table is

opened correctly or not. 34 Main Switch Turns the power on or off. 35 Interlock Switch Disables the front door, paper table,

master eject unit, and scanner unit

safety switches. 36 Air Knife Motor

Safety Switch

Cuts off the power line of the paper

table drive motor when the master eject

unit is open.

1-19

Page 34

1 December 1993

Index No. Name Function

37 Drum Rotation Switch Informs the CPU to rotate the drum at

10 rpm. 41 ADF Safety Switch Cuts the power line of the paper table

drive motor off when the ADF is open. 46 Master Eject Unit

Safety Switch

Cuts off the power line of the paper

table drive motor when the master eject

unit is open. (Also, cuts off the power

line of the main motor in the 220/240 V

version machines.) 60 Master Cut Button Informs the CPU to cut the master

paper leading edge. 62 Drum Unit Safety

Switch

72 Master Eject Box

Switch

Checks whether the drum unit is set

correctly or not.

Checks whether the master eject box is

set correctly. 78 Right Cutter Switch Detects when the cutter position is far

right (non-operation side). 82 Left Cutter Switch Detects when the cutter position is far

left (operation side).

Printed Circuit Board

8 CCD PCB Converts light intensity into an electrical

signal. 10 A/D Conversion PCB Converts the analog signal into a digital

signal. 17 Paper Detection PCB Detects the size of the paper set on the

table. 18 Cassette Size

Detection PCB

20 Image Processing

PCB

Detects the size of the cassette set on

the table.

Controls the image processing

performance. 24 Main PCB Controls all machine functions both

directly and through other boards. 55 AC Drive PCB Controls the AC component by relays. 59 Ink Detection PCB Controls the ink supply. 74 Thermal Head Drive

PCB

Supplies the power to the thermal head

according to the signal from the

scanner section.

1-20

Page 35

1 December 1993

Index No. Name Function

Counters

39 Total Counter Keeps track of the total number of

prints made.

Others

6 Fluorescent Lamp

Stabilizer

Stabilizes the power supplement to the

fluorescent lamp. 22 Transformer Steps down the wall voltage. 27 Power Supply Unit Provides power for all DC components. 32 Circuit Breaker Cuts the AC line off. 38 Drum Rotation LED Turns to green from red when the drum

stops to the home position. 43 Fluorescent Lamp Applies light to the original for exposure. 48 Noise Filter Fi lters electrical noise on the AC power

input lines. 53 Paper Table Drive

Motor Capacitor

75 Reverse Roller

Magnetic Clutch

Protects the AC drive PCB from

induced current.

Stops the reverse roller turning while

the master buckle sensor is OFF. 79 Thermal Head Plots the master using heat.

1-21

Page 36

1 December 1993

8. DRIVE LAYOUT

15 14 13 12 11

1. Reverse Roller Gear

2. Image Position Motor

3. Original Transport Motor

4. Master Eject Motor

5. Drum Drive Gear

6. Drum Unit Gear

7. Drum Drive Pulley

8. Main Drive Belt

9. Transport Belt

10. Printing Pressure Pulley

11. Printing Pressure Gear

12. Idle Gear

13. Idle Pulley

14. Main Motor

15. Paper Table Drive Motor

16. Paper Feed Cam Gear

17. Master Feed Motor

18. Timing Belt

19. Platen Roller Gear

20. Master Transport Roller Gear

1-22

Page 37

SECTION 2

SECTIONAL DESCRIPTION

Page 38

1 December 1993

1. MASTER EJECT SECTION

1.1 OVERALL

At the end of the printing cycle, the used master remains wrapped around the drum to prevent the ink on the drum surface from drying. When the Master Making key is pressed to make a new master, the used master is ejected from the drum.

The master is pulled off the drum, then it goes through the eject rollers and into the master eject box. A pressure plate then compacts the used master.

[D]

[G]

[C]

[A]

[F]

Drum

[E]

[B]

•

Drum [B] rotates in reverse (opposite to printing direction).

•

Master eject rollers [A] rotate.

•

Lower eject roller [C] is pressed against the drum.

•

The trailing edge of the master curls off the drum and passes between the upper [E] and lower [F] eject rollers, and the master [D] is dumped into the master eject box [G ].

[H]

•

The pressure plate [H] compacts the ejected master [I].

[I]

2-2

Page 39

1 December 1993

1.2 MASTER EJECT ROLLER ROTATING MECHANISM

[I]

[J]

[H]

[G]

[A]

[B]

[E]

[F]

[B]

[C]

[D]

[E]

[F]

When the original is set and the Master Making key is pressed, the main motor starts turning at 30 rpm in reverse. So now the drum also turns in reverse (compared with the printing rotations).

At this time, if the drum master detection sensor detects a master on the drum, the master eject motor [A] starts rotating. Drive is transmitted to gear [E] and to the upper first eject rollers [G] through the timing belt [B] and gears [C] and [D]. Gear [F] drives the lower first eject rollers [H]. The belts [I] transmit drive from the first eject rollers to the upper and lower second feed rollers [J].

(If the drum master detection sensor detects no master on the drum when the Master Making key is pressed, the machine skips the master eject process and goes directly to the master making process.)

After the master eject process is completed, the drum returns to its home position. The master eject rollers then stop rotating.

This model has five rollers on each eject roller shaft. The roller shafts can feed up to A3/DLT sized masters.

2-3

Page 40

1 December 1993

1.3 MASTER EJECT ROLLER DRIVE MECHANISM

[H]

[G]

[A]

[B]

[C]

[D]

[E]

[F]

The drum position is detected by the first [G] and second [H] drum position sensors. When the drum reaches its home position, the first drum position sensor [G] is activated by the interrupter [F] at the rear side of the drum.

To eject the master, the drum turns in reverse (opposite to the printing direction). When the A3/DLT drum is 70° from the home position, the master eject solenoid [A] turns on and the supporter [C] rotates counterclockwise on the upper eject roller shaft [D]. This forces the lower first eject roller [E] against the drum.

As the drum turns, the curled trailing edge of the master [B] passes between the upper and lower first eject rollers. The first eject rollers then peel the master from the drum.

2-4

Page 41

1 December 1993

[A]

[B]

[C]

[D]

When the A3/DLT drum is 109 degrees from the home position, the master eject solenoid [A] turns off, separating the lower first eject rollers [C] from the drum.

When the ejected master passes between the upper and lower first eject rollers, the master eject sensor [B] is actuated. The master is then dumped into the master eject box [D].

2-5

Page 42

1 December 1993

Print key on

First Drum Position Sensor

Master Eject Solenoid

Sensor ON Check

70°

Drum Rotation

Reverse Reverse

Master Eject Sensor

Master Eject Motor

Misfeed Indic at or Light s

39° 18°

50° 50°

68°

Foward

[Master Eject Misfeed Detection]

The misfeed indicator for the master eject section blinks in the following cases:

Case 1: The master eject sensor is not activated and the drum has turned

50 degrees more (still in reverse and after de-activation of the master eject solenoid). The machine knows that the eject rollers have failed to catch the master. So the drum returns 68 degrees (in the printing direction) to repeat the master eject process once again. The master eject solenoid is again energized while the drum turns another 18 degrees to try to catch the master.

If the master eject sensor once again fails to detect the master, then the drum returns to its home position and the misfeed indicator blinks.

Case 2: The drum finishes its rotation for the master ejecting process and

retuns to the home position, but the master eject sensor does not turn off. This means that the master is still in between the master eject rollers, the misfeed indicator blinks.

2-6

Page 43

1.4 MASTER EJECT CLAMPER MECHANISM

[G]

[F]

1 December 1993

[B]

[A]

[C]

[D]

[E]

When the drum rotates 306 degrees (in reverse) past the home position, the master eject clamper solenoid [A] turns on and lever [B] rotates counterclockwise as shown. This moves the cam [D] inside the drum. Drum rotation brings the clamper sector gear [E] against the cam [D]. Gear [F] turns counterclockwise as it engages the clamper sector gear, thus opening the master clamper [G]. This releases the master from the drum.

The drum keeps on turning until the interrupter at the rear side of the drum goes 13 degrees past the first drum position sensor. Then, the main motor turns off. Half a second later, the master eject clamper solenoid [A] turns off and spring [C] pulls cam [D] back to its initial position. The drum then rotates forward to its home position.

2-7

Page 44

1 December 1993

1.5 PRESSURE PLATE UP/DOWN MECHANISM

[B]

[M]

[C]

[L]

[D]

[A]

[K]

[E]

[F]

[G]

[I]

[H]

[J]

[Pressure Plate Down]

When the interrupter at the rear side of the drum interrupts the first drum position sensor (this means the end of the master eject process), the pressure plate motor [B] starts rotating. This drives gear [H] clockwise by means of gears [C], [D], [E], and [F].

Pin [I] on gear [H] moves link [G] down until the link interrupter [L] interrupts the lower pressure plate sensor [J]. Spring [M] pulls down on the pressure plate and the ejected master in the master eject box is compressed by the pressure plate [A].

If the full master detection sensor [K] does not turn on when the pressure plate goes down, it means the master eject box is filled with ejected masters. In this case, the Master Full indicator blinks, and the machine stops after a new master is wrapped around the drum.

Reset the Master Full indicator by turning the Master Eject Box switch OFF and ON. This is to prevent the master full indicator from being reset without removing the ejected masters from the box. When the Master Full indicator is blinking, the Master Making key does not work, but the Print Start key and Proof key work.

2-8

Page 45

1 December 1993

[A]

[B]

[G]

[C]

[F]

[D]

[E]

[Pressure Plate Up]

When the master has been wrapped around the drum in the master making process and the master cutter leaves the home position to cut the master, the pressure plate motor [B] starts rotating to raise the pressure plate.

When the pressure plate motor [B] turns, the gear [C] is driven through the relay gears. The pin [F] on the gear inserted into the link [D] rises and lifts the left end of the link, thus raising the pressure plate.

The gear [C] continues turning until the interrupter [G], installed in the front end of the pressure plate, blocks the upper pressure plate sensor [A]. At this time, the master eject motor [B] stops and the pressure plate is held in the upper position.

[Pressure Plate Motor Lock Detection]

To prevent the pressure plate motor from locking, "E-12" lights up on the operation display panel under the following conditions:

1. The upper [A] or lower [E] pressure plate sensor remains activated for more than 4 seconds after the pressure plate motor starts turning.

2. The lower pressure plate sensor [E] is not activated within 8 seconds of the pressure plate motor starts turning even though the upper pressure plate sensor [A] is de-activated.

3. The upper pressure plate sensor [A] is not activated within 8 seconds of the pressure plate motor starts turning even though the lower pressure plate sensor [E] is de-activated.

2-9

Page 46

1 December 1993

1.6 ELECTRICAL TIMING

First Drum Position Sens or Second Drum Position Sensor

Main Motor Reversing

30 rpm

Main Motor Forwarding

Master Eject Motor

Master Eject Solenoid Master Eject Clamper Solenoid

306°

T1: When the Master Making key is

pressed, the main motor and master eject motor start turning. At the same time, the paper table drive motor starts turning to lift the paper table to the paper feed position.

T2: When the drum rotates X1 degrees

past the first drum position sensor actuation position (drum home position), the master eject solenoid is energized. This presses the lower eject rollers against the drum surface. The master eject solenoid is de-energized when the drum rotates X2 degrees more.

13°

30 rpm

500 msec

0°

70°

39°

The drum rotation angles X1 and X2 depend on the drum type. This machine has two types of drums: one is the A3/DLT drum (standard), and the other is the A4/LT drum (optional). X1 and X2 for each drum are as follows:

Drum Type A3/DLT A4/LT X1 (degree) 70 137 X2 (degree) 39 50

2-10

Page 47

1 December 1993

T3: When the drum rotates 306

degrees past the home position, the master eject clamper solenoid is energized.

T4: When the drum rotates 13 degrees

past the drum home position, the drum stops rotating.

500 milliseconds later (the drum completely stops during this period), the master eject clamper solenoid is de-energized and the drum starts rotating forward. The drum then returns to its home position. The master eject process is now over.

Soon after this, the machine starts feeding a new master and the drum starts rotating in reverse to begin the master making process.

13°

0°

306°

0°

2-11

Page 48

1 December 1993

-24

-23

-22

-27

-26

-25

-30

-29

-28

-17

-16

-19

-18

Main PCB

GND

5V LED DRIVE

CN103

-21

24V

FU101

FU102

GND

-10

-20

-11

-19

-12

-25

-6 CN101

-20

-21

SOL

plate is at the hi ghest position.

plate is at the lowest position.

of the pressure pla te passes through the sensor. (M ast er fu l l det ect i on in the

[E]

[F]

[G]

[H]

[I]

1.7 CIRCUIT

[A]

[B]

[C]

[D]

Component

Name

Upper Pressure Plate Sensor [A]

Lower Pressure Plate Sensor [B]

Full Master Detection Sensor [C]

CN101

1 2

In/Ou t Main P C B Description

CN No. Signal Level

In 101-23 Signal goes High when t he pr essure

In 101-26 Signal goes High when t he pr essure

In 101-29 Signal goes High when t he i nter r upt er

master eject box.)

Master Eject Sensor [D]

Sensor LED [D] Out 101-16 Pulse signal goes to Low and the LED

Master Eject Solenoid [E]

Master Eject Motor [F]

Pressure Plate Motor [G]

Master Eject Clamper

In TP104 Signal goes High when the sensor

3 msec

3.5V

Out 103-10 Signal goes Low when the soleno i d

Out 103-11 Signal goes Low when the motor turn s

Out 103-12 Signal goes Low when the motor turn s

Out 103-6 Signal goes Low when the solenoid

24V

detects the master. This is a pulse signal.

lights when the main switch is turned on.

600

sec

turns on.

on.

turns on.

Solenoid [H] Master Eject

Box Switch [I]

In 101-20 Signal goes Low when the m aster eject

box is installed.

2-12

Page 49

2. SCANNER/OPTICS SECTION

2.1 OVERALL

1 December 1993

[A]

[G]

Thermal Head

[F]

[E]

Thermal Head Drive PCB

Operation Panel PCB

[D]

[B]

[C]

A/D Conversion PCB

Image Proccessing PCB

Main PCB

The first original [A] at the bottom of the stack on the original table is separated from the other originals by the original feed rollers [E] and the separation blade [B], and is fed onto the exposure glass [F].

The light of the fluorescent lamp [G] is reflected from the original and goes through the lens [D]. The light is changed to an electrical signal in the CCD (Charge Coupled Device) [C].

The electrical signal from the CCD is converted into an 8-bit digital signal in the A/D conversion PCB. Then the upper 6 bits of the 8 bits are used in the image processing PCB.

The binary circuit in the image processing PCB produces 1-bit data (white or black) from the 6-bit data and sends it to the thermal head dri ve PCB.

The thermal head plots image data on the master and is driven through the thermal head drive PCB.

2-13

Page 50

1 December 1993

[A]

[B]

[C]

[F]

[D]

[E]

[Light Source]

A high frequency (15 kHz) fluorescent lamp [D] is used as a light source for high speed reading. The light is reflected at two angles using a mirror [F]. This prevents shadows from the edges of cut-and-paste originals from appearing on the original [B]. The original guide plate [C] blocks part of the direct light from the fluorescent lamp to make the light intensity of both the direct light and reflected light the same. A heater [E] is wrapped around the fluorescent lamp. The lamp stays on for one minute when the main switch is turned on to quickly raise the lamp temperature. This prevents a loss in light intensity that would occur if the temperature were too low.

[Platen Cover]

The CCD reads the platen cover [A] to obtain a standard white level before the original is read. The standard white data are used to correct for distortion such as bright or dull spots in the light path (lamp, reflectors, exposure glass, mirrors, lens, and CCD).

2-14

Page 51

1 December 1993

Fluorescent

Lamp

CN608

-1

[D]

-2

-3

[C]

-4

Original Scanning Signal

Main PCB

CN601

-A13

+5V

+24V

4.3K TH601

110K

[B]

[A]

24K

A/D Conversion PCB

Q605

10K

18K

Q602

[Lamp Heater]

The thermistor [C] mounted in the lamp heater maintains the lamp temperature at about 40°C.

Lamp Heater

If the lamp temperature drops too low, the voltage at [B] goes High. This is because the resistance of thermistor [C] increases, causing the voltage at IC-pin 7 (operational amplifier) to go High. Q602 then turns on and the lamp heater [D] is energized. If the lamp temperature rises, the voltage at [B] becomes less than that at IC-pin 6. This causes IC-pin 7 to go Low, which turns off the lamp heater.

Thermistor TH601 in the A/D conversion PCB monitors the temperature inside the machine. If the temperature is low, the increased resistance of TH601 drops the voltage at [A] and the control temperature of the heater thermistor (heater ON/OFF temperature) is raised slightly. If the temperature is high, the control temperature is lowered slightly.

If Q605 turns on, the voltage at [B] becomes 0 volt and the lamp heater turns off. Q605 is turned on when the original scanning signal (active low) is sent from the main PCB. Consequently, the heater is always off during the original scanning process.

2-15

Page 52

1 December 1993

[A]

[B]

[C]

[Lens]

The lens assembly [B] consists of 6 lenses to transfer the image to the photoelectric elements of the CCD. It is possible to adjust the focus by moving the lens assembly.

[Shading Plate]

Compared with the ends, the middle of the lamp is too bright. To correct this, a shading plate [A] is placed in front of the lens. This blocks some of the light and distributes it more uniformly.

[CCD (Charge Coupled Device)]

The CCD [C] is a solid-state device similar to a photodiode array, but unlike a photodiode array, a CCD can read one complete scan line at a time. The CCD produces an analog signal which is converted into a digital signal in the A/D conversion PCB.

2-16

Page 53

2.2 ORIGINAL FEED MECHANISM

1 December 1993

[A]

[C]

[B]

[D]

[E]

[L]

[F]

[K]

[I]

[H]

[G]

[J]

[J]: Fluorescent Lamp [K]: Exposure Glass [L]: 2nd Original Transport Rollers

Two original feed modes can be selected by the ADF ON/OFF select switch.

[ADF Mode]

The originals [A] set on the original table are detected by the 1st original sensor [E]. When the Master Making key is pressed, the original pressure plate [D] presses the originals down. The pull-out rollers [F] start moving the lowest original forward at the same time. The lowest original is separated from the other originals by the original feed rollers [G] and the separation blade [C]. 350 milliseconds after the 2nd original sensor [H] detects the original, the 1st original transport rollers [B] start rotating. The rollers stop after the original activates the original registration sensor [I]. The 1st original transport rollers start rotating again after the drum section completes the preparation for the master making.

[SADF Mode]

The separation blade [C] and the original pressure plate [D] are released in the SADF mode. The original on the original table is fed to the original reading position one second after the 2nd original sensor [H] detects the original.

[Original Misfeed Detection]

The original misfeed indicator blinks in the following conditions:

1. The 2nd original sensor is not activated within 3 seconds after the ADF drive motor turns on.

2. The original registration sensor is not activated within 3.5 seconds after the 2nd original sensor is activated.

2-17

Page 54

1 December 1993

2.3 ORIGINAL FEED DRIVE MECHANISM

[A]

[L]

[K]

[J]

[I]

[H]

[G]

[B]

[C]

[D]

[E]

[F]

[M]

[N]

[M]

[B]

[O]

[P]

[E][B]

[E]

The original transport rollers [A] are driven by the original transport motor [C], which is a stepper motor. The original feed rollers [B] are driven by the ADF drive motor [F] (dc motor) through a series of gears [G] to [L]. The pull-out rollers [E] are driven by the ADF motor through a drive belt [D].

The original pressure plate [P] is pressed down on the originals by the original pressure solenoid [O]. The separation blade [M] is moved up and down by the ADF ON/OFF select switch [N].

2-18

Page 55

2.4 ORIGINAL SIZE DETECTION

1 December 1993

[F]

[E]

[D]

[C]

[A]

[B]

[A]

[B]

The original width detection plate [A] installed behind the rear original guide [B] has 4 photointerrupters.

The front and rear original guides are adjusted according to the original width. Depending on which original size sensors are interrupted, the machine determines the original width as shown in the below table. The original size sensors are 4 photointerrupters.

Original Size* A3 DLT B4 LT/LG A4 B5 A5 HLT Original Size Sensor - 3 [C] o x o x x o x x o Original Size Sensor - 2 [D] x o o x x o o o o Original Size Sensor - 1 [E] x x o o o o x x x Original Size Sensor - 0 [F] x x x x o o o o o

x: Non-blocked, o: Blocked * All of the above original sizes are for lengthwise feed.

2-19

Page 56

1 December 1993

The machine also checks the paper size on the paper feed table (both the length and width).

When the paper width is smaller than the original width (multiplied by the reproduction ratio), the machine indicates "Check paper size" on the operation display for 3 seconds when the Master Making key is pressed. If the operator ignores the indication and presses the Master Making key again, the machine goes ahead with normal processing.

If the original size is different from the paper size, the machine compares the length of the original and paper. The master’s length will be the shorter of the two. The machine runs the same procedure for the width. (The original length is detected by scanning the original.)

2-20

Page 57

2.5 ELECTRICAL TIMING

1 December 1993

First Drum Positi on Sensor

Second Drum Position Sensor

First Original Sensor

Master Motor Key

Main Motor Reversing

Lamp On Signal

ADF Drive Motor Original Pressure

Solenoid Second Original Sensor

Original Registration Sensor

Original Transport Motor

Master Eject Process Master Making Process

218.5° in Drum R otation

350 msec

15 mm

15.5 mm 20.5 mm

High Speed

Master Feed Motor

Original Scanni ng Sig nal

410 mm (Max.)

Master Plotting Signal

Plotting Signal Start Position

10 mm

15.5 mm

Scanning Signal Start Position

16 mm

15 mm

4.5 mm Original

Guide P late

Exposure Glass

CCD Scan Line

Original Registration Sensor

T1: When originals are inserted in the ADF unit, the first original sensor is

activated.

2-21

Page 58

1 December 1993

T2: When the Master Making key is pressed, the ADF drive motor starts

rotating and the lowest original in the ADF unit is fed. At the same time, the original pressure solenoid is energized and the pressure plate presses the originals against the pull-out rollers. The fluorescent lamp lights about 3 milliseconds after the lamp on signal turns on.

T3: The original transport motor starts rotating and turns the transport rollers.

This happens 350 milliseconds after the second original sensor is activated.

T4: The original transport motor stops rotating when the original is fed 15

millimeters past the original registration sensor actuation position. The leading edge of the original is stopped 5.5 millimeters before the scanning position. (See illustration on the previous page.)

T5: After the master eject process is finished, the drum rotates 218.5 degrees

more (in reverse) past the second drum position sensor actuation position and stops at the master clamping position.

When the drum stops, the original starts being fed and the original scanning starts. Since there is a 5.5 millimeter distance until the leading edge of the original reaches the scanning position, the CCD reads the platen cover as a standard white level during this period.

After the original is fed 15.5 millimeters, the master starts being fed and is plotted by the thermal head. At this time, the master has a 10 millimeters blank margin at its leading edge.

T6: When the original scanning for the plotting area is finished, the master

plotting signal is de-energized and the thermal head turns off. At the same time, the original transport motor speeds up (about 4 times) and spits out the original.

The plotting area of the master depends on whether the paper size or original size is smaller. If the original length is shorter than the paper length, then scanning finishes 20.5 millimeters after the trailing edge of the original has passed the original registration sensor.

If the paper length is the same or shorter than the original, scanning finishes when the master has been fed the length of the paper. For the A3/DLT drum, the master is fed 410 millimeters, at most, and for the A4/LT drum, the master is fed a maximum of 206 millimeters.

2-22

Page 59

[Electrical Timing for SADF Mode]

1 December 1993

First Original Sensor

Master Making Key

Lamp On Signal ADF Drive Motor

Original Pressure Solenoid

Second Original Sensor

Original Transport Motor

Original Registration Sensor

Scanning Signal Start Position

1 sec

14 mm

8.5 mm

6.5 mm

Master Eject Process

8.5 mm

Original

Guide Plate

Exposure Glass

CCD Scan Line

2 mm

Original Registration Sensor

T1: The original transport motor starts rotating 1 second after the leading

edge of the original activates the second original sensor. The ADF drive motor and original pressure solenoid do not work in the SADF mode.

T2: The original transport motor stops rotating when the original registration

sensor is activated and the original is fed 6.5 millimeters.

T3: When the Master making key is pressed, the original is fed 8.5

millimeters before it stops. From this point on, the timing continues in the same manner as in the ADF mode.

2-23

Page 60

1 December 1993

[Electrical Timing for Image Shifting Mode]

[Print]

[Original]

[Print]

+ L

Original Feeding Direction

The image is shifted in the sub-scanning direction by changing the start timing for the original feed or master feed. (In the main scanning direction, the image is shifted by changing the output timing of the image data in the image processing PCB. See "9.3 IMAGE PROCESSING PCB".)

When the original image moves forward in the sub-scanning direction on the print, the shift is represented by a minus (–). The opposite shift is represented by a plus (+). The shift length is represented as "L". For example, if the original image moves 100 millimeters backwards in the sub-scanning direction, this is represented as "L=(+)100 mm".

There are three image shift cases to consider:

1) No shift or a backward shift of 7 millimeters or less

2) A backward shift of 8 millimeters or more

3) A forward shift Because of the 10 millimeters blank margin at the top of the print and

because the first three millimeters of the original are not scanned, the backward shift works differently when it is between 1 and 7 millimeters and when it is 8 millimeters or more.

2-24

Page 61

1 December 1993

Second Drum Position Sensor

Main Motor Reversing Original Registration

Sensor Original Transport

Motor Master Feed Motor

Original Scan ni ng Signal

Master Plotting Signal

Plotting Signal Start Position

[Master Making Process]

218.5 in Drum Rot at ion

15.5 mm

8.5 mm

Scanning Signal Start Position

15.5 mm

3 mm

8.5 mm

410 mm(Max.)

15 mm

High Speed

20.5 mm

Original

Exposure Glass

CCD Scan Line

Original Registration Sensor

Guide Plate

1. 0 ≤ L ≤ 7 mm (L=0, 1, 2, ..., 7) The image of the original is moved backwards by advancing the master feed

timing during the master making process. First, the print must have a 10 millimeters blank margin at its leading edge. This is to let the machine easily peal the print off the drum. To allow for the margin, a 10 millimeters margin must also be made on the master; so plotting on the master starts from the line (on the master) that corresponds to the first line on the print immediately following the 10 millimeters margin. Prints and master will always have this margin when the value of L is between 0 and 7 millimeter

If the shifting length L is +7 millimeters, the master starts being fed and the master plotting signal is energized when the original is fed 8.5 millimeters (after the drum stops rotating). The image is scanned from 3 millimeters after the leading edge of the original. Then the scanned image is plotted on the master from the line (on the master) that corresponds to 10 millimeters from the leading edge of the print.

The master plotting signal is de-energized when the original scanning for the plotting area is finished. Then, the master feed motor turns off.

2-25

Page 62

1 December 1993

Second Drum Position Sensor

Main Motor Reversing Original Registration

Sensor Original Transport

Motor Master Feed Motor Original Scanning

Signal

[Master Making Pr ocess]

218.5 in Drum Rotation

High Speed

8.5 mm

410 mm(Max.)

Master Plotting Signa l

Plotting Signal Start Position

Expos ure Glass

2. 7 < L (L=8, 9, or more)

410 mm (Max.)

3 mm

CCD Scan Line

Scanning Signal Start Position

8.5 mm

15 mm

Original

Guide Plate

Original Registration Sensor

When the shifting length L is longer than 7 millimeters, the image of the original is moved backwards by advancing the master feed timing in the master making process.

If the shifting length L is +8 millimeters, the master starts being fed when the original is fed 7.5 millimeters (after the drum stops rotating). Thus the master feed timing is advanced 1 millimeter in the original transport length compared with the timing of "L=+7 millimeters". Therefore, the image is moved backwards 8 millimeters on the print. When L is more than 8 millimeters, the master feed timing is accordingly advanced.

If L is more than 7, the master plotting signal is energized when the original is fed 8.5 millimeters (after the drum stops rotating). Therefore, the original scanned from 3 millimeters after the leading edge of the original. When L is 8 millimeters, the scanned image is plotted on the master from the line that corresponds to the line (on the print) 11 millimeters from the leading edge. This means that the print has a blank of 11 millimeters or more on the leading edge when L is more than 8 millimeters.

2-26

Page 63

1 December 1993

Master Making Key

Lamp On Signal Second Original

Sensor Original Registration

Sensor Original Transport

Motor Original Scanning

Signal

Plotting Signal Start Position

Exposure Glass

[Master Eject Process]

3.5 sec

350 msec

6.5 mm

Scanning Signal

Shifting Range

15.5 mm 8.5 mm 6.5 mm

Start Position

8.5 mm

Original

Guide P late

CCD Scan Line

Original Registration Sensor

3. L < 0 (L=-1, -2, or less) The image of the original is moved forward by transporting the original during

the master eject process, before the master feed and plotting start. The original is fed 350 milliseconds after the second original sensor is

activated. Once the original stops when it is fed 6.5 millimeters after the original registration sensor is activated. The original again starts being fed 3.5 seconds after the lamp on signal turns on. This is to allow the fluorescent lamp to stabilize. At the same time, the original scanning signal is energized. The CCD reads the platen cover as a standard white level until the leading edge of the original reaches the CCD scanning position. The original is fed a little while after that. The waiting time depends on the image shifting length.

2-27

Page 64

1 December 1993

2.6 CIRCUIT

[A]

[B]

[C]

[D]

[E]

SOL

CN604

-1

-3

-2

CN603

-1

-3

-2

CN603

-4

-6

-5

CN607-1

-2

CN607

-3

-5

-4

CN607-6

A/D Conversion PCB

24V

GND

GND 24V

GND

CN601

-b7 CN402-A7

-b5

-a7

-a1

-a5

-b1

-a3

Image Processing PCB

CN404

-a11

-A5

-B7

-B1

-B5

-A1

-B3

-a2

-a3

-b31

-b30

-a1

-a10

Main PCB

CN109-B11

-B2

-B3

-A31

-A30

-B1

-B10

[F]

[G]

Original Transport Motor

-7

CN607-8

-9

CN605-1

-2

-3

-4

-5

-6

-7

-8

-9

-10

24V

GND

24V

-b3

-a9

-b9

-a10

-b10

-a11

-A3

-B9

-A9

-B10

-A10

-B11

-a4

-a12

-a13

-a14

-a15

-a16

-B4

-B12

-B13

-B14

-B15

-B16

2-28

Page 65

1 December 1993

Component

Name

Fluorescen t Lamp [A]

Fluorescent Lamp [A]

Second Original Sensor [B]

Original Registrati on Sensor [C]

Original Pressure Solenoid [D]

First Original Sensor [E]

ADF Drive Motor [F]

ADF Cover Switch [G]

In/Out A/D Conversion PCB Description

CN No. Signal Level

In 601-b7 Signal goes High when t he lam p on

Out 604- 3 Signal goes Lo w wh en the l am p on

In 603-3 Signal goes Low when t he se nsor

In 603-6 Signal goes Low when t he se nsor

Out 607- 2 Signal goes Lo w wh en the solenoid

1.5V

24V

3.5V

signal turns on.

detects original.

turns on. (2 lines from A/ D conversion PCB to main PCB increase current carrying capacity for safety purposes.)

5 msec

detects original.

on.

cover is closed.

In 607-5 Signal goes High when t he sensor

Out 607- 6 Signal goes Lo w wh en the m ot or tu rn s

In 607-8 Pulse signal goes to Low when the ADF

24V

7.5V 0V

2-29

Page 66

1 December 1993

3. MASTER FEED SECTION

3.1 OVERALL

[A]

[B]

[C]

The thermal head [B] burns the image (scanned by the CCD) on the master [A] as it is being fed to the drum [C]. The master is then clamped to and wrapped around the drum.

2-30

Page 67

3.2 MASTER CLAMPER OPENING MECHANISM

[A]

[B]

[C]

[G]

1 December 1993

[H]

[D]

[F]

[E]

After the master eject process is finished and the interrupter [A] is positioned in the first drum position sensor [B], the main motor turns on and the drum starts rotating (30 rpm) in reverse (opposite to the printing direction).

When the drum turns 160 degrees past the actuation position of the second drum position sensor [C], the cam [H] moves inside the drum and the master feed clamper solenoid [D] turns on.

When the drum turns another 58.5 degrees, the sector gear [F] rotates upwards as it contacts the cam [H]. This engages the sector gear and gear [E], which turns counterclockwise to open the clamper [G]. At the same time, the drum stops and the clamper remains open to clamp the master’s leading edge.

2-31

Page 68

1 December 1993

3.3 MASTER FEEDING MECHANISM

[E]

[D]

[C]

[B]

[A]

[F]

[L]

[G]

[K]

[J]

[I]

[H]

[L]

[M]

[O]

[N]

The drum rotates 218.5 degrees past the second drum position sensor and stops. At this time, the magnetic clutch [A] behind the reverse roller [L] and the master feed motor [H] turns on. The rotation of the master feed motor [H] is transmitted to the platen roller [E] through the belt [G] and the gear/pulley [F]. The platen roller then feeds the master and presses it against the thermal head [K]. Also, the rotation of the gear/pulley [F] is transmitted to a gear [J] through the relay gear [I] to drive the upper feed roller [D] and the lower feed roller [C] for master feeding.

When the magnetic clutch [A] turns on, the rotation of the upper feed roller [D] is transmitted to the reverse roller [L] through the relay gears [B], thus feeding the master. Also, the master is directed down to the clamper [N] of the drum by the reverse guide [O]. The counter rollers [M] are to prevent the leading edge of the master from wrapping around the reverse roller [L].

After the master is fed 59.5 millimeters, the magnetic clutch [A] turns off and the reverse roller [L] stops. Then, after the master is fed another 5 millimeters, the master feed clamper solenoid turns off because the master’s leading edge has already reached the clamper [N].

2-32

Page 69

3.4 MASTER WRAPPING MECHANISM

1 December 1993

[B]

[A]

[C]

[D]

[A]

[D]

[C]

[E]

When the magnetic clutch [B] is turned off, the reverse roller [A] stops. However, since the feed rollers [C] turn continuously, the master continues to

be fed, causing the master to buckle. This buckle [E] is detected by the master buckle sensor [D]. When the sensor turns on, the main motor turns on at 10 rpm to rotate the drum. The main motor turns off when the sensor turns off.

So, the master is fed by repeating the ON/OFF action of the master buckle sensor. This mechanism prevents the shockwave from having an effect on plotting when the drum pulls the master (for instance by jiggling the master above the thermal head).

2-33

Page 70

1 December 1993

3.5 CUTTER MECHANISM

[E]

[A]

[F]

[C]

[G]

[A]

[B]

[D]

After the master making process (plotting process) is finished, the master feed motor turns off and the cutter motor [A] starts turning.

The cutter motor [A] starts turning in reverse (arrows) when the cutter holder [B] pushes the left cutter switch at the front (operation side) end of the cutter rail (cutter holder home position). This drives the cutter holder [B] toward the rear (non-operation side) by means of the gear/pulley [C] and the wire [D] on which the cutter holder [B] is fixed.

When the cutter holder reaches the rear end of the cutter rail and pushes the right cutter switch, the cutter motor [A] changes the rotating direction, so the cutter holder [B] starts moving toward the front. Then, the cutter motor [A] stops turning when the cutter holder [B] goes back to its home position and pushes the left cutter switch. The master cutting process is now finished.

While the cutter holder [B] is traveling to the rear, the roller [E] installed in the cutter holder is turning clockwise because it touches the cutter rail. The roller [E] rotates the rotary cutter blade [F] as indicated by the arrow. The master is between the rotary blade and blade plate [G] and as the cutter moves back, it cuts the master. The blade plate also serves as a lower guide plate for the master.

After the master cutting process is finished, the master is fed another 40 millimeters and the master feed process is finished.

2-34

Page 71

3.6 ELECTRICAL TIMING

First Drum Position Sensor

1 December 1993

Second Drum Position Sensor

Main Motor Reversing

Original Transport Motor

Master Feed Motor

Reverse Roller Clutch

Master Feed Clamper Solenoid

Buckle Sensor

Main Motor Forwarding

Left Cutter Switch

Right Cutter Switch

Cutter Motor Reversing

218.5° in Drum Rotation

15.5 mm

21.5 mm

160° in Drum Rotation

Plotting Start

38 mm

5 mm

Plotting Max.

40 mm

To Trial Print

Cutter Motor For w ar ding

T1: After the master eject process is

completed, the main motor starts rotating in reverse (opposite to printing direction) at 30 rpm. At the same time, the master feed motor and the reverse roller magnetic clutch turn on to feed the master

21.5 millimeters.

T2: The master feed clamper solenoid

is energized when the drum rotates 160 degrees (in reverse) past the second drum position sensor actuation position.

80°

160°

0°

240°

2-35

Page 72

1 December 1993

T3: When the drum rotates 58.5

degrees more, the drum master clamper is completely open, and the drum stops.

When the drum stops, the original starts being fed. After the original has been fed 15.5 millimeters, the master starts being fed, and the thermal head starts plotting on the master.

At the same time, the reverse roller magnetic clutch also turns to feed the master 38 millimeters. The master starts buckling when the reverse roller magnetic clutch turns off.

T4: After the reverse roller magnetic

clutch turns off, the master is fed 5 millimeters more. Then, the master feed clamper solenoid is de-energized and the master clamper is closed. (At this moment, the master plotting has already begun.)

80°

0°

58.5°

160°

218.5°

0°

298.5°

240°

298.5°

Because the shockwave from clamping might affect plotting (for instance by jiggling the master above the thermal head), the extra 5 millimeters of the master feed will buckle the master and the buckle will absorb the shockwave.

2-36

298.5°

Page 73

1 December 1993

When the master feed clamper solenoid is de-energized, the drum starts rotating forward (the printing direction) at 10 rpm to wrap the master around the drum. The drum pulls the master and straightens out the buckle. The drum stops when the buckle sensor is de-activated. Then the master again buckles since the master feed motor keeps on feeding the master. The master is wrapped around the drum by repeating these steps, controlled by the ON/OFF action of the buckle sensor. The original transport and master feed motors speed up once the master plotting is done, so the master is now being wrapped more quickly. The master feeding length for the plotting area is fixed at 410 millimeters (maximum plotting length) in the standard A3/DLT drum (206 millimeters in the A4/LT drum). The master feed motor stops after the master is fed X1 and X2 millimeter. X1 and X2 depend on the drum type as follows:

Drum Type A3/DLT A4/LT

X1 (mm) 410 206 X2 (mm) 60 61

T5: The drum (main motor) stops after the master has been fed 537

millimeters. At the same time, the cutter motor starts rotating and the master is cut.

Then, the cutter motor changes the rotating direction when the cutter holder pushes the right cutter switch. The cutter motor stops when the cutter holder goes back to the home position and the left cutter switch is again activated. (The pressure plate motor also starts turning to raise the pressure plate at the same time.)

When the right cutter switch is activated, the drum starts rotating forward at 30 rpm to go back to its home position. The drum keeps rotating forward to make a trial print.

T6: When the left cutter switch is activated (the cutter home position) and the

cutter motor stops, the master feed motor again turns on to feed the master 40 millimeters more, then turns off.

2-37

Page 74

1 December 1993

3.7 CIRCUIT

[A]

[B]

[C]

[D]

[E]

CN108 1

-10

-11

-12

CN108

CN104

-7

-8

-9

-3

-1

-4

-2

-1

Main PCB

24V

GND

FU101

CN108-13

-14

CN109

-B33

-B34

-A1

-A2

-A3

Image Processing PCB

CN108-5

CN103-6

[F]

CN403

-1

-2

-3

-4

-5

[G]

+24V

CN706

-10

-9

-8

-7

-6

-5

-4

-3

-2

-1

Thermal Head Drive PCB

Master Feed Motor

Component

Name

Master Buckle Sensor [A]

Master Roll Detection Sensor [B]

Left Cutter Switch [C]

Right Cutter Switch [D]

Master Cut Button [E]

Reverse Roller Magnetic Clutch [F]

Cutter Motor (Forw ard) [G]

Cutter Motor (Reverse) [G]

In/Ou t Main PCB Desc ription

CN No. Signal Level

In 108-8 Signal goes High when t he sensor

In 108-11 Signal goes Low when the sensor

In 108-3 Signal goes Low when t he cu tter hol der

detects the master buckle.

detects the master on the master roll.

pushes the swit ch actuator (home position).

In 108-4 Signal goes Low when t he cu tter hol der

In 104-2 Pulse signal goes to Low when the

Out 108-14 Signal goes Low when the clutch i s

Out 108- 5 Signal goes Hi gh when the cutter

Out 108- 6 Signal goes Hi gh when the cutter

7.5V 0V

24V

5 msec

pushes the swit ch actuator.

button is pressed.

energized.

24V

holder is returning.

24V

holder is movi ng t owar d t he r ear .

2-38

Page 75

4. PAPER FEED SECTION

4.1 OVERALL

1 December 1993

[A]

[B]

[F]

[C]

[D]

[E]

This mechanism uses a center separation system, which consists of the separation plate [F], upper separation roller [B], and lower separation roller [E]. Because of the separation system, if a few sheets of paper are picked up from the paper stack (paper table) by the paper feed roller [A], only one sheet of paper is transported to the second upper feed roller [C] and second lower feed roller [D].

2-39

Page 76

1 December 1993

4.2 PAPER FEED ROLLER/UPPER SEPARATION ROLLER MECHANISM

[C]

[A]

[B]

[D]

[M]

[L]

[K]

[E] [F]

[J]

[I]

[H]

[G]

The sector gear [J], located on the non-operation side, rotates the paper feed roller [M] and the upper separation roller [A]. When the paper feed solenoid [G] turns on, the link [F] is pulled. When the cam roller [D] is positioned on top of the paper feed roller cam [C], the sector stopper [E] turns counterclockwise as a clearance is formed between the pin [I] and the stopper [E]. Then, the cam roller [D] of the sector gear moves along the cam face of the paper feed roller cam [C].

When moving the cam roller [D] from the bottom to the top of the paper feed roller cam [C], the sector gear [J] turns clockwise and the gear [H] is turned counterclockwise. The rotation of the gear [H] is transmitted to the upper separation roller shaft [B] by a one-way clutch inside the gear [H], and the upper separation roller [A] turns counterclockwise.

At the same time, the pulley [K] mounted on the upper separation roller shaft [B] turns, and the belt [L] rotates the paper feed roller [M] counterclockwise to feed the printing paper.

When the cam roller [D] moves from the top to the bottom of the paper feed roller cam [C], the sector gear [J] turns counterclockwise and the gear [H] is turned clockwise. However, due to the one-way clutch inside the gear [H], the upper separation roller [A] and the paper feed roller [M] do not turn.

2-40

Page 77

4.3 FEED ROLLER PRESSURE MECHANISM

[A]

1 December 1993

[B]

[C]

[D]

Due to the weight of the feed roller assembly [C] the paper feed roller presses the paper stacked on the paper table. This is because the feed roller assembly rotates freely around its shaft [D].

The spring [A] applies tension to the feed roller assembly in the direction in which the paper feed roller is pulled up. When the feed-pressure lever [B] is moved up, the spring [A] is also moved up. Thus, the tension of the spring is increased, weakening the feed roller pressure.

Originally, the feed-pressure lever is in the up position. When thick paper (132.5 to 215 g/m

, or 35.2 to 57 lb.) is used and frequently paper is not fed,

push down the feed-pressure lever. The feed roller pressure will increase.

2-41

Page 78

1 December 1993

4.4 PAPER SEPARATION MECHANISM

[A]

[B]

[D]

[C]

[E]

[G]

[F]

[C]

[A]

[D]

Spring tension [F] holds the separation plate [G] against the upper separation roller. A rubber pad is on top of the separation plate to separate a few sheets of paper before they reach the lower separation roller. If too many sheets of paper are fed to the lower separation roller at the same time, the lower separation roller will maybe not separate the sheets, it can separate only two or three sheets of paper.

Springs pull lever [A] and this pushes up the lower separation roller [E]. Then this roller presses the sheets to be fed against the upper separation roller [B]. Also, the lower separation roller does not turn in the paper feeding direction. (It turns in the opposite direction due to the one-way clutch bearings [D] provided on both right and left separation levers [A].) When 2 sheets of paper are fed, brake force is applied to the lower sheets of paper due to the friction between the paper and the lower separation roller. Then, the sheets are separated and a sheet of paper is fed to the second feed rollers.

The pressure between upper and lower separation rollers can be adjusted in two steps by changing the right and left separation pressure adjusting levers [C] as follows:

Levers Up: Separation pressure decreases. Levers Down: Standard position.

When dog-eared or wrinkled prints are delivered, the separation pressure should be decreased.

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Page 79

1 December 1993

[Fig. 2]

"E"

[Fig. 1]

[C]

[A]

[B]

[A]

[D]

View from

[C]

"E"

[F]

[G]

The lower separation roller [C] turns slightly (arrow Fig. 2) due to the one-way clutch bearings when paper passes through the roller. The lower separation roller [C] and its shaft [D] are slightly pushed down by the paper [B] when the upper separation roller [A] is feeding the paper. (Fig.1) Just when the paper is fed out from the rollers, the lower separation roller [C] and its shaft [D] spring back against roller [A]. (Fig. 2) This rotates the lower separation roller and insures that it will wear out evenly.

Four paper guide rollers [G] are there to reduce curl in the paper’s leading edge, and to feed the paper smoothly into the guide plates. There are four marks on the bracket [F] corresponding to the roller positions as shown in the lower figure.

2-43

Page 80

1 December 1993

[A]

[B]

[C]

The side pads [A] installed in the front and rear paper side guides prevent multiple feed. These are especially useful when thin paper is used. After adjusting the paper side plates to the proper paper width (so that they touch the paper lightly), move the front and rear side pad levers to the right. Normally, the side pads pressure should be released by moving the levers to the left.

The separation plate pressure can be adjusted to match the type of paper being used. The plate which supports the pressure plate spring [B] can be moved up or down by turning the eccentric cam shaft [C].

If multiple paper feed frequently occurs, the plate should be moved up. If paper misfeeds frequently, the plate should be moved down.

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Page 81

4.5 SEPARATION ROLLER PRESSURE RELEASE MECHANISM

[A]

[B]

[C]

1 December 1993

[D]

[E]

When printing is finished or a misfeed occurs, the paper table drive motor rotates for 500 milliseconds to lower the paper table. The paper on the paper table moves down from the paper feed roller [D] and the paper feed bracket [A] is pulled down by its own weight.

At this time, the shaft [B] pushes down the left separation lever [C] and this moves the lower separation roller [E] slightly downward.

This mechanism makes it easier to remove paper caught between the upper and lower separation rollers.

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Page 82

1 December 1993

4.6 SEPARATION PLATE PRESSURE RELEASE MECHANISM

[A]

[B]

[C]

[D]

When the paper table starts going down, the separation plate release solenoid [A] is energized. The pressure release arm [D] turns clockwise, and the separation plate [C] moves down from the upper separation roller. This mechanism allows for easy removal of any paper caught between the upper separation roller and the separation plate.

After the paper table is lowered, the separation plate release solenoid is de-energized. Spring [B] tension moves the separation plate back to the original position.

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Page 83

4.7 PAPER RETURN MECHANISM

1 December 1993

[D]

Paper Table Dri ve Motor

Paper Return Motor Forward

Paper Return Motor Reverse Separation Plate Rele ase

Solenoid

[A]

Printing End or Paper Misfeed

500 msec

900 msec

1.2 sec

[B]

[C]

[B]

[C]

When the paper feed stops, there may still be some paper between the upper and lower separation rollers. This mechanism returns any paper between the rollers back to the paper stack on the paper table.

When the paper table has been lowered, the paper return motor [B] (stepping motor) starts rotating. The paper return levers [A] then turn toward the paper table, and push the paper between the upper and lower separation rollers back onto the paper stack on the paper table.

The paper return levers turn toward the paper table for 900 milliseconds. Then, The paper return motor starts rotating in reverse. This helps the spring [D] pull back the levers. (In reverse, the motor does not turn the levers directly through the gears because one gear [C] has a one-way clutch.) The paper return motor keeps on rotating for 1.2 seconds. During this period the paper return levers hit the edge of a bracket and stop. When the paper return levers are stopped, the paper return motor is still turning. However, this rotation is not transmitted to the levers due to the one-way clutch in the gear [C].

2-47

Page 84

1 December 1993

4.8 SECOND FEED ROLLER MECHANISM

[J]

[A]

[I]

[B]

[H]

[C]

[D]

[G]

[E]

[F]

[Drive Mechanism]

The lower second feed roller [I] is driven by the sector gear [C] and the feed roller gear [E]. When the paper feed solenoid [G] turns on, the link [F] combined with the paper feed roller sector stopper [H] are pulled.

The bearing [J] of the sector gear moves along the second feed roller cam face. When the bearing of the sector gear comes to the top of the lower second feed roller cam [A], the stopper [B] is released from the sector gear as a clearance is formed between the pin of the sector gear [D] and the stopper.

When the feed roller gear turns counterclockwise, its rotation is not transmitted to the lower second feed roller due to the one-way clutch bearing press-fit into the gear.

When the bearing of the sector gear moves up from the bottom of the second feed roller cam, the sector gear turns counterclockwise and the feed roller gear turns clockwise. As the rotation of the feed roller gear is transmitted to the lower second feed roller, the lower second feed roller turns clockwise to feed the paper to the drum section.

2-48

Page 85

[A]

1 December 1993

[B]

[C]

[G]

[F]

[D]

[A]

[E]

[Release Mechanism]

The release mechanism does two things: it raises and lowers the upper second feed roller, and it activates the lower one. It also synchronizes these two steps.

The mechanism is made up of several parts. First, a cam which transmits motion to a sector gear [F]; then another cam [E] that is part of the sector gear. A lever [D] is rotated by this cam through the lever’s bearing. There are two rollers called the second feed rollers: the upper one [B] and the lower one [G]. The lever turns a shaft [C] and this shaft moves the upper roller.

At the beginning of each cycle the two rollers are apart, they will come together halfway through the cycle and at the end of the cycle they will again be apart.

At first, the rollers are apart, and the sector gear is ready to start moving clockwise. The lever’s bearing is in contact with the sector gear’s cam. As the gear turns clockwise, it causes the cam to turn the lever in the same direction (clockwise).

The lever then lowers the upper roller [B]. It does this by turning the roller’s eccentric shaft [C]. Eccentric means that the shaft does not go through the center of the roller, but actually is a little off center. So when the shaft turns the roller, the roller moves up or down.

2-49

Page 86

1 December 1993

When the cycle is halfway through, the sector gear has reached its maximum clockwise position. Now the upper roller touches the lower one and a pair of springs [A] apply tension at each end of the upper roller. Until now the lower roller has not turned.

At this point, the paper arrives from the first paper feed rollers. The leading edge hits the two rollers and the paper buckles slightly. This insures that the paper will go into the rollers straight.

The lower roller now begins turning and feeds the paper to the drum section. The sector gear is now turning counterclockwise, raising the upper roller. The gear returns to its original position and the cycle is now over.

2-50

Page 87

1 December 1993

4.9 PAPER TABLE SIDE ADJUSTMENT MECHANISM

[B]

[A]

[C]

[G]

[D]

[F]

[E]

The shaft [D] of the fine adjusting dial [F] is threaded. The inside of the sleeve [E] is also threaded. The sleeve is fixed to the paper table stay [B] through a bracket [A].

The paper table bracket [C] mounted under the table is fixed on both ends of the adjusting dial shaft. When the adjusting dial is turned clockwise, the feed table bracket [C] and the paper table move to the right.

The indicator [G] fixed to the bracket [A] shows the movement value of the paper table.

2-51

Page 88

1 December 1993

4.10 PAPER TABLE UP/DOWN MECHANISM

The paper table is raised and lowered by the paper table drive motor. The paper end sensor [E] (a reflective photosensor) is actuated when the

paper is set on the paper table. When the Print Start key is pressed, the paper table drive motor [H] starts turning clockwise and the worm gear [G] also turns. The worm wheel [F] turns clockwise and both gears [D] turn to raise the racks [C].

As the paper table rises, the paper pushes against the paper feed roller [I]. This, raises the lever [J] which is mounted on the paper feed bracket. This activates the paper table height sensor [K] (the phototransistor senses the light from the photocoupler, which up to now was cut off by the lever), and that causes the paper table motor [H] to turn OFF and stop raising the paper table.

As printing proceeds and the paper level runs down, the lever [J] cuts off the light of the photocoupler and the motor [H] turns clockwise until the phototransistor is reactivated. As a result, the top of the paper stack is constantly kept at the correct height.

When no paper is present, the paper end sensor [E] is not activated and the motor [H] turns counterclockwise to lower the paper table. The paper table is lowered until the actuator [A] (fixed to the front rack) interrupts the lower limit sensor [B].

When a misfeed occurs or printing is finished, the paper table motor [H] turns counterclockwise for 500 milliseconds, slightly lowering the paper table.

2-52

Page 89

1 December 1993

[C]

[D]

[A]

[B]

[E]

[C]

[D]

[F]

[G]

[H]

2-53

[I]

[J]

[K]

Page 90

1 December 1993

4.11 PAPER SIZE DETECTION

This machine uses two methods for detecting paper size. One method is used for the paper on the paper table, and the other is for the optional cassette.

The machine determines the master plotting area based on the detected paper size and the original size (which is detected during the original scanning process). If the original size is different from the paper size, the machine compares the length of the original and paper. The master’s length will be the shorter of the two. The machine runs the same procedure for the width. (The determined plotting area is not changed if paper on the paper table is replaced with another size paper during the master making process.) The master plotting area for each detected paper size is as follows:

Paper Size

Master Plotting Area

Width (mm) Length (mm)

A3 B4 A4

A4-S

B5-S

DLT

LG LT

LT-S

HLT

292 256 208 292 180 256 146 278 214 214 278 138

407 351 284 197 244 169 197 407 343 266 203 203

S: Sideways feed The machine can only distinguish standard sizes. If a non-standard sized

paper or original is used, the machine will judge the non-standard sized paper or original as a standard size. If the actual sized paper, the non-standard sized paper, or the original is larger than the judged paper size, the remaining area will not be plotted on the master.

In that case, the original width, paper size, and cassette size detections can separately be canceled using SP mode in order to obtain the entire image of the original. However, the press roller may become contaminated with ink when paper is smaller than the plotted image on the master. The ink will be transferred to the back side of the prints when the next printing is done with larger paper.

2-54

Page 91

[Paper Size Detection for Paper Table]

[B]

1 December 1993

[B]

[A]

[G]

[F]

[E]

[D]

[C]

The paper width detection plate [A] installed behind the front paper side guide [B] has several interrupters.

The front and rear paper side guides are adjusted to the paper width. Depending on which paper width sensors [C] [D] [E] [F] (4 photointerrupters) are interrupted and whether the paper length sensor [G] (a reflective sensor) on the paper detection PCB is activated, the machine determines the paper size as shown in the below table.

Paper Size A4-SLT-S B5-SLT A4 B5 A5 HLT A3 DLT B4 LG

Paper Width Sensor-0 [C] Paper Width Sensor-1 [D] Paper Width Sensor-2 [E] Paper Width Sensor-3 [F] Paper Length Sensor [G]

o x oxxxoxxooxox xooxxxooooxoox xxoooooxxxxxoo x x x xxoo ooox x x x x x x xxxx xxxo o o o

x: Non-blocked or Non-activated, o: Blocked or Activated S: Sideways feed

2-55

Page 92

1 December 1993

[Cassette Paper Size Detection]

[A] [B] [C] [D]

[E]

The machine determines the cassette size through the cassette size detection PCB [E]. The reed switches on this PCB are activated by magnets positioned on the back of the cassette. The magnets are positioned according to the paper size (the magnet position for each of size paper is described on the back of the cassette). Depending on which reed switches [A] [B] [C] [D] are activated, the machine determines the cassette size as shown in the table below:

Paper Size A3 B4 A4 A4-S B5 B5-S DLT LG LT LT-S Switch - 1 [D] x x x x x x x o o o Switch - 2 [C] x x x o o o o x x x Switch - 3 [B] x o o x x o o o x x Switch - 4 [A] o x o x o x o x x o

x: Not activated, o: Activated by magnet, S: Sideways feed

2-56

Page 93

1 December 1993

4.12 ELECTRICAL TIMING

Print key ON

Paper Table Heigh t Sen sor Paper Table Up Relay

(Table up) Paper Table Brake Relay

First Drum Position Sensor Second Drum Position Sensor

Paper Feed Solenoid Transport Vacuum M ot or

Air Knife Motor Main Motor (Forward)

Paper Table Down Relay

15 msec

50 msec

Stop key ON

30 msec

Counter Reset

500 msec

T1: When paper is set on the paper table and the Print key is pressed, the

paper table moves up until the paper table height sensor is activated. 15 milliseconds after the height sensor is activated, the paper table brake signal turns on for 50 milliseconds and SSR303 in the AC drive PCB is energized. Brake force is then applied to the paper table drive motor to prevent the paper table from overrunning.

T2: When the height sensor is activated, the transport vacuum motor and air

knife motors turn on. At the same time, the drum (main motor) starts turning forward (printing direction).

T3: The paper feed solenoid is energized when the interrupter at the rear side

of the drum activates the second drum position sensor.

T4: After the paper is fed, the top of the paper stack is a little lower and the

height sensor is de-activated. When the second drum position sensor is activated, the paper table drive motor starts rotating. This lifts the paper table until the height sensor is re-activated (approximately 30 millisecond after the motor starts). When the height sensor is re-activated, the motor stops rotating.

T5: After the Stop key is pressed, the paper feed solenoid is de-energized

and the second drum position sensor is activated. This will reset the counter on the operation panel.

T6: When the second drum position sensor is again activated after one more

drum rotation, the transport vacuum motor and air knife motors turn off. Then, the drum rotates once more and stops at the first drum position actuation position (the drum home position).

2-57

Page 94

1 December 1993

-15

-14

-18

-17

-15

-7

Main PCB

GND 5V

24V

GND

FU101

12V 12V

[H]

[I]

[J] [K]

CN104-8

-9

-10

-11

-12

-13

CN104-6

CN104-7

CN103-8

CN103-23 CN105

-11 CN302-5

-12

-13

-14

CN303-2

AC-N

[F]

SOL

[G]

SOL

SSR301

-4

SSR302

-3

SSR303

-2

AC Drive PCB

Paper Return Motor

4.13 CIRCUIT

[A]

[B]

CN903

[D]

Paper Table

CN903

[E]

Paper Detection PCB

[C]

-9

-8

-6

-7

-4

-5

CN901

-1 Delivery Table

CN903

-1

CN503-16

-3

CN502-12

CN501-4

AC-N

CN901-2

1 3

2 1

2 3

[D]

CN101-13

CN102-16

CN102-14

CN102

GND

12V

AC-N

PSU

CN102-6

Component Name In/Out Main PCB Description

CN No. Signal Level

5 msec

interrupted.

pressed. paper table and deli very table are

open and the switches are turned on. sensor detect s paper.

signal goes Lo w .

energized when the signal goes

Paper Table Lowe r Limit Sensor [A] Paper Table Heigh t Sensor [B] Paper Table Down Button [C] Paper Table & Delivery Table Open Switches [D] Paper End Sensor [E]

Separation Plate Release Solenoid [F] Paper Feed Solenoid [G] Paper Table Up Relay [H]

In 10 1- 15 Signal goes High when the sensor is

In 10 2- 18 Signal goes High when the sensor is In 10 2- 14 Signal goes Low when the button is In 102-7 Pulse si gnal goes Low when the

In 102-6 Pulse si gnal goes Low when the

Out 104-6 The sole noid is energized when th e Out 103-8 The sole noid is energized when th e Out 105-11 The paper table up r el ay is

0V 5V

7.5V 0V

24V

Low. (The tabl e m oves up.) Paper Table Down Relay [I]

Out 105-12 The paper table dow n relay is

24V

energized when the signal goes

Low. (The tabl e m oves down.) Paper Table Brake Relay [J]

Out 105-13 Activated for 50 milliseconds when

24V

50 msec

the paper table reac hes the upper or

lower limit. Brake force is applied to

the paper table drive motor. Common Rela y Li ne [K]

Out 105-14 Activated when the main switch is

24V

turned on.

Paper Table

2 1

2 13

Drive Motor

2-58

Page 95

5. PRINTING SECTION

5.1 OVERALL

[A]

1 December 1993

[B]

In this section, the paper detecting feeler [A] detects whether paper is fed correctly to the second paper feed roller section or not.

Only when the paper is correctly fed, printing pressure is applied (the press roller [B] touches the drum) to transfer the ink from the master to the printing paper.

2-59

Page 96

1 December 1993

5.2 PAPER DETECTING AND PRINTING PRESSURE ON/OFF MECHANISM

[F]

[E]

[G]

[A]

[D]

[C]

[B]

[F]

[H]

During the printing process, the main motor turns the gear [A] and pressure cam [B] clockwise.

When the bearing of the pressure ON/OFF lever [C] reaches the top of the pressure cam [B], the paper detecting arm [D] separates from the pressure ON/OFF lever [C]. At this moment, if paper is being fed, the paper fed presses down the paper detecting feeler [E]. Then, the paper detecting arm [D] turns clockwise to release the pressure ON/OFF lever. As a result, the pressure ON/OFF bearing continues moving along the pressure cam and the press roller [F] moves against the drum to apply printing pressure.

The printing pressure can be adjusted by the pressure spring [G]. The printing pressure sensor feeler [H] is away from the sensor while printing pressure is applied.

2-60

Page 97

1 December 1993

5.3 PRINTING PRESSURE ON/OFF MECHANISM FOR A4/LT DRUM

[A]

[B]

[C]

[F]

[E]

[D]

When the A3/DLT drum is used, printing pressure is applied while the bearing [D] of the pressure ON/OFF lever [E] is on the bottom of the pressure cam [C]. Pressure is released while the bearing is on top of the cam.

However, when the A4/LT drum is used, printing pressure should be released sooner because the master on the A4/LT drum is shorter than the master on the A3/DLT drum. This is to prevent the press roller from getting dirty.

Before the bearing [D] comes to the top of the pressure cam, the bearing [A] of the arm [B] (fixed with the pressure ON/OFF lever) rides up the A4/LT cam [F] and the arm moves (arrow).

As a result, the pressure ON/OFF lever turns clockwise and printing pressure is released.

2-61

Page 98

1 December 1993

5.4 PRINTING PRESSURE RELEASE MECHANISM

[A]

[B]

[G] [H]

[D]

[E]

[F]

[D]

The pressure release solenoid [G] energizes to release the pressure ON/OFF lever [D] when the paper feed solenoid energizes during normal operation.

If a jammed sheet of paper in the printing section presses down on the paper detecting feeler [A], the pressure ON/OFF lever [D] remains disengaged from the paper detecting arm [C]. Printing pressure will keep on being applied to the drum.

If printing pressure is still applied when an operator slides out the drum unit to remove the jammed sheet, the drum surface and the press roller may be damaged.

[C]

To prevent this, printing pressure is released from the drum if a paper misfeed is detected. When a misfeed is detected, the printing pressure solenoid [G] is de-energized. Then, the drum rotates to the home position. During the drum return to the home position, the bearing [E] will ride on top of the pressure cam [F]. This rotates the pressure ON/OFF lever [D] clockwise, then the stopper [H] engages the lever [D] (the stopper [H] is pressed down by spring tension). Thus, printing pressure is released since the lever [D] is connected to the press roller [B].

2-62

Page 99

1 December 1993

GND

5msec

Main PCB

24V

interrupted.

energized.

FU101

CN103

-28

-3

-24

-7

-23

-8

5.5 CIRCUIT

CN104

-3

[A]

Component

In/Ou t Main PCB Desc ription

Name

Printing

In 104-5 Activated when the sen sor i s Pressure Sensor [A]

Print Counter [B] Out 103-3 Activated whe n th e cou nt er is

Printing

Out 103- 7 Activated whe n th e sen sor i s ene rg i zed. Pressure SOL [C]

Paper Feed

Out 103- 8 Activated whe n th e sen sor i s ene rg i zed.

-5

-4

CN No. Signal Level

7.5V 0V

24V

SOL [D]

SOL

[B]

[C]

[D]

2nd Drum Position Sensor

Printing Pressure Solenoid

Printing Pressure Sensor

Print Counter

T1: When printing pressure is applied and the printing pressure sensor is not

interrupted, the print counter signal is applied for 100 milliseconds to increase the total counter and decrease the counter on the operation panel.

T2: When the printing pressure sensor is not interrupted and the copy

counter on the operation panel indicates "0", the paper feed solenoid and the printing pressure solenoid turn off to stop paper feeding and to release printing pressure.

2-63

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1 December 1993

6. DRUM SECTION

6.1 OVERALL

[F]

[A]: Doctor Roller [B ]: Ink [C]: Ink Roller [D]: Press Roller [E]: Paper [F]: Drum

[C]

[B]

[A]

[E]

[D]

In this section, ink is supplied from the ink cartridge and is applied to the ink roller uniformly. The ink is then transferred to the printing paper through the holes in the master.

2-64

Ricoh VT3500 S Service Manual vt3500

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS