Theory of Operation Bizhub 163_211_220

SERVICE MANUAL

2007.04Ver. 1.0

2007.04 Ver.1.0

© 2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Printed in JapanDDA09A-M-TE1

Use of this manual should be strictly supervised toavoid disclosure of confidential information.

THEORY OF OPERATION

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-19

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

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

bizhub 163/211/220 main bodyOutline ............................................................................................................................ 1

Composition/Operation ................................................................................................. 11

DF-605/MK-501Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 5

DF-502Outline ............................................................................................................................ 1


AD-504Outline ............................................................................................................................ 1


PF-502Outline ............................................................................................................................ 1


MB-501Outline ............................................................................................................................ 1


JS-503Outline ............................................................................................................................ 1


SF-501Outline ............................................................................................................................ 1

i

Composition/Operation................................................................................................... 3

ii

SAFETY AND IMPORTANT WARNING ITEMS

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-1


[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-2


[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.

kw

S-3


[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.

kw

S-4


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-5


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-6


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-7


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-8


• 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-9


• 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-10


• 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-11


[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-12


[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 5 mW

Maximum average radiation power (*) 6.32 µW

Wavelength 770-795 nm

A09AP0C501DA

Laser Aperture ofthe Print Head Unit

S-13


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 5 mW

bølgelængden 770-795 nm

S-14


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 5 mW

aallonpituus 770-795 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 5 mW

våglängden 770-795 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 5 mW

bølgelengde 770-795 nm

S-15


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.

A09AP0E505DA

A09AP0C503DA

S-16


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-17


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.

CAUTION:

WARNING INDICATIONS ON THE MACHINE

A09AP0C504DA

High voltage

High temperature

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.

S-18

MEASURES TO TAKE IN CASE OF AN ACCIDENT

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-19


Blank Page

S-20

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

GENERAL: 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-1

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 163/211/220: 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

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

Windows 98/Me/ NT/2000/XP

Paper size Feeding direction Notation

A4Long edge feeding A4

Short edge feeding A4S

A3 Short edge feeding A3

C-2

SERVICE MANUAL

2007.04Ver. 1.0

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, 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. A number within 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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2007/04 1.0 — Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

CONTENTS

bizhub 163/211/220 main body

Outline1. 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

Composition/Operation6. 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 ....................................................................................................... 23

9.2 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........................................................................................................ 28

11.2 Operation ............................................................................................................ 28

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

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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

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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...................................................................................... 51

18.1 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 ................................................................................................................... 55

19.4 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

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

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Outline1. System configuration1/2 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]

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

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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]

2

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

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2. Product specificationA. 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 plate

Fusing 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 22030 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 23°C)

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 lessADF scan: 11 sec. or less(Values in conditions of paper fed from tray 1 at a room temperature of 23°C 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 areas for inch)

Full size x 1.00

Reduction x 0.250, x 0.500, x 0.640, x 0.780


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

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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


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 paper

1 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 durability300,000 prints or 5 years, whichever is earlier(bizhub 211/bizhub 220)240,000 prints or 5 years, whichever is earlier (bizhub 163)

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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 less

240 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 30°C (with a fluctuation of 10°C 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

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

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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 recipient’s 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, A5Inch: 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 pagesWith expanded memory (64 MB): 1,024 pages*With standard A4-size documents

Compression encoding format

MH / MR / MMR / JBIG

6

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

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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

56

7

10

11

12

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8

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

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4. Paper path

4034G503BA

8

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

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5. Copy process

[1]PhotoelectricConversion

• 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 ImageProcessing

• 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

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

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[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.

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

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Composition/Operation6. Overall configuration

6.1 Timing Chart at Power ON

A08EE569AA

Fusing coolingfan motor (FM1)

Power unit coolingfan motor (FM2)

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

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6.2 Control Block Diagram

A08EC506AA

OperationPanel IR CCD

MFP board (MFPB)

EM-103

NC-503 orIC-206

Document related option

FAXB

NCUB

Printer control board (PRCB)

PH

PU

Process (Motor, Sensor, DC Power)

Paper SourceOption

High voltage unit

Paper ExitSource Option

Control System Line

Image Bus Line

12

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

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7. Scanner (IR)

7.1 Composition

A08EC514AA

A08EC508AA

A08EC579AA

Scanner motor (M5)

CCD board (CCDB)

Scanner Assy

Exposure Lamp

Scanner home position sensor (PS100)

Original size sensor 1 (PS101)

2nd/3rd Mirrors Carriage

Original cover set switch (S6)

Original cover sensor (PS8)

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

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7.2 Drive

A08EC515AA

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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<Marking copies through the Original Glass>

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 Scanner starts 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

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<Making copiers using DF-502>

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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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)<For Inch and Latin America (Inch) areas>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 11×17 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

mm284.5 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 S11×17

SA3

OFF ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S11×17

SA3

ON ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S11×17

SA3

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<For Metric, China and Latin America (Metric) areas>Pattern 1

Pattern 2


Original Size

Sensor~153.0

mm~187.0

mm~200.0

mm~215.0

mm~225.0

mm~262.0

mm~275.0

mm275.1 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

OriginalSize

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~

PS101

*PS102

OFF OFFInvoice

SA5 S B5 S 16K S A4 S

Letter S

B5 B5 16K Letter A4

ON OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S B4 S 8K S11×17

SA3

OFF ONLegal

SLegal

SLegal

SLegal

SLegal

SLegal

SB4 S B4 S 8K S

11×17 S

A3

ON ONLegal

SLegal

SLegal

SLegal

SLegal

SLegal

SB4 S B4 S 8K S

11×17 S

A3

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(2) Size Detection (When FLS/LEGAL Change is selected)For Inch and Latin America (Inch) areasPattern 1

Pattern 2

*: UN3 is an option.

Original Size

Sensor~144.7

mm~220.9

mm~221.0

mm

PS101 *PS102

OFF – Invoice S Letter S Letter

ON – FLS S FLS S 11×17 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

mm284.5 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 S11×17

SA3

OFF ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S11×17

SA3

ON ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S11×17

SA3

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

Pattern 1

Pattern 2


Original Size

Sensor~153.0

mm~187.0

mm~200.0

mm~215.0

mm~225.0

mm~262.0

mm~275.0

mm275.1 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

OriginalSize

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~

PS101

*PS102

OFF OFFInvoice

SA5 S B5 S 16K S A4 S

Letter S

B5 B5 16K Letter A4

ON OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S B4 S 8K S11×17

SA3

OFF ONLegal

SLegal

SLegal

SLegal

SLegal

SLegal

SB4 S B4 S 8K S

11×17 S

A3

ON ONLegal

SLegal

SLegal

SLegal

SLegal

SLegal

SB4 S B4 S 8K S

11×17 S

A3

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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

fθ Lens

SOS Sensor

LD Board

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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

Polygon Motor fθ Lens

SOS Mirror

PC Drum

SOS Sensor

LD Board

22

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 Drum Paper Separa-tor Fingers

Developing Roller

PC Drum

1st Toner Conveying Roller2nd Toner Conveying Roller

3rd Toner Conveying Roller

PC Drum Charge Corona

Cleaning Blade

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9.2 Operation

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

A08EC562AA

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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

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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

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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

27

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

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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

28

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

29

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

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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

2nd Toner Conveying Roller

A08EC520AA

PC Drum

Developing Bias Terminal

Developing Roller

30

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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

2nd Toner Conveying Roller

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 voltage value 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 Sensor from the Master Board at this time is fixed as the reference voltage.

The voltage input to the TCR Sensor from the Master Board is varied.2.37 V or more: Decrease the voltage.2.29 V or less: Increase the voltage.

31

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

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13. Toner replenishing

13.1 Composition

13.2 Drive

A08EC510AA

A08EC585AA

A08EC564AA

32

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

Metering Chamber

Toner Conveying Screw

Developer Mixing Chamber

Toner replenishing motor (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 density original).

T/C ratio (%) B/W ratio toner replenishing

More 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

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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. to complete the T/C recovery mode.

T/C is less than 8 %.

A toner-empty-stop condition results and the initiation of any 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 position sensor (PS6)

36

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

37

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

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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

38

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

39

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

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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

40

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

41

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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 through the 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 the Trailing 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

<For Metric>

<For Inch>

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, 11×14

– – – ON– B5 S, Invoice S

Activated A3, 11×17

– – 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

47

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

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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)

48

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

<When Paper is Present> <When Paper is not Present>


Paper

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

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17.3.2 Manual Feed Take Up Control

A08EE573AA

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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 roller clutch (CL1)

51

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

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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 roller clutch (CL1)

A08EC547AA

Paper Dust Remover

52

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

53

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

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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) 180°C 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

<Temperature Control in Standby State>

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

<Temperature Control in Standby State>

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.

58

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

59

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

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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

60

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/Vb to 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

61

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

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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

62

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


• 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.


• 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 Motor turns and at a speed reduction during other timings, thereby making the machine quieter without sacrificing cooling performance.

Motor Name Control Control Conditions


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


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

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SERVICE MANUAL

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CONTENTS

DF-605/MK-501

Outline1. Product specifications ............................................................................................. 1

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

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

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

Composition/Operation3. Composition ............................................................................................................ 5

4. Drive........................................................................................................................ 6

5. 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

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Outline1. Product specificationsA. 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 modePlain paper

1-Sided mode35 to 128 g/m2 (9.25 to 34 lb)


Mixed original detectionmodePlain paper

1-Sided / 2-Sided Mode50 to 128 g/m2 (13.25 to 34 lb)

FAX modePlain paper



Detectable documentsize*1

Metric areaB6S to A3Inch area5 1/2 × 8 1/2S / 5 1/2 × 8 1/2 to 11 × 17

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

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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

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

Book originalFeed failure, damage to the original, or drive failure

Original weighing less than 35g/m2 or129g/m2 or more

Feed 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 patchedPatched part folded or torn sheet, Sheets misfed

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 failure

Paper 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 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) Take-up failure

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

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F. Mixed original feed chartFor 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 within the Automatic Document Feeder)

DC 3.3 V (supplied from the main unit)

Max. Power Con-sumption

48 W or less

Dimensions582 (W) x 558 (D) x 145 (H) mm23 inch (W) x 20.5 inch (D) x 5.75 inch (H)

Weight 10 kg (22 lb) or less

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2. Paper Feed Path

2.1 In 1-sided mode

2.2 In 2-sided mode

4344T1C501AA

1: Feed (scanning the 1st side)

2: Transport and turnover

3: Exit

4344T1C502AA

1: Feed (scanning the 1st side)

2: Transport and switchback

3: Transport and turnover (scanning the 2nd side)

4: Transport and switchback

5: Transport

6: Exit

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Composition/Operation3. Composition

4344T2C501AA

Document feed section

Document exit sectionConveyance section Switchback section

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4. Drive

4344T2C502AATransport motor (M2-ADF)

Paper feed motor (M1-ADF)

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5. Operation

5.1 Document pick-up mechanism

• The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separa-tion Roller, and this section is driven by the Paper Feed Motor.

5.1.1 Pick-up operation

• When the Start key is pressed, the Paper Feed Motor starts turning backward, causing the Pick-Up Roller to lower and start turning at the same time. At the same time, the Feed Roller starts turning.

• The Pick-Up Rollers are in the raised position when in the standby state and in the low-ered position during feeding.

4344T2C503AA

Pick-Up Roller

Feed Roller

Paper feed motor (M1-ADF)

Separation Roller

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5.2 Document feed/transport mechanism

• When the document reaches the Registration Sensor, the Feed Roller starts turning for-ward and, at the same time that the Pickup Roller goes up, drive is then supplied to the Registration Roller.

• When the Transport Motor starts turning forward, the two Transport Rollers and the Exit/Turnover Roller feed the document toward the exit direction.

PartsDirection of

RotationDetails

Paper Feed Motor (M1-ADF)

Backward rotation

The Pickup Rollers lower and start turning and the Feed Roller turns.

Forward rotation

The Registration Roller turns.

Transport Motor (M2-ADF)

Backward rotation

The Transport Roller and Exit/Turnover Roller turn in the direction to turn over the original.

Forward rotation

The Transport Roller and Exit/Turnover Roller turn in the direction to feed the original out.

4344T2C504AA

Paper feed motor (M1-DF)Transport motor (M2-DF)

Transport Roller

Exit/Turnover Roller

Registration Roller

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A. Operation flow in the 1-sided mode

1. When the Start key is pressed, the Paper Feed Motor starts turning backward, causing the Pick-Up Roller to lower and start a paper take-up sequence.

2. The scanning of the 1st side is started after the lapse of a given period of time after the Original Detection Sensor has been activated by the leading edge of the origi-nal.

3. The original is transported for a given period of time after the trailing edge of the last page of the document has deactivated the Exit/Turnover Sensor. It is then fed into the Exit Tray and the Transport Motor is deenergized.

4344T2C506AA

Exit

Scanning the 1st side

Original Detection Sensor

Exit/Turnover Sensor

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B. Operation flow in the 2-sided mode1. When the Start key is pressed, the Paper Feed Motor starts turning backward,

causing the Pick-Up Roller to lower and start feeding the 1st page of the document. The scanning of the 1st side is started after the lapse of a given period of time after the Original Detection Sensor has been activated by the leading edge of the 1st page. The Transport Motor is deenergized to stop the original after the lapse of a given period of time after the trailing edge of the 1st page has deactivated the Exit/Turn-over Sensor.

2. The Transport Motor is turned backward to turn over the original. After the Registra-tion Roller, the Transport Motor is turned forward to allow the Scanner to scan the backside of the 1st page.

3. After the transport sequence for turnover has been started, the Exit Roller Retrac-tion Solenoid is energized so that the Exit/Turnover Roller is retracted.

4344T2C506AA

Scanning the 1st side

Original Detection Sensor

Exit/Turnover Sensor

Stop

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Stop

Turnover

Scanning the 2nd side

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4. To ensure that pages of the document are in the proper order, the page is turned over again before being ejected into the Exit Tray.

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Exit

Turnover

Scanning the 2nd side

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5.3 Raised/lowered position detecting mechanism

5.3.1 Document size detection

• The 15 degree Open Detection Mechanism enables the main unit to detect the document size when the DF is used as the Original Cover of the main unit, there is the Lever Actu-ator provided in the DF body that blocks or unblocks a sensor to initiate a reconfirmation of the original size as read by the original size detection sensors.

5.3.2 Raised/lowered position detection

• The Raised/Lowered Position Detection Mechanism uses a magnet installed in the DF body to allow the main unit to know that the DF is raised or lowered. This magnet actu-ates the Original cover set switch on the main unit to perform this operation.

4344T2C508AAOriginal cover set switch (S6)

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CONTENTS

DF-502

Outline1. Product specification ............................................................................................... 1

Composition/Operation2. Automatic Document Feeder (DF-502) ................................................................... 3

2.1 Composition.......................................................................................................... 3

2.2 Drive ..................................................................................................................... 4

2.3 Operation .............................................................................................................. 5

2.3.1 Document Pick-Up and Feed ........................................................................ 5

2.3.2 Document Transport...................................................................................... 6

2.3.3 Document Separating Mechanism................................................................ 7

2.3.4 Document Exit Mechanism ........................................................................... 8

2.3.5 Document Size Detection Mechanism .......................................................... 9

2.3.6 Raised/Lowered Position Detection Mechanism........................................... 9

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Outline1. Product specificationA. Type

B. Paper

C. Paper feed prohibited originals

D. Machine specifications

E. Operating environment• Conforms to the operating environment of the main unit.


Name Automatic document feeder

Installation Inserted in top portion of the copier

Modes Standard = 1-sided originalMixed original = 1-sided original

Document loading Left-hand side, face up

Standard Mixed original

Type Plain paper (50 to 110 g/m2) Plain paper (60 to 90 g/m2)

SizesA3, A4S, A4, A5S, B4, B5S, B5, 11 x 17, 11 x 14, Legal, LetterS, Letter, InvoiceS, and Invoice

A3 and A4, B4 and B5, 11 x 17 and Letter, Legal and LetterS, Legal and Invoice, LetterS and Invoice

Type of original Possible problems

Sheets stapled or clipped togetherTake-up failure, damaged sheet, defective drive mechanism due to jammed staples or clips

Sheets glued together Take-up failure, damaged sheet

Sheets folded, torn, or wrinkled Take-up failure, damaged sheet

Sheets severely curledSheet misfed due to its being dog-eared or fed in askew


Capacity 50 sheets max. (80 g/m2)

Power requirements DC24 V, DC5 V (supplied from the copier)

Power consumption 36 W or less

Dimensions 598 mm (W) x 483 mm (D) x 102 mm (H)

Mass 6.3 kg

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Composition/Operation2. Automatic Document Feeder (DF-502)

2.1 Composition

4688C501AA

4688C502AA

Main Motor

Pick-Up Roller

Exit Rollers

Registration Rollers

Feed Roller

Feed Clutch

4688C512AA

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2.2 Drive

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2.3 Operation

2.3.1 Document Pick-Up and Feed

• The document is taken up as the Pick-Up Roller and Feed Roller turn.• The Pick-Up Roller transports the document up to the Feed Roller.• After a scan is completed, the Main Motor is turned backward to raise the Pick-Up Roller.• The Pick-Up Roller and the Feed Roller are turned through the Paper Feed Clutch and by

a gear train and a belt driven by the Main Motor.• The Paper Empty Sensor is used to detect a document loaded on the Document Loading

Tray.• The Document Stoppers determine the leading edge position of the document loaded on

the Document Loading Tray. They are in the lowered, swung-down position in the standby state and swing upward when the document is to be taken up.

• The swing-up and swing-down motion of the Document Stoppers is operatively con-nected to the raising and lowering of the Pick-Up Roller.

4688C504AA

Paper empty sensor (PS2)

Main motor (M1)

Pick-Up Roller

Feed Roller

Document Stoppers

Paper feed clutch (CL1)

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2.3.3 Document 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

Since the friction coefficient on the top side of the paper is equal to that on the underside of the paper, the Separation Roller is turned by the Feed Roller. This feeds the paper forward.

When two or more sheets of paper are taken up

The friction coefficient between the sheets of paper is smaller than that between the paper and Separation Roller. This stops the Separation Roller, allowing only the first sheet of paper to be transported by the Feed Roller.

4688C507AA

Separation Roller

Feed Roller

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2.3.4 Document Exit Mechanism

• The document is fed out of the ADF by the Exit Roller.• The Exit Roller is driven by gears and a belt which are driven by the Main Motor.

4688C508AA

Main motor (M1)

Exit Rollers

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2.3.5 Document Size Detection Mechanism

• The document size is determined by means of two different systems of document width detection and document length detection.

A. Document Width Detection• The width of an original is detected by the combination of Paper Width Sensors as

detected while the original is being taken up.• Each sensor is located as follows with reference to the Document Edge Guide in the rear.

B. Document Length Detection• The length of the original is detected by the Paper Length Sensor when the document is

loaded in the unit.• The Paper Length Sensor is located at the Document Loading Tray.

2.3.6 Raised/Lowered Position Detection Mechanism

• There is a magnet installed in the ADF body to allow the copier to know that the ADF is raised or lowered.

• This magnet actuates the Original cover set switch on the copier.

4688C509AA

Original cover set switch (S6)

Magnet

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CONTENTS

AD-504


Composition/Operation2. Duplex Unit (AD-504) .............................................................................................. 3

2.1 Composition.......................................................................................................... 3

2.2 Drive ..................................................................................................................... 4

2.3 Operation .............................................................................................................. 4

2.3.1 Switchback Operation ................................................................................... 4

2.3.2 2-sided Copying with a Single Sheet of Paper Resident in the Unit.............. 5

2.3.3 2-sided Copying with Two Sheets of Paper Resident in the Unit .................. 6

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Outline1. Product specificationsA. Type

B. Paper

C. Machine specifications

D. Operating environment• Conforms to the operating environment of the main body.


Name Automatic duplex unit

Type Sheet duplex paper take-up section

Installation Installed to the right side door

Power requirements DC24 V (supplied from the copier)DC5 V

Size A3, A4S/A4, A5S/A5, B4, B5S/B5, FLS, Ledger, Legal, Letter, InvoiceS/ Invoice

Type Plain paper (60 to 90 g/m2), recycled paper (60 to 90 g/m2)


Max. power consumption 9 W or less

Dimensions 412 mm (W) x 215 mm (D) x 88 mm (H)16.25 inch (W) x 8.5 inch (D) x 3.5 inch (H)

Mass 2.5 kg (Duplex unit + Manual bypass assy

Operating environment Conforms to that of the copier

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Composition/Operation2. Duplex Unit (AD-504)

2.1 Composition

4532C515AA

4532C503AA

4532C516AA

Transport motor (M1)

Transport sensor (PS2)

AD drive board (ADDB)

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2.2 Drive

• The Duplex Unit Transport Motor provides the drive for the Duplex Unit.

2.3 Operation

2.3.1 Switchback Operation

• The paper printed on one side is switched back by the exit rollers on copier to transport it into the duplex unit.

• The switchback operation of transport rollers is carried out by the Switchback Motor.

4532C502AA

Transport Roller 1

Transport Roll 1

Transport Roller 2

Transport Roll 2

4532C504AA

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2.3.2 2-sided Copying with a Single Sheet of Paper Resident in the Unit

A. Operation

1. The first sheet of paper is taken up and the image of page 2 of the origi-nal is printed.

2. Immediately before the first sheet of paper leaves the Paper Exit Roller, the direction of rotation of the Paper Exit Roller is reversed and the first sheet of paper is transported toward and into the Duplex Unit.

3. The paper moving through the Duplex Unit is directly subjected to the second print cycle without being stopped.

4. The image of page 1 of the original is printed on the other side of the first sheet of paper.

5. While the first sheet of paper is being fed out of the copier, the image of page 4 of the original is printed on one side of the second sheet of paper.

6. Steps 2 through 5 are repeated.

4532C505AA

4532C506AA

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2.3.3 2-sided Copying with Two Sheets of Paper Resident in the Unit

A. Operation

1. The first sheet of paper is taken up and the image of page 2 of the origi-nal is printed.

2. Immediately before the first sheet of paper leaves the Paper Exit Roller, the direction of rotation of the Paper Exit Roller is reversed and the first sheet of paper is transported toward and into the Duplex Unit.

3. At the same time, the second sheet of paper is taken up and fed in.

4. The image of page 4 of the original is printed on one side of the second sheet of paper.

5. At the same time, the first sheet of paper is transported through the Duplex Unit.

6. The image of page 1 of the original is printed on the other side of the first sheet of paper that has been fed into the copier again.

7. At the same time, the second sheet of paper is subjected to a switchback sequence at the exit section.

8. It is then fed through the Duplex Unit without.

9. While the first sheet of paper is being fed out of the copier, the image of page 4 of the original is printed on one side of the second sheet of paper.

4532C505AA

4532C510AA

4532C511AA

4532C512AA

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10. While the second sheet of paper is being fed out of the copier, the third sheet of paper is taken up and the image of page 6 of the original is printed.

11. Steps 2 through 10 are repeated.

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CONTENTS

PF-502


Composition/Operation2. Paper Feed Unit (PF-502) ....................................................................................... 3

2.1 Composition.......................................................................................................... 3

2.2 Drive ..................................................................................................................... 4

2.3 Operation .............................................................................................................. 5

2.3.1 Edge Guide and Trailing Edge Stop .............................................................. 5

2.3.2 Paper Lifting Plate......................................................................................... 5

2.3.3 Tray-in-Position Detection ............................................................................. 6

2.3.4 Paper Empty Detection ................................................................................. 6

2.3.5 Paper Size Detecting Mechanism ................................................................. 7

2.3.6 Paper Separating Mechanism....................................................................... 8

2.3.7 Paper Feed Control ....................................................................................... 8

2.3.8 Paper Feed Retry Control ............................................................................. 9

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B. Paper




Name Add-on paper feed unit

Installation Installed on the underside of the copier

TypePlain paper (60 to 90 g/m2)

250 sheetsRecycled paper (60 to 90 g/m2)

SizesMetric areas: A3, A4S, A4, A5, B4, B5S, and B5Inch areas: Ledger (11 x 17), 11 x 14, Legal (8-1/2 x 14), LetterS (8-1/2 x 11S), and Invoice (5-1/2 x 8-1/2)

Paper alignment Center

Capacity 250 sheets



Dimensions590 mm (W) x 558 mm (D) x 108 mm (H)23.25 inch (W) x 22 inch (D) x 4.25 inch (H)

Weight 5.5 kg (12.25 lb)

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Composition/Operation2. Paper Feed Unit (PF-502)

2.1 Composition

4686C501AA

4686C502AA

4686C512AA

Trailing Edge Stop

Side Door

Paper Lifting PlateEdge Guide

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2.2 Drive

• Drive from the Main Motor (M1) is transmitted via a gear train to the paper feed mecha-nism for the Paper Feed Unit.

4686C503AA

Paper Feed Drive Mechanism

Vertical Transport Roller

Feed Roller

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2.3 Operation

2.3.1 Edge Guide and Trailing Edge Stop

• The Edge Guide and Trailing Edge Stop can be slid into any desired position.

2.3.2 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.

4686C504AA

Trailing Edge Stop Edge Guide

4686C505AA

Paper Lifting Spring

Paper Lifting Plate

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2.3.3 Tray-in-Position Detection

• When a tray is slid into the cabinet, the Tray Set Sensor is blocked and the copier deter-mines that the tray has been slid in position.

2.3.4 Paper Empty Detection

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

4686C506AA

Tray set sensor (PS3)

Light Blocking Plate

4686C507AA


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2.3.5 Paper Size Detecting 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 Detect switch.

• The length of the paper is detected when the lever that is operatively connected to the Trailing Edge Stop actuates or deactuates the switches on the Paper Size Detect Board.

Paper SizePaper size detect board (PSDTB)

Paper size detect switch (SW1)SW4 SW3 SW2 SW1

A3 ON — — — ON

B4 — — — — —

A4 S — ON ON ON —

A4 ON ON — — ON

B5 S ON ON ON ON —

B5 ON — — ON —

A5 — — ON — —

4686C508AA

Paper size detect board (PSDTB)

Paper size detect switch (SW1)

Trailing Edge Stop Edge Guide

SW4 SW3 SW2 SW1

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2.3.6 Paper Separating Mechanism

• A loop is formed in the paper between the Separator Fingers and the Feed Roller. The turning force of the Feed Roller overcomes the block of the Separator Fingers, causing the top sheet of paper to ride over the fingers and be fed out of the tray into the copier.

• When there are only two sheets of left in the tray and if the friction force of the Paper Lift-ing Plate is low, the bottom sheet of paper is taken up and fed into the copier with the top sheet of paper. To prevent this situation from occurring, there is a Friction Plate provided on top of the Paper Lifting Plate.

• Before the Feed Roller contacts the paper, the Feed Roller holds the paper down so that the paper remains stationary before its being taken up by the Feed Roller.

2.3.7 Paper Feed Control

• The operation of the Paper feed solenoid is controlled by the signal output from PJ3A-1 and 2 of the Control Board.

<For the 2nd Tray>

4686C509AA

Feed Roller

Paper

Separator Finger

Paper Lifting Plate

Friction Plate

Roll

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2.3.8 Paper Feed Retry Control

• To minimize the occurrence of paper misfeed, the Paper feed solenoid is energized a second time to carry out a paper feed retry sequence if a sheet of paper fails to reach the Registration sensor (for the 2nd Tray) or the Paper feed sensor (for the 3rd to 5th Tray) within a given period of time after a paper feed sequence has been initiated. This sequence is repeated a predetermined number of times.

<For the 2nd Tray>


Paper Feed Retry 1

4686C511AA

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SERVICE MANUAL

2007.04Ver. 1.0

THEORY OF OPERATION









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CONTENTS

MB-501


Composition/Operation2. Multiple Bypass (MB-501) ....................................................................................... 3

2.1 Composition.......................................................................................................... 3

2.2 Drive ..................................................................................................................... 4

2.3 Operation .............................................................................................................. 5

2.3.1 Paper Feed Mechanism ................................................................................ 5

2.3.2 Paper Empty Detection Mechanism.............................................................. 6

2.3.3 Paper Feed Control ....................................................................................... 6

2.3.4 Paper Feed Retry Control ............................................................................. 7

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B. Paper




Name Multiple bypass tray

Installation Screwed to the copier

Type

Plain paper (60 to 90 g/m2) 100 sheets

OHP film

20 sheetsThick paper (91 to 157 g/m2)

Postcards and labels

Envelopes 10 sheets

Recycled paper (60 to 90 g/m2) 100 sheets

SizeWidth 90 X 297 mm

Length 140 X 432 mm

SizesA3, A4S, A4, A5, A5S, B4, B5S, B5, FLS, Ledger, 11 x 14, Legal, LetterS, Letter, InvoiceS, Invoice, 8K, 16KS, and 16K

Registration Center

Capacity 100 sheets (80 g/m2)



Dimensions439 mm (W) x 435 mm (D) x 137 mm (H)17.25 inch (W) x 17.25 inch (D) x 5.5 inch (H)

Mass 3.1 kg (6.75 lb)

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Theory of Operation Ver. 1.0 Apr. 2007 2. Multiple Bypass (MB-501)

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Composition/Operation2. Multiple Bypass (MB-501)

2.1 Composition

4687C501AA

4687C502AA

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2.2 Drive

• Drive for bypass paper feed is provided by the Main Motor (M1).• The drive is transmitted through the Paper feed Solenoid.

4687C503AA

Main motor (M1)

Paper feed solenoid (SD1)


Feed Roller

4


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2.3 Operation

2.3.1 Paper Feed Mechanism

• The Paper Lifting Plate is raised to press the paper stack on the tray up against the Feed Roller.

• The Paper Lifting Plate is raised and lowered in time with a paper feed sequence.• The ascent and descent motion of the Paper Lifting Plate is accomplished when the drive

from the motor is transmitted to the cam through a solenoid to rotate the cam.

4687C504AA

Paper feed solenoid (SD1)Drive from Main Motor

Feed Roller

Cam

4687C505AA

Feed Roller

Cam

Paper

<Ascent/Descent Motion>

Main Motor (M1) is energized.

Feed Roller is turned.

Paper feed solenoid (SD1): Energized

Cam: Rotates

Tray: Raised

Paper feed solenoid (SD1): Deenergized

Paper take-up

Paper feed solenoid (SD1): Energized

Cam: Rotates

Tray: Lowered

Paper feed solenoid (SD1): Deenergized

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2.3.2 Paper Empty Detection Mechanism

• The Paper Empty Sensor detects a sheet of paper on the Multiple Bypass.

2.3.3 Paper Feed Control

4687C506AA

<When Paper is Present> <When Paper is not Present>

Paper feed solenoid (SD1)

Paper

4687E507AA

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2.3.4 Paper Feed Retry Control

• To minimize the occurrence of a paper misfeed, the paper feed sequence is temporarily halted if the paper fails to reach the Registration Roller Sensor within a given period of time after the sequence has been started. The paper feed sequence is then performed again. These paper feed sequences are repeated a given number of times.


Paper Feed Retry 2

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SERVICE MANUAL

2007.04Ver. 1.0

THEORY OF OPERATION









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CONTENTS

JS-503


Composition/Operation2. Job Separator (JS-503) ........................................................................................... 3

2.1 Construction ......................................................................................................... 3

2.2 Operation .............................................................................................................. 4

2.2.1 Tray Selecting Mechanism ............................................................................ 5

2.2.2 Tray-Full Detecting Mechanism..................................................................... 6

2.2.3 Job Tray Paper Detecting Mechanism........................................................... 6

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B. Paper




Type Add-on drawer

Installation Built into the exit section of the copier

Paper storage system Moving drawer system

Upper drawer Lower drawer

Plain paper (60 to 90 g/m2)100 sheets (A4S), 50 sheets (other than A4S)Load height up to 22 mm

150 sheets (A4S), 75 sheets (other than A4S)

OHP film

10 sheets 20 sheetsThick paper (91 to 157 g/m2)

Postcards, labels, and enve-lopes

Recycled paper (60 to 90 g/m2)100 sheets (A4S), 50 sheets (other than A4S)Load height up to 22 mm

150 sheets (A4S), 75 sheets (other than A4S)



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Theory of Operation Ver. 1.0 Apr. 2007 2. Job Separator (JS-503)

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Composition/Operation2. Job Separator (JS-503)

2.1 Construction

4688C510AA

4689C501AA

4689C507AA

Paper detecting board (PSDB)

Bin switching motor (M1)

Lower home position sensor (PS2)

Upper home position sensor (PS1)

Paper full sensor (PS3)Paper empty sensor (PS4)

JS drive board (JSDB)

Job Tray

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2.2 Operation

• The Main Motor (M1) provides drive for the Job Separator.

4689C502AA

Paper detecting board (M1)

Job Tray

4

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2.2.1 Tray Selecting Mechanism

• The paper is fed out into either the Exit Tray of the copier or the Job Tray. The active tray is selected according to the operating mode (either the fax, copier, or printer mode).

• The Exit Tray of the copier is for the copier. The Job Tray is, on the other hand, for the fax and printer.

• The corresponding tray is selected through the operation of the motor and sensor as shown below.

4689C504AA

4689C503AA4021M046AB

<When feeding paper into the Exit Tray: Copier>

<When feeding paper into the Job Tray: fax/printer>

Job Tray

Upper home position sensor (PS1): Activated

Bin switching motor (M1)

Lower Home position sensor (PS2): Activated

(M1: Backward Rotation)

Paper

Paper

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2.2.2 Tray-Full Detecting Mechanism

• Tray-full detection is valid only when paper is fed into the Job Tray (Job Tray in the low-ered position).

• A tray-full condition is detected when the sensor is blocked for a continuous given period of time (approx. 20 sec.).

2.2.3 Job Tray Paper Detecting Mechanism

• If paper is fed into the Job Tray when the machine is in a mode in which paper is fed into the Exit Tray (Job Tray in the raise position), the indicator lamp on the Paper Detecting Board lights to warn the user that there is paper in the Job Tray.

• A sensor is provided for detecting paper in the Job Tray.

4689C505AA

Exit Roller

Paper

Job Tray

Paper full sensor (PS3)

4689C506AA

<When Paper is not Present>

<When Paper is Present>

Paper detecting board (PSDB)


Paper

Job Tray

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CONTENTS

SF-501


Composition/Operation2. SHIFTING UNIT (SF-501) ....................................................................................... 3

2.1 Composition.......................................................................................................... 3

2.2 Operation .............................................................................................................. 4

2.2.1 Exit Position Shifting Mechanism .................................................................. 4

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Outline1. Product specifications

A. Machine specifications

B. Operating environment• Conforms to the operating environment of the main body.


Shifting amount 28 mm

Paper capacity 250 sheets

Power consumption Less than 63 W

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Theory of Operation Ver. 1.0 Apr. 2007 2. SHIFTING UNIT (SF-501)

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Composition/Operation2. SHIFTING UNIT (SF-501)

2.1 Composition

4690C501AA

4690C502AA

4690C505AA

SF drive board (SFDB)Home sensor (PS1)

Shift motor (M1)

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2.2 Operation

2.2.1 Exit Position Shifting Mechanism

• Paper is fed into the Shifting Unit along a straight path or shifted from the reference straight path position. This exit position shifting mechanism allows different finishing functions offered by the machine (Non-Sort, Sort, and Group) to be effected.

<Straight Feeding>• The paper that travels along a straight path is fed straight into the Shifting Unit without

being shifted sideways as the Exit Roller turns.

<Shifted Feeding>• When the trailing edge of the paper transported to the exit section moves past the Fusing

Roller, the Shift Motor is energized to move the Transport Roller sideways.• The paper is fed into the Shifting Unit as it is shifted sideways.• The Exit Roller is moved sideways by turning the motor forward or backward.• The Exit Roller is detected at its home position by a sensor.

4690C503AA

Exit Roller

Paper

4690C504AA

Shift motor (M1)

Home sensor (PS1)

Paper

Exit Roller

4

SERVICE MANUAL

2007.04Ver. 1.0

2007.04 Ver.1.0

© 2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Printed in JapanDDA09A-M-TE1

Use of this manual should be strictly supervised toavoid disclosure of confidential information.

THEORY OF OPERATION

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