Xerox 4110 Family Technical Information Manual 2q432m
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Xerox 4110 Family Technical Information Manual
Xerox Corporation Global Knowledge and Language Service 800 Phillips Road Bldg 128 Webster, NY 14650 701P ©
2007 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms and matters of copyrightable material and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. Printed in the United States of America. Xerox®, The Document Company®, The digital X, and Xerox product names and product numbers mentioned in this publication are trademarks of Xerox Corporation. Other company brands and product names may be trademarks or ed trademarks of the respective companies and are also acknowledged.
Table of Contents
Table of Contents........................................................................................................ i (Chain 1) Power .......................................................................................................... 1 Introduction....................................................................................................................................1 Module Overview ........................................................................................................................................ 1
Technical Overview .......................................................................................................................2 Switches, Power Supplies, and PWBs ....................................................................................................... 2 Component Name and Function............................................................................................................................... 2 Power and Control .................................................................................................................................................... 4 DC Power Distribution .............................................................................................................................................. 5
Operation Modes ........................................................................................................................................ 6 Interlocks Component Name and Function ................................................................................................ 8 Operation with an Interlock Open ............................................................................................................... 9
(Chain 2) Mode Selection ........................................................................................ 11 Introduction..................................................................................................................................11 Module Overview ...................................................................................................................................... 11
Technical Overview .....................................................................................................................12 UI ( Interface) Configuration.............................................................................................................. 12 Component Name and Function............................................................................................................... 13
(Chain 3) Machine Run Control............................................................................... 15 Introduction..................................................................................................................................15 Module Overview ...................................................................................................................................... 15
Technical Overview .....................................................................................................................16 Machine Self Test ..................................................................................................................................... 16 Billing Meter .............................................................................................................................................. 18 Billing Meter Type ................................................................................................................................................... 18 What is counted ...................................................................................................................................................... 20 When Counting Happens ....................................................................................................................................... 21 Counter Value Check/Correction............................................................................................................................ 22
(Chain 5)
DADF..................................................................................................... 23
Introduction..................................................................................................................................23 How to Load Documents .......................................................................................................................... 23 Document Stack Capacity ........................................................................................................................ 23
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Document Feed Sequence ....................................................................................................................... 23 Document Scan Speed............................................................................................................................. 24 Component Name and Function............................................................................................................... 25 Operation When Documents are Loaded ................................................................................................. 26 Document Size Sensing ........................................................................................................................... 27 Component Name and Function............................................................................................................... 28 First Document Pre-feed........................................................................................................................... 31 Second and Subsequent Document Pre-feeds ........................................................................................ 31 Pre-registration ......................................................................................................................................... 31 Preventing Document Damage................................................................................................................. 31 Rotating Regi Roll backward .................................................................................................................... 32 Pre Regi Roll’s free drive .......................................................................................................................... 32 Releasing Baffle........................................................................................................................................ 32
Document Scanning and Output ................................................................................................33 Component Name and Function............................................................................................................... 33 Document Scanning Operation................................................................................................................. 34 CIS Scanning............................................................................................................................................ 35
Document Transportation...........................................................................................................36
(Chain 6)
Imaging ................................................................................................. 37
Introduction..................................................................................................................................37 Document Scanning Overview ................................................................................................................. 41 Document Scanning Position Overview (DADF) ...................................................................................... 42 Initialization ............................................................................................................................................... 43 Document Size Sensing ........................................................................................................................... 44 Platen Document Scanning Operation ..................................................................................................... 47 DADF Document Scanning Operation...................................................................................................... 49
Adjustments or Corrections During Scanning..........................................................................51 AGC (Auto Gain Control) White Level Rough Adj. ................................................................................... 51 AOC (Auto Offset Control) ........................................................................................................................ 51 Shading Correction ................................................................................................................................... 51 White Fluctuation Adjustment ................................................................................................................... 52 Black Fluctuation Adjustment ................................................................................................................... 52 Dark Band Elimination .............................................................................................................................. 53 Image Processing ..................................................................................................................................... 54 Fan Control ............................................................................................................................................... 54 Fan Control ............................................................................................................................................... 55
ROS...............................................................................................................................................56 ROS Overview .......................................................................................................................................... 56 ROS Components..................................................................................................................................... 57 Laser Beam Flow...................................................................................................................................... 58 Laser Diode Control.................................................................................................................................. 58
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ROS Motor Control ................................................................................................................................... 58
(Chain 7)
Paper Supply........................................................................................ 59
Introduction..................................................................................................................................59 Tray Specifications......................................................................................................................60 Configuration ............................................................................................................................................ 60 Allowable Paper Sizes .............................................................................................................................. 61 Tray Capacity............................................................................................................................................ 62 Paper Weights .......................................................................................................................................... 63
Paper Transportation ..................................................................................................................64 Paper Flow................................................................................................................................................ 64 Drive Motors ............................................................................................................................................. 67
Trays 1 through 4.........................................................................................................................68 Component Name and Function............................................................................................................... 68 Trays 1 through 4 Paper Size Sensing ..................................................................................................... 70 Raising Trays 1 through 4......................................................................................................................... 72 Raising Operation ..................................................................................................................................... 73 Trays 1 through 4 Remaining Paper Detection......................................................................................... 73
MSI (Multiple Sheet Inserter) ......................................................................................................74 Component Name and Function............................................................................................................... 74 MSI Paper Size Sensing........................................................................................................................... 75 Raising and Lowering the MSI.................................................................................................................. 76
HCF (High Capacity Feeder) .......................................................................................................77 Component Name and Function............................................................................................................... 77 HCF Paper Size Sensing.......................................................................................................................... 78 Raising the HCF Trays ............................................................................................................................. 79 Trays 6 and 7 Remaining Paper Detection............................................................................................... 79
OHCF (Oversized High Capacity Feeder) ..................................................................................80 Overview................................................................................................................................................... 80 Paper Size .............................................................................................................................................................. 80 Paper Type ............................................................................................................................................................. 80 Power Consumption ............................................................................................................................................... 80 Dimensions ............................................................................................................................................................. 80 Weight..................................................................................................................................................................... 80
Interlock Switches..................................................................................................................................... 81 Paper Size Detection ................................................................................................................................ 82 Paper Size
s ................................................................................................................................83
Paper Availability Detection/Remaining Amount Detection ...................................................................... 85 Paper Feed ............................................................................................................................................... 86 Tray Shift .................................................................................................................................................. 88 Paper Separator Air Flow ......................................................................................................................... 89 Air Shutter................................................................................................................................................. 91
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Drive ......................................................................................................................................................... 92
(Chain 8) Paper Feed and Transportation.............................................................. 93 Introduction..................................................................................................................................93 Module Overview ...................................................................................................................................... 93
Technical Overview .....................................................................................................................94 Paper Transportation from Trays 1 through 4 to Registration ................................................95 Component Name and Function............................................................................................................... 95 Basic Control of Paper Transportation...................................................................................................... 97 Paper Feed from the Trays....................................................................................................................... 98 Paper Transportation from the Takeaway Rolls ....................................................................................... 99
Paper Transportation from the MSI to Registration................................................................101 Component Name and Function............................................................................................................. 101 Paper Feed from the MSI ....................................................................................................................... 102
Paper Transportation from the HCF to Registration...............................................................103 Component Name and Function............................................................................................................. 103 Paper Feed from the HCF ...................................................................................................................... 105 Paper Transportation to the HCF Exit Roll ............................................................................................. 106
Registration................................................................................................................................107 Component Name and Location ............................................................................................................. 107 Pre Registration Control ......................................................................................................................... 108 Registration Control ................................................................................................................................ 108 Side Registration Control........................................................................................................................ 109 Paper Length Sensing ............................................................................................................................ 110
(Chain 9) Marking ................................................................................................... 111 Introduction................................................................................................................................111 Module Overview .................................................................................................................................... 111
Technical Overview ...................................................................................................................112 Drum ...........................................................................................................................................113 Component Name and Function............................................................................................................. 113 Drum Motor Control ................................................................................................................................ 114 Drum Cartridge Replacement Detection................................................................................................. 115
Charging and Cleaning .............................................................................................................116 Component Name and Function............................................................................................................. 116 Charge Operation ................................................................................................................................... 118 Charge Corotron Cleaner Control........................................................................................................... 119 Toner Band ............................................................................................................................................. 120
Development ..............................................................................................................................121 Component Name and Function............................................................................................................. 121 Negative Charge Development............................................................................................................... 123 Toner Supply for the Deve Housing........................................................................................................ 124
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Development........................................................................................................................................... 126 Development Bias Control ...................................................................................................................... 127 Toner Empty Detection ........................................................................................................................... 129 Remaining Toner Detection .................................................................................................................... 129 Toner Cartridge Replacement Detection ................................................................................................ 130
Transfer and Stripping ..............................................................................................................131 Component Name and Function............................................................................................................. 131 Transfer Belt ing and Retracting................................................................................................. 133 Image Transfer onto Paper..................................................................................................................... 134 Stripping Paper ....................................................................................................................................... 134 Bias Roll.................................................................................................................................................. 135
Toner Collection ........................................................................................................................136 Component Name and Function............................................................................................................. 136 Toner Collection System......................................................................................................................... 138
Process Control .........................................................................................................................139 Component Name and Function............................................................................................................. 139 Process Control Overview ...................................................................................................................... 140 Potential Control Overview ..................................................................................................................... 141 Patch....................................................................................................................................................... 142 Mini Setup Operation .............................................................................................................................. 143 Operation During Printing/Copying ......................................................................................................... 144 Toner Dispense Control.......................................................................................................................... 145
(Chain 10a) Copy Transport .................................................................................. 147 Introduction................................................................................................................................147 Module Overview .................................................................................................................................... 147
Technical Overview ...................................................................................................................148 Paper Transportation after the F.......................................................................................149 Component Name and Function............................................................................................................. 149 Copy Output Control Overview ............................................................................................................... 151 Straight Output........................................................................................................................................ 154 Invert Output ........................................................................................................................................... 155 Duplex Output......................................................................................................................................... 156 Duplex Print Sequence ........................................................................................................................... 158
Fan Control ................................................................................................................................159 Component Name and Function............................................................................................................. 159
(Chain 10b) Fusing ................................................................................................. 161 Introduction................................................................................................................................161 Fusing.........................................................................................................................................162 Component Name and Function............................................................................................................. 162 F Assembly ...................................................................................................................................... 163
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F Heat Roll....................................................................................................................................... 164 F State ............................................................................................................................................. 165 F Temperature Control .................................................................................................................... 166 F Idling ............................................................................................................................................. 170 Countermeasure against Flicker............................................................................................................. 170 Phase Control ......................................................................................................................................... 171
F Drive.................................................................................................................................171 Component Name and Function............................................................................................................. 171 F Drive Control................................................................................................................................. 172
Heat Roll Cleaning .....................................................................................................................173 Component Name and Function............................................................................................................. 173 Web Motor Control.................................................................................................................................. 174 Extension of Web Life............................................................................................................................. 174 Remaining Web Detection ...................................................................................................................... 174
Finisher ................................................................................................................... 175 Introduction................................................................................................................................175 Technical Overview ...................................................................................................................175 Finisher Configurations........................................................................................................................... 175 Finisher Components.............................................................................................................................. 176 Output Tray Capacities ........................................................................................................................... 177 Paper Transportation .............................................................................................................................. 178 Functions and Output Tray Availability ................................................................................................... 180 Paper Size and Function ........................................................................................................................ 182 Billing Meters .......................................................................................................................................... 183 Power and Switches ............................................................................................................................... 184 Finisher Power Control ........................................................................................................................... 188 Decurler .................................................................................................................................................. 189 Decurler Control...................................................................................................................................... 189 Decurler Components and Operation ..................................................................................................... 190 Decurler Components and Operation ..................................................................................................... 190 Decurler Components............................................................................................................................. 190 Interposer................................................................................................................................................ 191 Interposer Tray Lift Components ............................................................................................................ 192 Interposer Tray Feed Components......................................................................................................... 193 Folder...................................................................................................................................................... 194 Components ........................................................................................................................................... 195 Components ........................................................................................................................................... 197 Components ........................................................................................................................................... 199 Folder Operation..................................................................................................................................... 200 Folder Operation..................................................................................................................................... 201 Punch...................................................................................................................................................... 202
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Punch Components ................................................................................................................................ 202 Punch Operation..................................................................................................................................... 204 Paper Transportation and Punching ....................................................................................................... 206 Paper Transportation / Top Tray............................................................................................................. 208 Output Selection ..................................................................................................................................... 209 Compiling, Stapling, and Ejecting the Sets............................................................................................. 210 Compiler and Stapler Operating Sequence ............................................................................................ 217 Buffer Path.............................................................................................................................................. 218 Buffer Path Sequence............................................................................................................................. 218 Stapling Positions ................................................................................................................................... 220 Stapler Travel ......................................................................................................................................... 220 Stack Tray Components and Operation ................................................................................................. 222 Stack Tray Indexing ................................................................................................................................ 223 Offset Stacking ....................................................................................................................................... 226 Booklet Maker......................................................................................................................................... 226 Booklet Maker Components ................................................................................................................... 226 Booklet Maker Operation ........................................................................................................................ 231 Enhanced Finisher.................................................................................................................................. 232 Software ............................................................................................................................................... 234 Parts List............................................................................................................................................................... 234 Adjustments .......................................................................................................................................................... 234
D3 Finisher ............................................................................................................................................. 234
(Chain 16) Printer ................................................................................................... 235 Introduction................................................................................................................................235 Module Overview .......................................................................................................................235 Technical Overview ................................................................................................................................ 235
Printer Configuration.................................................................................................................236 Component Name and Function............................................................................................................. 236 Hardware Configuration.......................................................................................................................... 237
Xerox 4112/4127 Differences................................................................................. 241 Introduction................................................................................................................................241 Technical overview....................................................................................................................241 Paper Registration .................................................................................................................................. 242 Multifeed Detection Sensor .................................................................................................................................. 242 Multifeed Detection Sensor operation .................................................................................................................. 243
Image Sensor (CIS) Sensor ...................................................................................................... 243 CIS operation........................................................................................................................................................ 243 Preregistration Sensor .......................................................................................................................................... 244 Registration Skew Sensor .................................................................................................................................... 244 CIS Control PWB .................................................................................................................................................. 245 Registration Motor ................................................................................................................................................ 246 Pretransfer Jam Sensor........................................................................................................................................ 246
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Paper Path Alignment............................................................................................................................. 246 Lead Edge Registration ........................................................................................................................................ 247 Side Edge Registration......................................................................................................................................... 247
Image Registration Control Technology (IreCT) Overview ..................................................................... 248 Fast Scan Magnification ....................................................................................................................................... 248 Slow Scan Magnification ...................................................................................................................................... 248 Image Squareness................................................................................................................................................ 249
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(Chain 1) Power
Introduction
Module Overview This module contains the names, locations and functions of the components in Standby Power.
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Technical Overview Switches, Power Supplies, and PWBs Component Name and Function This section describes the components shown in Figure 1.
1. Main Switch 6. PWS Outlet
2. AC Unit
Outlet
Reset Switch Inlet
AC Drive PWB
3. Main LVPS
5. 12VDC LVPS
4. 24VDC LVPS
Figure 1 AC and DC Components The Main Power Switch switches on and off the main power to the machine.
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The AC Unit consists of the AC Drive PWB, the Reset Switch, an Outlet and an Inlet. The AC Unit supplies AC power from the Inlet connection t the AC Drive PWB to control the power to each LVPS. The Main LVPS generates +5VDC, +12VDC, and +24VDC for use by the IOT. The 24VDC LVPS generates additional +24VDC for the IOT. The12VDC LVPS generates additional +12VDC for the IOT. The PWS Outlet is the 200 VAC outlet for the PWS.
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Power and Control Figure 2 shows the power distribution for Xerox 4110.
Figure 2 AC Power Distribution
AC Voltage is supplied through a Reset Switch and Circuit Breaker to the Main Switch, the 12VDC LVPS and Relays in the AC Unit. The 12VDC LVPS supplies +12VDC to the IOT DRIVER PWB. The AC Unit supplies +3.3VDC to the ESS PWB and +12VDC for the Relay in the AC Unit. When the Main Switch is turned ON, power is supplied to the area of the AC Unit that supplies the +3.3VDC to the ESS PWB. The ON/OFF status or the Main Switch is monitored and reported to the ESS PWB through the MCU PWB. The ESS PWB send the Main Power signal to the AC Unit, The Main LVPS and the +24VDC LVPS. The Main Unit, after receiving the Main Power signal, turns ON the Relay and supplies AC voltage to the Main LVPS. The Main LVPS generates +5VDC, +12VDC and+24VDC. The outputs of the Main LVPS
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go to the ESS PWB, the IOT DRIVER PWB, the MCU PWB, the Tray Module PWB, the IIT/IPS PWB and the HCF PWB if there is one on the machine. When power is turned off, the ON/OFF status is signaled to the ESS PWB. The ESS PWB sends the Ready Power signal to the Delay Circuit on the AC Drive PWB in the AC Unit. This signal allows the delay circuit, in the AC Unit, to turn off the Relay after a specified time. This turns off power to the machine. The delay circuit is used so that the machine will not turn off before the data is written to the Hard Drive When the Main Power Switch is still on and the machine enters the Power Saver mode, the ESS PWB sends the Main Power signal and the Ready Power signal to the AC Drive PWB in the AC Unit. This then controls the Power supplied to various components.
DC Power Distribution Figure 3 shows the DC power distribution.
Figure 3 DC Power Distribution
The +12VDC from the Main LVPS is supplied to the IIT/IPS PWB. The +24 VDC from the +24 LVPS is also supplied to the IIT/IPS PWB and the DS PWB. The +24VDC is supplied to the DADF PWB through the IIT/IPS PWB. The +24VDC is also supplied to the 1PDup PWB through the DS PWB. The IIT/IPS PWB generates +5VDC and +3.3VDC from the supplied +12VDC and supplies them to the DADF PWB. The DS PWB generates +12VDC and +3.3VDC from the +24VDC and supplies them to the Extension Memory PWB.
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The ESS PWB sends the IIT LVPS Enable signal to the IIT/IPS PWB and the DS PWB turning power ON/OFF to various components.
Operation Modes Table 1 shows the operating modes. Table 1 Mode Status Run Mode (Running Mode) Receives data, generates/records an image. Standby Mode (Ready Mode) Ready to go into Run Mode. Save Energy Mode 1 (Low Power Mode) Consumes less power than Standby Mode. Save Energy Mode 2* (Sleep Mode*) Consumes less power than Save Energy Mode 1 Save Energy Mode 3 (Semi Low Power Mode) Allows access to HDD alone in Save Energy Mode 2 *This complies with the international energy star program. Table 2 shows the requirements for the machine to shift from one mode to another. Table 2 Run Mode → Standby Mode (Running) (Ready) Standby Mode → Save Energy Mode 1 (Ready) (Low Power) Standby Mode → Save Energy Mode 2 (Ready) (Sleep) Standby Mode → Run Mode (Ready) (Running) Save Energy Mode 1→ Standby Mode (Low Power) (Ready) Save Energy Mode 2→ Standby Mode (Sleep) (Ready) Save Energy Mode 3→ Standby Mode (Semi Low Power) (Ready) Save Energy Mode 2→ Save Energy Mode 3 (Sleep) (Semi Low Power) Save Energy Mode 3→ Save Energy Mode 2 (Semi Low Power) (Sleep) Save Energy Mode 1→ Save Energy Mode 2 (Low Power) (Sleep)
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Immediately after the end of print operation, the MC shifts without receiving a command. After the end of print operation, the MC shifts receiving a command from ESS. After the end of print operation, the MC shifts receiving a command from ESS. The MC shifts receiving a command from ESS. The MC shifts receiving a command from ESS, taking Warm Up Time.
The MC shifts at the time of the outside’s access to HDD. After the end of the outside’s access to HDD, the MC shifts receiving a command from ESS. When the MC receives no command from ESS for a certain time after the end of print operation, the MC shifts to Save Energy Mode 1. Further, a certain time after the MC shifts to the mode 1, the MC shifts to the mode 2 receiving a command from ESS.
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Table 3 shows the state of the DC power supply in each operation mode and the operating status of each system. Table 3
Fusing System (F)
Run Running Mode Kept at operation temp Rotating at run speed Operating
Standby Ready Mode
Save Energy 1
Save Energy 2
Save Energy 3
Sleep Mode
Kept at ready temp
Low Power Mode Kept at low temp
Asleep
Semi Low Power Mode Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep (but rotating (low speed) for 60 min after power off.) Asleep Waiting to receive.
Asleep (but rotating (low speed) for 60 min after power off.) Asleep Waiting to receive.
Not accessible ○ × × × × × × × × × ×
Accessible
Exposure System (ROS) Record System (Transfer, development, etc.) F Exhaust Fan / F Intake Fan
Rotating (high speed)
Rotating (low speed)
Rotating (low speed)
Transfer Intake Fan ESS
Rotating Operating
Rotating On standby
HDD (Ref.)
Accessible
Accessible
Rotating HDD asleep. Waiting to receive. Accessible
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ × × ×
ESS
IOT
IIT
+3.3VDC +5VDC +12VDC +24VDC +5VDC +12VDC +24VDC F AC +5VDC +12VDC +24VDC
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ O = ON, X = OFF
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○ ○ ○ × × × × × × × ×
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Interlocks Component Name and Function Front Door Interlock Switch HCF Front Cover Interlock Switch MSI Interlock Switch
L/H Cover Interlock Switch (IOT) Figure 4 IOT Interlocks
The Front Door Interlock detects whether the Front Door is opened or closed. When open, it shuts off +24VDC to various motors. The MSI interlock (only on machine without the optional HCF) detects whether the MSI is opened or closed. If open it removes the power to various motors. The HCF Front Cover Interlock detects whether the HCF front cover is opened or closed. If open it removes +24VDC from the HCF Takeaway Motor. The L/H Cover Interlock detects whether the left hand cover is opened or closed. If open, it removes +24VDC from the Takeaway Motor 1 and Takeaway Motor 3.
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Operation with an Interlock Open Figure 5 shows that a machine without an HCF has the MSI and Front Door interlocks connected in series. If one of the switches opens, +24VDC for the motors and the HVPS will be removed.
Figure 5 Open Interlock
A machine that has an HCF will have a shorting wire in place of the MSI Interlock Switch (done at install) so the power will be removed from the above components if the Front Door Interlock Switch is opened. If the L/H Cover Interlock Switch of the HCF is open, the +24VDC is removed from Takeaway Motor 1 and Takeaway Motor 3. If the HCF Front Cover Interlock Switch (connected to the HCF PWB) is open, the +24VDC is removed from the HCF Takeaway motor. The Xerox 4110 interlock switches do not have a logic side. There is no +5VDC switched with the interlocks. Instead the MCU PWB monitors the opening and closing of the Front Door Interlock Switch and the ON/OFF status of the Drum Detect Switch (see the Xerographic Module) controlling the supply of +5VDC to the ROS.
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(Chain 2) Mode Selection
Introduction Module Overview This module contains the names, locations and functions of the components in Chain 2 Mode Selection.
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Technical Overview The main functions of this module are to store data selected through the use of the buttons and switches on the UI and touch . It is also to display the machine status on the UI.
UI ( Interface) Configuration The Xerox 4110 has a large UI screen as shown in Figure 6
Figure 6UI
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Component Name and Function
Inverter PWB
Touch
Back Light LCD PWB
LCD
UI I/F PWB
VR PWB
Switch/LED PWB Figure 7UI Components
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The Switch LED PWB consists of switches and LEDs required for operating the machine The VR PWB is equipped with the dial to adjust the brightness and of the screen. The LCD is the liquid crystal screen used to display the set-up data and display the machine status. The LCD PWB drives the LCD to display data from the UI I/F PWB The Inverter PWB turns on the Back Light The UI I/F PWB controls the switches, LEDs, LCD, etc. that belong to the control . Data to be controlled is sent from the ESS PWB. The Touch is used to make selections by touching icons on the LCD. The Back Light is used to illuminate the LCD.
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(Chain 3) Machine Run Control
Introduction Module Overview This module describes the names, locations, and functions of the chain 3.
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Technical Overview Machine Self Test This section describes the components shown in Figure 8.
DADF PWB IPS PWB BP PWB ESS PWB
NVM PWB Finisher PWB
I/F PWB IOT Driver PWB MCU PWB Tray Module PWB
HCF PWB
Figure 8PWB Locations
The MCU PWB controls the IOT, the HCF, and the Finisher. The IOT DRIVER PWB, the Tray Module PWB and the HCF PWB are connected to the MCU PWB. The NVM PWB is the nonvolatile memory installed on the MCU PWB. The IOT Driver PWB relays data from the MCU PWB and drives the components of the IOT. The IOT Driver PWB is connected the MCU PWB with an FCC Cable.
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The ESS PWB controls the entire system for scan, print, software etc. and is connected to the MCU PWB and the IPS PWB. The BP PWB connects the ESS PWB and the MCU PWB. The Tray Module PWB relay data from the MCU PWB and controls the components of the tray module The HCF PWB controls the functions of the HCF. The IPS PWB controls the IIT/IPS. The DADF PWB is connected to the IPS and is controlled by the IPS PWB. The DADF PWB controls the functions of the DADF. The Finisher PWB controls the Finisher functions other than the decurling area. The MCU PWB through the I/F PWB controls the Finisher PWB. The I/F PWB is the IOT to Finisher interface. Figure 9 shows this interconnectivity.
Figure 9 PWB Connections
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Billing Meter The billing meter is a software meter. The range of count is 0 39,999,999. The actual maximum display value is 9,999,999, just seven digits. Billing Management The Billing Meter is stored in three different areas so that no data will be lost. It is stored in: Master Meter:
EEPROM in the ESS PWB
Backup Meter 1:
NVM PWB on the ESS PWB
Backup Meter 2:
MCU PWB
Billing Meter Type Table 4 shows the current types of billing managed by the Xerox 4110.
Table 4 Billing Type Counter Type
Service for Counting Up
Print Service B & W
The following outputs under the Printer feature: Normal Print, Toner Save Mode Print, Report Print, and Print in Diagnostic Mode
Copy Service B & W
All the outputs under the Copy feature
Large Size B & W
Regardless of print or copy
(IBG only)
Paper equal to or larger than Fast Scan 279mm (11') x Slow Scan 400mm The same copy/print is recounted that another counter does.
Modal B&W
Modal Count* *Modal Count The modal count is used to learn the quantity of prints for discount billing The normal counter and the modal counter are used to count a predetermined quantity of prints. If the actual total count is larger than the predetermined one, the modal counter does not count the prints over the predetermined amount. The difference between normal count and modal count is used to determine the discount billing.
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Billing Meter Display Counts by the billing meters described in ‘Billing Meter Type’ are added for display the Meter 1, Meter 2, and Meter 3 in the check meter menu. The meters are displayed on the control panes by pressing the Check Machine (Check Meter) button. The relationship between the three meters and the types of counters to be added for display by the individual meters. Currently there are three Fx types and two IBG types as shown in Table 5 and in Table 6
Table 5 FX Meter Display and Counter Displayed
Billing Meter Type Billing 1
Billing 2
Billing 3
Print Service B & W
Print Service B & W
Print Service B & W
+ Copy Service B & W
+Copy Service B & W
+ Copy Service B & W
Meter 2
None
Copy Service B & W
Modal B&W
Meter 3
None
Print Service B & W
None
Meter 1
Table 6 IBG Meter Display and Counter Displayed
Billing Meter Type Billing 1
Billing 2
Print Service B & W
Print Service B & W
+Copy Service B & W
+ Copy Service B & W
Meter 2
Copy Service B & W
Modal B&W
Meter 3
Print Service B & W
None
Meter 1
The current default Billing Meter type is Billing 1 and can be changed in NVM (720-002) in the diagnostic mode. The procedure for changing the billing meter type is: Set the system data Billing Meter Type Change Flag to ON. Change to the desired Billing Meter Type. Note: Although it is possible to change the Billing Meter type, it should NEVER be done unless directed to do so by sales. Note: Setting the Billing Type Change Flag to ON or a specific value for Billing Meter Type requires and predefined code to be entered. This information will be given to you when the billing change is necessary.
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What is counted The items counted are explained in Table 7
Table 7 Counted Throughput Material Item
Count up
Normal Print
Y
(Print/Report/Copy) Insert (without image)
N
Cover (without image)
N
Print & Copy Service: A sheet inserted in the OHP Insert function Print & Copy Service: No Image (Blank Page) in the Cover function is selected. Print & Copy Service: The first page of text is specified as the cover. (For duplex, the first and second pages are treated as the cover.) Copy Service: Blank page, etc. inserted in the Build Job function In duplex print, an additional blank page, etc., which becomes the back of an oddnumbered page, for adjusting page quantity. A page for print resulting in a blank page is counted for billing. Wrong system data set for selecting paper size, improperly positioning tray guides and MSI paper size mismatch (If the MC stops before making a print, it is not counted for billing.) A print is made onto paper stock selected. It is counted for billing regardless of print quality. Copy Service: The MC makes a solid print if it detects anything reproduction of which is prohibited. A print in the case, where System has determined that the image can’t be guaranteed due to a failure and then output it. A test pattern for gradation adjustment is printed.
Cover (with image) Y Blank Sheet Insert (instructed by )
N
Blank Sheet Insert (System Operation)
N
Blank Page
Y
Print by wrong operation (Paper size mismatch)
Y
Print by wrong operation
Y
(Paper stock mismatch) Print for prevention of forgery (Solid print)
Y
Abnormal print (determined by System) N Gradation Adjust Chart
Outline
Non-CE Mode
Y
CE Mode Y
Other: report output
20
System-generated info is printed. (Report Service)
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When Counting Happens The meters are advanced when the following happens. 1. Normal Counting A properly printed page is counted when it is output into the Finisher. Simplex Print and Side 2 of Duplex Print: Top Tray: when the Top Tray Exit Sensor has sensed a print properly ing through. Stack Tray: when the Compiler Exit Sensor has sensed a print properly ing through and when in the case of sheet-by-sheet output, the Eject Sensor has sensed a print properly ing through. Folder Tray: when the Folder Path Sensor 3 has sensed a print properly ing through. Booklet Tray: when the Booklet In Sensor has sensed a print properly ing through. Side 1 of Duplex Print: when the trail edge of a properly printed page has ed the F Exit Switch n the process of inverting the paper. 2. Recovery and Correction count At the time of recovery from a problem etc., a print that has been counted is counted again. There is no subtraction for correction If side 2 of a duplex print cannot be completed due to a failure after side 1 is counted, recovery will be performed. To recover from a duplex failure, the machine starts with side1. At this time side 1 is not counted since it has been counted previously. If a job cannot be resumed due to a problem etc., prints output before the occurrence of the problem are treated as normal for counting. There is no correction made at this time.
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Counter Value Check/Correction The billing meter consists of the three counters in total, the main counter and two backup counters. The three counters are compared. If the values are different a correction will be made or action taken for a failure. The counter is checked at the following times: At power on (soft reset is included). When sleep mode is cleared. After the IOT cycle down. Like the Billing Meter data, the Product Number and Serial number are each stored in three locations. At the time the counter value is checked, all three pieces of data are compared. A check of the Product Number and Serial number is made before the meter value. If one of the three values is different, it will be treated as a system failure and no meter check will be made. If a meter check is made and one of the values does not match the other two, the mismatched value will be adjusted to match the other two. A manual correction needs to be made if one of the following happens: The result of the meter check shows that there are three different counts and the machine shuts down with a failure. The ESS PWB or the MCU PWB is replaced. The manual correction is made using dC132-Billing Data Matching and Serial Number Setup.
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(Chain 5) DADF
Introduction This module describes the names, locations, and functions of the Chain 5 Document Transportation. The main function of the DADF is to transport a document or series of documents and scan the images. This DADF uses a CVT (Constant Velocity Transport), which enables the scanning of both sides in one . Using the CVT method, the IIT Lamp Carriage is fixed at a certain position (Scan Position) where side one is scanned. At the same time, The CIS ( Image Sensor), install in the DADF, scans side two. The DADF does have the capability to invert a document, but this is not necessary or used in Xerox 4110.
DADF Specifications
How to Load Documents Documents are loaded image side up and ed at the center. When mixed size documents are loaded, the document guides are adjusted to the largest document and the smaller documents are aligned with the rear guide.
Document Stack Capacity The maximum numbers of sheets of paper that can be stacked in the document tray are as follows: Light paper (38-49gsm):
250
Plain paper (50-80gsm):
250
Heavy paper (81-128gsm):
150 (for reference)
Heavy paper (129-200gsm):
100 (for reference)
Document Feed Sequence The stacked documents are feed and transported one by one in sequence starting with the top document.
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Document Scan Speed When images on a document are scanned, the document is transported at a speed that depends on the magnification ratio. For an enlarged copy, the speed is reduced, while for a reduced copy the speed is the same as for an identical copy. Table 8 shows the transport speed corresponding to the magnifications. Table 8 Scan Speeds
Scan Magnification
Scan Speed (mm/sec)
25.0-100.0%
460.0
100.1-104.5%
440.0
104.6-150.0%
293.3
150.1-200.0%
220.0
200.1-300.0%
146.7
300.1-400.0%
110.0
Document Transport Path
Figure 10 Document Path, Drives and Sensors
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Loading Documents
Component Name and Function
DADF Level Sensor Tray Motor
Bottom Sensor
Tray Interlock
Figure 11 DADF 1
Feeder Cover Interlock Switch Document Set LED
Document Set Sensor
L/H Cover Interlock Sensor
Figure 12 DADF 2
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Tray APS Sensor 1 Tray APS Sensor 3
Tray APS Sensor 2
Figure 13 DADF Tray The Tray Motor is the stepper motor that rotates CCW to make the document tray rise, and rotates CW to make it lower. The DADF Level Sensor senses that the document tray has risen. The Bottom Sensor senses that the document tray is lowered. The Tray Interlock Sensor detects whether the document tray is opened or closed. The Document Set LED lights when the document tray is loaded with documents. The Document Set Sensor detects whether or not there are any documents in the tray The Feeder Cover Interlock Switch detects whether the Feeder Cover is open or closed. The L/H Cover Interlock Sensor detects whether the L/H Cover is open or closed. The Tray APS Sensor 1 senses the size of a document in the fast scan direction, based on the position of the document tray guides The Tray APS Sensor 2 senses the size of a document in the fast scan direction, based on the position of the document tray guides. The Tray APS Sensor 3 senses the size of a document in the fast scan direction, based on the position of the document tray guides.
Operation When Documents are Loaded When documents are properly loaded in the document tray, with their lead edges against the left side, the Document Set Sensor senses them. When the Start Copy button is pressed and documents are sensed in the tray or when documents are loaded, depending on the settings, the Tray Motor rotates CCW and raises the tray. When the top of the documents on the tray pushes up the Nudger Roll, the actuator blocks the DADF Level Sensor. This state means that the tray has reached the document feed position. The Tray Motor stops and documents start feeding from the tray.
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As documents are fed, the stack of documents is reduced in height. When this lowers the Nudger Roll enough to unblock the DADF Level Sensor, the Tray Motor rotates CCW and raises the tray to maintain the feed position. When all the documents are fed out the Document Set Sensor is blocked. The Tray Motor rotates in the CW direction to lower the tray. When the tray has lowered, the actuator blocks the Bottom Sensor, under the tray. The Tray Motor stops. At the same time the Document Set LED is turned off.
Document Size Sensing Document width sensing is based on the combinations of the sensors mentioned in Table 9 Table 9
Type
Sensor Name
How to sense
Sensor that senses width between doc guides
Tray APS Sensor 1 The Rack Gear and Actuator that move in Tray APS Sensor 2 synch with the doc tray guides make light blocked from each sensor or make light Tray APS Sensor 3 received by each.
Sensor that senses size of running paper in fast scan
No. 1 APS Sensor
Light is blocked from/received by each sensor during paper transportation.
No. 2 APS Sensor No. 3 APS Sensor
The guide width sensing is based on combinations of blocked and unblocked Tray APS Sensors 1 through 3. This is done through the movement of the side guides. Table 10 shows the states of the sensors based the width of the document. Table 10
Size in Fast Scan
Tray APS Sensor 1
Tray APS Sensor 2
Tray APS Sensor 3
297.0mm
H
L
H
279.4mm
H
L
L
266.7-267mm
H
H
L
254-257mm
H
H
H
215.9mm
L
L
H
210mm
L
L
L
203.2mm
L
H
L
182-194mm
L
H
L
139.7-148mm
L
H
H
Document size in the fast scan direction is determined when the lead edge of a document reaches the Pre Regi Sensor during the feed preregistration operation. The result of this document size sensing is sent to the IISS.
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Document length in the slow scan direction starts measurement when the document arrives at the Pre Regi Sensor. At this time the pulses of the Pre Regi Motor start being counted. When the trail edge of the document es the Feed Sensor the counting stops. The pulse count is then calculated to determine the length of the document in the slow scan direction.
Document Feed and Registration
Component Name and Function DADF Feed Clutch
DADF Feed Motor DADF Feed Sensor
Figure 14 DADF Feed 1
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DADF Pre Regi Motor
No2 APS Sensor
Pre Regi Sensor
No1 APS Sensor No3 APS Sensor DADF Regi Motor
Figure 15 DADF Feed 2
Lead Regi Sensor
Baffle Solenoid DADF Regi Sensor
Figure 16 DADF Registration The DADF Feed Motor is the stepper motor that rotates the Nudger Roll and the Feed Roll CCW and the Invert Roll in both directions The DADF Feed Clutch transfers drive from the DADF Feed Motor to the Nudger Roll and the Feed Roll The DADF Feed Sensor is located just behind the Feed Roll and sensed that a document feed out is finished. This triggers the start/end of pre-feed
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The DADF Pre Regi Motor is the stepper motor that drives the Takeaway Roll and the Pre Regi Roll CCW. The Pre Regi Sensor senses that the previous document has let the Pre Regi Roll and triggers the start of pre-registration of the next document. The No 1 APS Sensor senses the size of a document in the fast scan direction. The No 2 APS Sensor senses the size of a document in the fast scan direction. The No 3 APS Sensor senses the size of a document in the fast scan direction. The DADF Regi Motor is the stepper motor that drives the Regi Roll in both CCW and CW directions The DADF Regi Sensor senses that the document has left the Regi Roll. The Lead Regi Sensor senses the lead edge of a document immediately before scanning starts. The Baffle Solenoid releases the baffle to prevent damage to a document forming a buckle.
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First Document Pre-feed When the DADF Feed Motor starts and the DADF Feed Clutch turns on, the drive from the DADF Feed Motor is transferred to the Nudger and Feed Rolls. The Nudger Roll moves the document to the nip of the Feed and Retard Rolls. When the lead edge of the document reaches the Takeaway Roll, the DADF Feed Clutch turns off. When the DADF Feed Sensor detects the trail edge of the document, the next document starts pre-feed.
Second and Subsequent Document Pre-feeds When the DADF Feed Motor starts and the DADF Feed Clutch turns on, the drive from the DADF Feed Motor is transferred to the Nudger and Feed Rolls. The Nudger Roll moves the document to the nip of the Feed and Retard Rolls. When the DADF Feed Sensor detects the lead edge of a document, the DADF Feed Clutch turns off. This makes the document stop 5mm short of the Takeaway Roll. The remaining documents pre-feed in the same manner making the DADF faster.
Pre-registration The Feed Roll and Nudger Roll transport a pre-fed document to the Takeaway Roll. The Takeaway Roll transports the document to the Pre Regi Roll increasing its speed. The Pre Regi Roll drives the document and makes the lead edge of the document strike against the Regi Roll. Since the Regi Roll stops the document, and the trail is still being driven, this causes a buckle in the document. This corrects any skew in the document. After a specified time the Regi Motor drives the Regi Roll and transports the document to the scan position.
Preventing Document Damage If a document forms a buckle with its lead edge caught by the Regi Roll, it may cause damage to the document. To prevent this, the Regi Roll is rotated backwards for a brief period when the lead edge of the document strikes it. When the document forms a buckle the Pre Regi Roll captures its trail edge. If there is any strain of the document at that time it can cause damage to the document. To prevent this, the sliding rail allows the Pre Regi Roll to move freely in the direction of document movement and the Baffle Solenoid releases the baffle. If any load is on the document in the chute when it forms a buckle, it may cause damage to the document. To prevent this, the Regi Sensor On signals the Baffle Solenoid to lift the baffle.
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Techniques for Preventing Damage to Documents To prevent damage to documents, the three techniques are adopted. See Figure 17.
Rotating Regi Roll backward If a document forms a buckle with its lead edge caught by Regi Roll, it may cause damage to the document. To prevent this, Regi Roll is rotated backward for a moment when the lead edge of the document strikes there. This prevents the lead edge of the document from being caught by Regi Roll.
Pre Regi Roll’s free drive When the document forms a buckle, Pre Regi Roll captures its trail edge. If any load is on the document at this time, it may cause damage to the document. To prevent this, the sliding rail allows Pre Regi Roll with the captured trail edge to move freely in the direction of drive.
Releasing Baffle If any load is on the document in the chute when it forms a buckle, it may cause damage to the document. To prevent this, triggered by Regi Sensor On, the Baffle Solenoid operates and releases Baffle.
Figure 17 DADF Deskew
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Document Scanning and Output Component Name and Function
Invert Sensor 1
Platen Motor
Invert Sensor 2
Simp/Dup Gate Solenoid
Out Sensor Figure 18
CIS
CIS DC/DC Convert PWB
1P Duplex PWB
Figure 19
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DADF Exit Motor DADF Exit Sensor 2 Exit Roll Nip/Rls. Solenoid
DADF Exit Sensor 1
Exit Gate Solenoid
Figure 20
The Platen Motor drives the Platen Roll and the Out Roll to transport a document through the Scan Position. The Out Sensor detects the position of the document after the scan position. The Inverter Sensor 1 detects the document moving towards the Invert Roll. The Inverter Sensor 2 detects the document after it es the Invert Roll The Sip/Dup Solenoid operates the Sip/Dup Gate. The CIS DC/DC Convert PWB supplies power to the CIS. The CIS scans side two of a document. The 1P Duplex PWB controls the CIS through the CIS DC/DC Convert PWB. The DADF Exit Sensor 1 detects the lead and trail edges and signals for switching the output speed. The DADF Exit Sensor 2 detects the document that has ed Exit Roll 2. The DADF Exit Motor drives the Exit Roll. The Exit Gate Solenoid operates the Exit Gate. The Exit Roll Nip/Release solenoid controls the Inverter Roll’s nip.
Document Scanning Operation For Side 1 scanning, the Regi Motor drives the Regi Roll to feed a document to the Scan Position. At this time, the Pre Regi Motor drives the Pre Regi Roll and Takeaway Roll so that they can transport the document with its buckle retained, between Regi Roll and Pre Regi Roll. The Platen Motor drives the Platen Roll and Out Roll. The Platen Roll and Out Roll drive the document through the Scan Position. Receiving drive from Exit Motor, Exit Roll 1 transports the document that has left the Scan Position at scan speed. Triggered by the Pre Regi Sensor Off, the Baffle Solenoid closes the Baffle in preparation for the Pre-Registration operation of the next document Immediately after the document es the Scan Position, the CIS scans side 2.
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CIS Scanning
Figure 21 CIS Example A CIS ( Image Sensor) is an array of LEDs and sensors used to scan a document. CIS scanners gather light from red, green and blue LEDs (which combine to provide white light) and direct the light at the original document being scanned. The light that is reflected from the original is gathered by a Selfoc lens, with a very sort focal length, and directed at an image sensor array that rests close to the document being scanned. The sensor then records the images according to the intensity of light that hits the sensor. Figure 21 is an example of a CIS. In the Xerox 4110 the CIS DC/DC Convert PWB supplies power to the CIS. The CIS scans side two of a document. The 1P Duplex PWB controls the CIS through the CIS DC/DC Convert PWB. Recorded images are stored on the Extension Memory PWB.
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Document Transportation Figure 22 shows the path of a document from the document tray through delivery to the output for 1 two sided. To observe the 1-sided scan, which requires the document to be inverted, look at the animations in the EPSS CD.
Figure 22
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(Chain 6) Imaging
Introduction This module describes the names, locations, and functions of the Chain 6 Imaging. The main function of the Chain 6 consists of the IIT (document scan) and the ROS (image exposure data). The main functions are as follows: To have the Exposure Lamp scan a document and expose it to light. To have the CCD Image Sensor read and convert the analog image data into digital image data. To send the digital image data to the Controller (ESS). The first three items are functions of the IIT. To generate laser beams based on the image data from the Controller. To generate the latent electrostatic image on the drum using raster scanning with the laser. The last two items are functions of the ROS. The Xerox 4110 IIT has color scanning capability that is not currently used.
IIT/IPS The main functions of the IIT (Image Input Terminal) and the IPS are as follows: Initializing at power on. Document Size sensing Document Scanning Operation (scanning an image on the platen glass). Image processing.
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Technical Overview
IPS PWB PSDC PWB
1P Duplex PWB Extension Memory PWB
Figure 23
The IPS PWB is explained in Chain 3, Machine Run Control. The Extension Memory PWB controls the image data that the CCD Image Sensor has read and the image data from the 1P Duplex PWB. The Extension Memory PWB is loaded with memory. It writes data into memory and reads it out from the memory as required. The 1P Duplex PWB is thoroughly explained in Chain 5 DADF. The PSDC supplies a DC voltage to the Extension Memory PWB and the 1P Duplex PWB.
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Lamp Fan
IPS Fan
Lens and CCD
CCD Fan
Exposure Lamp
Lamp Ballast PWB
Figure 24
The Exposure lamp is a xenon lamp that exposes the document to light The Lamp Ballast PWB controls the on/off of the lamp using a signal from the IPS PWB. The Lens receives the scanned image and es it to the CCD Image Sensor. The CCD Image Sensor converts the analog image data received from the lens and converts it to digital data. The Lamp Fan prevents the temperature of the Exposure Lamp from rising when the lamp is still and the CVT is used to scan an image (DADF Operation). The IPS Fan prevents the temperature of boards such as the IPS PWB and the Extension Memory PWB from rising. The CCD Fan prevents the temperature of the CCD Image Sensor from rising.
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Carriage Motor Platen Angle Sensor
IIT Regi Sensor
APS Sensor2 APS Sensor1 Platen Interlock Switch
Figure 25 The APS Sensor 1 detects the document length in the slow scan direction. The APS Sensor 2 detects the long document length in the slow scan direction. The Platen Interlock Switch monitors the opening and closing of the Platen Cover or DADF. It also is used to determine when to read the size of a document on the platen glass. The Platen Angle Sensor monitors the Platen Cover or DADF to see what angle either of them is open. It also is used to determine when to read the size of a document on the platen glass. The Carriage Motor is the stepper motor that drives the Full Rate Carriage and the Half Rate Carriage. The IIT Regi Sensor detects the position of the Full Rate Carriage. The lower portion at the rear of the Full Rate Carriage functions as an actuator to block the IIT Regi Sensor.
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Document Scanning Overview Half Rate Carriage
No.2 Mirror
Full Rate Carriage Exposure Lamp No.1 Mirror
Lens and CCD
A IIT Regi Sensor
Carriage Motor
No.3 Mirror
Figure 26
The Full Rate Carriage and the Half Rate Carriage move to scan the document. The Exposure Lamp is installed on the Full Rate Carriage and is used to illuminate and expose the document on the platen glass. The Half Rate Carriage is linked to the Full Rate Carriage and moves half the distance. The analog image of the exposed document is reflected off the Number 1 Mirror on the Full Rate Carriage and the Number 2 Mirror and Number 3 Mirror on the Half Rate Carriage. From there, it is reflected through the Lens to the CCD Sensor and converted to a digital image.
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Document Scanning Position Overview (DADF) The Full Rate Carriage moves so the IIT can perform operations that will be discussed later. Figure 27 shows the position where the operations are performed.
White Ref Board Position Regi Position for Control White Ref Board Startup Position
Platen Regi Position
CVT Scan Position
• • •
•
AGC/AOC/Shading 1 Position Platen Scan White Fluctuation Adjust Position Platen Scan Black Fluctuation Adjust Position CVT Scan White Fluctuation Adjust Position (Monitor of light qty before job) (Platen/CVT Mode Overall
Magnification)
Doc Size Sensing Position
Full Rate Carriage IIT Regi Sensor
Shading 2 Position • (Platen/CVT Mode Overall Magnification) Figure 27
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Initialization At power on or when the machine returns from the power saver mode, the IIT performs an initialization of the carriage. Figure 28 shows the initialization operation Power ON .
Initializes Carriage Sets Full Rate Carriage at the white ref board position.
Exposure Lamp ON
Performs AGC
Carriage Initialization When the Full Rate Carriage is on the left side of the control regi position (closer to the startup position): The Full Rate Carriage is moved to the right side of the control regi position then to the left, and finally positioned at the white reference board position. When the Full Rate Carriage is on the right side of the control regi position (document size sensing position): The Full Rate Carriage is moved to the white reference position, then to the right side of the control regi position, and then left as far as the white reference board position.
Exposure Lamp OFF
Performs AOC.
Exposure Lamp ON
Acquires Shading Correction Data.
Adjusts White Fluctuation Adjust Reference Data Exposure Lamp OFF
Moves Carriage Sets Full Rate Carriage at the doc size sensing position
Standby Figure 28
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Document Size Sensing The CCD Image Sensor senses the width of a document (size in the fast scan direction) and the APS Sensors sense the length of a document (size in the slow scan direction). The size of a document is sensed when the Platen Cover is closed or when Start is pressed with the Platen Cover open. The CCD Image Sensor senses the width of the document in millimeters and determines the size in the fast scan direction. The APS Sensors detect whether there are any document of the same size in the fast scan direction. As a result, LEF (long edge feed) SEF (short edge feed) are determined APS Sensors 1 and 2 are capable of distinguishing 8.5 x 11 SEF, 8.5 x 13 SEF and 8.5 x 14 SEF from each other. Table 11 shows the standard sizes that can be sensed by the IIT. Table 11 Fast Scan Width (mm)
APS Sensor 1
APS Sensor 2
100
OFF
OFF
Fast Scan Size Sensing Range (mm) 90-115
OFF OFF OFF OFF OFF OFF ON
OFF OFF OFF OFF OFF OFF OFF
ON
-
ON
-
A4SEF
101.6 105 127 128 139.7 148 182 Taiwan) 194.0*9 GCO) 195.0*9 210
ON
- *18
8.5x11SEF*2
215.9
ON
OFF
8.5x12.4SEF*13 8.5x13SEF*13
215.9 215.9
ON ON
ON ON
8.5x14SEF*13 B4SEF
215.9 257 Taiwan) 267.0*9 GCO) 270.0*9 279.4 279.4
ON ON ON
ON ON -
Standard Doc Size Official postcard SEF*7 Post Card SEF*7 A6SEF*7 5x7SEF*15 B6SEF*15 5.5x8.5SEF*1 A5SEF*1 B5SEF 16 Fold SEF*10
8 Fold SEF*10 11x14.9SEF*4 11x17SEF*4*5 A3SEF*5 Official postcard LEF*1 Post Card LEF*1
44
mm
mm-2
Inch 13-1
Inch 13-2
Inch 14
∆*7
∆*7
×
×
×
90-115 90-115 115-134 115-134 134-163 134-163 163-202
× o*7 ∆*15 o*15 × o*1 o
× o*7 ∆*15 o*15 × o*1 o
∆*7 o*7 ∆*15 o*15 × o*1 o
∆*7 o*7 ∆*15 o*15 × o*1 ×
o*7 ∆*7 ○*15 ∆*15 o*1 × ×
188-202
o *9*10
▲ *9*10
×
×
×
202213*3 213*3226 202-226 202-226
o*3
o*3
o*3
×
×
▲*2* 3 × ×
▲*2* 3 × ×
○*3
○
○
∆*13 o*13
∆*13 ∆*13
202-226 226-267
× o*11
× o*11
∆*13 o*3*1 3 ∆*13 o
∆*13 ×
o*13 ×
o*10* 9*11 *12
▲*10 *9*11 *12
×
×
×
× ▲*5
∆*4 o*4
∆*4 o*4
∆*4 o*4
o*5 ∆*1
o ×
o ×
o ×
×
∆*1
∆*1
∆*1
ON
-
262*11275*12
ON ON
ON ON
267-289 267-289
297 148
ON OFF
ON -
289-307 138-163
× o*5*1 2 o*5 ∆*1
152.4
OFF
OFF
134-163
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Standard Doc Size
Fast Scan Width (mm)
APS Sensor 1
APS Sensor 2
B6LEF*14 B5SEF A5LEF
182 182 210
OFF OFF OFF
OFF OFF OFF
5.5x8.5LEF*2
215.9
OFF
OFF
8x10LEF*6 B5LEF*6
OFF OFF OFF
OFF OFF -
Executive LEF*6
254 257 Taiwan) 267.0*9 GCO) 270.0*9 266.7
8x10.5LEF*6
16Fold LEF*10
OFF
-
OFF
OFF
266.7
OFF
OFF
8.5x11LEF*8
279.4
OFF
OFF
A4LEF
297 OFF OFF ⊄ο…can be sensed.
Fast Scan Size Sensing Range (mm) × 163-202 202213*3 213*3226 226-262 226-262 262*11275*12 262275*12 262275*12 275*12289 289-307
Inch 13-1
Inch 13-2
Inch 14
o*14 o*3 ▲*2* 3 ×
× o*3 o*3
× × o
× × o
∆*6-1
∆*6-1
∆*6-1
o*11
o*11
o*6-2
×
×
o*10* 9*11 *12
▲*10 *9*11 *12
×
×
×
×
×
×
×
×
∆*6-1
o*6-2 *12 ∆*6-1
o*6-2 *12 ∆*6-1
o*8*1 2 o*8
▲*8
o
o*12
o*12
o*8
o
o
o
mm
mm-2
o*14 o*3 ▲*2* 3 ×
∆…can be sensed with other sizes unavailable ▲…can be sensed with the range of other sizes for sensing narrowed in NVM. ×…cannot be sensed (determined as another size or undetermined) *1: In NVM “A5SEF or Postcard” or “Official postcard LEF or Postcard LEF” can be selected. *2: In NVM “8.5x11SEF & 5.5x8.5LEF” available or unavailable for size sensing can be selected. *3: In NVM Fast Scan Threshold (213mm) for “A4SEF & A5LEF” and “8.5x11SEF & 5.5x8.5LEF” can be changed with “8.5x11SEF & 5.5x8.5LEF” available for sensing. (To prevent faulty sensing) *4: In NVM “11x17SEF” or “11x14.9SEF” can be selected. *5: In NVM “A3SEF” or “11x17SEF” or “Mix of A3SEF & 11x17SEF” can be selected. *6: In NVM “B5LEF or Executive LEF” or “Mix of 8x10LEF & 8x10.5LEF” or “B5LEF or Executive LEF, and 8x10LEF, and 8x10.5LEF unavailable for sensing” can be selected. *7: In NVM “A6SEF” or “Official postcard SEF (mm table) or Postcard (Inch table) “ can be selected. *8 In NVM “A4LEF” or “8.5x11LEF” or “Mix of A4LEF & 8.5x11LEF” can be selected. *9: In NVM “Taiwan” or “GCO “ can be selected as 16 Fold/8 Fold Size. *10: In NVM “16 Fold & 8 Fold” available or unavailable for sensing can be selected. *11: In NVM Fast Scan Threshold (262mm) for “B4SEF & B5LEF” and “16 Fold LEF & 8 Fold SEF” can be changed with “16 Fold & 8 Fold” available for sensing. (To prevent faulty sensing) *12: In NVM Fast Scan Threshold (275mm) for “8.5x11LEF & 11x17SEF” and “16 Fold LEF & 8 Fold SEF” can be changed with “16 Fold & 8 Fold” available for sensing. (To prevent faulty sensing)
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*13: In NVM “8.5x12.4SEF” or “8.5x13SEF” or “8.5x14SEF” can be selected. *14: In NVM “B6LEF” available or unavailable for sensing can be selected. *15: In NVM “B6SEF” or “5x7SEF” can be selected. *16: In NVM Fast Scan Threshold (226mm) for “A4SEF” and “B4SEF” can be changed. *17: In NVM Fast Scan Threshold (275mm) for “B4SEF” and “A3SEF” can be changed. *18: Undetermined because a border is sensed by APS Sensor 2
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Platen Document Scanning Operation When a document is to be scanned, the IIT performs the scanning after the size is sensed. Figure 29 shows the flow of document scanning. Size sensing is over.
Moves Carriage Sets Full Rate Carriage at White Ref Board Position.
Acquires/Sets Black Fluctuation Adjust Data. Exposure Lamp ON
Acquires/Sets White Fluctuation Adjust Data.
Performs Pre-scan. With pre-scan enabled. Acquires B/W Fluctuation Adjust Data.
Moves Carriage Sets Full Rate Carriage at Startup Position.
Image Scanning Operation Moves Full Rate Carriage to the end of the image area
Exposure Lamp OFF
Figure 29
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After scanning the document, the IIT performs the operation shown in Figure 30.
Scanning is over.
Stops Carriage.
(To reduce an effect of residual vibration on the carriage. No (more)
Is the time from when the last shading correction to the end of scanning a specified time or less? Moves Carriage. Sets Full Rate Carriage at White Ref Board Position. Yes Performs AGC. Performs AOC. Acquires Shading Correct Data. Acquires White Fluctuation Adjust Data.
Moves Carriage. Sets Full Rate Carriage at Doc Size Sensing Position.
Standby
Figure 30
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DADF Document Scanning Operation To scan documents from the DADF, the Full Rate Carriage operation flows as shown in Figure 31. DADF finishes size sensing. Carriage moves. Full Rate Carriage is set at White Ref Board Position. Exposure Lamp ON White Fluctuation Adjust Data is acquired/set. Exposure Lamp OFF Carriage moves. Full Rate Carriage is set at CVT Scanning Position.
Black Fluctuation Adjust Data is acquired/set.
Exposure Lamp ON
White Fluctuation Adjust Data is acquired/set. CVT Image Scanning is performed (DADF) Exposure Lamp OFF
Yes
Is there another document? No
To the operation at the end of doc scanning Figure 31
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After the DADF document is scanned, the carriage operation flows as shown in figure 32.
CVT Image Scanning is over. Full Rate Carriage is set at the control regi position.
Is the time from when the last shading correction to the end of image scanning a specified time or less?
No (more)
Carriage moves. Full Rate Carriage is set at White Ref Board Position. Yes Shading Correct Data is acquired. White Fluctuation Adjust Data is acquired.
Carriage moves. Full Rate Carriage is set at Doc Size Sensing Position.
Standby
Figure 32
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Adjustments or Corrections During Scanning The CCD Image Sensor reads image data from the document. To stabilize the image data, an adjustment is made to the CCD Image Sensor output and a correction to the image data. The CCD Image Sensor output is adjusted through the adjustment of the gain/offset voltage of the amplifier in the analog circuit. This adjustment is AGC and AOC. The reference data is acquired and the correction values are calculated to correct the image data. This data includes Shading correction, White Fluctuation adjustment, and Black Fluctuation adjustment. The following is a description of the adjustments and corrections.
AGC (Auto Gain Control) White Level Rough Adj. The AGC is the function that adjusts the gain so that when the Exposure Lamp is on, the CCD Image Sensor output value can be the target value. The AGC makes a rough adjustment of the white level of the image. The AGC is performed at initialization. With the Exposure Lamp on, the CCD Image Sensor reads on line of image data on the white reference board in the fast scan direction. The average of the readings is obtained, and it is compared with the target AGC value. If the average is not within specification, the gain is adjusted repeatedly per the same procedure until the average is within specification.
AOC (Auto Offset Control) The AOC is the function that adjusts the offset voltage so that when the Exposure Lamp is off, the CCD Image Sensor output value can be the target value. The AOC adjusts the black level of the image. The AOC is performed at initialization. With the Exposure Lamp off, the CCD Image Sensor reads several lines of image data on the white reference board in the fast scan direction. The difference between the average of the readings and the target AOC value is calculated and treated as the offset voltage.
Shading Correction The Shading Correction is the function that adjusts variations in the sensitivity of individual CCD Image Sensor pixels, as well as variations in the output values of individual CCD Image Sensor pixels that are caused by the optical systems non-uniform illumination in the fast scan direction. Shading corrections are performed at initialization.
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White Fluctuation Adjustment To adjust fluctuations in the light quantity of the Exposure Lamp, the white fluctuation adjustment is performed. The White Fluctuation adjustment consists of two processes; acquisition of the white fluctuation adjustment reference data at initialization and the white fluctuation adjustment during document scanning. The acquisition of the data happens when the Exposure Lamp is on and the CCD Image Sensor reads one line of image data on the white reference board in the fast scan direction. The average of the readings is treated as the white fluctuation adjustment reference data. The adjustment happens when the Exposure Lamp is on and the CCD Image Sensor reads one line of image data on the white reference board in the fast scan direction. The average of the readings is compared with the white fluctuation adjustment reference data so that a white level correction coefficient is calculated. With the DADF in use, the white fluctuation adjustment is performed, at both the platen white reference board position and the CVT scanning white reference board position.
Black Fluctuation Adjustment The black fluctuation adjustment is performed to adjust the fluctuations in the black level. The temperature drift of the CCD Image Sensor and the analog circuit cause these. With the Exposure Lamp off, the CCD Image Sensor reads several lines of the image data on the white reference board in the fast scan direction. From the readings, a black level correction coefficient is calculated. When using the platen. The black fluctuation adjustment is performed at the platen white reference board position. When using the DADF the CVT scanning position is used.
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Dark Band Elimination
Figure 33 Dark Band Elimination To prevent the occurrence of dark-band, the Xerox 4110 scanner uses two closely located sensors, a black/white sensor and the green sensor of the RGB color sensor. Both sensors receive the scanned image. If the sensors do not read the same image, it is judged as dust and the corresponding image data is eliminated from the scanned image data by the corrections made in the algorithm.
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Image Processing The image data read by the CCD Image Sensor is processed in the IPS PWB before being sent to the Controller, as shown in Figure 33.
X-Pro (ASIC WOZ2) Conversion of Detected Color Space Brightness→Lab
CCD
Input Correct
Density Adjust
Shading Correct B/W level correct CCD gap correct CVT streak correct CVT mirror image correct
Reflectance→ brightness Negative image editing AE removal
Color Space Convert Doc noise filter out Brightness→ Lab b correction
Detection Fast S. doc detect ACS Background level Doc density Doc noise
Resolution Convert Fast Scan enlarge/reduce Slow S. reduce
Fast Scan Mirror image Shift Repeat
Filter Space filter Edge detect Ghost correct Tag create
MWA/AER
Color Convert
TRC
ED
Adjustments (density/ contrast/color saturation/hue) Background suppress
L-γ correction Lab →XXXX Gamut mapping Black printer create Mono color create ２ colors create
Color balance adjust YMC Kγcorrection
Error diffusion binarize Dither matrix binarize (For multi-valued mode, through) Border erase, Center border erase
Figure 34
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Fan Control Temperature rise is prevented using two fans, the IPS Fan and the Lamp Fan. The fans are on as indicated below Lamp Fan At IIT power on it is at high speed then stops in 5 seconds During platen image scanning it is off During CVT image scanning it is at high speed At standby and any other operations it is off IPS Fan At IIT power on it is at high speed then goes to low speed after 5 seconds During platen image scanning it is on at high speed During CVT image scanning it is on at high speed At standby and any other operations it is at low speed
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ROS The ROS (Raster Output Scanner) emits a laser beams from laser diodes. The on/off emission of the beams is based on image density data from the controller on the ESS PWB. The laser beams are used to create a latent image on the drum surface. Warning – The laser beam is invisible and hazardous to the human eye. Before making and observation of the ROS ensure that the machine is powered off.
ROS Overview The ROS has a six-facet polygon mirror. The ROS exposes the drum to light using 32 beams to scan at the same time. The ROS uses a two-dimension array to do this. The array consists of 32 laser diodes, four in the fast scan direction and eight in the slow scan direction. This is shown in Figure 35.
Slow Scan direction Fast Scan direction LD×32
Figure 35
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ROS Components The ROS components are shown in Figure 36 Caution – Never open the cover. The ROS requires a high level of mechanical precision. Because of this, there are no adjustments on the inside. If the ROS unit is defective, the assembly should be replaced. The SOS PWB and the MPD PWB can, however, be replaced Lens L2
Drum Mirror1 Flat Mirror
Lens L1 Polygon Mirror
SOS PWB ROS Motor
SOS Lens MPD Lens Drum Mirror2
MPD PWB Slit LDD PWB
Drum
Cylinder Lens Wedge
Window SOS Mirror Figure 36 ROS
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The LDD PWB is equipped with 32 laser diodes and it controls the diodes. The LDD PWB is connected to the MCU PWB through which it receives image data from the ESS PWB. The LDD PWB receives a control signal through the MCU PWB. The ROS Motor drives the polygon mirror. The SOS PWB is equipped with the SOS Sensor. The SOS Sensor produces the SOS (Start Of Scan) signal that determines where exposure starts in the fast scan direction. The MPD (Monitor Photo Diode) PWB monitors the light quantity of the laser diode based on incident laser beams
Laser Beam Flow The laser beams become a little diffused by the Collimate Lens (between the Slit and the LDD PWB). The laser beams that have ed through the slit; through the Wedge to the Cylinder Lens. The Cylinder Lens converges the beams to the Polygon Mirror. The laser beams are also reflected off the Wedge and through the MPD Lens for monitoring by the MPD PWB. The Polygon Mirror is a six faceted mirror that rotates at a high speed. The ROS Motor drives the mirror. The rotation of the mirror changes the incidence and reflection angles of the laser beams. This causes the laser beams to scan the Drum from front to rear. The laser beams, from the Polygon Mirror, through lenses L1 and L2 to the Flat Mirror. The laser beams from the Flat Mirror are reflected off the Cylinder Mirrors 1 and 2 and through the window to the Drum surface. When the laser beams start, the one that is deflected closest to the front goes to the SOS Mirror. The SOS Mirror reflects the beam through the SOS Lens to the SOS Sensor. When the SOS Sensor detects the beam, it produces the SOS Signal
Laser Diode Control The laser diode output is controlled by APC (Auto Power Control) and switching control. This is done automatically by using the MCU PWB to control the LDD PWB. The APC automatically adjusts the laser diode light quantity during printing to be equal with a preset value. At certain times this is used to lighten or darken the image as explained in process control in the Marking Module.
ROS Motor Control The ROS Motor is the DC motor that drives the polygon mirror CCW. The MCU PWB controls the motor. The motor turns on when it receives a Cycle Up signal. It turns off after the end transmitting the final image in a series at a specified time after receiving the Cycle Down signal.
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(Chain 7)
Paper Supply
Introduction This module describes the names, locations, and functions of the Chain 7 Paper Supply. It then describes the names, locations, and functions of the Chain 7 Paper Supply components. The main functions of this module are: Tray specifications The layout of the paper transportation path from each tray to the exit Sensing the size of the paper in each tray Raising the trays to the feed position
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Tray Specifications Configuration The paper trays are referred to as shown n Figures 37 and 38.
MSI
Tray2
Tray3 Tray1
Tray 4
Figure 37 Standard Configuration
Tray5 (MSI)
Tray6 (HCF Tray1)
Tray7 (HCF Tray2)
Figure 38 With HCF The paper supply area consists of Trays 1, 2, 3, 4, and MSI as standard. The HCF is an option with Trays 6 and 7. The MSI is relocate to the top.
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Allowable Paper Sizes Table 12 shows the sizes of paper that the trays can hold. The X’s are where not to use and the O’s are where it can be used. Table 12 Paper Sizes Paper Size Standard
Official Postcard SEF Reply-paid postcard SEF A6 SEF B6 SEF A5 SEF A5 LEF B5 SEF B5 LEF A4 SEF A4 LEF A4-Cover SEF A4-Cover LEF Special A4 SEF Special A4 LEF B4 SEF A3 SEF SRA3 SEF Special A3 SEF 4”x6” SEF 5”x7” SEF 5.5”x8.5” SEF 6”x9” SEF 6”x9” LEF 7.25”x10.5” SEF 7.25”x10.5” LEF 8”x10” SEF 8”x10” LEF 8.46”x12.4” SEF 8.5”x11” SEF 8.5”x11” LEF 8.5”x13” SEF 8.5”x14” SEF 9”x11” SEF 9”x11” LEF 11”x15” SEF 11”x17” SEF 12”x18” SEF 12.6”x19.2” SEF 13”x18” SEF 13”x19” SEF 16 Fold SEF (TFX)
○
HCF 1 ×
HCF 2 ×
×
○
×
×
× × ○ × ○ ○ ○ ○ × × × × ○ ○ ○ × × × ○ × × × ○ ○ × × ○ ○ ○ ○ × × × ○ ○ ○ ○ ○ ×
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
Dimensions [mm] 100.0x148.0
Tray 1 ×
Tray 2 ×
Tray 3 ×
Tray 4 ×
148.0x200.0
×
×
×
105.0x148.0 128.0x182.0 148.0x210.0 210.0x148.0 182.0x257.0 257.0x182.0 210.0x297.0 297.0x210.0 223.0x297.0 297.0x223.0 226.0x310.0 310.0x226.0 257.0x364.0 297.0x420.0 320.0x450.0 328.0x453.0 101.6x152.4 127.0x177.8 139.7x215.9 152.4x228.6 228.6x152.4 184.2x266.7 266.7x184.2 203.2x254.0 254.0x203.2 215.0x315.0 215.9x279.4 279.4x215.9 215.9x330.2 215.9x355.6 228.6x279.4 279.4x228.6 279.4x381.0 279.4x431.8 304.8x457.2 320.0x488.0 330.2x457.2 330.2x482.6 194.0x267.0
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
× × ○ × ○ ○ ○ ○ × × × × ○ ○ ○ × × × ○ × × × ○ ○ × × ○ ○ ○ ○ × × × ○ ○ ○ ○ ○ ×
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Dimensions [mm] 267.0x194.0
Paper Size
Standard
Nonstandard
16 Fold LEF (TFX) 8 Fold SEF 267.0x388.0 (TFX) 16 Fold SEF 195.0x270.0 (GCO) 16 Fold LEF 270.0x195.0 (GCO) 8 Fold SEF 270.0x390.0 (GCO) Envelop Length 120.0x235.0 No. 3 SEF 139.7 width 330.0 182.0 length 488.0 100.0 width 330.0 148.0 length 488.0 297.0 width 330.0 210.0 length 241.0 o = can be fed x = can’t be fed
○
HCF 1 ×
HCF 2 ×
○
○
×
×
×
×
○
×
×
×
○
○
○
×
×
×
×
○
○
○
×
×
×
×
×
×
○
×
×
×
×
○
○
○
×
×
×
×
×
×
○
×
×
×
×
○
○
○
○
○
Tray 1 ×
Tray 2 ×
Tray 3 ○
Tray 4 ○
×
×
○
×
×
×
MSI
Tray Capacity Table 13 shows the amounts of paper, according to size, that each tray can hold Table 13 Tray Capacity
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Tray
Stack Height [mm]
Paper Quantity [sheets]
Tray1 Tray2 Tray3 Tray4 MSI HCF1 HCF2
120 175 60 60 27 220 220
80gsm 1100 1600 550 550 250 2000 2000
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Paper Weights Table 14 shows the weights of paper that the trays, the inverter and the duplex path can feed or transport. The X’s are where not to use and the O’s are where it can be used. Table 14 Paper Weights Paper Type Plain paper 64-105 [gsm] Heavy paper 106-216 [gsm] Heavy paper 217-253 [gsm] Carbonless 52-63 [gsm] Transparency Tab (Heavy 1) Tab (Heavy 2) Label Back side of used paper Punched paper
Invert *1
Duplex *1
○
○
Paper type Group*2 Plain
○
○
○
Heavy 1
×
×
×
×
Heavy 2
○
○
○
○
○
Plain
○ ○ ○ ○ ○
× × × × ○
× × × × ○
× ○ × × ○
× × × × ○
OHP Heavy 1 Heavy 2 Label Plain
Paper Feed Tray Tray Tray Tray 1 2 3 ○ ○ ○
Tray 4 ○
MSI
○
○
○
×
×
○ × × × × ○ ○
○
HCF 1 ○
HCF 2 ○
○
○
○
×
×
○
○
○
○
× × × × ○
× ○ × × ○
× ○ × × ○
○ ○ ○ ○ ○ ○ ○ ○ Plain *1 the invert/duplex can transport this paper as long as the paper length is less than 182.2mm *2 this paper type group is a category used for paper feed control.
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Paper Transportation Paper Flow Figures 39 and 40 show the layout of the paper transportation path from each tray.
Figure 39 Path Without HCF
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Figure 40 Path With HCF Paper Path Sensors 1 Tray 5(HCF MSI) Pre Feed Sensor 2 Tray 5(HCF MSI) Feed Out Sensor 3 Tray 6 Pre Feed Sensor 4 Tray 6 Feed Out Sensor 5 Tray 7 Pre Feed Sensor 6 Tray 7 Feed Out Sensor 7 HCF Exit Sensor 8 Feed Out Sensor 1 9 Trans Path Sensor 3 10
Feed Out Sensor 3
11
Feed Out Sensor 4
12
Tray 4 Pre Feed Sensor
13
Tray 4 Level Sensor
14
Tray 4 No Paper Sensor
15
Tray 4 Paper Size Sensor (S5)
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16
Tray 3 Pre Feed Sensor
17
Tray 3 Level Sensor
18
Tray 3 No Paper Sensor
19
Tray 3 Paper Size Sensor (S5)
20
Tray 1 Pre Feed Sensor
21
Tray 1 Level Sensor
22
Tray 1 No Paper Sensor
23
Trans Path Sensor 1
24
Trans Path Sensor 2
25
Feed Out Sensor 2
26
Tray 2 Pre Feed Sensor
27
Tray 2 Level Sensor
28
Tray 2 No Paper Sensor
29
Pre Regi Sensor
30
Side Regi Sensor
31
Side Regi Home Sensor
32
Regi Sensor
33
Duplex Out Sensor
34
Duplex Path Sensor 2
35
Invert Path Sensor
36
Duplex Path Sensor
37
Release Home Sensor
38
Duplex In Sensor
39
F Exit Sensor
40
Invert In Sensor
41
IOT Exit Sensor
42
Invert Out Sensor
Analog Sensors (Switches used in series or parallel with resistors to produce a changeable voltage) A-1
MSI Size Sensor
A-2
Tray 1 Size Sensor
A-3
Tray 2 Size Sensor
A-4
Tray 3 Size Sensor
A-5
Tray 4 Size Sensor
Interlock Switches
66
I-1
Front Cover Interlock Switch
I-2
Marking Drawer Interlock Switch
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I-3
Duplex Drawer Interlock Switch
I-4
Trans Path Interlock Switch
I-5
Left Hand Cover Interlock Switch
Drive Motors Figure 41 shows the rolls driven by the different motors
Figure 41 Drive Motors
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Trays 1 through 4 Component Name and Function Tray2 Nudger Solenoid
Tray2 Feed Lift Motor
Tray2 Level Sensor Tray2 Paper Size Sensor
Tray1 Feed Lift Motor Tray1 Nudger Solenoid
Tray2 No Paper Sensor
Tray1 Level Sensor
Tray1 Paper Size Sensor
Tray1 No Paper Sensor
Figure 42 Trays 1 and 2
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Tray3 Feed Lift
Tray3 Nudger Solenoid
Tray3 Paper Size Sensor
Tray3 Level Sensor Tray3 No Paper Sensor
Figure 43 Tray 3 Note: Trays 3 and 4 are functionally the same. This describes 3 only.
Trays 1,2,3 and 4 Paper Size Sensors detect whether the trays are inserted or not and the also sense the size of the paper in the trays. Trays 1,2,3 and 4 No Paper Sensors detect whether the trays contain paper or not. Trays 1,2,3 and 4 Feed Lift Motors are stepper motors the raise the trays by rotating CCW and feed paper by rotating CW. Trays 1,2,3 and 4 Nudger Solenoids raise and lower the Nudger Rolls in the trays. Trays 1,2,3 and 4 Level Sensors sense that the trays have raised to the feed position.
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Trays 1 through 4 Paper Size Sensing Paper size sensing in the trays is accomplished with a combination of on and off operations of the switches that make up the Tray Paper Size Sensors. When the paper guide of any tray is moved, the protrusions at the rear of the tray move with them. When this happens, there is a change in the on and off operations of the switches and how they are combined.
Figure 44 Tables 15 and 16 show the relationship between paper sizes and voltages that are output from the Tray Paper Size Sensors according to the on and off combinations. Trays 1 and 2 have two switches that make their Tray Paper Size Sensors. Table 15 Tray 1/2 Paper Size (Tray pulled out) -(*) B5 LEF or 7.25"x10.5" LEF -(*) 8.5"x11" LEF -(*) A4 LEF -(*) (*) Size is undecided
70
Tray Paper Size Sensor AD value AD range value 928 - 1023 956 864 - 927 800 - 863 828 496 - 799 432 - 495 459 368 - 431 304 - 367 334 0 - 303 -
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Output Voltage (V)
S1
S3
3.085±0.066 2.671±0.066 1.481±0.066 1.079±0.066 -
OFF OFF ON ON -
OFF ON OFF ON -
Xerox 4110 Family Technical Information Manual
Trays 3 and 4 have five switches that make up their Tray Paper Size Sensors. The paper size is determined by Switch 5 on or off position (digital value) in combination with the on or off combinations of Switches 1 through 4. Switches 1 though 4, in combination, create an output voltage (analog value) Table 16 Tray 3/4
Paper Size
Tray Paper Size Sensor Adj. Adj. range value
Output Voltage (V)
S1
S2
S3
S4
(Tray pulled out) OFF OFF OFF OFF 928 - 1023 956 3.085±0.066 -(*) OFF OFF OFF OFF -(*) OFF OFF OFF ON 864 - 927 892 2.877±0.066 -(*) OFF OFF OFF ON A5 SEF or 5.5"x8.5" SEF OFF OFF ON OFF 800 - 863 828 2.671±0.066 -(*) OFF OFF ON OFF -(*) OFF OFF ON ON 736 - 799 765 2.468±0.066 B5 SEF OFF OFF ON ON -(*) OFF ON OFF OFF 672 - 735 703 2.267±0.066 -(*) OFF ON OFF OFF 8.5"x13" SEF OFF ON OFF ON 608 - 671 640 2.064±0.066 8.5"x14" SEF OFF ON OFF ON A4 SEF OFF ON ON OFF 544 - 607 578 1.864±0.066 8.5"x11" SEF OFF ON ON OFF -(*) OFF ON ON ON 496 - 543 516 1.666±0.066 8"x10" SEF OFF ON ON ON -(*) ON OFF OFF OFF 432 - 495 459 1.481±0.066 12.6"x19.2" SEF or ON OFF OFF OFF 13"x19" SEF -(*) ON OFF OFF ON SRA3 SEF or 368 - 431 396 1.278±0.066 13"x18" SEF or ON OFF OFF ON 12"x18" SEF A4 LEF ON OFF ON OFF 304 - 367 334 1.079±0.066 -(*) ON OFF ON OFF A3 SEF ON OFF ON ON 240 - 303 273 0.881±0.066 -(*) ON OFF ON ON -(*) ON ON OFF OFF 192 - 239 214 0.691±0.066 B5 LEF or ON ON OFF OFF 7.25"x10.5" LEF 8 Fold GCO SEF or ON ON OFF ON 8 Fold TFX SEF 128 - 191 153 0.493±0.066 B4 SEF ON ON OFF ON 8.5"x11" LEF ON ON ON OFF 16 Fold GCO LEF or 64 - 127 93 0.300±0.066 ON ON ON OFF 16 Fold TFX LEF or 7.25"x10.5" LEF -(*) ON ON ON ON 0 - 63 33 0.106±0.066 11"x17" SEF ON ON ON ON In the adjustment data, “Above setup sizes” and “Depending on size group” can be selected.
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Raising Trays 1 through 4 Trays 1 through 4 are all raised in the same way. Their inner Bottom Plate is raised until it reaches the feed position. Figures 45 and 46 give an overview this operation.
Figure 45 Tray Down
Figure 46 Tray Raised
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Raising Operation When the tray is inserted, the Tray Nudger Roll Solenoid is turned on and lowers the Nudger roll. After a specified time the Tray Level Sensor detects whether of not the Bottom Plate is raised. If the bottom Plate is already raised with the Tray Level Sensor blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is turned on to operate CCW to raise the Bottom Plate. When the Tray Level Sensor becomes blocked, the Tray Feed Lift Motor is stopped. A specified time after the Tray Level Sensor is blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. During paper feed, before the Nudger Roll Solenoid is turned off, the Tray Level Sensor checks the stack height. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is operated CCW to lift the Bottom Plate until the Tray Level Sensor is blocked. When the tray is pulled out, the gears are disengaged and gravity lowers the tray.
Trays 1 through 4 Remaining Paper Detection When the tray is raised, as described in the previous section, the length of time to lift the tray is measured. Based on that time, the ratio of paper remaining in the tray is calculated. Table 17 shows the relationship. Table 17 Ratio of Remaining Paper 25% 50% 75% Full
Tray 1 7274 or more 5552 - 7273 3533 - 5551 0 - 3532
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Time required to lift up tray (msec) Tray2 10209 or more 7201 - 10208 4176 - 7200 0 - 4175
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Tray 3/4 1751 or more 1301 - 1750 851 - 1300 0 - 850
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MSI (Multiple Sheet Inserter) Component Name and Function
MSI Nudger Solenoid
MSI Lift Up Sensor
MSI Lift Up Motor
MSI Paper Set Sensor
MSI Paper Size Sensor
MSI Down Sensor
MSI No Paper Sensor
Figure 47 MSI The MSI Paper Size Sensor output a voltage value (analog) based on variable resistance. It senses paper width (fast scan direction). The MSI No Paper Sensor detects if there is paper on the MSI. The MSI Paper Set Sensor detects if the MSI is loaded with paper. The MSI Lift Up Sensor senses that the MSI Bottom Plate has been raised. The MSI Down Sensor senses that the MSI Bottom Plate has been lowered. The MSI Lift Up Motor is used to raise and lower the MSI Bottom Plate. The MSI Nudger Solenoid is used to raise and lower the MSI Nudger Roll.
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MSI Paper Size Sensing When the MSI Side Guides are moved, the variable resistance value of the MSI Paper Size Sensor changes. Based on a specific voltage output the paper width is calculated. The MSI Paper Size Sensor senses size in the fast scan direction only. The paper length is calculated based on the length of time from the start of the Registration Control to the trail edge of the paper ing the Regi Sensor. Based on the paper length and the width sensed, a standard size is automatically sensed. Table 18 shows the combinations. Table 18 Standard Size [mm]
Allowable Size Range [mm]
Paper Size A5 SEF 5.5x8.5 SEF B5 SEF A4 SEF 8.5x11 SEF 8.5x13 SEF 8.5x14 SEF B5 LEF B4 SEF A4 LEF A3 SEF 8.5x11 LEF 11x17 SEF
Distinguishable Size
width
length
width
length
FXAP/ GCO
XC
148.0 139.7 182.0 210.0 215.9 215.9 215.9 257.0 257.0 297.0 297.0 279.4 279.4
210.0 215.9 257.0 297.0 279.4 330.2 355.6 182.0 364.0 210.0 420.0 215.9 431.8
138.7 - 157.3 130.4 - 149.0 172.7 - 191.3 200.7 - 219.3 206.6 - 225.2 206.6 - 225.2 206.6 - 225.2 247.7 - 266.3 247.7 - 266.3 287.7 - 306.3 287.7 - 306.3 270.1 - 288.7 270.1 - 288.7
200.0 - 220.0 205.9 - 225.9 247.0 - 267.0 287.0 - 307.0 269.4 - 289.4 320.2 - 340.2 345.6 - 365.6 172.0 - 192.0 354.0 - 374.0 200.0 - 220.0 410.0 - 430.0 205.9 - 225.9 421.8 - 441.8
o o o o o o o -
o o o o o o
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Raising and Lowering the MSI Paper is raised and lowered by the MSI Lift Up Motor raising and lowering the MSI Bottom Plate. The raising is done to lift the paper into the feed position. The lowering is done so that paper can be loaded. The MSI Bottom Plate is raised when the MSI Paper Set Sensor detects paper and the MSI is selected as the feed tray. The MSI Nudger Solenoid is turned on lowering the Nudger Roll. After a specified time the MSI Lift Up Sensor detects if the Bottom Plate is raised. If the MSI Bottom Plate is already raised with the MSI Lift Up Sensor blocked, the MSI Nudger Solenoid is turned off and the Nudger Roll lifts. If the MSI Lift Up Sensor is unblocked, the MSI Feed Lift Up Motor is turned on to raise the Bottom Plate. When the MSI Lift Up Sensor becomes blocked, the MSI Feed Lift Up Motor is stopped. A specified time after the MSI Lift Up Sensor is blocked, the MSI Nudger Solenoid is turned off and the Nudger Roll lifts. During paper feed, before the MSI Nudger Roll Solenoid is turned off, the MSI Lift Up Sensor checks the stack height. If the MSI Lift Up is unblocked, the MSI Feed Lift Up Motor is operated to lift the Bottom Plate until the MSI Lift Up Sensor is blocked. Lowering the MSI Bottom Plate is when the MSI Down Sensor is unblocked at the following times At Power on When the MSI No Paper Sensor senses the supply has run out At the end of a job When the MSI Cover Interlock Switch and Front Cover Interlock Switch are both closed The MSI Lift Up Motor lowers the MSI Bottom Plate until the MSI Down Sensor is blocked. The MSI Lift Up Motor is then stopped.
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HCF (High Capacity Feeder) Component Name and Function
Tray 6 Feed Lift Motor
Tray 6 Paper Size Sensor (A3) Tray 6 Paper Size Sensor (Letter) Tray 6 Level Sensor Tray 6 No Paper Sensor
Tray 6 Nudger Solenoid
Tray 6 In Sensor
Figure 48 HCF Trays Note: Trays 6 and 7 are the same. This description will work for both. Trays 6 and 7 Paper Size Sensor A4 and Paper Size Sensor Letter sense the size of paper in the trays. Trays 6 and 7 In Sensors detect if the trays are inserted. Trays 6 and 7 No Paper Sensors detect if there is any paper in the trays. Trays 6 and 7 Feed Lift Motors are stepper motors used to raise the trays by rotating CCW and feed paper by rotating CW. Trays 6 and 7 Nudger Solenoids raise and lower the Nudger Rolls. Trays 6 and 7 Level Sensors sense that the bottom plates have been raised to the feed position.
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HCF Paper Size Sensing Sensing the size of the paper in the trays is based on a combination of on and off operations of two sensors, the Tray Paper Size Sensor A4 and the Tray Paper Size Sensor Letter. When the paper width and length guides are moved and the tray is inserted into the HCF, the state of both sensors checked. The combination of blocked or unblocked states determines the paper size. The sensors are located at the rear of the trays as indicated by Figure 49.
Letter Size Sensor
Tray A/B Size Sensor
Figure 49 HCF Size Sensors
Table 19 shows the relationship between paper sizes and combinations of the on and off operations of the Tray Paper Size Sensor A4 and Tray Paper Size Senor Letter. Table 19 Tray Paper Size Sensor A4 Letter B5 LEF or 7.25"x10.5" LEF * OFF OFF 8.5"x11" LEF ON OFF A4 LEF OFF ON A4 extension (non-standard setup) OFF OFF *Switching between B5 LEF and 7.25” x 10.5” LEF is done in NVM Paper Size
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Raising the HCF Trays When the tray is inserted, the Tray Nudger Roll Solenoid is turned on and lowers the Nudger roll. After a specified time the Tray Level Sensor detects whether of not the Bottom Plate is raised. If the bottom Plate is already raised with the Tray Level Sensor blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is turned on to operate CCW to raise the Bottom Plate. When the Tray Level Sensor becomes blocked, the Tray Feed Lift Motor is stopped. A specified time after the Tray Level Sensor is blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. During paper feed, before the Nudger Roll Solenoid is turned off, the Tray Level Sensor checks the stack height. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is operated CCW to lift the Bottom Plate until the Tray Level Sensor is blocked. When the tray is pulled out, the gears are disengaged and gravity lowers the tray
Trays 6 and 7 Remaining Paper Detection When the tray is raised, as described in the previous section, the length of time to lift the tray is measured. Based on that time, the ratio of paper remaining in the tray is calculated. Table 20 shows the relationship. Table 20 Ratio of Remaining Paper 25% 50% 75% Full
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Time required to lift up tray (msec) 8801 - 11530 6071 - 8800 3341 - 6070 0 - 3340
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OHCF (Oversized High Capacity Feeder) Overview Paper Size The OHCF is a Feeder that s the following paper: Capacity: 2,100 sheets (J Paper: 82gsm), 2,300 sheets (P Paper), 2,000 sheets (Xerox Digital Color Xpressions Plus: 90gsm) ed paper size: B5LEF (257.0x182.0mm) to 13”x19.2” SEF (330.2x488.0mm) Custom Sizes : 210mm – 330mm (width) and 182mm – 488mm (length) ed paper weight: 18lb. – 110lb. Cover (64 to 300gsm). When paper is loaded the tray raises into position. Sensors sense the size of the paper. The weight of the paper must be input through the UI to ensure feed reliability. Since the processor has center registration, the tray is shifted to the center position. When feed is initiated, depending on paper size and weight, a blower will come on to provide air for sheet separation. Another blower is capable of supplying warm air. Paper feed is accomplished with a motor and feed rolls. Paper path detection is done with sensors.
Paper Type A wide variety of paper types can be used including Heavyweight, Coated, Transparencies, and Labels.
Power Consumption 300 Watts maximum
Dimensions 39” wide x 31” deep x 37” high (988mm wide x 758mm deep x 930mm high 32” deep if 13” x 18” or 13” x 18” paper is loaded (801mm deep if 13” x 18” or 13” x 18” paper is loaded)
Weight 254lb. / 115kg maximum
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Interlock Switches The OHCF has 3 Interlock Switches:
Figure 50 Interlock Switches MSI (Tray 5) Interlock Switch – Detects the Opening and Closing of the MSI Top Cover. OHCF Front Interlock Switch – Detects the Open and Close states of the Front Cover. OHCF Tray Interlock Switch – Detects if the Tray is open or closed
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Paper Size Detection The paper size is detected by the Paper Side/End Guide Actuator using the combination of covered states from the 7 sensors that are distributed underneath the Bottom Plate of the Tray. To prevent the loading of spare reams of paper, due to the large size of the Paper Tray, each Front/Rear side of the Bottom Plate has Miss Set Sensors. The 7 sensors, the 2 Miss Set Sensors and the No Paper Sensor (Refer to Paper Availability Detection/Remaining Amount Detection) forms a mechanism that detects miss load of paper and notifies the to re-load the paper if it is loaded incorrectly.
Figure 51 Paper Size Detection Size Sensor (SNR0) Size Sensor 2 (SNR2) Size Sensor 1 (SNR1) Size Sensor 5 (SNR5) Size Sensor 4 (SNR4) Size Sensor 3 (SNR3) Size Sensor 6 (SNR6)
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The following table indicates the detection conditions No
SNR0 SNR1 SNR2 SNR3 SNR4 SNR5 SNR6
1 B5LEF (257.0x182.0) 2 7.25”x10.5” LEF (x11 ”1) (266.7x184.2) 3 16K LEF (TFX) (267.0x194.0) (*1) 4 16K LEF (FXCL) (270.0x195.0) (*1) 5 8”x10” LEF (254.0x203.2) 6 A4LEF (297.0x210.0) 7 8.5”x11” LEF (279.4x215.9) 8 B5SEF (Not ed) 9 8.5”x11” SEF (215.9x279.4) 10 A4SEF (210.0x297.0) 11 8.5”x13” SEF (215.9x330.2) 12 8.5”x14” SEF (215.9x355.6) 13 B4SEF (257.0x364.0) 14 8K SEF (TFX) (267.0x388.0) (*1) 15 8K SEF (FXCL) (270.0x390.0) (*1) 16 A3SEF (297.0x420.0) 17 11”x17” SEF (279.4x431.8) 18 12.6”x17.7” SEF (320x450) 19 12”x18” SEF (304.8x457.2) 20 13”x18” SEF (330.2x457.2) 21 13”x19” SEF (330.2x482.6) 22 12.6”x19.2” SEF (320.0x488.0)
0 0
1 1
0 1
0 0
0 0
0 0
-
0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1 1
1 1 1 0 1 0 0 0 0 1 1 1 0 1 0 0 0 0 0
1 1 0 1 1 0 0 0 0 0 1 1 1 1 1 1 0 0 1
0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 0 0
0 0 0 0 0 1 0 1 1 1 1 1 1 0 0 0 0 0
0 0 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0
0 (*2) 0 (*2) 1 (*2) -
*1: Can be selected in the machine NVM. *2: The output of Size Sensor 6 is used to differentiate between the size of 11”x17” and 8K SEF. Front Miss Set Sensor – Detects whether there is a miss loaded paper in the Tray. Installed at the Front side. Rear Miss Set Sensor – Detects whether there is miss loaded paper in the Tray. Installed at the Rear side. Miss loading is detected as follows when inserting the tray after paper is loaded. Check if the paper is loaded properly against the Lower No Paper Sensor at the front corner of the tray. If Yes: proceed to b. If No: no paper is detected The Size Sensors 0 to 6 detect the paper size. The machine logic will judge if the empty space in the tray can hold paper. If it is possible: proceed to c. If it is not possible: raising the tray starts. The Front/Rear Miss Sensors check for the existence of paper in the empty space. If Paper detected: Paper miss load is detected, Lift Up operation is interrupted and “Fail” is displayed If No Paper detected: Judged to be normal, and the Lift Up operation begins An example of a miss load is B5LEF loaded properly, and another B5LEF is loaded on
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the empty space.
Figure 52 Miss loaded paper
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Paper Availability Detection/Remaining Amount Detection Detects the existence of paper during loading/movement as well as the remaining amount of paper. This information is used to update the UI display.
Figure 53 Paper detection The names of the main parts related to the Paper Availability Detection/Remaining Amount Detection are as follows: Level Sensor – Detects the height of the Paper Feed Position and controls the height of the paper. Upper No Paper Sensor – Detects whether there is paper in the Tray during movement. Nudger Solenoid – Controls the separation between the paper surface (moving paper) and the Nudger Roll. OHCF Paper Level Sensor 3 – Detects the remaining amount of paper in the Tray in 4 levels. OHCF Paper Level Sensor 2 – Detects the remaining amount of paper in the Tray in 4 levels. OHCF Paper Level Sensor 1 – Detects the remaining amount of paper in the Tray in 4 levels.
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Remaining Paper Amount
Sensor Output SNR 1
SNR 2
SNR 3
1/4
1
0
0
1/4
1
1
0
1/2
0
1
0
1/2
0
1
1
3/4
0
0
1
Full
0
0
0
1:blocked, 0:unblocked Lower No Paper Sensor - Detects whether there is paper in the Tray during loading. (Used mainly for detection of paper miss load).
Paper Feed This section describes the Transport Section paper feed path and the Jam Detection Sensors.
Figure 54 Feed Sensors
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The names of the main parts related to the Paper Feed mechanism and their explanations are described as follows: Tray5 (HCF MSI) Feed Out Sensor – Detects whether there is paper being fed from the MSI. Also detects Jams. OHCF Exit Sensor – Detects whether there is paper being fed from the MSI/Tray. Also detects Jams. OHCF Feed Out Sensor – Detects whether there is paper being fed from the OHCF Tray. Also detects Jams. OHCF Pre Feed Sensor – Detects whether there is paper being fed from the OHCF Tray. Also used when deciding the mode selection of the Feed operation.
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Tray Shift As described in the overview, the Tray itself is of a Corner Registration. However, since the IOT is a Center Registration type, there is a Tray Shift mechanism that moves the Tray to the center position. The timing for backward and forward movement of the Tray is as follows. At Power ON When the machine returns form Sleep Mode (Energy Saving) When the tray is inserted after changing the paper size. When the tray is removed and reinserted in the middle of a shift operation. When exiting diagnostic mode. Two seconds after the above occurrences, the Tray will move to the Home Sensor Position. Then it moves again within a specified time to stop with center registration for the appropriate paper size. There is a mechanism consisting of In/Out Limit Sensors that stops the tray to prevent part damage in case the Tray attempts to move too far.
Figure 55 Tray Shift
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The names of the main parts related to the Tray shift mechanism and their explanations are described as follows: OHCF Shift Motor – Moves the Tray in the In/Out direction, and aligns the Side Regi to the IOT of the machine. OHCF Shift Front Limit Sensor – Detects overrun of the Tray in the Front direction OHCF Shift Home Sensor – Determines the Home Position of the Tray. OHCF Shift Rear Limit Sensor – Detects overrun of the Tray in the Rear direction.
Paper Separator Air Flow There are two blower fans installed at the front of the tray, as shown in the following figure, which are used to separate the paper. There are also 2 other optional blower fans that can be installed at the side of the tray below the feed head. The air that is blown by these blower fans, to the edge of the paper, breaks the adherence between the sheets of paper and prevents the occurrence of miss feeds and multi feeds. In addition, a heater is installed at the front of the tray to dry the air being supplied. Eliminating the stickiness of the lead edge of the paper which is very effective in preventing miss feed and multifeeds from happening. Warm air is only supplied to the lead edge. The ON/OFF control of the blowers and the control of air amount are performed by the software. The information that is used as a base for the control, is the paper type information selected at the UI. When a different type of paper is selected, the control will change to match that paper. There might be a problem where the selected paper is different from the loaded paper. Temperature control of the Heater is normally performed at power ON. When miss feed and multifeed problems still occur despite the usual control, the following troubleshooting controls in NVM are provided. NVM: 743-040 1 – Standard (Default) 2 – Multifeed Countermeasure 3 – Miss Feed Countermeasure
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Figure 56 Air Flow The names of the main parts related to the airflow system and their explanations are described as follows. OHCF Lead Blower Fan – Creates the airflow for separating the paper. If the Tray Lead Blower stops due to malfunction a fault will occur. OHCF End Blower Fan – Creates the airflow for separating the paper. If the Tray End Blower stops due to malfunction a fault will occur. OHCF Lead Heater – Warms the airflow for separating the lead edge of the paper. OHCF Lead Heater Temp Sensor – Measures the temperature at the surface of the Tray Lead Heater.
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Air Shutter When heavyweight or coated paper is selected on the UI, the pre blower function at paper feed follows the blower and heater temperature control execution. This pre blower function supplies or stops the air in short time periods to increase the effectiveness of paper separation. This Shutter performs this supply/stop control. The Air Shutter is not just solely for the purpose of controlling the pre blow. During pre blow and blow operation at feed, it is also responsible for moving the nozzle, where the air is coming out, up and down to ensure an even amount of air flows in between the sheets of paper. The operation of the Shutter, along with the Blower Fan operation and Heater temperature control, depends on a control table that is established from the paper size, type and operating environment for the most suitable control parameters.
Figure 57 Air Shutter OHCF End Shutter Home Sensor – Fixes the Home Position of the End Shutter. OHCF End Shutter Motor – Drives the End Shutter that changes the amount and direction of Air Flow for separating the paper. OHCF Lead Shutter Home Sensor – Fixes the Home Position of the Lead Shutter. OHCF Lead Shutter Motor – Drives the Lead Shutter that changes the amount and
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direction of Air Flow for separating the paper.
Drive This section describes all the Motors and transport paths found in the OHCF.
Figure 58 Drive
The names of the main parts related to the Drive mechanism and their explanations are described as follows. MSI Feed Motor – This supplies the rotational drive for every roll in the MSI. OHCF Feed Motor – This supplies the rotational drive for the Tray Feed Roll, Tray Nudger Roll and the Tray Retard Roll. Lift Motor – This supplied the drive t raise the tray bottom plate. OHCF Shift Motor – Moves the tray in the in/out direction and aligns the side regi to the IOT. Transport Motor – This supplies the rotational drive for every roll in the transport section via a drive belt.
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(Chain 8) Paper Feed and Transportation
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 8 Paper Transportation.
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Technical Overview This module describes the names, locations, and functions of the components of Chain 8 Paper Transportation. The main functions of Chain 8 Paper Transportation are paper transportation from each tray to registration and registration control.
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Paper Transportation from Trays 1 through 4 to Registration Component Name and Function
Takeaway Motor 2 Takeaway Clutch 2
Trans Path Sensor2
Takeaway Clutch 1
Tray 2 Feed Out Sensor Tray 2 Pre Feed Sensor
Takeaway Motor 1
Trans Path Sensor 1 Tray1 Feed Out Sensor
Tray1 Pre Feed Sensor
Takeaway Motor 3
Trans Path Sensor3 Tray 3 Pre Feed Sensor
Tray 3 Feed Out Sensor Tray 4 Pre Feed Sensor Tray 4 Feed Out Sensor
Figure 59
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Tray 1, 2, 3 and 4 Pre Feed Sensors detect paper fed from the trays. Tray 1, 2, 3 and 4 Feed Out Sensors detect paper fed out of the trays Trans Path Sensors 1 and 2 detect paper fed from Tray 2 that is being transported to registration. Trans Path Sensor 3 detects paper fed from trays 3 and 4 that is being transported to registration. Takeaway Motor 1 drives the Vertical Transport Roll 1, Takeaway Roll 1 and Vertical Transport Roll 2. Takeaway Motor 2 drives Takeaway Roll 2, Horizontal Transport Roll 1 and Horizontal Transport Roll 2. Takeaway Motor 3 drives Trans Roll 3 and Trans Roll 4. Takeaway Clutch 1 transfers drive from the Takeaway Motor 1 to Trans Roll 1. Takeaway Clutch 2 transfers drive from the Takeaway Motor 2 to the Horizontal Transport Roll 1.
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Basic Control of Paper Transportation Paper transportation is controlled based timing that is called Pitch time that is the base point of ing an image on the paper. The time when an image that is developed gets transferred to the paper is the base point. The paper size, paper type and paper feed tray determine a pitch time called Paper Pitch Interval. As paper length increases, Paper Pitch Interval increases. There are 11 different Paper Pitch Intervals. An image of Paper Pitch Interval is shown in Figure 60.
Figure 60 Paper Pitch
Paper Feed timing called P/H Control Standard depends on the time required to transport the paper to the position (Pitch) where the transfer of an image to the paper starts. A P/H control standard is relative to that of the MSI from which the paper takes the longest time to be transported to the image transfer position.
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Paper Feed from the Trays The feed time is a specified time after a certain P/H control standard. For each tray, this specified time is determined by the time required to transport paper from each tray to the position where and image is transferred onto the paper. Trays 1 though 4 each have their own feed time, but they all feed using the same method. Components of the paper feed for tray 4 are shown in Figure 61.
Figure 61 Paper Feed from Tray 4
At feed time, the Tray Nudger Solenoid is turned on lowering the Nudger roll. The Tray Lift Feed Motor is energized in the CW direction to feed paper. When the Tray Pre Feed Sensor detects the lead edge of the paper, the Tray Nudger Solenoid is de-energized and the Nudger roll is raised off the paper. If the Tray Pre Feed Sensor has detected paper at the start of feed, the Tray Feed Lift Motor is stopped once and then turned on in the CW direction. After the earliest one of the following list, the Tray Feed Lift Motor is stopped and it is the end of paper feed. A specified time after the Tray Feed Lift Motor is driven again A specified time after the Tray Pre Feed Sensor detects the paper When the Tray Feed Out Sensor detects the paper When the trail edge of the paper leaves, the Nudger roll is lowered again to hold the next paper to prevent shingling. A specified time after the Tray Feed Out Sensor detects the paper at the end of the feed cycle, the Tray Nudger Solenoid energizes to lower the Nudger roll. A specified time after the Tray Nudger Solenoid is de-energized to raise the Nudger roll.
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Paper Transportation from the Takeaway Rolls Figure 62 shows the rolls driven by the Takeaway Motor 1, Takeaway Motor 2 and Takeaway Motor 3. Takeaway Motor 1 drives the Vertical Transport Roll1 and Vertical Transport Roll 2. Takeaway Motor 2 drives the Horizontal Transport Roll 1 and Horizontal Transport Roll 2. Takeaway Motor 3 drives the Takeaway Roll 3, Takeaway Roll 4 and Vertical Transport Roll 3.
Figure 62 Paper Transportation from Each Tray
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A specified time after the start of paper feed from Tray 1, Takeaway Motor 1 drives Takeaway Roll 1. Takeaway Clutch 1 is energized and transfers drive from Takeaway Motor 1 to Vertical Transport Roll 1. These rolls transport the paper to the Pre Registration Roll. A specified time after the start of paper feed from Tray 2, Takeaway Motor 2 drives Takeaway Roll 2. Takeaway Clutch 2 is energized and transfers drive from Takeaway Motor 2 to Horizontal Transport Roll 2. These rolls transport the paper to the Pre Registration Roll. A specified time after the start of paper feed from Tray 3, Takeaway Motor 3 drives Takeaway Roll 3. Then at a specified time after the start of feed from Tray 3, Takeaway Motor 1 drives Vertical Transport Roll 2. Takeaway Clutch 1 is energized to transfer drive from Takeaway Motor 1 to Vertical Transport Roll 1. These rolls transport the paper to the Pre Registration Roll. A specified time after the start of paper feed from Tray 4, Takeaway Motor 3 drives Takeaway Roll 4 and Vertical Transport Roll 3. Then at a specified time after the start of feed from Tray 4, Takeaway Motor 1 drives Vertical Transport Roll 2. Takeaway Clutch 1 is energized to transfer drive from Takeaway Motor 1 to Vertical Transport Roll 1. These rolls transport the paper to the Pre Registration Roll.
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Paper Transportation from the MSI to Registration Component Name and Function
MSI Feed Motor
MSI Pre Feed Sensor
MSI Feed Out Sensor
Figure 63 MSI Feed The MSI Feed Sensor detects paper fed from the MSI. The MSI Feed Out Sensor detects paper fed out from the MSI. The MSI Feed Motor is used for drive to feed paper from the MSI.
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Paper Feed from the MSI The feed timing is a specified time after the P/H control standard. Figure 64 shows paper feed from the MSI.
Figure 64 Paper Feed from the MSI If an HCF is not installed, the paper from the MSI is transported to the registration position. If an HCF is installed, the paper is transported to the MSI Takeaway Roll, to the HCF Exit Roll and then to the registration position. At paper feed, the MSI Nudger Solenoid is energized to lower the Nudger Roll. After a specified time, The MSI Feed Motor is turned on to rotate in the CW direction to feed paper. When the MSI Pre Feed Sensor detects the paper, the MSI Nudger Solenoid is turned off to raise the Nudger Roll. If the MSI Pre Feed Sensor has already detected paper at the start of feed, a specified time after the MSI Nudger Solenoid is turned on, The MSI Nudger Solenoid is turned of and the Nudger Roll is raised. A specified time after the MSI Feed Out Sensor detects the paper; the MSI Feed Motor is stopped. When the trail edge of the paper leaves, the Nudger roll is lowered again to hold the next paper to prevent shingling. A specified time after the MSI Feed Out Sensor detects the paper at the end of the feed cycle, the MSI Nudger Solenoid energizes to lower the Nudger roll. A specified time after the MSI Nudger Solenoid is de-energized to raise the Nudger roll.
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Paper Transportation from the HCF to Registration Component Name and Function
Tray 6 Pre Feed Sensor Tray 6 Feed Out Sensor
HCF Exit Roll Clutch
HCF Feed Out Sensor
Tray 7 Pre Feed Sensor
Tray 7 Feed Out Sensor HCF Takeaway Motor
Figure 65 HCF
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The Tray 6 and 7 Pre Feed Sensors detect paper fed from the HCF trays. The Tray 6 and 7 Feed Out Sensors detect paper fed out of the HCF trays. The HCF Takeaway Motor drives the HCF Takeaway Rolls 1 through 8 and the HCF Exit Roll. The HCF Exit Sensor detects paper as it leaves the HCF.
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Paper Feed from the HCF Feed timing is determined by a specified time after P/H control standard. For each tray, that specified time varies according to the distance from the image transfer point. Although trays 6 and 7 have different feed times, they both feed in the same manner. Figure 66 shows paper feed from Tray 7.
Figure 66 Feed from HCF At paper feed, the Tray Nudger Solenoid is energized and the Nudger Roll is lowered. After a specified time the HCF Lift Feed Motor rotates CW and drives the Nudger Roll to feed paper. When the Tray Pre Feed Sensor detects the paper, the HCF Nudger Solenoid is de-energized and the Nudger Roll raises. A specified time after the Tray Feed Out Sensor detects the paper, the HCF Lift Feed Motor is stopped. When the trail edge of the paper leaves the Feed Roll, the Nudger Roll Solenoid is energized to lower the Nudger Roll to the top of the paper stack. This prevents another sheet from feeding with the first one. After a specified time the Nudger Roll Solenoid is de-energized and the Nudger Roll is raised.
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Paper Transportation to the HCF Exit Roll Figure 67 shows the paper path from the HCF paper trays and the MSI to exit from the HCF.
Figure 67 HCF Paper Path
A specified time after the start of paper feed, the HCF Takeaway Motor starts to drive HCF Takeaway Rolls 1 through 8. At the same time, the HCF Exit Roll Clutch is energized to drive the HCF Exit Roll in order to transport paper out of the HCF. If paper is on the HCF Exit Sensor after the Pre Registration Sensor detects paper, the HCF Exit Roll Clutch is de-energized. If there is continuous printing, the Exit Roll Clutch is energized after the paper es the HCF Exit Sensor. The HCF Exit Roll is freewheeling except when the clutch is energized. The HCF Takeaway Motor is stopped at a specified time after the Pre Registration Sensor detects the paper. If the next sheet of paper is being fed before the Pre Registration Sensor detects a sheet, the HCF Takeaway Motor does not stop.
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Registration Component Name and Location
Pre Registration Motor
Side Registration Home Sensor Registration Sensor
Side Registration Sensor
Pre Registration Sensor Registration Motor Side Registration Move Motor Figure 68 Registration
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The Pre Registration Sensor detects paper transported to the pre registration position. The Registration Sensor detects paper transported to the registration position. The Side Registration Sensor detects the edge of the paper in Side Registration Control. The Side Registration Home Sensor detects the home position of the Side Registration Sensor. The Pre Registration Motor is the stepper motor that drives the MSI Takeaway Roll 1 and the Pre Regi Roll. The Registration Motor is the stepper motor that drives the Registration Roll. The Side Registration Move Motor is the stepper motor that moves the Side Registration Sensor. The motor is reversible for driving the sensor front and back.
Pre Registration Control The purpose of the pre registration is to correct the skew of the paper transported from the trays to the Takeaway Rolls. It is also used to remove the skew from the paper that is transported from the duplex area. The start of pre registration is a specified time after the P/H control standard. The Pre Registration Motor and the Registration Motor control the pre registration operation. The Pre Registration Motor controls pre registration by operating at high speed to receive paper, mid speed, and low speed to drive paper against the Registration Roll. In the MSI and HCF Trays, the motor controls pre registration by just using high and low speeds. When paper is fed from trays 1 through 4, the Pre Registration Motor starts. At a specified time the speed of the Pre Registration Motor is increased to be equal to the speed of the paper that has been fed. A specified time after the Pre Registration Sensor detects the paper, the speed of the Pre Registration Motor is reduced to mid speed. When the Registration Sensor detects the paper, the Registration Motor turns on. A specified time after the Registration Sensor detects the paper; the speed of the Pre Registration Motor is reduced to the speed of the paper striking against the Registration Roll. At a specified time, the speed of the Pre Registration Motor is further reduced. Feeding from the HCF or the MSI works the same way at the reduced speed. At the end of pre registration, the Pre Registration and Registration Motors stay on at a lower speed. They stay this way because the Pre Registration Roll and the Registration Roll need to rotate to maintain the buckle that is formed with the paper against the Registration Roll.
Registration Control The purpose of registration control is to drive the Registration Roll at the appropriate time to transport the paper in the Regi area to the point of image transfer. This enables the image to be transferred properly to the paper. The start of the registration operation is specified time after the Registration sync notification. This generated when then lead edge of the image is a set distance from the transfer point. The specified time is determined on an individual tray basis. The Pre Registration and Registration Motors control registration. Registration is performed after pre registration. At the start of registration, the Pre Registration and Registration Motors are on at low speed. At a set time the motors are sped up then slowed to process speed. After the paper es the Pre Registration Sensor, the Pre Registration Motor is slowed. After a specified time the motor is stopped. After the paper es the Registration Sensor, the Registration Motor is slowed. A specified time later it is stopped. The trays 1 though 4, the HCF and the MSI all work the same way with one exception.
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With the HCF and the MSI, the motors are not put to process speed.
Side Registration Control The purpose of side registration is to correct misregistration in the fast scan direction. Side registration is necessary on Xerox 4110 because center registration is used in paper transportation. Each paper size has its own side registration position set up. By moving the Side Registration Sensor until it detects the edge of the paper in the registration area, a side misregistration amount is measured. Based on this amount, the ROS writing position is corrected. Side registration consists of three parts: Moving the Side Regi Sensor to the home position Moving the Side Regi Sensor to the waiting position Detecting the side edge Figure 69 illustrates the operations.
Figure 69 Side Registration Operation
The Side Registration Sensor moves to the home position at power on, start of print, when the interlocks are closed, when the side edge of a paper is detected and when there is a side registration failure. When the Side Registration senor needs to home, it is driven by the Side Registration Move Motor until its sensor flag blocks the Side Registration Home Sensor. At a set time after the Side Registration Sensor homes, it is moved the waiting position. The waiting position is based on the paper size being used. This calculation is converted to motor pulses used by the Side Registration Move Motor to position the Side Registration Sensor. Side registration is performed at a set time after the Pre Registration Sensor detects the paper. Starting from the waiting position when paper is being transported, the Side Registration Sensor is moved to detect the edge of the paper. The motor pulses from the Side Move Registration Motor are counted. This count is used to calculate where the ROS places the image on the drum. In this machine, the image is ed to the paper. Side registration is set using dC129. It is set in two modes, “With Comp” and “W/O Comp”. This is done in case the Side Registration Sensor fails. A Side Registration Sensor failure will only show up on the PWS. If the Side Registration Sensor fails, it is sent to the home position and not used. At that point W/O Comp setting is used.
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Paper Length Sensing Paper length sensing is a control function done as the paper is being transported over the Registration Sensor. The measured length of paper is compared to the paper that was selected via the UI or was automatically selected when a document was sensed as it was scanned. If there is a difference of +/- 10mm or more between the desired paper and the paper fed, there is a size mismatch error causing a stop print. This is done to prevent machine contamination. Size mismatch is detection is done only on side 1. If the target paper is tab paper or 120mm x 235mm paper size mismatch detection is not performed. The paper size 120mm x 35mm, which is the size of a number 3 envelope, cannot be set as a paper type. Paper of that size is recognized as an envelope with is flap included, even if it is non-standard, and the paper size mismatch is not performed.
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(Chain 9) Marking
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 9 Marking.
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Technical Overview The main functions of this module are to expose a document image on the charged drum using raster scanning with laser beams, to develop the latent image with toner, and to transfer the toner image to paper. This module also describes drum cleaning, paper transport belt cleaning and waste toner collection. There will be a description of charge control, exposure control and toner concentration (process control). Figure 70 shows the Marking layout.
Figure 70 Marking Layout
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Drum Component Name and Function
Drum CRUM PWB Drum
Drum Motor
Drum CRUM
Drum Detect Switch
Figure 71 Drum Area The Drum has an extremely light sensitive surface that is charged negatively to receive a latent image from the ROS and have it developed for transfer to a through put material. The Drum Motor is the DC motor that drives the Drum, the Drive Roll, the Drum Cleaning Brush and the Transfer Belt Cleaning Brush. The Drum Detect Switch detects the installed Drum Cartridge. The Drum CRUM is the memory that contains the information on the installed Drum. The Drum CRUM PWB uses wireless communication with the Drum CRUM and reads and writes information.
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Drum Motor Control Figure 72 shows how the Drum Motor drives the Drum and Transfer Belt using the Drive Roll.
Drum
Drum Motor
Drive Roll
Transfer Belt Figure 72 Drum Drive
The Drum Motor turns on at a set time after Start Print and turns off when the Erase Lamp turns off after the end of print. The Drum Motor rotates in reverse triggered by the Brake Signal On. The reverse rotation of Drum and Transfer Belt is used to correct any poor cleaning due to foreign objects like paper particles. The reverse operation is performed for a very short time during Print and in cycle down. The Reverse operation can be Enabled or Disabled in NVM 751-030.
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Drum Cartridge Replacement Detection The Drum Cartridge is a CSE replaceable unit. The Drum Cartridge loaded with a memory (CRUM) for recording information. The CRUM is wireless and consists of the Drum CRUM, the actual recording medium in the Drum Cartridge, and the Drum CRUM PWB connected to the machine MCU PWB. Wireless communication between the Drum CRUM PWB and the Drum CRUM allows reading and writing of information. In the CRUM is recorded drum usage status like print quantity and information unique to the Drum Cartridge like the serial number. In the CRUM, the number of drum cycles is used to detect the drum replacement time. It is detected in two stages, Drum Cartridge Replacement Time Near and Drum Cartridge Replacement Time Reached. The count is one cycle equaling one drum rotation.
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Charging and Cleaning Component Name and Function
Charge Corotron Cleaner Motor Charge Corotron
Charge Corotron Cleaner Motor Position Sensor
Erase Lamp
HVPS S6
Pre Clean Corotron
Cleaner Intake Fan Motor
Figure 73
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The Charge Corotron places a negative DC charge on the Drum surface. The Charge Corotron Cleaner Motor in the stepper motor the drives the Charge Corotron Cleaner. The Charge Corotron Cleaner Motor Position Sensor detects the home position of the Charge Corotron Cleaner Motor. The Pre Clean Corotron assists in placing a negative charge on the Drum surface. In the event of the transfer of an image to paper, the BTR places a positive charge on the underside of the Transfer Belt, causing a positive charge on the Drum surface. When this happens, the Pre Clean Corotron eliminates the transfer record by placing a negative charge on the Drum surface. The Erase Lamp eliminates the charge on the Drum surface after an image has been transferred. The Cleaner Intake Fan Motor runs the fan that cools down the Charge Corotron Cleaner and takes air from outside the machine to prevent Charge Corotron Wire contamination. The High Voltage Power Supply S6 generates corotron output and grid output supplied to the Charge Corotron and the Pre Clean Corotron.
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Charge Operation The Drum surface is evenly charged before exposure. The Drum is charged with negative DC from the Charge Corotron and the Pre Clean Corotron. The rated values of the corotron output are, Charge Corotron 5300 uA at –650 VDC and the Pre Clean Corotron 4340 uA at -400 VDC. The Charge Corotron consists of two wires, 1st Corotron Wire and 2nd Corotron Wire, and the Charge Corotron Grid as shown in Figure 74.
2nd Corotron Wire
CC Grid 1st Corotron Wire
Figure 74 The two Charge Corotron wires are used to place a more even charge on the drum. The Charge Corotron Grid is a metallic screen located between the Drum and the wires. A bias voltage of –820VDC is applied to the Grid for stability of the potential on the Drum surface and to prevent it from being excessively charged. At a set time after the Drum Motor starts, DC voltage is applied to the Charge Corotron wires and grid. Process Control determines the value of the voltage to the grid. The output is increased, gradually, in three steps. The Charge Corotron in turned off after the BTR and the Grid is turned off in three steps as it was turned on.
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Charge Corotron Cleaner Control The Charge Corotron Cleaner Motor drives the Charge Corotron Cleaner front to rear, to clean the wires. When the charge function is occurring, the cleaner is moved to the home position. If the Charge Corotron Cleaner is not moved to the home position, it will cause a toner band. It could also cause a fire. The Home Position Sensor is at the front of the corotron. The cleaner is considered parked when it blocks the Home Position Sensor. Figure 75 shows the components.
Charge Corotron Cleaner
Charge Corotron Cleaner Motor
Charge Corotron Cleaner Motor Position Sensor
Figure 75
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Toner Band Generation of a toner band is aimed to prevent deletions due to poor cleaning, Cleaning Blade creaking/being turned up, and a rough quality print of a document with a small ratio of area coverage (discharge of deteriorated toner from Developer Housing). The band is used to lubricate the Cleaning Blade on print/copy runs that may be long with little area coverage. The toner band is generated when ADC Patch is generated, when the total count of prints exceeds a preset threshold (which can be changed in the NVM), at power on, and after warm up. The toner band operation can be disabled by setting it in the NVM (751-037).
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Development Component Name and Function
Toner Cartridge CRUM PWB Cartridge Motor
Toner Cartridge CRUM
Cartridge Door Sensor
Dispense Motor Deve Motor
Low Toner Sensor
HVPS S5 Figure 76 Development
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The Deve Motor is the DC motor that drives the Auger and the Magnet Roll in the Deve Housing. The High Voltage Power Supply S5 generates the development bias (AC and DC outputs) to be applied to the Magnet Roll in the Deve Housing. The Toner Cartridge CRUM is the memory that stores information on the installed Toner Cartridge. The Toner Cartridge CRUM PWB conducts wireless communication with the Toner Cartridge CRUM and reads or writes information. The Cartridge Door Sensor detects the opening and closing of the Toner Cartridge Door The Dispense Motor is the DC motor that drives the auger in the Toner Dispense Housing. The Cartridge Motor is the DC motor that drives the agitator in the Toner Cartridge. The agitator is driven to mix toner while sending it to the Toner Dispense Housing. The Low Toner Sensor detects the amount of toner remaining in the Toner Dispense Housing.
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Negative Charge Development To see how negative charge development works, let’s assume that the Charge on the Photoreceptor Surface is an even -650VDC and the charge on the Toner particles is also -650VDC. Both charges are the same so there is no attraction of toner. The toner coverage in the fully charged areas will be blank (white). If the ROS discharges the drum surface charge down to a negative -100VDC, toner will be attracted to the discharged areas. If the entire surface is discharged or if the charge corotron fails to charge the drum, the copy will have solid coverage. If the ROS fails to discharge the drum you will get a blank copy because the drum will repel the toner on the Developer Roll. NEGATIVE CHARGE ON DRUM SURFACE
Figure 77 Negative Charge Development
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Toner Supply for the Deve Housing Figure 78 shows the flow of toner from the Toner Cartridge to the Deve Housing.
Cartridge Motor
Dispense Motor Auger
Deve Housing Toner Dispense Housing
Figure 78 Toner Flow
The Cartridge Motor drives the Agitator in the Toner Cartridge and makes it send toner to the Tone Dispense Housing. The Dispense Motor drives the Auger to transport toner to the Deve Housing. The Cartridge Motor drives when the toner remaining in the Toner Dispense Housing is low. The Low Toner Sensor monitors the amount of toner remaining in the Toner Dispense Housing. The Low Toner Sensor detects at 0.1-second intervals while the Dispense Motor is driving. When the sensor detects “No Toner” five consecutive times, the Cartridge Motor is driven for 10 seconds.
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The Dispense Motor drives when “Toner Dispense Time”, calculated in process control, is “Dispense Unit Time (10ms)” or more with the Deve Motor on. If “Toner Dispense Time” is 50ms or more, the Dispense Motor drives for 50ms stops once, then drives again for the remaining time. This is done to prevent image quality problems caused by a sudden increase in toner concentration. When the Deve Motor stops, the Dispense Motor stops. If the Dispense Motor was not able to complete a full “Toner Dispense Time”, it will complete the time the next time the Deve Motor runs.
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Development Toner supplied to the Deve Housing is mixed by the Auger in the Deve Housing and attracted to the Magnet Roll. The Deve Motor shown in Figure 79 drives the Magnet Roll and Auger.
Magnet Roll Deve Motor
Auger
Figure 79 Deve Drive
The development bias applied to the Magnet Roll allows attraction of toner from the Magnet Roll to a latent image on the Drum. Development uses a trickle system. The trickle stabilizes the tribo-electric charge of the developer. Toner and carrier are supplied to the Developer Housing together from the Toner Cartridge. Excess developer is discharged and collected in the Waste Toner bottle. This allows deteriorated carrier to be replaced.
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Development Bias Control Development bias has AC and DC output. The DC bias allows the toner to be transferred from the Magnetic Roll to the latent image on the Drum. It is also used to keep toner from attaching to non-image areas on the Drum. The AC bias is used to make toner movement more active. This helps with the attraction to the image area on the Drum and helps prevent attraction in non-image areas. The values are; DC output –600VDC and the AC output is switched among 960VAC/9100Hz, 700VAC/9000Hz, 1140VAAC/6000Hz and 800VAC/5000Hz. The DC Bias is turned on at the same time as the Charge Corotron Grid and turned off at the same time as the Charge Corotron Grid. To suppress the transfer of unnecessary toner and carrier to the Drum, the DC bias is controlled in three steps in sync with the Charge Corotron Grid. Process Control determines the value of the bias. Figure 80 shows the timing.
Figure 80 Development DC Bias On Timing Chart
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The AC Bias is turn on after the Charge Corotron Grid and a set time before image exposure. It is turned off after the Charge Corotron Grid and a set time after the image exposure. The steps are not used with AC on as they are with DC on. Figure 81 shows the timing.
Figure 81 Development AC Bias On/Off Timing Chart
The AC Bias output can be reset to Not OFF during print process in NVM 726-074. When this is done the AC Bias is on during the entire Developer on time instead of the way it is shown in Figure 81.
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Toner Empty Detection Toner Empty Detection informs the when the Toner Cartridge should be replaced. It also inhibits printing before a lack of toner caused extremely poor image quality. Table 21 shows the four levels of status indicating how much toner remains. Table 21 Status Name Normal Low Toner Toner Near Empty Toner Empty
Status Meaning Toner Cartridge has sufficient toner. Low Toner Sensor continues to detect “No toner” with low toner in Toner Cartridge. Toner Cartridge has almost no toner. Toner in Toner Dispense Housing is used for development. Toner Cartridge and Toner Dispense Housing have no toner. The Low Toner Sensor normally detects how much toner remains at intervals of 0.1 sec while the Dispense Motor is driving. When it detects “No Toner” 20 consecutive times, it indicates the “Low Toner” status. Once the status is “Low Toner”, the Low Toner Sensor detects how much toner remains at intervals of 0.1 sec even if the Dispense Motor is not driving. When it detects “Toner available” 10 consecutive times, “Low Toner” is cleared and back to normal. “Low Toner” is an internal status and is not displayed on the UI. When the “Low Toner” status and the total time of Dispense Motor on reaches a set time (NVM: 762-028 “Toner Near Empty Occurrence Time”), the status becomes “Toner Near Empty”, which is displayed on the UI. The machine can make 5000 prints after this status is declared. If the Low Toner Sensor detects toner available 10 consecutive times after “Toner Near Empty”, the status is cleared and back to normal. When the “Low Toner” status and the total time of Dispense Motor on reaches a set time (NVM: 762-029 “Toner Empty Occurrence Time”), the status becomes “Toner Empty”, which is displayed on the UI. The machine is disabled from printing until the Toner Cartridge is replaced.
Remaining Toner Detection This is used to detect the remaining toner so that the can make an informed decision on Toner Cartridge replacement time. Based on the total on time of the Dispense Motor, the amount of remaining toner is detected in five steps. This is shown is Table 22. Table 22 Level of Toner Remaining in Toner Cartridge Step 1 (Remaining Toner: 76-100%) Step 2: (Remaining Toner: 51-75%) Step 3 (Remaining Toner: 26-50%) Step 4 (Remaining Toner: 1-25%) Step 5 (Remaining Toner: 0%)
Detection Requirement “Dispense Time” is less than ‘Threshold 1.’ “Dispense Time” is ‘Threshold 1’ or more, and less than ‘Threshold 2.’ “Dispense Time” is ‘Threshold 2’ or more, and less than ‘Threshold 3.’ “Dispense Time” is ‘Threshold 3’ or more. ‘Toner Near Empty or Empty’
“Threshold 3” is set up as the “Threshold of Level of Toner Remaining in Toner Cartridge” in the NVM 762-039. The default is 4000 sec. “Threshold 1” is a third of “Threshold 3” and “Threshold 2” two thirds of ‘Threshold 3.’ The total time of the
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Dispense Motor on time is recorded in Toner Cartridge CRUM, as information unique to Toner Cartridge in use.
Toner Cartridge Replacement Detection The Toner Cartridge is a CRU (Customer Replaceable Unit). The Toner Cartridge has a memory (CRUM) for recording information. The CRUM is wireless and consists of the Toner Cartridge CRUM, the actual recording medium in the Toner Cartridge, and the Toner Cartridge CRUM PWB connected to the machine MCU PWB. Wireless communication between the Toner Cartridge CRUM PWB and the Toner Cartridge CRUM allows reading and writing of information. In the CRUM recorded are Toner Cartridge usage status such as status of how much toner remains (‘Low Toner’/’Toner Near Empty’/’Toner Empty’) and total time of Dispense Motor drive (Dispense Time), and information unique to Toner Cartridge such as its serial number. At power on and when the Toner Cartridge Door is closed, information is read from CRUM, and based on the status of how much toner remains, a decision is made on replacement. The statuses are as follows: Status of how much toner remains: ‘Normal’ is judged that Toner Cartridge is replaced with a new one. Status of how much toner remains: ‘Toner Empty’ is judged that Toner Cartridge is not replaced. Status of how much toner remains: ‘Toner Near Empty’/’Low Toner’ It is judged that Toner Cartridge is replaced with a used one.
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Transfer and Stripping Component Name and Function
HVPS S11
Toner Cartridge CRUM
BTR
Pre Transfer Corotron
Bias Roll Detack Saw
Transfer Intake Fan Motor HVPS S10
HVPS S3
Belt /Retract Solenoid
Figure 82
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The Belt /Retract Solenoid causes the Transfer Belt to or retract from the Drum. The Transfer Intake Fan Motor is the fan that takes air from outside the machine and blows it over the Transfer Belt. This prevents the rise in heat from the f and cools the Transfer Belt area. The Pre Transfer Corotron uses a negative DC charge. This controls what amount of negative charge should be used to charge the Drum surface and aids in transfer. The Bias Roll is a conductive roll that applies a negative charge to the underside of the Transfer Belt to prevent toner attachment. The CRUM is wireless and consists of the Toner Cartridge CRUM, the actual recording medium in the Toner Cartridge, and the Toner Cartridge CRUM PWB connected to the machine MCU PWB. The BTR (Bias Transfer Roll) is the conductive roll that applies a more positive charge to the under side of the Transfer Belt to transfer toner from the Drum surface to the paper. The Detack Saw applies a negative charge to the back of the paper to assist with the stripping of the paper from the Transfer Belt. It also helps prevent image defects. The HVPS (High Voltage Power Supply) S3 supplies an output to the Detack Saw. The HVPS High Voltage Power Supply S10 supplies an output to the BTR and Bias Roll. The HVPS (High Voltage Power Supply) S11 supplies an output to the Pre Transfer Corotron.
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Transfer Belt ing and Retracting A toner image formed on the Drum surface is transferred to the paper on the Transfer Belt. To prevent any problem due to belt deformation, the Transfer Belt stays retracted from the Drum except when a toner image is being transferred onto paper. The Transfer Belt /Retract Solenoid is use to accomplish this movement of the belt. See Figure 83.
Figure 83
The Belt /Retract Solenoid keeps the Transfer Belt ing or retracted from the Drum. The Transfer Belt s the Drum when the Drum Motor starts at the beginning of a job. The Transfer Belt retracts from the Drum when the final paper of the job is stripped from the Transfer Belt. The retracting also takes place when the Drum Motor stops for and emergency (jam etc) and when an ADC Patch/Toner Band is generated.
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Image Transfer onto Paper With the Transfer Belt in with the Drum, the BTR places a positive DC charge (2000 micro amps /+80 VDC) on the under side of the Transfer Belt. This a toner image to be attracted from the negatively charged Drum surface and transferred onto the paper on the Transfer Belt. The BTR is turned on and off for every image. A change is made to the output from BTR according to humidity levels (low/medium/high humidity) in order to prevent deletion along the trail edge of moist paper The Pre Transfer Corotron is used to prevent “toner trail” from occurring in the F, with moist paper in use or developer deteriorated, to enhance transfer onto moist paper, and to prevent toner dispersion from occurring when paper is being stripped from Transfer Belt with low humidity. It uses a negative DC charge (4050 micro amps / 230VDC) to control the amount charge applied to the toner on the Drum.
Stripping Paper Paper with a toner image is transported on the Transfer Belt. The Finger right behind the transfer point on the Drum prevents the paper from being rolled up by the Drum. When the paper is stripped from the Transfer Belt, the Detack Saw applies a negative charge to the back of the paper to stabilize the paper position. The Detack Saw prevents an IQ defect called “heat haze” due to exchanges of charges between the paper and adjacent parts at paper stripping.
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Bias Roll To prevent the problems mentioned below, the Bias Roll uses a negative DC charge (-650V) to apply the negative charge to the underside of Transfer Belt. “Toner Band” attachment to Transfer Belt (at the start/end of a job) Poor transfer onto moist paper “Background Toner” attachment to the Transfer Belt (inter-image) Toner attachment to the Transfer Belt after a Jam occurs, when a MSI size is mismatched, etc. (during cleaning cycle) The Bias Roll turns on when the Transfer Belt is in with the Drum. The Bias Roll changes its output for each of the above bulleted cases. To prevent the back of the paper from getting dirty a Cleaning Cycle is performed on the Transfer Belt. The Cleaning Cycle happens when there should be transfer of an image from the Drum to paper and the paper doesn’t show up, the image is larger than the selected paper, and when there is special paper like tabs or three hole punched.
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Toner Collection Component Name and Function
Auger Motor
Waste Toner Full Sensor Waste Bottle Set Sensor Figure 84
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Blower Fan Motor
Figure 85
The Auger Motor is the DC motor that drives the Waste Toner Auger, the F nip camshaft and the Inverter Roll. The Waste Toner Full Sensor senses when the waste bottle is full. The Waste Bottle Set Sensor detects the presence of the Waste Bottle. The Blower Fan Motor cools the Chute in the Duplex/invert area and the Cleaner area. The fan takes in air from these areas and discharges it through the Suction Filter and the Ozone Filter. The air to be discharged has ozone from near the Charge Corotron, the Pre Clean Corotron, and the Pre Transfer Corotron. It also has toner from around the Developer Housing and inside the Drum.
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Toner Collection System After an image is transferred, some toner remains on the Drum. There is also toner from the paper on the Transfer Belt. These residual toner particles cause degraded image quality and dirt on the back of the paper. The Drum and Transfer Belt cleaning system remove these particles. Cleaning is accomplished with a Cleaning Blade and a Cleaning Brush at the Drum and Transfer Belt. The Drum Motor drives the Cleaning Brush so cleaning is happening during print. The waste toner that is collected is transported the Waste Bottle by the auger. The Auger Motor drives the auger. Waste developer is transported in the same manner. See Figure 86.
Cleaning Blade Cleaning Brush Auger
Cleaning Blade
Auger
Cleaning Brush
Waste Toner Bottle Figure 86
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Process Control Component Name and Function
ESV Sensor ATC Sensor
ESV PWB
ADC PWB ADC Sensor
Humidity/Temperature Sensor
Figure 87
The ESV Sensor detects the potential on the Drum surface. The ESV PWB processes the data collected by the ESV. The ATC Sensor is the magnetometric sensor that detects the amount of toner remaining in the Deve Housing. The ADC Sensor detects the density of the Patch formed on the Drum. The ADC PWB processes the data detected by the ADC Sensor. The Humidity/Temperature measures the temperature and humidity inside the machine.
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Process Control Overview Process control is used to prevent changes in image quality due to changes is the temperature and humidity inside the machine. Process Control is mainly divided into potential control and toner dispense control. The potential control sets up charge potential (Charge Corotron Grid voltage), development bias potential and ROS LD light quality
Figure 88
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Potential Control Overview Potential control is performed based on the ESV Sensor-detected potential of the Drum surface, the ADC Sensor-detected density of a toner image on the Drum, and Environment Sensor-detected temperature and humidity. Patches are used to detect the potential of the Drum surface and density of a toner image. Potential control has two types of operations: the setup operation (mini setup) at power on and the operation during printing Table 23 shows when each setup item is controlled and what sensors are related to calculation of each set value. Table 23 Setup Item Charge potential Development bias LD light quantity
Sensor used ESV Sensor Humidity/Temperature Humidity/Temperature ESV Sensor Humidity/Temperature ADC Sensor
Performed at: Mini setup Mini setup Mini setup During printing
Table 24 shows how the Potential Control operation can be changed in NVM 752-002. Table 24 Mode Name Fixed Potential Mode Process Control Potential Mode Standard Potential Mode
NVM Value 0 1 (default) 2
Description Uses fixed values of charge potential & LD light qty. Uses a charge potential estimated from a measurement result by ESV Sensor, and a LD light qty estimated from measurement results by ESV Sensor & ADC Sensor Uses a potential estimated from a measurement result by ESV Sensor, and a LD light qty estimated from a measurement result by ESV Sensor. (No ADC Sensor-detected LD light qty correction)
The normal operation is the Process Control Potential Mode. The other modes are prepared in case no stable measurement value can be obtained if any sensors fail.
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Patch The Patch is used for detection of the potential on the Drum surface and the density of a toner image. It is not an image to be actually printed out, but a small image scanned and generated for process. Patches are generated on the Drum. Some of them are developed (with toner) and others not. The patches not developed are used for ESV Sensor to measure the potential of the Drum surface, while the developed patches for ADC Sensor to measure toner concentration. Table 25 shows the patch types
Table 25
142
Patch Type VH1 VH2 VH3 VM1
Deve Generation Timing Mini Setup Printing No ○ No ○ No ○ Yes ○
VM2
Yes
○
VM3
Yes
○
ADC
Yes
Vclean
No
Vdark
No
Cycle Up
○ ○ ○
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Description For charge potential control For charge potential control For charge potential control For LD light qty/toner dispense control For LD light qty/toner dispense control For LD light qty/toner dispense control For LD light qty/toner dispense control For ADC Sensor’s measurement of density standard value For measurement of dark current
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Mini Setup Operation During Mini Setup, charge potential, development bias and LD light quantity are calculated and set. The ATC correction amount used for the toner control is also calculated. These are all based on the time since the last Mini Setup, the age of the drum and the environmental conditions. The Mini Setup is done under the following conditions. At power on four hours after the last mini setup When the machine returns from the low power mode When the machine returns from the diagnostic mode At the end of a print job one hour or more after the last mini setup At the start of a print job if the environment has changed in temp and humidity since the last mini setup The order of the Mini Setup is as follows: Set various targets and determine development - the bias ADC Target, VH Target, VM Target and Bias Target are calculated according to humidity (measured by Environment Sensor) and Drum age. The Bias Target calculated here is Development Bias for setup. Determine the charge potential - the Patch VH is generated, the ESV Sensor measures the potential of the Drum surface at the patch. Charge Potential is calculated from the difference between the measured VH value and the VH Target calculated in step 1. Determine the ESV Sensor-detected LD light quantity - the Patch VM is generated and the ESV Sensor measures the potential of the Drum surface at the patch. The LD light quantity is calculated from the difference between the measured VM value and the VM Target calculated in step1. Determine the ADC Sensor-detected LD light quantity ADC correction amount - the Patch VM is generated, the ADC Sensor measures the toner density of the patch. The LD light quantity ACD correction value is calculated from the difference between the measured ADC Correction value and the ADC Target calculated in step 1. Determine the ATC LD correction amount – the ATC LD correction amount is calculated from the difference between the LD light quantity calculated by ESV Sensor and LD light quantity calculated by ADC Sensor. If the process control potential control mode (default) is used as potential control mode, the value obtained by adding the LD light quantity ADC correction amount, calculated in step 4, to the LD quantity, calculated in step 3, becomes the new LD quantity for setup. If the standard potential mode is used as the potential control mode, the LD quantity, calculated in step 3, is the new LD light quantity for setup.
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Operation During Printing/Copying The operation during printing/copying calculates and sets the LD light quantity. It also calculates the ATC correction amount to be used for toner dispense control (calculation of the ATC correction amount is made only in the process control potential mode). The operation during printing/copying occurs when 160 prints/copies are made in a row. It also occurs at the end of a job that has 50 or more prints/copies. The order of operation is as follows: Determine the ADC Target – the ADC Target is calculated according to humidity, measured by the Environment Sensor and the life of the Drum. Determine the ESV Sensor detected LD light quantity correction amount – the ESV Sensor detected LD light quantity correction is amount is calculated when an ADC patch is generated and the ESV Sensor measures the potential on the Drum surface at the patch. Determine the ADC Sensor detected LD light quantity ADC correction amount – the ADC Sensor detected LD light quantity ADC correction amount is calculated when an ADC patch is developed and the toner concentration is measured. This value is used with the ADC Target from step 1. Determine the ATC LD correction amount - the ATC LD correction amount is the difference between the LD light quantity calculated by the ESV Sensor and the LD light quantity calculated by the ADC Sensor. If the process control potential control mode (default) is used as potential control mode, the value obtained by adding the LD light quantity ADC correction amount, calculated in step 4, to the current LD quantity, becomes the new LD quantity for setup. If the standard potential mode is used as the potential control mode, the value obtained by adding the LD quantity, calculated in step 3, to the current LD light quantity, becomes the new LD light quantity for setup.
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Toner Dispense Control Toner Dispense Control calculates the toner dispense rate needed to keep image density at a certain level. The ICDC (Image Coverage Dispense Control) and the ATC Sensor detected amount of toner remaining in the Deve Housing are used in the calculation. The toner dispense rate is calculated as the amount of time that the Dispense Motor is driven. Table 26 shows that, using NVM 752-001, Dispense Control can be changed. Table 26 Mode Name Timer Toner Dispense Mode Process Control Toner Dispense Mode
NVM Value 0
Description Supplies a fixed amount of toner at regular intervals
1 (default)
ICDC Toner Dispense Mode
2
Calculates toner dispense amount from ICDC count +ATC Sensor output value, and supplies that amount of toner. Calculates toner dispense amount from ICDC count and supplies that amount of toner.
The ICDC calculates the dispense rate based on the pixel count from the ROS Module. In the ICDC Toner Dispense Mode, only the pixel count is used to determine the dispense rate. The ATC Sensor, at regular intervals with the Deve Motor on, detects the amount of toner still in the Developer housing. This is used by the ATC Sensor to calculate the dispense rate. The ATC calculation works as follows: The ATC Target is calculated based on the humidity measured by the Environmental Sensor, Drum age, toner in the Deve Housing and the ATC LD correction amount (calculated by potential control). The ATC output value is calculated from the amount of remaining toner measured by the ATC Sensor and the ATC Target calculated in step 1. The toner dispense rate is calculated from the ATC output (step 2) and a specified ATC coefficient. A correction is made to this calculation based on the ICDC count. In the Process Control mode, the toner dispense rate is calculated by using the ICDC count and the ATC Sensor toner dispense amount.
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(Chain 10a) Copy Transport
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 10 Copy Transportation.
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Technical Overview The main function of this module is to transport a copy from the F to the exit of the IOT. This includes the output of paper from F, Invert Control and Duplex Control.
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Paper Transportation after the F Component Name and Function
Invert Gate Solenoid IOT Exit Sensor Invert Out Sensor Invert In Sensor Exit Motor
Release Motor
Invert Release Home Sensor Duplex Path Sensor1 Invert Path Sensor
Duplex Out Sensor Duplex In Sensor
Duplex Path Sensor2
Duplex Gate Solenoid
Duplex Motor
Invert Motor
Figure 89 Copy Transportation after the F
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The IOT Exit Sensor detects paper leaving the IOT. The Invert In, Invert Out, and Invert Path Sensors detect paper being transported using the Invert area. The Invert Gate Solenoid moves the Invert Gate to direct the paper into the Invert area. The Exit Motor is the stepper motor that drives the IOT Exit Roll and the Invert Out Roll in the copy output area. The Release Motor is the stepper motor that is used to release the nip of the Invert Roll. The Invert Motor is the stepper motor that drives the Duplex In Roll, the Duplex Path Roll 1 and the Invert Roll in the Invert and Duplex areas. The Duplex Motor is the stepper motor that drives the Duplex Out Roll and the Duplex Path Roll 2 in the Duplex area. The Invert Release Home Sensor detects the home position of the Invert Roll in the release position. The Duplex In Sensor, Duplex Path Sensor 1, Duplex Path Sensor 2 and the Duplex Out Sensor detect paper being transported through the Duplex area.
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Copy Output Control Overview There are three output modes, the face up and invert mode for simplex, and the duplex mode. These are illustrated in Figure 90.
Figure 90
The simplex face up path has paper that has been fused directly transported to the output area as in Figure 91.
Figure 91
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The simplex face down path has paper that has been transported through the f directed to the invert area then transported to the output area as in Figure 92.
Figure 92
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When doing duplex side 1, the paper that has been through the f is sent to the invert area then directed to the duplex area. From the duplex area it is feed through the same area as paper from trays 1 through 4. After receiving an image, it is sent to the output area. This is shown in Figure 93.
Figure 93
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Straight Output
Figure 94 Straight Output
A set time after the Regi Roll is driven; the Invert Gate Solenoid is energized and the Invert Gate is switched to the Exit side. Note: Because of the type of solenoid that the Invert Gate solenoid is, the position of the gate is maintained after it is switched. With this type of solenoid it is not necessary to keep it energized at all times or actuate it at every . When the F Exit Sensor detects the paper, the Exit Motor drives the Exit Roll to transport the paper to the output area. After a specified time, the Exit Motor speed is increased. Note: Since the Exit Roll is linked to the Exit Motor through a torque limiter; the paper is transported at F Transport speed while going through the F and the Exit Roll’s speed after going through the F. After the paper es the IOT Exit Sensor, the Exit Motor is slowed, and then stopped.
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Invert Output
Figure 95 Invert Output At a specified time after the Regi Roll is driven, the Invert Gate Solenoid is energized and the Invert Gate is switched to the Invert side. After the paper es over the Invert In Sensor, the Duplex Gate Solenoid is energized and the Duplex Gate is switched to the Exit side. Note: Because of the type of solenoids that the Invert Gate solenoid and the Duplex Gate are, the position of the gate is maintained after it is switched. With this type of solenoid it is not necessary to keep it energized at all times or actuate it at every . When the F Exit Sensor detects the paper, the Auger Motor drives the Invert In Roll to transport paper to the Invert area. When the paper has ed the F Exit Sensor, the Auger Motor is stopped. Note: The Auger Motor drives the F Nip/Release and Toner Collection Auger as well as the Invert In Roll. At a specified time after the Invert In Sensor Detects the Paper, the invert operation starts. The Invert Motor drives the Invert Roll to pull the paper into the Invert area. After a set time, the speed of the Invert Motor is increased. When the paper es the Invert In Sensor, the speed is reduced. At a set time the direction of the Invert Motor is reversed and sped up to make the Invert Roll rotate in the opposite direction. After a set time the motor speed is reduced and the Invert Motor is stopped. The paper is transported inside the Mid Gate when entering the Invert area and outside the Mid Gate when being transported to the Exit area. The Invert Roll and Pinch Roll are released at Start Print. When the paper es the F Exit Sensor after Start Print, the Release Motor is energized to drive the Pinch Roll and the Invert Roll to transport the paper. When the Invert Release Sensor becomes unblocked, the Release Motor stops. At a set time after the Invert Roll is driven, it is released.
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When the paper es the Invert In Sensor the Exit Motor drives the Invert Out Roll and Exit Roll to transport the paper to the output area. A specified time later, the Exit Motor speed is increased. After the paper es the Invert Out Sensor, the speed is reduced. After the paper es the IOT Exit Sensor, the Exit Motor is slowed then stopped.
Duplex Output
Figure 96 Duplex Output At a specified time after the Regi Roll is driven, the Invert Gate Solenoid is energized and the Invert Gate is switched to the Invert side. After the paper es over the Invert In Sensor, the Duplex Gate Solenoid is energized and the Duplex Gate is switched to the Exit side. Note: Because of the type of solenoids that the Invert Gate solenoid and the Duplex Gate are, the position of the gate is maintained after it is switched. With this type of solenoid it is not necessary to keep it energized at all times or actuate it at every . When the F Exit Sensor detects the paper, the Auger Motor drives the Invert In Roll to transport paper to the Invert area. When the paper has ed the F Exit Sensor, the Auger Motor is stopped. Note: The Auger Motor drives the F Nip/Release and Toner Collection Auger as well as the Invert In Roll. At a specified time after the Invert In Sensor Detects the Paper, the invert operation starts. The Invert Motor drives the Invert Roll to pull the paper into the Invert area. After a set time, the speed of the Invert Motor is increased. When the paper es the Invert In Sensor, the speed is reduced. At a set time the direction of the Invert Motor is reversed and sped up to make the Invert Roll rotate in the opposite direction. At the same time, the Duplex In Roll and Duplex Path Roll 1 start so they can drive the paper into the Duplex area. After a set time the motor speed is reduced and the Invert Motor is stopped.
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The Invert Roll and Pinch Roll are released at Start Print. When the paper es the F Exit Sensor after Start Print, the Release Motor is energized to drive the Pinch Roll and the Invert Roll to transport the paper. When the Invert Release Sensor becomes unblocked, the Release Motor stops. At a set time after the Invert Roll is driven, it is released. The Duplex Motor is then used to drive the Duplex Path Roll 2 and the Duplex Out Roll to transport the paper to the Duplex area. At a set time, the motor speed is increased. After the paper es the Duplex Out Sensor, the Duplex Motor is slowed then stopped. At a specified time after the P/H control standard for side 2, the Duplex Motor drives the Duplex Path Roll 2 and the Duplex Out Roll to transport the out of the Duplex area. At a set time, the motor speed is increased. After the paper es the Pre Regi Sensor, the Duplex Motor is slowed then stopped.
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Duplex Print Sequence In continuous duplex printing, the side 1 and side 2 transfer sequences depends on the paper size. Paper sizes and transfer output patterns are shown in Table 27 and in Figure 97
Table 27 Duplex Sequence Paper Size B5L A4L, LetL A4S B4S A3S, 17”S 18”S, 19”S B5L, A4L, Letter L A4S, B4S, A3S, 17”S, 18”S, 19”S B5L, A4L, Letter L … 216gsm or less & OHP B5L, A4L, Letter L … over 216gsm & Labels A4S, B4S, A3S, 17”S, 18”S, 19”S
110-sheet MC
90-sheet MC
Case 1
Case 3
Case 3
Case 2 Case 2
Figure 97 Duplex Sequence
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Fan Control Component Name and Function
Exit Fan1 Exit Fan2
Duplex Chute Fan
Duplex Fan2
Duplex Fan1
Figure 98 Fans
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The Duplex Chute Fan is used to keep the temperature inside the machine from rising during the duplex mode. The fan also cools paper ing through the duplex area. Duplex Fans 1 and 2 are also used to keep the temperature inside the machine from rising during the duplex mode. The fans also cool paper ing through the duplex area. These fans bring in air from outside the machine. Exit Fans 1 and 2 assist in exhausting air from the F.
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(Chain 10b) Fusing
Introduction This module describes the names, locations, and functions of the Chain10 Fusing. The main function of this module are fuse toner in place by applying heat and pressure, cleaning the surface of the Heat Roll using a web and to output a finished print from the f.
Figure 99 F Cross Section
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Fusing Component Name and Function The F Nip Clutch transfers drive from the Auger Motor to the Cam Shaft to cause the Pressure Roll to make with the Heat Roll. The F Nip Sensor senses when the Pressure Roll is in with, or retracted from the Heat Roll. Auger Motor
F Nip Clutch F Nip Sensor Cam Shaft
Figure 100 F
Figure 101 Pressure Roll Nip Mechanism
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F Assembly The following figure identifies the F Rolls, components and sensors. Heat Roll Heat Roll Thermistor 2
Heat Roll Thermistor 1
Main Heater Rod 2
Heat Roll Thermistor 3
Thermostat 1 Thermostat 2 Sub Heater Rod 2
Pressure Roll Main Heater Rod 1 Figure 102 Fusing
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F Heat Roll The Heat Roll applies heat to the paper to fuse the toner in place. The Pressure Roll, with the Heat Roll, applies pressure to aid in fusing. The Heat Roll contains three 950-watt heat rods, 2 main heat rods that run the entire length of the Heat Roll and a sub heater rod that heats the center of the heat roll. The Heat Roll Thermistor 1 monitors the temperature at the center surface of the Heat Roll in the paper path. This temperature is used by process control as the target temperature. Heat Roll Thermistor 2 monitors the temperature between the center and the rear of the Heat Roll outside of the paper path. This thermistor detects “Hot Not Ready” during printing. Heat Roll Thermistor 3 monitors the temperature at the rear of the Heat Roll outside the paper path (not used for normal temperature control). Thermostat 1 monitors the Heat Roll and turns off the Main Heater Rod 1 circuit when the temperature of the Heat Roll is too high. Thermostat 2 monitors the Heat Roll and turns off the Main Heater Rod 2 and Sub Heater Rod circuits when the temperature of the Heat Roll is too high.
Rear side Front side
Heat Roll Thermistor 2 Heat Roll Thermistor 3
Heat Roll Thermistor 1
Heat Roll Main Heater Rod 1 Main Heater Rod 2 Sub Heater Rod Heating range
Heating range
Pressure Roll Figure 103 Side View
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F State Figure 104 and Table 28 show and explain the F’s transition form one state to another. Table 29 shows the definition of the F States.
Power Off ①
RelayOff
⑮
FsrWait
FsrOff ②
⑬
RelayOn ③
⑭
⑪ RelayOffWait
⑩
⑩ LowPower
Warmup
④
⑫ FsrStandby
⑩
Ready ⑦
⑤
Idling ColdNrdyWait
⑧
HotNrdyWait
⑨
⑥ FsrPrintProcess ⑩
Figure 104 Diagram of the F State Table 28 Conditions for the State Transition Transition No. 1 2 3 4
5 6 7 8 9 10 11 12 13 14 15
Conditions for Transition Power off All the conditions for F Relay On are met. 50[ms] have ed since Relay On, and control of F Motor for backward rotation is over. Warm Up Idling is available: the two conditions are met: Warm Up Idling time has been up; HRSTS1 has reached “HR Temp at the end of F Warm up.” Warm Up Idling is unavailable: HRSTS1 has reached “HR Temp at the end of F Warm up.” Print starts. (Paper Pitch for 1st paper received) Print Process by Cycle Down/Hard Down ends. Control of Lamp at control temp ends after the end of print. Print Process by Cycle Down/Hard Down ends after Cold Not Ready occurs. Print Process by Cycle Down/Hard Down ends after Hot Not Ready occurs. Conditions for F Relay Off occur. 50[ms] after Lamp Off Upon reception of an instruction to transit to Low Power Mode Upon reception of an instruction to clear Low Power Mode With Low Power Mode not cleared, F transits from Relay Off to Relay On and finishes Warm up. With Low Power Mode not cleared, F transits from Relay Off to Relay On and the conditions in 4 are already met.
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Table 29 Definition of the F State State Main State
Sub State RelayOn Warmup
FsrWait ColdNrdyWait HotNrdyWait Ready FsrStandby
LowPower FsrPrintProcess FsrOff
State Overview
Remarks
In preparation for controlling Heater Rods, only Relay is turned ON. Heater Rods are controlled so that the temperature of Heat Roll will be the Ready-to-Print temperature. To make the temperature even and warm up Pressure Roll, F Drive Motor is made to be idling. After Cold Not Ready occurs, Heat Rods are controlled so that the temp of Heat Roll will be the Ready-to-Print temp After Hot Not Ready occurs, Heat Rolls are controlled so that the temperature of Heat Roll will be the Ready-to-Print temperature. Data can be received for print.
Print Off
Idling
Print Off*
Print Off Print Off Data can be received for print. Data can be received for print.
Heater Rods are controlled so that the temp of Heat Roll can be prevented from overshooting a spec one after the end of printing (after the output of the last paper). LowPower When the MC receives a print instruction with Print Off power limited to the low level, the MC will be ready to print in a preset recovery time. PrintProcess Print is in progress. Print in progress RelayOffWait F waits for Heater Rods and Relay to be Print Off turned off. RelayOff Relay, Heater Rods and Motor are all OFF. Print Off *Print is inhibited, but data can be received for print and held in queue.
F Temperature Control The F changes from one state to another according to the temperature of the Heat Roll surface and the machine status. Each state has its own setup target temperature for control. A target temperature is made using a correction to a preset value based on an environment temperature detected by the Environmental Sensor. The F Ready temperature is 185 C and the running temperature is 180 C.. Currently there is no way of measuring this. The following tables and illustration show the patterns in which the Heater Rods are turned on and off when temperature control is performed. HRSTS1 is the temperature of the Heat Roll surface detected by Heat Roll Thermistor 1. HRSTS2 is the temperature of the Heat Roll surface detected by Heat Roll Thermistor 2. For the Heater Rods in Tables 30, 31, 32 and 33 marked with * next to ON/OFF, cutoff control is performed. Cut off control controls power consumption by turning on and off the heater rods repeatedly for a preset ultra short time.
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Table 30Control of Switching between Heater Rods in Warm Up Requirement
HRSTS1>/= “Warmup Control Temp (Heat Roll)” + “Hysteresis Temp” HRSTS1< “Warmup Control Temp (Heat Roll)”
HRSTS1>/=HRSTS2 + (“Wait Main/Sub Lamp Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF
HRSTS1
Main1: 10 ON Main2: 10 ON Sub: 2 OFF / 1 ON*
Main1: OFF Main2: 10 ON Sub: 10 ON
Table 31 Control of Switching between Heater Rods in Cold Not Ready Requirement
HRSTS1>/=HRSTS2
HRSTS1
+Tcold_ms*1 +Tcold_ms*1 + “Hysteresis Temp” HRSTS1>/= Main1: OFF Main1: OFF Tcold _cont*2 Main2: OFF Main2: OFF + “Hysteresis Temp” Sub: OFF Sub: OFF HRSTS1
HRSTS1>/=HRSTS2
HRSTS1
+ (Thot_ms*1)
+ (Thot_ms*1)
+ “Hysteresis Temp” Main1: OFF Main1: OFF Main2: OFF Main2: OFF Sub: OFF Sub: OFF Main1: 10 ON Main1: OFF Main2: 10 ON Main2: 10 ON Sub: OFF Sub: 10 ON *1 Tcold_ms is the same switching temperature as in the state before this process.
HRSTS1>/= Thot _cont*2 + “Hysteresis Temp” HRSTS1
*2 Tcold_cont is a temperature during the cycle of the paper that es immediately after the F’s transition to ColdNrdyWait. The temperature is changed with the size or stock. If retained, the first control temperature or second control temperature is retained.
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Table 33 Control of Switching between the Heater Rods in Standby Ready Requirement
HRSTS1>/= “Ready Control Temp (Heat Roll)” + “Hysteresis Temp” HRSTS1< “Ready Control Temp (Heat Roll)”
HRSTS1>/=HRSTS2
HRSTS1
+ (“Standby Main/Sub Lamp
+ (“Ready Main/Sub Lamp
Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF
Switching Temp”) Main1: OFF Main2: OFF Sub: OFF
Main1: 4 ON / 4 OFF* Main2: 4 OFF / 4 ON* Sub: OFF
Main1: OFF Main2: 10 ON Sub: 10 ON
Table 34Control of Switching between the Heater Rods Ready Requirement
HRSTS1>/= “Idling Control Temp (Heat Roll) + “Hysteresis Temp” HRSTS1< “Idling Control Temp (Heat Roll)”
HRSTS1>/=HRSTS2
HRSTS1
+ (“Standby Main/Sub Lamp
+ (“Ready Main/Sub Lamp
Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF Main1: 10 ON / 0 OFF* Main2: 10 ON / 0 OFF* Sub: OFF
Switching Temp”) Main1: OFF Main2: OFF Sub: OFF Main1: OFF Main2: 10 ON Sub: 10 ON
Table 35 Control of Switching between the Heater Rods in Low Paper Requirement
HRSTS1>/=HRSTS2
HRSTS1
+ (“Standby Main/Sub Lamp + (“Ready Main/Sub Lamp HRSTS1>/= “Low Power Control Temp (Heat Roll)” + “Hysteresis Temp” HRSTS1< “Low Power Control Temp (Heat Roll)”
168
Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF
Main1: OFF Main2: OFF Sub: OFF
Main1: 4 ON / 4 OFF* Main2: 4 OFF / 4 ON* Sub: OFF
Main1: OFF Main2: 10 ON Sub: 10 ON
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Print Control Temperature depends on the quantity of prints as shown in Figure 105
Figure 105 Table 36 Control of Switching between Heater Rods in Print Requirement
HRSTS1>/=HRSTS2
HRSTS1
+ (Tprint_ms*) + (Tprint_ms*) +”Hysteresis Temp” HRSTS1>/= Main1: OFF Main1: OFF Tprint + ”Hysteresis Temp” Main2: OFF Main2: OFF Sub: OFF Sub: OFF HRSTS1
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F Idling F idling is having the F Motor on during warm-up. This improves the temperature distribution and fusing level. F idling is performed when “F Motor Idling” is set to 1:enabled and Heat Roll STS-1 is at or below “Warmup Idling Judge Temp” when the f has transitioned to FsrWait_Warmup. F idling starts when HRSTS1 is “F Motor Idling Start Temperature”. Idling duration depends on the environment temperature and the input power voltage.
Countermeasure against Flicker When the F Heater Rods come on, power consumption sharply increases. This may cause fluorescent lights to flicker. To prevent this phenomenon, the following measures have been taken against the causes. Hysteresis Control Fluctuations in the resistance value of each Heat Roll Thermistor cause the detected temperature to be above or below the target. To prevent sharp changes in the voltage due to the Heater Rods turning on and off for short times, Hysteresis Control is performed on the target temperature. Hysteresis Temperature is added to the temperature for switching between Heater Rods. Preventing Heater Rods from turning on simultaneously If multiple Heater Rods turn on at the same time, a large change in current can cause power fluctuations. To prevent this, the Heater Rods are prevented from turning on at the same time. When multiple Heater Rods need to be turned on at the same time, their turn on time is staggered. See Figure 106
Figure 106
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Phase Control The Heater Rod is turned on with and intermittent current so that a gradually increasing amount of current is supplied. Then a continuous current is applied. A gradual decreasing amount of current is supplied to the Heater Rod is off. Figure 107 shows the waveform of the current to the Heater Rod
Figure 107
F Drive Component Name and Function The F Drive Motor is the DC motor that drives the Heat Roll The F Exit Sensor senses that paper has ed through the f. The F Intake Fan takes air from outside the machine and blows it on the Drum, the Transfer Belt Cleaner and the top of the F. The F Exhaust Fan discharges air warmed by the F
F Exhaust Fan
F Exit Sensor
F Intake Fan F Drive Motor
Figure 108 F Drive
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F Drive Control The F Drive Motor is controlled according to the state of the F, as shown in Table 37. Table 37 F State FsrOff_RelayOff FsrWait_RelayOn FsrWait_Warmup
FsrWait_ColdNrdyWait FsrWait_HotNrdyWait
FsrStandby_Ready
FsrStandby_Idling FsrPrintProcess
FsrOff_RelayOffWait LowPowerMode
172
F Drive Motor Control F Motor stops F Motor drives backward. When the conditions below are met, with Relay not On after a jam occurs, F Motor does not idle. (1) ”F Motor Idling” is set to the value representing “Disabled” in the NVM. (2) F Heat Roll STS-1 is 150degrees C when F has transited to FsrWait_Warmup. When, in any other case than the above, Relay is On after a jam, F Motor idles as follows: The motor starts driving at the timing F Heat Roll STS-1 Monitored Value>/=”F Motor Idling Start Temp.” It stops at the timing a preset idling duration has elapsed. (1) The motor continues driving. (2) It stops when no more print is in progress at the end of this state. (1) When F transits from Print Process by CycleDown, the motor stops at the time a preset “Idling Duration after Hot Not Ready” has elapsed since its transition to this state. (2) Even when F transits from Print Process by CycleDown, the motor stops at the time the conditions for ending this state are met. (3) When F transits from Print Process by HardDown, in this state F Motor does not drive or neither stops nor starts. (It has already stopped.) In this state F Motor does not drive or neither stops nor starts. (The motor follows the ”Normal Stop Control” timing preset in FsrWait_Warmup, FsrWait_HotNrdyWait or FsrStandby_Idling from which F has transited. The motor stops at the timing a preset “Idling Duration after the End of Print” (which depends on paper stock and can be changed in the NVM) has elapsed since F’s transition to this state. The motor starts driving at the timing a preset “F Motor Drive Delay Time” has elapsed since the pitch base timing for the first paper. “F Motor Drive Delay Time” can be changed in the NVM for every paper stock. If driving, F Motor stops for emergency. The motor stops.
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Heat Roll Cleaning Component Name and Function Web is a roll of cloth used to wipe the dirt off the Heat Roll. The Web Motor is a DC motor that drives the roll to take up the Web. The Web End Switch is the sensor that senses that the Web is completely used.
Web End Switch Web
Web Motor
Figure 109 Heat Roll Cleaning
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Web Motor Control The Web Motor drives the Web take-up roll. The Web in with the Heat Roll cleans toner and paper particles off the Heat Roll. The Web Motor Drive Duration is determined according to “Web Motor on Time”. Changing the Web Motor Drive duration can be done to extend F Web life, if causing jams and to cure electrostatic offset.
Extension of Web Life A smaller amount of Web is used when the density of a print is low or the temperature of the Heat Roll is high, because less toner is attached to the Heat Roll. The Web Motor drive duration is corrected based on ICDC Count (explained in Marking) and the detected Heat Roll Temperature. When a jam occurs, more toner is attached to the Heat Roll surface. The Web Motor drive duration is increased based on a certain coefficient. During Duplex, electrostatic offset occurs under certain environment temperature and humidity. The Web Motor drive duration is increased based on input from the Environment Sensor.
Remaining Web Detection The amount of Web remaining is calculated to predict when replacement is necessary. The amount of remaining Web is detected based on “Web Motor Total ON Time”. When the “Web Motor Total ON Time” exceeds a value calculated from a formula including “Web Remaining Amount Threshold”, a warning is issued. When the Web is out the Web End Switch detects it. At power on and when the interlocks are closed, Web End Switch is checked. If the switch detects the High level twice in a row, F Web End Fail will be declared. To clear the warning and Web End fail, replace the Web and then enter dC135 954-847 and clear or on the console press Stop then 9.
.
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Finisher
Introduction Technical Overview Finisher Configurations The Xerox 4110 Multi-Function Finisher comes in two configurations. The Finisher with the Punch and Stapler. This consists of the Stapler, Punch, Stack Tray, Top Tray and Interposer. The three hole punch is standard in the US and Canadian versions. A two and four hole punch is standard for Europe. The Finisher with Booklet Maker. This consists of a Booklet Maker added to the Finisher described above. The Booklet Maker includes a Saddle Stitcher. Either model may have a Folder added as an option. The folder can make “C” folds (8.5X11 or A4), large “Z” folds (11X17 or A3) and small “Z” folds (8.5X11 or A4). Bi-Folds require the Booklet Maker version of the Finisher. Both models are equipped with an automatic decurler to help control paper curl in the Finisher. The Stapler provides single, dual, and corner stitching capabilities.
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Finisher Components Figure 110 shows the Finisher subsystems. Top Output Tray
Punch Interposer
Stacker Output Tray Decurler Stapler
Booklet Maker Output Tray
Folder
Folder Output Tray
Booklet Maker
Figure 110 Finisher Subsystems
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Output Tray Capacities Table 38 shows the capacities of the various output trays and the interposer. Table 38 Output Tray Capacities No Stapling
Stapling *1
Top Tray
500 sheets
---
Stack Tray
3000 sheets
200 sets or 3000 sheets
Standard sizes of 7.2“ (182 mm) or more in FS direction and 8.5” (217 mm) or less in SS direction
1500 sheets
100 sets or 1500 sheets
Standard sizes of 8.5“ (217 mm) or more in FS direction and 17” (431.8 mm) or less in SS direction
1500 sheets
---
Standard sizes of more than 17” (431.8 mm) in SS direction
30 sheets
10 sheets
3000 sheets with 30 Z folded sheets
100 sets or 3000 sheets with 10 Z folded sheets
A mix of Z folded and flat sheets
2000 sheets
200 sets or 2000 sheets
Standard sizes of 7.2“ (182 mm) or more in FS direction and 8.5” (217 mm) or less in SS direction
1500 sheets
100 sets or 1500 sheets
Standard sizes of 8.5“ (217 mm) or more in FS direction and 17” (431.8 mm) or less in SS direction
1500 sheets
---
Standard sizes of more than 17” (431.8 mm) in SS direction.
30 sheets
10 sheets
2000 sheets with 30 Z folded sheets
100 sets or 2000 sheets with 10 Z folded sheets
20 sets
20 sets
5 sheets or less per set
---
15 sets
More than 5 sheets per set and 14” (364 mm) or more in SS direction.
---
10 sets
More that 5 sheets per set and less than 14” (364 mm) in the SS direction
---
---
The size of the output stack is determined by the Booklet Tray Full Sensor.
40 sheets +
---
The size of the output stack is determined by the Folder (Envelope) Tray Full Sensor.
Output Tray
(without Booklet Maker)
Stack Tray (with Booklet Maker
Booklet Maker Tray
Folder (Envelope) Tray Interposer
Requirements Flat Paper, any size with 5 mm or less curl.
Z folded paper only
Z folded paper only A mix of Z folded and flat sheets
250 sheets
FS = Fast Scan Direction SS = Slow Scan Direction 1* Applies to stapled sets of both the same size and mixed sizes of the same width. Mixed sizes may degrade stacking performance
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Paper Transportation Figure 111 shows the names of the paper transport rolls and the locations of the paper path sensors. The transport rolls are different than previous models to accommodate the toner used.
Figure 111 Paper Transport Rolls and Sensors
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Figure 112 shows the paper transportation paths.
Figure 112 Paper Transportation Path
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Table 39 Sensors (Refer to Figure 112) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sensor Name Decurler In Sensor Decurler Out Sensor Interposer Feed Out Sensor Interposer No Paper Sensor Folder Entrance Sensor Folder Path Sensor 1 Folder Path Sensor 2 Folder Path Sensor 3 Folder Path Sensor 4 Folder Exit Sensor Punch Out Sensor Buffer Path Sensor Top Tray Exit Sensor Compile Exit Sensor Compile Tray No Paper Sensor Booklet In Sensor Booklet Compile No Paper Sensor Booklet Folder Roll Exit Sensor Stacker Tray No Paper Sensor Booklet Tray No Paper Sensor
Functions and Output Tray Availability Not all output trays are available for all of the Finisher Functions. Table 40 shows the output trays available for each function or combination of functions Table 40 Functions and Output Tray Availability Function
Output Tray
Booklet Tray
Stack Tray
Top Tray
Folder Tray
Bi-Fold
Booklet
Stapling
Punching
C fold
Z fold
Interposer
Function
Interposer
NA
O
O
X
O
O
O
O
O
O
O
Z fold
O
NA
X
O
O
X
X
X
O
O
X
C fold
O
X
NA
X
X
X
X
O
X
X
X
Punching
X
O
X
NA
O
X
X
X
O
O
X
Stapling
O
O
X
O
NA
X
X
X
X
O
X
Booklet
O
X
X
X
X
NA
X
X
X
# *1
O
Bi-Fold
O
X
X
X
X
X
NA
X
X
X
O
O may be combined. # may be combined with some restrictions. X may not be combined.
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*1: The Stack Tray may be selected as an output tray when using the booklet maker provided that stapling is not selected at the same time. If stapling is selected the output is to the Booklet Tray.
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Paper Size and Function Not all Finisher functions are available for all paper sizes and feed orientations (long edge or short edge feed). Table 41 shows the relationships between paper size and function. Table 41 Paper Size and Function Type/Orientation Dimensions Post Card / SEF
4X6” 102X152 mm
Statement / LEF
5.5X8.5“ 139,7x215.9 mm
8X10 / LEF
8X10” 254X203.2 mm
A4 / SEF
8.3X11.7” 210X297 mm
A4 / LEF
11.7X8.3“ 297X210 mm
Letter / SEF
8,5X11” 215.9X279.4 mm
Letter / LEF
11X8.5“ 279.4X215.9 mm
8.5X13 / SEF
8.5X13” 215.9x330.2 mm
Legal / SEF
8,5X14” 215.9X355.6 mm
Ledger / SEF
11X17” 279.4X431.8 mm
A3+ / SEF
12X18” 304.8X457.2 mm
Top Tray
Stacker Stapler
Punch
Interposer
Booklet Maker
Z Fold
BiFold
C Fold
O
X
X
X
X
X
X
X
X
O
X
X
X
O
X
X
X
X
O
O
O
X
O*1
X
X
X
X
O
O
O
2h
O*4
O
O
O
O
O
O
O
2h/3h/4h
O
O
X
X
X
O
O
O
X
O*4
O
O
O
O
O
O
O
2h/3h/4h
O
O
X
X
X
O
O
O
X
O*2
O
X
O
X
O
O
O
X
O*2
O
X
O
X
O
O
O
2h/3h/4h
O
O
O
O
X
O
O*3
X
X
X
X
X
X
O may be used X may not be used *1: Select 8x10L in NVM (763-284) *2: Select either 8.5x14S or 8.5x13S in NVM (763-287) *3: Cannot be offset or output in sets *4 Select either A4S or Letter S in NVM (791-332?????)
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Billing Meters The Xerox 4110 Billing Meters count finished prints when they reach the exit trays. During a jam, it depends on the location of the paper as to whether or not it is counted. Refer to Figure 112 in this module for the location of the sensors involved with billing. Top Tray When paper exits the top tray and clears the Top Tray Exit Sensor. During a jam no correction is made for sheets that have ed the Exit Sensor. Stack Tray Sets are counted when they clear the Compiler Exit Sensor. No jam correction is made after a set has cleared the Compiler Exit Sensor. Single sheets are counted when they the Eject Sensor. No billing correction during a jam is made for paper that has ed the Eject Sensor Folder Tray When paper has cleared Folder Path Sensor 3. No billing corrections are made for paper that has ed Folder Paper Path Sensor 3. Booklet Maker When paper has cleared the Booklet In Sensor. If the following jams occur after paper has ed the Booklet In Sensor the sheets are not counted: 12-135 Booklet Folder Roll Exit Sensor ON Jam 12-155 Booklet Folder Roll Exit Sensor OFF Jam 12-171 Paper Remains at the Booklet Compiler No Paper Sensor 12-172 Paper Remains at the Booklet Folder Roll Exit Sensor.
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Power and Switches Figure 113 shows the location of Power Supplies and PWBs in the Finisher.
4. Folder PWB 2. Interposer PWB
3. I/F PWB
7. Relay PWB
6. 24VDC LVPS
1. Finisher Main PWB 5. Booklet Maker PWB
8. 220VAC Power Inlet
Figure 113 Power Supplies and PWBs
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1. Finisher Main PWB This PWB controls the operation of the Punch, Stapler, Stack Tray, and Top Tray. It also contains the Finisher Run Control Logic and generates +5VDC from the +24VDC supplied by the Finisher Low Voltage Power Supply (LVPS) 2. Interposer PWB Controls operation of the Interposer. 3. I/F PWB (Interface PWB) Is the interface between the IOT, Finisher, and Decurler. 4. Folder PWB Controls the operation of the Folder. 5. Booklet Maker PWB Controls the operation of the Booklet Maker. 6. LVPS (Low Voltage Power Supply) The LVPS generates +24VDC for use in the Finisher. 7. Relay PWB This PWB contains two power control relays. When the Interlock Switches are actuated, the relays energize and supply +24VDC to the Finisher components. 8. Power Inlet The Power Inlet supplies 220 VAC from the IOT.
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Figure 114 shows the sorter interlocks and switches.
3. Interposer Top Cover Interlock Switch (+24VDC)
4. Interposer Top Cover Switch (+5VDC)
8. Envelope Tray Open Switch
7. Decurler Switches
6. Booklet Tray Belt Switch
5. Folder Envelope Tray Switch
2. I/F Module Front Door Switch
1. Finisher Front Door Switch
Figure 114 Interlocks and Switches (reflects 2101 entrance configuration)
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Finisher Front Door Interlock Switch. Switches off the Finisher +24VDC from the when the Front Door is opened. I/F Module Front Door Switch. Switches off the Finisher +24VDC when the I/F Module Front Door is opened Interposer Top Cover Interlock Switch (+24VDC) Switches off the Finisher +24VDC when the Interposer Top Cover is opened. Interposer Top Cover Switch (+5VDC) Switches off the Finisher +5VDC when the Interposer Top Cover is opened. Folder Envelope Tray Switch. When the folder tray is opened this switch switches off +24VDC to the Folder. Booklet Tray Belt Switch. Pressing this switch switches on the Booklet Tray Transport belts. Decurler Switch. This switch allows the Decurler to be set for up curl correction, down curl correction, or no curl correction. Envelope Tray Open Switch. When this switch is actuated, the Envelope Tray Lock Solenoid is deenergized allowing the Tray to open.
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Finisher Power Control Figure 115 shows an overview of the Xerox 4110 Finisher power control.
AC Power 220 VAC Convenience Outlet
IOT Power Control
Signal Line
Relay PWB
LVPS 220 VAC from the IOT
DC Power
+24 VDC
Relays
Finisher Main PWB Interlock +24 VDC
+24 VDC Distribution
+24 VDC
Finisher Power Control
+5 VDC
Interlock Switches
+5 VDC Distribution
Figure 115 Finisher Power Control
220 VAC to power the Finisher is supplied by the IOT. In the Finisher the 220 VAC supplies the LVPS and the Convenience Outlet. The LVPS generates the +24 VDC for the Finisher. The LVPS is switched on or off by AC Power Control in the IOT. The Finisher Main PWB generates +5 VDC for distribution to the Finisher logic. If all of the interlock switches are closed, +24 VDC energizes the relays on the Relay PWB. This supplies +24 VDC Interlocked power through the Finisher Main PWB for Distribution to the PWBs, motors, clutches, solenoids, and switches in the Finisher. When power is switched on, the Finisher logic initializes and the Finisher components are moved to their home positions.
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Decurler The Decurler subsystem is located in the Finisher Interface (I/F) Module directly underneath the Interposer. The Decurler is standard for all Finisher configurations. Paper exiting the IOT may be curled due to the heat and pressure applied by the F and other components in the IOT. To straighten the curl, pressure is applied from the opposite direction of the curl. The Decurler is a double decurler to allow for the removal of both up and down curl. Unlike previous models the cam is fixed to the shaft.
Decurler Control Decurler operation is selected using the Decurler switch located on top of the Finisher (Figure 114). The state of the Decurler is indicated by the switch LEDs. The three selections are: Auto Decurl Enabled Decurl Disabled The default decurler mode is Auto. In Auto mode the decurling correction is applied automatically according to the paper size, paper type, and feed orientation. The IOT NVM locations that supply paper type information are: 763-310 Decurl value for plain paper 763-311 Decurl value for thick paper (1) The paper size and feed orientation are based on the job programming parameters. Even if the Auto Mode is selected, no decurl operation is performed for transparencies or labels. In Decurl Enabled mode, a set amount of decurl pressure is applied regardless of paper type, size, or feed orientation. In Decurl Disabled mode, no decurl operation is performed.
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Decurler Components and Operation Figure 116 shows the components of the Decurler assembly.
Figure 116 Decurler Assembly
Decurler Components Decurler In Sensor Detects when paper has entered the Decurler Decurler Home Sensor Detects the home position of the Decurler cam that positions the foam roll. The Foam Roll applies pressure to the paper to remove the curl. Decurler Out Sensor Detects when paper has exited the Decurler Decurler Transport Motor A brushless DC motor that drives the Decurler Components, the Interposer Transport Rolls 1 and 2, and the Entrance Roll in the Punch or the Folder (if installed). Decurler Cam Clutch Transfers drive to the Decurler cam. The cam position determines the amount of pressure the Foam Roll applies to the paper.
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Interposer The Interposer allows pre-printed or special stock to be inserted into the finished sets without having to go through the processor. This prevents possible contamination of the f or xerographic components in the IOT. In addition, it is a convenient method of adding covers and slip-sheets without having to send them through the IOT. Figures 117, 118, and 119 show the Interposer components.
Interposer Exit Roll
1. Interposer Drive Clutch
Interposer Transport Roll 1
Interposer Transport Roll 2
Figure 117 Interposer Transport Assembly
The Interposer Drive Clutch This is an electromagnetic clutch that conveys drive from the Decurler Transport Motor, to the Interposer Exit Roll and the Interposer Transport Rolls 1 and 2.
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2. Size Sensor
1. Interposer Tray Lift Motor
Figure 118
Interposer Tray Lift Components Interposer Tray Lift Motor This is a DC motor that drives the Lift Shaft. Size Sensor The side guide contains a variable resistor. The movement of the guide changes the voltage output of the resistor. The logic interprets the voltage to determine the paper size.
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5. Paper Length Sensor 6. No Paper Sensor 2. Tray Up Sensor 3. Feed Motor
4. Feed Out Sensor
Nudger Roll
Feed Roll 1. Nudger Solenoid
Figure 119
Interposer Tray Feed Components Nudger Solenoid The Nudger solenoid moves the Nudger Roll and Feed Roll down at the start of the feed cycle. Tray Up Sensor This sensor senses whether or not the Interposer Tray is in the feed position. Feed Motor The Feed Motor is a stepper motor that is switched on after the Tray Up sensor verifies that the tray is raised to the feed position and the No Paper sensor verifies that there is paper in the tray. Feed Out Sensor This sensor senses that paper feed has begun. Once paper is detected, the Nudger Roll solenoid is deenergized and the Feed Roll and Nudger Roll move up. Paper Length Sensor This sensor, in combination with the values detected by the Size Sensor (Figure 118, Item 2), determines both the size of the paper loaded and whether it is long or short edge feed. No Paper Sensor This sensor determines whether or not there is any paper in the tray. The feed cycle will not start if the tray is empty.
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Folder The folder is an optional device that provides the following folding capabilities. Large size Z fold (11X17) Large Z folds are folded to 8.5X11 and either inserted into letter size sets or output separately. May be punched and stapled Mixed size output is allowed but without punching or stapling. Output is to the Stack Tray C fold and small size Z fold Output is to the Folder Tray No punching or stapling No mixed size output NOTE: the Booklet Maker performs Bi-Folds. That will be discussed later in this module. The folder may be installed on both configuration Finishers (with or without the Booklet Maker). The Folder Tray is different from previous models to allow for center registration. Diagnostic routine dC128 is used to adjust the Booklet Maker, “Z” fold and “C” fold.
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Components Figure 120 shows the Folder drives and components.
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1. Entrance Motor 4. Gate Solenoid 1 Entrance Roll 8. Entrance Sensor
2. Drive Motor 1 9. Exit Sensor 3. Drive Motor 2
Exit Roll Transport Roll 7
6. Nip Release Solenoid
Transport Roll 1 10. Path Sensor 1 Transport Roll 2
Transport Roll 3
11. Path Sensor 2 Transport Roll 6
5.Gate Solenoid 2
13. Path Sensor 4 Transport Roll 5 12. Path Sensor 3 7.Tray Lock Solenoid
Transport Roll 4 Finger Assembly 14. C Solenoid
Figure 120 Folder Drives and Transport Components
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Components Entrance Motor This is a brushless DC motor that drives the Folder Entrance Roll, the Folder Exit Roll, and the Punch Entrance Roll Drive Motor 1 This is a stepper motor that drives Folder Transport Roll 1. Drive Motor 2 This is a brushless DC motor that drives Transport Rolls 2 through 7, Folding Roll 1, and Folding Roll 2. Gate Solenoid 1 This is the solenoid for switching the upper Folder gate to allow paper to enter the Folder Gate Solenoid 2 This solenoid opens the gate to allow folded paper to enter the Folder (Envelope) Tray. Nip Release Solenoid This solenoid releases the Pinch Roll from Transport Roll 1 Folder (Envelope) Tray Lock Solenoid This solenoid prevents the tray from opening until the folding operation is complete. Entrance Sensor Detects paper entering the Folder Exit Sensor Detects paper exiting the Folder Path Sensor 1 Detects paper jams in the Folder Path Sensor 2 Detects paper jams in the Folder Path Sensor 3 Detects paper jams in the Folder Path Sensor 4 Detects paper jams in the Folder C Solenoid Pushes the Finger Assembly against the paper so that curled corners won’t be folded during a C fold operation.
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Figure 121 shows the End Guide Assemblies. The End Guides are moved in the directions shown during the folding operation to control the width each fold. The width of the fold is determined by the size of the paper being folded and the type of fold selected.
1. End Guide Motor 1
3. End Guide Home Sensor 1
Nip Roll End Guide 1
Folding Roll 2
2. End Guide Motor 2
5. Envelope Tray Full Sensor
4. End Guide Home Sensor 2
End Guide 2
Figure 121 End Guide Positioning
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Components End Guide Motor 1 This is the stepper motor that moves End Guide 1 up or down. End Guide Motor 2 This is the stepper motor that moves End Guide 2 up or down. End Guide Home Sensor 1 This is the sensor that detects the home position of End Guide 1. End Guide Home Sensor 2 This is the sensor that detects the home position of End Guide 2. Envelope Tray Full Sensor This is a two part (transmitter and receiver) photo sensor that detects when the tray is full. The end guides are different than previous models to allow for center registration.
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Folder Operation Due to the fact that the folder operates at a high rate of speed it is difficult to directly observe the folding operation. Figure 122 shows the sequence for a typical fold. Top Gate
1.
Exit Roll
5.
2. 3. 4.
Transport Roll 1
Entrance Roll
Nip Release Sol. First Fold Rolls
First Fold Rolls
End Guide 1
6.
Second Fold Rolls
7.
8.
End Guide 1
9. Transport Roll 7 Transport Roll 6
Transport Roll 2 Transport Roll 3 End Guide 2
Transport Roll 5 Second Fold Rolls
Transport Roll 4 Lower Gate
Figure 122 Typical Fold Sequence
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Folder Operation. Paper Transport to the Folder Paper exiting the Decurler is transported to the Folder Top Gate by the Folder Entrance Roll. If the paper is to be folded, the Top Gate solenoid is energized and the sheet moves toward the First Fold Rolls. Paper that is not folded is transported to the Punch by the Exit Roll Adjusting End Guide 1 End Guide 1 is adjusted according to the paper size and the fold pattern (C or Z fold). Paper Transport to End Guide 1 Paper is transported to the End Guide by Transport Roll 1 (driven by Folder Drive Motor 1) Skew Correction When the paper is stopped by End Guide 1, the Nip Release Solenoid on Transport Roll 1 is energized, releasing the nip between the drive roll and the idler roll. This allows any paper skew to be corrected by the End Guide. First Fold After the skew is corrected, the Nip Release Solenoid is deenergized. As Transport Roll 1 drives the paper against End Guide 1, it forms a buckle and is drawn into the First Fold Rolls. The folded sheet is transported by the First Fold Rolls towards the second fold rolls. Adjusting End Guide 2 End Guide 2 is adjusted according to the paper size and the fold pattern (C or Z fold). Paper Transport to End Guide 2 Paper is transported to the End Guide by Transport Rolls 2 and 3 (driven by Folder Drive Motor 2) Second Fold As the paper is driven against End Guide 2, it forms a buckle and is drawn into the Second Fold Rolls. Folder Exit The folded sheet is then transported to either the Folder (Envelope) Tray or the Folder exit. If the output is a small Z or a C fold the Lower Gate Solenoid is energized and the sheets are directed into the Folder Tray. Transport Rolls 4, 5, 6, and 7 transport large Z folds into the Finisher.
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Punch A motor driven punch is standard for all of the Finisher configurations. A 2 /4 hole punch is available as an option. The punch is not a customer replaceable unit. If the customer prefers the 2 / 4 hole option the service representative will install it. The Punch assembly is 2 / 4 hole for XE and 2 / 3 holes for XC (the 2 holes in XC is for legal applications).
Punch Components Figure 123 shows the 3-hole punch configuration.
1. Punch Move Motor 3. Punch Move Clutch 9. Punch Home Sensor 13. Side Registration Home Sensor
14. Punch Cam Plate 10. Punch Front Sensor 8. Punch Move Home Sensor (B4) 7. Punch Move Home Sensor (B5) 2. Punch Motor
11. Punch Out Sensor
5. Punch Motor Sensor
4. Punch Box Sensor
15. Skew Correction Guides 6. Punch Move Home Sensor 12. Side Registration Sensor
Figure 123 3 Hole Punch Assembly
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Punch Move Motor This is a stepper motor that positions the Punch Assembly Punch Motor This is a DC motor that drives the punch cam plate, which drives the punches to punch the holes. Punch Move Clutch This clutch transmits the drive from the Punch Move Motor to position the Punch Assembly. Punch Box Sensor This sensor verifies that the punch scrap box is installed. Punch Motor Sensor This sensor determines the amount of rotation of the Punch Motor required to perform the punch operation. The sensor counts the pulses as the encoder wheel rotates. Punch Move Home Sensor (letter) This sensor determines the home position of the punch for punching 3 holes in letter size paper. Punch Move Home Sensor (B5) This sensor determines the home position of the punch for punching 3 holes in B5 size paper. Punch Move Home Sensor (B4) This sensor determines the home position of the punch for punching 3 holes in B4 size paper. Punch Home Sensor This sensor detects when the Punch Assembly is in the home position Punch Front Sensor This sensor detects the Punch Assembly position at the start of print. The punch stays at the previously used position and the logic uses this sensor along with the home sensors to determine if the Punch Assembly needs to be moved for the current job. Punch Out Sensor This sensor detects when the paper has exited the Punch. Side Registration Sensor This sensor detects the side edge of the paper Side Registration Home Sensor This sensor detects the home position of the Side Registration Sensor Punch Cam Plate Moves the punch pins to punch the paper. The cam plate is driven by the Punch Motor. Skew Correction Guides The Skew Correction Guides are pivoting spring loaded guides that allow paper to in the output direction and stop the paper when it is backed up into the punch position
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Punch Operation Sheets are punched one sheet at a time. The Punch assembly is adjusted so that the punches may be positioned according to the paper size. The punch unit is divided into two areas as shown in Figure 124. These are the: Sensor Assembly Punch Assembly The position of the complete assembly can be adjusted and the relative position between the two assemblies can also be adjusted. This allows for a complete range of adjustments based on the paper size being punched.
Side Registration Home Sensor
Punch Move Clutch
Side Registration Sensor
Sensor Assembly Rear
Front Punch Assembly
Punch Move Home Sensor
Figure 124 Punch Positioning
There are three adjustments made for positioning the Punch Assembly. Initialization Repositioning Punching The following is a description of each positioning operation Initialization: Initialization is performed at power on and at the end of a job. The sequence is: With the Punch Motor Clutch off, the Punch motor is switched on. This moves just the Punch Assembly toward the front until the Punch Move Home Sensor switches off. Then the Punch Motor reverses and drives the Punch Assembly towards the rear until the Punch Move Home Sensor switches on. The motor is reversed again and the Punch Assembly moves toward the front until the Side Registration Home Sensor switches off. The motor reverses once again and the Punch Assembly moves toward the rear until the Side Registration home sensor switches on. Steps 1 – 4 have adjusted the relative position between the Punch Assembly and the Sensor Assembly. Now the Punch Move Clutch and motor are switched on and both the Punch Assembly and the Sensor Assembly are driven toward the front until the Punch Move Home Sensor is switched off The motor reverses and both assemblies are driven toward the rear until the Punch Move Home Sensor switches on. The Punch is now in position for a letter size 3-hole punch.
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Repositioning If a paper size other than 8.5X11” is selected to be punched the punch will be repositioned at the start of the job. If the paper size to be punched is 8.5X11” no adjustment is needed. The punch was positioned for letter size during Initialization. At the end of the job the Punch will be repositioned for letter size. NOTE: If A4 paper is the default paper size for your market area, the punch will be positioned during Initialization for A4 rather than 8.5X11”. Punching The Punch position is adjusted to the location of the side edges for each sheet. This ensures that the holes will always be in the same location on each sheet The sequence for positioning the Punch to the side edges of the sheet is: With the paper in position to be punched, the Punch Drive Motor and Clutch are switched on. The whole punch assembly is moved towards the front. When the Side Registration Sensor switches off, which indicates that the side edge of the paper has been detected, the motor and clutch are switched off. The punch is now in position to punch the sheet.
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Paper Transportation and Punching Paper output from the IOT moves from the decurler, through the folder (if installed) and into the punch area. The Punch Entrance Roll is driven by the Decurler Transport Motor or the Folder Entrance Motor if a Folder is installed. Paper in the Punch area is transported by the Finisher Transport Motor and SCT Exit Motor (if output is the top tray) or the Compiler Exit Motor (if output is to the Stack Tray).
Output Direction
Skew Correction Direction
Front
Skew Correction Guides
Figure 125 Skew Correction
Removing Skew In order to de-skew the sheet, (Figure 125) the paper is driven past the punch position. After the Folder Exit Sensor detects the trail edge of the sheet, the Finisher Transport Motor and the SCT Exit Motor or the Compiler Exit Motor reverse direction and the paper is driven back towards the punch position. The paper is stopped by the Skew Correction Guides. The skew correction guides allow paper to travel in the output direction and block the sheet moving backwards. The sheet is now ready to be punched.
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Punching The Punch Motor moves the Punch Cam Plate that lowers the pins to punch the sheet. The encoder pulses counted by the Punch Motor Sensor determine the cam plate travel. After the correct number of pulses are counted, the Punch Motor reverses and is stopped when the Punch Home Sensor is blocked. Once the pins are retracted the paper is driven to the exit. The Punch is now ready to repeat the process for the next sheet.
108+/-1 mm
8.5X11” Paper NVM Loc: 791 – 217 Range: 60 – 170
32+/-3 mm
12+/-2 mm
Figure 126 Three Hole Punch Specifications
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Paper Transportation / Top Tray Figure 127 shows the components that feed paper to the Top Output Tray. 5. Compiler Exit Motor
4. SCT Exit Motor
T/A 2 Roll Top Exit Roll 1. Top Tray Exit Sensor
7. Finisher Transport Motor
2. Top Tray Full Sensor Compiler Exit Roll 9. Compiler Exit Sensor 6. Transport Gate Solenoid
Buffer Reverse Roll
S2 Gate
T/A 1 Roll
8. Booklet Gate Solenoid
Buffer Roll S1 Gate
Punch Reverse Roll
3. Buffer Path Sensor
Figure 127 Paper Transportation / Top Tray
Top Tray Exit Sensor Senses that paper has been transported to the Top Tray. Top Tray Full Sensor Senses when the Top Tray is full. Buffer Path Sensor Senses paper in the Buffer path. SCT Exit Motor A stepper motor that drives the T/A 2 and Top Exit Roll. Compiler Exit Motor A stepper motor that drives the Buffer Roll, Buffer Reverse Roll, and the Compiler Exit Roll.
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Transport Gate Solenoid Actuates the S2 Gate to direct paper to the Top Tray or the Compiler. Finisher Transport Motor A stepper motor that drives the T/A 1Roll, Punch Reverse Roll, and Booklet Maker In Roll. Booklet Gate Solenoid Actuates the S1 gate to direct paper into the Booklet Maker. Compiler Exit Sensor Senses that paper has reached the Compiler Tray
Output Selection Refer to Figure 128.
Top Tray
T/A 2 Roll
Top Exit Roll Buffer Reverse Roll
T/A 1 Roll
Compiler Exit Roll Gate S2
Stack Tray
Punch Reverse Roll Gate S1 Punch
Stapler Head Entrance Roll Booklet In Roll
Buffer Roll
Booklet Maker
Figure 128 Output Selection Gates S1 and S2 determine the destination of paper entering the Finisher. If the Booklet Gate (S1) Solenoid is de-energized, paper is routed to the Compiler or the Top Tray. If the solenoid is energized paper moves into the Booklet Maker. If the Transport Gate (S2) is de-energized paper moves into the Compiler. If the solenoid is energized paper moves to the Top Output Tray.
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Compiling, Stapling, and Ejecting the Sets When the machine is operating in the sets mode, the sheets are gathered in the Compiler Tray before being ejected into the Stack Tray. If the stapling option is selected, the sheets are stapled while in the Compiler Tray. Compiling is different than 2101 in that it is compiled for center registration. Figures 129 – 135 show the components of the Compiler and Stapler.
1. Tamper Home Sensor Tamper Paper Travel Direction 3. Compiler Tray No Paper Sensor
2. Tamper Motor
Figure 129 Tamper Assembly The Tamper ensures that the paper is stacked evenly front to back in the Compiler tray. Tamper Home Sensor This sensor detects the home position of the Tamper. Tamper Motor A stepper motor that drives the Tamper Compiler Tray No Paper Sensor Detects the presence of paper in the Compiler Tray
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Figure 130 shows the shelf that is extended from the Compiler Tray to the right hand side of the sheets stacked in the tray. The shelf is extended during the compile operation and retracted just before the set is ejected. 2. Shelf Motor Direction of Paper Travel
1. Shelf Home Sensor
Figure 130 Compiler Tray Shelf
Shelf Home Sensor Detects the home (closed) position of the shelf. Shelf Motor The stepper motor that drives the shelf
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Figure 131 shows the End Wall Assembly. This is different than previous models to accommodate center registration. 1. End Wall Open Sensor
Paper Travel Direction
2. End Wall Home (Closed) Sensor End Wall Assembly 3. End Wall Motor
Figure 131 End Wall Assembly
End Wall Open Sensor Detects when the End Wall is in the open position. End Wall Home Sensor Detects when the End Wall is closed. End Wall Motor The stepper motor that opens and closes the End Wall.
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Figure 132 is the Stapler Assembly. It consists of the Stapler Head and Base.
4. Stapler Head Assembly
2. Stapler Center Position Sensor
1. Stapler Home Sensor 3. Stapler Move Motor
Figure 132 Stapler Assembly
Stapler Home Sensor Detects when the Stapler Head is in the home position. Stapler Center Position Sensor Detects when the Stapler Head is in the center position. Stapler Move Motor Moves the Stapler Head to the staple positions. Stapler Head The Stapler Head consists of the Stapler Home Sensor, Stapler Drive Motor, the Low Staple Sensor, the Stapler Ready Sensor, and the Stapler Cartridge Sensor. The Stapler head is replaced as a unit. The individual components in the Stapler Head are not field replaceable. Stapler operation will be described later in this module.
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The paddles push the sheets against the End Wall. This, along with the action of the Tamper, keeps the edges of the paper stack aligned. Figures 133 and 134 show the Main and Sub Paddle components.
Compiler Main Paddles
1. Compiler Paddle Up/Down Solenoid Figure 133 Lower Exit Chute and Main Paddle Assembly
2. Sub Paddle Home Sensor 3. Sub Paddle Up/Down Solenoid
Paper Travel Direction 6. Eject Motor
Sub Paddles 4. Paddle Clutch 5. Paddle Motor
Figure 134 Sub Paddles and Paddle Drives Compiler Paddle Up/Down Solenoid Changes the Main Paddle Height as stack height increases. Sub Paddle Home Sensor Detects the home position of the Sub Paddle. Sub Paddle Up/Down Solenoid Changes the Sub Paddle Height as stack height increases. Paddle Clutch Transmits drive to the Sub Paddle Shaft. Paddle Motor The stepper motor that drives the Main and Sub Paddles.
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Eject Motor The stepper motor that drives the Compiler Exit Roll.
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Once the set is compiled and stapled (if selected), it is ejected into the Stack Tray. Figure 135 shows the eject components.
Paper Travel
4. Eject Safety Switch 1
Eject Clamp
2. Eject Clamp Motor
Feed Roll 1. Eject Sensor 3. Eject Up Sensor
Figure 135 Set Eject Components Eject Sensor Detects when the paper has ed the Eject Clamp Eject Clamp Motor This stepper motor raises and lowers the eject clamp. Eject Up Sensor Detects when the Eject Clamp is in the up position Eject Safety Switch 1 When the Compiler aperture is open this switch removes 24 VDC from the Stapler Motor in the Stapler Head.
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Compiler and Stapler Operating Sequence Now that you are familiar with the Output Components here is the sequence for outputting a stapled set. Extending the Shelf At the start of print the Shelf Motor is switched on and the Shelf is moved into position to the right hand edge of the set. Paper enters the Compiler Tray Sheet 1 The Eject Clamp is lowered so that the paper can be driven by the Compiler Exit Roll and the Eject Roll. When the trail edge of the sheet es the Compiler Exit Sensor the Eject Motor reverses and moves the sheet back into the Compiler Tray towards the raised End Wall. Sheets 2 through N. The Eject Clamp is raised and the second and subsequent sheets are dropped into the Compiler Tray. The Main and Sub Paddles move and hold the sheets against the End Wall. Tamping When the sheet has entered the Compiler Tray the Tamper is switched on it moves the paper into position in the tray and then retracts. This operation is repeated for each sheet. When the last sheet enters the tray, this operation is performed twice. Stapling When the completed set is in the Compiler Tray the Eject Clamp is lowered to clamp the set the Tamper is returned to its home position and the set is stapled as required. If a dual stitch was selected, the End Wall is lowered first so that it will not interfere with the movement of the Stapler head. Retracting the Shelf With the set still in the Compiler Tray, the Shelf is retracted in preparation for ejecting the set. Ejecting the Set The Eject Motor is switched on and the set is driven into the Stack Tray. Once the set has exited the tray the Eject Clamp is raised and the Compiler is ready to receive the next set.
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Buffer Path Under some circumstances the first sheets of the next set will begin to arrive at the Compiler Tray before the set already in the Tray is ready to be ejected. A combination of delayed paper feed (skipped pitches) and a buffer area in the Finisher are used to delay the sheets entering the Compiler. Keeping paper waiting in the buffer path is only used for A4 LEF, Letter LEF, and B5 LEF sets. Along with the buffer, a skipped pitch is used when the set requires either dual staples or a single rear staple. This gives the stapler time to move into position and staple the set.
Buffer Path Sequence The following is a description of buffer operation. Refer to Figure 136. The first sheet of the next set is transported toward the Compiler Tray. At a set time interval after the Punch Exit Sensor detects the trail edge of the first sheet, the S2 Gate Solenoid energizes. At this time the Compiler Exit Motor is reversed and the paper backs up into the buffer area. After another set time interval, the Compiler Exit Motor stops and the first sheet is held in the buffer area. When the second sheet clears the Punch Exit Sensor, Gate S2 is deenergized, the Compiler Exit Motor is switched on and both sheets are moved into the Compiler Tray, the second sheet on top of the first sheet.
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Top Tray
1.
Top Tray
2.
Stop Compiler
S2 Gate
Compiler Punch Exit Sensor
First Sheet
Booklet Maker
Booklet Maker
4.
3. Top Tray
Top Tray
Compiler
Compiler Second Sheet First Sheet
First Sheet
Second Sheet Stop
Booklet Maker
Booklet Maker
Figure 136 Buffer Path
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Stapling Positions There are two types of stapling available for the Xerox 4110, single stapling and dual stapling. This is accomplished using a single staple head. Single staples may be put at either the front or the rear of the sheet. Figure 137 shows the available stapling positions.
Figure 137 Stapling Positions
Stapler Travel When power is switched on the Stapler is positioned at the front. This is the home position. Depending on the job programming and the paper size the Stapler Head is moved to different positions. Stapling at the front When stapling at the front the Stapler is not moved because the home position is at the front.
1. 2.
Stapling at the Rear Corner (Figure 138) 1. At the Start of the job the Stapler is moved to the center position 2. The Stapler waits at the center until actually stapling. 3. The Stapler is moved to the stapling position. 4. After stapling, the Stapler is moved back to the center.
3.
4.
Figure 138 220
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Stapling Straight at the Rear (Figure 139) 1. At the start of the job the Stapler is moved to the center. 2. The Stapler waits at the center until actually stapling. 3. The stapler is moved to the End Wall opening/closing position and the End Wall is opened. 4. Stapler is moved to the straight stapling position at the rear then staples. 5. After stapling, the Stapler is moved back to the End Wall opening/closing position and the End Wall is closed. 6. The Stapler is moved back to the center.
1.
2.
3.
4.
5.
6.
Figure 139
Dual Stapling (Figure 140) 1. At the start of the job the Stapler is moved to the center. 2. The Stapler waits at the center until actually stapling. 3. The Stapler is moved to the End Wall open/close position and the End Wall is opened. 4. The Stapler is moved to the straight stapling position at the front and then staples. 5. The Stapler is moved to the straight stapling position at the rear and then staples. 6. After stapling the Stapler is moved back to the End Wall opening/closing position and the End Wall is closed. 7. The stapler is moved back to the center.
1.
2.
3.
4.
5.
6.
7.
Figure 140
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Stack Tray Components and Operation Figures 141, 142, and 143 show the location of the Stack Tray components.
1. Stack Height Sensor 1 (F)
3. Stack Height Sensor 3 (F)
2. Stack Height Sensor 2 (F)
4. Tray Height Sensor Lower (F)
3. Stack Height Sensor 3 (R) 1. Stack Height Sensor 1 (R) 2. Stack Height Sensor 2 (R)
4. Tray Height Sensor Lower (R)
5. Mix Stack Sensor 6. Half Stack Sensor 9. Elevator Motor
7. Full Stack Sensor
8. Lower Limit Sensor
Figure 141 Stack Tray Components (1)
Stack Height Sensor 1 (Front) Stack Height Sensor 1 (Rear) These sensors detect the height of the paper stack in the tray. Stack Height Sensor 2 (Front) Stack Height Sensor 2 (Rear) These sensors detect the height of the paper stack in the tray.
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Stack Height Sensor 3 (Front) Stack Height Sensor 3 (Rear) These sensors detect the height of the paper stack in the tray. They are added only when a Folder is installed. Tray Height Sensor Lower (Front) Tray Height Sensor Lower (Rear) This sensor senses whether or not paper has been removed from the tray. Mix Stack Sensor This sensor detects the upper position of the Stack Tray. Half Stack Sensor This sensor detects the middle position of the Stack Tray. Full Stack Sensor This sensor detects the lower position of the Stack Tray. Lower Limit Sensor This sensor detects the lower limit position of the Stack Tray. Elevator Motor A DC motor that drives the Stack Tray up and down. CAUTION Lower the Stack Tray to the bottom before disassembling the Elevator Motor or Drives. Failure to lower the tray will cause the tray to drop.
Stack Tray Indexing The Stack Tray is indexed up or down based on the height of the paper stack. When the tray indexes is determined by the state of one of the three sets of Stack Height Sensors. Which set is used is dependent on the output mode. They are: Stack Height Sensor 1 – Unstapled sets Stack Height Sensor 2 – Stapled sets Stack Height Sensor 3 – Sets containing Z folds (on Folder equipped machines) Using sensors that are positioned differently for each type of output allows for efficient stacking regardless of the thickness of the output set. During operation the Stack Tray moves up at the start of print until the Stack Height sensor for the appropriate mode is blocked. The tray then moves down until the sensor is not blocked. As paper enters the tray, it will move down each time the sensor is blocked. If the tray becomes full the machine will shut down until the tray is emptied. If paper is removed during printing the tray will move up until the height sensor is blocked and the cycle begins again. How full the tray is determined by the states of the Mix Stack Sensor, Half Stack Sensor, Full Stack Sensor, and Lower Limit Sensor.
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2. Stacker Safety Switch
3. Stacker Flap Motor 1. Stacker No Paper Sensor
Figure 142 Stacker Components (2)
Stacker No Paper Sensor This sensor detects whether or not paper is present in the tray. Stacker Safety Switch If this switch detects an obstacle under the Stack Tray it will Switch off the 24 VDC to the Elevator Motor Stacker Flap Motor This is a DC motor that raises and lowers the flap on the Stack Tray. When stapled sets of small size sheets are output, the set is higher at the stapled side. This reduces the capacity of the stack tray. To counteract this the flap on the Stacker is lowered. This lets the tray fill to its rated capacity.
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2. Set Clamp Solenoid
1. Stacker Front Position Sensor
3. Stacker Offset Motor
Figure 143 Stacker Components (3)
1. Stacker Front Position Sensor This sensor detects the offset position of the Stacker Tray 2. Set Clamp Solenoid This solenoid operates the Set Clamp in the Compiler Tray. 3. Stacker Offset Motor This is the DC motor that moves the Stacker Tray to the front or the rear to offset stack the output.
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Offset Stacking There are three modes of stacking. They are: Unstapled Sets – Offset Stacking Unstapled sets are stacked in two alternate positions, front and rear. Stapled Sets – Offset Stacking Stapled Sets are stacked in three alternate positions, front middle and rear. This allows for better stacking of stapled sets. Stapled Sets – No Offset Stacking NVM locations 763-340 (Stapling Offset Off) and 763-297 (Stapling Offset On) can be set if the customer would prefer not to have offset stacking for stapled sets. Offset stacking for stapled sets is the default mode.
Booklet Maker The booklet maker can compile up to 15 sheets, dual saddle stitch them, fold them and output them as a booklet. The Scanner and IOT logic will reduce or enlarge the images, and interpose (pre-collate) the sheets as necessary to ensure that the pages are in the correct order. The maximum number of sheets may be set to 25 stapled and 15 unstapled using NVM location 763-252. However, it should be noted that the fold quality cannot be guaranteed on unstapled sets of more than 5 sheets and stapled sets of more than 15 sheets. Diagnostic routine dC128 is used to adjust the Booklet Maker, “Z” fold and “C” fold. The booklet maker is an optional accessory. It cannot be installed in the field so if a customer wishes to purchase a Booklet Maker at a later date, the Finisher must be replaced.
Booklet Maker Components Figures 144 through 147 show the components of the Booklet Maker. CAUTION Do not slide out the Booklet Maker Assembly with the Finisher Interlocks cheated. Sliding out the Booklet Maker with power applied to the sensors could damage the sensors.
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Booklet Exit Roll 1. Booklet In Sensor Booklet Folding Rolls 3. Booklet Paper Path Motor Booklet Eject Roll
4.Booklet Fold Motor 2. Booklet Folder Roll Exit Sensor
5. Knife Solenoid
Figure 144 Booklet Maker Components (1)
1. Booklet In Sensor This is the sensor that detects that paper has entered the Booklet Maker area. 2. Booklet Folder Roll Exit Sensor This is the sensor that detects that paper has been transported to the Booklet Tray. 3. Booklet Paper Path Motor This is a stepper motor that drives the Booklet Exit Roll. 4. Booklet Fold Motor This is a DC motor with an encoder that drives the Booklet Folding Roll, Booklet Eject Roll, and the Knife. 5. Knife Solenoid The Knife Solenoid transmits drive from the Booklet Fold Roll Motor to the Knife.
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2. Booklet Tamper Home Sensor (R) 5. Booklet Tamper Motor (R) 4. Booklet Tamper Motor (F) 1. Booklet Tamper Home Sensor (F)
6. Knife Folding Sensor 7. Knife Home Sensor
3. Booklet Compiler No Paper Sensor
Knife
Figure 145 Booklet Maker Components (2) Booklet Tamper Home Sensor (Front) Detects the home position of the front Tamper. Booklet Tamper Home Sensor (Rear) Detects the home position of the rear Tamper. Booklet Compiler No Paper Sensor Detects whether or not there is paper in the Compiler Tray. Booklet Tamper Motor (Front) The stepper motor that drives the front Tamper in the Booklet Compiler Tray. Booklet Tamper Motor (Rear) The stepper motor that drives the rear Tamper in the Booklet Compiler Tray. Knife Folding Sensor Detects that the Knife is in the extended position. Knife Home Sensor
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Detects that the Knife is in the retracted position.
Front Tamper
Rear Tamper 1. Stapler Assembly
4. End Guide Motor
3. End Guide Home Sensor
Paddles
End Guide 5. Drawer Closed Sensor 2. Paddle Motor
Figure 146 Booklet Maker Components (3) Stapler Assembly This is the Stapler Assembly for the Booklet Maker. It consists of two stapler heads and the Stapler Drive Motor assembly. Paddle Motor This DC motor drives the Paddle Assembly. The paddles move the set against the End Guide. End Guide Home Sensor This sensor detects the home position of the End Guide. End Guide Motor A DC stepper motor that positions the End Guide for different size paper. Drawer Closed Sensor This sensor detects whether or not the Booklet Maker Drawer is closed and latched.
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1. Tray Belt Drive Motor
2. Booklet Tray No Paper Sensor
Figure 147 Booklet Maker Components (4) Tray Belt Drive Motor This motor drives the Booklet Tray Drive Belts. Booklet Tray No Paper Sensor This sensor detects paper in the Booklet Tray. The Booklet Tray is considered full when 15 booklets have been stacked after the sensor detects paper.
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Booklet Maker Operation As with the Folder it is difficult to see the Booklet Maker in operation. The following is a brief description of a typical booklet making and stapling operation.
1. 2.
3.
4.
Gate S1
Compiler Tray
End Guide
Stapler
5.
Fold Position
6.
Knife
Figure 148 Booklet Maker Sequence of Operation
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Adjusting the End Guide Position At the start of print the End Guide is positioned according to the paper size selected. Transporting Paper to the Booklet Maker Paper that has ed through the punch area is directed by Gate S1 into the Booklet Maker. The Booklet Paper Path Motor drives the paper into the End Guide. The tampers ensure that the paper stacks evenly and the paddles keep the paper against the End Guide. Positioning the Tray and Raising the Set for Stapling The sheets are compiled with the edges at the front of the tray. Once the set is complete, the tray moves toward the center to position the set so that the staples will be equidistant from the top and bottom of the set. The End Guide is raised to position the set for stapling in the center. The sheets are then stapled. Raising the Set for Folding The End Guide continues to raise the set until the center of the sheets lines up with the fold position. Folding the Set to Make the Booklet When the set is in the fold position, the Knife Solenoid is energized. This allows one rotation of the Knife gear. The Knife extends to push the set into the Fold Rolls and then retracts to the home position. Booklet Exit The now folded and stapled booklet is transported to the Booklet Tray. The Booklet Tray belts transport the booklets to the end of the Tray. NVM location 763-231 may be used to change the time that the belts run for each booklet. The end of the Booklet Tray may be dropped to allow the booklets to drop into a receptacle. It should be noted that the Booklet Maker might also be used for Bi-Folded single sheets. The stapler is not used but the fold operation is the same for each sheet.
Enhanced Finisher The new Enhanced D Finisher looks and is very similar to the D finisher that you have been servicing on the 4110. The Enhanced D Finisher is RoHS compliant, and will be the Finisher for the Xerox 4110 and 4110 EPS. New Features: “Z” fold capacity increased from 30 sheets to 80 sheets The “Z” fold productivity has been increased. A cut staple stapler with the same 100 sheet capacity as the previous one
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The new stapler is a cut staple stapler, and requires a Staple Waste Container. The customer will receive 1 Staple Waste Container with every 4 staple cartridges. The Staple Waste Container is sensor monitored to ensure that it is thrown away when it has been filled.
Staple Waste Container Senor
There are 3 Staple Waste Container Fault Codes displayed for the customer: 024 – 931 Staple Waste Container Full 024 – 932 Staple Waste Container Set Fail 012 – 400 Staple Waste Container Near Full
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One way to tell the difference between the D Finishers and the Enhanced D Finisher is by the product code: ANV – D2 Stapler/Finisher with 2/3 hole punch – US and Canada ANW – D2 Stapler/Finisher with 2/4 hole punch – Europe ANX – D2 Booklet Finisher with 2/3 hole punch – US and Canada ANY – D2 Booklet Finisher with 2/4 hole punch – Europe There have been several changes in the 4110/4590 EDOC associated with the new Enhanced Finisher. The BSDs for the Enhanced Finisher have their own separate section. The circuitry is the same as the D finisher but the Enhanced finisher wires have completely different wiring nomenclature. (Insert a captivate BSD finisher walk thru. Open your documentation. Open 4110/4590. Open 7 wirenets. Open BSDs. Open chain 12. Open 12.A.) There are also five new Fault Codes. Three associated with the Staple Waste Container 012 – 400 Staple Waste Container Near Full 024 – 931 Staple Waste Container Full 024 – 932 Staple Waste Container Set Fail and two others. 012 – 952 Envelope Folder Tray Pause Detect 027 – 728 Ext Server Req File Exceed
Software ‰ View the software procedure for the 4110 EPS on the EPSS CD Parts List The parts list will have two separate sections for the D finisher and Enhanced D Finisher. The new finisher will start at PL 17.101
Adjustments There are no new finisher adjustments. The ADJ 17.14.4 Finisher – D2 Dual Staple Skew/ Lead Position Adjustment is slightly different in that the cam has changed.
D3 Finisher The appearance of the new D3 finisher is very similar to the previous finisher. There are however improved features that have been added. The D3 Finisher can now staple up to 100 sheets using Variable Length Staple technology. The Booklet Maker capacity is now 20 sheets. There have been wiring changes and it is necessary to use the correct service manual when servicing the finisher. The service manual is on the new Xerox 4112/4127 EDOC. It is separate from the Xerox 4112/4127 Service Manual and the OHCF Service Manual.
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(Chain 16) Printer
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 16 Printer.
Technical Overview The main functions of this module are to Control and direct the printing operation.
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Printer Configuration Component Name and Function
HDD
ESS Fan ESS PWB
Memory (64MB)
Memory (256MB) NVM PWB
STD ROM Monza4 FCW PWB
Figure 149
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The ESS PWB controls the printer functions as well as the overall system. The NVM PWB (Nonvolatile Memory) is installed on the ESS PWB. The STD ROM is and extension font ROM. The System Memory has two slots on the ESS PWB. The top slot is standard 64MB SDRAM (RAM1) and the bottom is an extension slot (RAM2) THE 256MB Memory (2slots) is the memory for storing image data. The ESS Fan cools the ESS PWB. The Monza4 PWB is the interface PWB connected to the UI. The HDD is a 40G drive that is actually 38.4G partitioned as follows: 3.6G for Font, Job Template and SBM Folder 3.6G for EPC Print data 14.6G for Ext Mailbox, scan, report, etc 3.6G PDL/Mail temp 6.3G EPC Copy temp data 1.8G Scan server, Scan PC, Email, etc 0.9G DOMS Scan Data 0.9G Spool, recovery.
Hardware Configuration The Printer functions are controlled by the ESS PWB and components connected to it. Figure 150 and Table 42 show the ESS PWB hardware configuration and specifications.
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Figure 150 ESS PWB Hardware Configuration
Table 42 ESS PWB Hardware Specifications Function U Bridge System Memory
Program ROM (PCI Boot ROM)
Specification PPC750Cxe ZERO PC133SDRAM 2 Slots
Flash ROM MDIM For M 2-Slot PCI Boot 32-bit Bus wide
Standard Font ROM Extension Font ROM NVM/RTC SEEPROM 1
238
NVM capacity: 1MB J334 8K bits
Installed on On Board On Board 144 SO-DIMM
Config. 750-600M ○ Max512MB
144 SO-DIMM
Max512MB
144 SO-DIMM 144 SO-DIMM
(Max)32MB (Max)32MB
RAM1 J330 (Standard Slot) RAM2 J331 (Extension Slot) Standard (ROM1) J332 Option (ROM2) J333
On Board
○
Mask ROM
144 SO-DIMM
Op
72 SIMM
○
Socket
○
Installed on the same DIMM where Op Program ROM is. Battery Backup RTC: I2C I/F Stores I2C I/FmacAdd, (other)
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Function Page Memory
Installed on 144 SO-DIMM
Config. Max256MB
144 SO-DIMM
Max256MB
10BaseT/100BaseT x J340 1ch, Full Speed J342 P310 for Ultra66 P302 (Power)
On Board
○
Remarks PM1 (PWB solder side) J337 PM2 (PWB part side) J338 PHY: ICS1893Y
On Board
○
For only (CE)
40-pin connector 4-pin connector
3.5-inchHDD ○
PCI Arbiter
LD
On Board
○
UI I/F PCI Slot
MugelloP349 Slot J370 for JPEG Card
Sub-board 144-pin connector
○ ○
Riser
PCI Option P347
140-pin Riser
2 slots
The connector for 3.5inch HDD is installed on the PWB. 2.5-inch HDD requires a switchboard. Secondary PCI Also serves as Reboot Controller. Secondary PCI For Secondary PCI Kutani, JPEG Slot is installed on Riser. Unlike C2D/Emono, in the case of Secondary PCI Kutani, 1 Slot is for JPEG only.
EPSV FAN
P351 P311 (12V)
10-pin connector 3-pin connector
○ ○
Debug Serial/ IOT Serial Chameleon
P380
6-pin connector
○
P382
5-pin connector
○
PSW MCU I/F
P345 P335
IIT I/F VSEL I/F
J336 J390 (Data) P391(VSEL Power) P300 +3.3V: CR3601 Reboot3V: CR3602 Sleep3V: CR3603 +5V: CR3604 CR4501-4508 (8 bits)
120-pin connector 50-pin connector 50-pin connector 3-pin connector 16-pin connector Green Orange Yellow Yellow Green
○ ○ 61.83MHz ○ ○ ○ ○ ○ ○ ○ ○ ○
Ethernet USB (Target) IDE (IDE Power)
Main Power Power LED
Status LED
Specification SDRAM 2 Slots
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Fan Fail Interrupt ed Note that this is different in connector from another existing board for Chameleon2. Video CLK
Off in Reboot Mode Off in Sleep Mode Off in Sleep Mode Access via I2C Rohm: BU2098F in use. In Sleep Mode, the LED shall be turned off at the OS level.
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Xerox 4112/4127 Differences
Introduction This section provides information about the technical modifications made to the Xerox 4112/4127.
Technical overview Simply stated, the Xerox 4112/4127 is a faster Xerox 4110 that is more capable of accurate registration. The Xerox 4112/4127 has been designed to penetrate the light production market. As such, certain modifications have been made to meet the needs of that environment. Highlights of the modifications include: •
New components and technology in the registration subsystem to make the front-to-back registration more accurate (also customer adjustable to accommodate media characteristics)
•
New components in the drive subsystem to provide increased speed
•
A new finisher with increased capacity for stapling and booklet making
•
Software enhancements to improve image quality
•
Most of the Service Diagnostics will be performed from the UI
•
Customer replaceable F Web.
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Paper Registration Several new components have been added to the registration subsystem to ensure image registration accuracy and tighten jam detection.
Multifeed Detection Sensor A new Multifeed Detection Sensor has been added to the Registration Transport.
Located under the transport in this area
Sensor
Roller Actuator
Transport rotated 180º
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Multifeed Detection Sensor operation The sensor is a variable resistor. When paper enters the pre registration area, the thickness of the paper is measured by the movement of a roller actuator that mechanically moves a rheostat that in turn changes the resistors resistance. The change in resistance results in a corresponding change in the voltage measured at the MCU PWB. If a multisheet feed occurs, the additional thickness of the paper will create an out-of-range voltage, resulting in a misfeed.
Image Sensor (CIS) Sensor A new CIS Sensor detects the edge of the media as it enters the registration area. The sensor is located on the left side of the Registration Transport.
CIS Sensor Registration Transport rotated 180º
CIS operation The CIS sensor signals the MCU PWB with the location data for the side edge. The sensor functions similar to the second CIS Sensor in the Document Handler that scans the side-2 image during single- scan mode. The diagram below shows the sensor operation when light, reflected from the paper reaches the photo diode. The point of transition from a no light condition to light present condition is interpreted as the side edge.
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Preregistration Sensor The Preregistration Sensor monitors the paper prior to arrival at the registration area. This sensor controls the operation of the Preregistration Motor. The Preregistration Motor is bi-directional and serves as the preliminary registration of the paper. Final registration is performed by the Registration Sensor and Registration Motor.
Registration Skew Sensor Another new component in the registration system is the Registration Skew Sensor. This sensor works in unison with the CIS Sensor and the Registration Sensor to provide the CIS Control PWB additional information about the amount of skew in the lead edge of the paper. The diagram below shows the operation of all three sensors to determine the amount of skew.
Timing between edge detection of all three sensors is used to calculate the skew amount. The MCU then modifies the location of the image placed on the drum by the ROS to compensate for the mechanical skew in the paper. This system is much more accurate than attempting to mechanically correct the skew.
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CIS Control PWB The new CIS Control PWB is located under the Registration Transport and receives signals from the three sensors: CIS, Skew and Registration Sensors. Information from this PWB is then sent to the CIS Adaptor PWB mounted on the MCU PWB and from there directly to the MCU for image and registration control.
CIS PWB
Registration Transport rotated 180º
CIS Adaptor PWB
MCU PWB
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Registration Motor The Registration Motor remains a DC Stepper Motor however it is now capable of half-steps in order to provide more precise control. The Registration Sensor detects the lead edge and signals the MCU which in turn commands the motor to slow down or speed up, achieving correct image registration.
Pretransfer Jam Sensor A new Pretransfer Jam Sensor has been added for Jam detection. This sensor detects if the paper timing is incorrect or if the paper lingers too long in the transfer area.
Pretransfer Jam Sensor
Paper Path Alignment Paper Path Alignment is comprised of five different adjustments: •
Lead Edge Registration
•
Side Edge Registration
•
Fast Scan Magnification
•
Slow Scan Magnification
•
Image Squareness
Paper Path Alignment is performed separately for all paper trays by Xerox Service. Adjusting individual trays is a departure from the 4110 in that there are separate NVM locations for the adjustment values for each tray. This process baselines the machine for registration accuracy. When all of the paper trays have been adjusted, the customer () then has the option to perform a similar setup for specific paper stocks to compensate for different media characteristics. For example, some media will physically shrink or stretch as it is processed through the f. By enabling some latitude at the customer level, up to 20 different paper stocks can be profiled and assigned to a paper tray. The customer first
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assigns a name to the paper stock and then performs the alignment. The custom stock is then assigned to a specific tray. The following adjustment descriptions are for the service diagnostics, not customer. For a description of the customer alignment procedures, refer to the System istration Guide.
Lead Edge Registration The Lead Edge Registration adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Lead Edge Registration are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in advancing the paper or retarding its arrival at the registration subsystem by controlling the Registration Motor.
Side Edge Registration The Side Edge Registration adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Lead Edge Registration are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in controlling the start of scan so that the image is correctly ed side-to-side.
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Image Registration Control Technology (IreCT) Overview The following three adjustments for magnification and squareness are a part of the IreCT Technology. IreCT essentially is a software program that calculates the modification that needs to be made to the image based on measurements that are provided during the adjustment process. As part of the three adjustments, measurements are made on the output grid test pattern and then recorded using the UI. Then, a sophisticated software program repositions where pixels in the bit stream (image) are placed prior to developing the latent image. In this way, slight differences from printer-to-printer are corrected so that the resultant output is a very accurate rendition for both magnification and squareness. IreCT Technology has been used on color products for some time. The technology provides accurate color registration by developing standard patches (called chevrons) on the transfer belt and then using a device called a Mark On Belt (MOB) Sensor to detect where the patches are positioned. Using that data, the software ensures that the color registration is always accurate.
Fast Scan Magnification The Fast Scan Magnification adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Fast Scan Magnification are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in manipulating the pixel placement by the ROS so that the magnification is correct.
Slow Scan Magnification The Slow Scan Magnification adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Slow Scan Magnification are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in manipulating the pixel placement by the ROS so that the magnification is correct.
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Image Squareness The Image Squareness adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for adjusting Image Squareness are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in manipulating the pixel placement by the ROS so that the image is square on the media.
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Xerox Corporation Global Knowledge and Language Service 800 Phillips Road Bldg 128 Webster, NY 14650 701P ©
2007 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms and matters of copyrightable material and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. Printed in the United States of America. Xerox®, The Document Company®, The digital X, and Xerox product names and product numbers mentioned in this publication are trademarks of Xerox Corporation. Other company brands and product names may be trademarks or ed trademarks of the respective companies and are also acknowledged.
Table of Contents
Table of Contents........................................................................................................ i (Chain 1) Power .......................................................................................................... 1 Introduction....................................................................................................................................1 Module Overview ........................................................................................................................................ 1
Technical Overview .......................................................................................................................2 Switches, Power Supplies, and PWBs ....................................................................................................... 2 Component Name and Function............................................................................................................................... 2 Power and Control .................................................................................................................................................... 4 DC Power Distribution .............................................................................................................................................. 5
Operation Modes ........................................................................................................................................ 6 Interlocks Component Name and Function ................................................................................................ 8 Operation with an Interlock Open ............................................................................................................... 9
(Chain 2) Mode Selection ........................................................................................ 11 Introduction..................................................................................................................................11 Module Overview ...................................................................................................................................... 11
Technical Overview .....................................................................................................................12 UI ( Interface) Configuration.............................................................................................................. 12 Component Name and Function............................................................................................................... 13
(Chain 3) Machine Run Control............................................................................... 15 Introduction..................................................................................................................................15 Module Overview ...................................................................................................................................... 15
Technical Overview .....................................................................................................................16 Machine Self Test ..................................................................................................................................... 16 Billing Meter .............................................................................................................................................. 18 Billing Meter Type ................................................................................................................................................... 18 What is counted ...................................................................................................................................................... 20 When Counting Happens ....................................................................................................................................... 21 Counter Value Check/Correction............................................................................................................................ 22
(Chain 5)
DADF..................................................................................................... 23
Introduction..................................................................................................................................23 How to Load Documents .......................................................................................................................... 23 Document Stack Capacity ........................................................................................................................ 23
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Document Feed Sequence ....................................................................................................................... 23 Document Scan Speed............................................................................................................................. 24 Component Name and Function............................................................................................................... 25 Operation When Documents are Loaded ................................................................................................. 26 Document Size Sensing ........................................................................................................................... 27 Component Name and Function............................................................................................................... 28 First Document Pre-feed........................................................................................................................... 31 Second and Subsequent Document Pre-feeds ........................................................................................ 31 Pre-registration ......................................................................................................................................... 31 Preventing Document Damage................................................................................................................. 31 Rotating Regi Roll backward .................................................................................................................... 32 Pre Regi Roll’s free drive .......................................................................................................................... 32 Releasing Baffle........................................................................................................................................ 32
Document Scanning and Output ................................................................................................33 Component Name and Function............................................................................................................... 33 Document Scanning Operation................................................................................................................. 34 CIS Scanning............................................................................................................................................ 35
Document Transportation...........................................................................................................36
(Chain 6)
Imaging ................................................................................................. 37
Introduction..................................................................................................................................37 Document Scanning Overview ................................................................................................................. 41 Document Scanning Position Overview (DADF) ...................................................................................... 42 Initialization ............................................................................................................................................... 43 Document Size Sensing ........................................................................................................................... 44 Platen Document Scanning Operation ..................................................................................................... 47 DADF Document Scanning Operation...................................................................................................... 49
Adjustments or Corrections During Scanning..........................................................................51 AGC (Auto Gain Control) White Level Rough Adj. ................................................................................... 51 AOC (Auto Offset Control) ........................................................................................................................ 51 Shading Correction ................................................................................................................................... 51 White Fluctuation Adjustment ................................................................................................................... 52 Black Fluctuation Adjustment ................................................................................................................... 52 Dark Band Elimination .............................................................................................................................. 53 Image Processing ..................................................................................................................................... 54 Fan Control ............................................................................................................................................... 54 Fan Control ............................................................................................................................................... 55
ROS...............................................................................................................................................56 ROS Overview .......................................................................................................................................... 56 ROS Components..................................................................................................................................... 57 Laser Beam Flow...................................................................................................................................... 58 Laser Diode Control.................................................................................................................................. 58
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ROS Motor Control ................................................................................................................................... 58
(Chain 7)
Paper Supply........................................................................................ 59
Introduction..................................................................................................................................59 Tray Specifications......................................................................................................................60 Configuration ............................................................................................................................................ 60 Allowable Paper Sizes .............................................................................................................................. 61 Tray Capacity............................................................................................................................................ 62 Paper Weights .......................................................................................................................................... 63
Paper Transportation ..................................................................................................................64 Paper Flow................................................................................................................................................ 64 Drive Motors ............................................................................................................................................. 67
Trays 1 through 4.........................................................................................................................68 Component Name and Function............................................................................................................... 68 Trays 1 through 4 Paper Size Sensing ..................................................................................................... 70 Raising Trays 1 through 4......................................................................................................................... 72 Raising Operation ..................................................................................................................................... 73 Trays 1 through 4 Remaining Paper Detection......................................................................................... 73
MSI (Multiple Sheet Inserter) ......................................................................................................74 Component Name and Function............................................................................................................... 74 MSI Paper Size Sensing........................................................................................................................... 75 Raising and Lowering the MSI.................................................................................................................. 76
HCF (High Capacity Feeder) .......................................................................................................77 Component Name and Function............................................................................................................... 77 HCF Paper Size Sensing.......................................................................................................................... 78 Raising the HCF Trays ............................................................................................................................. 79 Trays 6 and 7 Remaining Paper Detection............................................................................................... 79
OHCF (Oversized High Capacity Feeder) ..................................................................................80 Overview................................................................................................................................................... 80 Paper Size .............................................................................................................................................................. 80 Paper Type ............................................................................................................................................................. 80 Power Consumption ............................................................................................................................................... 80 Dimensions ............................................................................................................................................................. 80 Weight..................................................................................................................................................................... 80
Interlock Switches..................................................................................................................................... 81 Paper Size Detection ................................................................................................................................ 82 Paper Size
s ................................................................................................................................83
Paper Availability Detection/Remaining Amount Detection ...................................................................... 85 Paper Feed ............................................................................................................................................... 86 Tray Shift .................................................................................................................................................. 88 Paper Separator Air Flow ......................................................................................................................... 89 Air Shutter................................................................................................................................................. 91
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Drive ......................................................................................................................................................... 92
(Chain 8) Paper Feed and Transportation.............................................................. 93 Introduction..................................................................................................................................93 Module Overview ...................................................................................................................................... 93
Technical Overview .....................................................................................................................94 Paper Transportation from Trays 1 through 4 to Registration ................................................95 Component Name and Function............................................................................................................... 95 Basic Control of Paper Transportation...................................................................................................... 97 Paper Feed from the Trays....................................................................................................................... 98 Paper Transportation from the Takeaway Rolls ....................................................................................... 99
Paper Transportation from the MSI to Registration................................................................101 Component Name and Function............................................................................................................. 101 Paper Feed from the MSI ....................................................................................................................... 102
Paper Transportation from the HCF to Registration...............................................................103 Component Name and Function............................................................................................................. 103 Paper Feed from the HCF ...................................................................................................................... 105 Paper Transportation to the HCF Exit Roll ............................................................................................. 106
Registration................................................................................................................................107 Component Name and Location ............................................................................................................. 107 Pre Registration Control ......................................................................................................................... 108 Registration Control ................................................................................................................................ 108 Side Registration Control........................................................................................................................ 109 Paper Length Sensing ............................................................................................................................ 110
(Chain 9) Marking ................................................................................................... 111 Introduction................................................................................................................................111 Module Overview .................................................................................................................................... 111
Technical Overview ...................................................................................................................112 Drum ...........................................................................................................................................113 Component Name and Function............................................................................................................. 113 Drum Motor Control ................................................................................................................................ 114 Drum Cartridge Replacement Detection................................................................................................. 115
Charging and Cleaning .............................................................................................................116 Component Name and Function............................................................................................................. 116 Charge Operation ................................................................................................................................... 118 Charge Corotron Cleaner Control........................................................................................................... 119 Toner Band ............................................................................................................................................. 120
Development ..............................................................................................................................121 Component Name and Function............................................................................................................. 121 Negative Charge Development............................................................................................................... 123 Toner Supply for the Deve Housing........................................................................................................ 124
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Development........................................................................................................................................... 126 Development Bias Control ...................................................................................................................... 127 Toner Empty Detection ........................................................................................................................... 129 Remaining Toner Detection .................................................................................................................... 129 Toner Cartridge Replacement Detection ................................................................................................ 130
Transfer and Stripping ..............................................................................................................131 Component Name and Function............................................................................................................. 131 Transfer Belt ing and Retracting................................................................................................. 133 Image Transfer onto Paper..................................................................................................................... 134 Stripping Paper ....................................................................................................................................... 134 Bias Roll.................................................................................................................................................. 135
Toner Collection ........................................................................................................................136 Component Name and Function............................................................................................................. 136 Toner Collection System......................................................................................................................... 138
Process Control .........................................................................................................................139 Component Name and Function............................................................................................................. 139 Process Control Overview ...................................................................................................................... 140 Potential Control Overview ..................................................................................................................... 141 Patch....................................................................................................................................................... 142 Mini Setup Operation .............................................................................................................................. 143 Operation During Printing/Copying ......................................................................................................... 144 Toner Dispense Control.......................................................................................................................... 145
(Chain 10a) Copy Transport .................................................................................. 147 Introduction................................................................................................................................147 Module Overview .................................................................................................................................... 147
Technical Overview ...................................................................................................................148 Paper Transportation after the F.......................................................................................149 Component Name and Function............................................................................................................. 149 Copy Output Control Overview ............................................................................................................... 151 Straight Output........................................................................................................................................ 154 Invert Output ........................................................................................................................................... 155 Duplex Output......................................................................................................................................... 156 Duplex Print Sequence ........................................................................................................................... 158
Fan Control ................................................................................................................................159 Component Name and Function............................................................................................................. 159
(Chain 10b) Fusing ................................................................................................. 161 Introduction................................................................................................................................161 Fusing.........................................................................................................................................162 Component Name and Function............................................................................................................. 162 F Assembly ...................................................................................................................................... 163
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F Heat Roll....................................................................................................................................... 164 F State ............................................................................................................................................. 165 F Temperature Control .................................................................................................................... 166 F Idling ............................................................................................................................................. 170 Countermeasure against Flicker............................................................................................................. 170 Phase Control ......................................................................................................................................... 171
F Drive.................................................................................................................................171 Component Name and Function............................................................................................................. 171 F Drive Control................................................................................................................................. 172
Heat Roll Cleaning .....................................................................................................................173 Component Name and Function............................................................................................................. 173 Web Motor Control.................................................................................................................................. 174 Extension of Web Life............................................................................................................................. 174 Remaining Web Detection ...................................................................................................................... 174
Finisher ................................................................................................................... 175 Introduction................................................................................................................................175 Technical Overview ...................................................................................................................175 Finisher Configurations........................................................................................................................... 175 Finisher Components.............................................................................................................................. 176 Output Tray Capacities ........................................................................................................................... 177 Paper Transportation .............................................................................................................................. 178 Functions and Output Tray Availability ................................................................................................... 180 Paper Size and Function ........................................................................................................................ 182 Billing Meters .......................................................................................................................................... 183 Power and Switches ............................................................................................................................... 184 Finisher Power Control ........................................................................................................................... 188 Decurler .................................................................................................................................................. 189 Decurler Control...................................................................................................................................... 189 Decurler Components and Operation ..................................................................................................... 190 Decurler Components and Operation ..................................................................................................... 190 Decurler Components............................................................................................................................. 190 Interposer................................................................................................................................................ 191 Interposer Tray Lift Components ............................................................................................................ 192 Interposer Tray Feed Components......................................................................................................... 193 Folder...................................................................................................................................................... 194 Components ........................................................................................................................................... 195 Components ........................................................................................................................................... 197 Components ........................................................................................................................................... 199 Folder Operation..................................................................................................................................... 200 Folder Operation..................................................................................................................................... 201 Punch...................................................................................................................................................... 202
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Punch Components ................................................................................................................................ 202 Punch Operation..................................................................................................................................... 204 Paper Transportation and Punching ....................................................................................................... 206 Paper Transportation / Top Tray............................................................................................................. 208 Output Selection ..................................................................................................................................... 209 Compiling, Stapling, and Ejecting the Sets............................................................................................. 210 Compiler and Stapler Operating Sequence ............................................................................................ 217 Buffer Path.............................................................................................................................................. 218 Buffer Path Sequence............................................................................................................................. 218 Stapling Positions ................................................................................................................................... 220 Stapler Travel ......................................................................................................................................... 220 Stack Tray Components and Operation ................................................................................................. 222 Stack Tray Indexing ................................................................................................................................ 223 Offset Stacking ....................................................................................................................................... 226 Booklet Maker......................................................................................................................................... 226 Booklet Maker Components ................................................................................................................... 226 Booklet Maker Operation ........................................................................................................................ 231 Enhanced Finisher.................................................................................................................................. 232 Software ............................................................................................................................................... 234 Parts List............................................................................................................................................................... 234 Adjustments .......................................................................................................................................................... 234
D3 Finisher ............................................................................................................................................. 234
(Chain 16) Printer ................................................................................................... 235 Introduction................................................................................................................................235 Module Overview .......................................................................................................................235 Technical Overview ................................................................................................................................ 235
Printer Configuration.................................................................................................................236 Component Name and Function............................................................................................................. 236 Hardware Configuration.......................................................................................................................... 237
Xerox 4112/4127 Differences................................................................................. 241 Introduction................................................................................................................................241 Technical overview....................................................................................................................241 Paper Registration .................................................................................................................................. 242 Multifeed Detection Sensor .................................................................................................................................. 242 Multifeed Detection Sensor operation .................................................................................................................. 243
Image Sensor (CIS) Sensor ...................................................................................................... 243 CIS operation........................................................................................................................................................ 243 Preregistration Sensor .......................................................................................................................................... 244 Registration Skew Sensor .................................................................................................................................... 244 CIS Control PWB .................................................................................................................................................. 245 Registration Motor ................................................................................................................................................ 246 Pretransfer Jam Sensor........................................................................................................................................ 246
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Paper Path Alignment............................................................................................................................. 246 Lead Edge Registration ........................................................................................................................................ 247 Side Edge Registration......................................................................................................................................... 247
Image Registration Control Technology (IreCT) Overview ..................................................................... 248 Fast Scan Magnification ....................................................................................................................................... 248 Slow Scan Magnification ...................................................................................................................................... 248 Image Squareness................................................................................................................................................ 249
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(Chain 1) Power
Introduction
Module Overview This module contains the names, locations and functions of the components in Standby Power.
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Technical Overview Switches, Power Supplies, and PWBs Component Name and Function This section describes the components shown in Figure 1.
1. Main Switch 6. PWS Outlet
2. AC Unit
Outlet
Reset Switch Inlet
AC Drive PWB
3. Main LVPS
5. 12VDC LVPS
4. 24VDC LVPS
Figure 1 AC and DC Components The Main Power Switch switches on and off the main power to the machine.
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The AC Unit consists of the AC Drive PWB, the Reset Switch, an Outlet and an Inlet. The AC Unit supplies AC power from the Inlet connection t the AC Drive PWB to control the power to each LVPS. The Main LVPS generates +5VDC, +12VDC, and +24VDC for use by the IOT. The 24VDC LVPS generates additional +24VDC for the IOT. The12VDC LVPS generates additional +12VDC for the IOT. The PWS Outlet is the 200 VAC outlet for the PWS.
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Power and Control Figure 2 shows the power distribution for Xerox 4110.
Figure 2 AC Power Distribution
AC Voltage is supplied through a Reset Switch and Circuit Breaker to the Main Switch, the 12VDC LVPS and Relays in the AC Unit. The 12VDC LVPS supplies +12VDC to the IOT DRIVER PWB. The AC Unit supplies +3.3VDC to the ESS PWB and +12VDC for the Relay in the AC Unit. When the Main Switch is turned ON, power is supplied to the area of the AC Unit that supplies the +3.3VDC to the ESS PWB. The ON/OFF status or the Main Switch is monitored and reported to the ESS PWB through the MCU PWB. The ESS PWB send the Main Power signal to the AC Unit, The Main LVPS and the +24VDC LVPS. The Main Unit, after receiving the Main Power signal, turns ON the Relay and supplies AC voltage to the Main LVPS. The Main LVPS generates +5VDC, +12VDC and+24VDC. The outputs of the Main LVPS
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go to the ESS PWB, the IOT DRIVER PWB, the MCU PWB, the Tray Module PWB, the IIT/IPS PWB and the HCF PWB if there is one on the machine. When power is turned off, the ON/OFF status is signaled to the ESS PWB. The ESS PWB sends the Ready Power signal to the Delay Circuit on the AC Drive PWB in the AC Unit. This signal allows the delay circuit, in the AC Unit, to turn off the Relay after a specified time. This turns off power to the machine. The delay circuit is used so that the machine will not turn off before the data is written to the Hard Drive When the Main Power Switch is still on and the machine enters the Power Saver mode, the ESS PWB sends the Main Power signal and the Ready Power signal to the AC Drive PWB in the AC Unit. This then controls the Power supplied to various components.
DC Power Distribution Figure 3 shows the DC power distribution.
Figure 3 DC Power Distribution
The +12VDC from the Main LVPS is supplied to the IIT/IPS PWB. The +24 VDC from the +24 LVPS is also supplied to the IIT/IPS PWB and the DS PWB. The +24VDC is supplied to the DADF PWB through the IIT/IPS PWB. The +24VDC is also supplied to the 1PDup PWB through the DS PWB. The IIT/IPS PWB generates +5VDC and +3.3VDC from the supplied +12VDC and supplies them to the DADF PWB. The DS PWB generates +12VDC and +3.3VDC from the +24VDC and supplies them to the Extension Memory PWB.
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The ESS PWB sends the IIT LVPS Enable signal to the IIT/IPS PWB and the DS PWB turning power ON/OFF to various components.
Operation Modes Table 1 shows the operating modes. Table 1 Mode Status Run Mode (Running Mode) Receives data, generates/records an image. Standby Mode (Ready Mode) Ready to go into Run Mode. Save Energy Mode 1 (Low Power Mode) Consumes less power than Standby Mode. Save Energy Mode 2* (Sleep Mode*) Consumes less power than Save Energy Mode 1 Save Energy Mode 3 (Semi Low Power Mode) Allows access to HDD alone in Save Energy Mode 2 *This complies with the international energy star program. Table 2 shows the requirements for the machine to shift from one mode to another. Table 2 Run Mode → Standby Mode (Running) (Ready) Standby Mode → Save Energy Mode 1 (Ready) (Low Power) Standby Mode → Save Energy Mode 2 (Ready) (Sleep) Standby Mode → Run Mode (Ready) (Running) Save Energy Mode 1→ Standby Mode (Low Power) (Ready) Save Energy Mode 2→ Standby Mode (Sleep) (Ready) Save Energy Mode 3→ Standby Mode (Semi Low Power) (Ready) Save Energy Mode 2→ Save Energy Mode 3 (Sleep) (Semi Low Power) Save Energy Mode 3→ Save Energy Mode 2 (Semi Low Power) (Sleep) Save Energy Mode 1→ Save Energy Mode 2 (Low Power) (Sleep)
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Immediately after the end of print operation, the MC shifts without receiving a command. After the end of print operation, the MC shifts receiving a command from ESS. After the end of print operation, the MC shifts receiving a command from ESS. The MC shifts receiving a command from ESS. The MC shifts receiving a command from ESS, taking Warm Up Time.
The MC shifts at the time of the outside’s access to HDD. After the end of the outside’s access to HDD, the MC shifts receiving a command from ESS. When the MC receives no command from ESS for a certain time after the end of print operation, the MC shifts to Save Energy Mode 1. Further, a certain time after the MC shifts to the mode 1, the MC shifts to the mode 2 receiving a command from ESS.
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Table 3 shows the state of the DC power supply in each operation mode and the operating status of each system. Table 3
Fusing System (F)
Run Running Mode Kept at operation temp Rotating at run speed Operating
Standby Ready Mode
Save Energy 1
Save Energy 2
Save Energy 3
Sleep Mode
Kept at ready temp
Low Power Mode Kept at low temp
Asleep
Semi Low Power Mode Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep
Asleep (but rotating (low speed) for 60 min after power off.) Asleep Waiting to receive.
Asleep (but rotating (low speed) for 60 min after power off.) Asleep Waiting to receive.
Not accessible ○ × × × × × × × × × ×
Accessible
Exposure System (ROS) Record System (Transfer, development, etc.) F Exhaust Fan / F Intake Fan
Rotating (high speed)
Rotating (low speed)
Rotating (low speed)
Transfer Intake Fan ESS
Rotating Operating
Rotating On standby
HDD (Ref.)
Accessible
Accessible
Rotating HDD asleep. Waiting to receive. Accessible
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○ ○ ○ × × ×
ESS
IOT
IIT
+3.3VDC +5VDC +12VDC +24VDC +5VDC +12VDC +24VDC F AC +5VDC +12VDC +24VDC
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ O = ON, X = OFF
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○ ○ ○ × × × × × × × ×
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Interlocks Component Name and Function Front Door Interlock Switch HCF Front Cover Interlock Switch MSI Interlock Switch
L/H Cover Interlock Switch (IOT) Figure 4 IOT Interlocks
The Front Door Interlock detects whether the Front Door is opened or closed. When open, it shuts off +24VDC to various motors. The MSI interlock (only on machine without the optional HCF) detects whether the MSI is opened or closed. If open it removes the power to various motors. The HCF Front Cover Interlock detects whether the HCF front cover is opened or closed. If open it removes +24VDC from the HCF Takeaway Motor. The L/H Cover Interlock detects whether the left hand cover is opened or closed. If open, it removes +24VDC from the Takeaway Motor 1 and Takeaway Motor 3.
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Operation with an Interlock Open Figure 5 shows that a machine without an HCF has the MSI and Front Door interlocks connected in series. If one of the switches opens, +24VDC for the motors and the HVPS will be removed.
Figure 5 Open Interlock
A machine that has an HCF will have a shorting wire in place of the MSI Interlock Switch (done at install) so the power will be removed from the above components if the Front Door Interlock Switch is opened. If the L/H Cover Interlock Switch of the HCF is open, the +24VDC is removed from Takeaway Motor 1 and Takeaway Motor 3. If the HCF Front Cover Interlock Switch (connected to the HCF PWB) is open, the +24VDC is removed from the HCF Takeaway motor. The Xerox 4110 interlock switches do not have a logic side. There is no +5VDC switched with the interlocks. Instead the MCU PWB monitors the opening and closing of the Front Door Interlock Switch and the ON/OFF status of the Drum Detect Switch (see the Xerographic Module) controlling the supply of +5VDC to the ROS.
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(Chain 2) Mode Selection
Introduction Module Overview This module contains the names, locations and functions of the components in Chain 2 Mode Selection.
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Technical Overview The main functions of this module are to store data selected through the use of the buttons and switches on the UI and touch . It is also to display the machine status on the UI.
UI ( Interface) Configuration The Xerox 4110 has a large UI screen as shown in Figure 6
Figure 6UI
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Component Name and Function
Inverter PWB
Touch
Back Light LCD PWB
LCD
UI I/F PWB
VR PWB
Switch/LED PWB Figure 7UI Components
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The Switch LED PWB consists of switches and LEDs required for operating the machine The VR PWB is equipped with the dial to adjust the brightness and of the screen. The LCD is the liquid crystal screen used to display the set-up data and display the machine status. The LCD PWB drives the LCD to display data from the UI I/F PWB The Inverter PWB turns on the Back Light The UI I/F PWB controls the switches, LEDs, LCD, etc. that belong to the control . Data to be controlled is sent from the ESS PWB. The Touch is used to make selections by touching icons on the LCD. The Back Light is used to illuminate the LCD.
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(Chain 3) Machine Run Control
Introduction Module Overview This module describes the names, locations, and functions of the chain 3.
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Technical Overview Machine Self Test This section describes the components shown in Figure 8.
DADF PWB IPS PWB BP PWB ESS PWB
NVM PWB Finisher PWB
I/F PWB IOT Driver PWB MCU PWB Tray Module PWB
HCF PWB
Figure 8PWB Locations
The MCU PWB controls the IOT, the HCF, and the Finisher. The IOT DRIVER PWB, the Tray Module PWB and the HCF PWB are connected to the MCU PWB. The NVM PWB is the nonvolatile memory installed on the MCU PWB. The IOT Driver PWB relays data from the MCU PWB and drives the components of the IOT. The IOT Driver PWB is connected the MCU PWB with an FCC Cable.
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The ESS PWB controls the entire system for scan, print, software etc. and is connected to the MCU PWB and the IPS PWB. The BP PWB connects the ESS PWB and the MCU PWB. The Tray Module PWB relay data from the MCU PWB and controls the components of the tray module The HCF PWB controls the functions of the HCF. The IPS PWB controls the IIT/IPS. The DADF PWB is connected to the IPS and is controlled by the IPS PWB. The DADF PWB controls the functions of the DADF. The Finisher PWB controls the Finisher functions other than the decurling area. The MCU PWB through the I/F PWB controls the Finisher PWB. The I/F PWB is the IOT to Finisher interface. Figure 9 shows this interconnectivity.
Figure 9 PWB Connections
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Billing Meter The billing meter is a software meter. The range of count is 0 39,999,999. The actual maximum display value is 9,999,999, just seven digits. Billing Management The Billing Meter is stored in three different areas so that no data will be lost. It is stored in: Master Meter:
EEPROM in the ESS PWB
Backup Meter 1:
NVM PWB on the ESS PWB
Backup Meter 2:
MCU PWB
Billing Meter Type Table 4 shows the current types of billing managed by the Xerox 4110.
Table 4 Billing Type Counter Type
Service for Counting Up
Print Service B & W
The following outputs under the Printer feature: Normal Print, Toner Save Mode Print, Report Print, and Print in Diagnostic Mode
Copy Service B & W
All the outputs under the Copy feature
Large Size B & W
Regardless of print or copy
(IBG only)
Paper equal to or larger than Fast Scan 279mm (11') x Slow Scan 400mm The same copy/print is recounted that another counter does.
Modal B&W
Modal Count* *Modal Count The modal count is used to learn the quantity of prints for discount billing The normal counter and the modal counter are used to count a predetermined quantity of prints. If the actual total count is larger than the predetermined one, the modal counter does not count the prints over the predetermined amount. The difference between normal count and modal count is used to determine the discount billing.
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Billing Meter Display Counts by the billing meters described in ‘Billing Meter Type’ are added for display the Meter 1, Meter 2, and Meter 3 in the check meter menu. The meters are displayed on the control panes by pressing the Check Machine (Check Meter) button. The relationship between the three meters and the types of counters to be added for display by the individual meters. Currently there are three Fx types and two IBG types as shown in Table 5 and in Table 6
Table 5 FX Meter Display and Counter Displayed
Billing Meter Type Billing 1
Billing 2
Billing 3
Print Service B & W
Print Service B & W
Print Service B & W
+ Copy Service B & W
+Copy Service B & W
+ Copy Service B & W
Meter 2
None
Copy Service B & W
Modal B&W
Meter 3
None
Print Service B & W
None
Meter 1
Table 6 IBG Meter Display and Counter Displayed
Billing Meter Type Billing 1
Billing 2
Print Service B & W
Print Service B & W
+Copy Service B & W
+ Copy Service B & W
Meter 2
Copy Service B & W
Modal B&W
Meter 3
Print Service B & W
None
Meter 1
The current default Billing Meter type is Billing 1 and can be changed in NVM (720-002) in the diagnostic mode. The procedure for changing the billing meter type is: Set the system data Billing Meter Type Change Flag to ON. Change to the desired Billing Meter Type. Note: Although it is possible to change the Billing Meter type, it should NEVER be done unless directed to do so by sales. Note: Setting the Billing Type Change Flag to ON or a specific value for Billing Meter Type requires and predefined code to be entered. This information will be given to you when the billing change is necessary.
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What is counted The items counted are explained in Table 7
Table 7 Counted Throughput Material Item
Count up
Normal Print
Y
(Print/Report/Copy) Insert (without image)
N
Cover (without image)
N
Print & Copy Service: A sheet inserted in the OHP Insert function Print & Copy Service: No Image (Blank Page) in the Cover function is selected. Print & Copy Service: The first page of text is specified as the cover. (For duplex, the first and second pages are treated as the cover.) Copy Service: Blank page, etc. inserted in the Build Job function In duplex print, an additional blank page, etc., which becomes the back of an oddnumbered page, for adjusting page quantity. A page for print resulting in a blank page is counted for billing. Wrong system data set for selecting paper size, improperly positioning tray guides and MSI paper size mismatch (If the MC stops before making a print, it is not counted for billing.) A print is made onto paper stock selected. It is counted for billing regardless of print quality. Copy Service: The MC makes a solid print if it detects anything reproduction of which is prohibited. A print in the case, where System has determined that the image can’t be guaranteed due to a failure and then output it. A test pattern for gradation adjustment is printed.
Cover (with image) Y Blank Sheet Insert (instructed by )
N
Blank Sheet Insert (System Operation)
N
Blank Page
Y
Print by wrong operation (Paper size mismatch)
Y
Print by wrong operation
Y
(Paper stock mismatch) Print for prevention of forgery (Solid print)
Y
Abnormal print (determined by System) N Gradation Adjust Chart
Outline
Non-CE Mode
Y
CE Mode Y
Other: report output
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System-generated info is printed. (Report Service)
Y
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When Counting Happens The meters are advanced when the following happens. 1. Normal Counting A properly printed page is counted when it is output into the Finisher. Simplex Print and Side 2 of Duplex Print: Top Tray: when the Top Tray Exit Sensor has sensed a print properly ing through. Stack Tray: when the Compiler Exit Sensor has sensed a print properly ing through and when in the case of sheet-by-sheet output, the Eject Sensor has sensed a print properly ing through. Folder Tray: when the Folder Path Sensor 3 has sensed a print properly ing through. Booklet Tray: when the Booklet In Sensor has sensed a print properly ing through. Side 1 of Duplex Print: when the trail edge of a properly printed page has ed the F Exit Switch n the process of inverting the paper. 2. Recovery and Correction count At the time of recovery from a problem etc., a print that has been counted is counted again. There is no subtraction for correction If side 2 of a duplex print cannot be completed due to a failure after side 1 is counted, recovery will be performed. To recover from a duplex failure, the machine starts with side1. At this time side 1 is not counted since it has been counted previously. If a job cannot be resumed due to a problem etc., prints output before the occurrence of the problem are treated as normal for counting. There is no correction made at this time.
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Counter Value Check/Correction The billing meter consists of the three counters in total, the main counter and two backup counters. The three counters are compared. If the values are different a correction will be made or action taken for a failure. The counter is checked at the following times: At power on (soft reset is included). When sleep mode is cleared. After the IOT cycle down. Like the Billing Meter data, the Product Number and Serial number are each stored in three locations. At the time the counter value is checked, all three pieces of data are compared. A check of the Product Number and Serial number is made before the meter value. If one of the three values is different, it will be treated as a system failure and no meter check will be made. If a meter check is made and one of the values does not match the other two, the mismatched value will be adjusted to match the other two. A manual correction needs to be made if one of the following happens: The result of the meter check shows that there are three different counts and the machine shuts down with a failure. The ESS PWB or the MCU PWB is replaced. The manual correction is made using dC132-Billing Data Matching and Serial Number Setup.
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(Chain 5) DADF
Introduction This module describes the names, locations, and functions of the Chain 5 Document Transportation. The main function of the DADF is to transport a document or series of documents and scan the images. This DADF uses a CVT (Constant Velocity Transport), which enables the scanning of both sides in one . Using the CVT method, the IIT Lamp Carriage is fixed at a certain position (Scan Position) where side one is scanned. At the same time, The CIS ( Image Sensor), install in the DADF, scans side two. The DADF does have the capability to invert a document, but this is not necessary or used in Xerox 4110.
DADF Specifications
How to Load Documents Documents are loaded image side up and ed at the center. When mixed size documents are loaded, the document guides are adjusted to the largest document and the smaller documents are aligned with the rear guide.
Document Stack Capacity The maximum numbers of sheets of paper that can be stacked in the document tray are as follows: Light paper (38-49gsm):
250
Plain paper (50-80gsm):
250
Heavy paper (81-128gsm):
150 (for reference)
Heavy paper (129-200gsm):
100 (for reference)
Document Feed Sequence The stacked documents are feed and transported one by one in sequence starting with the top document.
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Document Scan Speed When images on a document are scanned, the document is transported at a speed that depends on the magnification ratio. For an enlarged copy, the speed is reduced, while for a reduced copy the speed is the same as for an identical copy. Table 8 shows the transport speed corresponding to the magnifications. Table 8 Scan Speeds
Scan Magnification
Scan Speed (mm/sec)
25.0-100.0%
460.0
100.1-104.5%
440.0
104.6-150.0%
293.3
150.1-200.0%
220.0
200.1-300.0%
146.7
300.1-400.0%
110.0
Document Transport Path
Figure 10 Document Path, Drives and Sensors
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Loading Documents
Component Name and Function
DADF Level Sensor Tray Motor
Bottom Sensor
Tray Interlock
Figure 11 DADF 1
Feeder Cover Interlock Switch Document Set LED
Document Set Sensor
L/H Cover Interlock Sensor
Figure 12 DADF 2
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Tray APS Sensor 1 Tray APS Sensor 3
Tray APS Sensor 2
Figure 13 DADF Tray The Tray Motor is the stepper motor that rotates CCW to make the document tray rise, and rotates CW to make it lower. The DADF Level Sensor senses that the document tray has risen. The Bottom Sensor senses that the document tray is lowered. The Tray Interlock Sensor detects whether the document tray is opened or closed. The Document Set LED lights when the document tray is loaded with documents. The Document Set Sensor detects whether or not there are any documents in the tray The Feeder Cover Interlock Switch detects whether the Feeder Cover is open or closed. The L/H Cover Interlock Sensor detects whether the L/H Cover is open or closed. The Tray APS Sensor 1 senses the size of a document in the fast scan direction, based on the position of the document tray guides The Tray APS Sensor 2 senses the size of a document in the fast scan direction, based on the position of the document tray guides. The Tray APS Sensor 3 senses the size of a document in the fast scan direction, based on the position of the document tray guides.
Operation When Documents are Loaded When documents are properly loaded in the document tray, with their lead edges against the left side, the Document Set Sensor senses them. When the Start Copy button is pressed and documents are sensed in the tray or when documents are loaded, depending on the settings, the Tray Motor rotates CCW and raises the tray. When the top of the documents on the tray pushes up the Nudger Roll, the actuator blocks the DADF Level Sensor. This state means that the tray has reached the document feed position. The Tray Motor stops and documents start feeding from the tray.
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As documents are fed, the stack of documents is reduced in height. When this lowers the Nudger Roll enough to unblock the DADF Level Sensor, the Tray Motor rotates CCW and raises the tray to maintain the feed position. When all the documents are fed out the Document Set Sensor is blocked. The Tray Motor rotates in the CW direction to lower the tray. When the tray has lowered, the actuator blocks the Bottom Sensor, under the tray. The Tray Motor stops. At the same time the Document Set LED is turned off.
Document Size Sensing Document width sensing is based on the combinations of the sensors mentioned in Table 9 Table 9
Type
Sensor Name
How to sense
Sensor that senses width between doc guides
Tray APS Sensor 1 The Rack Gear and Actuator that move in Tray APS Sensor 2 synch with the doc tray guides make light blocked from each sensor or make light Tray APS Sensor 3 received by each.
Sensor that senses size of running paper in fast scan
No. 1 APS Sensor
Light is blocked from/received by each sensor during paper transportation.
No. 2 APS Sensor No. 3 APS Sensor
The guide width sensing is based on combinations of blocked and unblocked Tray APS Sensors 1 through 3. This is done through the movement of the side guides. Table 10 shows the states of the sensors based the width of the document. Table 10
Size in Fast Scan
Tray APS Sensor 1
Tray APS Sensor 2
Tray APS Sensor 3
297.0mm
H
L
H
279.4mm
H
L
L
266.7-267mm
H
H
L
254-257mm
H
H
H
215.9mm
L
L
H
210mm
L
L
L
203.2mm
L
H
L
182-194mm
L
H
L
139.7-148mm
L
H
H
Document size in the fast scan direction is determined when the lead edge of a document reaches the Pre Regi Sensor during the feed preregistration operation. The result of this document size sensing is sent to the IISS.
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Document length in the slow scan direction starts measurement when the document arrives at the Pre Regi Sensor. At this time the pulses of the Pre Regi Motor start being counted. When the trail edge of the document es the Feed Sensor the counting stops. The pulse count is then calculated to determine the length of the document in the slow scan direction.
Document Feed and Registration
Component Name and Function DADF Feed Clutch
DADF Feed Motor DADF Feed Sensor
Figure 14 DADF Feed 1
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DADF Pre Regi Motor
No2 APS Sensor
Pre Regi Sensor
No1 APS Sensor No3 APS Sensor DADF Regi Motor
Figure 15 DADF Feed 2
Lead Regi Sensor
Baffle Solenoid DADF Regi Sensor
Figure 16 DADF Registration The DADF Feed Motor is the stepper motor that rotates the Nudger Roll and the Feed Roll CCW and the Invert Roll in both directions The DADF Feed Clutch transfers drive from the DADF Feed Motor to the Nudger Roll and the Feed Roll The DADF Feed Sensor is located just behind the Feed Roll and sensed that a document feed out is finished. This triggers the start/end of pre-feed
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The DADF Pre Regi Motor is the stepper motor that drives the Takeaway Roll and the Pre Regi Roll CCW. The Pre Regi Sensor senses that the previous document has let the Pre Regi Roll and triggers the start of pre-registration of the next document. The No 1 APS Sensor senses the size of a document in the fast scan direction. The No 2 APS Sensor senses the size of a document in the fast scan direction. The No 3 APS Sensor senses the size of a document in the fast scan direction. The DADF Regi Motor is the stepper motor that drives the Regi Roll in both CCW and CW directions The DADF Regi Sensor senses that the document has left the Regi Roll. The Lead Regi Sensor senses the lead edge of a document immediately before scanning starts. The Baffle Solenoid releases the baffle to prevent damage to a document forming a buckle.
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First Document Pre-feed When the DADF Feed Motor starts and the DADF Feed Clutch turns on, the drive from the DADF Feed Motor is transferred to the Nudger and Feed Rolls. The Nudger Roll moves the document to the nip of the Feed and Retard Rolls. When the lead edge of the document reaches the Takeaway Roll, the DADF Feed Clutch turns off. When the DADF Feed Sensor detects the trail edge of the document, the next document starts pre-feed.
Second and Subsequent Document Pre-feeds When the DADF Feed Motor starts and the DADF Feed Clutch turns on, the drive from the DADF Feed Motor is transferred to the Nudger and Feed Rolls. The Nudger Roll moves the document to the nip of the Feed and Retard Rolls. When the DADF Feed Sensor detects the lead edge of a document, the DADF Feed Clutch turns off. This makes the document stop 5mm short of the Takeaway Roll. The remaining documents pre-feed in the same manner making the DADF faster.
Pre-registration The Feed Roll and Nudger Roll transport a pre-fed document to the Takeaway Roll. The Takeaway Roll transports the document to the Pre Regi Roll increasing its speed. The Pre Regi Roll drives the document and makes the lead edge of the document strike against the Regi Roll. Since the Regi Roll stops the document, and the trail is still being driven, this causes a buckle in the document. This corrects any skew in the document. After a specified time the Regi Motor drives the Regi Roll and transports the document to the scan position.
Preventing Document Damage If a document forms a buckle with its lead edge caught by the Regi Roll, it may cause damage to the document. To prevent this, the Regi Roll is rotated backwards for a brief period when the lead edge of the document strikes it. When the document forms a buckle the Pre Regi Roll captures its trail edge. If there is any strain of the document at that time it can cause damage to the document. To prevent this, the sliding rail allows the Pre Regi Roll to move freely in the direction of document movement and the Baffle Solenoid releases the baffle. If any load is on the document in the chute when it forms a buckle, it may cause damage to the document. To prevent this, the Regi Sensor On signals the Baffle Solenoid to lift the baffle.
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Techniques for Preventing Damage to Documents To prevent damage to documents, the three techniques are adopted. See Figure 17.
Rotating Regi Roll backward If a document forms a buckle with its lead edge caught by Regi Roll, it may cause damage to the document. To prevent this, Regi Roll is rotated backward for a moment when the lead edge of the document strikes there. This prevents the lead edge of the document from being caught by Regi Roll.
Pre Regi Roll’s free drive When the document forms a buckle, Pre Regi Roll captures its trail edge. If any load is on the document at this time, it may cause damage to the document. To prevent this, the sliding rail allows Pre Regi Roll with the captured trail edge to move freely in the direction of drive.
Releasing Baffle If any load is on the document in the chute when it forms a buckle, it may cause damage to the document. To prevent this, triggered by Regi Sensor On, the Baffle Solenoid operates and releases Baffle.
Figure 17 DADF Deskew
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Document Scanning and Output Component Name and Function
Invert Sensor 1
Platen Motor
Invert Sensor 2
Simp/Dup Gate Solenoid
Out Sensor Figure 18
CIS
CIS DC/DC Convert PWB
1P Duplex PWB
Figure 19
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DADF Exit Motor DADF Exit Sensor 2 Exit Roll Nip/Rls. Solenoid
DADF Exit Sensor 1
Exit Gate Solenoid
Figure 20
The Platen Motor drives the Platen Roll and the Out Roll to transport a document through the Scan Position. The Out Sensor detects the position of the document after the scan position. The Inverter Sensor 1 detects the document moving towards the Invert Roll. The Inverter Sensor 2 detects the document after it es the Invert Roll The Sip/Dup Solenoid operates the Sip/Dup Gate. The CIS DC/DC Convert PWB supplies power to the CIS. The CIS scans side two of a document. The 1P Duplex PWB controls the CIS through the CIS DC/DC Convert PWB. The DADF Exit Sensor 1 detects the lead and trail edges and signals for switching the output speed. The DADF Exit Sensor 2 detects the document that has ed Exit Roll 2. The DADF Exit Motor drives the Exit Roll. The Exit Gate Solenoid operates the Exit Gate. The Exit Roll Nip/Release solenoid controls the Inverter Roll’s nip.
Document Scanning Operation For Side 1 scanning, the Regi Motor drives the Regi Roll to feed a document to the Scan Position. At this time, the Pre Regi Motor drives the Pre Regi Roll and Takeaway Roll so that they can transport the document with its buckle retained, between Regi Roll and Pre Regi Roll. The Platen Motor drives the Platen Roll and Out Roll. The Platen Roll and Out Roll drive the document through the Scan Position. Receiving drive from Exit Motor, Exit Roll 1 transports the document that has left the Scan Position at scan speed. Triggered by the Pre Regi Sensor Off, the Baffle Solenoid closes the Baffle in preparation for the Pre-Registration operation of the next document Immediately after the document es the Scan Position, the CIS scans side 2.
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CIS Scanning
Figure 21 CIS Example A CIS ( Image Sensor) is an array of LEDs and sensors used to scan a document. CIS scanners gather light from red, green and blue LEDs (which combine to provide white light) and direct the light at the original document being scanned. The light that is reflected from the original is gathered by a Selfoc lens, with a very sort focal length, and directed at an image sensor array that rests close to the document being scanned. The sensor then records the images according to the intensity of light that hits the sensor. Figure 21 is an example of a CIS. In the Xerox 4110 the CIS DC/DC Convert PWB supplies power to the CIS. The CIS scans side two of a document. The 1P Duplex PWB controls the CIS through the CIS DC/DC Convert PWB. Recorded images are stored on the Extension Memory PWB.
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Document Transportation Figure 22 shows the path of a document from the document tray through delivery to the output for 1 two sided. To observe the 1-sided scan, which requires the document to be inverted, look at the animations in the EPSS CD.
Figure 22
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(Chain 6) Imaging
Introduction This module describes the names, locations, and functions of the Chain 6 Imaging. The main function of the Chain 6 consists of the IIT (document scan) and the ROS (image exposure data). The main functions are as follows: To have the Exposure Lamp scan a document and expose it to light. To have the CCD Image Sensor read and convert the analog image data into digital image data. To send the digital image data to the Controller (ESS). The first three items are functions of the IIT. To generate laser beams based on the image data from the Controller. To generate the latent electrostatic image on the drum using raster scanning with the laser. The last two items are functions of the ROS. The Xerox 4110 IIT has color scanning capability that is not currently used.
IIT/IPS The main functions of the IIT (Image Input Terminal) and the IPS are as follows: Initializing at power on. Document Size sensing Document Scanning Operation (scanning an image on the platen glass). Image processing.
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Technical Overview
IPS PWB PSDC PWB
1P Duplex PWB Extension Memory PWB
Figure 23
The IPS PWB is explained in Chain 3, Machine Run Control. The Extension Memory PWB controls the image data that the CCD Image Sensor has read and the image data from the 1P Duplex PWB. The Extension Memory PWB is loaded with memory. It writes data into memory and reads it out from the memory as required. The 1P Duplex PWB is thoroughly explained in Chain 5 DADF. The PSDC supplies a DC voltage to the Extension Memory PWB and the 1P Duplex PWB.
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Lamp Fan
IPS Fan
Lens and CCD
CCD Fan
Exposure Lamp
Lamp Ballast PWB
Figure 24
The Exposure lamp is a xenon lamp that exposes the document to light The Lamp Ballast PWB controls the on/off of the lamp using a signal from the IPS PWB. The Lens receives the scanned image and es it to the CCD Image Sensor. The CCD Image Sensor converts the analog image data received from the lens and converts it to digital data. The Lamp Fan prevents the temperature of the Exposure Lamp from rising when the lamp is still and the CVT is used to scan an image (DADF Operation). The IPS Fan prevents the temperature of boards such as the IPS PWB and the Extension Memory PWB from rising. The CCD Fan prevents the temperature of the CCD Image Sensor from rising.
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Carriage Motor Platen Angle Sensor
IIT Regi Sensor
APS Sensor2 APS Sensor1 Platen Interlock Switch
Figure 25 The APS Sensor 1 detects the document length in the slow scan direction. The APS Sensor 2 detects the long document length in the slow scan direction. The Platen Interlock Switch monitors the opening and closing of the Platen Cover or DADF. It also is used to determine when to read the size of a document on the platen glass. The Platen Angle Sensor monitors the Platen Cover or DADF to see what angle either of them is open. It also is used to determine when to read the size of a document on the platen glass. The Carriage Motor is the stepper motor that drives the Full Rate Carriage and the Half Rate Carriage. The IIT Regi Sensor detects the position of the Full Rate Carriage. The lower portion at the rear of the Full Rate Carriage functions as an actuator to block the IIT Regi Sensor.
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Document Scanning Overview Half Rate Carriage
No.2 Mirror
Full Rate Carriage Exposure Lamp No.1 Mirror
Lens and CCD
A IIT Regi Sensor
Carriage Motor
No.3 Mirror
Figure 26
The Full Rate Carriage and the Half Rate Carriage move to scan the document. The Exposure Lamp is installed on the Full Rate Carriage and is used to illuminate and expose the document on the platen glass. The Half Rate Carriage is linked to the Full Rate Carriage and moves half the distance. The analog image of the exposed document is reflected off the Number 1 Mirror on the Full Rate Carriage and the Number 2 Mirror and Number 3 Mirror on the Half Rate Carriage. From there, it is reflected through the Lens to the CCD Sensor and converted to a digital image.
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Document Scanning Position Overview (DADF) The Full Rate Carriage moves so the IIT can perform operations that will be discussed later. Figure 27 shows the position where the operations are performed.
White Ref Board Position Regi Position for Control White Ref Board Startup Position
Platen Regi Position
CVT Scan Position
• • •
•
AGC/AOC/Shading 1 Position Platen Scan White Fluctuation Adjust Position Platen Scan Black Fluctuation Adjust Position CVT Scan White Fluctuation Adjust Position (Monitor of light qty before job) (Platen/CVT Mode Overall
Magnification)
Doc Size Sensing Position
Full Rate Carriage IIT Regi Sensor
Shading 2 Position • (Platen/CVT Mode Overall Magnification) Figure 27
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Initialization At power on or when the machine returns from the power saver mode, the IIT performs an initialization of the carriage. Figure 28 shows the initialization operation Power ON .
Initializes Carriage Sets Full Rate Carriage at the white ref board position.
Exposure Lamp ON
Performs AGC
Carriage Initialization When the Full Rate Carriage is on the left side of the control regi position (closer to the startup position): The Full Rate Carriage is moved to the right side of the control regi position then to the left, and finally positioned at the white reference board position. When the Full Rate Carriage is on the right side of the control regi position (document size sensing position): The Full Rate Carriage is moved to the white reference position, then to the right side of the control regi position, and then left as far as the white reference board position.
Exposure Lamp OFF
Performs AOC.
Exposure Lamp ON
Acquires Shading Correction Data.
Adjusts White Fluctuation Adjust Reference Data Exposure Lamp OFF
Moves Carriage Sets Full Rate Carriage at the doc size sensing position
Standby Figure 28
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Document Size Sensing The CCD Image Sensor senses the width of a document (size in the fast scan direction) and the APS Sensors sense the length of a document (size in the slow scan direction). The size of a document is sensed when the Platen Cover is closed or when Start is pressed with the Platen Cover open. The CCD Image Sensor senses the width of the document in millimeters and determines the size in the fast scan direction. The APS Sensors detect whether there are any document of the same size in the fast scan direction. As a result, LEF (long edge feed) SEF (short edge feed) are determined APS Sensors 1 and 2 are capable of distinguishing 8.5 x 11 SEF, 8.5 x 13 SEF and 8.5 x 14 SEF from each other. Table 11 shows the standard sizes that can be sensed by the IIT. Table 11 Fast Scan Width (mm)
APS Sensor 1
APS Sensor 2
100
OFF
OFF
Fast Scan Size Sensing Range (mm) 90-115
OFF OFF OFF OFF OFF OFF ON
OFF OFF OFF OFF OFF OFF OFF
ON
-
ON
-
A4SEF
101.6 105 127 128 139.7 148 182 Taiwan) 194.0*9 GCO) 195.0*9 210
ON
- *18
8.5x11SEF*2
215.9
ON
OFF
8.5x12.4SEF*13 8.5x13SEF*13
215.9 215.9
ON ON
ON ON
8.5x14SEF*13 B4SEF
215.9 257 Taiwan) 267.0*9 GCO) 270.0*9 279.4 279.4
ON ON ON
ON ON -
Standard Doc Size Official postcard SEF*7 Post Card SEF*7 A6SEF*7 5x7SEF*15 B6SEF*15 5.5x8.5SEF*1 A5SEF*1 B5SEF 16 Fold SEF*10
8 Fold SEF*10 11x14.9SEF*4 11x17SEF*4*5 A3SEF*5 Official postcard LEF*1 Post Card LEF*1
44
mm
mm-2
Inch 13-1
Inch 13-2
Inch 14
∆*7
∆*7
×
×
×
90-115 90-115 115-134 115-134 134-163 134-163 163-202
× o*7 ∆*15 o*15 × o*1 o
× o*7 ∆*15 o*15 × o*1 o
∆*7 o*7 ∆*15 o*15 × o*1 o
∆*7 o*7 ∆*15 o*15 × o*1 ×
o*7 ∆*7 ○*15 ∆*15 o*1 × ×
188-202
o *9*10
▲ *9*10
×
×
×
202213*3 213*3226 202-226 202-226
o*3
o*3
o*3
×
×
▲*2* 3 × ×
▲*2* 3 × ×
○*3
○
○
∆*13 o*13
∆*13 ∆*13
202-226 226-267
× o*11
× o*11
∆*13 o*3*1 3 ∆*13 o
∆*13 ×
o*13 ×
o*10* 9*11 *12
▲*10 *9*11 *12
×
×
×
× ▲*5
∆*4 o*4
∆*4 o*4
∆*4 o*4
o*5 ∆*1
o ×
o ×
o ×
×
∆*1
∆*1
∆*1
ON
-
262*11275*12
ON ON
ON ON
267-289 267-289
297 148
ON OFF
ON -
289-307 138-163
× o*5*1 2 o*5 ∆*1
152.4
OFF
OFF
134-163
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Standard Doc Size
Fast Scan Width (mm)
APS Sensor 1
APS Sensor 2
B6LEF*14 B5SEF A5LEF
182 182 210
OFF OFF OFF
OFF OFF OFF
5.5x8.5LEF*2
215.9
OFF
OFF
8x10LEF*6 B5LEF*6
OFF OFF OFF
OFF OFF -
Executive LEF*6
254 257 Taiwan) 267.0*9 GCO) 270.0*9 266.7
8x10.5LEF*6
16Fold LEF*10
OFF
-
OFF
OFF
266.7
OFF
OFF
8.5x11LEF*8
279.4
OFF
OFF
A4LEF
297 OFF OFF ⊄ο…can be sensed.
Fast Scan Size Sensing Range (mm) × 163-202 202213*3 213*3226 226-262 226-262 262*11275*12 262275*12 262275*12 275*12289 289-307
Inch 13-1
Inch 13-2
Inch 14
o*14 o*3 ▲*2* 3 ×
× o*3 o*3
× × o
× × o
∆*6-1
∆*6-1
∆*6-1
o*11
o*11
o*6-2
×
×
o*10* 9*11 *12
▲*10 *9*11 *12
×
×
×
×
×
×
×
×
∆*6-1
o*6-2 *12 ∆*6-1
o*6-2 *12 ∆*6-1
o*8*1 2 o*8
▲*8
o
o*12
o*12
o*8
o
o
o
mm
mm-2
o*14 o*3 ▲*2* 3 ×
∆…can be sensed with other sizes unavailable ▲…can be sensed with the range of other sizes for sensing narrowed in NVM. ×…cannot be sensed (determined as another size or undetermined) *1: In NVM “A5SEF or Postcard” or “Official postcard LEF or Postcard LEF” can be selected. *2: In NVM “8.5x11SEF & 5.5x8.5LEF” available or unavailable for size sensing can be selected. *3: In NVM Fast Scan Threshold (213mm) for “A4SEF & A5LEF” and “8.5x11SEF & 5.5x8.5LEF” can be changed with “8.5x11SEF & 5.5x8.5LEF” available for sensing. (To prevent faulty sensing) *4: In NVM “11x17SEF” or “11x14.9SEF” can be selected. *5: In NVM “A3SEF” or “11x17SEF” or “Mix of A3SEF & 11x17SEF” can be selected. *6: In NVM “B5LEF or Executive LEF” or “Mix of 8x10LEF & 8x10.5LEF” or “B5LEF or Executive LEF, and 8x10LEF, and 8x10.5LEF unavailable for sensing” can be selected. *7: In NVM “A6SEF” or “Official postcard SEF (mm table) or Postcard (Inch table) “ can be selected. *8 In NVM “A4LEF” or “8.5x11LEF” or “Mix of A4LEF & 8.5x11LEF” can be selected. *9: In NVM “Taiwan” or “GCO “ can be selected as 16 Fold/8 Fold Size. *10: In NVM “16 Fold & 8 Fold” available or unavailable for sensing can be selected. *11: In NVM Fast Scan Threshold (262mm) for “B4SEF & B5LEF” and “16 Fold LEF & 8 Fold SEF” can be changed with “16 Fold & 8 Fold” available for sensing. (To prevent faulty sensing) *12: In NVM Fast Scan Threshold (275mm) for “8.5x11LEF & 11x17SEF” and “16 Fold LEF & 8 Fold SEF” can be changed with “16 Fold & 8 Fold” available for sensing. (To prevent faulty sensing)
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*13: In NVM “8.5x12.4SEF” or “8.5x13SEF” or “8.5x14SEF” can be selected. *14: In NVM “B6LEF” available or unavailable for sensing can be selected. *15: In NVM “B6SEF” or “5x7SEF” can be selected. *16: In NVM Fast Scan Threshold (226mm) for “A4SEF” and “B4SEF” can be changed. *17: In NVM Fast Scan Threshold (275mm) for “B4SEF” and “A3SEF” can be changed. *18: Undetermined because a border is sensed by APS Sensor 2
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Platen Document Scanning Operation When a document is to be scanned, the IIT performs the scanning after the size is sensed. Figure 29 shows the flow of document scanning. Size sensing is over.
Moves Carriage Sets Full Rate Carriage at White Ref Board Position.
Acquires/Sets Black Fluctuation Adjust Data. Exposure Lamp ON
Acquires/Sets White Fluctuation Adjust Data.
Performs Pre-scan. With pre-scan enabled. Acquires B/W Fluctuation Adjust Data.
Moves Carriage Sets Full Rate Carriage at Startup Position.
Image Scanning Operation Moves Full Rate Carriage to the end of the image area
Exposure Lamp OFF
Figure 29
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After scanning the document, the IIT performs the operation shown in Figure 30.
Scanning is over.
Stops Carriage.
(To reduce an effect of residual vibration on the carriage. No (more)
Is the time from when the last shading correction to the end of scanning a specified time or less? Moves Carriage. Sets Full Rate Carriage at White Ref Board Position. Yes Performs AGC. Performs AOC. Acquires Shading Correct Data. Acquires White Fluctuation Adjust Data.
Moves Carriage. Sets Full Rate Carriage at Doc Size Sensing Position.
Standby
Figure 30
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DADF Document Scanning Operation To scan documents from the DADF, the Full Rate Carriage operation flows as shown in Figure 31. DADF finishes size sensing. Carriage moves. Full Rate Carriage is set at White Ref Board Position. Exposure Lamp ON White Fluctuation Adjust Data is acquired/set. Exposure Lamp OFF Carriage moves. Full Rate Carriage is set at CVT Scanning Position.
Black Fluctuation Adjust Data is acquired/set.
Exposure Lamp ON
White Fluctuation Adjust Data is acquired/set. CVT Image Scanning is performed (DADF) Exposure Lamp OFF
Yes
Is there another document? No
To the operation at the end of doc scanning Figure 31
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After the DADF document is scanned, the carriage operation flows as shown in figure 32.
CVT Image Scanning is over. Full Rate Carriage is set at the control regi position.
Is the time from when the last shading correction to the end of image scanning a specified time or less?
No (more)
Carriage moves. Full Rate Carriage is set at White Ref Board Position. Yes Shading Correct Data is acquired. White Fluctuation Adjust Data is acquired.
Carriage moves. Full Rate Carriage is set at Doc Size Sensing Position.
Standby
Figure 32
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Adjustments or Corrections During Scanning The CCD Image Sensor reads image data from the document. To stabilize the image data, an adjustment is made to the CCD Image Sensor output and a correction to the image data. The CCD Image Sensor output is adjusted through the adjustment of the gain/offset voltage of the amplifier in the analog circuit. This adjustment is AGC and AOC. The reference data is acquired and the correction values are calculated to correct the image data. This data includes Shading correction, White Fluctuation adjustment, and Black Fluctuation adjustment. The following is a description of the adjustments and corrections.
AGC (Auto Gain Control) White Level Rough Adj. The AGC is the function that adjusts the gain so that when the Exposure Lamp is on, the CCD Image Sensor output value can be the target value. The AGC makes a rough adjustment of the white level of the image. The AGC is performed at initialization. With the Exposure Lamp on, the CCD Image Sensor reads on line of image data on the white reference board in the fast scan direction. The average of the readings is obtained, and it is compared with the target AGC value. If the average is not within specification, the gain is adjusted repeatedly per the same procedure until the average is within specification.
AOC (Auto Offset Control) The AOC is the function that adjusts the offset voltage so that when the Exposure Lamp is off, the CCD Image Sensor output value can be the target value. The AOC adjusts the black level of the image. The AOC is performed at initialization. With the Exposure Lamp off, the CCD Image Sensor reads several lines of image data on the white reference board in the fast scan direction. The difference between the average of the readings and the target AOC value is calculated and treated as the offset voltage.
Shading Correction The Shading Correction is the function that adjusts variations in the sensitivity of individual CCD Image Sensor pixels, as well as variations in the output values of individual CCD Image Sensor pixels that are caused by the optical systems non-uniform illumination in the fast scan direction. Shading corrections are performed at initialization.
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White Fluctuation Adjustment To adjust fluctuations in the light quantity of the Exposure Lamp, the white fluctuation adjustment is performed. The White Fluctuation adjustment consists of two processes; acquisition of the white fluctuation adjustment reference data at initialization and the white fluctuation adjustment during document scanning. The acquisition of the data happens when the Exposure Lamp is on and the CCD Image Sensor reads one line of image data on the white reference board in the fast scan direction. The average of the readings is treated as the white fluctuation adjustment reference data. The adjustment happens when the Exposure Lamp is on and the CCD Image Sensor reads one line of image data on the white reference board in the fast scan direction. The average of the readings is compared with the white fluctuation adjustment reference data so that a white level correction coefficient is calculated. With the DADF in use, the white fluctuation adjustment is performed, at both the platen white reference board position and the CVT scanning white reference board position.
Black Fluctuation Adjustment The black fluctuation adjustment is performed to adjust the fluctuations in the black level. The temperature drift of the CCD Image Sensor and the analog circuit cause these. With the Exposure Lamp off, the CCD Image Sensor reads several lines of the image data on the white reference board in the fast scan direction. From the readings, a black level correction coefficient is calculated. When using the platen. The black fluctuation adjustment is performed at the platen white reference board position. When using the DADF the CVT scanning position is used.
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Dark Band Elimination
Figure 33 Dark Band Elimination To prevent the occurrence of dark-band, the Xerox 4110 scanner uses two closely located sensors, a black/white sensor and the green sensor of the RGB color sensor. Both sensors receive the scanned image. If the sensors do not read the same image, it is judged as dust and the corresponding image data is eliminated from the scanned image data by the corrections made in the algorithm.
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Image Processing The image data read by the CCD Image Sensor is processed in the IPS PWB before being sent to the Controller, as shown in Figure 33.
X-Pro (ASIC WOZ2) Conversion of Detected Color Space Brightness→Lab
CCD
Input Correct
Density Adjust
Shading Correct B/W level correct CCD gap correct CVT streak correct CVT mirror image correct
Reflectance→ brightness Negative image editing AE removal
Color Space Convert Doc noise filter out Brightness→ Lab b correction
Detection Fast S. doc detect ACS Background level Doc density Doc noise
Resolution Convert Fast Scan enlarge/reduce Slow S. reduce
Fast Scan Mirror image Shift Repeat
Filter Space filter Edge detect Ghost correct Tag create
MWA/AER
Color Convert
TRC
ED
Adjustments (density/ contrast/color saturation/hue) Background suppress
L-γ correction Lab →XXXX Gamut mapping Black printer create Mono color create ２ colors create
Color balance adjust YMC Kγcorrection
Error diffusion binarize Dither matrix binarize (For multi-valued mode, through) Border erase, Center border erase
Figure 34
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Fan Control Temperature rise is prevented using two fans, the IPS Fan and the Lamp Fan. The fans are on as indicated below Lamp Fan At IIT power on it is at high speed then stops in 5 seconds During platen image scanning it is off During CVT image scanning it is at high speed At standby and any other operations it is off IPS Fan At IIT power on it is at high speed then goes to low speed after 5 seconds During platen image scanning it is on at high speed During CVT image scanning it is on at high speed At standby and any other operations it is at low speed
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ROS The ROS (Raster Output Scanner) emits a laser beams from laser diodes. The on/off emission of the beams is based on image density data from the controller on the ESS PWB. The laser beams are used to create a latent image on the drum surface. Warning – The laser beam is invisible and hazardous to the human eye. Before making and observation of the ROS ensure that the machine is powered off.
ROS Overview The ROS has a six-facet polygon mirror. The ROS exposes the drum to light using 32 beams to scan at the same time. The ROS uses a two-dimension array to do this. The array consists of 32 laser diodes, four in the fast scan direction and eight in the slow scan direction. This is shown in Figure 35.
Slow Scan direction Fast Scan direction LD×32
Figure 35
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ROS Components The ROS components are shown in Figure 36 Caution – Never open the cover. The ROS requires a high level of mechanical precision. Because of this, there are no adjustments on the inside. If the ROS unit is defective, the assembly should be replaced. The SOS PWB and the MPD PWB can, however, be replaced Lens L2
Drum Mirror1 Flat Mirror
Lens L1 Polygon Mirror
SOS PWB ROS Motor
SOS Lens MPD Lens Drum Mirror2
MPD PWB Slit LDD PWB
Drum
Cylinder Lens Wedge
Window SOS Mirror Figure 36 ROS
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The LDD PWB is equipped with 32 laser diodes and it controls the diodes. The LDD PWB is connected to the MCU PWB through which it receives image data from the ESS PWB. The LDD PWB receives a control signal through the MCU PWB. The ROS Motor drives the polygon mirror. The SOS PWB is equipped with the SOS Sensor. The SOS Sensor produces the SOS (Start Of Scan) signal that determines where exposure starts in the fast scan direction. The MPD (Monitor Photo Diode) PWB monitors the light quantity of the laser diode based on incident laser beams
Laser Beam Flow The laser beams become a little diffused by the Collimate Lens (between the Slit and the LDD PWB). The laser beams that have ed through the slit; through the Wedge to the Cylinder Lens. The Cylinder Lens converges the beams to the Polygon Mirror. The laser beams are also reflected off the Wedge and through the MPD Lens for monitoring by the MPD PWB. The Polygon Mirror is a six faceted mirror that rotates at a high speed. The ROS Motor drives the mirror. The rotation of the mirror changes the incidence and reflection angles of the laser beams. This causes the laser beams to scan the Drum from front to rear. The laser beams, from the Polygon Mirror, through lenses L1 and L2 to the Flat Mirror. The laser beams from the Flat Mirror are reflected off the Cylinder Mirrors 1 and 2 and through the window to the Drum surface. When the laser beams start, the one that is deflected closest to the front goes to the SOS Mirror. The SOS Mirror reflects the beam through the SOS Lens to the SOS Sensor. When the SOS Sensor detects the beam, it produces the SOS Signal
Laser Diode Control The laser diode output is controlled by APC (Auto Power Control) and switching control. This is done automatically by using the MCU PWB to control the LDD PWB. The APC automatically adjusts the laser diode light quantity during printing to be equal with a preset value. At certain times this is used to lighten or darken the image as explained in process control in the Marking Module.
ROS Motor Control The ROS Motor is the DC motor that drives the polygon mirror CCW. The MCU PWB controls the motor. The motor turns on when it receives a Cycle Up signal. It turns off after the end transmitting the final image in a series at a specified time after receiving the Cycle Down signal.
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(Chain 7)
Paper Supply
Introduction This module describes the names, locations, and functions of the Chain 7 Paper Supply. It then describes the names, locations, and functions of the Chain 7 Paper Supply components. The main functions of this module are: Tray specifications The layout of the paper transportation path from each tray to the exit Sensing the size of the paper in each tray Raising the trays to the feed position
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Tray Specifications Configuration The paper trays are referred to as shown n Figures 37 and 38.
MSI
Tray2
Tray3 Tray1
Tray 4
Figure 37 Standard Configuration
Tray5 (MSI)
Tray6 (HCF Tray1)
Tray7 (HCF Tray2)
Figure 38 With HCF The paper supply area consists of Trays 1, 2, 3, 4, and MSI as standard. The HCF is an option with Trays 6 and 7. The MSI is relocate to the top.
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Allowable Paper Sizes Table 12 shows the sizes of paper that the trays can hold. The X’s are where not to use and the O’s are where it can be used. Table 12 Paper Sizes Paper Size Standard
Official Postcard SEF Reply-paid postcard SEF A6 SEF B6 SEF A5 SEF A5 LEF B5 SEF B5 LEF A4 SEF A4 LEF A4-Cover SEF A4-Cover LEF Special A4 SEF Special A4 LEF B4 SEF A3 SEF SRA3 SEF Special A3 SEF 4”x6” SEF 5”x7” SEF 5.5”x8.5” SEF 6”x9” SEF 6”x9” LEF 7.25”x10.5” SEF 7.25”x10.5” LEF 8”x10” SEF 8”x10” LEF 8.46”x12.4” SEF 8.5”x11” SEF 8.5”x11” LEF 8.5”x13” SEF 8.5”x14” SEF 9”x11” SEF 9”x11” LEF 11”x15” SEF 11”x17” SEF 12”x18” SEF 12.6”x19.2” SEF 13”x18” SEF 13”x19” SEF 16 Fold SEF (TFX)
○
HCF 1 ×
HCF 2 ×
×
○
×
×
× × ○ × ○ ○ ○ ○ × × × × ○ ○ ○ × × × ○ × × × ○ ○ × × ○ ○ ○ ○ × × × ○ ○ ○ ○ ○ ×
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
Dimensions [mm] 100.0x148.0
Tray 1 ×
Tray 2 ×
Tray 3 ×
Tray 4 ×
148.0x200.0
×
×
×
105.0x148.0 128.0x182.0 148.0x210.0 210.0x148.0 182.0x257.0 257.0x182.0 210.0x297.0 297.0x210.0 223.0x297.0 297.0x223.0 226.0x310.0 310.0x226.0 257.0x364.0 297.0x420.0 320.0x450.0 328.0x453.0 101.6x152.4 127.0x177.8 139.7x215.9 152.4x228.6 228.6x152.4 184.2x266.7 266.7x184.2 203.2x254.0 254.0x203.2 215.0x315.0 215.9x279.4 279.4x215.9 215.9x330.2 215.9x355.6 228.6x279.4 279.4x228.6 279.4x381.0 279.4x431.8 304.8x457.2 320.0x488.0 330.2x457.2 330.2x482.6 194.0x267.0
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
× × × × × ○ × ○ × × × × × × × × × × × × × × ○ × × × × ○ × × × × × × × × × × ×
× × ○ × ○ ○ ○ ○ × × × × ○ ○ ○ × × × ○ × × × ○ ○ × × ○ ○ ○ ○ × × × ○ ○ ○ ○ ○ ×
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Dimensions [mm] 267.0x194.0
Paper Size
Standard
Nonstandard
16 Fold LEF (TFX) 8 Fold SEF 267.0x388.0 (TFX) 16 Fold SEF 195.0x270.0 (GCO) 16 Fold LEF 270.0x195.0 (GCO) 8 Fold SEF 270.0x390.0 (GCO) Envelop Length 120.0x235.0 No. 3 SEF 139.7 width 330.0 182.0 length 488.0 100.0 width 330.0 148.0 length 488.0 297.0 width 330.0 210.0 length 241.0 o = can be fed x = can’t be fed
○
HCF 1 ×
HCF 2 ×
○
○
×
×
×
×
○
×
×
×
○
○
○
×
×
×
×
○
○
○
×
×
×
×
×
×
○
×
×
×
×
○
○
○
×
×
×
×
×
×
○
×
×
×
×
○
○
○
○
○
Tray 1 ×
Tray 2 ×
Tray 3 ○
Tray 4 ○
×
×
○
×
×
×
MSI
Tray Capacity Table 13 shows the amounts of paper, according to size, that each tray can hold Table 13 Tray Capacity
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Tray
Stack Height [mm]
Paper Quantity [sheets]
Tray1 Tray2 Tray3 Tray4 MSI HCF1 HCF2
120 175 60 60 27 220 220
80gsm 1100 1600 550 550 250 2000 2000
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Paper Weights Table 14 shows the weights of paper that the trays, the inverter and the duplex path can feed or transport. The X’s are where not to use and the O’s are where it can be used. Table 14 Paper Weights Paper Type Plain paper 64-105 [gsm] Heavy paper 106-216 [gsm] Heavy paper 217-253 [gsm] Carbonless 52-63 [gsm] Transparency Tab (Heavy 1) Tab (Heavy 2) Label Back side of used paper Punched paper
Invert *1
Duplex *1
○
○
Paper type Group*2 Plain
○
○
○
Heavy 1
×
×
×
×
Heavy 2
○
○
○
○
○
Plain
○ ○ ○ ○ ○
× × × × ○
× × × × ○
× ○ × × ○
× × × × ○
OHP Heavy 1 Heavy 2 Label Plain
Paper Feed Tray Tray Tray Tray 1 2 3 ○ ○ ○
Tray 4 ○
MSI
○
○
○
×
×
○ × × × × ○ ○
○
HCF 1 ○
HCF 2 ○
○
○
○
×
×
○
○
○
○
× × × × ○
× ○ × × ○
× ○ × × ○
○ ○ ○ ○ ○ ○ ○ ○ Plain *1 the invert/duplex can transport this paper as long as the paper length is less than 182.2mm *2 this paper type group is a category used for paper feed control.
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Paper Transportation Paper Flow Figures 39 and 40 show the layout of the paper transportation path from each tray.
Figure 39 Path Without HCF
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Figure 40 Path With HCF Paper Path Sensors 1 Tray 5(HCF MSI) Pre Feed Sensor 2 Tray 5(HCF MSI) Feed Out Sensor 3 Tray 6 Pre Feed Sensor 4 Tray 6 Feed Out Sensor 5 Tray 7 Pre Feed Sensor 6 Tray 7 Feed Out Sensor 7 HCF Exit Sensor 8 Feed Out Sensor 1 9 Trans Path Sensor 3 10
Feed Out Sensor 3
11
Feed Out Sensor 4
12
Tray 4 Pre Feed Sensor
13
Tray 4 Level Sensor
14
Tray 4 No Paper Sensor
15
Tray 4 Paper Size Sensor (S5)
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16
Tray 3 Pre Feed Sensor
17
Tray 3 Level Sensor
18
Tray 3 No Paper Sensor
19
Tray 3 Paper Size Sensor (S5)
20
Tray 1 Pre Feed Sensor
21
Tray 1 Level Sensor
22
Tray 1 No Paper Sensor
23
Trans Path Sensor 1
24
Trans Path Sensor 2
25
Feed Out Sensor 2
26
Tray 2 Pre Feed Sensor
27
Tray 2 Level Sensor
28
Tray 2 No Paper Sensor
29
Pre Regi Sensor
30
Side Regi Sensor
31
Side Regi Home Sensor
32
Regi Sensor
33
Duplex Out Sensor
34
Duplex Path Sensor 2
35
Invert Path Sensor
36
Duplex Path Sensor
37
Release Home Sensor
38
Duplex In Sensor
39
F Exit Sensor
40
Invert In Sensor
41
IOT Exit Sensor
42
Invert Out Sensor
Analog Sensors (Switches used in series or parallel with resistors to produce a changeable voltage) A-1
MSI Size Sensor
A-2
Tray 1 Size Sensor
A-3
Tray 2 Size Sensor
A-4
Tray 3 Size Sensor
A-5
Tray 4 Size Sensor
Interlock Switches
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I-1
Front Cover Interlock Switch
I-2
Marking Drawer Interlock Switch
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I-3
Duplex Drawer Interlock Switch
I-4
Trans Path Interlock Switch
I-5
Left Hand Cover Interlock Switch
Drive Motors Figure 41 shows the rolls driven by the different motors
Figure 41 Drive Motors
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Trays 1 through 4 Component Name and Function Tray2 Nudger Solenoid
Tray2 Feed Lift Motor
Tray2 Level Sensor Tray2 Paper Size Sensor
Tray1 Feed Lift Motor Tray1 Nudger Solenoid
Tray2 No Paper Sensor
Tray1 Level Sensor
Tray1 Paper Size Sensor
Tray1 No Paper Sensor
Figure 42 Trays 1 and 2
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Tray3 Feed Lift
Tray3 Nudger Solenoid
Tray3 Paper Size Sensor
Tray3 Level Sensor Tray3 No Paper Sensor
Figure 43 Tray 3 Note: Trays 3 and 4 are functionally the same. This describes 3 only.
Trays 1,2,3 and 4 Paper Size Sensors detect whether the trays are inserted or not and the also sense the size of the paper in the trays. Trays 1,2,3 and 4 No Paper Sensors detect whether the trays contain paper or not. Trays 1,2,3 and 4 Feed Lift Motors are stepper motors the raise the trays by rotating CCW and feed paper by rotating CW. Trays 1,2,3 and 4 Nudger Solenoids raise and lower the Nudger Rolls in the trays. Trays 1,2,3 and 4 Level Sensors sense that the trays have raised to the feed position.
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Trays 1 through 4 Paper Size Sensing Paper size sensing in the trays is accomplished with a combination of on and off operations of the switches that make up the Tray Paper Size Sensors. When the paper guide of any tray is moved, the protrusions at the rear of the tray move with them. When this happens, there is a change in the on and off operations of the switches and how they are combined.
Figure 44 Tables 15 and 16 show the relationship between paper sizes and voltages that are output from the Tray Paper Size Sensors according to the on and off combinations. Trays 1 and 2 have two switches that make their Tray Paper Size Sensors. Table 15 Tray 1/2 Paper Size (Tray pulled out) -(*) B5 LEF or 7.25"x10.5" LEF -(*) 8.5"x11" LEF -(*) A4 LEF -(*) (*) Size is undecided
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Tray Paper Size Sensor AD value AD range value 928 - 1023 956 864 - 927 800 - 863 828 496 - 799 432 - 495 459 368 - 431 304 - 367 334 0 - 303 -
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Output Voltage (V)
S1
S3
3.085±0.066 2.671±0.066 1.481±0.066 1.079±0.066 -
OFF OFF ON ON -
OFF ON OFF ON -
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Trays 3 and 4 have five switches that make up their Tray Paper Size Sensors. The paper size is determined by Switch 5 on or off position (digital value) in combination with the on or off combinations of Switches 1 through 4. Switches 1 though 4, in combination, create an output voltage (analog value) Table 16 Tray 3/4
Paper Size
Tray Paper Size Sensor Adj. Adj. range value
Output Voltage (V)
S1
S2
S3
S4
(Tray pulled out) OFF OFF OFF OFF 928 - 1023 956 3.085±0.066 -(*) OFF OFF OFF OFF -(*) OFF OFF OFF ON 864 - 927 892 2.877±0.066 -(*) OFF OFF OFF ON A5 SEF or 5.5"x8.5" SEF OFF OFF ON OFF 800 - 863 828 2.671±0.066 -(*) OFF OFF ON OFF -(*) OFF OFF ON ON 736 - 799 765 2.468±0.066 B5 SEF OFF OFF ON ON -(*) OFF ON OFF OFF 672 - 735 703 2.267±0.066 -(*) OFF ON OFF OFF 8.5"x13" SEF OFF ON OFF ON 608 - 671 640 2.064±0.066 8.5"x14" SEF OFF ON OFF ON A4 SEF OFF ON ON OFF 544 - 607 578 1.864±0.066 8.5"x11" SEF OFF ON ON OFF -(*) OFF ON ON ON 496 - 543 516 1.666±0.066 8"x10" SEF OFF ON ON ON -(*) ON OFF OFF OFF 432 - 495 459 1.481±0.066 12.6"x19.2" SEF or ON OFF OFF OFF 13"x19" SEF -(*) ON OFF OFF ON SRA3 SEF or 368 - 431 396 1.278±0.066 13"x18" SEF or ON OFF OFF ON 12"x18" SEF A4 LEF ON OFF ON OFF 304 - 367 334 1.079±0.066 -(*) ON OFF ON OFF A3 SEF ON OFF ON ON 240 - 303 273 0.881±0.066 -(*) ON OFF ON ON -(*) ON ON OFF OFF 192 - 239 214 0.691±0.066 B5 LEF or ON ON OFF OFF 7.25"x10.5" LEF 8 Fold GCO SEF or ON ON OFF ON 8 Fold TFX SEF 128 - 191 153 0.493±0.066 B4 SEF ON ON OFF ON 8.5"x11" LEF ON ON ON OFF 16 Fold GCO LEF or 64 - 127 93 0.300±0.066 ON ON ON OFF 16 Fold TFX LEF or 7.25"x10.5" LEF -(*) ON ON ON ON 0 - 63 33 0.106±0.066 11"x17" SEF ON ON ON ON In the adjustment data, “Above setup sizes” and “Depending on size group” can be selected.
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S5 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON
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Raising Trays 1 through 4 Trays 1 through 4 are all raised in the same way. Their inner Bottom Plate is raised until it reaches the feed position. Figures 45 and 46 give an overview this operation.
Figure 45 Tray Down
Figure 46 Tray Raised
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Raising Operation When the tray is inserted, the Tray Nudger Roll Solenoid is turned on and lowers the Nudger roll. After a specified time the Tray Level Sensor detects whether of not the Bottom Plate is raised. If the bottom Plate is already raised with the Tray Level Sensor blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is turned on to operate CCW to raise the Bottom Plate. When the Tray Level Sensor becomes blocked, the Tray Feed Lift Motor is stopped. A specified time after the Tray Level Sensor is blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. During paper feed, before the Nudger Roll Solenoid is turned off, the Tray Level Sensor checks the stack height. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is operated CCW to lift the Bottom Plate until the Tray Level Sensor is blocked. When the tray is pulled out, the gears are disengaged and gravity lowers the tray.
Trays 1 through 4 Remaining Paper Detection When the tray is raised, as described in the previous section, the length of time to lift the tray is measured. Based on that time, the ratio of paper remaining in the tray is calculated. Table 17 shows the relationship. Table 17 Ratio of Remaining Paper 25% 50% 75% Full
Tray 1 7274 or more 5552 - 7273 3533 - 5551 0 - 3532
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Time required to lift up tray (msec) Tray2 10209 or more 7201 - 10208 4176 - 7200 0 - 4175
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Tray 3/4 1751 or more 1301 - 1750 851 - 1300 0 - 850
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MSI (Multiple Sheet Inserter) Component Name and Function
MSI Nudger Solenoid
MSI Lift Up Sensor
MSI Lift Up Motor
MSI Paper Set Sensor
MSI Paper Size Sensor
MSI Down Sensor
MSI No Paper Sensor
Figure 47 MSI The MSI Paper Size Sensor output a voltage value (analog) based on variable resistance. It senses paper width (fast scan direction). The MSI No Paper Sensor detects if there is paper on the MSI. The MSI Paper Set Sensor detects if the MSI is loaded with paper. The MSI Lift Up Sensor senses that the MSI Bottom Plate has been raised. The MSI Down Sensor senses that the MSI Bottom Plate has been lowered. The MSI Lift Up Motor is used to raise and lower the MSI Bottom Plate. The MSI Nudger Solenoid is used to raise and lower the MSI Nudger Roll.
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MSI Paper Size Sensing When the MSI Side Guides are moved, the variable resistance value of the MSI Paper Size Sensor changes. Based on a specific voltage output the paper width is calculated. The MSI Paper Size Sensor senses size in the fast scan direction only. The paper length is calculated based on the length of time from the start of the Registration Control to the trail edge of the paper ing the Regi Sensor. Based on the paper length and the width sensed, a standard size is automatically sensed. Table 18 shows the combinations. Table 18 Standard Size [mm]
Allowable Size Range [mm]
Paper Size A5 SEF 5.5x8.5 SEF B5 SEF A4 SEF 8.5x11 SEF 8.5x13 SEF 8.5x14 SEF B5 LEF B4 SEF A4 LEF A3 SEF 8.5x11 LEF 11x17 SEF
Distinguishable Size
width
length
width
length
FXAP/ GCO
XC
148.0 139.7 182.0 210.0 215.9 215.9 215.9 257.0 257.0 297.0 297.0 279.4 279.4
210.0 215.9 257.0 297.0 279.4 330.2 355.6 182.0 364.0 210.0 420.0 215.9 431.8
138.7 - 157.3 130.4 - 149.0 172.7 - 191.3 200.7 - 219.3 206.6 - 225.2 206.6 - 225.2 206.6 - 225.2 247.7 - 266.3 247.7 - 266.3 287.7 - 306.3 287.7 - 306.3 270.1 - 288.7 270.1 - 288.7
200.0 - 220.0 205.9 - 225.9 247.0 - 267.0 287.0 - 307.0 269.4 - 289.4 320.2 - 340.2 345.6 - 365.6 172.0 - 192.0 354.0 - 374.0 200.0 - 220.0 410.0 - 430.0 205.9 - 225.9 421.8 - 441.8
o o o o o o o -
o o o o o o
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XE/ DMO-E/ DMO-W o o o o o o o o -
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Raising and Lowering the MSI Paper is raised and lowered by the MSI Lift Up Motor raising and lowering the MSI Bottom Plate. The raising is done to lift the paper into the feed position. The lowering is done so that paper can be loaded. The MSI Bottom Plate is raised when the MSI Paper Set Sensor detects paper and the MSI is selected as the feed tray. The MSI Nudger Solenoid is turned on lowering the Nudger Roll. After a specified time the MSI Lift Up Sensor detects if the Bottom Plate is raised. If the MSI Bottom Plate is already raised with the MSI Lift Up Sensor blocked, the MSI Nudger Solenoid is turned off and the Nudger Roll lifts. If the MSI Lift Up Sensor is unblocked, the MSI Feed Lift Up Motor is turned on to raise the Bottom Plate. When the MSI Lift Up Sensor becomes blocked, the MSI Feed Lift Up Motor is stopped. A specified time after the MSI Lift Up Sensor is blocked, the MSI Nudger Solenoid is turned off and the Nudger Roll lifts. During paper feed, before the MSI Nudger Roll Solenoid is turned off, the MSI Lift Up Sensor checks the stack height. If the MSI Lift Up is unblocked, the MSI Feed Lift Up Motor is operated to lift the Bottom Plate until the MSI Lift Up Sensor is blocked. Lowering the MSI Bottom Plate is when the MSI Down Sensor is unblocked at the following times At Power on When the MSI No Paper Sensor senses the supply has run out At the end of a job When the MSI Cover Interlock Switch and Front Cover Interlock Switch are both closed The MSI Lift Up Motor lowers the MSI Bottom Plate until the MSI Down Sensor is blocked. The MSI Lift Up Motor is then stopped.
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HCF (High Capacity Feeder) Component Name and Function
Tray 6 Feed Lift Motor
Tray 6 Paper Size Sensor (A3) Tray 6 Paper Size Sensor (Letter) Tray 6 Level Sensor Tray 6 No Paper Sensor
Tray 6 Nudger Solenoid
Tray 6 In Sensor
Figure 48 HCF Trays Note: Trays 6 and 7 are the same. This description will work for both. Trays 6 and 7 Paper Size Sensor A4 and Paper Size Sensor Letter sense the size of paper in the trays. Trays 6 and 7 In Sensors detect if the trays are inserted. Trays 6 and 7 No Paper Sensors detect if there is any paper in the trays. Trays 6 and 7 Feed Lift Motors are stepper motors used to raise the trays by rotating CCW and feed paper by rotating CW. Trays 6 and 7 Nudger Solenoids raise and lower the Nudger Rolls. Trays 6 and 7 Level Sensors sense that the bottom plates have been raised to the feed position.
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HCF Paper Size Sensing Sensing the size of the paper in the trays is based on a combination of on and off operations of two sensors, the Tray Paper Size Sensor A4 and the Tray Paper Size Sensor Letter. When the paper width and length guides are moved and the tray is inserted into the HCF, the state of both sensors checked. The combination of blocked or unblocked states determines the paper size. The sensors are located at the rear of the trays as indicated by Figure 49.
Letter Size Sensor
Tray A/B Size Sensor
Figure 49 HCF Size Sensors
Table 19 shows the relationship between paper sizes and combinations of the on and off operations of the Tray Paper Size Sensor A4 and Tray Paper Size Senor Letter. Table 19 Tray Paper Size Sensor A4 Letter B5 LEF or 7.25"x10.5" LEF * OFF OFF 8.5"x11" LEF ON OFF A4 LEF OFF ON A4 extension (non-standard setup) OFF OFF *Switching between B5 LEF and 7.25” x 10.5” LEF is done in NVM Paper Size
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Raising the HCF Trays When the tray is inserted, the Tray Nudger Roll Solenoid is turned on and lowers the Nudger roll. After a specified time the Tray Level Sensor detects whether of not the Bottom Plate is raised. If the bottom Plate is already raised with the Tray Level Sensor blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is turned on to operate CCW to raise the Bottom Plate. When the Tray Level Sensor becomes blocked, the Tray Feed Lift Motor is stopped. A specified time after the Tray Level Sensor is blocked, the Tray Nudger Solenoid is turned off and the Nudger Roll lifts. During paper feed, before the Nudger Roll Solenoid is turned off, the Tray Level Sensor checks the stack height. If the Tray Level Sensor is unblocked, the Tray Feed Lift Motor is operated CCW to lift the Bottom Plate until the Tray Level Sensor is blocked. When the tray is pulled out, the gears are disengaged and gravity lowers the tray
Trays 6 and 7 Remaining Paper Detection When the tray is raised, as described in the previous section, the length of time to lift the tray is measured. Based on that time, the ratio of paper remaining in the tray is calculated. Table 20 shows the relationship. Table 20 Ratio of Remaining Paper 25% 50% 75% Full
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Time required to lift up tray (msec) 8801 - 11530 6071 - 8800 3341 - 6070 0 - 3340
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OHCF (Oversized High Capacity Feeder) Overview Paper Size The OHCF is a Feeder that s the following paper: Capacity: 2,100 sheets (J Paper: 82gsm), 2,300 sheets (P Paper), 2,000 sheets (Xerox Digital Color Xpressions Plus: 90gsm) ed paper size: B5LEF (257.0x182.0mm) to 13”x19.2” SEF (330.2x488.0mm) Custom Sizes : 210mm – 330mm (width) and 182mm – 488mm (length) ed paper weight: 18lb. – 110lb. Cover (64 to 300gsm). When paper is loaded the tray raises into position. Sensors sense the size of the paper. The weight of the paper must be input through the UI to ensure feed reliability. Since the processor has center registration, the tray is shifted to the center position. When feed is initiated, depending on paper size and weight, a blower will come on to provide air for sheet separation. Another blower is capable of supplying warm air. Paper feed is accomplished with a motor and feed rolls. Paper path detection is done with sensors.
Paper Type A wide variety of paper types can be used including Heavyweight, Coated, Transparencies, and Labels.
Power Consumption 300 Watts maximum
Dimensions 39” wide x 31” deep x 37” high (988mm wide x 758mm deep x 930mm high 32” deep if 13” x 18” or 13” x 18” paper is loaded (801mm deep if 13” x 18” or 13” x 18” paper is loaded)
Weight 254lb. / 115kg maximum
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Interlock Switches The OHCF has 3 Interlock Switches:
Figure 50 Interlock Switches MSI (Tray 5) Interlock Switch – Detects the Opening and Closing of the MSI Top Cover. OHCF Front Interlock Switch – Detects the Open and Close states of the Front Cover. OHCF Tray Interlock Switch – Detects if the Tray is open or closed
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Paper Size Detection The paper size is detected by the Paper Side/End Guide Actuator using the combination of covered states from the 7 sensors that are distributed underneath the Bottom Plate of the Tray. To prevent the loading of spare reams of paper, due to the large size of the Paper Tray, each Front/Rear side of the Bottom Plate has Miss Set Sensors. The 7 sensors, the 2 Miss Set Sensors and the No Paper Sensor (Refer to Paper Availability Detection/Remaining Amount Detection) forms a mechanism that detects miss load of paper and notifies the to re-load the paper if it is loaded incorrectly.
Figure 51 Paper Size Detection Size Sensor (SNR0) Size Sensor 2 (SNR2) Size Sensor 1 (SNR1) Size Sensor 5 (SNR5) Size Sensor 4 (SNR4) Size Sensor 3 (SNR3) Size Sensor 6 (SNR6)
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The following table indicates the detection conditions No
SNR0 SNR1 SNR2 SNR3 SNR4 SNR5 SNR6
1 B5LEF (257.0x182.0) 2 7.25”x10.5” LEF (x11 ”1) (266.7x184.2) 3 16K LEF (TFX) (267.0x194.0) (*1) 4 16K LEF (FXCL) (270.0x195.0) (*1) 5 8”x10” LEF (254.0x203.2) 6 A4LEF (297.0x210.0) 7 8.5”x11” LEF (279.4x215.9) 8 B5SEF (Not ed) 9 8.5”x11” SEF (215.9x279.4) 10 A4SEF (210.0x297.0) 11 8.5”x13” SEF (215.9x330.2) 12 8.5”x14” SEF (215.9x355.6) 13 B4SEF (257.0x364.0) 14 8K SEF (TFX) (267.0x388.0) (*1) 15 8K SEF (FXCL) (270.0x390.0) (*1) 16 A3SEF (297.0x420.0) 17 11”x17” SEF (279.4x431.8) 18 12.6”x17.7” SEF (320x450) 19 12”x18” SEF (304.8x457.2) 20 13”x18” SEF (330.2x457.2) 21 13”x19” SEF (330.2x482.6) 22 12.6”x19.2” SEF (320.0x488.0)
0 0
1 1
0 1
0 0
0 0
0 0
-
0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1 1
1 1 1 0 1 0 0 0 0 1 1 1 0 1 0 0 0 0 0
1 1 0 1 1 0 0 0 0 0 1 1 1 1 1 1 0 0 1
0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 0 0
0 0 0 0 0 1 0 1 1 1 1 1 1 0 0 0 0 0
0 0 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0
0 (*2) 0 (*2) 1 (*2) -
*1: Can be selected in the machine NVM. *2: The output of Size Sensor 6 is used to differentiate between the size of 11”x17” and 8K SEF. Front Miss Set Sensor – Detects whether there is a miss loaded paper in the Tray. Installed at the Front side. Rear Miss Set Sensor – Detects whether there is miss loaded paper in the Tray. Installed at the Rear side. Miss loading is detected as follows when inserting the tray after paper is loaded. Check if the paper is loaded properly against the Lower No Paper Sensor at the front corner of the tray. If Yes: proceed to b. If No: no paper is detected The Size Sensors 0 to 6 detect the paper size. The machine logic will judge if the empty space in the tray can hold paper. If it is possible: proceed to c. If it is not possible: raising the tray starts. The Front/Rear Miss Sensors check for the existence of paper in the empty space. If Paper detected: Paper miss load is detected, Lift Up operation is interrupted and “Fail” is displayed If No Paper detected: Judged to be normal, and the Lift Up operation begins An example of a miss load is B5LEF loaded properly, and another B5LEF is loaded on
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the empty space.
Figure 52 Miss loaded paper
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Paper Availability Detection/Remaining Amount Detection Detects the existence of paper during loading/movement as well as the remaining amount of paper. This information is used to update the UI display.
Figure 53 Paper detection The names of the main parts related to the Paper Availability Detection/Remaining Amount Detection are as follows: Level Sensor – Detects the height of the Paper Feed Position and controls the height of the paper. Upper No Paper Sensor – Detects whether there is paper in the Tray during movement. Nudger Solenoid – Controls the separation between the paper surface (moving paper) and the Nudger Roll. OHCF Paper Level Sensor 3 – Detects the remaining amount of paper in the Tray in 4 levels. OHCF Paper Level Sensor 2 – Detects the remaining amount of paper in the Tray in 4 levels. OHCF Paper Level Sensor 1 – Detects the remaining amount of paper in the Tray in 4 levels.
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Remaining Paper Amount
Sensor Output SNR 1
SNR 2
SNR 3
1/4
1
0
0
1/4
1
1
0
1/2
0
1
0
1/2
0
1
1
3/4
0
0
1
Full
0
0
0
1:blocked, 0:unblocked Lower No Paper Sensor - Detects whether there is paper in the Tray during loading. (Used mainly for detection of paper miss load).
Paper Feed This section describes the Transport Section paper feed path and the Jam Detection Sensors.
Figure 54 Feed Sensors
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The names of the main parts related to the Paper Feed mechanism and their explanations are described as follows: Tray5 (HCF MSI) Feed Out Sensor – Detects whether there is paper being fed from the MSI. Also detects Jams. OHCF Exit Sensor – Detects whether there is paper being fed from the MSI/Tray. Also detects Jams. OHCF Feed Out Sensor – Detects whether there is paper being fed from the OHCF Tray. Also detects Jams. OHCF Pre Feed Sensor – Detects whether there is paper being fed from the OHCF Tray. Also used when deciding the mode selection of the Feed operation.
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Tray Shift As described in the overview, the Tray itself is of a Corner Registration. However, since the IOT is a Center Registration type, there is a Tray Shift mechanism that moves the Tray to the center position. The timing for backward and forward movement of the Tray is as follows. At Power ON When the machine returns form Sleep Mode (Energy Saving) When the tray is inserted after changing the paper size. When the tray is removed and reinserted in the middle of a shift operation. When exiting diagnostic mode. Two seconds after the above occurrences, the Tray will move to the Home Sensor Position. Then it moves again within a specified time to stop with center registration for the appropriate paper size. There is a mechanism consisting of In/Out Limit Sensors that stops the tray to prevent part damage in case the Tray attempts to move too far.
Figure 55 Tray Shift
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The names of the main parts related to the Tray shift mechanism and their explanations are described as follows: OHCF Shift Motor – Moves the Tray in the In/Out direction, and aligns the Side Regi to the IOT of the machine. OHCF Shift Front Limit Sensor – Detects overrun of the Tray in the Front direction OHCF Shift Home Sensor – Determines the Home Position of the Tray. OHCF Shift Rear Limit Sensor – Detects overrun of the Tray in the Rear direction.
Paper Separator Air Flow There are two blower fans installed at the front of the tray, as shown in the following figure, which are used to separate the paper. There are also 2 other optional blower fans that can be installed at the side of the tray below the feed head. The air that is blown by these blower fans, to the edge of the paper, breaks the adherence between the sheets of paper and prevents the occurrence of miss feeds and multi feeds. In addition, a heater is installed at the front of the tray to dry the air being supplied. Eliminating the stickiness of the lead edge of the paper which is very effective in preventing miss feed and multifeeds from happening. Warm air is only supplied to the lead edge. The ON/OFF control of the blowers and the control of air amount are performed by the software. The information that is used as a base for the control, is the paper type information selected at the UI. When a different type of paper is selected, the control will change to match that paper. There might be a problem where the selected paper is different from the loaded paper. Temperature control of the Heater is normally performed at power ON. When miss feed and multifeed problems still occur despite the usual control, the following troubleshooting controls in NVM are provided. NVM: 743-040 1 – Standard (Default) 2 – Multifeed Countermeasure 3 – Miss Feed Countermeasure
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Figure 56 Air Flow The names of the main parts related to the airflow system and their explanations are described as follows. OHCF Lead Blower Fan – Creates the airflow for separating the paper. If the Tray Lead Blower stops due to malfunction a fault will occur. OHCF End Blower Fan – Creates the airflow for separating the paper. If the Tray End Blower stops due to malfunction a fault will occur. OHCF Lead Heater – Warms the airflow for separating the lead edge of the paper. OHCF Lead Heater Temp Sensor – Measures the temperature at the surface of the Tray Lead Heater.
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Air Shutter When heavyweight or coated paper is selected on the UI, the pre blower function at paper feed follows the blower and heater temperature control execution. This pre blower function supplies or stops the air in short time periods to increase the effectiveness of paper separation. This Shutter performs this supply/stop control. The Air Shutter is not just solely for the purpose of controlling the pre blow. During pre blow and blow operation at feed, it is also responsible for moving the nozzle, where the air is coming out, up and down to ensure an even amount of air flows in between the sheets of paper. The operation of the Shutter, along with the Blower Fan operation and Heater temperature control, depends on a control table that is established from the paper size, type and operating environment for the most suitable control parameters.
Figure 57 Air Shutter OHCF End Shutter Home Sensor – Fixes the Home Position of the End Shutter. OHCF End Shutter Motor – Drives the End Shutter that changes the amount and direction of Air Flow for separating the paper. OHCF Lead Shutter Home Sensor – Fixes the Home Position of the Lead Shutter. OHCF Lead Shutter Motor – Drives the Lead Shutter that changes the amount and
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direction of Air Flow for separating the paper.
Drive This section describes all the Motors and transport paths found in the OHCF.
Figure 58 Drive
The names of the main parts related to the Drive mechanism and their explanations are described as follows. MSI Feed Motor – This supplies the rotational drive for every roll in the MSI. OHCF Feed Motor – This supplies the rotational drive for the Tray Feed Roll, Tray Nudger Roll and the Tray Retard Roll. Lift Motor – This supplied the drive t raise the tray bottom plate. OHCF Shift Motor – Moves the tray in the in/out direction and aligns the side regi to the IOT. Transport Motor – This supplies the rotational drive for every roll in the transport section via a drive belt.
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(Chain 8) Paper Feed and Transportation
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 8 Paper Transportation.
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Technical Overview This module describes the names, locations, and functions of the components of Chain 8 Paper Transportation. The main functions of Chain 8 Paper Transportation are paper transportation from each tray to registration and registration control.
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Paper Transportation from Trays 1 through 4 to Registration Component Name and Function
Takeaway Motor 2 Takeaway Clutch 2
Trans Path Sensor2
Takeaway Clutch 1
Tray 2 Feed Out Sensor Tray 2 Pre Feed Sensor
Takeaway Motor 1
Trans Path Sensor 1 Tray1 Feed Out Sensor
Tray1 Pre Feed Sensor
Takeaway Motor 3
Trans Path Sensor3 Tray 3 Pre Feed Sensor
Tray 3 Feed Out Sensor Tray 4 Pre Feed Sensor Tray 4 Feed Out Sensor
Figure 59
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Tray 1, 2, 3 and 4 Pre Feed Sensors detect paper fed from the trays. Tray 1, 2, 3 and 4 Feed Out Sensors detect paper fed out of the trays Trans Path Sensors 1 and 2 detect paper fed from Tray 2 that is being transported to registration. Trans Path Sensor 3 detects paper fed from trays 3 and 4 that is being transported to registration. Takeaway Motor 1 drives the Vertical Transport Roll 1, Takeaway Roll 1 and Vertical Transport Roll 2. Takeaway Motor 2 drives Takeaway Roll 2, Horizontal Transport Roll 1 and Horizontal Transport Roll 2. Takeaway Motor 3 drives Trans Roll 3 and Trans Roll 4. Takeaway Clutch 1 transfers drive from the Takeaway Motor 1 to Trans Roll 1. Takeaway Clutch 2 transfers drive from the Takeaway Motor 2 to the Horizontal Transport Roll 1.
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Basic Control of Paper Transportation Paper transportation is controlled based timing that is called Pitch time that is the base point of ing an image on the paper. The time when an image that is developed gets transferred to the paper is the base point. The paper size, paper type and paper feed tray determine a pitch time called Paper Pitch Interval. As paper length increases, Paper Pitch Interval increases. There are 11 different Paper Pitch Intervals. An image of Paper Pitch Interval is shown in Figure 60.
Figure 60 Paper Pitch
Paper Feed timing called P/H Control Standard depends on the time required to transport the paper to the position (Pitch) where the transfer of an image to the paper starts. A P/H control standard is relative to that of the MSI from which the paper takes the longest time to be transported to the image transfer position.
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Paper Feed from the Trays The feed time is a specified time after a certain P/H control standard. For each tray, this specified time is determined by the time required to transport paper from each tray to the position where and image is transferred onto the paper. Trays 1 though 4 each have their own feed time, but they all feed using the same method. Components of the paper feed for tray 4 are shown in Figure 61.
Figure 61 Paper Feed from Tray 4
At feed time, the Tray Nudger Solenoid is turned on lowering the Nudger roll. The Tray Lift Feed Motor is energized in the CW direction to feed paper. When the Tray Pre Feed Sensor detects the lead edge of the paper, the Tray Nudger Solenoid is de-energized and the Nudger roll is raised off the paper. If the Tray Pre Feed Sensor has detected paper at the start of feed, the Tray Feed Lift Motor is stopped once and then turned on in the CW direction. After the earliest one of the following list, the Tray Feed Lift Motor is stopped and it is the end of paper feed. A specified time after the Tray Feed Lift Motor is driven again A specified time after the Tray Pre Feed Sensor detects the paper When the Tray Feed Out Sensor detects the paper When the trail edge of the paper leaves, the Nudger roll is lowered again to hold the next paper to prevent shingling. A specified time after the Tray Feed Out Sensor detects the paper at the end of the feed cycle, the Tray Nudger Solenoid energizes to lower the Nudger roll. A specified time after the Tray Nudger Solenoid is de-energized to raise the Nudger roll.
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Paper Transportation from the Takeaway Rolls Figure 62 shows the rolls driven by the Takeaway Motor 1, Takeaway Motor 2 and Takeaway Motor 3. Takeaway Motor 1 drives the Vertical Transport Roll1 and Vertical Transport Roll 2. Takeaway Motor 2 drives the Horizontal Transport Roll 1 and Horizontal Transport Roll 2. Takeaway Motor 3 drives the Takeaway Roll 3, Takeaway Roll 4 and Vertical Transport Roll 3.
Figure 62 Paper Transportation from Each Tray
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A specified time after the start of paper feed from Tray 1, Takeaway Motor 1 drives Takeaway Roll 1. Takeaway Clutch 1 is energized and transfers drive from Takeaway Motor 1 to Vertical Transport Roll 1. These rolls transport the paper to the Pre Registration Roll. A specified time after the start of paper feed from Tray 2, Takeaway Motor 2 drives Takeaway Roll 2. Takeaway Clutch 2 is energized and transfers drive from Takeaway Motor 2 to Horizontal Transport Roll 2. These rolls transport the paper to the Pre Registration Roll. A specified time after the start of paper feed from Tray 3, Takeaway Motor 3 drives Takeaway Roll 3. Then at a specified time after the start of feed from Tray 3, Takeaway Motor 1 drives Vertical Transport Roll 2. Takeaway Clutch 1 is energized to transfer drive from Takeaway Motor 1 to Vertical Transport Roll 1. These rolls transport the paper to the Pre Registration Roll. A specified time after the start of paper feed from Tray 4, Takeaway Motor 3 drives Takeaway Roll 4 and Vertical Transport Roll 3. Then at a specified time after the start of feed from Tray 4, Takeaway Motor 1 drives Vertical Transport Roll 2. Takeaway Clutch 1 is energized to transfer drive from Takeaway Motor 1 to Vertical Transport Roll 1. These rolls transport the paper to the Pre Registration Roll.
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Paper Transportation from the MSI to Registration Component Name and Function
MSI Feed Motor
MSI Pre Feed Sensor
MSI Feed Out Sensor
Figure 63 MSI Feed The MSI Feed Sensor detects paper fed from the MSI. The MSI Feed Out Sensor detects paper fed out from the MSI. The MSI Feed Motor is used for drive to feed paper from the MSI.
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Paper Feed from the MSI The feed timing is a specified time after the P/H control standard. Figure 64 shows paper feed from the MSI.
Figure 64 Paper Feed from the MSI If an HCF is not installed, the paper from the MSI is transported to the registration position. If an HCF is installed, the paper is transported to the MSI Takeaway Roll, to the HCF Exit Roll and then to the registration position. At paper feed, the MSI Nudger Solenoid is energized to lower the Nudger Roll. After a specified time, The MSI Feed Motor is turned on to rotate in the CW direction to feed paper. When the MSI Pre Feed Sensor detects the paper, the MSI Nudger Solenoid is turned off to raise the Nudger Roll. If the MSI Pre Feed Sensor has already detected paper at the start of feed, a specified time after the MSI Nudger Solenoid is turned on, The MSI Nudger Solenoid is turned of and the Nudger Roll is raised. A specified time after the MSI Feed Out Sensor detects the paper; the MSI Feed Motor is stopped. When the trail edge of the paper leaves, the Nudger roll is lowered again to hold the next paper to prevent shingling. A specified time after the MSI Feed Out Sensor detects the paper at the end of the feed cycle, the MSI Nudger Solenoid energizes to lower the Nudger roll. A specified time after the MSI Nudger Solenoid is de-energized to raise the Nudger roll.
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Paper Transportation from the HCF to Registration Component Name and Function
Tray 6 Pre Feed Sensor Tray 6 Feed Out Sensor
HCF Exit Roll Clutch
HCF Feed Out Sensor
Tray 7 Pre Feed Sensor
Tray 7 Feed Out Sensor HCF Takeaway Motor
Figure 65 HCF
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The Tray 6 and 7 Pre Feed Sensors detect paper fed from the HCF trays. The Tray 6 and 7 Feed Out Sensors detect paper fed out of the HCF trays. The HCF Takeaway Motor drives the HCF Takeaway Rolls 1 through 8 and the HCF Exit Roll. The HCF Exit Sensor detects paper as it leaves the HCF.
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Paper Feed from the HCF Feed timing is determined by a specified time after P/H control standard. For each tray, that specified time varies according to the distance from the image transfer point. Although trays 6 and 7 have different feed times, they both feed in the same manner. Figure 66 shows paper feed from Tray 7.
Figure 66 Feed from HCF At paper feed, the Tray Nudger Solenoid is energized and the Nudger Roll is lowered. After a specified time the HCF Lift Feed Motor rotates CW and drives the Nudger Roll to feed paper. When the Tray Pre Feed Sensor detects the paper, the HCF Nudger Solenoid is de-energized and the Nudger Roll raises. A specified time after the Tray Feed Out Sensor detects the paper, the HCF Lift Feed Motor is stopped. When the trail edge of the paper leaves the Feed Roll, the Nudger Roll Solenoid is energized to lower the Nudger Roll to the top of the paper stack. This prevents another sheet from feeding with the first one. After a specified time the Nudger Roll Solenoid is de-energized and the Nudger Roll is raised.
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Paper Transportation to the HCF Exit Roll Figure 67 shows the paper path from the HCF paper trays and the MSI to exit from the HCF.
Figure 67 HCF Paper Path
A specified time after the start of paper feed, the HCF Takeaway Motor starts to drive HCF Takeaway Rolls 1 through 8. At the same time, the HCF Exit Roll Clutch is energized to drive the HCF Exit Roll in order to transport paper out of the HCF. If paper is on the HCF Exit Sensor after the Pre Registration Sensor detects paper, the HCF Exit Roll Clutch is de-energized. If there is continuous printing, the Exit Roll Clutch is energized after the paper es the HCF Exit Sensor. The HCF Exit Roll is freewheeling except when the clutch is energized. The HCF Takeaway Motor is stopped at a specified time after the Pre Registration Sensor detects the paper. If the next sheet of paper is being fed before the Pre Registration Sensor detects a sheet, the HCF Takeaway Motor does not stop.
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Registration Component Name and Location
Pre Registration Motor
Side Registration Home Sensor Registration Sensor
Side Registration Sensor
Pre Registration Sensor Registration Motor Side Registration Move Motor Figure 68 Registration
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The Pre Registration Sensor detects paper transported to the pre registration position. The Registration Sensor detects paper transported to the registration position. The Side Registration Sensor detects the edge of the paper in Side Registration Control. The Side Registration Home Sensor detects the home position of the Side Registration Sensor. The Pre Registration Motor is the stepper motor that drives the MSI Takeaway Roll 1 and the Pre Regi Roll. The Registration Motor is the stepper motor that drives the Registration Roll. The Side Registration Move Motor is the stepper motor that moves the Side Registration Sensor. The motor is reversible for driving the sensor front and back.
Pre Registration Control The purpose of the pre registration is to correct the skew of the paper transported from the trays to the Takeaway Rolls. It is also used to remove the skew from the paper that is transported from the duplex area. The start of pre registration is a specified time after the P/H control standard. The Pre Registration Motor and the Registration Motor control the pre registration operation. The Pre Registration Motor controls pre registration by operating at high speed to receive paper, mid speed, and low speed to drive paper against the Registration Roll. In the MSI and HCF Trays, the motor controls pre registration by just using high and low speeds. When paper is fed from trays 1 through 4, the Pre Registration Motor starts. At a specified time the speed of the Pre Registration Motor is increased to be equal to the speed of the paper that has been fed. A specified time after the Pre Registration Sensor detects the paper, the speed of the Pre Registration Motor is reduced to mid speed. When the Registration Sensor detects the paper, the Registration Motor turns on. A specified time after the Registration Sensor detects the paper; the speed of the Pre Registration Motor is reduced to the speed of the paper striking against the Registration Roll. At a specified time, the speed of the Pre Registration Motor is further reduced. Feeding from the HCF or the MSI works the same way at the reduced speed. At the end of pre registration, the Pre Registration and Registration Motors stay on at a lower speed. They stay this way because the Pre Registration Roll and the Registration Roll need to rotate to maintain the buckle that is formed with the paper against the Registration Roll.
Registration Control The purpose of registration control is to drive the Registration Roll at the appropriate time to transport the paper in the Regi area to the point of image transfer. This enables the image to be transferred properly to the paper. The start of the registration operation is specified time after the Registration sync notification. This generated when then lead edge of the image is a set distance from the transfer point. The specified time is determined on an individual tray basis. The Pre Registration and Registration Motors control registration. Registration is performed after pre registration. At the start of registration, the Pre Registration and Registration Motors are on at low speed. At a set time the motors are sped up then slowed to process speed. After the paper es the Pre Registration Sensor, the Pre Registration Motor is slowed. After a specified time the motor is stopped. After the paper es the Registration Sensor, the Registration Motor is slowed. A specified time later it is stopped. The trays 1 though 4, the HCF and the MSI all work the same way with one exception.
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With the HCF and the MSI, the motors are not put to process speed.
Side Registration Control The purpose of side registration is to correct misregistration in the fast scan direction. Side registration is necessary on Xerox 4110 because center registration is used in paper transportation. Each paper size has its own side registration position set up. By moving the Side Registration Sensor until it detects the edge of the paper in the registration area, a side misregistration amount is measured. Based on this amount, the ROS writing position is corrected. Side registration consists of three parts: Moving the Side Regi Sensor to the home position Moving the Side Regi Sensor to the waiting position Detecting the side edge Figure 69 illustrates the operations.
Figure 69 Side Registration Operation
The Side Registration Sensor moves to the home position at power on, start of print, when the interlocks are closed, when the side edge of a paper is detected and when there is a side registration failure. When the Side Registration senor needs to home, it is driven by the Side Registration Move Motor until its sensor flag blocks the Side Registration Home Sensor. At a set time after the Side Registration Sensor homes, it is moved the waiting position. The waiting position is based on the paper size being used. This calculation is converted to motor pulses used by the Side Registration Move Motor to position the Side Registration Sensor. Side registration is performed at a set time after the Pre Registration Sensor detects the paper. Starting from the waiting position when paper is being transported, the Side Registration Sensor is moved to detect the edge of the paper. The motor pulses from the Side Move Registration Motor are counted. This count is used to calculate where the ROS places the image on the drum. In this machine, the image is ed to the paper. Side registration is set using dC129. It is set in two modes, “With Comp” and “W/O Comp”. This is done in case the Side Registration Sensor fails. A Side Registration Sensor failure will only show up on the PWS. If the Side Registration Sensor fails, it is sent to the home position and not used. At that point W/O Comp setting is used.
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Paper Length Sensing Paper length sensing is a control function done as the paper is being transported over the Registration Sensor. The measured length of paper is compared to the paper that was selected via the UI or was automatically selected when a document was sensed as it was scanned. If there is a difference of +/- 10mm or more between the desired paper and the paper fed, there is a size mismatch error causing a stop print. This is done to prevent machine contamination. Size mismatch is detection is done only on side 1. If the target paper is tab paper or 120mm x 235mm paper size mismatch detection is not performed. The paper size 120mm x 35mm, which is the size of a number 3 envelope, cannot be set as a paper type. Paper of that size is recognized as an envelope with is flap included, even if it is non-standard, and the paper size mismatch is not performed.
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(Chain 9) Marking
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 9 Marking.
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Technical Overview The main functions of this module are to expose a document image on the charged drum using raster scanning with laser beams, to develop the latent image with toner, and to transfer the toner image to paper. This module also describes drum cleaning, paper transport belt cleaning and waste toner collection. There will be a description of charge control, exposure control and toner concentration (process control). Figure 70 shows the Marking layout.
Figure 70 Marking Layout
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Drum Component Name and Function
Drum CRUM PWB Drum
Drum Motor
Drum CRUM
Drum Detect Switch
Figure 71 Drum Area The Drum has an extremely light sensitive surface that is charged negatively to receive a latent image from the ROS and have it developed for transfer to a through put material. The Drum Motor is the DC motor that drives the Drum, the Drive Roll, the Drum Cleaning Brush and the Transfer Belt Cleaning Brush. The Drum Detect Switch detects the installed Drum Cartridge. The Drum CRUM is the memory that contains the information on the installed Drum. The Drum CRUM PWB uses wireless communication with the Drum CRUM and reads and writes information.
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Drum Motor Control Figure 72 shows how the Drum Motor drives the Drum and Transfer Belt using the Drive Roll.
Drum
Drum Motor
Drive Roll
Transfer Belt Figure 72 Drum Drive
The Drum Motor turns on at a set time after Start Print and turns off when the Erase Lamp turns off after the end of print. The Drum Motor rotates in reverse triggered by the Brake Signal On. The reverse rotation of Drum and Transfer Belt is used to correct any poor cleaning due to foreign objects like paper particles. The reverse operation is performed for a very short time during Print and in cycle down. The Reverse operation can be Enabled or Disabled in NVM 751-030.
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Drum Cartridge Replacement Detection The Drum Cartridge is a CSE replaceable unit. The Drum Cartridge loaded with a memory (CRUM) for recording information. The CRUM is wireless and consists of the Drum CRUM, the actual recording medium in the Drum Cartridge, and the Drum CRUM PWB connected to the machine MCU PWB. Wireless communication between the Drum CRUM PWB and the Drum CRUM allows reading and writing of information. In the CRUM is recorded drum usage status like print quantity and information unique to the Drum Cartridge like the serial number. In the CRUM, the number of drum cycles is used to detect the drum replacement time. It is detected in two stages, Drum Cartridge Replacement Time Near and Drum Cartridge Replacement Time Reached. The count is one cycle equaling one drum rotation.
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Charging and Cleaning Component Name and Function
Charge Corotron Cleaner Motor Charge Corotron
Charge Corotron Cleaner Motor Position Sensor
Erase Lamp
HVPS S6
Pre Clean Corotron
Cleaner Intake Fan Motor
Figure 73
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The Charge Corotron places a negative DC charge on the Drum surface. The Charge Corotron Cleaner Motor in the stepper motor the drives the Charge Corotron Cleaner. The Charge Corotron Cleaner Motor Position Sensor detects the home position of the Charge Corotron Cleaner Motor. The Pre Clean Corotron assists in placing a negative charge on the Drum surface. In the event of the transfer of an image to paper, the BTR places a positive charge on the underside of the Transfer Belt, causing a positive charge on the Drum surface. When this happens, the Pre Clean Corotron eliminates the transfer record by placing a negative charge on the Drum surface. The Erase Lamp eliminates the charge on the Drum surface after an image has been transferred. The Cleaner Intake Fan Motor runs the fan that cools down the Charge Corotron Cleaner and takes air from outside the machine to prevent Charge Corotron Wire contamination. The High Voltage Power Supply S6 generates corotron output and grid output supplied to the Charge Corotron and the Pre Clean Corotron.
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Charge Operation The Drum surface is evenly charged before exposure. The Drum is charged with negative DC from the Charge Corotron and the Pre Clean Corotron. The rated values of the corotron output are, Charge Corotron 5300 uA at –650 VDC and the Pre Clean Corotron 4340 uA at -400 VDC. The Charge Corotron consists of two wires, 1st Corotron Wire and 2nd Corotron Wire, and the Charge Corotron Grid as shown in Figure 74.
2nd Corotron Wire
CC Grid 1st Corotron Wire
Figure 74 The two Charge Corotron wires are used to place a more even charge on the drum. The Charge Corotron Grid is a metallic screen located between the Drum and the wires. A bias voltage of –820VDC is applied to the Grid for stability of the potential on the Drum surface and to prevent it from being excessively charged. At a set time after the Drum Motor starts, DC voltage is applied to the Charge Corotron wires and grid. Process Control determines the value of the voltage to the grid. The output is increased, gradually, in three steps. The Charge Corotron in turned off after the BTR and the Grid is turned off in three steps as it was turned on.
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Charge Corotron Cleaner Control The Charge Corotron Cleaner Motor drives the Charge Corotron Cleaner front to rear, to clean the wires. When the charge function is occurring, the cleaner is moved to the home position. If the Charge Corotron Cleaner is not moved to the home position, it will cause a toner band. It could also cause a fire. The Home Position Sensor is at the front of the corotron. The cleaner is considered parked when it blocks the Home Position Sensor. Figure 75 shows the components.
Charge Corotron Cleaner
Charge Corotron Cleaner Motor
Charge Corotron Cleaner Motor Position Sensor
Figure 75
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Toner Band Generation of a toner band is aimed to prevent deletions due to poor cleaning, Cleaning Blade creaking/being turned up, and a rough quality print of a document with a small ratio of area coverage (discharge of deteriorated toner from Developer Housing). The band is used to lubricate the Cleaning Blade on print/copy runs that may be long with little area coverage. The toner band is generated when ADC Patch is generated, when the total count of prints exceeds a preset threshold (which can be changed in the NVM), at power on, and after warm up. The toner band operation can be disabled by setting it in the NVM (751-037).
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Development Component Name and Function
Toner Cartridge CRUM PWB Cartridge Motor
Toner Cartridge CRUM
Cartridge Door Sensor
Dispense Motor Deve Motor
Low Toner Sensor
HVPS S5 Figure 76 Development
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The Deve Motor is the DC motor that drives the Auger and the Magnet Roll in the Deve Housing. The High Voltage Power Supply S5 generates the development bias (AC and DC outputs) to be applied to the Magnet Roll in the Deve Housing. The Toner Cartridge CRUM is the memory that stores information on the installed Toner Cartridge. The Toner Cartridge CRUM PWB conducts wireless communication with the Toner Cartridge CRUM and reads or writes information. The Cartridge Door Sensor detects the opening and closing of the Toner Cartridge Door The Dispense Motor is the DC motor that drives the auger in the Toner Dispense Housing. The Cartridge Motor is the DC motor that drives the agitator in the Toner Cartridge. The agitator is driven to mix toner while sending it to the Toner Dispense Housing. The Low Toner Sensor detects the amount of toner remaining in the Toner Dispense Housing.
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Negative Charge Development To see how negative charge development works, let’s assume that the Charge on the Photoreceptor Surface is an even -650VDC and the charge on the Toner particles is also -650VDC. Both charges are the same so there is no attraction of toner. The toner coverage in the fully charged areas will be blank (white). If the ROS discharges the drum surface charge down to a negative -100VDC, toner will be attracted to the discharged areas. If the entire surface is discharged or if the charge corotron fails to charge the drum, the copy will have solid coverage. If the ROS fails to discharge the drum you will get a blank copy because the drum will repel the toner on the Developer Roll. NEGATIVE CHARGE ON DRUM SURFACE
Figure 77 Negative Charge Development
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Toner Supply for the Deve Housing Figure 78 shows the flow of toner from the Toner Cartridge to the Deve Housing.
Cartridge Motor
Dispense Motor Auger
Deve Housing Toner Dispense Housing
Figure 78 Toner Flow
The Cartridge Motor drives the Agitator in the Toner Cartridge and makes it send toner to the Tone Dispense Housing. The Dispense Motor drives the Auger to transport toner to the Deve Housing. The Cartridge Motor drives when the toner remaining in the Toner Dispense Housing is low. The Low Toner Sensor monitors the amount of toner remaining in the Toner Dispense Housing. The Low Toner Sensor detects at 0.1-second intervals while the Dispense Motor is driving. When the sensor detects “No Toner” five consecutive times, the Cartridge Motor is driven for 10 seconds.
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The Dispense Motor drives when “Toner Dispense Time”, calculated in process control, is “Dispense Unit Time (10ms)” or more with the Deve Motor on. If “Toner Dispense Time” is 50ms or more, the Dispense Motor drives for 50ms stops once, then drives again for the remaining time. This is done to prevent image quality problems caused by a sudden increase in toner concentration. When the Deve Motor stops, the Dispense Motor stops. If the Dispense Motor was not able to complete a full “Toner Dispense Time”, it will complete the time the next time the Deve Motor runs.
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Development Toner supplied to the Deve Housing is mixed by the Auger in the Deve Housing and attracted to the Magnet Roll. The Deve Motor shown in Figure 79 drives the Magnet Roll and Auger.
Magnet Roll Deve Motor
Auger
Figure 79 Deve Drive
The development bias applied to the Magnet Roll allows attraction of toner from the Magnet Roll to a latent image on the Drum. Development uses a trickle system. The trickle stabilizes the tribo-electric charge of the developer. Toner and carrier are supplied to the Developer Housing together from the Toner Cartridge. Excess developer is discharged and collected in the Waste Toner bottle. This allows deteriorated carrier to be replaced.
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Development Bias Control Development bias has AC and DC output. The DC bias allows the toner to be transferred from the Magnetic Roll to the latent image on the Drum. It is also used to keep toner from attaching to non-image areas on the Drum. The AC bias is used to make toner movement more active. This helps with the attraction to the image area on the Drum and helps prevent attraction in non-image areas. The values are; DC output –600VDC and the AC output is switched among 960VAC/9100Hz, 700VAC/9000Hz, 1140VAAC/6000Hz and 800VAC/5000Hz. The DC Bias is turned on at the same time as the Charge Corotron Grid and turned off at the same time as the Charge Corotron Grid. To suppress the transfer of unnecessary toner and carrier to the Drum, the DC bias is controlled in three steps in sync with the Charge Corotron Grid. Process Control determines the value of the bias. Figure 80 shows the timing.
Figure 80 Development DC Bias On Timing Chart
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The AC Bias is turn on after the Charge Corotron Grid and a set time before image exposure. It is turned off after the Charge Corotron Grid and a set time after the image exposure. The steps are not used with AC on as they are with DC on. Figure 81 shows the timing.
Figure 81 Development AC Bias On/Off Timing Chart
The AC Bias output can be reset to Not OFF during print process in NVM 726-074. When this is done the AC Bias is on during the entire Developer on time instead of the way it is shown in Figure 81.
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Toner Empty Detection Toner Empty Detection informs the when the Toner Cartridge should be replaced. It also inhibits printing before a lack of toner caused extremely poor image quality. Table 21 shows the four levels of status indicating how much toner remains. Table 21 Status Name Normal Low Toner Toner Near Empty Toner Empty
Status Meaning Toner Cartridge has sufficient toner. Low Toner Sensor continues to detect “No toner” with low toner in Toner Cartridge. Toner Cartridge has almost no toner. Toner in Toner Dispense Housing is used for development. Toner Cartridge and Toner Dispense Housing have no toner. The Low Toner Sensor normally detects how much toner remains at intervals of 0.1 sec while the Dispense Motor is driving. When it detects “No Toner” 20 consecutive times, it indicates the “Low Toner” status. Once the status is “Low Toner”, the Low Toner Sensor detects how much toner remains at intervals of 0.1 sec even if the Dispense Motor is not driving. When it detects “Toner available” 10 consecutive times, “Low Toner” is cleared and back to normal. “Low Toner” is an internal status and is not displayed on the UI. When the “Low Toner” status and the total time of Dispense Motor on reaches a set time (NVM: 762-028 “Toner Near Empty Occurrence Time”), the status becomes “Toner Near Empty”, which is displayed on the UI. The machine can make 5000 prints after this status is declared. If the Low Toner Sensor detects toner available 10 consecutive times after “Toner Near Empty”, the status is cleared and back to normal. When the “Low Toner” status and the total time of Dispense Motor on reaches a set time (NVM: 762-029 “Toner Empty Occurrence Time”), the status becomes “Toner Empty”, which is displayed on the UI. The machine is disabled from printing until the Toner Cartridge is replaced.
Remaining Toner Detection This is used to detect the remaining toner so that the can make an informed decision on Toner Cartridge replacement time. Based on the total on time of the Dispense Motor, the amount of remaining toner is detected in five steps. This is shown is Table 22. Table 22 Level of Toner Remaining in Toner Cartridge Step 1 (Remaining Toner: 76-100%) Step 2: (Remaining Toner: 51-75%) Step 3 (Remaining Toner: 26-50%) Step 4 (Remaining Toner: 1-25%) Step 5 (Remaining Toner: 0%)
Detection Requirement “Dispense Time” is less than ‘Threshold 1.’ “Dispense Time” is ‘Threshold 1’ or more, and less than ‘Threshold 2.’ “Dispense Time” is ‘Threshold 2’ or more, and less than ‘Threshold 3.’ “Dispense Time” is ‘Threshold 3’ or more. ‘Toner Near Empty or Empty’
“Threshold 3” is set up as the “Threshold of Level of Toner Remaining in Toner Cartridge” in the NVM 762-039. The default is 4000 sec. “Threshold 1” is a third of “Threshold 3” and “Threshold 2” two thirds of ‘Threshold 3.’ The total time of the
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Dispense Motor on time is recorded in Toner Cartridge CRUM, as information unique to Toner Cartridge in use.
Toner Cartridge Replacement Detection The Toner Cartridge is a CRU (Customer Replaceable Unit). The Toner Cartridge has a memory (CRUM) for recording information. The CRUM is wireless and consists of the Toner Cartridge CRUM, the actual recording medium in the Toner Cartridge, and the Toner Cartridge CRUM PWB connected to the machine MCU PWB. Wireless communication between the Toner Cartridge CRUM PWB and the Toner Cartridge CRUM allows reading and writing of information. In the CRUM recorded are Toner Cartridge usage status such as status of how much toner remains (‘Low Toner’/’Toner Near Empty’/’Toner Empty’) and total time of Dispense Motor drive (Dispense Time), and information unique to Toner Cartridge such as its serial number. At power on and when the Toner Cartridge Door is closed, information is read from CRUM, and based on the status of how much toner remains, a decision is made on replacement. The statuses are as follows: Status of how much toner remains: ‘Normal’ is judged that Toner Cartridge is replaced with a new one. Status of how much toner remains: ‘Toner Empty’ is judged that Toner Cartridge is not replaced. Status of how much toner remains: ‘Toner Near Empty’/’Low Toner’ It is judged that Toner Cartridge is replaced with a used one.
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Transfer and Stripping Component Name and Function
HVPS S11
Toner Cartridge CRUM
BTR
Pre Transfer Corotron
Bias Roll Detack Saw
Transfer Intake Fan Motor HVPS S10
HVPS S3
Belt /Retract Solenoid
Figure 82
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The Belt /Retract Solenoid causes the Transfer Belt to or retract from the Drum. The Transfer Intake Fan Motor is the fan that takes air from outside the machine and blows it over the Transfer Belt. This prevents the rise in heat from the f and cools the Transfer Belt area. The Pre Transfer Corotron uses a negative DC charge. This controls what amount of negative charge should be used to charge the Drum surface and aids in transfer. The Bias Roll is a conductive roll that applies a negative charge to the underside of the Transfer Belt to prevent toner attachment. The CRUM is wireless and consists of the Toner Cartridge CRUM, the actual recording medium in the Toner Cartridge, and the Toner Cartridge CRUM PWB connected to the machine MCU PWB. The BTR (Bias Transfer Roll) is the conductive roll that applies a more positive charge to the under side of the Transfer Belt to transfer toner from the Drum surface to the paper. The Detack Saw applies a negative charge to the back of the paper to assist with the stripping of the paper from the Transfer Belt. It also helps prevent image defects. The HVPS (High Voltage Power Supply) S3 supplies an output to the Detack Saw. The HVPS High Voltage Power Supply S10 supplies an output to the BTR and Bias Roll. The HVPS (High Voltage Power Supply) S11 supplies an output to the Pre Transfer Corotron.
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Transfer Belt ing and Retracting A toner image formed on the Drum surface is transferred to the paper on the Transfer Belt. To prevent any problem due to belt deformation, the Transfer Belt stays retracted from the Drum except when a toner image is being transferred onto paper. The Transfer Belt /Retract Solenoid is use to accomplish this movement of the belt. See Figure 83.
Figure 83
The Belt /Retract Solenoid keeps the Transfer Belt ing or retracted from the Drum. The Transfer Belt s the Drum when the Drum Motor starts at the beginning of a job. The Transfer Belt retracts from the Drum when the final paper of the job is stripped from the Transfer Belt. The retracting also takes place when the Drum Motor stops for and emergency (jam etc) and when an ADC Patch/Toner Band is generated.
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Image Transfer onto Paper With the Transfer Belt in with the Drum, the BTR places a positive DC charge (2000 micro amps /+80 VDC) on the under side of the Transfer Belt. This a toner image to be attracted from the negatively charged Drum surface and transferred onto the paper on the Transfer Belt. The BTR is turned on and off for every image. A change is made to the output from BTR according to humidity levels (low/medium/high humidity) in order to prevent deletion along the trail edge of moist paper The Pre Transfer Corotron is used to prevent “toner trail” from occurring in the F, with moist paper in use or developer deteriorated, to enhance transfer onto moist paper, and to prevent toner dispersion from occurring when paper is being stripped from Transfer Belt with low humidity. It uses a negative DC charge (4050 micro amps / 230VDC) to control the amount charge applied to the toner on the Drum.
Stripping Paper Paper with a toner image is transported on the Transfer Belt. The Finger right behind the transfer point on the Drum prevents the paper from being rolled up by the Drum. When the paper is stripped from the Transfer Belt, the Detack Saw applies a negative charge to the back of the paper to stabilize the paper position. The Detack Saw prevents an IQ defect called “heat haze” due to exchanges of charges between the paper and adjacent parts at paper stripping.
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Bias Roll To prevent the problems mentioned below, the Bias Roll uses a negative DC charge (-650V) to apply the negative charge to the underside of Transfer Belt. “Toner Band” attachment to Transfer Belt (at the start/end of a job) Poor transfer onto moist paper “Background Toner” attachment to the Transfer Belt (inter-image) Toner attachment to the Transfer Belt after a Jam occurs, when a MSI size is mismatched, etc. (during cleaning cycle) The Bias Roll turns on when the Transfer Belt is in with the Drum. The Bias Roll changes its output for each of the above bulleted cases. To prevent the back of the paper from getting dirty a Cleaning Cycle is performed on the Transfer Belt. The Cleaning Cycle happens when there should be transfer of an image from the Drum to paper and the paper doesn’t show up, the image is larger than the selected paper, and when there is special paper like tabs or three hole punched.
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Toner Collection Component Name and Function
Auger Motor
Waste Toner Full Sensor Waste Bottle Set Sensor Figure 84
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Blower Fan Motor
Figure 85
The Auger Motor is the DC motor that drives the Waste Toner Auger, the F nip camshaft and the Inverter Roll. The Waste Toner Full Sensor senses when the waste bottle is full. The Waste Bottle Set Sensor detects the presence of the Waste Bottle. The Blower Fan Motor cools the Chute in the Duplex/invert area and the Cleaner area. The fan takes in air from these areas and discharges it through the Suction Filter and the Ozone Filter. The air to be discharged has ozone from near the Charge Corotron, the Pre Clean Corotron, and the Pre Transfer Corotron. It also has toner from around the Developer Housing and inside the Drum.
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Toner Collection System After an image is transferred, some toner remains on the Drum. There is also toner from the paper on the Transfer Belt. These residual toner particles cause degraded image quality and dirt on the back of the paper. The Drum and Transfer Belt cleaning system remove these particles. Cleaning is accomplished with a Cleaning Blade and a Cleaning Brush at the Drum and Transfer Belt. The Drum Motor drives the Cleaning Brush so cleaning is happening during print. The waste toner that is collected is transported the Waste Bottle by the auger. The Auger Motor drives the auger. Waste developer is transported in the same manner. See Figure 86.
Cleaning Blade Cleaning Brush Auger
Cleaning Blade
Auger
Cleaning Brush
Waste Toner Bottle Figure 86
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Process Control Component Name and Function
ESV Sensor ATC Sensor
ESV PWB
ADC PWB ADC Sensor
Humidity/Temperature Sensor
Figure 87
The ESV Sensor detects the potential on the Drum surface. The ESV PWB processes the data collected by the ESV. The ATC Sensor is the magnetometric sensor that detects the amount of toner remaining in the Deve Housing. The ADC Sensor detects the density of the Patch formed on the Drum. The ADC PWB processes the data detected by the ADC Sensor. The Humidity/Temperature measures the temperature and humidity inside the machine.
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Process Control Overview Process control is used to prevent changes in image quality due to changes is the temperature and humidity inside the machine. Process Control is mainly divided into potential control and toner dispense control. The potential control sets up charge potential (Charge Corotron Grid voltage), development bias potential and ROS LD light quality
Figure 88
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Potential Control Overview Potential control is performed based on the ESV Sensor-detected potential of the Drum surface, the ADC Sensor-detected density of a toner image on the Drum, and Environment Sensor-detected temperature and humidity. Patches are used to detect the potential of the Drum surface and density of a toner image. Potential control has two types of operations: the setup operation (mini setup) at power on and the operation during printing Table 23 shows when each setup item is controlled and what sensors are related to calculation of each set value. Table 23 Setup Item Charge potential Development bias LD light quantity
Sensor used ESV Sensor Humidity/Temperature Humidity/Temperature ESV Sensor Humidity/Temperature ADC Sensor
Performed at: Mini setup Mini setup Mini setup During printing
Table 24 shows how the Potential Control operation can be changed in NVM 752-002. Table 24 Mode Name Fixed Potential Mode Process Control Potential Mode Standard Potential Mode
NVM Value 0 1 (default) 2
Description Uses fixed values of charge potential & LD light qty. Uses a charge potential estimated from a measurement result by ESV Sensor, and a LD light qty estimated from measurement results by ESV Sensor & ADC Sensor Uses a potential estimated from a measurement result by ESV Sensor, and a LD light qty estimated from a measurement result by ESV Sensor. (No ADC Sensor-detected LD light qty correction)
The normal operation is the Process Control Potential Mode. The other modes are prepared in case no stable measurement value can be obtained if any sensors fail.
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Patch The Patch is used for detection of the potential on the Drum surface and the density of a toner image. It is not an image to be actually printed out, but a small image scanned and generated for process. Patches are generated on the Drum. Some of them are developed (with toner) and others not. The patches not developed are used for ESV Sensor to measure the potential of the Drum surface, while the developed patches for ADC Sensor to measure toner concentration. Table 25 shows the patch types
Table 25
142
Patch Type VH1 VH2 VH3 VM1
Deve Generation Timing Mini Setup Printing No ○ No ○ No ○ Yes ○
VM2
Yes
○
VM3
Yes
○
ADC
Yes
Vclean
No
Vdark
No
Cycle Up
○ ○ ○
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Description For charge potential control For charge potential control For charge potential control For LD light qty/toner dispense control For LD light qty/toner dispense control For LD light qty/toner dispense control For LD light qty/toner dispense control For ADC Sensor’s measurement of density standard value For measurement of dark current
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Mini Setup Operation During Mini Setup, charge potential, development bias and LD light quantity are calculated and set. The ATC correction amount used for the toner control is also calculated. These are all based on the time since the last Mini Setup, the age of the drum and the environmental conditions. The Mini Setup is done under the following conditions. At power on four hours after the last mini setup When the machine returns from the low power mode When the machine returns from the diagnostic mode At the end of a print job one hour or more after the last mini setup At the start of a print job if the environment has changed in temp and humidity since the last mini setup The order of the Mini Setup is as follows: Set various targets and determine development - the bias ADC Target, VH Target, VM Target and Bias Target are calculated according to humidity (measured by Environment Sensor) and Drum age. The Bias Target calculated here is Development Bias for setup. Determine the charge potential - the Patch VH is generated, the ESV Sensor measures the potential of the Drum surface at the patch. Charge Potential is calculated from the difference between the measured VH value and the VH Target calculated in step 1. Determine the ESV Sensor-detected LD light quantity - the Patch VM is generated and the ESV Sensor measures the potential of the Drum surface at the patch. The LD light quantity is calculated from the difference between the measured VM value and the VM Target calculated in step1. Determine the ADC Sensor-detected LD light quantity ADC correction amount - the Patch VM is generated, the ADC Sensor measures the toner density of the patch. The LD light quantity ACD correction value is calculated from the difference between the measured ADC Correction value and the ADC Target calculated in step 1. Determine the ATC LD correction amount – the ATC LD correction amount is calculated from the difference between the LD light quantity calculated by ESV Sensor and LD light quantity calculated by ADC Sensor. If the process control potential control mode (default) is used as potential control mode, the value obtained by adding the LD light quantity ADC correction amount, calculated in step 4, to the LD quantity, calculated in step 3, becomes the new LD quantity for setup. If the standard potential mode is used as the potential control mode, the LD quantity, calculated in step 3, is the new LD light quantity for setup.
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Operation During Printing/Copying The operation during printing/copying calculates and sets the LD light quantity. It also calculates the ATC correction amount to be used for toner dispense control (calculation of the ATC correction amount is made only in the process control potential mode). The operation during printing/copying occurs when 160 prints/copies are made in a row. It also occurs at the end of a job that has 50 or more prints/copies. The order of operation is as follows: Determine the ADC Target – the ADC Target is calculated according to humidity, measured by the Environment Sensor and the life of the Drum. Determine the ESV Sensor detected LD light quantity correction amount – the ESV Sensor detected LD light quantity correction is amount is calculated when an ADC patch is generated and the ESV Sensor measures the potential on the Drum surface at the patch. Determine the ADC Sensor detected LD light quantity ADC correction amount – the ADC Sensor detected LD light quantity ADC correction amount is calculated when an ADC patch is developed and the toner concentration is measured. This value is used with the ADC Target from step 1. Determine the ATC LD correction amount - the ATC LD correction amount is the difference between the LD light quantity calculated by the ESV Sensor and the LD light quantity calculated by the ADC Sensor. If the process control potential control mode (default) is used as potential control mode, the value obtained by adding the LD light quantity ADC correction amount, calculated in step 4, to the current LD quantity, becomes the new LD quantity for setup. If the standard potential mode is used as the potential control mode, the value obtained by adding the LD quantity, calculated in step 3, to the current LD light quantity, becomes the new LD light quantity for setup.
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Toner Dispense Control Toner Dispense Control calculates the toner dispense rate needed to keep image density at a certain level. The ICDC (Image Coverage Dispense Control) and the ATC Sensor detected amount of toner remaining in the Deve Housing are used in the calculation. The toner dispense rate is calculated as the amount of time that the Dispense Motor is driven. Table 26 shows that, using NVM 752-001, Dispense Control can be changed. Table 26 Mode Name Timer Toner Dispense Mode Process Control Toner Dispense Mode
NVM Value 0
Description Supplies a fixed amount of toner at regular intervals
1 (default)
ICDC Toner Dispense Mode
2
Calculates toner dispense amount from ICDC count +ATC Sensor output value, and supplies that amount of toner. Calculates toner dispense amount from ICDC count and supplies that amount of toner.
The ICDC calculates the dispense rate based on the pixel count from the ROS Module. In the ICDC Toner Dispense Mode, only the pixel count is used to determine the dispense rate. The ATC Sensor, at regular intervals with the Deve Motor on, detects the amount of toner still in the Developer housing. This is used by the ATC Sensor to calculate the dispense rate. The ATC calculation works as follows: The ATC Target is calculated based on the humidity measured by the Environmental Sensor, Drum age, toner in the Deve Housing and the ATC LD correction amount (calculated by potential control). The ATC output value is calculated from the amount of remaining toner measured by the ATC Sensor and the ATC Target calculated in step 1. The toner dispense rate is calculated from the ATC output (step 2) and a specified ATC coefficient. A correction is made to this calculation based on the ICDC count. In the Process Control mode, the toner dispense rate is calculated by using the ICDC count and the ATC Sensor toner dispense amount.
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(Chain 10a) Copy Transport
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 10 Copy Transportation.
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Technical Overview The main function of this module is to transport a copy from the F to the exit of the IOT. This includes the output of paper from F, Invert Control and Duplex Control.
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Paper Transportation after the F Component Name and Function
Invert Gate Solenoid IOT Exit Sensor Invert Out Sensor Invert In Sensor Exit Motor
Release Motor
Invert Release Home Sensor Duplex Path Sensor1 Invert Path Sensor
Duplex Out Sensor Duplex In Sensor
Duplex Path Sensor2
Duplex Gate Solenoid
Duplex Motor
Invert Motor
Figure 89 Copy Transportation after the F
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The IOT Exit Sensor detects paper leaving the IOT. The Invert In, Invert Out, and Invert Path Sensors detect paper being transported using the Invert area. The Invert Gate Solenoid moves the Invert Gate to direct the paper into the Invert area. The Exit Motor is the stepper motor that drives the IOT Exit Roll and the Invert Out Roll in the copy output area. The Release Motor is the stepper motor that is used to release the nip of the Invert Roll. The Invert Motor is the stepper motor that drives the Duplex In Roll, the Duplex Path Roll 1 and the Invert Roll in the Invert and Duplex areas. The Duplex Motor is the stepper motor that drives the Duplex Out Roll and the Duplex Path Roll 2 in the Duplex area. The Invert Release Home Sensor detects the home position of the Invert Roll in the release position. The Duplex In Sensor, Duplex Path Sensor 1, Duplex Path Sensor 2 and the Duplex Out Sensor detect paper being transported through the Duplex area.
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Copy Output Control Overview There are three output modes, the face up and invert mode for simplex, and the duplex mode. These are illustrated in Figure 90.
Figure 90
The simplex face up path has paper that has been fused directly transported to the output area as in Figure 91.
Figure 91
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The simplex face down path has paper that has been transported through the f directed to the invert area then transported to the output area as in Figure 92.
Figure 92
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When doing duplex side 1, the paper that has been through the f is sent to the invert area then directed to the duplex area. From the duplex area it is feed through the same area as paper from trays 1 through 4. After receiving an image, it is sent to the output area. This is shown in Figure 93.
Figure 93
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Straight Output
Figure 94 Straight Output
A set time after the Regi Roll is driven; the Invert Gate Solenoid is energized and the Invert Gate is switched to the Exit side. Note: Because of the type of solenoid that the Invert Gate solenoid is, the position of the gate is maintained after it is switched. With this type of solenoid it is not necessary to keep it energized at all times or actuate it at every . When the F Exit Sensor detects the paper, the Exit Motor drives the Exit Roll to transport the paper to the output area. After a specified time, the Exit Motor speed is increased. Note: Since the Exit Roll is linked to the Exit Motor through a torque limiter; the paper is transported at F Transport speed while going through the F and the Exit Roll’s speed after going through the F. After the paper es the IOT Exit Sensor, the Exit Motor is slowed, and then stopped.
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Invert Output
Figure 95 Invert Output At a specified time after the Regi Roll is driven, the Invert Gate Solenoid is energized and the Invert Gate is switched to the Invert side. After the paper es over the Invert In Sensor, the Duplex Gate Solenoid is energized and the Duplex Gate is switched to the Exit side. Note: Because of the type of solenoids that the Invert Gate solenoid and the Duplex Gate are, the position of the gate is maintained after it is switched. With this type of solenoid it is not necessary to keep it energized at all times or actuate it at every . When the F Exit Sensor detects the paper, the Auger Motor drives the Invert In Roll to transport paper to the Invert area. When the paper has ed the F Exit Sensor, the Auger Motor is stopped. Note: The Auger Motor drives the F Nip/Release and Toner Collection Auger as well as the Invert In Roll. At a specified time after the Invert In Sensor Detects the Paper, the invert operation starts. The Invert Motor drives the Invert Roll to pull the paper into the Invert area. After a set time, the speed of the Invert Motor is increased. When the paper es the Invert In Sensor, the speed is reduced. At a set time the direction of the Invert Motor is reversed and sped up to make the Invert Roll rotate in the opposite direction. After a set time the motor speed is reduced and the Invert Motor is stopped. The paper is transported inside the Mid Gate when entering the Invert area and outside the Mid Gate when being transported to the Exit area. The Invert Roll and Pinch Roll are released at Start Print. When the paper es the F Exit Sensor after Start Print, the Release Motor is energized to drive the Pinch Roll and the Invert Roll to transport the paper. When the Invert Release Sensor becomes unblocked, the Release Motor stops. At a set time after the Invert Roll is driven, it is released.
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When the paper es the Invert In Sensor the Exit Motor drives the Invert Out Roll and Exit Roll to transport the paper to the output area. A specified time later, the Exit Motor speed is increased. After the paper es the Invert Out Sensor, the speed is reduced. After the paper es the IOT Exit Sensor, the Exit Motor is slowed then stopped.
Duplex Output
Figure 96 Duplex Output At a specified time after the Regi Roll is driven, the Invert Gate Solenoid is energized and the Invert Gate is switched to the Invert side. After the paper es over the Invert In Sensor, the Duplex Gate Solenoid is energized and the Duplex Gate is switched to the Exit side. Note: Because of the type of solenoids that the Invert Gate solenoid and the Duplex Gate are, the position of the gate is maintained after it is switched. With this type of solenoid it is not necessary to keep it energized at all times or actuate it at every . When the F Exit Sensor detects the paper, the Auger Motor drives the Invert In Roll to transport paper to the Invert area. When the paper has ed the F Exit Sensor, the Auger Motor is stopped. Note: The Auger Motor drives the F Nip/Release and Toner Collection Auger as well as the Invert In Roll. At a specified time after the Invert In Sensor Detects the Paper, the invert operation starts. The Invert Motor drives the Invert Roll to pull the paper into the Invert area. After a set time, the speed of the Invert Motor is increased. When the paper es the Invert In Sensor, the speed is reduced. At a set time the direction of the Invert Motor is reversed and sped up to make the Invert Roll rotate in the opposite direction. At the same time, the Duplex In Roll and Duplex Path Roll 1 start so they can drive the paper into the Duplex area. After a set time the motor speed is reduced and the Invert Motor is stopped.
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The Invert Roll and Pinch Roll are released at Start Print. When the paper es the F Exit Sensor after Start Print, the Release Motor is energized to drive the Pinch Roll and the Invert Roll to transport the paper. When the Invert Release Sensor becomes unblocked, the Release Motor stops. At a set time after the Invert Roll is driven, it is released. The Duplex Motor is then used to drive the Duplex Path Roll 2 and the Duplex Out Roll to transport the paper to the Duplex area. At a set time, the motor speed is increased. After the paper es the Duplex Out Sensor, the Duplex Motor is slowed then stopped. At a specified time after the P/H control standard for side 2, the Duplex Motor drives the Duplex Path Roll 2 and the Duplex Out Roll to transport the out of the Duplex area. At a set time, the motor speed is increased. After the paper es the Pre Regi Sensor, the Duplex Motor is slowed then stopped.
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Duplex Print Sequence In continuous duplex printing, the side 1 and side 2 transfer sequences depends on the paper size. Paper sizes and transfer output patterns are shown in Table 27 and in Figure 97
Table 27 Duplex Sequence Paper Size B5L A4L, LetL A4S B4S A3S, 17”S 18”S, 19”S B5L, A4L, Letter L A4S, B4S, A3S, 17”S, 18”S, 19”S B5L, A4L, Letter L … 216gsm or less & OHP B5L, A4L, Letter L … over 216gsm & Labels A4S, B4S, A3S, 17”S, 18”S, 19”S
110-sheet MC
90-sheet MC
Case 1
Case 3
Case 3
Case 2 Case 2
Figure 97 Duplex Sequence
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Fan Control Component Name and Function
Exit Fan1 Exit Fan2
Duplex Chute Fan
Duplex Fan2
Duplex Fan1
Figure 98 Fans
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The Duplex Chute Fan is used to keep the temperature inside the machine from rising during the duplex mode. The fan also cools paper ing through the duplex area. Duplex Fans 1 and 2 are also used to keep the temperature inside the machine from rising during the duplex mode. The fans also cool paper ing through the duplex area. These fans bring in air from outside the machine. Exit Fans 1 and 2 assist in exhausting air from the F.
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(Chain 10b) Fusing
Introduction This module describes the names, locations, and functions of the Chain10 Fusing. The main function of this module are fuse toner in place by applying heat and pressure, cleaning the surface of the Heat Roll using a web and to output a finished print from the f.
Figure 99 F Cross Section
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Fusing Component Name and Function The F Nip Clutch transfers drive from the Auger Motor to the Cam Shaft to cause the Pressure Roll to make with the Heat Roll. The F Nip Sensor senses when the Pressure Roll is in with, or retracted from the Heat Roll. Auger Motor
F Nip Clutch F Nip Sensor Cam Shaft
Figure 100 F
Figure 101 Pressure Roll Nip Mechanism
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F Assembly The following figure identifies the F Rolls, components and sensors. Heat Roll Heat Roll Thermistor 2
Heat Roll Thermistor 1
Main Heater Rod 2
Heat Roll Thermistor 3
Thermostat 1 Thermostat 2 Sub Heater Rod 2
Pressure Roll Main Heater Rod 1 Figure 102 Fusing
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F Heat Roll The Heat Roll applies heat to the paper to fuse the toner in place. The Pressure Roll, with the Heat Roll, applies pressure to aid in fusing. The Heat Roll contains three 950-watt heat rods, 2 main heat rods that run the entire length of the Heat Roll and a sub heater rod that heats the center of the heat roll. The Heat Roll Thermistor 1 monitors the temperature at the center surface of the Heat Roll in the paper path. This temperature is used by process control as the target temperature. Heat Roll Thermistor 2 monitors the temperature between the center and the rear of the Heat Roll outside of the paper path. This thermistor detects “Hot Not Ready” during printing. Heat Roll Thermistor 3 monitors the temperature at the rear of the Heat Roll outside the paper path (not used for normal temperature control). Thermostat 1 monitors the Heat Roll and turns off the Main Heater Rod 1 circuit when the temperature of the Heat Roll is too high. Thermostat 2 monitors the Heat Roll and turns off the Main Heater Rod 2 and Sub Heater Rod circuits when the temperature of the Heat Roll is too high.
Rear side Front side
Heat Roll Thermistor 2 Heat Roll Thermistor 3
Heat Roll Thermistor 1
Heat Roll Main Heater Rod 1 Main Heater Rod 2 Sub Heater Rod Heating range
Heating range
Pressure Roll Figure 103 Side View
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F State Figure 104 and Table 28 show and explain the F’s transition form one state to another. Table 29 shows the definition of the F States.
Power Off ①
RelayOff
⑮
FsrWait
FsrOff ②
⑬
RelayOn ③
⑭
⑪ RelayOffWait
⑩
⑩ LowPower
Warmup
④
⑫ FsrStandby
⑩
Ready ⑦
⑤
Idling ColdNrdyWait
⑧
HotNrdyWait
⑨
⑥ FsrPrintProcess ⑩
Figure 104 Diagram of the F State Table 28 Conditions for the State Transition Transition No. 1 2 3 4
5 6 7 8 9 10 11 12 13 14 15
Conditions for Transition Power off All the conditions for F Relay On are met. 50[ms] have ed since Relay On, and control of F Motor for backward rotation is over. Warm Up Idling is available: the two conditions are met: Warm Up Idling time has been up; HRSTS1 has reached “HR Temp at the end of F Warm up.” Warm Up Idling is unavailable: HRSTS1 has reached “HR Temp at the end of F Warm up.” Print starts. (Paper Pitch for 1st paper received) Print Process by Cycle Down/Hard Down ends. Control of Lamp at control temp ends after the end of print. Print Process by Cycle Down/Hard Down ends after Cold Not Ready occurs. Print Process by Cycle Down/Hard Down ends after Hot Not Ready occurs. Conditions for F Relay Off occur. 50[ms] after Lamp Off Upon reception of an instruction to transit to Low Power Mode Upon reception of an instruction to clear Low Power Mode With Low Power Mode not cleared, F transits from Relay Off to Relay On and finishes Warm up. With Low Power Mode not cleared, F transits from Relay Off to Relay On and the conditions in 4 are already met.
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Table 29 Definition of the F State State Main State
Sub State RelayOn Warmup
FsrWait ColdNrdyWait HotNrdyWait Ready FsrStandby
LowPower FsrPrintProcess FsrOff
State Overview
Remarks
In preparation for controlling Heater Rods, only Relay is turned ON. Heater Rods are controlled so that the temperature of Heat Roll will be the Ready-to-Print temperature. To make the temperature even and warm up Pressure Roll, F Drive Motor is made to be idling. After Cold Not Ready occurs, Heat Rods are controlled so that the temp of Heat Roll will be the Ready-to-Print temp After Hot Not Ready occurs, Heat Rolls are controlled so that the temperature of Heat Roll will be the Ready-to-Print temperature. Data can be received for print.
Print Off
Idling
Print Off*
Print Off Print Off Data can be received for print. Data can be received for print.
Heater Rods are controlled so that the temp of Heat Roll can be prevented from overshooting a spec one after the end of printing (after the output of the last paper). LowPower When the MC receives a print instruction with Print Off power limited to the low level, the MC will be ready to print in a preset recovery time. PrintProcess Print is in progress. Print in progress RelayOffWait F waits for Heater Rods and Relay to be Print Off turned off. RelayOff Relay, Heater Rods and Motor are all OFF. Print Off *Print is inhibited, but data can be received for print and held in queue.
F Temperature Control The F changes from one state to another according to the temperature of the Heat Roll surface and the machine status. Each state has its own setup target temperature for control. A target temperature is made using a correction to a preset value based on an environment temperature detected by the Environmental Sensor. The F Ready temperature is 185 C and the running temperature is 180 C.. Currently there is no way of measuring this. The following tables and illustration show the patterns in which the Heater Rods are turned on and off when temperature control is performed. HRSTS1 is the temperature of the Heat Roll surface detected by Heat Roll Thermistor 1. HRSTS2 is the temperature of the Heat Roll surface detected by Heat Roll Thermistor 2. For the Heater Rods in Tables 30, 31, 32 and 33 marked with * next to ON/OFF, cutoff control is performed. Cut off control controls power consumption by turning on and off the heater rods repeatedly for a preset ultra short time.
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Table 30Control of Switching between Heater Rods in Warm Up Requirement
HRSTS1>/= “Warmup Control Temp (Heat Roll)” + “Hysteresis Temp” HRSTS1< “Warmup Control Temp (Heat Roll)”
HRSTS1>/=HRSTS2 + (“Wait Main/Sub Lamp Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF
HRSTS1
Main1: 10 ON Main2: 10 ON Sub: 2 OFF / 1 ON*
Main1: OFF Main2: 10 ON Sub: 10 ON
Table 31 Control of Switching between Heater Rods in Cold Not Ready Requirement
HRSTS1>/=HRSTS2
HRSTS1
+Tcold_ms*1 +Tcold_ms*1 + “Hysteresis Temp” HRSTS1>/= Main1: OFF Main1: OFF Tcold _cont*2 Main2: OFF Main2: OFF + “Hysteresis Temp” Sub: OFF Sub: OFF HRSTS1
HRSTS1>/=HRSTS2
HRSTS1
+ (Thot_ms*1)
+ (Thot_ms*1)
+ “Hysteresis Temp” Main1: OFF Main1: OFF Main2: OFF Main2: OFF Sub: OFF Sub: OFF Main1: 10 ON Main1: OFF Main2: 10 ON Main2: 10 ON Sub: OFF Sub: 10 ON *1 Tcold_ms is the same switching temperature as in the state before this process.
HRSTS1>/= Thot _cont*2 + “Hysteresis Temp” HRSTS1
*2 Tcold_cont is a temperature during the cycle of the paper that es immediately after the F’s transition to ColdNrdyWait. The temperature is changed with the size or stock. If retained, the first control temperature or second control temperature is retained.
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Table 33 Control of Switching between the Heater Rods in Standby Ready Requirement
HRSTS1>/= “Ready Control Temp (Heat Roll)” + “Hysteresis Temp” HRSTS1< “Ready Control Temp (Heat Roll)”
HRSTS1>/=HRSTS2
HRSTS1
+ (“Standby Main/Sub Lamp
+ (“Ready Main/Sub Lamp
Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF
Switching Temp”) Main1: OFF Main2: OFF Sub: OFF
Main1: 4 ON / 4 OFF* Main2: 4 OFF / 4 ON* Sub: OFF
Main1: OFF Main2: 10 ON Sub: 10 ON
Table 34Control of Switching between the Heater Rods Ready Requirement
HRSTS1>/= “Idling Control Temp (Heat Roll) + “Hysteresis Temp” HRSTS1< “Idling Control Temp (Heat Roll)”
HRSTS1>/=HRSTS2
HRSTS1
+ (“Standby Main/Sub Lamp
+ (“Ready Main/Sub Lamp
Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF Main1: 10 ON / 0 OFF* Main2: 10 ON / 0 OFF* Sub: OFF
Switching Temp”) Main1: OFF Main2: OFF Sub: OFF Main1: OFF Main2: 10 ON Sub: 10 ON
Table 35 Control of Switching between the Heater Rods in Low Paper Requirement
HRSTS1>/=HRSTS2
HRSTS1
+ (“Standby Main/Sub Lamp + (“Ready Main/Sub Lamp HRSTS1>/= “Low Power Control Temp (Heat Roll)” + “Hysteresis Temp” HRSTS1< “Low Power Control Temp (Heat Roll)”
168
Switching Temp”) + “Hysteresis Temp” Main1: OFF Main2: OFF Sub: OFF
Main1: OFF Main2: OFF Sub: OFF
Main1: 4 ON / 4 OFF* Main2: 4 OFF / 4 ON* Sub: OFF
Main1: OFF Main2: 10 ON Sub: 10 ON
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Print Control Temperature depends on the quantity of prints as shown in Figure 105
Figure 105 Table 36 Control of Switching between Heater Rods in Print Requirement
HRSTS1>/=HRSTS2
HRSTS1
+ (Tprint_ms*) + (Tprint_ms*) +”Hysteresis Temp” HRSTS1>/= Main1: OFF Main1: OFF Tprint + ”Hysteresis Temp” Main2: OFF Main2: OFF Sub: OFF Sub: OFF HRSTS1
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F Idling F idling is having the F Motor on during warm-up. This improves the temperature distribution and fusing level. F idling is performed when “F Motor Idling” is set to 1:enabled and Heat Roll STS-1 is at or below “Warmup Idling Judge Temp” when the f has transitioned to FsrWait_Warmup. F idling starts when HRSTS1 is “F Motor Idling Start Temperature”. Idling duration depends on the environment temperature and the input power voltage.
Countermeasure against Flicker When the F Heater Rods come on, power consumption sharply increases. This may cause fluorescent lights to flicker. To prevent this phenomenon, the following measures have been taken against the causes. Hysteresis Control Fluctuations in the resistance value of each Heat Roll Thermistor cause the detected temperature to be above or below the target. To prevent sharp changes in the voltage due to the Heater Rods turning on and off for short times, Hysteresis Control is performed on the target temperature. Hysteresis Temperature is added to the temperature for switching between Heater Rods. Preventing Heater Rods from turning on simultaneously If multiple Heater Rods turn on at the same time, a large change in current can cause power fluctuations. To prevent this, the Heater Rods are prevented from turning on at the same time. When multiple Heater Rods need to be turned on at the same time, their turn on time is staggered. See Figure 106
Figure 106
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Phase Control The Heater Rod is turned on with and intermittent current so that a gradually increasing amount of current is supplied. Then a continuous current is applied. A gradual decreasing amount of current is supplied to the Heater Rod is off. Figure 107 shows the waveform of the current to the Heater Rod
Figure 107
F Drive Component Name and Function The F Drive Motor is the DC motor that drives the Heat Roll The F Exit Sensor senses that paper has ed through the f. The F Intake Fan takes air from outside the machine and blows it on the Drum, the Transfer Belt Cleaner and the top of the F. The F Exhaust Fan discharges air warmed by the F
F Exhaust Fan
F Exit Sensor
F Intake Fan F Drive Motor
Figure 108 F Drive
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F Drive Control The F Drive Motor is controlled according to the state of the F, as shown in Table 37. Table 37 F State FsrOff_RelayOff FsrWait_RelayOn FsrWait_Warmup
FsrWait_ColdNrdyWait FsrWait_HotNrdyWait
FsrStandby_Ready
FsrStandby_Idling FsrPrintProcess
FsrOff_RelayOffWait LowPowerMode
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F Drive Motor Control F Motor stops F Motor drives backward. When the conditions below are met, with Relay not On after a jam occurs, F Motor does not idle. (1) ”F Motor Idling” is set to the value representing “Disabled” in the NVM. (2) F Heat Roll STS-1 is 150degrees C when F has transited to FsrWait_Warmup. When, in any other case than the above, Relay is On after a jam, F Motor idles as follows: The motor starts driving at the timing F Heat Roll STS-1 Monitored Value>/=”F Motor Idling Start Temp.” It stops at the timing a preset idling duration has elapsed. (1) The motor continues driving. (2) It stops when no more print is in progress at the end of this state. (1) When F transits from Print Process by CycleDown, the motor stops at the time a preset “Idling Duration after Hot Not Ready” has elapsed since its transition to this state. (2) Even when F transits from Print Process by CycleDown, the motor stops at the time the conditions for ending this state are met. (3) When F transits from Print Process by HardDown, in this state F Motor does not drive or neither stops nor starts. (It has already stopped.) In this state F Motor does not drive or neither stops nor starts. (The motor follows the ”Normal Stop Control” timing preset in FsrWait_Warmup, FsrWait_HotNrdyWait or FsrStandby_Idling from which F has transited. The motor stops at the timing a preset “Idling Duration after the End of Print” (which depends on paper stock and can be changed in the NVM) has elapsed since F’s transition to this state. The motor starts driving at the timing a preset “F Motor Drive Delay Time” has elapsed since the pitch base timing for the first paper. “F Motor Drive Delay Time” can be changed in the NVM for every paper stock. If driving, F Motor stops for emergency. The motor stops.
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Heat Roll Cleaning Component Name and Function Web is a roll of cloth used to wipe the dirt off the Heat Roll. The Web Motor is a DC motor that drives the roll to take up the Web. The Web End Switch is the sensor that senses that the Web is completely used.
Web End Switch Web
Web Motor
Figure 109 Heat Roll Cleaning
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Web Motor Control The Web Motor drives the Web take-up roll. The Web in with the Heat Roll cleans toner and paper particles off the Heat Roll. The Web Motor Drive Duration is determined according to “Web Motor on Time”. Changing the Web Motor Drive duration can be done to extend F Web life, if causing jams and to cure electrostatic offset.
Extension of Web Life A smaller amount of Web is used when the density of a print is low or the temperature of the Heat Roll is high, because less toner is attached to the Heat Roll. The Web Motor drive duration is corrected based on ICDC Count (explained in Marking) and the detected Heat Roll Temperature. When a jam occurs, more toner is attached to the Heat Roll surface. The Web Motor drive duration is increased based on a certain coefficient. During Duplex, electrostatic offset occurs under certain environment temperature and humidity. The Web Motor drive duration is increased based on input from the Environment Sensor.
Remaining Web Detection The amount of Web remaining is calculated to predict when replacement is necessary. The amount of remaining Web is detected based on “Web Motor Total ON Time”. When the “Web Motor Total ON Time” exceeds a value calculated from a formula including “Web Remaining Amount Threshold”, a warning is issued. When the Web is out the Web End Switch detects it. At power on and when the interlocks are closed, Web End Switch is checked. If the switch detects the High level twice in a row, F Web End Fail will be declared. To clear the warning and Web End fail, replace the Web and then enter dC135 954-847 and clear or on the console press Stop then 9.
.
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Finisher
Introduction Technical Overview Finisher Configurations The Xerox 4110 Multi-Function Finisher comes in two configurations. The Finisher with the Punch and Stapler. This consists of the Stapler, Punch, Stack Tray, Top Tray and Interposer. The three hole punch is standard in the US and Canadian versions. A two and four hole punch is standard for Europe. The Finisher with Booklet Maker. This consists of a Booklet Maker added to the Finisher described above. The Booklet Maker includes a Saddle Stitcher. Either model may have a Folder added as an option. The folder can make “C” folds (8.5X11 or A4), large “Z” folds (11X17 or A3) and small “Z” folds (8.5X11 or A4). Bi-Folds require the Booklet Maker version of the Finisher. Both models are equipped with an automatic decurler to help control paper curl in the Finisher. The Stapler provides single, dual, and corner stitching capabilities.
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Finisher Components Figure 110 shows the Finisher subsystems. Top Output Tray
Punch Interposer
Stacker Output Tray Decurler Stapler
Booklet Maker Output Tray
Folder
Folder Output Tray
Booklet Maker
Figure 110 Finisher Subsystems
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Output Tray Capacities Table 38 shows the capacities of the various output trays and the interposer. Table 38 Output Tray Capacities No Stapling
Stapling *1
Top Tray
500 sheets
---
Stack Tray
3000 sheets
200 sets or 3000 sheets
Standard sizes of 7.2“ (182 mm) or more in FS direction and 8.5” (217 mm) or less in SS direction
1500 sheets
100 sets or 1500 sheets
Standard sizes of 8.5“ (217 mm) or more in FS direction and 17” (431.8 mm) or less in SS direction
1500 sheets
---
Standard sizes of more than 17” (431.8 mm) in SS direction
30 sheets
10 sheets
3000 sheets with 30 Z folded sheets
100 sets or 3000 sheets with 10 Z folded sheets
A mix of Z folded and flat sheets
2000 sheets
200 sets or 2000 sheets
Standard sizes of 7.2“ (182 mm) or more in FS direction and 8.5” (217 mm) or less in SS direction
1500 sheets
100 sets or 1500 sheets
Standard sizes of 8.5“ (217 mm) or more in FS direction and 17” (431.8 mm) or less in SS direction
1500 sheets
---
Standard sizes of more than 17” (431.8 mm) in SS direction.
30 sheets
10 sheets
2000 sheets with 30 Z folded sheets
100 sets or 2000 sheets with 10 Z folded sheets
20 sets
20 sets
5 sheets or less per set
---
15 sets
More than 5 sheets per set and 14” (364 mm) or more in SS direction.
---
10 sets
More that 5 sheets per set and less than 14” (364 mm) in the SS direction
---
---
The size of the output stack is determined by the Booklet Tray Full Sensor.
40 sheets +
---
The size of the output stack is determined by the Folder (Envelope) Tray Full Sensor.
Output Tray
(without Booklet Maker)
Stack Tray (with Booklet Maker
Booklet Maker Tray
Folder (Envelope) Tray Interposer
Requirements Flat Paper, any size with 5 mm or less curl.
Z folded paper only
Z folded paper only A mix of Z folded and flat sheets
250 sheets
FS = Fast Scan Direction SS = Slow Scan Direction 1* Applies to stapled sets of both the same size and mixed sizes of the same width. Mixed sizes may degrade stacking performance
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Paper Transportation Figure 111 shows the names of the paper transport rolls and the locations of the paper path sensors. The transport rolls are different than previous models to accommodate the toner used.
Figure 111 Paper Transport Rolls and Sensors
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Figure 112 shows the paper transportation paths.
Figure 112 Paper Transportation Path
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Table 39 Sensors (Refer to Figure 112) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sensor Name Decurler In Sensor Decurler Out Sensor Interposer Feed Out Sensor Interposer No Paper Sensor Folder Entrance Sensor Folder Path Sensor 1 Folder Path Sensor 2 Folder Path Sensor 3 Folder Path Sensor 4 Folder Exit Sensor Punch Out Sensor Buffer Path Sensor Top Tray Exit Sensor Compile Exit Sensor Compile Tray No Paper Sensor Booklet In Sensor Booklet Compile No Paper Sensor Booklet Folder Roll Exit Sensor Stacker Tray No Paper Sensor Booklet Tray No Paper Sensor
Functions and Output Tray Availability Not all output trays are available for all of the Finisher Functions. Table 40 shows the output trays available for each function or combination of functions Table 40 Functions and Output Tray Availability Function
Output Tray
Booklet Tray
Stack Tray
Top Tray
Folder Tray
Bi-Fold
Booklet
Stapling
Punching
C fold
Z fold
Interposer
Function
Interposer
NA
O
O
X
O
O
O
O
O
O
O
Z fold
O
NA
X
O
O
X
X
X
O
O
X
C fold
O
X
NA
X
X
X
X
O
X
X
X
Punching
X
O
X
NA
O
X
X
X
O
O
X
Stapling
O
O
X
O
NA
X
X
X
X
O
X
Booklet
O
X
X
X
X
NA
X
X
X
# *1
O
Bi-Fold
O
X
X
X
X
X
NA
X
X
X
O
O may be combined. # may be combined with some restrictions. X may not be combined.
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*1: The Stack Tray may be selected as an output tray when using the booklet maker provided that stapling is not selected at the same time. If stapling is selected the output is to the Booklet Tray.
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Paper Size and Function Not all Finisher functions are available for all paper sizes and feed orientations (long edge or short edge feed). Table 41 shows the relationships between paper size and function. Table 41 Paper Size and Function Type/Orientation Dimensions Post Card / SEF
4X6” 102X152 mm
Statement / LEF
5.5X8.5“ 139,7x215.9 mm
8X10 / LEF
8X10” 254X203.2 mm
A4 / SEF
8.3X11.7” 210X297 mm
A4 / LEF
11.7X8.3“ 297X210 mm
Letter / SEF
8,5X11” 215.9X279.4 mm
Letter / LEF
11X8.5“ 279.4X215.9 mm
8.5X13 / SEF
8.5X13” 215.9x330.2 mm
Legal / SEF
8,5X14” 215.9X355.6 mm
Ledger / SEF
11X17” 279.4X431.8 mm
A3+ / SEF
12X18” 304.8X457.2 mm
Top Tray
Stacker Stapler
Punch
Interposer
Booklet Maker
Z Fold
BiFold
C Fold
O
X
X
X
X
X
X
X
X
O
X
X
X
O
X
X
X
X
O
O
O
X
O*1
X
X
X
X
O
O
O
2h
O*4
O
O
O
O
O
O
O
2h/3h/4h
O
O
X
X
X
O
O
O
X
O*4
O
O
O
O
O
O
O
2h/3h/4h
O
O
X
X
X
O
O
O
X
O*2
O
X
O
X
O
O
O
X
O*2
O
X
O
X
O
O
O
2h/3h/4h
O
O
O
O
X
O
O*3
X
X
X
X
X
X
O may be used X may not be used *1: Select 8x10L in NVM (763-284) *2: Select either 8.5x14S or 8.5x13S in NVM (763-287) *3: Cannot be offset or output in sets *4 Select either A4S or Letter S in NVM (791-332?????)
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Billing Meters The Xerox 4110 Billing Meters count finished prints when they reach the exit trays. During a jam, it depends on the location of the paper as to whether or not it is counted. Refer to Figure 112 in this module for the location of the sensors involved with billing. Top Tray When paper exits the top tray and clears the Top Tray Exit Sensor. During a jam no correction is made for sheets that have ed the Exit Sensor. Stack Tray Sets are counted when they clear the Compiler Exit Sensor. No jam correction is made after a set has cleared the Compiler Exit Sensor. Single sheets are counted when they the Eject Sensor. No billing correction during a jam is made for paper that has ed the Eject Sensor Folder Tray When paper has cleared Folder Path Sensor 3. No billing corrections are made for paper that has ed Folder Paper Path Sensor 3. Booklet Maker When paper has cleared the Booklet In Sensor. If the following jams occur after paper has ed the Booklet In Sensor the sheets are not counted: 12-135 Booklet Folder Roll Exit Sensor ON Jam 12-155 Booklet Folder Roll Exit Sensor OFF Jam 12-171 Paper Remains at the Booklet Compiler No Paper Sensor 12-172 Paper Remains at the Booklet Folder Roll Exit Sensor.
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Power and Switches Figure 113 shows the location of Power Supplies and PWBs in the Finisher.
4. Folder PWB 2. Interposer PWB
3. I/F PWB
7. Relay PWB
6. 24VDC LVPS
1. Finisher Main PWB 5. Booklet Maker PWB
8. 220VAC Power Inlet
Figure 113 Power Supplies and PWBs
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1. Finisher Main PWB This PWB controls the operation of the Punch, Stapler, Stack Tray, and Top Tray. It also contains the Finisher Run Control Logic and generates +5VDC from the +24VDC supplied by the Finisher Low Voltage Power Supply (LVPS) 2. Interposer PWB Controls operation of the Interposer. 3. I/F PWB (Interface PWB) Is the interface between the IOT, Finisher, and Decurler. 4. Folder PWB Controls the operation of the Folder. 5. Booklet Maker PWB Controls the operation of the Booklet Maker. 6. LVPS (Low Voltage Power Supply) The LVPS generates +24VDC for use in the Finisher. 7. Relay PWB This PWB contains two power control relays. When the Interlock Switches are actuated, the relays energize and supply +24VDC to the Finisher components. 8. Power Inlet The Power Inlet supplies 220 VAC from the IOT.
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Figure 114 shows the sorter interlocks and switches.
3. Interposer Top Cover Interlock Switch (+24VDC)
4. Interposer Top Cover Switch (+5VDC)
8. Envelope Tray Open Switch
7. Decurler Switches
6. Booklet Tray Belt Switch
5. Folder Envelope Tray Switch
2. I/F Module Front Door Switch
1. Finisher Front Door Switch
Figure 114 Interlocks and Switches (reflects 2101 entrance configuration)
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Finisher Front Door Interlock Switch. Switches off the Finisher +24VDC from the when the Front Door is opened. I/F Module Front Door Switch. Switches off the Finisher +24VDC when the I/F Module Front Door is opened Interposer Top Cover Interlock Switch (+24VDC) Switches off the Finisher +24VDC when the Interposer Top Cover is opened. Interposer Top Cover Switch (+5VDC) Switches off the Finisher +5VDC when the Interposer Top Cover is opened. Folder Envelope Tray Switch. When the folder tray is opened this switch switches off +24VDC to the Folder. Booklet Tray Belt Switch. Pressing this switch switches on the Booklet Tray Transport belts. Decurler Switch. This switch allows the Decurler to be set for up curl correction, down curl correction, or no curl correction. Envelope Tray Open Switch. When this switch is actuated, the Envelope Tray Lock Solenoid is deenergized allowing the Tray to open.
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Finisher Power Control Figure 115 shows an overview of the Xerox 4110 Finisher power control.
AC Power 220 VAC Convenience Outlet
IOT Power Control
Signal Line
Relay PWB
LVPS 220 VAC from the IOT
DC Power
+24 VDC
Relays
Finisher Main PWB Interlock +24 VDC
+24 VDC Distribution
+24 VDC
Finisher Power Control
+5 VDC
Interlock Switches
+5 VDC Distribution
Figure 115 Finisher Power Control
220 VAC to power the Finisher is supplied by the IOT. In the Finisher the 220 VAC supplies the LVPS and the Convenience Outlet. The LVPS generates the +24 VDC for the Finisher. The LVPS is switched on or off by AC Power Control in the IOT. The Finisher Main PWB generates +5 VDC for distribution to the Finisher logic. If all of the interlock switches are closed, +24 VDC energizes the relays on the Relay PWB. This supplies +24 VDC Interlocked power through the Finisher Main PWB for Distribution to the PWBs, motors, clutches, solenoids, and switches in the Finisher. When power is switched on, the Finisher logic initializes and the Finisher components are moved to their home positions.
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Decurler The Decurler subsystem is located in the Finisher Interface (I/F) Module directly underneath the Interposer. The Decurler is standard for all Finisher configurations. Paper exiting the IOT may be curled due to the heat and pressure applied by the F and other components in the IOT. To straighten the curl, pressure is applied from the opposite direction of the curl. The Decurler is a double decurler to allow for the removal of both up and down curl. Unlike previous models the cam is fixed to the shaft.
Decurler Control Decurler operation is selected using the Decurler switch located on top of the Finisher (Figure 114). The state of the Decurler is indicated by the switch LEDs. The three selections are: Auto Decurl Enabled Decurl Disabled The default decurler mode is Auto. In Auto mode the decurling correction is applied automatically according to the paper size, paper type, and feed orientation. The IOT NVM locations that supply paper type information are: 763-310 Decurl value for plain paper 763-311 Decurl value for thick paper (1) The paper size and feed orientation are based on the job programming parameters. Even if the Auto Mode is selected, no decurl operation is performed for transparencies or labels. In Decurl Enabled mode, a set amount of decurl pressure is applied regardless of paper type, size, or feed orientation. In Decurl Disabled mode, no decurl operation is performed.
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Decurler Components and Operation Figure 116 shows the components of the Decurler assembly.
Figure 116 Decurler Assembly
Decurler Components Decurler In Sensor Detects when paper has entered the Decurler Decurler Home Sensor Detects the home position of the Decurler cam that positions the foam roll. The Foam Roll applies pressure to the paper to remove the curl. Decurler Out Sensor Detects when paper has exited the Decurler Decurler Transport Motor A brushless DC motor that drives the Decurler Components, the Interposer Transport Rolls 1 and 2, and the Entrance Roll in the Punch or the Folder (if installed). Decurler Cam Clutch Transfers drive to the Decurler cam. The cam position determines the amount of pressure the Foam Roll applies to the paper.
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Interposer The Interposer allows pre-printed or special stock to be inserted into the finished sets without having to go through the processor. This prevents possible contamination of the f or xerographic components in the IOT. In addition, it is a convenient method of adding covers and slip-sheets without having to send them through the IOT. Figures 117, 118, and 119 show the Interposer components.
Interposer Exit Roll
1. Interposer Drive Clutch
Interposer Transport Roll 1
Interposer Transport Roll 2
Figure 117 Interposer Transport Assembly
The Interposer Drive Clutch This is an electromagnetic clutch that conveys drive from the Decurler Transport Motor, to the Interposer Exit Roll and the Interposer Transport Rolls 1 and 2.
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2. Size Sensor
1. Interposer Tray Lift Motor
Figure 118
Interposer Tray Lift Components Interposer Tray Lift Motor This is a DC motor that drives the Lift Shaft. Size Sensor The side guide contains a variable resistor. The movement of the guide changes the voltage output of the resistor. The logic interprets the voltage to determine the paper size.
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5. Paper Length Sensor 6. No Paper Sensor 2. Tray Up Sensor 3. Feed Motor
4. Feed Out Sensor
Nudger Roll
Feed Roll 1. Nudger Solenoid
Figure 119
Interposer Tray Feed Components Nudger Solenoid The Nudger solenoid moves the Nudger Roll and Feed Roll down at the start of the feed cycle. Tray Up Sensor This sensor senses whether or not the Interposer Tray is in the feed position. Feed Motor The Feed Motor is a stepper motor that is switched on after the Tray Up sensor verifies that the tray is raised to the feed position and the No Paper sensor verifies that there is paper in the tray. Feed Out Sensor This sensor senses that paper feed has begun. Once paper is detected, the Nudger Roll solenoid is deenergized and the Feed Roll and Nudger Roll move up. Paper Length Sensor This sensor, in combination with the values detected by the Size Sensor (Figure 118, Item 2), determines both the size of the paper loaded and whether it is long or short edge feed. No Paper Sensor This sensor determines whether or not there is any paper in the tray. The feed cycle will not start if the tray is empty.
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Folder The folder is an optional device that provides the following folding capabilities. Large size Z fold (11X17) Large Z folds are folded to 8.5X11 and either inserted into letter size sets or output separately. May be punched and stapled Mixed size output is allowed but without punching or stapling. Output is to the Stack Tray C fold and small size Z fold Output is to the Folder Tray No punching or stapling No mixed size output NOTE: the Booklet Maker performs Bi-Folds. That will be discussed later in this module. The folder may be installed on both configuration Finishers (with or without the Booklet Maker). The Folder Tray is different from previous models to allow for center registration. Diagnostic routine dC128 is used to adjust the Booklet Maker, “Z” fold and “C” fold.
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Components Figure 120 shows the Folder drives and components.
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1. Entrance Motor 4. Gate Solenoid 1 Entrance Roll 8. Entrance Sensor
2. Drive Motor 1 9. Exit Sensor 3. Drive Motor 2
Exit Roll Transport Roll 7
6. Nip Release Solenoid
Transport Roll 1 10. Path Sensor 1 Transport Roll 2
Transport Roll 3
11. Path Sensor 2 Transport Roll 6
5.Gate Solenoid 2
13. Path Sensor 4 Transport Roll 5 12. Path Sensor 3 7.Tray Lock Solenoid
Transport Roll 4 Finger Assembly 14. C Solenoid
Figure 120 Folder Drives and Transport Components
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Components Entrance Motor This is a brushless DC motor that drives the Folder Entrance Roll, the Folder Exit Roll, and the Punch Entrance Roll Drive Motor 1 This is a stepper motor that drives Folder Transport Roll 1. Drive Motor 2 This is a brushless DC motor that drives Transport Rolls 2 through 7, Folding Roll 1, and Folding Roll 2. Gate Solenoid 1 This is the solenoid for switching the upper Folder gate to allow paper to enter the Folder Gate Solenoid 2 This solenoid opens the gate to allow folded paper to enter the Folder (Envelope) Tray. Nip Release Solenoid This solenoid releases the Pinch Roll from Transport Roll 1 Folder (Envelope) Tray Lock Solenoid This solenoid prevents the tray from opening until the folding operation is complete. Entrance Sensor Detects paper entering the Folder Exit Sensor Detects paper exiting the Folder Path Sensor 1 Detects paper jams in the Folder Path Sensor 2 Detects paper jams in the Folder Path Sensor 3 Detects paper jams in the Folder Path Sensor 4 Detects paper jams in the Folder C Solenoid Pushes the Finger Assembly against the paper so that curled corners won’t be folded during a C fold operation.
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Figure 121 shows the End Guide Assemblies. The End Guides are moved in the directions shown during the folding operation to control the width each fold. The width of the fold is determined by the size of the paper being folded and the type of fold selected.
1. End Guide Motor 1
3. End Guide Home Sensor 1
Nip Roll End Guide 1
Folding Roll 2
2. End Guide Motor 2
5. Envelope Tray Full Sensor
4. End Guide Home Sensor 2
End Guide 2
Figure 121 End Guide Positioning
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Components End Guide Motor 1 This is the stepper motor that moves End Guide 1 up or down. End Guide Motor 2 This is the stepper motor that moves End Guide 2 up or down. End Guide Home Sensor 1 This is the sensor that detects the home position of End Guide 1. End Guide Home Sensor 2 This is the sensor that detects the home position of End Guide 2. Envelope Tray Full Sensor This is a two part (transmitter and receiver) photo sensor that detects when the tray is full. The end guides are different than previous models to allow for center registration.
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Folder Operation Due to the fact that the folder operates at a high rate of speed it is difficult to directly observe the folding operation. Figure 122 shows the sequence for a typical fold. Top Gate
1.
Exit Roll
5.
2. 3. 4.
Transport Roll 1
Entrance Roll
Nip Release Sol. First Fold Rolls
First Fold Rolls
End Guide 1
6.
Second Fold Rolls
7.
8.
End Guide 1
9. Transport Roll 7 Transport Roll 6
Transport Roll 2 Transport Roll 3 End Guide 2
Transport Roll 5 Second Fold Rolls
Transport Roll 4 Lower Gate
Figure 122 Typical Fold Sequence
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Folder Operation. Paper Transport to the Folder Paper exiting the Decurler is transported to the Folder Top Gate by the Folder Entrance Roll. If the paper is to be folded, the Top Gate solenoid is energized and the sheet moves toward the First Fold Rolls. Paper that is not folded is transported to the Punch by the Exit Roll Adjusting End Guide 1 End Guide 1 is adjusted according to the paper size and the fold pattern (C or Z fold). Paper Transport to End Guide 1 Paper is transported to the End Guide by Transport Roll 1 (driven by Folder Drive Motor 1) Skew Correction When the paper is stopped by End Guide 1, the Nip Release Solenoid on Transport Roll 1 is energized, releasing the nip between the drive roll and the idler roll. This allows any paper skew to be corrected by the End Guide. First Fold After the skew is corrected, the Nip Release Solenoid is deenergized. As Transport Roll 1 drives the paper against End Guide 1, it forms a buckle and is drawn into the First Fold Rolls. The folded sheet is transported by the First Fold Rolls towards the second fold rolls. Adjusting End Guide 2 End Guide 2 is adjusted according to the paper size and the fold pattern (C or Z fold). Paper Transport to End Guide 2 Paper is transported to the End Guide by Transport Rolls 2 and 3 (driven by Folder Drive Motor 2) Second Fold As the paper is driven against End Guide 2, it forms a buckle and is drawn into the Second Fold Rolls. Folder Exit The folded sheet is then transported to either the Folder (Envelope) Tray or the Folder exit. If the output is a small Z or a C fold the Lower Gate Solenoid is energized and the sheets are directed into the Folder Tray. Transport Rolls 4, 5, 6, and 7 transport large Z folds into the Finisher.
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Punch A motor driven punch is standard for all of the Finisher configurations. A 2 /4 hole punch is available as an option. The punch is not a customer replaceable unit. If the customer prefers the 2 / 4 hole option the service representative will install it. The Punch assembly is 2 / 4 hole for XE and 2 / 3 holes for XC (the 2 holes in XC is for legal applications).
Punch Components Figure 123 shows the 3-hole punch configuration.
1. Punch Move Motor 3. Punch Move Clutch 9. Punch Home Sensor 13. Side Registration Home Sensor
14. Punch Cam Plate 10. Punch Front Sensor 8. Punch Move Home Sensor (B4) 7. Punch Move Home Sensor (B5) 2. Punch Motor
11. Punch Out Sensor
5. Punch Motor Sensor
4. Punch Box Sensor
15. Skew Correction Guides 6. Punch Move Home Sensor 12. Side Registration Sensor
Figure 123 3 Hole Punch Assembly
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Punch Move Motor This is a stepper motor that positions the Punch Assembly Punch Motor This is a DC motor that drives the punch cam plate, which drives the punches to punch the holes. Punch Move Clutch This clutch transmits the drive from the Punch Move Motor to position the Punch Assembly. Punch Box Sensor This sensor verifies that the punch scrap box is installed. Punch Motor Sensor This sensor determines the amount of rotation of the Punch Motor required to perform the punch operation. The sensor counts the pulses as the encoder wheel rotates. Punch Move Home Sensor (letter) This sensor determines the home position of the punch for punching 3 holes in letter size paper. Punch Move Home Sensor (B5) This sensor determines the home position of the punch for punching 3 holes in B5 size paper. Punch Move Home Sensor (B4) This sensor determines the home position of the punch for punching 3 holes in B4 size paper. Punch Home Sensor This sensor detects when the Punch Assembly is in the home position Punch Front Sensor This sensor detects the Punch Assembly position at the start of print. The punch stays at the previously used position and the logic uses this sensor along with the home sensors to determine if the Punch Assembly needs to be moved for the current job. Punch Out Sensor This sensor detects when the paper has exited the Punch. Side Registration Sensor This sensor detects the side edge of the paper Side Registration Home Sensor This sensor detects the home position of the Side Registration Sensor Punch Cam Plate Moves the punch pins to punch the paper. The cam plate is driven by the Punch Motor. Skew Correction Guides The Skew Correction Guides are pivoting spring loaded guides that allow paper to in the output direction and stop the paper when it is backed up into the punch position
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Punch Operation Sheets are punched one sheet at a time. The Punch assembly is adjusted so that the punches may be positioned according to the paper size. The punch unit is divided into two areas as shown in Figure 124. These are the: Sensor Assembly Punch Assembly The position of the complete assembly can be adjusted and the relative position between the two assemblies can also be adjusted. This allows for a complete range of adjustments based on the paper size being punched.
Side Registration Home Sensor
Punch Move Clutch
Side Registration Sensor
Sensor Assembly Rear
Front Punch Assembly
Punch Move Home Sensor
Figure 124 Punch Positioning
There are three adjustments made for positioning the Punch Assembly. Initialization Repositioning Punching The following is a description of each positioning operation Initialization: Initialization is performed at power on and at the end of a job. The sequence is: With the Punch Motor Clutch off, the Punch motor is switched on. This moves just the Punch Assembly toward the front until the Punch Move Home Sensor switches off. Then the Punch Motor reverses and drives the Punch Assembly towards the rear until the Punch Move Home Sensor switches on. The motor is reversed again and the Punch Assembly moves toward the front until the Side Registration Home Sensor switches off. The motor reverses once again and the Punch Assembly moves toward the rear until the Side Registration home sensor switches on. Steps 1 – 4 have adjusted the relative position between the Punch Assembly and the Sensor Assembly. Now the Punch Move Clutch and motor are switched on and both the Punch Assembly and the Sensor Assembly are driven toward the front until the Punch Move Home Sensor is switched off The motor reverses and both assemblies are driven toward the rear until the Punch Move Home Sensor switches on. The Punch is now in position for a letter size 3-hole punch.
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Repositioning If a paper size other than 8.5X11” is selected to be punched the punch will be repositioned at the start of the job. If the paper size to be punched is 8.5X11” no adjustment is needed. The punch was positioned for letter size during Initialization. At the end of the job the Punch will be repositioned for letter size. NOTE: If A4 paper is the default paper size for your market area, the punch will be positioned during Initialization for A4 rather than 8.5X11”. Punching The Punch position is adjusted to the location of the side edges for each sheet. This ensures that the holes will always be in the same location on each sheet The sequence for positioning the Punch to the side edges of the sheet is: With the paper in position to be punched, the Punch Drive Motor and Clutch are switched on. The whole punch assembly is moved towards the front. When the Side Registration Sensor switches off, which indicates that the side edge of the paper has been detected, the motor and clutch are switched off. The punch is now in position to punch the sheet.
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Paper Transportation and Punching Paper output from the IOT moves from the decurler, through the folder (if installed) and into the punch area. The Punch Entrance Roll is driven by the Decurler Transport Motor or the Folder Entrance Motor if a Folder is installed. Paper in the Punch area is transported by the Finisher Transport Motor and SCT Exit Motor (if output is the top tray) or the Compiler Exit Motor (if output is to the Stack Tray).
Output Direction
Skew Correction Direction
Front
Skew Correction Guides
Figure 125 Skew Correction
Removing Skew In order to de-skew the sheet, (Figure 125) the paper is driven past the punch position. After the Folder Exit Sensor detects the trail edge of the sheet, the Finisher Transport Motor and the SCT Exit Motor or the Compiler Exit Motor reverse direction and the paper is driven back towards the punch position. The paper is stopped by the Skew Correction Guides. The skew correction guides allow paper to travel in the output direction and block the sheet moving backwards. The sheet is now ready to be punched.
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Punching The Punch Motor moves the Punch Cam Plate that lowers the pins to punch the sheet. The encoder pulses counted by the Punch Motor Sensor determine the cam plate travel. After the correct number of pulses are counted, the Punch Motor reverses and is stopped when the Punch Home Sensor is blocked. Once the pins are retracted the paper is driven to the exit. The Punch is now ready to repeat the process for the next sheet.
108+/-1 mm
8.5X11” Paper NVM Loc: 791 – 217 Range: 60 – 170
32+/-3 mm
12+/-2 mm
Figure 126 Three Hole Punch Specifications
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Paper Transportation / Top Tray Figure 127 shows the components that feed paper to the Top Output Tray. 5. Compiler Exit Motor
4. SCT Exit Motor
T/A 2 Roll Top Exit Roll 1. Top Tray Exit Sensor
7. Finisher Transport Motor
2. Top Tray Full Sensor Compiler Exit Roll 9. Compiler Exit Sensor 6. Transport Gate Solenoid
Buffer Reverse Roll
S2 Gate
T/A 1 Roll
8. Booklet Gate Solenoid
Buffer Roll S1 Gate
Punch Reverse Roll
3. Buffer Path Sensor
Figure 127 Paper Transportation / Top Tray
Top Tray Exit Sensor Senses that paper has been transported to the Top Tray. Top Tray Full Sensor Senses when the Top Tray is full. Buffer Path Sensor Senses paper in the Buffer path. SCT Exit Motor A stepper motor that drives the T/A 2 and Top Exit Roll. Compiler Exit Motor A stepper motor that drives the Buffer Roll, Buffer Reverse Roll, and the Compiler Exit Roll.
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Transport Gate Solenoid Actuates the S2 Gate to direct paper to the Top Tray or the Compiler. Finisher Transport Motor A stepper motor that drives the T/A 1Roll, Punch Reverse Roll, and Booklet Maker In Roll. Booklet Gate Solenoid Actuates the S1 gate to direct paper into the Booklet Maker. Compiler Exit Sensor Senses that paper has reached the Compiler Tray
Output Selection Refer to Figure 128.
Top Tray
T/A 2 Roll
Top Exit Roll Buffer Reverse Roll
T/A 1 Roll
Compiler Exit Roll Gate S2
Stack Tray
Punch Reverse Roll Gate S1 Punch
Stapler Head Entrance Roll Booklet In Roll
Buffer Roll
Booklet Maker
Figure 128 Output Selection Gates S1 and S2 determine the destination of paper entering the Finisher. If the Booklet Gate (S1) Solenoid is de-energized, paper is routed to the Compiler or the Top Tray. If the solenoid is energized paper moves into the Booklet Maker. If the Transport Gate (S2) is de-energized paper moves into the Compiler. If the solenoid is energized paper moves to the Top Output Tray.
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Compiling, Stapling, and Ejecting the Sets When the machine is operating in the sets mode, the sheets are gathered in the Compiler Tray before being ejected into the Stack Tray. If the stapling option is selected, the sheets are stapled while in the Compiler Tray. Compiling is different than 2101 in that it is compiled for center registration. Figures 129 – 135 show the components of the Compiler and Stapler.
1. Tamper Home Sensor Tamper Paper Travel Direction 3. Compiler Tray No Paper Sensor
2. Tamper Motor
Figure 129 Tamper Assembly The Tamper ensures that the paper is stacked evenly front to back in the Compiler tray. Tamper Home Sensor This sensor detects the home position of the Tamper. Tamper Motor A stepper motor that drives the Tamper Compiler Tray No Paper Sensor Detects the presence of paper in the Compiler Tray
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Figure 130 shows the shelf that is extended from the Compiler Tray to the right hand side of the sheets stacked in the tray. The shelf is extended during the compile operation and retracted just before the set is ejected. 2. Shelf Motor Direction of Paper Travel
1. Shelf Home Sensor
Figure 130 Compiler Tray Shelf
Shelf Home Sensor Detects the home (closed) position of the shelf. Shelf Motor The stepper motor that drives the shelf
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Figure 131 shows the End Wall Assembly. This is different than previous models to accommodate center registration. 1. End Wall Open Sensor
Paper Travel Direction
2. End Wall Home (Closed) Sensor End Wall Assembly 3. End Wall Motor
Figure 131 End Wall Assembly
End Wall Open Sensor Detects when the End Wall is in the open position. End Wall Home Sensor Detects when the End Wall is closed. End Wall Motor The stepper motor that opens and closes the End Wall.
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Figure 132 is the Stapler Assembly. It consists of the Stapler Head and Base.
4. Stapler Head Assembly
2. Stapler Center Position Sensor
1. Stapler Home Sensor 3. Stapler Move Motor
Figure 132 Stapler Assembly
Stapler Home Sensor Detects when the Stapler Head is in the home position. Stapler Center Position Sensor Detects when the Stapler Head is in the center position. Stapler Move Motor Moves the Stapler Head to the staple positions. Stapler Head The Stapler Head consists of the Stapler Home Sensor, Stapler Drive Motor, the Low Staple Sensor, the Stapler Ready Sensor, and the Stapler Cartridge Sensor. The Stapler head is replaced as a unit. The individual components in the Stapler Head are not field replaceable. Stapler operation will be described later in this module.
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The paddles push the sheets against the End Wall. This, along with the action of the Tamper, keeps the edges of the paper stack aligned. Figures 133 and 134 show the Main and Sub Paddle components.
Compiler Main Paddles
1. Compiler Paddle Up/Down Solenoid Figure 133 Lower Exit Chute and Main Paddle Assembly
2. Sub Paddle Home Sensor 3. Sub Paddle Up/Down Solenoid
Paper Travel Direction 6. Eject Motor
Sub Paddles 4. Paddle Clutch 5. Paddle Motor
Figure 134 Sub Paddles and Paddle Drives Compiler Paddle Up/Down Solenoid Changes the Main Paddle Height as stack height increases. Sub Paddle Home Sensor Detects the home position of the Sub Paddle. Sub Paddle Up/Down Solenoid Changes the Sub Paddle Height as stack height increases. Paddle Clutch Transmits drive to the Sub Paddle Shaft. Paddle Motor The stepper motor that drives the Main and Sub Paddles.
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Eject Motor The stepper motor that drives the Compiler Exit Roll.
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Once the set is compiled and stapled (if selected), it is ejected into the Stack Tray. Figure 135 shows the eject components.
Paper Travel
4. Eject Safety Switch 1
Eject Clamp
2. Eject Clamp Motor
Feed Roll 1. Eject Sensor 3. Eject Up Sensor
Figure 135 Set Eject Components Eject Sensor Detects when the paper has ed the Eject Clamp Eject Clamp Motor This stepper motor raises and lowers the eject clamp. Eject Up Sensor Detects when the Eject Clamp is in the up position Eject Safety Switch 1 When the Compiler aperture is open this switch removes 24 VDC from the Stapler Motor in the Stapler Head.
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Compiler and Stapler Operating Sequence Now that you are familiar with the Output Components here is the sequence for outputting a stapled set. Extending the Shelf At the start of print the Shelf Motor is switched on and the Shelf is moved into position to the right hand edge of the set. Paper enters the Compiler Tray Sheet 1 The Eject Clamp is lowered so that the paper can be driven by the Compiler Exit Roll and the Eject Roll. When the trail edge of the sheet es the Compiler Exit Sensor the Eject Motor reverses and moves the sheet back into the Compiler Tray towards the raised End Wall. Sheets 2 through N. The Eject Clamp is raised and the second and subsequent sheets are dropped into the Compiler Tray. The Main and Sub Paddles move and hold the sheets against the End Wall. Tamping When the sheet has entered the Compiler Tray the Tamper is switched on it moves the paper into position in the tray and then retracts. This operation is repeated for each sheet. When the last sheet enters the tray, this operation is performed twice. Stapling When the completed set is in the Compiler Tray the Eject Clamp is lowered to clamp the set the Tamper is returned to its home position and the set is stapled as required. If a dual stitch was selected, the End Wall is lowered first so that it will not interfere with the movement of the Stapler head. Retracting the Shelf With the set still in the Compiler Tray, the Shelf is retracted in preparation for ejecting the set. Ejecting the Set The Eject Motor is switched on and the set is driven into the Stack Tray. Once the set has exited the tray the Eject Clamp is raised and the Compiler is ready to receive the next set.
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Buffer Path Under some circumstances the first sheets of the next set will begin to arrive at the Compiler Tray before the set already in the Tray is ready to be ejected. A combination of delayed paper feed (skipped pitches) and a buffer area in the Finisher are used to delay the sheets entering the Compiler. Keeping paper waiting in the buffer path is only used for A4 LEF, Letter LEF, and B5 LEF sets. Along with the buffer, a skipped pitch is used when the set requires either dual staples or a single rear staple. This gives the stapler time to move into position and staple the set.
Buffer Path Sequence The following is a description of buffer operation. Refer to Figure 136. The first sheet of the next set is transported toward the Compiler Tray. At a set time interval after the Punch Exit Sensor detects the trail edge of the first sheet, the S2 Gate Solenoid energizes. At this time the Compiler Exit Motor is reversed and the paper backs up into the buffer area. After another set time interval, the Compiler Exit Motor stops and the first sheet is held in the buffer area. When the second sheet clears the Punch Exit Sensor, Gate S2 is deenergized, the Compiler Exit Motor is switched on and both sheets are moved into the Compiler Tray, the second sheet on top of the first sheet.
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Top Tray
1.
Top Tray
2.
Stop Compiler
S2 Gate
Compiler Punch Exit Sensor
First Sheet
Booklet Maker
Booklet Maker
4.
3. Top Tray
Top Tray
Compiler
Compiler Second Sheet First Sheet
First Sheet
Second Sheet Stop
Booklet Maker
Booklet Maker
Figure 136 Buffer Path
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Stapling Positions There are two types of stapling available for the Xerox 4110, single stapling and dual stapling. This is accomplished using a single staple head. Single staples may be put at either the front or the rear of the sheet. Figure 137 shows the available stapling positions.
Figure 137 Stapling Positions
Stapler Travel When power is switched on the Stapler is positioned at the front. This is the home position. Depending on the job programming and the paper size the Stapler Head is moved to different positions. Stapling at the front When stapling at the front the Stapler is not moved because the home position is at the front.
1. 2.
Stapling at the Rear Corner (Figure 138) 1. At the Start of the job the Stapler is moved to the center position 2. The Stapler waits at the center until actually stapling. 3. The Stapler is moved to the stapling position. 4. After stapling, the Stapler is moved back to the center.
3.
4.
Figure 138 220
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Stapling Straight at the Rear (Figure 139) 1. At the start of the job the Stapler is moved to the center. 2. The Stapler waits at the center until actually stapling. 3. The stapler is moved to the End Wall opening/closing position and the End Wall is opened. 4. Stapler is moved to the straight stapling position at the rear then staples. 5. After stapling, the Stapler is moved back to the End Wall opening/closing position and the End Wall is closed. 6. The Stapler is moved back to the center.
1.
2.
3.
4.
5.
6.
Figure 139
Dual Stapling (Figure 140) 1. At the start of the job the Stapler is moved to the center. 2. The Stapler waits at the center until actually stapling. 3. The Stapler is moved to the End Wall open/close position and the End Wall is opened. 4. The Stapler is moved to the straight stapling position at the front and then staples. 5. The Stapler is moved to the straight stapling position at the rear and then staples. 6. After stapling the Stapler is moved back to the End Wall opening/closing position and the End Wall is closed. 7. The stapler is moved back to the center.
1.
2.
3.
4.
5.
6.
7.
Figure 140
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Stack Tray Components and Operation Figures 141, 142, and 143 show the location of the Stack Tray components.
1. Stack Height Sensor 1 (F)
3. Stack Height Sensor 3 (F)
2. Stack Height Sensor 2 (F)
4. Tray Height Sensor Lower (F)
3. Stack Height Sensor 3 (R) 1. Stack Height Sensor 1 (R) 2. Stack Height Sensor 2 (R)
4. Tray Height Sensor Lower (R)
5. Mix Stack Sensor 6. Half Stack Sensor 9. Elevator Motor
7. Full Stack Sensor
8. Lower Limit Sensor
Figure 141 Stack Tray Components (1)
Stack Height Sensor 1 (Front) Stack Height Sensor 1 (Rear) These sensors detect the height of the paper stack in the tray. Stack Height Sensor 2 (Front) Stack Height Sensor 2 (Rear) These sensors detect the height of the paper stack in the tray.
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Stack Height Sensor 3 (Front) Stack Height Sensor 3 (Rear) These sensors detect the height of the paper stack in the tray. They are added only when a Folder is installed. Tray Height Sensor Lower (Front) Tray Height Sensor Lower (Rear) This sensor senses whether or not paper has been removed from the tray. Mix Stack Sensor This sensor detects the upper position of the Stack Tray. Half Stack Sensor This sensor detects the middle position of the Stack Tray. Full Stack Sensor This sensor detects the lower position of the Stack Tray. Lower Limit Sensor This sensor detects the lower limit position of the Stack Tray. Elevator Motor A DC motor that drives the Stack Tray up and down. CAUTION Lower the Stack Tray to the bottom before disassembling the Elevator Motor or Drives. Failure to lower the tray will cause the tray to drop.
Stack Tray Indexing The Stack Tray is indexed up or down based on the height of the paper stack. When the tray indexes is determined by the state of one of the three sets of Stack Height Sensors. Which set is used is dependent on the output mode. They are: Stack Height Sensor 1 – Unstapled sets Stack Height Sensor 2 – Stapled sets Stack Height Sensor 3 – Sets containing Z folds (on Folder equipped machines) Using sensors that are positioned differently for each type of output allows for efficient stacking regardless of the thickness of the output set. During operation the Stack Tray moves up at the start of print until the Stack Height sensor for the appropriate mode is blocked. The tray then moves down until the sensor is not blocked. As paper enters the tray, it will move down each time the sensor is blocked. If the tray becomes full the machine will shut down until the tray is emptied. If paper is removed during printing the tray will move up until the height sensor is blocked and the cycle begins again. How full the tray is determined by the states of the Mix Stack Sensor, Half Stack Sensor, Full Stack Sensor, and Lower Limit Sensor.
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2. Stacker Safety Switch
3. Stacker Flap Motor 1. Stacker No Paper Sensor
Figure 142 Stacker Components (2)
Stacker No Paper Sensor This sensor detects whether or not paper is present in the tray. Stacker Safety Switch If this switch detects an obstacle under the Stack Tray it will Switch off the 24 VDC to the Elevator Motor Stacker Flap Motor This is a DC motor that raises and lowers the flap on the Stack Tray. When stapled sets of small size sheets are output, the set is higher at the stapled side. This reduces the capacity of the stack tray. To counteract this the flap on the Stacker is lowered. This lets the tray fill to its rated capacity.
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2. Set Clamp Solenoid
1. Stacker Front Position Sensor
3. Stacker Offset Motor
Figure 143 Stacker Components (3)
1. Stacker Front Position Sensor This sensor detects the offset position of the Stacker Tray 2. Set Clamp Solenoid This solenoid operates the Set Clamp in the Compiler Tray. 3. Stacker Offset Motor This is the DC motor that moves the Stacker Tray to the front or the rear to offset stack the output.
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Offset Stacking There are three modes of stacking. They are: Unstapled Sets – Offset Stacking Unstapled sets are stacked in two alternate positions, front and rear. Stapled Sets – Offset Stacking Stapled Sets are stacked in three alternate positions, front middle and rear. This allows for better stacking of stapled sets. Stapled Sets – No Offset Stacking NVM locations 763-340 (Stapling Offset Off) and 763-297 (Stapling Offset On) can be set if the customer would prefer not to have offset stacking for stapled sets. Offset stacking for stapled sets is the default mode.
Booklet Maker The booklet maker can compile up to 15 sheets, dual saddle stitch them, fold them and output them as a booklet. The Scanner and IOT logic will reduce or enlarge the images, and interpose (pre-collate) the sheets as necessary to ensure that the pages are in the correct order. The maximum number of sheets may be set to 25 stapled and 15 unstapled using NVM location 763-252. However, it should be noted that the fold quality cannot be guaranteed on unstapled sets of more than 5 sheets and stapled sets of more than 15 sheets. Diagnostic routine dC128 is used to adjust the Booklet Maker, “Z” fold and “C” fold. The booklet maker is an optional accessory. It cannot be installed in the field so if a customer wishes to purchase a Booklet Maker at a later date, the Finisher must be replaced.
Booklet Maker Components Figures 144 through 147 show the components of the Booklet Maker. CAUTION Do not slide out the Booklet Maker Assembly with the Finisher Interlocks cheated. Sliding out the Booklet Maker with power applied to the sensors could damage the sensors.
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Booklet Exit Roll 1. Booklet In Sensor Booklet Folding Rolls 3. Booklet Paper Path Motor Booklet Eject Roll
4.Booklet Fold Motor 2. Booklet Folder Roll Exit Sensor
5. Knife Solenoid
Figure 144 Booklet Maker Components (1)
1. Booklet In Sensor This is the sensor that detects that paper has entered the Booklet Maker area. 2. Booklet Folder Roll Exit Sensor This is the sensor that detects that paper has been transported to the Booklet Tray. 3. Booklet Paper Path Motor This is a stepper motor that drives the Booklet Exit Roll. 4. Booklet Fold Motor This is a DC motor with an encoder that drives the Booklet Folding Roll, Booklet Eject Roll, and the Knife. 5. Knife Solenoid The Knife Solenoid transmits drive from the Booklet Fold Roll Motor to the Knife.
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2. Booklet Tamper Home Sensor (R) 5. Booklet Tamper Motor (R) 4. Booklet Tamper Motor (F) 1. Booklet Tamper Home Sensor (F)
6. Knife Folding Sensor 7. Knife Home Sensor
3. Booklet Compiler No Paper Sensor
Knife
Figure 145 Booklet Maker Components (2) Booklet Tamper Home Sensor (Front) Detects the home position of the front Tamper. Booklet Tamper Home Sensor (Rear) Detects the home position of the rear Tamper. Booklet Compiler No Paper Sensor Detects whether or not there is paper in the Compiler Tray. Booklet Tamper Motor (Front) The stepper motor that drives the front Tamper in the Booklet Compiler Tray. Booklet Tamper Motor (Rear) The stepper motor that drives the rear Tamper in the Booklet Compiler Tray. Knife Folding Sensor Detects that the Knife is in the extended position. Knife Home Sensor
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Detects that the Knife is in the retracted position.
Front Tamper
Rear Tamper 1. Stapler Assembly
4. End Guide Motor
3. End Guide Home Sensor
Paddles
End Guide 5. Drawer Closed Sensor 2. Paddle Motor
Figure 146 Booklet Maker Components (3) Stapler Assembly This is the Stapler Assembly for the Booklet Maker. It consists of two stapler heads and the Stapler Drive Motor assembly. Paddle Motor This DC motor drives the Paddle Assembly. The paddles move the set against the End Guide. End Guide Home Sensor This sensor detects the home position of the End Guide. End Guide Motor A DC stepper motor that positions the End Guide for different size paper. Drawer Closed Sensor This sensor detects whether or not the Booklet Maker Drawer is closed and latched.
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1. Tray Belt Drive Motor
2. Booklet Tray No Paper Sensor
Figure 147 Booklet Maker Components (4) Tray Belt Drive Motor This motor drives the Booklet Tray Drive Belts. Booklet Tray No Paper Sensor This sensor detects paper in the Booklet Tray. The Booklet Tray is considered full when 15 booklets have been stacked after the sensor detects paper.
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Booklet Maker Operation As with the Folder it is difficult to see the Booklet Maker in operation. The following is a brief description of a typical booklet making and stapling operation.
1. 2.
3.
4.
Gate S1
Compiler Tray
End Guide
Stapler
5.
Fold Position
6.
Knife
Figure 148 Booklet Maker Sequence of Operation
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Adjusting the End Guide Position At the start of print the End Guide is positioned according to the paper size selected. Transporting Paper to the Booklet Maker Paper that has ed through the punch area is directed by Gate S1 into the Booklet Maker. The Booklet Paper Path Motor drives the paper into the End Guide. The tampers ensure that the paper stacks evenly and the paddles keep the paper against the End Guide. Positioning the Tray and Raising the Set for Stapling The sheets are compiled with the edges at the front of the tray. Once the set is complete, the tray moves toward the center to position the set so that the staples will be equidistant from the top and bottom of the set. The End Guide is raised to position the set for stapling in the center. The sheets are then stapled. Raising the Set for Folding The End Guide continues to raise the set until the center of the sheets lines up with the fold position. Folding the Set to Make the Booklet When the set is in the fold position, the Knife Solenoid is energized. This allows one rotation of the Knife gear. The Knife extends to push the set into the Fold Rolls and then retracts to the home position. Booklet Exit The now folded and stapled booklet is transported to the Booklet Tray. The Booklet Tray belts transport the booklets to the end of the Tray. NVM location 763-231 may be used to change the time that the belts run for each booklet. The end of the Booklet Tray may be dropped to allow the booklets to drop into a receptacle. It should be noted that the Booklet Maker might also be used for Bi-Folded single sheets. The stapler is not used but the fold operation is the same for each sheet.
Enhanced Finisher The new Enhanced D Finisher looks and is very similar to the D finisher that you have been servicing on the 4110. The Enhanced D Finisher is RoHS compliant, and will be the Finisher for the Xerox 4110 and 4110 EPS. New Features: “Z” fold capacity increased from 30 sheets to 80 sheets The “Z” fold productivity has been increased. A cut staple stapler with the same 100 sheet capacity as the previous one
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The new stapler is a cut staple stapler, and requires a Staple Waste Container. The customer will receive 1 Staple Waste Container with every 4 staple cartridges. The Staple Waste Container is sensor monitored to ensure that it is thrown away when it has been filled.
Staple Waste Container Senor
There are 3 Staple Waste Container Fault Codes displayed for the customer: 024 – 931 Staple Waste Container Full 024 – 932 Staple Waste Container Set Fail 012 – 400 Staple Waste Container Near Full
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One way to tell the difference between the D Finishers and the Enhanced D Finisher is by the product code: ANV – D2 Stapler/Finisher with 2/3 hole punch – US and Canada ANW – D2 Stapler/Finisher with 2/4 hole punch – Europe ANX – D2 Booklet Finisher with 2/3 hole punch – US and Canada ANY – D2 Booklet Finisher with 2/4 hole punch – Europe There have been several changes in the 4110/4590 EDOC associated with the new Enhanced Finisher. The BSDs for the Enhanced Finisher have their own separate section. The circuitry is the same as the D finisher but the Enhanced finisher wires have completely different wiring nomenclature. (Insert a captivate BSD finisher walk thru. Open your documentation. Open 4110/4590. Open 7 wirenets. Open BSDs. Open chain 12. Open 12.A.) There are also five new Fault Codes. Three associated with the Staple Waste Container 012 – 400 Staple Waste Container Near Full 024 – 931 Staple Waste Container Full 024 – 932 Staple Waste Container Set Fail and two others. 012 – 952 Envelope Folder Tray Pause Detect 027 – 728 Ext Server Req File Exceed
Software ‰ View the software procedure for the 4110 EPS on the EPSS CD Parts List The parts list will have two separate sections for the D finisher and Enhanced D Finisher. The new finisher will start at PL 17.101
Adjustments There are no new finisher adjustments. The ADJ 17.14.4 Finisher – D2 Dual Staple Skew/ Lead Position Adjustment is slightly different in that the cam has changed.
D3 Finisher The appearance of the new D3 finisher is very similar to the previous finisher. There are however improved features that have been added. The D3 Finisher can now staple up to 100 sheets using Variable Length Staple technology. The Booklet Maker capacity is now 20 sheets. There have been wiring changes and it is necessary to use the correct service manual when servicing the finisher. The service manual is on the new Xerox 4112/4127 EDOC. It is separate from the Xerox 4112/4127 Service Manual and the OHCF Service Manual.
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(Chain 16) Printer
Introduction Module Overview This module describes the names, locations and functions of the components in Chain 16 Printer.
Technical Overview The main functions of this module are to Control and direct the printing operation.
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Printer Configuration Component Name and Function
HDD
ESS Fan ESS PWB
Memory (64MB)
Memory (256MB) NVM PWB
STD ROM Monza4 FCW PWB
Figure 149
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The ESS PWB controls the printer functions as well as the overall system. The NVM PWB (Nonvolatile Memory) is installed on the ESS PWB. The STD ROM is and extension font ROM. The System Memory has two slots on the ESS PWB. The top slot is standard 64MB SDRAM (RAM1) and the bottom is an extension slot (RAM2) THE 256MB Memory (2slots) is the memory for storing image data. The ESS Fan cools the ESS PWB. The Monza4 PWB is the interface PWB connected to the UI. The HDD is a 40G drive that is actually 38.4G partitioned as follows: 3.6G for Font, Job Template and SBM Folder 3.6G for EPC Print data 14.6G for Ext Mailbox, scan, report, etc 3.6G PDL/Mail temp 6.3G EPC Copy temp data 1.8G Scan server, Scan PC, Email, etc 0.9G DOMS Scan Data 0.9G Spool, recovery.
Hardware Configuration The Printer functions are controlled by the ESS PWB and components connected to it. Figure 150 and Table 42 show the ESS PWB hardware configuration and specifications.
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Figure 150 ESS PWB Hardware Configuration
Table 42 ESS PWB Hardware Specifications Function U Bridge System Memory
Program ROM (PCI Boot ROM)
Specification PPC750Cxe ZERO PC133SDRAM 2 Slots
Flash ROM MDIM For M 2-Slot PCI Boot 32-bit Bus wide
Standard Font ROM Extension Font ROM NVM/RTC SEEPROM 1
238
NVM capacity: 1MB J334 8K bits
Installed on On Board On Board 144 SO-DIMM
Config. 750-600M ○ Max512MB
144 SO-DIMM
Max512MB
144 SO-DIMM 144 SO-DIMM
(Max)32MB (Max)32MB
RAM1 J330 (Standard Slot) RAM2 J331 (Extension Slot) Standard (ROM1) J332 Option (ROM2) J333
On Board
○
Mask ROM
144 SO-DIMM
Op
72 SIMM
○
Socket
○
Installed on the same DIMM where Op Program ROM is. Battery Backup RTC: I2C I/F Stores I2C I/FmacAdd, (other)
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Function Page Memory
Installed on 144 SO-DIMM
Config. Max256MB
144 SO-DIMM
Max256MB
10BaseT/100BaseT x J340 1ch, Full Speed J342 P310 for Ultra66 P302 (Power)
On Board
○
Remarks PM1 (PWB solder side) J337 PM2 (PWB part side) J338 PHY: ICS1893Y
On Board
○
For only (CE)
40-pin connector 4-pin connector
3.5-inchHDD ○
PCI Arbiter
LD
On Board
○
UI I/F PCI Slot
MugelloP349 Slot J370 for JPEG Card
Sub-board 144-pin connector
○ ○
Riser
PCI Option P347
140-pin Riser
2 slots
The connector for 3.5inch HDD is installed on the PWB. 2.5-inch HDD requires a switchboard. Secondary PCI Also serves as Reboot Controller. Secondary PCI For Secondary PCI Kutani, JPEG Slot is installed on Riser. Unlike C2D/Emono, in the case of Secondary PCI Kutani, 1 Slot is for JPEG only.
EPSV FAN
P351 P311 (12V)
10-pin connector 3-pin connector
○ ○
Debug Serial/ IOT Serial Chameleon
P380
6-pin connector
○
P382
5-pin connector
○
PSW MCU I/F
P345 P335
IIT I/F VSEL I/F
J336 J390 (Data) P391(VSEL Power) P300 +3.3V: CR3601 Reboot3V: CR3602 Sleep3V: CR3603 +5V: CR3604 CR4501-4508 (8 bits)
120-pin connector 50-pin connector 50-pin connector 3-pin connector 16-pin connector Green Orange Yellow Yellow Green
○ ○ 61.83MHz ○ ○ ○ ○ ○ ○ ○ ○ ○
Ethernet USB (Target) IDE (IDE Power)
Main Power Power LED
Status LED
Specification SDRAM 2 Slots
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Fan Fail Interrupt ed Note that this is different in connector from another existing board for Chameleon2. Video CLK
Off in Reboot Mode Off in Sleep Mode Off in Sleep Mode Access via I2C Rohm: BU2098F in use. In Sleep Mode, the LED shall be turned off at the OS level.
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Xerox 4112/4127 Differences
Introduction This section provides information about the technical modifications made to the Xerox 4112/4127.
Technical overview Simply stated, the Xerox 4112/4127 is a faster Xerox 4110 that is more capable of accurate registration. The Xerox 4112/4127 has been designed to penetrate the light production market. As such, certain modifications have been made to meet the needs of that environment. Highlights of the modifications include: •
New components and technology in the registration subsystem to make the front-to-back registration more accurate (also customer adjustable to accommodate media characteristics)
•
New components in the drive subsystem to provide increased speed
•
A new finisher with increased capacity for stapling and booklet making
•
Software enhancements to improve image quality
•
Most of the Service Diagnostics will be performed from the UI
•
Customer replaceable F Web.
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Paper Registration Several new components have been added to the registration subsystem to ensure image registration accuracy and tighten jam detection.
Multifeed Detection Sensor A new Multifeed Detection Sensor has been added to the Registration Transport.
Located under the transport in this area
Sensor
Roller Actuator
Transport rotated 180º
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Multifeed Detection Sensor operation The sensor is a variable resistor. When paper enters the pre registration area, the thickness of the paper is measured by the movement of a roller actuator that mechanically moves a rheostat that in turn changes the resistors resistance. The change in resistance results in a corresponding change in the voltage measured at the MCU PWB. If a multisheet feed occurs, the additional thickness of the paper will create an out-of-range voltage, resulting in a misfeed.
Image Sensor (CIS) Sensor A new CIS Sensor detects the edge of the media as it enters the registration area. The sensor is located on the left side of the Registration Transport.
CIS Sensor Registration Transport rotated 180º
CIS operation The CIS sensor signals the MCU PWB with the location data for the side edge. The sensor functions similar to the second CIS Sensor in the Document Handler that scans the side-2 image during single- scan mode. The diagram below shows the sensor operation when light, reflected from the paper reaches the photo diode. The point of transition from a no light condition to light present condition is interpreted as the side edge.
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Preregistration Sensor The Preregistration Sensor monitors the paper prior to arrival at the registration area. This sensor controls the operation of the Preregistration Motor. The Preregistration Motor is bi-directional and serves as the preliminary registration of the paper. Final registration is performed by the Registration Sensor and Registration Motor.
Registration Skew Sensor Another new component in the registration system is the Registration Skew Sensor. This sensor works in unison with the CIS Sensor and the Registration Sensor to provide the CIS Control PWB additional information about the amount of skew in the lead edge of the paper. The diagram below shows the operation of all three sensors to determine the amount of skew.
Timing between edge detection of all three sensors is used to calculate the skew amount. The MCU then modifies the location of the image placed on the drum by the ROS to compensate for the mechanical skew in the paper. This system is much more accurate than attempting to mechanically correct the skew.
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CIS Control PWB The new CIS Control PWB is located under the Registration Transport and receives signals from the three sensors: CIS, Skew and Registration Sensors. Information from this PWB is then sent to the CIS Adaptor PWB mounted on the MCU PWB and from there directly to the MCU for image and registration control.
CIS PWB
Registration Transport rotated 180º
CIS Adaptor PWB
MCU PWB
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Registration Motor The Registration Motor remains a DC Stepper Motor however it is now capable of half-steps in order to provide more precise control. The Registration Sensor detects the lead edge and signals the MCU which in turn commands the motor to slow down or speed up, achieving correct image registration.
Pretransfer Jam Sensor A new Pretransfer Jam Sensor has been added for Jam detection. This sensor detects if the paper timing is incorrect or if the paper lingers too long in the transfer area.
Pretransfer Jam Sensor
Paper Path Alignment Paper Path Alignment is comprised of five different adjustments: •
Lead Edge Registration
•
Side Edge Registration
•
Fast Scan Magnification
•
Slow Scan Magnification
•
Image Squareness
Paper Path Alignment is performed separately for all paper trays by Xerox Service. Adjusting individual trays is a departure from the 4110 in that there are separate NVM locations for the adjustment values for each tray. This process baselines the machine for registration accuracy. When all of the paper trays have been adjusted, the customer () then has the option to perform a similar setup for specific paper stocks to compensate for different media characteristics. For example, some media will physically shrink or stretch as it is processed through the f. By enabling some latitude at the customer level, up to 20 different paper stocks can be profiled and assigned to a paper tray. The customer first
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assigns a name to the paper stock and then performs the alignment. The custom stock is then assigned to a specific tray. The following adjustment descriptions are for the service diagnostics, not customer. For a description of the customer alignment procedures, refer to the System istration Guide.
Lead Edge Registration The Lead Edge Registration adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Lead Edge Registration are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in advancing the paper or retarding its arrival at the registration subsystem by controlling the Registration Motor.
Side Edge Registration The Side Edge Registration adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Lead Edge Registration are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in controlling the start of scan so that the image is correctly ed side-to-side.
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Image Registration Control Technology (IreCT) Overview The following three adjustments for magnification and squareness are a part of the IreCT Technology. IreCT essentially is a software program that calculates the modification that needs to be made to the image based on measurements that are provided during the adjustment process. As part of the three adjustments, measurements are made on the output grid test pattern and then recorded using the UI. Then, a sophisticated software program repositions where pixels in the bit stream (image) are placed prior to developing the latent image. In this way, slight differences from printer-to-printer are corrected so that the resultant output is a very accurate rendition for both magnification and squareness. IreCT Technology has been used on color products for some time. The technology provides accurate color registration by developing standard patches (called chevrons) on the transfer belt and then using a device called a Mark On Belt (MOB) Sensor to detect where the patches are positioned. Using that data, the software ensures that the color registration is always accurate.
Fast Scan Magnification The Fast Scan Magnification adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Fast Scan Magnification are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in manipulating the pixel placement by the ROS so that the magnification is correct.
Slow Scan Magnification The Slow Scan Magnification adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for Slow Scan Magnification are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in manipulating the pixel placement by the ROS so that the magnification is correct.
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Xerox 4110 Family Technical Information Manual
Image Squareness The Image Squareness adjustment is accessed through the UI Diagnostics /Tools path. The alignment series is contained in System Registration. The steps for adjusting Image Squareness are: 1. Select the Paper Tray 2. Print a grid test pattern 3. Measure the pattern against the specification 4. Enter the correction value 5. Confirm the correction The correction results in manipulating the pixel placement by the ROS so that the image is square on the media.
Xerox 4110 Family Technical Information Manual
9/5/2007
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