A109 Service Training Manual - Distrivisa · legend product code company gestetner ricoh savin a109 - nc5006 sc106 documentation history rev. no. date comments * 4/94 original printing

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SERVICE MANUAL

PN: RCSM5006

A109

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RICOH GROUP COMPANIES

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A109

SERVICE TRAININGMANUAL

It is the reader's responsibility when discussing the information contained within thisdocument to maintain a level of confidentiality that is in the best interest of RicohCorporation and its member companies.

NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY

FASHION AND DISTRIBUTED WITHOUT THE PRIOR

PERMISSION OF RICOH CORPORATION.

All product names, domain names or product illustrations, including desktop images,used in this document are trademarks, registered trademarks or the property of theirrespective companies.

They are used throughout this book in an informational or editorial fashion only and forthe benefit of such companies. No such use, or the use of any trade name, or website is intended to convey endorsement or other affiliation with Ricoh products.

2000 RICOH Corporation. All rights reserved.

LEGEND

PRODUCT CODE COMPANYGESTETNER RICOH SAVIN

A109 - NC5006 SC106

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS* 4/94 Original Printing

1 7/94 Revised

2 6/96 Reprint

TABLE OF CONTENTS

OVERALL MACHINE INFORMATION

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

2. MACHINE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . 1-5

3. COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3.2 DEVELOPMENT PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . 1-10

5. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

6. AIR FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

7. ELECTRICAL COMPONENT DESCRIPTIONS. . . . . . . . 1-15

DETAILED SECTION DESCRIPTIONS

1. PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1.1 Latent Image Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

1.1.2 Toner Density Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

1.2 PROCESS CNTTROL SELF CHECK. . . . . . . . . . . . . . . . . . . . . . 2-3

1.3 LATENT IMAGE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

1.3.1 Drum Potential Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

1.3.2 VSG Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

1.3.3 Gradation Patterns Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

1.3.4 Pointer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

1.3.5 Confirmation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

1.3.6 Related Abnormal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

1.4 TONER DENSITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

1.4.1 Toner Density Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

1.4.2 Toner Density Sensor Initial Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

1.4.3 Toner Supply Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

A109 i STM

1.4.4 Toner Supply Motor ON Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

1.4.5 VCNT Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

1.4.6 Toner End Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

1.4.7 Toner End Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2. DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.2 OPC DRUM CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.3 DRUM CHARGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.4 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5 DRUM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.5.1 Counter Blade System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.5.2 PCC and Cleaning Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.3 Toner Collection Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6 QUENCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

3. SCANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

3.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

3.2 SCANNER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

3.3 SCANNER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

3.4 COLOR CCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

3.5 WHITE PLATE SCANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

3.6 ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

3.7 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

3.8 SCANNER SECTION BLOCK DIAGRAM . . . . . . . . . . . . . . . . . 2-29

4. IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

4.2 SCANNER SECTION BLOCK DIAGRAM . . . . . . . . . . . . . . . . . 2-31

4.3 CCD BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

4.4 SCANNER CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

4.4.1 Signal Amplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

4.4.2 A/D Conversion and Signal Composition . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

4.4.3 Auto Shading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

STM ii A109

4.4.4 D/A Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

4.4.5 Scan Line Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

4.5 IPU SECTION BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 2-35

4.6 IPU INTERFACE BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

4.7 IPU BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

4.7.1 Scanner Gamma Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

4.7.2 Picture Element Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

4.7.3 Auto Color Selection (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

4.7.4 Auto Letter/Photo Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

4.7.5 Filter and Color Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

4.7.6 Main Scan Magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

4.7.7 Image Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

4.7.8 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

4.7.9 Auto Image Density (ADS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

4.7.10 Printer Gamma Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

4.7.11 Gradation Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

4.7.12 Video Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

4.7.13 Area Data Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

5. LASER EXPOSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

5.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

5.2 OPTICAL PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

5.2.1 Laser Diode Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

5.2.2 Cylindrical Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

5.2.3 Polygon Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

5.2.4 F-Theta Lenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

5.2.5 Drum Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

5.2.6 Laser Synchronizing Mirror and Detector Board . . . . . . . . . . . . . . . . . . . . 2-63

5.3 LASER EXPOSURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 2-64

5.4 GRADATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

5.5 AUTO POWER CONTROL (APC) . . . . . . . . . . . . . . . . . . . . . . . 2-67

5.6 LASER SYNCHRONIZING DETECTOR . . . . . . . . . . . . . . . . . . 2-68

5.7 LD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

6. DEVELOPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

A109 iii STM

6.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

6.2 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

6.3 DEVELOPER SUPPLY AND RELEASE . . . . . . . . . . . . . . . . . . 2-72

6.4 DEVELOPMENT BIAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

7. TONER TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

7.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

7.2 TONER TRANSPORTATION AND AGITATION . . . . . . . . . . . . 2-75

7.3 TONER BOTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

8. TRANSFER BELT UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

8.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

8.2 TRANSFER BELT DRIVE MECHANISM . . . . . . . . . . . . . . . . . . 2-78

8.3 TRANSFER BELT DRIVE CONTROL . . . . . . . . . . . . . . . . . . . . 2-79

8.3.1 Switch Back Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

8.3.2 Idling Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

8.4 TRANSFER BELT RELEASE MECHANISM . . . . . . . . . . . . . . . 2-82

8.5 TRANSFER BELT BIAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

8.6 TRANSFER BELT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85

8.6.1 Cleaning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

8.7 LUBRICATION MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

9. TRANSFER ROLLER UNIT . . . . . . . . . . . . . . . . . . . . . . . 2-87

9.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

9.2 ROLLER TOUCH AND RELEASE MECHANISM . . . . . . . . . . . 2-88

9.3 TRANSFER ROLLER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

9.4 TRANSFER ROLLER BIAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

9.5 PAPER DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

9.6 TRANSFER ROLLER CLEANING . . . . . . . . . . . . . . . . . . . . . . . 2-93

10. PAPER TRANSPORT AND IMAGE FUSING . . . . . . . . 2-94

10.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

10.2 FUSING ENTRANCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

STM iv A109

10.3 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

10.4 FUSING DRIVE RELEASE MECHANISM . . . . . . . . . . . . . . . . 2-97

10.5 OIL SUPPLY MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

10.6 CLEANING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

10.7 JAM DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

10.8 FUSING PRESSURE MECHANISM . . . . . . . . . . . . . . . . . . . 2-101

10.9 FUSING TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . 2-102

11. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

11.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

11.2 FRR FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

11.2.1 Pick-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

11.2.2 Feed and Separation Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

11.3 SLIP CLUTCH MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . 2-106

11.4 FRR FEED DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . 2-107

11.5 SEPARATION ROLLER RELEASE MECHANISM . . . . . . . . 2-109

11.6 PAPER RETURN MECHANISM . . . . . . . . . . . . . . . . . . . . . . 2-110

11.7 PAPER SKEW PREVENTION MECHANISM . . . . . . . . . . . . 2-111

11.8 PAPER LIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112

11.9 PAPER END DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114

11.10 PAPER SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . 2-115

11.11 VERTICAL TRANSPORT MECHANISM . . . . . . . . . . . . . . . 2-116

11.12 TRAY POSITIONING MECHANISM . . . . . . . . . . . . . . . . . . 2-117

11.13 BY-PASS FEED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118

11.13.1 Feed Mechanism / Paper End Detection . . . . . . . . . . . . . . . . . . . . . . . 2-118

11.13.2 Table Open/Close Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119

11.13.3 Paper Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120

11.14 PAPER REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121

11.15 REGISTRATION DRIVE MECHANISM . . . . . . . . . . . . . . . . 2-122

DUAL JOB FEEDER

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

A109 v STM

2. COMPONENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . 3-3

3. ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . 3-4

4. BASIC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4.1 ONE-SIDED ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4.2 TWO-SIDED ORIGINAL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

4.3 PRESET MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4.4 COMBINE 2 ORIGINALS MODE . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4.4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4.4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

5. ORIGINAL SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . 3-14

6. SEPARATION BELT DRIVE MECHANISM. . . . . . . . . . . 3-15

7. THIN / THICK ORIGINAL MODES. . . . . . . . . . . . . . . . . . 3-16

8. ORIGINAL SIZE DETECTION . . . . . . . . . . . . . . . . . . . . . 3-17

9. LIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

10. ORIGINAL MISFEED DETECTION . . . . . . . . . . . . . . . . 3-19

11. TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

11.1 DJF TIMING CHART (1SIDED ORIGINAL MODE) . . . . . . . . . 3-21

11.2 DJF TIMING CHART (COMBINE 2 ORIGINALS MODE) . . . . . . . . . . . . . . . . . 3-22

4. SORTER

1. OVERALL MACHINE INFORMATION. . . . . . . . . . . . . . . . 4-1

1.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.2 COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.2.1 Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.2.2 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.3 ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . 4-4

1.4 DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

STM vi A109

1.5 BASIC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2. DETAILED SECTION DESCRIPTIONS. . . . . . . . . . . . . . . 4-9

2.1 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

2.2 BIN GATE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

2.3 RELAY GUIDE PLATE RESET MECHANISM . . . . . . . . . . . . . . 4-11

2.4 ELECTRICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

2.5 JAM AND BIN COPY SENSORS . . . . . . . . . . . . . . . . . . . . . . . . 4-13

2.6 MISFEED SENSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

DISPLAY EDITOR

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2. OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

3. EXPLANATION FOR EACH KEY . . . . . . . . . . . . . . . . . . . 5-3

FILM PROJECTOR UNIT

1. SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

2. ELECTRICAL COMPONENT LAYOUT AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

3. SECTIONAL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . 6-3

3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

3.2 SHADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

3.3 MIRROR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

A109 vii STM

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals,

make sure that the copier power cord is unplugged.

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

3. Note that some components of the copier and the paper tray unit aresupplied with electrical voltage even if the main switch is turned off.

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

5. If the hot roller temperature is low when the main switch is turned on, thecopier starts process control self check automatically. Keep hands awayfrom the mechanical and the electrical components to avoid any injury.

6. If the start key is pressed before the copier completes the warm-upperiod (Start key starts blinking red and green alternatively), keep handsaway from the mechanical and the electrical components as the copierstarts making copies as soon as the warm-up period is completed.

7. The inside and the metal parts of the fusing unit become extremely hotwhile the copier is operating. Be careful to avoid touching thosecomponents with your bare hands.

HEALTH SAFETY CONDITIONS 1. Never operate the copier without the ozone filters installed.

2. Always replace the ozone filters with the specified ones at the specifiedintervals.

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

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a

customer service representative who has completed the training courseon those models.

2. The RAM board on the main control board has a lithium battery whichcan explode if replaced incorrectly. Replace the battery only with anidentical one. The manufacturer recommends replacing the entire RAMboard. Do not recharge or burn this battery. Used batteries must behandled in accordance with local regulations.

STM a A109

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner bottle or the used toner. Toner dust may

ignite suddenly when exposed to open flame.

2. Dispose of used toner, developer, and organic photoconductor accordingto local regulations. (These are non-toxic supplies.)

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

4. When keeping used lithium batteries in order to dispose of them later, donot put more than 100 batteries per sealed box. Storing larger numbersor not sealing them apart may lead to chemical reactions and heatbuild-up.

LASER SAFETYThe Center for Devices and Radiological Health (CDRH) prohibits the repairof laser-based optical units in the field. The optical housing unit can only berepaired in a factory or at a location with the requisite equipment. The lasersubsystem is replaceable in the field by a qualified Customer Engineer. Thelaser chassis is not repairable in the field. Customer engineers are thereforedirected to return all chassis and laser subsystems to the factory or servicedepot when replacement of the optical subsystem is required.

WARNING:Use of controls, or adjustment, or performance of procedures other thanthose specified in this manual may result in hazardous radiation exposure.

WARNING FOR LASER UNIT

Turn off the main switch before attempting any of theprocedures in the Laser Unit section. Laser beams canseriously damage your eyes.

WARNING:

CAUTION MARKING:

A109 b STM

MAIN BOARD REPLACEMENT

CAUTION: The RAM pack on the main control board has a lithiumbattery which can explode if replaced incorrectly. Replacethe battery only with an identical one. The manufacturerrecommends replacing the entire RAM board. Do notrecharge or burn this battery. Used batteries must behandled in accordance with local regulations.

STM c A109

TAB INDEX

TAB

PO

SIT

ION

1TA

B P

OS

ITIO

N 2

TAB

PO

SIT

ION

3TA

B P

OS

ITIO

N 4

TAB

PO

SIT

ION

5TA

B P

OS

ITIO

N 6

TAB

PO

SIT

ION

7TA

B P

OS

ITIO

N 8

OVERALL MACHINE INFORMATION


DUAL JOB FEEDER A376

SORTER A511

DISPLAY EDITOR A997

FILM PROJECTOR UNIT A998

OVERALLMACHINE INFORMATION

1. SPECIFICATIONSSpecifications are subject to change without notice.

Configuration: Console

Copy Process: Dry electrostatic transfer system

Resolutions: 400 dpi

Gradations: 256 gradations

Original Type: Sheet/book, object

Original Size: Maximum: A3 (lengthwise), 11" x 17"(lengthwise)

Original Alignment: Rear-left corner

Copy Paper Weight: • Paper Tray: 64 - 104.7g/m2 or 17 - 28 lb• Bypass Feed Tray: 64 - 157 g/m2 or 17 - 42 lb

NOTE: With paper heavier than 104.7g/m2 or28 lb, use the bypass feed tray andselect Thick Paper mode.

Available Copy Paper Size:

Tray Paper Direction A4/A3 version LT/DLT version

1stTray

Lengthwise A3, A4, 81/2" x 13" (F4),81/4" x 13"

11" x 17"(DLT), 11" x 15", 10" x 14" , 81/2" x 14"(LG),8" x 13"(F), 81/2" x 11"(LT),8" x 101/2", 8" x 10"

Sideways A4, A5 11" x 81/2"(LT), 81/2" x 51/2"(HLT)

2nd/3rdTray

Lengthwise A3, B4, A4, B5, A5, 11" x 17"(DLT), 11" x 15",10" x 14", 81/2" x 14"(LG), 81/2" x 13"(F4), 81/4" x 13",8" x 13"(F), 81/2" x 11"(LT), 8" x 101/2", 8" x 10",51/2" x 81/2"(HLT)

Sideways A4, B5, A5, 11" x 81/2"(LT), 81/2" x 51/2"(HLT)

Bypass

FeedTray

Lengthwise A3, B4, A4, B5, A5,B6, A6

11" x 17" (DLT), 10" x 14", 81/2" x 11" (LT), 8" x 13" (F),51/2" x 81/2" (HLT)

Sideways A4, B5, A5, B6, 81/2" x 11"

81/2" x 11" (LT)51/2" x 81/2" (HLT)

Odd paper size Horizontal direction: 148 – 432 mm or 5.8" – 17.0"Vertical direction: 100 – 297 mm or 3.9" – 11.7"

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STM 1-1 A109

Warm-up Time: About 8.5 minutes (at 20°C or 68°F)

First Copy Time:(A4 or 81/2" x 11" sideways)

• Full Color (4 scans): 15.5 seconds• Single Color:

Black. Yellow, Magenta, Cyan: 9.0 secondsRed, Green, Blue, Orange, Light Green: 11.0 seconds

NOTE: 1) When selecting OHP/Thick Papermodes, copying speed is reduced.

2) After changing some modes, thefirst copy time will take longer thanusual.

Copying Speed:(Standard modes)

• Full Color (4 scans): A4 or 81/2" x 11" sideways: 6 copies/minute

A3 or 11" x 17": 3 copies/minute• Single Color (Black, Yellow, Magenta, Cyan):

A4 or 81/2" x 11" sideways: 31 copies/minuteA3 or 11" x 17": 15 copies/minute

• Single Color (Red, Green, Blue, Orange, Light

Green):A4 or 81/2" x 11" sideways: 10 copies/minuteA3 or 11" x 17": 5 copies/minute

NOTE: When selecting OHP/Thick Papermodes, copying speed is reduced.

Non-reproduction Area: • Leading edge: 5±2 mm or 0.2"±0.08"• Side: 2±2 mm or 0.08"±0.08", Total less than 4mm or 0.16"• Trailing edge: 2±2 mm or 0.08"±0.08"

Copy Number Input: Number keys, 1 to 99

Automatic Reset: 1 minute standard setting; can also be set to 10to 900 seconds in 1 second steps, or to no autoreset.

Paper Feed: Paper Tray x 3 (500 sheets each)

Bypass Feed Tray (50 sheets with paper lighter than 104.7g/m2 or 28 lb)

A109 1-2 STM

Copy Tray Capacity: 100 sheets of paper

Toner Replenishment: Bottle type (340g/bottle)

Reproduction Ratio: • A4/A3 version: 25%, 50%, 65%, 71%, 75%, 82%, 93%, 100% (Full SIze), 115%, 122%, 141%, 200%, 400% + User ratio x 2

• LT/DLT version: 25%, 50%, 65%, 74%, 77%85%, 93%, 100% (Full Size), 121%, 129%, 155%, 200%, 400% + User ratio x 2

Zoom: From 25% to 400% in 1% steps

Power Source: 115 V 60 Hz, more than 12 A (for NA) 220 ∼ 240 V 50/60 Hz, more than 7 A (for EUand AA)

Power Consumption:(Copier only)

• Maximum: 1.4 kW• Warm-up: 1.25 kW• Stand-by: 0.5 kW• Copy Cycle: 1.15 kW

Noise Emission • Maximum: Copier Only: less than 62 dB (A) Full System: less than 69 dB (A)

• Stand-by: Copier Only: less than 40 dB (A) Full System: less than 44 dB (A)

• Copy-cycle: Copier Only: less than 56 dB (A) Full System: less than 58 dB (A)

Dimensions (W x D x H): • Copier Only:692 x 685 x 1026 mm or 27.3" x 27.0" x 40.4"• Full System*:1524 x 685 x 1099 mm or 60.0" x 27.0" x 43.2"(*= Copier + Dual Job Feeder + Sorter + Display Editor +

Holder)

Weight: • Copier Only: 200 kg or 440.8 lb

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STM 1-3 A109

Optional Equipment: • Dual Job Feeder• Sorter• Sorter Adapter• Projector Unit• Display Editor• Holder for Projector Unit/Display Editor• Key Counter

A109 1-4 STM

2. MACHINE CONFIGURATION

Item Note No.

Copier • English language ROM is installed 1

Dual Job Feeder • Common with A095/A096 copiers. 2

10-bin Sorter • Common with A099 copier. 3

• Sorter adapter (A527) is required forinstallation.

Display Editor • Holder (A702) is required forinstallation.

4

Film Projector Unit • Holder (A702) is required forinstallation.

5

Holder • Holder can be installed independentlyas an original table.

6

Language ROM(for operation panel)

• The following languages are available:English (A4), German, French, Italian,Spanish, (Universal)

—

<Copier>

1

<Full System>

4

6

52

3

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STM 1-5 A109

3. COPY PROCESS3.1 OVERVIEW

This copier scans the original image four times to develop the latent imageon the OPC drum with black, cyan, magenta, and yellow toner.

First, the drum is negatively charged by the charge corona unit [A] and isexposed by the laser beam [B] for producing the black latent image. Thenthe latent image is developed with negatively charged black toner by theblack development section [C]. (Refer to the development processdescription in section 2, 3.2)

When the developed black image has almost reached the transfer belt [D],the transfer belt contacts the drum and starts rotating at the same peripheralspeed of the drum (180 mm/sec). A high positive voltage is applied to thebelt bias roller [E] to attract black toner onto the transfer belt electrically.

When the whole black image is transferred to the transfer belt, the beltreleases from the drum and rotates the same amount in reverse.

After the black toner transfer to the transfer belt, the PCC (pre-cleaningcorona) [F] applies a strong ac corona discharge with a negative bias to thedrum surface. This makes it easier for the cleaning brush [G] to remove thetoner from the drum surface.

[A]

[D]

[G]

[J]

Y

Bk

[B]

[E]

[H]

[K]

M

[C]

[F]

[I]

[L]

C

A109 1-6 STM

Then the drum surface is cleaned by the cleaning brush and the cleaningblade [H]. The quenching lamp [I] exposes the drum to electrically neutralizethe drum surface.

Next the charged drum is exposed by the laser beam again for producing thecyan latent image. The image is developed with cyan toner and it istransferred to the transfer belt aligned with the black image.

The same image transfer process is performed for magenta and yellowtoners, producing the full color image on the transfer belt.

Then, the transfer roller [J] contacts the transfer belt and starts rotating at thesame speed as the transfer belt (180 mm/sec for normal paper mode, 90mm/sec for thick paper / OHP mode). Copy paper is fed to the nip bandbetween the transfer belt and transfer roller aligned with the lead edge of thefull color image.

A high positive voltage is applied to the transfer roller to attract toner onto thepaper.

A high ac voltage is applied to the discharge plate [K]. This discharges theremaining electricity on the paper to help the paper separate from thetransfer belt.

After the toner is transferred to the paper, the belt cleaning blade [L] contactsthe transfer belt to clean its surface.

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STM 1-7 A109

3.2 DEVELOPMENT PROCESS

A: OPC Drum B: Development Roller

Most copiers use either a positively charged photoconductor and negativelycharged toner or a negatively charged photoconductor and positivelycharged toner. However, this machine uses process where both the drumsurface charge and the toner charge are negative. This process has certainadvantages for laser printing, but some copy problems are exactly oppositefrom what many copier service people have intuitively come to expect. Thetable on the following page gives some of the differences between thestandard process and the this model’s process.

[A]

[B]

A109 1-8 STM

Standard Copier Process This Copier’s Process

Type of Laser He-neon(gas, 630nm)

He-neon orsemiconductor

Semiconductor (780 nm)

Photoconductor Se Drum OPC OPC

Charge Corona Positive Negative Negative

Carrier Charge Positive Negative Positive

Toner Charge Negative Positive Negative

PhotoconductorExposure

Background exposure(write to white) ⇒ Positivelatent image

Image exposure (write toblack)⇒ Negative latent image

P: Pitch (1/400" in this model)D: Laser beam diameter

VD: Drum potential (Dark)VB: Bias voltageVL: Drum potential (after laser exposure)L1, L2: Line width (L1< L2 for the samelaser beam diameter)

Copy Problems

1. No photoconductor charge

White copy Black solid copy

2. Low photoconductor charge

Low image density Dirty background

3. High development bias

Low image density Dirty background

4. Low development bias

Dirty background Low image density

5. Stained toner shield glass

Black stripes White stripes

P

P

V

V

0V

B

L

L1

D

VD

P

P

V

V

V

0V

B

L

L2

D

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STM 1-9 A109

4. MECHANICAL COMPONENT LAYOUT

11

10

13

12

16

2

3029282726

25

24

20

18

17

15 14

21

22

23

31

9

8

7

6

5

4

3

1

35343332

19

36

A109 1-10 STM

1. Pre-cleaning Corona Unit

2. Lubricant Brush

3. By-pass Feed Table

4. Transfer Belt

5. ID Sensor

6. Belt Cleaning Blade

7. Registration Rollers

8. Transfer Roller Blade

9. Transfer Roller

10. Relay Roller

11. Toner Catch Pan

12. Toner Collection Bottle

13. Paper Discharge Plate

14. Transport Belt

15. Magenta/YellowDevelopment Unit

16. 3rd Paper Tray

17. 2nd Paper Tray

18. 1st Paper Tray

19. Pressure Roller

20. Hot Roller

21. Development Ozone Filter

22. Black/Cyan DevelopmentUnit

23. Drum Potential Sensor

24. OPC Drum

25. 2nd Scanner

26. 1st Scanner

27. Drum Mirror

28. Toner Shield Glass

29. Charge Corona Unit

30. Quenching Lamp

31. Drum Cleaning Blade

32. Cleaning Brush

33. Lens

34. f-theta Lenses

35. CCD Board

36. Polygon Mirror

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STM 1-11 A109

5. DRIVE LAYOUT

1

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

7

6

5

43

2

8

A109 1-12 STM

1. Transfer Belt Position Clutch

2. Scanner Motor

3. Scanner Drive Pulley

4. Drum Drive Gear

5. Drum Motor

6. Bk-Sleeve Motor

7. Color-Development DriveMotor

8. Bk-Development Drive Gear

9. Bk-Development Drive Motor

10. Color-Development Drive Gear

11. Transport Unit Drive Gear

12. Fusing Unit Drive Gear

13. Transport Motor

14. Tray Lift Motors

15. Paper Feed Motor

16. 3rd Paper Feed Drive Pulley

17. Toner Collection Tank Drive Gear

18. 2nd Paper Feed Drive Pulley

19. 1st Paper Feed Drive Pulley

20. Transfer Roller Position Clutch

21. Registration Clutch

22. Relay Roller Drive Gear

23. By-pass Feed Drive Gear

24. Transfer Belt Drive Pully

25. Transfer Belt Motor

26. Lubricant Brush Clutch

27. Cleaning Motor

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STM 1-13 A109

6. AIR FLOW

111

10

9

8

7

6

5

4

3

2

1. Charge Inlet Fan

2. Fusing Exhaust Fan

3. LD Cooling Fan

4. Optics Exhaust Fan

5. IPU Cooling Fan

6. Polygon Motor Cooling Fan

7. Transport Fans

8. DC Power Supply Cooling Fan

9. Inner Cooling Fan

10. Development Exhaust Fans

11. Optics Cooling Fans

A109 1-14 STM

7. ELECTRICAL COMPONENT DESCRIPTIONSRefer to the electrical component layout on the water proof paper in thepocket for symbols and index numbers.

Symbol Name Function IndexNo.

Printed Circuit BoardsPCB 1 DC power supply Provides dc power. 18PCB 2 Lamp regulator Provides dc power for the exposure

lamp.1

PCB 3 AC drive Provides ac power for the fusingand pressure lamps.

9

PCB 4 High voltage supply -C/G

Supplies high voltage to the chargecorona and grid plate.

10

PCB 5 High voltage supply - B Supplies high voltage to the Y/M/C/Bksleeve rollers as development bias orto the OPC drum for drum potentialsensor calibration.

23

PCB 6 High voltage supply -T1/Pcc/BR

Supplies high voltage to the beltbias roller, pre-cleaning corona, andcleaning bias roller.

11

PCB 7 High voltage supply -T2

Supplies high voltage to the transferroller.

15

PCB 8 High voltage supply - D Supplies high voltage to the paperdischarge plate.

20

PCB 9 Main control Controls all copier functions bothdirectly or through other controlboards.

14

PCB10 Interface 1 Interfaces the input/output ofelectrical components with the maincontrol board.

19

PCB11 Interface 2 Interfaces the input/output ofelectrical components with the maincontrol board.

16

PCB12 Transfer belt motordrive

Controls the speed and direction ofthe transfer belt motor.

13

PCB13 Paper feed interface Interfaces the input/output ofelectrical components in the papersupply unit with the main controlboard.

17

PCB14 Noise filter Removes electrical noise. 21PCB15 ID sensor Detects the density of the ID sensor

pattern.120

PCB16 Operation panel Controls the touch panel display andmonitors the key matrix.

22

PCB17 Polygon motor drive Controls the polygon motor speed. 7PCB18 CCD Converts the light reflected from the

original into analog electrical signalsfor the three basic colors (R/G/B).

8

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STM 1-15 A109


PCB19 Scanner control Processes R/G/B video signals fromthe CCD board to be sent to the IPUboard.

6

PCB20 Scanner drive Interfaces the input/output electricalcomponents in the optics cavity withthe scanner control board.

3

PCB21 IPU board Processes R/G/B video signals fromthe scanner control board andsends Y/M/C/Bk video signals to theLD unit.

2

PCB22 IPU interface Changes the clock frequency ofR/G/B video signals and also sendsthe synchronizing signal for thepolygon motor.

4

PCB23 Option interface Interfaces the display editor and filmprojector unit with the main controlboard and IPU board.

12

PCB24 LD drive Generates the laser beam to thedrum for printing the image.

5

PCB25 Laser synchronizingdetector

Detects the laser beam to controlthe start timing of main scan writing.

62

PCB26 Paper width detecting Detects paper width in the by-passfeed table.

121

MotorsM 1 Bk - Development drive Drives the Bk dual mixing roller. 42M 2 C - Sleeve Turns the C - sleeve roller in both

directions.28

M 3 M - Sleeve Turns the M - sleeve roller in bothdirections.

32

M 4 Y - Sleeve Turns the Y - sleeve roller in bothdirections.

31

M 5 Drum Turns the OPC drum. 25M 6 Bk - Sleeve Turns the Bk - sleeve roller in both

directions.27

M 7 Transport Drives the transport unit, fusing unit,transfer roller, and transfer beltcleaning unit.

41

M 8 Color - Developmentdrive

Drives the Y/M/C - dual mixingrollers simultaneously.

24

M 9 Cleaning Drives the drum cleaning brush, thelubricant brush, and the transfer beltrelease mechanism.

29

M10 Scanner Drives the 1st and 2nd scanners. 26M11 Transfer belt Turns the transfer belt drive roller in

both directions.30

M12 Paper feed Drives the paper feed sections andthe cam gear for the toner collectionbottle.

36

M13 Polygon Turns the polygon mirror. 43

A109 1-16 STM


M14 Bk - Toner supply Drives the Bk - toner transport andagitation mechanism.

40

M15 C - Toner supply Drives the C - toner transport andagitation mechanism.

39

M16 M - Toner supply Drives the M - toner transport andagitation mechanism.

38

M17 Y - Toner supply Drives the Y - toner transport andagitation mechanism.

37

M18 1st tray lift Lifts the 1st tray bottom plate. 33M19 2nd tray lift Lifts the 2nd tray bottom plate. 34M20 3rd tray lift Lifts the 3rd tray bottom plate. 35

Fan MotorsFM 1 Fusing exhaust Removes the heat from around the

fusing unit.45

FM 2 Charge inlet Provides air flow around the drumcharge section.

44

FM 3 Inner cooling Provides air flow around the tonertank and development units.

53

FM 4 IPU cooling Provides air flow around the IPU board. 48FM 5 Polygon motor cooling Provides air flow around the polygon

motor.49

FM6/7 Transport Sucks in air to attract copy paper onthe transport belts.

51/50

FM8/9 Development exhaust Removes air and heat from aroundthe drum and development units.

54/55

FM10 Optics exhaust Exhausts air from under the lenshousing cover.

47

FM11 LD cooling Provides air flow to the LD unit. 46FM12/13 Optics cooling Blows air into the optics cavity. 56/57

FM14 DC power supplycooling

Provides air flow to transformers andradiation plates on the dc powersupply board.

52

SensorsS 1 By-pass feed table Detects if the by-pass feed table is

open or closed.67

S 2 Oil end Detects if the silicon oil tank isnearly empty or not.

86

S 3 Exit Detects misfeeds. 91S 4 Transfer belt position Detects if the transfer belt is in

contact with the drum or not.63

S 5 Humidity Detects humidity and temperature tocalculate the absolute humidity.

84

S 6 Drum potential Detects the drum surface potential. 118S 7 M - Toner density Detects the toner density in the M -

development unit.89

S 8 Y - Toner density Detects the toner density in the Y -development unit.

88

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STM 1-17 A109


S 9 Bk - Toner density Detects the toner density in the Bk -development unit.

92

S10 C - Toner density Detects the toner density in the C -development unit.

90

S11 Transport Detects misfeeds. 87S12 Registration Detects the lead edge or trailing

edge of copy paper to control therotation of the paper feed andregistration rollers.

70

S13 Registration guide set Detects if the registration guideplate is set or not.

66

S14 Transfer roller position Detects if the transfer roller is incontact with the transfer belt or not.

68

S15 By-pass paper end Detects if there is paper on theBy-pass feed table or not.

69

S16 By-pass length Detects if paper on the by-pass feedtable is longer than A4 (Letter)sideways or not.

65

S17 Toner overflow Detects if the toner collection bottleis full or not.

82

S18 1st lift Detects the height of the paperstack in the 1st paper tray to stopthe 1st tray lift motor.

72

S19 2nd lift Detects the height of the paperstack in the 2nd paper tray to stopthe 2nd tray lift motor.

73

S20 3rd lift Detects the height of the paperstack in the 3rd paper tray to stopthe 3rd tray lift motor.

76

S21 1st paper end Detects if there is paper in the 1stpaper tray or not.

85

S22 2nd paper end Detects if there is paper in the 2ndpaper tray or not.

83

S23 3rd paper end Detects if there is paper in the 3rdpaper tray or not.

80

S24 1st paper feed Controls the 1st paper feed clutchoff/on timing and the 1st pick-upsolenoid off timing.

78

S25 2nd paper feed Controls the 2nd paper feed clutchoff/on timing and the 2nd pick-upsolenoid off timing.

81

S26 3rd paper feed Controls the 3rd paper feed clutchoff/on timing and the 3rd pick-upsolenoid off timing.

79

S27 Original length - 1 Detects original length. 61S28 Original length - 2 Detects original length. 59S29 Original width Detects original width. 98S30 Scanner unit lift Detects if the scanner unit is lifted or

not.60

A109 1-18 STM


S31 Platen cover position Informs the CPU if the platen coveris up or down (related to APS/AREfunction).

58

S32 Scanner HP Informs the CPU if the 1st and 2ndscanners are at the home positionor not.

99

SwitchesSW1/2/3/4 Front door safety Cuts the ac power line through RA1

and detects if the front door is openor not.

94/95/96/97

SW5/6 Vertical transport set Cuts the ac power line through RA1and detects if the vertical transportguide is open or not.

74/75

SW 7 Main Provides power to the copier. Whenit is at stand by position, theelectrical power is supplied only tothe heaters (drum/opticsanticondensation/tray/transfer belt).

93

SW 8 2nd tray set Detects if the 2nd paper tray is setor not.

71

SW 9 3rd tray set Detects if the 3rd paper tray is set ornot.

77

SW10 1st paper size Detects the paper size for the 1stpaper tray and if the tray is set ornot.

64

Magnetic ClutchesMC1 Lubricant brush Transmits the drive from the

cleaning motor to the lubricant brush.101

MC2 Transfer belt position Controls the touch and releaseoperation of the transfer belt byusing the cleaning motor’s drive.

100

MC3 By-pass feed Starts paper feed from the by-passfeed table.

104

MC4 Registration Drives the registration rollers. 103

MC5 Transfer roller position Controls the touch and releaseoperation of the transfer roller unitby using the transport motor’s drive.

102

MC6 1st feed Starts paper feed from the 1st papertray.

106

MC7 2nd feed Starts paper feed from the 2ndpaper tray.

107

MC8 3rd feed Starts paper feed from the 3rd papertray.

108

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STM 1-19 A109


SolenoidsSOL 1 Cleaning entrance seal Controls the touch and release

operation of the cleaning entranceseal on the transfer belt cleaning unit.

115

SOL 2 Lubricant brush Controls the touch and releaseoperation of the lubricant brush.

117

SOL 3 Cleaning blade Controls the touch and releaseoperation of the belt cleaning blade.

116

SOL 4 By-pass pick-up Controls the up/down movement ofthe pick-up roller for by-pass feed.

105

SOL 5 1st pick-up Controls the up/down movement ofthe pick-up roller in the 1st feedstation.

114

SOL 6 2nd pick-up Controls the up/down movement ofthe pick-up roller in the 2nd feedstation.

112

SOL 7 3rd pick-up Controls the up/down movement ofthe pick-up roller in the 3rd feedstation.

110

SOL 8 1st separation roller Controls the up/down movement ofthe separation roller in the 1st feedstation.

113

SOL 9 2nd separation roller Controls the up/down movement ofthe separation roller in the 2nd feedstation.

111

SOL10 3rd separation roller Controls the up/down movement ofthe separation roller in the 3rd feedstation.

109

LampsL1 Fusing Provides heat to the hot roller. 135L2 Pressure roller Provides heat to the pressure roller. 134L3 Exposure Applies high intensity light to the

original for exposure.122

L4 Quenching Neutralizes any charge remainingon the drum surface after cleaning.

119

HeatersH1 Lower tray (option) Turns on when the main switch is off

to keep paper dry in the 3rd papertray.

129

H2 Upper tray (option) Turns on when the main switch is offto keep paper dry in the 1st and 2ndpaper trays.

127

H3 Transfer belt Turns on when the main switch is offto prevent moisture from forming onthe transfer belt.

128

H4 Opticsanti-condensation

Turns on when the main switch is offto prevent moisture from forming onthe optics.

140

A109 1-20 STM


H5 Drum Turns on when the main switch is offto prevent moisture around the drum.

124

ThermistorsTH1 Fusing Monitors the temperature of the hot

roller.126

TH2 Pressure roller Monitors the temperature of thepressure roller.

133

ThermofusesTF1 Fusing Opens the fusing lamp circuit if the

fusing unit overheats.125

TF2 Pressure roller Opens the pressure roller lampcircuit if the fusing unit overheats.

132

ThermoswitchTS1 Optics Opens the exposure lamp circuit if

the 1st scanner overheats.123

CountersCO1 Black total Keeps track of the total number of

scans for black development in boththe black and color copy modes.

136

CO2 Full color total Keeps track of the total number ofscans for Yellow, Magenta, andCyan developments in both thesingle and full color copy modes.

137

OthersCB1 Circuit breaker Provides back-up high current

protection for the electricalcomponents.

130

RA1 Main power relay Controls main power. 138NF1 Noise filter Removes electrical noise. 131CC1 Choke coil Removes high frequency current. 139

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STM 1-21 A109


1. PROCESS CONTROL1.1 OVERVIEW

This model uses two control methods. One compensates for variation in thedrum potential and toner chargeability (latent image control) and the othercontrols the toner concentration and toner supply amount (toner densitycontrol).

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A109 2-1 STM

1.1.1 Latent Image Control

<Factors that change the development potential>

After long usage following installation or PM, drum potential will graduallychange due to the following factors:

• Dirty charge corona and grid plate

• Change of the drum characteristics

Due to changes in humidity conditions, the toner potential (chargeability)varies and affects the image density even if the toner concentration is keptconstant.

• When humidity is low, toner chargeability increases resulting in lowerimage density.

• When humidity is high, toner chargeability decreases resulting in higherimage density.

Also, after long usage following installation or PM, the surface of carrierparticles is gradually coated with melted toner (filming). This decreases thetoner chargeability.

<Method to maintain the proper development potential>

In this copier, the change in drum potential is detected by the potentialsensor and the change in the toner potential is detected by the ID sensor.The following items are controlled to maintain good copy quality.

• Grid bias voltage

• Laser diode input current

• Development bias voltage

1.1.2 Toner Density Control

Toner density in the developer is controlled by the toner density sensor. Datafrom the toner density sensor is used to keep the toner concentration in thedeveloper at a constant level. Neither the ID sensor nor the drum potentialsensor affect the toner density control. This is different from previous modelsusing TD sensors.

Development potential

STM 2-2 A109

1.2 PROCESS CONTROL SELF CHECK

The following flow chart shows all the steps that will be performed under thefollowing conditions:

• Whenever the machine is turned on while the hot roller temperature isbelow 100°C.

• After the series of copy job is completed and more than 150 copies havebeen made since the last process control self check. This initializes all

the process control settings.

Main SW on (Fusing Temp. < 100o C)

Drum Potential Sensor Calibration

VSG Adjustment (ID Sensor)

Gradation Pattern Duplication (latent image)

Gradation Pattern Potential Detection (Potential Sensor)

Gradation Pattern Development

Gradation Pattern Density Detection (ID Sensor)

Pointer Control

VG, VB, ILD Correction

NOTE: Continue this procedure four times (Bk, C, M, Y)

Process Control Self Check, more than 150 copies since last check

* SeeNOTE:

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A109 2-3 STM

1.3 LATENT IMAGE CONTROL

1.3.1 Drum Potential Sensor Calibration

The drum potential sensor [A] is located just above the development unit.The sensor has a detector which detects the strength of the electric fieldfrom the electric potential on the drum. The output of the sensor depends onthe strength of the electric field.

Since the output of the sensor is affected by environmental conditions, suchas temperature and humidity, the sensor output is calibrated during processcontrol self check.

The High Voltage Supply Board - B [B] has two relay contacts. Usually RA#1 grounds the drum. However, during the self-check, the main CPU turnsRA #2 on and RA #1 off and applies the voltage to the drum shaft [C].In this condition, the OPC drum is isolated from ground (floating).

By measuring the output of the drum potential sensor when -200V (V200) or-800V (V800) are applied to the drum, the sensor output is calibratedautomatically. (The machine recognizes the relationship between actualdrum potential and the potential sensor output.)

[A]

[B]

[C]

Main board

RA #2

RA #1

RA #1 and #2 are packedin RL1 on the High voltageSupply Board – B.

Drum

Case

Sensor

Output

Amp.

STM 2-4 A109

1.3.2 VSG Adjustment

During drum conditioning, the ID sensor checks the bare drum’s reflectivityand calibrates the output of the ID sensor to 4 ± 0.2V.

1.3.3 Gradation Patterns Detection

10 grades of latent gradation patterns are created for each color (Bk, C, M,Y) by changing the LD input current.

The drum potential sensor detects the potential for each pattern and theoutput is stored in memory. Then the latent gradation patterns pass thedevelopment unit and are developed. The ID sensor detects the density ofthe gradation patterns and the output is stored in memory.

[LD power level]

40 mm

40 mm

10 mm

1st

2nd

3rd

10th

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A109 2-5 STM

1.3.4 Pointer Control

The main CPU converts the gradation pattern density (ID sensor output) tothe actual toner quantity on the pattern (mg/cm2) based on a characteristicstable stored in memory. Then the potential sensor output and pattern density (mg/cm2) for each ofthe 10 patterns are plotted as shown. The CPU approximates the line fromthe data and calculates the Development Potential (VDP).

The inclination of this line is called the development gamma (γ) factor. Itrepresents the characteristic between the drum potential and toner amountdeveloped on the drum.

From the VDP, the copier determines VD (Drum potential made withoutexposure), VB (Development bias), and VL (Drum potential with strongest LDexposure). Each VDP value points to a record containing the VD, VB, and VLvalues deemed optimal by this copier’s designers.

VDP, VD, VB, and VL have 20 sets of combination. These presetcombinations of VD,VB and VL are called pointers.

1.3.5 Confirmation Procedure

Using the selected VD, VB and VL data, the darkest (VL pattern: Patternmade with strongest LD exposure) and the lightest pattern (VD pattern:Pattern made without exposure) are duplicated again. The potential sensordetects the potential of each pattern (VD and VL) to evaluate whether thedrum potential for each pattern is within specification (±5 V from the target)or not.

Drum Potential

Pattern density(mg/cm2)

VBVK VL

VDPVD

1.0

STM 2-6 A109

If VD is out of specification, VG (Grid Voltage) is shifted. Then the VD isdetected again.

The same is done for VL with ILD (LD current).

VB is fixed at the value determined by the pointer control.

The above process continues until both VD and VL fall within specification.

1.3.6 Related Abnormal Conditions

If V200 or V800 at drum potential sensor calibration is out of specificationnothing is indicated on the LCD but SC counter (SC380) is incremented. IfVD or VL do not fall within specification for any color after VG or ILD areshifted 30 times, the machine stops VD or VL correction and uses theprevious VG and ILD values for all color during copying. When the VD is notadjustable (SC382) or VL is not adjustable (SC383), nothing is indicated onthe LCD but the SC counter (SC382 or 383) is incremented.

Related SC codes (see troubleshooting section for details):

Code Condition

380 Incomplete drum potential sensor calibration

381 Abnormal drum potential sensor detection

382 Abnormal VD detection

383 Abnormal VL detection

384 Abnormal LD current

390 Incomplete VSG adjustment

Rev. 7/94

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A109 2-7 STM

1.4 TONER DENSITY CONTROL

1.4.1 Toner Density Sensor

Developer consists of carrier particles (ferrite) and toner particles (resin andpigment). Inside the development unit, developer passes through a magneticfield created by coils inside the toner density sensor. When the tonerconcentration changes, the voltage output by the sensor changesaccordingly.

1.4.2 Toner Density Sensor Initial Setting

When new developer with the standard toner concentration (5% by weight,20g of toner in 400g of developer) is installed, developer initial setting mustbe performed by using SP mode.

During this setting, the output voltage (VCNT) from the auto gain controlcircuit (AGC) on the main control board varies to change the output voltagefrom the toner density (TD) sensor. This is done by changing the gain data,(see below).

VCNT = 12 (V) X Gain Data/256

If the data is high, VCNT becomes high, and the sensor output voltagebecomes high. As a result, the sensor characteristic becomes as illustratedby curve A. If the data is low, VCNT becomes low, and the sensor outputvoltage becomes low. As a result, the sensor characteristic shifts asillustrated by Curve C.

By selecting the proper gain data, the sensor output is set within the targetedcontrol level (VREF : 2.5 ± 0.1V). Now, the sensor characteristic is illustratedby curve B and the TD sensor initial setting is completed.

The selected gain data is stored in memory, and VCNT from the auto gaincontrol circuit stays constant during the toner sensor detection cycle.

1

2

3

4

5

0

New Developer

C B A

V

Toner Weight %

SensorOutput(V)

REF

2.5 5 7.5 10

A: VCNT (Gain data) is high. B: VCNT is within the specification. C: VCNT (Gain data) is low.

Toner Weight %

Main PCB12 V VCNT

AGC

TD Sensor

12 VGND

SensorOutput

VCNT = 12 x Gain256

STM 2-8 A109

1.4.3 Toner Supply Criteria

The toner density of the developper is checked every copy cycle. The sensoroutput voltage (VT) during the detection cycle is compared with the tonersupply level voltage (VREF).

1.4.4 Toner Supply Motor ON Time

1) Fuzzy controlTo stabilize toner concentration, the toner supply amount (toner supplymotor on time) is controlled by referring to VREF and VT.The toner supply amount is calculated every copy cycle. The tonersupply amount is determined by using the following factors.

Factor 1. Average of the previous 20 VT output values (VT(20))Factor 2. VT change tendency during the last 20 detections

By referring to these factors, the machine recognizes the differencebetween the current toner concentration and the target tonerconcentration. It then outputs the data to determine the toner supplymotor on time. The machine also understands by how much the tonersupply amount will probably change. The CPU also refers to the imagearea ratio of the original, informed from the IPU (image area integrationdata) to improve the precision of the toner density change prediction.By changing the toner supply amount precisely, toner concentration(image density) is kept at a constant level.Since the toner supply motor on time update is done under fuzzy control,the relation between factor 1, factor 2, and VREF cannot be expressed bya simple algebraic formula.The maximum toner supply amount is 60% (this corresponds to the tonerquantity for an A3 size original with 60% image area).

2) Supplementary control - by passes fuzzy control Under the following conditions, the toner concentration is low.• Just after the toner end recovery.• After continuous high image area ratio copies.

TD sensor

Factor 1

Factor 2SupplementaryControl(VREF< VT)

GainFuzzyControl

IPU

V VREFT -

TonerSupplyMotorON Time

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A109 2-9 STM

In these cases, the toner supply amount should be large but if the originalimage area ratio is low, the supply amount will be small because the imagearea ratio (image area integration data) affects the toner supply motor ontime, as mentioned above.

To help the toner concentration return to normal more quickly,supplementary control is used. The supplementary control supplies moretoner when the original image area ratio is low. Usually, the effect ofsupplementary control is much lower than that of fuzzy control.Supplementary control functions only when VT is larger than VREF andoriginal image ratio is less than 60%. When the original image ratio is greaterthan 60%, both fuzzy control and supplementary control function.

1.4.5 VCNT Correction

Even if the toner concentration is constant, the toner sensor output graduallyincreases after the new developer is installed because of developercharacteristics.This increases the toner concentration because the machine controls thetoner concentration so that VT stays constant.

To compensate for this, the VCNT gain data is decreased by 1 at every 200copies. The maximum compensation value is shown in the table below.

Bk Y M CMaximum CompensationValue

-6 -6 -6 -5

2.5 V

Copies

1 k

VT

STM 2-10 A109

1.4.6 Toner End Detection

1) Toner near endThe toner density sensor detects when toner is about to run out.Under the following conditions, a toner near end condition is detected:

Condition 1) VT (20) > VREF + 0.3 V and VT > VREF + 0.2 V

Condition 2) VT > VREF + 0.5 V

Condition 3) VT (20) > VREF +0.3 V and VT > VREF + 0.5 V

NOTE: VT (20): Average of the last 20 VT detected data

2) Toner endUnder the following conditions, a toner end condition is detected andcopying is allowed only for the following 10 copies:

Condition 1 is detected 5 times continuously.Condition 2 is detected 5 times continuously.Condition 3 is detected once.

When color toner (Y, M, C) runs out, black copies can still be made andwhen black toner runs out, single color copies can still be made.

1.4.7 Toner End Recovery

After the toner is added and the front door is closed, the machine detectswhether toner concentration has returned to normal.

The toner end recovery sequence is:

Doorclose

5 sec

1 sec

20 sec

VT detection(VT1)

20 sec2 sec

VT detection (VT2)

Continue 17 times

DevelopmentDriveMotor

TonerSupplyMotor

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A109 2-11 STM

Under the following condition, toner end recovery is completed.

VT1 - VT2 > 0.10 V or VT2 < VREF

If the above conditions are not satisfied, the toner end condition is notcanceled. After the front door is opened and closed, the machine starts thetoner end recovery again.

If the toner end recovery sequence is done 3 times and the above conditionis not satisfied, the toner end condition is reset and copying is enabled.

After toner end recovery, the first VT data is used as VT (20) for thesubsequent 20 copies.

STM 2-12 A109

2. DRUM UNIT2.1 OVERVIEW

The drum unit consists of the components shown in the above illustration.

An organic photoconductor drum (diameter: 120 mm) is used for this model.

45

6

7

8

9

10

11

1

2

3

1. OPC Drum

2. Drum Potential Sensor

3. Main Charge Corona Unit

4. Quenching Lamp

5. Drum Cleaning Blade

6. Cleaning Bias Roller

7. Drum Cleaning Brush

8. Toner Collection Coil

9. Cleaning Entrance Seal

10. Pre-Cleaning Corona Unit

11. ID Sensor

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A109 2-13 STM

2.2 OPC DRUM CHARACTERISTICS

An OPC has the characteristics of:

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

2. Dissipating the electrical charge when exposed to light. (Exposure to lightgreatly increases the conductivity of a photoconductor.)

3. Dissipating an amount of charge in direct proportion to the intensity of thelight. That is, where stronger light is directed to the photoconductorsurface, a smaller voltage remains on the OPC.

4. Being less sensitive to changes in temperature (when compared toselenium F type drums).

5. Being less sensitive to changes in rest time (light fatigue). This makes itunnecessary to compensate development bias voltage for variations inrest time.

STM 2-14 A109

2.3 DRUM CHARGE

This copier uses a double corona wire scorotron system for the drum charge.

The two corona wires apply a sufficient negative charge to the drum surface.The striped stainless steel grid plate [A] makes the corona charge uniformand controls the amount of negative charge on the drum surface by applyingthe negative grid bias voltage.

The high voltage supply board-C/G [B] gives a constant corona current(–700 µA)to the corona wires, and controls the grid voltage to maintainproper image density. Grid voltage is controlled to match changing factorssuch as a dirty grid plate, dirty charge corona casing, and OPC chargeability.(Refer to the Process Control section.)

The charge fan [C] provides a flow of air through the corona unit [D] in orderto prevent an uneven build up of negative ions. This helps maintain evenimage density.

[A]

[B]

[C]

[D]

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A109 2-15 STM

2.4 DRIVE MECHANISM

The drum rotation speed is 180 mm/second. The OPC drum is driven by thedrum motor [A]. This motor has a drive controller so that it can control thedrum rotation by itself. When the rotation speed becomes out ofspecification, the drive controller outputs a motor lock signal.

A fly-wheel [B] is installed on the end of the drum shaft to stabilize therotation speed.

The cleaning mechanism is driven by the cleaning motor [C]. The drive fromthe cleaning motor is transmitted to the cleaning drive gear [D] via the timingbelt.

The cleaning drive gear then rotates the cleaning brush [E], the cleaning biasroller [F], and the toner collection coil [G]. The cleaning bias roller has abevel gear at the front end to drive the upper toner collection coil [H].

[A]

[B]

Front

Rear

Front

Rear

[C]

[D]

[F]

[E]

[G]

[H]

STM 2-16 A109

2.5 DRUM CLEANING

2.5.1 Counter Blade System

This copier uses the counter blade system for drum cleaning.

The cleaning blade [A] is angled against drum rotation. This counter bladesystem has the following advantages:

• Less wearing of the cleaning blade edge

• High cleaning efficiency

The cleaning pressure is continuously applied with a pressure spring.

To remove the accumulated toner at the edge of the cleaning blade, thedrum turns in reverse for about 9 mm (0.05 sec.) before starting the normalrotation when the main switch is turned on. The accumulated toner isremoved by the cleaning brush.

[A]

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A109 2-17 STM

2.5.2 PCC And Cleaning Bias

To ensure OPC drum cleaning, the pre-cleaning corona (PCC) [A] applies anAC voltage with a negative DC bias to the surface of the drum. This givesthe residual toner a uniform negative charge (to be easily attracted by thecleaning bias) and neutralizes the positive charge on the drum (after theimage transfer, the drum surface is positively charged).

The cleaning brush (looped brush) [B] is used to support the cleaning blade.

The brush collects toner (mechanically and electrically) from the drumsurface and the remaining toner is scraped off by the cleaning blade [C].Toner on the cleaning brush is electrically attracted to the cleaning bias roller[D] then scraped off by the bias blade [E]. The toner falls on the tonercollection coil [F]. Toner is transported to the toner collection bottle by thetoner collection coil.

A +50V cleaning bias is applied to the cleaning bias roller and to the cleaningbrush which is an electrical conductor (resistance:107Ω)

[A]

[B]

[C]

[D]

[E]

[F]

DC+50 V

STM 2-18 A109

2.5.3 Toner Collection Mechanism

Toner collected by the cleaning section is transported to the toner collectionbottle [A] through the toner collection duct [B].

The drive from the OPC cleaning bias roller drives the upper toner collectioncoil [C]. Toner collected by the transfer belt cleaning section is alsotransported to the toner collection bottle through the toner collection coil [D].The drive from the relay roller [E] drives the lower toner collection coil.

The toner collection bottle is pressed against the cam gear [F] by a spring[G]. The drive from the paper feed motor drives the cam gear and shakes thetoner collection bottle front to rear to make the level of the collected tonereven.

The toner overflow sensor [H] detects when toner collection bottle is full.After the toner overflow sensor is activated, 250 copies are allowed, thencopying is prohibited and a call service indicator appears on the LCD.

[A]

[B]

[C]

[D]

[E]

[F]

[H]

[A][G]

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A109 2-19 STM

2.6 QUENCHING

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

The Quenching lamp turns on at the same time as the drum motor.

Red colored LEDs are used for the quenching lamp to reduce ultra violetlight that would cause light fatigue on the OPC drum.

The mylar [B] on the side of the quenching lamp stops the air flow from thecleaning section to the main charge corona to prevent the charge corona unitfrom becoming dirty with toner.

[A][B]

STM 2-20 A109

3. SCANNING3.1 OVERVIEW

An image of the original exposed by the exposure lamp (halogen lamp) [A] isreflected on a color CCD (charge coupled device) [B] via the 1st, 2nd, 3rdmirrors, filter [C], and lens.

The number of scan depends on the copy mode, black, full color, auto colorselect, or single color. The scanner moves 4 times at most, once for eachdevelopment cycle. The order of the cycles is black, cyan, magenta, andyellow.

One chip color CCD with R/G/B color filter is used for photo-electricconversion.

The scanning capability is 400 dpi (5,000 pixels).

[A]

[B][C]

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A109 2-21 STM

3.2 SCANNER UNIT

The 1st scanner consists of the exposure lamp [A], main and sub reflectors[B, C], and 1st mirror [D].

This model uses a halogen lamp for the exposure lamp unlike other digitalcopiers which use fluorescent lamps. This is because the color CCD requiresa greater light intensity than a black/white CCD due to its color filters. Theexposure lamp is energized by a dc current to avoid uneven light intensity inthe sub scan direction. The entire exposure lamp surface is frosted to ensureeven exposure in the main scan direction.

The light intensity reflected by the main and sub reflectors is almost even toreduce shadows of pasted originals.

The thermoswitch [E] is installed on the 1st scanner to protect againstoverheating. It turns off at around 140°C.

[A]

[B]

[C]

[D]

[E]

STM 2-22 A109

3.3 SCANNER DRIVE

A five phase stepper motor is used for scanner drive. The 1st and 2ndscanners [A, B] are driven by this scanner drive motor [C] via 4 scannerwires. The length of each wire is different.

In full size mode, the 1st scanner speed is 180 mm/sec. during scanning,and 1,040 mm/sec. when the scanner returns. The 2nd scanner speed is halfthat of the 1st scanner.

In reduction or enlargement mode, the scanning speed is changed accordingto the magnification ratio. The returning speed is always the same. Theimage length change in the sub scan direction is done by the scanner speedchange and that in the main scan direction is done by the image processingthrough the IPU board.

The number of scan changes according to the color selection mode asshown in the following table:

Mode Number ofscans

Development order Note

Black 1 Bk —

Auto ColorSelect

1 Bk For black/white originals

4 Bk–C–M–Y For colored originals

Single Color 1 C, M, or Y For toner colors

2 C–M, C–Y, or M–Y For complementary colors

4 Bk–C–M–Y For user color

Full Color 4 Bk–C–M–Y 4C mode

4 C–M–Y 3C mode

[A]

[B] [C]

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A109 2-23 STM

3.4 COLOR CCD

The color CCD converts light reflected from the original into three analogsignals, one for each of the three basic colors Red, Green, and Blue. Thesignals are called the R, G, and B signals. Each of the four scans (for tonercolors YMCBk) uses all three signals (RGB).

The CCD consists of three lines of 5000 elements, giving the CCD aresolution of 400 dpi (15.7 dots/mm). Each line of elements has a colorseparation filter for each of the three basic colors.

The lines are spaced 8 pixels apart for full size magnification. To correct thisspacing, the R, G, and B signals must be synchronized. This is done bydelay memories in the scanner control board before the three signals aresent to the IPU board (refer to the Image Processing section.)

1 pixel 14 µm

STM 2-24 A109

3.5 WHITE PLATE SCANNING

For auto shading, a white plate [A] is stuck on the exposure glass,underneath the left scale.

When this white plate is exposed, the output from all the CCD elements in aline should in theory be equal, but actually they are not, because of thefollowing:• Variations in sensitivity between elements of the CCD

• Variations in characteristics of the lens and mirror reflectivity

• Loss of brightness toward the ends of the exposure lampTo correct this uneven output from the CCD elements, auto shading isperformed based on the light reflected from the white reference plate.

Auto shading is done for every copy cycle at the scanner home positionbefore starting the first scan. However, it is done only once at the first copycycle during a multicopy run in single color (1C) mode because the intervalbetween copy cycles is too short.

AUTO GAIN CONTROL

The white reference plate is also used for Auto Gain Control (AGC) when themain switch is trurned on. During the AGC process, the copier adjusts theexposure lamp voltage.

The copier first sets the exposure lamp voltage below the target value, thengradually increases it until the output of one of the R, G, B lines of the CCDreaches its target (VREF= 2.7 volts).

At that time, the copier stops increasing the exposure lamp voltage andreads the output of the other two CCD lines. Withe this data the scannercontrol PCB determines the white (peak) reference level.

[A]

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A109 2-25 STM

3.6 ORIGINAL SIZE DETECTION

There are three reflective sensors (APS sensors) in the optics cavity for theoriginal size detection. Original Width Sensor [A] is used for sensing theoriginal width while Original Length Sensor-1 [B] and Original LengthSensor-2 [C] sense the original length.

Inside each APS sensor, there is an LED [D] and three photoelectric devices[E]. The light generated by the LED is broken up in three beams and eachbeam scans a different point of the exposure glass. If the original or platencover is present over the scanning point, the beam is reflected and eachreflected beam exposes a photoelectric device and activates it.

While the main switch is on, these sensors are active and the original sizedata is always sent to the main CPU. However, the main CPU checks thedata only when the platen cover is opened.

[E]

[D]

[A]

[C]

[B]

STM 2-26 A109

Original Size Length Sensor 1 LengthSensor 2

Width Sensor

A4/A3version

LT/DLT version 1 2 3 4 5 6 7

A3 11 x 17 (11 x 15) 1 1 1 1 1 1 1

B4 10 x 14 0 1 1 1 1 1 1

— 81/2 x 14 0 1 1 1 1 1 0

F4 81/2 x 13 (8 x 13) 0 0 1 1 1 1 0

A4–L 81/2 x 11 (8 x 10) 0 0 0 1 1 1 0

B5–L — 0 0 0 1 1 0 0

A5–L 51/2 x 81/2 0 0 0 1 0 0 0

A4–S 11 x 81/2 0 0 0 1 1 1 1

B5–S — 0 0 0 0 1 1 1

A5–S 81/2 x 51/2 0 0 0 0 1 1 0

NOTE: –L: Lengthwise–S: Sideways

The check is done when the platen position sensor [A] turns on. This is whenthe platen is positioned about 15 cm above the exposure glass. At this time,only the sensors located underneath the original receive the reflected lightand are on. Other sensors are off. Through the on/off data of the sevensensors, the main CPU can recognize the original size.

This original size detection method eliminates the necessity for a pre-scanand increases the machine’s productivity.

[A]

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A109 2-27 STM

3.7 OTHERS

A pair of optics cooling fans [A] are located at the left side of the opticscavity. These fans blow air into the optics cavity to prevent the exposurelamp and optics cavity from overheating during copy cycles.

The optics exhaust fan [B] is located at the right side of the optics cavityunder the lens housing cover. This fan blows air out to keep the CCD boardand the scanner control board from overheating.It rotates at low speed (15Vdc) in standby condition and at high speed(24Vdc) during copy cycles.

An anticondensation heater is installed on the left side of the optical baseplate. It turns on when the main switch is off.

For field servicing, the scanner unit [C] can be opened. When the scannerunit is lifted, the actuator of the scanner unit lift sensor [D] moves the sensorout. Then, for safety, the CPU prohibits the scanner motor from rotating. Thestart key stays red under this condition.

[A]

[B]

[C]

[D]

[D]

STM 2-28 A109

3.8 SCANNER SECTION BLOCK DIAGRAM

CCDBoard

ScannerControlBoard

DC PowerSupplyBoard

IPUInterfaceBoard

ScannerDriveBoard

S32

M10

FM12

FM13

S31

S30

S29

S28

S27

FM10

LampRequlator

ACDriveBoard

ScannerMotor

Exposure Lamp

Scanner H.P. Sensor

Platen Cover Position Sensor

Original Length Sensor 1

Scanner Unit Lift Sensor

Optics Cooling Fan

Original Width Sensor

Original Length Sensor 2

OpticsExhaustFan

LampRegulator

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A109 2-29 STM

4. IMAGE PROCESSING4.1 OVERVIEW

The CCD board has three CCD lines with red, green, and blue filters; itgenerates an analog video signal for each color when the original isscanned. Three signals are sent to the scanner control board.

The processing by the scanner control board includes:

Signal amplification, A/D conversion and signal composition, auto shading, D/A conversion, scan line correction

The processed R/G/B digital video signals (8 bits for each color) are sent tothe IPU (Image Processing Unit) board through the IPU interface board.These signals can be considered as the raw data from the original imagedetected by the scanner section.

Then the IPU board applies correction for the next step. According to theoperation mode, the following image processing is applied:

Auto color selection, auto letter/photo separation, filtering and colorconversion, magnification adjustment, image creation, printer gammacorrection, dither processing

Finally, the video controller on the IPU board sends 8-bit video data to theLD drive board at the proper time for each scanning cycle (Bk, C, M, Y).

STM 2-30 A109

4.2 SCANNER SECTION BLOCK DIAGRAM

15 MHz

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A109 2-31 STM

4.3 CCD BOARD

The color CCD converts the light reflected from the original into R/G/Banalog signals (15 MHz). Each CCD line has 5,000 pixels and the resolutionis 400 dots per inch (15.7 lines/mm).

Each color CCD has two output lines, odd and even, to the scanner controlboard. Since the processing speed for one pixel is very fast, odd and evenpixels are read from the CCD separately so that the signals can be amplifiedin the scanner control board properly. Therefore, the processing speed ofeach CCD output line is 7.5 MHz.

4.4 SCANNER CONTROL BOARD

4.4.1 Signal Amplification

Odd and even R/G/B analog signals from the CCD board are amplifiedindependently by operational amplifiers. The gain ranges of the operationalamplifier are controlled by the scanner CPU by judging the feedback signalsfrom the shading circuits.

4.4.2 A/D Conversion and Signal Composition

A/D conversion:The amplified analog signals are converted to 8-bit digital signals (7.5 MHz)for each color (R/G/B). This will give 256 gradations for each pixel.

Signal composition:Then the digitized odd and even signals for each color are merged by aswitching device, producing an 8-bit digital signal at 15 MHz.

STM 2-32 A109

4.4.3 Auto Shading

Before scanning the original, the machine reads a reference wave form fromthe white reference plate [A] (below the left scale) 16 times. The average ofthe white video level for each pixel is stored as the white shading data in thememory of the shading circuit.

To improve image reproduction for high density areas, the machine alsoreads the black video level 16 times with the exposure lamp turned off. Thisis done before white shading. The average of the black video level for eachpixel is stored as the black shading data in the memory of the shadingcircuits.

The video signal information for each pixel obtained during image scanningis corrected by the shading circuit as follows:

Output = (Video data) − (Black shading data)

(White shading data) − (Black shading data) x 255

RAMn1, n2, n3, .........n16

[A]

Shading Data(n1 + n2 + n3.......n16)

16

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A109 2-33 STM

4.4.4 D/A Conversion

The scanner CPU monitors the feed back signals from the shading circuitsand calculates correction factors. The digital data in the CPU is converted toanalog data to feed them back to the signal amplification and A/D conversionsections.

• Black level data is fed back to the signal amplification section.• White level data (Vref) is fed back to the A/D conversion section.

4.4.5 Scan Line Correction

The three CCD lines providing the R/G/B signals (red, green and blue) arespaced 8 pixels apart. To compensate for this discrepancy, the linecorrection circuits synchronize the output timing of the R/G/B signals to theIPU board by storing the scan data for each line in memory.

As the discrepancy between R/G/B video signals changes depending on themagnification ratio, the correction data is calculated as follows:

B: Standard (No correction)G: (8 lines) x (Magnification ratio) R: (16 lines) x (Magnification ratio)

If this calculation does not result in an integer, the correction data is set tothe closest integer, but further correction is needed (see section 4.7.2 fordetails).

(Enlargement)

(Reduction)

(Full Size)

CCD Line Interval

STM 2-34 A109

4.5 IPU SECTION BLOCK DIAGRAM

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A109 2-35 STM

4.6 IPU INTERFACE BOARD

The IPU interface board changes the clock frequency of the R/G/B videosignals from 15 MHz to 14.318 MHz to protect the signals from noise.

It also sends the synchronizing signal for the polygon motor and othercomponents to the scanner control board.

4.7 IPU BOARD

4.7.1 Scanner Gamma Correction

The R/G/B video signals detected by the CCD are converted to 8-bit digitalsignals in the scanner control board and sent to the IPU board. Thesesignals are proportional to the light intensity reflected from the original image(Fig. 1).

However, the IPU board converts the signal levels as shown in figure 2 byusing a gamma correction table in order to improve the color conversionaccuracy. The same table is used for R, G, and B signals.

The scanner γ correction converts the video signal levels as follows:

[Black] [White]Scanner Input (R/G/B) 0 255

After γ correction (R/G/B)→[Color Conversion]→

255 0

Printer Output (C/M/Y) 255 0

255

255

0

0Black White

<R/G/B signal from scanner control board>Fig. 2

<R/G/B signal after scanner γ correction>

(Dark) (Light)

<R/G/B Video Signal>

<Reflected light from originals>Fig. 1

(Dark) (Light)

STM 2-36 A109

4.7.2 Picture Element Correction

The discrepancy of the R/G/B signals from the CCD in the subscan directionis corrected by the line correction circuit of the scanner control board (seesection 4.4.5 for details). However, if the correction data corresponding tothe magnification ratio is not an integer, then further correction is needed tosynchronize the R/G/B signals.

If the CCD board is not positioned perpendicularly to the light axis, theposition of each pixel is different from the original image position. Thisdifference becomes larger towards the ends. Under this condition, verticalblack lines (in the subscan direction) at the ends are colored because Y, M,C toner dots are not properly positioned. (Example: vertical lines at the rightand left edge of the C4 color chart)

Therefore, the CCD line spacing is also corrected here. The target areas forthis correction are shown above. The vertical line correction level can bechanged by the SP mode (page 1-20, No.130).

Picture Element Correction

(Enlargement)

(Reduction)

(Full Size)

CCD Line Interval

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A109 2-37 STM

4.7.3 Auto Color Selection (ACS)

In auto color selection mode, the black copy mode or full color mode isautomatically selected according to the original image. During the 1stscanning cycle, the original image is developed with black toner according tothe corrected R/G/B video signals. If the original does not have any coloredimage, the 2nd scanning is aborted and the developed image is transferredfrom the transfer belt to copy paper. Then the black and white copy comesout. If the original has a colored image, copying operation resumes in the fullcolor copy mode (4 scans).

To recognize if the original has a colored image or not, R/G/B video signalsare compared. If the maximum difference among R/G/B signal levels iswithin a certain range, it is considered a black and white original.

STM 2-38 A109

4.7.4 Auto Letter/Photo Separation

In auto letter/photo mode, the original image is separated into letter andphoto parts (dot screen areas).

Generally letter parts have strong contrast between the image and thebackground. Photo parts (dot screen areas) have a middle range of signallevels of contrast. By using these characteristics and the following separationmethods, the original image is separated into black letter parts, colored letterparts, and photo parts for the final evaluation.(1) Edge separation

The edge of letters are separated by using the following characteristics:Strong contrast, continuity of black or color pixels, continuity of whitepixels around the black or color pixels

(2) Dot screen separationDot screen areas are separated from non-dot screen areas (mainlyletters) by using the following characteristics:White pixels are not detected around the pixels in dot screen areas.

(3) Colored letter separationBlack pixels and color pixels in letter parts are separated by judging thedifference among R/G/B maximum signal levels and the output levels ofR/G/B video signals.

The letter parts are processed in letter mode and the photo parts areprocessed in photo mode in the subsequent image processing steps.

However, auto letter/photo separation is mostly effective only for smallletters. If there are big letters or solid patterns in the original, only the edgesof those images is processed in the letter mode. The inside of those imagesis processed in photo mode.

letter Parts Photo Parts

Green

White

• Black Letter• Colored Letter• Photo Parts

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A109 2-39 STM

4.7.5 Filter and Color Conversion

(1) Filter

According to the results of auto letter/photo separation, the appropriatesoftware filters (fixed) are applied to R/G/B video signals.

• High contrast (emphasizing edges) filter for letter parts

• Smoothing filter for photo parts

(2) Positive/Negative Reverse

In the positive/negative image mode, colors are changed to theircomplement, as shown below:

Red – Cyan Green – Magenta Blue – Yellow Yellow – Blue Magenta – Green Cyan – Red Black – White White – Black

STM 2-40 A109

(3) Color Conversion

Bk R Y G C B M W

Y 1 1 1 1 0 0 0 0

M 1 1 0 0 0 1 1 0

C 1 0 0 1 1 1 0 0

Bk 1 0 0 0 0 0 0 0

R/G/B video signals from each scanning cycle are processed by colorcorrection and color conversion.

a) Color correctionThe transparency of each color toner is not ideal, as shown above. Colorcorrection compensates for the difference between ideal and actualcharacteristics. According to the actual transparency of each color toner,a proper masking coefficient is applied to R/G/B video signals to convertthem into Y/M/C/Bk video signals.

b) Color conversionIn color conversion mode, a selected color (C/M/Y/R/G/B/Bk/W) of anoriginal is converted into a different color on the copy. Up to 4 colors canbe converted at one time. Colors that can be used after conversion areYellow, Orange, Red, Magenta, Blue, Cyan, Green, Light Green, White,Black, Scan Color, and 3 User colors. Only one scan color can beselected at one time.

Color conversion is processed by changing the coefficients of the abovecolor conversion table.

For example, when changing Yellow to Black, coefficients for the Yellowvideo signal become as follows:

Y:1, M:1, C:1, Bk:1

When changing Green to Light Green, coefficients for Green video signalshould be as follows:

Y:1, M:0, C:0.5, Bk:0

<Color Conversion Table>

Original ColorToner

B G RToner’sTransparency

IdealTransparency

<Transparency of M Toner>

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A109 2-41 STM

c) UCR (Under Color Removal)

If for each color (Y/M/C) the same quantity of toner is put on the paper,ideally the image should become black, but in reality it becomes dark blue.

To compensate for this, an equal portion of the ID value for each color issubtracted. This reduces the amount of color toner on the paper, and aproportional amount of black toner is added. This turns dark blue results intoblack.

When a black image is copied, the ID values for all colors are equal (figure1). For each color, the ID value is reduced by 70% (UCR: 70%) and a blackID value is added to compensate for the color ID reduction (figure 2).

When a color image is copied, the color ID values are different from oneanother (figure 3). But the ID values for this image can be decomposed intotwo parts (figure 4): A set of values equal to the lowest color ID value, andthe remainder of the two higher values.

The part with equal values can be treated as a black image (figure 1 and 2),then added to the remainder part (figure 5). The final result gives us the copyID value for each color and for black (figure 6).

The UCR standard ratio in the photo mode is 70% on this model. But thisratio can be increased (made stronger) or decreased (made weaker) over 9steps by using the user tools.

The UCR standard ratio in letter mode is always 100% except for the verylow image density areas of the black component. The user tool will onlyaffect the low image density areas.

IDvalue

Fig. 1 Fig. 2

30%

70%

Y M C

Y M C B

CYY M C

Y M C Y

B

C

Y

M

C

Y M C

B

Fig. 3 Fig. 4

Fig. 5

IDvalue

IDvalue

Fig. 6

STM 2-42 A109

d) UCA (Under Color Addition)

Using only UCR processing, the copy image lacks depth. So, a specifiedratio of toner is added for each color (Y/M/C). The amount of additional tonerfor a color is in proportion to that color’s density. The UCA ratio is fixed and itis always ON for all modes (4 scan modes).

Y M C BkY M C Bk

UCA

ON

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A109 2-43 STM

4.7.6 Main Scan Magnification

Reduction and enlargement in the sub scan direction is done by changingthe scanner speed. However, reduction and enlargement in the main scandirection is handled by IPU board 1.

Scanning and laser writing are done at a fixed pitch (the CCD elementscannot be squeezed or expanded). So, to reduce or enlarge an image,imaginary points are calculated that would correspond to a physicalenlargement or reduction of the image. The correct image density is thencalculated for each of the imaginary points based on the image data of thenearest four true points. The calculated image data then becomes the new(reduced or enlarged) image data.

NOTE: The actual calculations for main scan magnification are performedfollowing the polynomial convolution method. This mathematicalprocess is beyond the scope of a service manual and will not becovered here.

1 2 3 4 5 6 7 8 9 10

1" 2" 3" 4" 5" 6" 7" 8" 9" 10" 11" 12" 13" 14"

1 2 3 4 5 6 7 8 9 10

1" 2" 3" 4" 5" 6" 7" 8"

80 % Reduction

140 % Enlargement

Scanned DataPointsCalculated DataPointsEnlarged ImageData Points

Scanned DataPointsCalculated DataPointsReduced ImageData Points

STM 2-44 A109

4.7.7 Image Creation

(1) Mirror Image

The image is inverted relative to the subscan axis.The main scanning data is transferred to the laser unit from the end.

(2) Slanted Image

The image is slanted as shown above. The slant angle can be selected at ±45 degrees by 1 degree steps. If a greater slant angle is selected, portions ofthe image might not be printed.

–45° +45°

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A109 2-45 STM

(3) Image Repeat

Part of the original image is copied repeatedly in the main scan direction.

There are three methods to designate the repeated image.

a) Size inputThe original image designated with the length in the main scan direction is repeated as many times as will fit on the copy width. The length (size) can be entered with thenumber keys. It should be less than 300 mm.

b) Number of imagesThe image is repeated in the mainscan direction for the specified number of image repetition (2 to 9).The repeated image width is calculated from the number of repetition, paper width, and magnification.

c) Editor inputWhen the display editor is equipped, the specified image with rectangle is repeated in the main scan direction. The repetitions are made one below the other, and are all aligned with the lead edge.

Length

13

(Number of image = 3)

Points

STM 2-46 A109

(4) Paint area

When the display editor is installed, the specified area is painted with aselected color. Colors that can be used for paint area are Yellow, Orange,Red, Magenta, Blue, Cyan, Green, Light Green, Black, and the 3 UserColors.

(5) Color Background

This mode adds the selected color to the entire image background. The background can be any of 13 colors: Yellow, Orange, Red, Magenta,Blue, Cyan, Green, Light Green, Black, Scan Color, and the 3 User Colors.

This mode is suitable for letter, and line originals since the color tone ofphoto/picture originals is changed due to the color of the background. Thecolor background density can be adjusted lighter or darker over 5 levels byuser tools.

Painted Area

Color Background

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A109 2-47 STM

(6) Outline image

When the outline mode is selected, the image data is converted into binarydata and only the outline image is printed. The outline width can be selectedfrom 0.25, 0.5, and 0.75 mm (0.01", 0.02", and 0.03").

(7) Shadow image

There are two types of the shadow image: offset shadowing (A) and blockshadowing (B).

The shadow falls below and to the right of the image (at 45 degrees). Theshadow can be any of the 13 colors: Yellow, Orange, Red, Magenta, Blue,Cyan, Green, Light Green, Black, Scan Color, and 3 User Colors.

The width (T) of the shadow can be adjusted between 1 and 4 mm (0.04"and 0.16") in 1mm (0.04") steps.

When the shadow image and the outline image are selected together, theshadow should be the same color as the original. Otherwise, the image willbe printed in a single color (selected shadow color).

(A) (B)

TT

STM 2-48 A109

4.7.8 Filter

The filter in section 4.7.5 is the fixed one for the letter and photo parts of theoriginal image. Other filters (smoothing filter and high contrast filter) are usedhere again to improve the printed image.

The smoothing filter improves the image by smoothing the gradient of thehalf tone areas. The high contrast filter improves letters by contrasting theedge of the image.

By changing the effect of the smoothing or high contrast filter, the image canbe made sharper or softer. It can be adjusted over 5 levels from the imageadjustment screen.

A B

• Photo mode

• Photo parts of AutoLetter/Photo mode

Smoothing filter

VideoData A

VideoData B

A B

• Letter mode

• Letter parts of AutoLetter/Photo mode

High contrast

VideoData A

VideoData B

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A109 2-49 STM

4.7.9 Auto Image Density (ADS)

Auto image density mode can be selected in black or single color (1C or 2C)modes. This mode prevents the background of an original from appearing oncopies.

The video signals from the original background do not include highfrequency components and their levels are lower than those from the actualimage. From these characteristics, video signals corresponding to thebackground are judged in this block and their output levels become zero.This treatment is done for each main scan line through the whole sub scandirection.

The threshold level (actually it is a range) of video signals for judging thebackground can be changed over 4 levels by user tools.

Unlike analog copiers, manual image density can be adjusted together withauto image density mode. This is useful when making copies from anoriginal that has light image density with background.

STM 2-50 A109

4.7.10 Printer Gamma Correction

(1) YMCBk Gamma

Ideally, the gamma curves for Yellow, Magenta, Cyan, and Black should beidentical, as shown in figure 1, but they are not because electricalcomponents always vary slightly, resulting in varying gamma curves, asshown in figure 2. To compensate for this discrepancy, the gamma curve foreach color can be adjusted by a service program (Page 4-3 to 4-6).

The gamma curve can be adjusted through 4 different modes: ID max, HighID, Low ID, and Middle ID

a) ID max

This mode is used to adjust the total image density level as shown in thefigure 3.

This adjustment should be done when replacing the OPC drum, or thespecified ID (Level 10 of the color gradation scale on the C- 4 test chart)cannot be obtained even after performing the process control self check inthe SP mode (Page 2-6, No.210). If ID max is adjusted, the High, Low, andMiddle ID’s should also be adjusted.

Y

HLL

HMBk

C

Y, M, C, Bk

HLL

H

Copy IDCopy ID

Original ID Original ID

Fig. 1 Fig. 2

HLL

H 0

8

0

8

Copy ID

Original ID

ID MAX

Darker

Lighter

If the value is incremented by 1,the ID is increased 5%.

Fig. 3

10

0

0

10

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A109 2-51 STM

b) High ID

The High ID mode should be used to adjust the image density betweenLevel 6 and Level 9 of the color gradation scale on the C-4 test chart (figure4).

c) Low ID

The Low ID mode should be used to adjust the image density between Level2 and Level 5 of the color gradation scale on the C-4 test chart (figure 5).

HLL

H0

8

0

8

20 Darker

0 Lighter

Copy ID

Original ID

High ID

Fig. 4

20

0

HLL

H

0

8

0

8

Copy ID

Original ID

Low ID

Fig. 5

20 Darker

0 Lighter

20

0

STM 2-52 A109

d) Middle ID

The Middle ID mode should be used to adjust the image density betweenLevel 3 and Level 7 of the color gradation scale on the C-4 test chart (figure 6).

(2) Image Density

Image density can be adjusted by the Manual Image Density setting in thetouch panel display. There are 9 levels of image density.

HLL

H

0

8

8

030 Darker

0 Lighter

Copy ID

Original ID

Middle ID30

0

HLL

H 1

5

9

Copy ID

Original ID

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A109 2-53 STM

(3) Contrast

Contrast between light parts and dark parts of the image can be adjustedover 9 levels by the Contrast setting of Image Adjustment in the touch paneldisplay. The slope of the line in the graph changes, but stays centeredaround point "A".

(4) Color Balance

Image density control changes every color density setting at the same time.But each color density setting can be changed independently by the ColorBalance Adjustment of Image Adjustment in the touch panel display.

(5) Pastel

This function can be used to decrease the copy density more than by usingthe image density control. The copies are made in pastel tones.

HLL

H

Copy ID

Original ID

A

Strong

Weak

Strong

Weak

HLL

H

9 steps

Copy ID

Original ID

STM 2-54 A109

4.7.11 Gradation Treatment

On this model, the following gradation treatment is applied to improve theimage quality:

Letter mode and letter parts in Auto L/P: 1 x 1 dot Photo mode and photo parts in Auto L/P: 2 x 1 dot (Main x Sub)

1 x 1 dot processing for the letter mode attaches importance to theresolution, while 2 x 1 dot dither processing for the photo mode attachesimportance to the gradation.

Each dot (pixel) has a video signal level between 0 and 255. In 2 x 1 ditherprocessing, the levels of 2 dots are summed up and the total level is written(exposed by the laser beam) at the first dot. If the total level exceeds 255,the remainder is written at the second dot. Therefore, if you look at the photoparts of the copy with a scope, you can recognize the alternating lines in themain scan direction.

1 x 1 dot processing corresponds to "Full Dot Pattern" and 2 x 1 dot ditherprocessing corresponds to "1 Dot Sub Scan Lines" of the test patterns (SPmode, Page 2-3, No.205).

<Letter Mode> <Photo Mode>

120 115 110 118 125 130

125 118 113 120 130 135

128 120 117 123 132 139

120 115 110 118 125 130

125 118 113 120 130 135

128 120 117 123 132 139

235

243

248

0

0

0

228

233

240

0

0

0

255

255

255

0

10

16

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A109 2-55 STM

4.7.12 Video Controller

The video controller has the following functions:

(1) It produces the final video signal data to be sent to the LD unit.

(2) It controls the writing timing from the IPU board, corresponding to thesynchronizing signal from the synchronizing detector board.

(3) It decides the start timing of main scan writing. This corresponds toside-to-side registration.

(4) It changes the clock frequency of the Y/M/C/Bk video signals from 14.318MHz to 18.6 MHz for LD writing.

(5) It sends a start signal for the transfer belt in order to align the LD writingposition with the image position on the transfer belt.

(6) It sums up the LD output levels to calculate the image area integrationdata. (This calculation is done by sampling one dot out of every threedots.) The data is sent to the main control board to be used for tonersupply control.

(7) It outputs the video data when printing the test patterns and the grayscales.

STM 2-56 A109

4.7.13 Area Data Processing

When using the display editor, the scanned image is stored in the Area block(see section 4.5). The Area block memory size is 2 M-bit and it can hold anentire 11" x 17" (DLT) image. One unit of Area block memory corresponds toa 4 x 4 dot section of the original image.

For this reason, the screen pointer of the display editor covers a 4 x 4 dotarea of the original, so users must allow for a tolerance of about 0.25 mm(0.01") between the editor and actual images.

Also, logging data text is processed in the Area block so that the resolutionfor data text is much lower (100DPI). The Area block has fonts to speed upthe output.

DLT

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A109 2-57 STM

5. LASER EXPOSURE5.1 OVERVIEW

This machine uses a laser diode to produce electrostatic images on an OPC(organic photoconductor) drum [L]. The laser diode unit [A] converts imagedata from the IPU board into laser pulses, and the optical components directthese pulses to the OPC drum.

To produce a high quality copy image, there are 256 gradations for the laserpulses, controlled through power modulation and pulse width modulation.

Exposure of the drum by the laser beam creates the latent image. The laserbeam makes the main scan while drum rotation controls the sub scan.

[E] [F]

[D]

[H] [I]

[A][B]

[C]

[G]

[E] [C][D]

[G]

[L]

[J]

[K]

A: Laser Diode UnitB: Cylindrical LensC: Polygon MirrorD: Polygon Motor Cooling FanE: fθ LensesF: Polygon Motor Drive Board

G: Drum MirrorH: Synchronizing MirrorI: Laser Synchronizing Detector BoardJ: Polygon MotorK: Toner Shield GlassL: OPC Drum

STM 2-58 A109

5.2 OPTICAL PATH

The output path from the laser diode to the OPC drum is shown above.

The LD unit [A] outputs the laser beam to the polygon mirror [B] through thecylindrical lens [C].

The polygon mirror reflects a full main scan line with a single surface of themirror. The laser beam goes through the 1st fΘ lens [D] and 2nd fΘ lens [E].The drum mirror [F] reflects the laser beam to the drum [G] through the tonershield glass [H].

To determine the main scan starting position, the laser beam is reflectedfrom the synchronizing mirror [I] to the laser synchronizing detector board [J].

[A][C]

[B]

[D]

[E]

[F]

[H]

[J]

[I]

[G]

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A109 2-59 STM

5.2.1 Laser Diode Unit

The laser diode unit consists of the laser diode [A], collimating lens [B],aperture [C], and LD drive board [D].

The LD drive board excites the laser diode, causing it to radiate coherentlight at 780 nm with about 10 mW power.

The collimating lens forms the radiating beams into a parallel beam.

After the collimating lens, the aperture alters the beam, giving it a smallercross-section, as shown above.

[A]

[B]

[C]

[D]

Laser beam(to cylindrical lens)

Laser beam crosssection aftercollimating lens

Laser beam crosssection afteraperture

STM 2-60 A109

5.2.2 Cylindrical Lens

The laser beam is focused by the cylindrical lens [A], and sent to the polygonmirror.

5.2.3 Polygon Mirror

The polygon mirror assembly consists of the polygon motor [B] and thepolygon mirror itself [C].

As the mirror rotates, it reflects the laser beam across the OPC drum, via thefΘ lens and the drum mirror. One main scan line is made by the beamreflected from one face of the polygon mirror.

The mirror is precisely ground to enable high reflectivity and to prevent pixel(picture element) misalignment on the drum in both the main scan and subscan directions.

The polygon mirror motor rotates at 21,260 rpm. One rotation corresponds toeight main scans.

[A]

[C]

[B]

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A109 2-61 STM

5.2.4 F-Theta Lenses

The angles between pixels are equal. However, if the beam were to godirectly to the drum as shown in the upper illustration, the spacing betweenpixels would differ according to the angle of the beam. The pixels near theend of the drum would be further apart than those near the middle of thedrum. The pixels would also be slightly thicker toward the ends of the drumthan in the middle.

The fΘ lenses [A] correct for this by deflecting the beam slightly inward toinsure uniform picture element spacing and diameter. The fΘ lenses alsocorrect for irregularities in the polygon mirror face, focusing irregular beamsonto the correct part of the drum.

Wide spaced

Narrow spaced

[A]

Evenly spacedpixels

STM 2-62 A109

5.2.5 Drum Mirror

The drum mirror [A] reflects the corrected laser beam to the drum [B].

5.2.6 Laser Synchronizing Mirror and Detector Board

At the start of each scan line, the synchronizing mirror [C] reflects the laserbeam to the laser synchronizing detector board [D] as shown above.Activation of this detector signals the start of main scan writing by the laserbeam.

[A]

[B]

[D]

[C]

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A109 2-63 STM

5.3 LASER EXPOSURE CONTROL

The IPU-CPU in the IPU board communicates with the main control boardthrough serial data transmission.

The image data scanned from an original via the CCD board is processed inthe scanner control board. Then the processed image data is sent to thegate array in the IPU board. The gate array sends the 8 bit video data to thevideo controller. The video controller holds it in one of two line buffers (linebuffer 1 or line buffer 2). The two line buffers are used alternately and holdone scan line of video data each.

When it is time for the data to be written to the drum, the gate array sendsthe 8 bit video data from the line buffer to the LD drive board.

The IPU-CPU controls the writing timing of the laser beam to the drum forboth the main and sub scans.

MainControlBoard

ScannerControlBoard

I P U

C P U

GateArray

VideoController

LineBuffer

1

LineBuffer

2

LD Drive

IPU Board

Board

STM 2-64 A109

5.4 GRADATION CONTROL

To make the latent image, the laser beam exposes the image area of thedrum surface. When the laser beam exposes the drum, the longer it is onand the stronger its intensity is, the darker the developed image becomes.

For one dot, the laser on time is controlled by pulse width modulation(PWM). The laser on/off timing is controlled by a pulse signal. Modulating(changing) the width of the pulse makes the on time of the laser longer orshorter. There are eight levels, meaning eight different laser on times foreach dot.

While the laser is on to make one dot, the intensity of the laser is controlledby power modulation (PM). The laser’s intensity is controlled by the amountof current sent to the laser diode. Modulating the power makes the laserbrighter or dimmer. There are 32 power levels, or laser intensity levels, foreach PWM level.

The power is modulated ONLY at the end of the on/off cycle. If the PWMlevel is 2, the laser is on for 2/8 of a cycle. It will be at full power for 1/8 of acycle and then the power will modulated to the required level for 1/8. If thePWM level is 5, the laser is at full power for 4/8 of a cycle, and then it will bemodulated for 1/8. If the PWM level is 1, the laser is not at full power, and ismodulated for 1/8 of a cycle. (See graph.)

Black(Y,M,C)

White0 255 Data

32

2416

8

PWM(8 levels)

Data: 0

1 dot

Data: 16 Data: 32 Data: 48 Data: 255Data: 64 Data: 136

1 8 1 1 2 2 5 8

PM(32 levels)

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A109 2-65 STM

By using the 8 PWM levels through the PWM IC and the 32 PM levelsthrough the current drive IC on the LD drive board, the latent image canhave 256 (= 8 x 32 = 28) gradations. These 256 gradations can be describedby the 8 bit video data, data 0 to data 255 as shown above.

Since each color (Y, M, C) can have 256 gradations, the theoretical colorgradations reproduced by this copier is as follows:

Y M C

256 x 256 x 256 = 16,777,216

28 x 28 x 28 = 224

STM 2-66 A109

5.5 AUTO POWER CONTROL (APC)

Even if a constant electric current is applied to the laser diode, the intensityof the output light changes with the temperature. The intensity of the outputdecreases as the temperature increases.

In order to keep the output level constant, the output light intensity ismonitored through a photo diode enclosed in the laser diode. The photodiode passes an electrical current proportionally according to the lightintensity and regardless of the temperature change.

Whenever the main switch is turned on, the current drive IC in the LD driveboard excites the laser diode at full power (32nd PM level) and stores thecurrent data of the photo diode as a reference. The current drive IC monitorsthe current passing the photo diode. Then it increases or decreases thecurrent to the laser diode as necessary, comparing with the referencecurrent data. Such auto power control is done in real time while exciting thelaser diode.

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A109 2-67 STM

5.6 LASER SYNCHRONIZING DETECTOR

The start of each scan line is controlled as follows:

The synchronizing mirror [A] reflects the laser beam to the synchronizingdetector board [B]. The detector board has an IC with a photo diode. Whenthe laser beam reaches the photo diode, a synchronizing signal is sent to thevideo controller on the IPU board. Then the video controller signals the startof main scan writing by the laser beam.

At the same time the video controller also outputs a PMSYNC signal which isused to control the operation of the IPU board and scanner control board.

[A]

[B]

I P UC P U

MainControlBoard

I P U Board

PMSYNC ScannerControlBoard

LD DriveBoard

Signal

VideoController

+5V

Detected

STM 2-68 A109

5.7 LD SWITCH

To ensure that the laser beam does not inadvertently expose the drum atservicing, there are two LD switches located at the front door. These twoswitches [A] are installed in series on the LD 12 V line coming from the dcpower supply unit through interface boards 1 and 2.

When a front door is opened, the switches cut the power to CN301-3 (LD 12V) of the IPU board. Then, the DC 12 volts (LD 12 V) for LD power [B]cannot be supplied to the LD drive board.

[A]

[B]

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A109 2-69 STM

6. DEVELOPMENT6.1 OVERVIEW

There are four sections in the development unit. From the left they are theblack development section [A], the cyan development section [B], themagenta development section [C] and the yellow development section [D].Each development section has a sleeve roller [E], dual mixing roller [F],doctor plate [G] and toner density sensor [H].

The development unit is separated in two parts. The black and cyandevelopment unit make up one part, the magenta and yellow developmentunit make up the other part.

The color development drive motor drives the dual mixing rollers in the cyan,magenta, and yellow development sections. The black development drivemotor drives those in the black development unit.

The sleeve rollers in each section are driven by independent sleeve motors.When the sleeve turns clockwise, developer is carried to the OPC drum [I].When the sleeve turns counterclockwise, all the developer left on the sleeveroller surface is returned to the development section.

The developer is trimmed to the desired thickness by the doctor blade, and itis then carried to the OPC drum where the latent image is developed.

Each development section can hold 400g of developer. Developer issupplied and removed by using SP modes.

Black is developed first, then in order, cyan, magenta, and yellow.

Rev. 7/94

[A]

[B]

[C]

[D]

[E]

[F]

[G]

[H]

[I]

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STM 2-70 A109

6.2 DRIVE MECHANISM

1) Developer mixing

When the color development drive motor [A] turns, C, M, Y developmentdrive gears are driven via a timing belt [B].

The black development drive gear is driven by the black development drivemotor [C] independently.

The life of the developer has a direct proportional relationship with its mixingtime. The black and color mixing drive sources are separated to allow thecolor developer mixture rest during the black copying process.This lengthens the life of the developer.

2) Dual mixing

As the dual mixing roller turns, the outer paddle [D] carries developer to thefront and the inner auger [E] carries developer to the rear.

[A][B]

[C]

[D]

[E]

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A109 2-71 STM

6.3 DEVELOPER SUPPLY AND RELEASE

The development sleeve rollers are driven separately by sleeve motors, notby the development drive motors.

[A]: Black sleeve [E]: Black sleeve motor

[B]: Cyan sleeve [F]: Cyan sleeve motor

[C]: Magenta sleeve [G]: Magenta sleeve motor

[D]: Yellow sleeve [H]: Yellow sleeve motor

When the sleeve motors turn in the direction of the black arrows, developeris carried up to the OPC drum. When the motors turn in the direction of thewhite arrows, developer is returned to the development unit. Only one colordevelopment section at a time can send developer to its development sleeveroller. The developer inside the other color sections is not carried up to thesleeve rollers. Since the black developer brush angle is more horizontal thanthat of the other brushes, it is rather difficult to carry the black developerback to the development section. To ensure that the black developer returns, the reverse rotation speed of theblack sleeve roller is 1/4 of the reverse rotation speed of the color sleeverollers.

The rotation speeds of sleeve rollers are as follows:

While developing the image (all colors) : 172 rpm

While returning black developer: 43 rpm

While returning color developer: 172 rpm

[A]

[B]

[C]

[D][E]

[F]

[G]

[H]

STM 2-72 A109

6.4 DEVELOPMENT BIAS

The high voltage supply board-B [A] applies the development bias to eachsleeve roller [B] through the receptacles [C] and the development rollershafts. The development bias prevents toner from being attracted tonon-image areas on the OPC drum where there is a residual voltage.

Bias voltage is decided during the process control self check. For additional information regarding development bias control, refer to theprocess control section.

[B]

[C]

[A]

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A109 2-73 STM

7. TONER TANK7.1 OVERVIEW

Each color (Bk, C, M and Y) has its own toner tank. The capacity of eachtank is at most 1500 cc (Bk), 1350 cc (C), 1400 cc (M, Y). This is about 1.5times the toner in quantity in new bottles. When the machine CPU sends thetoner supply motor [A] on signal based on the toner density sensor output (ineach color development section), the toner supply motor of each color tonertank turns on. The toner end condition is also decided based on the tonerdensity sensor output. (For details of toner supply control, refer to theprocess control section) The toner is agitated by the agitators [B] thentransported to the development unit via the transport coils [C].

Bk C M Y

[B]

[C]

[A]

[A]

[B] [C] [C]

[B]

STM 2-74 A109

7.2 TONER TRANSPORTATION AND AGITATION

The toner supply motors [A] turn on when the main switch is turned on or themachine CPU sends the toner supply signal.

There is an agitator [B] in each C,M and Y toner tank and there are twoagitators [C] in the black toner tank because the black toner supply tank iswider than the other color toner tanks.

When the toner supply motors turns on, the agitators start rotating. Therotation of the toner supply motor is also transmitted to the transport coil gearthrough the agitator gears. The toner is transported to the development unit[D] by the transport coil [E].

In order to prevent the toner agitators from being deformed, the toner supplymotor rotates in both directions when the main switch is turned on. Duringthis operation, the toner is not supplied. During the copy cycle, the tonersupply motor only rotates forward (black arrow).

The projection [F] on the agitator hits the agitation spring [G] and vibrates it.This vibration supports the toner agitation.

Also, this vibration is transmitted to the contacting vibration plate [H]. Thevibration plate prevents the toner from clogging in the upper part of the tonerhopper.

[F]

[G]

[H]

[C]

[A]

[E]

[B]

[D]

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A109 2-75 STM

7.3 TONER BOTTLE

At the top of the toner tank, there is a toner bottle guide which has apositioning pin [A], a notch cut-in [B], and an entrance seal [C].

A position for both the positioning pin and the notch cut-in matches eachcolor to prevent a color bottle from being installed on the wrong tank. Whenthe correct color toner bottle is set to the toner bottle guide, with the tab [D]aligned with the notch, the positioning pin fits into the notch cut-in of thetoner bottle. By rotating the bottle 90° clockwise, the inner shutter [E] of thetoner bottle is opened as the positioning pin holds the outer shutter [F]. Thenthe toner inside the bottle is supplied to the tank.

The entrance seal prevents toner from scattering when the toner bottle isbeing removed. This is necessary because the toner is very fine.

CAUTION: Even though the toner tank capacity exceeds theamount in one bottle, never add more than one bottle,and always wait until the Add toner indicator lights.

[A]

[A][B]

[C]

[D]

[F][E]

[B]

STM 2-76 A109

8. TRANSFER BELT UNIT8.1 OVERVIEW

Each single color image developed on the OPC drum [A] is transferredseparately on the transfer belt [B]. After each single color image has beentransferred to the transfer belt, the full color image is then transferred to thecopy paper by the transfer roller. (Refer to the transfer roller section.)

A single color image (Bk, C, M, Y) is transferred in one transfer cycle, so atmost four transfer cycles are performed during the full color copy process.They are performed in order: Bk, C, M, Y.

The belt bias roller [C] applies positive bias voltage to the transfer belt andattracts the negatively charged toner from the OPC drum onto the transferbelt.

After the copy image is transferred to the copy paper, the remaining toner onthe transfer belt is cleaned by the transfer belt cleaning blade [D].

The lubricant brush [E] applies a small amount of lubricant on the surface ofthe transfer belt to help the cleaning blade remove toner from the transferbelt.

[A]

[B]

[C]

[D]

[E]

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A109 2-77 STM

8.2 TRANSFER BELT DRIVE MECHANISM

The transfer belt [A] is driven by the transfer belt motor (stepping motor) [B]via a timing belt, coupling gears [C], and drive roller [D]. It rotates bothforward (black arrow) and in reverse (white arrow). There are three drivespeeds. Normally the transfer belt drive speed is 180 mm/sec. When thetransfer belt is driven in reverse for the switch back operation (refer to thenext page), the belt drive speed is 1135 mm/sec.

During the image transfer from the transfer belt to the paper, in OHP/thickpaper mode, the belt drive speed is 90mm/sec.

[C]

[D]

[A]

[B]

STM 2-78 A109

8.3 TRANSFER BELT DRIVE CONTROL

8.3.1 Switch Back Operation

To achieve accurate four single color (Bk, C,M,Y) image registration, afterone color image transfer is completed, the transfer belt [A] is separated fromthe OPC drum [B] and the transfer belt rotates in reverse exactly the sameamount as the transfer belt rotated for the single color image transfer justcompleted. ([C] corresponds to the leading edge of the transferred image)

The returned transfer belt waits there until the leading edge of the next colorimage on the OPC drum arrive. Then the transfer belt contacts the OPCdrum and starts to rotate forward for the next color image transfer.

There are only two transfer belt rotation amounts.

If the image size is letter (sideways) or shorter, the transfer belt rotates thesame amount as it would rotate for letter. If the image size is longer thanletter, the transfer belt rotates the same amount as it would rotate for doubleletter.

This switch back operation is done for all copy modes except 1C (singlecolor) mode.

[A]

[B]

[C]

[C]

[C]

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A109 2-79 STM

If the image is letter (sideways) or shorter, the leading edge of the image [A]on the transfer belt just after completing the entire transfer process (Bk, C,M, Y) is prior to the transfer roller [B]. In this case, the transfer belt rotatesforward to bring the leading edge of the image above the transfer roller[Fig.1]. If the image is longer than letter (sideways), the leading edge of the imageon the transfer belt just after completing the transfer process will havealready passed the transfer roller. In this case, the transfer belt rotates inreverse to bring the leading edge of the image above the transfer roller.Then, forward rotation starts to transfer the image onto the paper [C]. [Fig.2]

[A]

[A]

[B]

[Fig. 1]: If the image is letter (sideways) or shorter

[Fig. 2]: If the image is longer than letter (sideways)

[A][C]

[A] [A]

[A]

STM 2-80 A109

8.3.2 Idling Rotation

When 1C copies are continuously made, the transfer belt [A] tends to shift tothe front or rear because there is no reverse rotation during a continuous 1Ccopy job.

The belt stopper [B] prevents the transfer belt from being shifted too much.When the belt shifts, the belt stopper touches the edge of the transfer beltdrive roller [C] so that it does not shift anymore.

If a full color copy is made under this condition, the transfer belt positionreturns to the center position during the reverse rotation between the transferprocesses. This would result in a side-to-side mis-alignment of the colorimages.

To prevent this in 2C, 3C, 4C modes, before starting the copy process, thetransfer belt rotates three times in reverse to position the transfer belt to thecenter position.

[A][B]

[C]

[B]

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A109 2-81 STM

8.4 TRANSFER BELT RELEASE MECHANISM

The transfer belt is released from the OPC drum surface when the transferbelt is rotating in reverse. This release and touch operation is controlled bythe transfer belt position clutch [A].

When the transfer belt position clutch turns on, the drive from the cleaningmotor [B] via the timing belt is transmitted to the cam shaft and the releasecam [C] rotates 180 degrees. In this case, the rollers [D] are moved 3mmaway from the OPC drum. The transfer belt tension roller [E] is movedoutside to keep applying the constant belt tension.

When the transfer belt position clutch turns on again, the release camrotates another 180 degrees. In this case the bias roller is pressed againstthe OPC drum (the nip band is approximately 10mm) and the transfer belttension roller is also pushed inside.

The transfer belt position sensor [F] is actuated when the transfer belt movesaway from the drum.

[A]

[B][C]

[D] [E]

[F]

[C]

[D]

[E]

STM 2-82 A109

8.5 TRANSFER BELT BIAS

The high voltage supply board - T1/PCC/BR [A] - applies a positive biasvoltage to the transfer belt through the belt bias roller [B]. This bias voltageattracts negatively charged toner from the OPC drum onto the transfer belt.

During the second and subsequent image transfer cycles, a positive voltagehigher than that used in the previous cycle must be applied to the transferbelt to attract the next color toner from the drum to the transfer belt.

The transfer voltage of each mode is as follows (next page):

[A]

[B]

[B]

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A109 2-83 STM

<1C (C, M, Y single color) mode>

A humidity sensor is used to compensate the transfer belt bias voltage, (asmentioned in the table below) to maintain constant image quality againstchanges in the humidity of the surrounding area.The transfer voltage compensation also depends on paper mode.

Humidity

Papermode

Low Middle High

Less than 4.3 g/m3

4.3 ∼ 11.3g/m3 More than11.3 g/m3

Biasvoltage

Normal 2000 V 1600 V 1200 V

Thick 2000 V 2000 V 1200 V

OHP 2000 V 1200 V 1200 V

• When the humidity is low, the transfer bias is high.

This compensation is necessary because toner will not have sufficientcharge to transfer to the copy paper after only one cycle.

<2C ∼ 4C modes>

During several transfer cycles, the transfer belt continues to be charged bythe bias roller [A] and discharged by rollers [B]. This charges the tonerproperly and it does not require compensation as for 1C mode.The bias voltage for each color cycle is as follows regardless of the totalcycle number.

Copy cycle 1st 2nd 3rd 4th

Bias voltage 1200 1300 1400 1500

[B]

[A]

[B]

STM 2-84 A109

8.6 TRANSFER BELT CLEANING

After the image on the transfer belt is transferred to the paper, the remainingtoner on the transfer belt is removed by the cleaning blade [A]. The counterblade system is used, like the OPC cleaning section.

The entrance seal [B] prevents the removed toner from falling on the transferroller unit.

The cleaning blade and the entrance seal are away from the transfer beltduring the transfer process. The cleaning blade solenoid [C] and entranceseal solenoid [D] control the touch and release actions as shown. For thesetwo solenoids, the position of the plunger depends on the direction of thecurrent flowing through. When de-energized, the plunger stays where it isand does not return to the previous position. When the plunger of eachsolenoid is out, the cleaning blade and entrance seal contact the transfer belt.

The cleaning support roller [E] presses the transfer belt from the insideagainst the cleaning blade to ensure the transfer belt is cleaned properly.

The removed toner is transported from the cleaning unit to the tonercollection duct [F] by the toner collection coil in the unit. This coil is driven bythe transport motor via a timing belt.

Then the collected toner is transported to the toner collection bottle [G]through the lower toner collection coil [H]. This coil is driven by the drive fromthe relay roller [I].

[A]

[B]

[C]

[D]

[A]

[B][C]

[D]

[E] [F][G][H]

[I]

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A109 2-85 STM

8.6.1 Cleaning Mode

The machine performs extra transfer belt cleaning (Cleaning mode) underthe following conditions:

• After the last copy job is completed and more than 50 copies have beenmade since the last cleaning mode.

• In ADF mode, at every 150 copies, even if it is during a continuous copyjob. The machine temporarily stops the copy job (about 10 sec) until thecleaning mode is completed. Then it resumes the rest of the copy jobautomatically.

8.7 LUBRICATION MECHANISM

A small amount of lubricant is regularly applied on the surface of the transferbelt [A] to help the cleaning blade easily remove toner from the transfer belt.

The lubricant brush [B] distributes lubricant from the lubricant bar [C] to thetransfer belt.

The lubricant brush clutch [D] transmits the drive from the cleaning motor [E]to the lubricant brush.

Basically, the lubricant brush is away from the transfer belt and contacts thebelt under the control of the lubricant brush solenoid [F]. The position of thesolenoid’s plunger depends on the direction of the current flowing through.When de-energized, the plunger stays in the same position.When the plunger is in, the lubricant brush touches the belt.

[A]

[B]

[E]

[F]

[D]

[B]

[C]

STM 2-86 A109

9. TRANSFER ROLLER UNIT9.1 OVERVIEW

After the entire color (Bk, C,M,Y) image transfer is completed, the composedimage on the transfer belt [A] is transferred to the copy paper. The transferroller [B] applies a positive bias voltage to the back side of the copy paper toattract the negatively charged toner from the transfer belt.

The discharge plate [C] discharges the remaining electricity on the paper toseparate the paper from the transfer belt.

The transfer roller cleaning blade [D] scrapes off the toner left on the transferroller to prevent the rear side of the paper from being stained by the toner.

A humidity sensor [E] is used to compensate the transfer roller bias andtransfer belt bias to maintain a constant image quality against changes in thehumidity of surrounding areas.

[A]

[B]

[C]

[D]

[E]

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A109 2-87 STM

9.2 ROLLER TOUCH AND RELEASE MECHANISM

After the entire color (Bk, C,M,Y) image transfer is completed and the copypaper arrives at the registration rollers, the transfer roller position clutch [A]turns on to rotate the positioning cam [B] 180 degrees. The positioning camraises the whole transfer roller unit [C] to contact the transfer roller [D] withthe transfer belt [E]. In this case, the nip band width between the transfer beltand the transfer roller is approximately 1.2 mm (0.05").

When the transfer roller position clutch turns on again, the positioning camrotates another 180 degrees. In this case, the transfer roller unit moves awayfrom the transfer belt.

This release and contact operation is monitored by the transfer roller positionsensor [F].

[A]

[B]

[C][D]

[E]

[F]

[D]

STM 2-88 A109

9.3 TRANSFER ROLLER DRIVE

When the transfer roller unit is raised, the gear [A] engages the gear [B] andthe drive from the transport motor [C] is transmitted to the transfer roller [D].

[A]

[B]

[C]

[D]

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A109 2-89 STM

9.4 TRANSFER ROLLER BIAS

The high voltage supply board - T2 [A] applies positive bias voltage to thetransfer roller [B]. The transfer roller applies positive bias voltage to the backside of the copy paper [C] to attract the negatively charged toner from thetransfer belt.

In multiple color copy mode, during the second and subsequent imagetransfer cycles on the transfer belt, a positive voltage higher than that usedin the previous cycle is applied to the transfer belt. According to the chargeamount of toner particles on the transfer belt the transfer roller bias voltagediffers for different copy modes.

[B]

[C]

[A]

[B]

[D]

STM 2-90 A109

A humidity sensor [D] (see the illustration on the previous page) is used tocompensate the transfer roller bias voltage to maintain constant imagequality against changs in the humidity of surrounding areas.

HumidityPapermode

Cycle Low(4.3 g/m3 >)

Middle(4.3 ∼ 11.3

g/m3)

High(11.3 g/m3 <)

Biasvoltage

Normal 1C 1100 V 1000 V 800 V2C 1800 V 1600 V 1400 V3C 2100 V 1800 V 1450 V4C 1700 V 1300 V 1200 V

Thick 1C 1100 V 1000 V 800 V2C 2000 V 1600 V 1400 V3C 2000 V 1750 V 1200 V4C 1450 V 1300 V 1100 V

OHP(Length

-wise)

1C 1800 V 1400 V 1100 V2C 2050 V 2200 V 2200 V3C 2650 V 2650 V 2650 V4C 2000 V 2150 V 2150 V

OHP(Side-ways)

1C 1600 V 1500 V 1350 V2C 1950 V 2050 V 2100 V3C 2650 V 2650 V 2650 V4C 1800 V 2050 V 2100 V

• When humidity is low, paper resistance is high.Therefore, the bias voltage is high because the potential of the paperside facing the transfer belt is reduced due to the high resistance ofpaper.

• The transfer bias increases with each cycle. This is simply because thetoner quantity on the transfer belt increases.However in 4C mode, black toner is used instead of Y M C tonercombination (UCR), so that the toner quantity on the transfer belt is lowerthan in 3C mode. Therefore, the bias voltage in 4C mode is lower than in3C mode.

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A109 2-91 STM

9.5 PAPER DISCHARGE

The high voltage supply board - D [A] applies ac 4kV to the discharge plate[B].

The discharge plate discharges the remaining electricity on the paper [C] toseparate the paper from the transfer belt.

The high voltage supply board - D does not apply ac 4kV to the dischargeplate in OHP mode because the OHP is separated from the transfer belt byits stiffness.

[A]

[B]

[B]

[C]

STM 2-92 A109

9.6 TRANSFER ROLLER CLEANING

The transfer roller cleaning blade [A] scrapes off the toner adhering on thetransfer roller [B] to prevent the back side of the paper from being stained bytoner.

The transfer roller cleaning blade continuously cleans the transfer roller. Thetransfer roller surface is covered with a teflon tube to improve its cleaningability.

The removed toner is collected in the toner catch pan [C] in the transfer rollerunit.

[A]

[B]

[C]

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A109 2-93 STM

10. PAPER TRANSPORT AND IMAGEFUSING

10.1 OVERVIEW

After the image is transferred to the paper, the copy paper is transported bythe transport belts [A]. Two vacuum fans [B] hold the paper firmly against thetransport belts so that there is enough friction between the paper and thetransport belts for smooth transportation of the paper. Then the paper entersthe fusing unit and the image is fused to the copy paper by a heat andpressure process through the use of a hot roller [C] and pressure roller [D].

The fusing lamps located inside the hot roller (650W) and the pressure roller(400W) are turned on and off to maintain the operating temperature. TheCPU monitors the hot roller and pressure roller surface temperature throughthermistors which are in contact with the hot roller’s surface and the pressureroller’s surface. Two thermofuses that open at 150 degrees protect thefusing unit from overheating.

An oil supply pad [E] applies silicone oil to the hot roller. The hot rollerstrippers [F] separate the copy paper from the hot roller and direct it to theexit rollers [G].

[A][B]

[C]

[D]

[E]

[F]

[G]

STM 2-94 A109

10.2 FUSING ENTRANCE GUIDE

The entrance guide [A] for this machine is adjustable for thick or thin paper.

With thin paper, set the entrance guide in the upper position. This slightlylengthens the paper path which prevents the paper from creasing in thefusing unit. With thick paper, set the entrance guide in the lower position.

This is because thick paper does not bend as easily, and is therefore lessprone to creasing. Also, the lower setting allows more direct access to thegap between the hot and pressure rollers. This prevents thick paper frombuckling against the hot roller, which can cause blurring at the leading edgeof the copy.

The guide plate standard position is the center position (upper hole [B]).The guide plate position can be adjusted when the fixing screws are set tothe lower holes [C].

[A]

[C]

[B]

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A109 2-95 STM

10.3 DRIVE MECHANISM

The paper transport, fusing and the paper exit sections are driven by thetransport motor [A].

The drive from the transport motor is transmitted to the transport drive gear[B], to the fusing roller drive gear [C], then to the paper exit drive gear [D] viaidle gears.

When the OHP mode or thick paper mode is selected, the paper transportspeed becomes low (90 mm/sec) to sufficiently fuse toner onto the OHP orthick paper.This speed is half of the normal one (180 mm/sec).

[A]

[B]

[C]

[D]

STM 2-96 A109

10.4 FUSING DRIVE RELEASE MECHANISM

The fusing unit drive release mechanism automatically disengages thefusing unit drive gear [A] when the left front door [B] is opened.

This allows the fusing unit drive gear to rotate freely so that misfed papercan be easily removed.

When the left front door is opened, the actuator plate [C] pulls the releasewire [D] and the fusing unit drive gear is disengaged.

[A]

[B]

[C]

[D]

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A109 2-97 STM

10.5 OIL SUPPLY MECHANISM

Silicone oil is applied to the hot roller to help prevent toner and paper fromsticking to the hot roller, to reduce paper curl, and to help in roller cleaning.

A small pump with a one-way valve moves the oil from the oil tank [A] to theoil supply pad [B]. The oil pump lever [C] alternately presses and releasesthe rubber sleeve [D] between the valves as the oil cam [E] turns.

The oil supply pad then applies the oil to the hot roller as the roller turns. Theoil blade spreads the oil on the hot roller evenly. Excess oil flows down thefelt wick to the oil sump [F]. Oil flows out through hole [G] in the bottom of theoil sump and returns to the oil tank.

The oil supply pad distributes oil to the hot roller and removes the remainingtoner from the hot roller’s surface.

The hollow [H] collects foreign matter such as paper dust in the silicone oil.

The oil end sensor [I] detects the end condition. When the oil end conditionis detected, copying is immediately disabled and a call service guidance isdisplayed on the LCD.

[C]

[D]

[E]

[F]

[G]

[H][A]

[B]

[I]

STM 2-98 A109

10.6 CLEANING MECHANISM

The cleaning roller [A], which is always in contact with hot roller, collects thetoner and paper dust adhering on the surface of the hot roller [B]. This isbecause the teflon coating on the surface of the cleaning roller is more stickythan the hot roller surface (silicone rubber).

The collected matter is scraped off by a stainless steel blade [C].

[A]

[B]

[C]

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A109 2-99 STM

10.7 JAM DETECTION

The transport sensor [A] and the exit sensor [B] are jam detect sensors.

The transport sensor is a reflective sensor located above the transport belts[C]. When the machine detects that the paper is not properly separated fromtransfer belt and not arriving below the transport sensor, the machine stopsthe operation immediately (ON check only).

The exit sensor (photointerruptor) makes an ON and OFF check to detectthe paper jams..

[A]

[C]

[B]

STM 2-100 A109

10.8 FUSING PRESSURE MECHANISM

The pressure roller [A] is pressed up against the hot roller [B] by a pressurespring [C].

When the pressure release screw [D] is turned clockwise, the fusingpressure spring is pressed down to release the fusing pressure. The purposeof this screw is not for adjustment but just for pressure release. Normally thepressure release screw is fully loosened. This screw is tightened in thefactory to prevent deformation of the fusing rollers during transportation andstorage..

[A]

[B]

[C]

[D]

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A109 2-101 STM

10.9 FUSING TEMPERATURE CONTROL

To control the temperature of the hot roller and the pressure roller, the fusinglamps are turned off and on by the SSR (Solid State Relay).

Because there are fusing lamps in both hot and pressure rollers, there is nofusing idling needed for the machine to get ready when the main switch isturned on.

During stand by, the hot roller temperature is controlled at 170°C and thepressure roller temperature is controlled at 120°C.

While copying, the fusing temperature is controlled as shown in the tablebelow. The hot roller temperatures are lower than the ready temperature.

Condition Stand-by During copying

Modes Normal OHP/thick paper1C 2C,3C,4C 1C 2C,3C,4C

Hot rollertemp.

170°C 150°C 160°C 160°C

Pressureroller temp.

120°C 140°C

Two development exhaust fans are installed just above the fusing unit and afusing exhaust fan is installed at the rear left side. These fans let the hot airescape to prevent overheating.

Rev. 7/94

Hot roller temperature 120°C

162°C170°C

| ~

Main SW on

| Process control self check start

Ready Condition

~ Start copying

Time

STM 2-102 A109

11. PAPER FEED

11.1 OVERVIEW

This model has three drawer tray paper feed stations.

The first feed station is a 500 sheet universal tray, the second and third feedstations are 500 sheet trays.Paper can also be fed using the by-pass feed table [A] which has anindependent feed mechanism. The by-pass feed table can hold 50 sheets ofpaper.

All feed stations use an FRR feed system. Rotation of the pick-up roller [B]drives the top sheets of paper from each tray to the feed [C] and theseparation [D] rollers. The feed and separation rollers then take over paperdrive. If more than one sheet is fed by the pick-up roller, the separation rollerrotates in the opposite direction and prevents all but the top sheet frompassing through to the registration rollers [E].

[A]

[B]

[C]

[D]

[E]

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A109 2-103 STM

11.2 FRR FEED SYSTEM

This copier uses an FRR paper feed system using three rollers.

11.2.1 Pick-up Roller

The pick-up roller [A] is not in contact with the paper stack before it startsfeeding paper. Shortly after the Start key is pressed, the pick-up roller dropsdown and feeds the top sheet between the feed [B] and the separationrollers [C]. At almost the same time that the paper’s leading edge arrives atthe feed roller, the pick-up roller lifts off the paper stack so that it does notinterfere with the operation of the feed and separation rollers. The feed andseparation rollers then take over the paper feed process.

11.2.2 Feed and Separation Rollers

There is a one-way bearing inside the feed roller so it can turn only in onedirection. The separation roller is driven in the opposite direction to the feedroller. The separation roller, however, is driven through a slip clutch (torquelimiter clutch) which allows it to turn in either direction depending on thefriction between the rollers. The separation roller solenoid keeps theseparation roller in contact with the feed roller.

[B]

[A]

[C]

STM 2-104 A109

The direction in which the separation roller [A] turns depends on the frictionalforces acting on it. The slip clutch applies a constant clockwise force (F1).When there is a single sheet of paper being driven between the rollers, theforce of friction between the feed roller [B] and the paper (F2) is greater thanF1. So, the separation roller turns counterclockwise.

If two or more sheets are fed between the rollers, the forward force on thesecond sheet (F3), becomes less than F1 because the friction between thetwo sheets is small. So, the separation roller starts turning clockwise anddrives the second sheet back to the tray.

[B]

[A]

[B]

[A]

F2

F2 F1 F1

F2

F3

F3 F1F1

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A109 2-105 STM

11.3 SLIP CLUTCH MECHANISM

The slip clutch [A] consists of the input hub [B] and the output hub [C] whichis the case of the clutch as well. The magnetic ring [D] and the steel spacers[E] are fitted onto the input hub. The ferrite ring [F] is fitted into the outputhub. Ferrite powder [G] packed between the magnetic ring and the ferritering [F] generates a constant torque due to magnetic force. The input huband the output hub slip when the rotational force exceeds the constanttorque.

This type of slip clutch does not require lubrication.

[E][C]

[G][F]

[B]

[D]

[A]

STM 2-106 A109

11.4 FRR FEED DRIVE MECHANISM

The rotation of the paper feed motor is transmitted to the gear [A] via thetiming belt [B], and then transmitted to the separation roller via the feedclutch gear [C], gear [D], gear [E] and gear [F].

If the paper feed station is not selected, the separation roller solenoid [G]de-activates and the separation roller [H] rotates freely in the reversedirection of paper feeding.

Gear [A] also transmits the drive to the vertical transport roller [I] via gear [C],idle gear [J] and gear [K].

[A][B]

[J][K]

[I]

[C]

[C]

[E][F]

[G]

[A]

[D]

[H]

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A109 2-107 STM

When the paper feed station is selected and the Start key is pressed, thefeed clutch [A], separation roller solenoid [B], and the pick-up solenoid [C]turn on.

When the feed clutch [A] activates to rotate the feed roller [D], the feed rollerand the pick-up roller [E] turn together because they are linked by the idlegear [F].

When the separation roller solenoid [B] turns on, the separation roller [G]contacts the feed roller [D] and both rollers rotate together.The drive from the feed roller causes the separation roller to resist the drivefrom its shaft.Because of this resistance, the torque limiter between the separation rollerand the shaft breaks transmission of the drive from the shaft.

When the pick-up solenoid [C] activates, the pick-up roller [E] lowers to makecontact with the top sheet of the paper stack and send it to the feed andseparation rollers. When the paper feed sensor [H] detects the leading edge of the paper [I], thepick-up solenoid de-energizes to lift the pick-up roller and the paper feedclutch de-energizes at a certain time to wait until it is ready to feed to theregistration rollers.

[A]

[E]

[B]

[F]

[D]

[G]

[I]

[H]

[C]

STM 2-108 A109

11.5 SEPARATION ROLLER RELEASE MECHANISM

In this model, the separation roller [A] is normally away from the feed roller[B]. When the paper feed station is selected, the separation roller solenoid[C] contacts the separation roller to the feed roller as explained in theprevious two pages.

This contact/release mechanism has the following three advantages:

1. When the paper feed motor turns on, all separation rollers in each feedstation rotate. If the separation roller is away from the feed roller, itreduces the mechanical load to the paper feed motor and drivemechanism, and also reduces wear on the rubber surface of theseparation roller due to the friction between the feed roller and theseparation roller.

2. After paper feeding is completed, paper sometimes remains between thefeed roller and the separation roller.If the feed tray is drawn out in this condition, it is possible for theremaining paper to be torn. When the separation roller is away from the feed roller, remaining paperis released from between the feed and the separation rollers.

3. When paper misfeeds occur around this area, users can easily pull outjammed paper between the feed and the separation rollers because theseparation roller is away from the feed roller.

[C]

[A]

[B]

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A109 2-109 STM

11.6 PAPER RETURN MECHANISM

When the paper feed clutch [A] activates and the feed roller drive shaft [B]rotates, the lever [C] rotates together with the shaft. However, the lever isimmediately stopped by the stopper [D].

After all paper is fed and the paper feed clutch turns off, the paper feedmotor still rotates to turn the separation roller [E] in the reverse direction. Theseparation roller, still contacting the feed roller, turns the feed roller in thereverse direction until the lever hits the rubber cushion [F].

By this feed roller reverse mechanism, the paper remaining between thefeed and the separation rollers returns 3mm to the paper feed tray.

After that, the separation roller solenoid turns off to move the separationroller away from the feed roller. This releases the leading edge of the paperand drops the paper to the paper feed tray.

This prevents remaining paper from being torn when the feed tray is drawnout.

[A][D]

[B]

[E]

[C]

[F]

[C]

3 mm

[C]

STM 2-110 A109

11.7 PAPER SKEW PREVENTION MECHANISM

In this model, paper corner holders [A] are not used to facilitate paperloading.

Instead of the corner holders, both paper press arms [B] press down bothpaper side edges, especially in the case of paper with a face curl. This helpsthe tray side fences guide the paper to prevent paper skew or jams.

[A]

[B]

[B]

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A109 2-111 STM

11.8 PAPER LIFT MECHANISM

When the tray is set in the machine, the machine detects this condition byusing several detection methods as shown in the table:

Feed station Switches

1st Paper size switch

2nd Tray set switch

3rd Tray set switch

When the machine detects that the paper tray is set in the machine, the liftmotor [A] rotates and the coupling gear [B] on the tray lift motor engages thepin [C] of the lift arm shaft [D], then turns the tray lift arm [E] to lift the traybottom plate [F].

[F]

[D]

[C][B]

[A]

[E]

STM 2-112 A109

The lift motor turns on, the pick-up solenoid [A] activates to lower the pick-uproller [B]. When the top sheet of paper reaches the proper paper feed level,the paper pushes up the pick-up roller and the actuator [C] on the pick-uproller supporter [D] activates the lift sensor [E] to stop the lift motor.

After several paper feeds, the paper level gradually lowers then the liftsensor is de-activated and the lift motor turns on again until the lift sensor isactivated again.

When the tray is drawn out of the feed unit, the lift motor coupling gear [F]disengages the pin [G] of the lift arm shaft [H], then the tray bottom plate [I]drops.

Rev. 7/94

[A]

[D]

[B]

[E]

[C]

[F]

[G]

[H][I]

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A109 2-113 STM

11.9 PAPER END DETECTION

If paper is loaded in the paper tray, the paper end feeler [A] is raised by thepaper stack and the paper end sensor [B] is activated. When the paper trayruns out of paper, the paper end feeler drops in the cut out [C] of the traybottom plate and the paper end sensor is deactivated.

[A] [B]

[C]

STM 2-114 A109

11.10 PAPER SIZE DETECTION

For the second and the third feed trays, the paper size is stored in memoryby using the SP mode. ( SP Special Feature – PAGE 16)

For the first feed tray (universal tray), the paper size switch [A] detects thepaper size. The paper size switch has five microswitches inside. The papersize switch is actuated by an actuator plate [B] located on the rear of thetray. Each paper size has its own unique combination of actuation, as shownin the table, and the CPU judges the paper size by this combination ofactivated switches.

4

[A]

[B]

SW Actuate....0De-actuate....1

Paper size L: LengthwiseS: Sideways

A4/A3 Version

LT/DLT version

01111 A3–L 11 x 17–L00111 B4–L 81/2 x 14–L10011 A4–L 81/2 x 11–L01001 A4–S 81/2 x 11–S00100 81/2 x 13 51/2 x81/2–S00010 – 8 x 10–S00001 A5–S 8 x 10–L10000 – 8 x 13–L11000 – 10 x 14–L11100 – 11 x 15–L11110 A5–L 51/2 x81/2–L

1 2 3 4 5

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A109 2-115 STM

11.11 VERTICAL TRANSPORT MECHANISM

The vertical transport rollers [A] in each feed unit is driven by the paper feedmotor. The vertical transport rollers, and the driven vertical transport rollers[B] on the vertical guide plate [C], transport the paper from each feed unit tothe registration rollers.

The transport guide can be opened to access jammed paper in the verticaltransport area.

The vertical transport set switches [D] detect whether the vertical transportguide is open or not.

[A]

[C]

[B]

[D]

STM 2-116 A109

11.12 TRAY POSITIONING MECHANISM

- Tray Lock Mechanism -

When the feed tray is set in the paper feed unit, the lock lever [A] dropsbehind the lock plate [B] on the Accuride support bracket to lock the tray inthe proper position.

- Side-to-side Positioning Mechanism -

Side plates [C] are fixed on the positioning plate [D]. By moving thepositioning plate (fixed by four screws), the paper position can be changed toadjust the side-to-side registration.

NOTE: As the paper tray was commonly designed with other models, thisside-to-side positioning mechanism is on this model. However, donot use this adjustment in the field . The side-to-sideregistration can be adjusted for each feeding station by SP mode(SP1-3, No. 104).

[B]

[A]

[C]

[C]

[D]

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A109 2-117 STM

11.13 BY-PASS FEED TABLE

11.13.1 Feed Mechanism / Paper End Detection

The by-pass feed table uses the FRR feed system. The pick-up solenoid [A],and by-pass feed clutch [B] control paper feeding from the by-pass feedtable.

The by-pass paper end sensor [C] detects if there is paper on the by-passfeed table.

When there is no paper on the by-pass feed table, the paper end feeler [D]drops in the cut out of the lower guide plate and the paper end sensordeactivates. When paper is present on the by-pass feed table, the paperpushes up the end feeler [D] to activate the paper end sensor [C]. The CPUturns off the paper end indicator on the LCD panel and turns the start keyfrom red to green.

[B]

[A]

[C]

[D]

STM 2-118 A109

11.13.2 Table Open/Close Detection

When the by-pass feed table is opened, the by-pass feed table sensor [A] isactivated by the actuator [B]. Then the CPU turns on the by-pass feedindicator on the operation panel.

When the by-pass feed table is opened, the LCD indicates the OHP, Thickpaper, and Odd size keys.These modes can be selected only when the paper is fed from the by-bassfeed table.

On this model, opening the by-pass feed table does not shift the copier intointerrupt mode. The selected modes and input data before opening theby-pass feed table remain. Also other paper trays can be selected while theby-pass feed table is open.

The by-pass feed table is held by the latch [C]. When the upper left corner ofthe by-pass feed table is pressed, this latch comes out and unlocks the feedtable.When the by-pass feed table is closed, the latch is pressed in and catchesthe feed table.

The brush [D] on the by-pass feed table sensor actuator cleans the by-passlength sensor surface when the table is closed.

[C]

[D]

[E]

[A][B]

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A109 2-119 STM

11.13.3 Paper Size Detection

As for editing functions such as centering, edge erase etc. paper sizeinformation is necessary. The by-pass feed table is equipped with a papersize detection mechanism.

The paper width detecting board [A] monitors the paper width. The rear sidefence is connected to the terminal plate [B]. When the side fences arepositioned according to the paper width, the terminal plate is shiftedaccordingly. The terminal plate consists of four terminals and two of themalways touches the ground pattern [C]. The other two terminals touch thepatterns on the board. The pattern is separated into four areas [D], [E], [F],[G]. The high or low (grounded) condition of these four areas differ accordingto the paper size and the main CPU monitors each area condition andjudges the paper width.

The by-pass length sensor [H] detects whether the paper is longer than 8.5"x 11" (letter) sideways or not.By the combination of the paper width data and the paper length sensoroutput, the machine decides the paper size.

[A]

[B][D]

[E]

[F]

[G]

[H]

[A]

STM 2-120 A109

11.14 PAPER REGISTRATION

The registration rollers [A] have two functions. One is aligning the lead edgeof the paper with the leading edge of the image on the transfer belt.Registration clutch turns on at the programmed time. It turns off 30 pulsesafter the trailing edge of the paper is detected by the registration sensor.

The other function is to correct skewing of paper fed from the trays. Whenthe leading edge of the paper reaches the registration rollers, the verticaltransport rollers [B] and relay roller [C] continuously turn to transport thepaper. When the registration rollers are not turning, the leading edge of thepaper is pushed against the registration rollers. This creates a buckle on thepaper between the vertical transport rollers and the registration rollers tocorrect paper skew.

The registration sensor makes an "ON" check to detect if the paper isarriving correctly.

Shortly after the leading edge of the paper reaches the registration roller, theregistration clutch activates to feed the paper.

To have a large enough paper buckle during paper registration withoutdamaging the paper, the upper guide plate [D] (for paper from the papertrays) and the guide mylar [E] (for paper from the by-pass feed table) aremoved up by the paper when the paper buckle is fully created.

[A]

[E] [D]

[C]

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A109 2-121 STM

11.15 REGISTRATION DRIVE MECHANISM

Through the timing belt [A], transport motor [B] rotation is transmitted to theregistration clutch [C]. When the registration clutch activates, the transportmotor drive is transmitted to the upper registration roller [D], then to the lowerregistration roller [E] via two gears [F] at the front side.

[B]

[A]

[C]

[D]

[F]

[F] [E]

STM 2-122 A109

DUAL JOB FEEDER

A376

1. SPECIFICATIONSOriginal Feed Mode: Automatic document feed mode

Automatic reverse document feed modeSemi-automatic document feed modePreset modeCombine originals mode

Original Size, Weight and Table Capacity:

Paper Weight40.7g/m2 46.5 52.8 64.0 81.4 104.7 128.0

11 lb 12.5 14 17 22 28 34

Maximum number oforiginals to be set

50 50 50 50 50 30 25

A3 lengthwise

A4 lengthwise

A4 sideways

A5 sideways

B4 lengthwise

B5 lengthwise

B5sideways

F (8" x 13") lengthwise

11" x 17" lengthwise

81/2 x 14" lengthwise

81/2 x 11" lengthwise

81/2 x 11" sideways

51/2" x 81/2"lengthwise

51/2" x 81/2" sideways

8" x 13" (F) lengthwise

81/2 x 13" (F4)lengthwise

8" x 101/2" lengthwise

8" x 10" lengthwise

8" x 10" sideways



: Mixed Original modePreset modeADF mode (1 sided originals mode)ARDF mode (2 sided original(s) mode)SADF mode

: ADF mode, ARDF mode, SADF mode: ADF mode, SADF mode

A4/

A3

vers

ion

LT/D

LT v

ersi

on

Dua

l Job

Fee

der

A37

6

STM 3-1 A109

Original Standard Position: Rear left

Original Separation: Feed and friction belt

Original Transport: One flat belt

Power Source: DC24V from the copier, 2.0A (average)

Power Consumption: 70W

Dimensions (W x D x H): 680 x 508 x 116mm(26.8" x 20.0" x 4.6")

Weight: 13kg (28.7lb)

A109 3-2 STM

2. COMPONENT LAYOUT2.1 MECHANICAL COMPONENT LAYOUT

1. Friction Belt

2. Original Stopper

3. Press Roller

4. Side Fence

5. Original Table

6. Exit Roller

7. Inverter Pawl

8. Inverter Roller

9. Transport Belt

10. Pick-up Rollers

11. Pull-out Roller

12. Feed Roller

1 72

8

3

9

4

10

5

11

6

12

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STM 3-3 A109

3. ELECTRICAL COMPONENT DESCRIPTIONRefer to the electrical component layout on the reverse side of the attachedPoint to Point for symbols and index numbers.

Symbol Name Function Index No.Motors

M1 Feed-in Drives the feed-in system (pick-up,feed, pull-out rollers, separationbelts)

1

M2 Belt Drive Drives the transport belt. 2

M3 Feed-out Drives the feed-out and the invertersystem.

5

SensorsS1 DF Position Informs the CPU when the DJF is

being closed so that original sizedetection sensors can check theoriginal size.

7

S2 Feed-out Checks for original misfeeds andsets original stop timing when inauto-reverse mode.

8

S3 Registration–2 Detects the leading edge of theoriginal to turn off the feed-in clutchand to change the feed-in, belt drivemotors speed. Also detects theoriginal length.

10

S4 Original Width–3 Detects the original width. 11



S7 Registration–1 Detects the trailing edge of theoriginal to change the belt-drivemotor speed. Also, detects theoriginal length and original jam.

14

S8 Original Feed Detects if the originals reach thefeed roller or not.

15

S9 Original Set Detects if the originals are set onthe feed table.

16

S10 Pulse Count Counts the pulses generated by thepulse generator disc to determinethe original length.

19

SolenoidsSOL1 Inverter Energizes to invert the original

when copying two sided originals. 4

SOL2 Stopper Lifts the original stopper and lowersthe press roller to feed the set oforiginals to the feed roller.

9

SOL3 Separation Transmits drive to the separationbelts.

18

A109 3-4 STM

Symbol Name Function Index No.PCBs

PCB1 DF Main Board Controls all DJF functions. 3

PCB2 Indicator Panel Board Contains operator indicators. 21

SwitchesSW1 Lift Informs the CPU when the DJF is

lifted and also serves as the jamreset switch for the DJF.

6

SW2 Feed Cover Detects if the feed cover is closed. 17

ClutchesMC1 Feed-in Transmits the feed-in motor drive to

the pick-up and feed rollers, and tothe separation belts.

20

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STM 3-5 A109

4. BASIC OPERATION4.1 ONE-SIDED ORIGINAL FEED

When an original is set on the DJF feed table, the leading edge is stoppedby the stopper [A], and the feeler [B] activates the original set sensor. TheInsert Original indicator light goes out and the DJF informs the copier’s CPUthat the originals have been set.

When the Start key is pressed, the copier’s CPU sends the feed-in signal tothe DJF. On receipt of this signal, the stopper solenoid [C] activates to raisethe stopper to allow the originals to be fed in, and to lower the press rollers[D] to press the originals against the pick-up rollers as shown.

[A] [B]

[C]

[D]

[A]

A109 3-6 STM

The feed-in clutch [A] activates when the DJF receive the feed-in signal.200ms after the feed-in clutch activate, the feed-in motor feeds all originalsto the feed roller [B].When the originals reach the feed roller, the stopper solenoid [C]de-activates to lower the original stopper [D] and to lift up the original pressrollers [E].

When the originals pass through (between the separation belt [F] and feedroller), only the lowest original is separated and fed onto the exposure glass.Until then, the feed-in motor rotates slowly (372mm/sec) to ensure properoriginal feeding. When the leading edge of the original activates registrationsensor - 2 [G], the feed-in clutch [A] turns off to reduce the mechanical loadand prevent the next original from feeding. Also, the feed motor rotates morequickly (1250mm/sec).

[A]

[B]

[C]

[D]

[E]

[F]

[B]

[F]

[D]

[G] [E]

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STM 3-7 A109

When the leading edge of the original reaches the exposure glass, theoriginal is transported by the transport belt [A] (belt drive motor turns on 200ms after the start key is pressed).When the trailing edge of the original passes through registration sensor - 2[C], the feed-in motor turns off. When the trailing edge of the original passesthrough registration sensor - 2 [C], the belt drive motor gradually decreasesits speed to stop the original at the proper place on the exposure glass.200ms after the belt drive motor turns off, the feed-in motor turns on until thenext original activates registration sensor - 1 [B], the next original waits untilthe first original copy jobs complete. This operation reduces the original feedin time.

When the scanner reaches the return position, the copier’s CPU sends thefeed-out and feed-in signals to the DJF CPU in order to exchange theoriginal for the next original.When the DJF receives the feed-out signal, the belt drive and feed-outmotors turn on.When the scanner reaches the return position after scanning the lastoriginal, the copier’s CPU sends only the feed-out signal to feed-out the lastoriginal.

If the original is 8.5" X 11" sideways or smaller, the original just copied istransported to the right side of the exposure glass then waits until the nextoriginal copying is completed. Then the previous original is delivered. Thisoperation also reduces the original feed-in time.

[A][C][B]

A109 3-8 STM

4.2 TWO-SIDED ORIGINAL FEED

Unlike one-sided original feed, the back side of the original must be copiedfirst to keep the originals and copies in the correct order.

During original feed-in, the sequence is the same as for one-sided feed;however, the belt drive motor continues rotating until the original reaches theinverter section. The DJF CPU energizes the feed-out motor and the invertersolenoid [A] for a short time. After the inverter mechanism inverts the original (10 pulses after the feed-outsensor [B] activates), the belt drive motor reverses and the original is fedtowards the original scale. It is stopped at the correct position on theexposure glass, and the DJF CPU sends the copy start signal.When the scanner reaches the return position, the copier’s CPU sends theinvert original signal to the DJF CPU in order to make a copy of the frontside. The original is inverted in the same way as for back side copying.

[A]

[B]

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STM 3-9 A109

4.3 PRESET MODE

Two sets of originals for independent copy jobs can be set on the originaltray at the same time. While the first set of originals [A] remains on the original tray, both theoriginal set sensor feeler [B] and original feed sensor feeler [C] are actuated.If the second set of originals [D] has been set (stopped by the originalstopper [E]) and the first set of originals [A] are all fed-in, the original setsensor feeler [B] is still actuated and only the original feed sensor isdeactuated. Therefore, the copier’s CPU recognizes that the first job iscompleted.If the second job is already preset, the second set of originals isautomatically fed to the feed roller [F] in the same manner as the first set oforiginals was.

[A]

[B]

[C]

[D][E]

[F]

A109 3-10 STM

4.4 COMBINE 2 ORIGINALS MODE

4.4.1 Overview

2 originals are fed onto the exposure glass at once in the combine 2 originalsmode as shown in figure 1. This allows copying 2 originals onto one sheet ofpaper automatically either in the full size mode or in the reduction mode.

If odd numbered originals are placed on the original table, the first original isplaced on the exposure glass as shown in figure 2.

Only 1-sided originals can be used, and Auto Paper Select (APS) and AutoReduce/Enlarge modes cannot be used with this mode.

[Fig.2]

[Fig.1]

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STM 3-11 A109

4.4.2 Operation

The DF operation in the combine 2 original mode is as follows:

[Figure 1]The first original is fed in the same manner as the one-sided originalmode. When registration sensor-2 detects the trailing edge of thefirst original, the feed-in and the belt drive motors stop and thefeed-in clutch turns on again to prepare for the second original feed.

[Figure 2]As soon as the feed-in and the belt drive motor turn off, the beltdrive motor starts rotating in reverse to align the first original againstthe original scale. Then the belt drive motor turns off.

[Figure 3]50ms after the feed-in motor turns off, the feed-in motor turns onagain at a lower speed (372mm/sec) to feed the second original.A few pulses (0 ∼ 14 pulses: depends on the DIP switchcombinations 102-1-4) after the registration sensor-2 is activated bythe leading edge of the second original, the feed-in motor and thefeed-in clutch turn off.

Figure 1

Figure 2

Figure 3

A109 3-12 STM

[Figure 4]Soon after the feed-in motor turns off, both the feed-in and the beltdrive motors turn on again at the lower speed (372mm/sec).After registration sensor-2 detects the trailing edge of the secondoriginal, the feed-in motor turns off and gradually the belt drivespeed reduces to stop the original at the proper place on theexposure glass.

[Figure 5]After the copying of these originals is finished, the belt drive motorand the feed-out motor turn on to feed out the originals. 50mmbefore the trailing edge of the first original de-activates the feed-outsensor, both the belt drive and the feed-out motor rotate at the lowerspeed to improve original stacking.48 pulses after, the belt drive motor turns off and 60 pulses after thefeed-out sensor detect the trailing edge of the second original, thefeed-out motor turns off.

Figure 4

Figure 5

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STM 3-13 A109

5. ORIGINAL SEPARATION

The drive from the feed-in motor [A] is transmitted to the pick-up rollers [B]and the feed roller [C] through the feed-in clutch [D] as shown. The feedroller and the friction belts [E] are used to feed-in and separate the originals[F]. Only the bottom original is fed because the friction belt prevents anyother original from feeding.

Original feed starts when the feed roller starts turning and advances thebottom original of the stack. The feed roller moves the original past theseparation belt because the driving force of the feed roller is greater than theresistance of the friction belt. The friction belt prevents multiple feedsbecause the resistance of the friction belt is greater than the friction betweenoriginal sheets.

[A]

[B]

[C]

[D]

[E]

[C]

[E][F]

[B]

A109 3-14 STM

6. SEPARATION BELT DRIVE MECHANISM

Normally the separation belt is not driven. When the copy job is completed,the separation solenoid [A] activates for 100ms. to transmit the drive from thefeed-in motor [B] to the separation belts [C] as shown.By this operation, the part of the friction belt that contacts the feed roller [D]or the original changes to prevent multiple feeding.

[A]

[B]

[C]

[D]

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STM 3-15 A109

7. THIN / THICK ORIGINAL MODES

This document feeder has two different ways of stopping originals at thecorrect position on the exposure glass. They are called the thin originalmode and the thick original mode. The mode used is determined by usingthe copier’s User Tool No.12.

1. Thin Original Mode

The original is stopped at the correct position on the exposure glassbased on encoder pulse count. The belt drive motor stops shortlyafter the original trailing edge passes registration sensor - 2. (Exact timing depends on registration adjustment.)

2. Thick Original ModeWhen thick original mode is selected, the belt drive motor remainsenergized to carry the original approximately 10 mm pass the leftscale.Then, the belt drive motor pauses and reverses to feed the originalback against the original scale. This forces the original against theleft scale and thus aligns the trailing edge of the original with thescale.Thick original mode is selected at the factory.

A109 3-16 STM

8. ORIGINAL SIZE DETECTION

The DJF detects original width through the on/off combination of the threeoriginal width sensors -1 [A], -2 [B], -3 [C], it also detects the original lengththrough the use of the registration sensors -1 [D], -2 [E] and the pulse countsensor [F].

The DJF CPU counts the pulses between registration sensor - 2 [E] ontiming and registration sensor - 1 [D] off timing.Based on this pulse count, the CPU determine the original length.

The reason for using two registration sensors are:

1) Registration sensor -2 [E] is used to stop the pre-fed original to waituntil the previous original is fed out. For precise control, the originalstop position must be after the pull out rollers [G]. Therefore,registration sensor -2 is placed after the pull-out roller.

2) Registration sensor -1[D] checks the trailing edge of the original. Thischeck is used to place the original on the exposure glass.Enough distance is required between the sensor and the originalscale. Therefore, registration sensor -1 is placed 34.9 mm beforesensor -2.

The original size is determined by the combination of the detected originalwidth and the length.

[A]

[B]

[C]

[F]

[E][D]

[E]

[G]

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STM 3-17 A109

9. LIFT MECHANISM

When the DJF is opened, the lift springs [A] provide enough force to ensurethat the DJF does not fall onto the exposure glass. When the DJF is closed,points "➀", "➁", and "➂" are aligned and no upward force is provided to theDJF.

The lift switch [B] is actuated when the DJF is closed. The copier then shiftsto the document feeder mode. The lift switch also serves as the reset switchfor DJF misfeeds.

When a book or thick (maximum thickness 60 mm) original is copied, theDJF acts as a cover for the original as shown in the figure [C]. The lift switchis turned off during this condition, so the DJF does not function. The tensionof spring [D] returns the DJF to the normal condition after copying a thickoriginal.

[A]

[D]

[B]

[C]

➀

➀

➁

➂➁

➂

A109 3-18 STM

10. ORIGINAL MISFEED DETECTIONRegistration sensor -1 and the feed-out sensor are used for misfeed checksto light the original misfeed indicator.

1. One sided original

➀: If registration sensor -1 does not activate within 150 pulses after thefeed-in motor starts turning, the CPU determines that the original willnot arrive (ON check).

➁: If registration sensor -1 does not de-activate within 120 pulses, theCPU determines that the original is still there (OFF check).

➂: If the current paper size data is 40mm longer or 80mm shorter thanthe previous original size data (this check is disabled in the mixedsize original mode).

➃: If the feed out sensor does not activate within 125 pulses after thefeed-out motor starts turning, the CPU determines that the originalwill not arrive (ON check).

➄: If the feed-out sensor does not de-activate within 60 pulses after thefeed out motor slows down, the CPU determines that the original isstill there (OFF check).

RegistrationSensor – 1

Feed-out Sensor

Copying

Feed-in Motor

➀

➃

➁

➄

➂

Feed-out Motor

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STM 3-19 A109

2. Two sided original

Registration sensor -1 and the feed-out sensor are used for misfeed checksto light the original misfeed indicator.

Registration ON/OFF check is the same as for one-sided originals.

➀: If the feed-out sensor does not activate within 130 pulses after thefeed-out motor starts turning, the CPU determines that the originalwill not arrive (ON check).

➁: If the feed-out sensor does not de-activate within 200 pulses, theCPU determines that the original is still there (OFF check).

➂: If the feed-out sensor does not activate within 130 pulses after thefeed-out motor starts turning, the CPU determines that the originalwill not arrive (ON check).

➃: If the feed-out sensor does not de-activate within 200 pulses, theCPU determines that the original is still there(OFF check).

➄: If the feed out sensor does not activate within 125 pulses after thefeed-out motor starts turning, the CPU determines that the originalwill not arrive (ON check).

➅: If the feed-out sensor does not de-activate within 60 pulses after thefeed out motor slows down, the CPU determines that the original isstill there (OFF check).

Belt DriveMotor

Feed-out Sensor

1st Copying

Feed-outMotor

① ④②

⑤

③

2nd Copying

⑥Forward

Reverse

A109 3-20 STM

11. TIMING CHART 11.1 DJF Timing Chart (1 sided original mode)

RXD

TXD

Original Set SN

Stopper SOL

Feed-in MC

Original Feed SN

Registration-1

Registration-2

Feed-Out SN

Separation SOL

Feed-in M (M1)

Belt Drive M (M2)

Feed-out M (M3)

Feed-in Feed-out

Original set

Feed-in Feed-out

Pulse Count

No original

150 ms

Size Original stopSizeOriginal stop Feed-out Feed-out

200 ms

390 ms

480 ms

200 ms 200 ms

M1: 10 pls

M1: 5 pls M1: 5 pls

M3: 60 plsM3: 60 pls

Feed amount:M1: 3.7 mm/plsM2: 2.0 mm/plsM3: 2.7 mm/pls

Registration-1ONcheck (within 150 pls)

Registration-1 OFF check (within 200 pls)

Incorrect Original Size check (If more than 40 mm longer or more than 80 mm shorter than previous original).

Feed-out SN ON check (within 125pls)

Feed-out sensor OFF check (within 60 pls)

A109 3-21 STM

11.2 DJF TIMING CHART (COMBINE 2 ORIGINALS MODE)

NOTE: Adjustable (0 ~ 14 pls) by DIP SW102

Feed-out Feed-outRXD

TXD

Original Set SN

Stopper SOL

Feed-in MC

Original Feed SN

Registration-1

Registration-2

Feed-out SN

Separation SOL

Feed-in Motor (M1)

Belt drive Motor (M2)

Feed-out Motor (M3)

Original set

Combine: Feed-in Combine: Feed-out

Original StopSize

390 ms

480 ms

200 msM1:5pls

50 ms NOTE: 1

0 ~ 14 pls

Trailing EdgeM3: 48 pls

M3: 60 pls

M1: 3 pls

STM 3-22 A109

SORTER A511

1. OVERALL MACHINE INFORMATION1.1 SPECIFICATIONS

Paper Size for Bins: Maximum: A3 (lengthwise) or 11" x 17" (lengthwise)

Minimum: A5 (sideways) or 51/2" x 81/2" (sideways and lengthwise)

Copy Paper Weight: 52 - 90 g/m2 or 14 - 24 lb

Number of Bins: 10 bins + print bin + interrupt bin (total 12 bins)

Bin Capacity: Sort mode: 50 sheets/bin (A4 or 81/2" x 11")Stack mode: 40 sheets/bin (A4 or 81/2" x 11")

Top Bin Capacity: 150 sheets (A4 or 81/2" x 11")

Print Bin Capacity: 500 sheets (A4 or 81/2" x 11")150 sheets (other size)

Interrupt Bin Capacity: 100 sheets (A4 or 81/2" x 11")

Power Source: DC 24V from the copier

Power Consumption: 90W (MAX), 30W (Average)

Dimensions (W x D x H): 499 x 535 x 600 mm19.6" x 21.1" x 23.6"

Weight: Approximately 22 Kg or 49 lb

Interface Requirement: A sorter adapter (850 g) is needed.

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1.2 COMPONENT LAYOUT

1.2.1 Mechanical Components

1. Entry Sensor Photo Transistor

2. Vertical Drive Rollers

3. Pressure Rollers

4. Sorter Cover

5. Vertical Guide Unit

6. Sponge Roller

7. Inlet Sensor

8. Turn Gate Roller

9. Turn Gate

10. Entry Sensor LED

11. Discharge Brush

12. Interrupt Bin

13. Printer Bin

14. Standard Bins

1 23

4

5

6

7

8910

11

12

14

13

STM 4-2 A109

1.2.2 Electrical Components

1. Inlet Sensor

2. Entry Sensor Photo Transistor

3. Sorter Cover Safety Switch 1

4. Sorter Cover Safety Switch 2

5. Entry Sensor LED

6. 2nd Bin Solenoid

7. 3rd Bin Solenoid

8. 4th Bin Solenoid

9. 5th Bin Solenoid

10. 6th Bin Solenoid





15. Printer Bin Solenoid

16. Interrupt Bin Solenoid

17. Sorter Motor

18. Sorter Main Board

19. Exhaust Fan (A109 copier only)

12

3 4

5

6

7

8

9

10

11

12

13

14

15

1617

18

19

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1.3 ELECTRICAL COMPONENT DESCRIPTIONS


MotorsM1 Sorter Motor Drives all the sorter rollers. 17

M2 Exhaust Fan(A109 copier only)

Flow the air out from the copier fusingexhaust fan.

19

SolenoidsSOL1 2nd Bin Solenoid Open and close the 2nd bin gate. 6

SOL2 3rd Bin Solenoid Open and close the 3rd bin gate. 7

SOL3 4th Bin Solenoid Open and close the 4th bin gate. 8







SOL10 Printer Bin Solenoid Open and close the printer bin gate. 15

SOL11 Interrupt BinSolenoid

Open and close the interrupt bin gate. 16

SwitchesSW1 Sorter Cover

Safety Switch 1Detects when the sorter cover isopened.

3

SW2 Sorter CoverSafety Switch 2

Cut the +24 volts power line. 4

SensorsS1 Entry Sensor Detects misfeeds and when the copy

paper enters the bin.2 and 5

S2 Inlet Sensor Detects misfeeds and when the copypaper enters the sorter.

1

Printed Circuit BoardsPCB 1 Sorter Main Board Controls all sorter functions. 18

STM 4-4 A109

1.4 DRIVE LAYOUT

1. Vertical Drive Rollers (10 Rollers)

2. Sorter Motor

3. Turn Gate Roller Pulley

4. Sponge Roller Pulley

5. Timing Belt

1

2

3

4

5

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1.5 BASIC OPERATION

- Introduction -Sorter operation begins when the copier main motor turns on. At that time,the sorter motor turns on and the rollers start turning.

The sorter has two paper transport speeds. When the sorter motor turns on,it rotates at slow speed of 220 mm/s. This is the slightly faster than thecopier’s transport speed. When the trailing edge of the paper passes thecopier exit sensor, the sorter shifts to high speed which is about 550 mm/s.When the trailing edge of the paper passes the bin entry sensor, the sortershifts again to slow speed.

When the copier main motor turns off, the sorter motor also turns off.

- Clear Mode -The copies pass from the copier’s exit through the relay guide plates to theturn gate. The turn gate directs the paper to the vertical guide unit. Thevertical drive rollers then move the paper up until it reaches the turn guide.The turn guide directs the paper to the first bin. During transport of thecopies in this mode, none of the bin gates are used.

- Sort Mode -When in sort mode, the first sheet is placed in the first bin in the same wayas when in clear mode.

The second and subsequent copies follow the same path but are directed tothe bins in order from top to bottom (second copy to second bin, third to thethird bin, and so on). The appropriate bin gate solenoid turns on when theleading edge of the paper activates the inlet sensor and turns off when thetrailing edge of the paper passes the bin entry sensor.

If 11 or more is entered while in sort mode, the message display will indicate"Maximum number of sets is 10.", the Copy Quantity indicator will display 10.(The Start key remains green.)

STM 4-6 A109

- Stack Mode -When in stack mode, all sheets of the first copy run go to the top bin just asin clear mode. When the Start key is pressed again, the entire second run isdirected to the second bin. Similarly, the third run goes to the third bin, thefourth run to the fourth bin.

If the mode is not changed, the sorter will continue in this way, sending allcopies from a single run to one bin and dropping down one bin each run untilthere are copies in all 10 bins. Upon completion of the copy run to the 10thbin, copying will stop and the guidance display will indicate "Sorter bins arefull. Remove the copies." (The Start key remains green.) The operator cancopy 11th or more originals continuously when pressing the start key again.These copies run to the top bin and drop down one bin each run, asdescribed above.

If on any single copy run, the operator enters a number greater than 40 (themaximum bin capacity for stack mode), the 41st copy will automatically dropdown to the next bin.

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A109 4-7 STM

- Interrupt Mode -

If the Interrupt key is depressed during a multicopy run, the sorter continuesto place copies in the correct bins until that copy run is finished. Which binthe copies go to depends on the mode: sort, stack or clear mode.

Then, the operator presses the Start key to make interrupt copies.Only when the operator selects OHP/thick paper to be fed from the by-passfeed table, the interrupt copies enter the sorter and the sorter CPU energizesthe interrupt bin solenoid [A] and the copies are directed to the interrupt bin.All other copies taken by the interrupt mode are fed to the 1st bin.

When the interrupt mode is canceled, the previous settings and modes arereturned to resume the previous copy run that was interrupted.

- Sorter Misfeed -The sorter CPU starts the misfeed timing count when the inlet sensor turnson. If the copy is not fed into the bin within a specified period (different foreach bin) the sorter CPU will send a misfeed signal to the copier. The copierwill then light the Sorter Misfeed indicator and stop operation. (Any copies inthe paper path at the time will be finished first.)

The sorter CPU directs any copies that are being processed in the copier atthe time of a sorter misfeed to the interrupt bin. It also corrects the copierCopy Counter indicator so that it displays only the number of copies actuallyin the top 10 bins. After removing the misfed paper, the misfeed condition isautomatically cleared when the sorter cover is opened and closed.

[A]

STM 4-8 A109

2. DETAILED SECTION DESCRIPTIONS2.1 DRIVE MECHANISM

The sorter motor [A] is a servo motor and it is controlled by the sorter CPU.The sorter CPU also controls the motor rotation speeds: slow and high.

The sorter motor drives the sponge roller [B] and the other rollers through atiming belt [C].

[A]

[B]

[C]

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A109 4-9 STM

2.2 BIN GATE OPERATION

Each bin gate shaft [A] is individually controlled by a solenoid. Normally, thebin gates [B] are held out of the paper path by the return spring [C].

To feed paper into a bin, the sorter CPU energizes the appropriate solenoid.The solenoid plunger [D] then rotates the bin gate lever [E] and opens thegate out into the paper path. The curved inner face of the gate directs thepaper into the bin.

After the paper passes into the bin, the solenoid turns off and the returnspring pulls the bin gate lever back to the closed position.

[B]

[D]

[C]

[E]

[A]

STM 4-10 A109

2.3 RELAY GUIDE PLATE RESET MECHANISM

This mechanism prevents the relay guide plate [A] from being left up aftermisfed paper has been removed from the sorter. When the operator closesthe sorter cover [B], the reset lever [C] is pushed down, returning the relayguide plate to the horizontal position.

[B]

[A]

[C]

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A109 4-11 STM

2.4 ELECTRICAL CONTROL

24 V is supplied from the copier, the sorter main board generates a 5 V supply from the 24 V input.

The sorter has its own CPU which controls all the functions of the sorter. Thesorter CPU communicates with the copier through a serial interface bus.

Signals from the sensors and the safety switch are sent to the copier mainPCB. The copier main PCB sends the command signals for activation of themotor and the solenoids to the sorter CPU.

Main System

DCPowerSupplyBoard

MainBoard

CN150-1

SensorsSafety SWs

24 V

GND

Serial Interface

IC109

+ 24 V

+ 5 V

CN120-1

SorterCPU

OSC

Sorter Main Board

Solenoids

Motor

STM 4-12 A109

2.5 ENTRY (JAM AND BIN) COPY SENSOR

There is a jam sensor on the upper sensor board which detects sortermisfeeds. A LED on the lower sensor board is turned on by a pulse signalwhich is supplied from the sorter CPU.

When there is paper between either board, this pulse light does not activatethe phototransistor on the upper board. In this case, the sorter CPUdetermines that the vertical drive roller is misfeeding a copy. This pulsesignal detection system has an advantage over a photointerruptor systembecause there is no interference from external light.

Detect

Circuit

Main Board

Upper

Lower

+24V

+24V

+5V

CPU

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A109 4-13 STM

2.6 MISFEED SENSING

The three components indicated in the above timing chart are involved injam detection. There are four jam detection tests, as follows.

T1: The inlet sensor is checked 80 pulses (0.36s) after the copier’s exitsensor is turned ON. If the inlet sensor is not on, there is a jam is thecopier’s exit area.

T2: y pulses (see the table below) after the inlet sensor is turned ON,the inlet sensor turns OFF. If the inlet sensor is not OFF, there is ajam in the sorter entrance area.

T3: z pulses (see the table below) after the inlet sensor is turned ON,the entry sensor turns ON. If the entry sensor is not ON, there is ajam in the vertical transport area.

T4: z pulses after the inlet sensor is turned OFF, the entry sensor turnsOFF. If the entry sensor is not OFF, there is a jam in the sorter exitarea.

Paper Size 51/2 x 81/2 81/2 x 11 81/2 x 14 11 x 17 81/2 x 51/2 11 x 81/2

y pulse 380 484 620 752 240 376

Paper Size A3 B4 A4(L) A4(S) B5L B5(S) A5(L) A5(S)y pulse 732 532 516 364 448 316 364 256

Bin No. 1 2 3 4 5 6 7 8 9 10 Print Interrupt

z pulse 992 904 860 816 772 724 680 632 588 544 360 316

T1

T2

T3

T4

Copier’sExit Sensor

Inlet Sensor

Entry Sensor

STM 4-14 A109

DISPLAY EDITOR

A997

1. SPECIFICATIONSOriginal Size: Maximum: A3 (lengthwise) or

11" x 17" (lengthwise)(Scanned through the copier.)

Display: LCD (Monochrome), 8 gradations640 x 480 dots

Zoom In/Out: 100% (33 dpi), 150% (50 dpi), 200% (67 dpi),300% (100 dpi)

Display Speed: Less than 2 seconds

Editing: Screen and cursor

Power Consumption: 19.5W

Power Source: 5V/less than 1.5A and 24V/less than 10.5from the copier.

Dimensions (W x D x H): 280 x 232 x 50 mm11.0" x 9.14" x 1.97"

Weight: less than 1.5 Kg or 33.1 lb

Remarks: The holder is required for installation.

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STM 5-1 A109

2. OVERVIEW

The scanned image is sent to the display editor and displayed on the LCD(640 x 480 dot).

By using the cursor [A], the operator is able to designate an area of theoriginal image. The display [B] shows 8 levels of grayscale, and the datacommunication between the display editor and the IPU board is done by 3 bitparallel signal.

[B] [A]

[C] [D] [E] [F] [G] [H] [I] [J] [L]

[M]

[K]

A109 5-2 STM

3. EXPLANATION FOR EACH KEY

Key FunctionScan Key [C] Sends the scan start command to the copier, and scanning of

the original is performed. After the scanning, the entireoriginal image is shown on the display editor (100%).

Full Image Key [D] The data scanned with 100 dpi is changed to about 33 dpi.The entire A3 or DLT original image can be displayed.

Zoom 1 Key [E] The data scanned with 100 dpi is changed to 50 dpi. (150%enlargement)

Zoom 2 Key [F] The data scanned with 100 dpi is changed to about 67 dpi.(200% enlargement)

Zoom 3 Key [G] The data scanned with 100 dpi is displayed with about 100dpi. (300% enlargement)

Image Shift Key [H] Press to shift the image up and down, left and right by usingthe cursor key according to the block diagram displayed atthe lower left corner.

Cursor Key [I] The cursor on the display will appear at the center afterpressing the scan key, zoom keys and image shift key. Thecursor shown on the display will move to the desired positionby pressing this key.

Point Key [J] Sends the information of the current location of the cursor tothe copier.

Clear Key [K] The previously marked point before pressing the close keywill be canceled.

Close Key [L] Press to close an area.All Clear Key [M] All specified dimensions or areas will be canceled.

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STM 5-3 A109

FILM PROJECTOR UNIT

A998

1. SPECIFICATIONAcceptable Film Type: • Type: Positive film/Negative film

• Size: 35 mm - Approx. 140 x 210 mmOthers: 60 x 45 mm, 60 x 60 mm,

60 x 70 mm, 60 x 80 mm, 60 x 90 mm, 6 cm x 6 cm 4" x 5"

Max: 140 x 210 mm or 5.5" x 8.2"

• Mount: Yes (Up to 5 frames can be set in a film holder.)

• Strip: Yes (A series of 6 frames can be set in a film holder.)

Focusing: Fixed/ManualEffective Film Area: • 35 mm: Approx. 22.2 x 33.3 mm

• Other Sizes: Full SizeProjection Ratio • 35 mm: Approx. x 6

• Other Sizes: x 1Copy Image Size • 35mm mount: 124 x 195 mm

• 35mm strip: 133 x 200 mm• Other Sizes: Full Size

The reproduction features of the copier are available.

Power Source: inside page of the front cover. Power Consumption: Maximum: 55WDimensions (W x D x H): Projector: 300 x 442 x 204 mm

11.8" x 17.4" x 8.03"

Mirror Unit: 295 x 232 x 50 mm11.61" x 9.13" x 1.97"

Weight: 11 kg or 24.3 lbRemarks: The holder is required for installation.

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STM 6-1 A109

2. ELECTRICAL COMPONENT LAYOUT ANDDESCRIPTIONS

Symbol Name FunctionIndexNo.

PCB1Projector Lamp Regulator Supplies dc voltage to the projector

lamp and lamp cooling fan.4

PCB2Projector Control Board Controls the projector unit,

communicating with the copier mainboard.

5

PCB3Noise Filter Board(220–240V machine only)

Removes electrical noise.3

M1 Lamp Cooling Fan Blows air to the projector lamp section. 2

SW1 Projector Switch Provides power to the projector unit. 1

L1 Projector Lamp Applies light to the film for exposure. 7

TH1Lamp Thermistor Detects the temperature around the

projector lamp to control the lampcooling fan.

8

TF1Lamp Thermofuse Opens the projector lamp circuit if the

projector lamp section overheats.9

TR1Transformer Steps down the wall voltage to 17 ∼ 18

V ac.6

9

A109 6-2 STM

3. SECTIONAL DESCRIPTIONS

3.1 OVERVIEW

This film projector unit allows making copies from the following kinds of films:35 mm positive slides (both mount films and glass mount films)35 mm negative or positive strip filmsPositive or negative films of wide size

(60 x 45 / 60 x 60 / 60 x 70 / 60 x 80 / 60 x 90 mm / 4" x 5" / maximum size of 140 x 210 mm or 5.5" x 8.2")

The light from the projector lamp [A] is reflected by the reflector [B] andreaches the film (35 mm) in the film/slide holder [C] through thenon-spherical lens [D], heat filter [E], and condenser lenses [F]. Theprojected film image reaches the mirror [G] through the correction filter(positive or negative) [H] and projection lens [I]. Then the mirror reflects theimage to the exposure glass through the Fresnel lens [J]. The first scannermoves under the exposure glass to read the projected film image and thelight of the image is converted to R/G/B electrical signals by the CCD [K].

The projected image on the exposure glass is enlarged about 6 times the 35mm film’s image.

In the case of wide size films, the first scanner reads the film placed on theexposure glass directly using the light from the projector lamp.

The lamp cooling fan turns on and off according to the temperature of theprojector lamp section detected by the lamp thermistor. It turns on at around45°C and turns off at around 44°C.

[A]

[B]

[C]

[D]

[G]

[H]

[I][J]

[E]

[K]

[F]

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STM 6-3 A109

3.2 SHADING

When the projector unit is selected, shading should be done after selectingthe type of film. The shading should be done with a base film and theN-correction filter for the negative films and with the P-correction filter for thepositive films.

The N-correction filter corrects the color of the projected light. TheP-correction filter corrects the light intensity of the projected light so that itbecomes similar to that for the negative films.

When "Shading" [A] on the touch panel display is pressed, the first scannermoves and stops under the mirror unit. Then AGC (Auto Gain Control) forthe light intensity from the projector lamp is performed. Shading for black andwhite levels is also performed after the AGC.

This "Shading" should be performed whenever the type of film is changed orthe mirror unit is moved.

[35 mm Slide Positive] or [Positive Film Under Lens] On

[35 mm Strip Negative] or[Negative Film Under Lens] On

[A][A]

A109 6-4 STM

3.3 MIRROR UNIT

The film image projected through the projection lens [A] is reflected to theFresnel lens [B] by the mirror [C].

The Fresnel lens consists of two components, a circle pitch Fresnel lens [D]and a parallel pitch Fresnel lens [E]. The circle pitch Fresnel lens changesthe spreading light to the parallel light. The parallel Fresnel lens collects thelight from the circle pitch Fresnel lens in the main scan direction so that allthe light reaches the color CCD lens [F]. The use of these two types of Fresnel lens makes the most of the lightintensity from the projector lamp.

[A]

[B]

[C]

[F]

[D][E]

Subscandirection

Main scandirection

[A]

[B]

[C]

[F]

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STM 6-5 A109

A109 Service Training Manual - Distrivisa · legend product code company gestetner ricoh savin a109 - nc5006 sc106 documentation history rev. no. date comments * 4/94 original printing

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