Xerox B8090 Service Manual

Machine Overview........................................................................................................... 8-3

Power.............................................................................................................................. 8-5

User Interface..................................................................................................................8-10

Machine Run Control ...................................................................................................... 8-12

Single Pass Document Handler (SPDH)......................................................................... 8-18

Fusing and Copy Transportation..................................................................................... 8-33

Low Capacity Stapler Stacker (2K LCSS)....................................................................... 8-47

LVF BM ........................................................................................................................... 8-56

High Volume Finisher (HVF)........................................................................................... 8-75

Fax .................................................................................................................................. 8-98

Main Drive Module .......................................................................................................... 8-98

Scanner Module.............................................................................................................. 8-102

LED Print Head (LPH)..................................................................................................... 8-108

Paper Supply................................................................................................................... 8-111

Paper Transportation and Registration ........................................................................... 8-136

Xerographics................................................................................................................... 8-140

8 Principles of Operation

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

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Principles of Operation

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Xerox® AltaLink® B8090 Family Multifunction Printer

Machine Overview

Configuration Options

The Xerox® AltaLink® B8090 Family is available as a basic machine with trays 1, 2, 3, 4 and 5 (bypass tray) plus an optional tray 6 (external paper feede r platform - PFP). Five machine speeds are available in two variants.

First machine variant:

• AltaLink® B8045 - 45 ppm

• AltaLink® B8055 - 55 ppm Second machine variant:

• AltaLink® B8065 - 65 ppm

• AltaLink® B8075 - 75 ppm

• AltaLink® B8090 - 90 ppm Refer to Overview within the Main Drive Module section for details of the two variants and how

the speeds are achieved.

General

For the space requirements, environment range and the print out time. Refer to:

• GP 21 Installation Space Requirements.

• GP 23 Environmental Data.

• GP 25 First Copy / Print Out Time and Power On / Off Time.

Paper Supply and Paper Handling Options

• 200 sheet single pass document handler (SPDH).

• Two 500 sheet paper trays (designated tray 1 and tray 2).

• 3600 sheet high capacity feeder (designated trays 3 and 4).

• 100 sheet bypass tray (designated tray 5).

• Optional 3300 sheet high capacity feeder (designated tray 6).

Output Options

• A horizontal transport is also installed when a finisher is fitted.

• Office finisher (2K LCSS). See 2K LCSS General Description.

• Office finisher with booklet maker (LVF BM). See LVF BM General Description.

• High volume finisher (HVF). See HVF General Description.

• High volume finisher with booklet maker (HVF BM). See Booklet Maker Module.

• Post print inserter (PPI) used with an HVF BM. See Tray 7 Inserter .

• Tri-folder used with an HVF and HVF BM. See Tri-Folder.

Table 1 describes finisher and paper handling options for each speed variant.

Table 1 Paper handling and finisher options

Tray 6 (PFP)

45ppm Yes Centre tray or horizontal transport Yes Yes No 55ppm Yes Centre tray or horizontal transport Yes Yes No 65ppm Yes Centre tray or horizontal transport Yes Yes Yes 75ppm Yes Centre tray or horizontal transport Yes Yes Yes 90ppm Yes Horizontal transport only No No Yes

Centre tray or horizontal transport

2K LCSS LVF BM

HVF BM Tri folder/ PPI

NOTE: If an incompatible fin isher is installed the s tatus line will displa y Status Code 12.765 Incompatible/unknown finisher detec ted .

Registration

The AltaLink® B8090F are centre registered multifunction printers as follows:

• Side 1 scanning: – Centre registered document guides are used when the document is scanned

through the single pass document handler.

– Edge registered when the document is manually placed on the platen glass.

• Side 2 scanning - centr e registered document guides ar e used when the document is scanned through the single pass document handler.

• All paper trays use centre registered paper guides.

• The paper is not actively registered along the paper path.

•2K LCSS: – Stacking - centred by tampers – Stapling - centred by tampers – Hole punching - no active registration

• LVF BM: – Stacking - centred by tampers – Stapling - centred by tampers – Hole punching - no active registration – Booklet making - centred by tampers

•HVF BM: – Stacking - centred by tampers – Stapling - centred by tampers – Hole punching - centred by activ e re gistrat ion. A s ensor d etects th e to p edge of the

paper. The control board co mmands a motor to move the punch into the d esired position.

– Booklet making - centred by tampers

Accessories and Kits

• Workshelf.

• 50 sheet convenience stapler.

• 2 hole punch kit.

• Legal 2 hole punch kit.

• 3 hole punch kit.

• 4 hole punch kit.

• Swedish 4 hole punch kit.

• 1 Line Fax kit.

• 2 Line Fax kit.

• Scan to PC desktop SE - standard.

• Scan to PC desktop SE - professional.

• Nationalization kits.

• Foreign device interface kit.

• Tray 2/4 lock kit.

• Envelope tray feed kit.

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Principles of Operation

• Unicode international printing kit.

• Secure access kit.

• Common access card.

• McAfee Integrity Control enablement kit.

• XPS enablement kit.

• Wireless print kit.

• Smartcard kit.

• User interface external keyboard.

Consumables and Billing

There are three types of consumables:

• Print cartridge

• Toner cartridge

• Fuser for full details of consumables refer to GP 39. For full details of billing and service plans refer to

GP 9.

Machine Identificatio n

• Figure 1 AltaLink® B8075 with centre output tray and workshelf.

• Figure 2 AltaLink® B8055 with 2K LCSS.

• Figure 3 AltaLink® B8065/B8075 with LVF BM.

• Figure 4 AltaLink® B8090 with tray 6, HVF BM, inserter and tri folder.

Figure 2 Machine with 2K LCSS

Figure 1 With centre output tray and workshelf

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Figure 3 Machine with LVF BM

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Xerox® AltaLink® B8090 Family Multifunction Printer

Figure 4 With tray 6, HVF BM, tray 7, tri-folder

Power

Power Generation and Distribution

System Operating Modes

In order to comply with the environmental agency requirements the system must have different power states called o perating modes. Each mode has different levels of power consumption and system functionality. See also GP 22 Electrical Power Requirements.

Plug-in/Off Mode

This is not an operati ng mode. P lug in/off i s the condi tion of the machine when power is connected but the machine is powered down. When the power butt on is pressed to shut down (and confirmed) this is the condition of the machine.

This is the lowest power state that the mac hi ne c an ent er. On ly the LV PS and po wer man agement circuitry on the SBC is active.

The only method that can be used to power the machine on, in this mod e, is to press the UI power button.

Standby/Ready Mode

Also referred to as Level 1 power (Blue Angel RAL-UZ 171 specifications).

This is the n o rma l op er at i ng co nd i ti o n of th e m ac hi n e wh en it is r ea dy fo r wa lk-up copying . Th e UI is active and illuminated in this mode. This is the cond ition of the machine wh ile a user is programming a job via the UI or performing any other UI activity.

In this mode the system is ready to print/copy/fax with little or no delay in hard copy output. The system has full fun ctionality when in this mode, is capable of meeting FCO T (first copy out time) and FPOT (first print out time) requirements when in this mode only.

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

Run Mode

This is the condition of the machin e when it is acti vely print ing a job. The machine enters this mode when a user selec ts the final command to run a co py jo b. T he mac hi ne ente rs th is st ate when it executes a print job via the network.

In this mode the system is in the pr ocess of marking images and/or collating in an output device.

Sleep States

NOTE: The user will not be able to tell the di fference semi conscious state and deep sle ep state. Visually the machine appears the same.

Semi Conscious Mode

The machine enters semi conscious mode after a period of inactivity after the most recent print job or copy job. In semi-co ns cious mo de th e UI is i nactiv e a nd th e power button is illuminated. The delay time is preset but is adjustable by the customer in the range 0 to 30 minutes.

Semi conscious mode allows the system to perform the following limited functions:

• Access to the remote control panel via the web UI.

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Principles of Operation

• Wireless printing (if installed)

• All non print related network requ ests (including HDD a ccess), such as access from the web UI.

NOTE: If Wake on USB is enabled the sys tem remai ns in semi conscious mode and does not enter deep sleep mode.

Deep Sleep Mode

Also referred to as S3 power (Blue Angel RAL-UZ 171 specifications).

Recovery from this mod e to standby/read y is from either pressing the UI powe r button or an incoming fax and or print job. The machine does not wake from sleep mode upon insertion of a USB drive.

• Only standby power is available. SBC network control, power management.

• The system is able to wake up for network printing or incoming fax (if installed).

• The system is able to wake up when the user presses the UI power button.

• The system will be ‘rea dy to scan’ from any wak e up event i n less than 1 5 seconds w ith UI available within 1 second.

Auto Power Off

Enables the system to switch off aft er a specified time in deep sleep mode via an adjustab le timeout that is acc essed using tools or in the Web UI. The default is ‘disabled’. Once the machine has switched o ff it can be switched on via the po wer switch on the UI. When the machine has powered down auto matically it is in the same stat e as it would be after fir st con necting mains power.

Operating Mode Transitions

Warm Up

In this condition the system is booting up from plug in/off mode or recovering from sleep mode. The system will be ‘ready to scan’ with in 135 seconds from power up. Product perfor mance specification warm up times quoted are from ‘pow er save’ to ‘system ready’ (ac ceptance of scan, print or fax input) . Fus er war m up ti me wi ll v ar y de pen ding on li ne v ol tage , amb ie nt tem perature and time since machine was last switched on, etc.

Figure 1 shows the system operating modes and the associated transitions from mode to

mode that are required to ensure the s ystem meets all envir onmental a gency energy require ments.

Principles of Operation

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Figure 1 Operating mode state transition diagram

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LVPS Functions

The LVPS is split into the following main functions:

• Provides a +5V stand-b y supply to the powe r management c ontrol circuitry on th e SBC PWB. In plug-in off mode thi s consumes le ss than 0.5W AC to enable m onitoring for the power button.

• Switches on and off AC power to the output device outlet, and +5V and +24V main as directed by the SBC PWB.

• Provides +5V and +24V to power the SBC PWB in ready, and run modes.

• Provides main +5V interlocked power to the IOT PWB during normal operation.

• Provides main +24V non-interlocked power to the IOT PWB during normal operation.

• Provides power to the fuser using a combination of cycle switching and phase control patterns. Firmware within the LVPS us es look up ta bles based on power demand ed by the IOT software and the line voltage detected at the LVPS input.

There are two types of LVPS (PL 1.10 Item 1):

• A single 12 amp LVPS is used for the A ltaLin k® B8045/B 8055 1 10V or 23 0V and for the AltaLink® B8065/B8075/B8090 230V.

• A 16 amp LVPS is used for the A ltaLink ® B806 5/B807 5/B809 0 110V. T his LV PS h as an IEC320 C20 type mains connector.

Control Lines and Operating Modes

This section describe s the co ntrol line s between the SBC PW B, IOT P WB and LV PS used to control the operating modes by the switching of AC and DC supplies in the system.

Interlock Switches

When the interlock sw i tches ar e clos ed an d th e I OT C Fail s ig nal is lo w, th e L VP S ena ble s the +24V INTLK, and enables fuser power.

The front door interlock sw itch, S01 -300, and the le ft door interl ock switch , S01-305, are connected in series to the LVPS.

IOT-LVPS Interface Hotlines

POWER_FAIL

The IOTC_Fail signal is an early warning of an imminent loss of AC power.

LVPS to IOT Comms Line

The LVPS communicates with the IOT to signal power availability.

SBC-LVPS interface hotlines

PS_ON

When this signal is e nabled (low), the LVPS enables main +5V, +24V and +24 Interlocked power.

Entering/Exiting Power Modes

From Plug In/Off Mode

+5VSB power is act ive during all modes as soon as the mach ine is plugged in to a powered wall socket to monitor the UI power button.

From plug in/off mode to ready: User presses the UI power button which cause s the power management circuitry on the SBC PWB to enable th e PS_ON signal to switch on the main LVPS outputs. The system can then boot up and perform initialisation and the warm up sequence.

From Ready (Ready to Scan) Mode:

All power supply outputs are ‘on’ in this mode. A user pressing the UI power button invokes the pop-up: ‘power down option s, quick restart, enter power saver m ode or power off’ selection screen on the UI.

From ready (ready to scan) mo de to pl ug-in off m ode: If “ powe r down” is s elec ted, a fter c onfi rmation from all modules is ac cepted, the SBC PW B disables the P S_ON hotline. This in turn, removes all AC and DC outpu ts, except +5VSB. An additional met hod to achieve this is to keep the power button pressed for 5 seconds which overrides software.

From ready (ready to scan) mode to sleep mode: If “enter sleep mode” is selected, after confirmation from all modules is accepted , the PS_ON signal is disabled whic h removes the main DC outputs from the LVPS as well as AC power to the finisher. +5VSB remains on in this mode.

From ready (ready to scan) mode to quick restart: If quick restart is selected, the SB C PWB and IOT PWB perfor m soft resets and re-initi alize the system as per s witch on from plug in mode.

From Deep Sleep Mode or Semi Conscious Mode:

+5VSB output is activ e in thi s mod e. Only th e S B C P WB , f ax mo dule a nd the UI power button are active in this mode.

From sleep mode to s tand-by mode via wake up from incoming print job: T he SBC PWB is capable of waking the system from sleep m ode on receipt of any i ncoming job that re quires marking. The SBC PWB enables the PS_ON signal, which enables all main power.

From sleep mode to stand-by mode via wake up from incoming fax job: The fax modu le is capable of waking the system from slee p mode on receipt of an incoming job that requires marking. The PME signal is used to ind icate to the SB C PWB that the wake up call ha s been initiated. The SBC PWB enables the PS_ON signal, which enables all main power.

From sleep mode to stand-by mode via wake up from user intervention at UI: The UI is capable of waking the system from sleep mode by pressing the power button. The On Off Button signal is detected by the SBC PWB, which enables the PS_ON signal, which enables all main power.

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Principles of Operation

DC Power Distribution

Table 1 below shows how the power is distri buted from the LVPS to the rest of the su b-sys-

tems (excluding the AC distribution to the finisher and the fuser).

Table 1 LVPS DC power distribution

+24V

Module Description +5VSB +5V

Image output terminal controller (IOTC) yes yes yes Single board controller (SBC) yes yes yes Drives module yes

Other voltages are generate d and d is tribu ted by the SBC and IOT PWBs . Refe r to Tabl e 2 and

Table 3.

Table 2 SBC DC power distribution

Module Description +3.3V +5V +12V +24V

Fax module yes yes LED Print head (LPH) yes Scanner module yes yes yes yes User interface (UI) yes Hard disk drive (HDD) yes

Table 3 IOT PWB DC power distribution

Module Description +3.3V +5V

High voltage power supply (HVPS) yes Paper feed module (PFM), tray 1 and 2 yes yes High capacity feeder (HCF), tray 3 and tray 4 yes yes Tray 6 yes yes HCF transport motor yes Left door yes yes Tray 5 (bypass tray) yes Bypass tray clutch yes Horizontal transport yes yes Drives Module yes

INTLK

+24V INTLK

non INTLK

+24V non INTLK

System Power On/Off Times

Refer to Table 4.

Table 4 System power on/off times

Power on

Power Timings

Power LED on UI flashes <2s N/A <41s N/A First UI screen displayed N/A <4.5s N/A N/A Services Home Screen

displayed Ready to Scan (Fax, File

or E-mail send) Ready to Scan (Cop y) (3) <135s (1) <15s (2) <176s (1) N/A Ready to Mark <160s (1) <28s <201s (1) N/A Power Off N/A N/A N/A <36s Blue Angel recovery time

(45ppm) (4)

NOTE:

1. The time taken for a machine to power on, is dependent o n the numbe r and type of s ervices enabled on the de vice b eing evaluated . Th e val ues sho wn in the tabl e ass ume the basic configuratio n as shipped from the facto ry. i.e. Copy; Print From; ID Copy; Serve r Fax:. Additionally, automatic data integrity routines that can occur randomly after 20 power on events from a software alt -boot, can add up to 90 seconds to these ti mes. Therefore measurement of power on times needs to be done shortly after an Alt-boot.

2. Recovery from sleep is dependent on which of two sleep modes the machine has entered. Recovery from sleep can be considerably faster than the time shown .

3. Ready to Copy is indicated by the message “Ready to Scan” being displayed on the GUI.

4. Tested as per Blue Ange l RAL UZ-171 on 45ppm only. Higher speed machines have higher limits hence this is critical path.

from off

<120s (1) <15s <161s (1) N/A

<135s (1) <15s (2) <176s (1) N/A

N/A <25.58s(4) N/A N/A

Sleep Recovery (touch power button)

Ready from Restart

Power off from Ready

Principles of Operation

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High Voltage Power Supply

The high voltage power supply generates the voltages used by the xerographics system.

The IOT PWB supplies 24V to the HVPS.

The IOT PWB sends the following control signals to the HVPS. Refer to Table 5.

Table 5 HVPS control signals

Signal Description

BCR AC PWM Pulse-width-modulation control line for activation and setting of the BCR AC

BCR DC PWM Pulse-width-modulation control line for activation and setting of the BCR DC

BCR CLOCK Control line for BCR frequency. Typical 1.6 kHz. DB AC PWM Pulse-width-modulation control line for activation and setting of the DB AC

DB DC PWM Pulse-width-modulation control line for activation and setting of the DB DC

DB CLOCK Contr ol lin e for DB fre que ncy. Typi c al 9 kHz. BTR CC PWM Pulse-width-modulation control line for activation and setting of the BTR pos-

BTR MODE Control line which disables the BTR constant current mode, and then

DTS ON Control line which enables the DTS negative voltage source.

The HVPS returns a BTR MON signa l to the IOT PW B . The vo lta ge is scal ed ac cor di ng to this formula: BTR MON = 2.5 + (0.00045 x BTR Voltage). For example, BTR MON = 2.5 when BTR voltage = 0.

current source.

voltage source.

current source.

voltage source.

itive current source.

enables the BTR negative constant voltage mode.

Based on the inputs, the HVPS supplies the following to the xerographics system:

• BCR (Bias Charge Roll) is the sum of the BCR AC and BCR DC sources.

• DB (Developer Bias) is the sum of the DB AC and DB DC sources.

• BTR (Bias Transfer Roll) is either the BTR CC or BTR CV source, depending on the state of the BTR MODE input. Both sources are DC.

• DTS (DeTack Saw) is simply the DTS negative voltage source.

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Principles of Operation

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User Interface

The UI module is ma de of four assemblies, the LCD module, the contr ol PWB, the emotive LED PWB and the status/LED PWB, PL 2.10.

The UI includes the following features.

• A 10.1" LCD display and capacitive multi touch LCD screen.

• Emotive LED bar, an array of LED's for machine status indication.

• Machine power ON/OFF control with wh ite LED backlight for power sav er mode indication.

• Audio speaker.

• Near field communication (NFC) module.

The UI consists of 5 components, Figure 1.

1. LCD module (within the UI module).

2. UI control PWB (within the UI module).

3. UI status PWB (within the UI module).

4. UI emotive LED PWB (within the UI module).

5. UI interface PWB (mounted within machi ne frame) .

6. External keyboard (accessory).

Only the following components are accessible:

• UI module, PL 2.10 Item 1.

• UI interface PWB, PL 2.10 Item 15.

Principles of Operation

Figure 1 User interface components

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LCD Module

The LCD module comprises,

• a color TFT screen (Thin Film Transistor),

• embedded backlight,

• capacitive touch panel.

The cables are wired directl y into the LCD mod ule. All the LCD mo dule cable s connect to the UI control PWB. PJ numbers are detailed on the UI control PWB.

Display video input for the TFT display is provided from the control PWB; four Pairs of LVDS display data and one p ai r of c lo ck fr om the PS 862 2 de vice whi ch c onv erts di splay p or t da ta to required LVDS data which is driven to the TFT display through buffer FIN1108.

UI Control PWB

The control board is the main board in the UI assembly which supplies power and the required ON/OFF sequence for the TFT LCD module. Microcontroller MSP43 0F5510 provides PWM drive for the emotive LED and au dio, required control signal s for power sequencing and I2C bus for EEPROM access which stores EDID data. An RS-422 interface is used for communica tion to the SBC.

The UI module provides an audi tory response that indicates machi ne statuses such as fault conditions, authentica tio n, powe r s aver en try/e xi t a nd tou ch ton es. T h e UI c ont rol PWB stores all the audio files and includes a speaker on the board for the audio output.

UI Emotive LED PWB

The emotive LED PWB contains 4 blue LE Ds and 4 amber LED s. The emo tiv e PW B also con tains the required biasing resistor and the mai n drive circu it is loca ted in the con tr ol PW B.

• PJ915 connects to the UI control PWB.

UI Interface PWB

The UI interface PWB, PL 2.10 Item 15, connects the UI control PWB to the rest of the machine.

• PJ920 connects to the SBC PWB.

• PJ921 connects to the SBC PWB.

External Interface connectors/signal details

The SBC interface to th e main control PWB is via the UI interface board through an RJ150 connector for video and an 18 way DF11 connector for control and power signals. The connec

tor into the UI module from the UI interface board is via a 40 way FFC connector.

Grounding scheme

There is a common single digital ground. All the return c urrent is passed to the SBC via the interface connector. There is no chassis ground for the UI module as it as made of plastic.

Connections on the UI control PWB

• PJ900 to the LCD module - 1024 x 600 color TFT

• PJ901 to the LCD module - capacitive touch panel

• PJ902 to the UI interface PWB

• PJ903 to the UI emotive LED PWB

• PJ904 to the UI status PWB

• PJ906 to the LCD module - LED backlight

UI Status/Keyboard PWB

The Status/keyboard PWB contains the machine power button and the home button.

• The power ON/OFF but ton is for system power ON/OFF an d features an array of white LEDs as a back light driven direc tly from the SBC PWM signal. This LED is for pow er saver indic ation.

• The Home button returns the syste m to the ho me screen. This signal i s mapped directly to the SBC GPIO.

The UI module is provided with an NFC (near field communication) tag to enable printing functionality through NFC. The NFC antenn a and chi p are mo unte d on the UI sta tus PW B. A wh ite light LED on the UI status PWB illuminates when the NFC is active.

NFC provides the RF interfa ce for contactless communic ation with an external read er/writer, serial interface for contact communication with an external host, control logic for command pro cessing and various con trols. It also consists of access restr iction of RF communication by password. Supply voltage provided is 3.3 V.

• PJ910 connects to the UI control PWB.

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External keyboard (accessory)

A slide out keyboa rd, c on nec ted to a U SB po rt, c an be mou nted be neath the main UI modul e. This keyboard can be used as an alternative to the touchscreen keyboard. (PL 2.10 Item 14)

Principles of Operation

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Machine Run Control

Overview

The Single Board Controller (SBC) PWB interfaces with the Image Output Terminal (IOT) PWB, scanner, netw ork, fax, and the UI. Control of the subsystems is de legated to the IOT PWB, or the PWBs within the subsystem, while the SBC maintains system level control.

SBC Module Overview

The SBC module has different configuration options. When option al configurations are not used, blanking plates are needed.

Backup battery

LED print head

The SBC PWB supports existing optional PWB interfaces such as FDI, Common Interface Fax (CIF) and PWS.

Refer to PL 3.22. The SBC PWB is contained in a c ha ss is. T h e S BC PW B c has sis c onsis ts of a metal cage, interior bracke t, and top cover. The module co ntains the SBC PWB , HDD, and optionally, the fax module and FDI PW B , alon g with mec hanic al pa rts and harnesses. Refer to

Figure 1 and Figure 2.

HDD

Fax PWB SBC PWB

Ethernet port

USB host

USB device

IIT power

SIM card slot

SBC Performance

The image path for this color s cann er brin gs the sc anner v ideo d irectly t o the S oftware Ima ge Path (SWIP).

The SWIP is used as the main video controller for the high speed digital printer and multi function digital copier color applications. The device is controlled through a 32 bit, 66 MHz host PCI bus. The Calypso SWIP scan im age processing (with JPEG), print image proces sing, image data compression/decompression capability, rotation and merge engines, input data inter faces, and image outp ut capab ility. I mage data may be sto red in either EPC or system memory.

SD card

Figure 2 SBC PWB

IIT video

User interfac

User Interface power

Principles of Operation

Figure 1 SBC PWB module

The SBC PWB also contains a USB dev ice (singl e) and U SB host ( single and dual) por ts, as well as a three-speed (10/100/1000) Ethernet port, a debug port, a SIM port to configure machine speed and a For ei gn Devic e Int erfac e. T h e FD I P WB requi r es th e u se o f a s ep arate cable from the bulkhead to the actual FDI PWB.

Backup Battery

The backup battery is used to suppl y power to the real- time c lo ck and the powe r mana gem ent circuitry when the machine is not plugged in.

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Launch Issue

SBC PWB Interfaces

The SBC PWB interfaces with:

• IOT PWB (including hotlines)

• User interface

• Image input terminal

• LED print head

• Portable workstation

•Network

•Fax

• External debug communication port.

The SBC PWB has provisions for the plug in items listed in Table 1.

Table 1 Plug in items

Standard Configurat ion Optional Configuration

SD Memory Card FDI HDD Common Interface Fax SIM Card

UI Interface

• The RS-422 (TX and RX only) at a baud rate of 480K.

• A USB host is connected to the SBC PWB USB port through an on-board connector.

• The SBC PWB provides +3.3V DC and +12V DC power to the UI.

• The SBC PWB is capable of waking up from the UI Wake up switch (Wake UP switch signal).

• The interface supports a low vol tage differential signal (LVDS) output to drive a color LCD.

image Input T erminal

• The SBC PWB supplies +3.3V, +5V, +12V, and +24V DC to the scanner.

• The RS422 (RX and TX Only) at a baud rate up to 480K.

• The scanner PWB further connects to the SPDH PWB.

SD Memory Card

The SD card replaces the software module used on other products. The card will support these functions:

•Boot ROM

•NVM

• MFD feature key

NOTE: These functions are not accessible by the customer.

SIM Card Interface

Provides a slot accessible to the user for configuring the machine.

A cryptomemory card ca n be plugged into a SIM c ard slot on the SBC PWB t o authenticate machine features. The SBC will control this device via an I2C bus.

System Memory

System memory is 2GByte of DDR3 RAM. The chips are mounted directly to the SBC PWB.

Ethernet Base 10/100/1000T

• The Ethernet interface connects directly to the network.

• Is capable of waking up from sleep mode on detection of network traffic.

USB Interface

• The SBC PWB has 3 USB host ports and 1 USB device port. The USB host port 3 is connected to the UI USB port through an on-board connector.

• The Host ports support potential host functions, such as flash-drive plugability, biometrics (security), USB printing, software upgrade and other user-identification devices, etc. There are 2 ports acces sible through t he SBC tra y front and 1 p ort accessi ble within the SBC tray for front of machine (UI) access.

NOTE: The USB Host power for attached peripherals is limited to 2.5W per port.

• The device port suppo rts functions such as fi eld service PWS (Po rtable Work Stations ) connection, and direct USB printing.

Debug

• UART. The SBC provides a UA RT interface for software debug/Altb oot. This interface supports industry standard baud rates.

• Video. Video data, produced by the image path captured through debug connector on the SBC PWB.

• JTAG. As required for any board updates and for access to CPU for software debug.

• 7 segment LED display. As required for debug purposes.

SATA HDD (Hard Disk Drive)

• The system provides one SATA HDD with a capac it y of 78GB and a data rat e of approx i mately 100MB/s (for sequential data).

• The HDD is used to store jobs from scan to export and some other jobs as well as to store Ethernet jobs coming from the network.

Fax Card (Option)

The SBC PWB accommodates an interfa ce to the Fax . A Flat Pr inted Ci rcuit (FPC) cable pro vides the electrical interfa ce. The module pro vides 2 telephone line s, each serviced by a Fax Modem.

Foreign Device Interface (Option)

• The FDI PWB is an optional PWB. It is used to interface to external input devices such as coin input device.

• The FDI PWB option is an upgrade intended to be performed by a Xerox representative.

Harnesses

The SBC PWB module has its own set of har nesses to enabl e connecti vity of po wer and data to the items within itself. The module internal harnesses are:

• SBC PWB to HDD (power and data).

• SBC PWB to fax connector PWB.

• FDI PWB to cage backplane.

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Principles of Operation

Mechanical Enclosure of the SBC Module

The SBC enclosure consists of a removable c over which allows access to the HDD an d Fax bracket. The bracket is rem oved to gain ac cess to the SBC PWB. Th is enclo sure is located at the rear of the machine.

The SBC complies with MN2-950 and contains ESD warnings.

SBC Power Up Sequence

The following events occur after the machine is plugged in.

1. The LVPS begins generating +5VSB for the SBC.

2. On the SBC PWB, the +5VSB is converted to +3.3V for the power management circuitry.

3. The power management circuitry begins flashing LED CR23 on the SBC PWB. When the user presses the power button:

1. The power management circuitry activates the PS_ON signal.

2. The LVPS activates the main +5V and +24V supplies.

3. The power management circuitry begins enabling the remainder of the SBC.

4. The +5V is used to generate a number of voltages used by the main CPU.

5. The PWR_GOOD LED (CR7) will light.

6. The CPU will load the initial boot software from the SD card.

7. The initial boot software wil l enable the memory controller, SATA har d drive controller, etc. and update the 7-segment display.

8. The initial boot software wil l load config urati on for the Horizo n FPGA, and then swit ch off the Horizon_Configuration_Not_Done LED (CR19).

9. The Horizon FPGA will enable image path power, and hard disk power.

10. The KAMA_Configuration_Not_Done LED (CR11), and Image_Power_OK LED (CR6) will switch on, and the Xerox screen will appear on the UI.

11. The initial boot software will load the configuration for the KAMA FPGA from the SD card, and then switch off the KAMA_Configuration_Not_Done LED (CR11).

12. The initial boot software will read version number from each device on the SBC.

13. The main software kernel is loaded from the SD card.

14. The USB ports are searched for a software upgrade file. If available, the software is upgraded.

If no upgrade is found, the main software code is loaded from the hard drive.

IOT PWB

The IOT PWB is respons ible for the control of all functions within the IOT. It is an inte lligent controller containing a CPU with built-in flash ROM, RAM, and Magnetoresistive RandomAccess Memory (MR AM) to store NVM . Its primary funct ion is to drive the motors, solen oids and clutches within the IOT, supply control to the HVPS, contr ol the fuser power and mon itor sensors. The IOT PWB has the following interfaces:-

• Serial RS422 and page sync control interface to the SBC PWB.

• Serial RS422 interfaces to optional finishing devices.

• Motor drives for trays 1, 2, 3 and 4.

• Control of the main drive module in AltaLink® B8065/B8075/B8090.

Power On

On application of power, the IOT PWB will perfor m its POS T (powe r on self-t est). On succ ess ful POST:

• The IOT application will flash the IOT diagnostic LED (0.5 second on / 0.5 second off). The IOT will set sub-system defaults i.e. (load a copy of NVM to RAM pre-sets and messages.

e.g. fuser off and motors off.

The IOT will check communication channels (in order):

1. RS422/USB.

2. I2C for CRUM RFID reader.

3. Communication synchroni sation is attem pted between the IOT and finisher . If communications between IOT PWB an d finish er can no t be est ablished, a fault is decla red to the device controller.

4. Communication synchronisation is attempted with the SBC PWB.

5. Check paper path sensors are clear (no paper present).

6. Check interlocks are closed.

7. initialize the fuser (warm up).

8. initialize the paper trays (raise).

9. initialize the toner dispense system (ready to mark).

Power Off

When the power off button is pressed, the user will be offered the option to initiate a controlled power off via the user interface, put the system into power saver mode, reboot or cancel the power off request.

When the SBC software has estab li shed that power can be removed it will disa ble the P S_ON signal to the LVPS.

Principles of Operation

Prior to any occurrence of stopping the IOT, the IOT PWB will save CRUM data to NVM.

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Xerox® AltaLink® B8090 Family Multifunction Printer

Launch Issue

Software Loading

Overview

Software loading may be performed as part of a repair procedure or as a customer upgrade.

Software upgrades may inc lude software fixes, enhancements , maintenance, client softwa re tools and optional features.

Software Upgrade Methods

There are various methods to upgrade the software. Refer to Table 2.

Software Upgrade Process Descriptions

DLM

The System Administrator sends a *.dlm file containing all device software to the device via the network (received as a p rint job) . The de vice re cognize s the p rint job as a ‘D LM upgrad e’ and extracts the file. The DLM then updates the device.

NOTE: DLM needs to be enabled first.

Power on Software Compatibility Checking

Table 2 Software upgrade methods

Further

User Upgrade Type Occurs when

Power on upgrade. At install if an optional device is fit-

Customer DLM upgrade via a net-

work.

DLM upgrade via USB. A customer requires a SPAR or

CSE Altboot via USB (see

Note). Altboot via PWS (see

Note).

NOTE: A normal or forced AltBoot can be performed.

Software Compatibility Database (SCD)

Software upgrade relies on the Software Co mpatibil ity Database (S CD). The SCD spe cifies a set of compatible software versions for all software module s that can be p art of the system. The SCD also holds a collective version nu mber known as the Softwa re Set Number which uniquely defines the set of software versions in the SCD.

The Software Set Num ber inc lu des a Prod uc t ID tha t is u se d to chec k tha t th e S oftwa re S et i s correct for the product to be up graded. Pr oduct IDs are defined by the So ftware Confi guration Management (SCM) team.

The machine SCD is stored by the machine and is retained across power cycles. The machine SCD specifies the set o f software versions that the machine ex pects to be on its modules, known as the Machine Software Set. In additi on to the software ver sions, the machine SCD holds the Machine Software Set Number which uniquely defines the set of software versions in the machine SCD.

ted which has a different software level to the machine. During service when a new component is installed that has a different software level to the machine.

A customer requires a SPAR or later software installed.

later software installed. As directed by service procedures GP 4.

information

Refer to the ReadMe sup plied with the software.

GP 4. GP 4.

At power on the system verifies all modu le software versions. All inco mpatible software versions in any module are upgraded automatically.

USB Drive Upgrade

A software upgrade can be performed loc ally by downloading a DLM fil e from a USB drive to the device. This feature allows non-connected devices to have system upgrades without requiring a PWS or network drop.

NOTE: This is not an AltBoot upgrade and does not erase all of the data on the hard disk.

USB Drive AltBoot

USB drive AltBoot is used to repair problems where the network controller fails to boot due to a software problem. AltBoot erases all the data on the hard disk. USB drive AltBoot is invoked by inserting a USB drive with an AltBoot file on it.

If there is more than one AltBoot software file on the USB drive in the AltBoot directory the AltBoot software file with the most recent version will be selected.

Normal and Forced AltBoot Modes

Normal Altboot

A normal (unforced) AltBoo t will repartition and reformat the hard disk and when applicable, then install the software o n th e S BC h ar d dis k d riv e an d the mem ory mod ule . If a later version of software has been in stall ed, the AltBo ot will be follo wed by a power on upg rade of al l mod ules that had were at a lower software level.

Critical data and user settings are preserved by the AltBoot (as summarised below):

• Network Configuration settings including: – User NVM settings. – Web certificates. – Local template pool web user interface created Scan to File templates.

All other data is not backed up or restored by the AltBoot.

Forced Altboot

In addition to repartitioning and reformatting the hard disk then installing software, a forced AltBoot will upgrade all upgradable modules regardless of the current software version.

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Principles of Operation

Software Upgrade Progress

During the software upgrade, a progress screen is displayed on the UI (refer to GP 4).

Refer to Table 3 for details of which modules are represented by each pr og re ss bar dur in g the software upgrade.

Table 3 Represented modules

Progress bar Module

User Interface UI PWB Copy Controller Hard disk drive Network Controller Hard disk drive and memory module Print / Copy Engine IOT PWB Scan Engine Scanner PWB Fax HDD SBC Finisher 2K LCSS PWB, L V F PWB, HVF PWB

Upgradable Modules

Refer to Figure 3 and Figure 4. The followi ng modules ar e upgradable by a software upgr ade (GP 4):

• SBC PWB SD card.

• Hard disk drive.

• Scanner PWB.

• SPDH PWB.

• UI PWB.

•IOT PWB.

• Finishers (2K LCSS, LVF BM or HVF BM).

• Tray 6 module (Paper Feeder Platform) SBC PWB (CC/XUI/NC)

IOT PWB and Finishers

The IOT PWB is connected to the SBC PWB and the finisher. The IOT PWB receives software upgrades from the SBC PWB and sends software upgrade s to the finisher. The IOT PWB receives version number s from each installed finisher and sends the version numbers to the SBC PWB.

Tray 6 Module (Paper Feeder Platform)

The IOT PWB is connected to the tray 6 control PWB. The IOT PWB receives software upgrades from the SBC PWB and sends software upgrades to the tray 6 control PWB. The IOT PWB receives version the number from the installed tray 6 module and sends the version num ber to the IOT PWB.

The copy controll er, UI and networ k controller software modu les run o n the same SB C hardware platform (subsystem).

Software Upgrade (SWUP) runs on the SBC hardware platform and receives software upgrades for the software modu le s on the SBC PWB itself and the other par ts of the machi ne. The SWUP may obtain software u pgrades from the network controller, a USB driv e, or the PWS.

For the purposes of a soft war e up grade , the UI i s con nec ted to th e S BC PW B. T h e UI m odu le is upgradable by the SBC PWB.

Scanner and SPDH

Both the scanner PWB and SPDH PWB are upgradab le by the SB C PWB.

Principles of Operation

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Xerox® AltaLink® B8090 Family Multifunction Printer

Figure 3 Software upgrade information (1 of 2)

Figure 4 Software upgrade information (2 of 2)

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Principles of Operation

Single Pass Document Handler (SPDH)

Overview

The Single Pass Document Hand ler (SPDH) is mounted above the pl aten scanner. Together the SPDH and platen scanner form the image input terminal (IIT) for the AltaLink® B8090F machines. (See also Scanner Overview.)

The SPDH allows a user to scan origi nal documents of various sizes and original types to enable either the system c opy or system scan to file functional ity. The user inter acts with the SPDH in the following ways:

• Lifting and lowering the SPDH to access the document glass for registering original documents for platen scanning

• Lifting and lowerin g th e SP DH to a cc ess the do cu men t glas s an d CV T g lass s urfac es f or cleaning and maintenance

• Loading original documents into the input tray of the SPDH

• Adjusting the document width guide positions to register the original document

• Removing re-compile d original docume nts from the SPDH output t ray once scanning is complete

• Lifting and lowering the SPDH to ope n the SPDH paper path for the remov al of jammed sheets, and to allow access to the side 2 scan assembly for cleaning

The SPDH is a center registered automa tic doc ument han dler, that se parates and feeds up to 200 (face up) original documents of 80gsm individually in 1 to N order. It is capable of scanning simplex (this mode scan s only on e sid e of a doc ument set) and d uplex ( this mode scan s both sides of a document set) documents . For simplex images the SPDH transports documen ts over the CVT window of the pla ten scann er. The do cumen t is the n transpo rted to the r e-stac k tray. For duplex images side 2 of the document is scanned via the side 2 scan assembly as the document is transported to the re-s tack tr ay. The sid e 2 scan assemb ly is mo unted in ternal to the SPDH. Document output to the re-stack tray will be in the same order as input (face down),

Figure 1.

Input tray

Principles of Operation

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Restack tray

Figure 1 SPDH

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Xerox® AltaLink® B8090 Family Multifunction Printer

Counterbalances

Two counterbalance assemblies, Figure 2, secure the document handler to the scanner frame. A counterbalancing force is generated by compression springs acting on a cam-follower arrangement, all housed within sheet metal brackets. Above a set drop-down angle, the SPDH will hold or rise slowly to the maximum opening angle. Bel ow the set drop-down angle, the SPDH will gently close onto the sca nner. The right hand brac ket provides a me ans of adjust ment for document skew. In addition, the counterb alance assemblies are double-hinged to allow a customer to close the SPDH onto books of up to 25mm in thick ness without appl ying excessive force to the doc ument glass of the scanne r. This feature is known as bo ok-mode operation.

SPDH Power

The SPDH top cover interlock s witch, S05-305, Figure 3, is located at the rear of the SPDH. S05-305 controls the +24V supply to all clutches, solenoids, motors and the side 2 scan assembly via the SPDH PWB . The SPDH top cover switch isolates the SPDH +24V circuit when the top cover asse mbly is opened. The inte rlock is used to ensure o perator safety by

removing power to the SPDH driv es when not actuated. The scanner PWB su pplies +3.3V, +5V, +12V and +24V to the SPDH PWBA. The SPDH PWB then controls the output of powe r to all the components in the SPDH.

Right counterbalance Left counterbalance

Figure 2 Counterbalances

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Top cover interlock switch

Figure 3 Top cover interlock switch

Principles of Operation

Input Tray

Copies are placed into the input tray face up, 1 to N order. The capacity of the input tray is 200 originals of 80gs m w eight. The mi nimum siz e origi nal i s A5 ( 5.5 X 8.5 in ch), SEF o r LE F. The maximum size of original is A3 (11 X 17 inch), SEF only . Table 1 lists re cognized pape r sizes and orientations. Intermi xed lengths (feed direction) are accepta ble for a limited number of document pairs, which ar e des cribed b elow in the Mixed S ize M ode secti on. T he tray wi ll pro vide for center feedi ng in 1 to N sequ ence. Movable tray gu ides for the docume nt width are provided. Correct guide adjustmen t by the operator is imperati ve for reliabl e feeding and auto paper select. The SPDH document present sensor (Q05-309), detects originals loaded against the document registration wall. When the SPDH document present sensor is actuated the doc ument set LED (LP05-084), illuminates. Refer to Figure 4.

Refer to Table 1 and Table 2 for details of document sizes.

Document present sensor

Document width guide

T able 1 Document sizes

Document Sizes SEF Document LEF Document

8.5 x 11 Yes Yes

8.5 x 13 or 8.5 x 14 (1) Yes No

B4 Yes No A3 Yes No 11 x 7 Yes No

NOTE: (1) The SPDH cannot differen tiate between these sizes. The UI wil l display relevant media size dependent upon market region stored in NVM.

Table 2 Document sizes

Maximum and Minimum document size in the process direction

138mm/5.4 inches to 432mm/17 inches

Document Size Sensing and Selection

Document size sensing and selection is achieved by a combination of:

• Width sensing (cros s-process direction).

• Static and dynamic length detection (process direction).

• Mixed Size Mode. Static Size Sensing

Maximum and Minimum document size in the cross process direction

138mm/5.4 inches to 432mm/17 inch es

Document set LED

Figure 4 Input tray

Table 1 Document sizes

Document Sizes SEF Document LEF Document

A5 or 5.5 x 8.5 (1) Yes Yes B5 Yes Yes A4 Yes Yes

Principles of Operation

Document registration wall

The SPDH determines the s ize of th e of th e or i gin al d ocument and whether the paper is being fed long-edge feed (LEF) or shor t-edge feed (SEF) upon the combin ed sign als from the docu ment side guide width sensors and the input tray length sensors. Each combination of the input tray sensing regions have an associated default paper size, so when a user places a document into the input tray the SPDH makes an assumption of the loaded document size.

Static Width Sensing

Three document width s ensors determine the width of the ori ginal document, wi dth sensor 1 (Q05-325), width sensor 2 (Q05-326), and width sensor 3 (Q05-327). The width sensors detect flags mounted to the bottom of the movable in-board and out-board document side guides. The document side guides are cen trally register ed and synchrono usly move via a rack and pinion mechanism. As the guides mov e, the flags block and unblock the wi dth sensors. The SPDH uses the signals from the width sens ors to determine pape r width of the original docum ent. If the guides are not positioned correctly then the top edge registration and LE skew of the scanned documents cannot be guaranteed. The guides provide some resistance to movement so that they remain in position du ring the scanning of the original do cument. The side guide s also limit the maximum thickn es s of orig ina l doc um ent st ack tha t can be load ed wit h stack lim iting features.

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Launch Issue

Static Length Sensing

Auto Reduction/Enlargement

Static length detection is used to determine document length of the original document, for most document sizes and orientations. This is accomplished with two sensors, length sensor 1, Q05-315, and length sensor 2, Q05-320, located in the input tray, which are at appropriate dis tances from the docume nt r eg istr ation wall. The state of these two le ngth s ensor s whe n d ocu ments are loaded from against the document registration wall at start of a job will determine the stack length range.

Dynamic Length Sensing

Dynamic length sensing is utilized to determine the length of docu ments that are not recognized by the static le ngth sensors. This featur e only works if the paper su pply automatically select feature has been chosen by the operator.

At the start of a c opy job the i mage data of the first s canned docume nt of unknown length is reconciled with docu ment length data stored on SB C PWB. If the scanned image leng th is matched with stored document length data on the SBC PWB, image processing will continue. If no document length match is foun d the SB C PWB wil l reques t a UI stat us mess age to be d is played to the operator to enter the required paper size.

Dynamic length sensing is required for the document sizes shown in Table 3.

Table 3 Document sizes

Document size

8.5” x 11” SEF A5 LEF

8.5” x 5.5” LEF A5 SEF

8.5” x 5.5” SEF

In combination with mixed s ize mode the user can select auto reduction/enlargemen t. When selected the document will be scanned to the copy paper size. All copy enlargement and

reduction is controlled by the SBC PWB.

Mixed Size Mode

This option is selected thr oug h th e fea tures i n the us er in ter fac e a nd a llows the us er to c op y a set of documents th at contai n two di fferen t si ze s as l isted i n Ta ble 4. With all Mixed size origi nal jobs, both sizes in the pair must be of the same cross-process width.

Table 4 lists the valid pairs of doc ument sizes which the I IT will recognise and enable as a

mixed size mode job. Dur ing mixed size mode dynami c length sensing will be p erformed on each individual scanned document.

T able 4 Document sizes

Valid document pair Short doc length

A3 SEF + A4 LEF 210mm A4 SEF +A5 LEF 148mm

8.5” x 11 SEF + 8.5 x 5.5 LEF 139.7mm

8.5 x 14 SEF + 8.5 x 11 SEF 279.4mm 11 x 17 SEF + 8.5 x 11 LEF 216mm B4 SEF + B5 LEF 176mm

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Principles of Operation

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Drives

Three 24V motors provide the drive for the SPDH components, the feed motor and read motors are shown on Figure 5, the Tray elevator motor is shown on Figure 8.

Feed Motor

The feed motor (PL 5.18 Item 2) supplies continuous drive via a toothed belt and gears to both the takeaway roll clutch, CL05-425, and feed clu tch, CL05 -0 25, du ring the scan pr oces s of the document. The TAR clutch, when energized provides drive to the takeaway roll. The feed clutch when energized provides drive to th e feed, nudger and retard r olls that form the full y active retard feed assembly, via their respective gear trains, Figure 6.

Feed clutch

Feed motor

Feed roll

Nudger roll

TAR clutch

Principles of Operation

Feed motor Read motor

Figure 5 Feed motor and read motor

Fully active retard (FAR) feed mechanism

Takeaway roll assembly

Retard roll

Figure 6 Feed motor

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Launch Issue

Read Motor

The read motor (PL 5.1 8 Item 1) supplie s continuous dr ive to the pre scan r oll assembly and mid scan roll assembl y. The exi t roll assem bly is dr iven by a p ulley and to othed b elt arrang e ment from the mid scan roll, Figure 7. The rea d motor also provides the drive (when run in reverse) for the side 2 scan assembly calibration mechanism, shown in detail in Figure 16. The exit jam clearance knob (PL 5.17 Item 5), under the front left corner of the SPDH, can be used to clear jams and feed documents along the document path to activate sensors for diagnostics.

Tray Elevator Motor

The tray elevator motor (PL 5.30 Ite m 1 4) raises and lowe rs the input tr ay in order to mai ntain

the document stack at the optimum feed position, Figure 8. The motor drives a gear chain that rotates a pair of actuators that raise and lower the tray.

Lift Home Position Sensor

The lift home position (lowered) sensor, Q05-307 , is a flag actuated sensor th at senses the input tray is in the home position, Figure 8.

Exit jam clearance knob

Mid scan roll assembly

Pre scan roll assembly

Figure 7 Read motor

Read motor

Exit roll assembly

Lift home position sensor

Tray elevator motor

Actuators

Figure 8 Tray elevator motor

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Principles of Operation

Scanning Process

1. The document present s ensor, Q05- 309, detect s that a docum ent has be en loaded o nto the input tray and positioned against the registration wall of the separation assembly.

2. At the detection of a d oc ume nt, o r at p ower o n, t he S P DH i nit ial izes th e c alib ra tio n of the side 2 scan module and platen scanner.

3. The size of the document is calcula ted by a combinati on of signals from width se nsor 1, Q05-325, width sensor 2, Q 05-326, width se nsor 3, Q05-327, a nd length sensor 1 Q 05315, and length sensor 2, Q05-320.

4. The input tray elevator mechani sm, in con junct ion with the stack height sensor Q05 -310, raises the input tray to position the doc ument stack at the optimum heigh t for feeding at the start of a copy job . The tr a y he ig ht will r ais e in i nc re men ts (a ppr oxim ate ly at e ve ry 25 sheet feed for xerox 8 0gs m pa per) to ma in tai n a n o pti mum fe edi ng po sitio n throughout a copy job.

5. By means of a fully active reta rd feed mechanism the SPDH feeds the document s from the input tray into the paper path of the SPDH. The feed and read motor are activated and the feed clutch is energized. On activation of the feed clutch the nudger roll is driven down onto the document stack. Simultan eou sl y as the feede r me chani sm drive s the nud ger ro ll down it raises the two gate finge rs. The nudger drives the top document off the s tack across to the separation assembl y and in to the full y active re tard nip, fo rmed by the feed and retard rolls (see Docum ent Separation) . The nudger roll rema ins energized until the lead edge of the docu me nt arr ives at the feed se nsor , Q 05 -330. W he n th e l as t docum ent has been fed the feed m otor mom enta rily ru ns in r evers e, this ena ble th e feede r me cha nism to raise the nudger roll and drop the two gate fingers.

6. The feed sensor, Q05-330, positioned between the TAR nip and the separation nip detects the lead edge (LE) of a doc ument once it has been acquired and th en the trail edge (TE) to confirm an inter document gap (IDG).

7. The document momentarily butts against the takeaway roll assembly where the document realigns if skewed. The document has space to corrugate witho ut creasing within the buckle chamber of the document handler.

8. The feed clutch, CL05-025, is deenergized, thereby de-coupling the nudger and feed rolls and the takeaway clutch, CL 05-425, is energized and the take away roll assembly pulls the document through the FAR nip.

9. The document contin ues through the takea way nip until the lead edge is dete cted at the registration sensor, Q 05-340, and the ta keaway clutch , CL05-425, is de energized. If the SPDH has not received a feed request signal from the scanner PWB the takeaway clutch, CL05-425, will de-energise and the document feed will stop. If the feed request signal has been received the document will continue to be scanned.

10. The feed request signal starts the scanning operation. The read motor drives the pre scan roll assembly, which transpor ts the document across the image ar ray for scanning, and onto the mid scan roll assemb ly. Since the rolls driving the pap er are controlled by the same timing belt and motor, the velocity of the paper is constant.

11. If a simplex job has been requested the document passes the CVT window, is lifted by the CVT ramp, and is deliv ered into the re- stack tray. If a dupl ex job has been r equested a scan of side two of the document is made. The side 2 registration sensor, Q05-343, detects the lead edge of the doc ume nt in ord er to tim e the s tart of the side two scan. The document then continues into the re-stack tray after side two is scanned.

Document Separation

The separation of documents is performed by the feeder assembly working in conjunction with the separation ass emb ly and operates on a diff er enti al of fric ti on princ i ple . T he fe ed as sembl y contains the nudger a nd feed rolls and the separation assem bly contains the retard roll. The retard roll is dri ven via a s lip cl utch, and in the op erati onal positi on it is spr ung l oaded again st the feed roll to form the separation nip.

The feed roll has a high coefficie nt of friction with the do cuments fed from the in put tray. The retard roll also has a coeffic ient of friction with th e documents fed fro m the input tray but one that is lower than that of the feed roll, though higher than the coefficient of friction between two documents.

Once activated the nudger roll feeds the top document off the input tray and into the separation nip. In turn the feed roll drives the top document towards th e TAR assembly while the r etard roll is driven in the op posite direc tion, in order to seg regate all documents other than the top document passing through the FAR nip.

The feed roll transports the top document in the proc ess dir ec tion bec au se it has a high coe fficient of friction with the top document. The top document is given a coefficient of friction due to the force imparted by the feed roll and ov ercome s the torque suppli ed by the sl ip clutch of the retard roll. This causes the retard roll to be driven by the feed roll. If more than one document is fed from the document stack on the input tray, documents other than the top document are put in contact with the retard roll. The se lowe r docu men ts are pr evente d fr om be ing tra nspor ted in

the process direction because the torque of the ret ard roll slip c lutch is not ov ercome by the friction between the two docu ments, resulting in only the top sheet being tr ansported in the process direction toward the TAR assembly.

Principles of Operation

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5.4 SPDH Sensors

There are several sen sors located throughout the document path to detec t the positi on of the document. The signals from these sensors initiate operations within the SPDH, and also assist with jam detection, Figure 9.

Takeaway sensor

Feed sensor

Feed roll

Nudger roll

Retard roll

Pre scan roll

Registration sensor Side 1 scan line Mid scan roll

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CVT ramp

TAR roll

Side 2 registration sensor

Figure 9 SPDH document path

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Exit roll

Side 2 scan line

Principles of Operation

Sensor Types and Locations

Document Present Sensor

The document present sensor, Q05 -309 (PL 5.30 Item 6), is a r eflection a ctuated sen sor that senses the presence of a document loaded into the input tray, Figure 10. When the SPDH doc ument present sensor is actuated the docum ent set LED, LP05- 084, illuminates in the SPDH top cover. When the last she et has left the inp ut tray the sensor triggers t he signal to stop the document feeding process.

Stack Height Sensor

The stack height sensor, Q05-310 ( PL 5.20 Item 4) , is a flag ac tuated sensor that senses the paper stack and maintains the stack height by triggering activity of the tray elevator motor, Fig

ure 10.

Stack height sensor actuator

Length Sensor 1

The length sensor 1, Q05-3 15 (PL 5.30 Item 5), is a fl ag actuated sen sor that sense s documents in the input tray longer than 300mm, Figure 11.

Length Sensor 2

Length sensor 2, Q05-320 (PL 5.30 Item 5), is a flag actuated sensor that senses documents in the input tray longer than 240mm, Figure 11.

Document set LED

Principles of Operation

Figure 10 Paper stack sensors

Stack height sensor

Document present sensor

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Length sensor 2

Length sensor 1

Figure 11 Length sensors

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Calibration Home Position Sensor

The calibration home posit ion sensor , Q 05-36 0 ( PL 5.18 Item 9), is a flag actuated sensor that senses that the calibration strip of the side 2 scan assembly is in the home position, Figure 12.

Calibration home position sensor

Width Sensors: 1, 2 and 3

Width sens or s (PL 5.30 Item 5) 1, Q05-325, 2, Q05-326, and 3, Q05-327, are actuated by flags attached to the document wid th gu ide s o f the i npu t tray . The 3 wi dth se nsor s are p os itione d to allow the detection of common document widths. Working with length sens ors 1 and 2 they enable the machine software to determine various document sizes, Figur e 13.

Width sensor 1

Figure 12 Calibration home position sensor

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Width sensor 3 Width sensor 2

Figure 13 Width sensors

Principles of Operation

Feed Sensor

The feed sensor, Q 05-330 (PL 5.20 Item 9), is a reflection activated sensor that senses the lead edge and trail edge of documents leaving the feed assembly to confirm the presence of an inter document gap, Figure 14.

TAR Sensor

The takeaway sensor, Q0 5-335 (PL 5.20 Item 9), is a reflection acti vated sensor that senses the lead edge and tr ail edge of documen ts entering the takeaway roll ass embly. This sens or triggers the stop of the separation nip and nudger rotation. This allows the takeaway roll assembly to pull the doc ument through the separation nip to ensure an interdocum ent gap,

Figure 14.

Registration Sensor

Registration sens or, Q05-340 (PL 5.18 Item 9), is a reflection activated sensor that senses the lead edge and trail edge of documents just prior to the side 1 scan area, Figure 15.

Side 2 Registration Sensor

The side 2 registration se nsor, Q05-34 3 (PL 5.18 It em 9), is a reflection activated sensor that senses the lead edge and trail edge of documents just prior to the side 2 scan area, Figure 15.

Registration sensor (side 1)

Feed sensor Takeaway sensor

Figure 14 Feed and takeaway sensors

Principles of Operation

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Side 2 registration sensor

Figure 15 Registration sensors

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Side 2 Scan Assembly C al i b ra ti o n

The calibration mechanism consists of a white calibration strip attached to the glass surface of the scanner face on th e underside o f the scanner. The white strip on the glas s surface oper ates as a spring loaded sliding shutter driven by a pair of cams. The white calibration strip provides a scannable area for th e ful l w idt h of t he s ide 2 s c an a ssem bly , a nd s erv es as a uni for m reference for the video control system that uses it to calibrate the video data.

Calibration is nece ssary because tolerance variatio ns in the scanner may result in different video data. The calibration procedure scans the calibrati on strip, compares the sign als to set point values stor ed as Non-Volatile Memor y (NVM) data, and then cal culates a white point value to ensure consistent video data. There is no black calibration strip. Black calibration is performed with the lamp off.

Calibration of the side 2 scan assembly is performed at power on or the sensing of a document in the input tray. At the time of calibr ation the read moto r is driven in the op posite rotational direction to that of the scanning proc ess. The spring loaded sliding glas s of the side 2 scan assembly is moved by a cam and actuator arran gement. A pair of ca ms is rotated on a cam shaft via a belt and pulley syst em. In norm al oper ation th e mechanis m is prev ented from rotation by the use of a one way clutch-gear.

As the cams rotate they push against followers at either end of a pivot shaft that move a pair of actuators. The inboard a nd outboard actuators push against pegs attached to the s canner glass. The action of the actuators on the pegs cause the glass to slide in the scan process direction, positioning the calibration strip directly under the scan line of the side 2 scan assem bly. Once the calibration strip is in this position the calibration process takes place.

Further reverse rotation of the cam disengages the two actuators and the spring loaded shutter returns to it’s scannin g operation p osition. A flag on th e inboard end of the cam shaft s ignals the calibration hom e position sensor, Q05-360, that th e calibration strip of the side 2 scan assembly is in the home position, Figure 16.

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Principles of Operation

Side 2 Scan Assembly C al i b ra ti o n Drive Train

The drive train for the side 2 sca n assembly cal ibration mec hanism is as follows (refer to Fig-

ure 16):

1. Read motor, PL 5.18 Item 1(not shown).

2. Read motor idler gear, PL 5.19 Item 16.

3. Mid scan drive gear, PL 5.19 Item 12.

4. Mid scan roll, PL 5.17 Item 3.

5. Mid scan roll pulley PL 5.19 Item 18.

6. Exit roll drive belt, PL 5.19 Item 19.

7. Exit roll pulley, PL 5.19 Item 21.

8. Exit roll assembly, PL 5.17 Item 2.

9. Calibration shutter drive gear, PL 5.19 Item 8.

10. Calibration shutter idler gear, PL 5.19 Item 6.

11. Calibration shutter driven gear, PL 5.19 Item 7.

12. One way gear clutch.

13. Cam shaft

14. Front calibration cam, PL 5.19 Item 20.

15. Cam follower

16. Pivot shaft.

17. Outboard (front) actuator and inboard (rear) actuator.

Principles of Operation

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5. Mid scan roll pulley

6. Exit roll drive belt

7. Exit roll pulley

8. Exit roll assembly

14. Front calibration cam

15. Cam follower

13. Cam shaft

2. Read motor idler gear

9. Calibration shutter drive gear

12. One way gear clutch

17. Outboard actuator (front)

Actuator acting on peg

Pre scan roll

Calibration strip on the scanner glass 17.

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4. Mid scan roll

3. Mid scan drive gear

Pre scan roll drive gear

Figure 16 SPDH scanner calibration

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16. Pivot shaft

10. Calibration shutter idler gear

11. Calibration shutter driven gear

Calibration home position sensor

Calibration home position sensor flag

Inboard actuator (rear)

Principles of Operation

DC Routines and Adjustments

• dC604 Registration Setu p Procedure. This routi ne measures and adjustmen ts image to paper registration for the Image Output Terminal. It must be performed whenever a part is changed, removed or replaced within the SPDH and scanner module.

• dC608 Document Feeder Reg istration. This routine check s the registration of the document feeder and corrects any misalignment. The process runs automatically and does not require any user inter vention other than inserting three bla nk sheets in the document feeder. This routine must be performed whenever a part is changed, removed or replaced, including a complete SPDH module.

• dC609 Document Glass Registration. This feature checks the r egistration of the document glass and corrects an y misalignm ent . The process runs autom aticall y and doe s not require any user interventi on other tha n keepin g the SP DH open d uring the o peration . It routine must be p erformed when ever a part is changed, removed or r eplaced withi n the scanner module.

• dC610 CCD Lamp Profi le Adjus tment. Th is routin e adjusts the side 1 (scanner ) then the side 2 (SPDH) scan lamps to maintain optimum image quality.

• dC945 IIT Calibratio n. This rout ine auto matically calculates and sets the white-re ference correction factor for paper whit e and calibra tion strip v ariations. Thi s procedure must be run whenever a side 2 scan assembly, scan carriage assembly, scanner module, scanner module component, or a complete SPDH is removed

• ADJ 5.1 SPDH Drive Belts Adjustment

• ADJ 5.1 SPDH Height Adjustment

• ADJ 5.2 SPDH Skew Adjustment

• ADJ 5.3 SPDH Cleaning Procedure

Principles of Operation

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Fusing and Copy Transportation

Fusing

The primary function of th e fuser module is to fix the t oner to the media a nd to transport that media from the pr e fuser transport to the p ost fuser transport with no damage or excessi ve curl. Fixing the tone r to the me dia is done by a combina tion of heat and pressur e. There a re four fuser module configurations 45-55ppm (50Hz and 60Hz) and 65-90ppm (50Hz and 60Hz).

Heat warning lab els and fl ocking a re used t o prev ent the cus tomer f rom contac ting high temperature surfaces.

The fuser module receives its drive from the drive assembl y. After the toner image is trans ferred to the paper, the paper passes throug h the fus er . The pr essu re roller is press ed again st the heat roller to melt the toner and bond the image to the paper.

The fuser module is a customer replaceable unit (CRU) (PL 10.8). The average life of the fuser module is 350,000 prints. A CRU m onitor (CRUM) in the fuser module ensures the correct module is installed for the mar ket regi on of the mac hine and mo nitors th e remainin g life of the fuser. When a new fuser module is installed, the fuser life counters are reset.

There are four types of fuser (PL 10.8 Item 1):

• 50Hz for AltaLink® B8045/B8055

• 50Hz for AltaLink® B8065/B8075/B8090

• 60Hz for AltaLink® B8045/B8055

• 60Hz for AltaLink® B8065/B8075/B8090

If a 50Hz fuser is install ed in a US market re gion machine or if a 60Hz fuser is install ed in a European market region machine a 310-399-00 Fuser CRUM incompatibility fault will be declared.

The following information pertaining to fuser module life is available to the customer via the UI:

• Projected end of life (estimated days remaining).

• Image count (estimated pages remaining).

• Life remaining (estimated percent remaining).

• Re-order notification.

• Configuration of re-order information (set by System Administrator - 0 to 20 days).

Fuser Components

Fuser Roll

The fuser roll is heated by two internal halogen lamps, and contacts the pressure roll to form a nip through which t he media is tra nsported. Th e toner i s melte d by the fus er roll and pre ssed into the media by the pressure roll. Drive for the fuser module is provided by the main drive via a gear on the fuser roll.

Pressure Roll

The pressure roll is a metal shaft coated with a hard silicone rubber and a PFA sleeve. It maintains pressure on the paper pas sing between it and the heat r oller. This pressure bonds the melted toner to the paper.

Springs are used to force the fu ser roll and p ressure roll together. The pressure rol l is pulled upwards into the fuser roll by springs maintaining nip force. The pressure roll is at a 10 degree angle to the fuser roll. The pressure rol l has a slight symmetrical profil e with nominal outside diameter of 30mm.

Heat Lamps

Two halogen lamps are used to heat the fuser roll and are mounted in parallel along the bore of the fuser roll. Refer to Table 1 for the heat lamp power.

Table 1 Heat lamp power

Machine speed

45-55ppm 50Hz 825W @230V AC 655W @230V AC 65-90ppm 50Hz 825W @230V AC 910W @230V AC 45-55ppm 60Hz 825W @115V AC 655W @115V AC 65-90ppm 60Hz 825W @115V AC 910W @115V AC

Temperature Sensors

The temperature sensors are contac t thermist ors having a kno wn value of resis tance that varies with temperature. Ther e are two temperature sensors in the fuser. One is located at the center of the heat roller, the other is located toward the front of the heat roller. Both thermistors monitor the temperature of the heat roller. Refer to Figure 1.

Frequency End lamp

A4 (8.5 x 11 inches) SEF

The fuser roll is a s teel tube with a PFA coating . It has a symmetr ic profiled sh ape to ensu re the edges of the paper move slightly faster than the center for wrinkle control.

• AltaLink® B8045/B8 055 - the fuser roll is 0. 75mm thick and has a nom inal 30 mm diam eter.

• AltaLink® B8065/B8 075/B8090 - the fus er roll is 0.75mm thi ck and has a nomin al 30mm diameter.

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Figure 1 Lamps and temperature sensors layout

Principles of Operation

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Thermostats - Thermal Cutouts (TCO)

Two non resettable thermostats (TCOs) are mounted directly above the center of the fuser roll. They provide the final level of safety for the fuser system.

• In a case where the temperatu re control system fails to operate c orrectly the TCO will blow when the temperature at the thermistor is 227 degrees C.

• There is a temperature differ entiation between the th ermisto r and the fu ser due to the air gap between the two.

• When the thermistor detects 227 degrees C the temperature at the fuser roll will be approximately 272 degrees C.

When the TCO blows p ower to the lamps i s cut preventing damage to the modu le. If a TCO blows a new fuser module must be installed. Refer to Figure 2.

TCO 1 and TCO 2

Stripper Fingers

Five stripper fingers are kept in light contact with the fuser roll by spring tension. These prevent paper from remaining attached to the fuser roll. Refer to Figure 3.

Drawer connector

Stripper finger (5)

Pressure roll

Heat roll

Heat lamps (2)

Figure 3 Fuser components

Principles of Operation

Figure 2 TCOs and thermistors

Thermistor 1 and thermistor 2

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CRUM

The CRU monitor (CRUM) is used to identify the type and age of the fuser module. It also identifies the market reg ion and stores th e print count. It also acts a s an interloc k. If the machi ne senses that the CRUM is disconnected, the machine will not run. Refer to Figure 4.

CRUM

Drawer connector

Drawer Connector

The drawer connector (Fi gure 4) provide s the interfac e to the power and cont rol for the fuser. Refer to Figure 5 for pin number locations on the fuser side, PJ100:

• Pin 1 thermistor 1 and thermistor 2 RET.

• Pin 2: thermistor 1.

• Pin 3: thermistor 2.

• Pin 7: lamp 2 RET (A4 SEF).

• Pin 8: AC Supply.

• Pin 9: lamp 1 RET (A4 LEF).

• Pin 10: AC GND.

Pin 10 AC GND

Pin 7 Lamp 2 RET

Pin 3 Thermistor 2

Figure 4 CRUM and drawer connector

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Pin 9 Lamp 1 RET

Pin 1

Pin 8

Thermistor 1 and 2 RET

AC Supply

Figure 5 Fuser drawer connector pins

Pin 2 Thermistor 1

Principles of Operation

Fuser Paper Guides

Refer to Figure 6. The fuser has the following paper guides:

• Left input guide. This guides the paper into the fuser.

• Right input guide. The r ight input guide is floc ked and has the dual fun ction of assisting with the alignment of t he media on fus er entry and prev enting an operator from gaining access to the hot fuser ro ll. In addition, it help s guide the paper i nto the fuser, ensuring that the lead edge contacts the fuser roll first.

• Left output guide. This guide hinges open to aid jam clearance.

• Right output guide. Th is guides the pape r to the post fuser tra nsport roller. The st ripper fingers are mounted to this guide.

Left input guide

Right input guide

Fuser entrance

Right output guide

Fuser exit

Left output guide

Fuser Life Expectancy

Life expectancy of the fuser is dependent on the speed of the machine:

• 45ppm - 264,000 prints

• 55ppm - 300,000 prints

• 65ppm - 315,000 prints

• 76ppm - 330,000 prints

• 90ppm - 345,000 prints Several other factors can reduce fuser life:

• Greater than 5% coverage.

• Paper use larger than letter size.

• Printing on heavy media.

• Printing short-edge feed.

• Printing on transparencies or speciality media.

Fuser Operating States

Refer to Table 2. The fuser has the following operating states:

• Warm up state.

• Stand-by state.

• Run state.

• Power save (off) state.

• Power save (simmer) state.

Table 2 Fuser temperatures

NVM Description

FsrStandbyTemp

FsrRange Temperature range below

FsrRunTemp Target temperature during

HeavyWeightMediaTempOffset

Target temperature during standby mode.

FsrStandbyTemp at which start print can begin.

run mode. Temperature offset added to

fuser temperature media over 120gsm.

Machine speed (PPM) 45 55 65 75 90

60 C. 60 C. 60 C. 60 C. 60 C.

20 C 20 C 20 C 20 C 20 C

195 C. 195 C. 200 C. 200 C. 200 C.

+10 C +10 C +10 C +10 C + 10 C

Principles of Operation

Figure 6 Fuser guides

Warm up State

The fuser enters the warm up state when ‘thermistor measured temperature is less than (NVM value FsrStandbyTemp minus NV M value F srRunTe mp) wh en IOT i s powere d from pow er off state’.

When the fuser is in the warm up state, the IOT informs the device controller that the fuser is in the warm up state. The user is info rmed via the UI tha t the fuser is warming up and pri nting is inhibited until the me asured temperature is within (NVM value F srStandbyTemp minus NV M value FsrRunTemp) standby mode target temperature.

Warm-up is also trigg ered by user inter action with the device, such as pl acing a docu ment in the SPDH or a print command.

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Launch Issue

Standby State

When in the standby state, the measured temperature does not drop by greater than 2 degrees of the target temperature (NVM value FsrStandbyTemp).

The standby state may be entered from the following states:

• Warm-up

•Run

• Recovery

• Suspend

Run State

When in the run state, the fuser uses the nomina l target temperature of NVM value FsrRunTemp plus any offset applied.

When in the run state and A4 (8.5 x 11 inches) LEF media is selected, the measured temperature does not drop by greater than 2 de grees of the targ et temperature, NV M value FsrRunTemp plus any offset applied.

To compensate the type of media being fused and to ensure that the pressure roll has acquired an even temperature, t he fuser roll may ne ed additional time to reach and establi sh a stable run temperature. This is ach ieved by introd ucing a dela y when sending a read y to pri nt stat us to the IOT.

Power Save (Off) State

Entry to the power save (off) state is from the following states:

•Warm Up

• Stand-by

• Power Save (simmer)

When the front doo r interlock and the left door interlocks a re broken, AC power t o the fuser module is removed. The I OT, v ia the LV PS, i s infor med t hat pow er ha s been r emov ed. When the IOT detects that power has been removed the fuser enters the power off state.

Power to the fuser is not be applied when:

• A fuser module is not detected.

• The CRUM is not validated.

• Interlocks are broken.

In the power save (off) state the fu ser uses power lev el 0. When i n the powe r save (off) state, the fuser does not rais e a the rmistor fault when the front door inte rlock and the left do or inter locks are broken.

Fuser Control Watchdog Signal

The fuser is contr olled by the TT L serial comman ds sent to the LVPS by the IOT PWB. The commands can range from 0 to 20. The fu ser con tains two lamp s that are c ontroll ed inde pen dently.

The watchdog time fun ction is incorporated in the s erial link. The current demand fo r each lamp must be communicated to the IOT PWB every 2000ms or power to the lamps wil l be turned off by the LVPS.

Temperature Control

The fuser temperature needs to be controlled constantly and the temperature pr ofile varied depending on the machine’ s operating mode. The fuser transitions between fou r operating modes, warm-up, ready , print, and low power. Both heat lam ps can be controlled indepen dently to achieve all the r e quire d op er ating temperatures and which c omp ly wit h al l s afe ty a nd environmental legislation.

The surface temperature of the fus er roll is monitored us ing two thermistor s. The output from each thermistor is monitored by the IOT PWB, which then controls the output power to the heat lamps, via the fuser power cont rol module. This mai ntains a constant tem perature across the entire length of the fuser roll, regardless of the width of paper being passed through the fuser.

As the resistance of each thermistor changes with a change in fuser roll temperature, the resultant change in voltage is mon itored by the IOT PWB, via an anal ogue to digital converter. A control algorithm uses thi s feedba ck sign al to va ry the AC po wer to the heat lamps, in order to maintain the required tempe rature. The heat lamps are controlled independen tly within the fuser power control module.

Temperature Control and Productivity

To maintain a uniform tempe rature across the fuser roll surface, productiv ity is reduced to 10ppm for media with a width less than or equal to 150mm.

For low input voltage conditions, productivity will be reduced to allow the fuser to maintain temperature set point.

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Principles of Operation

Fuser Cooling

The AltaLink® B8045/B805 5 variants and the AltaLink® B8065/B8075/B809 0 variants have differing cooling arrangements.

AltaLink® B8045/B8055 variants

Two fans, MOT80-015 (PL 80.11 Item 9), mounted in the left door assembly provide cooling for the fuser and remove hot air from the xerographic subsystem. Refer to Figure 7 and Figure 8.

Left door fan 1, MOT80-015

Left door fan 2, MOT80-015

Cooling fans

Principles of Operation

Figure 7 Cooling fans in left door assembly

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Figure 8 Cooling fans in left door assembly

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AltaLink® B8065/B8075/B8090 variants

The higher speed variants do not have fans in the left door . A duct along the top of the left frame member extrac ts heat from th e machine and connects to a duct utilizing a single large fan inside the rear cover, Figure 9.

Duct drawing air from insid

Vents remain open but are not used

Cooling fanLocation of VOC filter accessed from

inside cover

Figure 9 Cooling duct and fan 65/75/90 machines

Fuser Cooling Fans Operation and Component Control

The fuser cooling fans don’t run conti nuous ly. The fans ar e started by the software dep ending on a number of factors in cluding the numbe r of prints in a prin t run and enviro nmental condi tions outside of the spec of the machine.

Component control code 80-01 5 is used to energ ise th e fuser c oolin g fans in bot h speed vari ants. Component control code 80-015 will energise the left door fans or the rear fan depending on the speed variant of the machine. Component control code 80-015 is calle d Left Do or Fans in both speed variants.

Removal of Volatile Organic Compounds (VOC)

• The B8065, B8075 and B8095 variants feature a filter to remove volatile orga nic compounds, such as ozone. The filter is situated in the air flow from the fuser as shown in Fig-

ure 9.

• The B8045 and B8055 variants do not include a VOC filter.

Fuser Safety

There are 3 fuser safety levels:

1. Feedback control softwar e detects the thermistor tempe rature. If the temperature goes high, software cuts the power (current software shutdown temperature is 240 degrees C).

2. Hardware comparator ci rcuit trips and la tches if the temperatu re goes too high ( current hardware comparator is set to 255 degrees C).

3. The thermostats (see TCOs in Fuse r Components) blow at 227 degrees C. If this happens, a new fuser module must be installed.

Copy/Print Transportation

The function of the copy tr ansportation subsystem is to transport im aged sheets after they have been fused to one of the following:

• The output tray.

• The horizontal transport (for transport to the finisher).

• The inverter for side 2 imaging.

NOTE: The duplex transport is located in the left door assembly.

The function of the horizonta l transport is to transport s implex or duplex copi es to one of the following finishing devices:

• Low capacity stapler stacker (2K LCSS).

• Low volume finisher/booklet maker (LVF BM).

• High volume finisher/booklet maker (HVF BM).

NOTE: The horizontal transport is installed when one of the optional finishing devices is installed.

Machine Speed

Machine speeds of 45, 55, 65, 75 and 90 prints per minute are available.

• The 45-55ppm IOT paper path runs at a process speed of 258.0 mm/s. Changing the inter document gap enables 45 or 55 prints per minute.

• The 65-90ppm IOT paper path runs at a different process speed for each print speed. – 65ppm process speed = 300.5 mm/s. – 75ppm process speed = 340.5 mm/s – 90ppm process speed = 362.6 mm/s

Refer to the main drive module Overview section for further details.

Copy/print Path

The system can operate in the following modes:

• Simplex to the IOT exit.

• Duplex to the IOT exit.

Copy/print Tra nsport

Refer to Figure 10 and Figure 11. The foll owing describes th e flow of operation of the paper transport subsystem:

1. A sheet is received from a paper tray.

2. The sheet is transported from the registration transport to the xerographic module.

3. The sheet is received from xerographic module and transported to the fuser module.

4. The sheet is received from the fuser module.

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Principles of Operation

5. The sheet is output:

• to the horizontal transport and then to the finisher.

• inverted sheets to the duplex path.

6. The sheet is re-registered at the registration rolls.

7. The sheet is transported to the xerographic module for duplex printing.

8. The sheet is received from xerographic module and transported to the fuser module.

9. The sheet is received from the fuser module.

10. The 2-sided sheet is output to the horizontal transport, then to the finisher.

Duplex paper path

Inverter/exit

Diverter output guide

Duplex pap er path

Inverter/exit

Simplex paper path

Fuser

Side 2 paper path

Registration transport

Simplex staging

location (SSL) Duplex staging location (DSL)

Figure 10 Copy/print transport with output tray

Diverter output guide

Output tray

Print cartridge

Fuser

Simplex paper path Side 2 paper path

Registration transport

Simplex staging location (SSL)

Duplex staging location (DSL)

Figure 11 Paper path with horizontal transport

Registration and Deskew

Refer to Figure 12. The lead edg e of sheets arriving fr om the vertical trans port, tray 5, or the duplex transport arrive at the registration rolls, which are stopped, before the sheets lead edge arrives at the registration nip.

For sheets coming from one of the paper trays, the TAR/bypass tray motor continues to run. As these nips push the sheet forward, the sheet is forced to buckle against the stationary registra tion nip. If the sheet is skewed, the bu ckle beco mes differen tial in th e cross-proc ess direc tion resulting in the lead edge of the sheet orientating itself square against the registration nip. The deskewing processes for the s implex and dupl ex sheets are sim ilar but use dif ferent nips and the same buckle area.

Horizontal transport

Finisher

Print cartridge

Principles of Operation

For sheets coming from the duplex transport, the duplex motor continues to run. As the duplex nips push the sheet forward, the sheet is forced to buckle against the stationary registr ation nip. If the sheet is skewed, the buckle becomes differential in the cross-process direction resulting in the lead edge of the sheet orientating itself square against the registration nip. The deskewing processes for the s implex and dupl ex sheets are sim ilar but use dif ferent nips and buckling spaces.

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Launch Issue

The time the buckling lasts is a parameter controlled by the IOT PWB. For simplex and duplex, the registration sensor si gnal is us ed as a trig ger to star t a timer. When the timer has expired, the registration motor is energized and the sheet is transported to the xerographic subsystem.

Registration roll idler

Invert to Dup l ex

Inverter Motor

The inverter motor, MO T10-030 is a 4-phase stepper motor used to rotate the inverter ro ll in forward and revers e direc tion. T he in verter roll is u sed to i nvert the paper to the d uplex pape r path. If the duplex pa per path is selected, t he inverter motor speed varies according to the paper size. The speed and direction of the motor is controlled by the IOT PWB.

• For sheets longer than 2 16mm in the process direction, the i nverter motor operates at process speed.

• For sheets equal to or sh orter than 216mm in the proc ess direction, the inverte r motor speed is increased.

Diverters

Refer to Figure 13. The paper path has on e active diverte r and one passiv e gate. The activ e diverter named the inverter gate, is driven by the inverter gate solenoid, SOL10-045. The inverter gate defaults to deliver sheets to the IOT exit. When the inverter gate solenoid is ener gized, if the shee t f oll ows a p ath to th e inv er te r. T he i nv erter m oto r, MOT 1 0-030, will drive the sheet forward until the trail edge is past the passive diverter. Once the trail edge of the sheet is past the passive diverter, the inver ter motor will operate in the reverse dire ction to drive the sheet to the duplex paper path.

The passive inverter gate, PL 10.13 Item 11 is located between the simplex paper path and the duplex paper path.

Buckle space guide

Figure 12 Registration transport

Lead Edge Registration

The time the sheet’s lea d edge arrives at the photorece ptor drum is governed mai nly by the time the registration motor rotation is started.

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Xerox® AltaLink® B8090 Family Multifunction Printe r

The sheet diverted to the duplex path travels under the passive gate until the trail edge is clear of the fingers. The trail edge then flips up above the gate. This is due to the geometry between the gate and the drive rolls. The rolls’ nip being higher than the gate causes the trail edge to flip up above the gate’s fingers. When the motor reverses the shee t then passes over the top of the gate and into the exit path.

The machine will by default deliver sheets to the IOT exit nip image facing down.

The inverter function is p rovi ded by an i nv er ter ro ll that rotates i n the for ward di r ection and the reverse direction. The inverter gate guides the sheet to the inverter after the post fuser nip.

Principles of Operation

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Duplex nip drive rolls, (MOT83-060)

Passive diverter

Post fuser nip drive roll, (MOT10-020)

Inverter roll, (MOT10-030)

Exit nip drive roll, (MOT10-020)

Inverter gate

Duplex Motor

Refer to Figure 14. The duplex motor, MOT83-060 is a 4-phase stepper motor used to rotate 4 sets of duplex paper path rolls wi thin the duplex transpor t. The duplex transport i s located in the left door assembly. The duplex motor runs at du plex speed to trans port the lead edge of the sheet from the inverter to the duplex staging location (DSL). The speed of the motor is con trolled by the IOT PWB.

The AltaLink® B8065/B807 5/B8090 variants use a mo re powerful duplex motor to co pe with the increased speed, PL 80.22 Item 8.

Figure 13 Inverter and duplex paper path

Fuser/Exit Motor

The fuser/exit motor, MOT10-020 is a brus hless DC motor and drives the fuser ni p, the post fuser nip and the exit nip.

Offset Motor

The offset motor, MOT10-500 m oves the offset shuttle inboard to outb oard to provide offset between sheets or sets being delivered to the output tray.

If a horizontal transport is fitted the offs et shuttle is not used and the offset shuttl e is held in place by the offset motor.

Duplex Transport

The duplex transport is a racetrack type d uplex system. The n ips in the duplex tra nsport are driven by the duplex motor, MOT83-060 via a drive gear and drive belt. The speed of the motor is controlled by the IOT PWB.

Principles of Operation

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Nip 4 idler

Nip 4

Nip 3

Drive Belt

Nip 2

Duplex motor, MOT83-060

Nip 1

Left door latch handle

Jam clearance handle

Nip 2 idler

Nip 1 idler

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

Figure 14 Duplex transport

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Principles of Operation

Print/copy Path Sensor Locations

Refer to Figure 15 and Figur e 16.

1. Registration Sensor The registration senso r, Q82-150 is loca ted in the pr int/copy path imme diately be fore the

registration rolls. Thi s senso r is used for print/ copy path ti ming, jam detect ion and buc kle creation.

2. Post Fuser Sensor The post fuser sensor, Q10-120 is located in the print/copy path downstream of the fuser.

This sensor is used for print/copy path timing and jam detection.

3. Duplex Sensor The duplex sensor, Q83-16 0 is located between the 3rd duplex nip and 4th duple x nip.

This sensor is used for print/copy path timing and jam detection.

4. Offset Sensor The offset sensor, Q10-120 is located just past the IOT exit nip and detects the position of

the offset shuttle. The sensor is located in the center of the print/copy path.

5. Horizontal Transport Entry Sensor In a machine equipped with a finishing device, the horizontal transport entry sensor, Q10-

141 is located just befo re the first nip in the horizontal t ransport. This sensor is used fo r print/copy path timing and jam detection.

Inverter roll idler

Duplex sensor, Q83-160

Bypass tray (tray 5) retard roll

Figure 15 Paper path with output tray

Inverter/exit

Inverter roll

Post fuser sensor, Q10-120

Registration sensor, Q82-150

Exit roll idler

Offset sensor, Q10-300

Offset motor, MOT10-500

Output tray

Inverter roll idler Inverter roll

Duplex sensor, Q83-160

Bypass tray (tray 5) retard roll

Exit roll idler

Inverter/exit

Exit roll

Horizontal transport

Post fuser sensor, Q10-120

Registration sensor, Q82-150

Figure 16 Paper path with horizontal transport

Horizontal transport entry sensor, Q10-120

Finisher

Principles of Operation

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Xerox® AltaLink® B8090 Family Multifunction Printer

Horizontal Transport Assembly

The horizontal transport module is installed when a finisher is installed.

Refer to Figure 17. The electrical components in the horizontal transport are:

• Horizontal transport motor, MOT10-040 (PL 10.16 Item 1).

• Horizontal transport entry sensor, Q10-041(PL 10.15 Item 7).

Refer to Figure 18 and Figure 19 for details of components in the horizontal transport.

Entry sensor

Horizontal transport exit nip

Figure 17 Circuit diagram

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Figure 18 Horizontal transport module front view

Principles of Operation

Horizontal transport motor (behind support)

Horizontal transport motor motor drive belt

Horizontal transport belt

Figure 19 Horizontal transport module rear view

All of the pulleys on the horizontal transport act as one-way clutches. This allows the finisher to accelerate sheets out wh ile the sheet is stil l in the transport nip s. The clutches facilit ate jam clearance from the finisher side while the trail edge of a sheet is still in the transport.

Principles of Operation

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Xerox® AltaLink® B8090 Family Multifunction Printer

Low Capacity Stapler Stacker (2K LCSS)

2K LCSS General Description

The 2K LCSS provides two destinations bins, a 250 sheet capacity top tray and a high capacity 2000 sheet stacker tray. Refer to Table 1 for the capacity of the top tray (bin 0), the stacker tray (bin 1). Refer to Table 2 for media constraints.

When the top tray is selected the output will be stacked. When the high capacity stacker tray is selected the output will be compi led, tamped, and sets will be offset 20mm to 30m m for set separation.

Table 1 2K LCSS bin capacity

Sheet Capacity (80gsm)

Top Tray Bin 0

Stacker tray Bin 1

Media type Specification

Tabs Top tray only, tabs must be on lead edge Envelopes Top Tray only

The user may choose from the following finishing options when output is directed to the stacker tray.

• Offsetting of sets (25mm) to create a visible set boundary stacking feature.

• Hole punching of sheets 2, 3 or 4 hole, Swedish 4 and Legal 2 hole configuration.

• Automatic stapling of up to 50 s hee ts (80 gs m, 20 lb) s ets , with the us er abl e to s el ect one of the following three positions dependant upon paper size and feed direction:

– Single front – Single rear –Dual

Configuration

The 2K LCSS is configured wi th two output bi ns; bin 0 (top tray ) and bin 1 (stac ker tray). The capacity of the compiler is 50 sheets in collating or collating and stapling mode.

Machine Interface

The 2K LCSS PWB receives and sends serial input and output data to and from the IOT PWB. The machine interface c omp ri ses o f the 2K LCS S P WB, the communication cable, a bulkh ead

connector, and a harness. The communication cable is the elect rica l connec ti on betwe en the IOT PW B and the 2K LCSS

PWB. Communications between the IOT PWB and the 2K LCSS PWB are provided by the communi-

cation cable.

250 A6 (4.25 x 5.5 inches) SEF to A3 (11 x

2000 A5 (8.5 x 5.5 inches) SEF or LEF to A3

Paper sizes Paper weight

60 - 216gsm (16-57lb)

17 inches) SEF

60 - 216gsm (16-57lb)

(11 x 17 inches) SEF

T able 2 Media constraints

Power/Interlock

Refer to Figure 1. The 2K LCSS requires a dedicated power cord which is connected to the self adjusting 2K LCSS power supply module located inside the 2K LCSS. The power supply mod ule will accept 90 to 265V AC at 50Hz or 60Hz.

Refer to Figure 2. Interlock switc hes in the 2 K LCSS inte rrupt +24V power whe n either of the following are open during jam clearance or service:

• Front door interlock switch, S12-303

• Top cover interlock switch, S12-197

2K LCSS PWB

Power supply module

Figure 1 Power supply module and 2K LCSS PWB

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Principles of Operation

2K LCSS Paper Path

Refer to Figure 3.

Docking interlock switch, S12-177

Figure 2 2K LCSS interlock switches

Top cover interlock switch, S12-197

Front door interlock switch, S12-303

Top tray exit sensor, Q12-106

Transport rolls 1 and 2

- driven by transport motor 2 MOT12-224

Exit diverter gate exit diverter solenoid , SOL12-225

Entrance Rolls 1 and 2 - driven by transport motor 1

Idler roll

Punch sensor 1 Q12-078

Idler roll

Bin 0 (top tray)

Hole punch - hole punch motor, MOT12-243

Compiler rolls 1 and 2 driven by transport motor 2 MOT12-224

Compiler exit sensor, Q12-106

Idler roll

Bin 1 (stacker tray)

Principles of Operation

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Entry sensor, Q12-077

Figure 3 2K LCSS paper path

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Xerox® AltaLink® B8090 Family Multifunction Printer

Entrance Paper Path

The entrance paper path is lo cated in the middle le ft side of the 2K LCSS. It receives printed sheets from the host machine and transp orts the sheets through the vertic al paper transport. From there the sheets are d irec ted to ei the r b in 0 ( top tr ay) or to th e hole punch unit and com piler and then to bin 1 (stacker tray).

Entry Sensor

Refer to Figure 4. The entr y sens or, Q12 -077 is loca ted in the 2K LCSS ent ranc e paper p ath. In addition to supplyi ng th e 2K LCS S PWB wi th ja m de tec tion i nfor m atio n, th e s ensor s ign al is used to time the operation of components in the 2K LCSS.

Transport Motor 1

Refer to Figure 5. Transport motor 1, MOT12-223, is a stepper motor located on the rear frame. The output shaft o f the motor drives a toothed t iming belt, that transfers m echanical

drive to two sets of nip rolls in the entrance paper path.

Exit Diverter Gate

Sheets continue up the entran ce pape r path, by way of two sets of ni p roll s, to the exit div ert e r gate. The gate is opened by the exit diverter gate solenoid, SOL12-225.

If the gate is open, sheets are diverted to bin 0. If the gate is closed, sheets continue to the hole punch unit, compiler, and bin 1 (stacker tray).

Top tray exit sensor, Q12-107

Transport motor 2 MOT12-224

Exit diverter solenoid, SOL12-225

Figure 4 Entry sensor

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

Entry sensor, Q12-077

Entrance Nip

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Transport motor 1 MOT12-223

Figure 5 Transport components

Principles of Operation

Bin 0 (Top Tray)

Bin 0 receives all transpar ency jobs, lab el jobs and all jo bs not selected by the operator to be made into compiled sets or compiled and stapled sets.

Bin 0 Paper Path and Trans port Motor 2

Refer to Figure 5. Transport motor 2, MOT12-224, is a stepper motor loc ated on the rear frame. The output sh aft of the motor drives a tooth ed timing belt, that transfe rs mechanical drive to the driven components in the upper paper path. Sheets leavi ng the vertical transport via the opened upper diverter gate are transported to bin 0 (top tray) by the upper paper path.

Bin 0 Operation

Refer to Figure 5. The top tray exit sen sor, Q12-107 is used to detect jams in th e top tray. When the trail edge c lears t he sen sor, it si gnals the contr ol lo gic that th e shee t has e xited the upper paper path.

Sheet edge detection is disabled until just before either edge is expected (approximately 30mm). This is done to avoid reading false signals caused by sensor bounce.

As the paper is ejected, it drops vertically to the surface of the top tray. Subsequent sheets settle on top of the previous sheets, creating a stack.

Hole Punch Unit

Refer to Figure 6. As sheets are received in the 2K LCSS entrance paper path, the exit diverter gate remains closed and th e sh eets are d ir ected to the hole punch unit. If hole punc hin g is not requested, sheets pass straight through the hole punch unit to the compiler.

If hole punching has bee n requested, punch se nsor 1, Q12-078 senses th e trail edge of the sheet, the sheet is halted in the correct position by the 2K LCSS PWB co ntrolling transport motor 2, MOT12-223. The hole punch motor, MOT12-243 is then energized to punch the sheet, the hole punch mo tor continues to be driv en until the punch head home sensor, Q12194 sends a signal to the 2K LCSS PWB, so that the hole punch motor is stopped at the home position.

Hole punch motor, MOT12-243

Punch head home sensor, Q12-194

Punch sensor 1 Q12-078

Punch head present sensor, Q12-195

Principles of Operation

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Chad bin level sensor, Q12-193

Figure 6 Hole punch unit

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Xerox® AltaLink® B8090 Family Multifunction Printer

Compiling

Refer to Figure 7. As each sh eet arrives in the compile r, the paddle sh aft assembly is rotated by the paddle roll motor, MOT12-238, one revolution from the home position to drive the sheet fully to the left of the c omp il er. T he h ome po sitio n i s s ensed whe n the flag on the padd le s haft enters the paddle home sensor, Q12-186.

The home position is arrang ed to p ark t he padd le fin gers i nside of the outp ut cov er pro file, so that set ejection is not impeded by the rubber paddle fingers.

As each sheet is registered against the backstops, it is tamped to ensure a neat set. When the set is complete it is stapled, if required, before being ejected into bin 1 (stacker tray).

Paddles

Tamping

Refer to Figure 8. The purpose of th e tamping fu nction is to a lign the sheets in the compile r carriage to eliminate skew and offs et. T am ping r egi ster s all s hee ts in the c orr ec t positi on, as a set, for correct stapling.

Rear tamper home sensor, Q12-181

Front tamper motor, MOT12-226

Rear tamper away sensor, Q12-183

Front tamper away sensor, Q12-182

Front tamper home sensor, Q12-180

Paddle roll home sensor, Q12-186

Figure 7 Paddle shaft assembly

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

Paddle roll motor, MOT12-238

Rear tamper motor, MOT12-227

Figure 8 Tamping components

When the first she et of a s et is abou t to enter the co mpiler, th e tamper arms are m oved fr om the home or away p osition to th e ready p osition. The r eady position is paper size depend ent and the information is obta ined from the IOT. When e ach sheet of the set is fully within the compiling area, the tam per arms are moved to the tamp position an d then back to the read y position to wait for the n ex t sh eet. The ta mper arms are moved back to t he r ea dy pos ition at a slower speed so that an over-tamp buckle is avoided which could move sheets out of the regis tered position.

The front tamper is move d along a track by a toothed belt driven by the front ta mper motor, MOT12-226. The home p osition of the front tamper is sens ed by the front tamper home sen sor, Q12-180. This home position is used for wide paper. The away position of the front tamper is sensed by the front tam per a way sen sor, Q12-18 2. This away positi on is used for nar rower paper to reduce front tamper movement when tampin g narrower paper. The task of the front tamper is to align the front of the set, half of the paper width from the centre of the finisher.

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Principles of Operation

The rear tamper is moved alon g a track by a toothed belt driven by the rear tamp er motor, MOT12-227. The home position of the rear tamper is sensed by the rear tamper home sensor, Q12-181. This home positi on is used for wide pap er. The away pos ition of the rear ta mper is sensed by the rear ta mper away sensor, Q12-183. T his away position is us ed for narrower paper to reduce rear tamper movement when tamping nar rower paper. The task of the rear tamper is to align the rear of the set half of the paper width from the centre of the finisher.

The tampers are also used to perform the required offset to the finished set by mov ing in unison by 25mm (1 inch) to the rear as alternate finished sets are ejected to bin 1.

Stapling

Refer to Figure 9 and Figure 10. The purpose of the stapler is to staple the compiled sets in the compiler tray. Up to 50 sheets of (80gsm/20lb) paper can be stapled. Single or double stapling is available on the left edge of the set, corner stapling is also available.

Staple head

SU 1 motor, MOT12-249

Stapler index sensor, Q 12-168

Principles of Operation

Staple home sensor, Q12-135

Stapler Unit 1: staple head 1 motor, MOT12-247, low staple sensor, Q12-133, stapler jaw home sensor, Q12-318, cartridge present sensor, Q12-363

Figure 9 Stapler unit 1 compone nts

The staple head unit 1 as sembly is mounted on the stapler traverse a ssembly, which mo ves the stapler to the various staplin g positions within the c ompiler. Dr ive is pro vided by the S U 1 motor, MOT12-249 which drives the stapler mounting along a track via a toothed rubber belt, to position the stapler . The stapler home sensor, Q12-135 se nses when the stapler is at the home position.

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Launch Issue

Once the signal has been recei ved to staple, the staple head 1 moto r, MOT12-247 (located within the staple he ad) is energiz ed. The motor rema ins energiz ed until the cam h as made a complete revolution and the stapl er jaw home sensor, Q12-318 has been act uated. The one revolution of the cam enab les a staple to be driven th ough the set, clinched , and then return the staple head to the home (open) position for the next staple.

SU 1 Motor, MOT12-249

The stapler traverse assembly contains a linear slide and ‘J’ shaped guide with a sliding stapler mounting which is driven by the SU 1 motor, MO T12- 2 49. The s tapl er tra vers e asse mbl y posi tions the stapler at the various positions necessary for the stapling operation

Staple index sensor, Q12-168

Stapler traverse assembly

Stapler Index Sensor, Q12-168

The stapler index sensor, Q12-168 is located at the right of the stapler mounting. All stapler traverse positions are achieved by this sensor locating fixed flags at each stapling position on the stapler traverse assembly.

Self Priming Sensor, Q12-134

Priming of the staple hea d is the pre-forming o f the first two staples in the staple stick. I f the staple head home sens or is low at machine initialization, the SH1 priming sensor (located

within the staple head) is chec ked for staple hea d primed ( H) (high = primed ). If the sensor is high then the initialization is comple te. If the staple head pr imed si gnal is low, the co ntrol logi c will cycle the staple hea d 1 motor, MOT12-247 until th e self priming sens or, Q12-134 signal goes (H).

Stapler Jaw Home Sensor, Q12-318

After the staple has be en form ed in th e compil ed set, the sta ple hea d cam con tin ues to rot ate until it has made one comp lete rev olution and the stapl er jaw home s ensor, Q12-318 (lo cated within the staple he ad) h as been actuated, sending a (H) signal to the control logic to sto p the staple head 1 motor at the home position.

Low Staple Sensor, Q12-133

The low staple sensor, Q12-133 (located within the staple head) is used to detect the presence of staples in the staple head unit. The sensor signals the control logic when the cartridge is low on staples.

Cartridge Present Sensor, Q12-363

The cartridge present s ensor, Q12-363 ( located within the s taple head) is u sed to detect the presence of a staple cartridg e in the staple head unit. The sensor signals the control logic when the cartridge is missing.

Staple head unit

Figure 10 Staple head and traverse assembly

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

Self priming sensor, Q12-134 (located in staple head unit)

SU1 motor, MOT12-249

SH1 paper sensor, Q12-196

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Principles of Operation

Set Ejection

The ejector ejects sets in the compiler into bin 1 when the following conditions are met:

• A maximum of 50 sheets of an unstapled job is in the compiler

• An unstapled collated job has completed

• A stapled job has been completed.

Refer to Figure 11. When any of these conditions are met, the ejector motor, MOT12-234 is run to eject the set. The motor rotates clockwise, d riving the ejector belt. T he ejector belt mov es the ejector forward to eject the set into bin 1 (stacker tray). When the ejector actuates the ejec tor out sensor, Q12-185, the eje ctor motor rotates coun ter clockwise. When the ejector actuates the ejector home sensor, Q12-184, the motor is stopped.

Ejector out sensor, Q12-185

Ejector Out Sensor, Q12-185

The ejector out sensor, Q 12-1 85 detects the ej ector whe n it is in the f ully forward ( eject) posi tion.

Ejector Home Sensor, Q12-184

The ejector home sensor, Q12-184 detects the ejector when it is in the home position.

Ejector Motor, MOT12-234

The ejector motor, MOT12-234 drives a pulley which in turn drives the ejector belt to move the ejector. The rotates counter clo ckwise to eject sets a nd clockwi se to retu rn to the home posi tion.

Ejector home sensor, Q12-184

Principles of Operation

Ejector belt

Figure 11 Eject asse m bly components

Ejector fingers

Ejector motor, MOT12-234 and ejector motor encoder sensor, Q12-096

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Xerox® AltaLink® B8090 Family Multifunction Printer

Bin 1 Stacking and Positioning

Refer to Figure 12 and Figure 13. Bin 1 of the 2K LCSS provides a platform to stack up to 2000 sheets. The bin 1 tray surface or the top of th e sta ck in bin 1, ass i sts in the com pili ng mod e by providing an extended surface to support longer documents, e.g. SEF A4 (8.5 x 11 inches) and A3 (11 x 17 inches).

Bin 1 upper limit switch, S12-190

Bin 1 90% full sensor, Q12-187

Bin 1 motor encoder sensor, Q12-163

The bin 1 upper level sensor, Q12-188 senses the top of the stac k. This signal is used by the 2K LCSS PWB to determi ne when to low er bin 1 in steps to main tain the correc t stac k heig ht, with regard to the output from the comp il er. Th e bin 1 90% ful l sens or , Q12- 187 i s used to sig nal when bin 1 is 90% full. T he contr ol log ic will a llow 10% more set feeds p rior to de clarin g a bin 1 full status to the 2K LCSS PWB.

Bin 1 upper level sensor, Q12-188

Bin 1 elevator motor, MOT12-241

Bin 1 lower limit switch, S12-190

Figure 12 Bin 1 components

As the paper stack increas es in the tr ay, the bin 1 elevat or moto r, MOT12- 241 low ers the tr ay to the appropriate eject height to receive the set.

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

April 2017

Figure 13 Bin 1 upper level sensor

Principles of Operation

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LVF BM

LVF BM General Description

The LVF provides three selectable destination bins. Refer to Table 1 for the capacity of the top tray (bin 0), the stac ker tra y (bin 1), and the boo klet maker (bi n 2) . Refer to Table 2 fo r med ia constraints.

Table 1 LVF BM bin capacity

Sheet Capacity (80gsm) Paper sizes

Top Tray Bin 0

Stacker tray Bin 1

Booklet maker Bin 2

Media type Specification

Tabs Top tray only, tabs must be on lead edge Envelopes Top Tray only

When bin 0 is the destination, the output will be stacked un-tamped.

When bin 1 is the des tination, the output w ill be comp iled and tamped. T he user may c hoose the following finishing options when output is directed to the stacker tray:

• Offsetting of sets (25mm) to create a visible set boundary - stacking feature.

• Punching (optional 2, 3 or 4 hole).

• Automatic stapling of up to 50 sheet (80gs m) sets, with the user able to se lect one of the following three positions dependant upon paper size and feed direction:

– Single front (front corner) – Single rear –Dual

When bin 2 is the destination, the user may select between fold mode or staple and fold mode.

250 A6 (4.25 x 5.5 inches) SEF to

2000 A5 (8.5 x 5.5 inches) SEF or

30 booklets of 1-5 sheets A3 (11 x 17 inches), 8.5 x 14 20 booklets of 6-10 sheets 10 booklets of 11-15 sheets

Table 2 Media constraints

A3 (11 x 17 inches) SEF

LEF to A3 (11 x 17 inches) SEF

inches, A4 (8.4 x 11 inches), and 8.5 x 13 inches SEF

Paper weight

60 - 216gsm (16-57lb)

Control

Refer to Figure 1. The functions of the LVF BM are controlled by the IOT via a communications cable connected betwee n the IOT PWB and the LVF PWB. Commun ication signals travel in both directions to and from the processors in both devices.

Top cover interlock switch, S12-197

Front door interlock switch, S12-303

LVF PWB

Docking interlock switch, S12-177

Power supply module

LVF BM PWB

Power Supply

AC power is supplied from the IOT via a power cable to the power supply module in the rear of the LVF BM. The LV F B M is p owere d o n/off by the IOT. The powe r su pply mo dul e is s up pli ed with an input of eith er 22 0 to 24 0V AC at 50Hz or 110 to 12 7V AC at 6 0Hz an d ha s outp uts of +24V, +5V and 0V.

Principles of Operation

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Communication cable

Power cable

Figure 1 Power , control and interlock components

Launch Issue

Xerox® AltaLink® B8090 Family Multifunction Printer

Safety Interlocks

Refer to Figure 1. Safety interlocks are provided to pr event the ener gizing of mot ors and sol enoids while components may be exposed during jam clearance or maintenance operations.

The top cover interlock switch , S12 -197 c uts the +24V sup pl y from th e powe r suppl y modu le if the exit cover is open.

The front door interlock switch, S12-303 cuts the +24V supply from the power supply module if the LVF BM front door is open.

Paper Paths

Paper entering the LVF BM has three possible output destinations:

• Bin 0 on the top of the LVF BM. This output has no finishing capabilities and a capacity of 250 sheets of 80gsm (20 lb) paper.

• Bin 1 on the right side of the LVF BM. This output has the capability of hole punching, set collating, set stapling, offsetti ng and stacking, with a capacity of 2000 sheets of 80g sm (20 lb) paper.

• Bin 2 on the bottom right of the LVF BM. This output has a capability of producing stapled and un-stapled boo klets and a c apa city of 2 0 b ook l ets o f 6 to 1 0 s he ets o f 8 0gs m (20 l b) paper.

Paper Path to Bin 0

Refer to Figure 2. Paper feed sequence to bin 0:

1. Paper enters the LVF BM, then actuates the finisher entry sensor, Q12-077.

2. The de-energized bo oklet diverter gate sol enoid, SOL12-258 hol ds the booklet diverter gate in position to send th e paper upwards thr ough the paper entry guid e assemb ly and left paper guide to the bin0/bi n 1 diverte r gate. The paper is driven by the l ower feed roll assembly and the upper feed roll assembly, both are driven by transport motor 1, MOT12-

223.

3. The energized bin 0/bin 1 diverter solenoi d holds the bi n 0/bin 1 di verter gate in position to send the paper upwards between the paper guide and the exit cover, driven by the feed roll shaft.

4. The paper actuates the top tray exit sensor, Q12-107 and gets fed into bin 0 by the ejector drive shaft. The feed roll sh aft a nd th e ej ec tor dr ive sh aft a re dr iven b y t rans port m otor 2, MOT12-224.

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Principles of Operation

Bin 0

Ejector drive shaft

Exit cover

Top tray exit sensor, Q12-107

Paper guide

Feed roll shaft

Bin 0/bin 1 diverter gate

Left paper guide

Upper feed roll assembly

Exit diverter solenoid SOL12-225

Lower feed roll assembly

Paper entry guide assembly

Principles of Operation

Transport motor 2, MOT12-224

Transport motor 1, MOT12-223

Figure 2 Paper path to bin 0 components

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Finishe r entry sensor, Q12-077

Booklet diverter gate

Booklet diverter gate solenoid, SOL12-258

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Paper Path to Bin 1

Refer to Figure 3. Paper feed sequence to bin 1:

1. Paper enters the LVF BM, then actuates the finisher entry sensor, Q12-077.

2. The de-energized bo oklet diverter gate sol enoid, SOL12-258 hol ds the booklet diverter gate in position to send th e paper upwards th rough the paper entry guid e and le ft paper guide to the bin0/bin 1 diver ter gate The paper is driven by the lowe r feed roll assembly and the upper feed roll assembly, both are driven by transport motor 1, MOT12-223.

3. The de-energized bi n 0/bi n 1 di verter sole noid h olds the bin 0/ bin 1 diver ter gate in position to send the paper to the right and through the left paper guide and hole punch.

4. The paper is then d riven by the feed roll shaft through th e gap between the u pper and lower right paper guides

5. The paper actuates t he 2nd to top tray exit sens or, Q12-10 7 and gets fed into the com piler by the ejector drive shaft. The feed roll shaft and the ejector drive shaft are driven by transport motor 2, MOT12-224.

6. The compiler receiv es the pap er. If set co mpiling is required the pages are accum ulated and tamped into a set. If set stapling is required, the stapler is ener gi zed to s tapl e the set in the specified places. The completed set is then ejected into bin 1 by the ejector.

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Principles of Operation

Compiler exit sensor, Q12-106

Upper right paper guide

Compiler

Bin 1

Ejector drive shaft

Lower right paper guide

Feed roll shaft

Hole punch unit

Bin 0/bin 1 diverter gate

Left paper guide

Upper feed roll assembly

Paper entry guide assembly

Lower feed roll assembly

Finisher entry sensor, Q12-077

Booklet diverter gate

Principles of Operation

Transport motor 2, MOT12-224

Figure 3 Paper path to bin 1 components

Exit diverter solenoid, SOL12-225

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Ejector

Booklet diverter gate solenoid, SOL12-258

Transport motor 1, MOT12-223

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Paper Path to Bin 2

Refer to Figure 4. Paper feed sequence to bin 2:

1. Paper enters the LVF BM, then actuates the finisher entry sensor, Q12-077.

2. The energized bookle t dive rter gate solen oid, SOL 12-258 ho ld s the book let di verter g ate in position to send the paper dow nwards through the upper and lower gui des then actu ates the BM entry sensor, Q12-089.

3. The crease rolls a re d riven in reve rse as the lead edge o f the f irst sheet o nly p asse s the crease rolls to avoid the lead edge stubbing into the static rolls.

4. The paper continu es into the booklet compiler area where the flapper motor rotates the flappers to register the pages against the previously positioned back stop.

5. If stapling is required , when the full set of booklet pages ha ve been compi led, the backstop clamps and lifts the set to the stapling position, two staples are inserted by the booklet stapler assembly.

6. The set is then li fted fur th er to the crease position wh er e the crea se b lad e p ress es a fo ld into the set and pushes the fold into the nip of the crease rollers.

7. The crease rollers turn to pull the boo klet throu gh the nip, the nip ro llers are dr iven back wards and forwards a few times to improve t he crease, then they feed the completed booklet to the exit roll ass embly where the booklet it ejected past the BM exit sensor, Q12-213 into bin 2.

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Principles of Operation

Upper guide

Booklet diverter gate

Finisher entry sensor, Q12-077

Transport motor 1, MOT12-223

Booklet diverter gate solenoid, SOL12-258

Lower guide

2nd feed roll

BM exit rolls

Booklet maker entrance guide

1st feed roll

BM entry sensor, Q12-089

BM exit sensor, Q12-213

Booklet compiler

BM backstop

BM exit guides

Bin 2

Principles of Operation

Figure 4 Paper path to bin 2 components

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Hole Punch Unit

Refer to Figure 5. A hole punch unit is available as a kit. Once the kit is installed, the existence of a hole punch op tion is r eported to the system contr oller by the pun ch he ad pre sent sen sor, Q12-195. Hole punching i s made av ail abl e to the u ser v ia the use r inte rf ac e. The spe cifi c type of punch (2, 3 or 4 hole) is not reported.

Pages that are required to be punched are sent along the paper path towards bin 1. The punch sensor, Q12-078 signals the LVF P WB co ntrol ler when the trail edge of the sheet is seen. The LVF PWB then drives the hole pun ch motor for one cycle to punch the pap er one sheet at a time. The punch head home sensor, Q12- 194 signals the LVF PWB contr oller when the rota tion of the punch cam shaft has reached the home position, the LVF PWB controller then turns off the hole punch motor.

The chad from the hole p unc hi ng o perat ion fal ls down into the chad bin below the hole punch. A cam on the front of the hol e p unc h u nit r otat es to t amp the ch ad in the ch ad b in to set tle the contents and increase the capacity. The chad bin level sensor , Q 12-19 3 si gn als the LVF PWB controller when the chad bin needs to be emptied, this results in a message being displayed on the user interface, requesting that the chad bin be emptied.

Hole punch motor, MOT12-243

Punch sensor, Q12-078

Chad bin level sensor, Q12-193

Compiler

Refer to Figure 6. The compiler c ollects pages o f ou tput and comp iles the m into sets tha t can be stapled in various ways, then offsets the sets into bin 1. The left section of the compiler is formed by the shape of th e output cover, the right si de of the compiler is for med by the two tamper arms. The support fingers of the ejector assembly support the pages from below.

Tamper assembly

Paddle shaft assembly

Punch head home sensor, Q12-194

Punch head present sensor, Q12-195

Figure 5 Hole punch unit components

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Chad bin

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Output cover

Stapler assembly

Figure 6 Compiler components

Support fingers

Ejector as sembly

Principles of Operation

Tamper Assembly

Refer to Figure 7. The purpose of th e tamping f unction is to a lign the sheets in the compil er carriage to eliminate skew an d offs et. Ta mping r egi st ers a ll shee ts in the cor rec t pos it ion , as a set, for correct stapling.

When the first sheet of a set is about to enter the compil er, the tamper arms are mov ed from the home position to the ready position. The ready position is paper size dependent and the information is obtain ed from the IOT. W hen each sheet of the set is fully within the compili ng area, the tamper arms are moved to the tamp posi tion and then back to the ready pos ition to wait for the next sheet. The tamper arms are mov ed back to the ready position at a slower speed so that an o vertamp buckle i s avoided whic h could move sheets out of the registered position.

Rear tamper home sensor, Q12-181

Rear tamper motor, MOT12-227

Rear tamper away sensor, Q12-183

The rear tamper is moved along a track by a toothed belt driven by the rear tamper motor, MOT12-227. The home position of the rear tamper is sensed by the rear tamper home sensor, Q12-181. This home posi tion is used for wide paper. The away p osition of the rea r tamper is sensed by the rear ta mper away sensor, Q12-183. Thi s away position is used fo r narrower paper to reduce rear tam per movement when tamping na rrower paper. The task of the rea r tamper is to align the rear of the set. This a lignment position va ries for different pape r sizes and is derived from the size of the paper registered in the paper tray being used.

The tampers are also used to perform the required offset to the finished set by movi ng in unison by 25mm (1 inch) to the rear as the finished set is ejected to bin 1.

Paddle Shaft Assembly

Refer to Figure 8. The paddle sh aft assembly is positioned in the top s ection of the output cover and is used to drive the sheets of paper fully left against the edge of the output cover.

As each sheet arrives in the compiler, the paddle shaft assembly is rotated one revolution from the home position to drive th e sheet fully to the left of the compi ler. The home position is sensed when the flag on the paddle shaft enters the paddle home sensor, Q12-186. The home position is arranged to park the paddl e finger s insid e of the output cove r profile , so th at pape r movement is not impeded by the rubber paddle fingers.

Paddle shaft assembly

Front tamper away sensor, Q12-182

Front tamper motor, MOT12-226

Figure 7 Tamper assembly components

The front tamper is moved a long a track by a toothed bel t driven by the front tampe r motor, MOT12-226. The home p osition of the fron t tamper is sense d by the front tam per home sen sor, Q12-180. The task of the front tamper is to align the front of the set with the inner front wall of the output cover, this alignment position is the same for all paper sizes.

Principles of Operation

Front tamper home sensor, Q12-180

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Paddles

Paddle home sensor, Q12-186

Figure 8 Paddle wheel assembly components

Xerox® AltaLink® B8090 Family Multifunction Printer

Flag

Paddle roll rotor assembly MOT12-238

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Stapler Assembly

Refer to Figure 9. The stapler assembly is used to staple the compiled sets in the compiler. Up to 50 sheets of 80gsm (20lb) paper can be stapled. Single or double stapling is available in portrait or landscape mode, corner stapling is also available.

The stapler is mounted on a traverse assembly, which moves the stapler to the various stapling positions w ithin the compiler. Drive is provided by the stapler uni t motor, MOT12-249 which drives the st apler traverse assembly, to position the stapler. The stapler hom e sensor, Q12-135 senses when the staple head is at the home (corner) position.

Once the signal has been rece ived to stapl e, the tamp er arms are mo ved to the tam p positi on to hold the set until the stapling operation is completed. The stapler head 1 motor, MOT12-247 (located within the staple he ad) is then ene rgized . The mo tor remai ns energ ized until the cam has made a complete revolution and the stapler jaw home sensor, Q12-318 (located within the staple head) has b een actuat ed. The on e revoluti on of the cam enab les a stap le to be driven though the set, cli nched, and then return the staple head to the home (open) positi on for the next staple.

During machine initialization, the stapler unit motor, MOT12-249, is driven towards the rear for a short distance. Aft er this movement, t he moto r is stopped and d riven towa rds the front until the home position is detected by the stapler home sensor, Q12-135. All traverse values for sta pling positions are relative to the home position.

SH1 paper sensor, Q12-196

Stapler index sensor, Q12-168

Stapling unit motor, MOT12-249

Priming of the staple he ad is the pre-forming o f the first two staples in th e staple stick. If the stapler jaw home sensor, Q12- 318 is low at machine initialization, the self primin g sensor, Q12-134 (located within the staple head) is checked for staple head primed (H) (high = primed). If the sensor is high then the initialization is complete. If the staple head primed signal is low, the control lo gic will cycle the s tapler head 1 mo tor, MOT12-247 unti l the self priming sensor signal goes high.

The SH1 low staples sensor, Q12-133 ( located within the s taple head) is used to detect the presence of staples in the stapler . The sensor signals the control l ogic when the cartridge is low on staples.

The cartridge present sensor, Q12-363 ( located within the staple head) is u sed to detect the presence of a staple cartridge in the stapler. The sensor signals the control logic when the car tridge is missing from the staple head.

Stapler traverse assembly

Staple head assembly: staple head motor, MOT12247,staples low sensor, Q12-133, stapler jaw home sensor,Q12-318, cartridge present sensor, Q12-363

Stapler home sensor, Q12-135

Figure 9 Stapler assembly components

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Principles of Operation

Ejector assembly

Refer to Figure 10. The ejector is used to move the finished set from the compiler to bin 1.

When the first sheet of a set is about to enter the compiler, the ejector is moved from the home position to the out position. T his is done so that th e ej ec tor su ppor t fing er s can s upp ort the set from below as the set is built in the c ompiler. Th is also give s the staple head enough room to traverse to all staple positions if required.

The ejector slides between the home and out positions supported on tw o paral le l s hafts and is driven by the ej ector motor, MO T12-234. The ejector home sensor, Q 12-184 monitors the home position of the ejec tor and the ej ector o ut sen sor, Q 12-18 5, mon itors th e out posit ion of the ejector.

The ejector support fingers are spring mounted onto the ejector. When the set is complete and the stapler head is in the home (corner) position, the ejector is driven to the home position, dur ing travel to the hom e p os ition the s upp ort fi nge r s ar e d efl ected downwards under the set and spring back upwards at the home position where they are clear o f the edge of the set. The ejector is then move d to the out positi on thereby ejec ting the set to bi n 1. If the set jus t pro duced was the last o r on ly set of the j ob, th e e jec to r no w r etu rns to the h ome po siti on. If the re are further sets to be produced in the job, the eject or remain s in the out pos ition whi le the next set is built in the compiler.

Ejector support fingers

Ejector home sensor, Q12-184

Principles of Operation

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Ejector out sensor, Q12-185

Figure 10 Ejector assembly components

Ejector motor encoder Ejector motor, MOT12-234

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sensor, Q12-096

Launch Issue

Bin 1

Refer to Figure 11. Bin 1 of the LVF BM provides a platform to stack up to 2000 sheets. The bin 1 tray surface or the top of the st ack in bin 1, a ssists in the com piling mode by providing an extended surface to support longer documents, e.g. SEF A4 (8.5 x 11 inches) and A3 (11 x 17 inches).

As the paper ejected from the compi ler increases the stack height in the bin, the top of the stack actuates the bin 1 upper leve l sensor, Q12- 188. When the L VF BM controll er sees this signal. It energizes the bin 1 elevator motor, MOT12-241 to lower bin 1. The controller then deenergizes the bin 1 elevator motor.

The bin 1 90% full sensor, Q12-187 is positioned so that a flag mounted on the rear belt clamp enters the sensor when bin 1 is approximately 90% full. The signal from this sensor results in a message being displayed on the user interface requesting the operator to unload bin 1.

The bin 1 upper li mit switch, S 12-190 and bin 1 lower l imit switch, S12- 191 are posi tioned to monitor any over travel of bin 1. T he y will re move th e +24 V s up ply to th e bin 1 elevator motor, MOT12-241 if over travel occurs due to component failure.

Rear belt clamp

Bin 1

Bin 1 upper level sensor, Q12-188

Bin 1 upper limit switch, S12-190

Bin 1 elevator motor, MOT12-241

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Bin 1 drive belt (front)

Bin 1 lower limit switch, S12-191

Figure 11 Bin 1 elevator components

Bin 1 drive belt

Bin 1 90% full sensor, Q12-187

Booklet Maker

Refer to Figure 12. The booklet maker can collect and process output to form booklets from A3 (11 x 17 i n ch es ) , A4 (8 . 5 1 1 i n ch es ) , 8 . 5 x 1 4 i n ch es , 8. 5 x 13 i nches, and 8 .5 x 11 inches s h o rt edge feed stock to form A4 (8.5 x 11 inches), A5 (8.5 x 5.5 inches), 8.5 x 7 inches and 8.5 x 6.5 inches booklets re spectively (sta pled and non stapled) . The finished booklets a re stacked on bin 2. If stapled booklets are selected they will be dual stapled on the fold line.

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Principles of Operation

BM entrance

Lower entrance guide

BM booklet tampers

Upper guide

Lower guide

BM compiler guide assembly

BM crease blade assembly

Upper crease roll

BM exit guide

Principles of Operation

BM staple head assembly

BM backstop assembly

BM staple cartridge

Lower crease roll

Figure 12 Booklet maker components

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Bin 2

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Fold Mode

This mode collates and folds between 1-5 sheets of 80gsm (20lb) paper delivered to bin 2. The fold position, relative to the center line of the sheet, i s service engineer adjust able via NVM within +/-3mm.

Belt drive to the paper entry upper and lower feed roll assemblies.

Staple and Fold Mode

This mode staples and fo lds up to 15 sheets of 80g sm (20lb) paper or equival ent thickness (e.g. 10 sheets of 120gsm), paralle l to the lead edg e with no trimming , delivere d to bin 2. One cover of up to 216gsm may be included within the quoted s heet capacity cons istent with the paperweight of the body of the booklet (i.e. 13 sheets 80gsm + 1 cover sheet of 160gsm). Sta ple orientation will be w ith the c linc he d le gs on the i ns id e of the f old . T he f old pos i tio n, rel ati ve to the center line of the sheet, is service engineer adjustable via NVM within +/-3mm.

Transport Motor 1 and Gearbox

Refer to Figure 13. Transport motor 1, M OT12- 223 is used to dri ve the paper entry upp er and lower feed roll a ssemblies (fo r bin 0 an d bin 1) and also the b ooklet maker 1st and 2n d feed rolls. This is achieved by taking the drive from the motor through two one way clutches. Clutch A is arranged to engage i n a coun ter cloc kwise direc tion, cl utch B is arran ged to eng age in a clockwise direction. In this way when the motor is driven clockwise, clutch B will engage, clutch A will disengage and dr ive is taken to out put pulley B to d rive the bookle t maker 1st and 2nd feed rolls. When the motor is driven in a c ounter clockwise direction, cl utch A will engage, clutch B will disengag e and driv e is tak en to ou tput pul ley A to dr ive the u pper a nd lowe r feed roll assemblies.

Transport motor 1, MOT12-223

Clutch A

Output pulley A

Output pulley B

Clutch B

Belt drive to the BM 1st and 2nd feed rolls.

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Figure 13 Transport motor 1 components

Principles of Operation

BM Backstop Assembly

Refer to Figure 14. When the firs t she et ar riv es a t the BM entry sensor, Q12- 089, the tam per s are moved to the ready position. If the sheet is longer than 330mm the backstop motor, MOT12-255 is energized to move the backstop assembly to a ready po sition based on the paper size value p rovided by the IOT PWB. The positioning of the b ackstop for long paper such as A3 (11 x 17 inches), is measured in stepper motor pulse s from the backstop home sensor, Q12-204. F or shorter paper suc h as A4 (8.5 x 11 inches), the backs top positio ning is measured from the backstop mid home position sensor, Q12-440.

After the last sheet of the set has bee n rec eiv ed and c om piled, the BM backstop motor mov es the backstop to lift the set the s tapling position, the upward movement caus es the set clamp arm to move to the r ight and hold the set in place during movement . After stapling, the BM backstop motor moves the backstop to lift the stapled set to the creasing position.

BM end stop mid home sensor, Q12-440

BM Entrance

Refer to Figure 15. The booklet maker receives sheets fr om the BM div erter gate , throug h the 1st feed roll nip, the BM en try s en so r, Q 12-08 9 and the 2nd feed roll ni p. As ea ch shee t i s fed through the 2nd feed roll nip, it is driven downwards until it rests against the backstop.

The 2nd feed roll has smaller hard rollers and larger soft foam rollers. As the lead edge of each sheet touches the backstop , the trai l edge is r eleased by the ha rd rolle r nip, but i s still he ld by the soft roller, which pushes the s hee t unde r the rolle r an d aga inst the right side of the booklet compiler. This ensures that the trail edge of every compiled sheet is always located on the right side of the following sheet, thus eliminating both stubbing and sheet order errors.

BM diverter gate

Upper guide

BM guide home sensor, Q12-204

Figure 14 BM backstop assembly components

Principles of Operation

Backstop assembly

Backstop motor, MOT12-255

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1st feed roll assembly

Lower gui de

BM entry sensor, Q12-089

2nd feed roll assembly

Figure 15 BM entrance components

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Xerox® AltaLink® B8090 Family Multifunction Printer

BM Booklet Tampers

Refer to Figure 16. Cross process registrati on of the booklet is maintained by using two tampers, which move in o pposite directi ons simultan eousl y, and a re d riven by th e bookle t ta mper motor, MOT12-256. Tampin g aligns the center of the sheets with the cente r of the booklet compiler tray. The tamping position is a preset number of motor steps from the booklet tamper home sensor, Q12-205 and is based on the pape r size of the c ompiled sh eet, pro vided by the IOT PWB.

The tampers are moved from the home position to a ready positio n stored in NVM, whe n the lead edge of the first sheet in the set is detected at the BM entry sensor, Q12-089.

700ms after the trail edge o f each s heet has l eft the BM entry se nsor, the tamper s are mov ed from the ready position to the tamping position, then returned to the ready position. For the last sheet of the set, the tamping stroke is repeated once more. After the last sheet in a set is com piled and tamped, the tampers are moved to the home position.

Booklet tamper arms

BM Flapper Assembly

Refer to Figure 17. The BM flapper (located wit hin the BM compiler gui de assembly) is powered for two cycles 280ms after the tra il edge of each sheet has lef t the BM entr y sensor. T he BM flapper motor, MOT12-271 provides mechanical drive to the BM flapper and the position of the flapper is controlled by the flapper home sensor, Q12-207. The fingers on the fla ppe r push the sheet into the booklet tray to aid the registr ation and de-skewing process. T he flapper rotates after each sheet is tampe d. The flappe rs are then parked in the home positi on, so that the fingers on the flapper do not impede the next sheet fed into the booklet compiler tray.

At the end of the set compilation:

• If the accumulated weight of the set is less than 400gsm the flappers are cycled 3 times.

• If the accumulated weight of the set is between 400 and 800gsm the flappers are cycled 4

times.

• If the accumulated weight of the set is more than 800gsm the flappers are cycled 5 times.

BM flapper motor, MOT12-271

Booklet tamper motor, MOT12-256

Booklet tamper home sensor, Q12-205

Figure 16 Booklet tamper components

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Booklet tamper frame assembly

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BM flapper

BM compiler guide

BM flapper home sensor, Q12-207

BM flapper

Figure 17 BM flapper assembly components

Principles of Operation

BM Booklet Stapler Assembly

Refer to Figure 18. On the right side of the bookl et compile r, two B M staple cartridge a ssemblies are mounted on a fixed bracket in the base of the finisher. Each staple cartridge assembly contains the forming jaws and the stock of flat staple pins as well as three sensors.

The BM front staple car tridge primed sensor, Q12-442 m onitors that the staples have b een primed to the forming ja ws of the fro nt stap le c ar trid ge. Th e BM SH1 sta pl es low s en so r, Q1 2412 monitors the stock leve l of the staple pins of the fr ont staple cartrid ge. The BM front car tridge present sensor, Q12-450 monitors that the front staple cartridge is correctly installed.

The BM rear staple ca rtridge primed sensor, Q12-443 monitors that the staples hav e been primed to the forming jaw s of the r ear stapl e cartr idge. The B M SH2 s taples low senso r, Q12414 monitors the stock level of the stapl e pins of the rear st aple cart ridge. T he BM rear staple cartridge present sensor, Q12-451 monitors that the rear staple cartridge is correctly installed.

On the left side of the booklet com piler, the booklet stapler assembl y is mounted on a fixed frame. The booklet stapler is a travelling stapler anvil that is used to first clinch the front (home) staple, then travel to the rear (away) stapl e position to cl inch the rear sta ple, in this way, two staples are placed in the center of the comp iled set, spaced 120m m apart using a single sta pler.

The stapler is cam driven by a BM stapler stitch motor, MOT 12-437 and contains a stapler jaw home sensor, Q12-441. The BM paper present sensor, Q12-170 is mounted on a bracket con nected to the booklet tamper assembly. This sensor is used to prevent the staplers being energized if there is no paper present in the booklet compiler, thereby preventing staple jams.

BM staple cartridge assemblies

BM staple unit away sensor, Q12-439

Once the stapler jaw reache s the home positio n, a dynamic b rake is applied to pre vent overrun. The stapler motor wil l be reversed if the staple r jaw home sensor, Q12- 411 is not made after the stapling operation, in an attempt to bring the stapler home and avoid a fault.

Once the front staple has been completed the BM staple unit move motor, MOT12-435 is energized to move the BM staple head from the home position to the away position. The BM staple unit home sensor, Q12 -4 38 m oni tors the ho me p os ition of t he B M s ta ple he ad. T h e B M st ap le unit away sensor, Q12-43 9 monitors the a way position of the BM stapl e head. Once the r ear staple has been com pleted the B M stap le un it move motor, MOT12 -435 is en ergize d to mo ve the BM staple head from the away position to the home position in readiness for the next book let.

Principles of Operation

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BM paper present sensor, Q12170

Figure 18 BM stapling assembly components

BM stapler frame

BM staple unit move motor, MOT12-435

Xerox® AltaLink® B8090 Family Multifunction Printer

BM staple unit home sensor, Q12-438

Launch Issue

Creasing

Refer to Figure 19. The bookl et creasing sy stem consists of a crease blade, a pair of crease rolls, crease roll cover guides and the backstop assembly.

The crease roll cover guides are used to cover the entry nip into the crease rolls. This prevents sheets from coming into cont act with the crease rol ls during co mpiling. Th e crease rol l cover guides are spring loaded and are moved by the action of the crease blade to provide access to the crease rolls.

After the set is compi led and s tapled (if st apling was selecte d), the back stop rais es the set to the fold position, so that the center line of the set is directly in line with the crease blade.

The crease roll motor , MOT12- 253 is ene rgized whe n the bac kstop reac hes the fol d position. An encoder wheel is mounte d on the sha ft of the cre as e roll moto r. The enc oder whe el i s read by the crease roll motor encoder sensor, Q12-216 to control the roll surface speed and position of the blade.

A stapled set is folded by the combi ned func tion of the crea se rolls and the crea se blade. T he crease blade pushes the center of th e set i nto the c rease roll s nip . The cr ease blade is driv en by the crease blade mo tor, MOT12-252. The crease blade home sensor, Q12-214 and the crease blade motor encoder sensor , Q12-215 are used to monitor the locatio n of the crease blade during the folding process.

During booklet folding, the crea se blade mov es from th e home pos ition by a preset numbe r of encoder pulses to wards the crease rolls to fold the set and push it into the crea se rolls. The crease roll motor is then revers ed to the ho me position . As the creas e blade approa ches the nip of the crease rol ls, the c rease blade bearings con tact th e front an d rea r crease roll l evers, these levers open the c reas e r o ll ni p sli gh tly to ai d the entr y of the folded set into t he nip . T hi s is done to prevent the tendency of the outer sheet being torn away from the staples.

The crease roll motor is controlled to roll the booklet fold 2 times for a sheet length of mo re than 400mm (15.75 inches) or 4 times for a sheet length of less than 400mm (15.75 inches). At the end of the creasing operations, the crease roll motor continues to run until the BM exit sen sor, Q12-213 is made, the crease roll motor is then run at a faster speed to eject the bo oklet into bin 2. When the BM exit sensor goes clear, the crease roll motor is de-energized.

The BM exit roll assembly is driven by a toothed belt from the lower crease roll. The BM exit roll assembly assists in the transport of the finished booklet to bin 2.

The BM exit sensor, Q12-213, located just after the crease rolls, is also used to detect jams.

As the booklets accumulate on bin 2, they lift the bail arm assembly. The bin 2 90% full sensor, Q12-206 is actuated b y a flag on the bail arm resulting in a message being displayed asking the operator to empty bin 2.

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Principles of Operation

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Crease blade

Crease blade motor encoder sensor, Q12-215

Crease blade home sensor, Q12-214

Crease blade motor, MOT12-252

Crease roll motor, MOT12-253

BM exit roll assembly

BM exit sensor, Q12-213

Principles of Operation

Upper crease roll

Lower crease roll

Bin 2 90% full sensor, Q12-206

Bail arm assembly

Bin 2

Figure 19 BM creasing components

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Crease roll motor encoder sensor, Q12-216

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High Volume Finisher (HVF)

HVF General Description

The high volume finisher (HVF) provides the following functions:

• A top tray with a capacity of 250 sheets at 80gsm/20lb.

• A bin 1 output, providing compi led, mu ltiple sheet s ets, wit h a capac ity of 3 000 sheets at 80gsm/20lb. When a tri-folder module is fitted, the bin 1 capacity is 2000 sheets at 80gsm/20lb.

• A booklet maker wit h a minimum capacity of 10 set s of 15-sheet, stapled booklets at 80gsm / 20lb.

• A tri-folder, capable of prod ucing Z-folds or C-folds. Thi s has an output bin with a minimum capacity of 50 single-sheet tr i-folder jobs at 80gsm, (20lb). It can fold 60-12 0gsm, (15-30lb) sheets.

• An HVF stapler with a maximum capacity of 100 sheets at 80gsm/20lb.

• An HVF hole punch.

• Inserter, which will allow paper to be inserted at any point into compiled sets.

The range of paper weights handl ed by the top tray, bin 1, bo oklet mak er and in serter is 60 to 216gsm, 15 to 54lb. The tri-folder paper weight range is 60 to 120gsm, 15 to 30lb.

Configuration

The HVF comprises the following main systems which are described in this document:

• Machine Interface

• Power/Interlocks

• Paper Paths

• Compiler

• Stacker

• Hole Punch

• Tray 7 Inserter

• Booklet Maker Module

• Tri-Folder

• Booklet Maker Bin 2

Machine Interface

The harness between the rear of the machine, (PJ966), and the HVF PWB carries the communications between the two modules on serial data lines. The machine identifies the type of output device by the voltag es on the I D lines i n this ha rness. Comm unications between the HVF PWB, (PJ133), and the booklet make r PWB are ca rried on ser ial data l ines. A ‘book let make r present’ link is also present in this harness. The inserter module does not have dedicated com munications to the HVF PWB. The ‘inserter present’ information is carried on PJ701 to the HVF PWB. The tri-folde r module does not in clude a dedicat ed communications line to the booklet maker PWB. The ‘tri- folder present’ link is carr ied in the harness to PJ563 into the booklet maker PWB.

Power/Interlocks

Power to the HVF m odule is supplied by a dedicated PS U in the ba se of the HV F. This sup plies +5V and +24V. This PSU includes its own power cord.

A harness from the HVF c ontrol PW B, (PJ131), to the b ooklet maker PWB supplie s +5V and +24V. The booklet maker PWB, (via PJ553), supplies the tri-folder with +5V and +24V.

The inserter module is powered from the HVF c ontrol PWB, throug h a complex connector at the base of the insert er. Th is conn ector ha s of tw o lines of ter minals, TO55 / TO77, supplyi ng the signals and the +5V, and AO55 / AO77. It also provides one higher current terminal at each corner of the connector body, supplying the +24V, 0V and ground to the inserter, plus the drive line for the inserter el ectr ic clutc h. The i ns er ter in ter lo cks are de sc rib ed i n th e Ins erte r s ect ion, and the tri-folder interlocks are described in the Tri-folder section.

In the HVF module, two interlocks, wired in series, pass +24V to the module. These are:

• Top cover interlock switch, S12-197.

• Front door interlock switch, S12-303. When all three interloc k switches are clo sed, the +24V inter lock indicator, LE D 8 on the HVF

control PWB is lit and the +24V supply is available to motors, solenoids and clutches.

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Principles of Operation

Figure 1 shows the LEDs on the HVF PWB. These are:

Figure 2 shows the LEDs on the BM PWB. These are:

• LED 1 - red, toggling. The LED c hanges state every time one of the following even ts occurs:

– When the support fingers are fully extended. – When the rear wall sensor stops sensing the paper stack rear wall. – When the stapler mode for the current set is not multiple, dual or rear stapling.

• LED 2 - red. Not used.

• LED 3 - red, flashing. The LED indica tes CPU functi on. When flas hing at 2Hz, ( every 1/2 second), the software is running normally. Whe n flashing at about 1/4 Hz, (every 4 sec onds), this indicates that the software is encountering a code problem and a possible software upgrade is neede d. If this LED is OFF, the CPU do es not funct ion and a new HVF control PWB is required.

• LED 4 - red. Not used.

• LED 5 - red, toggling. The LED changes state whenever the paper is accelerated to 1,300 m/s. It is only used for paper that is longer than 220mm.

• LED 6 - red, steady . When the LED is illuminated, a paper jam has been detected. It remains illuminated until the HVF successfully ini tializes. In all other cases this LED is off.

• LED 7 - red. The LE D is used du ring the mach ine producti on and is connected with the activity of the stacker nearly full sensor.

• LED 8 - red, steady. The indi cates that the HVF top cover, front d oor and dockin g interlocks are all closed and +24V is available at the HVF module.

• LED 9 - red, steady. The LED indicates that the +5V supply is present in the HVF module.

• LED 1 - red, steady. The LED indicates a fault or other abnormal status.

• LED 2 - yellow, flashing at about 1H z. The LE D ind icate s tha t the so ftware i s ope ratin g in normal mode. In other modes, e.g., software downloading, the flashing rate is higher.

• LED 3 - orange, steady. The LED indicates either: – that the tri-folder front door and top cov er interlocks are c losed, and +24V is a vail-

able to the BM module or, if the tri-folder in not installed;

– that the interlock cheater is present in PJ553 on the BM control PWB the logic

cheater is present in PJ563 on the BM control PWB.

• LED 4 - orange, steady. The LED indicates that the +24V supply is within voltage and current limits, and that the power limiting circuit has not been active over a set time limit.

• LED 5 - blue, steady. The LED indicates that the +5V supply is present in the BM module.

Principles of Operation

Figure 1 LEDs on the HVF control PWB

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Figure 2 LEDs on the BM control PWB

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Paper Paths

This covers the motors, sensors and solenoids, etc., along the paper paths.

• Entry Sensor, Q12 -077. This is a reflective se nsor at the HVF i nput transport, rec eiving paper from the finisher transport. Refer to Figure 3.

• Buffer position sensor, Q12-086. A reflective sensor at the end of the input transport. This senses paper fed to the hole punch and beyond, to the buffer transport. Refer to Figure 3.

• Transport motor 1, MOT12- 223. This is a s tepper motor, lo cated at the rear of th e HVF, and driving a toothed belt. This provides the drive to the input path from the finisher trans port. It also drives the vertical paper path from the inserter and takes the paper through to the hole punch. Refer to Figure 3.

Transport motor 1 (MOT12-223)

• Bypass feed motor, MOT12-263. A stepper motor, located at the rear of the HVF and driving a toothed belt. It ta kes the p aper fro m the ho le punc h to th e buffer transp ort or to the booklet maker, dependi ng on the act ion of the boo klet maker div erter solenoid . Refer to

Figure 4.

• Set clamp solenoid , SOL12-056. Actuates during multi ple-sheet compiled output jobs. When actuated, it holds the trail ing edge of the first sheet in the buffer pock et until the arrival of the second sheet, at whic h time both sheet are fed to the ejecto r. The action is as follows:

– The first sheet is fed v ertically up into the buffer transpor t until it is releas ed by the

action of the nip split motor, which mo ved the idler rolls to the left, away from the paper. At the same time, the buffer feed motor stops.

– The sheet then drops in to the buffer pocket, whe re it is held by the set cla mp sole-

noid until the second sheet arrives . This actio n main tains the inter -set gap . Ref er to

Figure 4.

• Booklet maker diverter solenoid, SOL12-258. Actuates to pass paper to the booklet maker. In the non-actuated condition, it allows paper to pass to the buffer transport. Refer to Figure 4.

• HVF booklet exit sensor, Q12-087. A flag sensor, located in the paper guide leading to the booklet maker. It senses paper exiting the HVF for the booklet maker. Refer to Figure 4.

Booklet maker diverter solenoid (SOL12-258)

Entry sensor (Q12-077)

Figure 3 Entry sensor and entry feed motor

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Buffer position sensor (Q12-086)

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Bypass feed motor (MOT12-263)

HVF booklet exit sensor (Q12-087)

Buffer Pocket

Set clamp solenoid (SOL12-056)

Figure 4 Buffer area components

Principles of Operation

• Buffer motor, MOT12-262. A st epper motor located at the rear of the HVF. It ta kes the paper from the booklet maker diverter to the top tray or stacker. Refer to Figure 5.

• Buffer path sensor, Q12-321. A reflective sensor, located in the buffer transport. It senses paper being fed to the top tray or stacker. Refer to Figure 5.

Buffer path sensor

Buffer motor

(Q12-321)

(MOT12-262)

• Nip split motor, MOT12-26 4. A DC motor, lo cated in a housi ng at the rear of the 5b jam clearance guide. It opens the nip in the v er ti cal buf fer path by movi ng the id ler roll s to the left, away from the paper. This allows the first sheet of a multi-sheet compiled job, to drop into the buffer pocket, as expl ained in the ‘Buffer clamp sole noid’ bulleted item, above. Refer to Figure 6.

• Nip split sensor, Q12-091. A flag sensor, operated by a cylindrical flag on the nip split cam shaft. It senses the open position of the nip. Refer to Figure 6.

• Nip home senso r, Q12-088. A flag sen sor, operate d by a cy lindrical fla g on the nip split cam shaft. It senses the closed position of the nip. Refer to Figure 6.

Nip split motor (MOT12-264)

Principles of Operation

Figure 5 Buffer motor and buffer path sensor

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Nip split sensor (Q12-091)

Nip home sensor (Q12-088)

REAR VIEW

Figure 6 Nip split mechanism

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• Transport motor 2, MOT12-224. A stepper motor, located at the rear of the HVF and driving two toothed belts. It takes the paper from the exit diverter and feeds it either to the top tray, via the top exit sensor, or to the stacker , via the stac ker exit sen sor. Refer to Figure

• Exit diverter solenoi d, SOL12 -225. Actuates to diver t the p aper f rom the bu ffer to the top tray. In the non-actuated condition, it allows the paper to pass to the stacker. Refer to Fig

ure 7.

• Top tray exit sensor, Q12-1 07. A flag sensor located in the upper exit paper gui de. It senses paper passing out to the top tray. Refer to Figure 7.

• Compiler exit sensor, Q12-106. A reflective sensor located on the top jam clearance paper guide. It senses paper passing out to the stacker. Refer to Figure 7.

Exit diverter solenoid (SOL12-225)

Top tray exit sensor (Q12-107)

Compiler

This section includes the fun ctions of paper pusher, upper and lower pa ddles, tamping, stapling, paper ejection, pressing and support.

Paper Pusher: The final roll at the stac ker exit (refer to Fi gure 7), corrugate s the paper to give

it stiffness. The paper pus her mo ves down as each she et leav es the final roll, and p ushes the sheet down to the ejector unit. The components associated with the paper pusher are:

• Paper pusher motor, MOT12-265. A stepper motor located at the inboard end of the compile exit upper guide. The motor dr ives pinions that engage with racks integ ral with the pusher. Refer to Figure 8.

• Paper pusher upper s ensor, Q12 -092. A flag sensor that de tects the pushe r in the u pper position. Refer to Figure 8.

• Paper pusher lower sensor , Q12-094. A flag sens or that detects the pu sher in the lower position. Refer to Figure 8.

• Stapler safety switch, S12-319. A mi cro switch located at the inboard left of the paper pusher. This switch disab les the +24V supply to the stapler when the paper pus her is away from the lower positi on. This is to ensure personal safety wh en it is possible to reach the stapler jaws, under the paper pusher. Refer to Figure 8.

Paper pusher motor (MOT12-265)

Paper pusher upper sensor (Q12-092)

sensor (Q12-106)

Transport motor 2 (MOT12-224)

Figure 7 Top tray and stacker components

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Paper pusher lower

Stacker exit rollCompiler exit

Figure 8 Paper pusher components

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sensor (Q12-094)

Stapler safety switch (S12-319)

Principles of Operation

Upper Paddle: As the p aper pusher moves down wi th t he f ir st s hee t, th e p add le uni t m ov es to the lower position. A s t he p ape r pus her retu rn s to the upper position, ready for th e ne xt sh eet, the paddles rotate to position the first sheet correctly in the ejector. The sheet is correctly posi tioned when its trailing edge is in contact with the upright posts in the stapler module.

The number of cycles the paddle rotates depends on the size and orientation of the paper. The paddle unit remains in the lower p osition and eve ry sheet in the set is positio ned in this way. When the final sh eet in the set ha s been posi tioned by the p addle, the pad dle unit re turns to the upper position.

The components associated with the paddle unit are:

• Paddle unit motor, MOT1 2-239. A stepper motor located on the rear frame. It d rives the paddle unit down to the working position and back up at the end of each set. Refer to Fig

ure 9.

• Paddle unit lower sensor , Q12- 17 5. A fl ag senso r loc ate d on a bra cket bes ide the p add le unit, and sensing the paddle unit in the lower position. Refer to Figure 9.

• Paddle unit upper sensor, Q12-174. A flag sensor located on a bracket beside the paddle unit, and sensing the paddle unit in the upper position. Refer to Figure 9.

Paddle unit upper sensor (Q12-174)

Paddle unit lower sensor (Q12-175)

Principles of Operation

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Paddle unit motor (MOT12-239)

Figure 9 Paddle unit components

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• Paddle roll motor, MOT12-23 8. A DC motor located in the paddle unit. The paddle is turned one complete revolution. Refer to Figure 10.

• Paddle roll home sensor, Q1 2-186. A fl ag sensor located i n the pa ddle uni t, sensing the paddle roller in the home position. Refer to Figure 10.

Paddle roll home sensor (Q12-186)

Pusher

Lower Paddle: A sin gle paddle that is in tegrated into the e jector unit, which o perates on the first sheet only in each set. The low er paddle tu rns at the sa me time as the uppe r paddle. It i s actuated by the ejec tor roll motor, turning in the reverse di rection. The action of this motor in the forward direction i s described later . The components associated with the lower p addle function are:

• Ejector roll motor, MOT 12-233. A DC motor located at the rear underside of th e ejector unit. It runs in the reverse direction to rotate the lower paddle. Refer to Figure 11.

• Ejector roll motor e ncoder sensor , Q12- 097. A normal flag type e ncoder sens or, sen sing the motor rotation. Refer to Figure 11.

• Ejector home sensor, Q 12-184. A normal flag type sen sor, sensing the ejector home. Refer to Figure 11.

Paddle roll motor (MOT12-238)

Figure 10 Paddle roller components

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Ejector motor encoder sensor (Q12-097)

Figure 11 Ejector roll motor and sensors

Ejector roll motor (MOT12-233)

Ejector home sensor (Q12-184)

Principles of Operation

• Ejector lower paddle home switch, S12-099. A micro switch located at the front underside of the ejector unit, sensing the home posi tion of the low er paddle. Th is switch al lows the paddle to rotate for one complete cycle. Refer to Figure 12.

Tamping and Offsetting: Offsetting of the compiled sets is performed by the front and rear tampers. Offsetting is p erformed immediately before ejection. If sta pling is selected , offsetting is performed after stapling. When a stapling operation is selected, the rear tamper operates before stapling, to en sure that eac h set is corr ectly positio ned for stap ling a t its outb oard e nd. After stapling the sets ar e alternately either left at the outboard end, or offset to wards the inboard end by the front tamper. The components associated with the tamping and offset func tions are:

Ejector lower paddle home switch (S12-099)

Ejector lower paddle

• Front tamper motor, M OT12-226. A DC motor, located ab ove the bracket on the front frame. This motor moves the front tamper to the away and hom e positions. Refe r to Fig

ure 13.

• Front tamper home sensor, Q12 -180. A flag sensor, located under the bracket on the front frame. This sensor detects the front tamper in the home position. Refer to Figure 13.

• Front tamper away sensor, Q12-182. A flag sensor, located under the bracket on the front frame. This sensor detects the front tamper in the away position. Refer to Figure 13.

Front tamper motor (MOT12-226)

Front tamper away sensor (Q12-182)

Front tamper home sensor (Q12-180)

Figure 13 Front tamper components

EJECTOR RIGHT UNDERSIDE VIEW

Principles of Operation

Figure 12 Ejector lower paddle and home sensor

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• Rear tamper motor, MOT12-227. A ste pper motor, loca ted immedia tely to the rear of the ejector unit. This motor between the rear and home positions. Refer to Figure 14.

• Rear tamper home sensor, Q12-181. A flag sensor, located to the rear of the rear tamper motor. This sensor detects the rear tamper in the home position. Refer to Figure 14.

• Rear tamper away sensor, Q 12-183. A flag s ensor, located to th e rear of the rea r home sensor. This sensor detects the rear tamper in the away position. Refer to Figure 14.

Stapling: The stap ling funct ions of the HV F, are dis tinct from those of the booklet m aker and are performed on each set imm ediately after compiling the last she et of each set. A single, travelling stapler unit is used. When ‘one staple’ is selected, the stapler unit remains at the out board end of its travel, and the corner of each set is stapled. When two or more staples are selected, the stapler unit travel s from out boar d to inboa rd betwee n each sta pl e, then travel s to the mid home position whe r e it remai ns duri ng th e tam pi ng a nd e jec tion fu nc tio ns . T he sta ple r unit then returns to th e home pos ition. The compo nents associ ated with the stapling func tion are:

Rear tamper motor (MOT12-227)

Rear tamper away sensor (Q12-183)

Rear tamper home sensor (Q12-181)

• Stapler head 1 motor, MOT12-24 7. A DC motor that drives the closing of the stap ler ja ws and the forming of the s taple from a strai ght bar . The mo tor is a n integ ral part of the sta pler and cannot be serviced. The high current to the stapler necessitates mul tiple wires between the HVF PWB and the stapler unit.

• Stapler self priming sensor, Q12-134. This is an integral part of the stapler and cannot be serviced. It detects the staples in the correct position, ready for forming and stapling.

• Stapler cartridge sens or, Q12-317. This is an i ntegral part of the stapl er and cannot be serviced. It detects the presence of cartridge, correctly fitted in position.

• Stapler jaw home sensor, Q 12-318. This is an integral part of th e stapler and canno t be serviced. It senses that the stapler jaws are correctly positioned, ready for a stapling cycle.

• Low staples sensor, Q12 -133. This is an integral p art of the stapler and cannot b e serviced. It senses when the staples are running low and warns the user.

• Stapler safety switch, S12 -319. This is described also i n the paper pusher section. The stapler gate safety switch is a micro switch located at the inboard left of the paper pusher. This switch disabl es the +24V supply to the stapler m otor drive circuit, when the paper pusher is away from the lower position. This is to ensure personal safety when it is possi ble to reach the stapler jaws, under the paper pusher. Refer to Figure 8.

Figure 14 Rear tamper components

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Principles of Operation

• Stapler home sensor, Q12-135 . A flag sensor, located at the ou tboard end of the bed of the stapler unit. It detects the stapler unit in the home position. Refer to Figure 15.

• Stapler unit mid home sensor, Q12-176. A flag sensor, located towards the inboard end of the bed of the stapler modul e. It detects the stapler at the inb oard en d of its travel . Refer to Figure 15.

Stapler unit mid home sensor (Q12-176)

Paper ejection, pressing an d s uppo r t: Inclu des all actio ns nec es sary to tr an sfe r the pap er se ts from the compiler to the stacker. W hen the set is com piled, and the pap er pusher and paddle units have returned to the upper position the ejector unit moves to the out position. The support fingers move out, takin g the pressing fingers down to hold the previous set in pla ce on the stacker. The ejector roll motor turns the belts and th e ejector fingers push the s et out to the stacker. The pressing and support fingers then return to the home position. The ejector fingers are carried round on the belts to their home position as the ejector unit moves back to its home position. The components associated with these functions are:

Principles of Operation

Stapler home sensor (Q12-135)

Figure 15 Stapling components

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• Ejector motor, MOT12-236. A DC moto r, loca ted at the front und er side of the ej ec tor unit. This motor moves the ejector unit to the ‘out’ and ‘home’ positions. Refer to Figure 16.

• Ejector motor encoder sensor , Q12-096. A standard flag, encoder-di sc sensor, sensing the rotation of the ejector unit motor. Refer to Figure 16.

• Ejector out sensor, Q12-185. A flag sensor that senses the ejector unit in the out position. Refer to Figure 16.

• Ejector home sensor, Q12 -184. A flag sensor that senses the ej ector unit in the home position. Refer to Figure 16.

Ejector motor (MOT12-236)

• Ejector roll motor, MOT12 -233. A DC moto r, located at the rea r underside of the ejector unit. This motor turns in the forward direction to move the belts holding the ejector fingers. Its function in the reverse direction was described earlier. Refer to Figure 17.

• Ejector roll encoder s ensor, Q12-09 7. A flag sens or located at the rear of the ejecto r roll motor. This senses the movement of the ejector roll motor. Refer to Figure 17.

• Ejector home sensor, Q12-184. A flag sensor, located at the rear of the ejector assembly, under the ejector belt . T hi s dete ct s the eje ct fi ngers i n th e h ome po sitio n. Refer to Figure

17.

Ejector roll motor (MOT12-233)

Ejector motor encoder sensor (Q12-096)

Ejector home sensor (Q12-184)

Figure 16 Ejector unit components

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Ejector out sensor (Q12-185)

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Ejector roll motor encoder sensor (Q12-097)

Ejector plate home sensor (Q12-184)

Figure 17 Ejector roll components

Principles of Operation

• Pressing and suppor t moto r, MOT1 2-323 . A DC m otor, located belo w the HVF r ear tam per. This motor moves the supp ort fingers to the ‘out’, ‘init’ and ‘home’ positi ons. The pressing fingers are m echan ically linked to the s uppor t fing ers so that as the suppo rt fin gers leave the home position, the pressing fingers move down to hold the previous set on the stack. Refer to Figure 18.

• Pressing and support encoder sensor, Q12-093. This is a standard flag, encoder-disc sensor, sensing the rotation of the pressing and support motor. Refer to F igur e 18.

• Pressing and suppo rt A sens or, Q12-172 . A flag sensor, d etecting the suppor t fingers in the ‘home’ position. Refer to Figure 18.

• Pressing and suppo rt B sens or, Q12-171 . A flag sensor, d etecting the suppor t fingers in the ‘init’ position. Refer to Figure 18.

• Pressing and support C s ensor, Q1 2-173. A fla g sensor, detecting the support fingers in the ‘out’ position. Refer to Figure 18.

Pressing and support A sensor (Q12-172)

Pressing finger

Support finger

Pressing and support B sensor (Q12-171)

Principles of Operation

Pressing and support motor (MOT12-323)

Figure 18 Ejector roll components

Pressing and support C sensor (Q12-173)

Gear wheel

Pressing and support encoder sensor (Q12-093)

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Xerox® AltaLink® B8090 Family Multifunction Printer

Stacker

This section covers bin 1 tray mov ement and control . As the bin fills, the tray mov es down to maintain the top of the stack at the correct level. This is controlled by the bin 1 upper level sen sor, which is in tw o parts, an d also by the pape r pressing sensor th at senses the top e dge of the rear wall of the stack of paper. If the paper stack is flat, the paper pressing sensor will con trol the stack height, an d if the paper sta ck is curved, th e bin 1 upper level sensor wi ll detect the top of the stack and control its height. There is a 90% full sensor, used to warn the user that the bin is nearly full, and there are uppe r and lower limit switches, to keep the tray within its allowable range of movement. The active components comprising the stacker are:

• Bin 1 elevator motor, MOT12-241. A DC motor, located on the rear frame. This motor lifts and lowers the paper s tack via a gear chain, driving two toothed belts. In the forward direction, this motor drives the stack down. In the reverse direction, the stack is driven up. Refer to Figure 19.

• Bin 1 motor encoder sen so r, Q1 2-163 . A s tan dar d f lag , encoder-disc sensor, sensing the rotation of the bin 1 elevator motor. Refer to Figure 19.

• Bin 1 upper level sensor, Q12-188 - Consisting of two sensors, located in the frame at the front and the rear o f the tray. The r ear sens or is used as the receiving sensor, while the front sensor is used as the transmitter sensor. Refer to Figure 19.

• Paper pressing sensor, Q12- 322. A reflective sensor, located be neath the ejector front cover. This sensor detects the top of the rear wall of the paper stack. Refer to Figure 19.

• Bin 1 90% full sensor, Q12-187. A flag sensor, located on the rear frame and mounted on the same bracket as the lower limit switch. Th e bracket has two pos sible positions; the lower position, used when a tri-folder module is not installed, and the upper position, used when a tri-folder is pr esent. This sensor is actuated by a flag on the bin 1 rear bar lift bracket. Refer to Figure 19.

• Bin 1 upper limit switch, S12-190. A micro switch, located on the rear frame. This switch is actuated when the t ray is above its normal level of operation. W hen this switch is actu ated, the reverse, upwa rds, direction of the elevator motor is disabled, but the m otor is allowed to drive the stack down. Refer to Figure 19.

• Bin 1 lower limit switch, S12 -1 91. A mi cro s wit ch, loc ate d on th e rear fram e and moun ted on the same bracket as the 90% full sensor. The switch is actuated when the tray is at its lowest allowable limi t of operation. When this switch is actua ted, the forwards, down wards, direction of the elevator motor is disab led, but the motor is allo wed to drive the stack up. Refer to Figure 19.

Bin 1 motor encoder sensor

Paper pressing sensor (Q12-322)

Bin 1 upper level sensor (transmitter) (Q12-188)

Bin 1 upper level sensor (receiver)

Bin 1 upper limit

switch (S12-190)

Bin 1 90% full sensor (Q12-187)

(Q12-163)

Bin 1 elevator motor (MOT12-241)

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Bin 1 lower limit switch (S12-191)

Figure 19 Stacker components

Principles of Operation

Hole Punch

The hole punch is a n optional modul e, providing 2 or 3 h ole options, 4 hole, Swedish 4 ho le and Legal 2 hole. Each option is provided as a kit, easily in stalled, using a knurled thumb screw. When the hol e punc h modu le is not i nstalle d, a blankin g ass embly is fit ted in its p lace. When the hole punch is installed, the punch pre sent link is dete cted at power o n by the HVF PWB, and the hole punch i s acknowledged on the UI. The active components of the hole punch are:

• Punch head motor, MOT12-244. A DC motor, driving the punch head to operate all punches simultaneously, via eccentric cams. Refer to Figure 20.

• Punch head home sensor, Q12-194. A flag sensor, detecting the punch head in the home position, via a notched, cylindrical flag at the end of the cam shaft. Refer to Figure 20.

• Punch unit motor, MOT12-245. A stepper motor, driving the punch unit between the home and ‘paper edge detected’ positions. Refer to Figure 20.

• Punch unit home senso r, Q12-114. A f lag sensor, dete cting the punch u nit in the home, (outboard), position. Refer to Figure 20.

• Punch sensor 1, Q12-078. A reflective sensor, detecting the front, (outboard), edge of 8.5 x 11 inch LE fed paper. The punch unit motor MOT12-245, drives the punch unit forwards until the paper edge is d etected. The punch unit is then in t he correct position for the punch head to operate. Refer to Figure 20.

• Punch sensor 2, Q12-075. A reflective sensor, detecting the rear, (inboard), edge of 8.5 x 11 inch SE fed paper. The punch unit motor MOT12 -245, driv es the punch unit forwards until the paper edge is d etected. The punch unit is then in t he correct position for the punch head to operate. Refer to Figure 20.

• Punch sensor 3, Q12-076. A reflective sensor, dete cting the rear, (inboa rd), edge of A4 LE fed paper. The punch unit motor drives the punch unit forwards until the paper edge is detected. The punch unit is then in the correct position for the punch head to oper ate. Refer to Figure 20.

Punch sensor 1 (Q12-078)

Punch sensor 2 (Q12-075)

Punch head motor (MOT12-244)

Punch head home sensor (Q12-194)

Punch unit home sensor (Q12-114)

Punch unit motor (MOT12-245)

REAR VIEW

Punch sensor 3 (Q12-076)

Figure 20 Hole punch components

Principles of Operation

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• Chad bin present s ensor, Q12- 118. A f lag sensor, detectin g the pr esence of a chad b in, under the hole punch module. Refer to Figur e 21.

• Chad bin level sens or, Q12-193. A reflective sensor, detec ting the presence of chad, through a hole, high in the side of the chad bin. Refer to Figure 21.

Chad bin level sensor (Q12-193)

Chad bin present sensor (Q12-118)

Figure 21 Chad bin components

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Principles of Operation

Tray 7 Inserter

The inserter enable s the user to i nsert a shee t at a pre-defi ned point in a set. For exam ple it may be used to insert cover shee ts or separators. The media ins erted can be hole-pu nched, stapled or folded, as required. The active components of the Inserter are:

Inserter clutch (CL12-260)

Inserter TE sensor (Q12-084)

• Inserter motor, MOT12- 261. A stepper motor, located at the rear of the i nserter. This motor runs forward to drive the paper tray up and to feed the paper . The motor runs in reverse to drive the paper tray down. Th is is a variab le spee d motor, under the control of the software. The variable speed is used to synchronize the inserted media with the printed sheets coming from the IOT, and compensates for any speed mis-match. In the forward direction, this motor turns the retard roll in the reverse direction, via a torque lim iter. The retard roll thus acts as a retard pad, continually renewing its point of contact with the paper, thereby increasing its life and effectiveness. Refer to Figure 22.

• Inserter clutch, CL12-260. Located at the r ear of the inserter , this clutch pas ses the drive to the feed roll and nudger roll. Refer to Figure 22.

• Inserter pickup senso r, Q12-315. A refl ective sensor, located on the underside of the inserter top cover. The p icku p se nsor co ntrol s th e elec tr ic cl utch to sta rt fe eding . Refer to

Figure 22.

• Inserter TE sensor, Q12-084. This is a reflective sensor, located mid-module, immediately in front of the feed roll. The pickup sensor detects the trailing edge of the sheet, to control the electric clutch and is part of the speed compensation system. Refer to Figure 22.

• Inserter LE sensor, Q12- 083. A reflective se nsor, located mi d-module, immed iately after the feed roll. The paper path sens or detects the leading edge of the sheet, to v erify that the sheet was successfully fed. Refer to Figure 22.

• Inserter acceleration sensor, Q12-316. A reflective sensor, located behind the inserter left hand door. This sensor det ects th e leadi ng edge of the sheet an d oper ates tog ether with the inserter LE sen sor, to determi ne the spee d of the pape r. When the s peed has been measured, the information is used to control the speed of the inserter motor. Refer to Fig

ure 22.

• Inserter standby sensor , Q12-32 0. A reflec tive se nsor, loc ated on the HVF v ertical transport, below the inserter. It senses the leading edge of the sheet passing into the HVF from the inserter and pr ovides the fin al go/w ait informat ion , for feedi ng the sheet into the HVF at the correct inter-document gap (IDG). Refer to Figure 22.

Inserter LE sensor (Q12-083)

Inserter pickup sensor (Q12-315)

Inserter Acceleration sensor (Q12-316)

Inserter motor (MOT12-261)

Inserter standby sensor (Q12-320)

Principles of Operation

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Figure 22 Inserter paper path components

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• Inserter unit empty s ensor, Q12-082. A reflec tive sensor, located on t he inserter paper

tray. This sensor detects the pr esence of paper in the inserter tray. In nor mal operation, once this sensor detects no paper in the tray, the tray lowers after approximately two sec onds. Refer to Figure 23.

• Inserter paper length sensor 1, Q12-079. A reflective sensor, located on the sensor tray. It detects paper longer than 203 x 330mm (8 x 13 inches). Refer to Figure 23.

• Inserter paper length sensor 2, Q12-080. A reflective sensor, located on the sensor tray. It detects paper longer than 203 x 280mm (8 x 11 inches). Refer to Figure 23.

• Inserter paper length sensor 3, Q12-090. A reflective sensor, located on the sensor tray. It detects paper less than 203 x 280mm (8 x 11 inches). Refer to Figure 23.

• Inserter paper width sensor 1, Q12-081. The detector i ncorporates two width sensors. Width sensor 1 is a flag sensor, actuat ed by the paper wid th guide posi tion. The sens or changes state at 285mm, (11 1/4 inches) and 210mm, (8 1/4 inc he s) pa per wid ths . Ref er to Figure 23.

• Inserter paper width sensor 2, Q12-169. A flag sensor, actuated by the paper width guide position. The sensor changes state at 273m m, (10 3/ 4) in ches pap er wi dth. Refe r to Fig

ure 23.

Inserter paper width sensor 1 (Q12-081)

Inserter paper length sensor (Q12-080)

• Inserter jam cover interlock, S12-179. A micro switch, located behind the top inside cover.

This switch is wired in series with the inserter top cover interlock, to supply +24V to the inserter. When both in ter lock s are c lo sed, the +24V LED on the in se rter PW B is l it. Refe r to Figure 24.

• Inserter top cover interlock , S12-1 78. A micr o switc h, lo ca ted be hin d the front cover. This switch is wired in s eries with the inser ter left hand d oor interlock, to sup ply +24V to the inserter. When both in ter lock s are c lo sed, the +24V LED on the in se rter PW B is l it. Refe r to Figure 24.

Inserter unit empty sensor (Q12-082)

Figure 23 Inserter paper sensors

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Inserter paper length sensor 1 (Q12-079)

Inserter paper length sensor 3 (Q12-090)

Inserter paper width sensor 2 (Q12-169)

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Inserter jam cover interlock (S12-179)

Figure 24 Inserter interlocks

Inserter top cover i nt erlock (S12-178)

Principles of Operation

Booklet Maker Module

The booklet maker module receiv es, compile s, staples, folds and delivers finished booklets to bin 2. Booklets can be up to 15 sheets, including a cover.

Compiling and Tamping

When a booklet maker job is requested, but prior to the first sheet arriving at the booklet maker, the BM back stop motor, MOT12-255 is en ergi zed to mo ve the back st op a ssem b ly to a preset receiving pos ition based on the paper size value provided by the media path driver PWB. The positionin g of the backs top is m easur ed i n st eppe r motor pu ls es fro m the B M gui de home sensor, Q12-204.

The booklet maker mod ule receives sheets from the lower di verter gate and th rough the BM entry roll nips. As each shee t is fed through the entry ni p, it is driven downwar ds until it rests against the backstop.

The BM entry roll has smaller hard rollers and larger soft foam rollers. As the lead edge of each sheet touches the backsto p, the trail edge is relea sed by the ha rd ro ller nip , but is sti ll held by the soft roller, which pushes the sheet unde r the ro ller and aga in st th e right s ide of the booklet compiler tray. This ensures that the trail edge of every compiled sheet is always located on the same side of the following sheet, thus eliminating both stubbing and sheet order errors.

Cross process registr ation is ma intain ed by using two tamper s, wh ich m ove in o pposi te direc tions simultaneously, and are dri ven by the B M tamper 1 m otor, MO T 12-2 56. Tampi ng alig ns the centre of the sheets with the centre of the booklet compiler tray.

The tamping position is a pre set number of moto r steps from the BM tam per 1 home senso r, Q12-205 and is based o n the paper size of the compiled sheet, provi ded by the media path driver PWB.

The tampers are moved from the home position to a ready positio n stored in NVM, whe n the lead edge of the first sheet in the set is detected at the BM entry sensor, Q12-089.

As each sheet enters the booklet compiler tray, the tampers are moved from the ready position to the tamping position, then r eturned to the ready positi on. For the last sheet of the se t, the tamping stroke is repeated once more. After the last sheet in a set is compiled and tamped, the tampers are moved to the home position.

Backstop Movement

The BM backstop system consists of a ba ckstop assembly, mounted on a near vertical slide driven by the BM backstop motor, MOT12-255, via a toothed belt. A flag mounted on the back stop assembly actuat es the BM guide home sens or, Q12-204 to signal the home position of the backstop.

After the last sheet of t he set has been r eceived and comp iled, the BM s tack hold soleno ids, SOL12-259 are energiz ed to hold the set in place. Th e BM backstop motor then m oves the backstop to the stapling position. The BM motor now performs a short up, then down to jog the set into place. After stapling, the BM backs top motor mov es the back sto p to the crea si ng posi tion.

Booklet Stapling

Two BM staple head assemblies are mounted on a bracket, which can be pivoted open for staple jam clearance. The BM staple head carrier closed sensor , Q12-217 detects the closed position of the stapler bracket assembly.

When the staplers are actua ted, two staples are place d in the centre of the compiled stac k, spaced 120mm apart. The max im um c apa city for the stapl in g and f old ing in th e boo klet ma ke r is given in Table 1.

Table 1 Booklet maker stapling and folding capacity

Maximum No. of

Media Paper weight

Plain paper 60 to 80gsm (16 to 21lb

Heavyweight 90gsm (24lb bond) 13 52 Heavyweight 120gsm (32lb bond) 10 40 Heavyweight 160gsm (43lb bond) 7 28 Heavyweight 216gsm (58lb bond) 5 20 Plain paper with

heavyweight cover

bond)

60 to 80gsm (16 to 21lb bond) with 160gsm (43lb bond) cover

sheets

15 60

14 including 1 cover 56

Maximum No. of booklet pages

The BM flapper is util ized when t he tam pers s tart thei r retu rn s troke f rom the tam p positi on to the ready position. The BM fla pper motor, MOT12-271 provides mechanical drive to the BM flapper and the positi on of the flapp er is cont rolled b y the flapper home se nsor Q12-207 . The fingers on the flapp er push the sh eet int o the b ookle t tray to aid th e regis tration and de- skew ing process. The flappe r rotates after each she et is tamped. The flapper s are then parked in the home position, so that the finger s on the flapper do n ot imped e the nex t sheet fe d into the booklet compiler tray.

The set is then ready to be moved into position for the next operation of stapling.

Principles of Operation

April 2017

Each stapler is cam dr iven by a DC motor and c ontains a home po sition switch. Eac h of the staplers also contain a l ow s ta ple s switc h to inform the control logic of a lo w st apl es condi ti on. The BM paper present sen sor, Q12- 170 is mounted on the stapl er brac ket asse mbly betwe en the two staplers. Thi s sensor is used to prevent the sta plers being energized if there is no

paper present in the booklet compiler tray, thereby preventing staple jams.

The stapling sequence operates as follows:

1. The tampers are energized to engage the stack and keep both edges in place.

2. After 50ms, the front stapler is energized.

3. After a further 80ms the rear stapler is energized. This sequence pr events wrinkling of the paper and limits the load imposed on the power supply.

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Once the staplers reach the home position, a dynamic brake is applied to prevent overrun. The stapler motor will be reversed if the home switch is not made, after the stapling operation, in an attempt to bring the stapler home and avoid a fault.

Folding and Creasing

Bin 2 is mounted at the lower ri ght side of the booklet maker, below bin 1. Bi n 2 has two bail arms and two parallel c onveyor belts over a flat surf ace. With the tray exten sion rais ed, bin 2 has a capacity of 10 booklets of 11 -1 5 sheet s, o r 20 bookl ets of 6-10 s he ets , or 30 bo oklets of 1-5 sheets. With the tray extension lowered, the booklets can be allowed to drop into a suitable box on the floor.

The booklet creasing system consists of a crease blade, two pairs of crease rolls, a crease roll gate and the backstop assembly.

The crease roll gate is used to cover the entry nip into t he crease rolls. T his prevents s heets from coming into contact with the crease rolls during compiling.The crease roll gate is raised to expose the crease rolls , or low ered to cover th e opening to the cr ease rol ls, by the crease roll gate motor, MOT12-273. The ho me pos i tion (fully ra is ed) is sen sed by the BM crea se r ol l gate home sensor, Q12-222.

After the stapling operation is complete, the backstop raises the stapled set to the fold position, so that the centre li ne of th e set is dire ctly in line with th e cre ase b lade. At th e sam e time, the crease roll gate motor moves the crease roll gate up until it actuates the crease roll gate home sensor.

The BM crease roll moto r, MOT12- 253 i s energize d when th e backs top re aches the fold po sition, and continues to run until 220m s afte r the trail ed ge of th e folde d book is detec ted at the BM exit sensor, Q12- 213. An encod er wheel i s mou nted on th e outpu t shaft o f the BM crease roll motor. The encoder wheel is read by the BM crease roll motor encoder sensor, Q12-216 to control the roll surface speed.

A stapled set is folded by the combi ned func tion of the crea se rolls and the crea se blade. T he crease blade pushes the centre of th e set i nto the c rease ro lls nip . The cr ease blade is driv en by the BM crease blade motor, MOT12-252. The BM crease blade home sensor, Q12-214 and the BM crease blade motor encoder sens or, Q12-215 are used to monitor the loc ation of the crease blade during the folding process.

During booklet folding, the crease blade moves from home position when the backstop reaches the fold position. The blade stroke is 36 pulses of the crease bla de motor encoder sensor from the blade home position.

The BM eject sensor, loca ted a t the ex it, p ro vides c ont rol l ogi c sig nal s a nd m onitor s the p ape r path for jam detection and timing control for actuation of the BM conveyor belt drive motor.

When a booklet has been c ompil ed, it pa sses und er the BM eject s ensor an d push es par tiall y through the bail arm rollers. 200 ms after the lead edge is detected at the BM eject sensor, the BM conveyor belt driv e motor , MOT12 -274, is turned on and dri ves th e two conve yor b elts for a preset time dependent on the booklet size.

The BM bin 2 90% full sensor, Q12-206 is an optical sensor located at the right of bin 2 between the conveyor belts.

As the booklets travel along the conveyor belts, they will actuate the BM bin 2 90% full sensor. After 2000ms, the con trol log ic will de clare a 90% tray full c ondition . At this point a c ounter is set and the total number of books allowed after that point is determined by the number of books already on the tray. Any additional books allowed to be stacked is based on the number of times the BM eject sensor is actuated and the sizes of the books.

BM Paper Path Transport Motor

The BM compiler motor , MO T12 -2 51 i s dr iv en a t ho st spe ed and provides mechanic al d riv e to the BM entry roll nip.

Refer to Figure 25 and Figure 26 for component location.

During banner sheet foldi ng, a delay of 700ms f rom the trail edge at the BM e ntry sensor is used before the crease blade moves from the home position.

The crease blade is held at the fold position by a dynamic brake for 250ms to allow the banner sheet or stapled set to be drawn into the crease rolls. The BM crease blade motor is then reversed to drive the cre ase blade back to its home position a s the crease rolls crease and feed the booklet. Th e BM exit sensor, Q12-213, locate d just after the crease rolls, de tects jams. When the BM eject sensor is clear, the crease roll gate motor moves the crease roll gate down to cover the crease rolls.

For a booklet consisting o f 10 or mo re she ets , or when handling 8.5 x 11 inch paper, fo lding is executed four times before ejecting to provide extra creasing.

Bin 2

After a booklet is folded, it is ejected onto bin 2 by the crease roll nip.

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Principles of Operation

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Crease rolls

Crease roll gate

BM staple head assembly

Crease roll gate motor

BM staple head carrier closed sensor

BM Crease blade sensor

BM tamper 1 home sensor

Crease roll motor

Booklet maker PWB

BM complier motor

BM entry roll nips

BM flapper assembly

Crease motor blade

BM backstop motor

Backstop assembly

Backstop guide home sensor

BM stack hold solenoids

Figure 25 Booklet maker module components (1) Figure 26 Booklet maker module components (2)

Principles of Operation

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Tri-Folder

When the job does not require a tr i-fold, the tri-folder becomes a straight-thr ough paper path from the booklet maker to the output tray. When a tri-fold is requested, the tri-folder clutc h, diverter solenoid, and for C-folds only, the assist gate solenoid are brought into use.

The tri-folder does not require a d edicated drive motor, but takes its motive power using a toothed belt and drive coupler, fro m the crease roll moto r in the booklet ma ker. The driv e cou pler engages when the booklet maker is pushed into the home position. The belt turns as each sheet is folded and stops as each sheet leaves the tri-folder.

When the tri-folder is not in stalled, a shorting link fitted to PJ 553 in the booklet maker PWB, simulates the tri-folder interlocks, to feed +24V to the booklet maker PWB.

The tri-folder works in conjunction with the booklet maker, to produce ‘C’ or ‘Z’ folds. The booklet maker makes the first fold, and pas ses the sheet to the tri-folde r to make the second fold. One sheet at a time is folded, and the tri-folder can fold 60-120gsm, (15-30lbs) sheets.

Figure 27 shows how the C-folds and the Z-fold s ar e formed . Th e diff erence lies i n wher e the

first fold is made in the sheet, by the booklet maker. For a C-fold, the backstop is raised to pro duce a fold near the leading edge of the sheet. For a Z-fold, the backstop is lowered to produce a fold near the trailing edge of the sheet, effectively inverting the sheet.

Booklet maker

Backstop

Booklet maker

Backstop

Tri-folder

C-FOLD

Z-FOLD

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Figure 27 C and Z folds

Principles of Operation

The active components of the tri-folder are:

• Tri-folder entry se nsor, Q12-164. A flag senso r, located in the input paper guide. This sensor detects the sheet entering the tri-folder from the booklet maker. Re fer to Figure

28.

• Crease roll clutch drive, CL12 -269. The clutch is located at the rear of the tri-folder, and actuates to drive the tri-folder crease rolls via a toothed belt. Refer to Figure 28.

• Tri-folder diverte r solenoid, SOL12-267. The solen oid is located at the rear of the trifolder, and diverts single, tri-fold job sheets into the folder mechanism. It is actuated immediately after the drive belt from the BM starts to turn, and de-actuates as each sheet leaves the tri-folder. Refer to Figure 28.

• Tri-folder assist gate sens or, Q12-165. A fla g sensor, loc ated in the rolle r assembly, and is mounted on the adjustabl e backstop plate. Thi s sensor detects th e sheet entering the roller assembly to be folded. Refer to Figure 28.

• Tri-folder assist gate s olenoid, SOL12 -268. The sole noid is located at th e rear of the t rifolder. The assist gate s olenoid is only actu ated during C-folds , to assist the first folded flap into the crease rolls. It actuate s as the s heet enter s the cr ea se rol ls and ens ures that the trailing edge of the first fold stays inside the crease of the second fold. Refer to Figure

28.

Drive clutch (CL12-269)

Tri-folder entry sensor (Q12-164)

• Tri-folder exit sensor, Q12-166. A flag sensor, located in the exit paper guide. This sensor detects the sheets as they leave the tri-folder. Refer to Figure 29.

Tri-folder exit sensor (Q12-166)

(SOL12-268)

Figure 28 Entry sesor and folding components

Principles of Operation

Tri-folder assist sensor (Q12-165)

Tri-folder diverter solenoid (SOL12-267)Tri-folder assist gate solenoid

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Figure 29 Tri-folder exit sensor

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• Tri-folder top cover in ter lo ck s wi tch. A si ngle- po le mic ro s wi tch , loc ated at t he fr o nt of the tri-folder. This switc h is co nnecte d in s eries with t he fron t door interlo ck switc h, S12 -209. When both switches are mad e, the +24V supply is fed to the tri-folder PWB and the BM PWB. The BM PWB h as +24V LE D i ndi catio n, as described in Power/Interlocks. Refer to

Figure 30.

• Tri-folder top cover interlock s ensor, Q12-21 0. A flag sensor, loc ated toward s the rear of the tri-folder top cover. This sensor detects whether the top cover is open or closed. Refer to Figure 30.

• Tri-folder front door inter lock switch, S12-209. A dou ble-pole switch, loca ted behind the top of the tri-folder fr ont door. One p ole of this swi tch is connected in series wi th the trifolder top cover interlock switch. When both switches are made, the +24V supply is fed to the tri-folder PWB and the BM PWB. The s econd pole of thi s switch dete cts whether the tri-folder front door is open or closed. Refer to Figure 30.

Tri-folder top cover interlock (Q12-210)

Booklet Maker Bin 2

Bin 2 receives the fold ed output from the tri-f older, and the booklets fr om the booklet maker and/or the tri-folder module. The components associated with this tray are:

• BM conveyor drive motor, MOT12-274. A stepper motor, driving the conveyer belts. Refer to Figure 31.

• Bin 2 90% full sensor, Q12-206. A flag sensor, detecting a nearly-full tray. Refer to Figure

31.

Figure 30 Tri folder interlock components

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Tri-folder front door interlock (S12-209)

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BM bin 2 90% full sensor (Q12-206)

BM conveyo r driv e motor (MOT12-274)

Figure 31 Bin 2 components

Principles of Operation

Fax

Overview

The common interfa ce F ax (C IF) is an optional 1 or 2 lin e fa x mod ule lo ca ted in the ca rd cage with the single board controller (SCB) and the hard disk drive (HDD). Refer to Figure 1

The fax PWB is fitted with either one or two MultiTech MT92 34SMI modems. The PWB su pports fax modem reset con trol, presence indicator, audio v olume control and board revisi on information. The Fax PWB is connected directly to the SCB PWB, and is controlled by software running on the SBC PWB.

Fax functionality is selected and controlled via the UI.

Hard disk drive

Main Drive Module

Overview

There are 2 separate drive modules, a 45-55 ppm module and a 65-90 ppm module.

• The 2 machine variants AltaLink® B8045/B8055 and AltaLink® B8065/B8075/B8090 have differing main drive modules with the same fit and identical harnessing.

• Motor speeds on the 45/55ppm variant are con trolled direct from the main driv e module clock.

• Motor speeds on the 65/75/90ppm variant are under software control from the IOT PWB.

• The 45/55 ppm module ru ns at a process s peed of 257 mm/s. Cha nging the inter do cument gap enables 45 or 55 prints per minute.

• The 65/75/90 ppm module runs at 3 process speeds controlled by the IOT. – 65 ppm - 300mm/s – 75 ppm - 340mm/s – 90 ppm - 362mm/s

Refer to Figure 1. The main dri ve module is mou nted dir ectly to the rear fram e of the IO T and is located by 2 dowels and secured by 6 screws.

Mounting screws

Principles of Operation

Phone jacks (2)

Figure 1 Fax location

Fax module

SBC PWB

Dowels

The main drive module has three motors:

• Fuser drive motor

• Cartridge drive motor

• Registration motor

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Mounting screws

Figure 1 Main Drive Module mounting

Launch Issue

Xerox® AltaLink® B8090 Family Multifunction Printer

Description of Operation

Fuser Drive Motor

The fuser drive motor is a brushless DC motor and is used to provide drive to the fuser and the post fuser drive components. The fuser motor provides drive to:

• The fuser through a swing-arm gear drive mechanism.

• The post fuser paper path and exit paper path through a belt and drive pulley.

Registration Motor

A stepper motor is used to rotate t he registration s haft. It is contr olled by the IOT PWB. It is switched on after a print request and off after a controlled time.

The registration motor provides drive to the registration drive shaft via a drive gear.

Print Cartridge Drive Motor

A brushless DC motor is used to rotate the photoreceptor, the developer, and the toner recycle auger in the process direc tion. It is controlled by an enab le signal from the IOT PWB i n the form of a logic signal. It is switched on after a print request and off after a controlled time.

The cartridge drive motor provides drive to:

• The photoreceptor through a shaft and drive coupling.

• The developer through a drive coupling.

• The toner recycle auger through a drive coupling.

Electrical Connections

Refer to Figure 2. The only inputs to the main drive module are electrical.

The AltaLink® B8045/B8055 and the AltaLink® B8065/B8075/B8090 variants use the sa me harnessing to the main drive module.

The Low Voltage Power Supply (LVPS) provides the following via PJ656:

• +24V (used on both speed variants)

• +24V RET (used on both speed variants)

• +5V logic supply (not connected)

• Ground (DC Return) (n ot connected)

The IOT PWB provides the following via PJ761:

• Fuser drive motor enable signal (used on both speed variants)

• Cartridge motor enable signal (used on both speed variants)

• Fuser motor clock (used on 65/75/90ppm variant only)

• Cartridge motor clock (used on 65/75/90ppm variants only)

The IOT PWB provides the following via PJ762:

• Registration motor pulse A+

• Registration motor pulse A-

• Registration motor pulse B+

• Registration motor pulse B-

Refer to Overview for a full explanation of how the speeds are achieved.

Launch Issue Xerox® AltaLink® B8090 Family Multifunction Printe r

April 2017

8-99

Principles of Operation

Component Locations

Figure 3 shows the location of the main driv e mo tors in the main driv e mod ule . Th e mai n driv e

module on the AltaLink® B8045/B8055 and the AltaLin k® B8065/B8075/B8090 var iants are visually identical.

Fuser drive motor MOT10-020

Principles of Operation

Figure 2 Circuit diagram

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Print cartridge motor MOT93-045

Figure 3 Main drive module

Registration motor MOT80-040

Launch Issue

Xerox® AltaLink® B8090 Family Multifunction Printer

Xerox B8090 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

8 Principles of Operation

Machine Overview

Power

User Interface

Machine Run Control

Single Pass Document Handler (SPDH)

Fusing and Copy Transportation

Low Capacity Stapler Stacker (2K LCSS)

LVF BM

High Volume Finisher (HVF)

Main Drive Module