Sharp AR-F15, AR-PN4, AR-F16 Service Manual

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Page 1

SERVICE MANUAL

CODE: 00ZARF16//A2E

DIGITAL COPIER/PRINTER/ MULTIFUNCTIONAL SYSTEM OPTION FINISHER/PUNCH MODULE

AR-F15

AR-F16

AR-F15 AR-F16

AR-PN4

CONTENTS

CHAPTER 1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

CHAPTER 2 FINISHER UNIT BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . 2-1

CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION . . . . . . . . . . . . . . . 3-1

CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION . . . . . . . . . . . . 4-1

CHAPTER 5 MECHANICAL CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . 5-1

MODEL

AR-PN4

CHAPTER 6 MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . 6-1

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

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

NOTE: This manual is based on the AR-F11/F12/PN3 manuals.

The sections marked with or are different sections from the AR-F11/F12/PN3 manuals.

Parts marked with “ ” are important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safety and performance of the set.

F15/F16

PN4

SHARP CORPORATION

This document has been published to be used for after sales service only. The contents are subject to change without notice.

Page 2

General Precautions for Installation/Servicing/Maintenance for the Finisher

AR-F15/F16, Hole punch unit AR-PN4

The installation and service should be done by a qualified service technician.

When installing the Finisher AR-F15/F16, Hole punch unit AR-PN4 to the Plain Paper Copier, be sure to follow the instructions described in the “Unpacking/Set-Up Procedure for the AR-F15/F16/AR-PN4” booklet which comes with each unit of the AR-F15/F16/AR-PN4.

2. The AR-F15/F16, AR-PN4 should be installed by an authorized/qualified person.

3. Before starting installation, servicing or maintenance work, be sure to turn off and unplug the copier first.

4. When selecting the installation site, avoid placing the AR-F15/F16 and copier on different levels or inclined floors.

5. When servicing or maintaining the AR-F15/F16/AR-PN4, be careful about the rotating or operation sections such as gears, pulleys, sprockets, cams, belts, etc.

When parts are disassembled, reassembly is the reverse of disassembly unless otherwise noted in this manual or other related materials. Be careful not to reassemble small parts such as screws, washers, pins, E-rings, toothed washers to the wrong places.

7. Basically, the machine should not be operated with any parts removed or disassembled.

Delicate parts for preventing safety hazard problems (such as breakers, thermofuses, fuses, door switches, sensors, etc. if any) should be handled/installed/ adjusted correctly.

9. Use suitable measuring instruments and tools.

10. During servicing or maintenance work, be sure to check the serial No. plate and other cautionary labels (if any) to see if they are clean and firmly fixed. If not, take appropriate actions.

11. The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband, because the ICs on it may be damaged due to static electricity. Before using the wrist band, pull out the power cord plug of the copier and make sure that there is no uninsulated charged objects in the vicinity.

12. For the recovery and disposal of used AR-F15/F16/AR-PN4s, consumable parts, packing materials, used batteries, and RAM-ICs including lithium batteries, it is recommended that the relevant local regulations/rules.

13. After completing installation, servicing and maintenance of the AR-F15/F16/AR-PN4, return the AR-F15/F16/AR-PN4 to its original state, and check operation.

14. When you move the finisher, do not move it in the direction of the arrow as shown in the figure below otherwise it might fall down.

Page 3

INTRODUCTION

This Service Manual contains basic data and figures for the Finisher (AR-F15)/Saddle

Finisher (AR-F16) needed to service the machine in the field.

This manual comprises the following chapters:

Chapter 1 “General Description” introduces the finisher’s features, specifications, and

names of parts, and shows how to operate the finisher.

Chapter 2 “Finisher Unit Basic Operation” discusses the principles of operation used for

the finisher mechanical and electrical systems. It also explains the timing at which these systems are operated.

Chapter 3 “Saddle Finisher Unit Basic Operation” discusses the principles of operation

used for the saddle stitch unit’s mechanical and electrical systems. It also explains the timing at which these systems are operated.

Chapter 4 “Puncher (option) Unit Basic Operation” discusses the principles of operation

used for the puncher unit’s mechanical and electrical systems. It also explains the timing at which these systems are operated.

Chapter 5 “Mechanical System” discusses how the finisher is constructed mechanically,

and shows how it may be disassembled/assembled and adjusted.

Chapter 6 “Maintenance and Inspection” provides tables of periodically replaced parts

and consumables and durables, together with a scheduled servicing chart.

Chapter 7 “Troubleshooting” shows how to troubleshoot possible faults and gives electri-

cal parts arrangement diagrams, LED/check pin diagrams by PCB, and self diagnosis tables.

“Appendix” contains diagrams showing tables of signals, overall circuit diagrams and tables of solvents/oils.

Descriptions regarding installation are not mentioned in this Service Manual as the Finisher (AR-F15)/Saddle Finisher (AR-F16)’s packing boxes contain Installation Procedures.

The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins.

All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins, and be able to identify and isolate faults in the machine.

Page 4

CHAPTER 1 GENERAL DESCRIPTION

CONTENTS

I. FEATURES ..................................1-1

II. SPECIFICATIONS .......................1-2

A. Finisher specifications

(AR-F15/F16) ...........................1-2

B. Punch unit specifications

(AR-PN4)..................................1-8

C. Engine specification

(AR-F15/F16/PN4) .................. 1-9

D. Cross Section......................... 1-11

III. Using the Machine.....................1-14

A. Removing Paper Jams from the

Finisher Unit ...........................1-14

B. Supplying the Finisher Unit with

Staples ...................................1-15

C. Removing Staple Jams from the

Finisher Unit ...........................1-17

D. Removing Paper Jams from the

Saddle Stitch Unit

(Saddle Finisher) .................... 1-18

E. Supplying the Saddle Stitch

Unit with Staples

(Saddle Finisher) .................... 1-20

F. Removing Staple Jams from the

Saddle Stitch Unit

(Saddle Finisher) .................... 1-21

G. Removing Paper Jams from the

Puncher Unit (option) .............1-23

H. Removing Punched Scrap from

the Puncher Unit (option) .......1-25

IV. MAINTENANCE BY THE

USER ........................................1-26

A. Maintenance by the User .......1-26

I. BASIC OPERATION ....................2-1

A. Outline......................................2-1

B. Outline of Electrical Circuitry .... 2-2

C. Inputs to and Outputs from the

Finisher Controller PCB ...........2-4

II. FEED/DRIVE SYSTEM .............2-10

A. Outline....................................2-10

B. Type of Delivery Paths............2-15

C. Feeding and Delivering ..........2-18

D. Job Offset...............................2-21

E. Staple Operation ....................2-24

F. Stapler Unit ............................ 2-32

G. Tray Operation ........................ 2-38

H. Detecting the Height of

Stack on the Tray ....................2-40

I. Shutter Operation...................2-42

J. Buffer Path Operation............. 2-46

K. Detecting Jams ......................2-51

III. POWER SUPPLY SYSTEM.......2-56

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Page 5

iii

I. BASIC OPERATION ....................3-1

A. Outline ...................................... 3-1

B. Electrical Circuitry ....................3-2

C. Inputs to and Outputs from the

Saddle Stitch Controller PCB ...3-3

II. FEEDING/DRIVE SYSTEM ......... 3-8

A. Outline ...................................... 3-8

III. PAPER OUTPUT

MECHANISM.............................3-14

A. Outline .................................... 3-14

B. Controlling the Inlet

Flappers .................................3-17

C. Controlling the Movement of

Sheets .................................... 3-21

D. Aligning the Sheets ................3-23

E. Controlling the Phase of the

Crescent Roller ......................3-26

IV. STITCHING SYSTEM ............... 3-28

V. FOLDING/DELIVERY

SYSTEM....................................3-31

VI. CHECKING FOR A JAM ...........3-38

VII. POWER SUPPLY ......................3-43

CHAPTER 3 SADDLE STITCH UNIT

BASIC OPERATION

I. BASIC OPERATION ....................4-1

A. Outline...................................... 4-1

B. Inputs to and Outputs from

Punch Driver PCB ....................4-2

II. PUNCH OPERATION ..................4-5

A. Outline......................................4-5

B. PUNCH OPERATION...............4-7

C. Horizontal Registration

Operation ...............................4-11

III. POWER SUPPLY SYSTEM.......4-14

CHAPTER 4 PUNCHER UNIT (OPTION)

BASIC OPERATION

CHAPTER 5 MECHANICAL CONSTRUCTION

I. FINISHER UNIT ..........................5-1

A. Externals and Controls............. 5-1

B. FEEDING SYSTEM .................5-9

C. PCBs ...................................... 5-15

II. SADDLE STITCH UNIT .............5-16

A. Externals and Controls........... 5-16

B. SADDLE UNIT .......................5-19

C. PCBs ...................................... 5-29

D. Accessory ..............................5-30

III. PUNCHER UNIT (OPTION) ...... 5-31

A. Externals and Controls ...........5-31

B. Puncher Driver System ..........5-32

C. PCBs......................................5-43

Page 6

I. PERIODICALLY REPLACED

PARTS .........................................6-1

A. Finisher Unit .............................6-1

B. Saddle Stitch Unit ....................6-1

C. Puncher Unit (option) ............... 6-1

II. CONSUMABLES AND

DURABLES .................................6-2

A. Finisher Unit .............................6-2

III. Consumable parts replacement

procedures ..................................6-3

A. Paddle replacement .................6-3

B. Knurled belt replacement .........6-4

IV. PERIODICAL SERVICING ........6-10

CHAPTER 7 TROUBLESHOOTING

I. ADJUSTMENTS ..........................7-1

A. Electrical System

(finisher unit) ............................ 7-1

B. Electrical System

(saddle stitch unit) ....................7-5

C. Electrical System

(puncher unit (option)) .............. 7-7

II. ARRANGEMENT OF

ELECTRICAL PARTS .................. 7-9

A. Finisher Unit .............................7-9

B. Saddle Stitch Unit ..................7-16

C. Puncher Unit (option) ............. 7-22

D. Light-Emitting Diodes (LED)

and Check Pins by PCB .........7-26

III. TROUBLESHOOTING...............7-28

A. Finisher Unit ...........................7-28

B. Saddle Stitch Unit ..................7-38

C. Puncher Unit (option) .............7-45

CHAPTER 6 MAINTENANCE AND INSPECTION

APPENDIX

A. FINISHER UNIT GENERAL

TIMING CHART.......................... A-1

B. SADDLE STITCH UNIT

GENERAL TIMING CHART........ A-2

C. PUNCHER UNIT (option)

GENERAL TIMING CHART........ A-3

D. SIGNAL AND

ABBREVIATIONS ....................... A-4

E. ACTUAL WIRING CHART .......... A-6

F. SOLVENTS AND OILS ............. A-13

Page 7

CHAPTER 1

GENERAL DESCRIPTION

I. FEATURES ..................................1-1

II. SPECIFICATIONS .......................1-2

A. Finisher specifications

(AR-F15/F16) ............................. 1-2

B.Punch unit specifications

(AR-PN4) ...................................1-8

C. Engine specification

(AR-F15/F16/PN4) .................... 1-9

D. Cross Section ..........................1-11

III. Using the Machine.....................1-14

A. Removing Paper Jams from the

Finisher Unit............................. 1-14

B. Supplying the Finisher Unit with

Staples ..................................... 1-15

C. Removing Staple Jams from the

Finisher Unit............................. 1-17

D. Removing Paper Jams from the

Saddle Stitch Unit

(Saddle Finisher) ..................... 1-18

E. Supplying the Saddle Stitch

Unit with Staples

(Saddle Finisher) ..................... 1-20

F. Removing Staple Jams from the

Saddle Stitch Unit

(Saddle Finisher) ..................... 1-21

G. Removing Paper Jams from the

Puncher Unit (option) ............... 1-23

H. Removing Punched Scrap from

the Puncher Unit (option) ......... 1-25

IV. MAINTENANCE BY THE

USER ........................................1-26

A. Maintenance by the User ......... 1-26

Page 8

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CHAPTER 1 GENERAL DESCRIPTION

1-1

I. FEATURES

1. Accommodates large quantities of sheets

• Normally, the finisher holds a stack of sheets 250 mm in height in its two bins (small-size paper: equivalent to 2000 sheets)/140 mm in height (large-size paper: equivalent to 1000 sheets)

2. Has high paper transportation performance

• The finisher is capable of handling papers between 60 and 256 gm/m².

3. Offers a job offset function

• The finisher has a job offset function for sorting non-stapled stacks of copies.

4. Offers four types of auto stapling

• The finisher offers a choice of four stapling modes (1-point stapling at rear, diagonal stapling at front, diagonal stapling at rear, 2-point stapling).

5. Uses a buffer roller

• The use of a buffer roller enables the finisher to accept copies without interruption from the host machine even during stapling or offset operation.

6. Has a saddle stitch function (Saddle Finisher AR-F16)

• The finisher can staple along the center of paper and fold it in two (up to 15 sheets).

7. Offers a punch function (option)

• The use of the puncher unit enables the finisher to punch sheets for binders before they are output. (The puncher unit is capable of handling papers between 60 and 256 gm/m². It cannot handle special paper, postcards and transparencies.)

8. Insert function (option)

• Enable the use of special type of paper and printed paper in addition to the staple sorting or the hole punching mode (Available when the optional staple sorting and the hole punching mode units are installed.) This paper is not run through fuser (heat).

ITEM MODEL NOTE

Finisher

AR-F15 AR-F16 Saddle stitch finisher

Punch unit

AR-PN4A 2 holes (φ6.5) Europe AR-PN4B 2 holes/3 holes automatic selection(φ8.0) North America AR-PN4C 4 holes (φ6.5) (80mm pitch) France AR-PN4D 4 holes (φ6.5) (70, 21mm pitch) Sweden

7 Stapler for Finisher

5000 staples

Staple cartridge x3

5000 x 3 SF-SC11 20

Cartridge for AR-F15/16

Common with S55,S55N,FN8/9

8 Stapler for Saddle

Stitch 2000 staples

Staple cartridge x3

2000 x 3 AR-SC3 40

For AR-F16 (Saddle Stitch Finisher)

Common with FN9

F15/F16

PN4

F15/F16

Page 10

CHAPTER 1 GENERAL DESCRIPTION

1-2

II. SPECIFICATIONS

A. Finisher specifications (AR-F15/F16)

1. Finisher (AR-F15)

(1) Stack section

Type Floor installation Stacking method Upper/Lower tray: Ascent/descent type offset tray Transport speed 55 to 70 sheet/minute Tray type Upper/Lower Tray Ascent/descent type offset tray Output paper size AB series A4, B5, A5R, 16K, A3, B4, A4R, B5R, 8K, 16KR

Inch series 8.5 x 11, 5.5 x 8.5R, 11 x 17, 8.5 x 14, 8.5 x 13,

8.5 x 11R, 7.25 x 10.5R

Paper weight Plain paper: 60 to 105 g/m

Thick paper: 106 to 256 g/m

Paper transport reference

Center reference

Mode type Non-staple, staple Offset paper size A3, A4, A4R, B4, B5, 8K, 16K, 11 x 17, 8.5 x 14, 8.5 x 13, 8.5 x 11, 8.5 x 11R Offset volume 30mm Stacking performance Non-offset In horizontal direction: max. 30mm

In vertical direction: max. 50mm (In the non-staple mode on the offset tray)

Offset In horizontal direction:

15mm or less for a same set,

15mm or more between different sets Matching Max. deviation width 2.5mm Output paper capacity <Tray1 / Tray2>

Non-staple:

2000 sheets (250mm ± 7mm)

A4, B5, A5R, 16K, 8.5 x 11, 5.5 x 8.5R: 80g/m

1000 sheets (140mm ± 7mm)

A3, B4, A4R, B5R, 8K, 16KR, 11 x 17, 8.5 x 14, 8.5 x 13,

8.5 x 11R, 7.25 x 10.5R: 80g/m

Stacking limit:

Tray1: Stack capacity from Tray1 & Tray2 = less than 2000 sheets Tray2: Stack capacity from Tray2 = less than 2000 sheets

Staple:

110mm ± 7mm or 750 sheets or 100 sets

A4, B5, 8.5 x 11, 16K (S size)

74mm ± 7mm or 500 sheets or 100 sets

A3, B4, A4R, 11 x 17, 8.5 x 14, 8.5 x 13, 8.5 x 11R, 8K (L size)

Page 11

CHAPTER 1 GENERAL DESCRIPTION

1-3

(2) Staple section

Height of mixed load When power is turned

on. (When there is paper on the tray.)

29mm ± 7mm Equivalent to 150 sheets/50 sets

Size mixed load (No bind, mixed load)

74mm ± 7mm

Equivalent to 500 sheets Staple mixed load (Bind, mixed load)

74mm ± 7mm

Equivalent to 500 sheets/100 sets Mode mixed load (No bind / Bind, Mixed load)

29mm ± 7mm

Equivalent to 150 sheets

Paper detection Available Reliability MCBJ: Based on the main unit

MCBF: Based on the main unit

Life Based on the main unit Dimensions (W) 785 x (D) 630 x (H) 1150mm Occupied dimensions 1165 x 630mm (shifted 380mm for removal of misfed paper) Weight 51Kg Power source Supplied from main unit (DC24V, 3.0A) Power consumption 72W

Paper size to be stapled

One-point staple in the front (Slant staple)

A3, B4, A4, A4R, B5, 8K, 16K, 11 x 17, 8.5 x 14,

8.5 x 13, 8.5 x 11, 8.5 x 11R

One-pint staple at the back (Slant staple)

A3, B4, A4, B5, 8K, 16K, 11 x 17, 8.5 x 11

One-pint staple at the back

A4R, 8.5 x 14, 8.5 x 13, 8.5 x 11R

Two-point staple A3, B4, A4R, A4, B5, 8K, 16K, 11 x 17, 8.5 x 14,

8.5 x 13, 8.5 x 11, 8.5 x 11R

Stapling capacity S size: 50 sheets

L size: 30 sheets Mixed stapling: 30 sheets Max.: 2 sheets of 256g/ m²

paper + 48 sheets of 80g/ m² paper Staple load system Staple cartridge (5,000 staples) Staple empty detection Available Manual stapling Not available

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CHAPTER 1 GENERAL DESCRIPTION

1-4

: Jan. 9 2004

(Stapling position)

Staple in the front

* Stapling position when viewed with the

copy surface up

One-point staple at the back

One-point staple in the front (Slant staple)

Two-point staple

4.4 ± 2.5 mm

Paper transport direction

(30˚)

Paper width

A A4 Long 204.0 LG Long, LT Long 210.0

(6.0 ± 2.5 mm)

5.0 ± 2.5 mm

Paper transport direction

Paper width

A A3 Long, A4 Short 291.0 B4 Long, B5 Short 251.0 LD Long, LT Short 273.5

(6.0 ± 2.5mm)

4.0 ± 2.5 mm

Paper transport direction

Paper width

(30˚)

AB A3 / A4 83 ± 4 203 ± 4 B4 / B5 63 ± 4 183 ± 4 LD / LT 74 ± 4 194 ± 4 A4R 62.5 ± 4 138.5 ± 4 LT-R / LG 62.5 ± 4 144.5 ± 4 8K / 16K

69.5 ± 4 189.5 ± 4

Paper transport direction

5.0 ± 4 mm

Paper width

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CHAPTER 1 GENERAL DESCRIPTION

1-5

: Jan. 9 2004

2. Saddle stitch finisher (AR-F16)

(1) Stack section

Type Floor installation Stacking method Upper/Lower tray: Ascent/descent type offset tray Transport speed 55 to 70 sheets/minute Tray type Upper/Middle Tray Ascent/descent type offset tray

Lower Tray Book tray for saddle stitch

Output paper size AB series A4, B5, A5R, 16K, A3, B4, A4R, B5R, 8K, 16KR

Inch series 8.5 x 11, 5.5 x 8.5R, 11 x 17, 8.5 x 14, 8.5 x 13,

8.5 x 11R, 7.25 x 10.5R

Paper weight Plain paper: 60 to 105 g/m

Thick paper: 106 to 256 g/m

Paper transport reference

Center reference

In vertical direction: max. 50mm (In the non-staple mode on the offset tray)

Offset In horizontal direction:

15mm or less for a same set,

15mm or more between different sets Matching Max. deviation width 2.5mm Output paper capacity

<Tray1 / Tray2> Non-staple:

Equivalent to 2000 sheets (250mm ± 7mm)

A4, B5, A5R, 16K, 8.5 x 11, 5.5 x 8.5R: 80g/m

Equivalent to 1000 sheets (140mm ± 7mm)

A3, B4, A4R, B5R, 8K, 16KR, 11 x 17, 8.5 x 14, 8.5 x 13,

8.5 x 11R, 7.25 x 10.5R: 80g/m

Stacking limit:

Tray1: Stack capacity from Tray1 & Tray2 = less than 2000 sheets Tray2: Stack capacity from Tray2 = less than 2000 sheets

Staple:

110mm ± 7mm or equivalent to 750 sheets or 100 sets

A4, B5, 8.5 x 11, 16K

74mm ± 7mm or equivalent to 500 sheets or 100 sets

A3, B4, A4R, 11 x 17, 8.5 x 14, 8.5 x 13, 8.5 x 11R, 8K

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CHAPTER 1 GENERAL DESCRIPTION

1-6

: Jan. 9 2004

(2) Staple section

(3) Saddle stitch section (Non-printed area in the center of paper)

Height of mixed load When power is turned on29mm ± 7mm

Equivalent to 150 sheets/50 sets

Size mixed load (No bind, mixed load)

74mm ± 7mm Equivalent to 500 sheets

Staple mixed load (Bind, mixed load)

74mm ± 7mm Equivalent to 500 sheets/100 sets

Mode mixed load (No bind / Bind, Mixed load)

29mm ± 7mm Equivalent to 150 sheets

Paper detection Available Reliability MCBJ: Based on the main unit

MCBF: Based on the main unit Life Based on the main unit Dimensions (W) 785 x (D) 630 x (H) 1150mm Occupied dimensions 1165 x 630mm (shifted 380mm for removal of misfed paper) Weight Saddle available: 71Kg Power source Supplied from main unit (DC24V, 3.0A) Power consumption 72W

Paper size to be stapled

One-point staple in the

front (Slant staple)

A3, B4, A4, A4R, B5, 8K, 16K, 11 x 17, 8.5 x 14,

8.5 x 13, 8.5 x 11, 8.5 x 11R

One-point staple at the

back (Slant staple)

A3, B4, A4, B5, 8K, 16K, 11 x 17, 8.5 x 11

One-point staple at the

back

A4R, 8.5x14, 8.5x13, 8.5x11R

Two-point staple A3, B4, A4R, A4, B5, 8K, 16K, 11 x 17, 8.5 x 14,

8.5 x 13, 8.5 x 11, 8.5 x 11R

Number of sheets stapled

S size: 50 sheets

L size: 30 sheets

Mixed stapling: 30 sheets

Max.: 2 sheets of 256g/ m² paper + 48 sheets of 80g/ m² paper Staple load type Staple cartridge type (5,000 staples) Staple empty detection Available Manual stapling Not available

Stitch method Center 2-position binding, bundle 2-folding Folding position Center folding (adjustment available) Saddle stitching paper

size

A3, A4R, B4, 8K, 11x17, 8.5x11R

Weight allowed for saddle stitching

60g/m

to 256g/m

One cover paper 1 sheet (Thick paper) 106 to 256 g/m

Page 15

CHAPTER 1 GENERAL DESCRIPTION

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: Jan. 9 2004

Number of sheets stapled

Max.: 15 sheets (256g/m2 1 sheet + 80g/m2 14 sheets)

Number of sets loaded 10 sets (11 to 15 sheets), 20 sets (6 to 10 sheets), 25 sets (1 to 5 sheets) Staple load type Staple cartridge type (2,000 staples) Staple empty detection Available Paper empty detection Available Binding position

* Binding position adjustment for paper center is available.

Image inhibit area The center margin of 4mm or more is required.

±1.0mm or less

AB A3 long 83.0 203.0 B4 long 63.0 183.0 A4 long 39.5 159.5 LD long 74.0 194.0 LT long 42.0 162.0 8K long 69.5 189.5

4mm or more

Page 16

CHAPTER 1 GENERAL DESCRIPTION

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: Jan. 9 2004

B. Punch unit specifications (AR-PN4)

*1 : Hole punch changes from three holes to two holes automatically.

(Kind of hole punch)

Finisher available for installation of the punch module

Finisher and saddle stitch finisher

Kind of hole punch 2-hole / 3-hole / 4-hole/ 4-hole (Broad space)

One of the above four punch unit can be attached.

Paper size to be punch 2-hole A3, A4, A4R, B4, B5, B5R, 11 x 17, 8.5 x 14,

8.5 x 13, 8.5 x 11, 8.5 x 11R, 8K, 16K, 16KR

3-hole *1

3-hole: A3, A4, 11 x 17, 8.5 x 11

2-hole: A4R, 8.5 x 11R 4-hole A3, A4 4-hole (Broad space)

A3, A4, A4R, B4, B5, B5R, 11 x 17, 8.5 x 14,

8.5 x 13, 8.5 x 11, 8.5 x 11R

Paper weight

60 to 256g/m

Life 1000K (80g/m2) Power consumption Supplied from finisher External dimensions W x D x H 95 x 560 x 170mm Weight About 3.5kg

Kind Hole position Hole size

2-hole A: 80 ± 1mm

B: 12 ± 3mm

φ6.5mm

3-hole A: 108 ± 1mm

B: 12 ± 3mm

φ8.0mm

4-hole A: 80 ± 1mm

B: 12 ± 3mm

φ6.5mm

4-hole (Broad space)

A: 70 ± 1mm B: 12 ± 3mm C: 21 ± 1mm

φ6.5mm

ABAA

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CHAPTER 1 GENERAL DESCRIPTION

1-9

. Engine specification (AR-F15/F16/PN4)

Staple position

(Media supported)

*1. China destination only *2. Only one sheet per one bundle.

Paper capacity 4000 sheets (small size), 2000 sheets (large size) Tray1/Tray2 Lift type tray

2000 sheets (small size: 80 g/m²) 1000 sheets (large size: 80 g/m²) Face-down Job offsetting Paper full detection Multi-position stapler (1 edge 3 positions) Stapling Time Less than 1.0 second (1 position) Stapling sheet capacity 50 sheets (small size: 80 g/m²)

30 sheets (large size: 80 g/m²) Staple quantity : 5000 staples Stapler type : Flat clinch

Tray3 (Only saddle stitch Finisher)

Saddle stitch tray Saddle stitch sheet capacity 15 sheets (60 pages)

Staple position The basic output pattern and staple position are showed in the

followings.

Punch (OPTION) Available paper width 182mm to 297mm (2 holes/2 to 3 holes)

270mm to 297mm (4 holes) Available paper length 182mm to 432mm

Tray # Mode Size Weight Tray 1 Tray 2

Face-down Non-staple mode

All supported sizes 60 to 256 g/m²

Offset mode 11 x 17, Legal, Letter, Letter-R,

Foolscap, B5, A4, A4R, B4, A3, 8K, 16K *1

60 to 256 g/m²

Staple mode 11 x 17, Legal, Letter, Letter-R,

Foolscap, B5, A4, A4R, B4, A3, 8K, 16K, 16KR *1

60 to 256 g/m²

Punch 11 x 17, Legal, Letter, Letter-R,

Executive-R, Foolscap, B5, B5R, A4, A4R, B4, A3

60 to 256 g/m²

Tray 3 Saddle stitch mode only A3, A4R, B4

Letter-R, 11 x 17, 8K *1

60 to 90 g/m² 90 to 256 g/m² *2

Paper exit direction

Back side of the paper

Page 18

CHAPTER 1 GENERAL DESCRIPTION

1-10

: Jan. 9 2004

(Combination of functions)

(Staple sheet capacity)

(Sheet capacity of stack trays)

*1. This mode is selected by key operator program *2. N is a number of sheets stacked at tray 2

NOTE: 180 degrees image rotation should be needed for staple mode. So all of the mode (including staple

mode) executes 180 degrees image rotation.

– Offset Staple Punch Saddle stitch

Offset – ✕❍✕ Staple ✕ – ❍✕ Punch ❍❍ – ✕ Saddle stitch ✕✕✕–

Size Capacity

50 sheetsA4 Letter Letter-R

30 sheets

A4R Legal Foolscap B4 A3 11 x 17 Saddle stitch 15 sheets (60 pages)

Select output mode *1

Cascade output mode Random output mode

Tray 1 2000 sheets (Max)

(2000 - N) sheets *2

Tray 2 2000 sheets 2000 sheets

Page 19

CHAPTER 1 GENERAL DESCRIPTION

1-11

D. Cross Section

1. Finisher Unit

Figure 1-204

[1] Tray 1/2 [10] Saddle stitch flapper [2] Shutter [11] Inlet feed roller [3] Delivery roller [12] Feed roller 1 [4] Swing guide [13] Vertical path [5] Feed roller 2 [14] Stapler [6] Height sensor [15] Feed belt [7] Wrap flapper [16] Tray lift motor [8] Buffer roller [17] Saddle stitch unit

(saddle finisher AR-F12)

[9] Buffer inlet flapper

[15][17][16] [14] [13] [12]

[1] [2] [3] [4] [5] [6] [8]

[7] [10] [11][9]

Page 20

CHAPTER 1 GENERAL DESCRIPTION

1-12

2. Saddle Stitch Unit

Figure 1-205

[1] Guide plate [7] No.1 flapper [2] Paper folding roller [8] No. 2 flapper [3] Delivery guide plate [9] Stitch mount [4] Holding roller [10] Paper pushing plate [5] Stitch (front, rear) [11] Crescent roller [6] Inlet roller [12] Paper positioning plate

[5]

[6]

[4] [3]

[2]

[1]

[12]

[11]

[10]

[9]

[8]

[7]

Page 21

CHAPTER 1 GENERAL DESCRIPTION

1-13

3. Puncher Unit (option)

Figure 1-206

[1] Punch motor [6] LED PCB [2] Cam [7] Horizontal registration motor [3] Hole puncher (Punch blade) [8] Scrap full detector PCB unit [4] Die [9] Punched scrap container [5] Photosensor PCB

[1]

[2]

[3]

[4]

[5] [6]

[7] [8]

[9]

Page 22

CHAPTER 1 GENERAL DESCRIPTION

1-14

III. Using the Machine

A. Removing Paper Jams

from the Finisher Unit

If the host machine indicates the finisher paper jam message, perform the following to remove the jam.

1) Holding the finisher unit as shown, move it to

detach it from the host machine.

Figure 1-301

2) Remove any jam visible from the outside.

Figure 1-302

3) Open the upper cover, and check the inside of the finisher.

Figure 1-303

4) Lift the buffer roller cover, and remove the jam.

Figure 1-304

5) Lift the buffer roller, and remove the jam.

Figure 1-305

Page 23

CHAPTER 1 GENERAL DESCRIPTION

1-15

: Jan. 9 2004

6) Return the buffer roller and the buffer roller cover to their original positions, and close the upper cover.

Figure 1-306

7) Connect the finisher to the host machine.

Figure 1-307

8) Operate as instructed on the display.

B. Supplying the Finisher

Unit with Staples

If the host machine indicates the finisher unit staple supply message, perform the following to supply it with staples.

1) Open the front cover.

Figure 1-308

Figure 1-309

3) When the staple cartridge has slightly slid

out, hold and pull it out.

Figure 1-310

2) Shift down the green lever.

Page 24

CHAPTER 1 GENERAL DESCRIPTION

1-16

: Jan. 9 2004

4) Hold the empty staple case on its sides, and slide it out.

Figure 1-311

5) Set a new staple case.

Figure 1-312

6) Pull the length of tape (used to hold the staples in place) straight out.

Figure 1-313

Figure 1-314

8) Check to make sure that the stapler has been locked in place, and close the front cover.

Figure 1-315

Reference:

You may set no more than one staple cartridge at a time. Make sure that the new cartridge is one specifically designed for the finisher unit.

7) Push in the stapler unit until the green lever returns to its original position.

Page 25

CHAPTER 1 GENERAL DESCRIPTION

1-17

: Jan. 9 2004

C. Removing Staple Jams

from the Finisher Unit

If the host machine indicates the finisher unit staple jam message, perform the following to remove the jam.

1) Remove the stack waiting to be stapled from

the delivery tray.

Figure 1-316

2) Open the front cover.

Figure 1-317

Figure 1-318

4) When the staple cartridge has slightly slid out, hold and pull it out.

Figure 1-319

5) Shift down the tab on the staple cartridge.

Figure 1-320

6) Remove all staples that have slid out of the staple case.

Figure 1-321

3) Shift down the green lever.

Page 26

CHAPTER 1 GENERAL DESCRIPTION

1-18

7) Return the tab on the staple cartridge to its original position.

8) Return the staple cartridge to its original position, and close the front cover.

Figure 1-322

D. Removing Paper Jams

from the Saddle Stitch Unit (Saddle Finisher)

If the host machine indicates the saddle stitch unit paper jam message, perform the following to remove the jam.

1) Holding the saddle stitch unit as shown,

move it to detach it from the host machine.

Figure 1-323

2) Open the front lower cover.

Figure 1-324

Reference

When the cover has been closed, the stapler unit will automatically execute idle punching several times to advance the staples.

Page 27

CHAPTER 1 GENERAL DESCRIPTION

1-19

3) Turn the knob on the left side.

Figure 1-325

4) Turn the knob on the right side while pushing it in.

Figure 1-326

5) Remove the jam.

Figure 1-327

6) Open the inlet cover, and remove the jam.

Figure 1-328

7) Close the front lower cover.

Figure 1-329

8) Connect the finisher unit.

9) Operate as instructed on the display.

Page 28

CHAPTER 1 GENERAL DESCRIPTION

1-20

E. Supplying the Saddle

Stitch Unit with Staples (Saddle Finisher)

If the host machine indicates the saddle stitch

unit staple supply message, perform the following to supply it with staples.

1) Open the front lower cover.

Figure 1-330

2) Slide out the stitch unit.

Figure 1-331

3) Pull the stitch unit to the front once, and then shift it up.

Figure 1-332

4) Hold the empty cartridge on its sides, and remove it.

Figure 1-333

5) Set a new cartridge.

Figure 1-334

Reference

You must always replace both cartridges at the same time.

Page 29

CHAPTER 1 GENERAL DESCRIPTION

1-21

6) Pull the stitch to the front once, and then return it to its original position.

Figure 1-335

7) Push in the stitch unit, and close the front cover.

Figure 1-336

F. Removing Staple Jams

from the Saddle Stitch Unit (Saddle Finisher)

If the host machine indicates the saddle stitch unit staple jam message, perform the following to remove the jam.

1) Open the front lower cover.

Figure 1-337

2) Slide out the stitch unit.

Figure 1-338

3) Pull the stapler of the stitch unit to the front

once, and then shift it up.

Figure 1-339

Page 30

CHAPTER 1 GENERAL DESCRIPTION

1-22

4) Hold the cartridge on its sides, and remove it.

Figure 1-340

5) Push down on the area identified as A, and pull up the tab identified as B.

Figure 1-341

6) Remove the staple jam, and return the tab B to its original position.

Figure 1-342

7) Return the cartridge to its original position.

Figure 1-343

8) Pull the stitch of the stitch unit to the front once, and then return it to its original position.

Figure 1-344

9) Push the stitch unit back to its original position, and close the front lower cover.

Figure 1-345

Reference

Whenever you have removed a staple jam, be sure to execute staple edging.

Page 31

CHAPTER 1 GENERAL DESCRIPTION

1-23

G. Removing Paper Jams

from the Puncher Unit (option)

If the display indicates a paper jam on the puncher unit, perform the following to remove the jam:

1) Open the front cover of the puncher unit.

Figure 1-346

2) Align the triangle mark on the knob within

the range marked by .

Figure 1-347

3) Close the front cover of the puncher unit.

Figure 1-348

4) Holding the finisher unit as shown, move it to detach it from the most machine.

Figure 1-349

5) Remove any jam visible from the outside.

Figure 1-350

6) Open the upper cover, and check the inside of the finisher.

Figure 1-351

7) Lift the buffer roller cover, and remove the jam.

Figure 1-352

Page 32

CHAPTER 1 GENERAL DESCRIPTION

1-24

8) Return the buffer roller and the buffer roller cover to their original position, and close the upper cover.

Figure 1-353

9) Connect the finisher to the host machine.

Figure 1-354

10) Operate as instructed on the display.

Page 33

CHAPTER 1 GENERAL DESCRIPTION

1-25

H. Removing Punched Scrap

from the Puncher Unit (option)

If the display indicates a punched scrap full state on the puncher unit, perform the following to remove the punched scrap:

1) Open the front cover of the puncher unit.

Figure 1-355

2) Slide out the punched scrap container.

Figure 1-356

3) Discard the punched scrap.

Figure 1-357

4) Return the punched scrap container to its original position.

Figure 1-358

Page 34

CHAPTER 1 GENERAL DESCRIPTION

1-26

IV. MAINTENANCE BY THE USER

A. Maintenance by the User

Table 1-401

No. Item Timing

1 Replacing the staple cartridge (finisher unit) When the appropriate indication is made on

the host machine’s display.

Replacing the staple cartridge (saddle stitch unit)

Caution:

The finisher unit and the saddle stitch unit use different cartridge types. Be sure that the appropriate type is used for each.

Page 35

CHAPTER 2

FINISHER UNIT BASIC OPERATION

I. BASIC OPERATION ....................2-1

A. Outline ....................................... 2-1

B. Outline of Electrical Circuitry...... 2-2

C. Inputs to and Outputs from the

Finisher Controller PCB .............2-4

II. FEED/DRIVE SYSTEM .............2-10

A. Outline ..................................... 2-10

B. Type of Delivery Paths .............2-15

C. Feeding and Delivering ............2-18

D. Job Offset ................................2-21

E. Staple Operation ......................2-24

F. Stapler Unit ..............................2-32

G. Tray Operation ..........................2-38

H. Detecting the Height of

Stack on the Tray......................2-40

I. Shutter Operation ....................2-42

J. Buffer Path Operation ..............2-46

K. Detecting Jams ........................2-51

III. POWER SUPPLY SYSTEM.......2-56

1. This chapter discusses the purpose and role of each of the finisher’s functions, and the principles of operation used for the finisher mechanical and electrical systems. It also explains the timing at which these systems are operated. The symbol in drawings indicates transmission of mechanical drive, and signals marked by together with the signal name indicates the flow of electrical signals.

2. In descriptions of digital circuits on the finisher, “1” indicates a high signal voltage level, while “0” indicates a low signal voltage level. Voltage values differ according to circuit.

A microprocessor is used on the finisher. A description of microprocessor operation is omitted in this chapter as it is practically impossible to check internal operation of the microprocessor.

Descriptions in this chapter also assume that PCBs will not be repaired at user sites. For this reason, descriptions of circuits on PCBs is limited to block diagrams. Two types of block diagrams are provided for separate functions: diagrams indicating details from sensors up to input sections of major PCBs, and diagrams indicating details from the output sections of major PCBs up the loads.

Page 36

Page 37

2-1

CHAPTER 2 FINISHER UNIT BASIC OPERATION

I. BASIC OPERATION

A. Outline

The finisher is designed to deliver copies arriving from its host machine, and its modes of

delivery include simple stacking, job offset

(Note)

, and staple.

All operations involved in these modes are controlled by the finisher controller PCB, according

to the appropriate commands from the host machine.

In the case of the Saddle Finisher, copies from the host machine may be routed to the saddle

stitch unit.

Swing guide drive system

Alignment drive system

Stapler drive system

Delivery drive system

Feeder drive system

Shutter drive system

Tray drive system

Saddle stitch unit control system (Saddle Finisher)

Control system

Figure 2-101

Note:

The term job offset refers to shifting each sorting job, separating a single stack into several stacks.

Page 38

2-2

CHAPTER 2 FINISHER UNIT BASIC OPERATION

B. Outline of Electrical Circuitry

The finisher’s sequence of operation is controlled by the finisher controller PCB. The finisher

controller PCB is a 16-bit microprocessor (CPU), and is used for communication with the host machine (serial) in addition to controlling the finisher’s sequence of operations.

The finisher controller PCB responds to the various commands coming from the host machine

through a serial communications line to drive solenoids, motors, and other loads. In addition, it communicates the finisher’s various states (information on sensors and switches) to the host machine through a serial communications circuit.

In the case of the Saddle Finisher, the finisher controller PCB not only communicates with the

saddle stitch controller PCB but also communicates the saddle stitch unit’s various states (informa- tion on sensors and switches) to the host machine.

The ICs used on the finisher controller PCB are designed for the following:

●

IC1 (CPU) Controls sequence of operations.

●

IC2 (EP-ROM) Backs up adjustment values.

●

IC3 Contains sequence programs.

●

IC6/IC7 (RAM) Backs up initial setting data.

●

IC4 (communications IC) Communicates with the host machine and the saddle stitch unit.

●

IC9 (regulator IC) Generates PWM.

Figure 2-102 shows the flow of signals between the finisher and the options controller.

Page 39

2-3

CHAPTER 2 FINISHER UNIT BASIC OPERATION

IC1

CPU

IC2

EEP-ROM

IC4

IC3

EP-ROM

IC6/IC7

RAM

IC9

Saddle stitch controller PCB (Saddle Finisher)

Punch driver PCB (Puncher unit (option))

Host machine (DC controller PCB CPU)

Finisher controller PCB communication

Regulator IC

Connecting with inserter

Motor

Solenoid

Switch

Sensor

IC1

CPU

IC2

EEP-ROM

IC4

IC3

EP-ROM

IC6/IC7

RAM

IC9

Saddle stitch controller PCB (Saddle Finisher)

Punch driver PCB (Puncher unit (option))

Inserter

driver PCB

(Inserter unit

(option)

)

Host machine (DC controller PCB CPU)

Finisher controller PCB communication

Regulator IC

Motor

Solenoid

Switch

Sensor

Figure 2-102

Page 40

2-4

CHAPTER 2 FINISHER UNIT BASIC OPERATION

C. Inputs to and Outputs from the Finisher Controller PCB

1. Inputs to the Finisher Controller PCB

Figure 2-103

Page 41

2-5

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Inputs to the Finisher Controller PCB

Figure 2-104

Page 42

2-6

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Inputs to the Finisher Controller PCB

Figure 2-105

Page 43

2-7

CHAPTER 2 FINISHER UNIT BASIC OPERATION

: Jan. 9 2004

4. Inputs to and Outputs from the Finisher Controller PCB

+24V

JS1-1

-2

-3

-4

-8

-9

-10

-5

J2-5

-7

-8

-3

-4

-9

Communication line

Figure 2-106

Page 44

2-8

CHAPTER 2 FINISHER UNIT BASIC OPERATION

5. Outputs from the Finisher Controller PCB

Figure 2-107

Page 45

2-9

CHAPTER 2 FINISHER UNIT BASIC OPERATION

6. Outputs from the Finisher Controller PCB

Stapler shift motor

Staple motor

Tray 1 lift motor

Tray 2 lift motor

Swing motor

Second feed motor

Inlet feed motor

Finisher controller PCB

According to rotation direction/speed, changes between + and - in sequence.

According to rotation direction/speed, changes between + and -.

According to rotation direction/speed, changes between + and - in sequence.

According to rotation direction/speed, changes between + and -.

J115-1

-2

-1

-2

Figure 2-108

Page 46

2-10

CHAPTER 2 FINISHER UNIT BASIC OPERATION

II. FEED/DRIVE SYSTEM

A. Outline

The finisher is designed to operate according to the commands from its host machine to deliver

arriving copies to trays in the appropriate mode: simple stacking, job offset, stapling.

See Figure 2-201 for a diagram of the three modes of delivery (four for the Saddle Finisher).

Method of delivery

Normal delivery

Simple stacking

Job offset

Staple

Front diagonal

Rear 1-point

Rear diagonal

2-point

Saddle stitch delivery (Saddle Finisher only)

Figure 2-201

Normal delivery tray

To saddle stitch unit (Saddle Finisher)

Figure 2-202

Page 47

2-11

CHAPTER 2 FINISHER UNIT BASIC OPERATION

1. Normal Delivery

a. Simple Stacking

The finisher delivers copies directly to the tray.

Tray Tray

CopiesCopies

Delivery roller

Feed roller 2

Feed roller 1

Figure 2-203

Page 48

2-12

CHAPTER 2 FINISHER UNIT BASIC OPERATION

b. Job Offset

The finisher forwards all copies of each sort job to the stapling tray. The first sort job on the

stapling tray is delivered with a shift to the front of about 30 mm, and the second sort job is delivered without being shifted. Whether the first copy or the last copy of a sort job should be shifted is determined by the host machine.

Tray

Each sort job is stacked alternately.

Figure 2-204

Swing guide

Stapling tray

Delivery roller

Stopper

Feed roller 1

Figure 2-205

Results of Delivering 4 Sets

Direction of delivery

Copies handled by job offset

Figure 2-206

Page 49

2-13

CHAPTER 2 FINISHER UNIT BASIC OPERATION

c. Stapling

The finisher stacks copies arriving from its host machine on the stapling tray. Then, it staples

and delivers the copies to the appropriate tray.

Tray

Copies Staple

Swing guide

Delivery roller

Stapling tray

Stopper

Feed roller 1

Figure 2-207

Front diagonal stapling

Rear diagonal stapling

2-point stapling

Paper width/2

Rear 1-point stapling

Figure 2-208

Page 50

2-14

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Saddle Stitch Delivery (Saddle Finisher)

A copy arriving in the finisher from the host machine is routed to the saddle stitch by the paper

deflecting plate. The saddle stitch executes stitching and saddling operations on the copy and then delivers it to the saddle stitch tray.

For discussions of stacks in the saddle stitch, see Chapter 3.

To saddle stitch

Figure 2-209

Page 51

2-15

CHAPTER 2 FINISHER UNIT BASIC OPERATION

B. Type of Delivery Paths

The finisher has three different paper paths for delivery, each selected to suit paper size and

delivery mode.

1. Straight Path

When stacking copies shown in Table 2-201, the copies pass under the buffer roller.

Copy size The paper length is less than 182mm, or the paper width is less than

182mm, or the paper length is 251mm or more.

Typical copy examples

A3, A3-wide, B4, A4-R, B5-R, A5-R, LD, LG, LT-R, ST-R, Postcard, thick paper

Table 2-201

Delivery roller

Buffer roller

Figure 2-210

2. Buffer Paper Path 1

When stacking copies shown in Table 2-202, the copies pass over the buffer roller, increasing

the distance between copies.

Copy size The paper length is 182mm or more, and the paper width is 182mm or

more, and the paper length is 250mm or less.

Typical copy examples A4, B5, LT (excluding thick paper)

Table 2-202

Buffer roller

Feed roller 2

Delivery roller

Figure 2-211

F15/F16

Page 52

2-16

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Buffer Paper Path 2

This is the paper path when copy sizes shown in Table 2-203 are stacked. A maximum of three

copies (three originals or more in the staple mode) are wrapped round the buffer roller, during which job offset and stapling are performed on the stapling tray.

Copy size Length 182 to 232mm, and width 182 to 297mm Typical copy examples A4, B5, LT, (excluding transparencies and thick stock)

Table 2-203

The following shows paper delivery operation in the case of three originals in the staple mode.

1) The first copy is moved in the direction of the buffer roller.

Buffer roller

First copy

Figure 2-212

2) The first copy wraps around the buffer roller and, at the same time, the second copy arrives from the host machine.

First copy

Second copy

Figure 2-213

Page 53

2-17

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3) The second copy is laid over the first copy and, at the same time, the third copy arrives from the host machine.

First copy

Second copy

Third copy

Figure 2-214

4) The first, second and third copies are simultaneously pulled into the stapling tray.

Second copy

Third copy

First copy

Figure 2-215

Cauiton:

The third copy as explained here is moved through buffer paper path 1. This fact is omitted from the discussion to avoid interrupting the sequence of operations.

Page 54

2-18

CHAPTER 2 FINISHER UNIT BASIC OPERATION

C. Feeding and Delivering

1. Outline

The finisher moves copies arriving from the host machine to the delivery tray, stapling tray, or the saddle stitch unit (Saddle Finisher) according to the mode of delivery. On the stapling tray, the copies are subjected to job offset or stapling as instructed by the host machine.

The first feed motor (M1), second feed motor (M8) and inlet feed motor (M9) are stepping motors, and delivery motor (M2) is a DC motor. These motors are controlled by the microprocessor (CPU) on the finisher controller PCB, and rotate either clockwise or counterclockwise.

The paper paths are equipped with the following four sensors for detection of paper (arrival, passage):

●

Inlet sensor (PI1)

●

Delivery sensor (PI3)

●

Stapling tray sensor (PI4)

●

Buffer path paper sensor (PI14)

In addition, each delivery tray is equipped with a sensor designed to detect the presence/absence of paper on it.

●

No.1 tray paper sensor (PI11)

●

No.2 tray paper sensor (PI12)

If a copy fails to reach or move past each sensor within a specific period of time, the finisher controller PCB identifies the condition as a jam, and stops the ongoing operation, and at the same time, informs the host machine of the condition. When all doors are closed after the paper jam is removed, the buffer path inlet paper sensor (PI17) checks whether or not copies are being detected in addition to the above four sensors (inlet sensor, delivery sensor, stapling tray sensor and buffer path paper sensor). If the sensors detect a copy, the finisher unit judges that paper jams have not completely been removed, and sends the paper jam removal signal to the host machine again.

Page 55

2-19

CHAPTER 2 FINISHER UNIT BASIC OPERATION

SL3 SL2 SL1 SL7

PI20

SL6

PI10

PI24

PI23

PI9

PI19

M1M8 M9

SL5

Escape solenoid drive signal ESCPSL

Tray 2 lift motor drive signal

Shift motor clock signal 1 SFTCLK 21

Shift motor clock signal 2 SFTCLK 22

Alignment motor drive signal

Delivery motor drive signal

Delivery motor clock signal DELCLK

Swing motor drive signal

Swing motor clock signal SWGCLK

Shift motor clock detection signal 1 SFTCLK11

Shift motor clock detection signal 2 SFTCLK12

Paddle solenoid drive signal PDLSL

Second feed motor drive signal

First feed motor drive signal

Inlet feed motor drive signal

Buffer outlet solenoid drive signal EXITSL

Buffer inlet solenoid drive signal EXTSL

Flapper solenoid drive signal FLPSL

Belt escape solenoid drive signal BESCPSL

Stapler motor drive signal

Stapler shift motor drive signal

Finisher controller PCB

Tray 1 lift motor drive signal

Figure 2-216

Page 56

2-20

CHAPTER 2 FINISHER UNIT BASIC OPERATION

PI1

PI14

PI17

PI4

PI3

PI11

PI12

No. 2 tray paper detection signal SNDTRAY

No. 1 tray paper detection signal FSTTRAY

Stapling tray paper detection signal STPTY

Buffer path paper

detection signal BUFPASS

Delivery detection signal PDEL

Buffer path inlet paper

detection signal BUFENTR

Inlet paper detection signal PENT

Finisher controller PCB

Figure 2-217

Page 57

2-21

CHAPTER 2 FINISHER UNIT BASIC OPERATION

D. Job Offset

1. Outline

In the job offset mode, sort jobs and entire copy groups are shifted to the front for delivery to

the tray, and other copies are delivered to the tray without a shift.

The copies are shifted by the alignment plate. The alignment plate is checked by the alignment

plate home position sensor (PI6) to find out whether it is at the home position.

The finisher controller PCB drives the alignment motor (M3) at power-on to return the align-

ment plate to its home position.

The finisher controller PCB stops the delivery motor (M2) when the trailing edge of the copy has moved past the feed roller 2. Then, the finisher controller PCB rotates the delivery motor counterclockwise, and drives the swing motor (M7). As a result, the drive of the delivery motor is transmitted to the swing guide to move up the guide. When the swing guide open sensor (PI18) detects the swing guide, the delivery motor stops, and the swing guide is held at the up position.

When the swing guide has moved up, the feed belts attached to the feed roller 2 move the copy to the stapling tray. The presence of paper on the stapling tray is monitored by the stapling tray sensor (PI4). (The first sheet is fed to the stapling tray while the swing guide is moving up.)

The finisher controller PCB drives the alignment motor (M3) in advance, and keeps the alignment plate in wait at a point 10 mm behind the trailing edge of a sheet. Whenever one sheet is moved to the stapling tray, each sheet is aligned, and when the 3rd or last sheet in a sort job/group is fed to the stapling tray, the escape solenoid (SL6) moves the guide plate away and under the stapling tray. From then on, the alignment motor shifts the sheets to the front by 30 mm.

When the copy has been shifted, the finisher controller PCB rotates the alignment motor counterclockwise to move the alignment plate to a point 10 mm behind the trailing edge of the sheet. This alignment operation is repeated until alignment of the 3rd or last sheet in a sort job is completed. At this time, the swing guide is moved down and is closed, and the delivery motor rotates clockwise to deliver the sheet.

F15/F16

Page 58

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Guide plate

Escape solenoid (SL6)

Paper

Alignment plate

Alignment plate home position sensor (PI6)

Alignment motor (M3)

Figure 2-218

Sequence of Operation (job offset)

Delivery motor (M2)

First feed motor (M1)

Inlet sensor (PI1)

Start signal Host machine delivery signal

Delivery sensor (PI3)

Staple tray sensor (PI4)

Second feed motor (M8)

Alignment motor (M3) Alignment plate home

position sensor (PI6)

Swing guide open sensor (PI18)

Swing guide closed detecting switch 1 (MS2)

Swing motor (M7)

Inlet feed motor (M9)

Escape solenoid (SL6)

: Motor CW rotation : Motor CCW rotation

Figure 2-219

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Flow of Job Offset Operations

1) The swing guide moves up and, at the same time, the feed belts move the sheet to the stapling

tray.

Offset sheet

Swing guide

Tray 1/2

Delivery roller

Stapling tray

Feed roller 2

Knurled belts

Stopper

Figure 2-220

2) The alignment plate shifts the sheet to the front.

Existing stack

Alignment plate

Offset sheet

Figure 2-221

3) The swing guide moves down and, at the same time, the delivery roller delivers the sheet.

Offset sheet

Swing guide

Feed roller 2

Knurled belts

Tray 1/2

Delivery roller

Stapling tray

Stopper

Figure 2-222

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

E. Staple Operation

1. Outline

The stapler unit staples a stack of as many sheets as specified. The stapling position differs according to the selected staple mode and paper size. The stapler unit is checked by the stapler shift home position sensor (PI7) to find out whether it

is at the home position.

When starting operation after power-on, the finisher controller PCB drives the stapler shift motor (M4) to return the stapler unit to the home position. If the stapler is already at the home position, it is kept as it is in wait.

Sheets

Stapler shift home position sensor (PI7)

Stapler shift motor (M4)

Stapler

Figure 2-223

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Front diagonal stapling

2-point stapling

Paper width/2

Rear diagonal stapling

Rear 1-point stapling

Figure 2-224

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. First Sheet

The finisher controller PCB stops the delivery motor (M2) as soon as the trailing edge of the first sheet has moved past the feed roller 2. Then, it rotates the delivery motor clockwise to switch the gear drive to the swing motor (M7), causing the swing guide to move up. When the swing guide open sensor (PI18) finds the swing guide at the up position, the swing motor stops, maintaining the swing guide at the up position.

When the swing guide has moved up, the knurled belts of the feed roller 2 move the sheet to the stapling tray. (The first sheet is fed to the stapling tray while the swing guide is moving up.) The presence of paper on the stapling tray is detected by the stapling tray sensor (PI4).

The finisher controller PCB drives the alignment motor (M3) when the stapling tray paper sensor has detected paper to put sheets in order. The alignment plate is kept in wait in advance at a point 10 mm behind the trailing edge of the paper.

The swing guide is kept in wait at the up position until the last sheet is output onto the stapling tray.

Swing guide

First sheet

Tray 1/2

Delivery roller

Stapling tray

Feed roller 2

Knurled belts

Stapler

Figure 2-225

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Swing guide

Swing guide open sensor (PI18)

Swing guide closed detecting switch 1,2 (MS2/MS6)

Delivery roller

Swing motor clock sensor (PI20)

Delivery motor clock sensor (PI10)

Delivery motor (M2)

Swing motor (M7)

Figure 2-226

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Second and Subsequent Sheets

The finisher controller PCB turns on the belt escape solenoid (SL7) before the trailing edge of the second and subsequent sheets have moved past the feed roller 2 to make the knurled belt escape. This operation is performed to reduce the time it takes for the trailing edge of the paper to fall on the stapling tray, and to improve the product duty. The finisher controller PCB turns on the paddle solenoid (SL5) as soon as the trailing edge of the second and subsequent sheets have moved past the feed roller 2, causing the drive of the second feed motor (M8) to rotate the paddle. The sheets are pushed by the paddle and moved to the stapling tray. Almost simultaneously with the trailing edge of the sheet falling into the stapling tray, the belt escape solenoid turns off to return the knurled belts that were in the escape position to its original position, and feed the sheet onto the stapling tray. When the sheet has been output onto the stapling tray, the finisher controller PCB rotates the alignment motor (M3) to put the sheets in order.

SL7

Swing guide

Second and subsequent sheets

Paddles

Feed roller 2

Knurled belts

Belt escape solenoid

Tray 1/2

Delivery roller

Stapling tray

Stapler

Figure 2-227

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Knurled belts

Escape direction

Belt escape solenoid (SL7)

Figure 2-228

Paddles

Paddle solenoid (SL5)

Second and subsequent sheets

First sheet

Stapler

Stopper

Second feed motor

Figure 2-229

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

4. Last Sheet

When the last sheet has been put in order, the finisher controller PCB turns on the alignment motor (M3) to move the alignment plate to the alignment position (to butt the plate against the stack). Then, the finisher controller PCB rotates the swing motor (M7) counterclockwise to move down the swing guide.

The finisher controller PCB moves the stapler according to the staple mode for stapling.

From then on, it rotates the delivery motor (M2) clockwise to deliver the stack to the tray.

Swing guide

Sheets

Tray 1/2

Delivery roller

Stapling tray

Feed roller 2

Knurled belts

Stapler

Figure 2-230

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Swing guide

Swing motor (M7)

Delivery motor (M2)

Delivery roller

Figure 2-231

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

F. Stapler Unit

Stapling is executed by the staple motor (M6). A single rotation of the cam by the motor results in one stapling operation.

The cam is checked by the staple home position sensor (PI22) to find out whether it is at the home position.

The stapler motor is controlled by the microprocessor (IC1) on the finisher controller so that it is rotated clockwise or counterclockwise.

When the stapling home position sensor is off, the finisher controller PCB rotates the stapler motor clockwise until the sensor turns on so as to return the stapling cam to its initial state.

The presence/absence of the staple cartridge is detected by the staple switch (MS8). The presence/absence of staples inside the staple cartridge is detected by the staple detecting switch (MS9). The staple edge sensor (PI21) is used to find out whether a staple has been edged out to the end of the cartridge.

The finisher controller PCB does not drive the staple motor (M6) unless the swing guide closed detecting switch 2 (MS6) is on (i.e., the swing guide is closed). This is to protect against injuries that could occur when a finger is stuck inside the stapler.

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Figure 2-232

Staple edge detection signal

Staple motor drive

signal

Stapling home

position detection signal

Cartridge detection signal

Staple detection signal

Finisher controller PCB

Figure 2-233

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Start signal Host machine delivery signal

First sheet

Stacking

Second sheet

Stapling

Delivery

Delivery motor (M2)

First feed motor (M1)

Inlet feed motor (M9)

Second feed motor (M8)

Inlet sensor (PI1)

Delivery sensor (PI3)

Alignment motor (M3) Alignment guide home

position sensor (PI6) Swing guide open

sensor (PI18)

Stapling tray sensor (PI4)

Swing guide closed detecting switch 1 (MS2)

Paddle solenoid (SL5)

Stapler shift motor (M4)

Staple motor (M6)

Belt escape solenoid (SL7)

Staple home position sensor (PI22)

: Motor CW rotation : Motor CCW rotation

Figure 2-234

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

5. Shifting the Stapler Unit

The stapler unit is moved by the stapler shift motor (M4). Its home position is detected by the stapler shift home position sensor (PI7). When the start signal arrives from the host machine, the stapler moves to the center of its movement range. This movement occurs regardless of the selected mode of delivery, as no specific mode is recognized at this point in time. When the command for stapling arrives from the host machine after the first sheet has reached the host machine pre-registration sensor, the stapler moves to the staple wait position to suit the appropriate stapling position and paper size.

See Figures 2-235 and later for an idea of the wait position according to the stapling mode.

a. Front Diagonal Stapling

The position is the same as the stapling position.

Stapling tray delivery direction

Stopper

Guide plate

Stapler

Figure 2-235

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

b. Rear 1-Point Stapling

The stapler is kept in wait at the center position. The stapler is moved to and from the stapling

position for each stapling operation.

Stopper

Stapling position

Wait position

Stapler

Stopper

Guide plate

Stapling tray delivery direction

Figure 2-236

c. Rear Diagonal Stapling

For A4, LT and B5 sizes, the stapler is kept in wait toward the rear away from the stapling

position. The stapler is moved to and from the stapling position for each stapling operation.

Stapler

Wait position

Stapling position

Stopper

Guide plate

Stapling tray delivery direction

Figure 2-237

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

d. 2-Point Stapling

The stapler is kept in wait at the center of the paper. Stapling occurs at two points, first at the rear and then at the front.

Stapling tray delivery direction

Stopper

Stapling position

Wait position

Stapler

Stapling position

Stopper

Guide plate

Figure 2-238

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

G. Tray Operation

The finisher has two delivery trays-upper tray 1 and lower tray 2. The upper and lower trays

move up and down independently.

Tray 1 is moved up and down by the tray 1 lift motor (M5), and tray 2 by the tray 2 lift motor

(M10).

The tray 1 position is detected by counting the clock pulses of tray 1 lift motor clock sensors 1 and 2 (PI9 and PI19) in relation to the tray 1 home position sensor (P18). The tray 2 position is detected by counting the clock pulses of tray 2 lift motor clock sensors 1 and 2 (PI23 and PI24) in relation to the tray 2 home position sensor (PI25).

When the tray is already at the home position, it is moved away from the home position once, then returned to that position.

When both tray 1 and tray 2 are at the home position, the above operation is performed for tray 1 and tray 2 in this order.

The finisher controller PCB moves up and down the tray selected by the host machine so that it is positioned at the delivery slot.

The upper limit of the tray is detected by the tray coming close detecting switch (MS9). The finisher controller PCB stops the drive (up) of the tray 1 lift motor (M5) as soon as the tray upper limit detecting switch turns on.

The height of the stack on the tray is identified by the height sensor (PS1), which measures its distance from the top of the stack. The tray is moved down when the distance between the top of the stack and the delivery assembly drops to a specific measurement.

The finisher controller PCB cuts off the +24V power of the tray 1 lift motor (M5) as soon as the safety zone switch (MS3) turns on while the shutter and the swing guide are open, stopping the operation of the finisher.

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Tray 1 lift motor clock sensor / and 2

Tray 1 lift motor

Tray coming close detection switch

Rack

One way gear

Tray 2 lift motor clock sensor / and 2

Tray 2 lift motor

One way gear

Figure 2-239

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

: Jan. 9 2004

H. Detecting the Height of Stack on the Tray

1. Outline

The number of sheets delivered to the tray and the number of sets (number of stapling operations) are stored in memory by the finisher controller PCB. The height of the stack is checked by the height sensor (PS1). See Table 2-204 for the maximum loading capacity of each tray.

The finisher controller PCB stops operation when the conditions in Table 2-204 occur, informing the host machine that the tray is full.

Stacking

mode

Height

Small-size

250 mm high (equivalent to 2,000 sheets)

Large-size

140 mm high (equivalent to 1000 sheets)

Small-size

110 mm high (equivalent to 750 sheets/ 100 sets)

Non-staple sort Staple sort

Mixed sizes

74 mm high (equivalent to 500 sheets)

Large-size

74 mm high (equivalent to 500 sheets/ 100 sets)

Mixed sizes

22 mm high (equivalent to 500 sheets/ 100 sets)

Notes: 1. The capacity for the non-staple sort mode is approximate and computed based on 80 g/m2 paper.

2. Alignment for stacks containing 750 sheets or more is not guaranteed.

3. Stacking height precision is ±7 mm.

4. OHP and OHP mixed load: 100 sheets

Caution:

1. The term “small-size” stands for A4, LT, B5 and 16K.

2. The term “large-size” stands for A3, A4-R, B4, LG, LD, LT-R, Foolscap and 8K.

Table 2-204

F15/F16

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Height sensor (PS1)

Paper

Figure 2-240

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

I. Shutter Operation

When the tray 1 passes the delivery slot, the finisher controller PCB closes the shutter mounted on the delivery slot before moving the tray, preventing the existing stack on the tray by the delivery slot and intrusion of the hands.

The shutter moves up (to close) when the second feed motor (M8) rotates counterclockwise, and is held in position when the motor stops. When the second feed motor rotates counterclockwise once again, it moves down (to open) to enable delivery.

When the shutter is held at the up position, claws slide out of the swing guide to engage the back of the shutter. This way, the existing slack and the swing guide engage while the tray is moved, preventing the guide from opening. The claws slide in when the shutter is moved down to release the engagement.

The upward movement of the shutter is monitored by the shutter closed detecting switch (MS4), and the downward movement is monitored by the shutter open sensor (PI5).

See the following diagrams for how these operations take place.

1) The second feed motor rotates counterclockwise to move the shutter up.

Second feed motor

Figure 2-241

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2) The tray 1,2 lift motor rotates, and the new tray moves to the stacking lower limit. The distance of movement is detected by the tray 1 lift motor clock sensor 1/2 (PI9/19) or tray 2 lift motor clock sensor 1/2 (PI22/PI24).

Tray 2 lift motor

M1 0

Tray 1 lift motor

Figure 2-242

3) The second feed motor rotates counterclockwise, and the shutter moves down.

Second feed motor

Figure 2-243

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4) The tray lift motor rotates, and the tray moves to suit the height of the stack. The appropriate height in relation to the existing stack is checked by the height sensor (PS1).

Tray 2 lift motor

Height sensor (PS1)

M10

Figure 2-244

Claw

Shutter closed detecting switch (MS4)

Shutter open sensor (PI5)

Shutter

Claw

One-way cam

Second feed motor

Figure 2-245

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

Sequence Operations (shutter drive)

Move from Tray 1 to Tray 2

Second feed motor (M8)

Shutter closed

Tray moved

Shutter opened

Tray 1 lift motor (M5)

Tray 2 lift motor (M10) Shutter closed detecting

switch (MS4)

Shutter open sensor (PI5)

Height sensor (PS1)

Correct height detected

Motor CW rotation Motor CCW rotation

Figure 2-246

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J. Buffer Path Operation

1. Outline

This machine is provided with a buffer paper path for continuously receiving paper from the

host machine during stapling and job offset operation on the stapling tray. A maximum of three copies (three originals or more in the staple mode) are wrapped around the buffer roller. During this time, job offset and stapling are performed on the stapling tray.

The following shows operation on the buffer paper path.

1) When the first sheet arrives, the buffer inlet solenoid (SL2) remains off. The first sheet enters the buffer path.

OFF

SL2

First sheet

Buffer inlet solenoid

Figure 2-247

2) When the leading edge of the sheet has moved past the buffer path inlet paper sensor (PI17), the buffer outlet solenoid (SL3) turns on so as to cause the sheet to wrap around the buffer roller.

SL3

Buffer outlet solenoid

Buffer path inlet paper sensor (PI17)

Figure 2-248

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3) When the leading edge of the sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the second sheet.

First sheet

Second sheet

Buffer path paper sensor (PI14)

Figure 2-249

4) When the second sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer roller starts to operate once again.

Second sheet

Inlet sensor (PI1)

First sheet

Figure 2-250

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5) The buffer roller continues to rotate, and the second sheet overlaps the first sheet.

First sheet

Second sheet

Figure 2-251

6) When the trailing edge of the second sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the third sheet.

First sheet

Second sheet

Third sheet

Buffer path paper sensor (PI14)

Figure 2-252

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7) When the third sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer roller starts to operate once again.

First sheet

Second sheet

Third sheet

Inlet sensor (PI1)

Figure 2-253

8) When the leading edge of the third sheet reaches the inlet sensor (PI1), the buffer outlet solenoid (SL3) turns off so that the path is directed in the direction of delivery. (The actual switchover will occur after the trailing edge of the first sheet has moved past the flapper.)

OFF

SL3

Buffer outlet solenoid

First sheet

Second sheet

Third sheet

Inlet sensor (PI1)

Figure 2-254

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

9) The buffer roller continues to rotate, the third sheet overlaps the first and second sheets, and the three sheets are fed together towards the delivery roller.

Figure 2-255

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K. Detecting Jams

The following sensors are used to detect the presence/absence of paper and to make sure that

sheets are moved properly:

●

Inlet sensor (PI1)

●

Delivery sensor (PI3)

●

Stapling tray sensor (PI4)

●

Buffer path paper sensor (PI14)

A jam is identified with reference to the presence/absence of paper at each specific sensor at the

times programmed in the memory of the microprocessor (CPU) on the finisher controller PCB.

When the CPU identifies a jam, it suspends the finisher’s delivery operation and informs the host machine DC controller of the presence of a jam. After the paper jam is removed, the buffer path inlet paper sensor (PI17) checks whether or not copies are being detected in addition to the above four sensors (inlet sensor, delivery sensor, stapling tray sensor and buffer path paper sensor). If the sensors detect a copy when all doors are closed, the finisher unit judges that paper jams have not completely been removed, and sends the paper jam removal signal to the host machine again.

The tray 1 paper sensor (PI11) and tray 2 paper sensor (PI12) are not used to detect jams.

PI1

PI14

PI4

PI3

Figure 2-256 Table 2-205

No. Sensor names

PI1 Inlet sensor PI3 Delivery sensor PI4 Stapling tray sensor

PI14 Buffer path paper sensor

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

1. Inlet Sensor Delay Jam

The inlet sensor does not detect paper when feeding an equivalent of 400 mm from when the

host machine delivery signal has been issued.

Host machine delivery signal Host machine delivery signal

Jam check

Equivalent of 400 mm

Inlet sensor (PI1)

Normal

Inlet feed motor (M9)

Jam check

Inlet sensor (PI1)

Inlet feed motor (M9)

Jam

Equivalent of 400 mm

Figure 2-257

2. Inlet Sensor Stationary Jam

The sheet does not move past the inlet sensor when an equivalent of twice the feeding length of

the sheet has been fed after the sensor turned on.

Jam check

Equivalent of size x 2

Inlet sensor (PI1)

Normal

Inlet feed motor (M9)

Jam check

Equivalent of size x 2

Inlet sensor (PI1)

Jam

Inlet feed motor (M9)

Figure 2-258

3. Buffer Path Paper Sensor Delay Jam

The buffer path paper sensor does not detect paper when an equivalent of 550 mm has been fed

after the inlet sensor turned on.

Jam check

Equivalent of 550 mmEquivalent of 550 mm

Inlet sensor (PI1)

Buffer path paper sensor (PI14)

Normal

First feed motor (M1)

Jam check

Inlet sensor (PI1)

Buffer path paper sensor (PI14)

First feed motor (M1)

Jam

Figure 2-259

F15/F16

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

4. Buffer Path Paper Sensor Stationary Jam

The sheet does not move past the buffer path paper sensor when an equivalent of twice the feeding length of the sheet has been fed after the sensor turned on.

Jam check

Equivalent of size x 2

Buffer path paper sensor (PI14)

Normal

First feed motor (M1)

Jam check

Equivalent of size x 2

Buffer path paper sensor (PI14)

Jam

First feed motor (M1)

Figure 2-260

5. Delivery Sensor Delay Jam

a. Straight Path

The delivery sensor does not detect paper when an equivalent of 363 mm has been fed after the inlet sensor turned on.

Jam check

Inlet sensor (PI1)

Normal

Delivery sensor (PI3)

First feed motor (M1) Second feed motor

(M8)

Jam check

Inlet sensor (PI1)

Delivery sensor (PI3)

First feed motor (M1) Second feed motor

(M8)

Jam

Equivalent of 363 mm Equivalent of 363 mm

Figure 2-261

F15/F16

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

b. Buffer Path

The delivery sensor does not detect paper when an equivalent of 652 mm has been fed after the

inlet sensor turned on.

Jam check

Inlet sensor (PI1)

Normal

Delivery sensor (PI3)

First feed motor (M1) Second feed motor

(M8)

Jam check

Inlet sensor (PI1)

Delivery sensor (PI3)

First feed motor (M1) Second feed motor

(M8)

Jam

Equivalent of 652 mm Equivalent of 652 mm

Figure 2-262

6. Delivery Sensor Stationary Jam

The sheet does not move past the delivery sensor when an equivalent of twice the feeding

length of the sheet has been fed after the delivery sensor turned on.

Jam check

Equivalent of size x 2 Equivalent of size x 2

Delivery sensor (PI3)

Normal

Second feed motor (M8)

Delivery motor (M2)

Jam check

Delivery sensor (PI3) Second feed motor

(M8)

Delivery motor (M2)

Jam

Figure 2-263

F15/F16

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

7. Stapling Tray Sensor Stationary Jam

The sheet does not move past the stapling tray sensor 1 sec after the delivery motor (M2) turned on.

Jam check

1 sec 1 sec

Stapling tray sensor (PI4)

Normal

Delivery motor (M2)

Jam check Stapling tray

sensor (PI4) Delivery motor (M2)

Jam

Figure 2-264

8. Staple Jam

When the staple motor (M6) is rotating clockwise, the staple home position sensor (PI22) does not turn on within 0.5 sec. after it has turned off. However, the sensor turns on within 0.5 sec. after the motor has been rotated counterclockwise.

9. Power-On Jam

One of the inlet sensor (PI1), delivery sensor (PI3), buffer path paper sensor (PI4) or buffer path inlet paper sensor (PI17) detects paper at power-on.

10. Door Open Jam

One of the joint sensor (PI15), door open sensor (PI16) or door switches (MS1) detects the cover open during operation (including front door switch (MS2P) when the optional puncher unit is mounted).

11. Punch Jam

The punch home sensor (PI3P) does not turn on again within 200 msec after turning off.

F15/F16

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CHAPTER 2 FINISHER UNIT BASIC OPERATION

III. POWER SUPPLY SYSTEM

1. Outline

The finisher controller PCB is supplied with 24 VDC power when the host machine is turned on. Power is also supplied from the finisher controller PCB to the saddle stitch controller PCB. In addition, power is also supplied to the punch driver PCB when the optional puncher unit is mounted.

Some of the 24 VDC power used to drive motors is cut off when the door switch (MS1) is open. The power to the saddle stitch controller PCB, however, will not be cut off.

Figure 2-301 is a block diagram showing the power supply system.

Power source

Figure 2-301

2. Protection Functions

The 24 VDC power line used to drive motors and solenoids is equipped with a circuit breaker (CB1) for protection against overcurrent. The 24 V line used to drive the first feed motor (M1), alignment motor (M3), and stapler shift motor (M4) are equipped with a fuse, which is designed to blow when an overcurrent occurs.

F15/F16

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CHAPTER 3

SADDLE STITCH UNIT

BASIC OPERATION

I. BASIC OPERATION ....................3-1

A. Outline ....................................... 3-1

B. Electrical Circuitry ......................3-2

C. Inputs to and Outputs from the

Saddle Stitch Controller PCB.....3-3

II. FEEDING/DRIVE SYSTEM .........3-8

A. Outline ....................................... 3-8

III. PAPER OUTPUT

MECHANISM.............................3-14

A. Outline ..................................... 3-14

B. Controlling the Inlet

Flappers ...................................3-17

C. Controlling the Movement of

Sheets...................................... 3-21

D. Aligning the Sheets..................3-23

E. Controlling the Phase of the

Crescent Roller ........................3-26

IV. STITCHING SYSTEM ............... 3-28

V. FOLDING/DELIVERY

SYSTEM....................................3-31

VI. CHECKING FOR A JAM ...........3-38

VII. POWER SUPPLY ......................3-43

1. This chapter discusses the purpose and role of each of the saddle stitch functions, and the principles of operation used for the stitch mechanical and electrical systems. It also explains the timing at which these systems are operated.

The symbol in drawings indicates transmission of mechanical drive, and signals marked by together with the signal name indicates the flow of electrical signals.

2. In descriptions of digital circuits on the stitch, “1” indicates a high signal voltage level, while “0” indicates a low signal voltage level. Voltage values differ according to circuit.

A microprocessor is used on the stitch. A description of microprocessor operation is omitted in this chapter as it is practically impossible to check internal operation of the microprocessor.

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CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION

I. BASIC OPERATION

A. Outline

The unit “stitches” (2 points) a stack of sheets delivered by the finisher unit and folds it in two for delivery. All these operations are controlled by the saddle stitch controller PCB in response to commands from the host machine via the finisher unit.

Finisher unit control system

Control system

Guide plate drive system

Paper positioning plate

drive system

Alignment drive system

Saddle stitch drive system

Delivery drive system

Feed drive system

Paper pushing plate

drive system

Paper folding roller

drive system

Figure 3-101

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CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION

B. Electrical Circuitry

The sequence of operations used for the saddle stitch is controlled by the saddle stitch controller PCB. The saddle stitch controller PCB has a microprocessor. This microprocessor is used to control the sequence of operations and to handle serial communications with the finisher controller PCB, driving solenoids and motors in response to the various commands from the finisher controller PCB.

The saddle stitch controller PCB is also used to communicate the state of various sensors and switches to the finisher controller PCB in serial.

The functions of the major ICs mounted on the saddle stitch controller PCB are as follows:

●

Q1 Controls the sequence of operations.

●

Q2 Contains the sequence program.

●

Q3 Controls the sequence of operations.

●

Q4 Handles IPC communications.

Electrical circuitry block diagram

Sensors

Switches

Q1 CPU

ROM

RAM

Communi-

cations IC

Saddle stitch

controller PCB

Motors

Solenoids

Host machine

Finisher controller

PCB

Figure 3-102

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CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION

C. Inputs to and Outputs from the Saddle Stitch Controller PCB

1. Inputs to the Saddle Stitch Controller PCB

Paper folding motor clock sensor

Alignment plate home position sensor

Paper positioning plate home position sensor

Tray paper sensor

PI7S

J402A

J402

J502

J106-3

-1

-2

PI6S

J100-3

-1

-2

J6-7

-9

-8

J6-4

-6

-5

-3

-1

-2

-1

-3

-2

J202A

J302

J202

-6

-4

-5

-1

-3

-2

-3

-1

-2

-4

-6

-5

PI5S

J101-3

-1

-2

J11-1

-3

-2

PI4S

J102-1

-2

-3

J11-6

-5

-4

PI3S

J103-3

-1

-2

J11-7

-9

-8

-3

J303-1

-2

-1

J203-3

-2

-3

J309-1

-2

-1

J209-3

-2

PI2S

J104-3

-1

-2

J11-10

-12

-11

PI1S

J107-1

-2

-3

J11-15

Saddle stitch controller PCB

When the paper pushing plate motor is rotating, alternately between “1” and “0”.

+5V LUNGECLK

When the front door is open, “0”.

+5V FDR

When the paper folding motor is rotating, alternately between “1” and “0”.

+5V FLDCLK

When the alignment plate is at home position, “1”.

+5V JOGHP

When paper is present on the tray, “1”.

+5V TRYPAR

When the paper positioning plate is at the home position sensor, “1”.

+5V PAPPOS

When the delivery cover is open, “0”.

+5V EJCVR

-14

-13

Paper pushing plate motor clock sensor

Front door open/closed sensor

Delivery cover sensor

Figure 3-103

Page 98

3-4

CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION

2. Inputs to the Saddle Stitch Controller PCB

PI8S

J105-3

-1

-2

-1

-3

-2

-3

-1

-2

J6-1

+5V

When paper is present at the paper positioning plate, “1”.

PPOSPAR

-3

-2

J301A

J225

J425

J301

J201

PI9S

J124-3

-1

-2

J10-6

+5V

When the inlet cover is closed, “1”.

INLTCVR

-8

-7

PI11S

J525-3

-1

-2

-4

-3

-1

-2

J9-1

+5V

When paper is present in the delivery sensor unit, “1”.

DELV

-3

-2

J425

J325

-2

-4

-3

-1

-2

J225

J125

PI12S

J126-3

-1

-2

J9-4

+5V

When the flag of the crescent roller is at the sensor, “1”.

FDRLHP

-6

-5

PI13S

J127-3

-1

-2

J9-7

+5V

When the guide is at home position, “1”.

GIDHP

-9

-8

PI14S

J128-3

-1

-2

J9-10

+5V

When the paper pushing plate is at home position, “1”.

LUNGEHP

-12

-11

PI15S

J129-3

-1

-2

J9-13

+5V

When the paper pushing plate is at the leading edge, “1”.

LUNGETOP

-15

-14

PI16S

J131-3

-1

-2

J13-1

+5V

When the stitch unit is housed, “0”.

STPLHP*

-3

-2

PI17S

J132-3

-1

-2

-1

-3

-2

-4

-2

-3

J13-4

+5V

When paper is present in the vertical path, “1”.

When the paper folding roller is at home position, “0”.

VPJM

-6

-5

J308A

J308

J208

PI21S

J130-3

-2

-1

J18-1

+5V PAFLDHP*

-3

-2

Saddle stitch controller PCB

Paper positioning plate paper sensor

Inlet cover sensor

Delivery sensor

Crescent roller phase sensor

Guide home position sensor

Paper pushing plate home position sensor

Paper pushing plate top position sensor

Stitch unit IN sensor

Vertical path paper sensor

Paper folding home position sensor

Figure 3-104

Page 99

3-5

CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION

3. Inputs to the Saddle Stitch Controller PCB

Saddle stitch controller PCB

When paper is present at the No.1 paper sensor, “1”. When paper is present at the No.2 paper sensor, “1”. When paper is present at the No.3 paper sensor, “1”.

When the stitch unit is at the home position for stitching, “0”.

When no staple is present, “0”.

When the stitcher unit is at the home position for stitching, “0”.

When no staple is present, “0”.

PI18S

Paper sensor PCB

Stitch unit (front)

PI19S

PI20S

MS6S

MS7S

-2

-3

-4

J123-5

-2

J109-3

-2

J110-3

-3

J111-2

+5V 1STPA

STCHHP1*

HKEMP1

2NDPA 3RDPA

-1

-4

-3

-2

J10-1

-5

-4

-3

-2

-1

-5

-2

-3

-4

-5

-1

J304A

J304

J204

-7

J315-5

-6

-1

J8-3

-2

-1

-3

-2

-7

-5

-6

No.1 paper sensor

No.2 paper sensor

No.3 paper sensor

Stitch home position sensor (front)

Staple sensor (front)

Stitch home position sensor (rear)

Staple sensor (rear)

When the inlet door is closed, “1”.

When the front door is closed, “1”.

When the delivery door is closed, “1”.

Stitch unit (rear)

MS4S

MS5S

Inlet door switch

MS1S

N.O.

+24V

+24U

STCHHP2*

HKEMP2

INLTCVRMS

FDROPN

-7

J316-5

-6

-8

-2

J8-10

J4-1

Front door switch

MS2S

N.O.

-4

J4-3

-9

-1

-3

-2

-7

-5

-6

DELVMS

Delivery door switch

MS3S

N.O.

-6

J4-5

J305

J205

JD2

JD1

J306

J121

J305

J120

-1

-2

-1

-2

Figure 3-105

Page 100

3-6

CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION

4. Outputs from the Saddle Stitch Controller PCB

SL1S

J118

-1 -2

+24V

FLPSL1*

When “0”, the solenoid turns ON.

Saddle stitch controller PCB

-2

J15-1

-2-1

SL2S

J117

-1 -2

+24V

FLPSL2*

When “0”, the solenoid turns ON.

-2

J15-3

-4-1

SL4S

J116

-1 -2

+24V

RLNIPSL*

When “0”, the solenoid turns ON.

-2

J15-5

-6-1

-1 -4

-4 -1

-3 -2

-2 -3

+24V

The pulse signals change according to the rotation of the motor.

J7-1

-2

-3

-4

-5

J113-5

-4

-3

-2

-1

M5S

The pulse signals change according to the rotation of the motor.

J5-1

-2

-3

-4

M1S

+24V

The pulse signals change according to the rotation of the motor.

J7-6

-7

-8

-9

-10

J114-5

-4

-3

-2

-1

M4S

+24V

The pulse signals change according to the rotation of the motor.

J12-1

-2

-3

-4

-5

J119-5

-4

-3

-2

-1

M3S

The states (+ and -) change according to the rotation of the motor.

J4-8

-7

J112-2

-1

M2S

J115A

No.1 paper deflecting solenoid

No.2 paper deflecting solenoid

Feed plate contact solenoid

Feed motor

Paper folding motor

Guide motor

Paper positioning plate motor

Alignment motor

Figure 3-106