Sharp AR-120E, AR-150E Service Manual. Parts Catalog

AR-150E

[1] GENERAL

1. Major functions

Item

Model

AR-120E 12CPM SB Opt

AR-150E 15CPM SB Opt

Descriptions of items

CPM: Copy speed (Copies Per Minute) SB/MB: SB = Manual feed single bypass, MB = Manual feed multi bypass 2 tray: Second cassette unit. SPF: Original feed unit R-SPF: Duplex original feed unit FAX: FAX function. GDI with USB: GDI printer function with USB. GDI without USB: GDI printer function without USB. PCL with USB: PCL printer function with USB. SOPM: Scan Once Print Many function (Many copies are made by one scan.) Duplex: Auto duplex copy function

Descriptions of table

: Standard provision :

CPM SB/MB 2 Tray SPF R-SPF FAX

No function or no option available

GDI

with USB

without

2. System Configuration

GDI

USB

PCL

with USB

SOPM Duplex

(AR-120E) (AR-150E)

Options (AL-10PK/AL-11PK)

∗ AR-150E, the memory has been already installed in the machine and is not supplied in the printer upgrade kit(AL-10PK).

Screws ... 4

Memory ... 1 ∗Printer board ... 1

Operation manual ... 1

1 – 1

Printer driver

(CD-ROM) ... 1

Interface cable ... 1

(for IBM PC/AT or compatible computers)

Screwdriver ... 1

AR-150E

[2] SPECIFICATIONS

1. Copy mode

A. Type

Type Desk-top

B. Machine composition

AR-120E 12 cpm / 1 tray / SB

AR-150E 15 cpm / 1 tray / SB / SOPM

(1) Option

Machine Model Power supply

AL-10PK GDI printer expansion kit

(for AR-150E)

AL-11PK

(AR-120E)

C. Copy speed

(1) Continuous copy speed (Sheets/min)

a. AR-120E

Paper size Normal

A4 12 12 11

system

b. AR-150E

system

B5 12 12 12

8.5" × 14" 10 10 10

Inch

8.5" × 11" 12 12 12

Paper size Normal

A4 15 15 15

B5 15 15 15

8.5" × 14" 12 12 12

Inch

8.5" × 11" 15 15 15

Supplied by the copier.

Enlargement

(200%)

Enlargement

(200%)

Reduction

(50%)

Reduction

(50%)

(1) Paper feed section of the copier

Paper feed size A4, B5, A5, 8.5" × 14", 8.5" × 11", 8.5" × 5.5"

Paper feed capacity

Detection Paper empty detection available

Weight 56 ∼ 80g/m

Special paper Recycled paper

250 sheets (56 ∼ 80g/m2 equivalent) (15 ∼ 21 lbs.)

(15 lbs. ∼ 21 lbs.)

(2) Manual paper feed section

Paper feed size A4 ∼ A6, 11" × 17" ∼ 8.5" × 5.5"

Paper feed capacity

Detection

Weight 52 ∼ 128g/m2 (14 ∼ 34 lbs.)

Special paper Recycled paper, OHP film, labels

1 sheets (Single bypass feed tray)

Size detection not available, paper empty detection available

G. Multi copy

Max. number of multi copy 99 sheets

H. Warmup time

Warmup time

Pre-heat Available

Approx. 0 sec (Condition: Standard condition)

I. Copy magnification ratio

Fixed magnification ratio

Zooming 50 ∼ 200%

AB system: 50, 70, 81, 100, 141, 200%

Inch system: 50, 64, 78, 100, 129, 200%

J. Print density

Density mode Auto/Manual/Photo

No. of manual adjustment

5 steps (Manual/Photo)

D. First copy time

First copy time 9.6 sec

E. Document

Max. document size B4, 10" × 14"

Document reference position Left side center

Detection (Platen) None

F. Paper feed

Copy size (Max. ∼ Min.)

Paper feed system

(A4 ∼ A6) 8.5" × 14" ∼ 8.5" × 5.5"

AR-120E

AR-150E

1 cassette + Single manual paper feed

K. Void width

Void area

Image loss

Leading edge

Lead edge 1 ∼ 4mm, rear edge 4mm or less, both sides 4mm or less

Same size: 3.0mm or less Enlarge: 1.5mm or less Reduction: 6.0mm or less

L. Auto duplex

Standard/Option Not installable

M. Paper exit/finishing

Paper exit section capacity Face down 100 sheets

2 – 1

AR-150E

N. Additional functions

Auto paper selection (APS) No

Auto magnification ratio selection

Binding margin No

1 set 2 copy No

Edge erase No

Center erase No

Cover insertion No

Index paper insertion No

OHP index paper insertion No

Job memory No

Auditor No

Key operator program No

Communication conformity No

Process control No

Toner save mode

Pre-heat mode

Auto power shut off mode

Yes (Time setup/cancel can be made with the user simulation.)

Yes (Time setup can be made with the user simulation.)

Yes (Time setup/cancel can be made with the user simulation.)

S. Power consumption

Max. power consumption About 1.0KWh

∗ EnergyStar standard (The second level conformity)

Pre-heat About 40Wh

Auto power shut off 18wh

T. Digital performance

Resolution

Gradation

Reading 400 dpi

Writing 600 dpi

256 gradations /

8 bits

U. Maintenance lamp

The maintenance lamp is provided in this model. (Not provided in the AL series)

O. Other specifications

Photoconductor type OPC (Organic Photo Conductor)

Photoconductor drum dia. 30mm

Copy lamp Xenon lamp

Developing system

Charging system Saw teeth charging

Transfer system (+) DC corotron

Separation system (–) DC corotron

Fusing system Heat roller

Cleaning system Contact blade

Dry 2-component magnetic brush development

P. Package form

Body Body/Accessaries

Q. External view

External dimensions (W × D × H)

Occupying area (W × D) 607.6 × 445mm (AR-120E/150E)

Weight about 17.2 kg (AR-120E/150E)

292.6 × 518 × 445mm

R. Power source

Voltage AC110V/120V/127V/220V/230V/240V

Frequency 50/60Hz common

2 – 2

AR-150E

5) Tilt the DV box unit and rotate the DV18T clockwise to remove developer.

6) Clean the DV box unit by sucking or blowing with a vacuum cleaner to remove developer from the MG roller and toner from the DV box unit. Check that there is no toner or no foreign material attached to the connector and the gear.

7) Shake the developer bottle 10 times up and down, and remove the bottle cap and supply developer into the DV box unit.

• Slowly slant the bottle to supply developer evenly.

• Check the label to insure that developer is suitable for the model.

11) Face the toner supply port of the TH box unit upward, and press and insert the refill hose into the toner supply port with the toner bottle kept straight up.

• Hold the left side of the TH box with your hand.

• Press and insert the refill hose completely.

12) Lift the toner bottle and shake it left and right and supply toner until the bottle and the filling hose are empty.

• It takes about one minute to fill toner completely in TH BOX UN from lifting the toner bottle to emptying the bottle and the hose.

• If toner remains in the hose, when removing the hose from TH BOX UN, the remaining toner may disperse. Use great care for that.

8) Install the THBOX unit.

• Insert two bosses of TH box on the drive side into the positioning hole of the DV box and fix together.

9) Remove the toner cap, look into the toner supply port and stop the THD Mylar at the position shown in the figure below. (Rotate the THK gear on the rear side of the TH box counterclockwise to rotate the TM shaft.)

10) Shake the toner box 20 times up and down, and remove the bottle

cap and install the refill hose. Check the label to insure that toner is suitable for the model.

13) Check that there is no toner remaining in the bottle and remove the hose, and slowly pull and remove the hose. (If there is any toner remaining in the bottle or the hose, perform toner supply again.) Bend the refill hose and remove it from the TH box unit without dispersing toner. Attach the toner cap.

• Attach the toner cap with the toner supply port of the TH box unit faced upward.

14) Clean the DV box unit with alcohol and attach the DV blade.

• After drying the unit, attach the DV blade.

• After attachment, check that there is no scratch and waves on

the DV blade.

• After attachment, be careful not to damage the DV blade.

• Check that there is no foreign material in the DV blade and the

section.

0.5

0.5 0

15) Install the DVF cover to the DV-TH box unit.

16) Clean the waste toner box unit and install it to the DV box unit. (Check that there is no toner in the waste toner box) Be careful of the pawl.

3 – 3

AR-150E

17) Replace the IC connector. Check that there is no oil on the IC connector pins. (Do not touch with fingers.)

Put a white mark on the above position. At that time, put marking for checking of the number of refilling.

18) Check the operations of the DV lever and the toner box shutter.

19) Shake the DV box unit 5 times horizontally. Rotate the DV18T clockwise and check developer state on the MG roller. (Visually check that developer state is normal and there is no foreign material.)

20) Install the MG cover. Put the unit straight with the MG roller on the upper side. Rotate the DV18T several times forward and reverse to store developer on the MG roller into the inside. Check that there is no developer on the MG roller surface, and install the MG cover.

Note: When attaching the MG cover, be careful not to wind around

the DV blade.

Note for MG cover installation

• When installing, check that there is no breakage and peel-off of the MG cover sheet and the MG cover molt attached to the MG cover.

• Check that there is no winding into the DV blade, deformation and scratches of DV molt F and R.

3 – 4

AR-150E

[The reattachment procedure]

Remove the side sheets on the both sides of DV box unit. Clean the DV box unit with alcohol and reattach the side sheets F and R to the both sides.

00.5

0.5

DV box unit F side

Remove glue completely before reattaching.

After drying alcohol, attach the side sheet F,R.

DV box unit R side

Remove the DV molt F,R and DV molt and clean with alcohol. After attaching the DV molt F and R, attach the DV molt with the DV molt R edge as the reference.

DV molt F attachment reference (DV box edge)

00.5

DV molt attachment reference (DV box edge)

0.5

DV molt attachment reference (DV box edge)

0.5

DV molt attachment reference (DV box edge)

0.5

DV molt R attachment

0 0.5

reference (DV box edge)

Do not allow clearance between DV molt and DV molt F.

(Pull and attach them. Overlap may be allowed.)

Remove glue completely before reattaching.

After drying alcohol, attach the DV side sheet.

00.5

projection in the arrow direction is not allowed.

0.5

When attaching the DV molt F,

When attaching the DV molt R, projection in the arrow direction is not allowed.

0.5

3 – 5

0 0.5

AR-150E

B. Drum unit

1) Check the external view.

• Check for damage or cracks on the boss and the boss hole.

• Check to insure that the waste toner pipe shutter slides smooth-

ly.

• Check to insure that the star ring and the CRU washer rotate smoothly.

3) Remove the drum fixing plate and the photoconductor drum. (Note) Dispose the drum fixing plate which was removed.

(2)

(3)

4) Check the cleaning blade and the red felt for no damage.

• If there is any damage, execute all procedures from item 5) and

later.

• If there is no damage, execute the procedure of item 12).

5) Remove the main charger.

(Cleaning the screen grid and the sawteeth.)

2) Remove the drum cover. (4 Lock Tabs)

6) Remove the cleaning blade. Note: Dispose the cleaning blade which was removed.

3 – 6

AR-150E

7) Clean the cleaning section and the waste toner pipe to remove waste toner completely with a vacuum cleaner.

8) Remove the felt and duplex tape completely.

Note: Be careful not to scratch or bend the sub blade.

9) Attach the cleaning blade. Securely insert the plate section of the cleaning blade into the dove and fix it with a screw. Do not touch the cleaning blade rubber with your hand. When attaching the cleaning blade, press the cleaning blade in the arrow direction and attach.

10) Attach the felt.

12) Attach the drum fixing plate and the photoconductor drum. Apply grease to the inside of the photoconductor drum. (Dia. 2)

Attach the drum from (b). (Prevention against the sub blade edge breakage) Attach the drum so that its position with the sub blade is as shown.

13) Attach the detection gear.

Note:

• The detection gear is not installed to the drum cartridge packed with the main body. Add a new one.

Attach the mocket with slightly pressing section A of the cleaning blade. Do not touch the tip of the cleaning blade. Do not put the mocket under the cleaning blade. Do not put the mocket on the sub blade. Do not press the sub blade with the mocket.

11) Attach the main charger. Securely set the MC holder on the projection of the process frame. Securely insert two projections of the MC holder into the groove in the process frame. When attaching the MC holder ass’y, be careful not to make contact with the cleaning blade.

14) Attach the drum cover. Note: After attaching the drum cover, do not make a copy.

When attaching the drum cover, engage the detection gear 20T rib with the 30T gear rib, and attach the drum cover to the process frame.

15) Mark the number of times of recycling on the side of the cover with

white paint. Max. times of recycling: 5 times

Note: Another method of cleaning the drum counter is avail-

3 – 7

able with SIM 24-07.

[4] EXTERNAL VIEWS AND INTERNAL STRUCTURES

1. Appearance

(1)

(2)

AL-1000/1010

(4)

(6)

(5)

(1) Original table (2) Original cover (3) Side cover (4) Operation panel (5) Front cover (6) Paper tray

(7) Side cover open button (8) Paper guides (9) Handle (10) Paper output tray (11) Paper output tray extension (12) Power cord socket (13) Power switch

(7)

(8)

(12)

(3)

(9)

(13)

(10)

(11)

(9)

4-1

AL-1000/1010

2. Operational panel

Exposure mode selector key

(1)

and indicators Copy ratio selector key and

(4)

copy ratio indicators

(1)

(2)

(3)

Light and dark keys and

(2)

exposure indicators

200% 129%

100%

78% 64% 50%

(4)

MAX.

51/281/

100%

81/214

81/211 MIN.

81/211

51/281/

(5)

(6)

ZOOM

(10)

(7)

(11)

(12)

(3) Alarm indicators

(5) Zoom indicator (6) Copy ratio display (%) key

(9)(8)

(13)

∗1

(7) Display (8) ON LINE indicator (9) Power save indicator (10) Zoom keys (11) Copy quantity keys (12) Clear key (13) Print key and ready indicator

∗1

Drum replacement required indicator

When the drum counter reaches 17,000 copies, the indicator lights up. After 1,000 additional copies are made, the indicator starts blinking and machine will hard-stop (after current job) until a new cartridge is installed.

Misfeed indicator

TD cartridge replacement required indicator

When toner density is lower than a specified level, the TONER DEVELOPER CARTRIDGE REPLACEMENT indicator lights up to warn the user. If toner is not added after approximately 10 sheets are copied, the indicator starts blinking and machine starts to supply toner.(Toner Developer cartridg replacement indicator keeps lighting up) If toner density is not back to specific level after two minutes, the READ indicator goes out and Toner Developer indicator starts blinking, and the copier stops.

∗2 ON: Indicates that the machine is in the energy saving (pre-heat) mode.

Blink: Indicates that the machine is in the process of resetting from the energy saving mode or just after supplying the power. OFF: Indicates that resetting from the energy saving mode is completed and that the fusing temperature is in ready state. The combinations of the above display lamps are as follows: (● = ON, ✕ = OFF)

Lamp Immediately after power ON Ready Copying Pre-heat lamp Blink ✕✕ Ready lamp ●●✕ Other lamps ●●●

Copy is started during

resetting from energy

saving mode

Lamp

Energy saving mode (Pre-

heating)

Energy saving mode

(Auto power shut off)

Resetting from energy

saving mode

Pre-heat lamp ●●Blink Blink Ready lamp ●✕●✕ Other lamps ●✕●●

4-2

3. Internal

AL-1000/1010

(1)

(5)

(2)

(6)

(3)

(4)

(8)

(7)

(1) TC cartridge lock release button (2) TD cartridge (3) Drum cartridge (4) Drum cartridge handle (5) Paper feed roller (6) Fusing unit release lever (7) Charger cleaner (8) Transfer charger

4-3

AL-1000/1010

4. Motors and solenoids

(3)

(2)

(4)

(1)

(5)

(7)

(6)

No. Part name Control signal Function,operation

(1) Main motor MM Drives the copier. (2) Mirror motor MRMT Drives the optical mirror base (scanner unit). (3) Toner motor TM Supplies toner. (4) Cooling fan motor VFM Cools the optical section. (5) Resist roller solenoid RRS Resist roller rotation control solenoid (6) Paper feed solenoid CPFS1 Cassette Paper feed solenoid (7) Multi paper feed solenoid MPFS Multi manual pages feed solenoid

4-4

5. Sensors and switches

AL-1000/1010

(1)

(2)

(3)

(4)

(5)

(6)

(9)

(8)

No. Name Signal Type Function Output

Mirror home position

(1)

sensor

(2) POD sensor POD Transmissions sensor Paper exitdetection “H” at paper pass (3) PPD2 sensor PPD2 Transmission sensor

Cassette detection

(4)

switch Manual feed detection

(5)

switch

(6) PPD1 sensor PPD1 Transmission sensor

(7) Door switch DSW Micro switch

(8) Door switch DSW Micro switch

(9) Drum reset switch DRST Micro switch

MHPS Transmission sensor

CED1 Microswitch

MFD Transmission sensor

(7)

Mirror (scanner unit) home position detection

Paper transport detection 2

Cassette installation detection

Manual feed paper detection (single only)

Paper transport detection 1

Door open/close detection (safety switch for 5V)

Door open/close detection (safety switch for 24V)

New drum detection switch

“H” at home position

“L” at paper pass

“H” at cassette insertion

“L” at paper detection

“L” at paper pass

1 or 0V of 5V at door open

1 or 0V of 24V at door open

Instantaneously “H” at insertion of new drum

4-5

AL-1000/1010

6. PWB unit

(1)

(2)

(5)

(8)

(6)

(4)

(3)

(7)

No. Name Function

(1) Exposure lamp invertor PWB Exposure lamp (Xenon lamp) control (2) Main PWB (MCU) Copier control (3) Operation PWB Operation input/display (4) Power PWB AC power input, DC voltage control, High voltage control (5) CCD sensor PWB For image scanning (6) LSU motor PWB For polygon motor drive (7) TCS PWB For toner sensor control (8) LSU PWB For laser control

4-6

7. Cross sectional view

AL-1000/1010

(2)

(1)

(5)

(3)

(4)

(6)

(15)

(14)

(13)

(7) (8)

(9)

(10)

(11)

(12)

No. Part name Function and operation

(1) Scanner unit (2) Exposure lamp Exposure lamp (Xenon lamp) Illuminates original

(3) Lens unit Scans the original image with the lens and the CCD. (4) LSU (Laser unit) Converts the original image signal into laser beams and writes onto the drum. (5) Paper exit roller Roller for paper exit (6) Main charger Provides negative charges evenly to the drum surface. (7) Heat roller Fuses toner on the paper. (Teflon roller) (8) Pressure roller Fuses toner on the paper. (Silicon rubber roller)

(9) Drum Forms images. (10) Transfer unit Transfers images onto the drum. (11) Pickup roller Picks up the manual feed paper. (In multi feed only)

(12)

(13) (14) PS roller unit Takes synchronization between the lead edge and the rear edge of the paper.

(15) Paper feed roller Picks up a sheet of paper from the cassette.

Manual paper feed tray

Manual paper feed roller

Illuminates the original with the copy lamp and passes the reflected light to the lens unit (CCD).

Tray for manual feed paper

Transport the paper from the manual paper feed port.

4-7

AL-1000/1010

[5] UNPACKING AND INSTALLATION

1. A WORD ON COPIER INSTALLATION

Improper installation may damage the copier. Please note the following during initial installation and whenever the copier is moved.

Do not install your copier in areas that are:

● damp, humid, or very dusty

● exposed to direct sunlight

● subject to extreme temperature or humidity changes, e.g.,

near an air conditioner or heater.

Be sure to allow the required space around the machine for servicing and proper ventilation.

8"(20cm)

● poorly ventilated

4" (10cm)

(10cm)

2. CHECKING PACKED COMPONENTS AND ACCESSORIES

Open the carton and check if the following components and accessories are included.

Power cord

Operation manual

Copier

TD cartridge

5-1

Drum cartridge

(installed in copier)

AL-1000/1010

3. UNPACKING

Unpack the copier and carry it to the installation location by holding the handles on both sides of the copier.

4. REMOVING PROTECTIVE PACKING MATERIALS

(1) Remove pieces of tape (a), (b), (c), (d), (e), (f), (g) and (h)

and protective cover (i). Then open the original cover and remove protective materials (j) and (k).

(2) Remove the CAUTION tape from the front cover and

remove the two protective pins from the fusing unit by pulling the strings upward one at a time.

CAUTION tape

Protective pins

(3) Push gently on both sides of the front cover to open the

cover.

(2) Use a coin (or suitable object) to remove the screw.

Store the screw in the paper tray because it will be used if the copier has to be moved.

5. INSTALLING THE TD CARTRIDGE

(1) Open the side cover while pressing the side cover open

button.

(4) Remove the TD cartridge from the bag. Remove the

protective paper. Hold the cartridge on both sides and shake it horizontally four or five times.

(5) Hold the tab of the protective cover and pull the tab to your

side to remove the cover.

(6) Gently insert the TD cartridge until it locks in place, while

pushing the lock button.

Lock button

5-2

AL-1000/1010

(7) Close the front cover and then the side cover by pressing

the round projections near the side cover open button.

6. LOADING COPY PAPER (installing the paper tray)

(1) Raise the handle of the paper tray and pull the paper tray

out until it stops.

(4) Adjust the paper guides on the paper tray to the copy paper

width and length.Squeeze the lever of paper guide (A) a and slide the guide to match with the width of the paper. Move paper guide (B) to the appropriate slot as marked on the tray.

Paper guide (B)

(5) Fan the copy paper and insert it into the tray. Make sure

the edges go under the corner hooks.

Paper guide (A)

(2) Remove the pressure plate lock. Rotate the pressure plate

lock in the direction of the arrow to remove it while pressing down the pressure plate of the paper tray.

(3) Store the pressure plate lock which has been removed in

step 2 and the screw which has been removed when unpacking (see page 5-2, step 2 of REMOVING PROTECTIVE PACKING MATERIALS) in the front of the paper tray. To store the pressure plate lock, rotate the lock to fix it on the relevant location.

(6) Gently push the paper tray back into the copier.

7. PLUGGING IN THE COPIER

(1) Ensure that the power switch of the copier is in the OFF

position. Insert the attached power cord into the power cord socket at the rear of the copier.

Pressure plate lock

Screw

(2) Plug the other end of the power cord into the nearest outlet.

5-3

[6] Printing process

(1) Functional diagram

An OPC drum is used for the photoconductor. (Structure of the OPC drum layers)

Main charger

AL-1000/1010

OPC layer (20microns thick) Pigment layer (0.2 to 0.3 microns thick) Aluminium drum

(Basic operation cycle)

Laser beam

MG roller

Main high voltage unit

Cleaning blade

Drum

Transfer unit

Resist roller

Semiconductor laser

Focus correction lens

Exposure

To face down tray

Saw tooth

Cleaning blad e

Waste toner box

Paper release Fusing

Heat roller

Heater lamp

Cleaning

Separation

Electrode

Charge

6-1

Drum

Transfer

Transfer charger

Transfer high voltage unit

Developing

Cassette

paper feed

Synchronization

with drum

Toner

Developer

PS roller

Manu al feed

Pr int proces s

Paper transport route

AL-1000/1010

(2) Outline of print process

This printer is a non-impact printer that uses a semiconductor laser and electrostatic print process. This printer uses an OPC (Organic Photo Conductor) for its photoconductive material. First, voltage from the main corona unit charges the drum surface and a latent image is formed on the drum surface using a laser beam. This latent image forms a visible image on the drum surface when toner is applied. The toner image is then transferred onto the print paper by the transfer corona and fused on the print paper in the fusing section with a combination of heat and pressure.

Step-1: Charge Step-2: Exposure

∗ Latent image is formed on the drum.

Step-3: Developing

Latent image formed on the drum is then changed into visible image with toner.

Step-4: Transfer

The visible image (toner image) on the drum is transfered onto the print paper.

Step-5: Cleaning

Residual toner on the drum surface is removed and collected by the cleaning blade.

Step-6: Optical discharge

Residual charge on the drum surface is removed, by semiconductor laser beam.

Semiconductor laser

Exposure (semiconductor laser)

Drum surface charge sfter the exposure

Non-image area Image area

OPC layer

Pigment layer

Aluminum drum

OPC layer

Pigment layer

Aluminum layer

(3) Actual print process

Step-1: DC charge

A uniform negative charge is applied over the OPC drum surface by the main charging unit. Stable potential is maintained by means of the Scorotron charger. Positive charges are generated in the aluminum layer.

About

DC5.5KV

(–580V/–400V)

Step-3: Developing (DC bias)

A bias potential is applied to the MG roller in the two component magnetic brush developing method, and the toner is charged negative through friction with the carrier. Non-image area of the drum surface charged with negative potential repel the toner, whereas the laser exposed portions where no negative charges exist, attract the toner. As a result, a visible image appears on the drum surface.

: Carrier (Magnetized particle) : Toner (Charge negative by friction) (N) (S) :Permanent magnet (provided in three locations)

Step-2: Exposure (laser beam, lens)

A Laser beam is generated from the semiconductor laser and controlled by the print pattern signal. The laser writes onto the OPC drum surface through the polygon mirrors and lens. The resistance of the OPC layer decreases for an area exposed by the laser beam (corresponding to the print pattern signal). The beam neutralizes the negative charge. An electrostatic latent image is formed on the drum surface.

6-2

–400V ± 8V

MG roller

AL-1000/1010

Non-image area

-600

Drum surface potential

-400

Developing bias

Image area

Residual potential (-50 to -100V)

Charge Exposure Developing Transfer

Toner at tract potential

Time

Charge

Discharge

Toner is attracted over the shadowed area because of the developing bias.

Step-4: Transfer

The visible image on the drum surface is transferred onto the print paper by applying a positive charge from the transfer corona to the backside of the print paper.

Step-7: Optical discharge (Semiconductor laser)

Before the drum rotation is stopped, the semiconductor laser is radiated onto the drum to reduce the electrical resistance in the OPC layer and elimate residual charge, providing a uniform state to the drum surface for the next page to be printed. When the electrical resistance is reduced, positive charges on the aluminum layer are moved and neutralized with negative charges on the OPC layer.

Semiconductor laser

Charge by the Scorotron charger Function

The Scorotron charger functions to maintain the surface potential of the drum even at all times which. It is used to control the surface potential regardless of the charge characteristics of the photoconductor.

Basic function

A screen grid is placed between the saw tooth and the photoconductor. A stable voltage is added to the screen grid to maintain the corona current on the photoconductor. As the photoconductor is charged by the saw tooth from the main corona unit, the surface potential increases. This increases the current flowing through the screen grid. When the photoconductor potential nears the grid potential, the current turns to flow to the grid so that the photoconductor potential can be maintained at a stable level.

About DC 5.2kV

Step-5: Separation

Since the print paper is charged positively by the transfer corona, it is discharged by the separation corona. The separation corona is connected to ground.

Step-6: Cleaning

Toner remaining on the drum is removed and collected by the cleaning blade. It is transported to the waste toner collecting section in the cleaning unit by the waste toner transport roller.

Process controlling Function

The print pattern signal is converted into an invisible image by the semiconductor laser using negative to positive (reversible) developing method. Therefore, if the developing bias is added before the drum is charged, toner is attracted onto the drum. If the developing bias is not added when the drum is charged, the carrier is attracted to the drum because of the strong electrostatic force of the drum. To avoid this, the process is controlled by adjusting the drum potential and the grid potential of the Scorotron charger.

Basic function

Voltage added to the screen grid can be selected, high and low. To make it easily understood, the figure below shows voltage transition at the developer unit.

START STOP

Toner attract potenti al

Low

High

Print potentioal

Developing bias

Drum potential

Time

6-3

AL-1000/1010

Start

1) Because the grid potential is at a low level, the drum poten-

tial is at about –400V. (Carrier may not be attracted though the carrier is pulled towards the drum by the electrostatic force of –400V.

2) Developing bias ( –400V) is applied when the photoconduc-

tor potential is switched from LOW to HIGH.

3) Once developing bias (–400V) is applied and the photo con-

ductor potential rises to HIGH, toner will not be attracted to the drum.

Stop

The reverse sequence takes place. Retaining developing bias at an abnormal occurrence

Function

The developing bias will be lost if the power supply was removed during print process. In this event, the drum potential slightly abates and the carrier makes deposits on the drum because of strong static power. To prevent this, the machine incorporates a function to retain the developing bias for a certain period and decrease the voltage gradually against possible power loss.

Basic function

Normally, the developing bias voltage is retained for a certain time before the drum comes to a complete stop if the machine should stop before completing the normal print cycle. The developing bias can be added before resuming the operation after an abnormal interruption. Therfore, carrier will not make a deposit on the drum surface.

6-4

[7] OPERATIONAL DESCRIPTIONS

(1) Outline of operation

The outline of operation is described referring to the basic configuration.

(Basic configuration)

AL-1000/1010

Operation

section

Printer section

Scanner section

MCU (Main control/image process section)

LSU (Laser unit) Laser diode, Polygon mirror lens

Laser beam

Process section

Cassette paper

feed section

CCD

Paper exit

Fusing section

Paper transport section

Manual paper

feed section

Outline of copy operation

Setting conditions

1) Set copy conditions such as the copy quantity and the copy density with the operation section, and press the COPY button. The information on copy conditions is sent to the MCU.

Image scanning

2) When the COPY button is pressed, the scanner section starts scanning of images. The light from the copy lamp is reflected by the document and passed through the lens to the CCD.

Photo signal/Electric signal conversion

3) The image is converted into electrical signals by the CCD circuit and passed to the MCU.

Image process

4) The document image signal sent from the CCD circuit is processed under the revised conditions and sent to the LSU (laser unit) as print data.

Electric signal/Photo signal (laser beam) conversion

5) The LSU emits laser beams according to the print data. (Electrical signals are converted into photo signals.)

6) The laser beams are radiated through the polygon mirror and various lenses to the OPC drum.

Printing

7) Electrostatic latent images are formed on the OPC drum according to the laser beams, and the latent images are developed to be visible images (toner images).

8) Meanwhile the paper is fed to the image transfer section in synchronization with the image lead edge.

9) After the transfer of toner images onto the paper, the toner images are fused to the paper by the fusing section. The copied paper is discharged onto the exit tray.

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AL-1000/1010

(2) Scanner section

1) How to scan documents

The scanner has sensors that are arranged in a line. These sensors scan a certain area of a document at a time and deliver outputs sequentially. When the line is finished, the next line is scanned, and this procedure is repeated. The figure below shows the case where the latter two sections of an image which are scanned are shown with solid lines and the former two sections which are being transmitted are shown with dotted lines. The direction of this line is called “main scanning direction,” and the scanning direction “sub scanning direction.” In the figure above, one line is divided into 4 sections. Actually, however, one line is divided into thousands of sections. For scanning, the light receiving element called CCD is used. The basic resolution indicates the scanner capacity. The basic resolution is expressed in dpi (dot/inch) which shows the number of light emitting elements per inch on the document. The basic resolution of this machine is 400dpi. In the sub scanning direction, at the same time, the motor that drives the optical system is controlled to scan the image at the basic resolution.

Main scanning direction

5 4 3 2

Sub scanning direction

Sensor scanning area

Original

Image data sent to the ICU PWB

To MCU PWB

2) Basic structure of scanner section

(1)

(11)

(4)

(7)

1 Copy lamp (Xenon lamp) 2 Reflector (light conversion plate) 3 No. 1 mirror 4 No. 2 mirror 5 No. 3 mirror 6 Lens 7 No. 2/3 mirror unit 8 Copy lamp unit 9 CCD

10 Mirror motor 11 MHPS (Mirror home position sensor)

The scanner unit performs scanning in the digital optical system. The light from the light source (Xenon lamp) is reflected by a document and passed through three mirrors and reduction lenses to the CCD element (image sensor) where images are formed. This system is known as the reduction image sensor system. Photo energy on the CCD element is converted into electrical signals (analog signals). (Photo-electric conversion). The output signals (analog signals) are converted into digital signals (A/D conversion) and passed to the MCU (main control/image process section). The resolution at that time is 400dpi. The mirror unit in the scanner section is driven by the mirror motor. The MHPS is provided to detect the home position of the copy lamp unit.

(2)

(3)

(8)

(6)(5)

(9)

(10)

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AL-1000/1010

(3) Laser unit

The image data sent from the MCU (image process circuit) is sent to the LSU (laser unit), where it is converted into laser beams.

1) Basic structure

The LSU unit is the writing section of the digital optical system. The semiconductor laser is used as the light source, and images are formed on the OPC drum by the polygon mirror and fθ lens, etc. The laser beams are passed through the collimator lens, the cylindrical lens, the polygon mirror, the fθ lens, and the mirror to form images on the OPC drum in the main scanning direction. The laser emitting PWB is provided with the APC (auto power control) in order to eliminate fluctuations in the laser power. The BF PWB works for measurement of the laser writing start point.

(3)

(5)

No. Component Function

(1) Semiconductor laser Generates laser beams. (2) Collimator lens

Polygon mirror,

(3)

polygon motor BD (Mirror, lens,

(4)

PWB)

(5) fθ lens

(1)(2)

(4)

: Laser beam

path for BF PWB

Converges laser beams in parallel.

Reflects laser beams at a constant rpm.

Detects start timing of laser scanning.

Converges laser beams at a spot on the drum.

Makes the laser scanning speeds at both ends of the drum same as each other. (Refer to the figure below.)

2) Laser beam path

3) Composition

Effective scanning width: 216mm (max.) Resolution: 600dpi Beam diameter: 75um in the main scanning

direction, 80um in the sub scanning direction

Image surface power:

Polygon motor section:

0.20 ±0.03mW (Laser wavelength 780 – 795nm)

Brushless motor 20.787rpm No. of mirror surfaces: 6 surfaces

Makes the laser scanning speeds at both ends of the drum same as each other.

a ≠ b ≠ c

ab c

LENS

d = e = f

def

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AL-1000/1010

Fuser section

1. General description

General block diagram (cross section)

Thermal fuse

Separator pawl

PPD2

B. Separator pawl

Three separator pawls are used on the upper heat roller. The separator pawls are teflon coated to reduce friction with the roller and prevent a smear on the paper caused by the separator pawl.

C. Thermal control

1. The heater lamp, thermistor, main PWB, DC power supply PWB, and triac within the power supply unit are used to control the temperature in the fuser unit. To prevent against abnormally high temperature in the fuser unit, a thermal breaker and thermal fuse are used for safety purposes.

Heated by the

hea ter lam p.

(950W )

Safety dev ice

(therma l breaker, therm al

fuse)

Triac (in the power supply unit)

The surface temperature

of the upp er heat roller

is sensed by the thermisto r.

Level of the thermistor is controlled by the main PWB.

Thermistor

Heat roller

Paper guide

Pressure roller

Top view

Thermal fuse

Heater lamp

Heat roller

Thermistor

Separator pawl

A. Heat roller

A pressure roller is used for the heat roller and a silicone rubber roller is used for the lower heat roller for better toner fusing performance and paper separation.

With the signal from the main PWB, the triac is

controlled on and o ff.

(power supply PWB )

2. The surface temperature of the upper heat roller is set to 165˚C ∼ 190˚C. The surface temperature during the power save mode is set to 100˚C.

3. The self-check function comes active when one of the following malfunctions occurs, and an "H" is displayed on the multicopy window.

a. When the heat roller surface temperature rises above

240˚C.

b. When the heat roller surface temperature drops below

100˚C during the copy cycle. c. Open thermistor d. Open thermal fuse e. When the heat roller temperature does not reach 190˚C

within 27 second after supplying the power.

D. Fusing resistor

Fusing resistor

This model is provided with a fusing resistor in the fusing section to improve transfer efficiency. General descriptions are made in the following.

General descriptions

Since the upper heat roller is conductive when copy paper is highly moistured and the distance between the transfer unit and the fusing unit is short, the transfer current leaks through the copy paper, the upper heat roller and the discharging brush.

7-4

Paper feed section and paper transport section

1. Paper transport path and general operations

AL-1000/1010

(2)

(1)

(5)

(3)

(4)

(6)

(7) (8)

(9)

(10)

(11)

(13)

(15)

(1) Scanner unit (6) Main charger (11) Pickup roller (2) Copy lamp (7) Heat roller (12) Manual paper feed tray (3) Lens unit (8) Pressure roller (13) Manual paper feed roller (4) LSU (Laser unit) (9) Drum (14) PS roller unit (5) Paper exit roller (10) Transfer unit (15) Paper feed roller

Paper feed is made in two ways; the tray paper feed and the manual paper feed. The tray is of universal-type, and has the capacity of 250 sheets. The front loading system allow you to install or remove the tray from the front cabinet. The general descriptions on the tray paper feed and the manual paper feed are given below.

(14)

(12)

A. Cassette paper feed operation

1. The figure below shows the positions of the pick-up roller, the paper feed clutch sleeve, and the paper feed latch in the initial state without pressing the COPY button after lighting the ready lamp. The paper feed latch is in contact with the projection of the clutch sleeve.

2. When the COPY button is pressed, the main drive motor starts rotating to drive each drive gear. The pick-up drive gear also is driven at that time. Since, however, the paper feed latch is in contact with the projection of the clutch sleeve, rotation of the drive gear is not transmitted to the pick-up roller, which does not rotate therefore.

PFS

RRS

OFF

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