konica minolta bizhub 163, 211, 220 theory of operation service manual

5/28/2018 KONICA MINOLTA BizHub 163, 211, 220 Theory of Operation Service Manual

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SERVICE MANUAL

2007.04

Ver. 1.0

THEORY OF OPERATION



Revision history

After publication of this service manual, the parts and mechanism may be subject to change for

improvement 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 be

issued with a revision mark added as required.

Revision mark:

To indicate clearly a section revised, show to the left of the revised section.

A number within represents the number of times the revision has been made.

To indicate clearly a section revised, show in the lower outside section of the correspond-

ing page.


NOTE

Revision 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.

1

1

1

1

2007/04 1.0 Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision



bizhub163/211/220

Outline

Composition/Operation

Theory of Operation Ver. 1.0 Apr. 2007

i

CONTENTS

bizhub 163/211/220 main body

Outline

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

2. Product specification ............................................................................................... 3

2.1 Fax kit (FK-506): (Option) ..................................................................................... 6

3. Cross sectional view................................................................................................ 7

4. Paper path...............................................................................................................8

5. Copy process .......................................................................................................... 9


6. Overall configuration ............................................................................................. 11

6.1 Timing Chart at Power ON..................................................................................11

6.2 Control Block Diagram........................................................................................12

7. Scanner (IR).......................................................................................................... 13

7.1 Composition........................................................................................................ 13

7.2 Drive ................................................................................................................... 14

7.3 Operation............................................................................................................ 15

7.3.1 Scanner Moving Mechanism/Control .......................................................... 15

7.3.2 Original Size Detection ...............................................................................16

7.3.3 Determination of Original Size .................................................................... 17

7.3.4 For Metric, China and Latin America (Metric) areas ................................... 20

8. PH (Writing section) .............................................................................................. 21

8.1 Composition........................................................................................................ 21

8.2 Drive ................................................................................................................... 22

9. Imaging unit........................................................................................................... 23

9.1 Construction ....................................................................................................... 239.2 Operation............................................................................................................ 24

10. PC Drum ............................................................................................................... 25

10.1 Composition........................................................................................................ 25

10.2 Drive ................................................................................................................... 25

10.3 Operation............................................................................................................ 26

10.3.1 Grounding of the PC Drum .........................................................................27

11. PC Drum charging................................................................................................. 28

11.1 Composition........................................................................................................ 2811.2 Operation............................................................................................................ 28

12. Developing ............................................................................................................ 29



bizhub163/211/220

Outline



ii

12.1 Composition ....................................................................................................... 29

12.2 Drive ................................................................................................................... 29

12.3 Operation............................................................................................................ 30

12.3.1 Developing Roller........................................................................................ 30

12.3.2 Developing Bias.......................................................................................... 30

12.3.3 TCR Sensor ................................................................................................ 31

12.3.4 TCR Sensor Automatic Adjustment............................................................ 31

13. Toner replenishing................................................................................................. 32

13.1 Composition ....................................................................................................... 32

13.2 Drive ................................................................................................................... 32

13.3 Operation............................................................................................................ 33

13.3.1 Toner Replenishing Mechanism.................................................................. 33

13.4 Toner Replenishing Control ................................................................................ 34

13.4.1 T/C Recovery Mode.................................................................................... 35

13.4.2 Toner Bottle Home Position Detection ........................................................ 36

14. Image transfer and paper separation section........................................................ 37

14.1 Composition ....................................................................................................... 37

14.2 Drive ................................................................................................................... 37

14.3 Operation............................................................................................................ 38

14.3.1 Image Transfer Section............................................................................... 38

14.3.2 Paper Separation Section........................................................................... 38

15. Toner recovery ...................................................................................................... 39

15.1 Composition ....................................................................................................... 39

15.2 Drive ................................................................................................................... 39

15.3 Operation............................................................................................................ 40

16. Paper feed............................................................................................................. 41

16.1 Composition ....................................................................................................... 41

16.2 Drive ................................................................................................................... 42

16.3 Operation............................................................................................................ 43

16.3.1 Paper Separating Mechanism..................................................................... 43

16.3.2 Drawer in Position Detection....................................................................... 43

16.3.3 Paper Empty Detection Mechanism............................................................ 44

16.3.4 Paper Lifting Plate....................................................................................... 44

16.3.5 Universal Tray Paper Size Detection Mechanism ....................................... 45

16.3.6 ON/OFF Positions of Paper Size Detecting Switches and

Corresponding Paper Size Detected .......................................................... 46

16.3.7 Paper feed Control...................................................................................... 47

16.3.8 Paper feed Retry Control ............................................................................ 47

17. Manual bypass section.......................................................................................... 48



bizhub163/211/220

Outline



iii

17.1 Composition........................................................................................................ 48

17.2 Drive ................................................................................................................... 48

17.3 Operation............................................................................................................ 49

17.3.1 Paper Detection Mechanism....................................................................... 49

17.3.2 Manual Feed Take Up Control..................................................................... 50

18. Registration roller section...................................................................................... 5118.1 Composition........................................................................................................ 51

18.2 Drive ................................................................................................................... 51

18.3 Operation............................................................................................................ 52

18.3.1 Paper Dust Remover................................................................................... 52

19. Fusing unit section ................................................................................................ 53

19.1 Composition (for bizhub 163).............................................................................. 53

19.2 Composition (for bizhub 211/220)....................................................................... 54

19.3 Drive ................................................................................................................... 5519.4 Operation............................................................................................................ 55

19.4.1 Fusing Roller Pressure Mechanism............................................................ 55

19.4.2 Fusing Temperature Control (for bizhub 163) .............................................56

19.4.3 Fusing Temperature Control (for bizhub 211/220) ...................................... 57

19.4.4 PPM Control (bizhub 163 Only) ..................................................................58

20. Paper exit (for bizhub 163) .................................................................................... 59

20.1 Composition........................................................................................................ 59

20.2 Drive ................................................................................................................... 59

21. Paper exit (for bizhub 210/220) .............................................................................60

21.1 Construction ....................................................................................................... 60

21.2 Operation............................................................................................................ 60

22. Image stabilization system .................................................................................... 61

22.1 Composition........................................................................................................ 61

23. Others ................................................................................................................... 62

23.1 Fan Control .........................................................................................................62

23.1.1 Composition ................................................................................................62

23.1.2 Operation .................................................................................................... 63



bizhub163/211/220

Outline



iv

Blank Page



Theory of Operation Ver. 1.0 Apr. 2007 1. System configuration

1

bizhub163/211/220

Outline

Outline

1. System configuration

1/2 System front view

*1: The standard bizhub 220 configuration is the main body plus 1-drawer paper feed unit.

*2: Standard only on the bizhub 163 and bizhub 211/220 for china

*3: To be mountable only on bizhub 211/220*4: Standard only the main body for china (but separately packaged upon shipment from

factory)

*5: Standard only on bizhub 220 (but separately packaged upon shipment from factory)

[1] bizhub 163/211/220 *1 [8] Paper feed unit (PF-502)

[2] Original cover (OC-504) *2 [9] Desk (DK-703)

[3] Automatic document feeder (DF-502) [10] Desk (DK-702)

[4] Reverse automatic document feeder(DF-605) *3

[11] Desk (DK-701)

[5] Shift tray (SF-501) [12] Job separator (JS-503)

[6] Automatic duplex unit (AD-504) *3 *5 [13] Key counter mount kit 1

(previous models for minolta.)

Key counter mount kit 2

(previous models for konica)

[7] Multi bypass tray (MB-501) *4 [14] Mechanical counter (MC-503)

A08EE501AA

[2]

[1]

[12]

[13]

[14]

[3] [4]

[5]

[6]

[7]

[8]

[9]

[10]

[11]



1. System configuration Theory of Operation Ver. 1.0 Apr. 2007

2

bizhub163/211/220

Outline

2/2 System rear view

* It is not possible to mount these units at the same time.

[1] Expanded memory unit (EM-103) [3] Image controller (IC-206) *

[2] Fax kit (FK-506) [4] Network interface card (NC-503) *

A08EE502AA

[1]

[2]

[3][4]



Theory of Operation Ver. 1.0 Apr. 2007 2. Product specification

3

bizhub163/211/220

Outline

2. Product specification

A. Copier

B. Functions

Type Console/desktop type

Platen Stationary

Original scanning system CCD line sensor

Photoconductor Organic photoconductor

Copying system Electrostatic dry powdered image transfer to plain paper with a laser

Resolution 600 600 dpi

Paper feeding system Max. six-way system

Exposure system Mirror scanning

Developing system HMT system

Charging system Comb electrode DC negative corona with scorotron system

Image transfer system Roller image transfer

Paper separating system Paper separator fingers and charge neutralizing plateFusing system Heat roller

Paper discharging system Charge neutralizing brush

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

Max. original size A3 or 11 17

Multiple copies 1 to 99

Warming-up time

15 sec. or less: bizhub 211/bizhub 220

30 sec. or less: bizhub 163(when the auxiliary power switch is turned ON from a stabilized state, in which

the main power switch is ON and auxiliary power switch is OFF, with the rated

power source voltage and at a room temperature of 23C)

Image lossLeading edge: 4 mm (1/4 inch), trailing edge: 4 mm (1/4 inch),

Rear edge: 4 mm (1/4 inch), front edge: 4 mm (1/4 inch)

First copy time

(A4, full size)

Scan through glass: 7 sec. or less

ADF scan: 11 sec. or less

(Values in conditions of paper fed from tray 1 at a room temperature of 23C

and with a rated power source)

Processing speed 93 mm/s

Copying speed for

multi-copy cycle

(A4, 8-1/2 x 11)

21 cpm or more (bizhub 211: metric areas)

22 cpm or more (bizhub 220)

20 cpm or more (bizhub 211: inch areas)

16 cpm or more (bizhub 163)

Fixed zoom ratios

(Europe, china)

Full size x 1.00

Reduction x 0.250, x 0.500. x 0.700, x 0.810

Enlargement x 1.150, x 1.410, x 2.000, x 4.000

Fixed zoom ratios

(Latin america areasfor inch)

Full size x 1.00

Reduction x 0.250, x 0.500, x 0.640, x 0.780Enlargement x 1.210, x 1.290, x 2.000, x 4.000



2. Product specification Theory of Operation Ver. 1.0 Apr. 2007

4

bizhub163/211/220

Outline

C. Paper

*1: Capacity of manual bypass: 1 sheet

*2: If the width set 297 mm, the max. length is to 420 mm.

If the length set 432 mm, the max. width is to 279 mm.

D. Maintenance

Fixed zoom ratios

(Latin america area for

metric)

Full size x 1.00

Reduction x 0.250, x 0.500, x 0.700, x 0.780

Enlargement x 1.150, x 1.410, x 2.000, x 4.000

Variable zoom ratios 0.250 to 4.000 in 0.001 increments

Paper size usedTray 1 A3 to A5S, Letter, LedgerS, 11 x 14,

LegalS, Invoice, 8K, 16K, FLSManual bypass

Paper capacity

(Tray 1)

Plain paper/recycled paper 250 sheets

Special paper (thick paper, overhead

projector transparencies, postcards,

label sheets)

20 sheets

Envelopes 10 sheets

Paper capacity

(Manual bypass)

Plain paper/recycled paper/special

paper1 sheets

Tray1 Paper feed unit Manual bypass

Type

Plain paper (60 to 90 g/m2) (250 sheets) *1

Transparencies (20 sheets) *1

Thick Paper (91 to 157 g/m2) (20 sheets) *1

Postcards (20 sheets) *1

Labels (20 sheets) *1

Envelopes (10 sheets) *1

SizeWidth 90 to 297 mm *2 182 to 297 mm *2 90 to 297 mm *2

Length 140 to 432 mm *2

Machine durability

300,000 prints or 5 years, whichever is earlier

(bizhub 211/bizhub 220)

240,000 prints or 5 years, whichever is earlier (bizhub 163)



Theory of Operation Ver. 1.0 Apr. 2007 2. Product specification

5

bizhub163/211/220

Outline

E. Machine specifications

*1: Including the original cover

*2: Including MB-501 and original cover

F. Operating environment

G. Built-in controllers

Power requirementsVoltage AC100 V, AC120V, AC220-240V

Frequency 50/60 Hz

Max power consump-

tion

bizhub 163

100/110/120 area 1000 W 10% or less

127/230 area 1050 W 10% or less

220 area 940 W 10% or less240 area 1100 W 10% or less

bizhub 211/220

110/120/220 area 1200 W 10% or less

127/240 area 1350 W 10% or less

230 area 1250 W 10% or less

Dimensions

599 (W) x 620 (D) x 520 (H) mm *1

760 (W) x 620 (D) x 604 (H) mm *2 (bizhub 220 for China)

760 (W) x 620 (D) x 520 (H) mm *2 (bizhub 163 for China)

Space requirements998 (W) x 665 (D) mm (bizhub 211/220)

998 (W) x 620 (D) mm (bizhub 161)

Mass 89 kg (when fully equipped)

Temperature 10 to 30C (with a fluctuation of 10C or less per hour)

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

Printing Speed bizhub 211: 21 printed pages/min (A4, 300 dpi)

12 printed pages/min (A4, 600 dpi)

bizhub 163: 16 printed pages/min (A4, 300 dpi)

12 printed pages/min (A4, 600 dpi)

Memory Shared with the copier

Interface USB revision 2.0 compatible

Printer language GDI

Font Windows

Complying OS Windows XP (SP2 or later), Windows 2000 (SP4 or later), Windows ME,Windows 98 SE



2. Product specification Theory of Operation Ver. 1.0 Apr. 2007

6

bizhub163/211/220

Outline

2.1 Fax kit (FK-506): (Option)

*1: This is the speed for transmitting an A4-size, or Letter-size document containing approx-

imately 700 characters at high-speed (33.6 kbps) using the standard resolution (8 dots/mm

x 3.85 lines/mm (200 dpi x 100 lpi)). The transmission time for only the image information

and the communication control time are not included. In addition, the actual transmission

time differs depending on the contents of the document, the recipients fax machine and the

condition of the wiring.

*2: Real-time transmission is supported only with the document feeder.

Transmission mode G3

Compatible wiring General subscriber telephone line, NCC each line

Connection method Direct connection (using a modular jack)

Transmission speed 33.6, 31.2, 28.8, 26.4, 24.0, 21.6, 19.2, 16.8, 14.4, 12.0, 9.6, 7.2, 4.8, 2.4

kbps (automatic switching)

Transmission time 3 seconds *1

Scanning density 8 dots/mm x 3.85/7.7/15.4 lines/mm, 16 dots/mm x 15.4 lines/mm *2

Document size Maximum A3 (Ledger), banner documents (maximum 1000 mm (39-1/4

inches)) possible

Print paper size Metric: A3, B4, A4, B5, A5

Inch: Invoice (8-1/2 x 5-1/2), Letter, Legal (8-1/2 x 14), Ledger (11 x 17)

Scanning storage With built in memory (5 MB): 280 pages

With expanded memory (64 MB): 1,024 pages

*With standard A4-size documents

Compression encoding

format

MH / MR / MMR / JBIG



Theory of Operation Ver. 1.0 Apr. 2007 3. Cross sectional view

7

bizhub163/211/220

Outline

3. Cross sectional view

[1] Automatic document feeder DF-502

(Option)

[7] Paper feed unit PF-502 (Option)

[2] Scanner [8] Copy table DK-703 (Option)

[3] Job separator JS-503 (Option) [9] Paper feed tray/1

[4] Fusing unit [10] PH unit

[5] Image transfer section [11] Imaging unit

[6] Multiple bypass MB-501 (Option) [12] Exit section

4034G502BA

1

2

3

4

5

6

7

10

11

12

9

8



4. Paper path Theory of Operation Ver. 1.0 Apr. 2007

8

bizhub163/211/220

Outline

4. Paper path

4034G503BA



Theory of Operation Ver. 1.0 Apr. 2007 5. Copy process

9

bizhub163/211/220

Outline

5. Copy process

[1]Photoelectric

Conversion

A CCD sensor is used to convert the image data represented by light

reflected off the original to a corresponding electric signal which, in turn,

is output to the IR image processing section.

[2]IR Image

Processing

The analog electric signal is converted to an 8-bit digital image

signal (A/D conversion) which, in turn, goes through appropriate

corrections before being output to the PH image processing

section.

[3]PH ImageProcessing

After going through corrections, the digital image signal is con-verted to a corresponding electric signal (D/A conversion), with

which the laser is turned ON or OFF as necessary.

[4] PC Drum Made up of an aluminum pipe coated with a photoconductive

layer, on which an electrostatic latent image is formed.

[5] Drum Charging A uniform negative DC charge is deposited across the entire

surface of the PC Drum.

[6] Laser Exposure The laser beam strikes the surface of the PC Drum, forming an

electrostatic latent image.

[7] Developing

Toner negatively charged in the Developer Mixing Chamber is

attracted onto the electrostatic latent image changing it to a vis-

ible, developed image.

A developing bias (Vb) is applied to the Developing Roller to

prevent toner from being attracted onto those areas of the PC

Drum which correspond to the background areas of the original.

[8] Paper Feed Paper is supplied from the paper feed tray.

[9] Image Transfer

A DC positive charge is applied to the Image Transfer Roller to

transfer the visible image on the surface of the PC Drum onto

the paper.

A08EE568AA

[1] Photoelectric Conversion

[2] IR Image Processing

[3] PH Image Processing

[4] PC Drum

[5] Drum Charging[6] Laser Exposure

[7] Developing

[8] Paper Feed

[9] Image Transfer

[10] Paper Separation

[11] Cleaning

[12] Main Erase

[13] Fusing

[14] Paper Exit



5. Copy process Theory of Operation Ver. 1.0 Apr. 2007

10

bizhub163/211/220

Outline

[10] Paper Separation

The PC Drum Paper Separator Fingers remove paper from the

surface of the PC Drum.

The Charge Neutralizing Plate neutralizes any charge left on

the paper.

[11] Cleaning Residual toner on the surface of the PC Drum is scraped off.

The toner is then recycled back to the Developing Unit.

[12] Main Erase The surface of the PC Drum is irradiated with light and any sur-face potential remaining there after cleaning is neutralized.

[13] Fusing The developed image is permanently fused to the paper by the

combination of heat and pressure applied by the Fusing Roller.

[14] Paper Exit

The paper is fed out onto the Exit Tray.

The optional Job Separator (JS-503), when mounted on the

copier, allows a specific tray, in which paper is fed, to be

selected according to the operating mode.



Theory of Operation Ver. 1.0 Apr. 2007 6. Overall configuration

11

bizhub163/211/220



6. Overall configuration

6.1 Timing Chart at Power ON

A08EE569AA

Fusing coolingfan motor (FM1)

Power unit cooling

fan motor (FM2)



6. Overall configuration Theory of Operation Ver. 1.0 Apr. 2007

12

bizhub163/211/220


6.2 Control Block Diagram

A08EC506AA

OperationPanel IR CCD

MFP board (MFPB)

EM-103

NC-503 orIC-206

Document relatedoption

FAXB

NCUB

Printer control board(PRCB)

PH

PU

Process (Motor, Sensor, DC Power)

Paper Source

Option

High voltage unit

Paper ExitSource Option

Control System Line

Image Bus Line



Theory of Operation Ver. 1.0 Apr. 2007 7. Scanner (IR)

13

bizhub163/211/220


7. Scanner (IR)

7.1 Composition

A08EC514AA

A08EC508AA

A08EC579AA

Scanner motor (M5)

CCD board (CCDB)

ScannerAssy

Exposure Lamp

Scanner homeposition sensor(PS100)

Original size sensor 1 (PS101)

2nd/3rd Mirrors Carriage

Originalcover setswitch (S6)

Original cover sensor(PS8)



7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007

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bizhub163/211/220


7.2 Drive

A08EC515AA




15

bizhub163/211/220


7.3 Operation

7.3.1 Scanner Moving Mechanism/Control

The Scanner is moved by the Scanner Motor at a given speed.

The Scanner Home Position Sensor detects the Scanner at its home position.

The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner. It thereby keeps

constant the optical path length between the original and the PC Drum.

A. Operation

1. The Scanner generally stands by at the shading position.

When the Original Cover or ADF is raised to an angle of 15 or more, the Scanner

moves to the original size detection position.

2. When the Original Cover or ADF is raised to an angle of less than 15 with an orig-

inal placed on the Original Glass (when the Original Cover Sensor is activated), the

lamp turns ON and the original size is detected.

3. When the Size Reset Switch is turned ON with the Original Cover or ADF fully low-

ered, the Scanner moves to the shading position to carry out shading.

4. If the Start key is not immediately pressed, the lamp goes out after the lapse of 11

sec. after it has turned ON.

5. If the Start key is pressed immediately and the lamp remains ON, the Scannerstarts a scan motion immediately.

6. After the original has been scanned, the Scanner makes a return motion and its

home position is detected. Then, the Scanner moves to, and stops at, the home

position.

A08EE572AA




16

bizhub163/211/220


1. When the original is loaded and the Start key pressed, the Scanner performs shad-

ing.

2. The Scanner then moves to the scanning position under the ADF glass.

The original is scanned as it is moved.

3. After the original has been scanned, the home position of the Scanner is detected.

Then, the Scanner moves to, and stops at, the home position.

7.3.2 Original Size Detection

Original Size Sensor 1 and the CCD mounted in the optical section are used to detect

the size of the original.

A08EE578AA

A08EE570AA

PS101

PS102 (Option)




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bizhub163/211/220


7.3.3 Determination of Original Size

The Original Size Sensor is used to determine the size of the original.

Two size conversion patterns are available depending on the applicable marketing area.

Refer to the Field Service (CCD APS SIZE) for setting.

(1) Size Detection (Standard)

Pattern 1

Pattern 2

*: PS102 is an option.

Original Size

Sensor~144.7

mm

~220.9

mm

~221.0

mm

PS101 *PS102

OFF Invoice S Letter S Letter

ON Legal S Legal S 1117 S

Original Size

Sensor~143.9

mm

~153.0

mm

~187.0

mm

~213.0

mm

~220.9

mm

~225.0

mm

~262.0

mm

~284.4

mm

284.5

mm~

PS101 *PS102

OFF OFFInvoice

SA5 S B5 S A4 S Letter S B5 B5 Letter A4

ON OFF FLS S FLS S FLS S FLS S FLS S FLS S B4 S1117

SA3

OFF ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S1117

SA3

ON ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S1117

SA3




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Pattern 1

Pattern 2

*: PS102is an option.

Original Size

Sensor~153.0

mm

~187.0

mm

~200.0

mm

~215.0

mm

~225.0

mm

~262.0

mm

~275.0

mm

275.1

mm~

PS101 *PS102

OFF A5 S B5 S 16K S A4 S B5 B5 16K A4

ON FLS S FLS S FLS S FLS S FLS S B4 S 8K S A3

Original

Size

Sensor~143.9

mm

~153.0

mm

~187.0

mm

~200.0

mm

~213.0

mm

~220.9

mm

~225.0

mm

~262.0

mm

~274.7

mm

~284.4

mm

284.5

mm~

PS

101

*PS

102

OFF OFFInvoice

SA5 S B5 S 16K S A4 S

Letter

SB5 B5 16K Letter A4

ON OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S B4 S 8K S1117

SA3

OFF ONLegal

S

Legal

S

Legal

S

Legal

S

Legal

S

Legal

SB4 S B4 S 8K S

1117

SA3

ON ONLegal

S

Legal

S

Legal

S

Legal

S

Legal

S

Legal

SB4 S B4 S 8K S

1117

SA3




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(2) Size Detection (When FLS/LEGAL Change is selected)

For Inch and Latin America (Inch) areas

Pattern 1

Pattern 2

*: UN3 is an option.

Original Size

Sensor~144.7

mm

~220.9

mm

~221.0

mm

PS101 *PS102OFF Invoice S Letter S Letter

ON FLS S FLS S 1117 S

Original Size

Sensor~143.9

mm

~153.0

mm

~187.0

mm

~213.0

mm

~220.9

mm

~225.0

mm

~262.0

mm

~284.4

mm

284.5

mm~

PS101 *PS102

OFF OFFInvoice

S A5 S B5 S A4 S Letter S B5 B5 Letter A4

ON OFF FLS S FLS S FLS S FLS S FLS S FLS S B4 S1117

SA3

OFF ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S1117

SA3

ON ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S1117

SA3




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7.3.4 For Metric, China and Latin America (Metric) areas

Pattern 1

Pattern 2

*: PS102is an option.

Original Size

Sensor~153.0

mm

~187.0

mm

~200.0

mm

~215.0

mm

~225.0

mm

~262.0

mm

~275.0

mm

275.1

mm~

PS101 *PS102

OFF A5 S B5 S 16K S A4 S B5 B5 16K A4

ON Legal S Legal S Legal S Legal S Legal S B4 S 8K S A3

Original

Size

Sensor~143.9

mm

~153.0

mm

~187.0

mm

~200.0

mm

~213.0

mm

~220.9

mm

~225.0

mm

~262.0

mm

~274.7

mm

~284.4

mm

284.5

mm~

PS

101

*PS

102

OFF OFFInvoice

SA5 S B5 S 16K S A4 S

Letter

SB5 B5 16K Letter A4

ON OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S B4 S 8K S1117

SA3

OFF ONLegal

S

Legal

S

Legal

S

Legal

S

Legal

S

Legal

SB4 S B4 S 8K S

1117

SA3

ON ONLegal

S

Legal

S

Legal

S

Legal

S

Legal

S

Legal

SB4 S B4 S 8K S

1117

SA3



Theory of Operation Ver. 1.0 Apr. 2007 8. PH (Writing section)

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8. PH (Writing section)

8.1 Composition

A08EC516AA

A08EC508AA

A08EC580AA

Polygon Motor

fLens

SOS Sensor

LD Board



8. PH (Writing section) Theory of Operation Ver. 1.0 Apr. 2007

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8.2 Drive

When a laser beam strikes the Polygon Mirror, light reflected off the Polygon Mirror is

directed at the PC Drum by way of the lens and return mirror.

The Polygon Mirror has seven faces, being turned at high speeds by the Polygon Motor.

The SOS Mirror and SOS Sensor keep constant the timing, at which emission of a laser

beam is started for each main scanning line.

A08EC526AA

PolygonMotor fLens

SOS Mirror

PC Drum

SOS Sensor

LD Board



Theory of Operation Ver. 1.0 Apr. 2007 9. Imaging unit

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9. Imaging unit

9.1 Construction

A08EC517AA

A08EC509AA

A08EC581AA

PC DrumPaper Separa-tor Fingers

Developing Roller

PC Drum

1st Toner Conveying Roller

2nd Toner Conveying Roller

3rd Toner Conveying Roller

PC Drum ChargeCorona

Cleaning Blade



9. Imaging unit Theory of Operation Ver. 1.0 Apr. 2007

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9.2 Operation

The Main Motor provides drive for the PC Drum, Developing Roller, and other mechani-

cal components.

A08EC562AA

Recycled Toner Conveying Screw

Recycled Toner

Recycling Coil2nd Toner Conveying Roller

Developing Roller

Main motor (M1)



Theory of Operation Ver. 1.0 Apr. 2007 10. PC Drum

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10. PC Drum

10.1 Composition

10.2 Drive

A08EC509AA

A08EC582AA

A08EC563AA



10. PC Drum Theory of Operation Ver. 1.0 Apr. 2007

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10.3 Operation

The PC Drum used in this copier is the organic photoconductor (OPC).

The drum is a lamination of the Charge Transport Layer and Charge Generating Layer

coating an aluminum alloy base.

Handling Precaution

The PC Drum of this type exhibits light fatigue after being exposed to light for a

long time, which results in its sensitivity being changed. Always, therefore, wrap

the drum in the PC Drum Cloth or a soft cloth immediately after it has been

removed from the copier. Utmost care should also be used when handling the PC

Drum to ensure that its surface is not contaminated.

A08EC527AA

Charge Transport LayerAluminum Base

Charge Generation Layer

(PC Drum Cross-Section)

PC Drum



Theory of Operation Ver. 1.0 Apr. 2007 10. PC Drum

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10.3.1 Grounding of the PC Drum

The ground contact (Ground Plate) of the PC Drum is located on the inside on its left-

hand side. It remains in contact with the drum shaft at all times. When the Imaging Unit is

loaded in the copier, the drum shaft comes into contact with the Ground Plate of the PC

Drum. The potential on the surface of the PC Drum exposed to the laser beam is then

grounded through the Ground Plate to the frame of the copier.

A08EC528AA

PC Drum

Frame

Ground Plate



11. PC Drum charging Theory of Operation Ver. 1.0 Apr. 2007

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11. PC Drum charging

11.1 Composition

11.2 Operation

The surface of the PC Drum is deposited with charge through corona discharge from the

PC Drum Charge Corona.

The grid mesh interposed between the corona wire and the PC Drum ensures that a uni-

form charge is deposited across the entire surface of the PC Drum. The corona unit has a comb electrode that discharges only toward the grid mesh. This

results in the amount of ozone produced being smaller than with the wire electrode.

A08EC509AA

A08EC583AA

A08EC529AA

Comb Electrode

Grid Mesh



Theory of Operation Ver. 1.0 Apr. 2007 12. Developing

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12. Developing

12.1 Composition

12.2 Drive

A08EC509AA

A08EC584AA

A08EC518AA



12. Developing Theory of Operation Ver. 1.0 Apr. 2007

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12.3 Operation

12.3.1 Developing Roller

The Developing Roller consists of an outer sleeve roller and an inner magnet roller.

The roller conveys developer to the point of development.

The developer (carrier and toner) in the Developer Mixing Chamber is conveyed onto the

point of development by the Toner Conveying Rollers and the Developing Roller.

12.3.2 Developing Bias

Vb (-DC, AC) is applied to the Developing Roller.

Vb (-DC) is applied to prevent toner from sticking to the background of the image.

Vb (AC) is applied to enhance good separation of toner from carrier.

The amount of toner sticking to the surface of the PC Drum is varied according to the dif-

ference in potential between the voltage (Vi) on the surface of the PC Drum and

Vb (-DC). Large difference = A greater amount of toner sticks.

Small difference = A smaller amount of toner sticks.

A08EC519AA

PC Drum

Developing Roller

1st Toner Conveying Roller Point of Development

Toner

Carrier

Toner/Carrier


A08EC520AA

PC Drum

Developing BiasTerminal

Developing Roller



Theory of Operation Ver. 1.0 Apr. 2007 12. Developing

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12.3.3 TCR Sensor

The TCR Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Developer

Mixing Chamber.

12.3.4 TCR Sensor Automatic Adjustment

The reference value for the TCR Sensor is automatically adjusted as detailed below

using the TCR Sensor Automatic Adjustment mode.

A08EC521AA


TCR Sensor

3rd Toner Conveying Roller

Developing Roller

1st Toner Conveying Roller

With the copier set in the TCR Sensor Automatic Adjustment mode, press the Start key.

The developer is mixed.

The TCR Sensor converts the reference T/C (14 %) to a corresponding voltagevalue and outputs it.

Does the output voltage fall within the range from 2.28 to 2.36 V?

YES NO

The voltage input to the TCR Sensorfrom the Master Board at this time is fixedas the reference voltage.

The voltage input to the TCR Sensor fromthe Master Board is varied.2.37 V or more: Decrease the voltage.

2.29 V or less: Increase the voltage.



13. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2007

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13. Toner replenishing

13.1 Composition

13.2 Drive

A08EC510AA

A08EC585AA

A08EC564AA



Theory of Operation Ver. 1.0 Apr. 2007 13. Toner replenishing

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13.3 Operation

13.3.1 Toner Replenishing Mechanism

Toner is supplied from the Toner Bottle to the Developer Mixing Chamber.

1. The Toner Replenishing Motor (M2) turns the coupling, which turns the Toner Bot-

tle.

2. To regulate the amount of toner supplied from the Toner Bottle, there is a Metering

Chamber provided in the outer race of the coupling.

3. When the Toner Bottle turns, toner in the Metering Chamber drops.

4. Toner from the metering chamber is conveyed by the Toner Conveying Screw into

the Developer Mixing Chamber.

5. The Toner Conveying Screw is turned by the Toner Replenishing Motor (M2).

A08ET2C522AA

A08EC561AA

Coupling Toner Bottle

MeteringChamber

Toner Conveying Screw

Developer Mixing Chamber

Toner replenishingmotor (M2)




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13.4 Toner Replenishing Control

Replenishing of the supply of toner is determined based on the T/C ratio and B/W ratio.

If T/C is 14 % or more, toner replenishing is not carried out regardless of the B/W value.

If T/C is less than 14 %, toner replenishing is determined according to the B/W value.

Toner is replenished until T/C becomes 14 %.

The greater the value of B/W in the table, the higher the B/W ratio (high image densityoriginal).

T/C ratio (%) B/W ratio toner replenishingMore than 14 not supplied

13.5 to 14 More than 2000 supplied

13 to 13.5 More than 1000 supplied

12.5 to 13 More than 500 supplied

12 to 12.5 More than 500 supplied

10 to 12 More than 0 supplied

Less than 7 Proceeds to the T/C recovery mode



Theory of Operation Ver. 1.0 Apr. 2007 13. Toner replenishing

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13.4.1 T/C Recovery Mode

A toner-empty condition is reset when the Front Cover is opened and closed after a T/C

of 10 % or more is detected with the supply of toner replenished.

A toner-empty-stop condition is reset when the Front Cover is opened and closed after a

T/C of 8 % or more is detected with the supply of toner replenished. A toner-empty con-dition results, however, if T/C falls within the range between 8 % and 10 % when the

Front Cover is opened and closed.

The machine enters the T/C recover mode when a T/C of 10 % or less is detected.

Toner is replenished for 90 sec.

T/C is recovered by 1 % or more.

T/C is not recovered by 2 % or more,or T/C is less than 12 %.

T/C is recovered by 2 % or more,or is 12 % or more.

T/C is not recovered by 1 % or more,or T/C is less than 12 %.

A toner-empty condition is detected.Toner is replenished for 30 sec. tocomplete the T/C recovery mode.

T/C is less than 8 %.

A toner-empty-stop condition results and the initiation ofany new copy cycle is prohibited.

Toner is replenished for 60 sec.




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13.4.2 Toner Bottle Home Position Detection

The toner supply port is on the upper side whenever the toner bottle is at its home posi-

tion. The toner bottle home position sensor (PS6) detects the toner bottle at its home

position.

A08EC530AA

Toner Supply Port

Toner bottle home positionsensor (PS6)



Theory of Operation Ver. 1.0 Apr. 2007 14. Image transfer and paper separation section

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14. Image transfer and paper separation section

14.1 Composition

14.2 Drive

A08EC511AA

A08EC591AA

A08EC565AA



14. Image transfer and paper separation section Theory of Operation Ver. 1.0 Apr. 2007

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14.3 Operation

14.3.1 Image Transfer Section

A positive charge is applied to the Image Transfer Roller to transfer the toner image

formed on the surface of the PC Drum onto the paper.

The charge applied to the Image Transfer Roller is varied according to the following con-

ditions to ensure that image transfer efficiency is stabilized.

1. Paper Type: The amount of charge is made less for OHP film.

2. Paper width: The smaller the paper width, the greater the amount of charge.

3. B/W ratio of image: The lower the B/W ratio, the greater the amount of charge.

A negative charge is applied to the Image Transfer Roller to return toner sticking to the

Image Transfer Roller to the PC Drum. It is performed in the following timings:

(At the start and end of a copy cycle; when the Power Switch is turned ON; when a mis-

feed or malfunction is reset)

14.3.2 Paper Separation Section

Paper separation is accomplished through the curvature separation system that works

on the diameters of the PC Drum and the Image Transfer Roller.Since the PC Drum has a small diameter, there is no likelihood that the paper will be

wound around the PC Drum. The paper is separated by its own weight.

The Charge Neutralizing Plate neutralizes any charge left on the paper after image trans-

fer, thereby preventing discharge noise that could otherwise occur when the paper is

separated.

The PC Drum Paper Separator Fingers properly separate from the surface of the PC

Drum thin paper or other type of paper that is hard to separate.

A08EC531AA

PC Drum Paper Separator Fingers

Charge Neutralizing Plate

PC Drum

Image Transfer Roller



Theory of Operation Ver. 1.0 Apr. 2007 15. Toner recovery

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15. Toner recovery

15.1 Composition

15.2 Drive

A08EC509AA

A08EC585AA

A08EC567AA



15. Toner recovery Theory of Operation Ver. 1.0 Apr. 2007

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15.3 Operation

The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum.

The spent toner is conveyed through the Recycling Duct and eventually back to the

Developer Mixing Chamber.

The following control is provided to prevent paper dust from being wedged between the

Cleaning Blade and the PC Drum. When the cumulative period of time through which the

PC Drum has been driven reaches a predetermined value, the PC Drum is turned back-ward (by turning the Main Motor backward). Shoulder gears comprising two different

parts are provided on the copier. This ensures that the drive is transmitted only to the

Imaging Unit, but not any other parts, during backward rotation.

Cumulative Time Through Which PC Drum Has Been Driven PC Drum Backward Rotation Time

Approx. 330 sec. 50 ms

A08EC532AA

Cleaning Blade

Spent Toner Recycling Coil

PC Drum

Spent Toner Conveying Screw 2

Spent Toner Conveying Screw 1

Spent Toner Recycling Duct

Developer Mixing Chamber



Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed

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16. Paper feed

16.1 Composition

A08EC533AA

A08EC557AA

A08EC587AA

Paper size detect board (PSDTB)

Paper size sensor (S5)

Paper empty sensor/1 (PS4)

Feed Roller/1

Separation Roller/1

Paper Lifting Plate



16. Paper feed Theory of Operation Ver. 1.0 Apr. 2007

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16.2 Drive

The Main Motor (M1) provides the drive for paper feed operations.

The drive is transmitted through the Paper feed solenoid/1.

A08EC534AA

Main motor (M1)

Paper feed solenoid/1 (SD1)

Feed Roller




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16.3 Operation

16.3.1 Paper Separating Mechanism

The coefficient of friction between the Feed Roller and Separation Roller is effectively

used to prevent double feed of paper.

When one sheet of paper is taken up:

The coefficient of friction on the front side of the sheet of paper taken up and fed throughthe space between the Feed Roller and Separation Roller is the same as that on the back-

side of the sheet of paper, allowing the paper to be properly fed into the machine.

When two or more sheets of paper are taken up:

The coefficient of friction between the paper and the Separation Roller is greater than that

between the sheets of paper, which allows only the top sheet of paper to be fed into the

machine.

16.3.2 Drawer in Position Detection

When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor.

The copier then knows that the drawer has been slid in position.

A08EC535AA

Feed Roller

Paper

Separation Roller

A08EC536AA

Tray set sensor (PS5)




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16.3.3 Paper Empty Detection Mechanism

The Paper Empty Sensor detects a paper-empty condition in the drawer.

16.3.4 Paper Lifting Plate

The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked

when the tray is slid into the unit.

The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times.

A08EC537AA

Paper empty sensor/1 (PS4)

A08EC538AA

Spring

Paper Lifting Plate




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16.3.5 Universal Tray Paper Size Detection Mechanism

Both the width (in the crosswise direction) and length (in the feeding direction) of the

paper are detected and the copier CPU determines the paper size based on the combi-

nation of the two readings.

The width of the paper is detected when the lever that is operatively connected to the

Edge Guide activates or deactivates the Paper Size Detection Sensor.

The length of the paper is detected when the lever that is operatively connected to theTrailing Edge Stop actuates or deactuates the switches on the Paper size detect board.

A08EC539AA

Paper size detect board (PSDTB)Paper size sensor (S5)

1 2 3 4




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16.3.6 ON/OFF Positions of Paper Size Detecting Switches and Corresponding

Paper Size Detected

Paper Size Detect Board (PSDTB)Paper size sensor (S5) Paper Size

SW1 SW2 SW3 SW4

B4 ON Activated A3

ON ON A5 S

ON ON Activated A4

ON A5, postcards

ON ON ON A5 S

ON ON ON Activated A4

ON ON B5

ON ON ON A4 S

ON ON ON ON B5 S

Paper Size Detect Board (PSDTB)Paper size sensor (S5) Paper Size

SW1 SW2 SW3 SW4

B4, Legal

Activated B4, 1114

ON B5 S, Invoice S

Activated A3, 1117

ON ON A5 S, Invoice S

ON ON Activated A4, Letter

ON A5, Invoice

ON ON ON A5 S, Invoice S

ON ON ON Activated A4, Letter

ON ON B5, Invoice

ON ON ON A4 S, Letter S

ON ON ON ON B5 S, Letter S




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16.3.7 Paper feed Control

16.3.8 Paper feed Retry Control

To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo-rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given

period of time after the sequence has been started. The paper take-up sequence is then

performed again. These paper take-up sequences are repeated a given number of times.

A08EE588AA

No. of Paper Feed Retry Sequences

Paper Feed Retry 2

A08EE589AA



17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2007

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17. Manual bypass section

17.1 Composition

17.2 Drive

A08EC512AA

A08EC590AA

A08EC566AA

Main motor (M1)

Paper set sensor/bypass (PS2)

Paper feed solenoid/bypass (SD2)



Theory of Operation Ver. 1.0 Apr. 2007 17. Manual bypass section

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17.3 Operation

Drive for bypass paper feed is provided by the Main Motor (M1).

The drive is transmitted through the Paper feed solenoid/bypass.

17.3.1 Paper Detection Mechanism

The Sensor detects a sheet of paper on the Manual Bypass.

A08EC542AA

Main motor (M1)


Paper feed solenoid/bypass (SD2)

A08EC543AA


Paper



17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2007

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17.3.2 Manual Feed Take Up Control

A08EE573AA



Theory of Operation Ver. 1.0 Apr. 2007 18. Registration roller section

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18. Registration roller section

18.1 Composition

18.2 Drive

A08EC558AA

A08EC586AA

A08EC545AA

Registration roller

Paper Dust Remover

Registration sensor(PS1)

Registration rollerclutch (CL1)



18. Registration roller section Theory of Operation Ver. 1.0 Apr. 2007

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18.3 Operation

The Synchronizing Roller ensures that the paper is fed off from the transport section in

time with the exposure timing of the exposure section (PH).

Drive from the Main Motor (M1) is transmitted through a gear train to the Registration

roller clutch (CL1).

18.3.1 Paper Dust Remover

The Paper Dust Remover collects paper dust on the paper.

A08EC546AA

Main motor (M1)

Registration rollerclutch (CL1)

A08EC547AA

Paper Dust Remover



Theory of Operation Ver. 1.0 Apr. 2007 19. Fusing unit section

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19. Fusing unit section

19.1 Composition (for bizhub 163)

Heat and pressure from the Fusing Roller permanently fuse toner onto the paper.

A08EC548AA

A08EC559AA

A08EC592AA

Heater Lamp

Fusing Roller/rt

Pressure Lever

Thermostat

Thermistor (TH1)

Fusing Roller



19. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2007

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19.2 Composition (for bizhub 211/220)

A08EE571AA

Sub Heater Lamp)

Fusing Roller/rt

Pressure Lever

Thermistor (TH1)Thermistor (TH2)

Thermostat

Fusing Roller

Heater Lamp




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19.3 Drive

The main motor (M1) provides the drive for the fusing unit.

19.4 Operation

19.4.1 Fusing Roller Pressure Mechanism

To provide a nip width between the rollers, a Pressure Spring is used functioning to press

the Fusing Roller/Rt up against the Fusing Roller.

A08EC549AA

Main motor (M1)

Fusing roller

Fusing Roller/Rt

A08EC550AA

Pressure Spring

Fusing Roller/Rt

Fusing Roller

Pressure Lever




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19.4.2 Fusing Temperature Control (for bizhub 163)

The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the

surface of the Fusing Roller.

The Fusing Roller surface temperature is detected by using a thermistor that translates

the temperature to a corresponding electrical signal.

If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater

Lamp is shut down.

Machine Condition or Paper Type Mode 1 Mode 2 Mode 3

Standby 180 C 180 C 170 C 170 C

Plain paper (width: 250 mm or more;

length: less than 360 mm)190 C 190 C 170 C 170 C

Plain paper (width: less than 250 mm) 180C 180 C 165 C 165 C

Thick paper (width: 250 mm or more) 210 C 210 C 190 C 190 C

Thick paper (width: less than 250 mm) 200 C 200 C 190 C 190 C

OHP film (width: 250 mm or more) 180 C 180 C 165 C 165 C

OHP film (width: less than 250 mm) 155 C 155 C 155 C

A08EE574AA

Warm-up completed




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19.4.3 Fusing Temperature Control (for bizhub 211/220)

The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the

surface of the Fusing Roller.

The Fusing Roller surface temperature is detected by using a thermistor that translates

the temperature to a corresponding electrical signal.

If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater

Lamp is shut down.

Machine Condition or Paper Type Mode 1 Mode 2 Mode 3

Standby 180 C 180 C 165 C 165 C

Plain paper (width: 221 mm or more) 180 C 180 C 180 C

Plain paper (width: 220 mm or less) 180 C 180 C 180 C

Thick paper (width: 201 mm or more) 200 C 200 C 200 C

Thick paper (width: 200 mm or less) 200 C 200 C 200 C

OHP film (width: 201 mm or more) 165 C 165 C 165 C

OHP film (width: 200 mm or less) 165 C 165 C 165 C

A08EE576AA

Warm-up completed




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19.4.4 PPM Control (bizhub 163 Only)

If paper of a small size (width of 250 mm or less) or thick paper is used to run a multi-

copy cycle, the temperature on the edges of the Fusing Rollers tends to run high, mean-

ing that the temperature of the Fusing Rollers varies among different spots of the rollers.

When the cumulative number of copies made through continuous copy cycles * exceeds

30, the paper take-up interval is made longer, thereby allowing the temperatures of the

Fusing Rollers at different spots to be uniform.* Continuous copy cycle: Continuous copy cycles run with an interval of 2 min. or less

between cycles.



Theory of Operation Ver. 1.0 Apr. 2007 20. Paper exit (for bizhub 163)

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20. Paper exit (for bizhub 163)

20.1 Composition

20.2 Drive

The main motor (M1) provides the drive for the exit section.

A08EC560AA

A08EC593AA

A08EC553AA

Main motor (M1)

Exit Roller



21. Paper exit (for bizhub 210/220) Theory of Operation Ver. 1.0 Apr. 2007

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21. Paper exit (for bizhub 210/220)

21.1 Construction

21.2 Operation

The exit rollers are driven by the switchback motor (M3).

A08EC560AA

A08EC593AA

A08EE575AA

Switchback motor (M3)

Exit Roller



Theory of Operation Ver. 1.0 Apr. 2007 22. Image stabilization system

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22. Image stabilization system

22.1 Composition

The following image stabilization controls are provided to ensure stabilized copy image.

Purpose Means Control

To stabilize image

density.

Grid voltage (Vg) and devel-

oping bias (Vb) control

The Vg/Vb control voltage is varied to bring Vg/Vbto an appropriate level according to the following

settings.

Tech. Rep. Choice: ID Adjustment

Tech. Rep. Choice: VG Adjustment

User's Choice: Print Density

SUPPLIES LIFE COUNT.

Paper type

To stabilize image

transfer.

Image transfer output con-

trol

The image transfer output is varied to bring the

image transfer current to an appropriate level

according to the following conditions.

Paper type Paper width

B/W ratio of image

A08EE577AA



23. Others Theory of Operation Ver. 1.0 Apr. 2007

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23. Others

23.1 Fan Control

23.1.1 Composition

A08EC555AA

A08EC556AA

Power unit cooling fan motor (FM2)

Fusing cooling fan motor (FM1)

Ozone Filter



Theory of Operation Ver. 1.0 Apr. 2007 23. Others

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23.1.2 Operation

A. Function

B. Fan control

Motor Name Control Conditions

Fusing cooling

fan motor (FM1)

A fan motor draws air from the area around the Fusing Unit to the out-

side to prevent the machine interior temperature from running high. In

addition, the fan motor pulls paper being transported up through suc-tion force to help stabilize paper transport.

Ozone produced from the PC Drum Charge Corona is absorbed by

the Ozone Filter from the air drawn by a fan motor to the outside.

The fan motor is turned at full speed during a print cycle and at a

speed reduction during other timings, thereby making the machine

quieter without sacrificing cooling performance.

Power unit cooling

fan motor (FM2)

A cooling fan motor draws air from the area around the Power Supply

Unit to the outside to prevent the Power Supply Unit temperature from

running high.

The cooling fan motor is turned at full speed when the Main Motorturns and at a speed reduction during other timings, thereby making

the machine quieter without sacrificing cooling performance.

Motor Name Control Control Conditions

Fusing cooling

fan motor (FM1)

Full speed

During a print cycle (full speed rotation after the lapse

of a given period of time after the start of the print

cycle)

Half speed

Half speed rotation after the lapse of a given period of

time after the end of the print cycle Half speed rotation at any timing other than the full

speed and stop control

Stop When a malfunction occurs

When the right door is open

Power unit cooling

fan motor (FM2)

Full speed When power is turned ON or Sleep is canceled

Stop

Half speed rotation if the main motor (M1) is deener-

gized after the lapse of a given period of time after the

full speed rotation



23. Others Theory of Operation Ver. 1.0 Apr. 2007

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Blank Page



SERVICE MANUAL

2007.04

Ver. 1.0

THEORY OF OPERATION



Revision history

After publication of this service manual, the parts and mechanism may be subject to change for

improvement 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 be

issued with a revision mark added as required.

Revision mark:

To indicate clearly a section revised, show to the left of the revised section.


To indicate clearly a section revised, show in the lower outside section of the correspond-

ing page.


NOTE

Revision 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.

1

1

1

1

2007/04 1.0 Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision



DF-605/MK-501

Outline



i

CONTENTS

DF-605/MK-501

Outline

1. Product specifications .............................................................................................1

2. Paper Feed Path ..................................................................................................... 4

2.1 In 1-sided mode.................................................................................................... 4

2.2 In 2-sided mode.................................................................................................... 4


3. Composition ............................................................................................................ 5

4. Drive........................................................................................................................ 65. Operation ................................................................................................................ 7

5.1 Document pick-up mechanism ............................................................................. 7

5.1.1 Pick-up operation ..........................................................................................7

5.2 Document feed/transport mechanism................................................................... 8

5.3 Raised/lowered position detecting mechanism................................................... 12

5.3.1 Document size detection............................................................................. 12

5.3.2 Raised/lowered position detection .............................................................. 12



DF-605/MK-501

Outline



ii

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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications

1

Outline

DF-605/MK-501

Outline

1. Product specifications

A. Type

B. Functions

C. Paper

*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 Paper feed from top of stack

Turnover Switch back system

Paper exit Straight exit system

Installation Screw cramp to the main unit

Document alignment Center

Document loading Left image side up

Modes 1-sided mode / 2-sided mode

Type of document

Standard mode

Plain paper

1-Sided mode

35 to 128 g/m2(9.25 to 34 lb)

2-Sided mode

50 to 128 g/m2(13.25 to 34 lb)

Mixed original detection

mode

Plain paper

1-Sided / 2-Sided Mode

50 to 128 g/m2(13.25 to 34 lb)

FAX mode

Plain paper

1-Sided mode

35 to 128 g/m2(9.25 to 34 lb)

2-Sided mode

50 to 128 g/m2(13.25 to 34 lb)

Detectable document

size*1

Metric area

B6S to A3

Inch area

5 1/2 8 1/2S / 5 1/2 8 1/2to 11 17

Capacity 80 sheets (80 g/m2) or load height of 11 mm or less.



1. Product specifications Theory of Operation Ver. 1.0 Apr. 2007

2

Outline

DF-605/MK-501

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

Original that is stapled or clipped.Feed failure, damage to the original, or drive

failure due to clip clogging

Book original

Feed failure, damage to the original, or drive

failure

Original weighing less than 35g/m2or

129g/m2or moreFeed failure

Torn original Feed failure, damaged sheet

Highly curled original (15 mm or more) Original misfeed due to dog-ear or skew

OHP transparencies Feed failure

Label Sheet Feed failure

Offset master Feed failure

Sheets clipped or notched Damaged sheet

Sheets patched Patched part folded or torn sheet, Sheetsmisfed

Type of original Possible trouble

Sheets lightly curled (Curled amount: 10 - 15 mm) Dog-eared, exit failure

Heat sensitive paper Edge folded, exit failure, transport failure

Coated paper (Ink Jet paper) Take-up failure, transport failure

Translucent paper Take-up failure, transport failurePaper immediately after paper exit from the main unit Take-up failure, transport failure

Paper with many punched holes (e.g., loose leaf) limited

to vertical feedingMulti-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) Take-up failure

Sheets foldedImage deformation, multi-page feed, take-up

failure



Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications

3

Outline

DF-605/MK-501

F. Mixed original feed chart

For Metric

For Inch

G. Machine specifications

H. Operating

Conforms to the operating environment of the main unit.

NOTE These specifications are subject to change without notice.

Max. original size 297 mm 257 mm 210 mm 182 mm 148 mm

Mixed original size A3 A4 B4 B5 A4S A5 B5S A5S

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 OK OK

128 mm B6S NG NG NG NG NG NG NG OK

Max. original size 11 8.5 5.5

Mixed original size 11 x 17 8.5 x 11 8.5 x 14 8.5 x 11S 5.5 x 8.5 8.5 x 5.5S

1111 x 17 OK OK - - - -

8.5 x 11 OK OK - - - -

8.58.5 x 14 OK* OK* OK OK OK -

8.5 x 11S OK* OK* OK OK OK -

5.58.5 x 5.5 NG NG OK OK OK -

8.5 x 5.5S NG NG NG NG NG OK

OKMixed original feed available

(Tilted with in 1.5% or less)

NG NO. mixed original feed

- Can not set original

* Tilted with in 2% or less is 80%

Power Requirements

DC 24 V (supplied from the main unit)

DC 5 V (generated wit

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