bizhub_c650_c550_c451_fe4_theory_of_operation_dda00j-m-te8.pdf

SERVICE MANUAL

2008.06Ver. 8.0

THEORY OF OPERATION

This service manual is designed for machine with firmware card ver. J8 and onward.This service manual is designed for machine with firmware card ver. J8 and onward.

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THEORY OF OPERATION TOTAL CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1

IMPORTANT NOTICE ................................................................................................S-1

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1

SAFETY WARNINGS .................................................................................................S-2

WARNING INDICATIONS ON THE MACHINE ........................................................S-18

MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-21

Composition of the service manual ................................................................................. C-1

Notation of the service manual ....................................................................................... C-2

bizhub C650/C550/C451 Main bodyOutline ............................................................................................................................ 1

Composition/Operation ................................................................................................. 19

DF-611/610Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 7

LU-301Outline ............................................................................................................................ 1


ZU-603Outline ............................................................................................................................ 1

Construction/Operation................................................................................................... 9

FS-517/518/608Outline ............................................................................................................................ 1


PI-503Outline ............................................................................................................................ 1


PK-512/513Outline ............................................................................................................................ 1


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FS-519/PK-510/OT-602Outline ............................................................................................................................ 1

Composition/Operation................................................................................................... 9

MT-502Outline ............................................................................................................................ 1


SD-505Outline ............................................................................................................................ 1


JS-504Outline ............................................................................................................................ 1

Construction and operation ............................................................................................ 5

SAFETY AND IMPORTANT WARNING ITEMS

S-1

Read carefully the safety and important warning items described below to understand them before doing service work.

Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.Changes may have been made to this product to improve its performance after this Service Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that the information contained in this service manual is complete and accurate.The user of this service manual must assume all risks of personal injury and/or damage to the product while servicing the product for which this service manual is intended.Therefore, this service manual must be carefully read before doing service work both in the course of technical training and even after that, for performing maintenance and control of the product properly.Keep this service manual also for future service.

In this Service Manual, each of three expressions “ DANGER”, “ WARNING”, and “ CAUTION” is defined as follows together with a symbol mark to be used in a limited meaning. When servicing the product, the relevant works (disassembling, reassembling, adjustment, repair, maintenance, etc.) need to be conducted with utmost care.

Symbols used for safety and important warning items are defined as follows:


IMPORTANT NOTICE

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION

DANGER: Action having a high possibility of suffering death or serious injury

WARNING: Action having a possibility of suffering death or serious injury

CAUTION: Action having a possibility of suffering a slight wound, medium trouble, and property damage

:Precaution when servicing theproduct. General

precautionElectric hazard High temperature

:Prohibition when servicing the product. General

prohibitionDo not touch with wet hand

Do not disassemble

:Direction when servicing the product. General

instructionUnplug Ground/Earth


S-2

[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network.Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degradation in performance and safety. Such modifications are therefore strictly prohibited. the points listed below are not exhaustive, but they illustrate the reason-ing behind this policy.

SAFETY WARNINGS

Prohibited Actions

DANGER• Using any cables or power cord not specified by KMBT.

• Using any fuse or thermostat not specified by KMBT.

Safety will not be assured, leading to a risk of fire and

injury.

• Disabling fuse functions or bridging fuse terminals with

wire, metal clips, solder or similar object.

• Disabling relay functions (such as wedging paper between

relay contacts)

• Disabling safety functions (interlocks, safety circuits, etc.)

Safety will not be assured, leading to a risk of fire and

injury.

• Making any modification to the product unless instructed

by KMBT

• Using parts not specified by KMBT


S-3

[2] POWER PLUG SELECTION

In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.

Power Cord Set or Power Plug

WARNING• Use power supply cord set which meets the following

criteria:

- provided with a plug having configuration intended for the connection to wall outlet appropriate for the prod-uct's rated voltage and current, and

- the plug has pin/terminal(s) for grounding, and

- provided with three-conductor cable having enough cur-rent capacity, and

- the cord set meets regulatory requirements for the area.

Use of inadequate cord set leads to fire or electric shock.

• Attach power plug which meets the following criteria:

- having configuration intended for the connection to wall outlet appropriate for the product's rated voltage and current, and

- the plug has pin/terminal(s) for grounding, and

- meets regulatory requirements for the area.

Use of inadequate cord set leads to the product connect-ing to inadequate power supply (voltage, current capacity, grounding), and may result in fire or electric shock.

• Conductors in the power cable must be connected to ter-

minals of the plug according to the following order:

•Black or Brown:L (line)

•White or Light Blue:N (neutral)

•Green/Yellow:PE (earth)

Wrong connection may cancel safeguards within the product, and results in fire or electric shock.

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S-4

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi-neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure. In order to maintain safety and reliability, the CE must perform regular safety checks.

1. Power Supply

Connection to Power Supply

WARNING• Check that mains voltage is as specified.

Connection to wrong voltage supply may result in fire or electric shock.

• Connect power plug directly into wall outlet having same

configuration as the plug.

Use of an adapter leads to the product connecting to inadequate power supply (voltage, current capacity, grounding), and may result in fire or electric shock.

If proper wall outlet is not available, advice the customer to contact qualified electrician for the installation.

• Plug the power cord into the dedicated wall outlet with a

capacity greater than the maximum power consumption.

If excessive current flows in the wall outlet, fire may result.

• If two or more power cords can be plugged into the wall

outlet, the total load must not exceed the rating of the wall

outlet.

If excessive current flows in the wall outlet, fire may result.

• Make sure the power cord is plugged in the wall outlet

securely.

Contact problems may lead to increased resistance, overheating, and the risk of fire.

• Check whether the product is grounded properly.

If current leakage occurs in an ungrounded product, you may suffer electric shock while operating the product.

Connect power plug to grounded wall outlet.

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S-5

Power Plug and Cord

WARNING• When using the power cord set (inlet type) that came with

this product, make sure the connector is securely inserted

in the inlet of the product.

When securing measure is provided, secure the cord with

the fixture properly.

If the power cord (inlet type) is not connected to the prod-uct securely, a contact problem may lead to increased resistance, overheating, and risk of fire.

• Check whether the power cord is not stepped on or

pinched by a table and so on.

Overheating may occur there, leading to a risk of fire.

• Check whether the power cord is damaged. Check

whether the sheath is damaged.

If the power plug, cord, or sheath is damaged, replace with a new power cord (with plug and connector on each end) specified by KMBT. Using the damaged power cord may result in fire or electric shock.

• Do not bundle or tie the power cord.

Overheating may occur there, leading to a risk of fire.

• Check whether dust is collected around the power plug

and wall outlet.

Using the power plug and wall outlet without removing dust may result in fire.

• Do not insert the power plug into the wall outlet with a wet

hand.

The risk of electric shock exists.

• When unplugging the power cord, grasp the plug, not the

cable.

The cable may be broken, leading to a risk of fire and electric shock.


S-6

2. Installation Requirements

Wiring

WARNING• Never use multi-plug adapters to plug multiple power cords

in the same outlet.

If used, the risk of fire exists.

• When an extension cord is required, use a specified one.

Current that can flow in the extension cord is limited, so

using a too long extension cord may result in fire.

Do not use an extension cable reel with the cable taken up. Fire may result.

Prohibited Installation Places

WARNING• Do not place the product near flammable materials or vola-

tile materials that may catch fire.

A risk of fire exists.

• Do not place the product in a place exposed to water such

as rain.

A risk of fire and electric shock exists.

When not Using the Product for a long time

WARNING• When the product is not used over an extended period of

time (holidays, etc.), switch it off and unplug the power

cord.

Dust collected around the power plug and outlet may cause fire.


S-7

Ventilation

CAUTION• The product generates ozone gas during operation, but it

will not be harmful to the human body.

If a bad smell of ozone is present in the following cases, ventilate the room.

a. When the product is used in a poorly ventilated roomb. When taking a lot of copiesc. When using multiple products at the same time

Stability

CAUTION• Be sure to lock the caster stoppers.

In the case of an earthquake and so on, the product may slide, leading to a injury.

Inspection before Servicing

CAUTION• Before conducting an inspection, read all relevant docu-

mentation (service manual, technical notices, etc.) and

proceed with the inspection following the prescribed pro-

cedure in safety clothes, using only the prescribed tools.

Do not make any adjustment not described in the docu-

mentation.

If the prescribed procedure or tool is not used, the prod-uct may break and a risk of injury or fire exists.

• Before conducting an inspection, be sure to disconnect

the power plugs from the product and options.

When the power plug is inserted in the wall outlet, some units are still powered even if the POWER switch is turned OFF. A risk of electric shock exists.

• The area around the fixing unit is hot.

You may get burnt.


S-8

Work Performed with the Product Powered On

WARNING• Take every care when making adjustments or performing

an operation check with the product powered.

If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.

• Take every care when servicing with the external cover

detached.

High-voltage exists around the drum unit. A risk of elec-tric shock exists.

Safety Checkpoints

WARNING• Check the exterior and frame for edges, burrs, and other

damage.

The user or CE may be injured.

• Do not allow any metal parts such as clips, staples, and

screws to fall into the product.

They can short internal circuits and cause electric shock or fire.

• Check wiring for squeezing and any other damage.

Current can leak, leading to a risk of electric shock or fire.

• Carefully remove all toner remnants and dust from electri-

cal parts and electrode units such as a charging corona

unit.

Current can leak, leading to a risk of product trouble or fire.

• Check high-voltage cables and sheaths for any damage.



S-9

• Check electrode units such as a charging corona unit for

deterioration and sign of leakage.

Current can leak, leading to a risk of trouble or fire.

• Before disassembling or adjusting the write unit (P/H unit)

incorporating a laser, make sure that the power cord has

been disconnected.

The laser light can enter your eye, leading to a risk of loss of eyesight.

• Do not remove the cover of the write unit. Do not supply

power with the write unit shifted from the specified mount-

ing position.

The laser light can enter your eye, leading to a risk of loss of eyesight.

• When replacing a lithium battery, replace it with a new lith-

ium battery specified in the Parts Guide Manual. Dispose

of the used lithium battery using the method specified by

local authority.

Improper replacement can cause explosion.

• After replacing a part to which AC voltage is applied (e.g.,

optical lamp and fixing lamp), be sure to check the installa-

tion state.


• Check the interlock switch and actuator for loosening and

check whether the interlock functions properly.

If the interlock does not function, you may receive an electric shock or be injured when you insert your hand in the product (e.g., for clearing paper jam).

• Make sure the wiring cannot come into contact with sharp

edges, burrs, or other pointed parts.


Safety Checkpoints

WARNING


S-10

• Make sure that all screws, components, wiring, connec-

tors, etc. that were removed for safety check and mainte-

nance have been reinstalled in the original location. (Pay

special attention to forgotten connectors, pinched cables,

forgotten screws, etc.)

A risk of product trouble, electric shock, and fire exists.

Safety Checkpoints

WARNING

Handling of Consumables

WARNING• Toner and developer are not harmful substances, but care

must be taken not to breathe excessive amounts or let the

substances come into contact with eyes, etc. It may be

stimulative.

If the substances get in the eye, rinse with plenty of water immediately. When symptoms are noticeable, consult a physician.

• Never throw the used cartridge and toner into fire.

You may be burned due to dust explosion.

Handling of Service Materials

CAUTION• Unplug the power cord from the wall outlet.

Drum cleaner (isopropyl alcohol) and roller cleaner (ace-tone-based) are highly flammable and must be handled with care. A risk of fire exists.

• Do not replace the cover or turn the product ON before

any solvent remnants on the cleaned parts have fully

evaporated.



S-11

• Use only a small amount of cleaner at a time and take

care not to spill any liquid. If this happens, immediately

wipe it off.


• When using any solvent, ventilate the room well.

Breathing large quantities of organic solvents can lead to

discomfort.

Handling of Service Materials

CAUTION


S-12

[4] Used Batteries Precautions

ALL AreasCAUTION

Danger of explosion if battery is incorrectly replaced.Replace only with the same or equivalent type recommended by the manufacturer.Dispose of used batteries according to the manufacturer’s instructions.

GermanyVORSICHT!

Explosionsgefahr bei unsachgemäßem Austausch der Batterie.Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.Entsorgung gebrauchter Batterien nach Angaben des Herstellers.

FranceATTENTION

Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.Remplacer uniquement avec une batterie du même type ou d’un type équivalent recom-mandé par le constructeur.Mettre au rebut les batteries usagées conformément aux instructions du fabricant.

DenmarkADVARSEL!

Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med batteri af samme fabrikat og type.Levér det brugte batteri tilbage til leverandøren.

Finland, SwedenVAROlTUS

Paristo voi räjähtää, jos se on virheellisesti asennettu.Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.

VARNINGExplosionsfara vid felaktigt batteribyte.Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-tillverkaren.Kassera använt batteri enligt fabrikantens instruktion.

NorwayADVARSEL

Eksplosjonsfare ved feilaktig skifte av batteri.Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.Brukte batterier kasseres i henhold til fabrikantens instruksjoner.


S-13

[5] Laser Safety

• This is a digital machine certified as a Class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.

5.1 Internal Laser Radiation

*at laser aperture of the Print Head Unit

• This product employs a Class 3B laser diode that emits an invisible laser beam. The laser diode and the scanning polygon mirror are incorporated in the print head unit.

• The print head unit is NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit should not be opened under any circumstances.

semiconductor laser

Maximum power of the laser diode 30 mW

Maximum average radiation power (*) bizhub C650 15.2 µW

bizhub C550/C451 12.9 µW

Wavelength 775-800 nm

A00JP0C501DA

Laser Aperture ofthe Print Head Unit


S-14

U.S.A., Canada(CDRH Regulation)• This machine is certified as a Class 1 Laser product under Radiation Performance Stan-

dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of the U.S. Department of Health and Human Services (DHHS). This means that the device does not produce hazardous laser radiation.

• The label shown on page S-16 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States.

.

All Areas

Denmark

CAUTION• Use of controls, adjustments or performance of procedures other than those

specified in this manual may result in hazardous radiation exposure.

semiconductor laser



CAUTION• Use of controls, adjustments or performance of procedures other than those

specified in this manual may result in hazardous radiation exposure.

semiconductor laser



ADVARSEL• Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion.

Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825-1 sikkerheds kravene.

halvlederlaser

Laserdiodens højeste styrke 30 mW

bølgelængden 775-800 nm


S-15

Finland, Sweden

Norway

LUOKAN 1 LASERLAITEKLASS 1 LASER APPARAT

VAROITUS!• Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat-

taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser-säteilylle.

puolijohdelaser

Laserdiodin suurin teho 30 mW

aallonpituus 775-800 nm

VARNING!• Om apparaten används på annat sätt än i denna bruksanvisning specificerats,

kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass 1.

halvledarlaser

Den maximala effekten för laserdioden 30 mW

våglängden 775-800 nm

VARO!• Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättomälle laser-

säteilylle. Älä katso säteeseen.

VARNING!• Osynlig laserstråining när denna del är öppnad och spärren är urkopplad.

Betrakta ej stråien.

ADVERSEL• Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisn-

ing, kan brukeren utsettes för unsynlig laserstrålning, som overskrider grensen for laser klass 1.

halvleder laser

Maksimal effekt till laserdiode 30 mW

bølgelengde 775-800 nm


S-16

5.2 Laser Safety Label

• A laser safety label is attached to the inside of the machine as shown below.

5.3 Laser Caution Label

• A laser caution label is attached to the outside of the machine as shown below.

A00JP0E507DA

* Only for the U.S.A.

A00JP0C503DA


S-17

5.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

• When laser protective goggles are to be used, select ones with a lens conforming to the above specifications.

• When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC drum, be sure first to turn the printer OFF.

• If the job requires that the printer be left ON, take off your watch and ring and wear laser protective goggles.

• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use utmost care when handling tools on the user’s premises.

• The Print head is not to be disassembled or adjusted in the field. Replace the unit or Assembly including the control board. Therefore, remove the laser diode, and do not per-form control board trimmer adjustment.


S-18

Caution labels shown are attached in some areas on/in the machine.When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock.

WARNING INDICATIONS ON THE MACHINE

Do not burn used toner cartridges.Toner expelled from the fire is dangerous.

Do not position the used waste toner box so that it is standing on end or tilted, otherwise toner may spill.

Do not burn used Imaging Units.Toner expelled from the fire is dangerous.

The area around the fusing unit is extremely hot.Touching any part other than those indicated may result in burns.

WARNING

WARNING

WARNING

CAUTION


S-19

A00JP0E509DA

This area generates high voltage.Be careful not to touch here when the power is turned ON to avoid getting an electric shock.

High voltage


High voltage


S-20

CAUTION:

A00JP0E510DA


High voltage


High voltage

• You may be burned or injured if you touch any area that you are advised not to touch by any caution label. Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot be read, contact our service office.

MEASURES TO TAKE IN CASE OF AN ACCIDENT

S-21

1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.

2. If a report of a serious accident has been received from a customer, an on-site evalua-tion must be carried out quickly and KMBT must be notified.

3. To determine the cause of the accident, conditions and materials must be recorded through direct on-site checks, in accordance with instructions issued by KMBT.

4. For reports and measures concerning serious accidents, follow the regulations speci-fied by every distributor.



S-22

Blank Page

C-1

Composition of the service manualThis service manual consists of Theory of Operation section and Field Service section to

explain the main machine and its corresponding options.

Theory of Operation section gives, as information for the CE to get a full understanding of

the product, a rough outline of the object and role of each function, the relationship

between the electrical system and the mechanical system, and the timing of operation of

each part.

Field Service section gives, as information required by the CE at the site (or at the cus-

tomer’s premise), a rough outline of the service schedule and its details, maintenance

steps, the object and role of each adjustment, error codes and supplementary information.

The basic configuration of each section is as follows. However some options may not be

applied to the following configuration.

<Theory of Operation section>

<Field service section>

OUTLINE: Explanation of system configuration,

product specifications, unit configuration, and paper path

COMPOSITION/OPERATION: Explanation of configuration of each unit,

operating system, and control system

OUTLINE: Explanation of system configuration, and product

specifications

MAINTENANCE: Explanation of service schedule, maintenance steps, ser-

vice tools, removal/reinstallation methods of major parts,

and firmware version up method etc.

ADJUSTMENT/SETTING: Explanation of utility mode, service mode, and mechanical

adjustment etc.

TROUBLESHOOTING: Explanation of lists of jam codes and error codes, and

their countermeasures etc.

APPENDIX: Parts layout drawings, connector layout drawings, timing

chart, overall layout drawing are attached.

C-2

Notation of the service manualA. Product nameIn this manual, each of the products is described as follows:

B. Brand nameThe company names and product names mentioned in this manual are the brand name or

the registered trademark of each company.

C. Feeding direction• When the long side of the paper is parallel with the feeding direction, it is called short

edge feeding. The feeding direction which is perpendicular to the short edge feeding iscalled the long edge feeding.

• Short edge feeding will be identified with [S (abbreviation for Short edge feeding)] on thepaper size. No specific notation is added for the long edge feeding. When the size has only the short edge feeding with no long edge feeding, [S] will not beadded to the paper size.

<Sample notation>

(1) bizhub C650/C550/C451: Main body

(2) Microsoft Windows 98: Windows 98

Microsoft Windows Me: Windows Me

Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT

Microsoft Windows 2000: Windows 2000

Microsoft Windows XP: Windows XP

Microsoft Windows Vista: Windows Vista

When the description is made in combination of the OS’s mentioned above:

Windows 98/Me

Windows NT 4.0/2000

Windows NT/2000/XP/Vista

Windows 98/Me/ NT/2000/XP/Vista

Paper size Feeding direction Notation

A4Long edge feeding A4

Short edge feeding A4S

A3 Short edge feeding A3

SERVICE MANUAL

2008.06Ver. 8.0

THEORY OF OPERATION

Revision historyAfter publication of this service manual, the parts and mechanism may be subject to change forimprovement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine.

When any change has been made to the descriptions in the service manual, a revised version will beissued with a revision mark added as required.

Revision mark:• To indicate clearly a section revised, is shown at the left margin of the revised section.

The number inside represents the number of times the revision has been made.

• To indicate clearly a page that contains the revision, is shown near the page number of thecorresponding page.The number inside represents the number of times the revision has been made.

NOTERevision marks shown in a page are restricted only to the latest ones with the old ones deleted.

• When a page revised in Ver. 2.0 has been changed in Ver. 3.0: The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.

• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0: The revision marks for Ver. 2.0 are left as they are.

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2008/06 8.0 Description addition of function enhanced version 4 firmware (Card Ver. J8)

2008/05 7.0 Description addition of optional finisher FS-518

2008/03 6.0Description addition of optional Z-folding unit ZU-603

2008/01 5.0Description addition of function enhanced version 3 firmware (Card Ver. 88)/Error corrections

2007/08 4.0Description addition of function enhanced version 2 firmware/Error corrections

2007/05 3.0Description addition of bizhub C650/Error corrections

2007/04 2.0Description addition of bizhub C451/Error corrections

2007/02 1.0 — Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 8.0 Jun. 2008

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CONTENTS

bizhub C650/C550/C451 Main body

Outline1. System configuration............................................................................................... 1

1.1 C650 ..................................................................................................................... 1

1.2 C550 ..................................................................................................................... 3

1.3 C451 ..................................................................................................................... 5

2. Product specifications ............................................................................................. 8

3. Section configuration............................................................................................. 15

4. Paper path............................................................................................................. 16

4.1 C650/C550 ......................................................................................................... 16

4.2 C451 ................................................................................................................... 17

5. Image creation process......................................................................................... 18

Composition/Operation6. Overall composition............................................................................................... 21

6.1 Control block diagram......................................................................................... 21

7. Scanner section (IR section) ................................................................................. 22

7.1 Composition........................................................................................................ 22

7.1.1 CCD unit ..................................................................................................... 23

7.2 Drive ................................................................................................................... 23

7.3 Operation ............................................................................................................ 24

7.3.1 Scan and exposure lamp control................................................................. 24

7.3.2 Preventing stain on the DF original glass.................................................... 27

7.3.3 Original size detection control ..................................................................... 30

8. Write section (PH section)..................................................................................... 33

8.1 Composition........................................................................................................ 33

8.2 Operation ............................................................................................................ 34

8.2.1 Outline......................................................................................................... 34

8.2.2 Laser exposure process.............................................................................. 35

8.2.3 Laser emission timing ................................................................................. 36

8.2.4 Laser emission area.................................................................................... 37

8.2.5 Color registration control (color shift correction) system............................. 38

8.2.6 Color skew correction control ...................................................................... 40

8.2.7 PH unit temperature detection control ........................................................ 41

9. Imaging unit........................................................................................................... 42

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9.1 Composition ....................................................................................................... 42

9.2 Drive ................................................................................................................... 43

9.3 Operation............................................................................................................ 44

9.3.1 IU life control ............................................................................................... 44

10. Photo conductor section ....................................................................................... 46

10.1 Composition ....................................................................................................... 46

10.2 Drive ................................................................................................................... 46

10.3 Operation............................................................................................................ 47

10.3.1 PC drum drive mechanism ......................................................................... 47

10.3.2 K PC drum phase control............................................................................ 48

10.3.3 PC drum small amount rotation control ...................................................... 49

11. Charge Corona section ......................................................................................... 50

11.1 Operation............................................................................................................ 51

11.1.1 PC drum charge corona ON/OFF control ................................................... 51

11.1.2 Charge corona cleaning control.................................................................. 51

11.1.3 Cleaning/main erase mechanism ............................................................... 53

12. Developing section................................................................................................ 55

12.1 Composition ....................................................................................................... 55

12.2 Drive ................................................................................................................... 56

12.3 Operation............................................................................................................ 57

12.3.1 Developing drive control ............................................................................. 57

12.3.2 Developer flow ............................................................................................ 58

12.3.3 Developing bias .......................................................................................... 60

12.3.4 HMT (high grade micro toning) development.............................................. 61

12.3.5 Developer Scattering Preventive Mechanism ............................................. 62

12.3.6 TCR sensor control..................................................................................... 64

13. Toner supply section ............................................................................................. 65

13.1 Composition ....................................................................................................... 65

13.2 Drive ................................................................................................................... 66

13.3 Operation............................................................................................................ 67

13.3.1 Toner replenishing mechanism/control ....................................................... 67

13.3.2 Toner cartridge life control .......................................................................... 70

13.3.3 Toner cartridge life control .......................................................................... 70

13.3.4 Shutter mechanism..................................................................................... 72

14. Transfer Corona section ........................................................................................ 73

14.1 Composition ....................................................................................................... 73

14.1.1 1st Image Transfer section.......................................................................... 73

14.1.2 2nd Image Transfer section......................................................................... 74

14.2 Drive ................................................................................................................... 75

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14.2.1 1st Image Transfer Section ......................................................................... 75

14.2.2 2st Image Transfer Section ......................................................................... 76

14.3 Operation ............................................................................................................ 76

14.3.1 Transfer belt speed control .......................................................................... 76

14.3.2 1st Image Transfer Roller mechanism......................................................... 77

14.3.3 2nd image transfer roller pressure mechanism........................................... 82

14.3.4 IDC sensor shutter mechanism................................................................... 84

14.3.5 ATVC (Auto transfer voltage control) ........................................................... 85

14.3.6 Transfer belt cleaning .................................................................................. 86

14.3.7 2nd image transfer roller cleaning............................................................... 87

14.3.8 Charge neutralization and separation of paper ........................................... 88

14.3.9 Detection of new transfer belt unit............................................................... 89

14.3.10 Pressure/retraction control during ACS mode............................................. 90

14.3.11 Electric discharge control before the 2nd image transfer ............................ 92

15. Toner collecting section......................................................................................... 93

15.1 Composition........................................................................................................ 93

15.2 Drive ................................................................................................................... 94

15.3 Operation ............................................................................................................ 95

15.3.1 Toner collecting mechanism........................................................................ 95

15.3.2 Waste toner agitation control ...................................................................... 96

15.3.3 Waste Toner Box-in-position detection........................................................ 96

15.3.4 Waste Toner Near-Full/Full detection control .............................................. 97

16. Paper feed section................................................................................................. 99

16.1 Composition........................................................................................................ 99

16.1.1 Tray1, 2 ....................................................................................................... 99

16.1.2 Tray3 ......................................................................................................... 100

16.1.3 Tray4 ......................................................................................................... 101

16.2 Drive ................................................................................................................. 102

16.2.1 Tray1, 2 ..................................................................................................... 102

16.2.2 Tray3 ......................................................................................................... 103

16.2.3 Tray3 horizontal transport.......................................................................... 103

16.2.4 Tray4 ......................................................................................................... 104

16.3 Operation .......................................................................................................... 105

16.3.1 Tray1, 2 ..................................................................................................... 105

16.3.2 Tray3, 4 ..................................................................................................... 111

17. Bypass section .................................................................................................... 119

17.1 Composition...................................................................................................... 119

17.2 Drive ................................................................................................................. 120

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17.3 Operation.......................................................................................................... 121

17.3.1 Bypass paper take-up control ................................................................... 121

17.3.2 Paper empty detection .............................................................................. 121

17.3.3 Bypass paper lifting motion control........................................................... 122

17.3.4 Paper size detection ................................................................................. 123

17.3.5 Bypass unit open/close mechanism ......................................................... 125

17.3.6 Bypass sub tray open/close detection ...................................................... 125

18. Timing roller section............................................................................................ 126

18.1 Composition ..................................................................................................... 126

18.2 Operation.......................................................................................................... 127

18.2.1 Timing roller control .................................................................................. 127

18.2.2 OHP detection .......................................................................................... 128

18.2.3 Speed control............................................................................................ 129

19. Fusing section..................................................................................................... 130

19.1 Composition ..................................................................................................... 130

19.2 Drive ................................................................................................................. 132

19.3 Operation.......................................................................................................... 133

19.3.1 Heating roller structure ............................................................................. 133

19.3.2 Whole area heating/Center heating switch control ................................... 133

19.3.3 Fusing roller drive control ......................................................................... 135

19.3.4 Fusing loop control ................................................................................... 136

19.3.5 Fusing pressure roller pressure/retraction mechanism............................. 137

19.3.6 Fusing temperature control....................................................................... 138

19.3.7 Protection from abnormally high temperature........................................... 144

19.3.8 Sensor disconnection detection control .................................................... 146

19.3.9 Heating roller rotate detection................................................................... 146

19.3.10 Detection of a new fusing unit................................................................... 146

19.3.11 PPM control .............................................................................................. 147

20. Paper exit section................................................................................................ 149

20.1 Composition ..................................................................................................... 149

20.2 Drive ................................................................................................................. 150

20.3 Operation.......................................................................................................... 151

20.3.1 Switchback control .................................................................................... 151

21. Duplex section .................................................................................................... 152

21.1 Composition ..................................................................................................... 152

21.2 Drive ................................................................................................................. 153

21.2.1 Duplex unit drive ....................................................................................... 153

21.3 Operation.......................................................................................................... 154

21.3.1 Duplex unit transport control..................................................................... 154

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21.3.2 Duplex print ............................................................................................... 155

22. Image stabilization control................................................................................... 161

22.1 Overview........................................................................................................... 161

22.2 Operation .......................................................................................................... 162

22.2.1 IDC registration sensor adjustment control ............................................... 162

22.2.2 Max. density adjustment control ............................................................... 162

22.2.3 LD (laser diode) intensity adjustment control ............................................ 162

22.2.4 Gamma correction control......................................................................... 162

22.3 Operation sequence ......................................................................................... 163

22.4 Operation timing ............................................................................................... 164

23. Image processing................................................................................................ 168

23.1 Scanner section image processing block diagram............................................ 168

23.2 Write section image processing block diagram ................................................ 169

24. Other control ....................................................................................................... 172

24.1 Fan control ........................................................................................................ 172

24.1.1 Construction.............................................................................................. 172

24.1.2 Operation .................................................................................................. 173

24.2 Counter control ................................................................................................. 178

24.2.1 Construction.............................................................................................. 178

24.3 Power supply unit.............................................................................................. 179

24.4 Parts operated when the main power switch and sub power switch are turned ON.......................................................................................................................... 180

24.4.1 Parts operated when the main power switch and sub power switch areturned ON ................................................................................................. 180

24.5 Authentication unit (Biometric type) (AU-101)................................................... 181

24.6 Authentication unit (IC card type: AU-201) ....................................................... 181

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Blank Page

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Theory of Operation Ver. 8.0 Jun. 2008 1. System configuration

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Outline1. System configuration

1.1 C650

1/2 System front view

[1] Main body [6] Large capacity unit LU-301

[2] Authentication unit: Biometric type [7] Z folding unit ZU-603

AU-101 [8] Finisher FS-517/518

[3] Authentication unit: IC card type [9] Finisher FS-608

AU-201 [10] Post inserter PI-503

[4] Working table WT-502 [11] Punch kit PK-512/513

[5] Local interface kit EK-602/603 [12] Output tray OT-503

[1]

[2]

[4]

[5]

[6]

[7][8]

[11]

[12]

A00HT1C301AB

[10]

[11][10]

[9]

[3]

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1. System configuration Theory of Operation Ver. 8.0 Jun. 2008

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2/2 System rear view

*: Except for the North America area.

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[1] Main body [7] Scan accelerator kit* Standard

SA-501

[2] Stamp unit SP-501

[3] Fax kit FK-502 [8] Fax multi line ML-501

[4] Security kit SC-503 [9] Key counter kit KIT-1

[5] Image controller IC-409 [10] i-Option LK-101*/102*/103

[6] Video interface kit* Standard

VI-504 [11] Upgrade kit UK-201

A00HT1E001DB

[2]

[1]

[4]

[3]

[9]

[10] [11]

[6]

[8]

[5]

[7]

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1.2 C550


[1] Main body [6] Large capacity unit LU-301

[2] Authentication unit: Biometric type [7] Z folding unit ZU-603

AU-101 [8] Finisher FS-517/518

[3] Authentication unit: IC card type [9] Finisher FS-608

AU-201 [10] Post inserter PI-503

[4] Working table WT-502 [11] Punch kit PK-512/513

[5] Local interface kit EK-602/603 [12] Output tray OT-503

[1]

[2]

[4]

[5]

[6]

[8]

[11]

[12]

A00JT1C301AB

[10]

[11][10]

[9]

[3]

[7]

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[1] Main body [7] Scan accelerator kit SA-501

[2] Stamp unit SP-501 [8] Fax multi line ML-501

[3] Fax kit FK-502 [9] Key counter kit KIT-1

[4] Security kit SC-503 [10] i-Option LK-101*/102*/103

[5] Image controller IC-409 [11] Upgrade kit UK-201

[6] Video interface kit VI-504

A00HT1E001DB

[2]

[1]

[4]

[3]

[9]

[10] [11]

[6]

[8]

[5]

[7]

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1.3 C451


[1] Main body [10] Output tray (for FS-519) OT-602

[2] Authentication unit: Biometric type AU-101 [11] Punch kit PK-510

[3] Authentication unit: IC card type AU-201 [12] Mailbin kit MT-502

[4] Working table WT-502 [13] Saddle sticher SD-505

[5] Local interface kit EK-602/603 [14] Output tray (for main body) OT-503

[6] Mount kit MK-715 [15] Finisher FS-608

[7] Large capacity unit LU-301 [16] Finisher FS-517

[8] Job separator JS-504 [17] Post inserter PI-503

[9] Finisher FS-519 [18] Punch kit PK-512/513

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[1]

[2]

[4]

[5]

[7]

[11]

A00KT1C203AB

[9]

[12]

[3]

[6]

[8]

[14]

[13]

[10]

A00KT1C204AA

[1]

[16]

[18][17][18][17]

[15]

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[1] Main body [7] Scan accelerator kit SA-501

[2] Stamp unit SP-501 [8] Fax multi line ML-501

[3] Fax kit FK-502 [9] Key counter kit KIT-1

[4] Security kit SC-503 [10] i-Option LK-101*/102*/103

[5] Image controller IC-409 [11] Upgrade kit UK-201

[6] Video interface kit VI-504

A00HT1E001DB

[2]

[1]

[4]

[3]

[9]

[10] [11]

[6]

[8]

[5]

[7]

4

4

4

Theory of Operation Ver. 8.0 Jun. 2008 2. Product specifications

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2. Product specificationsA. Type

Type Combination scanner and printer console type

Copying system Electrostatic dry-powdered image transfer to plain paper

Printing process Laser electrostatic printing system

PC drum type OPC drum: KM-12 (OPC with high mold releasability)

Scanning density 600 dpi

Exposure lamp White rare-gas fluorescent lamp 30 W

Platen Stationary (mirror scan)

Original scanningMirror scanning CCD optical system* Sheet through system when DF-610 or DF-611 is used

Registration Rear left edge

Paper feeding separation system

Manual bypass : Roller separation system with pick-up mechanismTray 1 : Roller separation system with pick-up mechanismTray 2 : Roller separation system with pick-up mechanismTray 3 : Roller separation system with pick-up mechanismTray 4 : Roller separation system with pick-up mechanism

Exposure system 1 polygon 2 beam x 4 LD exposure and polygon mirror scan system

Exposure densityEquivalent to 1800 dpi in main scanning direction × 600 dpi in sub scanning direction

Developing system Dry 2 components developing method, HMT developing system

Charging system DC comb electrode scorotron system with electrode cleaning function

Neutralizing system Red LED system

Image transfer system Belt image transfer system (1st)/roller image transfer system (2nd)

Paper separating system

Combination of curvature, separating claws, and bias system

Fusing system Belt IH fusing system

Heating system Heating: IH heating, Soaking: Halogen lamp

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2. Product specifications Theory of Operation Ver. 8.0 Jun. 2008

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B. Functions

Types of original Sheets, books, and three-dimensional objects

Max. original size A3 or 11 x 17

Max. original weight Max. 2 kg

Multiple copies 1 to 9999

Warm-up time(at ambient tempera-ture of 23° C/73.4° F and rated source volt-age)

When the sub power switch is turned ON at any timing while the main power switch remains ON for a predetermined period of time or more

C650/C550/C451 30 sec. or less (Monochrome print, Color print)

C550: Taiwan only 60 sec. or less (Monochrome print, Color print)

C451: Taiwan only30 sec. or less (Monochrome print)

60 sec. or less (Color print)

When the main power switch is turned ON during the sub power switch being ON

C650/C550/C451 85 sec. or less (Monochrome print, Color print)

C550: Taiwan only 115 sec. or less (Monochrome print, Color print)

C451: Taiwan only85 sec. or less (Monochrome print)

115 sec. or less (Color print)

Image loss Leading edge: 4.2 mm (3/16 inch), Trailing edge: 3 mm (1/8 inch), Rear edge: 3 mm (1/8 inch), Front edge: 3 mm (1/8 inch)

First copy time (Tray1/2 A4 or 8 1/2 x 11, full size)

C6503.8 sec. or less (Monochrome print)6.0 sec. or less (Color print)



Processing speedPlain papermonochrome

C650: 310.00 mm/s

C550: 264.00 mm/s

C451: 216.00 mm/s

Plain paper/full colorC650: 240.00 mm/s

C550/C451: 216.00 mm/s

Thick 1, Thick 1+C650: 155.00 mm/s

C550/C451: 132.00 mm/s

Thick 2, Thick 3, Thick 4, OHP, Post card, Envelope, Label sheet

C650: 120.00 mm/s

C550/C451: 108.00 mm/s

Copying speed for multi-copy cycle(A4 or 8 1/2 x 11, plain paper)

Monochrome

C650: 1-sided: 65 copies/min *1, 2-sided: 65 copies/min

C550: 1-sided: 55 copies/min, 2-sided: 55 copies/min


Full color


C550/C451: 1-sided: 45 copies/min, 2-sided: 45 copies/min

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*1: 1-sided from tray 3 or tray 4. 1-sided from tray 1: 63 copies/min; 1-sided from tray 2: 64 copies/min

Fixed zoom ratios Full size x1.000

ReductionMetric area x0.500, x0.707, x0.816, x0.866

Inch area x0.500, x0.647, x0.733, x0.785

EnlargementMetric area x1.154, x1.224, x1.414, x2.000

Inch area x1.214, x1.294, x1.545, x2.000

Zoom ratios memory Metric area 3 memories

Variable zoom ratios x0.250 to x4.000 Inch area in 0.001 increments

Paper size

Tray 1/Tray 2

Metric area A3 Wide, A3 to A5S, A6S, post card

Inch area11 x 17 to 8 1/2 x 11, 8 x 13 *1, 16K, 8K, 12 1/4 x 18

Tray 3/Tray 4 A4, B5, A5, 8 1/2 x 11, 5 1/2 x 8 1/2, 16K, postcard S

Manual bypass tray

Metric area A3 wide, A3 to B6S, A6S, postcard

Inch area11 x 17 to 5 1/2 x 8 1/2, 8 x 13 *1, 16K, 8K, 12 1/4 x 18

Copy exit tray capacity(When OT-503 is mounted)

Plain paper 250 sheets

Thick paper 10 sheets

OHP transparencies 1 sheet

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C. Paper

*1: Excluding damp paper, curled paper, and recycled paper.

Type

Paper source (maximum tray capacity)

Tray 1 Tray 2 Tray 3 Tray 4Multiple bypass

Paper type

Plain paper (64 to 90 g/m2 / 17

to 24 lb)

❍ (500 sheets)

❍ (500 sheets)

❍ (1500 sheets)

❍ (1000 sheets)

❍ (150 sheets)

Translucent paper – – – – –

OHPtransparencies

– – – –❍

(20 sheets)*3

Thick paper 1 *1(91 to 120 g/m2 / 24.25 to 32 lb)

❍ (400 sheets)

❍ (400 sheets)

❍ (1150 sheets)

❍ (750 sheets)

❍ (100 sheets)

Thick paper 1+ *1 (121 to 157 g/m2 / 32 to 41.75 lb)

❍ (280 sheets)

❍ (280 sheets)

❍ (800 sheets)

❍ (500 sheets)

❍ (80 sheets)

Thick paper 2 *1(158 to 209 g/m2 / 42 to 55.5 lb)

❍ (250 sheets)

❍ (250 sheets)

❍ (700 sheets)

❍ (450 sheets)

❍ (70 sheets)

Thick paper 3 *1,2(210 to 256 g/m2 / 55.75 to 68 lb)

❍ (200 sheets)

❍ (200 sheets)

❍ (600 sheets)

❍ (400 sheets)

❍ (60 sheets)

Thick paper 4 *1,2(257 to 300 g/m2 / 68.25 to 80 lb)

– – – –❍

(50 sheets)

Postcards – –❍

(200 sheets)❍

(200 sheets)❍

(50 sheets)

Envelopes – – – –❍

(10 sheets)

Labels – – – –❍

(50 sheets)

Long Size Paper *4 – – – –❍

(1 sheet)

Copy paper dimen-sions

Width139.7 to 311.1 mm5 1/2 to 12 1/2 inch

A4, B5, A5, 8 1/2 x 11, 5 1/2 x 8 1/2, 16K, postcard S

90 to 311.1 mm3 1/2 to 12 1/4 inch

Length182.0 to 457.2 mm7 1/4 to 18 inch

139.7 to 457.2 mm5 1/2 to 18 inch

Long Size

Paper *4

Width – – – –

210 to 297 mm8 1/4 to 11 3/4 inch

Length – – – –

457.2 to 1200 mm18 to 47 1/4 inch

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*2: Image is not guaranteed when thick paper 3/4 is used.*3: Monochrome print only.*4: Paper to be reliably fed through only for C451 (127 to 210 g/m2 (33.75 to 55.75 lb))

Automatic duplex unit : Only the plain paper weighing 64 to 90 g/m2 (17 to 24 lb) or thick paper weighing 91 to 256 g/m2 (24.25 to 68 lb) are reliably fed.

D. Maintenance• C650

• C550

• C451

7No. of pages printed per month (average)

Color print 7,700 prints

Monochrome print 30,800 prints

Standard copy modeColor print 5 pages/job

Monochrome print 7 pages/job

Standard original density

Color print C, M, Y, K 5%

Monochrome print K 5%


















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E. Machine specifications• C650

*1: Width when the manual bypass tray is closed*2: Space requirements are the values when the finisher is slid to the maximum, the paper

feed tray is slid to the maximum, and the upper right door is open.

• C550/C451

*1: Width when the manual bypass tray is closed*2: Space requirements are the values when the finisher is slid to the maximum, the paper

feed tray is slid to the maximum, and the upper right door is open.

2

Power requirements

Voltage: AC 100 V, 120 V, 127 V, 220-240 V

Current: 100 V 15 A + 7A

110 V 15 A + 7A

120 V 16 A

127 V 16 A

230 V 10 A

Frequency: 50 to 60 Hz ± 3 Hz

Max power consumption

100 V 2,000 W or less

110 V 2,000 W or less

120 V 2,000 W or less

127 V 2,000 W or less

230 V 2,000 W or less

Dimensions650 *1 (W) x 777 (H) x 1,155 mm (H)25.5 *1 (W) x 30.5 (D) x 45.5 inch (H)

Space requirements 2,360 (W) x 1,483 mm (D) *293.0 (W) x 58.25 inch (D) *2

WeightMachine Approx. 190.0 kg / 419.0 lb (without IU and TC)

IU and TC Approx. 14.5 kg / 32.0 lb

2

Power requirements

Voltage: AC 100 V, 120 V, 127 V, 220-240 V

Current: 100 V 15 A

110 V 15 A

120 V 16 A

127 V 16 A

230 V 10 A

Frequency: 50 to 60 Hz ± 3 Hz

Max power consumption

100 V 1,500 W or less

110 V 1,650 W or less

120 V 1,920 W or less

127 V 2,000 W or less

230 V 2,000 W or less

Dimensions650 *1 (W) x 777 (H) x 1,155 mm (H)25.5 *1 (W) x 30.5 (D) x 45.5 inch (H)

Space requirements 2,360 (W) x 1,483 mm (D) *293.0 (W) x 58.25 inch (D) *2

WeightMachine Approx. 190.0 kg / 419.0 lb (without IU and TC)

IU and TC Approx. 14.5 kg / 32.0 lb

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F. Operating environment

G. Print functions

H. Scan functions

NOTE• These specifications are subject to change without notice.

Temperature 10 to 30° C / 50 to 86° F (with a fluctuation of 10° C / 18° F or less per hour)

Humidity 15 to 85% (Relative humidity with a fluctuation of 10%/h)

Levelness Difference between front and back, right and left should be 1 degree or under.

Type Built-in printer controller

RAM 1,024 MB (shared with the main body)

HDD 60 GB (shared with the main body)

InterfaceStandard

Ethernet (1000Base-T/100Base-TX/10Base-T)USB2.0/1.1

Option USB 2.0

Frame type Ethernet 802.2, Ethernet 802.3, Ethernet II, Ethernet SNAP

Supported protocols TCP/IP, IPX/SPX, NETBEUI, Apple Talk (EtherTalk)

Print speed (A4 or 8 1/2 x 11, plain paper)

Monochrome printC650: 1-sided: 65 ppm, 2-sided: 65 ppmC550: 1-sided: 55 ppm, 2-sided: 55 ppmC451: 1-sided: 45 ppm, 2-sided: 45 ppm

Color printC650: 1-sided: 50 ppm, 2-sided: 50 ppmC550/C451: 1-sided: 45 ppm, 2-sided: 45 ppm

Printer languagePCL5e/c Emulation, PCL6 (XL Ver. 3) EmulationPostScript 3 Emulation (3016)XPS

Print resolutionEquivalent to 1800 dpi in main scanning direction × 600 dpi in sub scanning direction

Printer fonts PCL Latin 80 Fonts Postscript 3 Emulation Latin 137 Fonts

Supported computer IBM PC/AT compatible machine, Macintosh (PowerPC/Intel processor)

Supported operating systems

ServerWindows NT4.0 (SP6)/2000 (SP3)/2003 (incl. 64 bit)

Client

Windows Vista (incl. 32/64 bit)Windows 2000 (SP3)/XP (incl. 64 bit)Windows NT4.0 (SP6)Mac OS 9.2 or later/Mac OS X 10.2, 10.3, 10.4Linux

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Driver KONICA MINOLTA scanner driver

Compatible operating systems

Windows 2000, Windows XP/XP (incl. 64 bit)

Scan speed(A4 or 8 1/2 x 11, Resolution 300 dpi)

C650: DF-610Monochrome: 75 pages/minFull color: 70 pages/min

C550/C451: DF-611Monochrome: 70 pages/minFull color: 70 pages/min

Scannable range Same as the copier (Max. A3)

Functions Scan to E-mail, Scan to FTP, Scan to SMB, Scan to BOX

Resolution 200/300/400/600 dpi

3. Section configuration Theory of Operation Ver. 8.0 Jun. 2008

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3. Section configuration

2

A00JT1C201AA

Scanner section (IR section)

Fusing section

Transfer corona section

Write section (PH section)

Bypass section

Paper feed section (Tray1)

Paper feed section (Tray2) Toner collecting sectionIn front door (dotted line section)

Imaging unit section (IU section)

Toner supply section



Duplex section (standard)

Auto document feed section * Standard C650: DF-610 C550/C451: DF-611

Theory of Operation Ver. 8.0 Jun. 2008 4. Paper path

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4. Paper path

4.1 C650/C5502

A00JT1C201AA

1

4. Paper path Theory of Operation Ver. 8.0 Jun. 2008

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4.2 C4511

A00KT1C202AA

Theory of Operation Ver. 8.0 Jun. 2008 5. Image creation process

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5. Image creation process

[1]Photoelectric conversion

• The light reflected off the surface of the original is separated into dif-ferent colors using the color filters (R, G, and B); CCD then converts it into a corresponding electric signal and outputs the signal to the IR imaging processing section.

[2] IR image processing• The electric signal is converted to 8-bit digital image signals. After

going through some corrections, video signals (C, M, Y, and K) are output to the printer image processing section.

[3]Printer image processing

• D/A conversion will be performed after the VIDEO signals (Y, M, C, Bk) are corrected. This data will control the emission of the laser diode.

[4] PC drum• The image of the original projected onto the surface of the PC drum is

changed to a corresponding electrostatic latent image.

[5] PC drum charging • Supply DC ( - ) charge on the PC drum.

[6] Laser exposure• Expose photo conductor to a laser beam to develop electrostatic

latent image.

[7] Developing

• The toner, agitated and negatively charged in the developer mixing chamber, is attracted onto the electrostatic latent image formed on the surface of the PC drum. It is thereby changed to a visible, devel-oped image.

• AC and DC negative bias voltages are applied to the developing roller, thereby preventing toner from sticking to the background image portion.

[8] 1st image transfer

• A DC positive voltage is applied to the backside of the transfer belt, thereby allowing the visible, developed image on the surface of each of the PC drums (Y, M, C, and K) to be transferred onto the transfer belt.

A00JT1C203AA

[4] PC drum

[1] Photoelectric conversion

[2] IR image pro-cessing

[3] Printer image processing

[7] Developing [12] PC drum cleaning

Y M C

K

Y M C K

[13] Main erase

[5] PC drum charging

[5] PC drum charging (K)

[9] 2nd image transfer

[4] PC drum (K)

[11] Transfer belt cleaning

[8] 1st image transfer [10] Paper

separation

[6] Laser exposure

5. Image creation process Theory of Operation Ver. 8.0 Jun. 2008

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[9] 2nd image transfer• A DC positive voltage is applied to the backside of the paper, thereby

allowing the visible, developed image on the surface of the transfer belt to be transferred onto the paper.

[10] Paper separation• The paper, which has undergone the 2nd image transfer process, is

neutralized so that it can be properly separated from the transfer belt by the paper separator claws.

[11] Transfer belt cleaning• Residual toner on the surface of the transfer belt is collected for

cleaning by cleaning brush.

[12] PC drum cleaning • The residual toner left on the surface of the PC drum is scraped off.

[13] Main erase• The surface of the PC drum is irradiated with light, which neutralizes

any surface potential remaining on the surface of the PC drum.

3

Theory of Operation Ver. 8.0 Jun. 2008 6. Overall composition

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Composition/Operation6. Overall composition

6.1 Control block diagram

Exposure lamp (FL201)

Inverter board (INVB)

CCD board (CCDB)

Image processing board (IPB)

MFP board (MFPB)

Image processing

PH relay board (REYB/PH)

Integrated PH unit /Y/M/C/K

Control line

Image path line

Original glass moving motor (M202)

Original glass position control boar (OGPCB)

Scaner elay board (REYB/SCAN)

Scanner motor (M201)

Operation panel

Printer control board (PRCB)

Mechanical control (CPU)

Finisher option (FS-517, FS-608 FS-519, JS-504)

Automatic document feeder (DF-610,DF-611) as standard

Process

IH fusing

Paper feed/transport drive bord (PFTDB)

Paper feed, transport, duplex unit

Large paper feed option (LU-301)

Scanner part

Printer part

A00HT2E306AA

3

7. Scanner section (IR section) Theory of Operation Ver. 8.0 Jun. 2008

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7. Scanner section (IR section)

7.1 Composition

A00JT2E522DA

A00JT2C028AAA00JT2C001AA

20 degree sensor (PS202)

Scanner relay board (REYB/SCAN)


Original size detection 2 sensor (PS205)

Lens

CCD unit

Original cover sen-sor (RS201)

Mirror unit

Original glass movingmotor (M202)

Exposure unitScanner home sensor (PS201)

Glass moving unit

Inverter board (INVB)

Optical cooling fan motor (FM201)

Original glass posi-tion control board

Original size detection 1 sensor (PS204)

Theory of Operation Ver. 8.0 Jun. 2008 7. Scanner section (IR section)

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7.1.1 CCD unit

7.2 Drive

R

G

B

9.325 µm

9.325 µm

4036ma2602c0

37.3 µm

37.3 µm

CCD sensorScanning direction

Sub

sca

nnin

g di

rect

ion

Main scanning direction

A00JT2C003DA

Scanner drivecable/R

Mirror unit

Exposure unit


Scanner drivecable/F Scanner home sensor (PS201)

Original glass movingmotor (M202)

Glass moving unit


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7.3 Operation

7.3.1 Scan and exposure lamp control

A. When the power is ON1. The exposure unit moves from the scanner standby position to the home position.2. Exposure unit moves from the home position to the shading position (under the

shading correction sheet) and stops (in scanning direction).3. The gain value of the CCD sensor output voltage is adjusted for R, G, and B.4. A shading correction is made.5. After the adjustment has been made, the exposure unit moves in the return direc-

tion and stops at the home position.6. The exposure unit moves in the scan direction and stops at the standby position.

A00JT2C004DA

A00JT2C002AA

Exposure lamp (FL201) ON

Scanner movement

Home position

Shading position

Shading position

Scanning directionReturning direction

Standby position

Gain adjustment and shading correction

Standby position

Home position

Power is ON


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B. When the Start key is pressed(1) Original cover mode

1. Turning the Start key ON will turn the exposure lamp ON (at the standby position)2. The exposure unit moves in the return direction and stops at the shading position.

At the shading position, the gain adjustment is made.3. The exposure unit moves in the return direction and stops at the scan start posi-

tion.4. To start a scan, the exposure unit moves from the scan start position to the leading

edge of an original while performing shading correction. The exposure unit will start reading the original image from the leading edge. The unit will finish reading the image at the back edge of the image.

5. The exposure lamp will be OFF when the reading is complete.6. The exposure unit moves in the return direction and stops at the home position.

Then the exposure unit moves in the scan direction and stops at the standby posi-tion. It scans only once even for the color-copies, since R, G, and B data will all be memorized in one scanning.

A00JT2C003AA

A00JT2C005DA

Shading position

Home position Standby position

Standby position

Scan start position

Scan start position

Leading edge of the image

OriginalBack edge of the image

Scan

Return

Shading position

Home position

Leading edge of the image

Scan

Return

Exposure lamp (FL201) ON

Back edge of the image

Start key ON


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(2) DF mode• The original fed by the document feeder will be read at the original DF glass for. The

Exposure unit will move to the reading position and stops. The document will be read as the paper is transferred.

9J07T2C005DA


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7.3.2 Preventing stain on the DF original glass

A. DF original glass movement• The reading lines will occur when DF original glass has stain. Shift mechanism for the DF

original glass is provided to avoid this trouble.• The stand-by position for the DF original glass will be detected by the glass home sen-

sor.• DF original glass will move back and forth by the original glass moving motor.

B. Details on DF original glass movement• The DF original glass makes four different movements. Each of the four modes available

uses different glass movements.• The following explains the four different movements and the four different modes.

(1) Normal movement performed each time after reading a sheet of original• The DF original glass moves slightly back or forth every time after reading a sheet of

multiple originals. This changes the image reading position on the DF original glass and prevents the repeated occurrence of lines in the sub scan direction due to the same stain on the glass.

• The movement of the DF original glass is varied according to the specific model of the reverse automatic document feeder installed, as each model has a specific rating of scanning speed.

A00JT2C007DA

Original glass moving motor (M202)

Glass home sensor (PS203)

2

The first original The second original

DF original glass

Image reading position Image reading position


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(2) DF original glass cleaning movement performed each time after reading a sheet of original

• While reading multiple originals consecutively, the DF original glass moves widely back and forth between each original reading.

• Due to the effect of the step sheet that makes contact with the DF original glass, stain on the DF original glass can be removed from the reading position and reduce image streaks in the sub scan direction.

• Stain collected on the DF original glass is removed from the reading section by the trail-ing edge of an original that is passing by.

(3) DF original glass cleaning movement performed after completing a job• After the completion of a job, the DF original glass moves widely back and forth to

remove stain remaining on the surface. This reduces the occurrence of lines in the sub scan direction.

(4) Split line erase movement• While reading originals, the DF original glass moves widely. This is to remove stain on

the glass and to enable the image processing board to detect lines produced by stain. The detected lines are corrected in the image-processing step to prevent the occurrence of lines. After the completion of image reading, the DF original glass returns to the origi-nal position.

• This movement can be done when level 2 or higher is selected from 0 to 6 levels in the Detection during paper passage setting. To make this setting, press keys as follows. Ser-vice Mode → [System 2] → [Split Line Detect. Setting]

DF original glassImage reading position

Step sheet

A00JT2C544DA

StainDF original glass

Original

Image reading position


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C. DF original glass movement in each mode(1) Normal mode

(2) Stain reduction mode (available from the copy mode screen)

(3) Split line erase mode (available from the service mode)

D. Step sheet• The step sheet is provided in order to reduce the stain on the DF original glass.• It is installed to the operator side of the DF original glass in order to reduce the area orig-

inal touches the glass.

1 Repeats the normal movement each time after reading a sheet of original

2

Makes the DF original glass cleaning movement after completing a job

NOTEThis cleaning operation is not performed when the setting is made in the service mode as follows. [System 2] - [Split Line Detect. Setting] - [Prior Detection] - [Not Set]

1Repeats the DF original glass cleaning and the normal movements each time after reading a sheet of original

2 Makes the DF original glass cleaning movement after completing a job

1While reading originals, the DF original glass moves to remove stain and to correct lines pro-duced by stain by processing images. This reduces the occurrence of lines.

2 Makes the DF original glass cleaning movement after completing a job

9J07T2C007DA

Step sheet

DF original glass


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7.3.3 Original size detection control

A. Detection method• For detection of the original size, the reflective size sensors detect the length of the orig-

inal while the CCD detects the width of the original.• Mounting the optional sensor on a machine intended for the metric areas permits detec-

tion of inch sizes. Mounting the optional sensor on a machine intended for the inch areas permits detection of metric sizes.

• With Image processing board, the original size will be judged by the original size sensor and CCD.

• An original of an irregular size is rounded to the nearest standard size.

NOTE• Table 1 or 2 can be selected in the service mode.

A00JT2C029AA

4037T2E597AA

Automatic document feeder


CCD unitExposure unit

Original standard position

Original readposition

Exposure unit

313.5 mm

Original sizedetectionsensor 1 (PS204)

20 degrees

Original sizedetectionsensor 2 (PS205)

346.1 mm


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Metric area & china areas

Table 1

Table 2

*: Option

Inch areas

Table 1

Table 2

*: Option

Original size

detectionsensor 1

CCD width (mm)

~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~261.5 ~275.0 278.1~

OFF A5S B5S 16KS A4S B5 B5 16k A4

ON - - - - FLS B4 8k A3

Original sizedetectionsensor

CCD width (mm)

1 2* ~143 ~153 ~187 ~200 ~213 ~220.9 ~225 ~261.5 ~274.7 ~284.4 284.5~

OFF OFF51/2 ×81/2 S

A5S B5S 16KS A4S81/2 ×11 S

- B5 16K81/2 ×

11A4

ON OFF - - - - FLS FLS FLS - - - -

OFF ON - - - - - - - - - - -

ON ON - - - - - - - B4 8K 11 × 17 A3

Original sizedetectionsensor 1

CCD width (mm)

~144.7 ~220.9 ~221.0

OFF 51/2 × 81/2 S 81/2 × 11 S 81/2 × 11

ON - 81/2 × 14 11 × 17

Original sizedetectionsensor

CCD width (mm)

1 2* ~143 ~153 ~187 ~213 ~220.9 ~225 ~262 ~284.4 284.5~

OFF OFF 51/2 × 81/2 S A5S B5S A4S 81/2 × 11 S - B5 81/2 × 11 A4

ON OFF - - - FLS FLS FLS - - -

OFF ON - - - - 81/2 × 14 - - - -

ON ON - - - - 81/2 × 14 - B4 11 × 17 A3


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B. Detection timing

Original size sensors 1 (PS203), and 2 (PS204)


Exposure lamp (FL201)

Original cover/DF open sensor (RS201)

Validates the original length Validates the original size

A00JT2E511DA

Theory of Operation Ver. 8.0 Jun. 2008 8. Write section (PH section)

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8. Write section (PH section)

8.1 Composition


A00JT2C001DA

Return mirror (light source)

Cylindrical lens

Index mirror

Index lens

Polygon mirror

Laser drive board/Y(LDDB/Y)

Laser drive board/C (LDDB/C)

Laser drive board/M (LDDB/M)

G1 lensG2 lens

G3 lens

Synthetic mirror (Y,C,M)

Laser drive board/K (LDDB/K) Skew correction motor/

Y,M,C (M35,M36,M37)

PH unit

Index board (INDEXB)

8. Write section (PH section) Theory of Operation Ver. 8.0 Jun. 2008

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8.2 Operation

8.2.1 Outline

• The surface of the photo conductor is irradiated with a laser light and an electrostatic latent image is thereby formed.

• The PH unit has a single-piece construction. The PH unit has four semiconductor lasers with one laser for each four different color. A single polygon motor is used to make a scan.

• To be compatible with the high speed printing system, a seven sided polygon mirror is used. The two beam array LD is used to control the growth of the polygon motor rotation speed.

• The two-beam array LD consists of two LD elements arranged vertically. Two lines are scanned with two laser beams emitted from these two LD elements through a single face of the polygon mirror.

A00JT2C008DA

2 line One scan

G3 lens

polygon mirror

Laser diode

Transfer belt

PC drum YY M C K

PC drum

Beam A

Beam B

PC

drum rota-

tory direction

Beam A

Beam B

Return mirror/1

Return mirror/2

PC drum surface

G1 lens


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8.2.2 Laser exposure process

A. Operation1. The K laser light enters the cylindrical lens via the return mirror (light source). The

Y, M, and C laser light enter the cylindrical lens via the synthetic mirror and return mirror (light source).

2. At the cylindrical lens, each laser light is condensed in the vicinity of the polygon mirror.

3. Since the angle of incidence for each color of laser light varies, the laser light reflected by the polygon mirror is reflected in a different angle for each color.

4. The condensing angle of each color of laser light is corrected by the G1 and G2 lenses and then reaches each return mirror.

5. The K laser light is condensed on the PC drum surface via the G3 lens and return mirror /1. The Y and M laser light is condensed on the PC drum surface via the return mirror /1, G3 lens, and return mirror /2. The C laser light is condensed on the PC drum surface via the return mirror /1, return mirror /2, G3 lens, and return mirror /3.

A00JT2E510DA

Cylindrical lens

Laser drive board/Y (LDDB/Y)


Laser drive board/K (LDDB/K)

Index board (INDEXB)Return mirror (light source)

Index lens

Polygon motor

Synthetic mirror (Y,C,M)

G1

G2

Y M C K

Polygon mirror

G1 G2 Return mirror

Return mirror



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8.2.3 Laser emission timing

• After a print cycle has been started, when the stable rotation signals of PC drum and polygon motor are detected, a laser ON signal is output from the printer control board.

• The laser ON signal triggers each laser light emission.• After passing through the return mirror (light source), cylindrical lens, polygon mirror, G1

lens, G2 lens, index mirror, and index lens, the K laser light is applied to the index board. This generates an index signal.

• This index signal has a function of keeping the same laser light emission timing per every two lines in the main scanning direction.

• The index signal is only generated from the K laser beam but for the other colors, the emission timing is determined with K as a basis.

A00JT2C010DA

G1 lens

G2 lens

Laser drive board/Y(LDDB/Y)



Laser drive board/K (LDDB/K)

Index board (INDEXB)

Polygon mirror

Index lens

Index mirror


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8.2.4 Laser emission area

A. Main scanning direction• The print start position in the CD direction is determined by the CD print start signal (/

HSYNC) that is output from the printer control board and the width of the paper.• The laser emission area is determined by the paper size. The area of 3 mm/0.118 inch

on both edges of the paper is, however, the void image area.

B. Sub scanning direction• The print start position in the sub scanning direction is determined by the image write

start signal (/TOD) that is output from the printer control board and the length of the paper.

• The laser emission area is determined by paper size. However, there are void areas that are 4.2 mm/0.165" from the leading edge and 3 mm/0.118" from the trailing edge of paper.

4138to2595c0

Void width: 3 mm/0.118”

Void width: 4.2 mm/0.165”

Void width: 3 mm/0.118”

Void width: 3mm/0.118”


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8.2.5 Color registration control (color shift correction) system

• In a tandem engine, each four different color has an independent image reproduction process. Color shift may occur because of variations in part accuracy. The color registra-tion control system automatically detects color shift and correct color shift in the main and sub scanning directions.

• The color shift detection sequence proceeds as follows. A detection pattern each in the main scanning direction is produced at the front and rear on the transfer belt. Each of IDC registration sensor F and R at the front and rear reads the corresponding pattern. The amount of color shift in the sub scanning direction is then calculated and stored in memory. A detection pattern each in the sub scanning direction is next produced at the front and rear on the transfer belt. Each of IDC registration sensor F and R at the front and rear reads the corresponding pattern. The amount of color shift in the main scanning direction is then calculated and stored in memory. Based on the data representing the amounts of color shift, the machine calculates how much each of the different colors should be corrected. The correction data is further stored in memory. Based on the data stored in memory, the machine controls each dot during production of image outputs, thereby correcting the color shift.

4038T2C007AA

A00JT2C034DA

IDC registration sen-sor/F (IDCS/F)

IDC registration sensor/R (IDCS/R)Transfer belt

Detection pattern for sub scanning direction

Detection pattern for main scanning direction


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A. Color shift correction method• Black (K) is used as a standard of reference when other colors, yellow (Y), magenta (M),

and cyan (C), are individually corrected.

(1) Color shift in the main scanning direction• The following two methods are available to correct color shift in the main scanning direc-

tion.1. Adjustment in the main scanning direction: Change of image write start timing in

the main scanning direction.2. Overall scaling: Change of writing clock frequency.

(2) Color shift in the sub scanning direction1. Adjustment in the sub scanning direction: Change of image write start timing in the

sub scanning direction.2. Color skew correction:

Adjustment of the PH unit G3 lens skew.The G3 lens is driven by the skew correction motor.

• For an easier explanation, the above illustration uses the relation between black toner (K) and color toners (Y, M, C) that are transferred onto the transfer belt.

B. Color registration control operation timingThe color registration control and the image stabilization control operate at one time. For detail, refer to the image stabilization control section.

Color shift by inappropriate scaling

Color shift in the main scanning direction

KY,M,C Y,M,C

K

The direction in which the transfer belt moves


KY,M,C

Color shift in the sub scan-ning direction

KY,M,C

Color skew




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8.2.6 Color skew correction control

• Temperature may change inside the PH unit and the components can change over time. This may cause color skew problems. To prevent the problems, individual G3 lenses that correspond to Y, M, and C respectively have a color skew auto adjustment mechanism.

• When the skew correction motor runs, the G3 lenses moves up and down to perform an automatic color skew correction.

A. Operation timing• The color registration control and the color skew control operate at one time.• By using the CD registration pattern detected, the color skew amount is calculated for

each color. Each color skew is corrected using the previous correction data as a stan-dard of reference.

A00JT2C011DA

A00JT2C012DA

A00JT2C026AA

Y M CK

Skew correction motor/Y,M,C (M35,M36,M37)

G3 lens holder

Skew adjustment


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8.2.7 PH unit temperature detection control

• Temperature change inside the PH unit may cause color shift. To prevent the problem, temperature inside the PH unit is measured by the PH thermistor. The color registration control and the color skew control start to operate when the machine detects a certain amount of temperature change between the current temperature and the one measured when the color registration was performed last time.

• This temperature detection control is carried out when the main power switch is turned ON.

A00JT2C023AA PH thermistor (TH7)

9. Imaging unit Theory of Operation Ver. 8.0 Jun. 2008

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9. Imaging unit

9.1 Composition

A00JT2C032AA

A00JT2C031AA

A00JT2C014DAA00JT2C013DA

Imaging unit/K

Cleaning bladePC drum

Toner collecting screw

Imaging unit/Y, M, C

Developing unit/Y, M, CDeveloping unit/K

Cleaning blade

PC drumToner collecting screw

PC drum charge coronaPC drum charge coronaPC drum charge corona

A00JT2C007AA

Theory of Operation Ver. 8.0 Jun. 2008 9. Imaging unit

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9.2 Drive

A00JT2C537DA

K developing motor (M19)

Color PC drum motor (M16)

Color developing motor (M17)

K PC drum motor (M18)

9. Imaging unit Theory of Operation Ver. 8.0 Jun. 2008

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9.3 Operation

9.3.1 IU life control

• Each IU has EEPROM board that detects a new IU and keeps track of the service life of the IU.

A. New IU detection• New IU is detected when 24 V is turned ON as the main power switch is turned OFF and

ON or the front door is opened and closed.• When a new IU is detected, an TCR adjustment sequence is carried out.

4036ma2133c0

Operation when a new IU is detected

Transfer belt is retracted

Image stabilization

Transfer belt is retracted

Operation when a new IU is not detected

Image stabilization

TCR automatic adjustment

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B. When life is reached• The IU life counter is used to keep track of IU life.• When the life value is reached, a warning message is given on the screen. When a pre-

determined number of printed pages are produced after the life value has been reached, the machine inhibits the initiation of a new print cycle with a message prompting the user to replace the IU given on the screen.

• Warning screen and IU replacement screen is displayed differently by making adjust-ments to promoting expendable supplies in the service mode, choice of unit replacement and IU life stop setting in the security mode.

• If one of the color IUs reaches its life and a certain number of sheets are printed, the machine stops printing. In this case, by pressing the Continue operation key on the screen, monochrome copies instead of color copies can be made.

A00KT2E005DAA00JT2E501DA

When the machine stops printing due to the end of IU (K) life

When a life value is reached1

A00KT2E006DA A00JT2E504DA

When the machine stops printing due to the end of color IU life

Continue operation key

1

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10. Photo conductor section

10.1 Composition

10.2 Drive

A00JT2C033AA

4036ma2338c0

Charge transport layer

Charge generating layer

Aluminum cylinder

PC drum

A00JT2C016DA

PC drum/C

PC drum/MPC drum/Y

Color PC drum motor(M16)


PC drum/K

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10.3 Operation

10.3.1 PC drum drive mechanism

• Two independent PC drum motors (for color and monochrome) are used for the drive mechanism to suppress incorrect color registration and uneven pitch.

• The color PC drum motor drives the PC drums/Y, M, and C, while the K PC drum motor drives the PC drum/K.

• Drive is transmitted to each of the PC Drums when the triangular coupling is engaged with the mating part that also has a triangular shape.

• CPM is different between color and monochrome printing. The K PC drum drive gear is larger than the color PC drum drive gear.

A00JT2C017DA

4036ma2051c0

A00JT2C034AA

Color PC drum motor (M16) K PC drum motor (M18)

Shaft

Large-diameter Gear Coupling

Coupling

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10.3.2 K PC drum phase control

• The K PC drum drive gear has a diameter larger than that of the color PC drum drive gears to enable the high-speed monochrome printing.

• The K PC drum diameter is also larger than that of the color drums. (Kφ60 / YMCφ30)• It is impossible to perform the conventional phase control due to the difference in the PC

drum diameters. By controlling the K PC drum motor speed, the machine reduces irregu-lar rotation (color shift) caused by eccentricity of the K PC drum drive gear.

• The two K PC drum encoder sensors detect the rotation speed of the K PC drum drive gear. Based on the data, the K PC drum motor speed is controlled.

• The K PC drum position sensor detects the PC drum drive gear speed detection start position.

A00JT2C095DAK PC drum drive gear

K PC encoder sensor/2 (PS46)K PC encoder sensor/1

(PS45)

Encoder

K PC drum position sensor (PS18)

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10.3.3 PC drum small amount rotation control

• Humidity around the IU can produce a difference in sensitivity among different PC drums. This could lead to drum memory, allowing black bands to occur in the image. In addition, ozone stagnant in areas near the PC drum charge corona reduces sensitivity of the PC drums, causing white bands to occur in the image.

• To prevent these image problems, that the PC drum is turned at regular intervals to keep the surface sensitivity uniform as temperature and humidity change.

A. PC drum small amount rotation operation timing• During the standby state after the end of a print cycle, the PC drum small amount rota-

tion is made under the following timings.• The machine continues to print for more than a predetermined period of time. (The PC

drum continues to run for more than a predetermined period of time.)• The machine prints intermittently for a given period of time with an intermission of less

than 10 minutes between print jobs. (The machine detects that the cumulative rotation time of the PC drum exceeds a given period of time.)

• PC drum cumulative rotation time is calculated based on cumulative drive distance of the PC drum.

• The time interval between small amount rotations is set different depending on how long the PC drum has been used and what the humidity and the temperature are inside the machine.


PC drum/K PC drum/Y,M,C

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11. Charge Corona section

A00JT2C007AA


A00JT2C019DA A00JT2C018DA

4038T2C027AA

IU/K IU/Y,M,C

Corona wire

Corona Wire Cleaning Lever

Grid mesh

Cleaning blade

Corona wire

PC drum charge corona

PC drum charge corona

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11.1 Operation

11.1.1 PC drum charge corona ON/OFF control

• The grid voltage (Vg) applied to the grid mesh is controlled through the image stabiliza-tion control.

11.1.2 Charge corona cleaning control

• A dirtied PC drum charge corona may cause bands or uneven image problems and the increase of the electric potential on the surface of the PC drum. To prevent those prob-lems, the charge corona has a cleaning mechanism that periodically cleans the needle electrode and the grid mesh.

• The cleaner is driven by the charge cleaning motor/K.• When the power switch is turned ON or the front door is opened/closed, the charge

corona cleaner home position is detected.• The charging cleaner home sensor detects the position (rear) of the charge corona

cleaner. The charging cleaner return sensor (this side) detects the return position.• Only IU/K has this cleaning control system as the IU/K operates longer hours than the

other IUs.• IU/Y, M, C needs to be cleaned by hand with the cleaning jig attached to each IU.



Drum charge corona bias/Y,M,C

Drum charge corona bias/K

K PC developing motor (M19)


Charge corona(Mounted separately for each of Y, M,C, and K)

A00JT2E512DA

A00JT2C035DA

Charging cleaner return sensor (PS44)

Charge cleaning motor/K (M15)

Charging cleaner home sensor (PS43)

cleaner


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A. Operation timing• When the count goes over 2700 during a print job, the cleaning operation starts after the

completion of the print job. However, when the remaining number of pages of the job is 50 or more, the job is stopped and the cleaning operation is performed.

• The count method is shown below.

• C650/C550

• C451

2

Paper length in the sub scanning direction Count

216 mm or less 1

Over 216 mm and up to 432 mm 2

Over 432 mm 3


216 mm or less 1





Over 1080 mm 6

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11.1.3 Cleaning/main erase mechanism

A. Main erase lamp/K control• IU/K has a main erase lamp/K located on the upstream side of the cleaning blade to

improve cleaning performance.• Main erase lamp/K radiation onto the surface of the PC drum removes electric charge

remaining on the surface and makes the cleaning operation by the cleaning blade easier.

A00JT2C036AAA00JT2C013DA

< IU/K > Main erase lamp/K (EL/K)(Main body)

PC drum/KToner collecting screw

Cleaning blade

Cleaning blade


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B. Main erase lamp/Y,M,C control• The main erase lamp/Y, M, C radiation onto the PC drum surface neutralizes potential left

on the surface of the PC drum.

C. Cleaning/main erase operation1. After the image transfer process, the PC drum surface is irradiated by the main

erase lamp/K to remove potential left on the surface. (Only for IU/K)2. The cleaning blade is pressed up against the surface of the PC drum, scraping

residual toner off the surface (Blade abutting PC drum in a counter direction).3. Toner, which has been scraped off the surface of the PC drum, is conveyed to the

front side of the machine by the toner collecting screw. It is collected into the waste toner collecting box.

4. The PC drum surface is irradiated by the main eraser lamp/Y,M,C to remove (neu-tralize) potentials left on the surface.

A00JT2C014DA

Main erase lamp/Y, M, C (EL/Y, M, C)(Machine side)

< IU/Y,M,C >

Cleaning blade

Toner collecting screw

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12. Developing section

12.1 Composition

A00JT2C020DA

A00JT2C021DA

4037T2C513AA

A00JT2C007AA

< K developing unit>

< Color developing unit >





PC drum/K

PC drum/Y

Developing roller

Supply/agitating/conveying screws


Developing roller

Doctor blade


Doctor blade

Developing roller

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12.2 Drive

A00JT2C021DA





PC drum/K

PC drum/Y

Developing roller



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12.3 Operation

12.3.1 Developing drive control

Print request received



LD enable (K)



Developing bias DC (Y/M/C)

Developing bias DC (K)

Main erase (Y/M/C)

Main erase (K)

Developing bias AC (Y)

Developing bias AC (M)

Developing bias AC (C)

Developing bias AC (K)

TOD signal

Video data (Y)

Video data (M)

Video data (C)

Video data (K)

1st image transfer pressure retraction motor (M21)2nd image transfer pressure retraction motor (M3)

Charge corona grid (K)

Charge corona grid (Y/M/C)

Charge corona remote signal (Y/M/C)

Charge corona remote signal (K)

LD enable (Y/M/C)

A00JT2E546DA


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12.3.2 Developer flow

A. IU/K1. Toner supplied from the front end of the Developing Unit is fed to the lower screw. It

is then fed to the rear of the unit, while being mixed with developer and electrically charged by the Supply/Agitating/Conveying Screws.

2. The TCR sensor installed on the underside of the developing unit detects toner-to-carrier ratio during this time.

3. The developer conveyed to the rear of the unit is carried to the screw on the right.4. The developer is conveyed onto the developing roller. The doctor blade then con-

trols the height of the developer brush to ensure that the developer on the develop-ing roller levels out.

5. Toner sticks to the electrostatic latent image on the surface of the PC drum. Devel-oper that is left on the sleeve is returned to the screw on the right by the magnetic pole positioning of the developing roller. It is then conveyed to the front of the unit.

A00JT2C058AAA00JT2C022DAA00JT2C022DA


PC drum/K

Developing roller

Toner supplied from sub hopper

Doctor blade

TCR sensor (TCRS/K)


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B. IU/Y,M,C1. Toner supplied from the front end of the Developing Unit is fed to the lower screw. It

is then fed to the rear of the unit, while being mixed with developer and electrically charged by the Supply/Agitating/Conveying Screws.

2. The TCR Sensor installed on the underside of the Developing Unit detects toner-to-carrier ratio during this time.

3. The developer, fed to the rear of the Developing Unit, is conveyed further to the upper screw.

4. The developer is conveyed onto the developing roller. The doctor blade then con-trols the height of the developer brush to ensure that the developer on the develop-ing roller levels out.

5. The Toner sticks to the electrostatic latent image on the surface of the PC Drum. The developer that is left on the Sleeve is returned to the upper screw by the mag-netic pole positioning of the Developing Roller. It is then conveyed to the front side of the Developing Unit.

4036ma2605c0Supply/agitating/conveying screws

PC drum/Y,M,C Developing roller

Toner supplied from sub hopper

Doctor blade


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12.3.3 Developing bias

• The developing bias voltage (Vdc) is applied to the developing roller so that an adequate amount of toner is attracted onto the surface of the PC drum.

• To help toner to be attracted more easily to the surface of the PC drum, the developing bias (Vb) of Vdc+Vac is applied during development. AC component is applied only while development is taking place. At any other timing, only Vdc is applied.

• The developing bias (Vb) is supplied from high voltage unit /1.

A00JT2C035AA

4036ma2507c0

Imaging unit/K

Imaging unit/Y,M,C

Developing roller

Developing bias

Developing rollerDeveloping bias


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12.3.4 HMT (high grade micro toning) development

• The machine employs the two-component non-contact development system.• With the HMT method, the magnetic developer brush does not rub against the surface of

the PC drum (the images). Accordingly, sharper line images can be reproduced, involv-ing no uneven image density at the trailing edge or thin lines and achieving even finer reproduction of the solid image areas.

4036ma2013c0

PC drumDeveloping roller


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12.3.5 Developer Scattering Preventive Mechanism

• To prevent the image and the machine interior from being dirtied, the color toner suction fan motor and K toner suction fan motor are incorporated to trap toner particles rising up inside the machine.

A. IU/Y, M, C• For IU/Y, M, C, a color toner filter is installed at the rear of the machine and toner parti-

cles are trapped by the color toner suction fan motor during development.

4038T2C025DA

K toner suction fan motor (FM8)

Path for drawing toner particles in IU/Y, M, C

Path for drawing toner particles in IU/K

IU/Y

IU/K

Color toner suction fan motor (FM7)

A00JT2C026DA


Color toner filter


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B. IU/K• For IU/K, a black toner filter is installed under the IU and toner particles are trapped by

the K toner suction fan motor during development.• As the K suction black toner filter and the IU unit come together as one piece, they are

replaced together.

A00JT2C027DA

IU

Black toner filter


Vent


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12.3.6 TCR sensor control

• The TCR sensor is mounted on the underside of each of the developing sections. The sensor for C, M, Y and K is a magnetic type. Each of these sensors detects toner-to-car-rier ratio (T/C) of the developer. The reading is used for determining the amount of toner supplied.

• Individual TCR sensors are automatically adjusted when a new imaging unit is installed in the machine and they cannot be adjusted manually.

• The target T/C ratio is 7% for both color and K.• The target T/C ratio can be changed in the TCR level setting available from the service

mode.• The magnetic permeability (powder density) of the carrier in the developer is measured

to determine the T/C.• A mylar is provided for the conveying screw portion to scrape toner off the surface of the

TCR sensor. (Only IU/Y, M, C)• The TCR sensor is integrated with the imaging unit. When the TCR sensor is to be

replaced with a new one, the entire imaging unit must be replaced.


A00JT2C028DA

4036ma2188c0

TCR sensor/Y,M.C TCR sensor/K

TCR sensor/Y,M,C (TCRS/Y,M,C)

TCR sensor/K (TCRS/K)

Cleaning film

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13. Toner supply section

13.1 Composition

A00JT2C057AA


A00JT2C029DA

A00JT2C007AA

EEPROM board/K(TC ERB/K)

EEPROM board/Y,M,C(TC ERB/Y,M,C)

Toner cartridge/Y,M,C

Toner supply drive section/M

Toner supply drive section/Y

Toner supply drive section/K

Toner supply drive section/C

Conveyance screw /Y, M, C

Conveyance screw /K

Toner cartridge/Y, M, C

Toner cartridge/K

Toner cartridge/K

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13.2 Drive

A00JT2C031DA

Toner cartridge motor C/K (M14)

Toner cartridge motor Y/M (M13)


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13.3 Operation

13.3.1 Toner replenishing mechanism/control

A. Overview• Toner replenishing mechanism consists of two toner supply steps. One replenishment

step is from the toner cartridge to the sub hopper and the other is from the sub hopper to the developing unit.

B. Mechanism of toner replenishing to the sub hopper

• In the toner replenishing step from the toner cartridge to the sub hopper, a single toner supply motor is turned either forward or backward to supply toner of two different colors. (A toner cartridge motor for K/C and a toner cartridge motor for Y/M)

• The toner empty sensor located in the sub hopper detects the remaining toner amount and controls toner replenishment from the toner cartridge to the sub hopper.

C. Operation of toner replenishment to the sub hopper1. Drive of the toner cartridge motor is transmitted through a gear train to the drive

gears of the toner cartridges of two colors. A one-way clutch is used for each of these drive gears, meaning that the drive gears turn in one direction only. Either one of these two drive gears is turned according to whether the toner cartridge motor turns forward or backward.

2. As the drive gear turns, the conveyance screw installed inside the toner cartridge rotates to transfer the toner to the toner cartridge replenishing port. Then the toner goes through the carrier pipe of the main body and drops into the sub hopper port to replenish toner to the sub hopper.

Toner cartridge motor C/K

K toner C tonerToner cartridge

motor Y/MY toner M toner

Turned forward EnergizedDeener-

gizedTurned forward Energized

Deener-gized

Turned backward Deenergized Energized Turned backwardDeener-

gizedEnergized

A00JT2C032DA

Toner cartridge motor C/K (M14)

Toner cartridge motor Y/M (M13)

One-way clutch

1


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D. Control of toner replenishment to the sub hopper• Toner is supplied from the toner cartridge to the sub hopper based on the detection of

the toner empty sensor.

E. Replenishing speed selection control• Depending on the toner amount to be replenished, the toner cartridge motor selects a

rotation speed of either low or high.• When much toner remains in the cartridge, the toner cartridge motor rotates at the low

speed.• When the toner cartridge near empty is detected, toner amount that can be replenished

within a certain time decreases. Therefore, toner cartridge motor starts to operate at high speed.

A00JT2C033DA

Toner cartridge motor (M13,M14) Sub hopper

Conveyance screw

Toner empty sensor/Y,M,C,K (PZS/C, PZS/M, PZS/Y, PZS/K)


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F. Control of toner replenishment to the developing unit• Toner, which has been supplied from the toner cartridge to the sub hopper, is replen-

ished to the developing unit by the toner supply motors that independently operate for Y, M, C, and K

• T/C is detected when the developing clutch/K is energized for K or when the color devel-oping motor is energized for C, M, and Y.

• Based on T/C ratio detected by the TRC sensor and amount of consumption calculated by the dot counter, toner replenishing time (amount) is determined.

• When the machine determines the toner replenishing, sometime it detects the toner amount that surpasses the maximum volume for one replenishing control. If it is not pos-sible to replenish the supply of the required amount of toner within this maximum replen-ishing time, the reminder time is stored in memory and added to the replenishing time for the next replenishing sequence.

A00JT2C097DA

Agitating seat

conveying screws

Toner empty sensor/Y,M,C,K (PZS/C, PZS/M, PZS/Y, PZS/K)

Toner supply motors/ Y,M,C,K (M9,10,11,12)


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13.3.2 Toner cartridge life control

A. Toner cartridge detection/new unit detection timing• Individual cartridge detection is controlled by means of accessing the data of EEPROM

board when the front upper door is closed or the power switch is turned ON.• Based on the data, the machine confirms if the cartridge is mounted or not.• After detecting the presence of the cartridge, with the data machine checks if the car-

tridge is new or not.

13.3.3 Toner cartridge life control

• The amount of toner remaining in the cartridge is displayed as the four states, normal, toner cartridge near empty, toner cartridge empty, and sub hopper empty.

• Normal: The number of pages that can be printed is 7,000 or more.• Toner cartridge near empty: The number of pages that can be printed is less than 5,000-

7,000.• Toner cartridge empty: No toner remains in the toner cartridge.

The number of pages that can be printed is less than 1,400.• Sub hopper empty: The machine stops printing.

A. Toner cartridge near empty detection control• When new toner is set, toner remaining level is set to TC EEPROM board. Based on the

remaining level, the machine calculates the toner near empty detection timing. When the hours for which the toner cartridge motor has turned at the low speed exceeds a prede-termined period of time and the sub hopper toner empty sensor continuously detects toner empty 10 times or more, the toner near empty warning is displayed.


Remaining toner amount Description

NormalEnough toner remains in the toner cartridge and the sub hopper.(Low speed replenishment)

Toner cartridge near empty

Low speed replenishment cannot supply the required amount of toner to the sub hopper within a certain time. (Switch to the high speed replenishment)

Toner cartridge emptyEven high speed replenishment cannot supply the required amount of toner to the sub hopper within a certain time.

Sub hopper emptyToner inside the sub hopper is running out and the T/C ratio in the develop-ing unit is becoming lower than the threshold.

3


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B. Toner cartridge empty control• After the toner cartridge empty condition is detected, if the sub hopper toner empty sen-

sor continuously detects toner empty 10 times or more, the toner empty warning is dis-played.

C. Sub hopper toner empty detection• After a near-empty condition is detected, the toner density detected by the TCR sensor,

at every T/C ratio detection timing, is compared with the target toner density to calculate the density difference. The count number defined according to each density difference is added, and when the value reaches the given level, toner empty warning is displayed.

• A different toner empty screen is displayed if “User” is selected for “Unit change” avail-able from the Service Mode.

A00KT2E007DA

A00JT2E506DAA00HT2E307AA

Toner cartridge empty Toner cartridge near-empty

Sub hopper empty

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13.3.4 Shutter mechanism

• To prevent toner from being spilled when the toner cartridge is removed from the machine, there is a shutter mechanism provided. When the toner cartridge is installed in the machine, the shutter opens.

• Put the replacement port face down to keep the cover close.

A00JT2C043AA A00JT2C044AA

Before toner cartridge is installed When toner cartridge is installed

Shutter

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14. Transfer Corona section

14.1 Composition

14.1.1 1st Image Transfer section

A00JT2C036DA

A00JT2C037DA

A00JT2C045AA

A00JT2C020AA

1st Image transfer roller/C

1st Image transfer roller/K

Transfer belt drive roller

Cleaning brush

1st Image transfer roller/Y

1st Image transfer roller/M

1st Image transfer pressure/retraction motor (M21) Pressure cam

Pressure welding alienation sensor color (PS52)

Pressure welding alienation sensor/K (PS51)

1st image transfer pressure retraction motor (M21)

14. Transfer Corona section Theory of Operation Ver. 8.0 Jun. 2008

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14.1.2 2nd Image Transfer section

A00JT2C050AA

A00JT2C027AA

A00JT2C038DA


2nd Image transfer roller


Shutter

Pressure welding alienation sensor (PS50)

2nd image transfer pressure retraction motor (M3)

IDC registration sensor/F (IDCS/F)

IDC registration sensor/R (IDCS/R)

Temperature/humidity sensor (TEM/HUMS)


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14.2 Drive

14.2.1 1st Image Transfer Section

A00JT2C042DA

A00JT2C041DA

Transfer belt motor (M1)


1st Image transfer roller/K

1st Image transfer roller/Y

1st Image transfer roller/M

1st Image transfer roller/C

Transfer belt

Cleaner motor (M38)


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14.2.2 2st Image Transfer Section

14.3 Operation

14.3.1 Transfer belt speed control

• The Transfer Belt is driven by the Transfer belt motor.• The appropriate belt speed is selected according to the print mode and paper type as

detailed below.

A00JT2C043DA





Cam

Pressure lever

Shutter


Paper Source Print ModeTransfer belt speed (mm/ s)

C650 C550 C451

Plain paper (64 to 90g m2)

Monochrome 310 264 216

Color 240 216 216

ACS 240 216 216

Thick paper 1 (91 to 120g/ m2)Thick paper 1+ (121 to 157g/ m2)

- 155 132 132

Thick paper 2 (158 to 209g/ m2)Thick paper 3 (210 to 256g/ m2)Thick paper 4 (257 to 300g/ m2)OHP transparencies, postcards, envelopes, label sheet

- 120 108 108

2


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14.3.2 1st Image Transfer Roller mechanism

• The machine is provided with a mechanism that presses the 1st Image Transfer Rollers up against the inside of the Transfer Belt during the 1st image transfer stage. The 1st Image Transfer pressure retraction motor provides the drive for this operation.

• The retraction position sensor /K detects the retraction position of the 1st image transfer roller /K, and then detects the retraction position of the 1st image transfer rollers /Y, M, C.

• To detect pressure and retraction positions, the K and color sliding plate positions are detected respectively.

• In the pressure operation, a predetermined pulse controls the stop position.

A. Pressure/retraction operation• Pressure operation

1. Drive from the 1st Image transfer pressure retraction motor is transmitted through a gear train to the drive gear.

2. Rotation of the drive gear turns the pressure cam, which allows the Sliding Plate to move.

3. As the Sliding Plate moves, the spring is released. This lowers the 1st Image Trans-fer Roller and the roller presses against the Transfer Belt.

• Pressure operation1. Under the pressure operation, if the drive gear turns either forward or backward,

the pressure cam rotates. This pushes and moves the sliding plate.2. As the Sliding Plate moves, the Pressure Lever is then pressed to raise the 1st

Image Transfer Roller, allowing the roller to leave the Transfer Belt.


A00JT2C044DA

Color cam

K cam

K Sliding plateColor sliding plate


When Retracted When Pressed

1st Image Transfer Roller

Spring


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B. Operation timing• The pressure operation starts when a print cycle starts and ends when the print cycle

completes.


1st Image transfer pressure retraction motor (M21)

Pressure welding alienatioin sensor/color (PS52)

Pressure welding alienatioin sensor/color (PS51)

Start key ON Paper Moves Past 2nd Image transfer roller

A00JT2E514DA


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C. Pressure position changing mechanism• To extend the service life of the PC Drum/Y, M, C, the pressure position of the 1st Image

Transfer Roller is changed between the monochrome mode and the color mode. In the monochrome mode, the 1st Image Transfer Roller/Y, M, C is left in the retracted position and the PC Drum/Y, M, C is stopped.

• The pressure position is changed by varying the pulse count of the 1st Image Transfer Pressure Retraction Motor, which results in the pressure cam stop position being varied. The pressure position of the Image Transfer Roller is also changed by changing the stop position of the Sliding Plate.

• In order to reduce the first print time, the machine uses the cam that can turn both for-ward and backward. With the least rotation of the cam, the 1st transfer roller position can be changed.

(1) Types of cams• Three types of cams are arranged on a shaft.• K cam: for the pressure and retraction operation of the 1st image transfer roller /K and

the K retraction roller.• Color cam: for the pressure and retraction operation of the 1st image transfer roller /Y, M,

C and the color retraction roller.• Retraction roller cam: for the pressure and retraction operation of the color retraction

roller.

A00JT2C059AA

K sliding plate

Color cam

Retraction roller cam

K camColor sliding plate


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(2) Color mode• The pressure position of the Image Transfer Roller is where the PC Drum is in contact

with the Transfer Belt for all four colors of toner.

(3) Monochrome mode• The pressure position of the Image Transfer Roller/Y, M, C is where the PC Drum/Y, M, C

leaves the Transfer Belt. While that of the Image Transfer Roller/K is where the PC Drum/K is in contact with the Transfer Belt. This allows the PC Drum/Y, M, C to remain station-ary in this mode.

A00JT2C047DA

Retracted position

Monochrome mode

Color mode

Cam position

K Sliding plate

Cam position (K)

Cam position (Color)

Transfer belt

1st Image Trans-fer roller

PC drum

Retraction roller Cam

Color sliding plate

Y M C K

Y M C K

Y M C K


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D. Retraction mechanism• In addition to the change of the pressure position of the 1st image transfer roller, the

machine moves the color retraction roller or the K retraction roller up and down to change the position of the image transfer on the surface of the transfer belt depending on the print mode of each job.

• Similar to the pressure position change mechanism, the retraction mechanism changes the position at which the pressure cam stops in order to move the retraction lever so that the retraction roller moves up and down.

(1) Color retraction roller• The color retraction roller is driven by the color cam.

(2) K retraction roller• The K retraction roller is driven by the K cam.

A00JT2C048DA

Retracted Position

Cam position

Driven roller

Retraction lever

Monochrome Mode Color Mode

Color retraction roller

A00JT2C049DA

1st image transfer roller/K

Retracted Position

Color Mode

K Retraction roller

Monochrome Mode


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14.3.3 2nd image transfer roller pressure mechanism

• The 2nd image transfer roller has the pressure/retraction mechanism which presses to and retracts from the transfer belt so the patterns made on the transfer belt except by printing (such as detection pattern during image stabilization) will not affect the 2nd image transfer roller.

A. Pressure/retraction operation1. Drive from the 2nd image transfer pressure/retraction motor is transmitted through

a gear train to the drive gear.2. The drive gear rotates to rotate the cam. Pressing down the pressure lever will

pushes the 2nd image transfer roller against the transfer belt.3. At this timing, the 2nd image transfer pressure position sensor detects that the 2nd

image transfer roller gets to the pressure position. The 2nd image transfer pressure retraction motor is stopped.

4. The cam rotates further when the motor turns ON again. Releasing the pressure lever will move the 2nd image transfer roller to the retraction position. At this timing, the 2nd image transfer pressure position sensor detects that the roller gets to the retraction position. The 2nd image transfer pressure retraction motor is stopped.

A00JT2C047AA

4036ma2168c0 4036ma2023c1


Cam

When Retracted When Pressed

Drive roller


Cam




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B. Operation timing• The pressure operation starts when a print cycle starts and ends when the print cycle

completes.


2nd Image transfer pressureretraction motor (M3)Pressure welding alienatioinsensor (PS50)

Start key ON Paper moves past 2nd Image transfer roller

A00JT2E515DA


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14.3.4 IDC sensor shutter mechanism

• The IDC sensor can be contaminated with toner since it is located under the transfer belt. There is a shutter mechanism provided for the sensor to prevent it from being contami-nated.

• The shutter opens and closes in synchronism with the pressure and retraction motion of the 2nd image transfer roller. When the 2nd image transfer roller is retracted from the transfer belt, the pressure pin pushes the shutter holder. This moves the shutter at the IDC sensor to the front side.

• When the 2nd image transfer roller is pressed against the transfer belt, on the other hand, the shutter of the IDC sensor is moved by a spring force to the rear side and closed.

2nd image transfer roller Shutter

Retracted Open

Pressed Closed

A00JT2C050DA


4036ma2171c0


ShutterShutter holder

Pressure pin

When Sensor Shutter is Closed When Sensor Shutter is Open




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14.3.5 ATVC (Auto transfer voltage control)

• To adjust the 2nd image transfer output to the correct voltage, ATVC system is installed.A constant current is output to the 2nd image transfer roller to measure voltage. The measured voltage is corrected to be used for automatic adjustment of the 2nd image transfer output voltage.

A. Overview of ATVC operation

B. 2nd image transfer ATVC operation1. Constant current of the 2nd image transfer which is output from the high pressure

unit will be fed back to the printer control board through 2nd image transfer roller, transfer belt, and the transfer belt drive roller.

2. The measured resistance, together with the type of paper, temperature and humid-ity, and the color or monochrome mode 1st side/2nd side, is used as the basis for determining the optimum 2nd image transfer voltage.

C. 1st and 2nd image transfer ATVC operation timing• After the power switch is turned ON. (Mainly just before the image stabilization opera-

tion).• Before the machine starts a print cycle for the first time after the temperature change

inside the machine went over the threshold, ATVC operation is performed.

Constant current

2nd image transfer roller

Transfer belt

Transfer belt drive roller

HV2

Output a constant current to the 2nd image transfer roller.

Calculate the resistance value of the 2nd image transfer roller.

Determine the 2nd image transfer output voltage.


Measures the voltage


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14.3.6 Transfer belt cleaning

• To scrape residual toner off the surface of the transfer belt, the transfer belt is provided with a cleaning brush and a charging brush.

• The cleaning brush is a rotary brush. To enhance its ability to scrape residual toner off the surface of the transfer belt, the brush is turned in a direction opposite to that of the transfer belt. The cleaner motor provides the drive for this system.

• To make toner on the surface of the transfer belt easier to be removed, two types of bias (+DC and –DC) are applied to the belt through a different route.

• Residual toner on the surface of the transfer belt is in a state of mixture of positive and negative charges. The charging brush supplies negative charge to the toner to make the toner negatively charged. The toner collecting roller supplies positive charge to collect toner with the cleaning brush.

1. +DC bias: Toner collecting roller → Cleaning brush → Transfer belt → Driven roller → GND

2. -DC bias: Charging brush → Transfer belt → Driven roller → GND

A. Operation timing• During a print cycle, an image stabilization operation, the 2nd transfer roller cleaning,

and other states whenever the transfer belt operates.

A00JT2C051DA

A00JT2C045AA

Cleaning brush

GND

Transfer beltToner collecting roller

Driven roller

HV2Toner collecting screw

Charging brush

Cleaning start signal


Cleaner motor (M38)

Cleaning bias (+/-)

A00JT2E516DA


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14.3.7 2nd image transfer roller cleaning

• To remove residual toner off the surface of the 2nd Image transfer roller, a +/- DC bias is applied alternately to the roller, thereby moving the residual toner to the surface of the transfer belt.

• The cleaning brush then scrapes off the toner on the surface of the transfer belt.

A. Operation timing• The sequence is carried when the power switch are turned ON or the cover is opened

and closed when a print cycle has been abnormally terminated due to a misfeed or mal-function.

• The sequence is also carried out at the end of a print cycle that is run after the cumula-tive number of printed pages produced has exceeded 300, or during a print cycle that is run after the cumulative number of printed pages produced has exceeded 3000, since the previous cleaning operation.

HV2

---

--

- --

4036ma2175c0

+

Cleaning brush

Transfer belt 2nd Image transfer roller

Paper length in the sub scanning

directionPrint mode Count

216 mm or lessColor 3

Monochrome 1

Over 216 mmColor 6

Monochrome 2

Retracted

Retracted

Pressure

2nd Image Transfer reverse bias



A00JT2E517DA

Start the 2nd image transfer roller cleaning operation

2nd image transfer roller cleaning after the completion of a print cycle


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14.3.8 Charge neutralization and separation of paper

• To neutralize any charge potential left in the paper which has undergone the 2nd image transfer stage, a Charge Neutralizing Cloth is installed to the guide plate after the 2nd Image Transfer Roller.

• The output of the Charge Neutralizing Cloth is switched automatically using the high volt-age unit according to the paper type and the environmental conditions, and whether the print cycle is for printing the 1st side or 2nd.

• In order to separate thin paper or curled paper caused by 2-sided printing from the trans-fer belt without fail after the 2nd image transfer, transfer belt separator claws are mounted at 5 places.

• Switching of output of the charge neutralizing cloth

HV2

A00JT2C022AA

Charge Neutralizing Cloth

Paper Separator Claws

Transfer Belt 2nd Image Transfer Roller

Paper Type Ambience Control Detailed description

1-sided printing on the plain paper

Low humidity Bias applied • A negative charge, which is the reverse polarity to the positive output from the 2nd Transfer Roller, is applied to prevent the paper from being wound around the Transfer Belt.

Normal Bias applied

High humidityGND through

resistors• To prevent separation noise, grounded through

resistors regardless of the ambient conditions.

2nd side of 2-sided printing on the plain paper

– Bias applied

• Bias is applied regardless of the ambient condi-tions, since the paper to go to the 2nd side print cycle, which has undergone the fusing process, has the condition equivalent to paper under low humid-ity ambience.

Special paper other than plain paper

–GND through

resistors

• Paper is stiff enough to present no separation prob-lems.

• To prevent separation noise, grounded through resistors regardless of the ambient conditions.


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14.3.9 Detection of new transfer belt unit

• When a new transfer belt unit is installed in the machine, the life counter is automatically cleared through new unit detection.

• The new unit detection is made when the power switch is turned OFF and ON, the front door is opened and closed or the right door is opened and closed.

• New unit detection timing/operation.

Life counter is cleared

Check detection of the new unit

Image stabilization

Initial operation of the transfer belt

Power OFF/ON, front door open/close, right door open/close


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14.3.10 Pressure/retraction control during ACS mode

• For monochrome printing in the ACS mode, the pressure/retraction operation of the 1st image transfer roller is controlled according to the number of monochrome originals that continue during multiple copies. It promotes high productivity and extends consumables life.

* ACS: Auto color selection

A. Operation• ACS control starts counting the number of multi-copies of the monochrome original when

switched from the color original to the monochrome original.• When the number of multi-copies is as specified or under.

: The monochrome printing will start with color mode. (with the 1st image transfer roller /Y/M/C being pressed)The transfer belt being pressed saves time since the 1st image transfer roller does not need to be retracted.

• When the number of multi-copies is as specified or over.: The monochrome printing will start when the color mode is complete and the 1st image

transfer roller /Y/M/C is retracted to be switched to the monochrome mode.The transfer belt being retracted prevents IU to be wasted by useless rotation.

• Number of multiple copies of monochrome originals when the paper feed speed is 216 mm/s (Plain paper).

• Number of multiple copies of monochrome originals when the paper feed speed is 132 mm/s, or 108 mm/s (Thick stock 1, Thick stock 1+, Thick stock 2, Thick stock 3, Thick stock 4, Special paper).

Paper length in the sub scanning direction

monochrome printing in color modeMonochrome printing after switched

to monochrome mode

216 mm or less 4 sheets or less 5 sheets or more

Over 216 mm and up to 297 mm

3 sheets or less 4 sheets or more




1 sheet or less 2 sheets or more

Over 432 mm 1 sheet or less 2 sheets or more

Paper length in the sub scanning direction

monochrome printing in color modeMonochrome printing after switched

to monochrome mode

216 mm or less 3 sheets or less 4 sheets or more







Over 432 mm 1 sheet or less 2 sheets or more


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• ACS control operates only after the number of multi-copies for monochrome original is counted.“The pressure/retraction control for ACS mode” will not be properly executed with only one sheet of print job, since on the first copy, the control can be performed only for where the original is read and counted.The ACS control performs effectively for the print jobs as listed below.

For the 2nd set of prints onward in electronic sortingprinting using job programs

A00JT2C053DA

A00JT2C052DA

Y M C K

When printing in monochrome with color mode(effecting monochrome printing with the four PC drums rotating)

First sheet of color mode First sheet of monochrome mode

Switching to monochrome mode

First sheet of color mode

First sheet of color mode First sheet of monochrome mode

Third sheet of monochrome mode

Fourth sheet of monochrome mode

Fifth sheet of monochrome mode

Second sheet of monochrome mode

Y M C K Y M C K

Y M C K Y M C K Y M C K

Y M C K Y M C K Y M C K


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14.3.11 Electric discharge control before the 2nd image transfer

• The small roller and the 2nd image transfer guide are installed under the drive roller to carry paper parallel to the transfer belt. This reduces electric discharge before the 2nd image transfer process and toner scattering when solid images are being printed.

A00JT2C094DA

Transfer belt

2nd Image transfer guide


Small roller

Theory of Operation Ver. 8.0 Jun. 2008 15. Toner collecting section

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15. Toner collecting section

15.1 Composition

A00JT2C054DA


IU toner collecting screw

Transfer belt toner collecting screw

Agitating screw

Waste toner box

Cleaning brush

15. Toner collecting section Theory of Operation Ver. 8.0 Jun. 2008

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15.2 Drive

A00JT2C055DA


Cleaning brush

Agitating screw

Toner collecting roller

Cleaner motor (M38)




Waste toner agitating motor (M20)


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15.3 Operation

15.3.1 Toner collecting mechanism

• Toner collected by the cleaning brush of the transfer belt and waste toner in each of the imaging units are conveyed by the corresponding toner collecting screws to the waste toner box.

A00JT2C056DA

IU toner collecting screw

Waste toner box



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15.3.2 Waste toner agitation control

• In order to avoid detecting an incorrect waste toner amount, the agitating coil is set in the waste toner box so that waste toner can build up evenly in the box.

• The agitating coil is driven and rotated by the waste toner agitating motor.• The waste toner agitating motor lock sensor detects the waste toner agitating motor lock.

A. Operation timing• The waste toner agitating motor operates when the TCR sensor performs an automatic

adjustment, toner is forcefully replenished, and the transfer belt is driven.

15.3.3 Waste Toner Box-in-position detection

• The waste toner box set sensor is provided to detect a waste toner box loaded in posi-tion. Timing for this detection is when the power switch is turned OFF and ON, or the front door is opened and closed. If the waste toner box is found to be out of position, the machine inhibits the initiation of a new print cycle.

A00JT2C057DA

Waste toner agitating motor (M20)

Waste toner agitating motor lock sensor (PS23)

Agitating screw

A00JT2C096DA

Waste toner box set sensor (PS53)

Waste toner box


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15.3.4 Waste Toner Near-Full/Full detection control

A. Waste toner near-full detection control• An optical sensor is used to detect waste toner. When the sensor is blocked for a given

period of time, the machine determines that the Waste Toner box is nearly full of waste toner.

• At this time, a corresponding warning (near-full warning) is given on the control panel.

B. Waste toner full detection control• Upon the waste toner near full detection, the counter exclusive for waste toner inside the

machine starts counting. When the number of color pages reaches around 3,000 sheets (A4) or the number of monochrome pages reaches around 12,000 sheets (A4), the machine detects a waste toner full condition and stops printing.

• Counting method of the counter exclusive for the waste toner is corrected to count the value appropriately according to the color or monochrome mode or paper length.

• When the waste toner full counter reads 12,000, the machine regards that the waste toner box is full.

• C650/C550

• C451

2

Paper length in the sub scanning direction Print mode Count


Monochrome 1

Over 216 mm and up to 432 mmColor 8

Monochrome 2

Over 432 mmColor 12

Monochrome 3

Paper length in the sub scanning direction Print mode Count


Monochrome 1


Monochrome 2


Monochrome 3


Monochrome 4


Monochrome 5

Over 1080 mmColor 24

Monochrome 6

1


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• After the waste toner box has been replaced and the waste toner full sensor has been unblocked for a given period of time, the machine cancels the copying-disabled condi-tion, while at the same time automatically clearing the counter exclusive for the waste toner.

A different toner full warning screen is displayed if “User” is selected for “Unit Change” available from the Service Mode.

A00KT2E008DAA00JT2E508DA

A00JT2E521DA

A00JT2C048AAWaste toner box

Waste toner full sensor (PS54)

Before near-full condition is detected

Waste toner

Near-full condition detected

Near-Full Condition Warning Display Full Condition Warning Display

1

Theory of Operation Ver. 8.0 Jun. 2008 16. Paper feed section

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16. Paper feed section

16.1 Composition

16.1.1 Tray1, 2

• Tray1 and 2 are same sensor position.

A00JT2C286AA

Tray1 paper feed sensor (PS5)

Tray1 device detection sensor (PS1)

Tray1 near empty sensor (PS3)

Paper size detect board/1 (PSDTB/1)

Tray1 CD paper size sensor/1 (PS7)

Tray1 paper empty sensor (PS2)

Tray1 vertical transport sensor (PS4)Tray1 upper limit sensor (PS6)


A00JT2C202AA

A00JT2C277AA

16. Paper feed section Theory of Operation Ver. 8.0 Jun. 2008

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16.1.2 Tray3

A00JT2C300AA


Tray3 upper limit sensor (PS20)

Tray3 near empty sensor (PS22)

Tray3 paper feed section

Tray3 paper empty sensor (PS19)

A00JT2C204AA

Horizontal transport section (upper section)

A00JT2C273AA


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16.1.3 Tray4

A00JT2C294AA



Tray4 near empty sensor (PS27)Tray4 paper empty sensor (PS24)

A00JT2C205AA

A00JT2C276AA


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16.2 Drive

16.2.1 Tray1, 2

• Take-up motor drives the tray1 and 2 paper feed rollers.• Each paper feed roller has a clutch that is turned ON when it needs to be driven.

A00JT2C286AA

Tray1 lift-up motor (M6)

Tray1 vertical transport motor (M5)

Take-up motor (M22)

Tray1 vertical transport roller

Tray1 paper feed roller

Tray 1 paper feed clutch (CL1)


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16.2.2 Tray3

16.2.3 Tray3 horizontal transport

A00JT2C301AA

Tray3 paper feed clutch (CL5)

Tray

Tray3 transport clutch (CL6)

Transport motor (M25)



Coupling

Transport roller

A00JT2C303AA

Vertical transport motor (M26)

Horizontal transport clutch 1 (CL3)


Intermediate roller

Horizontal transport clutch 2 (CL4)

Horizontal transport roller 2Horizontal transport roller 1


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16.2.4 Tray4

A00JT2C295AA


Tray




Tray4 paper transport roller

Coupling

Tray4 take-up axis



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16.3 Operation

16.3.1 Tray1, 2

• Tray1 and Tray2 are controlled in the same control procedure.• Paper transport speed from Tray1 and Tray2 is the same as the system speed.

A. Paper feed control

Paper type Plain paper Plain paper Thick paper 1, 1+Thick paper 1, 2, 3, 4

Special paper

Print mode Monochrome Color Monochrome/Color Monochrome/Color

Paper transport speed

C650 310 mm/s 240 mm/s 155 mm/s 120 mm/s

C550 264 mm/s 216 mm/s 132 mm/s 108 mm/s

C451 216 mm/s 216 mm/s 132 mm/s 108 mm/s

2

2

*Tray1 paper feed control timing

Take-up motor (M22)

Tray 1 paper feed clutch (CL1)



Tray1 vertical transport sensor (PS4)

Start key ON Timing roller drive

A00JT2E524DA

Timing sensor ON (OHP sensor ON for 264m/s or more)


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B. Paper feed speed reduction control• When paper reaches the tray1 (tray2) paper feed sensor, if the interval between the

paper and the preceding paper is short, the take-up motor speed is reduced temporarily to adjust the paper interval to the proper one.

• When paper reaches the tray1 (tray2) vertical transport sensor, if the interval between the paper and the preceding paper is short, the tray1 (tray2) vertical transport motor reduces its speed (in the case of transport speed 216 mm/s or more) or stops (in the case of transport speed 132 mm/s or less) in order to adjust the paper interval to the proper one.

• Paper from the Tray1 and Tray2 is transported at the same speed with the system speed.

C. Double feed control• After the take-up motor is turned ON, if it is not turned OFF (no paper) by the time when

the paper is supposed to be at the paper feed sensor, the machine judges that a double feed is occurring and reduces the rotation speed of the paper feed roller (take-up motor).

A00JT2C317AA

Preceding paper

Paper to be controlled

Sensor

Short paper interval

Example: Short paper interval

A00JT2C213AA

Timing roller sensor (PS38)





Timing roller


First sheet of paper

Second sheet of paper



Tray1

Tray2

3


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D. Paper supply level• The amount of remaining paper is indicated by the LED on the right side of each tray and

by the screen of the control panel.• The following shows how the level is displayed.

*1: LED turns OFF when Paper Remainder is set to Type 2: Service Mode → System 1 → Machine State LED Setting → Paper Remainder.

E. Paper near-empty/Paper empty detection• Paper near empty is detected by the tray1 (tray2) near empty sensor.• Paper empty is detected by the tray1 (tray2) paper empty sensor.• The paper supply level when a paper near-empty condition is detected is about 50 ± 30

sheets.

Tray condition Empty Near emptyOther statuses

(Including during lift-up and no tray conditions)

LED ON Blinking *1 OFF

3

A00JT2C269AA

Tray1 empty LED

Tray2 empty LED

A00JT2C311AA

A near-empty condition

Tray1 near empty sensor (PS3)Tray1 near empty sensor (PS11)

Tray1 lift-up motor (M6)Tray1 lift-up motor (M8)

An empty condition

A00JT2C312AA

Tray1 paper empty sensor (PS2)Tray2 paper empty sensor (PS10)


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F. Paper size detection control• Paper width/length are detected to determine the paper size from their combination.

Metric area

Inch area

• This combination will also be used due to the sensor’s ability.H: BlockingL: Unblocking*: One of the following paper sizes can be selected to be set for FLS.

220 x 330 mm, 8 × 13, 8.125 × 13.25, 8.25 × 13, 8.5 × 13

Paper size

Paper size detect board/1 (PSDTB/1)Paper size detect board/2 (PSDTB/2)




Tray2 CD paper size sensor/2 (PS16)Switch 1 Switch 2 Switch 3 Switch 4

A3 OFF ON/OFF OFF OFF H L

B4 OFF OFF OFF ON H L

A4S ON ON/OFF OFF OFF L H

A4 ON/OFF ON ON ON H L

B5S ON ON OFF ON L L

B5 OFF OFF ON ON H L

A5S ON/OFF ON ON ON L L

Paper size

Paper size detect board/1 (PSDTB/1)Paper size detect board/2 (PSDTB/2)


Tray2 CD paper size sensor/1

(PS15)


Tray2 CD paper size sensor/2

(PS16)Switch 1 Switch 2 Switch 3 Switch 4

12 × 18S ON OFF OFF ON H L

11 × 17 OFF ON OFF OFF H H

81/2 × 14 OFF OFF OFF ON L H

81/2 × 11S OFF ON ON OFF L H

81/2 × 11 ON ON ON ON H H

FLS *1 OFF OFF OFF OFF L H

8K (8 Open) S(270 mm × 390 mm)

OFF OFF ON OFF H H

16K (16 Open)(270 mm × 195 mm)

OFF ON ON ON H H


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Guide

A00JT2C313AA

4 3 2 1Paper size detect board/1 (PSDTB/1)Paper size detect board/2 (PSDTB/2)


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G. Tray lifting motion control(1) When tray is slid in• When the upper limit sensor is unblocked (OFF) with the tray being closed, lift-up motor

will rotate to start lifting up the paper lifting plate.• When the upper limit sensor is blocked (ON) after the paper lifting plate starts moving up,

the trays 2 lift-up motor will stop to stop lifting the paper lifting plate.• The lifting motion is controlled not to make more than two trays are lifted at the same

time.

(2) During a print cycle• When the amount of paper decreases as the unit keeps printing, the pick-up roller will

gradually come down to unblock the upper limit sensor. The lift-up motor will rotate again to lift up the paper lifting plate.

• When the upper limit sensor is blocked (ON), the lift-up motor will stop to stop lifting the paper lifting plate.

• The sequence of these operations is repeated to keep constant the pressure between the pick-up roller and paper stack (paper take-up pressure) regardless of the amount of paper still available for use.

A00JT2C314AA

A00JT2C315AA

Paper lifting plate

Tray1 upper limit sensor (PS6)Tray2 upper limit sensor (PS14)

Tray1 lift-up motor (M6)Tray2 lift-up motor (M8)

A00JT2E525DA

Tray3,4 Set detection sensor

Tray3,4 upper limit sensor (PS22,PS27)

Tray1,2 Lift-up motor (M6,M8)

Tray set

Lifting completed

Paper consumption


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16.3.2 Tray3, 4

A. Paper Feed control(1) Tray3• When the interval between the paper and the preceding paper both fed from the tray3 is

short, the tray3 transport clutch is stopped to adjust the paper interval to the proper one.• When paper reaches the intermediate roller, if the interval between the paper and the

preceding paper is short, the vertical transport motor is stopped to adjust the paper inter-val to the proper one.

• The horizontal transport clutch 1 and 2 make the control in the same timing.

• Paper is fed from Tray3 and Tray4 at a speed faster than the system speed.• Paper feed speed varies in order to feed paper at a faster speed to ensure a proper

paper interval when the interval gets longer.

A00JT2E526DA



Tray3 transport clutch (CL6)


Horizontal Transport clutch 1 (CL3)Horizontal Transport clutch 2 (CL4)

Horizontal transport sensor (PS29)

Intermediate roller sensor (PS28)

vertical transport motor (M26)





Start key ON Timing motor ON

Plain paper: OHP detection sensor ONThick paper: Timing roller sensor ON

* When there is no preceding paper

System speed (mm/s) Transport speed (mm/s)

310 to 216 420

155 to 108 219

2


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(2) Tray4• When paper reaches the intermediate roller, if the interval between the paper and the

preceding paper is short, the vertical transport motor is stopped to adjust the paper inter-val to the proper one.

(3) Sensor and roller arrangement

A00JT2E527DA










Start key ON Timing motor ON


A00JT2C227AA

Intermediate roller



OHP detect sensor (PS40)


Timing roller


Horizontal transport roller 2




Tray3 transport roller


Horizontal transport sensor (PS29)



Horizontal transport roller 1


Tray3

Tray4

3


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B. Display of paper supply level• The amount of remaining paper is indicated by the LED on the right side of each tray and

by the screen of the control panel.• The following shows how the level is displayed.

*1: LED turns OFF when Paper Remainder is set to Type 2: Service Mode → System 1 → Machine State LED Setting → Paper Remainder.

C. Paper supply level detection control• Paper supply level is detected by calculation of the paper remaining level based on the

time when the tray is lifted.• Plain paper is used as the reference of the calculation for the paper supply level.• When the thick paper is set, off set value is used to calculate the paper supply level.

Ex: When thick paper 2 is set, paper supply level is calculated as a half of the plain paper level.

• Lifting time is measured when the power is turned ON, save mode is released and a tray is inserted.

Tray condition Empty Near empty *1Other statuses

(Including during lift-up and no tray conditions)

LED ON Blinking OFF

3

A00JT2C269AA

Tray3 empty LED

Tray4 empty LED

Tray condition Paper full Paper near full Paper remained

Paper supply level 100 to 66% 65 to 33% 33% to 51 sheets

Tray3 paper supply level 1500 to 1000 sheets 999 to 501 sheets 500 to 51 sheets

Tray4 paper supply level 1000 to 666 sheets 665 to 334 sheets 333 to 51 sheets


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D. Paper near-empty/paper empty detection• Paper near empty is detected by the tray3 (tray4) near empty sensor (blocking).• Paper empty is detected by the tray3 (tray4) paper empty sensor (tray3: unblocking,

tray4: blocking).• The paper supply level when a paper near-empty condition is detected is about 50 ± 30

sheets.

A00JT2C288AA

A00JT2C297AA

A near-empty condition An empty condition

Tray3 near empty sensor (PS22) Tray3 paper empty sensor (PS19)Tray3

Tray4

Tray4 near empty sensor (PS27) Tray4 paper empty sensor (PS24)

A00JT2C306AA

A00JT2C306AA


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E. Tray lifting motion control(1) Tray lifting motion• The tray is hung with the wire connected to the front and the back.• The wire is winded by the rotation of the lift-up motor, which lifts up the tray.• When the tray is pulled out, the lift-up motor is disconnected from the hoisting axis, which

lifts down the tray due to its own weight.

(2) When tray is slid in• While a tray is being closed, when the upper limit sensor of tray3 is unblocked or that of

tray4 is blocked, the lift up motor rotates and starts lifting up the tray.• After the machine starts to lift up the tray, when the upper limit sensor of tray3 is blocked

or that of tray4 is unblocked, the lift up motor stops and finishes lifting up the tray.• The lifting motion is controlled not to make more than two trays are lifted at the same

time.

A00JT2C305AA

Tray3 lift-up motor (M23)Tray4 lift-up motor (M24) Coupling

Hoisting axis

A00JT2C099DA

Tray3 upper limit sensor (PS22) Tray4 upper limit sensor (PS27)

A00JT2E528DA

Tray3,4 set detection

Tray3,4 upper limit sensor (PS22,PS27)

Tray3,4 Lift-up motor (M23,M24)

Tray set

Lifting completed

Paper consumption


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(3) During a print cycle• When the amount of paper decreases as the machine continues printing, a tray will grad-

ually go down making the upper limit sensor of tray3 unblocked or that of the tray4 blocked. The lift-up motor starts rotating again and lifting up the tray.

• When the upper limit sensor of tray3 is unblocked or that of tray4 is blocked, the lift- up motor stops and finishes lifting up the tray.

• The sequence of these operations is repeated to keep constant the pressure between the pick-up roller and paper stack (paper take-up pressure) regardless of the amount of paper still available for use.

A00JT2C296AA




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F. Paper size detection• Tray3 and 4 don’t have paper size detection function.• To set a different paper size, press keys as follows.

Service mode → System setting 2 → LCC size setting• Slide the paper guide plates to the positions that match the selected paper size and

secure them with paper guide plate (screw cramp).

A00JT2E533DA

A00JT2C318AA

Paper guide plate/ rear

End guide plate

Paper guide plate/ front


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G. Dehumidification heater control• Tray3 and 4 come equipped with the dehumidification heater.• Power switch of the dehumidification heater locates the bottom of the back of the main

body.• When the PC motor is running, the dehumidification heater is turned OFF to reduce

power consumption.

Dehumidification heater Color PC motor Black PC motor During fine rotation

ON Halt Halt OFF

ON - - ON

OFF Running Halt OFF

OFF Halt Running OFF

OFF Running Running OFF

A00JT2C279AA

Dehumidifier heater transformer (T)

Dehumidification heater switch (SW2)

A00JT2C278AA

Tray3 dehumidifier heater (DH1)Tray4 dehumidifier heater (DH2)

Theory of Operation Ver. 8.0 Jun. 2008 17. Bypass section

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17. Bypass section

17.1 Composition

A00JT2C274AA

A00JT2C282AA

A00JT2C206AA

Bypass paperfeed roller

Multi FD size sensor/3 (PS33)

Bypass tray separator roller


Paper lifting plate

Bypass sub tray set sensor (PS37)

Bypass paper width detection resistor (VR)Bypass paper empty

sensor (PS34)


Bypass Tray

Paper side plate


17. Bypass section Theory of Operation Ver. 8.0 Jun. 2008

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17.2 Drive

A00JT2C283AA

Bypass paper lower sensor (PS36)

Bypass paper feed motor (M27)

Bypass paper feed roller

Bypass paper limit sensor (PS35)

Paper lifting plate


Bypass tray up down motor (M28)



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17.3 Operation

17.3.1 Bypass paper take-up control

• Bypass paper feed starts after the bypass tray up down motor lifts up paper to the take-up position.

• Paper is fed with the bypass paper feed motor.• When paper reaches the tray1 vertical transport sensor, if the interval between the paper

and the preceding paper is short, the tray1 vertical transport motor reduces its speed (in the case of transport speed 216 mm/s or more) or stops (in the case of transport speed 132 mm/s or more) to adjust the paper interval to the proper one.

17.3.2 Paper empty detection

• Paper empty is detected by the bypass paper empty sensor.• Paper empty is detected both at the standby and the paper feed positions.

A00JT2E529DA


Normal rotation

Inverse rotation





Start key ON

Paper feed position

Paper feed finishTiming motor ON


A00JT2C217AA

When there is no paper

When there is paper

Bypass paper empty sensor (PS34)


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17.3.3 Bypass paper lifting motion control

A. Move to paper feeding position• When the bypass paper feeding starts, the bypass tray up down motor makes a normal

rotation to move the paper lifting plate up to the paper feeding position. When the paper lifting plate is moved up, the bypass paper limit sensor turns ON to stops the bypass tray motor at the feeding position.

• When the paper supply level goes down during paper feeding and the bypass paper limit sensor turns OFF, the bypass tray motor rotates positively to move it up to the paper feeding position.

B. Move to standby position• When there is no print request from the bypass tray and the paper fed from the bypass

tray turns off the exit sensor, the paper lifting plate is lowered.• Though other jobs are being processed, if the above conditions are met, the paper lifting

plate is lowered.• When the sensor detects the bypass paper empty at the feeding position, the paper lift-

ing plate is moved to the standby position.• When paper jam occurs, the paper lifting plate stops at the paper feeding position. After

paper jam is resolved, the paper lifting plate moves to the standby position.

A00JT2C285AA




Bypass paper empty detection

Paper lifting plate


Inverse rotation

Normal rotation



Start key ON

Paper feeding positionStandby position

Occurrence of the event that moves to standby position

A00JT2E530DA


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17.3.4 Paper size detection

• The size of the paper is detected by the combination of ON or OFF positions of three multi FD size sensors and the bypass paper width detection resistor.

• Moving the paper guide varies the resistance value of the bypass paper width detection resistor.

Metric area

*: One of the following paper sizes can be selected to be set for FLS.220 x 330 mm, 8 × 13, 8.125 × 13.25, 8.25 × 13, 8.5 × 13

Multi FD size sensor/1



Bypass paper width detection resistor Paper detection size

Width (mm)

OFF OFF OFF

80 to less than 115 A6S

115 to 144 inclusive B6S

196 to 225 inclusive A5

242 to 268 inclusive B5

ON OFF OFF

133 to 164 inclusive A5S

169 to less than 196 B5S

196 to 225 inclusive A4S

255 to less than 288 81/2 × 11


ON ON OFF 188 to 235 inclusive FLS*

ON ON ON

201 to 231 inclusive 81/2 × 14

242 to less than 268 B4

268 to less than 288 11 × 17

288 to less than 301 A3

301 to 330 inclusive 12 × 18


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Inch area

*: One of the following paper sizes can be selected to be set for Foolscap.8 × 13, 8.125 × 13.25, 8.25 × 13, 8.5 × 13, 8.65 × 13




Bypass paper width detection resistor Paper detection size

Width (mm)

OFF OFF OFF

80 to less than 115 A6S

115 to 144 inclusive B6S

201 to 231 inclusive 51/2 × 81/2

242 to 282 inclusive 71/4 × 101/2

ON OFF OFF

125 to 155 inclusive 51/2 × 81/2 S

169 to less than 201 71/4 × 101/2 S

201 to 231 inclusive 81/2 × 11 S

225 to less than 288 81/2 × 11


ON ON OFF 188 to 235 inclusive Foolscap*

ON ON ON

201 to 231 inclusive 81/2 × 14

242 to less than 268 B4

268 to less than 288 11 × 17

288 to less than 301 A3

301 to 330 inclusive 12 × 18

A00JT2C264AA



Bypass paper width detection resistor (VR)



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17.3.5 Bypass unit open/close mechanism

• The bypass unit open/close function has been installed to enable easier access to the jam controller and the tray1 paper feed part.

17.3.6 Bypass sub tray open/close detection

• The bypass sub tray set sensor has been installed to detect if the sub tray is open or close in order to prevent the false detection made by the multi FD size sensor/2, /3 when the bypass sub tray is closed.

• In this system both sensors don’t function when the bypass sub tray is closed.

A00JT2C265AA

Bypass unit

Tray1 paper feed partLock tab

A00JT2C264AA

Bypass sub tray set sensor (PS37)

Bypass sub tray



18. Timing roller section Theory of Operation Ver. 8.0 Jun. 2008

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18. Timing roller section

18.1 Composition

• Drive

A00JT2C207AA

A00JT2C272AATiming roller

2st image transfer roller

A00JT2C308AA

Registration motor (M2)(broken line)

Timing roller

Theory of Operation Ver. 8.0 Jun. 2008 18. Timing roller section

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18.2 Operation

18.2.1 Timing roller control

• The paper will create a loop between the tray 1 vertical transport roller (or ADU transport roller 4) and the regist motor when the paper is being conveyed in order to correct the skew.

• Timing roller is controlled in order to synchronize the timing the unit starts writing the image and conveying paper.

A. Adjustment• The amount of the loop of the paper can be adjusted in the “Service Mode - [Machine] -

[Printer Regist Loop]”. Changing the adjustment value will change the OFF timing of the tray 1 vertical transport motor (or ADU transport motor 2).

A00JT2C223AA


Registration motor (M2)


Timing roller rotation start

Tray1 vertical roller stopTray1 vertical transport roller rotation start

Registration start

Paper loop is created before the timing roller

A00JT2C222AA

Timing roller


OHP detection sensor (PS40)

Loop creating


PaperTray1 paper feed roller

18. Timing roller section Theory of Operation Ver. 8.0 Jun. 2008

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18.2.2 OHP detection

• OHP detection sensor checks to prevent printing on the paper other than OHP.• OHP detection will be performed after paper made the loop at the timing roller. When the

OHP detection shows the different result from the setting on the operation panel, printing will stop to display “Error.”

Paper type set from control panel

Results of OHP detection sensor (PC4) detection

Operation

OHP Other than OHP Stops printing promptly based on the detec-tion of paper type inconsistencyOther than OHP OHP

A00JT2C225AA

Prism

Sensor output

LED remote

OHP detection sensor (PS40)

Timing roller

Theory of Operation Ver. 8.0 Jun. 2008 18. Timing roller section

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18.2.3 Speed control

• It controls the timing the paper reaches to the timing roller sensor.

A. Operation• The tray1 vertical transport roller, the tray2 vertical transport roller and the intermediate

roller may speed up, slow down or stop temporarily during paper transportation in order to adjust the paper interval.

A00JT2C228AA

Timing roller


Tray1 vertical transport roller (Speed increase, speed reduction, halt)

Tray2 vertical transport roller (Speed increase, speed reduction, halt)

Intermediate roller (Speed increase, halt)

19. Fusing section Theory of Operation Ver. 8.0 Jun. 2008

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19. Fusing section

19.1 Composition

A00JT2C271AA

A00JT2C208AA

A00JT2C258AA

Soaking roller thermistor/1 (TH5)Soaking roller thermistor/2 (TH6)Soaking roller thermostat (TS2)

Brush roller

Soaking roller heater lamp (FH2)

Soaking roller

Fusing unit

IH coil unit(Fixed at the main body side)

Heating roller

Fusing pressure roller thermistor (TH4)

NC sensor (TEMS)Heating roller thermistor/1 (TH1)Heating roller thermistor/2 (TH2)Heating roller thermistor/3 (TH3)Heating roller thermostat (TS1)

IH coil (FH1)

Fusing unit (Periodically replaced parts)

IH coil unit

Fusing pressure roller

Separator finger

Theory of Operation Ver. 8.0 Jun. 2008 19. Fusing section

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(1) Configuration of the temperature detector element of fusing unit

A00JT2C316AA

Heating roller thermostat (TS1)

NC sensor (TEMS)

Heating roller thermistor/1 (TH1)


< Heating roller >

Fusing pressure roller thermistor (TH4)

< Fusing pressure roller >

< Soaking roller >

Soaking roller thermostat (TS2)

Soaking roller thermistor/1 (TH5)

Soaking roller thermistor/2 (TH6)

Front side Rear side

Center



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19.2 Drive

A00JT2C299AA

Fusing pressure retraction motor (M29)

Pressure home sensor (PS55)

Fusing motor (M30)



Fusing retraction position sensor (PS59)

Front side


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19.3 Operation

19.3.1 Heating roller structure

• The inside surface of the heating roller is formed with Ni layer.• Ni layer of the heating roller is the nonmagnetic conducting layer in which eddy current is

generated with magnetic flux.

19.3.2 Whole area heating/Center heating switch control

• The heating system will be switched from whole area heating to center area heating in order to prevent the edge temperature from heating up while the small size paper passes or during standby mode.

• When the demagnetization coil turns ON, the magnetic field around the end of the Main coil is degaussed and only center area of the soaking roller is heated.

• C650 uses two different types of demagnetization coils, each having a specific dimen-sion.

• The demagnetization coil is controlled with the heating roller thermistor/3.• Each demagnetization coil is controlled to turn ON or OFF according to the CD length

and the temperature of the heating roller at its end.• The main coil is identified by the wire color of the + side for correct application in a spe-

cific model: blue for C650 and orange for C550/C451.

A00JT2C230AA

Fusing belt

Ni layer (coated back side)

Fusing roller

2

2

2

2

A00HT2C301AA

Main coil1st demagnetization coil

C650

C550/C451

2nd demagnetization coil

1st demagnetization coil

2nd demagnetization coil


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Demagnetization coil ON conditions

C650 C550/C451

Heating roller end temperature (Degrees centigrade)

CD length (mm) 1st demagnetization coil 2nd demagnetization coil 1st demagnetization coil

265 or more250 degrees centigrade

or moreAround 150 degrees

centigrade200 degrees centigrade

or more

265 to 240Around 175 degrees

centigradeAround 100 degrees


or more




or more




centigrade

StandbyAround 200 degrees



centigrade

2


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19.3.3 Fusing roller drive control

A. Fusing pressure roller rotating speed control• In order to avoid fusing error, the rotation speed of the fusing belt is exchanged according

to the paper type or the print mode• By selecting the gloss mode, fusing speed slows down by 50% from the normal speed.• Fusing speed is set to 80 mm/s during standby mode.• The fusing motor stops as IH coil is not conducted during power save mode.

(1) C650 fusing speed



2

Paper type Print mode Fusing speed (mm/second)

Plain paper (60 g/m2 to 90 g/m2)Monochrome 310

Color 240

Thick paper 1/1+ (91g/m2 to 157 g/m2)Monochrome

155Color

Thick paper 2/3/4 (158g/m2 to 300 g/m2)Postcard, Envelopes, Label sheet

Monochrome

120Color

OHP Monochrome



Color 216


132Color


Monochrome

108Color

OHP Monochrome



Color 216


132Color


Monochrome

108Color

OHP Monochrome


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19.3.4 Fusing loop control

A. Adjustment of the loop amount• By creating a paper loop, the speed difference between the fusing and paper convey-

ance at 2nd transfer part will be adjusted. It prevents the double transferred image or brush effect.

• The fussing speed is controlled (speed up/speed down) according to the amount of paper loop.

• The loop amount detection sensor/1, /2 turns ON in different timing according to the loop amount so that the loop amount can be detected in three stages.

B. Operation flow1. It starts controlling when the front-edge of the paper reaches to the predetermined

position before the fusing pressure roller.2. When the fusing speed goes faster, the paper will create fewer loops between the

2nd image transfer roller and the pressure roller.3. The control will finish when the back-edge of the paper passes the predetermined

position on the back of the transfer roller.

Loop amount detection sensor/1

Loop amount detection sensor/2

Loop amount Fussing speed

Unblocking Blocking large Speed - up - Fast

Unblocking Blocking average Speed - up - Slow

Blocking Blocking small Slowdown

A00JT2C260AA

Loop amount: small


Loop amount: large

Loop amount detection sensor/1 (PS41)Loop amount detection sensor/2 (PS42)

Block timing differs according to the shape

2nd image transfer roller


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19.3.5 Fusing pressure roller pressure/retraction mechanism

• To ensure prolonged durability of the heating roller, the heating roller and fusing pressure roller is retracted *1 from the fusing belt during any time other than a print cycle. (The roller is, however, retracted *1 during a print cycle using envelopes.)*1: The fusing pressure roller does not completely retract but is slightly pressed to the pressure roller.

• The fusing pressure retraction motor is turned forward or backward to press the pressure roller up against, and retract it from, the heating roller. When the motor rotates, the fan-shaped gear will rotate to move the pressure roller.

• Pressed position of the fusing pressure roller is detected by the roller pressure home sensor. The alienation is detected by the fusing retraction position sensor.

• When there is no change in output of the fusing retraction position sensor even if the given time has passed after the fusing pressure retraction motor started its rotation, it is judged as abnormal spacing and “Trouble code C3101: abnormal in fusing pressure roller pressure welding alienation” message appears.

• Pressure/retraction timing


Heating roller Sector gear

Pressure operation Retraction operation


Pressed by the heating roller

Conditions Pressure/retraction operation

Warm-up

C650

Heater temperature is less than 160 degrees centigrade

Retraction

Heater temperature is 160 degrees centigrade or more

Pressure

C550/C451


Retraction


Pressure

C451: Taiwan only


Retraction


Pressure

Standby Normal Retraction

PrintingFor paper types other than envelopes Pressure

For envelopes Retraction

Power save mode ON – Retraction

Heater OFF – Retraction

2


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19.3.6 Fusing temperature control

• The surface temperature of the heating roller and the fusing pressure roller are detected to control the amount of the heat of the IH heater and the fusing pressure roller heater lamp in the soaking roller in order to maintain the appropriate fusing temperature.

Example: C550 temperature control (Plain paper)

*1: Temperature is not controlled because the IH heater is OFF.

[1] Controlled temperature at warm-upHeating roller temperature: 170 degrees centigradeFusing pressure roller temperature: 90 degrees centigradeSoaking roller temperature: 50 degrees centigrade

[4] Standby (normal operation)Heating roller temperature: 150 degrees centi-gradeFusing pressure roller temperature: 125 degrees centigradeSoaking roller temperature: 120 degrees centi-grade

[2] Controlled temperature at stand by (nor-mal operation)Heating roller temperature: 150 degrees centigradeFusing pressure roller temperature: 125 degrees centigradeSoaking roller temperature: 120 degrees centigrade

[5] Low power modeHeating roller temperature: - *1 Fusing pressure roller temperature: 100 degrees centigradeSoaking roller temperature: 160 degrees centi-grade

[3] Printing (Plain/color)Heating roller temperature: 170 degrees centigradeFusing pressure roller temperature: 115 degrees centigradeSoaking roller temperature: 115 degrees centigrade

[6] Sleep modeHeating roller temperature: - (room temperature) Fusing pressure roller temperature: - (room tem-perature)Soaking roller temperature: - (room temperature)

0

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

time

temp

A00JT2C233AA


Soaking roller

Heating roller

Power save modeStart key ONSub-power switch ON

Sleep modePrint is available

2


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A. Temperature adjustment control of IH heater• Temperature of the heating roller is controlled within the given range during warm-up,

printing and standby.• Temperature of the heating roller is measured with the NC sensor, and the temperature

change (up/down) is monitored by comparing the current temperature with the value of one second before.

• When the temperature goes up beyond the upper limit, the electric energy goes down.• When the temperature goes down under the target figure, the electric energy goes up.

B. Operation flow during warm-up• When the temperature of the heating roller reaches a predetermined level, the pressure

roller starts pressing.• When the temperatures of all rollers go beyond the temperature set for warm-up, printing

becomes available.• If printing request comes, the machine starts printing. If not, the mode goes to “standby

temperature control”.• A different warm-up completion time is set only for the C451 for Taiwan because of its

low power that can be used.

(1) C650/C550/C451 warm-up completion temperature

(2) C550 only for Taiwan warm-up completion temperature

(3) C451 only for Taiwan warm-up completion temperature

A00JT2C231AA

Temperature change of heating roller One second Temperature check

Temperature

Upper limit

Targettemperature

Lower limit

High

Low

Electric energy

Time (sec.)

2

Warm-upCompletion

timeHeating roller temperature

Fusing pressure roller temperature

Soaking roller temperature

In monochrome and color

30 seconds 170 degrees centigrade 70 degrees centigrade 50 degrees centigrade

2

Warm-upCompletion




In monochrome and color

60 seconds 170 degrees centigrade 90 degrees centigrade 50 degrees centigrade

2

Warm-upCompletion




In monochrome 30 seconds 165 degrees centigrade 70 degrees centigrade 50 degrees centigrade

In color 60 seconds 185 degrees centigrade 100 degrees centigrade 70 degrees centigrade


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C. Temperature control during stand-by• The fusing temperature in the standby state is prevented from being dropped.• The temperature is controlled by each modes (low temperature, normal, high humidity),

within predetermined time from standby control start.• The temperature is controlled by normal mode, after predetermined time from standby

control start.* Counted period for standby control includes the printing time.

• Temperature control setting during standby is changed according to the environment condition when the power is turned ON.Normal mode: When the fusing pressure roller temperature at start-up is over 60 degrees centigrade and the absolute humidity inside is less than 18.Low temperature mode: When the fusing pressure roller temperature at start-up is less than 60 degrees centigrade and the absolute humidity inside is less than 18.High humidity mode: When the absolute humidity inside is over18.* Absolute humidity: Water volume contained in the air (1m3) in form of vapor regardless of the temperature.

• A different control temperature is set only for the C451 for Taiwan because of its low power that can be used.

(1) C650 control temperature

(2) C550/C451 control temperature

(3) C451 only for Taiwan control temperature

2

Environment condition when

the power is turned ON

Pressure/spacing of

fusing pressure roller

Rotation of fusing

pressure roller

Set tempera-ture of heating roller (Degrees

centigrade)

Set tempera-ture of fusing

pressure roller (Degrees

centigrade)

Set tempera-ture of soaking roller (Degrees

centigrade)

Normal

Spacing Rotation

160 125 125

Low temperature 180 130 130

High humidity 170 130 130



Pressure/spacing of


Rotation of fusing

pressure roller


centigrade)



centigrade)


centigrade)

Normal

Spacing Rotation

150 125 120





Pressure/spacing of


Rotation of fusing

pressure roller


centigrade)



centigrade)


centigrade)

Normal

Spacing Rotation

150 125 120




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D. Temperature control during printing• Temperature is controlled to maintain the optimal fusing status when the temperature is

getting down due to the paper type, the printing mode, the small size paper or paper passing, or due to warm-up with cooled fusing unit.*The controlled temperature shown below is changed according to the environment sta-tus, start-up conditions or etc.

• A different control temperature is set only for the C451 for Taiwan because of its low power that can be used.

(1) C650 control temperature

(2) C550/C451 control temperature

2

Paper type (Same control in monochrome

and color)

Heating roller setting temperature

(Degree centigrade)

Fusing pressure roller setting temperature

(Degree centigrade)

Soaking roller setting temperature (Degree centigrade)

Plain paper (Duplex print) 180

115 115

Plain paper/glossy mode (Duplex print)

160

Thick paper 1 170

Thick paper 1+ 180

Thick paper 2, 3, 4 185

Thick paper 1 (Duplex print) 170

Thick paper 1+ (Duplex print) 180

Thick paper 2, 3, 4 (Duplex print) 185

Envelopes 180

Postcards 185

OHP: Black-and-white print only 140


and color)


(Degree centigrade)


(Degree centigrade)



115 115


150

Thick paper 1 170

Thick paper 1+ 180





Envelopes 180

Postcards 185

Long paper/ When the paper length is over 457 mm (C451 only)

170



140

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(3) C451 only for Taiwan control temperature


and color)


(Degree centigrade)


(Degree centigrade)



115 115


150

Thick paper 1 170

Thick paper 1+ 180





Envelopes 180

Postcards 185

Long paper/ When the paper length is over 457 mm

170



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E. Fusing temperature control during printing.• Fusing temperature control prevents declining of the image stability as well as reduces

curling of the paper, uneven waxing, offset, etc., according to the paper type to be used.• Fusing temperature control can be set from “Service mode/machine/fusing temperature”.• Adjust the fusing temperature at heating side first. If the further adjustment is necessary,

adjust on the pressure side.

F. Temperature control during low power mode• The IH coil stops to reduce the power consumption at low power mode and make tem-

perature control by lowering the fusing temperature.• Usually the pressure roller stops at low power mode though, the roller rotates slightly

every certain period to prevent the brush roller from being distorted.

*1: The temperature of the pressure roller is not controlled because the IH coil is turned OFF.

Paper typeHeated site

(Heating roller temperature)Pressured side

(Fusing pressure roller temperature)

Plain paper

- 20 °C to + 5 °C (step: 5 °C) - 20 °C to + 5 °C (step: 5 °C)

OHP

Thick paper 1, 1+

Thick paper 2

Thick paper 3

Thick paper 4

Postcards

Envelopes - 5 °C to + 5 °C (step: 5 °C) - 5 °C to + 5 °C (step: 5 °C)

Machine models

Pressure/spacing of


Rotation of fusing

pressure roller

Set temperature of heating roller

(Degree centigrade)

Set temperature of fusing pressure roller (Degree

centigrade)

Set temperature of soaking roller

(Degree centigrade)

C650Spacing Stop - *1

80 120

C550/C451 100 160

2


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19.3.7 Protection from abnormally high temperature

• The machine provides protection against abnormally high temperature of the fusing unit in the following three steps.

A. < Soft protection >• When the controlled temperature of each roller is detected higher than the predeter-

mined value for more than 1 second, the temperature is judged to be abnormally high, and the trouble code appears.

• When the trouble code is displayed, printing will be prohibited.

B. < Hard protection >• Next level is provided when the level 1 cannot detect due to CPU overrun.• The heater relay, through the electronic control board, is turned OFF in the second level

operation to block the power supply to the IH heater and the heater lamp.• When the controlled temperature of each roller is detected higher than the predeter-

mined value, the temperature is judged to be abnormally high, and the trouble code appears.

• Through these control procedures, the power supply to the IH heater and heater lamps can be shut down before the thermostat is activated in the third level. It thereby sup-presses damage to the fusing unit itself.

Roller name Sensor name

Detected temperature

(Degrees centigrade)

Trouble code

Heating roller

NC sensor: TEMS 225 C3725Fusing high temperature abnormality_NC sensor

Heating roller thermistor/2: TH2

270 C3721Fusing high temperature abnormality_heating center


285 C3722Fusing high temperature abnormality_heating edge

Fusing pres-sure roller

Fusing pressure roller ther-mistor: TH4

215 C3723Fusing high temperature abnormality_pressure

Soaking rollerSoaking roller thermistor/1: TH5

200 C3724Fusing high temperature abnormality_Soaking

2

Roller name Sensor name: code

Controlled temperature

(Degrees centigrade)

Trouble code

Heating roller


195

C3721Fusing high temperature abnormality_heating centerHeating roller thermistor/2:

TH2225


220 C3722Fusing high temperature abnormality_heating edge

Soaking roller

Soaking roller thermistor/1: TH5Soaking roller thermistor/2: TH6

165 C3724Fusing high temperature abnormality_Soaking

2


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C. < Overheat protection >• If the abnormal high temperature of soft protection/hard protection cannot be detected

due to thermistor trouble, thermostat blocks the power supply to each heater lamp.• The thermostat rating is 210 degrees centigrade for both the heating roller thermostat

and the pressure roller thermostat.• The ratings do not, represent the actual surface temperature of the corresponding rollers,

since the thermostats are installed in a non-contact fashion with respect to each of the rollers.


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19.3.8 Sensor disconnection detection control

• If the temperature of the NC sensor/thermistor fails to reach the specified temperature in the given period after the warm-up started, the sensor is judged to have disconnection, and the trouble code will appear.

19.3.9 Heating roller rotate detection

• If the heating roller doesn’t rotate even after the IH heater is conducted, an appropriate temperature measurement and temperature control cannot be made. If the IH heater is ON without rotating of the heating roller for a long time, the heat concentrate on the cer-tain area and the roller may get damaged due to the heat.

• If the heating roller doesn’t rotate even after the IH heater ON, the trouble message for heater roller rotating failure appear. (C3102)

• As two heating roller rotation sensors are used, the rotation can be detected even if either sensor get broken, which improves the safety.

19.3.10 Detection of a new fusing unit

• When a new fusing unit is installed in the machine, the life counter is automatically cleared through the machine’s capability of detecting a new fusing unit.

• The new unit is detected when the sub power switch is turned ON.

Roller name Sensor name: code Trouble code

Heating roller

NC sensor: TEMS C3925Fusing high temperature abnormality_NC sensor

Heating roller thermistor/2: TH2 C3921Fusing high temperature abnormality_heating center

Heating roller thermistor/3: TH3 C3922Fusing high temperature abnormality_heating edge

Fusing pres-sure roller

Fusing pressure roller thermistor: TH4 C3923Fusing high temperature abnormality_pressure

Soaking roller

Soaking roller thermistor/1: TH5 C3924Fusing high temperature abnormality_Soaking

2

A00JT2C267AA

Heating roller

Heating roller rotation detection gear

Heating roller rotation sensor/2 (PS57)

Cam gear

Heating roller rotation sensor/1 (PS56)


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19.3.11 PPM control

• PPM (PCM) control is made to secure the paper space and reduce the number of print-ing per minutes so that the center temperature of the heating roller and pressure roller can be reduced, which prevents the edge temperature from going up.

• With this PPM control, the productivity is decreased by between 40 to 90% compared with the normal mode.

• Select the correction rate by three judgment steps, make the PPM control in minimum rate.Ex: In case the 1st judgment: 70%, 2nd judgment: 60%, 3rd judgment: 100%, it will con-trol with 60% correction rate.

• PPM control makes the judgment in every given period to print with the corrected PPM controlEx: In case the printing of 55 sheets/minute with 60% correction rate, it will be 33 sheets/minute.

• The speed is adjusted (up/down) by 10% in every given period.

Example: C550 PPM control

2

2

Judge-ment

Measurement time

CriteriaCorrected

rate

15 seconds after print starts

Low temperature mode when print starts and the temperature inside the unit is 18 degrees centigrade or below

70%

Other than above 100%

260 seconds after print start

Low temperature mode when print starts and the temperature inside the unit is 18 degrees centigrade or below

70%

Other than above

Central temperature of the heating roller is lower than setting value by up to 15 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by up to 35 degrees centi-grade

100%

Central temperature of the heating roller is lower than setting value by between 15 to 25 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by up to 5 degrees centi-grade

80%

Central temperature of the heating roller is lower than setting value by over 25 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by up to 5 degrees centi-grade

70%

Central temperature of the heating roller is lower than setting value by between 15 to 25 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by between 5 to 35 degrees centigrade

70%

Central temperature of the heating roller is lower than setting value by over 25 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by between 5 to 35 degrees centigrade

60%


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Judge-ment

Measurement time

CriteriaCorrected

rate

260 seconds after print start

Other than above

Central temperature of the heating roller is lower than setting value by up to 15 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by over 35 degrees centi-grade

70%

Central temperature of the heating roller is lower than setting value by between 15 to 25 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by over 35 degrees centi-grade

60%

Central temperature of the heating roller is lower than setting value by over 25 degrees centigradeCentral temperature of the fusing pressure roller is lower than setting value by over 35 degrees centi-grade

50%

3

60 seconds for single side/120 seconds for duplex after print start

CD length is 290mm or more 100%

CD length is 190 to 290mm

System speed is 155 to 108mm/s and temperature inside the unit is over 18 degrees centigrade

100%

System speed is 155 to 108mm/s and temperature inside the unit is 18 degrees centigrade or less

80%


Central temperature of the heating roller is less than 240 degrees centigrade

100%

Central temperature of the heating roller is 240 to 250 degrees centigrade

50%

Central temperature of the heating roller is 250 degrees centigrade or more

40%


Central temperature of the heating roller is less than 220 degrees centigrade

100%


90%


70%


50%

Central temperature of the heating roller is 250 degrees centigrade or more

40%

2

Theory of Operation Ver. 8.0 Jun. 2008 20. Paper exit section

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20. Paper exit section

20.1 Composition

A00JT2C309AA

A00JT2C210AA

A00JT2C280AA

Exhaust sensor (PS39)

Paper exit roller/1

Paper exit roller/2

Switchback paper exit section

Switchback roller

Paper exit section

Paper exit change gate

20. Paper exit section Theory of Operation Ver. 8.0 Jun. 2008

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20.2 Drive

• The exit and switch roller are driven by the exclusive motor.

A00JT2C310AA

Fusing drive motor (M4)

Paper exit roller

Paper exit roller/2

Switchback Motor (M33)

Theory of Operation Ver. 8.0 Jun. 2008 20. Paper exit section

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20.3 Operation

20.3.1 Switchback control

• When the fusing is completed on the first side of duplex print, switchback snap is switched down to transport the sheet to the switchback part. When the fusing is com-pleted on the sheet of single print or second side of duplex print, the sheet is transported to the exit section.

• The paper transported to the switchback part stops at the switchback position and then the switchback roller turns around to transport the sheet to the duplex section.

• Before the switchback roller starts to turn the opposite direction, the exit switch gate is switched to the upward direction.

A00JT2C235AA


Switchback sectionSwitchback position

When the exit part are transported

Duplex section

Fusing section

Paper exit roller 1

paper exit roller

ADU transport roller 1

Paper exit section

When the switchback part are transported

Paper exit roller 2

Exit switch gate

Fusing motor (M30)


Gate switch solenoid (SD)

Switchback motor (M33)Nomal rotation

Inverse rotation

ADU transport motor/1 (M31)

Instruction form the optimal paper position

Switchback motor turns around

A00JT2E531DA

21. Duplex section Theory of Operation Ver. 8.0 Jun. 2008

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21. Duplex section

21.1 Composition

A00JT2C291AA

A00JT2C211AA

A00JT2C275AA

ADU transport sensor/1 (PS47)

ADU door sensor (PS49)


Theory of Operation Ver. 8.0 Jun. 2008 21. Duplex section

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21.2 Drive

21.2.1 Duplex unit drive

A00JT2C291AA



ADU transport roller/4





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21.3 Operation

21.3.1 Duplex unit transport control

• The paper transported to the switchback part stops at the stop position 1 and then the switchback roller turns around to transport the sheet to the duplex unit.

• When a sheet of paper being less than 127 mm is passing by the ADU transport roller/2 in the duplex unit, if the preceding paper has not reached the timing roller, the sheet stops at the stop position 2.

• The paper transported to the duplex part always stops at the stop position 3 and wait until paper is re-supplied.

• When the paper is supplied, it is transported to the timing roller.

A00JT2C245AA

Switchback part

Switchback roller

Stop position 1


Stop position 2

Timing rollerADU transport roller/3


Stop position 3




Duplex part


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21.3.2 Duplex print

• Duplex print changes its control method according to the paper length.

A. 1 sheet alternate supply

Paper sizeDuplex print method

Lower limit Upper limit

- Less than 217 mm Three alternative paper feed

217 mm or more Less than 433 mm Two alternative paper feed

433 mm or more Less than 459 mm One paper feed

Operation 1• One sheet of paper is supplied and the image of the sec-

ond page is printed.

2

A00JT2C236AA

A00JT2C237AA

2

Operation 2• After the paper transported to the switchback part stops at

the stop position 1, the switchback roller turns around to send the sheet to the duplex part (Switchback).

Stop position 1

A00JT2C238AA

2

Operation 3• The paper transported to the duplex part is transported to

the stop position 3 faster than the system speed.• It stops at the stop position 3.

Stop position 3


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• Steps 2 through 5 are repeated.

• One sheet A4-size original at double sided print• When the re-supplied paper length is less than 217 mm, only the ADU transport motor/2

turns ON.

Operation 4• The image of the first page is printed on the paper re-sup-

plied from the duplex section.

A00JT2C239AA

1 2

Operation 5• Exhaust the first sheet of the paper.• At the same time, the image of fourth page is printed on

the second sheet.

A00JT2C240AA

1

2

4



Gate switch solenoid (SD)

Exit motor (M4)

Switchback motor (M33)Normal rotation

Inverse rotation



Toolcami sensor/2 (PS48)

Instruction form the optimal paper position

A00JT2E532DA

Stop before re-supply of paper


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B. 2 sheets alternate supply

Operation 1• The first sheet of paper is supplied and the image of the

second page is printed.

2

A00JT2C236AA

Operation 2• First sheet of the paper is turned around at the switchback

part and transported to the duplex part.• At the same time, the second sheet of paper is supplied.

A00JT2C242AA

2

Operation 3• The image of the fourth page is printed on the second

sheet of paper.• At the same time, the first sheet of the paper is sent trough

the duplex part and stops at the stop position 3.

A00JT2C243AA

4

2

Operation 4• The first sheet of the paper is re-supplied and an image of

the first page is printed on.• The second sheet of paper is turned around at the switch-

back part and transported to the duplex part.• At the same time, the third sheet of paper is supplied.

A00JT2C244AA

1

4

6

2


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Operation 5• Exhaust the first sheet of paper.• At the same time, the image of the sixth page is printed on

the third sheet of paper.• The second sheet of the paper stands by at the stop posi-

tion 3 until the paper pitch for third sheet is assured.

A00JT2C246AA

1

4

2

6

Operation 6• The third sheet of paper is turned around at the switch-

back part and transported to the duplex part.• At the same time, the second sheet of the paper is re-sup-

plied.

A00JT2C247AA

1

4

2

6

Operation 7• The image of the third page is printed on the second sheet

of paper.• At the same time, the third sheet of paper is transported in

the duplex part.• At the same time, the fourth sheet of paper is supplied.

A00JT2C248AA

1

2

6

43

Operation 8• Exhaust the second sheet of the paper.• At the same time, the image of eighth page is printed on

the fourth sheet of the paper.• The third sheet of paper stands by at the stop position 3

until the paper pitch for the fourth sheet is assured.

A00JT2C249AA

1

2

68

3

4


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C. 3 sheets alternate supply

Operation 1• The first sheet of paper is supplied and the image of the

second page is printed.

2

A00JT2C236AA

Operation 2• The first sheet of paper is turned around at the switchback

and transported to the duplex part.• At the same time, the second sheet of paper is supplied.

A00JT2C242AA

2

Operation 3• The image of fourth page is printed on the second sheet of

the paper and the paper is transported to the switchback part.

• At the same time, the first sheet of the paper is transported and stops at the stop position 3.

• At the same time, the third sheet of paper is supplied.

A00JT2C250AA

4

2

Operation 4• The image of sixth page is printed on the third sheet of the

paper.• At the same time, the second sheet of the paper is turned

around at switchback part, transported to the duplex part and stops at the stop position 2.

• The first sheet of the paper stands by at the stop position 3 until the paper pitch for third sheet is assured.

A00JT2C251AA

6

2

4Stop position 2

Stop position 3


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Operation 5• First sheet of the paper is re-supplied and an image of the

first page is printed on, then it is transported to the paper exist part.

• At the same time, the second sheet of the paper is trans-ported to the stop position 3.

• At the same time, the third sheet of the paper is turned around at the switchback part and then transported to the duplex part.

• At the same time, the fourth sheet of the paper is supplied. A00JT2C252AA

1 2

4

6

Operation 6• Exhaust the first sheet of paper.• At the same time, the image of the eighth page is printed

on the fourth sheet of paper.• The third sheet of the paper is transported to the stop posi-

tion 2 and stops there.• The second sheet of the paper stands by at the stop posi-

tion 3 until the paper pitch for fourth sheet is assured.

A00JT2C253AA

1

2 8

4

6

Operation 7• The second sheet of the paper is re-supplied and the

image of the third page is printed on, then it is transported to the paper exist part.

• At the same time, the third sheet of the paper is trans-ported to the stop position 3.

• At the same time, the fourth sheet of the paper is turned around at the switchback part and then transported to the duplex part.

• At the same time, the fifth sheet of the paper is supplied. A00JT2C254AA

1

2

43

6

8

Operation 8• Exhaust the second sheet of paper.• At the same time, the image of tenth page is printed on the

fifth sheet of the paper.• At the same time, the fourth sheet of the paper is trans-

ported to the stop position 2 and stops there.• The third sheet of the paper stands by at the stop position

3 until the paper pitch for fifth sheet is assured.

A00JT2C255AA

1

23

4

10

6

8

Theory of Operation Ver. 8.0 Jun. 2008 22. Image stabilization control

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22. Image stabilization control

22.1 Overview

• The machine provides the following image stabilization control to ensure stabilized copy image.

* An explanation is given of the control for each section.

Purpose Control Control means

To stabilize image densityTo stabilize gradation

• IDC registration sensor adjust-ment control

• Max. density adjustment control• LD intensity adjustment control• Registration control (color shift

correction)• Gamma correction control

IDC registration sensorTemperature/humidity sensor

PH temperature sensor

To stabilize toner density * TCR control (Y,M,C,K) TCR sensor

To stabilize image transfer* Image transfer output control2nd image transfer ATVC

Temperature/humidity sensor

PCdrum/

Y

PCdrum/

M

PCdrum/

CPC

drum/K

TCR sensor Developing bias Vdc

Toner replenishing control

Toner supply motor

Grid voltage Vg

IDC sensor

Transfer ATVC control

IN

OUT

Image densityGradation controlGamma correction dataGradation correction table

Temperature/humidity sensor

OUT/IN

· To be set on control panelD MAX densityBackground voltage marginATDC toner supply


Color skew correction

PH temperature sensor

G3/Y G3/M G3/C

A00JT2E518DA

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22.2 Operation

22.2.1 IDC registration sensor adjustment control

• Controls changes in characteristics due to change with time and contamination of the transfer belt and IDC registration sensor, part-to-part variations in the sensors, and change of environment.

• The intensity (current value) of the IDC registration sensor is adjusted on the surface of the transfer belt, on which no toner sticks (background level).

22.2.2 Max. density adjustment control

• The developing bias (Vdc) is adjusted to control changes in the solid density resulting from variations in developing characteristics and IDC registration sensor intensity, varia-tions in sensitivity of the PC drum, and changes in the environment, durability, and the amount of charge in toner.

• Patterns are produced on the surface of the transfer belt and the IDC registration sensor detects the amount of toner sticking to them.

• Referring to the detected data and the environment data taken by the temperature/humidity sensors, the developing bias value that results in the appropriate maximum density is calculated and stored in memory.

• Thereafter, the grid voltage (Vg) value, including the background margin adjustment value, is calculated and stored in memory.

22.2.3 LD (laser diode) intensity adjustment control

• It adjusts the variation in reproducibility of the thin line and the reverse outline, which is resulting from the variations in electrostatic characteristics of the PC drum, developing characteristics and transfer characteristics in terms of individual difference, environment and durability, to make it the target level.

• It produces detection patterns on the surface of the transfer belt with the given level of LD intensity and detects the output value of IDC sensor.

• LD intensity is calculated from the detected IDC sensor data.

22.2.4 Gamma correction control

• The intensity of LD in all gradation levels is adjusted to correct changes in gradation characteristics to a linear one. The changes in gradation characteristics are caused by variations in the PC drum sensitivity and developing characteristics and changes with time and in environment.

• It produces gradation patterns on the transfer belt and calculates gradation characteris-tics output by the current engine with the IDC registration sensor.

• The gamma correction data is calculated using the density measurements of different gradation levels. The optimum LD intensity is set for each of the different gradation levels


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22.3 Operation sequence

* Max. density adjustment control 1: Use default for characteristic tilted value and Vdc value.

Max. density adjustment control 2: Use previous setting value for characteristic tilted value and Vdc value.

* LD (laser diode) intensity adjustment control 1: Use default for LD intensity for adjustment pattern.

LD (laser diode) intensity adjustment control 2: Use previous setting value for LD intensity for adjustment pattern.

Gamma correction 1: Performs normal gamma correction.Gamma correction 2: Performs simplified gamma correction.

Sequence Mode 1 Mode 2 Mode 3 Mode 4 Mode 5

1IDC registration sensor adjust-ment

IDC registration sensor adjust-ment

Registration RegistrationIDC registration sensor adjust-ment

2Dmax density adjustment 1

Dmax density adjustment 2

Gamma correc-tion 2

-Dmax density adjustment 2

3LD light intensity adjustment 1

LD light intensity adjustment 2

- -LD light inten-sity adjustment 2

4Dmax density adjustment 2

Registration - -Gamma correc-tion 1

5LD light intensity adjustment 2

Gamma correc-tion 1

- - -

6 Registration - - - -

7Gamma correc-tion 1

- - - -


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22.4 Operation timing

A. Image stabilization when not printing

Mode Operation condition

Mode 1

• A new transfer belt is detected• IU units are removed and installed.• A new IU is detected (Image stabilization sequence is executed only for a new IU that

has been installed)• Skew adjustment is reset (Service mode)• After initialization and image stabilization (Service mode)

Mode 2

• The main power switch is turned ON• The trouble codes and jam messages are reset• After image stabilization control is discontinued, a door is closed.• While a warning code is being displayed, the front door is opened and closed.• Image stabilization (Service mode)

Mode 4• The threshold of PH temperature change is detected during the standby state or dur-

ing a print cycle.

Mode 5 • Gradation Adjust


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B. Image stabilization during printing

*1 When the gamma correction data are out of the specified range in the last image stabili-zation sequence, image stabilization control of mode 2 is executed.

*2:A copy of A4 size or equivalent is counted as one.

• C650/C550

• C451

Mode Operation condition Operation timing

Mode 2

• Temperature change inside the machine is detected. (The machine detects absolute humidity that reaches the threshold temperature change for the first time since the image stability sequence performed last time.)

• When gamma correction data are out of the specified range in the last image stabilization sequence, Vg and Vdc are adjusted again.

• The last color registration adjustment was not success-ful. (Alert codes P-21 or P-22)

• When the print mode changes from mono-chrome to color

• At the end of a print cycle

Mode 3

• The predetermined count is detected. *1 and 2(For details, see, in the following page, image stabiliza-tion execution flow based on a count while a print cycle is progressing.)



• When a print job includes many pages, no image stabili-zation may be performed during the printing. In this case, the machine forcefully execute image stabiliza-tion.*1(For details, see, in the following page, image stabiliza-tion execution flow based on a count while a print cycle is progressing.)

• Between each print set after the predetermined count is reached.

• When the predetermined count is reached, the machine stops printing and the image stabiliza-tion is executed.

Mode 4

• If the machine detects the threshold PH temperature change, only the color registration correction is exe-cuted.(For details, see, in the following page, image stabiliza-tion execution flow based on a count while a print cycle is progressing.)


• When the count of remaining pages reaches the predetermined count, the machine stops print-ing and the image stabili-zation is executed.


2


216 mm or less 1


Over 432 mm 3


216 mm or less 1





Over 1080 mm 6


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C. Basic image stabilization operation flow

Make a check for each print signal

Is there achange in print

conditions?

Is there a print mode change

from black to color?

Is there a print mode change

from black to color?

Does the count of the pages

reach the predetermined

count?

Image stabilizationsequence executed

Is this thelast page of the

print job?

Is this thelast page of the

print job?

Image stabilizationsequence not executed

Image stabilizationsequence not executed

Is there aPH temperature

change?

Does the count of the remaining pages

reach the predetermined

count?

Registrationcontrol executed

YES

YES

YES

YES

YES

YES

YES

YES

A00JT2E519DA


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D. Image stabilization execution flow based on a count while a print cycle is pro-gressing

A00JT2E520DA

Does the count of the pages reach

the predetermined count?





Is there a print mode change from

black to color?

A print job is being processed

Is this the last page of the

print job?

Delimited by each print set?

Image stabilization sequence executed

YES

YES

YES

YES

YES

YES

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23. Image processing

23.1 Scanner section image processing block diagram

• The following detail the image processing operations performed by the scanner section.1. A reduction type CCD sensor is used to read the light reflected off the original and

convert the optical data to a corresponding electric signal. To make data process-ing faster, data transfer and output are done through two channels, one for even-numbered pixels and the other for odd-numbered pixels.

2. The odd and even analog signals output from the CCD sensor chips are synthe-sized to form a single string of signal data which is in turn converted to 8-bit digital signals (256 gradation levels).

3. A correction is made of errors that occur due to variations in sensitivity of each CCD chip and the light distribution varying along the length of the exposure lamp. The shading correction is made by holding the peak value, i.e., the maximum value of readings taken of multiple lines, to prevent adverse effects on the image due to dust on the shading sheet.

4. Memory called FIFO is employed to compensate for a deviation in the scanning position of the original, which represents a gap between two adjacent CCD chips, thereby matching the output timing of R, G, and B data. Also, the color aberration of the lens is compensated at this time.

• The image data is transmitted to MFP board on the write section through the interface cable.

1. Photoelectric conversion

2. Analog-to-digital conversion

3. Shading correction

4. Line-to-line variation correction/color aberration correction

CCD sensor board

Image processing board

To the MFP board

Theory of Operation Ver. 8.0 Jun. 2008 23. Image processing

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23.2 Write section image processing block diagram

PC print data

Multi-valued data(8 bit data)

Bin

ary

data

Multi-valued data(8 bit data)

Mode other than photo Photo mode

6. Color conversion processing

7. Image area discrimination

8. Miscellaneous processing (improved reproduction of black text, edge emphasis, smoothing and color balance)

9. BTC compression

12. Input buffer memory

16. Memory access coordinator

17. Frame memory

18. Output buffer memory

14. File (code) memoryDRAM:1024MB (standard)HDD:60GB (standard)

21. Area discrimination FEET

22. Interpolation

23. Gamma correction

24. Screening

To PH unit

19. BTC expansion

11. Error diffusion (binary)

13. JBIG compression

15. JBIG expansion

2. Resolution conversion processing in the sub scanning direction

4. AE processing

5. Image data editing

26. Main scanning position correc-tionMain scanning speed conver-sionModulation

10. Gamma correction

3. ACS processing

1. Resolution conversion processing in the main scanning direction/movement processing

20. Color conversion processing

25. Delay control for the interval of PC drums

MFP board

Photo mode Mode other than photo

Binary data

From scanner section

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• The following detail the image processing operations performed by MFP board on the Write section.

1. FIFO memory is used to enlarge or reduce images in the main scanning direction. The image is enlarged by increasing the number of data readings and reduced by decreasing the number of data readings.

2. Reduction processing is conducted in sub scanning direction. No processing is done at same size or zoom, but at reduction, the lines are thinned out.

3. The scanning area is divided into multiple blocks. The ratio of color or monochrome is calculated for each of these blocks. The machine then determines whether the entire original is colored or monochrome. A histogram of lightness is also created for later AE processing.

4. The scanning area is divided into two in the FD direction. The lightness histogram for AE processing is generated by the lightness histogram generated through ACS processing. The AE level of the original is determined based on this histogram and AE processing is performed.

5. R, G, and B data are then converted to value and color component data for adjust-ments of saturation, lightness, and hue.

6. When copying in a mode other than photo mode, the color component data (R, G, B) are converted to Y, M, C, and K density data. Also, the masking processing, which compensates for the deviation in the spectral reflection characteristics of the toner, and UCR/BP processing are performed on the image data.

7. Each image area, whether it is a color edge area, black edge area, dot area, or a continuous gradation area, is discriminated.

8. Other types of processing performed are the improved reproduction of black text, edge emphasis, smoothing and color balance.

9. In photo mode and PC print, each image data of R, G, B is compressed to reduce the consumption of data capacity.

10. Binary data gets gamma correction at this time. Makes the necessary corrections so that the printed gradations have linear characteristics, since the image density of the input image data is not directly proportional to that of the printed image because of the changing developing and PC drum characteristics.

11. In photo mode and PC print, the image is processed as multi-valued data (8-bit data). In any mode other than photo, the error diffusion method is employed to pro-cess the image as binary (1-bit) data.

12. Temporarily stores the BTC-compressed image data and error diffusion data.13. The stored image data is compressed in the JBIG (Joint bi-level image experts

group) format. 14. When copying in a photo mode or making PC print, the R, G, and B image data are

stored. When coping in a mode other than photo mode, the Y, M, C, and K image are stored.

15. The image data read from the file memory is uncompressed through a method in a reverse way of JBIG compression. At this time, image rotating or sorting processing is conducted.

16. JBIG image data are expanded in the frame memory.17. When copying in the photo mode or making PC print, each image data of R, G, and

B are stored to reduce data volume. When copying in a mode other than photo mode, the binary data of Y, M, C, and K are stored. For PS printing, multi-valued data of Y, M, C, and K are stored.

18. Temporarily stores the image data output from the frame memory.19. Image data is expanded using the method opposite to that used in BTC compres-

sion. Only when copying in a photo mode (multi-valued data) or making PC pint, the steps from “19. BTC expansion” to “24. Screening” are performed.

Theory of Operation Ver. 8.0 Jun. 2008 23. Image processing

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20. When copying in a photo mode or making PC print, the R, G, and B data is con-verted to the Y, M, C, and K density data. Also, the masking processing, which compensates for the deviation in the spectral reflection characteristics of the toner, and UCR/BP processing are performed on the image data.For PS printing, multi-valued data of Y, M, C, and K are stored and there is no need of converting or processing those data.

21. Edge of letter and lineal drawing gets area discrimination and FEET processing is conducted according to the discrimination result.

22. When FEET processing is conducted, interpolation is done so that no influence is given to continuous gradation portion.

23. Multi-valued data (photo mode) gets gamma correction at this time. Makes the nec-essary corrections so that the printed gradations have linear characteristics, since the image density of the input image data is not directly proportional to that of the printed image because of the changing developing and PC drum characteristics.

24. Creates the density distribution of a predetermined pattern to enable outstanding gradation reproduction.

25. Image data of the file memory is developed to the frame memory and output delay control for the interval of PC drums, Y, M, C, K is conducted.

26. Correct the shear in printing start position in the main scanning direction, which occurs when each PH unit of Y, M, C, K is exposed on the PC drum. Adjust the pro-cessing speed in the board (main scanning) to conform to the input processing speed. The laser is emitted according to the laser intensity information.

24. Other control Theory of Operation Ver. 8.0 Jun. 2008

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24. Other control

24.1 Fan control

24.1.1 Construction

A00JT2C284AA

Cooling fan motor (FM3)

IU cooling fan motor (FM15)


IH cooling fan motor/1 (FM10)

CPU cooling fan motor (built into MFP board)

MFP control board cooling fan motor (FM17)

Rear side cooling fan motor (FM16)

Power supply cooling fan motor (FM9)

Writing cooling fan motor (M14)


Fusing cooling fan motor/1 (FM2)

Paper cooling fan motor (FM13)

Ozone ventilation fan motor (FM6)





Suction fan motor (FM1)


Theory of Operation Ver. 8.0 Jun. 2008 24. Other control

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24.1.2 Operation

A. Function

Motor name Control conditions


• Paper will be sucked between transfer part and fusing part, so it will have a stable behavior and go smoothly into the fusing roller. The air inside will be exhausted outside the unit.

• A Dust filter/Vertical transfer are mounted inside the ventilation duct in order to remove dust the suction fan sucked with the air inside the unit.


• Odor accumulated in the fusing part is absorbed by the odor filter to be removed.

• Heat accumulated inside the unit will be discharged outside in order to avoid temperature increase etc., at the fusing part.

Cooling fan motor/1 (FM3)• Heat accumulated inside the unit will be discharged outside in order to

avoid temperature increase etc, at the transfer part or the fusing part.

Fusing cooling fan motor/2 (FM4)Fusing cooling fan motor/3 (FM5)

• Odor accumulated between TC part and fusing part is absorbed by the odor filter to be removed.

• In order to keep the temperature between TC part and fusing part as well as motor part, heat accumulated inside the unit will be discharged.


• A white belt may occur on the image because of the lower sensitivity of the PC drum due to ozone accumulated around the PC drum charge corona. In order to avoid this trouble, ozone filter removes the ozone inside the PC drum charge corona to keep the sensitivity of the PC drum.

• Ozone accumulated around PC drum charge corona will be absorbed by ozone filter and be removed.


• Toner fume attached to the surface of the color IU is absorbed to be removed outside.


• Toner fume attached to the surface of the K_IU is absorbed to be removed outside.


• Heat accumulated inside the unit will be discharged outside in order to avoid temperature increase etc, at the power part.


• Heat accumulated inside the unit will be discharged outside in order to avoid temperature increase at the IH power used for fusing part.

IH cooling fan motor/2 (FM11)IH cooling fan motor/3 (FM12)

• In order to avoid the temperature increase around IH power used for the fusing part, the outside air is sucked into the unit to cool it.


• In order to avoid toner adhesion to other things, outside air is sent to ejected paper to cool it down.

Writing cooling fan motor (FM14)

• In order to avoid the temperature increase around PH, the outside air is sucked into the unit to cool it.


• In order to avoid the temperature increase around TC part, IU part, trans-fer unit, etc., the outside air is sucked into the unit to cool it.


• Heat accumulated inside the unit will be discharged outside in order to avoid temperature increase at rear side of the unit, such as the board box.

MFP control board cooling fan motor (FM17)

• Heat accumulated inside the unit will be discharged in order to avoid tem-perature increase at the printer control board.

Scanner cooling fan motor (FM201)

• Heat accumulated inside the IR part will be discharged in order to avoid temperature increase at the scanner motor.


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B. Fan control

Exit cooling fan motor/1, /2, /3 (FM101, FM102, FM103)

• In order to avoid toner attachment while the exit plate kit is used, outside air is applied to the paper to cool it.

• Fan motor for the exit plate kit (0T-503)

Motor name Control conditions

Motor name Control Control conditions (outline)


Stop

• Plug-in/Sub-power switch OFF• In standby• In low-power or sleep• When updating the firmware• At paper-jam, in trouble, or when the door is open• All drive systems are OFF due to the cause except paper

jam, trouble, or door being open

Half speed -

Full speed• At warm-up, initial operation, image stabilization• When cleaning the transfer belt• When printing

Power supply cooling fan motor/1 (FM2)

Stop

• Plug-in/Sub-power switch OFF• When sleep• In standby• When updating the firmware

Half speed

• In standby or low-power• At paper-jam, in trouble, or when the door is open• All drive systems are OFF due to the cause except paper


Full speed *1

• At warm-up, initial operation, image stabilization, function*1, or printing

• When cleaning the transfer belt• When printing


Stop

• Plug-in/sub-power switch OFF• When in low power or sleep• When updating the firmware• At paper-jam, in trouble, or when the front door is open• All drive systems are OFF due to the cause except paper


Half speed • In standby

Full speed• At warm-up, initial operation, image stabilization• When printing

Fusing cooling fan motor/2 (FM4)Fusing cooling fan motor/3 (FM5)

Stop

• Plug-in/sub-power switch OFF• In low-power or sleep• When updating the firmware• In standby or low-power• At paper-jam, in trouble, or when the front door is open• All drive systems are OFF due to the cause except paper



Full speed *2

• At warm-up, initial operation, image stabilization• When cleaning the transfer belt• When printing


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Stop• Plug-in/sub-power switch OFF• In sleep• When updating the firmware

Half speed

• In standby, low power• At paper-jam, in trouble, or when the door is open• All drive systems are OFF due to the cause except paper


Full speed *1

• At warm-up, initial operation, image stabilization, function• At toner replenishing, after detecting charge leakage• When printing


Stop

• Plug-in/sub-power switch OFF• At warm-up, low power, or initial operation• At low power, or sleep• At paper-jam, in trouble, or when the door is open.• All drive systems are OFF due to the cause except paper

jam, trouble, or door being open.

Half speed -

Full speed• At image stabilization, toner replenishing, after detecting

charge leakage• When printing


Stop

• Plug-in/sub-power switch OFF• At warm-up, low power, or initial operation• At low power, or sleep• At paper-jam, in trouble, or when the door is open.• All drive systems are OFF due to the cause except paper


Half speed -

Full speed• At image stabilization, toner replenishing, after detecting

charge leakage• When printing


Stop • When sleep

Half speed

• Plug-in/sub-power switch OFF• At stand by, low power• When updating the firmware• At paper-jam, in trouble, or when the door is open.• All drive systems are OFF due to the cause except paper


Full speed• At warm-up, initial operation, image stabilization, function• At toner replenishing, after detecting charge leakage• When printing


Stop

• Plug-in/sub-power switch OFF• In low-power or sleep• When updating the firmware• At paper-jam, in trouble, or when the front door is open• All drive systems are OFF due to the cause except paper



Full speed• At warm-up, initial operation, image stabilization• When printing



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IH cooling fan motor/2 (FM11)IH cooling fan motor/3 (FM12)

Stop

• Plug-in/sub-power switch OFF• In low-power or sleep• When updating the firmware• At paper-jam, in trouble, or when the door is open• All drive systems are OFF due to the cause except paper


Half speed -

Full speed *2

• At warm-up, initial operation, image stabilization• When printing


Stop



Half speed• In standby• When the front door is open


Writing cooling fan motor (FM14)

Stop




Full speed *1

• At warm-up, initial operation, image stabilization• When printing


Stop

• Plug-in/sub-power switch OFF• In standby• In low-power or sleep• When updating the firmware• At paper-jam, in trouble, or when the door is open• All drive systems are OFF due to the cause except paper


Half speed -



Stop

• Plug-in/sub-power switch OFF• In standby• In low-power or sleep• When updating the firmware• At paper-jam, in trouble, or when the door is open• All drive systems are OFF due to the cause except paper


Half speed -

Full speed *1

• At warm-up, initial operation, image stabilization• When cleaning the transfer belt• When printing



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*1: It rotates in full speed for 30 seconds after the mode is changed.*2: It rotates in full speed for 10 seconds after the mode is changed.Half speed control: When switching from stop to half speed control, the fan will rotate at full speed and then will rotate at half speed.

MFP control board cool-ing fan motor (FM17)

Stop

• Plug-in/sub-power switch OFF• In low-power or sleep• When updating the firmware• At paper-jam, in trouble, or when the door is open• All drive systems are OFF due to the cause except paper



Full speed• At warm-up• At initial operation, image stabilization• When printing


Full speed • While the exposure lamp (FL201) is ON

Exit cooling fan motor/3 (FM103)

Full speed • When paper is discharged

Exit cooling fan motor/1, /2 (FM101, FM102)

Full speed • When the paper size is bigger than B5 at paper discharging.



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24.2 Counter control

24.2.1 Construction

NOTE• The counting modes can be selected at [billing setting] of service mode.

For details, see [Field service/adjustment/setting/billing setting].

Name Function/system

Total counter• Displays the cumulative number of copies and prints of all jobs.• A mechanical counter driven by an electric signal• Counts one when an exit signal is applied to it

Electronic counter

• Number of total copies/prints in copy/print/scan/fax mode will be dis-played on the screen as described below.

• Black, full color, mono color, and 2 color• Total counter, large size counter, color total (copy + printer), print

counter, scan counter, fax TX counter, fax RX counter, No. of origi-nals counter, No. of prints counter, total duplex counter

• Counts one when an exit signal is applied to it

Key counter (option)

• When charging prints by using the key counter, copies cannot be made with out the key counter. However PC prints and fax TX/RX service are available without the key counter.

• Displays the cumulative number of copies while the key counter is being mounted.

• A mechanical counter driven by an electric signal• Counts one when a paper take-up start signal or image forming start

signal, whichever occurs earlier, is applied to it

A00JT2C257AA

Total counter

Electronic counter

Key counter (option)


Slide Interface board (REYB/SL)

MFP board (MFPB)


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24.3 Power supply unit

A. C650/C550/C451• The main body uses a single outlet.

B. C650 (Only Taiwan)• The main body uses two outlets (15 A + 7 A) to achieve an even higher printing speed

and a shorter warm-up time.

2

A00HT2C305AA

Power supply

A00HT2C303AA

Power supply 2: 7A

Power supply 1:15A


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24.4 Parts operated when the main power switch and sub power switch are turned ON

24.4.1 Parts operated when the main power switch and sub power switch are turned ON

• When the sub power switch is turned ON, MFP board detects it and sends a control sig-nal to the DC power supply through the printer control board.

• The DC power supply then supplies 3.3 VDC, 5VDC, 12VDC, 15V DC, and 24 V DC to all PWBs and options. It also turns ON the relays in the PWBs and power can be supplied to the IH heater and the heater lamp.

NOTE• To turn OFF the main power switch, turn OFF the sub power switch before and

make sure that blue lighting of the start key turns orange and then goes out. (Check that power supply to the HDD is shut down. Turning OFF the main power switch while the HDD is running could result in a defective HDD.)

• To turn OFF and ON the main power switch, first turn OFF the main power switch and wait for 10 sec. or more before turning it ON again. If a setting value or values in the tech. rep. mode are changed, it takes 10 sec. or more to incorporate the set-ting changes properly in the machine.

• Power switch OFF/ON procedure1. Turn OFF the sub power switch. 2. Turn OFF the main power switch.3. Wait for 10 sec.4. Turn ON the main power switch. 5. Turn ON the sub power switch.

A00JT2E534DAMain power switch

Sub power switch

3


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24.5 Authentication unit (Biometric type) (AU-101)

• A finger vein pattern is used for personal identification.• Vein patterns are inside the body and cannot be visually recognized. This makes vein

patterns extremely difficult to forge or falsify. The vein pattern authentication system can provide high security.

• With ultra-red LED radiation, a finger vein pattern is captured by camera and its image is created. The vein pattern image is registered and a person can be identified if the per-son’s vein pattern matches the registered one at the time of user authentication.

24.6 Authentication unit (IC card type: AU-201)

• A non-contact IC card, such as an employee ID card, is used for personal identification.• The system supports the communications protocol in compliance with Type A, Type B,

and Felica (Type C) of ISO14443.• Only Felica and Type A cards can be used for C650, C550, and C451 machines.• Simply placing the IC card on the authentication unit will let the unit read the data from

the card.

A00JT2C256AA

Ultra-red LED

Vein imageCamera

Finger

VeinAuthentication unit (AU-101)

3

3

ABCDE_Co.

Abcde Fgdhi

A00HT2C302AA

Non-contact IC card

Authentication unit (AU-201)


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Blank Page

SERVICE MANUAL

2007.05Ver. 2.0

THEORY OF OPERATION









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2007/05 2.0Description addition of DF-610/Error corrections



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Theory of Operation Ver. 2.0 May 2007

i

CONTENTS

DF-611/610

Outline1. Product specifications ............................................................................................. 1

2. Section configuration............................................................................................... 5

3. Paper path............................................................................................................... 5

Composition/Operation4. Composition ............................................................................................................ 7

5. Drive........................................................................................................................ 8

6. Operation ................................................................................................................ 9

6.1 Document feed tray ascent/descent mechanism.................................................. 9

6.1.1 Document feed tray ascent ........................................................................... 9

6.1.2 Document feed tray descent ......................................................................... 9

6.2 Feeding the original ............................................................................................ 10

6.2.1 Feeding operation ....................................................................................... 10

6.3 Transfer mechanism ........................................................................................... 11

6.4 Transfer mechanism for turnover/paper exit........................................................ 12

6.5 Switching mechanism for turnover/paper exit ..................................................... 13

6.5.1 Turnover section.......................................................................................... 13

6.5.2 Paper exit section........................................................................................ 13

7. Paper path............................................................................................................. 14

7.1 1-sided mode...................................................................................................... 14

7.2 2-sided mode...................................................................................................... 15

7.3 Mixed original/AMS mode................................................................................... 16

8. Original size detection........................................................................................... 18

8.1 Detecting the width of the original 1 ................................................................... 18

8.2 Detecting the width of the original 2 ................................................................... 18

8.3 Detecting the length of the original 1 .................................................................. 18

8.4 Detecting the length of the original 2 .................................................................. 18

9. Detecting the open/close....................................................................................... 19

9.1 DF 20 degree open/close detection.................................................................... 19

9.2 DF open/close detection..................................................................................... 19

10. Cooling inside the unit ........................................................................................... 20

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Theory of Operation Ver. 2.0 May 2007 1. Product specifications

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Outline1. Product specificationsA. Type

B. Functions

C. Paper type

*1: For the combined original detection mode, refer to the mixed original detection enabled size combination table.

Name Reverse automatic document feeder

Type

Paper feed section Paper feed from top of stack

Image reading section Sheet-through system

Turnover section Switchback system

Exit section Straight exit system

Installation Screw cramp to the main body

Document alignment Center

Document loading Face up

Modes Standard mode / Mixed original detection mode / FAX mode

Type of document

Standard modePlain paper

1-sided mode35 to 210 g/m2 (9.25 to 55.75 lb)

2-sided mode50 to 128 g/m2 (13.25 to 34 lb)

Mixed original detection modePlain paper

1-sided / 2-sided mode50 to 128 g/m2 (13.25 to 34 lb)

FAX modePlain paper

1-sided mode35 to 210 g/m2 (9.25 to 55.75 lb)

2-Sided Mode50 to 128 g/m2 (13.25 to 34 lb)

Detectable document size*1

Standard mode/FAX modeMetric area: B6S to A3Inch area: 5 1/2 x 8 1/2 to 11 x 17

Capacity 100 sheets (80 g/m2) or stack of 14 mm and below

1. Product specifications Theory of Operation Ver. 2.0 May 2007

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D. Paper feed prohibited originals• If fed, trouble occurrence will be highly possible.

E. Paper feed not guaranteed originals• If fed, paper feed will be possible to some extent but trouble occurrence will be possible.

Type of original Possible trouble

Sheets stapled or clipped togetherPaper feed failure, damaged sheet, defective drive mechanism due to jammed staples or clips

Sheets glued together Paper feed failure, damaged sheet

Book original Paper feed failure, damaged sheet

Original weighing less than 35 g/m2 (9.25 lb) or 210 g/m2 (55.75 lb) or more

Paper feed failure, transport failure

Sheets folded, torn or wrinkledPaper feed failure, damaged sheet, transport failure

Sheets severely curledSheets misfed due to being dog-eared or fed in askew

OHP film (Transparency film) Paper feed failure, transport failure

Label paper Paper feed failure, transport failure

Offset master paper Paper feed failure, transport failure

Glossy photographic paper or glossy enamel paper

Transport failure, damaged sheet

Sheets clipped or notched Damaged sheet, transport failure

Sheets patched Patched part folded or torn sheet

Type of Original Possible Trouble

Sheets lightly curled (Curled amount: 10 to 15 mm) Dog-eared, exit failure, transport failure

Heat sensitive paper Edge folded, exit failure, transport failure

Ink jet paper Paper feed failure, transport failure

Sheets with smooth surface (Coated paper) Paper feed failure, transport failure

Intermediate paper Paper feed failure, transport failure

Paper immediately after paper exit from the main unit Paper feed failure, transport failure

Paper with many punched holes (e.g., loose leaf) limited to vertical feeding

Multi-page feed due to flashes from holes

Sheets with 2 to 4 holes Transport failure

Sheets two-folded or Z-folded Transport failure, image deformation

Sheets with rough surface (e.g., letterhead) Paper feed failure


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F. Mixed original feed chartFor metric

For inch

Max. original size

297 mm 257 mm 210 mm 182 mm 148 mm 128 mm

Mixed original size A3 A4 B4 B5 A4S A5 B5S A5S B6S

297 mmA3 OK OK - - - - - -

A4 OK OK - - - - - -

257 mmB4 OK OK OK OK - - - -

B5 OK OK OK OK - - - -

210 mmA4S OK OK OK OK OK OK - -

A5 NG NG OK OK OK OK -

182 mm B5S NG NG OK OK OK OK OK

148 mm A5S NG NG NG NG NG NG NG OK

128 mm B6S NG NG NG NG NG NG NG OK OK

Max. original size 11 8 1/2 5 1/2

Mixed original size 11 x 17 8 1/2 x 11 8 1/2 x 14 8 1/2 x 11S 5 1/2 x 8 1/2 5 1/2 x 8 1/2S

1111 x 17 OK OK - - - -

8 1/2 x 11 OK OK - - - -

8 1/2

8 1/2 x 14 OK OK OK OK OK -

8 1/2 x 11S OK OK OK OK OK -

5 1/2 x 8 1/2 NG NG OK OK OK -

5 1/2 5 1/2 x 8 1/2S NG NG NG NG NG OK

OK Mixed original feed available (Tilted with in 1.5% or less)

NG No. mixed original feed

- Can not set original

1

1. Product specifications Theory of Operation Ver. 2.0 May 2007

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G. Machine specifications

H. Operating environmentConforms to the operating environment of the main body.


Power requirementsDC 24 V (supplied from the main unit)

DC 5 V (generated within the DF-611/DF-610)

Max. power consumption

60 W or less

Dimensions618 mm (W) x 575 mm (D) x 130 mm (H)24.25 inch (W) x 22.75 inch (D) x 5 inch (H)

WeightDF-611: 16.1 kg (35.5 lb)DF-610: 16.2 kg (35.75 lb)

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Theory of Operation Ver. 2.0 May 2007 2. Section configuration

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3. Paper path

1

Transport section Paper feed section Paper exit section

Turnover section Paper exit turnover section

1

Feed tray

Document read position

Feed tray

3. Paper path Theory of Operation Ver. 2.0 May 2007

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Theory of Operation Ver. 2.0 May 2007 4. Composition

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Composition/Operation4. Composition1

[1] Transportation cover [5] Document guide

[2] Document feed tray [6] Original read section

[3] Hookup cord [7] Magnet

[4] Turnover cover

A01HT2C001AA A01HT2C002AA

[1] [2] [3]

[4][5] [6] [7]

Pick-up roller

Separation roller Switch back roller

Reading roller 1

Switch back registration roller

Reading roller 2

Exit switch back roller

Exit roller

Feed roller

Registration roller

1

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5. Drive(1) C650

(2) C550/C451

1

Reading motor (M1)

Exit motor (M3)

Take-up motor (M2)

Regist motor (M7)

1

Reading motor (M1)

Exit motor (M3)

Take-up motor (M2)

Theory of Operation Ver. 2.0 May 2007 6. Operation

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6. Operation

6.1 Document feed tray ascent/descent mechanism

• The document feed tray will move up to feed the original.• Ascent/descent of the document feed tray will be performed by the lift-up motor.

6.1.1 Document feed tray ascent

• The document feed tray will stay in the stand-by position when in stand-by status.• Setting the original and turning the Start key ON will move the document feed tray up.• The lift-up motor will rotate the drive cam through the gear. The lift up lever will move

above the cam, and the document feed tray will move up.• The document feed tray will stop moving up when the lift up upper sensor is transmitted.

6.1.2 Document feed tray descent

• When all the originals are fed and the empty sensor is interrupted, the lift-up motor will reverse.

• The lift-up motor will rotate the drive cam through the gear. The lift up lever will move above the cam, and the document feed tray will move down.

• The document feed tray will stop moving down when the lift up lower sensor is inter-rupted.

Lift up lever

Lift-up motor (M6)

Lift up lower sensor (PS15)

Empty sensor (PS14)

Lift up upper sensor (PS16)

Descent position

Ascent position

Drive cam

1

6. Operation Theory of Operation Ver. 2.0 May 2007

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6.2 Feeding the original

6.2.1 Feeding operation

(1) C650• The paper feed section consists of the pick-up roller, feed roller as well as the separation

roller, and is directly driven by the take-up motor.• Pressing the Start key will transfer the original to the registration roller by the pick-up

roller and the feed roller.

(2) C550/C451• Paper feed section consists of the pick-up roller, feed roller as well as the separation

roller, and is driven by the take-up motor.• Transmission of the pick-up roller drive and the feed roller drive are controlled by the

take-up clutch.• Pressing the Start key will transfer the original to the registration roller by the pick-up

roller and the feed roller.

1

Take-up motor (M2)

Pick-up roller

Separation roller

Feed roller

1

Take-up clutch (CL2)

Take-up motor (M2)

Pick-up roller

Separation roller Feed roller


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6.3 Transfer mechanism

(1) C650• The original transferred from the paper feed section will be transferred to the paper exit

section or turnover section by the registration roller, the reading roller 1 and 2, and the switch back roller.

• The registration roller and the switch back roller are driven by the regist motor.• Reading roller 1 and 2 are driven by the reading motor.

(2) C550/C451• The original transferred from the paper feed section will be transferred to the paper exit

section or turnover section by the registration roller, the reading roller 1 and 2, and the switch back roller.

• The registration roller and the switch back roller are driven by the take-up motor.• Reading roller 1 and 2 are driven by the reading motor.

1

Reading motor (M1)

Registration sensor (PS3)

Reading roller 1

Reading roller 2

Switch back rollerRegist motor (M7)

Registration roller

1

Reading motor (M1)

Registration sensor (PS3)

Registration roller

Reading roller 1

Reading roller 2

Switch back rollerTake-up motor (M2)

Regist clutch

1

6. Operation Theory of Operation Ver. 2.0 May 2007

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6.4 Transfer mechanism for turnover/paper exit

(1) C650• The original transferred from the transport section will switch back or exit by the exit

roller, the switch back roller, and the exit switch back roller.• The exit roller and the exit switch back roller are driven by the exit motor.• The switch back roller is driven by the regist motor.

(2) C550/C451• The original transferred from the transport section will switch back or exit by the exit

roller, the switch back roller, and the exit switch back roller.• The exit roller and the exit switch back roller are driven by the exit motor.• The switch back roller is driven by the take-up motor.

1

Exit motor (M3)

Regist motor (M7)

Switch back rollerExit switch back roller

Exit roller

1

Exit motor (M3)

Take-up motor (M2)

Switch back rollerExit switch back roller

Exit roller


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6.5 Switching mechanism for turnover/paper exit

6.5.1 Turnover section

• Pathway of the original will be switched and the original will turnover by the switch back lever.

• Switch back lever is switched by ON/OFF of the switch back solenoid.

6.5.2 Paper exit section

• The exit lever will switch the pathway of the original to exit.• The exit lever will be switched by ON/OFF of the exit switch back solenoid.

When in 1-sided mode: Switch back solenoid will be OFF

When in 2-sided/mixed original/AMS (1-sided, 2-sided) mode: Switch back solenoid will be ON

Switch back solenoid (SD1)

Exit roller

Switch back roller

Switch back lever

When in 1-sided mode: Exit switch back solenoid will be OFFWhen in 2-sided/mixed original/AMS (1-sided, 2-sided) mode: Exit switch back solenoid will be ON

Exit switch back solenoid (SD2)

Exit lever

Exit switch back roller

1


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7. Paper path

7.1 1-sided mode

(1) C6501. Pressing the start key will lift up the feed tray and press the reading roller 1.2. After the feed tray is lifted up, the feed motor is started and the pick-up roller and

the feed roller will start rotating to start feeding the first sheet of paper.3. When the paper reaches the registration roller, a loop is formed in the paper. Then,

the regist motor is started, so that the registration roller transfers the paper.4. The take-up motor and regist motor are deenergized when a predetermined period

of time elapses after the registration sensor has been activated. The reading motor and the exit motor will start running.

5. It starts reading from the front edge of the original when the before read sensor turned ON and the specified period of time has passed.

6. Reading roller 1 will be retracted right before the back edge of the original passes through the reading roller 1. The retracted reading roller 1 will be pressed again to prepare for the next original.

7. The original will be exit by the reading roller 2 and the exit roller.8. All motors will turn OFF after the back edge of the original turns OFF the exit sen-

sor and the specified period of time is passed.

(2) C550/C4511. Pressing the start key will lift up the feed tray, press the reading roller 1, then after

the feed tray was lifted up, the feed motor will start, and then the take-up clutch will be ON, the pick-up roller and the feed roller will start rotating and it will start feeding the first sheet.

2. When the paper reaches the registration roller, the paper will make a loop and the regist clutch will be ON. The registration roller will then transfer the paper.

3. The take-up clutch will turn OFF when the specified period of time passed after the registration sensor turned ON. The reading motor and the exit motor will start run-ning.


5. Reading roller 1 will be retracted right before the back edge of the original passes through the reading roller 1. The retracted reading roller 1 will be pressed again to prepare for the next original.

6. The original will be exit by the reading roller 2 and the exit roller.7. All motors will turn OFF after the back edge of the original turns OFF the exit sen-

sor and the specified period of time is passed.

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Theory of Operation Ver. 2.0 May 2007 7. Paper path

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7.2 2-sided mode

1. The fist side of the original will be read.2. The original will be transferred to the turnover section (switch back solenoid will be

ON)3. In order to read the second side of the original which is transferred to the turnover

section, the switch back roller will reverse by the switch pack operation of the regist motor (C650) or take-up motor (C550/C451), and transfer the original to the take-up part.

4. The switch back registration sensor will turn ON and the switch back registration roller will rotate by the exit motor to transfer the original to the original read section.


6. The original will be transferred to the paper exit turnover section after it is read. (switch back solenoid will be ON) Exit switch back roller will reverse by the exit motor’s reverse operation.

7. In order to keep the proper order of the original, exit switch back roller will rotate for-ward by the exit motor’s forward operation. The original will be turned over and be discharged.

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7.3 Mixed original/AMS mode

• Paper path control will be the same as the 2-sided mode.1. The original will be fed to detect the paper length. (It will not read the original)

The length of the original will be judged by the before read sensor ON time, and the width of the original will be judged by the mixed sensor 1, 2, and 3.

2. The original will be fed without the 2nd side being read.

3. After reading the fist side, the original will be transferred again to the switch back part to read the second side.

Theory of Operation Ver. 2.0 May 2007 7. Paper path

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4. The original will be transferred to the paper exit turnover section after second side is read. (switch back solenoid will be ON) Exit switch back roller will reverse by the exit motor’s reverse operation.

5. In order to keep the proper order of the original, exit switch back roller will rotate for-ward by the exit motor’s forward operation. The original will be turned over and be discharged.

8. Original size detection Theory of Operation Ver. 2.0 May 2007

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8. Original size detection

8.1 Detecting the width of the original 1

• The width of the original will be detected by the document width detection variable resis-tor under the document feed tray.

• Reference for setting the original on the document feed tray is its center.

8.2 Detecting the width of the original 2

• Three mixed sensors are mounted to where the paper passes immediately after it is fed. It is for detecting the width of the original for mixed original/AMS.

8.3 Detecting the length of the original 1

• The length of the original will be detected by the length sensor 1/2/3/4.• Length sensors 1, 2, 3, and 4 are mounted in this order with the length sensor 2 being

closest to the feed roller.

8.4 Detecting the length of the original 2

• Length of the mixed original/AMS will be calculated by the time before read sensor is interrupted.

Length sensor 1 (PS10)




Before read sensor (PS9)

Mixed sensor 1 (PS19)



Document width detection variable resistor (VR1)

Theory of Operation Ver. 2.0 May 2007 9. Detecting the open/close

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9. Detecting the open/close

9.1 DF 20 degree open/close detection

• The lever actuator is provided to detect the original size when using the auto document feeder as the original cover.

• When lowering the auto document feeder to 20 degree angle or lower, the angle detec-tion lever for the original cover on the copier will be pressed to turn ON the 20 degree sensor.

9.2 DF open/close detection

• The magnet is installed to detect the open/close of the auto document feeder on the copier side.

• The original cover/DF open sensor on the copier will turn ON by the magnet when lower-ing DF-611/610.

1

A01HT2C003AAOriginal cover/DF open sensor (RS201)

MagnetLever

10. Cooling inside the unit Theory of Operation Ver. 2.0 May 2007

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10. Cooling inside the unit• The air will be blown inside the unit by the cooling fan in order to avoid the temperature

increase of the driving motor and the board.

A01HT2C004AA


SERVICE MANUAL

2007.05Ver. 2.0

THEORY OF OPERATION









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2007/05 2.0 Change of a control method, Error corrections



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CONTENTS

LU-301

Outline1. Product specification ............................................................................................... 1


3. Paper feed path....................................................................................................... 2


5. Drive........................................................................................................................ 4

6. Operations............................................................................................................... 5

6.1 Paper Feed and Transport Control ....................................................................... 5

6.2 Paper level detection ............................................................................................ 7

6.3 Paper empty detection.......................................................................................... 8

6.4 Paper level indicator ............................................................................................. 8

6.5 Tray lift-up control ................................................................................................. 9

6.5.1 Tray ascend/descend mechanism................................................................. 9

6.5.2 Paper size detection.................................................................................... 11

6.6 Dehumidification heater control .......................................................................... 11

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Theory of Operation Ver. X.X XXX. 20XX 1. Product specification

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Outline1. Product specificationA. Type

B. Paper type

*1: Images are out of guarantee.*2: Excluding damp paper, curled paper, and recycled paper.

C. Machine specifications

D. Operating environment• Conforms to the operating environment of the main body.


Name 3,000 sheets Large Capacity Unit

Type External option attached to the right side of the main body


Type Size Weight Capacity

Plain paper

A4, 8 1/2 x 11

64 g/m2 to 90 g/m2 3,000 sheets

Thick paper 1 91 g/m2 to 120 g/m2 2,500 sheets *2

Thick paper 1+ 121 g/m2 to 157 g/m2 1,750 sheets *2

Thick paper 2 158 g/m2 to 209 g/m2 1,550 sheets *2

Thick paper 3 210 g/m2 to 256 g/m2 1,300 sheets *1 *2

1

Power requirements DC 24 V, DC 5 V, DC 3.3 V (supplied from the main body)


23 W or less

Dimensions367 mm (W) x 528 mm (D) x 405 mm (H)14.5 inch (W) x 20.75 inch (D) x 16 inch (H)

Weight 18.0 kg (39.75 lb)

2. Section configuration Theory of Operation Ver. 2.0 May 2007

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3. Paper feed path

A03NT1C002AA

Paper feed sectionPaper storage sectionPaper transport section

Dehumidification heater

A03NT1C001AA

Transportation to main body

LU-301Main body

Paper feed from the tray


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Composition/Operation4. Composition

A03NT2C213AA

A03NT2C204AA

Upper limit sensor (PS2)

Paper feed sensor (PS3)

Paper empty sensor (PS4)

Near empty sensor /1 (PS5)


Tray LED (LED)

Dehumidification heater (DH)

LU door switch (MS1)

LU drive board (LUDB)

Tray set sensor (PS1)

Lift-up motor (M1)

5. Drive Theory of Operation Ver. 2.0 May 2007

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5. Drive

A03NT2C214AA


Paper feed motor (M2)

Transport roller

Feed roller

Theory of Operation Ver. X.X XXX. 20XX 6. Operations

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6. Operations

6.1 Paper Feed and Transport Control

• A paper take-up and feed sequence starts if there are no preceding sheet of paper or if the leading edge of the preceding paper has moved past the tray 2 vertical transport roller.

• When a predetermined period of time elapses after a sheet of paper blocks the paper feed sensor, the LCT transport roller is brought to a halt to suspend the transportation of the sheet that was fed. After the leading edge of the preceding paper passes by the tim-ing roller and an enough paper interval is ensured, the halt of the LCT transport roller is released.If there is no preceding paper or if the leading edge of the immediately preceding paper has already passed by the timing roller by the time when the engine receives a print request, the above-mentioned halt does not occur.

• The paper transport speed is faster than the system speed.

System speed (mm/s) Paper transport speed (mm/s)

310 to 216 420

155 to 108 219

1

A03NT2C001AA

Paper feed motor (M2)



Start key ON



6. Operations Theory of Operation Ver. 2.0 May 2007

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• Layout of sensors and rollers

A03NT2C002AA



Feed roller


LU-301Main body

Transfer roller

Theory of Operation Ver. 2.0 May 2007 6. Operations

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6.2 Paper level detection

• The level of the paper still available for use is determined based on the outputs from near empty sensor/1 and sensor/2.

• A near empty condition is detected when the amount of paper left still available for use is about 50 sheets ± 30 sheets.

Reference data: plain paper

Paper full Paper near full Paper available Near empty

Paper level 3000 to 2000 sheets 2000 to 1000 sheets 1000 to 51 sheets 50 to 1 sheets

Near empty sensor /1 blocking blocking unblocking unblocking

Near empty sensor /2 unblocking blocking blocking unblocking

A03NT2C203AA


Paper level detection plate


NotchNotch


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6.3 Paper empty detection

• The paper empty sensor detects a paper empty condition.

6.4 Paper level indicator

• The amount of paper still available for use, or the paper level, is indicated by the LED provided on the right-hand side of the unit as viewed from the front.

• Following describe different paper level conditions.

A03NT2C205AA

A03NT2C205AA

Paper empty sensor (PS4)

Paper empty condition

Paper still availableUpper limit sensor (PS2)

Paper condition Empty Near emptyOther than empty and near empty conditions,

during lift-up

LED display ON blinking OFF

A03NT2C204AA

Tray LED


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6.5 Tray lift-up control

6.5.1 Tray ascend/descend mechanism

• The tray is suspended by the wires at the front and rear.• Rotation of the lift-up motor winds the wires, which causes the tray to go up.• Opening the LU door disconnects the lift-up motor from the tray ascend/descend mecha-

nism, causing the tray to lower by its own weight.• There is a drive assist spring used for bringing the tray to a stop at an appropriate height.

A03NT2C215AA

Coupling

Lift-up motor (M1)

Drive assist spring

LU door

Wire

Paper tray

Lift-up axis


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A. Closing the LU door• The condition of the upper limit sensor signal is checked when the LU door is closed. If

the upper limit sensor is unblocked, the lift-up motor is energized so that lifting of the tray is started.

• When the upper limit sensor is blocked after the lifting of the tray has been started, the lift-up motor is deenergized to complete the lifting of the tray.

B. During a print cycle• As the paper is consumed for a number of print cycles carried out, the pickup roller grad-

ually lowers and eventually unblocks the upper limit sensor. The lift-up motor is then energized again and the lifting of the tray is started.

• When the upper limit sensor is blocked, the lift-up motor is deenergized to complete the lifting of the tray.

• The sequence of these operations is repeated. This maintains the pressure (paper take-up pressure) between the pickup roller and the paper stack at a constant level regardless of the level of the paper stack left.

A03NT2C216AA


Paper tray

A03NT2C207AA

LU door switch (MS1)


Lift-up motor (M1)

LU door closed Lifting completed

A03NT2C208AAA03NT2C209AA

Upper limit sensor (PS2)Pick-up Roller


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6.5.2 Paper size detection

• The LCT is not capable of detecting the paper size.• The paper size is set by Service Mode → System 2 → LCT Paper Size Setting.

6.6 Dehumidification heater control

• The LCT is equipped with a dehumidification heater as standard.• ON/OFF control of the dehumidification heater is operatively associated with turning on

or off of the dehumidifier heater of the machine.

A03NT2E500DA

A03NT2C212AA

Dehumidification heater (DH)

Right side surface


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SERVICE MANUAL

2008.05Ver. 2.0

THEORY OF OPERATION









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Theory of operation Ver. 2.0 May 2008

i

CONTENTS

ZU-603



3. Paper path............................................................................................................... 7

Construction/Operation4. Conveyance section ................................................................................................ 9

4.1 Composition.......................................................................................................... 9

4.2 Drive ................................................................................................................... 10

4.3 Operation ............................................................................................................ 12

4.3.1 Conveyance path switching......................................................................... 12

4.3.2 Conveyance line speed switching ............................................................... 14

4.3.3 Registration control ..................................................................................... 17

5. Punch section........................................................................................................ 18

5.1 Composition........................................................................................................ 18

5.2 Drive ................................................................................................................... 18

5.3 Operation ............................................................................................................ 19

5.3.1 Punch control .............................................................................................. 19

5.3.2 Punch position movement control ............................................................... 21

5.3.3 Punch hole switching control....................................................................... 24

6. Punch scraps conveyance section ........................................................................ 25

6.1 Composition........................................................................................................ 25

6.2 Drive ................................................................................................................... 26

6.3 Operation ............................................................................................................ 27

6.3.1 Punch scraps conveyance control............................................................... 27

6.3.2 Punch scraps control .................................................................................. 28

7. Z-folding section .................................................................................................... 29

7.1 Composition........................................................................................................ 29

7.2 Drive ................................................................................................................... 30

7.3 Operation ............................................................................................................ 31

7.3.1 1st folding control ........................................................................................ 31

7.3.2 2nd folding control....................................................................................... 33

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Theory of operation Ver. 2.0 May 2008 1. Product specification

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B. Functions

Type Z-folding multi punching device

Punch Punching method Reciprocal punching method (punching each paper)

No. of holes Metric area : 2 holes/4 holes (switched automatically)Inch area : 2 holes/3 holes (switched automatically)

Hole diameter Metric area : 6.5 mmInch area : 8.0 mm

Hole position

Folding method Buckle folding method with the roller pair

A07TT1C012AA

Hole pitch Metric area : 80 mmInch area : 70 mm

Metric area : 10.5 mmInch area : 9.5 mm

Center of the paper

Inch area : 9.5 mm

Metric area : 10.5 mm

Center of the paper

Center of the paper

Hole pitch 108 mm

Hole pitch 80 mm

Hole pitch 80 mm

Hole pitch 80 mm

Hole pitch 108 mm

1

1. Product specification Theory of operation Ver. 2.0 May 2008

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Z-folding Folding length

Folding precision

Folding Folding length

Folding precision

A07TT1C010AA

a

L

1

Paper size L (mm) a (mm)

A3 209 or less

4 ± 2B4 181 or less

11 x 17 215 or less

8K *1 194 or less

A07TT1C011AA

1st folding 2nd folding

2 mm or less 2 mm or less

A07TT1C003AA

L

Paper size L (mm)

8-1/2 x 14 241.7 or less

A07TT1C004AA

2 mm or less


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*1: Only for the Taiwan market

Maximum tray capacity (80 g/m2) The maximum number of sheets for the FS main tray at the Z-folding operation• Z-folding continuous: Max. 30 sheets• Z-folding/stapling: See the table below

No. of sheets per stapleNo. of set on the main trayNo. of fold sheets

No. of unfold sheets

1 sheet 1 to 40 sheets 20 set

2 sheets 0 to 30 sheets 10 set



5 sheets 0 sheet 2 set

6 to 30 sheets Stapling not available

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1. Product specification Theory of operation Ver. 2.0 May 2008

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C. Type of paper

*1: Only for the Taiwan market

No punch mode Same as the main body.

Punch mode Paper size• Combination with the folding/saddle stitching mode is not available.

Metric area 2holes:A3, B4, A4, A4S, B5, B5S, A5, A5S, 8K *1, 16K *1, 16KS *1,8 x 13, 8-1/2 x 13, 8-1/4 x 13, 8-1/8 x 13-1/4

4holes:A3, B4, A4, B5, 8K *1, 16K *1

Inch area 2holes:11 x 17, 8-1/2 x 14, 8-1/2 x 11, 8-1/2 x 11S, 5-1/2 x 8-1/2, 5-1/2 x 8-1/2S, 7-1/4 x 10-1/2 , 7-1/4 x 10-1/2S3holes:11 x 17, 8-1/2 x 11

Type of paper 64 to 90 g/m2 of the high-quality paper and the plain paper• Special paper is not guaranteed. The punching of label

paper, tab paper, OHP paper, blueprint master and bind-ing-holed paper are not allowed.

Z-folding mode Paper size A3, B4, 11 x 7, 8K• For B4 paper (including the mix of the paper), the com-

bination with the stapling mode is not available.

Type of paper 64 to 90 g/m2 of the high-quality paper and the plain paper• Special paper is not supported. Label paper, tab paper,

transparency film, paper, holed paper, and low stiffness paper are not supported in Z-folding mode.

Folding mode Paper size 8-1/2 x 14

Type of paper 64 to 90 g/m2 of the high-quality paper and the plain paper• Special paper is not supported. Label paper, tab paper,

transparency film, paper, holed paper, and low stiffness paper are not supported in folding mode.

Paper curling

a : Excluding the OHP paper : Amount of curl: 15 mm or less OHP paper : Amount of curl: 10 mm or less

1

A07TT1C006AA

5 sheets of paper immediately after the printinga

1


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D. Maintenance

E. Machine specifications

F. Operating environment


Maintenance Same as the main body.

Machine service life Same as the main body.

Power requirements 100 to 240 VAC (automatic switching)

DC5 V (supplied from the main body)


120 W or less

Dimensions 169 mm (W) x 660 mm (D) x 1027.5 mm (H)6.75 inch (W) x 26 inch (D) x 40.5 inch (H)

Weight 45 kg (99 lb)

Temperature 10 to 30 °C

Humidity 15 to 85 % RH (with no condensation)

2. Section configuration Theory of operation Ver. 2.0 May 2008

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A07TT1C009AA

Punch section

Punch scraps conveyance section

Z-folding section Conveyance section

Main bodyZU-603Finisher

Theory of operation Ver. 2.0 May 2008 3. Paper path

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3. Paper pathA. Straight mode/punch mode (for the small size paper : A5, 5-1/2 x 8-1/2)

B. Punch mode (excluding the small size paper)

A07TT1C005AA

A07TT1C007AA

3. Paper path Theory of operation Ver. 2.0 May 2008

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C. Z-folding mode/punch + Z-folding mode

A07TT1C013AA

From the main body to the 1st folding

From the 2nd folding to the paper exit

From the 1st folding to the 2nd folding

Theory of operation Ver. 2.0 May 2008 4. Conveyance section

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Construction/Operation4. Conveyance section

4.1 Composition

A07TT2C001AA

Conveyance sensor (PS1)

Gate solenoid/Lw (SD1)

Exit sensor (PS9)

Gate solenoid/Up (SD2) Conveyance encoder sensor (PS10)

4. Conveyance section Theory of operation Ver. 2.0 May 2008

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4.2 Drive

A. Conveyance drive

A07TT2C002AA

Main motor (M6)

2nd folding roller

Gate/Up

Registration roller

Conveyance roller

1st folding roller

Gate/Lw

Exit roller



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B. Gate drive

A07TT2C003AA

Gate /Up

Gate /Lw

Gate solenoid /Lw (SD1)

Gate solenoid /Up (SD2)


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4.3 Operation

4.3.1 Conveyance path switching

• The gates /Lw and /Up switch the conveyance path. • The gate solenoids /Lw (SD1) and the gate solenoids /Up (SD2) drive the gates /Lw and

the gate solenoids /Up respectively.

A. Gate /Lw• The gate /Lw switches the paper path between the straight conveyance path and the

upper conveyance path.• The gate /Lw is set to the straight conveyance path when the gate solenoid /Lw (SD1)

turns OFF. • The gate /Lw is set to the upper conveyance path when gate solenoid /Lw turns ON.

A07TT2C004AA

<Gate solenoid /Lw : OFF> <Gate solenoid /Lw : ON>

Gate /Lw

Straight conveyance path Upper conveyance path



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B. Gate /Up• The gate /Up switches the paper path of the paper that was conveyed to the upper con-

veyance path by the gate /Lw. • The gate /Up is set to the paper path to the exit side when the gate solenoid /Up (SD2)

turns OFF. • The gate /Up is set to the paper path to the 1st folding stopper when gate solenoid /Up

turns ON.

C. Operation timing(1) Z-folding mode

1. In the Z-folding mode for the all paper size, the gate solenoid /Lw (SD1) and the gate solenoid /Up (SD2) turn ON when the paper size detect board (PSDTB) detects the leading edge of the paper.

2. The gate /Lw is set to the upper conveyance path and the gate /Up is set to the conveyance path to the 1st folding stopper.

3. The gate solenoid /Lw and the gate solenoid /Up turn OFF a specified period of time after the last paper turns OFF the exit sensor (PS9).

A07TT2C006AA

<Gate solenoid /Up : OFF> <Gate solenoid /Up : ON>

Gate /Up

Conveyance path to the exit side Conveyance path to the 1st folding stopper

Gate solenoid /Up (SD2) 1st folding stopper

A07TT2E035AA

Leading edge of the paper detected by the paper size detect board

Gate solenoid /Lw (SD1) and gate solenoid /Up (SD2) turned OFF

Paper size detect board (PSDTB)

Exit sensor (PS9)


Gate solenoid /Up (SD2)


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(2) Punch mode for the small size paper (A5, 5-1/2 x 8-1/2)• Gate solenoids /Lw (SD1) and gate solenoids /Up (SD2) always remain OFF, and never

turn ON.• The gate /Lw remains being set to the straight conveyance path.

(3) Punch mode for the large size paper (other than the small size paper)• The gate solenoid /Lw (SD1) turns ON when the paper size detect board (PSDTB)

detects the leading edge of the paper, and then the gate /Lw is set to the upper convey-ance path. The gate solenoid /Up (SD2) remains OFF and the gate /Up remains being set to the paper path to the exit side.

• The gate solenoid /Lw turns OFF a specified period of time after the last paper turns OFF the exit sensor (PS9).

(4) Straight exit mode• Gate solenoids /Lw (SD1) and gate solenoids /Up (SD2) always remain OFF, and never

turn ON.• The gate /Lw remains being set to the straight conveyance path.

4.3.2 Conveyance line speed switching

• The main motor (M6) drives the conveyance drive roller, the 1st folding roller, and the 2nd folding roller, which perform the folding operation, as well as the conveyance roller and the exit roller.

• The paper size detect board (PSDTB), the conveyance sensor (PS1), and the exit sensor (PS9) detect the paper.

A07TT2C007AA

1st folding roller2nd folding roller

Conveyance roller

Exit roller

Registration roller

Exit sensor (PS9)



Conveyance drive roller


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A. Operation timing(1) Z-folding

1. Transmitting the paper pass signal from the horizontal transfer, the main motor (M6) turns ON and rotates in high speed.

2. The main motor rotates in low speed and perform the 1st and 2nd folding opera-tions a specified period of time after the paper size detect board (PSDTB) detects the leading edge of the paper.

3. The main motor rotates in high speed to perform the paper exit operation of the 1st paper and to convey the 2nd paper in sync with the paper exit speed of the main body when the conveyance sensor (PS1) detects the leading edge of the paper and turns ON after the 2nd folding operation.

4. The main motor turns OFF when the exit sensor (PS9) detects the trailing edge of the last paper.

[1] Paper pass signal from the horizontal transfer

[6] 1st paper

[2] Main motor (M6) driven in low speed [7] 2nd paper

[3] 1st and 2nd folding operations [8] 3rd (last) paper

[4] Main motor driven in high speed [9] Main motor turned OFF when the trailing edge of the last paper is detected[5] Paper exit operation

A07TT2E031AA[1] [2] [4][3]

[6] [7] [8]

[5][9]



Exit sensor (PS9)

Main motor (M6) High speed

Low speed


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(2) Punch + Z-folding1. Transmitting the paper pass signal from the horizontal transfer, the main motor

(M6) turns ON and rotates in high speed.2. The main motor rotates in low speed and perform the 1st folding operation a speci-

fied period of time after the paper size detect board (PSDTB) detects the leading edge of the paper.

3. The main motor turns OFF for the punching operation a specified period of time after paper size detect board detects the trailing edge of the paper.

4. After the punching operation, The main motor turns ON and perform the 2nd fold-ing operation.

5. The main motor rotates in high speed to perform the paper exit operation of the 1st paper and to convey the 2nd paper in sync with the paper exit speed of the main body when the conveyance sensor (PS1) detects the leading edge of the paper and turns ON after the 2nd folding operation.

6. The main motor turns OFF when the exit sensor (PS9) detects the trailing edge of the last paper.


[6] Paper exit operation

[2] Main motor (M6) driven in low speed [7] 1st paper

[3] Main motor stopped for the punching operation

[8] 2nd paper

[4] 2nd folding operation [9] 3rd (last) paper

[5] Main motor driven in high speed [10] Main motor turned OFF when the trailing edge of the last paper is detected

A07TT2E032AA[1] [2] [4] [5][3]

[7] [8] [9]

[6][10]



Exit sensor (PS9)

Main motor (M6) High speed

Low speed


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4.3.3 Registration control

• The registration control corrects paper skew in the Z-folding mode and the punch mode.• The paper exited from the main body is pressed against the stopped registration roller

and forms a loop to correct skew of the paper, and then the paper is conveyed with its leading edge nipped.

• The registration motor (M1) drives the registration roller.

A. Operation timing(1) Punch + Z-folding

1. Transmitting the paper pass signal from the horizontal transfer, the registration motor (M1) turns ON.

2. The registration motor stops a specified period of time after the paper size detect board (PSDTB) detects the leading edge of the paper conveyed from the main body.

3. The paper is pressed against the registration roller and forms a loop to correct paper skew.

4. The registration motor turns ON and the conveyance is restarted a specified period of time after the paper contacts with the registration roller.

5. The registration motor turns OFF a specified period of time after the paper is exited.

• No registration control is conducted in the straight mode.

A07TT2C009AA

Leading edge of the paper

Registration roller


Loop


[3] A loop formed

[2] Registration motor (M1) stopped [4] Conveyance restarted

A07TT2E033AA[1] [2] [4][3]


Registration motor(M1)

High speed

Low speed

5. Punch section Theory of operation Ver. 2.0 May 2008

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5. Punch section

5.1 Composition

5.2 Drive

A07TT2C014AA


Punch home sensor (PS6)

Punch switchover switch (MS2)

A07TT2C013AA

Punch clutch (CL1)Punch switchover motor (M8)

Cam cover

Eccentric cam Punch motor (M4)Cam holder

Punch switchover cam

<Top side view> <Rear side view>

<Right side view>

Eccentric cam (Metric type: 4 piece) (Inch type : 5 piece)

Cam cover

Front direction


Punch switchover motor (M8)

Punch edges Rack

Belt

Punch shift motor (M5)

Punch clutch (CL1)Punch motor (M4)

Theory of operation Ver. 2.0 May 2008 5. Punch section

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5.3 Operation

• The punch operation is conducted for every paper.• The controls related to the punch operation is the punch unit position movement control,

the punch operation control, and the punch hole switching control.

5.3.1 Punch control

• The punch operation is conducted by transmitting the rotation of the punch motor (M4) to the eccentric cam by the punch clutch (CL1) and reciprocating the punch edges con-nected to the cam holder once.

• The punch motor drives the eccentric cam and performs the punch operation when punch clutch turns ON.

• The punch motor rotates clockwise from the view of the rear. • The punch motor keeps rotating during the punch operation.• The punch home sensor (PS6) detects the home position of the punch edges.

A07TT2C015AA

Eccentric camPunch clutch (CL1)

Cam holder

Front direction

<Home position> <Punching position>

Upper positionLower position

Eccentric cam

Punch edges

Paper

Punch motor (M4)

Punch home sensor (PS6)

Cam holder


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A. Operation timing• The registration motor (M1) and the main motor (M6) turn OFF to stop the conveyance

during the punch operation.

1. The punch motor (M4) turns ON when the paper size detect board (PSDTB) detects the leading edge of the paper.

2. The punch clutch (CL1) turns ON and performs the punch operation a specified period of time after the paper size detect board detects the trailing edge of the paper.

3. The punch clutch turns OFF after a specified period of time. 4. The punch motor turns OFF a specified period of time after the punch clutch turns

OFF.5. After the punch operation, the registration motor and the main motor turn ON to exit

the paper.

[1] Leading edge of the paper detected [3] Punch clutch (CL1) turned OFF

[2] Punch clutch (CL1) turned ON

A07TT2C016AA[1] [2] [3]


Punch motor (M4)

Punch clutch (CL1)


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5.3.2 Punch position movement control

• The punch shift motor (M5) moves the punch unit to move the punch hole position in the main scan direction.

• 5 sensors of the paper size detect board (PSDTB) detects the punch hole position.• The front side sensor among 5 sensors detects the leading/trailing/side edge of the

paper and the other 4 sensors detect the side edge of the paper. The different sensor is used depending on the paper size.

• The punch shift home sensor (PS5) detects the home position.• The registration motor (M1) controls the punch position in the sub scan direction by its

stop position.

A07TT2C017AA


Leading/trailing/side edge sensor

Punch unit


Side edge sensors

Front direction Punch shift home sensor (PS5)

Belt


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A. Standby position movement of the punch unit• In the punch mode, the punch unit is set to the standby position in accordance with the

paper size before the paper is conveyed.• The punch shift motor (M5) moves the punch unit so that the sensor corresponding to the

paper size among 5 sensors of the paper size detect board (PSDTB) (in case of A4 paper, the sensor is used) is positioned 5 mm inward from the side edge of the paper.

• This operation is not conducted in the no punch mode.

A07TT2C018AA


Standby position

Punch unit


Side edge of the paper

Paper conveyance direction

Ex. : The sensor used at A4 paper

Paper

Punch blade

5 mm


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B. Punch position correction• The punch unit positioned 5 mm inward from the side edge of the paper conducts the

punch position correction operation by moving the punch unit back and forth while con-veying the paper to correct the misalignment between the conveyed paper and the punch position.

1. Move the punch unit backward until the certain side edge sensor (In case of A4 paper) detects the side edge of the paper.

2. Then, move the punch unit forward until the side edge sensor detects the side edge of the paper (the side edge reference position detection).

3. Move the punch unit forward further so that the center of the punch edges is posi-tioned to the center of the paper.

A07TT2C019AA


Standby position

Punch unit

Center of the paper

Paper conveyance direction

Ex. : The sensor used at A4 paper

Paper

Punch edges Center of the punch

Moves backward

Moves forward

Side edge of the paper


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5.3.3 Punch hole switching control

1. Transmitting the paper pass signal from the horizontal transfer, the punch switcho-ver motor (M8) switches the number of holes in the punch mode.

2. The punch switchover motor rotates the punch switchover cam clockwise and moves the eccentric cams and back and forth via the cam cover.

3. When switching between the 2 holes punching and the 4 holes punching in Metric Type, 2 eccentric cams in the middle remain being held in the cam holders because they are shared in both cases.

4. When the cam cover moves forward, the eccentric cams at the outside for the 4 holes punching are held in the cam holder so that the total of 4 eccentric cams are driven.

5. When the cam cover move backward, 2 outside eccentric cams are disengaged.6. For the switchover between the 2 holes punching and the 3 holes punching in Inch

Type, the 2 holes eccentric cams and the 3 holes eccentric cams work exclusively.7. When the cam cover moves forward, the 3 holes eccentric cams are held in the

cam holder and the 2 holes eccentric cams are disengaged.8. This operation is not conducted if the number of holes is same with the previous

printing.

A07TT2E034AA


<Upper side view>

Cam cover

Front side direction Punch switchover switch (MS2)

Cam holder


Eccentric cam (2 holes/4 holes)

Eccentric cam (4 holes)<Right side view>

Eccentric cam (2 holes/4 holes)Eccentric cam (4 holes)


Punch switchover switch (MS2)

Front side direction

Moves backward

Moves forward

Theory of operation Ver. 2.0 May 2008 6. Punch scraps conveyance section

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6. Punch scraps conveyance section

6.1 Composition

A07TT2C020AA

Punch scraps full sensor (PS8)

Punch scraps box set sensor (PS7)

Punch scraps conveyance motor (M7)

6. Punch scraps conveyance section Theory of operation Ver. 2.0 May 2008

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6.2 Drive

A07TT2C021AA

Punch scraps conveyance screw gear

Punch scraps conveyance motor (M7)

Theory of operation Ver. 2.0 May 2008 6. Punch scraps conveyance section

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6.3 Operation

6.3.1 Punch scraps conveyance control

• The punch scraps are conveyed by the punch scraps conveyance screw driven by the punch scraps conveyance motor (M7).

• They are conveyed to the punch scraps box via the punch scraps collective duct.• The punch scraps conveyance motor turns ON to rotate the punch scraps conveyance

screw a specified period of time after the paper edge sensor detects the trailing edge of the paper in the punch mode.

• The punch scraps are sent to the forward by the rotation of the screw and collected in the punch scraps box via the punch scraps collective duct.

15kvt2c019na

Punch scraps collective duct

Punch scraps box

Punch scraps conveyance motor (M7)Punch scraps conveyance screw

6. Punch scraps conveyance section Theory of operation Ver. 2.0 May 2008

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6.3.2 Punch scraps control

• The punch scraps box set sensor (PS7) and the punch scraps full sensor (PS8) monitor the punch scraps box.

A. Punch scraps full detection• The punch scraps full sensor (PS8) detects whether the punch scraps box is full or not.• The punch scraps full sensor turns ON and transmits the punch scraps full signal to the

main body when the punch scraps box becomes full of punch scraps, and then the main body displays the message on its operation panel.

B. Punch scraps box detection• The punch scraps box set sensor (PS7) detects whether the punch scraps box is housed

or not. • The punch scraps box set sensor turns ON and transmits the “no punch scraps box” sig-

nal to the main body when the punch scraps box is not set, and then the main body dis-plays the message on its operation panel.

A07TT2C023AA

Punch scraps box

Punch scraps full sensor (PS8)

Punch scraps box set sensor (PS7)

Theory of operation Ver. 2.0 May 2008 7. Z-folding section

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7. Z-folding section

7.1 Composition

A07TT2C001AA

2nd stopper home sensor (PS4)

Conveyance sensor (PS1)1st stopper home sensor (PS3)

Exit sensor (PS9)

7. Z-folding section Theory of operation Ver. 2.0 May 2008

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7.2 Drive

A07TT2C026AA

A07TT2C025AA


1st stopper home sensor (PS3)


1st stopper motor (M2)

<1st stopper drive>

<2nd stopper drive>

1st stopper

2nd stopper

2nd stopper motor (M3)



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7.3 Operation

7.3.1 1st folding control

• The registration roller, the conveyance roller, and the 1st folding roller convey the paper to the 1st folding stopper section via the gate /Up.

• A loop is formed between the 1st folding roller and the conveyance drive roller when the leading edge of the paper is pressed against the 1st folding stopper.

• The loop grows, and then it is caught by these rollers and the 1st folding is conducted. • The paper is then conveyed to the 2nd folding stopper section.• The position of the 1st folding depends on the position of the 1st folding stopper. • The 1st stopper motor (M2) sets the position in accordance with the number of steps

from the 1st stopper home sensor (PS3).• In the Z-folding mode with the punch mode, the registration motor (M1) and the main

motor (M6) stops to conduct the punch operation after the 1st folding operation, and then the registration motor and the main motor turns ON to conduct the 2nd folding operation.

A07TT2C027AA

1st folding stopper


Registration roller

2nd folding direction

1st folding

Front side


Conveyance roller

Gate /Up

Loop

1st folding roller


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A. Operation timing1. The 1st folding stopper motor (M2) turns ON to drive the 1st folding stopper to the

appropriate position in accordance with the paper size a specified period of time after transmitting the paper pass signal from the horizontal transfer.

2. Transmitting the termination signal from the main body, The 1st folding stopper motor replaces the 1st folding stopper to the home position.


[3] Termination signal

[2] 1st folding stopper moving to the paper size

[4] 1st folding stopper returning to the home position

A07TT2C028AA[1][2] [3] [4]


1st folding stopper motor (M2)

Exit sensor (PS9)


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7.3.2 2nd folding control

1. The paper conveyed from the 1st folding section to the 2nd folding section is stopped by the 2nd folding stopper and forms a loop between conveyance drive roller and the 2nd folding roller.

2. The loop grows, and then it is caught by these rollers and the 2nd folding is con-ducted.

3. The 2nd stopper motor (M2) turns ON to move the 2nd stopper to the evacuation position for the paper conveyance when the leading edge of the paper (crease of the 1st folding) conveyed to the paper exit direction passes the conveyance sensor (PS1).

4. The 2nd folding is not conducted for 8.5 x 14 paper.

A07TT2C029AA

2nd folding stopper*Folding position


Paper exit direction

2nd folding

Front side



Loop

1st folding roller

Exit sensor (PS9)

Paper exit direction

2nd folding roller

2nd folding stopper*Home position


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A. Operation timing1. The 2nd folding stopper motor (M3) turns ON to drive the 2nd folding stopper to the

appropriate position in accordance with the paper size when the paper size detect board (PSDTB) detects the leading edge of the paper.

2. The 2nd folding stopper motor rotates in the reverse direction to move the 2nd fold-ing stopper to the home position when the conveyance sensor (PS1) detects the leading edge of the paper after the 2nd folding. It opens the paper exit path.

3. The 2nd folding stopper motor turns ON to replace the stopper to the original posi-tion for the subsequent Z-folding when the exit sensor (PS9) detects the trailing edge of the paper.


[3] Moving to the home position

[2] Moving to the 2nd folding position [4] Moving to the 2nd folding position for the subsequent paper

A07TT2C030AA

[1] [3] [4][2]



Exit sensor (PS9)

2nd stopper motor (M3)


SERVICE MANUAL

2008.05Ver. 5.0

THEORY OF OPERATION









11

1

1

2008/05 5.0 Addition of FS-518


2007/05 3.0 Addition of parts, Error corrections




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i

CONTENTS

FS-517/518/608


2. Paper feed path....................................................................................................... 4

2.1 Non-sort/sort/group mode .................................................................................... 4

2.2 Sub tray mode ...................................................................................................... 5

2.3 Stapling mode....................................................................................................... 6

2.4 Folding/saddle stitching mode (FS-608) ............................................................... 7

2.5 Tri-folding mode (FS-608) ..................................................................................... 8


4. Horizontal transfer section..................................................................................... 10

4.1 Composition........................................................................................................ 10

4.2 Horizontal transfer mechanism ........................................................................... 11

4.2.1 Paper transport ........................................................................................... 11

4.2.2 Fan motor.................................................................................................... 12

5. Transfer section ..................................................................................................... 13

5.1 Drive ................................................................................................................... 13

5.2 Operation ............................................................................................................ 14

5.2.1 Punch registration control (available only when PK is installed) ................. 14

5.2.2 FS transfer control....................................................................................... 14

5.2.3 Gate drive control........................................................................................ 15

5.2.4 Bypass gate control .................................................................................... 16

5.2.5 Shift control ................................................................................................. 18

5.2.6 Paper exit roller control ............................................................................... 20

5.2.7 Paper exit opening solenoid control ............................................................ 22

5.2.8 Paper exit opening control........................................................................... 23

5.2.9 Finishing tray2 paper exit control ................................................................ 27

6. Finishing tray1 section........................................................................................... 28

6.1 Drive ................................................................................................................... 28

6.2 Operation ............................................................................................................ 29

6.2.1 Tray lift control ............................................................................................. 29

7. Stacker section (FS-517/518)................................................................................ 31

7.1 Drive ................................................................................................................... 31

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7.2 Operation............................................................................................................ 32

7.2.1 Alignment control ........................................................................................ 32

7.2.2 Stopper control ........................................................................................... 33

7.2.3 Stacker entrance transfer control ................................................................ 34

7.2.4 Stacker paper exit control ........................................................................... 37

8. Stacker section (FS-608) ...................................................................................... 39

8.1 Drive ................................................................................................................... 39

8.2 Operation............................................................................................................ 40

8.2.1 Alignment /Up control ................................................................................. 40

8.2.2 Alignment /Lw control ................................................................................. 41

8.2.3 Stopper control ........................................................................................... 42

8.2.4 Stacker entrance transfer control ................................................................ 46

8.2.5 Stacker paper exit control ........................................................................... 51

9. Stapler (FS-517/518) ............................................................................................ 53

9.1 Drive ................................................................................................................... 53

9.2 Operation............................................................................................................ 54

9.2.1 Stapler movement control ........................................................................... 54

9.2.2 Stapler control............................................................................................. 55

10. Stapler (FS-608) ................................................................................................... 57

10.1 Drive ................................................................................................................... 57

10.2 Operation............................................................................................................ 58

10.2.1 Stapler movement control ........................................................................... 58

10.2.2 Stapler control............................................................................................. 61

11. Folding/saddle stitching/tri-folding (FS-608).......................................................... 63

11.1 Drive ................................................................................................................... 63

11.2 Operation............................................................................................................ 64

11.2.1 Folding knife control.................................................................................... 64

11.2.2 Folding transfer control ............................................................................... 65

11.2.3 Tri-folding gate control ................................................................................ 66

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1. Product specificationsA. Type

B. Functions

C. Stapling

*1: The stapling capacity for the following types of paper is 30 sheets.• A3 paper stored in environment with a temperature exceeding 30 °C and humidity

exceeding 85%• Invoice paper

Name

FS-517 Flat-stapling finisher: 50 sheets staple

FS-518 Flat-stapling finisher: 100 sheets staple

FS-608 Multi folding multi stapling finisher

Type Staple finisher attached to the side of the main body

InstallationIncluding horizontal transport unit (Built-in finisher that is mounted from the left of the main body)

Document alignment

Center

Consumables Staples

Modes

FS-517/FS-518

Non-sort, sort, offset, group offset, sort stable

FS-608Non-sort, sort, offset, group offset, sort stable, folding, saddle stitching, tri-folding

Max. flat-stapling capacity

FS-517 64 to 90 g/m2: 50 sheets or 48 sheets + 2 sheets (209 g/m2) *1

91 to 120 g/m2: 30 sheets

121 to 209 g/m2: 22 sheets

FS-518 64 to 80 g/m2: 100 sheets or 94 sheets + 2 sheets (209 g/m2) *1, *3, *4, *5

81 to 90 g/m2: 30 sheets or 28 sheets + 2 sheets (209 g/m2)

91 g/m2 or more: 2 sheets of thick paper or more not guaranteed

FS-608 64 to 80 g/m2: 50 sheets or 48 sheets + 2 sheets (209 g/m2) *1, *2

81 to 90 g/m2: 16 sheets or 14 sheets + 2 sheets (209 g/m2)

91 g/m2 or more: 2 sheets of thick paper or more not guaranteed

Max. saddle stitch-ing capacity

FS-608 64 to 80 g/m2: 20 sheets or 19 sheets + 1 sheet (209 g/m2)

81 to 90 g/m2: 16 sheets or 15 sheets + 1 sheet (209 g/m2)

91 g/m2 or more: 1 sheet of thick paper or more not guaranteed

Stapling position FS-517/FS-518

Back of the corner (0 to 45 degrees, Adjustable depending on paper size)Front of the corner (0 to 45 degrees, Adjustable depending on paper size)Center staple two points (Staple interval is fixed to 162 mm.)

FS-608 Back of the corner (45 degrees, Paper width 297 mm or less), Back of the corner (0 degree, Paper width over 297 mm),Front of the corner (0 degree),Center staple two points (Staple interval is adjustable between 128 mm and 160 mm.)

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*2: The stapling capacity for colored paper and enamel paper is 30 sheets (recommended paper).

*3: The stapling capacity for colored paper and enamel paper is 35 sheets (recommended paper).

*4: And the stapling thickness is 10 mm or less and the stack thickness including curl is 25 mm or less.

*5: The stapling capacity for A3 or 11x17 paper is 50 sheets maximum.

D. Max. paper capacity

5

Tray 1 (80 g/m2) FS-517/FS-518

Non-sort, sort, group

3,000 sheets :A4/A4S, B5/B5S, 8 1/2 x 11/8 1/2 x 11S, 16K/16KS, 7 1/4 x 10 1/2 /7 1/4 x 10 1/2 S

1,500 sheets :A3, B4, 8 x 13, 8 1/4 x 13, 8 1/2 x 13, 8 1/2 x 13 1/4, 12 1/4 x 18, 11 x 17, 8 1/2 x 14, 8K

500 sheets :A5/A5S, B6S, A6S, 5 1/2 x 8 1/2 /5 1/2 x 8 1/2 S

10 sheets :Envelope, OHP

Stapling No. of sheets per stapling

Size in the sub scan direction is 418 mm or longer

The others

2 to 9 50 copies 100 copies





51 to 60(FS-518 only)

- 15 copies

61 to 100(FS-518 only)

- 10 copies

FS-608 Non-sort, sort, group

2,500 sheets :A4/A4S, B5/B5S, 8 1/2 x 11/8 1/2 x 11S, 16K/16KS, 7 1/4 x 10 1/2 /7 1/4 x 10 1/2 S

1,500 sheets :A3, B4, 8 x 13, 8 1/4 x 13, 8 1/2 x 13, 8 1/2 x 13 1/4, 12 1/4 x 18, 11 x 17, 8 1/2 x 14, 8K

500 sheets :A5/A5S, B6S, A6S, 5 1/2 x 8 1/2 /5 1/2 x 8 1/2 S

10 sheets :Envelope, OHP

Stapling No. of sheets per stapling

Size in the sub scan direction is 418 mm or longer

The others






Tray 2 (80 g/m2) 100 sheets

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E. Type of paper

F. Machine specifications

*: Size when the paper output tray is pulled out

G. Operating environment• Conforms to the operating environment of the main body.

NOTEHow product names appear in the document• FS-517, FS-518, FS-608: Finisher

Tray 3 FS-608 Folding A3, B4, A4S, 12 1/4 x 18, 11 x 17, 8 1/2 x 14, 8 1/2 x 11S, 8KMin. : 210 mm x 280 mm (8.25 inch x 11 inch)Max. : 311.1 mm x 457.2 mm (12.25 inch x 18 inch)3 sheets folding: 25 to 33 sets

Saddle stitching A3, B4, A4S, 8 1/2 x 11S, 8KMin. : 210 mm x 280 mm (8.25 inch x 11 inch)Max. : 311.1 mm x 457.2 mm (12.25 inch x 18 inch)5 sheets stitching: 15 to 20 sets

Tri-folding A4S, 8 1/2 x 11S, 16KS1 sheet folding: 50 sets or less

Size A3, B4, A4/A4S, B5/B5S, A5/A5S, B6S, A6S, postcardS, 5 1/2 x 8 1/2 S, 8 x 13, 8 1/4 x 13, 8 1/2 x 13, 8 1/8 x 13 1/4, 12 1/4 x 18, 11 x 17, 8 1/2 x 14, 8 1/2 x 11/8 1/2 x 11S, 7 1/4 x 10 1/2 /7 1/4 x 10 1/2 S, 8K, 16K/16KSMin. : 100 mm x 139 mm (4 inch x 5.5 inch)Max. : 311.1 mm x 457.2 mm (12.25 inch x 18 inch)

Type Plain paper, thick paper 1/1+/2/3/4, OHP transparencies, postcard, envelope, label, letterhead

Weight 64 to 300 g/m2

Power requirements

DC 24 V (supplied from the main body)



80 W or less

Dimensions

680 (W) x 656 (D) x 1027.5 (H) mm26.75 (W) x 25.75 (D) x 40.5 (H) inch800 (W) x 656 (D) x 1027.5 (H) mm *31.5 (W) x 25.75 (D) x 40.5 (H) inch *

Weight

FS-517 63 kg (138.75 lb)

FS-518 65 kg (143.3 lb)

FS-608 68 kg (150 lb)

Horizontal transport unit

6 kg (13.25 lb)

4

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2. Paper feed path Theory of Operation Ver. 5.0 May 2008

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2.1 Non-sort/sort/group mode

[1] Gate [5] Finishing tray1

[2] Paper in the horizontal transport unit [6] Paper exit unit

[3] Paper path from the main body [7] Shift unit (sort/group mode only)

[4] Paper path from the horizontal transport unit

A07RT1C001AA

[1] [2]

[5]

[3][7]

[4]

FS-608 only

[6]

Theory of Operation Ver. 5.0 May 2008 2. Paper feed path

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2.2 Sub tray mode

[1] Gate [4] Paper path from the horizontal transport unit

[2] Paper in the horizontal transport unit [5] Finishing tray1

[3] Paper path from the main body

A07RT1C002AA

[1] [2][5] [3]

[4]

FS-608 only


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2.3 Stapling mode

*: The illustrations for the clincher and stapler are for FS-608.

[1] Gate [6] Flat-stapling stopper

[2] Paper in the horizontal transport unit [7] Stapler *

[3] Paper path from the main body [8] Finishing tray1

[4] Paper path from the horizontal transport unit [9] Paper exit unit

[5] Clincher *

A07RT1C003AA

[1] [2]

[5]

[3]

[4]

FS-608 only

[9]

[6]

[8]

[7]

Theory of Operation Ver. 5.0 May 2008 2. Paper feed path

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2.4 Folding/saddle stitching mode (FS-608)

[1] Gate [6] Folding knife

[2] Paper in the horizontal transport unit [7] Saddle stitching stopper



[9] Stapler

[5] Clincher [10] Paper exit unit

A07RT1C004AA

[1] [2]

[5]

[3]

[4]

[10]

[6]

[9]

[7]

[8]


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2.5 Tri-folding mode (FS-608)

[1] Gate [5] Folding knife

[2] Paper in the horizontal transport unit [6] Saddle stitching stopper



[8] Tri-folding stopper

A07RT1C005AA

[1] [2] [3]

[4]

[5]

[8]

[6]

[7]

4


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Composition/Operation3. Composition• FS-517/FS-518 and FS-608 share the same construction for the horizontal transfer sec-

tion, transfer section, and finishing tray 1 (tray1). They have different arrangements for the stacker section and stapler.

4

4

A07RT2C001AA

Finishing tray1 Horizontal transfer section

Stapler (FS-608)

Stacker section(FS-608)

Stacker section(FS-517/518)

StaplerFS-517: 50 sheets stapleFS-518:100 sheets staple

Folding/saddle stitching/Tri-folding(FS-608)

Transfer section

4. Horizontal transfer section Theory of Operation Ver. 5.0 May 2008

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4.1 Composition

• The horizontal transfer section is available in two different types: one mounted with a fan motor (*1) and the other not mounted with the fan motor. The specific type depends on the time of manufacture of the horizontal transfer section.

• The specific type of the horizontal transfer section is identified by whether there are ven-tilation holes provided in the horizontal transport cover.

• C650 uses only the type mounted with the fan motor.• C550 and C451 can use both the type mounted and not mounted with the fan motor.

* Difference in appearance

2

A07RT2C201AA

Transfer motor (M201)

Paper pass sensor (PS202)Door open/close sensor (PS201)

Transfer control board (TRCB)

Fan motor/Rr (FM2) *1

Fan motor/Fr (FM1) *1

There are ventilation holes.

A07RT2C202AA

horizontal transport coverThere are no ventilation holes.

Type mounted with the fan motor Type not mounted with the fan motor

Theory of Operation Ver. 5.0 May 2008 4. Horizontal transfer section

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4.2 Horizontal transfer mechanism

4.2.1 Paper transport

• The horizontal transfer section transfers paper fed out from the machine to the finisher.• The transfer motor provides drive for the transfer rollers.• On the finisher side, drive from the FNS transfer motor transfers the paper into the fin-

isher.

2

A07RT2C002AA

A07RT2C001DA


Finisher side Main body side

Transfer roller

Transfer roller

Horizontal transfer section

4. Horizontal transfer section Theory of Operation Ver. 5.0 May 2008

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4.2.2 Fan motor

• The fan motor cools the paper fed out from the main body.• The fan motor rotates only if the horizontal transfer section is mounted in C650.• The fan motor does not rotate even if the type mounted with the fan motor is used with

C550 or C451.

(1) Function

(2) Fan control

2

A07RT2C201AA

Fan motor/Rr (FM2)

Fan motor/Fr (FM1)

Motor name Function

Fan motor/Fr (FM1)Fan motor/Rr (FM2)

• In order to avoid toner attachment while the finisher is used, outside air is applied to the paper to cool it.


Fan motor/Fr (FM1)Fan motor/Rr (FM2)

Full speed

• The interior temperature of the main body is 18 °C or more dur-ing paper exit.

• Continues rotating for a 30-sec. period following the stop of a print cycle.

4

Theory of Operation Ver. 5.0 May 2008 5. Transfer section

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5. Transfer section

5.1 Drive

[1] FNS transfer motor (M1) [12] Shift roller

[2] PI transfer roller [13] Finishing tray1 exit roller

[3] Entrance roller [14] Paper exit opening solenoid (SD4)

[4] Transfer roller /A [15] Paper exit roller motor (M7)

[5] Transfer roller /B [16] sub tray paper exit motor (M21)

[6] Bypass gate [17] Finishing tray2 paper exit roller

[7] Intermediate transfer roller [18] Paper exit motor (M8)

[8] Bypass gate solenoid (SD5) [19] Shift roller motor (M2)

[9] Paper exit belt [20] Finishing tray2 transfer roller

[10] Paper exit arm [21] Gate motor (M12)

[11] Gate [22] Paper assist arm (FS-518 only)

A07RT2C007AA

[3]

[4]

[5]

[6]

[2]

[1][21][20][19][18][17][16][15]

[14]

[13]

[12][11]

[10]

[9] [7][8]

[22]

4

5. Transfer section Theory of Operation Ver. 5.0 May 2008

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5.2 Operation

5.2.1 Punch registration control (available only when PK is installed)

• The entrance roller is temporarily stopped a predetermined period of time after the paper pass sensor of the horizontal transfer section has detected the leading edge of the paper. As a result, the paper hits against the entrance roller, so that a loop [3] is formed in the paper. Skew in the paper is thereby corrected. After the lapse of a predetermined period of time, the entrance roller starts rotating again to transfer paper up to the punch posi-tion.

• This operation is not performed when the wide paper (220 mm or more in the transfer direction) is used or in the no punching mode.

5.2.2 FS transfer control

• The FS transfer is conducted by the 24V DC motor controlled by the FNS control board.

A. Door switch control• The FS transfer drive control is started when transmitting the start signal from the main

body.• However, en error message is transmitted to the main body’s printer control board and

the control is not started if the door switch turns OFF.

B. FS transfer control• The FNS transfer motor rotates in high speed when pressing the start button. • In the mode the paper is exited from the main body in slow speed, the FNS transfer

motor rotates in slow speed when the main body exhaust sensor turns ON. Then it rotates in high speed after a specified period of time since the FNS entrance sensor turns ON.

• When exiting to the finishing tray1, the FNS transfer motor rotates in middle speed to in sync with the FS paper exit line speed after a specified period of time since the FNS entrance sensor detects the trailing edge of the paper. Then after a specified period of time, the FNS transfer motor returns to rotate in high speed and waits for the subsequent paper.

[1] Horizontal transfer [4] Main body

[2] Entrance roller [5] PK (option)

[3] Loop

[5]

[3]

[2][1]

[4]

A07RT2C008AA


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5.2.3 Gate drive control

• The gate switches among the paper transfer path to the finishing tray1, the one to the fin-ishing tray2, and the one to the stacker.

A. Gate operation• The gate motor [1] drives the gate cam [2], and then two cams /UP [3] and /Lw [4] of the

gate cum drive the two gates /UP [5] and /Lw [6] respectively.• The gate home sensor [7] detects the home position.

B. Gate control• The FNS control board controls the gate.• The gate turns ON when transmitting the FS operation signal from the main body, and

then it stops either at the finishing tray2 (home position) [1], stacker [2], or finishing tray1 [3]. It does not move when exiting to the finishing tray2 because the finishing tray2 is the home position.

• When completing the printing, the gate home sensor detects the home position and stops the gate.

[1] Gate motor (M12) [5] Gate /Up

[2] Gate cam [6] Gate /Lw

[3] Cam /Up [7] Gate home sensor (PS16)

[4] Cam /Lw

[1]

[2][7]

[3]

[4]

[5][6]

15jkt2c004na

[1] Finishing tray2 (home position) [3] Finishing tray1

[2] Stacker

[1] [2] [3] 15jkt2c005na


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5.2.4 Bypass gate control

• The bypass gate is located in the paper path to the stacker section.• The bypass gate is the gate to transfer the subsequent paper during the stapling opera-

tion for eliminating the time loss and increasing the productivity.

A. Bypass gate operation• The bypass gate solenoid [2] drives the bypass gate [1].• For the small size paper (A4, B5, and 81/2 x 11), it operates only for the 1st page of the

2nd and following copies to transfer the paper to the bypass route [3].• The 2nd page of the 2nd and following copies is transferred to the regular route [4] and

overlapped under the 1st page, and then the transferred to the stacker section.

[1] Bypass gate [3] Bypass route

[2] Bypass gate solenoid (SD5) [4] Regular route

[1]

[2]

[3]

[3]

[4]

15jkt2c006na


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B. Bypass gate control• The bypass gate only operates for the small size paper (A4, B5, and 81/2 x 11) in the sta-

pling mode.• The FNS control board controls the bypass gate solenoid.• When stapling two sheets of paper for three copies, the bypass gate solenoid operates

as follows.

(1) For the 1st copy• When the paper for the 1st copy [1] is transferred, the bypass gate solenoid does not

operate.

(2) For the 2nd copy• The bypass gate solenoid turns ON and draws the 1st paper of the 2nd copy to the

bypass after a specified period of time since the staple operation for the 1st copy is started [4].

• The bypass gate solenoid turns OFF after a specified period of time since the FNS entrance sensor detects the trailing edge of the paper [6].

(3) For the 3rd and following copies• The bypass gate turns ON and draws the 1st paper of the 3rd copy to the bypass after a

specified period of time since the FNS entrance sensor detects the trailing edge of the last paper of the 2nd copy [7].

• The bypass gate solenoid turns OFF after a specified period of time since the FNS entrance sensor detects the trailing edge of the paper [8].

[1] The 1st copy [5] Drawing the 1st paper of the 2nd copy to the bypass

[2] The 2nd copy [6] Trailing edge of the 1st paper of the 2nd copy

[3] The 3rd copy [7] Trailing edge of the last paper of the 2nd copy

[4] Stapling operation for the 1st copy started [8] Trailing edge of the 1st paper of the 3rd copy

[5][6] [7] [8][4]

[2][1] [3]

A07RT2E031AA

FNS entrance sensor (PS4)

FNS transfer motor (M1)

Bypass gate solenoid (SD5)

Stapler movement motor (M11)


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5.2.5 Shift control

• The FNS transfer motor drives the shift roller. The shift roller moves itself backward to shift the paper while transferring the paper to the main tray.

A. Shift operation• During conveying the paper to the finishing tray1 [1], the crank mechanism [3] shifts the

shift movable section [5] including the shift roller [4] approximately 30 mm backward [6] to shift and exit the paper when shift roller motor [2] rotates.

• The shift roller home sensor [7] detects the shift position.

[1] To the finishing tray1 [5] Shift movable section

[2] Shift roller motor (M2) [6] Rear

[3] Crank mechanism [7] Shift roller home sensor (PS18)

[4] Shift roller

[1]

[2]

[3]

[5]

[5]

[6]

[7] [2][4]

[3]

[4]

[7]

15jkt2c008na


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B. Shift control• In the sort/group mode, the shift roller motor turns ON [2] and shifts the shift movable

section after a specified period of time since the FNS entrance sensor detects the trailing edge of the paper [1].

• The FNS transfer motor drives the shift roller. It shifts the paper while transferring it.• The shift roller motor stops when the shift roller completes the shift operation and the

shift roller home sensor turns ON [3].• Then, the shift roller motor turns ON [4] again after a specified period of time since it

stops. It stops when the shift roller home sensor turns OFF [5]. This operation replaces the shift movable section to its original position, and then it stands by for the subsequent paper to be shifted.

• These operations are repeated for every paper to offset it.

[1] Trailing edge of the paper detected [4] Moving to the home position started

[2] Shift started [5] Moving to the home position completed

[3] Shift completed

[3][2]

[1]

[5][4]

A07RT2E032AA


shift roller motor (M2)

shift roller home sensor (PS18)

FNS transfer motor (M1)

930 mm/s

400 mm/s


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5.2.6 Paper exit roller control

• The paper exit roller motor controlled by the FNS control board drives the finishing tray1 paper exit roller and the paper exit belt.

A. Non-sort/sort/group mode• The paper exit roller motor rotates in high speed when the FNS entrance sensor detects

the leading edge of the paper [1]. The paper exit roller motor rotate in low speed [2] and exits the paper after a specified period of time since the FNS entrance sensor detects the trailing edge of the paper.

• To transfer the subsequent paper, the paper exit roller motor rotate in high speed again after a specified period of time since the main tray paper exit sensor detects the trailing edge of the paper [3].

• The paper exit roller motor stops after a specified period of time since the tray1 paper exit sensor detects the last paper.

[1] Leading edge of the paper detected [3] Preparing to transfer the subsequent paper

[2] Paper exit started

[2][1] [3] A07RT2E033AA


Paper exit roller motor (M7)

400 mm/s

253 mm/s

Tray1 paper exit sensor (PS6)


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B. Stapling mode (when the paper length is B5S or longer in the paper feed direc-tion)

• Transmitting the FNS signal [1] from the main body, the paper exit roller motor rotates to drive the paper exit belt in the stacker section.

• The paper exit roller motor stops and the paper exit arm moves to the home position for the stapling mode when the paper exit belt home sensor turns ON [3].

• The paper exit opening is open if the paper length is longer than B5S in the paper feed direction. The paper exit motor closes the paper exit opening when the stapling operation is completed.

• The paper exit roller motor rotates to drive the paper exit arm when the paper exit home sensor detects the opening is closed [6]. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits the paper to the finishing tray1.

• The paper exit roller motor stops when the paper exit belt home sensor turns ON [7].

[1] FNS signal turned ON [5] Closing the paper exit opening

[2] Opening the paper exit opening [6] Paper exit opening closed

[3] Paper exit arm home position [7] Paper exit arm home position

[4] Stapling operation completed

[7][6][5][4][3][2][1]A07RT2E034AA


Paper exit belt home sensor (PS9)

Stapler motor /Rr (M8)

Paper exit home sensor (PS12)


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5.2.7 Paper exit opening solenoid control

• The paper exit roller is usually releasing the nip except when exiting the paper because its rotation is slower than the transfer roller. However, the nip movable section moves to nip the paper when the paper reaches to the paper exit opening.

A. Paper exit opening solenoid operation• When the paper reaches to the paper exit opening, the paper exit opening solenoid [1]

moves the nip movable section [2] to nip the paper by pressurizing the nip roller [4] to the finishing tray1 paper exit roller [3] and exit the paper to the finishing tray1 direction [5].

• The tray1 paper exit sensor [6] detects the paper exit.

B. Timing to turn ON the paper exit opening solenoid(1) Non-sort/sort/group mode• The paper exit opening solenoid turns ON after a specified period of time since the FNS

entrance sensor detects the trailing edge of the paper.

(2) Stapling mode• The paper exit opening solenoid turns ON to nip the paper after a specified period of time

since the stapling operation is completed.

C. Timing to turn OFF the paper exit opening solenoid• In all modes, the paper exit opening solenoid turns OFF after a specified period of time

since the finishing tray1 paper exit sensor detects the paper.

[1] Paper exit opening solenoid (SD4) [4] Nip roller

[2] Nip movable section [5] To the finishing tray1

[3] Main tray exit roller [6] Tray1 paper exit sensor (PS6)

[1][1]

[2]

[2] [3]

[5]

[6]

[4]

[4]

15jkt2c011na

4


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5.2.8 Paper exit opening control

• In the stapling mode (when the paper length is B5S or longer in the paper feed direction) and the folding/saddle stitching/tri-folding mode, the paper exit opening is opened from the beginning of the printing operation to the end of the stapling operation because the paper protrudes.

A. Paper exit opening/closing operation• The paper exit opening unit [3] opens/closes by the crank mechanism [2] when the paper

exit motor [1] rotates. The paper exit home sensor [4] and 100pcs paper exit home sen-sor [5] detects the opening/closing of the paper exit opening.

B. Paper exit opening/closing control (FS-517/FS-608)(1) Stapling mode (when the paper length is B5S or longer in the paper feed direc-

tion)• Transmitting the FNS signal [1] from the main body, the paper exit motor rotates [2] to

open the paper exit opening.• When the stapling operation completes, the paper exit motor turns ON [3] again to close

the paper exit opening. It stops when the paper exit home sensor detects the paper exit opening is closed.

• These operations are repeated for every stapled bundle.

4

[1] Paper exit motor (M8) [4] Paper exit home sensor (PS12)

[2] Crank mechanism [5] 100pcs paper exit home sensor (PS32)

[3] Paper exit unit

[1]

[1]

[2]

[2]

[3] [3]

[4][4] 15vlt2c002na[5]

4

4

[1] FNS start signal turned ON [4] Paper exit opening closed

[2] Opening the paper exit opening [5] Paper nipped by the paper exit opening solenoid (SD4)[3] Closing the paper exit opening

[2][1]

[5]

[4][3]A07RT2E035AA

Stapler motor /Fr (M14)Clincher motor /Fr (M15)

Stapler motor /Rr (M9)Clincher motor /Rr (M10)

Paper exit opening solenoid (SD4)


Paper exit motor (M8)


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(2) Folding/saddle stitching/tri-folding mode (FS-608 only)• Transmitting the start signal [1] from the main body, the paper exit motor rotates [2] to

open the paper exit opening.• The paper exit motor turns ON [3] again to close the paper exit opening after a specified

period of time since the folding paper exit sensor or the folding full sensor detects the trailing edge of the last page. It stops when the paper exit home sensor detects the paper exit opening is closed [4].

4

[1] FNS start signal turned ON [3] Closing the paper exit opening

[2] Opening the paper exit opening [4] Paper exit opening closed

[2][1] [4][3]

Folding paper exit sensor (PS25)



A07RT2E036AA

4


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C. Paper exit opening/closing control (FS-518)(1) Stapling mode (when 51 or more sheets of paper are stapled with the size in the

sub scan direction shorter than B5S)• When the stacker entrance sensor detects [1] the leading edge of the 51st sheet of paper

while in the• paper stack, the paper exit motor turns ON to open the paper exit opening. As a result,

when the paper exit• home sensor turns OFF [2], M8 turns off.• When the alignment (close) of the last paper to be stapled is completed [7], the stapling

operation starts. At the• same time, M8 also turns ON to close the paper exit opening. As a result, when the

100pcs paper exit home sensor turns ON, M8 turns off.• After the paper exited, the paper exit opening returns to the home position, which is

maintained until the stacking operation of the 50th sheet of paper for the next stapling is completed.

4

[1] Start of the paper stack of the 51st sheet ofpaper/Start of opening operation of the paper exit opening

[5] Completion of the paper stack of the 52nd sheet of paper

[2] Paper exit opening being opened [6] Start of the paper stack of the last paper to be stapled

[3] Completion of the paper stack of the 51st sheet of paper

[7] Completion of the alignment (close) of the last paper/Start of the closing operation of the paper exit opening

[4] Start of the paper stack of the 52nd sheet of paper

[8] 100pcs paper exit home sensor OFF

[1] [3][2] [4] [5] [6] [7] [8]A07PT2C001AA

Stacker entrance motor (PS5)

Alignment motor /Up (M5)

Stapler motor /Fr (M14)




100pcs paper exit home sensor (PS32)

Close

Open


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(2) Stapling mode (when the size in the sub scan direction is B5S or longer)• The FS operation signal [1] from the main body allows the paper exit motor to rotate [2] to

open the paper exit opening.• Upon completion of the stapling operation, the paper exit motor turns ON [3] again to

start the closing operation of the paper exit opening, and it turns off when the paper exit home sensor detects [4] the close position.

• This operation is repeated for each bundle of paper to be stapled.

4

[1] FS operation start signal turned ON [4] Paper exit opening being closed

[2]Start of the opening operation of the paper exit opening

[5]Paper nip by means of the paper exit open-ing solenoid (SD4)

[3]Start of the closing operation of the paper exit opening

[2][1]

[5]

[4][3]



Paper exit opening solenoid (SD4)



A07RT2E037AA


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5.2.9 Finishing tray2 paper exit control

• The sub tray paper exit motor controlled by the FNS control board drives the finishing tray2 paper exit roller.

A. Sub tray paper exit motor control• The sub tray paper exit motor rotates in high speed when the tray2 paper exit sensor

detects the leading edge of the paper.• The sub tray paper exit motor rotates in low speed after a specified period of time since

the FNS entrance sensor detects the trailing edge of the paper.• The sub tray paper exit motor stops after a specified period of time since the tray2 paper

exit sensor detects the trailing edge of the paper.

B. Sub tray full detection• When the exited paper on the sub tray reached to a specified thickness, the tray2 paper

full sensor turns ON and the sub tray full information is sent to the main body. Then, the main body displays the message on its display panel.

6. Finishing tray1 section Theory of Operation Ver. 5.0 May 2008

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6. Finishing tray1 section

6.1 Drive

[1] Lift pulley /Up [4] Lift pulley /Lw

[2] Lift wire [5] Finishing tray1

[3] Tray1 lift motor (M3)

15jkt2c015na

[1]

[4]

[5]

[2]

[3]

Theory of Operation Ver. 5.0 May 2008 6. Finishing tray1 section

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6.2 Operation

6.2.1 Tray lift control

A. Tray lift operation• The worm gear installed in the shaft of the tray1 lift motor [6] winds up the lift wire.• It lifts up or down the finishing tray1 [9] depending on the winding direction.• Rotating the lift pulley /Lw clockwise and counterclockwise in view of front, the finishing

tray1 is lifted up and down respectively.

B. Paper detection• The tray1 upper limit sensor [2] and the stapler paper exit upper limit sensor [1] keep the

specified distance between the upper surface of the paper exited to the finishing tray1 (the upper surface of the finishing tray1 if there is no exited paper) and the paper exit opening to eliminate the misalignment of the exited paper.

• During the consecutive printing operation, FS counts the number of exited paper and stops the printing when it reaches the maximum capacity.

• If the exited paper is ejected during the printing operation, the tray moves up and the counter reset sensor [3] turns ON and resets the counter. It makes possible to exit paper with no limitation.

• The tray1 lower limit sensor [4] detects the lower limit of the tray.• During the intermittent printing operation, The tray1 lower limit sensor controls the

capacity of the paper exit because the counter does not integrate the total number of exited paper.

[1] stapler paper exit upper limit sensor (PS7) [6] Tray1 lift motor (M3)

[2] Tray1 upper limit sensor (PS2) [7] Lift pulley /Lw

[3] Counter reset sensor (PS15) [8] Lift pulley /Up

[4] Tray1 lower limit sensor (PS3) [9] Finishing tray1

[5] Timing belt

15jkt2c016na

[1]

[2]

[3]

[4]

[7]

[8]

[9]

[5]

[6]

6. Finishing tray1 section Theory of Operation Ver. 5.0 May 2008

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C. Tray lift control• The tray1 lift motor lifts up and down the finishing tray1 by rotating in the forward and

reverse direction respectively.• The FNS control board controls tray1 lift motor.

(1) Non-sort/sort/group mode• Transmitting the FNS signal from the main body, the tray1 lift motor lifts up the tray until

the tray1 upper limit sensor turns ON.• The tray1 lift motor lifts down the tray when the paper passes the tray1 paper exit sensor.• The tray1 lift motor lifts up the tray again after a specified period of time since the tray1

upper limit sensor turns OFF, and then stops when the tray1 upper limit sensor turns ON.• These operations are repeated for every paper.

(2) Stapling mode• Transmitting the FNS signal from the main body, the tray1 lift motor lifts up the tray until

the stapler paper exit upper limit sensor turns ON.• The tray1 lift motor lifts down the main tray after a specified period of time since the

paper exit roller motor turns ON.• After a specified period of time, the tray1 lift motor rotates in the reverse direction to lift

up the finishing tray1, and then stops when the stapler paper exit upper limit sensor turns OFF.

[1]

[2]



Tray1 lift motor (M3)

UP

DOWN

A07RT2E038AA

[1] FNS start signal turned ON [2] Paper exited to the finishing tray1

[1] FNS start signal turned ON [3] Finishing tray1 lifted down

[2] Paper bundle exited to the finishing tray1 [4] Finishing tray1 lifted up

[1]

[2]

[3] [4]A07RT2E039AA


Tray1 lift motor (M3)

Stapler paper exit upper limit sensor (PS7)

400 mm/s

253 mm/s

Reverse

UP

DOWN

4

Theory of Operation Ver. 5.0 May 2008 7. Stacker section (FS-517/518)

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7. Stacker section (FS-517/518)

7.1 Drive

4

[1] Coupling (from M7) [8] Paper exit belt

[2] Alignment motor /Up (M5) [9] Swing belt /Lw

[3] Paper assist motor (M51) [10] Swing belt /Up

[4] Stacker entrance motor (M13) [11] Paper exit arm

[5] Paper assist solenoid (SD51) [12] Alignment plate /Up

[6] Stacker entrance roller [13] Paper assist arm (FS-518 only)

[7] Paper assist roller [14] Paper guide (FS-518 only)

4

A07PT2C002AA

[11]

[12]

[10]

[1]

[2]

[2][3]

[4]

[4] [5]

[6][6]

[7][8]

[9][14]

[13]

4

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7. Stacker section (FS-517/518) Theory of Operation Ver. 5.0 May 2008

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7.2 Operation

7.2.1 Alignment control

• The alignment motor /Up rotates in the forward/reverse direction to open/close the align-ment plate /Up to perform the alignment of the paper transferred to the stacker in the main scan direction.

A. Alignment operation• The alignment motor /Up rotates to open/close the alignment plate /Up via the alignment

belt /Up.• The alignment home sensor /Up detects the home position of the alignment plate /Up.

[1] Alignment motor /Up (M5) [3] Alignment plate /Up

[2] Alignment home sensor /Up (PS8)

FRONT

[1]

[3]

[2]

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B. Alignment control• Transmitting the FNS signal from the main body, the alignment motor /Up rotates to close

the alignment plate, and then it stops the alignment plate at the standby position that is a little wider than the paper width.

• The alignment motor /Up performs the alignment operation by rotating in the forward and reverse direction to move the alignment plate back and forth after a specified period of time since the stacker entrance sensor detects the trailing edge of the paper.

• The alignment operation is performed for every paper.

7.2.2 Stopper control

• The secured five stoppers determine the position where the paper transferred to the stacker stops.

• When stapling at the corner, the three stoppers excluding the two outside stoppers secured to the stapler unit determine the position because the stapler moves to the front and rear sides.

[1] FNS start signal turned ON [3] Alignment operation

[2] Standing by for the paper at the paper size

[1] [2] [3]

A07RT2E040AA

Stacker entrance sensor (PS5)

Alignment home sensor /Up (PS8)


CLOSE

OPEN

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7.2.3 Stacker entrance transfer control

• The stacker entrance motor drives the stacker entrance roller, swing belt /Up, and the swing belt /Lw to transfer the paper to the stacker, align the trailing edge of the paper, and adjust the staple wait timing.

A. Stacker entrance operation• The downsizing of the device is achieved by adopting the stack method whose incline

angle is approximately 70°.• The corrugation roller is adopted for the stacker entrance roller [5] to assist the paper exit

to the stacker.• After the paper falls to the stacker, the swing belts /Up [7], swing belts /Lw [6] and the

paper guide (FS-518 only) align the paper with its trailing edge.• To assist in aligning the curled paper with the trailing edge according to the number of sheets stacked

and the paper size, the paper assist solenoid [3] pressurizes the paper while the paper assist motor [1] drives the paper assist roller [2].

4

[1] Paper assist motor (M51) [5] Stacker entrance roller

[2] Paper assist roller [6] Swing belt /Lw

[3] Paper assist solenoid (SD51) [7] Swing belt /Up

[4] Stacker entrance sensor (PS5) [8] Paper guide (FS-518 only)

4[1]

[2]

[3]

[4]

[5]

[6]

[7]

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B. Stacker entrance transfer control(1) Stapling mode (the paper size is not A4, B5, or 81/2 x 11, without the bypassing

operation)• Transmitting the FNS signal from the main body [1], the stacker entrance motor turns ON

and rotates in high speed.• The stacker entrance motor rotates in low speed to transfer the paper in low speed [3]

when the stacker entrance sensor detects the trailing edge of the paper.• When the paper assist roller is driven, the paper assist motor and the paper assist sole-

noid operate to assist the stacking operation.• The stacker entrance motor rotates in high speed and stands by for the subsequent

paper after a specified period of time since it rotates in low speed.• After the last paper of the copy passes, the stacker entrance motor stops when the sta-

pling operation is started.• The stacker entrance motor turns ON and rotates in high speed to stand by for the sub-

sequent paper when the paper exit motor completes the closing operation.

[1] FNS start signal turned ON [5] Stapling operation

[2] 1st to 9th paper [6] Closing the paper exit opening

[3] Paper transferred to the stacker in low speed

[7] Standing by for the paper of the subsequent copy

[4] Paper assist roller in operation

[7][4][2]

[1][6]

[5][3]

A07RT2E041AA


Paper assist motor (M51)


Stapler motor (M9, M14)

Paper assist solenoid (SD51)

Stacker entrance motor (M13)

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(2) Stapling mode (the paper size is A4, B5, or 81/2 x 11, with the bypassing opera-tion)

• The 1st copy is transferred by the same operation for the paper whose size is other than A4, B5, or 81/2 x 11.

• When transferring the 1st and 2nd paper of the 2nd and following copies, the stacker entrance motor stops after a specified period of time since the stacker entrance sensor detects the trailing edge of the last paper of the 1st copy [3].

• To prevent the paper of the 2nd copy is transferred to the stacker before the stapling operation for the 1st copy is completed, the 1st paper for the 2nd copy stands by in the bypass path.

• The stacker entrance motor turns ON and rotates in high speed after a specified period of time since the FNS entrance sensor detects the trailing edge of the 2nd paper.

• Then the 1st and 2nd paper are overlapped and transferred to the stacker.

• When transferring the 3rd and following paper of the 2nd and following copies, the paper is transferred to the stacker by the same operation for the paper of the 1st copy.

[1] FNS start signal turned ON [4] 1st paper of the 2nd copy


[5] 2nd paper of the 2nd copy

[3] Trailing edge of the last paper of the 1st copy detected

[6] 1st and 2nd paper of the 2nd copy trans-ferred simultaneously

[1] [2]

[3]

[6]

[4] [5]

A07RT2E042AA




High speed

Low speed

stapler motor /Fr (M14)

4


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7.2.4 Stacker paper exit control

• The paper exit roller motor controlled by the FNS control board drives the paper exit belt of the stacker via the coupling gear.

A. Paper exit belt operation• The paper exit arm [2] mounted on the paper exit belt [1] exits the paper to the finishing

tray1 in the stapling mode.• The paper exit roller motor [4] drives the paper exit belt [1] via the coupling pin [3].• The paper exit belt home sensor [5] detects the home position of the paper exit arm.• Only with FS-518 if six or more sheets of A4S or larger paper are stacked in staple mode,

paper exit roller motor rotates reversely to feed the paper exit belt in reverse direction. By this operation, the paper assist arm [6] (equipped in FS-518 only) slips under stacked sheets of paper and warps the paper for paper curl prevention.

4

[1] Paper exit belt [4] Paper exit roller motor (M7)

[2] Paper exit arm [5] Paper exit belt home sensor (PS9)

[3] Coupling pin [6] Paper assist arm (FS-518 only)

4

[1]

[2]

[3]

[4]

[5]

A07PT2C004AA

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B. Paper exit arm control(1) Stapling mode (when the paper length is shorter than B5S in the paper feed

direction)• Completing the stapling operation, the paper exit roller motor rotates to drive the paper

exit belt in the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits the paper to the finishing tray1. The paper exit roller motor stops when the paper exit belt home sensor turns ON.

(2) Stapling mode (when the paper length is B5S or longer in the paper feed direc-tion)

• Completing the stapling operation, the paper exit motor rotates. When the paper exit home sensor detects the paper exit opening is closed, the paper exit roller motor rotates to drive the paper exit arm in the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits the paper to the finishing tray1.

• The paper exit roller motor stops when the paper exit belt home sensor turns ON.

Theory of Operation Ver. 5.0 May 2008 8. Stacker section (FS-608)

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8. Stacker section (FS-608)

8.1 Drive

[1] Coupling (from M7) [9] Alignment plate /Lw

[2] Alignment motor /Up (M5) [10] Flat stitching stopper release solenoid/Rr (SD8), flat stitching stopper release sole-noid/Fr (SD7)

[3] Stacker entrance motor (M13)

[4] Stacker entrance roller [11] Paper assist roller

[5] Flat-stapling stopper /Fr, Flat-stapling stopper /Rr

[12] Paper assist solenoid (SD51)

[6] Alignment motor /Lw (M16) [13] Paper exit arm

[7] Saddle stitching stopper [14] Paper assist motor (M51)

[8] Saddle stitching stopper motor (M18) [15] Alignment plate /Up

15jmt2c001na

[15][14][13][12]

[10]

[11]

[1]

[2][3]

[4]

[5]

[6]

[7]

[8][9]

8. Stacker section (FS-608) Theory of Operation Ver. 5.0 May 2008

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8.2 Operation

8.2.1 Alignment /Up control

• In the stapling/saddle stitching/tri-folding mode, the alignment motor /Up rotates in the forward/reverse direction to open/close the alignment plate /Up to perform the alignment of the paper transferred to the stacker in the main scan direction.

A. Alignment /Up operation• The alignment motor /Up rotates to open/close the alignment plate via the alignment belt.• The alignment home sensor /Up detects the home position of the alignment plate.

B. Alignment /Up control• Transmitting the FNS signal from the main body, the alignment motor /Up rotates to close

the alignment plate /Up [1], and then it stops the alignment plate at the standby position that is a little wider than the paper width [2].

• The alignment motor /Up performs the alignment operation by rotating in the forward and reverse direction to move the alignment plate /Up back and forth after a specified period of time since the stacker entrance sensor detects the trailing edge of the paper.

• The alignment operation is performed for every paper [3].

[1] Alignment motor /Up (M5) [3] Alignment plate /Up

[2] Alignment home sensor /Up (PS8)

FRONT

[1]

[3]

[2]

15jmt2c023na

[1] Closing the alignment plate /Up (FNS sig-nal)

[3] Alignment operation for every paper

[2] Standby position of the alignment plate /Up

[1] [2] [3]A07RT2E043AA


Alignment home sensor /Up (PS8)


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OPEN


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8.2.2 Alignment /Lw control

• In the saddle stitching/folding/tri-folding mode, the alignment plate /Up and the alignment plate /Lw move back and forth to align the paper in the main scan direction.

• The alignment motor /Lw performs the alignment operation by rotating in the forward and reverse direction to move the alignment plate back and forth.

A. Alignment /Lw operation• The alignment motor /LW rotates to open/close the alignment plate via the alignment

belt.• The alignment home sensor /Lw detects the home position of the alignment plate.

B. Alignment /Lw control• In the saddle stitching/folding/tri-folding mode, transmitting the FNS signal from the main

body, the alignment motor /Lw rotates to close the alignment plate /Lw [1], and then it stops the alignment plate at the standby position that is a little wider than the paper width [2].

• The alignment motor /Lw performs the alignment operation by rotating in the forward and reverse direction to move the alignment plate /Lw back and forth after a specified period of time since the stacker entrance sensor detects the trailing edge of the paper.

• The alignment operation is performed for every paper [3].

[1] Alignment home sensor /Lw (PS24) [3] Alignment plate /Lw

[2] Alignment motor /Lw (M16)

FRONT

15jmf5c024na

[3]

[2]

[1]

[1] Closing the alignment plate /Lw (FNS signal)

[3] Alignment operation for every paper

[2] Standby position of the alignment plate /Lw

[1][2] [3]A07RT2E044AA

Alignment home sensor /Lw (PS24)

Alignment motor /Lw (M16)

CLOSE

OPEN



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8.2.3 Stopper control

• The stopping position in vertical direction of paper conveyed to the stacker is different among the stapling mode, the saddle stitching mode, and the folding mode.

• Two stoppers (the saddle stitching stopper and the flat-stapling stopper) control the stop-ping position of paper.

A. Stopper operation• In the stapling mode, the flat-stapling stopper [1] is set on the paper path by the pushing

pressure by the spring [2]. The flat-stapling stopper [1] determines the position of the leading edge of the fallen paper.

• In the saddle stitching/folding/tri-folding mode, the flat-stapling release solenoids turn ON and evacuate the flat-stapling stopper from the paper path. Then, the paper falls down to the saddle stitching stopper [3] without contacting with the flat-stapling stopper.

• The saddle stitching stopper motor [5] moves the saddle stitching stopper up and down in accordance with the paper size. The saddle stitching stopper home sensor [6] detects the home position.

[1] Flat-stapling stopper [4] Flat stitching stopper release solenoid (SD7, SD8)

[2] Spring [5] Saddle stitching stopper motor (M18)

[3] Saddle stitching stopper [6] Saddle stitching stopper home sensor (PS23)

[3]

[1] [1]

[5]

15jmt2c004na[3]

[4]

[6]

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B. Stopper control(1) Folding mode• Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor

rotates [2] to move down the saddle stitching stopper to the stopping position in accor-dance with the paper size.

• After completing the alignment operation of the last paper [3], the saddle stitching stop-per motor rotates [4] to move down the saddle stitching stopper to the folding position.

• After completing the folding operation, when the folding paper exit sensor detects the trailing edge of the paper bundle, the saddle stitching stopper motor rotates [5] to move up the saddle stitching stopper to the alignment position in accordance with the paper size and stand by for the paper of the subsequent copy.

[1] FNS start signal turned ON [4] Moving to the folding position for the paper size

[2] Moving to the alignment position for the paper size

[5] Moving to the alignment position for the subsequent copy

[3] Last paper of the copy aligned

[1]

[3]

[5][2] [4]

A07RT2E045AA



Saddle stitching stopper home sensor (PS23)

Saddle stitching stopper motor (M18)


UP

DOWN


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(2) Saddle stitching mode• Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor


• After completing the stapling operation [3], the alignment motors /Up and /Lw open the alignment plate and the saddle stitching stopper motor rotates [4] to move down the sad-dle stitching stopper to the folding position.

• After completing the folding operation, when the folding paper exit sensor detects the trailing edge of the paper bundle, the saddle stitching stopper motor rotates [5] to move up the saddle stitching stopper to the saddle stitching position in accordance with the paper size and stand by for the paper of the subsequent copy.

[1] FNS start signal turned ON [4] Moving to the folding position for the paper size

[2] Moving to the saddle stitching position for the paper size

[5] Moving to the saddle stitching position for the subsequent copy

[3] Stapling operation

[1]

[3]

[5][2] [4]

A7RT2E046AA

Stapler motor /Fr (M14)Clincher motor /Fr (M15)

Stapler motor /Rr (M9)Clincher motor /Rr (M10)





UP

DOWN



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(3) Tri-folding mode• Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor


• After completing the alignment operation of the last paper [3], the saddle stitching stop-per motor rotates [4] to move down the saddle stitching stopper to the 1st folding position in the tri-folding.

• After completing the folding operation, when the folding paper exit sensor detects the trailing edge of the paper bundle, the saddle stitching stopper motor rotates [5] to move up the saddle stitching stopper to the alignment position in accordance with the paper size and stand by for the paper of the subsequent copy.

(4) Flat-stapling mode• The saddle stitching stopper motor does not operate in the flat-stapling mode.

[1] FNS start signal turned ON [4] Moving to the 1st folding position

[2] Moving to the alignment position for the paper size

[5] Moving to the alignment position for the subsequent copy

[3] Last paper of the copy aligned

[1]

[3]

[5][2] [4]A07RT2E047AA






UP

DOWN


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8.2.4 Stacker entrance transfer control

• The stacker entrance motor drives the stacker entrance roller, swing belt to transfer the paper to the stacker, align the trailing edge of the paper, and adjust the staple wait timing.

A. Stacker entrance operation• The downsizing of the device is achieved by adopting the stack method whose incline

angle is approximately 70°. The corrugation roller is adopted for the stacker entrance roller [5] to assist the paper exit to the stacker.

• After the paper falls to the stacker, the swing belt [6] align the paper with its trailing edge.• To assist in aligning the curled paper with the trailing edge according to the number of

sheets stacked and the paper size, the paper assist solenoid [1] pressurizes the paper while the paper assist motor [3] drives the paper assist roller [2].

[1] Paper assist solenoid (SD51) [5] Stacker entrance roller

[2] Paper assist roller [6] Swing belt

[3] Paper assist motor (M51) [7] Stacker empty sensor (PS20)

[4] Stacker entrance sensor (PS5)

[5][6][7]

[2]

[1]

[3]

[4]

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B. Stacker entrance transfer control(1) Stapling mode (the paper size is not A4, B5, or 81/2 x 11, without the bypassing

operation)• Transmitting the FNS signal from the main body [1], the stacker entrance motor turns ON

and rotates in high speed.• The stacker entrance motor rotates in low speed [3] when the stacker entrance sensor

detects the trailing edge of the paper and then the paper assist roller starts to rotate to transfer the paper to the stacker in low speed.

• When the paper assist roller is driven, the paper assist motor and the paper assist sole-noid operate to assist the stacking operation.

• The stacker entrance motor rotates in high speed and stands by for the subsequent paper after a specified period of time since it rotates in low speed.

• After the last paper of the copy passes, the stacker entrance motor stops when the sta-pling operation is started [5].

• The stacker entrance motor turns ON [6] and rotates in high speed to stand by for the subsequent paper when the paper exit motor completes the closing operation.


[2] 1st to 9th paper [6] Closing the paper exit opening


[7] Standing by for the paper of the subsequent copy

[4] Paper assist roller in operation

[1]

[7][4]

[6][5][3]

[2]

A07RT2E048AA



High speed

Low speed

Paper assist motor (M51)

Paper assist solenoid (SD51)

Stapler motor (M9, M14)



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(2) Stapling mode (the paper size is A4, B5, or 81/2 x 11, with the bypassing opera-tion)

• The 1st copy is transferred by the same operation for the paper whose size is other than A4, B5, or 81/2 x 11.

• When transferring the 1st and 2nd paper of the 2nd and following copies, the stacker entrance motor stops after a specified period of time since the stacker entrance sensor detects the trailing edge of the last paper of the 1st copy [3]. To prevent the paper of the 2nd copy is transferred to the stacker before the stapling operation for the 1st copy is completed, the 1st paper for the 2nd copy stands by in the bypass path.

• The stacker entrance motor turns ON and rotates in high speed after a specified period of time since the FNS entrance sensor detects the trailing edge of the 2nd paper [5]. Then the 1st and 2nd paper are overlapped and transferred to the stacker [6].

• When transferring the 3rd and following paper of the 2nd and following copies, the paper is transferred to the stacker by the same operation for the paper of the 1st copy.

[1] FNS start signal turned ON [4] 1st paper of the 2nd copy


[5] 2nd paper of the 2nd copy

[3] Trailing edge of the last paper of the 1st copy detected

[6] 1st and 2nd paper of the 2nd copy trans-ferred simultaneously

[1] [2]

[3]

[6]

[4] [5]

A07RT2E049AA





High speed

Low speed


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(3) Folding/saddle stitching mode• Transmitting the FNS signal from the main body [1], the stacker entrance motor turns ON

and rotates in high speed.• The stacker entrance motor rotates in low speed [2] to transfer the paper in low speed

when the stacker entrance sensor detects the trailing edge of the paper.• The stacker entrance motor rotates in high speed and stands by for the subsequent

paper after a specified period of time since it rotates in low speed.• The stacker entrance motor stops after completing the alignment operation [4] of the last

paper of the copy [3].• The stacker entrance motor turns ON and rotates in high speed to stand by for the sub-

sequent paper when the folding paper exit sensor detects the trailing edge of the paper bundle [5].

[1] FNS start signal turned ON [4] Last paper of the copy aligned


[5] Folding paper exit operation

[3] Last paper of the copy [6] Standing by for the paper of the subsequent copy

[1]

[6]

[5][4][2]

[3]

A07RT2E050AA



Alignment motor /Up, /Lw (M5, M16)


High speed

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(4) Tri-folding mode• Transmitting the FNS signal from the main body [1], the stacker entrance motor turns ON

and rotates in high speed.• The stacker entrance motor rotates in low speed [2] to transfer the paper in low speed

when the stacker entrance sensor detects the trailing edge of the paper.• The stacker entrance motor rotates in high speed and stands by for the subsequent

paper after a specified period of time since it rotates in low speed.• The stacker entrance motor stops after completing the alignment operation of the last

paper of the copy [3] and the movement of the saddle stitching stopper to the tri-folding position [4].

• The stacker entrance motor turns ON and rotates in high speed to stand by for the sub-sequent paper when the folding paper exit sensor detects the trailing edge of the paper bundle [5].

[1] FNS start signal turned ON [4] Saddle stitching stopper moving to the tri-folding position


[5] Tri-folding paper exit operation

[3] Last paper of the copy [6] Standing by for the paper of the subsequent copy

[1] [2]

[3]

[4] [5]

[6]

A07RT2E051AA





High speed

Low speed

DOWN

UP


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8.2.5 Stacker paper exit control

• The paper exit roller motor controlled by the FNS control board drives the paper exit belt of the stacker via the coupling gear.

A. Paper exit belt operation• The paper exit arm [2] mounted on the paper exit belt [1] exits the paper to the finishing

tray1 in the stapling mode.• The paper exit roller motor [4] drives the paper exit belt via the coupling pin [3].• The paper exit belt home sensor [5] detects the home position of the paper exit arm.

[1] Paper exit belt [4] Paper exit roller motor (M7)

[2] Paper exit arm [5] Paper exit belt home sensor (PS9)

[3] Coupling pin

[1]

[2]

[3]

[4]

[5]

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B. Paper exit arm control(1) Stapling mode (when the paper length is shorter than B5S in the paper feed

direction)• Completing the stapling operation, the paper exit roller motor rotates to drive the paper

exit belt in the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits the paper to the finishing tray1.


(2) Stapling mode (when the paper length is B5S or longer in the paper feed direc-tion)

• Completing the stapling operation, the paper exit motor rotates. When the paper exit home sensor detects the paper exit opening is closed, the paper exit roller motor rotates to drive the paper exit arm in the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits the paper to the finishing tray1.


(3) Folding/saddle stitching mode• After completing the stapling operation, the saddle stitching stopper motor drives the

saddle stitching stopper to move the paper to the folding position. To prevent the paper exit arm to contact with the paper standing by at the folding position, the paper exit arm does not rotate.

(4) Tri-folding mode• The paper exit roller motor rotates in the reverse direction to assist in transferring the

paper to the tri-folding position after completing the paper alignment operation.• The paper exit roller motor stops when the paper exit belt home sensor turns ON.

4

Theory of Operation Ver. 5.0 May 2008 9. Stapler (FS-517/518)

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9. Stapler (FS-517/518)

9.1 Drive

4

[1] Stapler /Rr [8] Stapler movement motor (M11)

[2] Stapler rotation shaft /Rr [9] Stapler movement home sensor (PS11)

[3] Rack mounting platform [10] Stapler drive rack /Fr

[4] Stapler spring /Rr [11] Stapler spring /Fr

[5] Parallel stapling position [12] Stapler rotation shaft /Fr

[6] One-corner stapling position [13] Stapler /Fr

[7] Stapler drive rack /Rr [14] Pinion gear

15jkt2c026na

[1][14] [2] [3][11] [12] [13]

[4]

[7][10] [8][9]

[5]

[6]

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9.2 Operation

9.2.1 Stapler movement control

A. Stapler movement operation• Since the stapler /Fr [11] and the stapler /Rr [1] operate symmetrically, the explanation is

given of the stapler /Rr [1].• The stapler movement motor [9] moves the stapler.• When the stapler movement motor rotates as shown in [10], it drives the stapler drive

rack /Rr [8] backward with the stapler via the pinion gear [12].• The stapler spring /Rr [6] always applies a rotational force to [7] on the stapler. However,

the stapler does not rotate because the height of the stapler guide roller [3] is restricted to the same height as the stapler rotational shaft by the rack mounting platform [4].

• When the stapler moves backward, the guide roller is pressed into the flute [5] on the rack mounting platform and the stapler rotates as much as the difference to the stapler rotation shaft /Rr [2] so that the stapler moves to the one-corner stapling position.

B. Stapler movement control(1) Size movement in 1 staple• Transmitting the FNS signal from the main body, the stapler movement motor turns ON to

widen the distance between the staplers. It stops when they are positioned at the speci-fied positions.

(2) 2 staples• The staplers do not move because the stapling operation is performed at the home posi-

tion.

[1] Stapler /Rr [7] Pressed by the spring

[2] Stapler rotation shaft /Rr [8] Stapler drive rack /Rr

[3] Guide roller [9] Stapler movement motor (M11)

[4] Rack mounting platform [10] Rotational direction at the one-corner stapling

[5] Flute [11] Stapler /Fr

[6] Stapler spring /Rr [12] Pinion gear

15jkt2c029na

[1] [2] [3] [4][11] [12]

[6][5]

[7][10] [8][9]

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9.2.2 Stapler control

• The stapling operation is performed by the stapler motors /Rr and /Fr.

A. Stapling operation• In the stapling operation, the stapler motors /Rr and /Fr [3] in the staplers /Rr and /Fr

drive the clincher side [2] to press the paper [1]. Then, the staple is pushed out from the stapler side [4] and bent at the clincher side.

[1] Paper [3] Stapler motors /Rr (M9) and /Fr (M14)

[2] Stapler (clincher side) [4] Stapler (stapler side)

15jkt2c027na

[1]

[4]

[2]

[3]

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B. Staple control(1) Stapling• After completing the alignment operation of the alignment plate, the stapler motors /Rr

and /Fr perform the stapling operation.• The stapling operation is completed when the stapler motor home sensors /Rr and /Fr in

the staplers /Rr and /Fr detect the home position and turn ON.

(2) Nip operation of stapler (FS-518 only)• When 60 or more sheets of paper are stapled, the staplers/Rr and /Fr perform the nip

operation to prevent paper bending. With 60 to 89 sheets, it is performed for every 5 sheets and with 90 to 100 sheets, it is performed for every single sheet.

(3) Clogged staple detection• During the stapling operation, it is determined that the staple has been clogged and the

stapler motors /Rr and /Fr turn OFF if the stapler motor home sensors /Rr and /Fr do not turn ON after a specified period of time since they turn OFF.

(4) Cartridge detection• The cartridge set switches /Rr and /Fr detect the presence of a cartridge or the incorrect

setting of a cartridge.• When no cartridge is set or it is set incorrectly, the main body displays the error message

on its display panel.

(5) Staple detection control• When the staples run out, the staple empty switches /Rr and /Fr turn ON and the main

body displays the error message on its display panel.

4

Theory of Operation Ver. 5.0 May 2008 10. Stapler (FS-608)

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10. Stapler (FS-608)

10.1 Drive

[1] Stapler movement motor (M11) [7] Stapler /Fr

[2] Upper side of the timing belt [8] Stapler movement home sensor (PS11)

[3] Clincher rotation motor (M4) [9] Stapler /Rr

[4] Clincher /Rr [10] Stapler rotation motor (M6)

[5] Clincher /Fr [11] Timing belt

[6] Lower side of the timing belt

15jmt2c014na

[6][5] [4] [3]

[2]

[1]

[11][10][2][9][8]

[7][6]

[4] [3]

[10][9]

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10.2 Operation

10.2.1 Stapler movement control

• The staplers move in the horizontal direction for adjusting their distance. The stapler at the rear also rotates. The movement is made according to the stapling mode.

A. Horizontal movement operation• The stapler movement motor [1] moves the staplers in the horizontal direction.• The stapler /Rr [8] and the clincher /Rr [3] are mounted at the top [2] of the timing belt [9]

and the stapler /Fr [6] and the clincher /Fr [4] are mounted at the bottom [5] of the timing belt.

• The stapler movement home sensor [7] detects the distance between the stapler and the clincher.

[1] Stapler movement motor (M11) [6] Stapler /Fr

[2] Upper side of the timing belt [7] Stapler movement home sensor (PS11)

[3] Clincher /Rr [8] Stapler /Rr

[4] Clincher /Fr [9] Timing belt

[5] Lower side of the timing belt

[5][4]

[3]

[2]

[1]

[9][2][8][7]

[6][5]

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B. Rotational movement operation• The stapler /Rr and the clincher /Rr rotate 45° for performing 1 staple/one-corner stapling

at rear.• The stapler rotation motor [10] rotates the stapler /Rr [9] and the clincher rotation motor

[5] rotates the clincher /Rr [7].• The ball rock mechanism that consists of the ball [1] and the spring [2] securely locks the

stapler and the clincher at 0° or 45°. • The illustrations [3] and [4] show the mechanism locked and unlocked respectively.

[1] Ball [6] Clincher rotation home sensor (PS14)

[2] Spring [7] Clincher /Rr

[3] Locked [8] Stapler rotation home sensor (PS13)

[4] Unlocked [9] Stapler /Rr

[5] Clincher rotation motor (M4) [10] Stapler rotation motor (M6)

[1]

[6]

[5]

[10]

[8]

[7]

[2]

[3] [4]

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C. Stapler movement control(1) Size movement in 1 staple/front and 2 staples• Transmitting the FNS signal from the main body, the stapler movement motor turns ON to

widen the distance between stapler and clincher. It stops when they are positioned at the specified positions.

• The stapler movement motor turns ON after a specified period of time since the finishing tray1 paper exit sensor detects the last paper. The stapler movement motor stops when the stapler movement home sensor turns ON.

(2) Size movement in 1 staple/one-corner stapling at rear• Transmitting the FNS signal from the main body [1], the stapler movement motor turns

ON to widen the distance between the stapler and the clincher [2].• The stapler rotation motor and the clincher rotation motor turn ON to rotate the stapler /

Rr and the clincher /Rr and move them diagonally [3] after a specified period of time since the stapler movement motor turns ON.

• The clincher rotation motor and the stapler rotation motor turn ON and rotate the stapler /Rr and the clincher /Rr to the home position [5] after a specified period of time since the trailing edge of the last paper passes the main tray paper exit sensor. The rotations are stopped when the stapler rotation home sensor and the clincher rotation home sensor turn ON. At the same time, the stapler movement motor turns ON [6], and it stops when the stapler movement home sensor turns ON.


[2]Stapler /Rr and clincher /Rr moving horizon-tally

[5]Stapler /Rr and clincher /Rr moving to the home position rotational

[3] Stapler /Rr and clincher /Rr rotating 45° [6]Stapler /Rr and clincher /Rr moving to the home position horizontally

[1] [5]

[6][2]

[4][3]

A07RT2E052AA

Stapler movement home sensor (PS11)

Stapler movement motor (M11)

Stapler rotation home sensor (PS13)

Stapler rotation motor (M6)

Clincher rotation home sensor (PS14)

CLOSE

OPEN

Forward

Reverse

Forward

Reverse

Clincher rotation motor (M4)


Clincher motor /Rr (M10)



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10.2.2 Stapler control

• The stapling operation is performed by the stapler motors /Rr and /Fr and the clincher motors /Rr and /Fr.

A. Stapling operation• In the stapling operation, the stapler motors /Rr and /Fr in the staplers /Rr and /Fr [6]

push out the paper press section [4] to the clinchers [2] by the cam mechanism [5] to hold the paper [1] and punch out the staples [3]. Then, the clincher motors /Rr and /Fr in the staplers /Rr and /Fr bend the staples.

[1] Paper [4] Paper press section

[2] Clincher [5] Cam mechanism

[3] Staple [6] Staplers /Rr and /Fr

[6][3]

[2]

[4]

[5]

[6] [1]

[2]

[3]

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B. Staple control(1) Stapling• After completing the alignment operation of the alignment plate, the stapler motors /Rr

and /Fr perform the stapling operation.• After a specified period of time, the clincher motors /Rr and /Fr bend the staples.• The stapling operation is completed when the clincher motor home sensors /Rr and /Fr

and the stapler motor home sensors /Rr and /Fr detect the home position and turn ON.

(2) Clogged staple detection• During the stapling operation, it is determined that the staple has been clogged and the

stapler motors /Rr and /Fr and the clincher motors /Rr and /Fr rotate in the reverse direc-tion to replace the staplers and the clinchers to the home positions if the stapler motor home sensors /Rr and /Fr and the clincher motor home sensors /Rr and /Fr do not turn ON after a specified period of time since they turn OFF.

(3) Cartridge detection• The cartridge set switches /Rr and /Fr detect the presence of a cartridge or the incorrect

setting of a cartridge.• When no cartridge is set or it is set incorrectly, the main body displays the error message

on its display panel.

(4) Staple detection control• When the staples run out, the staple empty switches /Rr and /Fr turn ON and the main

body displays the error message on its display panel.

Theory of Operation Ver. 5.0 May 2008 11. Folding/saddle stitching/tri-folding (FS-608)

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11. Folding/saddle stitching/tri-folding (FS-608)

11.1 Drive

[1] Folding knife [5] Tri-folding gate solenoid (SD6)

[2] Folding knife motor (M19) [6] Tri-folding gate

[3] Folding transfer motor (M20) [7] Folding roller

[4] Tri-folding roller

15jmt2c019na

[3]

[4]

[7][6]

[5][1]

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11.2 Operation

11.2.1 Folding knife control

• The folding knife motor drives the folding knife.• The folding knife is used in the folding/saddle stitching/tri-folding mode.• In the tri-folding mode, it is used at the 1st folding.

A. Folding knife operation• The folding knife motor rotates the crank shaft a half turn via the gear and pushes the

paper [2] to the nip section with the folding knife [5].• The folding rollers [4] draw and fold the paper.• The position of the saddle stitching stopper [6] controls the folding position.

B. Folding knife control• The folding knife motor turns ON and sticks out the folding knife to the paper after a spec-

ified period of time since the folding passage sensor [3] detects the paper and the saddle stitching stopper stops at the folding position.

• The folding knife motor stops when the folding knife reciprocates and the folding knife home sensor [1] turns OFF.

[1] Folding knife home sensor (PS22) [4] Folding roller

[2] Paper [5] Folding knife

[3] Folding pass-through sensor (PS26) [6] Saddle stitching stopper

[5][1]

[2]

[3][6]

[4]

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Theory of Operation Ver. 5.0 May 2008 11. Folding/saddle stitching/tri-folding (FS-608)

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11.2.2 Folding transfer control

• The folding transfer motor drives the folding roller.• Then, the folding roller drives the tri-folding roller.

A. Folding transfer control• The folding knife motor turns ON [2] after a specified period of time since the folding pas-

sage sensor detects the paper and the saddle stitching stopper stops at the folding posi-tion.

• When the folding knife motor turns ON the folding knife home sensor, the folding transfer motor turns ON [3] and drives the folding roller to perform the 1st folding and the tri-fold-ing roller to perform the 2nd folding at the tri-folding operation, and then it exits the paper to the finishing tray3.

• The folding transfer motor stops after a specified period of time since the folding paper exit sensor detects the trailing edge of the paper bundle.

B. Finishing tray3 full detection• The folding full sensor that consists of the LED light emitting section and the light receiv-

ing section detects the booklet tray paper full.• It determines the booklet tray is full if the exited paper shields the folding full sensor for

the specified period of time.

[1] Saddle stitching stopper moved [3] Paper fold

[2] Paper pressed to the folding roller by the folding knife

[4] Paper transferred

[5] Standby position of the folding knife

[2][1]

[5]

[3] [4]A07RT2E053AA

Folding pass-through sensor (PS26)


Folding knife home sensor (PS22)

Folding knife motor (M19)

Folding transfer motor (M20)


400 mm/s

80 mm/s

DOWN

UP

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11.2.3 Tri-folding gate control

• The tri-folding gate switches between the folding/saddle stitching path and the tri-folding path.

• The tri-folding gate solenoid drives the tri-folding gate.

A. Tri-folding 2nd folding operation• The tri-folding gate solenoid [5] drives the tri-folding gate [6] to switch the paper path to

the tri-folding path for leading the paper exited from the folding roller [1] to the tri-folding stopper [4].

• To perform the 2nd folding, the loop [2] formed when the paper contacts with the tri-fold-ing stopper are drawn between the folding roller and the tri-folding roller [3]. Then the paper is exited to the booklet tray [8].

• The position of the tri-folding stopper determines the folding position in the 2nd folding.

B. Tri-folding gate control• After the saddle stitching stopper stops at the tri-folding position, the tri-folding gate sole-

noid [5] turns ON and drive the tri-folding gate [6] to switch the paper path to the tri-fold-ing stopper.

• The tri-folding gate solenoid turns OFF after a specified period of time since the folding paper exit sensor [9] detects the trailing edge of the paper bundle.

[1] Folding roller [6] Tri-folding gate

[2] Loop [7] Paper

[3] Tri-folding roller [8] Finishing tray3

[4] Tri-folding stopper [9] Folding paper exit sensor (PS25)

[5] Tri-folding gate solenoid (SD6)

[6][5]

[2]

[3]

[8]

[4]

[7][9][1]

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[3]

SERVICE MANUAL

2007.08Ver. 2.0

THEORY OF OPERATION









11

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Theory of Operation Ver. 2.0 Aug. 2007

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CONTENTS

PI-503


2. Paper feed path....................................................................................................... 2

2.1 Auto sheet feeding (online operation) ................................................................... 2

2.2 Manual sheet feeding (offline operation) .............................................................. 2


4. Paper feed section................................................................................................... 4

4.1 Drive ..................................................................................................................... 4

4.1.1 Paper feed drive ............................................................................................ 4

4.1.2 Tray lift drive .................................................................................................. 5

4.2 Operation .............................................................................................................. 6

4.2.1 Tray lift mechanism ....................................................................................... 6

4.2.2 Pick-up mechanism....................................................................................... 7

4.2.3 Separation mechanism ................................................................................. 8

4.2.4 Registration control ....................................................................................... 9

4.2.5 Paper size detection control ........................................................................ 10

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Blank Page

Theory of Operation Ver. 2.0 Aug. 2007 1. Product specification

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B. Functions

C. Paper type

D. Machine specifications

E. Operating environment• Conforms to the operating environment of the main body.


Name Post inserter unit

Type Torque limiter separation type seat feeding device

Auto sheet feeding (online operation)

Feeds the sheet to finisher automatically under the instruction from the main body.

Manual sheet feeding (offline operation)

Feeds the sheet to finisher under the instruction from the operation panel of PI.You can select the following 5 post processing modes:• 1 staple/back mode• 2 staples (flat-stapling) mode• Punch mode (when PK-512/PK-513 is installed on finisher)• Saddle stitching mode (when installed on FS-608)• Tri-folding mode (when installed on FS-608)

Size Tray /Up A4/A4S, B5/B5S, A58 1/2 x 11, 8 1/2 x 11S, 5 1/2 x 8 1/2, 7 1/4 x 10 1/2S, 16K, 16KSCustom paper (Max. 311.1 x 297 mm, Min. 182 x 139 mm)

Tray /Lw A3, B4, A4/A4S, B5/B5S, A58 x 13S, 8 1/4 x 13S, 8 1/2 x 13S, 8 1/8 x 13 1/4S, 12 x 18, 11 x 17, 8 1/2 x 14, 8 1/2 x 11, 8 1/2 x 11S, 5 1/2 x 8 1/2, 8K, 16K, 16KS, 7 1/4 x 10 1/2, 7 1/4 x 10 1/2SCustom paper (Max. 311.1 x 457.2 mm, Min. 182 x 139 mm)

Type Plain paper, recycle paper, color paper, special paper, coated paper, high-quality paper

Weight 64 g/m2 to 209 g/m2

Capacity Tray /Up 200 sheets (80 g/m2) or 30 mm or less in height

Tray /Lw 200 sheets (80 g/m2) or 30 mm or less in height

Power requirements DC 24 V, DC 5 V (supplied from the main body)


30 W or less

Dimensions511 mm (W) x 635 mm (D) x 220 mm (H)20 inch (W) x 25 inch (D) x 8.75 inch (H)


1

2. Paper feed path Theory of Operation Ver. 2.0 Aug. 2007

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2. Paper feed path

2.1 Auto sheet feeding (online operation)

2.2 Manual sheet feeding (offline operation)

[1] Paper path from the tray /Up [2] Paper path from the tray /Lw

[1]

[2]15jft1c002na

[1] Paper path from the tray /Lw

[1]

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Theory of Operation Ver. 2.0 Aug. 2007 3. Composition

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Tray /Up section Pick-up /Up section

Separation /Up section

Transfer section

Separation /Lw sectionPick-up /Lw section

Tray /Lw section

4. Paper feed section Theory of Operation Ver. 2.0 Aug. 2007

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4. Paper feed section

4.1 Drive

4.1.1 Paper feed drive

[1] Pick-up roller /Lw [10] Paper feed roller /Lw

[2] Pick-up roller /Up [11] Transfer roller /Lw

[3] Pick-up solenoid /Up (SD201) [12] Separation roller /Lw

[4] Paper feed roller /Up [13] Pick-up solenoid /Lw (SD202)

[5] Transfer clutch /Up (CL201) [14] Transfer motor (M203)

[6] Separation roller /Up [15] Pick-up solenoid /Up, /Lw (SD201, SD202)

[7] Transfer clutch /Lw (CL202) [16] Front

[8] Transfer roller /Up [17] Pick-up roller /Up and /Lw

[9] Registration clutch (CL203) [18] Paper feed roller /Up and /Lw

[17]

[18]

15jft2c002na

[2][1] [3] [4]

[5]

[6]

[7]

[8]

[9]

[10]

[11][12][13]

[14]

[15]

[16]

Theory of Operation Ver. 2.0 Aug. 2007 4. Paper feed section

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4.1.2 Tray lift drive

[1] Front [3] Tray lift motor /Up (M201)

[2] Tray lift motor /Lw (M202)

[3]

[2]

[1]

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4.2 Operation

4.2.1 Tray lift mechanism

• The tray lift motors /Up and /Lw move up and down the trays /Up and /Lw by rotating in the forward and reverse direction to drive the lift arms /Up and /Lw and move up and down the lift plates /Up and /Lw, respectively.

• At the upper limit positions, the tray upper limit sensors /Up and /Lw detect the actuators lifted up by the lift plates.

• At the lower position of the tray, the tray lower limit sensors /Up and /Lw detect the actua-tors coupled with the lift arms /Up and /Lw.

[1] Tray upper limit sensor /Up (PS204) [6] Tray lift plate /Lw

[2] Tray lift motor /Up (M201) [7] Tray lift motor /Lw (M202)

[3] Tray upper limit sensor /Lw (PS209) [8] Tray lift plate /Up

[4] Lift arm /Lw [9] Tray lower limit sensor /Up (PS205)

[5] Tray lower limit sensor /Lw (PS210) [10] Lift arm /Up

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[2]

[3]

[4][5]

[6]

[7]

[8][9] [10]


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4.2.2 Pick-up mechanism

• The pick-up solenoids /Up and /Lw turn ON to pick up the paper.• The release arm held upward by the spring lifts up the pick-up roller mounting plate to

release the pick-up roller.• When the pick-up solenoids /Up and /Lw turn ON, the release arm moves backward, and

then the pick-up roller mounting plate and the pick-up roller fall down by their own weight.• The pick-up roller driven by the transfer motor presses the paper and picks it up to trans-

fer it to the separation section.

[1] Spring [4] Pick-up roller mounting plate

[2] Pick-up solenoid /Up (SD201) [5] Release arm

[3] Pick-up roller

[4] [5]

[1]

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4.2.3 Separation mechanism

• The separation roller is driven to rotate in the opposite direction from the paper transfer direction. When transferring no or 1 sheet of paper, the separation roller rotates in the paper transfer direction to transfer the paper to the paper transfer section because the frictional force between the paper feed roller or the paper and the separation roller is stronger than the frictional force of the torque limiter.

• When transferring 2 or more sheets of paper, the separation roller rotates in the reverse direction to prevent the bottom sheet from being transferred because the frictional force between the sheets is stronger than the frictional force of the torque limiter.

[1] Paper feed roller [5] 2nd sheet

[2] Paper transfer direction [6] 1st sheet

[3] Torque limiter [7] Pick-up roller

[4] Separation roller

[1]

[2]

[3][4]

[5]

[6][7]

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4.2.4 Registration control

• Transmitting the FS start signal, the transfer motor rotates in low speed and the pick-up solenoids /UP and /Lw turn ON. At the time, the tray lift motors /Up and /Lw rotate in the forward direction to lift up the trays /Up and /Lw.

• The tray lift motors /Up and /Lw stop when the tray upper limit sensors /Up and /Lw turn ON, and after a specified period of time, the transfer clutchs /Up and /Lw turn ON and the paper is picked up from the tray. Only 1 sheet of paper is transferred by the transfer roller because of the separation roller.

• The transfer motor rotates in high speed when the paper reaches the paper entrance sensors /Up and /Lw. At the time, the paper is pressed against the transfer roller and forms a loop because the registration clutch is OFF. After a specified period of time, the registration clutch turns ON and the transfer motor drives the paper to FS.

• The transfer motor switches to rotate in low speed to feed the subsequent paper since the paper passed the paper entrance sensors /Up and /Lw, and then the registration clutch turns OFF after a specified period of time.

[1] FS start signal turned ON [4] Registration clutch (CL203) turned ON

[2] Tray reached at the upper limit [5] Trailing edge of the paper passed the paper entrance sensors /Up (PS201) and /Lw (PS206)[3]

Paper reached the paper entrance sensors /Up (PS201) and /Lw (PS206)

15jft2c007nb[1] [2] [4][3] [5]


Transfer clutch /Lw (CL202)

Tray lift motor /Lw (M202)

Tray upper limit sensor /Lw (PS209)

Pick-up solenoid /Lw (SD202)

Paper entrance sensor /Lw (PS206)

Registration clutch (CL203)

253 mm/s

670 mm/s


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4.2.5 Paper size detection control

• The paper size VRs /Up and /Lw coupled with the side guide detects the paper size in the main scan direction.

• The paper set sensors /Up and /Lw and the L size sensor /Lw detects the paper size in the sub scan direction.

[1] Paper size VR /Up (VR201) [4] Paper set sensor /Lw (PS208)

[2] Side guide plate [5] Paper set sensor /Up (PS203)

[3] Paper size VR /Lw (VR202) [6] L size sensor (PS212)

[1]

[2][6]

[5] [4] [3]15jft2c008na

SERVICE MANUAL

2007.02Ver. 1.0

THEORY OF OPERATION









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Theory of Operation Ver. 1.0 Feb. 2007

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CONTENTS

PK-512/513


2. Unit composition...................................................................................................... 2

3. Paper path............................................................................................................... 3

Composition/Operation4. Punch section.......................................................................................................... 5

4.1 Composition.......................................................................................................... 5

4.2 Drive ..................................................................................................................... 6

4.2.1 Punch shift drive ........................................................................................... 6

4.2.2 Punch drive ................................................................................................... 7

4.2.3 PK-513 .......................................................................................................... 9

4.3 Operation ............................................................................................................ 10

4.3.1 Punch standby position movement control ................................................. 10

4.3.2 Punch position correction control ................................................................ 11

4.3.3 Punch control .............................................................................................. 12

5. Punch scraps box section ..................................................................................... 16

5.1 Composition........................................................................................................ 16

5.2 Drive ................................................................................................................... 16

5.3 Operation ............................................................................................................ 16

5.3.1 Punch scraps box control............................................................................ 16

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Blank Page

Theory of Operation Ver. 1.0 Feb. 2007 1. Product specifications

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Outline1. Product specificationsA. Type

B. Functions

C. Paper type

D. Machine specifications

E. Operating environment• Conforms to the operating environment of the main body.


Name Punch unit

Type FS-integrated type punching operation device

Punching method Stops and punches every paper

No. of holesPK-512 2-3 holes / 2-4 holes

PK-513 4 holes

Hole diameter φ 8.0 mm (2-3 holes), φ 6.5 mm (2-4 holes)

Supported mode Punch mode, through mode

Applicable post processing mode

Sort, group, staple

Size

2 hole punch setting:A3, B4, A4/A4S, B5/B5S, A5/A5S8 x 13, 8 1/4 x 13, 8 1/2 x 13, 8 1/8 x 13 1/4, 11 x 17, 8 1/2 x 14,

8 1/2 x 11/8 1/2 x 11S, 5 1/2 x 8 1/2S, 8K, 16K/16KS

7 1/4 x 10 1/2, 7 1/4 x 10 1/2S

3 hole/4 hole punch setting:A3, B4, A4, B511 x 17, 8 1/2 x 11, 7 1/4 x 10 1/2, 8K, 16K

Supported paperPlain paper, bond paper, colored paper, coated paper (Main unit specifications prioritized)

Weight 64 to 128 g/m2

Punch prohibited paperLabel paper, tab paper, transparency film, 2nd base paper, holed paper, and the other paper that may interfere with the operation of the punch unit or the punch blade.

Power requirementsDC 24 V (supplied from the main body)


Max. power consumption 40 W or less

Dimensions130 mm (W) x 470 mm (D) x 115 mm (H)5 inch (W) x 18.5 inch (D) x 4.5 inch (H)


2. Unit composition Theory of Operation Ver. 1.0 Feb. 2007

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2. Unit composition

A04ET1C001AA

Punch section

Punch scraps box section

Theory of Operation Ver. 1.0 Feb. 2007 3. Paper path

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3. Paper path

[1] Punch unit [3] Punch scraps box

[2] Paper path from the main body

A04ET1C002AA

[3]

[1][2]

3. Paper path Theory of Operation Ver. 1.0 Feb. 2007

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Blank Page

Theory of Operation Ver. 1.0 Feb. 2007 4. Punch section

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Composition/Operation4. Punch section

4.1 Composition

A04ET2C003AA

Punch blade

Punch blade

Punch unitPaper size detect board (PSDTB)

Entrance roller

4. Punch section Theory of Operation Ver. 1.0 Feb. 2007

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4.2 Drive

4.2.1 Punch shift drive

[1] Punch unit [5] Punch shift motor (M302)

[2] Guide shaft [6] Rack

[3] Belt [7] Punch shift home sensor (PS303)

[4] Front

A04ET2C004AA

[2][3][5]

[4]

[6] [7] [1]


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4.2.2 Punch drive

A. PK-512 (2 to 3 holes)

[1] Punch motor (M301) [8] Groove of the switching cam

[2] Eccentric cam [9] Projection of the punch blade

[3] Slide link [10] Projection of the switching cam

[4] Switching cam [11] Punch blade

[5] When the punch blade is driven [12] Punch blade of the 3-hole punch

[6] When the punch blade is not driven [13] Punch blade of the 2-hole punch

[7] Switching cam shaft

[3]

[3] [1]

[4][7][6] [5]

[8]

[9][10] [11]

[13][12]

[2]

[2]

[1]

[3]

[3]

[4][7][5] [6]

[8]

[9]

[10] [11]

A04F2TE001AA


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B. PK-512 (2 to 4 holes)

[1] Punch motor (M301) [8] Groove of the switching cam

[2] Eccentric cam [9] Projection of the punch blade

[3] Slide link [10] Projection of the switching cam

[4] Switching cam [11] Punch blade

[5] When the punch blade is driven [12] Punch blade of the 4-hole punch

[6] When the punch blade is not driven [13] Punch blade of the 2-hole punch

[7] Switching cam shaft

A04F2TE002AA

[3]

[3]

[3] [1]

[4][7][6] [5]

[8]

[9][10] [11]

[3]

[4][7][5] [5]

[8]

[9][10] [11]

[13][12]

[2]

[2]

[1]


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4.2.3 PK-513

[1] Eccentric cam [3] Punch blade

[2] Drive arm [4] Punch motor (M301)

[4]

[1]

[2]

[3]

A04ET2C005AA


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4.3 Operation

4.3.1 Punch standby position movement control

Turning ON the device, the punch shift motor rotates to move the punch unit [6] to the home position until the punch shift home sensor turns ON.Selecting the punch mode, the punch shift motor rotates to move the punch unit [6] so that the paper size detect board [1] of the punch unit [6] is positioned 5 mm inward [2] from the side edge of the paper.The paper size detect board consists of five sensors. Each sensor detects the following paper.

* The sensors are numbered 1 to 5 from the front side

And, when the stand-by position is 5 mm for B5 and B4 paper sizes, the corner of the paper passes through below the punch hole and the stand-by position is changed to 1.5 mm to prevent the hitching of the paper.The punch unit returns to the home position at the end of the job.

NOTE• In the model PK-512, the paper size detect board is positioned on the front side

and its operation is contrary to that in the above illustration on the right and left sides.

Sensor Paper size

1 A5S, 5 1/2 x 8 1/2S

2 B5S, 16KS

3 A4S, A5, 8 1/2 x 11S, 8 1/2 x 14S, 5 1/2 x 8 1/2, 8 1/2 x 13, 8 1/4 x 13, 8 1/8 x 13 1/4, 8 x 13

4 B4, B5, 8K, 16K

5 A3, A4, 11 x 17, 8 1/2 x 11

[1] Paper size detect board (PSDTB) [4] Paper

[2] Moving distance from the paper edge [5] Punch blade

[3] Paper transfer direction [6] Punch unit

[4]

[3]

[1][6][5][2]

A04ET2C006AA


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4.3.2 Punch position correction control

For the punch unit positioned from the side edge of the paper to the inside, the punch posi-tion is adjusted in the following procedure so that punching is made symmetrically to the center of paper at all times. The punch position correction is operated by moving the punch unit back and forth while conveying the paper.• When the FNS entrance sensor detects the leading edge of the paper, the punch unit

[11] is moved to the rear side until the paper size detect board [2] detects the side edge of the paper.Then, the punch unit [11] is moved to the front side until the paper size detect board [2] detects the side edge of the paper (the side edge reference position detection).

• Once it detects the side edge reference position [3], the punch unit is moved further [11] so that the center of the punch blade [1] is positioned to the center of the paper [5]. The moving distance and its direction are depending on the paper size. It is stopped tempo-rarily at the side edge reference position if it is moved to the rear side.

NOTE• In the model PK-512, the paper size detect board is positioned on the front side

and its operation is contrary to that in the above illustration on the right and left sides.

[1] Center of the punch blade [7] Punch unit moving direction

[2] Paper size detect board (PSDTB) [8] Rear side

[3] Side edge reference position [9] Front side

[4] Paper [10] Punch blade

[5] Center of the paper [11] Punch unit

[6] Paper transfer direction

A04ET2C007AA[5]

[9] [8]

[7]

[6]

[4]

[3]

[2][1][11][10]


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4.3.3 Punch control

A. Registration loop controlThe FNS conveyance motor turns OFF temporarily to stop conveyance of paper when the specified time has passed since paper exit sensor detected the leading edge of the paper. Thus the paper is pressed against the entrance roller forming a loop to correct the bend. When the specified time has passed, FNS transfer motor turns ON to restart conveying the paper.The above operation is not performed when conveying a large paper (220 mm and longer in the sub scan direction) and in the non-punching mode.

[1] Entrance roller [3] PK

[2] Loop

[1]

[2]

[1][3]

A04ET2C008AA


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B. Punch control (PK-512)The FNS transfer motor is driven by the main body start signal.In the punching mode, the motor the FNS transfer motor stops temporarily after the FNS entrance sensor detects the rear edge of paper. At the same time, the punch motor [3] rotates in the direction according to the number of punched holes. Number of punched holes of PK-512 is switched between 2 to 4 and 2 to 3 holes depending on the country. The motor the punch motor drives the slide link in the main scanning direction through the eccentric cam. As a result, the projection of the switching cam is pushed in the slide link moving direction and the switching cam is rotated around its axis. And then the punching blade [7] lowers to punch a hole. The projection of the punch blade is fitted into the groove of the switching cam.Moving distance of the slide link [5] is controlled by detecting the eccentric cam actuator [4] with the punch home sensor [1]. When the actuator rotates 180 degrees, first punching is completed. In the second punching, the punch motor is reversed. When the actuator reverses 180 degrees, punching is completed. Forward and reverse rotations are repeated alternately.The rotating speed of the punch motor is controlled by detecting the rotation of the punch encoder plate [6] fixed to the axis of the punch motor with the punch encoder sensor [2].Then, the punch motor reverses and the punch home sensor [1] returns to ON and the The punch motor stops finally.When a specified time elapsed after the FNS transfer motor stops temporarily, the FNS transfer motor resumes rotating and paper is transferred.

[1] Punch home sensor (PS301) [7] Punching blade

[2] Punch encoder sensor (PS306) [8] Operation of 3-hole punching in the 2 to 3 hole

[3] Punch motor (M301) mode and 4-hole punching in the 2 to 4 hole mode

[4] Actuator [9] Operation of 2-hole punching in the 2 to 3 hole

[5] Slide link mode and 2-hole punching in the 2 to 4 hole mode

[6] Punch encoder plate

A04F2TE003AA

[1]

[2]

[3]

[4][5]

[7] [6]

[1]

[1]

[9]

[8]


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(1) 2 to 3 holes modeIn the 2 to 3 punched hole mode, the groove of the switching cam of the 3-hole punching blade is shaped so that the rear side is concentric with the rotating axis and the front side is curved toward the rotating axis. For this reason, when the switching cam is rotated clock-wise, the punching blade is driven downward and when the cam is rotated counterclock-wise, the punching blade is not driven. The shape of the groove of the punching blade for 2 holes is contrary to it on the right and left sides. When the switching cam is rotated counter-clockwise, the punching blade is driven.

(2) 2 to 4 holes modeIn the 2 to 4 holes mode, the 2 punching blades at both ends are driven only when the switching cam is rotated clockwise in the same way as in the 2 to 3 hole mode. As the 2 punching blades at the center should be driven in both cases of 2 or 4 hole punching, shape of the groove of the switching cam is symmetrical on the right and left sides and both the front and rear sides are curved in the rotating axis direction.


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C. Punch control (PK-513)Transmitting the start signal from the main body, the FNS conveyance motor rotates.In the punch mode, M1 stops temporarily a specified period of time after the FNS entrance sensor detects the trailing edge of the paper.At the same time, the punch motor [9] drives the shaft [10] to rotate a full circle. The eccen-tric cams [2] rotate in sync with the shaft to move down the punch blade [1] to conduct the punch operation. The punch motor stops and the punch operation is completed when the punch home sensor [3] turns ON.The punch motor rotates again to convey the paper a specified period of time after it stops temporarily.

[1] Punch blade [6] Paper

[2] Eccentric cam [7] Punch blade at the upper position

[3] Punch home sensor (PS301) [8] Front side

[4] Punch blade at the lower position [9] Punch motor (M301)

[5] Drive arm [10] Shaft

[3]

[1]

[2][10]

[9]

[8]

[7] [4]

[2]

[5]

[1]

[6]

[2]

A04ET2C009AA

5. Punch scraps box section Theory of Operation Ver. 1.0 Feb. 2007

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5. Punch scraps box section

5.1 Composition

5.2 Drive

• The punch scraps box section comprises no moving parts.

5.3 Operation

5.3.1 Punch scraps box control

A. Punch scraps box full detectionThe punch scraps generated by the punch operation falls in the punch scraps box [3]. The punch scraps box full sensor [1] turns ON and transmits the “no punch scraps box” informa-tion to the main body when the punch scraps box becomes full of punch scraps.

B. Punch scraps box detectionThe punch scraps box set sensor detects whether the punch scraps box is set or not. The scraps box set sensor turns OFF and transmits the “no punch scraps box” information to the main body if the punch scraps box is not set.

A04ET2C010AA

Scraps box full sensor (PS302)

Punch scraps box

Front side

Scraps box set sensor (PS304)

SERVICE MANUAL

2007.08Ver. 2.0

THEORY OF OPERATION









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CONTENTS

FS-519/PK-510/OT-602


1.1 FS-519.................................................................................................................. 1

1.2 PK-510.................................................................................................................. 4

1.3 OT-602 .................................................................................................................. 5

2. Paper feed path....................................................................................................... 7

2.1 Feeding paper to the 1st exit tray ......................................................................... 7

2.2 Feeding paper to the 2nd exit tray ........................................................................ 7

2.3 Feeding paper to the 2nd exit tray (When OT-602 is mounted) ............................ 8


4. Drive...................................................................................................................... 10

5. Operations............................................................................................................. 11

5.1 Transport section ................................................................................................ 11

5.1.1 Entrance/transport section .......................................................................... 12

5.1.2 Intermediate transport section .................................................................... 12

5.1.3 Storage section ........................................................................................... 13

5.1.4 Exit transport section .................................................................................. 13

5.2 Elevator section .................................................................................................. 14

5.2.1 Elevator mechanism.................................................................................... 14

5.2.2 Elevator tray ascent/descent ....................................................................... 14

5.2.3 Tray position detection mechanism ............................................................. 15

5.2.4 Shutter open/close mechanism................................................................... 18

5.3 Paper aligning section ........................................................................................ 19

5.3.1 Paper aligning mechanism (sub scan direction) ......................................... 19

5.3.2 Paper aligning mechanism (main scan direction) ....................................... 20

5.3.3 Exit mechanism........................................................................................... 21

5.4 Staple section ..................................................................................................... 23

5.4.1 Stapling mechanism.................................................................................... 23

5.4.2 Stapling unit moving mechanism ................................................................ 24

5.4.3 Stapling position.......................................................................................... 24

5.4.4 Staple sheet empty detection...................................................................... 25

6. Punch Kit (PK-510) ............................................................................................... 26

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6.1 Composition ....................................................................................................... 26

6.2 Operation............................................................................................................ 26

6.2.1 Skew correction mechanism....................................................................... 26

6.2.2 Punch mechanism ...................................................................................... 27

6.2.3 Punch status detection ............................................................................... 27

6.2.4 Punch trash box full detection mechanism ................................................. 28

7. Output tray (OT-602) ............................................................................................. 29

7.1 Composition ....................................................................................................... 29

7.2 Operation............................................................................................................ 29

7.2.1 Overview ..................................................................................................... 29

Theory of Operation Ver. 2.0 Aug. 2007 1. Product specifications

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02Outline

1. Product specifications

1.1 FS-519

A. Type

B. Functions

C. Paper type(1) Non sort/sort/group

*: Long size paper is available only for non-sort mode.

Name Multi staple finisher built into the copier

Installation Installed in the copier


Consumables Staples

ModesSort, group, sort offset, group offset, sort stable, and punch (when PK-510 is mounted)

Type Size Weight Max. capacity

Plain paperRecycled paper

A6S, A5S/A5, B5S/B5, B6S, A4S/A4, B4, A3, A3Wide5 1/2 x 8 1/2S/5 1/2 x 8 1/2, 8 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17, 12 1/4 x 18

Max.311.15 mm x 457.2 mm12.25 x 18 inchMin. 90 mm x 139.7 mm3.5 x 5.5 inch

64 to 90 g/m2

17 to 24 lb

Exit tray1

200 sheets

Exit tray2

A4S, 8 1/2 x 11Sor less

1000 sheets

B4, 8 1/2 x 14or greater

500sheets

Government standardpostcards

91 to 210 g/m2

24.25 to 55.75 lb

20 sheets

Envelope —

OHP transpar-encies

—

Translucentpaper

—

Label —

Letterhead —

Thick paper 191 to 120 g/m2

24.25 to 32 lb

Thick paper 1+121 to 157 g/m2

32.25 to 41.75 lb


42 to 55.5 lb


55.75 to 68 lb


68.25 to 79.75 lb

Long size paper *

210 mm to 297 mm x 457.2 mm to 1200 mm

127 to 160 g/m2

33.75 to 42.5 lb—

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02 (2) Sort offset/group offset

(3) Sort staple

*: The number of sheets to be stapled is limited for high-density images.(Color wise: 20 sheets x 20 sets)

(4) Punch

*: The punched holes is different because of the difference of area.



A5, B5S/B5, A4S/A4, B4, A38 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17Max. 297 mm x 431.8 mm11.75 x 17 inchMin. 182 mm x 148.5 mm7.25 x 5.75 inch

64 to 90 g/m2

17 to 24 lb

Exit tray1

200 sheets

Exit tray2


1000 sheets


500sheets

Thick paper91 to 300 g/m2

24.25 to 79.75 lb—

1


No. of sheets to be

stapled


A5, B5S/B5, A4S/A4, B4, A38 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17Max. 297 mm x 431.8 mm11.75 x 17 inchMin. 182 mm x 148.5 mm7.25 x 5.75 inch

64 to 90 g/m2

17 to 24 lb

Exit tray1

200 sheets

50sheets*Exit

tray2


1000 sheets


500sheets

Thick paper 1

91 to 209 g/m2

24.25 to 55.5 lb

—30

sheets

Thick paper 1+ —15

sheets

Thick paper 2 —15

sheets

1

Type Size Weight Punched holes Exit tray


B5S/B5 to A38 1/2 x 11S/8 1/2 x 11 to

11 x 17

64 to 209 g/m2

17 to 55.5 lb2, 3, 4 *

Exit tray1Exit tray2OT-602MT-502

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02D. Stapling

E. Hole Punch

F. Machine specifications

G. Operating environment• Conforms to the operating environment of the main unit.

Staple filling mode Dedicated staple cartridge (5000 staples)

Staple detection Available (Nearly Empty: 20 remaining staples)

Stapling position

Back of the corner (30 degree) A4, A3, B5, B48 1/2 x 11, 11 x 17Front of the corner (30 degree)

Back of the corner (Parallel) A4S, B5S, A58 1/2 x 11S, 8 1/2 x 14Front of the corner (Parallel)

Side: Parallel 2 pointA4S/A4, A3, B5S/B5, B4, A58 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17

Manual staple None

No. of holes Metric: 4 holes, Inch: 2 holes/3 holes, Sweden: 4 holes

Punch dust full detection Available

Power requirementsDC 24 V (supplied from the main unit)

DC 5.1 V (generated by finisher)

Max. power consumption 66 W or less

Dimensions352 mm (W) x 558 mm (D) x 589 mm (H)13.75 inch (W) x 22 inch (D) x 23.2 inch (H)


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02 1.2 PK-510

A. Type

B. Machine specifications

C. Operating environment• Conforms to the operating environment of the main unit.

Name Punch kit PK-510

Installation Built into the finisher

Paper size

Metric B5S, A4, B4, A3

Inch (2 holes) 8 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17

Inch (3 holes) 8 1/2 x 11, 11 x 17

Sweden B5S, A4, B4, A3

Paper type Plain Paper, Recycled paper (64 to 209 g/m2, 17 to 55.5 lb)

Punch hole Metric: 2 holes, 4 holes, Inch: 2/3 hole, Sweden: 4 holes

Number of stored punch wastes

Metric (2 holes): For 2,500 sheets of paper (64 g/m2)Metric (4 holes): For 1,500 sheets of paper (80 g/m2)Inch (2/3 holes): For 1,000 sheets of paper (75 g/m2)Sweden (4 holes): For 1,500 sheets of paper (80 g/m2)


1

Power requirements Supplied by the finisher

Dimensions114 mm (W) x 461 mm (D) x 106 mm (H)4.5 inch (W) x 18.25 inch (D) x 4.25 inch (H)

Weight Approx. 1.9 kg (4.25 lb) or less


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021.3 OT-602

A. Type

B. Paper type

Name Output tray OT-602

Installation Fixed to the finisher

ModeSort, group, and sort stableSort, group, sort offset, group offset, and sort stable

Number of bins 1 bin


Mode Size Type Capacity

Sort/group

A6S, A5S/A5, B5S/B5, B6S, A4S/A4, B4, A3, A3Wide5 1/2 x 8 1/2S/5 1/2 x 8 1/2, 8 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17

Max.311.15 mm x 457.2 mm12.25 x 18 inchMin. 90 mm x 139.7 mm3.5 x 5.5 inch

Plain Paper 64 to 90 g/m2,

17 to 24 lb200 sheets(up to a height of 24 mm)Recycled

paper

Special

Government standardpostcards

20 sheets

Envelope

OHP transparencies

Translucentpaper

Label

Letterhead

Thick paper 1

91 to 120 g/m2

24.25 to 32 lb

Thick paper 1+

121 to 157 g/m2

32.25 to 41.75 lb

Thick paper 2

158 to 209 g/m2

42 to 55.5 lb

Thick paper 3

210 to 256 g/m2

55.75 to 68 lb

Thick paper 4

257 to 300 g/m2

68.25 to 79.75 lb

Sort offset/ group off-set

A5, B5S/B5, A4S/A4, B4, A38 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17

Max.297 mm x 431.8 mm11.75 x 17 inchMin.182 mm x 148.5 mm7.25 x 5.75 inch


17 to 24 lb200 sheets(up to a height of 24 mm)Recycled

paper

Thick paper

91 to 300 g/m2

24.25 to 79.75 lb—

Sort stable


17 to 24 lb200 sheets or 20 copies (up to a height of 24 mm)Recycled

paper

Thick paper

91 to 209 g/m2

24.25 to 55.5 lb—

1

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02 C. Machine specifications

D. Operating environment• Conforms to the operating environment of the main unit.

NOTEHow product names appear in the document• FS-519: Finisher• PK-510: Punch kit• OT-602: Output tray

Dimensions282 mm (W) x 368 mm (D) x 57 mm (H)11 inch (W) x 14.5 inch (D) x 2.25 inch (H)


Theory of Operation Ver. 2.0 Aug. 2007 2. Paper feed path

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022. Paper feed path

2.1 Feeding paper to the 1st exit tray

2.2 Feeding paper to the 2nd exit tray

9J08T1C106AA

Feeding paper to the 1st exit trayTransporting paper from the main body

Transporting paper to the 1st exit tray

9J08T1C107AA

Feeding paper to the 2nd exit tray

Transporting paper from the main body

Transporting paper to the 2nd exit tray

2. Paper feed path Theory of Operation Ver. 2.0 Aug. 2007

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02 2.3 Feeding paper to the 2nd exit tray (When OT-602 is mounted)

9J08T1C108AA

Feeding paper to the 2nd exit tray

Transporting paper from the main body

Transporting paper to the 2nd exit tray


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02Composition/Operation

3. Composition

9J08T1C100AA

Entrance transport section/Intermediate transport section

Staple section

Elevator section

Storage section/Exit transport section

Entrance switch section

4. Drive Theory of Operation Ver. 2.0 Aug. 2007

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4. Drive

9J08T2C201AA

FS-519

PK-510

Horizontal transport drive section

Elevator drive section

Theory of Operation Ver. 2.0 Aug. 2007 5. Operations

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025. Operations

5.1 Transport section

• The transport section is divided into the entrance transport section, intermediate trans-port section, storage section, and the exit transport section. It controls to transport the paper fed from the main body, stop the paper at the punching and creasing positions, and drive the paper for feeding into the exit section.

9J08T2C202AA

Entrance transport section

Intermediate transport section

Exit transport section

Storage section

5. Operations Theory of Operation Ver. 2.0 Aug. 2007

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5.1.1 Entrance/transport section

• The paper fed from the main body is transported to the intermediate transport section.• The entrance motor provides the drive for transporting the paper.• When the entrance motor is energized, the entrance transport roller is driven to rotate.• When the skew registration clutch is energized, the registration roller is driven to rotate.• The entrance sensor detects the paper in the transport section.

5.1.2 Intermediate transport section

• The paper transported from the entrance transport section is brought to a stop at the punching and creasing position. The paper is also transported to the storage section.

• Drive for the intermediate transport section is provided by the transport motor/1. Drive of the transport roller 1 is controlled.

• The entrance sensor detects paper in the intermediate transport section.

9J08T2C004DA

Paper

Entrance motor (M1)Entrance sensor (PS1)

Entrance transport roller

Registration roller

Skew registration clutch (CL1)

9J08T2C005DA

Transport motor/1 (M2) Entrance sensor (PS1)

Paper

Transport roller 1


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025.1.3 Storage section

• The paper transported from the intermediate transport section is transported to the stor-age section.

• Drive for the storage section is provided by the transport motor/2. Drive of the transport roller 2 and storage roller are controlled.

• The entrance sensor and transport sensor detects paper in the storage section.

5.1.4 Exit transport section

• The paper transported from the storage section is transported onto each of the exit trays.• The exit motor provides drive for the exit roller, storage paddle, and exit paddle.

9J08T2C006DA

Transport roller 2

Transport motor/2 (M3)

Transport sensor (PS2)

Storage roller

Paper

9J08T2C203AA

Exit roller motor (M10)

Exit motor (M4)

Exit roller Storage paddle

Exit paddle

Paper


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5.2 Elevator section

5.2.1 Elevator mechanism

• The elevator mechanism is operated to select a specific exit port, thereby feeding the paper out onto a specific exit tray.

5.2.2 Elevator tray ascent/descent

• The elevator tray is moved up or down by the elevator motor that turns forward or back-ward to drive the front and rear belts.

• The elevator tray lower limit sensor detects the elevator tray at its lower limit position.• Elevator tray switch is mounted for preventing the elevator tray’s overrun for both upper

and lower parts.• The shutter is mounted for preventing the hand from being caught at the exit when the

tray moves up and down.• The shutter detect switch is mounted for preventing the hand from being caught when the

shutter opens or closes.

4349T2C508AA

Elevator motor (M11)

4349T2C515AA

Elevator tray switch (SW3)

Elevator tray lower limit sensor (PS13)


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025.2.3 Tray position detection mechanism

• The tray moves up or down according to the amount of paper fed onto it.• If the elevator top face detection sensor is activated when a sheet of paper is fed onto the

tray, the elevator tray is temporarily lowered until the elevator top face detection sensor is deactivated and then the tray is raised to a level, at which the elevator tray.

• Elevator top face detection sensor is activated again. This is done when each time a sheet of paper is fed onto the tray to keep the same height at all times for the elevator top face detection sensor of the paper on the tray.

4349T2C512AA

Elevator top face detection sensor (PS12)


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A. Tray position detection• Tray position detection is controlled according to the number of times the elevator tray

home position sensor is activated after the elevator tray lower limit sensor has been acti-vated.

(1) Tray position detection operation1. During the initial operation sequence, the elevator tray is subjected to a descent

motion until the elevator tray lower limit sensor is activated.

2. After the elevator tray lower limit sensor has been activated, the elevator tray is subjected to an ascent motion.

3. When the elevator tray home position sensor is activated a first time after the ascent motion of the elevator tray has been started, it is determined that the eleva-tor tray is now located at the exit port for the 1st exit tray.

Elevator tray home position sensor (PS11)

Elevator tray lower limit sensor (PS13)

4349T2C514AA

Elevator tray home position sensor (PS11)


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024. When the elevator tray home position sensor is activated a second time after the

ascent motion of the elevator tray has been started, it is determined that the eleva-tor tray is now located at the exit port for the 2nd exit tray.

5. Drive is stopped when the elevator top face detection sensor is activated with the home position sensor of the target tray in the activated position.

* If an additional OT-601 tray is installed, the additional tray is at the exit port when the position sensor is activated twice and the 2nd tray is at the exit port when the home posi-tion sensor is activated three times.

B. Paper full detection• When the elevator tray home position sensor changes from the activated to deactivated

state with the elevator top face detection sensor in the activated state, a paper full condi-tion is detected and the corresponding message will appear on the control panel.

• The shutter is closed to cover the exit while the elevator tray is moving.• The elevator motor provides the drive for the elevator tray.• The shutter motor opens or closes the exit port.


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5.2.4 Shutter open/close mechanism

• The shutter at the exit is open with the opening for exit being disclosed. When the tray moves, the shutter closes to prevent the hand from being caught at the exit.

• The shutter is opened or closed by the shutter motor that turns a gear train for raising or lowering the shutter.

• The shutter home position sensor detects the position of the gear, thereby determining the position of the shutter.

• The shutter detection switch is mounted to prevent the hand from being caught when the shutter opens and closes. Pressing the shutter detection switch will stop the shutter’s opening or closing operation as well as tray’s up or down movement.

9J08T2C008DA

Shutter detect switch (SW2)

Shutter home position sensor (PS14)

Shutter


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025.3 Paper aligning section

5.3.1 Paper aligning mechanism (sub scan direction)

• Sheets of paper are aligned properly and stapled together inside the transport section before being fed out onto the corresponding exit tray.

• In the sort, group copy, staple, or center crease/center staple mode, each copy set is stored in the storage tray with the upper exit roller separated from the lower exit roller.

• The storage tray detect sensor detects paper in the storage tray.• The storage paddle and aligning belt are driven when the exit motor is rotated in reverse.

A. Operation1. The paper fed out from the main body is held downward by the drop lever and

dropped down into the storage tray by the stepped roller.2. The paper dropped into the storage tray is pressed against the stopper by the pad-

dle and aligning belt so that it is aligned properly in the sub scan direction.

4349T2C528AB 4349T2C517AB

9J08T2C009DA

Storage paddle

Aligning belt

Storage tray detecting sensor (PS3)

Stepped roller

Paper stopper

Aligning belt

Storage paddle

Exit motor (M4)

Drop lever


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5.3.2 Paper aligning mechanism (main scan direction)

• Aligning plates are moved and the paddle is rotated so as to align the paper at the sta-pling position.

• The paper in the storage tray is aligned in the main scan direction by two align motors and aligning plates.

A. Aligning plates• The aligning plates are moved to the front or rear in accordance with the paper size.• The alignment home position sensor controls the position of each aligning plate.

B. Paper aligning sequence• In normal print and staple mode, the paper is fed into the tray at its center position.• If no stapling is involved in the sort or group copy mode, the aligning plate shifts 15 mm

to the front or rear from the center. This stacks copy sets/stacks in a saw tooth manner, each being offset by about 30 mm with respect to the others.This shifting motion is not performed when sets/stacks are fed into the mail bins or the saddle unit.

9J08T2C010DA

Paper stoppers

Align motor/1 (M5)

Align motor/2 (M6)

Alignment home position sensor /1 (PS7)

Alignment home position sensor /2 (PS8)

Aligning platePaper aligning portion

4349T2C511AA

Center

approx. 30 mm

Normal/Staple Shift (sort/group copy)

Aligning plate


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025.3.3 Exit mechanism

• There is a paper holding paddle provided at the exit roller for preventing the copy set/stack on the exit tray from being pushed by a new copy set/stack that is being fed out (Except the staple mode).

• The subsequent copy set/stack is fed out with the copy sets/stacks previously resident on the tray being held down by the paper holding paddle.

• The exit paddle home position sensor, spring clutch, and exit paddle solenoid control the retracted position and paper holding position of the paper holding paddle.

9J08T2C011DB

Exit paddle solenoid (SD2)

Exit paddle home position sensor (PS6)

Paper holding paddle9J08T1C102AA


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A. Upper exit roller up/down motion mechanism• The exit roller motor moves the upper exit roller away from the lower exit roller or presses

the upper exit roller up against the lower exit roller.• When one copy set/stack is stored in the storage tray, the upper exit roller is moved

downward to be pressed up against the lower exit roller and the two rollers feed the copy set/stack out onto the exit tray.The exit roller home position sensor detects the position of the upper exit roller, whether it is in the raised or lowered position.

9J08T2C205AA

9J08T2C206AA9J08T2C207AA

Exit roller motor (M10)

Exit roller home position sensor (PS5)

Blocked (pressed) Unblocked (separated)


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025.4 Staple section

5.4.1 Stapling mechanism

• Stapling is performed by the stapling unit.• When the stapling motor is rotated, the clinch arm lowers. The stapler thereafter goes up

to drive a staple in the paper.• Five different types of stapling are available: parallel front one point, parallel rear one

point, slant front one point, slant rear one point and parallel two points.

9J08T2C012DA

Clinch arm

Stapling motor

Stapling unit


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5.4.2 Stapling unit moving mechanism

• The stapling unit is moved by the stapling unit moving motor.• The stapling unit moving motor drives the belt so that the stapling unit is moved to the

corresponding stapling position.• The stapling stop position is controlled by the period of time during which the stapling

unit moving motor is kept energized, as counted from the time when the staple home position sensor has been activated.

• The stapler unit will move to the stapler save position during the saddle mode.(The stapler unit needs to be in the save since the moving part of the holding section shifts from horizontal to 20 degrees angles during the saddle mode.)

• The stapler save position is detected by the stapler save position sensor.

5.4.3 Stapling position

• A single stapling unit is moved to perform 2-point stapling.

9J08T2C013DA

Staple home position sensor (PS9)

Stapling unit moving motor (M7)

Stapling unit

Home position

Staple change position

Stapler save position sensor (PS10)

Save position

4349T2C523AA

Parallel one point staplingSlant one point stapling

Parallel two points stapling

<Typical stapling positions>


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025.4.4 Staple sheet empty detection

• Staple empty detection sensor 1, 2 detect whether or not there is a staple sheet still left.• When the number of staples left in the staple cartridge becomes about 20, a staple sheet

empty condition results, causing a corresponding empty message to appear on the con-trol panel.

• When the empty condition is detected, the corresponding empty indication is given on the control panel. At the same time, the Stapling Unit moves to the front.

• When a new staple cartridge is loaded, the stapling motor is energized until the self-priming sensor detects a staple, which results in the staple to be fed up to the stapling position.

Staple empty detection sensor1,2

Self-priming sensor1, 2

4643M021AB

6. Punch Kit (PK-510) Theory of Operation Ver. 2.0 Aug. 2007

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6. Punch Kit (PK-510)

6.1 Composition

6.2 Operation

6.2.1 Skew correction mechanism

• For punch and center crease operations, a loop is formed in the paper at the registration roller to correct skew.

• The entrance sensor detects the leading edge of the paper and the registration roller forms a loop in the paper.

• The skew registration clutch is then energized after a given period of time after the entrance sensor is activated by the leading edge of the paper, this causes the registra-tion roller to start turning.

4512T2C001DA

4512T2C002DA

Registration roller

Entrance sensor (PS1)

Theory of Operation Ver. 2.0 Aug. 2007 6. Punch Kit (PK-510)

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026.2.2 Punch mechanism

• The entrance sensor will detect the back edge of the paper, and stop feeding the paper at the specified time. The puncher will move down to make the punch hole at the back edge of the paper. (The punch hole will be made sheet by sheet.)

• The drive cam will be rotated by the punch motor inside the punch unit to move the slide cam back and forth. The slide cam will move the puncher down to make the punch holes.

6.2.3 Punch status detection

• The punch status is detected by using the punch cam sensor, punch home position sen-sor, and the punch motor pulse sensor.

4349T2C525AA


Puncher

Punch motor (M99)

Slide cam

Paper feed direction

4349T2C526AA

Punch cam sensor (PS500)

Punch motor pulse sensor (PS502)

Punch home position sensor (PS501)

6. Punch Kit (PK-510) Theory of Operation Ver. 2.0 Aug. 2007

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6.2.4 Punch trash box full detection mechanism

• Punch trash produced as a result of punching operation is stored in the punch trash box.• The punch trash box is provided with the punch trash full sensor. When a punch waste is

detected, the corresponding message is displayed on the control panel.• The punch trash full sensor is a reflector type sensor that detects height of the punch

trash.• Punch trash full sensor also detects whether or not the punch dust box is mounted.

“Punch dust full” message will be displayed on the control panel when the punch trash box is not mounted.

4349T2C527AA

Punch trash full sensor (PS503)

Theory of Operation Ver. 2.0 Aug. 2007 7. Output tray (OT-602)

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027. Output tray (OT-602)

7.1 Composition

7.2 Operation

7.2.1 Overview

• Mounting the optional output tray (OT-602) provides a total of three exit trays.• The output tray is attached at different positions depending on whether options MT-502/

SD-505 are mounted or not.The capacity of each of the different trays depends on the specific positions they are attached.

• When the short-circuit connector shipped with the output tray is mounted, the machine determines that the output tray has been mounted.

4349T2C531AA

4349T2C530AAFS-519 Only When MT-502/SD-505 is Installed

200 sheet

200 sheet

200 sheet

200 sheet

200 sheet

500 sheet

7. Output tray (OT-602) Theory of Operation Ver. 2.0 Aug. 2007

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SERVICE MANUAL

2007.08Ver. 2.0

THEORY OF OPERATION









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CONTENTS

MT-502


2. Paper path............................................................................................................... 2


4. Drive........................................................................................................................ 4

5. Operations............................................................................................................... 5

5.1 Paper transport mechanism.................................................................................. 5

5.2 Paper path selection mechanism.......................................................................... 6

5.3 Paper detection..................................................................................................... 7

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B. Machine specifications

C. Operating environment• Conforms to the operating environment of the main unit.


Name Mailbin kit

Installation Install at the top section of the finisher elevator tray.

Number of bins 4 bins

Number of sheets stored per bin 125 sheets (Total 500 sheets) (90 g/m2, 24 lb)

Storable paperPlain paper

64 to 90 g/m2 (17 to 24 lb)Recycled paper

Storable paper sizeMetric area A5S, B5, A4

Inch area 5 1/2 x 8 1/2S, 8 1/2 x 11

1

Power requirementsDC 24 V (Supplied from the finisher)DC 5 V (Generated inside the mail bin)

Dimensions340 mm (W) x 509 mm (D) x 387 mm (H)13.5 inch (W) x 20 inch (D) x 15.25 inch (H)

Weight 8 kg (17.75 lb)

2. Paper path Theory of Operation Ver. 2.0 Aug. 2007

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2. Paper path

4510T2C501AA


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4510T1C600AA


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4. Drive

4510T2C502AAExit rollers

Transport rollers



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5. Operations

5.1 Paper transport mechanism

• When the mailbin is selected as the exit source, paper is fed off from the finisher (FS-519) and toward the mailbin.

• Drive for the transport rollers of the mailbin is transmitted from the transport motor by way of a belt.

• As each of the transport rollers is driven, paper fed off from the finisher is transported into the mailbin.

4510T2C503AA

Transport rollers



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5.2 Paper path selection mechanism

• The bin entrance switching solenoids are energized or deenergized to direct paper fed from the finisher into a specific tray.

• There are three bin entrance switching solenoids provided that will be energized or deen-ergized to operate the corresponding bin entrance gate, thereby selecting a specific paper path into a specific tray.

4510T2C504AA

Bin entrance gate

Bin entrance switching solenoid


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5.3 Paper detection

• The paper detection sensor detects any sheet of paper that is fed into the tray.• As the paper stacks up and eventually deactivates the paper full detecting sensor, at

which time a paper full condition is detected.

4510T2C505AA

Paper full detection sensor

Paper detection sensor


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SERVICE MANUAL

2007.08Ver. 2.0

THEORY OF OPERATION









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CONTENTS

SD-505


2. Paper path............................................................................................................... 2


4. Drive........................................................................................................................ 4

4.1 Center creasing section ........................................................................................ 4

4.2 Center stapling section ......................................................................................... 4

5. Operations............................................................................................................... 5

5.1 Paper transport mechanism.................................................................................. 5

5.2 Exit roller pressure/release................................................................................... 6

5.2.1 Pressure/release mechanism ....................................................................... 6

5.2.2 Operation ...................................................................................................... 7

5.3 Stapling mechanism ............................................................................................. 8

5.4 Layable guide........................................................................................................ 9

5.4.1 Layable guide mechanism............................................................................. 9

5.4.2 Operation timing............................................................................................ 9

5.5 Center creasing mechanism............................................................................... 10

5.5.1 Operation .................................................................................................... 11

5.6 In & out guide ..................................................................................................... 12

5.6.1 In & out guide mechanism .......................................................................... 12

5.7 Tray paper detection ........................................................................................... 13

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B. Paper type

C. Machine specifications

*1: Size when the paper output tray is pulled out

D. Operating environment• Conforms to the operating environment of the main unit.

E. Consumables• Staples 2000 (MS-2C) x 2


Name Saddle sticher SD-505

Type Built into the finisher

Installation Screwed to the finisher


Stapling functionCenter parallel two pointsNo. of sheets to be stapled together: 2 to 15

Type

Plain paper 64 g/m2 to 90 g/m2

17 to 24 lbRecycled paper

Thick paper91 g/m2 to 209 g/m2

24.25 to 55.5 lb

SizeB5S to A38 1/2 x 11S to 11 x 17

Capacity 200 sheets or 20 copies

1

Power requirementsDC 24 V (supplied from the finisher)DC 5 V

Max. power consumption 9.5 W or less

Dimensions

Crease unit48 mm (W) x 399 mm (D) x 121 mm (H)2 inch (W) x 15.75 inch (D) x 4.75 inch (H)

Saddle unit

445 mm (W) x 478 mm (D) x 203 mm (H)17.5 inch (W) x 18.75 inch (D) x 8 inch (H)576 mm (W) x 478 mm (D) x 281 mm (H) *122.75 inch (W) x 18.75 inch (D) x 11 inch (H) *1

WeightCrease unit 1.9 kg (0.5 lb)

Saddle unit 7.4 kg (2.0 lb)


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2. Paper path

4511T2C504AA


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4511T1C600AA

Center stapling section

Center creasing section


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4. Drive

4.1 Center creasing section

4.2 Center stapling section

4511T2C001DA

Crease roller

Crease chopper

Crease motor (M10)

4511T2002DA

Upper exit roller

Saddle exit open/close motor (M9)

Saddle exit motor (M8)


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5. Operations

5.1 Paper transport mechanism

• Paper is transported by the exit rollers of the finisher and exit rollers of the saddle kit.• The saddle exit motor provides the drive for the exit rollers of the saddle kit.• If a center stapling operation is made with a copy set/stack (that has been creased at the

center or is to be stapled at the center) stored in the storage tray, the copy set/stack is transported to the center stapling position, through a pulse control of the exit roller of the finisher.

• The copy set/stack is thereafter fed out by the exit rollers of the saddle kit.

4511T2C502AA

4511T2C003DA

Exit rollers of the saddle kit

Exit rollers of the finisher


Saddle exit motor (M8)

Lower exit roller of the saddle kit


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5.2 Exit roller pressure/release

5.2.1 Pressure/release mechanism

• The upper exit roller is moved away from, or pressed up against, the lower exit roller, when the paper is fed out as a copy set/stack.

• The saddle exit roller home position sensor is used to control the pressure/release posi-tion of the upper exit roller.

4511T2C004DA

4511T1C601AASaddle exit roller home position sensor (PS18)

Upper exit roller

Lower exit roller


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5.2.2 Operation

1. The upper exit roller is moved up or down by the cams which are driven by the sad-dle exit open/close motor.

2. When the copy set/stack moves past the exit roller, the motor is energized to press the upper exit roller up against the lower exit roller, thereby feeding the copy set/stack out into the tray.

4511T2C005DA


Upper exit roller

Cam

Cam

Cams are rotated The upper exit roller is moved upward(retraction)

Cams are rotated. + The upper exit roller is moved downward (pressing)

Cam

Upper exit roller


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5.3 Stapling mechanism

• There are two the stapling units in the saddle kit, each being fixed to a specific position.• Since the unit is for center stapling only, it is made up of the upper clincher portion and

the lower stapling portion. The copy set/stack moves through the space between the upper and lower portions of the staplers.

• When stapling, the clincher portion moves downward to perform the stapling operation.

4511T2C508AA

Clincher unit

Stapling unit

Clincher


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5.4 Layable guide

• The movable guide is used to guide the leading edge of the first sheet of paper when the first sheet of paper is stored, thereby preventing the leading edge from contacting the stapling unit and curving.

5.4.1 Layable guide mechanism

• The layable guide motor turns the cams at the front and rear, thereby moving the layable guide up or down.

• The layable guide home sensor detects the position of the layable guide motor.

5.4.2 Operation timing

1. Raising the movable guide(power ON, sleep cancelled, error reset, paper removed from tray)

2. Lowering the movable guide(When the transport of a copy set/stack to the center stapling position is com-pleted)

3. Raising the movable guide(When the trailing edge of a copy set/stack deactivates the saddle exit sensor)

4511T2C006DA

Layable guide motor (M14)

Layable guide home sensor (PS24) Cam


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5.5 Center creasing mechanism

• The entrance sensor detects the trailing edge of the paper.• The paper feed amount is determined for each paper size as counted from the timing

when the trailing edge is detected. Center creasing is effected as follows. Specifically, the paper undergoes a switchback operation and is transported to the center creasing posi-tion as the motor is turned backward.

• The crease chopper is lowered and the center of the paper is pinched between the crease rollers and this creates a crease in the paper.

• After the center creasing, the paper is transported by the transport roller and then the registration roller as they are driven in that order.

4511T2C510AA

Crease motor (M10)

Crease chopper

Crease roller home position sensor (PS22)

Transport roller Registration roller


Crease chopper

Transport sensor (PS2)


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5.5.1 Operation

• When the crease motor is energized for one cycle of operation, the lower transport guides are retracted to the right and left and the crease chopper makes one up-and-down reciprocating motion. In synchronism with the sequence of these operations, the crease roller turns one complete turn to pull the paper downward at its center.

• At the same time that the lower transport guides returns to their original position, the crease chopper goes up.

• The position of the crease chopper is detected by the crease roller home position sensor.

4511T2C008DA

Crease chopper

Crease roller

Crease roller home position sensor (PS22)

Crease roller


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5.6 In & out guide

• When the papers are discharged to the tray, the in and out guide keeps the front edge of the large size paper so the discharged paper will not be pushed at its back edge by the following discharged paper.

• The guide operates only when holding the paper which size is 257 mm or over (B4 or over).

• The in & out guide advances when the entrance sensor of the finisher is deactivated and retracts when the trailing edge of the paper leaves the saddle exit sensor.

5.6.1 In & out guide mechanism

• The in & out guide motor drives the in & out guide.• The position of the in and out sensor will be detected by the in and out guide home sen-

sor.

4511T2C009DA

In & out guideIn & out guide

In & out guide motor (M13)

In & out guide home sensor (PS23)


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5.7 Tray paper detection

• When paper is fed onto the tray, it pushes the actuator, which causes the paper detection sensor to detect the paper.

4511T2C010DA

Saddle tray empty sensor (PS21)


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SERVICE MANUAL

2007.08Ver. 1.0

THEORY OF OPERATION









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CONTENTS

JS-504


2. Paper path............................................................................................................... 3

2.1 Exit to the Upper tray ............................................................................................ 3

2.2 Exit to the Lower tray ............................................................................................ 3

Construction and operation3. Construction ............................................................................................................ 5

4. Drive........................................................................................................................ 6

5. Operation ................................................................................................................ 7

5.1 Transport/exit section............................................................................................ 7

5.1.1 Paper transport ............................................................................................. 7

5.1.2 Transport path switching ............................................................................... 8

5.1.3 Full-of-paper detecting mechanism............................................................. 12

5.2 Paper shift section .............................................................................................. 13

5.2.1 Paper shift mechanism................................................................................ 13

5.2.2 Shift operation overview.............................................................................. 14

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B. Functions

C. Paper

Type Built-in type 2-bin stacker

Installation Installed in main body

Document align-ment

Center

Modes Sort, group, sort offset, group offset

Exit tray Size Type Capacity

Upper tray

A5S, B5S/B5, A4S/A4, B4, A38-1/2 X 11S/8-1/2 X 11, 8-1/2 X 14, 11 X 17Max.: 297 mm X 431.8 mm11.75 inch X 17 inchMin.: 148 mm X 210 mm5.75 inch X 8.25 inch

Plain paper (64 to 90 g/m2)(17 to 24 lb)

50 sheets

Lower tray

A6S, A5S/A5, B6S, B5S/B5, A4S/A4, B4, A3, A3 Wide, Post card S5-1/2 X 8-1/2S/5-1/2 X 8-1/2, 8-1/2 X 11S/8-1/2 X 11, 8-1/2 X 14, 11 X 17, 12-1/4 X 18Max.: 311.1 mm X 1200 mm12.25 inch X 47.25 inchMin.: 90 mm X 139.7 mm3.5 inch X 5.5 inch

Plain paper (64 to 90 g/m2)(17 to 24 lb)

150 sheets

Special paper

Thick paper 1 (91 to 120 g/m2)(24.25 to 32 lb)

20 sheets

Thick paper 1 +(121 to 157 g/m2)(32.25 to 41.75 lb)

Thick paper 2 (158 to 209 g/m2)

(42 to 55.5 lb)

Thick paper 3 (210 to 256 g/m2)(55.75 to 68 lb)

Thick paper 4 (257 to 300 g/m2)(68.25 to 72.75 lb)

OHP film

Post card

Label

Envelope 10 sheets

Long size paper 1 sheet

1. Product specification Theory of Operation Ver. 1.0 Aug. 2007

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D. Offset function

E. Machine specifications

*1: Size when the paper exit tray is pulled out

F. Operating environment• Conforms to the operating environment of the main body.


Exit tray Lower tray

Shift amount 30 mm

Types of paper to be used

Plain paper, Thick paper 1/1+/2/3/4

SizeB5S/B5, A4S/A4, B4, A38-1/2 X 11S/8-1/2 X 11, 8-1/2 X 14, 11 X 17

Power require-ments

DC 24 V ± 10 % (supplied from the main body)

DC5 V ± 5 %

Max. power con-sumption

40 W or less

Dimensions

431 mm (W) X 540 mm (D) X 131 mm (H)17 inch (W) X 21.25 inch (D) X 5.15 inch (H)543 mm (W) X 477 mm (D) X 129.5 mm (H) *122 inch (W) X 21.25 inch (D) X 5.15 inch (H) *1

Weight 5.0 kg (11 lb)

Theory of Operation Ver. 1.0 Aug. 2007 2. Paper path

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2. Paper path

2.1 Exit to the Upper tray

2.2 Exit to the Lower tray

A0D5T1C101AA

A0D5T1C102AA


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Theory of Operation Ver. 1.0 Aug. 2007 3. Construction

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Construction and operation3. Construction

A0D5T2C101AA

Lower tray

Upper trayTransport path switching mechanism

Paper shift mechanism

A0D5T2C112AA

A0D5T2C113AA

Upper tray exit sensor (PS2)

Lower tray exit sensor (PS1)

Route change home sensor(PS4)

Shift home sensor (PS6)

Front door sensor (PS3)


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4. Drive

A0D5T2C102AA

Upper tray exit roller

Lower tray exit roller

JS control board (JSCB)


Retraction motor (M3)

Shift motor (M2)

Theory of Operation Ver. 1.0 Aug. 2007 5. Operation

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5. Operation

5.1 Transport/exit section

5.1.1 Paper transport

• The transport motor is energized a predetermined period of time after the paper has acti-vated the paper exit sensor of the copier.

• Drive of the transport motor rotates the exit roller, so that paper is transported into the corresponding tray.

A0D5T2C103AA

Lower tray exit roller

Upper tray exit rollerTransport motor (M1)

5. Operation Theory of Operation Ver. 1.0 Aug. 2007

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5.1.2 Transport path switching

A. Overview• The paper path switching guide adequately switches the paper transport path to ensure

that the paper is transported properly into the upper or lower tray as necessary.• The output tray is determined according to the setting made in Output Tray Setting of

Administrator Setting and options of finishing, paper type, and paper size as selected for copy job setup.

Output tray Output Tray Setting Finishing Paper type Paper size

Upper tray Set to upper tray –Plain paper,

Recycled paper–

Lower tray Set to lower tray SortPlain paper,

Recycled paper,Special paper

A3wide, A5A6S, B6S

A0D5T2C106AA

Feeding from main body

Paper path switching guideUpper tray

Lower tray


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B. Operation• Drive from the route change motor moves the paper path switching guide up or down to

select the output tray for the paper.• The route change home sensor detects the position of the paper path switching guide.

Output tray Guide moving direction Route change home sensor

Upper tray Guide swung down Unblocked

Lower tray Guide swung up Blocked

A0D5T2C105AA

Paper path switching guide

Guide swung down(to feed paper into upper tray)

Guide swung up (to feed paper into lower tray)

A0D5T2C104AA

Route change home sensor (PS4)

Cam

Route change motor (M3)



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(1) Predrive• The route change motor is energized to move the paper path switching guide into a posi-

tion for feeding paper into the lower tray when the copier is turned ON or released from the sleep mode, or a malfunction is reset.

(2) Paper exit into the upper tray• The route change home sensor is used to determine the position, at which the paper

path switching guide is stopped, so that the motion of the switching guide can be con-trolled as necessary.

• Control for feeding paper into upper tray - paper path switching guide moved, feeding out two sheets of paper

Route change home sensor

Paper path switching guide stop position

Control details

Unblocked Paper fed into upper tray Not applicable

Blocked Paper fed into lower trayThe route change motor is energized to move the paper path switching guide into the position, at which paper is fed into the upper tray.

A0D5T2C108AABefore switching After switching


[1] 1st sheet of paper activating exit sensor of copier

[5] 2nd sheet of paper activating exit sensor of copier

[2] Drive of route change motor started [6] 2nd sheet of paper reaching upper tray

[3] Drive of transport motor started [7] 2nd sheet of paper fed out, transport motor deenergized

[4] 1st sheet of paper reaching upper tray

[7][6][5][4][3][2][1]A0D5T2C119AA

Exit sensor at copier


Shift motor (M2)


Lower exit sensor (PS1)

Upper exit sensor (PS2)




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(3) Paper exit into the lower tray• The route change home sensor is used to determine the position, at which the paper

path switching guide is stopped, so that the motion of the switching guide can be con-trolled as necessary.

• Control for feeding paper into lower tray - paper path switching guide not moved, feeding out two sheets of paper

Route change home sensor

Paper path switching guide stop position

Control details

Unblocked Paper fed into upper trayThe route change motor is energized to move the paper path switching guide into the position, at which paper is fed into the lower tray.

Blocked Paper fed into lower tray Not applicable

A0D5T2C107AABefore switching After switching



[4] 2nd sheet of paper activating exit sensor of copier

[2] Drive of route change motor started [5] 2nd sheet of paper reaching lower tray

[3] 1st sheet of paper reaching lower tray [6] 2nd sheet of paper fed out, transport motor deenergized

[5] [6][4][3][2][1]A0D5T2C110AA



Shift motor (M2)







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5.1.3 Full-of-paper detecting mechanism

• Each tray is mounted with a tray paper full detect board that detects a full-of-paper condi-tion of the tray.

• The tray paper full detect board consists of a light emitter (LED) and a photoreceiver that are paired up to serve for each tray. The system determines that the tray is in a full-of-paper condition when paper blocks the LED light.

• When a full-of-paper condition is detected, the copier feeds paper being printed out and then stops, with a corresponding message shown on the control panel.

• A stack of 150 sheets of plain paper (lower tray) is detected as a full-of-paper condition, excluding curled paper.

A083T2C514AA

Lower tray paper full detect board/LED (T1FDTB/LED)

Upper tray paper full detect board/LED (T2FDTB/LED)

Upper tray paper full detect board/PR (T2FDTB/PR)

Lower tray paper full detect board/PR (T1FDTB/PR)


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5.2 Paper shift section

5.2.1 Paper shift mechanism

• The shift section is shifted forward during paper exit so that print jobs can be offset, one job from another.

• The shift section is moved by drive supplied from the shift motor.• The shift operation is executed when the sort function is used by the user.

A083T2C513AA

Shift motor (M2)Shift home sensor (PS6)

Shift sectionFront RearLower tray exit roller

Shift direction


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5.2.2 Shift operation overview

• The shift motor is energized to slide the shift section in a forward direction at a predeter-mined timing during paper exit into the lower tray after the trailing edge of the paper has moved past the exit roller of the copier.

• The position of the shift section is controlled as detailed below.

• After the current sheet of paper has been fed out at the shift position, the shift section is returned to its home position before the next sheet of paper reaches the lower tray exit roller.

Shift section position Position control Shift home sensor

Home position – rearward Shift home sensor output Blocked

Shift position – forward Shift motor speed (number of pulses) (Unblocked)

A083T2C520AA

Home position Shift position

Shift sectionPaper

Shift home sensor

Shift motor


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• 1st sheet of paper fed out normally with the 2nd sheet of paper fed out at shift position


[5] 2nd sheet of paper reaching lower tray

[2] Drive of transport motor started [6] Shift operation for 2nd sheet of paper started

[3] 1st sheet of paper reaching lower tray [7] 2nd sheet of paper fed out at shift position

[4] 1st sheet of paper fed out at normally posi-tion

Shift section returned to its home position

[6] [7][5][4][3][2][1]A0D5T2C111AA

Forward rotationBackward rotation



Shift motor (M2)







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© 2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.© 2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Printed in JapanPrinted in JapanDDA00J-M-TE8DDA00J-M-TE8

Use of this manual should be strictly supervised toavoid disclosure of confidential information.Use of this manual should be strictly supervised toavoid disclosure of confidential information.

bizhub_c650_c550_c451_fe4_theory_of_operation_dda00j-m-te8.pdf

Documents

service manual2008

s notice

firmware card

important warning items

safety warnings