SHARP SFT 4015 User Manual

 IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

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

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

3. Note that the optional tray heater and the optional anti-condensation heaters are supplied with electrical voltage even if the main switch is turned off.

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

5. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands.

HEALTH SAFETY CONDITIONS

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

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

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do not incinerate toner cartridges or used toner. Toner dust may ignite suddenly when exposed to open flame.

2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are non-toxic supplies.)

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

SECTION 1

OVERALL

MACHINE INFORMATION

20 December 1996 SPECIFICATIONS

1. SPECIFICATIONS

Configuration: Desk Top Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum: A3/11" x 17" Copy Paper Size: Maximum: A3/11" x 17"

Minimum:

1/2

A5/5

1/2

A6/5

Non-standard sizes:

Vertical 45 mm ~ 308 mm, 1.8" ~ 12" Horizontal 148 mm ~ 432 mm, 5.8" ~ 17"

Copy Paper Weight: Paper tray feed: 64 to 90 g/m

By-pass feed: 52 to 157 g/m

" x 8 " x 8

1/2

" sideways (Paper tray feed)

1/2

" lengthwise (By-pass feed)

, 17 to 24 lb

, 14 to 42 lb

Overall

Information

Reproduction Ratios:

Enlargement

Full Size 100% 100%

Reduction

Metric Version Inch Version

200% 141% 122%

93% 82% 71% 50%

200% 155% 129%

93% 74% 65% 50%

Zoom: From 50% to 200% in 1% steps Copying Speed: 15 copies/minute (A4/8.5" x 11" sideways)

9 copies/minute (A3/11" x 17")

Warm-up Time:

120 V machines: Less than 30 seconds (at 23°C)

230 V machines: Less than 45 seconds (at 23°C) First Copy Time: Less than 6.9 seconds (A4/8.5" x 11" sideways) Copy Number Input: Number keys, 1 to 99 Manual Image Density

7 steps Selection:

Automatic Reset: 1 minute standard setting; can also be set to 3

minutes or no auto reset

1-1

SPECIFICATIONS 20 December 1996

Paper Capacity: Paper tray: 500 sheets or less than 56 mm stack

height

By-pass feed entrance:

Standard paper 80 sheets OHP 10 sheets Others 1 sheet

Toner Replenishment: Bottle exchange (215 g/bottle) Copy Tray Capacity: 100 sheets Power Source: 120 V/60 Hz: More than 15 A (for North America)

220 ~ 240 V/50 Hz: More than 8 A (for Europe)

220 V/50 Hz: More than 8 A (for Asia)

220 V/60 Hz: More than 8 A (for Middle East/Asia)

110 V/60 Hz: More than 15 A (for Taiwan)

127 V/60 Hz: More than 15 A (for Middle East) Power Consumption:

Dimensions:

Copier only Full system*

Maximum 1.4 kW

(120 V machines)

0.9 kW

(230 V machines) Copy cycle 0.71 kW 0.74 kW Warm-up 0. 95 kW 0. 95 kW Stand-by 0.25 kW 0.25 kW Energy saver 0.2 kW 0.2 kW

*Full system : Copier with document feeder and 10 - bi n sorter

Width Depth Height

Copier 579 mm

(22.8")

Full system* 775 mm

(30.2")

*Full system : Copier with document feeder and 10 - bi n sorter

560 mm

(22.1")

560 mm

(22.1")

1.5 kW

(120 V machines)

1.0 kW

(230 V machines)

420 mm

(16.6")

508 mm

(19.8")

1-2

20 December 1996 SPECIFICATIONS

Noise Emissions: Sound pressure level (the measurements are

made in accordance with ISO 7779 at the operator position.)

Copying Less than 57 dB Less than 61 dB

*Full system : Co pi er w i th d ocument feeder an d 10- bi n sorter

Copier only Full system*

Sound power level (the measurements are made in accordance with ISO 7779)

Overall

Information

Weight:

Optional Equipment: (Sales items)

Optional Equipment: (Servi ce items)

Copier only Full system*

Stand-by Less than 40 dB Less than 40 dB

Copy cycle Less than 63 dB Less than 67 dB

*Full system : Co pi er w i th d ocument feeder an d 10- bi n sorter

Copier only

Full system *

*Full system : Co pi er w i th d ocument feeder an d 10- bi n sorter

42 kg (93.0 lb)

55 kg (121 lb)

Document feeder (A662) 10-bin sorter (A657)

Optics anti-condensation heater Tray heater

•

Specifications are subject to change without notice.

1-3

COPY PROCESS AROUND THE DRUM 20 December 1996

2. COPY PROCESS AROUND THE DRUM

1-4

A219V503.wmf

20 December 1996 COPY PROCESS AROUND THE DRUM

1. DRUM CHARGE

In the dark, the charge corona unit gives a uniform negative charge to the organic photoconductive (OPC) drum. The charge remains on the surface of the drum because the OPC drum has a high electrical resistance in the dark.

2. EXPOSURE

An image of the original is reflected to the drum surface via the optics assembly. The charge on the drum surface is dissipated in direct proportion to the intensity of the reflected light, thus producing an electrical latent image on the drum surface.

3. ERASE

The erase lamp illuminates the area of the charged drum surface that will not be used for the copy image. The resistance of the drum in the illuminated areas drops and the charge on those areas dissipates.

4. DEVELOPMENT

Positively charged toner is attached to the negatively charged areas of the drum, thus developing the latent image. (The positive triboelectric charge is caused by friction between the carrier and toner particles.)

Overall

Information

5. IMAGE TRANSFER

Paper is fed to the drum surface at the proper time so as to align the copy paper and the developed image on the drum surface. Then, a strong negative charge is applied to the back side of the copy paper, producing an electrical force which pulls the toner particles from the drum surface to the copy paper. At the same time, the copy paper is electrically attracted to the drum surface.

6. PAPER SEPARATION

A strong positive dc charge is applied to the back side of the copy paper via a discharge plate, reducing the negative charge on the copy paper and breaking the electrical attraction between the paper and the drum. Then, the stiffness of the copy paper causes the paper to separate from the drum surface.

7. CLEANING

The cleaning blade scrapes the toner off the drum. The collected toner is recycled.

8. QUENCHING

Light from the quenching lamp electrically neutralizes the drum surface.

1-5

MECHANICAL COMPONENT LAYOUT 20 December 1996

3. MECHANICAL COMPONENT LAYOUT

26 25

98654321

11 12

1. 2nd Mirror

2. 1st Mirror

3. Exposure Lamp

4. Hot Roller

5. Lens

6. Quenching Lamp

7. Charge Corona Unit

8. 6th Mirror

9. Erase Lamp

10. 4th Mirror

11. 5th Mirror

12. Toner Bottle Holder

13. By-pass Feed Roller

21 20

A219V500.wmf

14. By-pass Feed Table

15. Relay Rollers

16. Tray Paper Feed Rollers

17. Registration Rollers

18. Development Roller

19. Transfer/Separation Unit

20. Drum

21. Cleaning Blade

22. Pressure Roller

23. Paper Tray

24. Copy Tray

25. Exit Rollers

26. 3rd Mirror

1-6

20 December 1996 DRIVE LAYOUT

4. DRIVE LAYOUT

Overall

Information

543

1. Lens Motor

2. Fusing Unit Drive Gear

3. Main Motor

4. Drum Drive Gear

5. Tray Paper Feed Clutch Gear

6. Relay Roller Clutch Gear

A219V501.wmf

7. By-pass Paper Feed Clutch

8. Registration Clutch Gear

9. Toner Supply Motor

10. 4th/5th Mirror Motor

11. Scanner Drive Motor

1-7

PAPER PATH 20 December 199 6

5. PAPER PATH

1. By-pass Feed

2. Paper Tray Feed

3. Copy Tray

A219V502.wmf

1-8

20 December 1996 ELECTRICAL COMPONENT DESCRIPTIONS

6. ELECTRICAL COMPONENT DESCRIPTIONS

Refer to the electrical component layout and the point-to-point diagram on the waterproof paper in the pocket for symbols and index numbers.

Symbol Name Function Index No.

Motors

M1 M2 Scanner Drive M ot or Drives the sca nners (1st and 2nd). 9 M3

Main Motor Drives all th e m ai n unit component s except

for the optics u ni t and f ans.

Lens Motor Moves the lens position in accor dance with

the selecte d m agnification.

4th/5th Mirror Motor Moves the 4th/5th mirror position in

accordanc e w ith the selected magnification.

Toner Supply M ot or Rotates the to ner bot tle to supply toner to the

development uni t .

Optics Cooling Fan Motor

Exhaust Fan Mot or Removes heat fro m a ro und the fusing uni t

Prevents buil d- up of hot air in the opti cs cavity.

and blows the ozone built up aro und the charge corona unit towards the ozone filter.

Overall

Information

Clutches

CL1

CL2 CL3 Relay Roller Clutch Drives the relay rollers for paper tray feed. 13

CL4 Registration Clutch Drives the registration rollers. 11

Switches

SW1 Main Switch Supplies power to the copier. 38 SW2

SW3

SW4

Sensors

Tray Paper Feed Clutch

By-pass Paper F eed Clutch

Interlock Switch Cuts all power when the front cover is

Tray Paper Size Switch

Right Vertical Guide Switch

4th/5th Mirro r Hom e Position Sensor

ADS Sensor Detects the bac kground density of th e

Transfers ma in motor drive to the paper feed roller.

Starts paper fee d fr om t he by-pass feed table.

opened. Determines what size of paper is in the

paper tray. Cuts the +24 V dc power line of the relay

roller clutch.

Informs the CPU when the 4th/5th mirror assembly is at the home position (full size position).

original.

1-9

ELECTRICAL COMPONENT DESCRIPTIONS 20 December 1996

Symbol Name Function Index No.

Tray Paper End Sensor

Informs the CPU when the paper tray runs out of paper.

Registratio n Sensor Detects the leading edge of th e copy paper

to determin e th e stop timing of the re l ay

roller clutc h , and detects misfeed s.

By-pass Feed Paper End Sensor

Informs the CPU w hen there is no paper in the by-pass tray.

29 S6 Exi t Sensor D etects misfeeds. 23 S7

Scanner Home Position Sensor

Lens Home Posit ion Sensor

Toner Density (TD) Sensor

Informs the CPU w hen the 1st scanner i s at the home position.

Informs the CPU when the lens is at the home posit ion.

Detec ts the ra tio of ton er to car rier in th e developer.

Printed Circuit Boards

PCB1 Main Control Board Controls all copier funct i ons. 1

PCB2

High Voltage Supply Board - C/G/B/T/S

Provides high voltage to the charge corona, grid, development bias, transfer corona, and

discharge plate.

PCB3

AC Drive/DC Power Supply Board

Drives the exp o sure lamp, fusing l amp, and main motor. Rectifies 30 Vac and 8 Vac input

and outputs 5 Vdc and 24 Vdc.

PCB4

Operation Pane l Board

Informs the CPU of the selected mode s and displays the si t uation on the panel.

Lamps

Erase Lamp Discharges t he drum outside of th e i m age

area. (Provides leading/trailing edge and side erases.)

Quenching Lamp Neutralizes any charge remain i ng on the

drum surfa ce af t er cl eaning.

Exposure Lamp Applies high intensity light to the original for

exposure.

L4 Fusing Lamp Provides heat to the hot roller. 25

Others

CO1

TF1

Total Counter Keeps track of the t ot a l number of copies

made.

Tray Heater (Opt i on) Turns on when t he main switch is of f to keep

paper in the pa per tray dry.

Optics Anti-condensat i on Heater (Opti on)

Exposure Lamp Thermofuse

Turns on when t he main switch is of f to prevent moisture from accumulating in the optics.

Provide back-up overheat protection around the exposure lamp.

1-10

20 December 1996 ELECTRICAL COMPONENT DESCRIPTIONS

Symbol Name Function Index No.

TF2

TH1

TH2

Fusing Therm of u se Provide back-up overheat pro te ct i on i n t he

fusing unit.

Fusing Therm i st or Monitor s th e te mperature around t he

exposure lam p for overheat prot ect i on.

Optics Therm i st or Monitors th e te mperature around t he

exposure lam p for overheat prot ect i on.

Transformer Steps down the wall vol t age to 30 Vac and 8

Vac.

Overall

Information

1-11

SECTION 2

DETAILED DESCRIPTIONS

20 December 1996 DRUM

1. DRUM

1.1 OPC DRUM CHARACTERISTICS

The OPC (Organic Photoconductor) drum used in this copier is small in diameter (30 mm), ensuring good paper separation. An OPC drum has the following characteristics.

1. The drum is able to accept a high negative electrical charge in the dark. (The electrical resistance of a photoconductor is high in the absence of light.)

2. It dissipates the electrical charge when exposed to light. (Exposure to light greatly increases the conductivity of a photoconductor.)

3. The amount of charge dissipated is in direct proportion to the intensity of the light. That is, where stronger light is directed to the photoconductor surface, a smaller voltage remains on the drum.

4. An OPC drum is less sensitive to changes in temperature (when compared to selenium F type drums).

Detailed

Descriptions

5. During the drum’s life, drum residual voltage gradually increases and the photoconductive surface becomes worn. Therefore, some compensation for these characteristics is required.

2-1

DRUM 20 December 1996

1.2 DRIVE MECHANISM

[C]

[E]

[D]

[B]

[A]

A219D520.wmf

The drive from the main motor [A] is transmitted to the drum [B] through a series of gears, a timing belt [C], and the drum drive shaft [D].

When the imaging unit is installed in the copier, the drum drive shaft engages inside the drum’s flange [E] as shown.

2-2

20 December 1996 CHARGE

2. CHARGE

2.1 OVERVIEW

[A]

[B]

A219D505.wmf

[C]

Detailed

Descriptions

[D]

A219D521.wmf

This copier uses a single wire scorotron to charge the drum. The corona wire [A] generates a corona of negative ions when the high voltage supply unit applies a negative voltage. The stainless steel grid plate [B] ensures that the drum coating receives a uniform negative charge as it rotates past the corona unit.

The exhaust fan [C] causes a flow of air above and through the charge corona section. This prevents an uneven build-up of negative ions that can cause uneven image density.

An ozone filter [D], which absorbs ozone (O

) generated by the charge corona, is located beside the exhaust fan. The ozone filter decreases in efficiency over time as it absorbs ozone. The ozone filter should be replaced every PM cycle (45 k copies).

2-3

CHARGE 20 December 1996

2.2 CHARGE CORONA WIRE CLEANER MECHANISM

[C]

[D]

[A]

[B]

A219D536.wmf

Pads [A] move along the charge corona wire as the wire cleaner knob [B] is manually slid in and out.

The cleaner pad bracket [C] is connected to the wire cleaner knob. When the knob is pulled out, the pads move into contact with the corona wire as shown, since the casing [D] is narrower away from the home position.

The pads move away from the wire when the wire cleaner knob is fully inserted and the pad bracket is pushed back to the home position.

After copier installation, the key operator should be instructed to use this mechanism when copies have white streaks or uneven image density. Instruct the operator to firmly push the pad bracket into the home position. Poor copy quality will result if the cleaning pads remain in contact with the charge corona wire.

2-4

20 December 1996 CHARGE

2.3 CHARGE CORONA CIRCUIT

Main Board High Voltage Supply Board

24 V

GND

C Trigger

CN102-7 CN102-6 CN102-5

DC/DC

Converter

T Trigger

B-PWM

S Trigger

4.7 k

5 V

CN102-4

CN102-3

CN102-2

CN102-1

DC/DC

Converter

DC/DC

Converter

Zener Diode

DC/DC

Converter

Protection

Circuit

Drum

A219D506.wmf

Detailed

Descriptions

The main board supplies +24 V to the high voltage supply board at CN102-7. After the



key is pressed, the CPU drops CN102-5 from +24 V to 0 V. This activates the charge corona circuit which applies a high negative voltage of approximately –5 k volts to the charge corona wire. The corona wire then generates a negative corona charge.

The grid plate limits the charge voltage to ensure that the charge does not fluctuate and that an even charge is applied to the entire drum surface. The grid plate is connected to ground through a zener diode in the high voltage supply unit. The grid plate drains any charge in excess of –910 V, which is discharged to ground through the zener diode.

2-5

OPTICS 20 December 1996

3. OPTICS

3.1 OVERVIEW

[C][C] [A][B] [K] [E] [I] [G]

[D]

[F]

[H]

[J]

A219D507.wmf

During the copy cycle, an image of the original is reflected onto the drum surface through the optics assembly as follows:

Light path: Exposure Lamp [A] → Original → First Mirror [B] → Second Mirror [C] → Third Mirror [D] → Lens [E] → Blue Filter [F] → Fourth Mirror [G] → Fifth Mirror [H] → Sixth Mirror [I] → Drum [J]

This copier has eight standard reproduction ratios and a zoom function. The operator can also change the reproduction ratio in one-percent steps from 50% to 200%. Stepper motors are used to change the positions of the lens and 4th/5th mirrors to enlarge/reduce the image across the page. Changes in reproduction ratio down the page are achieved by changing the scanner speed.

The CPU monitors the temperature around the optics through a thermistor which is located on the scanner frame. When the temperature reaches 40°C, the optics cooling fan [K] starts rotating to draw cool air into the optics cavity. The fan operates until the temperature drops below 38°C.

Additionally, a thermofuse on the 1st scanner provides back-up overheat protection. It opens when the temperature reaches 128°C and cuts ac power to the exposure lamp.

A blue filter is located just after the lens to improve the reproduction of red areas of the original on copies.

2-6

20 December 1996 OPTICS

3.2 SCANNER DRIVE

[H]

[F]

[D]

[C]

[A]

Detailed

Descriptions

[E]

[B]

A219D522.wmf

[G]

A stepper motor [A] is used to drive the scanners. The first scanner [B], which consists of the exposure lamp and the first mirror,

is connected to the first scanner belt [C]. The second scanner [D], which consists of the second and third mirrors, is connected to the second scanner belt [E]. Both the scanners move along the guide rod [F].

There are no scanner drive wires, and only one side of the scanner is supported (by a rod and guide rail). Therefore, the scanners should be moved by moving the timing belt, and never by moving the scanners directly.

The pulley [G] drives both the first and second scanner belts. The 2nd scanner moves at half the speed of the first scanner. This maintains the focal distance between the original and the lens during scanning.

The scanner home position is detected by a home position sensor [H]. The scanner return position is determined by counting the scanner motor drive pulses.

2-7

OPTICS 20 December 1996

3.3 LENS DRIVE

[A]

[C]

A219D509.wmf

[B]

: Reduction : Enlargement

The lens motor [A] (stepper motor) changes the lens [B] position through the timing belt [C] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and the drum surface.

[D]

The rotation of the lens drive pulley moves the lens back and forth in discrete steps. The home position of the lens is detected by a home position sensor [D]. The main board keeps track of the lens position based on the number of pulses sent to the lens motor.

2-8

20 December 1996 OPTICS

3.4 4TH/5TH MIRROR DRIVE

[D]

[A]

[C]

[B]

A219D510.wmf

The 4th/5th mirror drive motor [A] (stepper motor) changes the 4th/5th mirror assembly position through the pinion gears [B] and the rack gear [C] in accordance with the selected reproduction ratio to provide the proper optical distance between the lens and drum surface.

Detailed

Descriptions

The home position of the 4th/5th mirror assembly is detected by a home position sensor [D]. The main board keeps track of the lens position based on the number of pulses sent to the 4th/5th mirror motor.

2-9

OPTICS 20 December 1996

3.5 AUTOMATIC IMAGE DENSITY SENSOR

[A]

A219D511.wmf

A219D512.wmf

The auto ID sensor [A], a photodiode, is mounted on the upper front frame. The sensor cover has a hole in it to allow light to fall directly onto the sensor.

Sampling starts 6 millimeters from the leading edge of the original and continues for 11.5 millimeters from the leading edge of original in full size mode. These lengths "a" and "b" will vary depending on the selected reproduction ratio. The lengths "a" and "b" for each reproduction ratio are calculated as follows:

Every original in ADS mode, the photosensor circuit converts the light intensity to a voltage. The detected voltage is amplified and sent to the main board. If less light is reflected from the original (the image is darker), the sensor outputs a lower voltage. The CPU compares the maximum ADS output voltage with the standard ADS reference voltage and compensates the copy image density by changing the development bias voltage in

accordance with the difference. The standard ADS reference voltage (2.5 ±

0.1 V) is generated by SP 56. Details about changes to the development bias voltage are explained in "Development Bias for Image Density Control".

2-10

20 December 1996 OPTICS

3.6 EXPOSURE LAMP VOLTAGE CONTROL

The main board controls the exposure lamp voltage through the ac drive/dc power supply board. The exposure lamp voltage is based on the base lamp voltage and various correction factors. The method of control is different depending on whether the image density is manually selected or the auto image density mode is selected.

The exposure lamp voltage is determined by the following factors:

Lamp Voltage = Base Lamp Voltage Setting (SP48)

*Image Density Adjustment Factor (SP34)

*Manual Image Density Setting Factor

Correction 1 Factor (SP62)

Correction 2 Factor

Reproduction Ratio Correction Factor

*NOTE:

SP34 (Image Density Adjustment Factor) is applied for ADS mode only. The "Manual Image Density Factor" is applied for manual ID mode only.

1) Base Lamp Voltage Setting The lamp voltage is determined by the SP48 setting.

Detailed

Descriptions

Base Lamp Voltage = SP48 setting x 0.5 (120 V machines)

SP48 setting x 1.0 (230 V machines)

The default setting is: 140 = 70 V (120 V machines)

140 = 140 V (230 V machines)

The current lamp voltage (after all correction factors are included) can be viewed with SP 51.

2-11

OPTICS 20 December 1996

2) Image Density Adjustment Factor (SP34) Depending on the SP34 setting, the development bias and the exposure

lamp settings are increased or decreased during ADS mode.

SP34 Setting Setting Dev. Bias Exposure Lamp

0Normal0 0 1 Light –40 V 0 2 Dark +40 V 0 3 Lightest –40 V +4 steps 4 Darkest +40 V –4 steps

1 step = 0.5 V (120 V machines) or 1.0 V (230 V machines)

3) Manual Image Density Setting Factor Depending on the manual image density setting on the operation panel, the

exposure lamp voltage is changed as shown in the table below:

LighterDarker

Manual ID

Level

Exposure Lamp Voltage Factor

Development Bias Voltage (Volts)

1234567

– 6

steps

–200 –200 –200 –200 –200 –240 –240

V0 – 4

steps

V0 – 2

steps

V0 + 2

steps

: Base lamp voltage setting (SP48)

1 step = 0.5 V (120 V machines) or 1.0 V (230 V machines)

V0 + 6

steps

V0 + 12

steps

2-12

20 December 1996 OPTICS

4) VL Correction 1 Factor The light intensity may decrease because of dust accumulated on the optics

parts. Additionally, the drum sensitivity gradually decreases during the drum’s life. This may cause dirty background on copies. To compensate for this, V

corrections 1 and 2 are done. The exposure lamp voltage is increased by two steps at the set copy count

interval (a step is +2.0 V for 230 V machines, and +1 V for 120 V machines). The table below shows the relationship between the SP setting and the interval.

SP62 Setting VL Correction Interval

0 2 steps/8,000 copies 1 2 steps/6,000 copies 2 2 steps/4,000 copies 3 2 steps/2,000 copies 4 2 steps/1,000 copies 5 No correc t i on

(Default setting: 2)

Detailed

Descriptions

VL correction 1 compensates for the decrease of drum sensitivity and the decrease in reflectivity of the 4th, 5th, and 6th mirrors due to dust.

5) V

Correction 2 Factor

correction 2 compensates for dust on the lens and mirrors 1 to 3, but is

independent of the drum condition. The ADS sensor receives the light reflected through the 1st, 2nd and 3rd

mirrors from the white plate located under the middle part of the left scale. The photosensor circuit converts this light intensity to a voltage, and the CPU stores this in memory as the white plate reference voltage. This is done every time SP56 (ADS reference voltage adjustment) is done, before sampling starts for the ADS sensor adjustment.

Every 500 copies, the machine reads the intensity of light reflected from the white plate and compares it with the white plate reference voltage.

If the measured voltage difference is more than 0.1 volt, +2 steps will be

added to the exposure lamp setting as the V The sum of V

correction factors 1 and 2 cannot exceed +40 steps.

correction 2 factor.

correction factors 1 and 2 are automatically reset every time the light

intensity is adjusted with SP48. (SP56 must be done immediately after SP48; see Service Remarks for details.)

2-13

OPTICS 20 December 1996

6) Reproduction Ratio Correction Factor The exposure lamp voltage is increased depending on the selected

magnification ratio in order to compensate for the change in concentration of light on the drum.

Magnification Ratio Reproduction Ratio Correction Factor

50% to 61% +2 steps 62% to 119% 0 120% to 139% +2 steps 140% to 159% +4 steps 160% to 179% +8 steps 180% to 200% +12 steps

1 step = 0.5 V (120 V machines) or 1.0 V (230 V machines)

2-14

20 December 1996 ERASE

4. ERASE

4.1 OVERVIEW

A219D513.wmf

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[A]

Detailed

Descriptions

A219D527.wmf

The erase lamp [A], which is installed in the copier main frame, consists of a single row of white LEDs (38 LEDs) extended across the full width of the drum. The erase lamp has the following functions: leading edge erase, side erase and trail edge erase. (Trail edge erase begins after the trailing edge of the copy paper; therefore, the trailing edge of the copy will not be erased.) In side erase mode, the appropriate LEDs turn on in accordance with the modes selected by the user.

2-15

ERASE 20 December 1996

4.2 LEAD EDGE ERASE

The entire line of LEDs turn on when the main motor turns on. They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum (Lead Edge Erase Margin). This prevents the shadow of the original edge from being developed on the copy. At this point, side erase starts. The width of the leading erase margin can be adjusted using SP41.

4.3 SID E ERASE

Based on the combination of copy paper size and the reproduction ratio data, the LEDs turn on in blocks (labeled "a" to "n" on the previous page). This reduces drum cleaning load.

Also, to prevent horizontal black lines from appearing on the edge of copies as a result of light leaking under the edge of the DF belt, the side erase combination is changed between platen mode and DF mode; in DF mode, more of the image is erased at the sides. (The setting of SP24 must be 0.)

-Platen Mode-

Blocks On Paper Size

None 99% to 200%

a to b 95% to 98%

a to c a to d 88% to 91% a to e

a to f 80% to 83%

a to g 75% to 79% a to h

a to i a to j 63% to 67%

a to k B5 59% to 62%

a to l 54% to 58%

a to m 50% to 53%

All (a to n)

11" x 17",

11" x 8

B4, B5

sideways

1/2

" x 11",

1/2

" x 5

Lengthwise

Lead Edge and Trai l Edge Erase

Reproduction

1/2

Ratio (%)

92% to 94%

84% to 87%

72% to 74%

68% to 71%

-DF Mode-

Blocks On Paper Size

None 99% to 200%

a to b 97% to 98% a to c a to d 90% to 92% a to e

a to f 81% to 85%

a to g 77% to 80% a to h

a to i a to j 65% to 69%

a to k B5 61% to 64%

a to l 56% to 60%

a to m 50% to 55%

All (a to n)

11" x 17",

11" x 8

B4, B5

sideways

1/2

" x 11",

1/2

" x 5

Lengthwise

Lead Edge and Trai l Edge Erase

Reproduction

1/2

Ratio (%)

93% to 96%

86% to 89%

73% to 76%

70% to 72%

2-16

20 December 1996 ERASE

4.4 TRAILING EDGE ERASE

This minimizes toner consumption. The entire line of LEDs turns on when the drum has turned 9 mm at the end

of scanning (about 100 ms). The LEDs stay on to erase the leading edge of the latent image in the next copy cycle. After the final copy, the erase lamps turn off at the same time as the main motor.

Detailed

Descriptions

2-17

DEVELOPMENT 20 December 1996

5. DEVELOPMENT

5.1 OVERVIEW

[D]

[C]

[A]

[E]

[B]

A219D514.wmf

When the main motor turns on, the development roller [A] and two agitators [B] and [C] start turning.

There are permanent magnets in the development roller which attract the developer particles (which are about 50 µm in diameter) to the roller. The turning sleeve of the development roller carries the developer past the doctor blade [D] which trims the developer to the desired thickness.

The development roller sleeve continues to turn, carrying the developer to the drum [E]. When the developer brush contacts the drum surface, the negatively charged areas of the drum surface attract and hold the positively charged toner. In this way, the latent image is developed.

The development roller is given a suitable negative bias for preventing toner from being attracted to the non-image areas on the drum which may have a residual negative charge. The bias also controls image density.

2-18

20 December 1996 DEVELOPMENT

5.2 DRIVE MECHANISM

[B]

[C]

[A]

A219D515.wmf

When the main motor [A] turns on, the drive is transmitted to the development drive shaft [B] through gears and a timing belt. The rotation of the development roller gear is transmitted to the agitator gears [C] through other gears.

Detailed

Descriptions

2-19

DEVELOPMENT 20 December 1996

5.3 CROSS-MIXING

[B]

[D]

[C]

[A]

A219D516.wmf

A cross-mixing mechanism is used to keep the toner and developer evenly mixed. It also helps agitate the developer to prevent developer clumps from forming and helps create the triboelectric charge.

Two agitators (helical coils) [A] and [B] are used for cross-mixing. The 1st agitator [A] moves the developer from left to right. The toner supplied from the cutout in the toner cartridge holder is mixed with the developer by the 1st agitator. The 2nd agitator [B] rotates to move the developer back from right to left. In this way, the developer is evenly distributed in the development unit.

The magnets in the development roller [C] attract the developer, and the development roller sleeve rotates to carry the developer to the drum. The doctor blade [D] trims the developer on the development roller to the desired thickness.

2-20

20 December 1996 DEVELOPMENT

5.4 DEVELOPMENT BIAS FOR IMAGE DENSITY CONTROL

The image density is controlled by changing two items: the amount of bias voltage applied to the development roller sleeve, and the amount of voltage applied to the exposure lamp.

Applying a bias voltage to the development sleeve reduces the potential between the development roller and the drum, thereby reducing the amount of toner transferred. As the bias voltage becomes greater, the copy becomes lighter.

The method of control depends on whether the image density is manually selected or auto image density is used.

The development bias voltage applied to the development roller sleeve has the following factors:

Development bias voltage = Base Bias Voltage

(Manual or auto image density mode)

*Image Bias Adjustment Factor (SP33)

*Image Density Adjustment Factor (SP34)

Drum Residual Voltage (V

) Correction Factor

Detailed

Descriptions

*NOTE:

Image Bias Adjustment Factor (SP33) is applied for manual ID mode only. Image Density Adjustment Factor (SP34) is applied for ADS mode only.

2-21

DEVELOPMENT 20 December 1996

5.4.1 Base Bias Voltage Factor in Manual Image Density Mode

Manual ID

Level

Exposure Lamp Voltage Factor

Development Bias Voltage (Volts)

1234567

– 6

steps

–200 –200 –200 –200 –200 –240 –240

V0 – 4

steps

V0 – 2

steps

V0 + 2

steps

: Depends on th e set t i ng of SP48

V0 + 6

steps

LighterDarker

V0 + 12

steps

When manual ID level 6 or 7 is selected, –40 V is added to the base bias voltage.

Using SP33 (Image Bias Adjustment), the base bias voltage can be increased or decreased for all manual ID levels as follows:

SP Setting Setting Dev. Bias Note

0Normal0 Default 1 Darkest +40 V 2Darker+20 V 3 Light er –20 V 4 Lightest –40 V

2-22

20 December 1996 DEVELOPMENT

5.4.2 Base Bias Voltage Factor in Automatic Image Density (ADS) Mode

The bias voltage for ADS mode depends on the background image density of the original which is measured by the ADS sensor. (See "Automatic Image Density Sensor" for more information about the ADS sensor.)

The CPU checks the voltage output from the automatic ID circuit. This circuit has a peak hold function. The peak hold voltage is the maximum ADS sensor output voltage, which corresponds to the maximum reflectivity of the original. The CPU then determines the proper base bias level by comparing this voltage (read from the original) with the standard ADS reference voltage.

The table below shows the relationship between the original background density (ADS voltage ratio) and the base bias voltage.

Detailed

Descriptions

ADS Voltage Ratio [α] (%)

80 to 100 (light ) –200 V

75 to 79 –240 V 70 to 74 –280 V 60 to 69 –320 V 29 to 59 –360 V

0 to 28 (dark) –380 V

ADS Voltage Ratio [α]

ADS0

: Standard ADS Reference Voltage (2.5 ± 0.1 V)

Maximum ADS Output Voltage

Bias Voltage

ADS0

Using SP34, the base bias voltage and the exposure lamp setting can be increased or decreased for the ADS mode as follows:

SP Setting Setting Dev. Bias Exposure Lamp

0Normal0 0 1 Light er –40 V 0 2Darker+40 V 0 3 Lightest –40 V +4 steps 4 Darkest +40 V –4 steps

(D efault Setting: 0)

5.4.3 Drum Residual Voltage (VR) Correction Factor

During the drum’s life, drum residual voltage (V

) will gradually increase. To

compensate for this, the bias voltage is increased by –20 V every 5 k copies. The V

correction is done up to 20 k copies. The VR correction will not

change after 20 k copies.

2-23

DEVELOPMENT 20 December 1996

5.5 DEVELOPMENT BIAS CIRCUIT

Main Board High Voltage Supply Board

24 V

GND

C Trigger

CN102-7 CN102-6 CN102-5

DC/DC

Converter

T Trigger

B-PWM

S Trigger

4.7 k

5 V

CN102-4

CN102-3

CN102-2

CN102-1

DC/DC

Converter

DC/DC

Converter

Zener Diode

DC/DC

Converter

Protection

Circuit

Drum

A219D506-2.wmf

The main board supplies +24 volts to the high voltage supply board from CN102-7. When the



key is pressed, the CPU starts sending the bias trigger pulses from CN102-3. This energizes the development bias circuit within the high voltage supply board, which applies a high negative voltage to the development roller. The development bias is applied whenever the drum is rotating.

2-24

20 December 1996 TONER SUPPLY

6. TONER SUPPLY

6.1 TONER BOTTLE REPLENISHMENT MECHANISM

[F]

[E]

[I]

[A]

[J]

[H]

[G]

Detailed

Descriptions

[D][C] [B]

A219D517.wmf

[K]

A219D518.wmf

When a toner bottle is placed on the bottle holder unit [A] and pushed back in completely, the following happens automatically.

•

The pin [B] on the imaging unit toner shutter [C] is pushed out (shutter opened) by the projection [D].

•

The pin [E] on the toner shutter [F] is pulled up (shutter opened) as a result of the shape of the developer cartridge.

When the toner bottle holder lever [G] is pushed down to the operation position, the following happens automatically to allow toner to be supplied to the development unit.

•

The shaft [H] is pushed out from the machine by the curved rail behind the toner bottle holder lever, and this pulls out the cap [I] into the chuck [J], where it is held.

The toner end detection system determines when to drive the toner bottle replenishment mechanism (see Toner End Detection). The toner supply mechanism transports toner from the bottle to the development unit. The toner bottle has a spiral groove [K] that helps move toner to the development unit.

When the bottle holder unit is pulled out to add new toner, the following happens automatically to prevent toner from scattering.

•

The chuck releases the toner bottle cap into its proper position.

•

Both shutters shut as a result of pressure from springs.

2-25

TONER SUPPLY 20 December 199 6

6.2 TONER SUPPLY MECHANISM

[A]

[B]

[E]

[C]

[F]

[D]

A219D519.wmf

The toner supply motor [A] drives the toner bottle [B] and the mylar blades [C]. First, the toner falls down into the toner holder. The two toner supply mylar blades transfer the toner to the opening [D], then the toner falls down into the development unit.

There is a notch [E] on the toner bottle, and a roller [F] located under the toner bottle. They both shake the toner bottle to prevent toner clumps from forming. They also help to transport the toner inside the toner bottle when the amount of toner inside is low.

2-26

20 December 1996 TONER SUPPLY

6.3 TONER DENSITY DETECTION MECHANISM

[B]

[A]

Detailed

Descriptions

A219D516-2.wmf

A toner density sensor (TD sensor) [A] is used for toner density control. The TD sensor is located under the 1st agitator [B]. The developer being

conveyed by the 1st agitator passes over the top of the sensor. As the toner in the developer is consumed during development, the toner to carrier ratio changes, resulting in a change in the magnetic permeability of the developer. This in turn is converted to a corresponding voltage. The CPU monitors the voltage to control the toner supply mechanism.

When new developer is installed, and SP66 (TD Sensor Initial Setting) is done, the machine starts idling for developer initialization. During developer initialization, the CPU adjusts the TD sensor control voltage so that the TD sensor outputs 1.9 ± 0.1 V for the toner to carrier ratio of new developer (4.0% by weight). This voltage is used as the standard TD sensor voltage.

2-27

TONER SUPPLY 20 December 199 6

6.4 TD SENSOR CHECK AND TONER SUPPLY TIMING

(seconds)

Original Scan

Drum Charge

TD Sensor

2 s

Toner Supply Motor

The TD sensor voltage is monitored for two seconds when the 1st copy drum charge starts. The CPU checks the voltage every 40 ms and stores the second highest voltage of every 240 ms period. The stored voltages during the two seconds are averaged, and then the average is used as the TD sensor value for that detection period. The related amount of toner is added by the toner supply motor (as described in Toner Supply Amount). The TD sensor is monitored for two-second intervals is until the last original scan is finished. Unlike a toner supply clutch mechanism, with a toner supply motor, the copier can add toner during image development.

2 s

A219D540.wmf

2-28

20 December 1996 TONER SUPPLY

6.5 TONER SUPPLY CONTROL

6.5.1 Modes Available NOTE:

The following pages explain how the various settings control the toner supply mechanism. They should not be adjusted in the field, unless instructed to do so as a countermeasure for a specific problem that may occur in the future.

SP30

Setting

3 4

Toner Supply

Mode

Detect Supply Mode

Fixed Supply Mode None Fixed

Target Toner

Sensor Voltage

Depends on the initial TD sensor setting (1.9 ± 0.1 V).

Depends on SP53 (input manually).

Depends on the initial TD sensor setting (1.9 ± 0.1 V).

Depends on SP53 (input manually).

Toner Supply

Depends on the TD sensor outp ut .

Fixed

Toner Near/End

Amount

Default setting: 0

Detection

Yes

No No

Depending on the SP30 setting, Detect Supply mode or Fixed Supply mode is selected. If 0, 1, 2, or 3 is selected with SP30, Detect Supply mode is used. If 4 is selected, Fixed Supply mode is used.

Detailed

Descriptions

Note that when 2, 3, or 4 is selected, the machine will not perform the toner near-end/end detection. Normally, SP30 should always be kept at the default setting. The following pages describe the toner supply mode settings in detail.

6.5.2 Detect Supply Mode

In Detect Supply mode, the CPU monitors the TD sensor voltage, which depends on the toner to carrier ratio in the developer. As the toner in the developer is consumed, the TD sensor output voltage increases.

The TD sensor voltage is compared with the standard voltage (known as the Target Toner Sensor Voltage), and toner is supplied when the TD sensor output is higher than this target voltage.

The machine has two ways of calculating the target toner sensor voltage (either the initial TD sensor setting is used, or a value can be input using SP53); the method used depends on SP30. The toner supply amount can also be changed using SP31 or 32.

2-29

TONER SUPPLY 20 December 199 6

1) Target Toner Sensor Voltage

- Method 1 -

Normally (if 0 or 2 is selected with SP30) the voltage is determined by the following factors:

Target Toner Sensor Voltage (V

) = Initial Developer Setting Voltage (VT0)

Toner Density Adjustment Factor

a) Initial Developer Setting Voltage (V

) This voltage is adjusted to 1.9 ± 0.1 V during developer initialization (refer to Toner Density Detection).

b) Toner Density Adjustment Factor The target toner density can be changed by customers or service engineers using SP mode 38 or user tool No. 6.

SP 38 Setting

0 0 Normal 0 1 1 Darker –S x 1/2 2 2 Lighter +S x 1/2 3Darkest–S 4 Lightest +S

User Tool 6

Setting

S: TD Sensor Sensitivity (SP36) De fa ul t : Nor m al

Toner Density

Adjustment Factor (β)

The sensor sensitivity is stored in SP36. TD Sensor Sensitivity (S) [V/wt%] = Change of TD sensor output [V]/Change of toner density [wt%] = SP36 setting x 0.05 [V] (Default: SP36 = 15)

- Method 2 -

If 1 or 3 is selected with SP30, the setting of SP53 is used as the target toner sensor voltage. In this case, the target toner sensor voltage is determined by the following formula:

Target Toner Sensor Voltage = SP53 setting x 0.02 [V] (Default: 97 = 1.94 V) The TD sensor initial setting is not changed by this SP mode. However, it is

ignored if method 2 is selected.

2-30

20 December 1996 TONER SUPPLY

2) Toner Supply Amoun t

- Method 1 -

Normally (if 0 or 1 is selected with SP30), the toner supply amount is determined by the difference between the actual TD sensor voltage (V the target toner sensor voltage (V

). The following table shows the

) and

relationship between the sensor output and the toner supply motor on time for each copy.

Toner Supply Level TD Sensor Voltage Level [VT] Toner Supply Motor On Time

1 2 3 4 5 6 (Near End Level) 7 (Toner End Level)

< VT ≤ VTS + S/16

+ S/16 < VT ≤ VTS + S/8

+ S/8 < VT ≤ VTS + S/4

+ S/4 < VT ≤ VTS + S/2

+ S/2 < VT ≤ VTS + 4S/5

≥ VTS + 4S/5

≥ VTS + S

The toner supply tim e unit "t" can be chang ed using SP31. t = SP31 setting x 0.1 [secon d] (Def ault: 4 = 0.4 second) S: TD Sensor Sensitivity (SP36) * This value can be changed using SP35.

t 2 x t 4 x t 8 x t

16 x t *10 seconds *10 seconds

- Method 2 -

If 2 or 3 is selected with SP30, a fixed amount of toner is supplied when the TD sensor voltage becomes higher than the target toner sensor voltage. The amount of toner can be selected using SP32.

SP32 Setting

00.3 3.5

10.6 7

21.2 15

32.4 30

43.6 45

54.8 60

7 0 (No toner supply) 0

Toner Supply Motor O n Ti me

(seconds)

Stays on until the TD sensor voltage becomes lower than the target voltage.

Corresponding image area ratio

(%)

Detailed

Descriptions

2-31

TONER SUPPLY 20 December 199 6

6.5.3 Fixed Supply Mode

If 4 is selected with SP30, the TD sensor is not used for toner supply control. A fixed amount of toner is supplied every copy cycle. The toner supply amount is determined by the SP32 setting.

6.5.4 Abnormal Condition in To ner D ensi t y D etection

If the output of the TD sensor goes below 0.2 volts (indicating far too much toner), the CPU determines that the toner density supply is abnormal. The CPU changes from the detect supply mode to the fixed supply mode. At the same time, either the Auto ID indicator or the selected manual ID level starts blinking, and the machine can be used. No SC code is generated. Under this condition, the machine will not perform the toner end detection.

If the value recovers above 0.2 volts, or the main switch is turned off and on, this condition is canceled and the toner density detection will recover to the toner supply mode that was in use immediately before the abnormal condition occurred.

2-32

20 December 1996 TONER SUPPLY

6.6 TONER END

Toner Supply Level TD Sensor Voltage Level [VT] Toner Supply Motor On Time

1 2 3 4 5 6 (Near End Level) 7 (Toner End Level)

6.6.1 Toner Near End

< VT ≤ VTS + S/16

+ S/16 < VT ≤ VTS + S/8

+ S/8 < VT ≤ VTS + S/4

+ S/4 < VT ≤ VTS + S/2

+ S/2 < VT ≤ VTS + 4S/5

≥ VTS + 4S/5

≥ VTS + S

The toner supply tim e unit "t" can be chang ed using SP31. t = SP31 setting x 0.1 [secon d] (Def ault: 4 = 0.4 second) S: TD Sensor Sensitivity (SP36) * This value can be changed using SP35.

t 2 x t 4 x t 8 x t

16 x t *10 seconds *10 seconds

Detailed

Descriptions

If the CPU detects toner supply level 6 (V

≥ VTS + 4S/5) five times

consecutively, the toner end indicator blinks and the machine goes to the toner near end condition.

In this condition, the toner supply motor is energized for 10 seconds for every copy (this time can be changed using SP35). Also, the toner supply motor stays on continuously between pages of a multi-copy job.

If a toner sensor voltage lower than V

+ 4S/5 is detected twice consecutively while the toner supply motor is on, the machine recovers from the toner near end condition. Also, if this condition is detected during the normal copy cycle, the toner near end is canceled.

6.6.2 Toner End

If toner supply level 6 is detected, the machine supplies toner between copies and for 10 seconds after the copy job is finished (as explained above). While the toner supply motor is on, if the CPU detects toner supply level 7

≥ VTS +S) three times consecutively, a toner end condition is detected

(V and copier operation is disabled.

If the toner sensor voltage stays at level 6 after the toner near end condition is detected, 50 more copies can be made. After 50 copies, the toner end indicator lights and copying is disabled.

2-33

TONER SUPPLY 20 December 199 6

6.6.3 Toner End Recovery

If the main switch is turned off and on, or the front door is opened and closed during a toner end condition, the machine checks the toner bottle for replacement. The main motor turns on and the toner supply motor is intermittently energized. If the TD sensor voltage does not recover from level 7 within 40 seconds, the machine stops, keeping the toner end condition. If

the TD sensor voltage becomes lower than V

+3S/5 in this period, the machine recovers from the toner end condition. Then the toner supply motor stops, but the main motor continuously rotates for 40 seconds to distribute toner evenly inside the development unit.

2-34

20 December 1996 IMAGE TRANSFER AND PAPER SEPARATION

7. IMAGE TRANSFER AND PAPER

SEPARATION

7.1 OVERALL

Detailed

Descriptions

[B]

[A]

A219D528.wmf

A high negative voltage (approximately –5 kV) is applied to the transfer corona wire [A], and the corona wire generates negative ions. These negative ions are applied to the back side of the copy paper. This negative charge forces the paper against the drum and attracts the positively charged toner onto the paper.

A high positive voltage (approximately +2.2 kV) is applied to the discharge plate [B]. The negative charge on the copy paper is discharged after image transfer by this discharge plate to ensure paper separation from the drum.

2-35

IMAGE TRANSFER AND PAPER SEPARATION 20 December 1996

7.2 TRANSFER CORONA AND DISCHARGE PLATE CIRCUIT

Main Board High Voltage Supply Board

24 V

GND

C Trigger

CN102-7 CN102-6 CN102-5

DC/DC

Converter

T Trigger

B-PWM

S Trigger

4.7 k

5 V

CN102-4

CN102-3

CN102-2

CN102-1

DC/DC

Converter

DC/DC

Converter

Zener Diode

DC/DC

Converter

Protection

Circuit

Drum

A219D506-3.wmf

When the CPU drops CN102-4 from +24 V to 0 V, the transfer corona is applied to the drum. When the CPU drops CN102-2 from 24 V to 0 V, a high positive voltage (+2.2 kV) is applied to the discharge plate.

2-36

20 December 1996 DRUM CLEANING

8. DRUM CLEANING

8.1 OVERVIEW

[A]

Detailed

Descriptions

A219D528-2.wmf

A counter blade system is used for drum cleaning. The cleaning blade [A] scrapes off any toner remaining on the drum after the image is transferred to the paper.

The removed toner is transported into the developer to be recycled.

2-37

DRUM CLEANING 20 December 1996

8.2 TONER RECYCLING MECHANISM

[A]

[B]

A219D530.wmf

The toner removed from the drum falls onto the toner collection coil [A]. The drum gear rotation is directly transmitted to the toner collection coil drive gear.

As the coil rotates, the toner moves from rear to front until it reaches the toner recycling belt [B]. The paddles of the belt, which is driven by the toner collection coil shaft, transports the toner into the developer, and the toner is recycled.

2-38

20 December 1996 QUENCHING

9. QUENCHING

[A]

Detailed

Descriptions

A219D513-2.wmf

In preparation for the next copy cycle, light from the quenching lamp (QL) [A], which is installed in the upper unit, neutralizes any charge remaining on the drum.

LEDs are used for quenching and the lamp is turned on whenever the main motor rotates.

2-39

PAPER FEED AND REGISTRATION 20 December 1996

10. PAPER FEED AND REGISTRATION

10.1 OVERVIEW

[B]

[C]

[D]

[E]

[A]

A219D500.wmf

This copier has one paper feed station and a by-pass feed table. The paper feed station uses a paper tray [A] which can hold 500 sheets. The

by-pass feed table [B] can hold 80 sheets. The paper tray uses two semicircular feed rollers [C] and a corner separator.

The semicircular feed rollers make one rotation to drive the top sheet of the paper stack to the relay rollers [D]. The paper tray has two corner separators, which allow only one sheet to feed. They also hold the paper stack. When the paper tray is drawn out of the machine, the spring pressure is released, and the tray bottom plate drops. In addition, there is no need to press the bottom plate down when putting the tray back in.

The by-pass feed table uses a feed roller and friction pad system to feed the top sheet of paper to the registration rollers.

In humid environments, copy paper may crease as it comes out of the fusing unit. The optional tray heater [E] is available as a service part to keep copy paper dry.

2-40

20 December 1996 PAPER FEED AND REGISTRATION

10.2 PAPER TRAY FEED

10.2.1 Paper Lift Mechanism

[A]

[B]

[H]

[C]

[J]

[E]

[D]

A219D534.wmf

[I]

[G]

[F]

[K]

A219D535.wmf

The capacity of this tray is higher than usual for a corner separator type. Because of this, there are two springs to lift the bottom plate.

As the tray is pushed into the machine, shutter [A] under the tray pushes against projection [B]. As the shutter slides past the projection, the shutter rotates, which forces the main lift spring [C] to pull the bottom plate lever [D]. The secondary lift spring [E] also pulls the bottom plate lever (this is described below).

The tension applied to the main lift spring is always the same. However, the secondary spring is only used when wider paper is installed, to lift the extra weight of the paper stack. The tension applied to the secondary lift spring depends on the paper width. Below a certain threshold width, tension is not applied. Above this width, the wider the paper, the more tension is applied. To apply spring tension for wider paper, projection [F] stops against the end of rail [G]. When this happens, lever [H] swings out in the direction shown above, which stretches the spring as the tray is pushed in. The side fence position affects the orientation of [F]; wider paper causes [F] to contact [G] earlier, leading to greater spring tension when the tray has been pushed all the way in. For narrow paper, the secondary lift spring is not needed. The side fence orients projection [F] so that it slides past the rail as the tray is pushed into the machine, and the spring stays slack.

Detailed

Descriptions

The bottom plate stopper [I] rests on the bottom plate [J]. It stops the bottom plate at the maximum height. When the tray is getting empty, the corner separators [K] start to rise, and continue to rise as the amount of paper in the tray decreases, so that the paper is always at the correct height.

2-41

PAPER FEED AND REGISTRATION 20 December 1996

10.2.2 Paper Feed Mechanism

[E]

[D]

[A]

[C]

[B]

A219D508.wmf

[H]

[F]

[G]

A219D523.wmf

Through several gears and a timing belt, main motor rotation is transmitted to the tray paper feed clutch gear [A] and the relay roller clutch gear [B].

-Feed rollers-

The tray paper feed clutch gear is on the same shaft as the semicircular feed rollers [C]. After the



key is pressed, the tray paper feed clutch [D] is energized for 250 milliseconds to release the stopper [E]. Then the drive of the main motor is transmitted, and the feed rollers make one complete rotation to feed the top sheet of paper which is enough for the leading edge of the paper to be caught by the relay rollers [F]. The feed rollers stop when the stopper drops back into the notch at the end of one complete turn.

-Relay rollers-

The relay roller clutch gear is on the same shaft as the relay rollers. The rotation timing of the relay rollers is controlled by the relay roller clutch [G]. The CPU energizes the relay roller clutch after the



key is pressed (at the same time as the tray paper feed clutch). Paper is fed from the relay rollers to the registration rollers [H].

2-42

20 December 1996 PAPER FEED AND REGISTRATION

10.3 BY-PASS FEED

10.3.1 Overview

[A]

Detailed

Descriptions

A219D501.wmf

The by-pass feed table [A] can hold 80 sheets of paper. This machine does not have a by-pass feed cover sensor. The by-pass feed

indicator is always displayed on the operation panel. The Add Paper indicator will light when the user selects by-pass feed while the by-pass feed table is closed or if there is no paper on the by-pass feed table.

After the



key is pressed, the cpu energizes the by-pass feed clutch and

the by-pass feed roller starts to feed paper to the registration roller. This machine does not have any sensor or switch to determine the paper

size for by-pass feed. The machine will perform a full scan for all copies.

2-43

PAPER FEED AND REGISTRATION 20 December 1996

10.3.2 Paper Feed Mechanism and Paper End Detection

[A]

[C]

[D]

[B]

[F]

A219D524.wmf

[E]

A219D502.wmf

This machine uses a feed roller [A] and friction pad [B] mechanism, with drive from the main motor [C] transmitted when the by-pass feed clutch [D] turns on. The friction pad prevents all but the top sheet from feeding. Therefore, during paper feed, the top sheet of paper is separated from the stack and fed to the registration rollers.

Before placing paper on the by-pass feed table, the user must lower the by-pass feed table by using the lever [E]. This is to ensure that the paper is placed between the friction pad and the feed roller. Then, before starting to copy, it must be put back up to move the paper stack into contact with the feed roller.

When there is no paper on the by-pass feed table, the paper end feeler [F] drops into the cutout in the by-pass feed table and the by-pass feed paper end sensor is activated.

2-44

20 December 1996 PAPER FEED AND REGISTRATION

10.4 PAPER REGISTRATION

[A]

[B]

[E][F]

[C]

[D]

A219D529.wmf

A219D523-2.wmf

Main motor rotation is transmitted to the registration roller clutch gear [A] through several gears and a timing belt. When the registration clutch [B] is energized, the rotation of the clutch gear is transmitted to the lower registration roller [C].

Detailed

Descriptions

The registration sensor [D], which is positioned just before the registration rollers, controls the relay roller clutch stop timing. The relay roller clutch stays on for 130 milliseconds after the leading edge of the paper actuates the registration sensor. The CPU then turns off the relay roller clutch. This delay allows time for the paper to press against the registration rollers and buckle slightly to correct skew.

The CPU energizes the registration clutch at the proper time to align the paper with the image on the drum.

The registration sensor is also used for paper misfeed detection. The paper dust mylar [E] on the upper registration roller [F] removes paper

dust before the paper reaches the transfer/separation unit.

2-45

PAPER FEED AND REGISTRATION 20 December 1996

10.5 SIDE FENCE DOUBLE STOPPER MECHANISM

[B]

[A]

[B]

A219D503.wmf

There is a side fence stopper mechanism for both the front and rear side fences.

If the tray is closed with excessive force after loading paper, paper may come over the rear side fence, because the fence is deformed by the weight of the paper leaning against it. As a result, skewing or paper jams may occur. To prevent this, a side fence stopper mechanism has been added to the rear side fence.

The release levers [A] each have a stopper which contains teeth like those on a gear. The guide rails [B] also have teeth. When the release lever is pushed, the gear teeth release each other and the side fences can be moved.

2-46

20 December 1996 PAPER FEED AND REGISTRATION

10.6 PAPER END DETECTION

[B]

[D]

[A]

Detailed

[E]

Descriptions

[C]

A219D504.wmf

The paper end feeler [A] is on the same shaft as the paper end actuator [B]. When the paper tray runs out of paper, the paper end feeler drops into the cutout [C] in the tray bottom plate. The paper end actuator activates the paper end sensor [D].

The paper end actuator is in contact with the lever [E]. When the tray is drawn out, the lever turns as shown by the arrow in the diagram. Then the lever pushes up the actuator. As a result, the feeler rotates upwards. This mechanism is necessary to prevent the feeler from getting damaged by the paper tray body.

2-47

PAPER FEED AND REGISTRATION 20 December 1996

10.7 PAPER FEED AND MISFEED DETECTION TIMING

Start Key

Main Motor

Tray Paper Feed Clutch

Relay Roller Clutch

Registration Clutch

Registration Sensor

Exit Sensor

A4 sideways

0.10 0.35

0.13

2.09

2.01

(1)

4.97

(2)

(second)

7.45

(3)

7.80

(4)

A219D526.wmf

The registration sensor and the exit sensor are used for misfeed detection. If the CPU detects a misfeed, the Check Paper Path and the Location indicators turn on.

Just after the main switch is turned on, the CPU checks these sensors for any jammed paper.

During the copy cycle, the CPU performs four kinds of misfeed detection. The following explains jam detection timing for copying A4 sideways paper.

(1): Checks whether the registration sensor is actuated within 2.01 seconds

after the

(2): Checks whether the exit sensor is actuated within 4.97 seconds after

the

(3): Checks whether the copy paper has passed through the registration

sensor 7.45 seconds after the

(4): Checks whether the copy paper has passed through the exit sensor

7.80 seconds after the

NOTE:

, ,

The detection timing for



key is pressed.



key is pressed.



key is pressed.



key is pressed.

(1) and , (2) are detected from the lead edge of the copy paper. (3) and , (4) are detected from the trail edge of the copy paper.

(3) and , (4) will vary with the

copy paper size in use.

2-48

20 December 1996 PAPER FEED AND REGISTRATION

10.8 OTHERS

[C]

(from right to left)

Size

1/2

"x13" )

"x14"

[B]

A219D525.wmf

A3, F( 8 A4 Lengthwise A4 Sideways A5 Sideways,

11"x17" B4, 8 B5 Sideways,

1/2

[A]

●: ON (Not pushed ) ❍: OFF (Pushed)

"x11"

B5 Lengthwise, 11"x8

* (Asterisk)

10.8.1 Paper Size Detection

There are four microswitches [A] on the front right plate of the main frame. The sensors are actuated by a paper size actuator [B] behind the paper size indicator plate on the front right of the tray. Each paper size has its own actuator, with a unique combination of notches. To determine which size tray has been installed, the cpu reads which switches have been pressed. The cpu disables paper feed if the paper size cannot be detected. If the paper size actuator is broken, or if there is no tray, the Add Paper indicator will light.

1234

●●●❍

●❍●❍

●●❍❍

●❍❍❍ ❍●❍❍ ❍❍❍❍

❍❍●❍ ❍❍●●

Detailed

Descriptions

When the paper size actuator is at the "*" mark, the paper tray can be set up to accommodate one of a wider range of paper sizes. The setting for this mode is performed with SP74. Paper length will be taken from this setting, and not from the registration sensor readings.

Because of the limited space on the operation panel, not all the paper sizes possible with the paper size actuator can be displayed on the operation panel. In some cases, the " * " mark will be displayed, but the machine will operate in accordance with the selected paper size. The paper size switch also acts as a tray open sensor.

10.8.2 Shock Absorber

At the position shown, a damper [C] is installed to reduce the shock to the paper tray when it is pushed back into the copier. This is to prevent the stack of paper inside the paper tray from coming over the corner separators, which will cause double feeding or image skew on copies.

2-49

IMAGE FUSING 20 December 1996

11. IMAGE FUSING

11.1 OVERVIEW

[A]

[E]

[B]

[D]

[F]

[C]

A219D531.wmf

[G]

A219D539.wmf

After the image is transferred, the copy paper enters the fusing unit. The image is fused to the copy paper by heat and pressure using a hot roller [A] and a pressure roller [B].

The CPU monitors the hot roller temperature through a thermistor [C] which is in contact with the hot roller surface. A thermofuse [D] prevents the fusing unit from overheating.

The hot roller strippers [E] separate the copy paper from the hot roller and direct it to the exit rollers. The exit sensor [F] monitors the progress of the copy paper through the fusing unit and acts as a misfeed detector. The exit rollers [G] drive the copy paper to the copy tray.

2-50

20 December 1996 IMAGE FUSING

11.2 FUSING DRIVE MECHANISM

[B]

[A]

[D]

A219D539-2.wmf

[E]

[C]

Detailed

Descriptions

[F]

[G]

A219D532.wmf

Drive from the main motor [A] is transmitted to the hot roller [B] through idle gears and a timing belt. The hot roller always rotates while the main motor rotates.

The fusing unit drive release mechanism automatically disengages the fusing drive gear [C] when the front cover [D] is opened. This allows the fusing unit drive gear to rotate freely so that misfed paper can be easily removed.

When the front cover is opened, the actuator plate [E] pulls the release wire [F]. The wire pulls the fusing unit gear bracket [G] and the fusing unit drive is disengaged.

2-51

IMAGE FUSING 20 December 1996

11.3 FUSING LAMP CONTROL

The CPU monitors the temperature of the hot roller surface using a thermistor. The fusing lamp is turned on and off to keep the hot roller surface at the target temperature. The target temperature depends on the machine condition as follows:

Machine Condition

Ready

After the main switch is turned on, until one minut e has passed since the fusing temperature reached the R eady condition.

After the above time period, the copier enters the energy saver mode.

During copying

Fusing Lamp ON/ O FF

Threshold

165°C: 120 V machines 172°C: 230 V machines

190°C

120°C: 120 V machines 130°C: 230 V machines

190°C

A219D533.wmf

Remarks

—

After the fusing temperature reaches the read y temperature, the fusing lam p i s kept on until it reaches 190°C.

When the  key is pressed, the red indicator blinks and copying starts after the fusing temperature reaches the Ready condition.

—

2-52

20 December 1996 IMAGE FUSING

When the main switch is turned on, the CPU turns on the fusing lamp. When the fusing thermistor detects the ready temperature, the machine enters the ready condition. After the ready temperature is detected, the CPU keeps the fusing temperature at 190°C for one minute, then the target temperature is

changed to 120°C (120 V machines) or 130° C (230 V machines). When the



key is pressed, if the fusing lamp temperature is higher than the ready temperature, the machine starts copying immediately. If the temperature is lower, the fusing lamp is turned on and the start indicator turns red and blinks. Copying starts after the fusing temperature reaches the ready temperature, and the fusing temperature is kept at 190ÉC during copying.

After copying is finished, the fusing temperature is kept at 190°C for one minute.

To prevent any copy quality problem caused by exposure lamp intensity fluctuation, the fusing lamp does not turn on while the exposure lamp is on, even if the fusing temperature drops below 190°C.

Detailed

Descriptions

2-53

IMAGE FUSING 20 December 1996

11.4 FUSING LAMP CONTROL CIRCUIT

11.4.1 Overview

CN113-1

Trigger Pulse

24 V

0 V

Main Board

CN113-2 5 V

CN101-3

24 V

CN101-4

CN207-7

CN207-6

FU1

T202

AC Power Source

T201

PC2

T208

✽

C20

✽

RY1

T207

T205

T206

T204

T203

AC Drive/DC Power

Supply Board

Fusing

Thermistor

Fusing Lamp

Main Switch

Interlock Switch

✽

230 V machines only

A219D537.wmf

The main board monitors the fusing temperature through a thermistor. It uses the zero cross signal generated by the ac drive/dc power supply board to control the applied power accurately.

Normally, the voltage applied to the lamp is the full duty cycle of the ac waveform. However, through SP29, fusing power can be set to phase control mode. (Phase control is used only if the customer has a problem with electrical noise or interference.)

2-54

20 December 1996 IMAGE FUSING

11.4.2 On/Off Control

When the main switch is turned on, the main board starts to output a trigger pulse, which has the same timing as the zero cross signal, to the ac drive/dc power supply board. This trigger pulse allows maximum ac power to be applied to the fusing lamp. When the operating temperature is reached, the CPU stops outputting the trigger pulse (the trigger stays HIGH) and the fusing lamp turns off.

11.4.3 Phase Control Mode

Detailed

Descriptions

A219D538.wmf

The main board sends the fusing lamp trigger pulse (LOW active) to the ac drive/dc power supply board, which provides ac power to the fusing lamp at the falling edge of each trigger pulse. The trigger pulse goes HIGH when the main board receives the zero cross signal.

The amount of time that power is applied to the fusing lamp depends on the temperature of the hot roller.

The trigger pulse (LOW part) is wider [C1] and power is supplied for longer [D1] when the hot roller temperature is lower. It is narrower [C2] and power is supplied for a shorter time [D2] when the hot roller is near the operating temperature.

2-55

IMAGE FUSING 20 December 1996

11.4.4 Overheat Protection

There is an overheat protection circuit in the main board. If the hot roller temperature reaches 245°C during the main motor off condition, or 255°C

during the main motor on condition, the resistance of the thermistor (between CN113-1 and CN113-2) becomes too low. If the main board detects this condition, "E-53" lights on the operation panel and power to the fusing lamp is cut.

Even if the thermistor overheat protection fails, the thermofuse opens when it reaches 169°C, removing power from the fusing lamp.

2-56

SECTION 3

INSTALLATION

20 December 1996 INSTALLATION REQUIR EM ENTS

1. INSTALLATION REQUIREMENTS

1.1 ENVIRONMENT

1. Temperature Range: 10°C to 30°C (50°F to 87°F)

2. Humidity Range: 15% to 90% RH

3. Ambient Illumination: Less than 1,500 lux (Do not exposure to direct

sunlight.)

4. Ventilation: Room air should turn over at least 3 times per

hour

5. Ambient Dust: Less than 0.15 mg/m

(4 x 10-3 oz/yd3)

6. If the place of installation is air-conditioned or heated, do not place the

machine:

1) Where it will not be subjected to sudden temperature changes.

2) Where it will not be directly exposed to cool air from an air-conditioner.

3) Where it will not be directly exposed to heat from a heater.

7. Do not place the machine where it will be exposed to corrosive gasses.

8. Do not install the machine at any location over 2,000 m (6,500 feet)

above sea level.

9. Place the copier on a strong and level base.

10. Do not place the machine where it may be subjected to strong vibrations.

1.2 MACHINE LEVEL

1. Front to back: Within 5 mm (0.2") of level

Installation

2. Right to left: Within 5 mm (0.2") of level

3-1

INSTALLATION REQUIREMENTS 20 December 1996

1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing clearance as shown:

More than 10 cm, 4.0"

More than 20 cm, 7.9"

More than 70 cm, 27.6"

1.4 POWER REQUIREME NTS

More than 21 cm, 8.1"

A219I506.wmf



CAUTION

1. Make sure the plug is firmly inserted in the outlet.

2. Avoid mult i- wiring.

3. Do not set anything on the power cord.

1. Input voltage level: 110 ~ 127 V/60 Hz: More than 15 A

220 ~ 240 V/50/60 Hz: More than 8 A

2. Permissible voltage

10%

fluctuation:

3-2

20 December 1996 COPIER (A219)

2. COPIER (A219)

2.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following list:

1. Model Name Decal (-10, -22 machines)

2. Symbol Explanation Decal - Multi-language

3. Installation Procedure - Multi-language (-10, -15, -22, -26 machines)

4. Operation Instructions - English (-10, -15, -17, -19, -22, -26, -29 machines)

5. NECR - English (-17 machines)

6. NECR - Multi-language (-27, -29 machines)

7. Copy Tray

8. User Survey Card (-17 machines)

9. Envelope for NECR (-17 machines)

Installation

3-3

COPIER (A219) 20 December 1996

2.2 INSTALLATION PROCEDURE

[B]

[A]

A219I500.wmf

[C]

[E]

A219I501.wmf



CAUTION

Do not plug in the power cord before starting the following procedure.

1. Remove all strips of tape shown above.

2. Pull out the paper tray [A], and remove the cardboard [B].

[D]

3. Open the front cover and raise the toner bottle holder lever [C]. Then pull down the securing lever [D], and remove the toner bottle holder [E].

3-4

20 December 1996 COPIER (A219)

[B]

[F]

[C]

[E]

[D]

[A]

Installation

A219I502.wmf

[G]

A219I503.wmf

4. Turn the "B1" lever [A] counterclockwise to lower the transfer corona unit.

5. Remove the knob screw [B] and gently pull out the imaging unit [C]. Then place it on a clean sheet of paper.

6. Remove the cover [D] from the imaging unit (1 screw and 1 snap [E]).

7. Pour in the developer [F] evenly into the imaging unit. Then rotate the outer gear [G] for one or two turns to distribute the developer as shown.

NOTE:

When installing new developer or manually rotating the development roller, always make sure to turn the gear in the direction shown above. Also do not rotate the gear more than 3 turns to prevent damage to the unit.

8. Remount the cover on the imaging unit, and install the unit in the copier (1 knob screw). Then turn the "B1" lever clockwise to raise the transfer corona unit.

3-5

COPIER (A219) 20 December 1996

[B]

[D]

[F]

[C]

[H]

[G]

[A]

[E]

A219I504.wmf

9. Install the toner bottle holder [A] in the copier as shown.

10. Shake the toner bottle [B] well.

NOTE:

Do not remove the bottle cap [C] of the toner bottle at this time.

11. Unscrew the bottle cap and insert the toner bottle into the holder, so that the rib [D] rides the rail [E].

NOTE:

Do not open the inner bottle cap [F].

12. Reposition the holder by making sure that the securing lever [G] clicks. Then press down the holder lever [H] to secure the bottle. Close the front cover.

3-6

20 December 1996 COPIER (A219)

[E]

[C]

[B]

[A]

[C]

[D]

A219I505.wmf

13. Pull the paper tray [A] out and turn the paper size dial [B] to select the appropriate size. Adjust the side guides [C] and the end guide [D] to match the paper size.

NOTE:

1) Make sure the stack of paper is aligned, and that there is no space between the side guides and the paper stack.

Installation

2) Always push the paper tray in gently.

14. Plug in the copier and turn on the main switch. Wait until it warms up. (It takes about 45 seconds.)

15. Enter the SP mode as follows:

1) Press the



key.

2) Enter "107" using the numeric keys.

3) Hold down the



key for more than 3 seconds.

16. Perform the TD sensor initial setting as follows:

1) Enter "66" using the numeric keys.

2) Press the "Auto Image Density" key.

NOTE:

The machine will automatically stop when completed. (It takes about 1 minute.)

17. Turn the main switch off and on to exit SP mode.

18. Check the copy quality and machine operation.

19. Inform the customer of the notes in step 13 concerning the paper tray. Also find out if the customer changes paper sizes frequently. If not, inform the customer that the side guides can be fixed with a screw [E] to achieve better paper feed quality (use tapping screw M3 x 8).

3-7

DOCUMENT FEEDER (A 662) 20 December 1996

3. DOCUMENT FEEDER (A662)

3.1 ACCESSORY CHECK

Check the accessories against the following list: Description Q’ty

1. Voltage Reference Decal.................................................. 1

2. Thumb Screw M4 x 12...................................................... 2

3. Stud Screw (M3)............................................................... 2

4. Installation Procedure - English........................................ 1

5. NECR - Multi-language..................................................... 1

6. Interface Unit for A219 copier .......................................... 1

7. Accessory Kit for A203 copier .......................................... 1

Interface Unit Bracket.................................................. 1

•

Stud Screw (M4).......................................................... 2

•

Harness Clamp ........................................................... 1

•

Upper Unit Stand...... .................. ................................. 1

•

Stepped Screw (Short)................................................ 1

•

Stepped Screw (Long)................................................. 1

•

Magnet......................................................................... 1

•

Operation Decal .......................................................... 1

•

Screw Driver................................................................ 1

•

3-8

20 December 1996 DOCUMENT FEEDER (A662)

3.2 INSTALLATION PROCEDURE

[B]

[A]

[F] 230 ~ 240 V

[C]

[D] 220 ~ 230 V

[E]

A662I500.wmf

Installation



CAUTION

When installing the DF, make sure the copier is unplugged.

1. Remove the platen cover [A] from the copier.

2. Replace the 2 screws with the 2 stud screws [B].

Use the M3 stud screws for A219.

•

Use the M4 stud screws for A203.

•

3. Remove the strips of tape from the DF.



CAUTION

The next step (step 4) must be done only in 240 volt areas.

4. Perform the conversion from 220 ∼ 230 V to 240 V as follows:

1) Remove the main board cover [C] (2 screws).

2) Disconnect the connector for 220 ∼ 230 V [D] (Black Wire) from the ac

harness connector [E] and connect the connector for 240 V [F] (White Wire) to the ac harness connector.

A662I501.img

3) Reinstall the cover.

3-9

DOCUMENT FEEDER (A 662) 20 December 1996

[A]

[C]

[B]

A662I502.img

[F]

[E]

A662I503.wmf

[G]

[J]

[H]

[I]

A662I504.wmf

5. Insert the DF [A] into the holes [B] in the copier upper cover.

6. Secure the DF to the copier (2 thumb screws [C]).

7. Remove the rear cover [D] (2 screws) and cut away the portion [E] with cutting pliers as shown.

8. Locate the 4P connector [F] and connect it to the ADF interface board [G], then secure the DF interface unit [H] to the copier (1 screw).

[D]

9. Plug the connector [I] (3P) in to CN202 on the ac drive dc power supply board [J].

3-10

20 December 1996 DOCUMENT FEEDER (A662)

[C]

[A]

[B]

A662I505.wmf

[E]

[F]

[D]

A662I514.img

Installation

[F]

A662I515.img

10. Reinstall the rear cover.

11. Plug the optics fiber cable [A] into the DF and the copier.

12. Plug the power supply cord [B] of the DF into the outlet in the copier rear cover.

13. Attatch the voltage reference decal [C].

14. Check that the rubber pad [D] is in contact with the top of the operation panel cover. If it is not, remove the DF grip [E] (2 screws), then adjust the position of the magnet catch [F] so that the rubber pad is in contact with the top of the operation panel cover.

15. Turn on the main switch and check the operation of the DF.

3-11

SORTER (A657) 20 December 1996

4. SORTER (A657)

4.1 ACCESSORY CHECK

Check the accessories against the following list: Description Q’ty

1. Holder Bracket.................................................................. 1

2. Magnet Catch ................................................................... 1

3. Tapping Screw M4 x 6...................................................... 6

4. Grounding Screw M4 x 8.................................................. 1

5. Snap Ring......................................................................... 1

6. NECR - Multi-language..................................................... 1

7. Installation Procedure - English........................................ 1

3-12

20 December 1996 SORTER (A657)

4.2 INSTALLATION PROCEDURE

[A]

[C]

[B]

NOTE:

A657I500.wmf

[E]

[D]

A657I501.wmf

1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to an another location in the future.

2) Proper installation of the shipping retainers is required in order to avoid any transport damage.

Installation

3) Do not grasp the sorter by the top cover and stay as shown by [A]. Hold both sides of the sorter as shown by [B]. This is to prevent damage to the anti-static brush [C].



CAUTION

Unplug the copier power cord before star ting the follo wing procedure.

1. Remove the copy tray from the copier.

2. Remove the strips of tape [D] and styrofoam blocks [E].

3-13

SORTER (A657) 20 December 1996

[A]

[B]

[D]

A657I502.wmf

[C]

A657I503.wmf

3. Remove the 2 portions [A] on the left hand side of the copier with cutting pliers as shown.

4. Remove the rear cover [B] (2 screws).

5. Mount the sorter holder bracket [C] on the copier frame (3 tapping screws).

6. Mount the magnetic catch [D] near the exit cover (2 tapping screws).

3-14

20 December 1996 SORTER (A657)

[B]

[E]

[C]

[D]

[F]

[G]

[A]

A657I504.wmf

Installation

7. Install the sorter [A] on the sorter holder bracket [B] (1 snap ring) as shown.

8. Insert the sorter harness [C] and the grounding wire [D] through the opening in the lower left cover. Plug the connector in to CN130 [E] on the main control board, and secure the grounding wire to the copier frame [F] (1 M4 x 8 sc rew).

9. Secure the bracket [G] (1 tapping screw).

10. Reinstall the rear cover.

11. Plug in the copier power cord and turn on the main switch.

12. Enter SP mode as follows:

1) Press the

2) Enter "107" using the numeric keys.

3) Hold down the

13. Press the following sequence of keys to change the "SP 71" value to "1".

→ 3 →





key.



key for more than 3 seconds.

→ 3 →



14. Turn the main switch off and on.

15. Check the sorter’s operation.

3-15

OTHERS 20 December 1996

5. OTHERS

5.1 OPTICS ANTI-CONDENSATION HEATER INSTALLATION

(OPTION)

[E]

[B]

[A]

[C]

[D]

A219I507.wmf

NOTE:



Unplug the copier power cord before star ting the follo wing procedure.

1. Remove the rear cover. (See "Replacement and Adjustment - Exterior

2. Remove the exposure glass. (See "Replacement and Adjustment -

3. By using the timing belt [A], manually move the 1st and 2nd scanner units

The optics anti-condensation heater keeps water from condensing on the copier’s mirrors. Such condensation occurs at cold temperatures with high humidity, and causes the first few copies of the day to be dark, or even black. The heater is available as a service part. (See the parts catalog.)

CAUTION

Cover Removal".)

Exposure Glass Removal".)

away from the home position.

NOTE:

Move the scanners by using the timing belt as shown in the diagram. Do not handle the scanners directly.

3-16

20 December 1996 OTHERS

4. Pass the connector [B] through the opening [C], and mount the anit-condensation heater [D] as shown (1 screw).

5. Connect the red two-pin connector [E] at the rear of the copier to the heater’s connector [B] (red).

6. Make sure that scanner drive belt and mirrors do not touch the heater harness while they are functioning.

NOTE:

Tell the customer that even when the copier main switch is turned off, the copier power cord should be plugged in. Otherwise, the optics anti-condensation heater will not function.

Installation

3-17

OTHERS 20 December 1996

5.2 TRAY HEATER INSTALLATION (OPTION)

NOTE:

[H]

[G]

[F]

[E]

[C]

[B]

[A]

[D]

A219I508.wmf

The optional tray heater keeps copy paper dry. In humid environments, copy paper may crease as it comes out of the fusing unit. The heater is available as a service part. (See the parts catalog.)



CAUTION

Unplug the copier power cord before star ting the follo wing procedure.

1. Remove the paper tray. (See "Replacement and Adjustment - Paper Tray Removal".)

2. Connect the interface harness [A] to the tray heater [B]. Then mount the heater on the heater bracket [C] as shown (1 screw).

3. Mount the heater bracket on the bottom of the copier main frame, while passing the connector [D] through the opening [E] in the copier main frame as shown (1 screw).

4. Remove the rear cover [F] (2 screws).

5. Remove the transformer [G] (2 screws).

6. Locate the red two-pin connector [H] at the rear of the copier, and connect it to the heater’s connector (red), as shown.

NOTE:

Tell the customer that even when the copier main switch is turned off, the copier power cord should be plugged in. Otherwise, the tray heater will not function.

3-18

SECTION 4

SERVICE TABLES

20 December 1996 SERVICE REMARKS

1. SERVICE REMARKS

1.1 GENERAL CAUTIONS

1. To prevent physical injury, keep hands away from the mechanical drive components when the main switch is on (especially during the warm-up cycle). If the the Start indicator starts blinking and the copier starts making copies as soon as the warm-up cycle is completed.

2. Before disassembling or assembling any parts of the copier, make sure that the power cord is unplugged.

1.2 IMAGING UNIT

1. Always ensure the following when removing the imaging unit from the copier.



key is pressed before the copier finishes the warm-up cycle,

Do not touch the drum surface with bare hands. When the drum

•

surface is touched with fingers or becomes dirty, wipe it with a dry cloth.

Place the imaging unit on a clean and level place. Take care not to

•

scratch the drum from under the unit as there is no cover to protect it. Cover the imaging unit with sheets of paper to prevent the drum from

•

being exposed to light. Do not turn the imaging unit upside down. Toner and developer may

•

fall out from the unit.

2. Before pulling out the imaging unit, place a sheet of paper under the unit to catch any spilled toner.

3. Never use alcohol to clean the drum; alcohol dissolves the drum surface.

4. Take care not to scratch the drum as the photoconductive layer is thin and is easily damaged.

5. Never expose the drum to corrosive gases such as ammonia gas.

6. Store the imaging unit in a cool, dry place away from heat.

7. Do not touch the charge corona wire or the grid plate with bare hands. Oil stains may cause uneven image density on copies.

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Service

8. Clean the charge corona wire by pulling on the wire cleaning knob.

9. Clean the charge grid with a blower brush (not with a cloth).

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SERVICE REMARKS 20 December 1996

10. Be careful not to damage the edge of the cleaning blade.

11. After installing a new cleaning blade, be sure to apply setting powder evenly on the surface and edge of the blade.

12. When installing a

drum, do the following:

NEW

1) Apply setting powder to the entire surface of the drum.

2) Reinstall the drum and all other parts. Perform SP93 (V

Correction

Reset).

3) Open SP33 (Image Bias Adjustment - Manual ID Mode) and return the

setting to the normal value if it has been changed.

4) SP48 (Light Intensity Adjustment) - see the SP mode table for details.

5) SP56 (ADS Reference Voltage Adjustment) - see the SP mode table

for details.

13. When replacing developer, make sure that all toner and developer are cleaned from inside the imaging unit.

14. After installing

developer, reinstall the machine and perform SP66

NEW

(TD Sensor Initial Setting).

1.3 OPTICS

1. Clean the exposure glass with glass cleaner and a dry cloth to reduce the amount of static electricity on the glass surface.

2. Only use a clean soft cloth to clean the mirrors and reflectors.

3. Only use a blower brush to clean the 6th mirror and the lens.

4. Do not touch the following parts with bare hands:

1) Reflectors

2) Exposure Lamp

3) Mirrors and Lens

5. Do not change the cutout position of the reflectors as they are adjusted at the factory.

6. Always replace the 1st scanner unit as an assembly, as the matching of each set of exposure lamp and reflectors is performed at the factory.

7. Only use the scanner timing belts when manually moving the scanner units.

4-2

20 December 1996 SERVICE REMARKS

8. Whenever cleaning or replacing the optics, all the following actions must be done in order.

1) Optics cleaning

2) Open SP33 (Image Bias Adjustment - Manual ID Mode) and return the

setting to the normal value if it has been changed.

3) SP48 (Light Intensity Adjustment) - see the SP mode table for details

4) SP56 (ADS Reference Voltage Adjustment) - see the SP mode table

for details

1.4 TRANSFER CORONA

1. Clean the corona wire and casing with a blower brush.

2. Never loosen the two screws securing the entrance guide plate. The position is set with a special instrument at the factory to ensure proper image transfer onto the copy paper.

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1.5 FUSING UNIT

1. Be careful not to damage the edges of the hot roller strippers or their tension springs.

2. Do not touch the fusing lamp with bare hands.

3. Make sure that both fusing lamp insulators are properly set in the holders.

4. When handling the fusing unit, hold the unit by the bottom frame. Do not grasp it by the hot roller stripper bracket or by the fusing entrance guide as they are easily damaged. The upper frame tends to hold more heat than the lower frame. Be careful.

5. Do not rotate the rollers while the pressure springs are not installed and the hot roller strippers are in place. If done, the hot roller may be damaged by the strippers.

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SERVICE REMARKS 20 December 1996

1.6 PAPER FEED

1. Do not touch the feed rollers with bare hands.

2. The side fences and the end fence of the paper tray should be positioned correctly so that they securely hold the paper. Make sure the stack of paper is aligned, and that there is no space between the side guides and the paper stack.

3. Always push the paper tray in gently. The paper stack might go over the side fence or the corner separators, causing double feed or image skewing problems.

4. Avoid storing paper for a long time. At high temperature and high humidity, or at low temperature and low humidity, store paper in a plastic bag. This is especially important to decrease the amount of curls or waves that would lead to paper misfeeds.

5. Find out if the customer changes the paper size in the paper tray frequently. If not, inform the customer that the side guides can be fixed with a screw to achieve better paper feed quality (use tapping screw M3 x

8).

1.7 OTHERS

1. When replacing the main board, remove the EEPROM (IC112) from the old main board and place it on the new main board. Then install the new main board in the copier.

2. After installing a new main board with a new EEPROM (IC112), the Clear All Memory (SP99) procedure must be performed. (Do not perform SP99 if you have placed the old EEPROM on the new main board.)

3. Never perform SP99 (Clear All Memory) except for the following two cases:

a) When the copier malfunctions due to a damaged EEPROM. b) When replacing the EEPROM.

4. Whenever SP99 (Clear All Memory) is performed, the drum and developer must be replaced with new ones. Otherwise, copy quality might be seriously affected.

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20 December 1996 SERVICE REMARKS

5. Securely tighten the screws used for grounding the following PCBs when reinstalling them.

Main Control Board

•

AC Drive/DC Power Supply Board

•

High Voltage Supply Board C/G/B/T/S

•

6. If the optional tray and anti-condensation heaters have been installed, keep the copier power cord plugged in, even when the copier main switch is turned off. This keeps the heaters energized.

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4-5

PROGRAM MODES 20 December 1996

2. PROGRAM MODES

2.1 BASIC OPERATION

1. Component

This copier is equipped with two program modes. One is the Service Program (SP) Mode for factory and field technician usage, and the other is the User Program (UP) mode for the user. Both program modes have a different access procedure, but all the UP mode functions can be accessed from the SP mode.

To be able to reset a service call (E5) condition using SP mode, the SP mode can be accessed while the error condition exists. The error code will not be displayed in the copy counter during these conditions.

2. Operation

To access these program modes, certain keys must be pressed after turning on the main switch. After accessing, select the required mode number and perform the procedure needed for that function. It is possible to move on to the next required mode without exiting each time.

To exit these modes, turn the main switch off/on.

3. Display

The Copy Counter is used to display the program mode number. The Magnification Ratio display is used to display the current value.

When the to

accept a program mode number

displayed when you input it.) The Magnification Ratio display is blinking at this time.

When the machine is ready to the current adjustment value on the Magnification Ratio display.

4. Notes

With the exception of SP57, all copies made inside the program modes are made with ID level 4 (center value).

Copy Counter is blinki ng

Copy Counter stops blinki ng

accept an adjustment value

, and the . (The program mode number is

dot is lit

, and the

, the machine is ready

dot starts blinking

, and it may be displaying

, the

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20 December 1996 PROGRAM MO D ES

2.2 SP MODE

1. Service Program Mode Access Procedure

How to enter the SP mode

1. Press the following keys in sequence.

→



NOTE:

2. When SP mode is selected, "1" blinks in the Copy Counter, and a dot (•) will appear in the top left corner of the Copy Counter. Also, the Auto Image Density indicator starts blinking, and the magnification ratio display turns off.

How to enter the UP mode

1. Press the following keys in sequence to enter the UP mode.



* Hold the final

2. How to Select the Program Number

1. By using the Number keys, enter the required program number. At this point, the Copy Counter will be blinking, and the dot (•) will be lit.

1) The above procedure must be finished within 20 seconds.

2) Hold the final

→





→



→





key for more than 3 seconds.

→



key for more than 3 seconds.



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2. When the Auto Image Density key is pressed, the number which is currently blinking in the Copy Counter will be entered as the selected program number.

3. Changing the Value of an SP Mode

1. Enter the desired value or setting using the Number keys.

NOTE:

2. When the Auto Image Density key is pressed, the number which is currently displayed in the Copy Counter will be entered as the new value or setting, and will be stored in memory.

3. The copier is ready to accept a new program number. Repeat from step 1 or leave SP mode by turning the main switch off/on.

After changing the value (setting), the previous value (setting) can be recalled again if the

4-7



key is pressed at this point.

PROGRAM MODES 20 December 1996

2.3 SP MODE QUICK REFERENCE TABLE

SP Mode

No.

Function

Forced Start (Free Run)

Free Run with Exposure Lamp Off

SP Mode

No.

*41

*42

Function

Lead Edge Erase Margi n Adjustment

Registration Adjustment

6 Misfeed Detection Off *43 Vertical Magnification Adjustment 7

Free Run

*44

Horizontal M agnification Adjustment

8 Input Ch eck 45 Registratio n Buckle Adjustment 9

Output Check

Registration Buckle Adjustment -

A5 Paper 10 Scanner Free Run *47 F ocus Adjustment 11 All Indicators On *48 Light Intensity Adjustment 14 Auto Shut Off Time (Energy Star) 49 Fusing Temperature Adjustment

Auto Reset Time Set t ing (Energy Saver)

Fusing Ready Tem perature

Adjustment 16 Count Up/Down Selection 51 Exposure Lamp Voltag e D i spl ay 17 Narrow Paper Select Mode 52 Fusing Temperature Display

Auto Feed Station Shift (Japanese Market Only)

TD Sensor Target Control

Voltage Adjustme nt 19 ADS Priority 54 TD Sensor Gain Adjustment 22 SADF Shut Off Time 55 TD Sensor Output Display Data

Horizontal Edge Margin Widt h Adjustment

ADS Reference Voltage

Adjustment 28 Auto Sort Select 57 ADS Output Voltage Display

Fusing Temperature Control Selection

Toner Supply Mode Selection

Toner Supply Amount (TD Sensor Mode )

Toner Supply Amount (Fixed Supply Mode)

Image Bias Adjust ment (Manual ID Mode)

Image Density Adj ust m ent (ADS Mode)

Total Toner Supply ON Time During Toner Near/End Condition

Optics Temperature Disp lay

Drum Potential M easurement

(With Paper)

Drum Potential M easurement

(Without Paper)

Correction Interval

Forced Toner Supp l y

Correction Value

TD Sensor Initial Setting

36 TD Sensor Sensitivity Setting 67 TD Sensor Initial Output Display

38 Toner Density Adjustment 68 V

Correction Selection

* Items listed on the factory setting data sheet

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20 December 1996 PROGRAM MO D ES

SP Mode

No.

Function

69 Imaging Unit Counter Disp l ay 94 V 71 Sorter Operation 95 V

SP Mode

No.

Function

Correction Reset

Correction Reset 74 Special Paper Size Setting 96 Toner End Force Cancel 76 Sorter Bin Capacity 97 Service Call (E5) Reset

Auto Shut Off (Energy Star) On/Off

Total Counter Clear

78 Auto Energy Saver Mode On/Off 99 Clear All Memory 81

Factory Initialization

Data Communication

100

101

By-pass Feed Copy Counter Display

Paper Feed Tray Copy Counter

Display 83 Factory Potential Adjustment 106 DF Origina l Counter Display 88 Total Copy Counter Display 130 Total Service Calls 90 Factory Data and Counter Clear 131 Total Misfeeds

93 V

Correction Reset

* Items listed on the factory setting data sheet

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Service

2.4 UP MODE AND SP MODE CROSS REFERENCE TABLE

UP Mode No. SP Mode No. Function

1 34 Image Densi t y Adj ustment (ADS Mode) 2 17 Narrow Paper Select Mode 3 15 Auto Reset Tim e Set ting (Energy Saver) 4 78 Auto Energy Saver Mode On/Off 5 14 Auto Shut Off Time Setti ng (Energy Star) 6 38 Toner Density Ad just ment 7 16 Count Up/Down Selection

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PROGRAM MODES 20 December 1996

2.5 SERVICE PROGRAM MODE TABLE

1. In the

2. In the

Function

Settings

column, comments (extra information) are in italics.

column, the default value is printed in bold letters.

3. If there is a ✝ mark in the Mode No. column, copies can be made within this SP Mode.

Mode No. Function Settings

Forced Start (Free Run)

Free Run with Exposure Lamp Off

Misfeed Detection Off

Free Run Performs a free run with the exposure lamp on.

Performs a free run with a forced start. Press the  key to start the free tun. Press the  key to stop the free run.

If this mode is swi t ched on, the copier st ar ts the free run even if the fusing temperature has not reached the required value yet. This mode i s per f o r m ed w i t h the selected paper size and magnif i cat i on ratio without the paper feed clutch or total counter increment.

Normally, use SP7 to prevent fusing-related service call conditions from occurring.

A free run is performed without exposure. Press the  key to start the free run. Press the  key to stop the free run.

This mode i s per f o r m ed w i t h the selected paper size and magnif i cat i on ratio without the paper feed clutch or total counter increment.

Normally, u se SP7 t o reduce the cleaning blade load.

Copies are made without misf eed detection by the registration, exit sensors, and sorter paper sensor.

✝

Press the  key to make a copy. It stops when reaching th e set count, or when the  key is pressed.

Use this mode to check whether a pap er misfeed was caused b y a sensor malfunction.

The total counter increments when copi es ar e made in this mode.

Press the  key to start the free run. Press the  key to stop the free run.

This mode i s per f o r m ed w i t h the selected paper size and magnif i cat i on ratio without the paper feed clutch or total counter increment.

Before starting, close the platen cover to reduce the clea n ing blade lo ad.

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SHARP SFT 4015 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

 IMPORTANT SAFETY NOTICES

DETAILED DESCRIPTIONS

INSTALLATION

SERVICE TABLES