THEORY OF OPERATION
SERVICE MANUAL
®
magicolor 5430 DL
®
magicolor 5440 DL
®
magicolor 5450
2005.04
Ver. 3.0
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SAFETY AND IMPORTANT WARNING ITEMS
SAFETY AND IMPORTANT WARNING ITEMS
Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
(hereafter called the KMBT) strongly recommends that all servicing be performed only by
KMBT-trained service technicians.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.
DESCRIPTION ITEMS FOR DANGER,
WARNING AND CAUTION
In this Service Manual, each of three expressions "
CAUTION" is defined as follows together with a symbol mark to be used in a limited
meaning.
DANGER", "
WARNING", and
"
When servicing the product, the relevant works (disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with utmost care.
DANGER: Action having a high possibility of suffering death or serious injury
WARNING: Action having a possibility of suffering death or serious injury
CAUTION: Action having a possibility of suffering a slight wound, medium
trouble, and property damage
Symbols used for safety and important warning items are defined as follows:
:Precaution when servicing the
product.
General
precaution
Electric hazard High temperature
:Prohibition when servicing the
product.
General
prohibition
Do not touch
with wet hand
Do not
disassemble
:Direction when servicing the
product.
Unplug
Ground/Earth
General
instruction
S-1
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SAFETY AND IMPORTANT WARNING ITEMS
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.
KONICA MINOLTA brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.
DANGER : PROHIBITED ACTIONS
• Using any cables or power cord not specified by KMBT.
• Using any fuse or thermostat not specified by KMBT.
Safety will not be assured, leading to a risk of fire and
injury.
• Disabling fuse functions or bridging fuse terminals with
wire, metal clips, solder or similar object.
• Disabling relay functions (such as wedging paper between
relay contacts)
• Disabling safety functions (interlocks, safety circuits, etc.)
Safety will not be assured, leading to a risk of fire and
injury.
• Making any modification to the product unless instructed
by KMBT
• Using parts not specified by KMBT
S-2
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SAFETY AND IMPORTANT WARNING ITEMS
[2] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE
Konica Minolta brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and customer engi-
neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical
equipment may be subject to parts wear and eventual failure. In order to maintain safety
and reliability, the CE must perform regular safety checks.
1. Power Supply
WARNING: Wall Outlet
• Check that mains voltage is as specified. Plug the power
cord into the dedicated wall outlet with a capacity greater
than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
• If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.
WARNING: Power Plug and Cord
• Make sure the power cord is plugged in the wall outlet
securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
• Check whether the power cord is damaged. Check
whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord (with plug and connector on each
end) specified by KMBT. Using the damaged power cord
may result in fire or electric shock.
• When using the power cord (inlet type) that came with this
product, be sure to observe the following precautions:
a. Make sure the connector is securely inserted in the inlet
on the left side panel of the product.
b. If the power cord or sheath is damaged, replace with a
new power cord (with plugs on both ends) specified by
KMBT.
If the power cord (inlet type) is not connected to the
product securely, a contact problem may lead to
increased resistance, overheating, and risk of fire.
S-3
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SAFETY AND IMPORTANT WARNING ITEMS
WARNING: Power Plug and Cord
• Check whether the power cord is not stepped on or
pinched by a table and so on.
Overheating may occur there, leading to a risk of fire.
• Do not bundle or tie the power cord.
Overheating may occur there, leading to a risk of fire.
• Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
WARNING: Wiring
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.
• When an extension cord is required, use a specified one.
Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
S-4
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SAFETY AND IMPORTANT WARNING ITEMS
WARNING: Ground Connection
• Check whether the product is grounded properly.
If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
2. Installation Requirements
WARNING: Prohibited Installation Places
• Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.
• Do not place the product in a place exposed to water such
as rain.
A risk of fire and electric shock exists.
WARNING: When not Using the Product for a long time
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
CAUTION: Ventilation
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
CAUTION: Stability
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
S-5
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SAFETY AND IMPORTANT WARNING ITEMS
CAUTION: Inspection before Servicing
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure, using only the prescribed tools. Do not make any
adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect
the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
• The area around the fixing unit is hot.
You may get burnt.
WARNING: Work Performed with the Product Powered On
• Take every care when making adjustments or performing
an operation check with the product powered.
If you make adjustments or perform an operation check
with the external cover detached, you may touch live or
high-voltage parts or you may be caught in moving gears
or the timing belt, leading to a risk of injury.
• Take every care when servicing with the external cover
detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
WARNING: Safety Checkpoints
• Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
S-6
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SAFETY AND IMPORTANT WARNING ITEMS
WARNING: Safety Checkpoints
• Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.
Current can leak, leading to a risk of electric shock or
fire.
• Carefully remove all toner remnants and dust from electri-
cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
• Check high-voltage cables and sheaths for any damage.
Current can leak, leading to a risk of electric shock or
fire.
• Check electrode units such as a charging corona unit for
deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mount-
ing position.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
S-7
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SAFETY AND IMPORTANT WARNING ITEMS
WARNING: Safety Checkpoints
• After replacing a part to which AC voltage is applied (e.g.,
optical lamp and fixing lamp), be sure to check the installa-
tion state.
A risk of fire exists.
• Check the interlock switch and actuator for loosening and
check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).
• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.
• Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
WARNING: HANDLING OF CONSUMABLES
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
S-8
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SAFETY AND IMPORTANT WARNING ITEMS
CAUTION: HANDLING OF SERVICE MATERIALS
• Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.
• Do not replace the cover or turn the product ON before
any solvent remnants on the cleaned parts have fully
evaporated.
A risk of fire exists.
• Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
A risk of fire exists.
• When using any solvent, ventilate the room well.
Breathing large quantities of organic solvents can lead to
discomfort.
S-9
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SAFETY AND IMPORTANT WARNING ITEMS
[3] MEASURES TO TAKE IN CASE OF AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immedi-
ately take emergency measures to provide relief to affected persons and to prevent
further damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
[4] CONCLUSION
1. Safety of users and customer engineers depends highly on accurate maintenance and
administration. Therefore, safety can be maintained by the appropriate daily service
work conducted by the customer engineer.
2. When performing service, each product on the site must be tested for safety. The cus-
tomer engineer must verify the safety of parts and ensure appropriate management of
the equipment.
S-10
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SAFETY AND IMPORTANT WARNING ITEMS
[5] Laser Safety
• This is a digital machine certified as a class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.
5.1 Internal Laser Radiation
semiconductor laser
Maximum power of the laser diode
Maximum average radiation power (*)
Wavelength
15 mW
7.2 µW
770-800 nm
*:at laser aperture of the Print Head Unit
• This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.
• The print head unit is NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
Laser Aperture of
the Print Head Unit
This figure shows the view
inside the Front Door.
4138safe002c0
S-11
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SAFETY AND IMPORTANT WARNING ITEMS
the U.S.A., Canada
(CDRH Regulation)
• This machine is certified as a Class I Laser product under Radiation Performance Stan-
dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory
for Laser products marketed in the United States and is reported to the Center for
Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.
• The label shown to page 14 indicates compliance with the CDRH regulations and must
be attached to laser products marketed in the United States.
.
CAUTION
• Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
Maximum power of the laser diode
Wavelength
15 mW
770-800 nm
All Areas
CAUTION
• Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
Maximum power of the laser diode
Wavelength
15 mW
770-800 nm
Denmark
ADVARSEL
• Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion.
Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825-1
sikkerheds kravene.
halvlederlaser
Laserdiodens højeste styrke
bølgelængden
15 mW
770-800 nm
S-12
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SAFETY AND IMPORTANT WARNING ITEMS
Finland, Sweden
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
VAROITUS!
• Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat-
taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser-
säteilylle.
puolijohdelaser
Laserdiodin suurin teho
aallonpituus
15 mW
770-800 nm
VARNING!
• Om apparaten används på annat sätt än i denna bruksanvisning specificerats,
kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen
för laserklass 1.
halvledarlaser
Den maximala effekten för laserdioden
våglängden
15 mW
770-800 nm
VARO!
• Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättomälle laser-
säteilylle. Älä katso säteeseen.
VARNING!
• Osynlig laserstråining när denna del är öppnad och spärren är urkopplad.
Betrakta ej stråien.
Norway
ADVERSEL
• Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisn-
ing, kan brukeren utsettes för unsynlig laserstrålning, som overskrider grensen
for laser klass 1.
halvleder laser
Maksimal effekt till laserdiode
bølgelengde
15 mW
770-800 nm
S-13
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SAFETY AND IMPORTANT WARNING ITEMS
5.2 Laser Safety Label
• A laser safety label is attached to the the machine as shown below.
4138safe004c0
S-14
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SAFETY AND IMPORTANT WARNING ITEMS
5.3 Laser Caution Label
• A laser caution label is attached to the inside of the machine as shown below.
4138safe001c0
5.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT
• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
• When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC Drum, be sure first to turn the printer OFF.
• If the job requires that the printer be left ON, take off your watch and ring and wear laser
protective goggles.
• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the user’s premises.
• The Print Head are not to be disassembled or adjusted in the field. Replace the Unit or
Assembly including the Control Board. Therefore, remove the Laser Diode, and do not
perform Control Board trimmer adjustment.
S-15
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SAFETY AND IMPORTANT WARNING ITEMS
WARNING INDICATIONS ON THE MACHINE
Caution labels shown are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.
High voltage
High temperature
4138fsS001c0
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SAFETY AND IMPORTANT WARNING ITEMS
High voltage
High voltage
4138fsS002c0
S-17
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SAFETY AND IMPORTANT WARNING ITEMS
S-18
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THEORY OF OPERATION
SERVICE MANUAL
®
magicolor 5430 DL
®
magicolor 5440 DL
®
magicolor 5450
Main Unit
2005.04
Ver. 3.0
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magicolor 5430 DL /5440 DL /5450 Theory of Operation
I
Outline
1.
2.
System configuration............................................................................................1-1
Product specifications ..........................................................................................1-2
2.1 Type ...................................................................................................................1-2
2.2 Functions ...........................................................................................................1-3
2.3 Maintenance ......................................................................................................1-5
2.4 Machine Specifications......................................................................................1-5
2.5 Operating Environment......................................................................................1-5
3.
Center cross section ............................................................................................1-6
Paper path............................................................................................................1-7
Image creation process........................................................................................1-8
4.
5.
1.
Overall composition..............................................................................................2-1
1.1 Timing chart at machine powerup .....................................................................2-1
1.2 Control block diagram........................................................................................2-2
2.
Print head (PH) ....................................................................................................2-3
2.1 Composition.......................................................................................................2-3
2.2 Operation...........................................................................................................2-4
2.2.1 Overview.......................................................................................................2-4
2.2.2 Laser exposure process ...............................................................................2-4
2.2.3 Laser emission timing...................................................................................2-5
2.2.4 Laser emission area .....................................................................................2-5
2.2.5 Laser light intensity control...........................................................................2-6
2.2.6 Registration correction control......................................................................2-6
3.
Toner Cartridge (TC) / TC Overall composition....................................................2-7
3.1 Composition.......................................................................................................2-7
3.2 Drive ................................................................................................................2-10
3.3 Operation.........................................................................................................2-12
3.3.1 Configuration of Toner Cartridge ................................................................2-12
3.3.2 Loading/unloading mechanism of Toner Cartridge.....................................2-12
3.3.3 Toner Cartridge life control .........................................................................2-13
4.
Toner Cartridge / Hopper ...................................................................................2-14
4.1 Composition.....................................................................................................2-14
4.2 Operation.........................................................................................................2-15
4.2.1 Toner Level Detection (magicolor 5430DL/5440DL)...................................2-15
4.2.2 Toner Level Detection (magicolor 5450).....................................................2-15
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magicolor 5430 DL /5440 DL Theory of Operation
4.2.3 Toner near-empty condition detection ........................................................ 2-15
4.2.4 Toner empty condition detection................................................................. 2-17
4.2.5 Toner replenishing mechanism/control....................................................... 2-19
Toner Cartridge / Photo Conductor.................................................................... 2-22
5.
5.1 Composition .................................................................................................... 2-22
5.2 Operation......................................................................................................... 2-22
5.2.1 Photo Conductor drive mechanism ............................................................ 2-22
5.2.2 Photo Conductor post-exposure control..................................................... 2-23
6.
Toner Cartridge / Charge corona section........................................................... 2-25
6.1 Composition .................................................................................................... 2-25
6.2 Operation......................................................................................................... 2-26
6.2.1 Charge Corona Unit ON/OFF control......................................................... 2-26
6.2.2 Output during pre-process ......................................................................... 2-26
6.2.3 Output during post-process........................................................................ 2-26
6.2.4 Ozone ventilation mechanism .................................................................... 2-27
7.
Toner Cartridge / Developing Unit...................................................................... 2-28
7.1 Composition .................................................................................................... 2-28
7.2 Operation......................................................................................................... 2-30
7.2.1 Developing drive control............................................................................. 2-30
7.2.2 Toner flow................................................................................................... 2-31
7.2.4 Developing bias Vpp control (Ds compensation control)............................ 2-33
7.2.5 Developing bias duty control (compensation control of the maximum
7.2.6 Gamma correction control.......................................................................... 2-35
8.
1st transfer section............................................................................................. 2-37
8.1 Composition .................................................................................................... 2-37
8.2 Drive................................................................................................................ 2-39
8.3 Operation......................................................................................................... 2-40
8.3.1 Transfer Belt speed control......................................................................... 2-40
8.3.2 1st transfer output control........................................................................... 2-40
8.3.3 1st Transfer Roller pressure/retraction control............................................ 2-41
8.3.4 1st Transfer Roller pressure/retraction failure detection control ................. 2-44
8.3.5 Transfer Belt cleaning................................................................................. 2-45
8.3.6 Toner Collecting Port Shutter mechanism.................................................. 2-46
9.
2nd transfer section............................................................................................ 2-47
ii
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magicolor 5430 DL /5440 DL /5450 Theory of Operation
9.1 Composition.....................................................................................................2-47
9.1.1 Drive ...........................................................................................................2-48
9.2 Operation.........................................................................................................2-49
9.2.3 2nd transfer voltage control ........................................................................2-51
Control)......................................................................................................2-52
9.2.5 2nd transfer voltage fine-adjustment control...............................................2-53
9.2.7 2nd Transfer Roller cleaning control ...........................................................2-53
9.2.8 2nd Transfer Roller cleaning operation timing ............................................2-54
10. Toner collecting section......................................................................................2-55
10.1 Composition.....................................................................................................2-55
10.2 Drive ................................................................................................................2-56
10.3 Operation.........................................................................................................2-57
10.3.1 Toner collecting mechanism .......................................................................2-57
10.3.2 Toner Collecting Port Shutter mechanism ..................................................2-57
10.3.3 Waste Toner Box locking mechanism.........................................................2-58
10.3.6 Waste toner near-full condition detection ...................................................2-59
10.3.7 Waste toner full condition detection control................................................2-61
11. AIDC Sensor ......................................................................................................2-63
11.1 Composition.....................................................................................................2-63
11.1.1 Drive ...........................................................................................................2-64
11.2 Operation.........................................................................................................2-64
11.2.1 Toner density detection control...................................................................2-64
11.2.2 AIDC Sensor calibration control .................................................................2-65
11.2.3 AIDC Sensor shutter mechanism ...............................................................2-66
12. Paper feed section (magicolor 5430 DL)............................................................2-67
12.1 Composition.....................................................................................................2-67
12.2 Drive ................................................................................................................2-68
12.3 Operation.........................................................................................................2-69
12.3.1 Paper Lift Plate mechanism........................................................................2-69
12.3.2 Paper separation mechanism.....................................................................2-69
12.3.3 Paper feed control ......................................................................................2-70
12.3.4 Paper supply level detection control ...........................................................2-70
12.3.5 Paper empty condition detection control.....................................................2-71
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magicolor 5430 DL /5440 DL Theory of Operation
12.3.7 Trailing Edge Guide Plate........................................................................... 2-71
12.3.8 Paper size detection control ....................................................................... 2-72
12.3.9 Paper misfeed detection control................................................................. 2-72
13. Paper feed section (magicolor 5440DL/5450).................................................... 2-73
13.1 Composition .................................................................................................... 2-73
13.2 Drive................................................................................................................ 2-74
13.3 Operation......................................................................................................... 2-74
13.3.2 Paper separation mechanism..................................................................... 2-75
13.3.3 Paper feed control ...................................................................................... 2-75
13.3.4 Paper supply level detection control........................................................... 2-76
13.3.5 Paper empty condition detection control .................................................... 2-76
13.3.7 Trailing Edge Guide Plate........................................................................... 2-77
13.3.8 Tray detection control ................................................................................. 2-78
13.3.9 Paper misfeed detection control................................................................. 2-78
14. Manual feed section (magicolor 5440DL/5450) ................................................. 2-79
14.1 Composition .................................................................................................... 2-79
14.2 Drive................................................................................................................ 2-80
14.3 Operation......................................................................................................... 2-81
14.3.2 Paper separation mechanism..................................................................... 2-82
14.3.3 Paper feed control ...................................................................................... 2-82
14.3.4 Paper empty condition detection control .................................................... 2-83
14.3.6 Paper misfeed detection control................................................................. 2-84
15. Conveyance section........................................................................................... 2-85
15.1 Composition .................................................................................................... 2-85
15.2 Drive................................................................................................................ 2-86
15.3 Operation......................................................................................................... 2-87
15.3.1 Conveyance speed control......................................................................... 2-87
15.3.2 Synchronizing Roller control....................................................................... 2-87
15.3.3 Control of loop formed before Synchronizing Roller................................... 2-88
15.3.4 Control of loop formed before 2nd transfer................................................. 2-89
15.3.5 Control of loop formed before fusing section.............................................. 2-90
15.3.6 Paper neutralization.................................................................................... 2-91
15.3.7 OHP film detection control.......................................................................... 2-91
iv
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magicolor 5430 DL /5440 DL /5450 Theory of Operation
15.3.8 Size error detection control.........................................................................2-92
15.3.9 Conveyance system paper misfeed detection control ................................2-93
15.3.10 Control of detection of paper left in conveyance system ............................2-94
15.3.11 Control of detection of paper left in machine upon stoppage of paper
conveyance................................................................................................2-95
15.3.12 Temperature/humidity Sensor.....................................................................2-95
16. Fusing section....................................................................................................2-96
16.1 Composition.....................................................................................................2-96
16.2 Drive ................................................................................................................2-98
16.3 Operation.........................................................................................................2-99
16.3.2 Fusing Pressure Roller drive control ..........................................................2-99
16.3.3 Fusing temperature control.......................................................................2-104
16.3.5 Warm-up control.......................................................................................2-106
16.3.6 Post-warm-up control................................................................................2-108
16.3.7 Wait control...............................................................................................2-108
16.3.8 Print control ..............................................................................................2-109
16.3.9 Post-print control.......................................................................................2-110
16.3.10 Heater OFF control...................................................................................2-110
16.3.11 Heater control...........................................................................................2-111
16.3.12 PPM control..............................................................................................2-111
16.4 Malfunction detection.....................................................................................2-112
16.4.1 Fusing Unit malfunctions ..........................................................................2-112
16.4.2 Fusing Motor abnormal rotation detection control ....................................2-112
16.4.3 Warm-up failure detection control.............................................................2-113
16.4.4 Abnormally low temperature detection control .........................................2-113
16.4.5 Abnormally high temperature detection control........................................2-114
16.4.6 Open-circuited Heating Roller Thermistor
16.4.7 Open-circuited Fusing Pressure Roller Thermistor
(incorrect installation) detection control...................................................2-115
16.4.8 Abnormal temperature increase rate detection control.............................2-115
16.4.9 Protection against abnormally high temperature......................................2-116
17. Image stabilization control................................................................................2-118
17.1 Overview of image stabilization control .........................................................2-118
17.1.1 Complete correction control......................................................................2-118
17.1.2 Simplified correction control .....................................................................2-119
17.1.3 Image stabilization control execution request...........................................2-120
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magicolor 5430 DL /5440 DL Theory of Operation
17.1.4 Conditions enabling execution of stabilization control at the end of
a print cycle of given conditions .............................................................. 2-120
17.1.5 Combination and execution sequence of different sub-controls............... 2-121
17.2 Operation flow of image stabilization control upon replacement of unit ........ 2-122
18. Miscellaneous .................................................................................................. 2-123
18.1 Fan control..................................................................................................... 2-123
18.1.1 Composition ............................................................................................. 2-123
18.1.2 Control...................................................................................................... 2-124
vi
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Main Unit Theory of Operation
System Configuration
I Outline
1. System Configuration
System Front View
[7]
[1]
[2]
[3]
[6]
[5]
[4]
4138fs1501c4
[1] Duplex Option
[2] Optional DIMM
[5] Optional Lower Feeder Unit
[6] Optional Lower Feeder Unit
Optional Camera Direct Photo Print Card
(magicolor 5440 DL only)
[3]
[7] Main Unit
Optional Hard Disk Drive (HDD)
(magicolor 5450 only)
[4]
1-1
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Product Specifications
Main Unit Theory of Operation
2. Product Specifications
2.1 Type
Type
Desktop tandem full-color laser beam printer
Semiconductor laser and electrostatic image transfer to plain paper
Printing System
Exposure System
PC Drum Type
4 laser diode and polygon mirror
OPC (organic photo conductor)
Photoconductor
Cleaning
Blade cleaning system
magicolor 5430 DL/5440 DL
2400 x 600 dpi x 1 bit, 1200 x 600 dpi x 1 bit, 600 x 600 dpi x 1 bit
Print Density
magicolor 5450
600 x 600 dpi x 4 bit
magicolor 5430 DL
One-way system (Tray 1: 250 sheets)
* Expandable up to a three-way system by adding optional Lower Feeder Units
(up to two)
magicolor 5440 DL
Paper Feeding
System
Two-way system (Tray 1: 500 sheets, Manual Feed Tray: 100 sheets)
* Expandable up to a four-way system by adding optional Lower Feeder Units
(up to two)
magicolor 5450
Two-way system (Tray 1: 100 sheets, Tray 2: 500 sheets)
* Expandable up to a four-way system by adding optional Lower Feeder Units
(up to two)
Developing System
Charging System
Single-element developing system
DC comb electrode Scorotron system
Image Transfer
System
Intermediate transfer belt system
Paper Separating
System
Curvature separation + charge-neutralizing system
Fusing System
Belt fusing
Paper Exit System
Face down (Output Tray capacity: 250 sheets)
1-2
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Main Unit Theory of Operation
Product Specifications
2.2 Functions
Average: 30 sec. or less
(at ambient temperature of 23° C/73.4° F and rated source voltage)
Warm-up Time
System Speed
152 mm/sec (Plain Paper)
First-Page-Out Time
(Plain Paper)
1-sided: 14.2 seconds; 2-sided: 22.3 seconds (A4)
1-sided: 14.1 seconds; 2-sided: 22.3 seconds (Letter)
magicolor 5430 DL
1-sided: 20 pages/min; 2-sided: 11.5 pages/min (A4)
1-sided: 21 pages/min; 2-sided: 11.8 pages/min (Letter)
* When feeding the paper from Tray1
magicolor 5440 DL
Print Speed
(Plain Paper)
1-sided: 25.6 pages/min; 2-sided: 12.3 pages/min (A4)
1-sided: 27 pages/min; 2-sided: 12.5 pages/min (Letter)
* When feeding the paper from Tray1
magicolor 5450
1-sided: 25.6 pages/min; 2-sided: 12.3 pages/min (A4)
1-sided: 27 pages/min; 2-sided: 12.5 pages/min (Letter)
* When feeding the paper from Tray 2
magicolor 5430 DL
Paper width: 92 to 216 mm (3.6 to 8.5 inch) (Tray 1)
Paper length: 148 to 297 mm (5.8 to 11.7 inch) (Tray 1)
magicolor 5440 DL
Custom Paper Sizes
Paper width: 92 to 216 mm (3.6 to 8.5 inch) (Manual Feed Tray)
Paper length: 148 to 356 mm (5.8 to 14.0 inch) (Manual Feed Tray)
magicolor 5450
Paper width: 92 to 216 mm (3.6 to 8.5 inch) (Tray 1)
Paper length: 148 to 355.6 mm (5.8 to 14.0 inch) (Tray 1)
magicolor 5430 DL
Tray 1
2
• Plain paper (60 to 90 g/m / 16 to 24 lb)
2
• Recycled paper (60 to 90 g/m / 16 to 24 lb)
• OHP transparencies
2
• Thick stock 1 (91 to 150 g/m / 24 to 40 lb)
Media Types
2
• Thick stock 2 (151 to 210 g/m / 41 to 56 lb)
• Postcards
• Double postcards (Print before folding)
• Envelopes
• Letterhead
• Labels
1-3
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Product Specifications
Main Unit Theory of Operation
magicolor 5440 DL
Tray 1
2
• Plain paper (60 to 90 g/m / 16 to 24 lb)
2
• Recycled paper (60 to 90 g/m / 16 to 24 lb)
Manual Feed Tray
2
• Plain paper (60 to 90 g/m / 16 to 24 lb)
2
• Recycled paper (60 to 90 g/m / 16 to 24 lb)
• OHP transparencies
2
• Thick stock 1 (91 to 150 g/m / 24 to 40 lb)
2
• Thick stock 2 (151 to 210 g/m / 41 to 56 lb)
• Postcards
• Double postcards (Print before folding)
• Envelopes
• Letterhead
• Labels
Media Types
magicolor 5450
Tray 1
2
• Plain paper (60 to 90 g/m / 16 to 24 lb)
2
• Recycled paper (60 to 90 g/m / 16 to 24 lb)
• OHP transparencies
2
• Thick stock 1 (91 to 150 g/m / 24 to 40 lb)
2
• Thick stock 2 (151 to 210 g/m / 41 to 56 lb)
• Postcards
• Double postcards (Print before folding)
• Envelopes
• Letterhead
• Labels
Tray 2
2
• Plain paper (60 to 90 g/m / 16 to 24 lb)
2
• Recycled paper (60 to 90 g/m / 16 to 24 lb)
magicolor 5430 DL
Plain paper and recycled paper: 250 sheets (Tray 1)
Letterhead: 150 sheets (Tray 1)
Transparencies, thick stock 1, thick stock 2, postcards, double postcards, and
labels: 20 sheets (Tray 1)
Envelopes: 10 sheets (Tray 1)
magicolor 5440 DL
Plain paper and recycled paper: 500 sheets (Tray 1)
Plain paper and recycled paper: 100 sheets (Manual Feed Tray)
Transparencies, thick stock 1, thick stock 2, postcards, double postcards,
letterhead, and labels: 20 sheets (Manual Feed Tray)
Envelopes: 10 sheets (Manual Feed Tray)
Tray Capacities
magicolor 5450
Plain paper and recycled paper: 100 sheets (Tray 1)
Transparencies, thick stock 1, thick stock 2, postcards, double postcards,
letterhead, and labels: 20 sheets (Tray 1)
Envelopes: 10 sheets (Tray 1)
Plain paper and recycled paper: 500 sheets (Tray 2)
1-4
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Main Unit Theory of Operation
Product Specifications
magicolor 5430 DL/5440 DL
• USB 2.0 (High-Speed) compliant
• 10 Base-T/100 Base-TX (IEEE 802.3) Ethernet
• The magicolor 5440 DL also has a Host USB port, which supports Camera
Direct Photo Printing from PictBridge-enabled cameras when an optional
Camera Direct Photo Print Card is installed.
Interfaces
magicolor 5450
• Parallel (IEEE 1284) Support only an ECP mode
• USB 2.0 (High-Speed) compliant
• 10 Base-T/100 Base-TX/1000 Base-T (IEEE 802.3) Ethernet
magicolor 5430 DL/5440 DL
ARM9 956EJ-S 200 MHz
CPU
magicolor 5450
Motorola PowerPC 7447A 667 MHz
magicolor 5430 DL/5440 DL
64 MB (Expandable up to a 576 MB)
Standard memory
Hard disk
magicolor 5450
256 MB (Expandable up to a 1024 MB)
Optional (magicolor 5450 only)
40 GB
Lower Feeder Unit: Only plain paper and recycled paper weighing 60 to 90 g/m2 (16 to 24
lb) can be loaded.
Duplex Option:
Only plain paper and recycled paper weighing 60 to 90 g/m2 (16 to 24
lb) can be fed through the unit.
☞
For details, see the Service Manual for each option.
2.3 Maintenance
Machine Durability
400,000 prints or 5 years, whichever comes first
2.4 Machine Specifications
Power Requirements AC 110 to 127 V
Voltage: AC 220 to 240 V
Frequency: 50/60 Hz 3 Hz
Max Power
1250 W
Consumption
420 mm (W) x 520 mm (D) x 440 mm (H)
16.5 inch (W) x 20.5 inch (D) x 17.3 inch (H)
Dimensions
magicolor 5430 DL
Approx. 30 kg (66.25 lb) without TC
Weight
magicolor 5440 DL/5450
Approx. 31 kg (66.25 lb) without TC
During standby : 39 dB (A) or less
During printing : 54 dB (A) or less
Operating Noise
1-5
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Product Specifications
Main Unit Theory of Operation
2.5 Operating Environment
Temperature
Humidity
10° to 35° C / 50° to 95° F (with a fluctuation of 10° C / 18° F or less per hour)
15% to 85% (with a fluctuation of 20%/h)
NOTE
• These specifications are subject to change without notice.
1-6
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Main Unit Theory of Operation
Center Cross Section
3. Center Cross Section
[7]
[8]
[9]
[10]
[1]
[2]
[3]
[6]
[4]
[5]
4138to1502c1
[1] Fusing Unit
[6] Waste Toner Box
[7] Toner Cartridge /Y
[8] Toner Cartridge /M
[2] Transfer Belt Unit
[3] Print head Unit
[4] Manual Feed Tray (magicolor 5440 DL only) [9] Toner Cartridge /C
Tray 1 (magicolor 5450 only)
[5] Tray 1 (magicolor 5430 DL/5440 DL)
Tray 2 (magicolor 5450)
[10] Toner Cartridge /K
NOTE
• Be sure to note that feed trays [4] and [5] are named differently depending upon
the printer model.
magicolor 5430 DL / 5440 DL magicolor 5450
MANUAL FEED TRAY
TRAY1
TRAY1
TRAY2
TRAY3
TRAY4
TRAY2
TRAY3
• Throughout this manual, the magicolor 5430 DL/5440 DL names are used for these
trays.
1-7
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Main Unit Theory of Operation
Image Creation Process
5. Image Creation Process
[8] Paper Separation
[7] 2nd Image Transfer
[9] Transfer Belt Cleaning
[6] 1st Image Transfer
[10] PC Drum Cleaning
[2] PC Drum
[5] Developing
[3] PC Drum Charging
[1] Printer Processing
[4] LD Exposure
[1] Printer Processing
• The intensity of the laser light is controlled based on the image
signal transmitted from the host computer.
[2] PC Drum
• The image of the original projected onto the surface of the PC
Drum is changed to a corresponding electrostatic latent image.
[3] PC Drum Charging
[4] LD Exposure
• Apply DC (-) charge to the photo conductor.
• The surface of the PC Drum is irradiated with laser light, and an
electrostatic latent image is thereby formed.
[5] Developing
• The toner, agitated and negatively charged in the Toner Chamber,
is attracted onto the electrostatic latent image formed on the sur-
face of the PC Drum. It is thereby changed to a visible, developed
image.
[6] 1st Image Transfer
• A DC positive voltage is applied to the backside of the Transfer
Belt, thereby allowing the visible, developed image on the surface
of each of the PC Drums (Y, M, C and K) to be transferred onto
the Transfer Belt.
[7] 2nd Image Transfer
[8] Paper Separation
• A DC positive voltage is applied to the backside of the paper,
thereby allowing the visible, developed image on the surface of
the Transfer Belt to be transferred onto the paper.
• The paper, which has undergone the 2nd image transfer process,
is neutralized so that it can be properly separated from the Trans-
fer Belt.
[9] Transfer Belt Cleaning
[10] PC Drum Cleaning
• The residual toner left on the surface of the Transfer Belt is
scraped off.
• The residual toner left on the surface of the PC Drum is scraped
off.
1-9
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Image Creation Process
Main Unit Theory of Operation
1-10
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Main Unit Theory of Operation
Overall Composition
II Composition/Operation
1. Overall Composition
1.1 Timing chart at machine powerup
Conditions: A4 plain paper, 2 printed pages/job
Polygon Motor (M8)
LD
Intermediate
Transport Motor (M3)
Color PC Drum
Motor (M2)
Developing
Motor/YMC (M1)
Developing
Motor/K (M5)
Charge K
Charge YMC
Developing Y
Developing M
Developing C
Developing K
TOD Y
TOD M
TOD C
TOD K
1st transfer
pressure/retraction
1st transfer Rem
2nd transfer
pressure/retraction
2nd transfer Rem
2nd transfer (-)
First Page
2nd Page
4138to2126e0
2-1
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Overall Composition
Main Unit Theory of Operation
1.2 Control block diagram
Control Panel (PWB-OP)
Print Control Board (PWB-P)
Mechanical Control
Board (PWB-A)
Paper feed and
conveyance
Image
CPU
processing
Process
Fusing
LD Control Board (PWB-C)
TC/Y
TC/M
TC/C
TC/K
Control system line
Image bus line
Lower Feeder Unit
Duplex Unit
4138to2127e0
2-2
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Main Unit Theory of Operation
Print Head (PH)
2. Print Head (PH)
2.1 Composition
4138to2001c0
4138to2501c0
[1]
[10]
[1]
[2]
[3]
[4]
[5]
[9]
[8]
[7]
[6]
4138to2002c0
Key
[1]
Name
G2 Lens/Y, M, C, K
Function/system
•
Condenses the incident laser light and irradiates the K Photo
Conductor or Return Mirror/2nd of each color with the con-
densed laser light.
[2] SOS Lens
•
•
•
Condenses the incident laser light/K onto the SOS Sensor.
Generates an SOS signal based on the incident laser light/K.
[3] SOS Sensor
Separation Mirror
Reflects the laser light/K, the condensing angle of which has
been corrected by the G1 Lens, onto the G2 Lens/K.
Reflects the laser light/K (for SOS), the condensing angle of
which has been corrected by the G1 Lens, onto the SOS Lens.
[4]
•
•
•
Return Mirror/1st
Reflects the laser light/Y, M, C condensed by the G1 Lens onto
the G2 Lens/Y, M, C.
[5]
[6]
Synthetic Mirror/Y, M, C, K
Reflects the laser light emitted by the semiconductor laser of
each color onto the Polygon Mirror.
[7] Semiconductor laser/Y, M, C, K
•
•
Emits a laser light of each color.
Polygon Mirror
[8]
Lets the incident laser light scan in the main scan direction and
then strike the Separation Mirror.
[9] G1 Lens
•
•
Corrects the condensing angle of the incident laser light.
Return Mirror/2nd
[10]
Reflects the laser light condensed by the G2 Lens onto the sur-
face of the Photo Conductor/Y, M, C.
2-3
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Print Head (PH)
Main Unit Theory of Operation
2.2 Operation
2.2.1
Overview
• Four semiconductor lasers provided, one for each of the four different colors. A single
Polygon Motor is used to make a scan motion.
• Each Photo Conductor is irradiated with a laser light so that an electrostatic latent image
is formed on it.
NOTE
• The magicolor 5430 DL/5440 DL uses a different PH unit than does the magicolor
5450. When replacing the PH unit, be sure to use the PH unit for the appropriate
model. Using the incorrect PH unit will adversely affect image quality.
2.2.2
Laser exposure process
1. The laser light emitted by each of the Semiconductor Laser/Y, M, C, and K is reflected
onto the Polygon Mirror via the Synthetic Mirror.
2. Since the angle of incidence for each color of laser light varies, the laser light reflected
by the Polygon Mirror is reflected at a different angle for each color.
3. The condensing angle of each color of laser light is corrected by the G1 Lens before
reaching each Return Mirror.
4. The K laser light is condensed on the surface of the Photo Conductor through the Sep-
aration Mirror and G2 Lens.
5. The Y, M, or C laser light is condensed on the Photo Conductor through the Separation
Mirror, G2 Lens, and Return Mirror.
SOS Sensor
SOS Lens
G1 Lens
Separation Mirror
Polygon Mirror
Y
Return Mirror/1st
M
C
Y
Semiconductor
Laser
K
M
K
C
Synthetic Mirror
Y
Photo Conductor
M
C
K
Return Mirror/2nd
G2 Lens
M
C
Y
K
C
K
M
Y
4138to2502c0
2-4
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Main Unit Theory of Operation
2.2.3 Laser emission timing
Print Head (PH)
• When a Ready signal is detected after the lapse of a given period of time after the print
cycle has been started, a Laser ON signal is output from the Print Control Board (PWB-
P).
• The Laser ON signal triggers the firing of each laser light, which illuminates the SOS
Board via the Polygon Mirror, G1 Lens, Separation Mirror (K), and SOS Lens. This gen-
erates an SOS signal.
• This SOS (Start of Scan) signal unifies the timing at which the laser lights are irradiated
for each main scan line.
• The SOS signal is generated only from the K laser light. For the other colors, the emis-
sion timing is determined with reference to K.
2.2.4
Laser emission area
A. Main scan direction (FD)
• The print start position in the FD direction is determined by the FD Print Start signal
(HSYNC) that is output from the Print Control Board (PWB-P) and the width of the
media.
• The laser emission area is determined by the media size.
B. Sub scan direction (CD)
• The print start position in the CD direction is determined by the CD Print Start signal
(TOD) that is output from the Print Control Board (PWB-P) and the length of the media.
However, there is a 4 mm/0.157" wide void area on both edges of the media.
• The laser emission area is determined by the media size. However, there is a 4 mm/
0.157" wide void area on both the leading and trailing edges of the media.
Void width: 4 mm/0.157"
Void width: 4 mm/0.157"
Void width: 4 mm/
0.157"
Void width: 4 mm/
0.157"
4138to2595c0
2-5
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Print Head (PH)
2.2.5 Laser light intensity control
Main Unit Theory of Operation
• The laser light intensity control corrects the target level of fluctuations in fine line repro-
duction and reverse image (white on black) reproduction that occur due to variations in
photo conductor electrostatic characteristics, developing characteristics, and transfer
characteristics (part-to-part variations, environment, durability).
• It is controlled integrally with other control items by the image stabilization control.
of an image stabilization sequence.
☞
2-120
2.2.6
Registration correction control
• In a tandem engine that has an image forming process for each color of toner, incorrect
color registration tends to occur due to variations in parts of the machine used for regu-
lating the drawing positions. The registration correction control automatically detects and
corrects this incorrect color registration.
• It is controlled integrally with other control items by the image stabilization control.
• The registration correction control is performed when there is a request made for execu-
tion of image stabilization sequence.
☞
2-120
2-6
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Main Unit Theory of Operation
Toner Cartridge (TC) / TC Overall Composition
3. Toner Cartridge (TC) / TC Overall Composition
3.1 Composition
[5]
4138to2017c0
4138to2503c0
[1]
[21]
[22]
[27], [28]
[25], [26]
[2]
[3]
[19]
[18]
[4]
[5]
[6]
[7]
[20]
[17]
[16]
[15]
[14]
[13]
[12]
[11]
[8]
[9]
[10]
[23], [24]
4138to2005c1
Key
Name
Function/system
[1] Conveyance Screw
• Feeds toner in the Hopper to the Conveyance Pipe
Conveyance Pipe
[2]
• The pipe through which toner is conveyed from the
Hopper to the Developing Unit
Charge Neutralizing Sheet
Developing Roller
• Electrically removes toner off of the surface of the
Developing Roller
• The charge neutralizing bias voltage is applied to this
sheet
[3]
[4]
[5]
• Supplies toner fed by the Supply Roller to the surface
of the Photo Conductor
• Conveys toner to the surface of the Photo Conductor
through potential difference
• The developing bias voltage is applied to this roller
• A given distance from the Photo Conductor is main-
tained by means of the Ds Roll
• Single component developing system
Photo Conductor
• The drum surface on which an image of each color of
toner is formed for subsequent transfer of the image to
the Transfer Belt
• OPC drum (φ30 mm)
2-7
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Toner Cartridge (TC) / TC Overall Composition
Main Unit Theory of Operation
Function/system
Key
[6]
Name
Grid Mesh
• Evens out the charge deposited from the Electrode to
make the surface potential uniform throughout the sur-
face of the Photo Conductor
• The grid voltage is applied to the Grid Mesh
Cleaning Blade
• Scrapes residual toner off the surface of the Photo
Conductor
[7]
[8]
[9]
Toner Collecting Screw
Cleaning Unit
• Conveys the waste toner scraped off by the Cleaning
Blade into the Waste Toner Storage Tank
• Recovers waste toner from the surface of the Photo
Conductor and stores it
Waste Toner Storage Tank
• Stores waste toner of each color
• Fixed type; requires no service jobs, including disposi-
tion of the stored waste toner
• The storage tanks for Y, M, and C are of the same
shape, while that for K is larger than the others to
accommodate a greater amount of waste toner
[10]
Charge Corona
• Deposits a charge to the surface of the Photo
Conductor
[11]
[12]
[13]
[14]
• DC comb electrode Scorotron system
Electrode
• DC comb electrode Scorotron system
• Maintenance free; no cleaning mechanism is available
Regulator Blade/1st, 2nd
• Regulates the height of toner on the surface of the
Developing Roller
• The blade bias voltage is applied to the blade
Toner Chamber
Supply Roller
• Tank in which toner fed off from the Hopper is tempo-
rarily stored
• Supplies toner in the Toner Chamber to the Develop-
ing Roller
• Conductive elastic roller
• Conveys toner to the surface of the Developing Roller
through potential difference
[15]
• The supply bias voltage is applied to this roller
Agitating Screw
• Agitates toner fed off by the Replenishing Screw with
that in the Toner Chamber so that it is charged
• Two-shaft agitating system
[16]
[17]
Replenishing Screw
• Feeds toner through the Conveyance Pipe to the
Toner Chamber
• Mixes toner in the Toner Chamber so that it is charged
• Two-shaft agitating system
[18] Connection
• Conveys toner from the Hopper to the Developing Unit
• Agitates toner in the Hopper
[19] Agitating Blade
TC Detection Board (CSIC)
• Detects a TC installed in the machine; it detects not
only a new TC, but also a half-used one
• Stores information on each individual TC (period of
time of use, etc.)
[20]
2-8
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Main Unit Theory of Operation
Toner Cartridge (TC) / TC Overall Composition
Function/system
Key
Name
Hopper
• Loaded with toner that is conveyed onto the Develop-
ing Unit by way of the Conveyance Pipe
• Capacity
Toner Cartridge shipped with machine: Quantity equiv-
alent to 3000 printed pages
[21]
Standard Toner Cartridge: Quantity equivalent to 6000
printed pages
High-Capacity Toner Cartridge (magicolor 5440 DL/
5450 only): Quantity equivalent to 12,000 printed
pages
• Single-component SMT toner
Developing Unit
• Applies a uniform coat of toner fed from the Hopper to
the surface of the Photo Conductor
[22]
[23]
Developing Motor/Y, M, C (M1)
• Drives the rollers and screws of the Y, M, or C Devel-
oping Unit
• De-energized in the monochrome mode
• Brushless DC motor
Developing Motor/K (M5)
• Drives the rollers and screws of the K Developing Unit
• Provides drive also for the Waste Toner Box
• Brushless DC motor
[24]
[25]
[26]
Color PC Drum Motor (M2)
Intermediate Transport Motor (M3)
• Drives the Y, M, and C Photo Conductors
• De-energized in the monochrome mode
• Brushless DC motor
• Drives the K Photo Conductor
• Provides drive also for the conveyance section, 2nd
transfer section, media feed section, and other parts
[27] Toner Supply Motor/Y, M (M6)
• Drives the Agitating Blades and Conveyance Screws
of the Y, M, C, and K Hoppers
• Stepping motor
Toner Supply Motor/C, K (M7)
[28]
2-9
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Toner Cartridge (TC) / TC Overall Composition
Main Unit Theory of Operation
3.2 Drive
[1]
[6]
[5]
[4]
[2]
4138to2599c0
[3]
[1]
[6]
[7]
[8]
4138to2019c0
[1] Toner Supply Motor/C, K (M7)
[2] Intermediate Transport Motor (M3)
[3] Developing Motor/K (M5)
[5] Color PC Drum Motor (M2)
[6] Toner Supply Motor/Y, M (M6)
[7] Agitating Blade
[4] Developing Motor/Y, M, C (M1)
[8] Conveyance Screw
2-10
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Main Unit Theory of Operation
Toner Cartridge (TC) / TC Overall Composition
[2]
[5]
[3]
[4]
K
C
M
Y
[9]
[10]
4138to2022c0
[3]
[9]
[10]
4138to2599c0
[1] Toner Supply Motor/C, K (M7)
[2] Intermediate Transport Motor (M3)
[3] Developing Motor/K (M5)
[6] Toner Supply Motor/Y, M (M6)
[7] Agitating Blade
[8] Conveyance Screw
[4] Developing Motor/Y, M, C (M1)
[9] Agitating Screw, Replenishing Screw,
Supply Roller, Developing Roller, Toner
Collecting Screw
[5] Color PC Drum Motor (M2)
[10] Photo Conductor
2-11
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Toner Cartridge (TC) / TC Overall Composition
Main Unit Theory of Operation
3.3 Operation
3.3.1
Configuration of Toner Cartridge
• The Toner Cartridge is U-shaped, positioned so as to enclose the Transfer Belt Unit. It
consists of three major sections: the Hopper, Developing Unit, and Connection.
Hopper
Transfer Belt Unit
Developing Unit
Connection
4138to2005c2
3.3.2
Loading/unloading mechanism of Toner Cartridge
A. Loading procedure
• Hold the handle on the upper part of the Toner Cartridge with your left hand and support
the front face of the cartridge with your right hand.
• Position the Hopper in alignment with the rail on the machine side and insert the car-
tridge into the machine.
• When the upper handle contacts the machine frame, place it down and push the front
side of the cartridge with your right hand.
B. Pressure mechanism
• To avoid a contact between the Transfer Belt and Toner Cartridge, the Toner Cartridge is
inserted along the rail from a lowered position. The rail raises the cartridge as the car-
tridge reaches the rear end of the machine.
• At the same time that the cartridge is loaded in the machine, it is pressed into the prede-
termined position (upward) by springs in the order of its rear end and its front end.
• The pressure mechanisms provided at the front and rear ends ensure that the entire
pressure is not applied to the cartridge all at once.
• After the cartridge has been pressed upward, a lock pawl is engaged. The cartridge is
thus clicked in position to let the user know that it is properly loaded in position.
4138to2009c1
C. Drop preventive mechanism
• To prevent the Toner Cartridge from being dropped as it is unloaded, there is a drop pre-
ventive claw provided at the upper handle.
• Unless the upper handle is placed up, the cartridge is stopped halfway, which prevents
the cartridge from being slid out further.
2-12
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Main Unit Theory of Operation
Toner Cartridge (TC) / TC Overall Composition
D. Removal procedure
• The Toner Cartridge is pressed in the predetermined position. Pushing down the front
handle once will disengage the lock pawl.
• Hold the front handle with your right hand and withdraw the Hopper.
• When the drop preventive claw of the upper handle is about to hit against the machine
frame, raise the upper handle. This retracts the drop preventive claw.
• Holding onto the upper handle with your left hand, slide out the Toner Cartridge.
Drop preventive claw
Front handle
Upper handle
4138to2010c0
3.3.3
Toner Cartridge life control
• The Toner Cartridge life is determined based on toner empty condition detection and the
period of time through which the Photo Conductor has been turned.
• Each Toner Cartridge is provided with a TC Detection Board (CSIC) that detects a new
TC, a toner near-empty condition, and a toner empty condition.
A. Cartridge detection and new cartridge detection timing
• The machine attempts to perform a detection sequence when the Front Door is closed.
B. Cartridge detection
• The machine accesses the TC Detection Board (CSIC) to check for data stored in it.
Using that data, the machine determines whether or not a cartridge is loaded.
C. New cartridge detection
• After a cartridge has been detected, the machine determines whether it is new or not
based on the data acquired.
D. Operation after new cartridge detection
Start
Transfer Belt cleaning control
2nd Transfer cleaning control
Transfer ATVC control
Image stabilization sequence
End
4138to2132e0
2-13
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Toner Cartridge / Hopper
Main Unit Theory of Operation
4. Toner Cartridge / Hopper
4.1 Composition
[1]
[2]
[3]
[4]
[5]
4138to2503c1
4138to2011c0
Key
[1]
Name
Function/system
Hopper
• Loaded with toner that is conveyed onto the Develop-
ing Unit by way of the Conveyance Pipe
• Capacity:
Toner Cartridge shipped with machine: Quantity equiv-
alent to 3,000 printed pages
Standard Toner Cartridge: Quantity equivalent to
6,000 printed pages
High-Capacity Toner Cartridge (magicolor 5440 DL/
5450 only): Quantity equivalent to 12,000 printed
pages
• Single-component SMT toner
[2] Agitating Blade
• Agitates toner in the Hopper
[3] Conveyance Screw
• Feeds toner in the Hopper off to the Conveyance Pipe
Conveyance Pipe
[4]
• The pipe through which toner is conveyed from the
Hopper to the Developing Unit
Toner Supply Motor/Y, M (M6)
• A single motor is turned either forward or backward to
drive the Agitating Blades and Conveyance Screws of
the Y or M Hopper to accomplish supply of toner
• Stepping motor
[5]
Toner Supply Motor/C, K (M7)
• A single motor is turned either forward or backward to
drive the Agitating Blades and Conveyance Screws of
the C or K Hopper to accomplish supply of toner
• Stepping motor
2-14
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Main Unit Theory of Operation
Toner Cartridge / Hopper
4.2 Operation
4.2.1
Toner Level Detection (magicolor 5430 DL/5440 DL)
• The toner level is determined by the accumulated time of rotation of the toner supply
motor and the PC Drum.
• The toner levels of the magicolor 5430 DL/5440 DL can be checked through the “MENU/
SPECIAL PAGES/PRINT CONFIG PAGE” or “MENU/CONSUMABLE USAGE” configu-
ration menu.
NOTE
• When the toner remaining in the cartridge is between 88% and 100%, the display
shows “100%,” regardless of the actual amount. The amount of toner supplied to
the toner cartridge may vary slightly. Also, some toner is consumed when check-
ing the screen during manufacture.
• When the amount of toner is 87% or less, the display shows the exact amount of
toner.
4.2.2
Toner Level Detection (magicolor 5450)
• The toner level is determined by the accumulated time of rotation of the toner supply
motor and the PC Drum.
• The toner levels of the magicolor 5450 can be checked through the “PRINT MENU/STA-
TISTICS PAGE” configuration menu.
NOTE
• When the toner remaining in the cartridge is between 95% and 100%, the display
shows “100%,” regardless of the actual amount. The amount of toner supplied to
the toner cartridge may vary slightly. Also, some toner is consumed when check-
ing the screen during manufacture.
• When the amount of toner is 94% or less, the display shows the exact amount of
toner.
4.2.3
Toner near-empty condition detection
• The cumulative period of time through which the Toner Supply Motor is energized is
detected as the basis for determining whether there is a toner near-empty condition.
• When a new Toner Cartridge is detected, the cumulative energization time counter is
reset to let it start counting the time anew.
• <Near-empty decision>
1. The machine determines whether there is a toner near-empty condition when the
cumulative energization time counter of the Toner Supply Motor exceeds a predeter-
mined value.
• <Resetting near-empty condition>
1. A toner near-empty condition is reset when a new Toner Cartridge is detected.
• About 500 to 1500 printed pages can be produced during the period of time that begins
when a near-empty condition is detected and ends when an empty condition is detected
(for a standard original of a 5% coverage rate and using a standard Toner Cartridge).
• A warning message is displayed when a near-empty condition is detected.
2-15
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Toner Cartridge / Hopper
Main Unit Theory of Operation
• <Toner near-empty messages>
The relevant warning message is displayed when a toner near-empty condition is
detected.
magicolor 5430 DL / 5440 DL
C TONER LOW
magicolor 5450
TONER LOW
Y
TONER LOW
M
M TONER LOW
Y TONER LOW
K TONER LOW
TONER LOW
C
TONER LOW
K
2-16
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Main Unit Theory of Operation
4.2.4 Toner empty condition detection
Toner Cartridge / Hopper
• A toner empty condition is detected by the LED and toner level sensor mounted on the
Toner Level Sensor Board (PWB-D) provided in the machine.
• Light emitted from the LED travels through the light guiding path and is guided into the
Toner Cartridge.
• The toner level sensor detects the intensity of the transmitted light guided through the
light guiding path from the inside of the Toner Cartridge. The toner level is thereby esti-
mated.
• To ensure correct detection of the intensity of transmitted light by the toner level sensor, a
cleaning sheet is provided that cleans the window in the light guiding path periodically.
LED
Sensor
Cleaning Sheet
Light Guiding Path
Cleaning Sheet
4138to2012c2
4138to2012c1
• Detection start timing
1. When the Developing Unit is driven evenly
2. LED steady light is stabilized
3. When the above two conditions are met, the machine starts a toner empty detection
sequence. Detection control is, however, interrupted during registration correction and
gamma correction, in which it is not possible to acquire output values of the toner level
sensor.
• <Empty decision>
1. A sequence is started for detecting a toner empty condition when a toner near-empty
condition is detected.
2. The machine determines that there is a toner empty condition when the toner level sen-
sor output value remains below a predetermined value and if the following event is
detected a predetermined number of consecutive times: the output value of the toner
level sensor remains a predetermined value or lower for more than a predetermined
period of time.
3. The consecutive detection count is retained even when power is turned OFF.
• <Resetting empty condition>
A toner empty condition is reset when a new Toner Cartridge is detected.
2-17
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Toner Cartridge / Hopper
Main Unit Theory of Operation
• <Toner empty messages>
The relevant warning message is displayed when a toner empty condition is detected.
magicolor 5430 DL/5440 DL magicolor 5450
TONER EMPTY
REPLACE TONER CYAN
REPLACE TONER MAGENTA
REPLACE TONER YELLOW
REPLACE TONER BLACK
REPLACE
Y
TONER EMPTY
REPLACE
M
TONER EMPTY
REPLACE
C
TONER EMPTY
REPLACE
K
2-18
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Main Unit Theory of Operation
Toner Cartridge / Hopper
4.2.5
Toner replenishing mechanism/control
A. Toner replenishing mechanism
• The Toner Supply Motor is energized according to the condition of the toner level sensor
for each color of toner. Toner is then supplied from the Hopper to the Developing Unit as
necessary.
• A single Toner Supply Motor is turned either forward or backward to accomplish supply of
toner of two different colors (one motor is for Y and M, and the other for C and K). That is,
M (K) toner cannot be supplied while Y (C) toner is being supplied.
• Toner is supplied only while the Developing Unit is being driven. This is because of the
following reason: if toner is supplied from the Hopper while the Developing Unit remains
stationary, toner stagnates at the Developing Unit.
Direction of rotation
(as viewed from above of motor
shaft)
Toner supply (Agitating Blade/Conveyance Screw)
Toner Supply
Motor
Y
M
C
K
Forward (clockwise)
Backward (counterclockwise)
Forward (clockwise)
Turned
Stationary
Turned
Stationary
Stationary
Turned
Stationary
Stationary
Stationary
Turned
/Y, /M (M6)
/C, /K (M7)
Stationary
Stationary
Stationary
Stationary
Stationary
Backward (counterclockwise)
Stationary
When the motor turns forward
When the motor turns backward
Toner Supply Motor (M6)
Toner Supply Motor (M7)
K
C
M
Y
4138to2014c0
4138to2013c0
Y/C one-way clutch turns.
M/K one-way clutch turns.
B. Toner replenishing decision control
• Toner replenishing decision control is provided only while the Developing Unit is driven
evenly.
• The machine determines that toner replenishing for the Developing Unit is necessary
when the toner level sensor output value remains below a predetermined value and if the
following event is detected a predetermined number of consecutive times: the output
value of the toner level sensor remains a predetermined value or lower for more than a
predetermined period of time.
• The toner replenishing decision control is interrupted during registration correction and
gamma correction, in which it is not possible to acquire output values of the toner level
sensor.
2-19
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Toner Cartridge / Hopper
Main Unit Theory of Operation
C. Toner Supply Motor control
• The Toner Supply Motor control is carried out when all of the following conditions are met
while the Developing Motor turns evenly.
1. The toner level sensor output value indicates that toner replenishing for the Developing
Unit is required.
2. The Toner Supply Motor has not been energized for a predetermined period of time or
more after the condition, in which the Developing Unit needs toner to be replenished,
has been established.
3. A predetermined period of time elapses after the Toner Supply Motor has been ener-
gized for a predetermined period of time or more after the condition, in which the Devel-
oping Unit needs toner to be replenished, was established.
D. Toner Supply Motor control start timing (1)
• The Toner Supply Motor starts turning when all of the following conditions are met:
1. The Developing Motor turns evenly.
2. The toner level sensor output value indicates that toner replenishing for the Developing
Unit is required.
3. A predetermined period of time elapses after the Toner Supply Motor has been ener-
gized for a predetermined period of time or more after the condition, in which the Devel-
oping Unit needs toner to be replenished, was established.
E. Toner Supply Motor control start timing (2)
• The Toner Supply Motor starts turning when all of the following conditions are met:
1. The Developing Motor turns evenly.
2. The Toner Supply Motor has not turned for a predetermined period of time during the
last toner replenishing sequence.
F. Toner Supply Motor starting timing control
• Since a single Toner Supply Motor is turned forward or backward to replenish the supply
of either one of two colors of toner, M (K) toner cannot be supplied while Y (C) toner is
being supplied.
• Control is provided to assign a uniform replenishing timing, thereby ensuring that the four
colors of toner are supplied evenly.
1. A replenishing sequence is started when it becomes necessary to replenish the supply
of Y/C toner (M/K toner).
2. The supply of Y/C toner is replenished for a predetermined period of time. If there is a
request for replenishing the supply of M/K toner thereafter, a replenishing sequence is
started again.
Note, however, that the new replenishing sequence can be started only after the lapse
of a predetermined period of time after the supply of Y/C toner (M/K toner) has been
replenished. If another request is made for replenishing the supply of Y/C toner (M/K
toner) after the lapse of this predetermined period of time, and if there is no request for
replenishing the supply of M/K toner (Y/C toner), the supply of Y/C toner (M/K toner) is
replenished again.
3. If the other Toner Supply Motor is being started when a toner replenishing sequence
using one Toner Supply Motor is to be started, this replenishing sequence is not
started. The sequence is started only after rotation of the other Toner Supply Motor has
become stable.
2-20
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Main Unit Theory of Operation
Toner Cartridge / Hopper
G. Toner Supply Motor control termination timing
• The Toner Supply Motor is brought to a stop or interrupted under any of the following
conditions:
1. The Developing Motor stops completely or turns unevenly.
2. The Toner Supply Motor has turned for a predetermined period of time.
3. Toner Supply Motor rotation prohibition timing
• If a toner replenishing sequence is interrupted, the Toner Supply Motor turns for the
remaining period of time to replenish the supply of toner when the Developing Motor is
energized next time.
2-21
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Toner Cartridge / Photo Conductor
Main Unit Theory of Operation
5. Toner Cartridge / Photo Conductor
5.1 Composition
[1]
Aluminum base
Charge Transport
Layer
Charge
Generating
Layer
Direction of
rotation
4138to2505c1
4138to2004c0
Key
[1]
Name
Function/system
Photo Conductor/Y, M, C, K • Drum surface on which an image of each color of toner is
formed for subsequent transfer of the image to the Transfer Belt.
• OPC drum (φ30 mm)
5.2 Operation
5.2.1
Photo Conductor drive mechanism
• Motors are used for the drive mechanism independently of the developing system to sup-
press incorrect color registration and uneven pitch.
• To stop the drive for the color Toner Cartridges in the monochrome mode, different
motors are used to drive the color Photo Conductors and black Photo Conductor.
• The Color PC Drum Motor (M2) drives the Photo Conductor/Y, M, and C, while the Inter-
mediate Transport Motor (M3) drives the Photo Conductor/K.
• In addition to the Photo Conductor/K, the Intermediate Transport Motor (M3) also drives
the transfer system, paper feed system, and synchronizing drive system.
• Gears having a large diameter are used to enhance rotating accuracy of the Photo Con-
ductors.
• The use of gears having a large diameter provides a large number of gear teeth, which
suppresses uneven pitch and eccentricity.
• Drive is transmitted to each of the Photo Conductors when the coupling on the drive end
is engaged with that on the driven end.
Intermediate Transport Motor (M3)
Color PC Drum Motor (M2)
Large-diameter
gear
K
C
M
Coupling
4138to2027c0
Y
2-22
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Main Unit Theory of Operation
5.2.2 Photo Conductor post-exposure control
Toner Cartridge / Photo Conductor
• The entire surface of the Photo Conductor is exposed to light before the Photo Conductor
stops rotating during the stop sequence or color change sequence (from the color print to
monochrome print) after a print cycle.
• Ozone stagnant in areas near the Charge Corona Unit is adsorbed on the surface of the
Photo Conductor. This reduces sensitivity of the Photo Conductor, causing white bands
to occur in the image.
• To prevent this image failure from occurring, the entire surface of the Photo Conductor is
exposed to light and thus neutralized. This effectively prevents the surface of the Photo
Conductor from absorbing ozone.
• <Execution timing>
position (to prevent dirt on the background due to a potential difference between the
Photo Conductor and the Developing Unit).
5.2.3
Photo Conductor total exposure control upon recovery
• If the “Photo Conductor post-exposure control” described above is not correctly done, the
entire surface of the Photo Conductor is exposed to light, thereby preventing ozone from
being adsorbed on the surface of the Photo Conductor.
• If the “Photo Conductor post-exposure control” is not performed due to a media misfeed
or malfunction, the entire surface of the Photo Conductor is exposed to light at the same
time that the “2nd Transfer Roller cleaning control” is performed during the recovery pro-
cedure from the media misfeed or malfunction.
☞
2-53
• <Execution timing>
1. If a media misfeed or malfunction was present when the Power Switch was turned OFF
last time, the “Photo Conductor total exposure control upon recovery” sequence is per-
formed at the same time with the 2nd Transfer Roller cleaning control when the Power
Switch is next turned ON.
2. The control is executed during the recovery procedure from a media misfeed or mal-
function.
2-23
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Toner Cartridge / Photo Conductor
Main Unit Theory of Operation
5.2.4 Photo Conductor small amount rotation control
• Ozone stagnant in areas near the Charge Corona Unit reduces sensitivity of the Photo
Conductors, causing white bands to occur in the image.
• To prevent this image problem, the Photo Conductor is turned so as to allow its surface
facing the Charge Corona Unit to deviate, thereby preventing the surface sensitivity from
being reduced.
A. Photo Conductor small amount rotation timing
• The number of execution sequences is determined when the post process following a
print cycle is completed. The control is executed while the Color PC Drum Motor (M2) or
Intermediate Transport Motor (M3) is in the standby state.
• If the color Photo Conductors need to be turned a small amount during the monochrome
mode, the control is executed also for the color Photo Conductors.
Photo Conductor
Charge Corona Unit
4138to2018c4
2-24
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Main Unit Theory of Operation
Toner Cartridge / Charge Corona Section
6. Toner Cartridge / Charge Corona Section
6.1 Composition
[1]
[2]
[3]
[4]
[5]
[6]
4138to2020c0
4138to2018c5
Key
[1]
Name
Function/system
Cleaning Blade
Grid Mesh
• Scrapes residual toner off the surface of the Photo
Conductor
• Evens out the charge deposited from the Electrode to
make the surface potential uniform throughout the sur-
face of the Photo Conductor
[2]
[3]
• The grid voltage is applied to the Grid Mesh
Electrode
• DC comb electrode Scorotron system
• Using the comb electrode ensures that the charge is
concentrated on the grid mesh, thus reducing the
amount of ozone produced
• The charge corona voltage is applied
• Maintenance free; no cleaning mechanism is available
Charge Corona
• Deposits a charge to the surface of the Photo
Conductor
[4]
[5]
• DC comb electrode Scorotron system
Toner Collecting Screw
• Conveys the waste toner scraped off by the Cleaning
Blade into the Waste Toner Storage Tank
• Screw type
Waste Toner Storage Tank
• Stores waste toner of each color
• Fixed type; requires no service jobs, including disposi-
tion of the stored waste toner
• The storage tanks for Y, M, and C are of the same
shape, while that for K is larger than others to accom-
modate a greater amount of waste toner
[6]
2-25
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Toner Cartridge / Charge Corona Section
Main Unit Theory of Operation
6.2 Operation
6.2.1
Charge Corona Unit ON/OFF control
Polygon Motor (M8)
Semiconductor laser
Intermediate Transport
Motor (M3)
Color PC Drum Motor
(M2)
Developing Motor/
Y, M, C (M1)
Developing Motor/
K (M5)
Charge K
Charge YMC
4138to2133e0
6.2.2
Output during pre-process
• Color mode: The charge corona voltage for all colors of toner is applied after rotation of
the Color PC Drum Motor (M2) has stabilized.
• Monochrome mode: The charge corona voltage for K is applied after rotation of the Inter-
mediate Transport Motor (M3) has stabilized.
• Image formation is possible for the area, to which the charge corona voltage is applied.
6.2.3
Output during post-process
• The output of the charge corona voltage is shut down when the entire exposed area of
the Photo Conductor moves past the charge corona section after the 1st transfer process
has been completed.
2-26
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Main Unit Theory of Operation
6.2.4 Ozone ventilation mechanism
Toner Cartridge / Charge Corona Section
• Ozone stagnant in areas near the Charge Corona Unit reduces sensitivity of the Photo
Conductor, causing white bands to occur in the image.
• The Ozone Filter is used to remove ozone produced by the Charge Corona Unit, thereby
preventing sensitivity of the Photo Conductor surface from being degraded.
• The urethane rubber affixed to the side face of the Charge Corona Unit is brought into
contact the Photo Conductor, which makes the Charge Corona Unit in tight contact with
the Photo Conductor.
• Outside air is drawn in through the opening provided at the front end of the Charge
Corona Unit and is discharged together with ozone through the opening provided in the
rear.
• The Ozone Ventilation Fan Motor (M12) located in the rear of the machine draws air to
allow the discharged ozone to be removed by the Ozone Filter.
• The Ozone Ventilation Fan Motor (M12) is kept energized for 3 min. after the print cycle
has been completed.
• The Ozone Ventilation Fan Motor (M12) also functions to cool down the Print Head.
K
C
M
Y
Ozone Filter
Ozone Ventilation Fan Motor (M12)
4138to2021c0
2-27
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Toner Cartridge / Developing Unit
Main Unit Theory of Operation
7. Toner Cartridge / Developing Unit
7.1 Composition
[11]
[10]
[9]
[1]
[2]
[8]
[7]
[3]
[4]
[6]
[5]
4138to2024c1
4138to2018c7
[13]
[12]
C
K
M
Y
4138to2029c1
4138to2030c1
Key
[1]
Name
Function/system
Photo Conductor/Y, M, C, K
• The drum surface on which an image of each color of
toner is formed for subsequent transfer of the image to
the Transfer Belt
• OPC drum (φ30 mm)
Cleaning Blade
• Scrapes residual toner off the surface of the Photo
Conductor
[2]
[3]
Toner Collecting Screw
Waste Toner Storage Tank
• Conveys the waste toner scraped off by the Cleaning
Blade into the Waste Toner Storage Tank
• Stores waste toner of each color
• Fixed type; requires no service jobs, including disposi-
tion of the stored waste toner
• The storage tanks for Y, M, and C are of the same
shape, while that for K is larger than others to accom-
modate a greater amount of waste toner
[4]
[5]
Regulator Blade/1st, 2nd
• Regulates the height of toner on the surface of the
Developing Roller
• The blade bias voltage is applied to the blade
2-28
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Main Unit Theory of Operation
Toner Cartridge / Developing Unit
Function/system
Key
Name
Developing Roller
• Supplies toner fed by the Supply Roller to the surface
of the Photo Conductor
• Conveys toner to the surface of the Photo Conductor
through potential difference
• The developing bias voltage is applied to this roller
• A given distance from the Photo Conductor is main-
tained by means of the Ds Roll
[6]
• Single component developing system
Toner Chamber
Supply Roller
• Tank in which toner fed off from the Hopper is tempo-
rarily stored
[7]
[8]
• Supplies toner in the Toner Chamber to the Develop-
ing Roller
• Conductive elastic roller
• Conveys toner to the surface of the Developing Roller
through potential difference
• The supply bias voltage is applied to this roller
Agitating Screw
• Agitates toner fed off by the Replenishing Screw with
that in the Toner Chamber so that it is charged
• Two-shaft agitating system
[9]
Charge Neutralizing Sheet
• Electrically removes toner off the surface of the Devel-
oping Roller
[10]
• The charge neutralizing bias voltage is applied to this
sheet
Replenishing Screw
• Feeds toner fed through the Conveyance Pipe to the
Toner Chamber
[11]
[12]
[13]
• Agitates toner in the Toner Chamber
• Two-shaft agitating system
Developing Motor/Y, M, C (M1)
Developing Motor/K (M5)
• Drives the rollers and screws of the Y, M, or C Devel-
oping Unit
• De-energized in the monochrome mode
• Brushless DC motor
• Drives the rollers and screws of the K Developing Unit
• Provides drive also for the Waste Toner Box
☞
2-57
• Brushless DC motor
2-29
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Toner Cartridge / Developing Unit
Main Unit Theory of Operation
7.2 Operation
7.2.1
Developing drive control
Polygon Motor (M8)
Intermediate Transport Motor (M3)
Color PC Drum Motor (M2)
Developing Motor/Y, M, C (M1)
Developing Motor/K (M5)
Charge K
Charge YMC
Developing Y
Developing M
Developing C
Developing K
1st transfer pressure
1st transfer Rem
2nd transfer pressure
2nd transfer Rem
4138to2147e0
2-30
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Main Unit Theory of Operation
7.2.2 Toner flow
Toner Cartridge / Developing Unit
1. Toner stored in the Hopper is agitated by the Agitating Blade and conveyed onto the
front side of the Hopper by the Conveyance Screw.
2. The toner conveyed onto the front side of the Hopper is conveyed down to the Toner
Chamber through the Conveyance Pipe.
3. The toner conveyed from the Hopper is conveyed onto the Toner Chamber by the
Replenishing Screw.
4. The toner level detection system provided on the front side of the Developing Unit (the
sensor is mounted on the machine side) detects, at this time, the level of toner still
available for use in the Toner Chamber.
5. The toner conveyed to the Toner Chamber is agitated (charged) by the Replenishing
Screw and Agitating Screw.
6. Toner conveyed onto the rear side of the Toner Chamber is fed to the Supply Roller.
7. Toner fed to the Supply Roller is conveyed onto the Developing Roller.
At this time, the Regulator Blade/1st and /2nd regulate the height of toner on the sur-
face of the Developing Roller.
8. Toner on the Developing Roller is fed to the electrostatic latent image formed on the
surface of the Photo Conductor.
9. Toner left on the Developing Roller is neutralized and returned to the Supply Roller.
10. The toner on the surface of the Photo Conductor is transferred onto the Transfer Belt.
11. Toner left on the surface of the Photo Conductor is scraped off by the Cleaning Blade.
12. The toner scraped off by Cleaning Blade is conveyed to the Waste Toner Storage Tank
by the Toner Collecting Screw.
13. The toner conveyed by the Toner Collecting Screw is stored as waste toner in the
Waste Toner Storage Tank.
K
C
M
Y
4138to2030c0
Photo Conductor
Replenishing Screw
Agitating Blade
Transfer Belt
Conveyance Screw
Conveyance Pipe
Agitating Screw
Replenishing
Screw
Supply Roller
Developing Roller
Toner
Collecting Screw
Waste Toner
Storage Tank.
4138to2018c1
4138to2011c1
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Toner Cartridge / Developing Unit
7.2.3 Developing system
Main Unit Theory of Operation
• Two types of developing systems are used, a non-contact developing system and an
alternating current application system.
1. A negative charge (supply bias voltage Vr) is applied the Supply Roller to regulate the
amount of toner sticking to the Developing Roller.
2. A negative charge (blade bias voltage Vb1) is applied to the Regulator Blade/1st to
negatively charge the toner and form a thin layer of toner.
3. Toner on the surface of the Developing Roller is evened out by the Regulator Blade/
2nd.
4. During development, DC + AC developing bias voltage (Vb) is applied to Developing
Roller. The AC component of the developing bias voltage is applied only during devel-
opment. At any time other than the development, only the DC component of the devel-
oping bias voltage is applied.
5. Toner sticks to the Photo Conductor when the AC component of the developing bias
voltage (Vpp) is negative. The time length of the negative component (Vpp) determines
the image density.
6. A negative charge (charge neutralizing bias voltage: same potential as the developing
bias) is applied to the Charge Neutralizing Sheet to neutralize any toner left on the sur-
face of the Developing Roller. The neutralized toner is returned to the Supply Roller.
Photo Conductor
Charge Neutralizing Sheet
Supply Roller
Developing Roller
Regulator Blade/1st
Regulator Blade/2nd
4138to2018c2
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Main Unit Theory of Operation
Toner Cartridge / Developing Unit
7.2.4 Developing bias Vpp control (Ds compensation control)
• If the developing bias voltage AC component (Vpp) is too high for the Ds distance in each
Toner Cartridge, a leak image (background leak, image area leak) or halftone reproduc-
tion failure results.
• As a means for preventing this phenomenon, this control detects a Vpp range, in which
no image failure occurs, to set the optimum Vpp.
• The Vpp control may be either the simplified check or complete correction.
• The developing bias Vpp is controlled integrally with other control items by the image sta-
bilization control.
• The developing bias Vpp control is performed when there is a request made for execu-
tion of image stabilization sequence.
☞
2-120
A. Simplified check
1. The leak decision criterion value is measured.
2. A leak decision is made based on the data acquired during the last complete correction
control.
3. If it is determined that there is no leak occurring, the last Vpp value is applied.
4. If it is determined that there is a leak occurring, the control proceeds to the complete
correction and the Vpp correction procedure is performed.
B. Complete correction control
1. The leak decision criterion value is measured.
2. The Vpp value for the leak decision is detected.
3. The leak marginal value is detected.
4. Calculate and determine the set Vpp value based on the leak marginal value.
Simplified check
Complete correction control
Start
Start
Measure the leak criterion value.
Perform leak margin check.
Measure the leak criterion value.
Detect the marginal Vpp value.
Determine the set Vpp value.
Determine whether it is necessary
to shift to Vpp correction.
End
End
4138to2135e0
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Toner Cartridge / Developing Unit
Main Unit Theory of Operation
7.2.5
Developing bias duty control (compensation control of the maximum
amount of toner sticking to the Transfer Belt)
• This control corrects to achieve the target amount of toner sticking to the Transfer Belt to
form the solid image.
• The duty control may be either the simplified correction or complete correction.
• The developing bias duty control is performed integrally with other control items by the
image stabilization control.
• The developing bias duty control is performed when there is a request made for execu-
tion of image stabilization sequence.
☞
2-120
A. Simplified correction control
2. The detection pattern of each color of toner is produced on the Transfer Belt using the
calculated duty value for detection.
3. The detection pattern is detected by the AIDC Sensor.
4. If the detected value for at least any one color of toner varies by a predetermined value
or more from the duty value set through the last complete correction control, the simpli-
fied correction is first made and then the control proceeds to the complete correction
control.
5. If the detected value for at least any one color of toner varies by a predetermined value
or more from the duty value set through the last gamma correction control, the simpli-
fied correction is first made and then the control proceeds to the gamma correction
control.
☞
2-35
6. If the detected value varies only within a predetermined value range, the current setting
value is calculated and set based on the previous setting value.
B. Complete correction control
1. The duty value for detection is calculated from the previous setting value.
2. The detection pattern of each color of toner is produced on the Transfer Belt using the
calculated duty value for detection.
3. The detection pattern is detected by the AIDC Sensor and the set duty value is deter-
mined.
Start
Calculate the duty value for detection.
Produce and detect the detection pattern.
Determine the set duty value.
End
4138to2136e0
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Main Unit Theory of Operation
7.2.6 Gamma correction control
Toner Cartridge / Developing Unit
• A gradation pattern is produced on the surface of the Transfer Belt. The AIDC Sensor
measures the density of this pattern and transmits the results of measurement to the
controller for gradation correction.
• The gamma correction is controlled integrally with other control items by the image stabi-
lization control.
• The gamma correction control is performed when there is a request made for execution
of image stabilization sequence.
☞
2-120
A. Correction control
1. A detection pattern of each color of toner is produced on the surface of the Transfer
Belt.
2. The detection pattern is detected by the AIDC Sensor.
3. The mean value of the readings taken is calculated.
4. Noise is removed from the mean value.
5. Rearrange the readings in descending order.
6. Normalize the readings.
Start
Produce the detection pattern
and detect it.
Average out the AIDC output value
for each gradation level.
Remove noise.
Rearrange readings.
Normalize readings.
End
4138to2141e0
2-35
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Toner Cartridge / Developing Unit
Main Unit Theory of Operation
7.2.7
Cleaning mechanism
A. Cleaning operation
1. The Cleaning Blade is pressed against the surface of the Photo Conductor to remove
toner left off the surface (trailing system).
2. The toner, which has been scraped off by the Cleaning Blade, is conveyed by the Toner
Collecting Screw and collected in the Waste Toner Storage Tank.
3. The toner is then stored as waste toner in the Waste Toner Storage Tank.
The waste toner is collected together with the Toner Cartridge when the Toner Car-
tridge is replaced with a new one. The Waste Toner Storage Tank is not detachable
from the cartridge.
Cleaning Blade
Photo Conductor
Cleaning Blade
Toner
Collecting
Screw
Waste Toner
Storage Tank
4138to2023c0
4138to2018c2
2-36
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1st Transfer Section
Main Unit Theory of Operation
Key
Name
Function/system
• Drives the Transfer Belt
[1] Transfer Belt Drive Roller
• Driven by the Intermediate Transport Motor (M3)
• Grounded to allow the 2nd transfer current to flow through
it
[2] 1st Transfer Roller/K
• Transfers the toner image from the K Photo Conductor to
the Transfer Belt (1st transfer)
• The transfer voltage (T1) is applied
• The applied transfer voltage (T1) has the same potential
for all four colors
• A transfer Roller retraction mechanism using a Pressure
Cam and a Retraction Lever is provided for all rollers but
the 1st Transfer Roller/K
[3] Pressure Cam
• Drives the Sliding Plate
[4] 1st Transfer Roller/C
[5] 1st Transfer Roller/M
[6] 1st Transfer Roller/Y
• Transfers the toner image from each color of Photo Con-
ductor to the Transfer Belt (1st transfer)
• The transfer voltage (T1) is applied
• The applied transfer voltage (T1) has the same potential
for all four colors
• The Retraction Lever is operated by an actuator on the
machine side
• The roller is retracted in the ordinary standby state, mono-
chrome mode, and during image stabilization control
[7] Driven Roller
• Rotated as driven by the Transfer Belt
[8] Cleaning Blade
[9] Toner Collecting Screw
• Scrapes residual toner off the surface of the Transfer Belt
• Conveys the toner scraped off by the Cleaning Blade into
the Waste Toner Box
[10] Retraction Position Sensor/1st
Image Transfer (PC9)
• Detects the operating condition of the Sliding Plate
(retraction of the 1st Transfer Roller)
[11] Sliding Plate
• Drives the Retraction Lever/Y, M, C
[12] Retraction Lever/Y, M, C
• Retracts the 1st Transfer Roller/Y, M, C from the Photo
Conductor/Y, M, C
[13] Transfer Belt
• The image of each color of toner is transferred from the
1st Transfer Roller of each color to this Transfer Belt in the
order of Y, M, C, and K, thereby forming a full color toner
image
[14] Pressure/Retraction Clutch/1st
Image Transfer (CL1)
• Transmits the drive from the Intermediate Transport Motor
(M3) to the Pressure Cam
• Presses or retracts the 1st Transfer Roller/Y, M, C.
[15] Intermediate Transport Motor (M3) • Drives the Transfer Belt
• Provides drive also for the conveyance section, 2nd trans-
fer section, media feed section, and other parts
• Brushless DC motor
[16] Toner Collecting Port
• Port through which toner conveyed by the Toner Collecting
Screw is dumped into the Waste Toner Box
• Provided with a shutter that prevents toner from being
spilled
2-38
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Main Unit Theory of Operation
1st Transfer Section
8.2 Drive
[5]
[4]
4138to2038c0
Mechanism for driving the belt
[5]
[4]
[1]
[3]
[2]
4138to2041c1
Mechanism for driving the pressure/retraction motion
[7]
[6]
[9]
[7]
[8]
4138to2036c1
[1] Transfer Belt Drive Roller
[2] Driven Roller
[6] 1st Transfer Roller/Y, /M, /C, /K
[7] Sliding Plate
[3] Transfer Belt
[8] Toner Collecting Screw
[9] Pressure Cam
[4] Intermediate Transport Motor (M3)
[5] 1st Transfer Roller/Y
Pressure/Retraction Clutch/1st Image
Transfer (CL1)
2-39
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1st Transfer Section
Main Unit Theory of Operation
8.3 Operation
8.3.1
Transfer Belt speed control
• The Transfer Belt is driven by the Intermediate Transport Motor (M3).
• The appropriate belt speed is selected according to the print mode and media type as
detailed below.
Media type/print mode
Plain paper
Belt speed
1 (standard)
Reason
Thick stock, envelopes, postcards,
label OHP film (monochrome print)
To ensure good fusing
performance
1/2 (one-half speed)
1/3 (one-third speed)
To ensure good light trans-
mission performance
OHP film (color print)
• For the first print, the machine makes the above decision before starting a print/media
feed sequence and, based on the established speed, starts the print/media feed
sequence.
8.3.2
1st transfer output control
• To transfer the toner image from the Photo Conductor to the Transfer Belt, the transfer
voltage (T1) is applied to the 1st Transfer Roller.
• A charge of the same potential is applied to each of the 1st Transfer Rollers.
A. Color mode pre-process control
1. After rotation of the Intermediate Transport Motor (M3) has been stabilized, the 1st
Transfer Roller/Y, M, C is pressed against the Transfer Belt.
2. The transfer voltage (T1) is set according to the system speed, environmental condi-
tions, and other factors.
3. The transfer voltage (T1) is applied.
B. Monochrome mode pre-process control
1. After rotation of the Intermediate Transport Motor (M3) has been stabilized, the transfer
voltage (T1) is set according to the system speed, environmental conditions, and other
factors.
2. The transfer voltage (T1) is applied.
C. Transfer voltage application timing
• The transfer voltage (T1) is applied after the 1st Transfer Roller/Y, M, C is pressed
against the Transfer Belt.
• The transfer voltage (T1) is applied after the 1st Transfer Roller/Y, M, C is pressed
against the Transfer Belt through the color change sequence (from monochrome to color,
or vice versa).
D. Print control
• The transfer voltage is kept applied during transfer of the toner image.
• The voltage is kept applied even for unexposed areas between two images.
E. Color mode post-process control
1. The transfer output is turned OFF after the last image moves past the 2nd transfer sec-
tion and before the 1st Transfer Rollers are retracted.
F. Monochrome mode post-process control
1. The transfer output is turned OFF after the last image moves past the 2nd transfer sec-
tion.
2-40
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Main Unit Theory of Operation
8.3.3 1st Transfer Roller pressure/retraction control
1st Transfer Section
• To extend the service life of the Photo Conductor/Y, M, C, the pressure position of the 1st
Transfer Roller is changed between the monochrome mode and the color mode.
The 1st Transfer Roller/K is not provided with a retraction mechanism; the Transfer Belt is
pressed against the Photo Conductor/K at all times.
• The Intermediate Transport Motor (M3) provides the drive for pressure/retraction opera-
tion of the 1st Transfer Roller/Y, M, C. The pressure/retraction sequence is carried out
while the Intermediate Transport Motor (M3) and Color PC Drum Motor (M2) turn evenly.
A. Monochrome mode
• The 1st Transfer Roller/Y, M, C is moved inward the unit (for retraction) and the Photo
Conductor/Y, M, C is stopped. The transfer roller is moved (retracted) and the Photo
Conductor is stopped also in the ordinary standby state.
B. Color mode
• During the 1st transfer in the color mode, the 1st Transfer Roller/Y, M, C is moved toward
the Photo Conductor (pressed) so that Transfer Belt is pressed against the Photo Con-
ductor.
C. Others
• The transfer roller is moved (retracted) and the Photo Conductor is stopped in the ordi-
nary standby state.
D. Pressure operation
1. Rotation of the Intermediate Transport Motor (M3) is transmitted by a gear train to the
Pressure/Retraction Clutch/1st Image Transfer (CL4).
2. Rotation of the Pressure/Retraction Clutch/1st Image Transfer (CL4) turns the Pressure
Cam, which moves the Sliding Plate.
3. As the Sliding Plate moves, the Retraction Lever turns.
4. As the Retraction Lever turns, the 1st Transfer Roller is pressed against the Transfer
Belt.
Sliding Plate
Pressure Cam
Retraction Lever
1st Transfer Roller
Photo Conductor
4138to2044c1
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1st Transfer Section
Main Unit Theory of Operation
E. Retraction operation
1. Rotation of the Intermediate Transport Motor (M3) is transmitted by a gear train to the
Pressure/Retraction Clutch/1st Image Transfer (CL4).
2. Rotation of the Pressure/Retraction Clutch/1st Image Transfer (CL4) turns the Pressure
Cam, which moves the Sliding Plate.
3. As the Sliding Plate moves, the Retraction Lever turns.
4. As the Retraction Lever turns, the 1st Transfer Roller is retracted from the Transfer Belt.
Sliding Plate
Pressure Cam
Retraction Lever
1st Transfer Roller
Photo Conductor
4138to2045c1
F. Pressure position control
• The pressure and retraction operation of the 1st Transfer Roller is controlled as the
Retraction Position Sensor/1st Image Transfer (PC9) detects the movement of the Slid-
ing Plate.
1. The Pressure/Retraction Clutch/1st Image Transfer (CL4) is energized.
2. The Sliding Plate is moved to press the 1st Transfer Rollers up against the Transfer
Belt, which blocks the Retraction Position Sensor/1st Image Transfer (PC9).
3. After the lapse of a predetermined period of time after the Retraction Position Sensor/
1st Image Transfer (PC9) has been blocked, the Pressure/Retraction Clutch/1st Image
Transfer (CL4) is de-energized.
2-42
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Main Unit Theory of Operation
1st Transfer Section
G. Retraction position control
• The pressure and retraction operation of the 1st Transfer Roller is controlled as the
Retraction Position Sensor/1st Image Transfer (PC9) detects the movement of the Slid-
ing Plate.
1. The Pressure/Retraction Clutch/1st Image Transfer (CL4) is energized.
2. The Sliding Plate is moved to retract the 1st Transfer Rollers from the Transfer Belt. As
a result, the Retraction Position Sensor/1st Image Transfer (PC9), which has been
blocked, is now unblocked.
3. After the lapse of a predetermined period of time after the Retraction Position Sensor/
1st Image Transfer (PC9) has been unblocked, the Pressure/Retraction Clutch/1st
Image Transfer (CL4) is de-energized.
Retraction Position Sensor/1st Image Transfer
Sliding Plate
4138to2046c1
H. Pressure/retraction operation timing
1st Image Transfer Roller retracted
1st Image Transfer Roller pressed
Retraction Position Sensor/
1st Image Transfer (PC9) blocked
Retraction Position Sensor/
1st Image Transfer (PC9) unblocked
Pressure Cam angle
4138to2046c2
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1st Transfer Section
Main Unit Theory of Operation
8.3.4 1st Transfer Roller pressure/retraction failure detection control
• The machine monitors the state of the Retraction Position Sensor/1st Image Transfer
(PC9) for detection of failures.
A. Detection of failure during pressure operation
• If the Retraction Position Sensor/1st Image Transfer (PC9) is not blocked within a prede-
termined period of time after the Pressure/Retraction Clutch/1st Image Transfer (CL4)
has been energized, the machine determines that there is an Intermediate Transfer Belt
pressure failure.
B. Detection of failure during retraction operation
• If the Retraction Position Sensor/1st Image Transfer (PC9) is not unblocked within a pre-
determined period of time after the Pressure/Retraction Clutch/1st Image Transfer (CL4)
has been energized, the machine determines that there is an Intermediate Transfer Belt
retraction failure.
C. Detection of pressure/retraction failure during a print cycle
• A media misfeed in control logic results if there is a condition developing in which a pres-
sure/retraction sequence is not carried out at correct timing during the 1st transfer
sequence.
• A pressure/retraction sequence is not completed at timing, at which printing starts in the
sub scan direction.
D. 1st transfer control provided when a malfunction occurs
• If a media misfeed or malfunction is detected with a toner image left on any one of the Y,
M, C, and K Photo Conductors, the toner image on the Photo Conductor is first trans-
ferred onto the Transfer Belt and then the subsequent procedures are performed.
1. It is determined that the machine stops in mid-printing operation due to a media mis-
feed or malfunction.
2. The output of each laser diode is shut down so as not to form an electrostatic latent
image on the surface of the Photo Conductor.
3. The developing bias output for each color is shut down so as not to allow development
to take place.
4. The Transfer Belt is driven for the distance between exposure and transfer, thereby
transferring the toner image on the surface of the Photo Conductor onto the Transfer
Belt. Drive of the Transfer Belt is then stopped.
2-44
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Main Unit Theory of Operation
8.3.5 Transfer Belt cleaning
1st Transfer Section
• To scrape residual toner off the surface of the Transfer Belt, the Transfer Belt is provided
with a Cleaning Blade.
• The Cleaning Blade is in pressed contact with the Transfer Belt at all times. That is, it
cleans the surface of the Transfer Belt as long as the belt turns.
• The Toner Collecting Screw conveys toner scraped off by the Cleaning Blade into the
Waste Toner Box.
☞
2-57
Cleaning Blade
Transfer Belt
Toner Collecting
Screw
4138to2035c1
A. 1st Transfer Belt cleaning control
• If there is a possibility of the machine being stopped with toner left on the surface of the
Transfer Belt between the Cleaning Blade position and the 2nd transfer position (due to a
media misfeed or malfunction), the Intermediate Transport Motor (M3) is energized to
turn the Transfer Belt. The residual toner is thereby removed from the Transfer Belt.
• No forced cleaning sequence is carried out to clean the entire surface of the Transfer
Belt.
4138to2049c1
1st Transfer Belt cleaning area
B. 1st Transfer Belt cleaning operation timing
• The 1st transfer cleaning sequence is carried out before the 2nd transfer cleaning as part
of the initial operation sequence.
• The 1st transfer cleaning sequence is carried out before the ATVC 2nd transfer cleaning
sequence.
C. 1st Transfer Belt backward rotation control
• To prevent paper dust, toner, and other foreign matter from being wedged in the Cleaning
Blade while the Transfer Belt remains stationary, the Transfer Belt is turned backward so
that the foreign matter can be removed.
• Once the Transfer Belt is started turning backward, this operation takes precedence over
any other request for energizing the Intermediate Transport Motor (M3). Such a request
is honored after the backward rotation control is completed.
• The backward rotation control is not executed at high temperatures.
2-45
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1st Transfer Section
Main Unit Theory of Operation
D. 1st Transfer Belt backward rotation execution conditions
• After the lapse of a predetermined period of time after the Transfer Unit stop sequence.
• A predetermined number of printed pages are produced after the execution of the last
backward rotation control.
E. 1st Transfer Belt backward rotation operation
1. The machine remains in the standby state for a predetermined period of time after the
2. After the lapse of another predetermined period of time, the Intermediate Transport
Motor (M3) is turned backward for a predetermined period of time.
3. After the Transfer Belt has been turned backward, the machine remains in the standby
state for a predetermined period of time.
8.3.6
Toner Collecting Port Shutter mechanism
• A dual-shutter mechanism is provided to prevent waste toner from being spilled from the
Toner Collecting Port when the Waste Toner Box is removed and reinstalled.
1. Placing the Lock Lever of the Waste Toner Box in the “locked” position (the 9 o'clock
position) closes the First Shutter of the Toner Collecting Port.
2. Removing the Waste Toner Box closes the Second Shutter.
☞
2-57
Second Shutter
First Shutter
4138to2040c0
4138to2043c0
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Main Unit Theory of Operation
2nd Transfer Section
9. 2nd Transfer Section
9.1 Composition
[1]
4138to2096c0
4138to2037c1
[1]
[1]
[6]
[6]
[2]
4138to2061c0
[5]
[3]
4138to2048c0
[4]
Key
[1]
Name
2nd Transfer Roller
Function/system
• Transfers the toner images in four colors of toner on
the Transfer Belt to the media
• Constant voltage control (ATVC) system
[2] Retraction Lever
• Retracts the 2nd Transfer Roller
Pressure/Retraction Clutch/2nd
Image Transfer (CL5)
• Transmits the drive from the Intermediate Transport
Motor (M3) to the Retraction Cam
[3]
Retraction Position Sensor/2nd Image • Detects the operating condition of the Retraction Cam
[4]
[5]
[6]
Transfer (PC10)
(retraction of the 2nd Transfer Roller)
Retraction Cam
• Drives the Retraction Lever
• Drives the AIDC Sensor Lever
Pre-transfer Guide Plate
• Presses the media up against the Transfer Belt in a
stage before the 2nd transfer
2-47
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2nd Transfer Section
Main Unit Theory of Operation
9.1.1
Drive
[4]
[1]
[4]
[3]
[1]
4138to2585c0
[3]
[2]
4138to2048c0
[2]
[1] Pressure/Retraction Clutch/2nd Image
Transfer (CL5)
[3] Retraction Cam
[2] Retraction Position Sensor/2nd Image
Transfer (PC10)
[4] Transfer Belt drive roller
2-48
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Main Unit Theory of Operation
2nd Transfer Section
9.2 Operation
9.2.1
2nd Transfer Roller pressure mechanism
• The machine is provided with a mechanism that presses the 2nd Transfer Roller up
against, and retracts it from, the Transfer Belt. This is done to prevent the 2nd Transfer
Roller from being dirtied due to patterns produced for purposes other than an actual
printing operation. Such patterns may be produced during the image stabilization
sequence or another function.
A. 2nd Transfer Roller pressure
• The 2nd Transfer Roller is pressed against the Transfer Belt to allow the toner image on
the Transfer Belt to be transferred onto the media.
• The 2nd Transfer Roller is pressed against the Transfer Belt to allow the roller to be
cleaned.
B. 2nd Transfer Roller retraction
• The 2nd Transfer Roller is retracted from the Transfer Belt when a detection pattern is
produced on the Transfer Belt for registration correction control, image stabilization con-
trol, or other control.
• The 2nd Transfer Roller is retracted from the Transfer Belt when the toner image on the
Transfer Belt cannot be transferred to the media due to a paper empty condition occur-
ring during printing.
• The 2nd Transfer Roller is retracted from the Transfer Belt after the 2nd transfer of the
last image is completed during a multi-print cycle.
C. Pressure/retraction operation
1. Rotation of the Intermediate Transport Motor (M3) is transmitted to the drive roller of
the Intermediate Transfer Belt Unit.
2. Rotation of the drive roller is transmitted to the Pressure/Retraction Clutch/2nd Image
Transfer.
3. When the Pressure/Retraction Clutch/2nd Image Transfer is energized, the rotation is
transmitted to the Pressure Cam via a coupling gear.
4. When the Pressure Cam turns a half turn to push up the Pressure Lever, the 2nd Trans-
fer Roller is pressed against the Transfer Belt.
5. At the same time, the AIDC Sensor Lever is pushed up to open the AIDC Sensor
Cover.
6. The light blocking plate fitted on the shaft of the Pressure Cam blocks the Retraction
Position Sensor/2nd Image Transfer (PC10) and a pressed position of the 2nd Transfer
Roller is detected.
7. When the Pressure/Retraction Clutch/2nd Image Transfer is energized a second time,
the Pressure Cam is turned another half turn. This releases the Pressure Lever, caus-
ing the 2nd Transfer Roller to be retracted from the Transfer Belt. At the same time, the
AIDC Sensor Lever is released, which closes the AIDC Sensor Cover.
8. The light blocking plate unblocks the Retraction Position Sensor/2nd Image Transfer
(PC10) and a retracted position of the 2nd Transfer Roller is detected.
2-49
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2nd Transfer Section
Main Unit Theory of Operation
2nd Transfer Roller
4138to2071c0
TransferBelt
drive roller
Retraction
Lever
Retraction
Cam
Pressure/Retraction
Clutch/2nd Image
Transfer (CL5)
4138to2063c0
When pressed
When retracted
2nd Transfer
Roller
Retraction Lever
41382070c0
4138to2064c0
Retraction Cam
D. Pressure/retraction operation
Retraction Position Sensor/
2nd Image Transfer (PC10) blocked
Retraction Position Sensor/
2nd Image Transfer (PC10) unblocked
2nd Transfer Roller pressed
2nd Transfer Roller retracted
AIDC Sensor cover open
AIDC Sensor cover closed
4138to2586c0
Pressure Cam angle
4138to2585c1
4138to2585c2
4138to2585c1
Retracted
Pressed
Retracted
2-50
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Main Unit Theory of Operation
2nd Transfer Section
9.2.2 2nd Transfer Roller pressure position deviation preventive mechanism
• When the Right Door is opened and closed, the Pressure Cam is rotated to prevent the
2nd Transfer Roller from deviating from the pressure position.
A. Operation
• The lever moves up or down as the Right Door is opened or closed, thereby locking rota-
tion of the coupling gear that drives the Pressure Cam.
When the Right Door is closed
When the Right Door is opened
Right Door open/
close lever
Pressure Cam
9.2.3
2nd transfer voltage control
• The transfer voltage (T2) is applied to the 2nd Transfer Roller in order to transfer the
toner image from the Transfer Belt to the media.
• The transfer voltage (T2) is applied after the 2nd Transfer Roller has been pressed
against the Transfer Belt.
2-51
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2nd Transfer Section
Main Unit Theory of Operation
9.2.4 2nd transfer voltage setting control (ATVC: Auto Transfer Voltage Control)
• The transfer voltage (T2) is corrected to reduce effect from the Transfer Belt and environ-
mental changes of toner.
A. Overview of 2nd transfer ATVC operation
Start
Constant current is applied to
the 2nd Transfer Roller.
The current value of the 2nd
Transfer Roller is measured.
The 2nd transfer output voltage
is established.
End
4138to2142e0
B. 2nd transfer ATVC operation timing
• The ATVC control operation is performed for every period of time equivalent to a prede-
termined number of printed pages produced.
• The control operation is performed when the Intermediate Transfer Belt Unit is replaced
with a new one (as started when the Transfer Belt time counter is reset).
• Execution of the transfer ATVC control is, as a rule, synchronized with the image stabili-
zation control. The image stabilization sequence is carried out after the execution of the
ATVC control.
☞
2-118
C. 2nd transfer ATVC operation
1. The Transfer Belt is driven as in the monochrome mode (but charging, developing, or
1st transfer operation is not performed).
2. The 2nd Transfer Roller is pressed against the Transfer Belt.
3. A constant current is applied to the 2nd Transfer Roller.
4. The voltage value is read and, using a conversion formula, the output value of the
transfer voltage (T2) is determined.
5. The established output value is backed up and the transfer output is produced accord-
ing to the environment before the print cycle is started.
6. The last output value is used when an ATVC detection error occurs.
2-52
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Main Unit Theory of Operation
9.2.5 2nd transfer voltage fine-adjustment control
2nd Transfer Section
• The voltage value established through the ATVC control is fine-adjusted according to the
type of media.
• The following adjustment values are used for labels, coated stock, and recycled paper,
for which no setting values are defined.
Type of media
Plain paper, recycled paper
OHP film
Adjustment value
Plain paper
OHP film
Thick stock 1, coated stock
Thick stock 2
Thick stock 1
Thick stock 2
Postcards
Postcards
Envelopes, labels
Envelopes
9.2.6
2nd Transfer Roller pressure/retraction failure detection control
• The machine monitors the state of the Retraction Position Sensor/2nd Image Transfer
(PC10) for detection of failures.
A. Detection of failure during pressure operation
• If the Retraction Position Sensor/2nd Image Transfer (PC10) is not blocked within a pre-
determined period of time after the 2nd Transfer Roller pressure sequence has been
started, the machine determines that there is a 2nd Transfer Roller pressure/retraction
failure.
• The machine considers that there is a control misfeed if the 2nd Transfer Roller is
retracted when it should be pressed.
B. Detection of failure during retraction operation
• If the Retraction Position Sensor/2nd Image Transfer (PC10) is not unblocked within a
predetermined period of time after the 2nd Transfer Roller pressure sequence has been
started, the machine determines that there is a 2nd Transfer Roller pressure/retraction
failure.
9.2.7
2nd Transfer Roller cleaning control
• DC positive and negative transfer bias voltages are alternately applied to the 2nd Trans-
fer Roller. This allows toner residue on the surface of the 2nd Transfer Roller to be trans-
ferred back to the Transfer Belt, thus cleaning the 2nd Transfer Roller.
• Any voltage for other control purposes is not applied during the cleaning procedure.
• The toner transferred back to the Transfer Belt is collected by the Cleaning Blade.
2nd Transfer Roller
Transfer Belt
HV1
Cleaning Blade
4138to2579c0
2-53
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2nd Transfer Section
9.2.8 2nd Transfer Roller cleaning operation timing
Main Unit Theory of Operation
• The 2nd Transfer Roller cleaning sequence is carried out after the Intermediate Transfer
Belt has been cleaned during recovery from a media misfeed or malfunction.
• The cleaning sequence is carried out if 100 printed pages are produced after the last
cleaning sequence.
• The cleaning sequence is carried out when a media size error occurs.
1. The 2nd Transfer Roller is pressed.
2. The 2nd transfer bias voltage of reverse polarity is applied for the period of time corre-
sponding to one revolution of the 2nd Transfer Roller.
3. The 2nd transfer bias voltage of forward polarity is applied for the period of time corre-
sponding to one revolution of the 2nd Transfer Roller.
4. Steps 2 and 3 are repeated five times.
5. The 2nd Transfer Roller is retracted.
2nd Transfer Roller
Pressed
Retracted
2nd transfer bias (reverse polarity)
2nd transfer bias (forward polarity)
4138to2148e0
2-54
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Main Unit Theory of Operation
Toner Collecting Section
10. Toner Collecting Section
10.1 Composition
[1]
[2]
[3]
4138to2072c0
4138to2051c0
[4]
[5]
[8]
[7]
[6]
[4]
4138to2052c0
4138to2075c0
Key
[1]
Name
Function/system
Box Tray
• Tray on which the Waste Toner Box is mounted
• Moves up or down depending on the weight of the
waste toner collected, thus blocking the Waste Toner
Full Sensor (PC11)
Box Lock Lever
• Used to secure the Waste Toner Box in position
• Placing the lever in the unlock position opens the
Shutter
[2]
[3] Cap
• Prevents toner from being spilled
[4] Shutter
Toner Collecting Screw
• Conveys toner fed from the Intermediate Transfer Unit
into the Waste Toner Box
[5]
[6] Waste Toner Full Sensor (PC11)
• Detects the amount of waste toner
Belt
[7]
• Transmits drive from the Developing Motor to the
Toner Collecting Screw
Developing Motor/K (M5)
[8]
• Drives the Toner Collecting Screw in the Waste Toner
Box via a belt
• Drives also the K Developing Unit
• Brushless DC motor
2-55
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Main Unit Theory of Operation
Toner Collecting Section
10.3 Operation
10.3.1
Toner collecting mechanism
• Toner scraped off by the Cleaning Blade of the Intermediate Transfer Belt Unit is con-
veyed into the Waste Toner Box.
☞
2-45
• The toner is conveyed into the Waste Toner Box by the Toner Collecting Screw provided
in the Waste Toner Box.
Toner Collecting Screw
4138to2052c0
10.3.2
Toner Collecting Port Shutter mechanism
• A shutter and a cap are used to prevent waste toner from being spilled from the Toner
Collecting Port when the Waste Toner Box is removed and reinstalled.
1. Placing the Box Lock Lever of the Waste Toner Box in the “locked” position (the 9
o'clock position) closes the Shutter of the Toner Collecting Port.
2. After the Waste Toner Box has been removed, plug the Toner Collecting Port with the
cap fitted to the side face of the box.
Cap
4138to2077c0
2-57
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Toner Collecting Section
10.3.3 Waste Toner Box locking mechanism
Main Unit Theory of Operation
• When the Box Lock Lever is in the unlocked position (the 12 o'clock position), the protru-
sion provided at the Toner Collecting Port interferes with the machine frame, thus pre-
venting the Waste Toner Box from being removed.
• When the Box Lock Lever is in the locked position (the 9 o'clock position), the Waste
Toner Box can be removed.
Box Lock Lever
Toner Collecting Port
Protrusion
4138to2078c0
10.3.4
Waste Toner Box locked position detection mechanism
• When the Box Lock Lever is in the locked position (the 9 o'clock position), the protrusion
provided in the Front Door interferes with the Box Lock Lever. As a result, the Front Door
cannot be closed.
• When the Box Lock Lever is in the unlocked position (the 12 o'clock position), the Front
Door can be closed.
Unlock
Lock
4138to2080c0
10.3.5
Waste Toner Box-in-position detection mechanism
• The Waste Toner Box Set Detection Lever is provided to detect a Waste Toner Box
loaded in position.
• When the Waste Toner Box is not loaded, the Set Detection Lever lowers by its own
weight to plug the Set Detection Window.
• The protrusion provided in the Front Door interferes with the Set Detection Lever that
plugs the Set Detection Window. Then, the Front Door cannot be closed.
• When the Waste Toner Box is loaded in position, it pushes up the Set Detection Lever to
uncover the Set Detection Window.
Set Detection Lever
Set Detection
Window
4138to2079c0
2-58
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Main Unit Theory of Operation
10.3.6 Waste toner near-full condition detection
Toner Collecting Section
• A waste toner near-full condition is detected using the output state of the Waste Toner
Full Sensor.
• A waste toner full condition is detected based on the dot count.
• The output value of the Waste Toner Full Sensor cannot be acquired during the AIDC
control (registration correction, gamma correction). During this period, therefore, the fol-
lowing control procedures are not performed: “waste toner status decision,” “waste toner
full condition reset decision,” “waste toner near-full condition reset decision,” and “waste
toner near-full condition detection control.”
Near-full
condition reset
Waste toner /
Status decision
Near-full
condition
Full condition
detection
Power source
Full condition
reset decision
Full condition
4138to2137e0
A. Waste toner near-full condition detection control
• A waste toner near-full condition is detected when the Waste Toner Full Sensor (PC11)
continuously outputs a voltage of a predetermined value or more for a predetermined
period of time or more.
• At this time, a waste toner near-full condition warning is given on the panel.
• To prevent false detection, a conveying screw is installed in the Waste Toner Box, ensur-
ing that waste toner is uniformly accumulated in the box.
When the sensor is unblocked
When the sensor is blocked
Box Tray
4138to2081c0
Waste Toner Full Sensor (PC11)
2-59
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Toner Collecting Section
Main Unit Theory of Operation
B. Waste toner status decision after detection of a waste toner near-full condition
• Opening and closing the Front Door resets a waste toner near-full condition. The control
state then proceeds to “waste toner status decision.”
• If the Waste Toner Full Sensor (PC11) produces an output of a predetermined voltage or
more for a continuous period of a predetermined time a second time during “waste toner
status decision,” the control state proceeds to “waste toner full detection.”
• If the Waste Toner Full Sensor (PC11) does not produce an output of a predetermined
voltage or more for a continuous period of a predetermined time during “waste toner
status decision,” the control state proceeds to “waste toner near-full condition reset
decision.”
Near-full
condition reset
Waste toner /
Status decision
Near-full
condition
Full condition
detection
Power source
Full condition
reset decision
Full condition
4138to2137e1
C. Waste toner near-full condition reset decision after detection of a waste toner
near-full condition
• If a waste toner near-full condition is not detected during “waste toner status decision,” a
“waste toner near-full condition reset decision” is made. (Control for preventing false
detection of a waste toner near-full condition.)
• If a waste toner near-full condition is not detected a second time when the number of
print dots (waste toner detection dot count) reaches a predetermined value after the
Front Door has been closed, the waste toner near-full condition is reset. If a waste toner
near-full condition is detected a second time, the machine determines that there is a
waste toner near-full condition.
• If a waste toner near-full condition is detected a second time before the number of print
dots (waste toner detection dot count) reaches a predetermined value after the Front
Door has been closed, the machine determines that there is a waste toner near-full con-
dition.
2-60
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Main Unit Theory of Operation
Toner Collecting Section
Near-full
condition reset
Waste toner /
Status decision
Near-full
condition
Full condition
detection
Power source
Full condition
reset decision
Full condition
4138to2137e2
10.3.7
Waste toner full condition detection control
A. Waste toner full condition detection control
• A waste toner full condition is detected when the cumulative total number of print dots
(waste toner detection dot count) exceeds a predetermined value after a Waste Toner
Box near-full condition has been detected.
• A waste toner full condition warning is given on the panel at this time.
• The machine accepts no print job after the waste toner full condition has been detected.
B. Waste toner dot count
• The waste toner dot count is taken since the waste toner near-full condition was
detected.
C. Waste toner status decision after detection of a waste toner full condition
• Opening and closing the Front Door resets a waste toner full condition. The control state
then proceeds to “waste toner status decision.”
• If the Waste Toner Full Sensor (PC11) continuously outputs a voltage of a predetermined
value or more for a predetermined period of time or more during “waste toner status deci-
sion,” the control state proceeds to “full condition.”
• If the Waste Toner Full Sensor (PC11) does not output continuously a voltage of a prede-
termined value or more for a predetermined period of time or more during “waste toner
status decision,” the control state proceeds to “waste toner full condition reset decision.”
Near-full
condition reset
Waste toner /
Status decision
Near-full
condition
Full condition
detection
Power source
Full condition
reset decision
Full condition
4138to2137e3
2-61
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Toner Collecting Section
Main Unit Theory of Operation
D. Waste toner full condition reset decision after detection of a waste toner full
condition
• If the Waste Toner Full Sensor (PC11) does not output continuously a voltage of a prede-
termined value or more for a predetermined period of time or more during “waste toner
status decision,” a “waste toner full condition reset decision” is made. (Control for pre-
venting false detection of a waste toner full condition.)
• If the Waste Toner Full Sensor (PC11) continuously outputs a voltage of a predetermined
value or less for a predetermined period of time when the number of print dots (waste
toner detection dot count) reaches a predetermined value after the Front Door has been
closed, the waste toner full condition is reset.
• If the Waste Toner Full Sensor (PC11) continuously outputs a voltage of a predetermined
value or more for a predetermined period of time before the number of print dots (waste
toner detection dot count) reaches a predetermined value after the Front Door has been
closed, the machine determines that there is a waste toner full condition.
Near-full
condition reset
Waste toner /
Status decision
Near-full
condition
Full condition
detection
Power source
Full condition
reset decision
Full condition
4138to2137e4
2-62
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Main Unit Theory of Operation
AIDC Sensor
11. AIDC Sensor
11.1 Composition
4138to2037c0
4138to2060c0
[1]
[1]
[2]
[1]
4138to2082c0
[5]
[3]
[4]
4138to2083c0
Key
[1]
Name
AIDC Sensor/Rt, Lt (AIDC R/L)
Function/system
• Detects the density of the toner on the Intermediate
Transfer Belt
[2] AIDC Sensor Lever
• Drives the AIDC Sensor Cover
Pressure/Retraction Clutch/2nd
Image Transfer (CL5)
• Transmits the drive from the Intermediate Transport
Motor (M3) to the Retraction Cam
[3]
Retraction Cam
[4]
• Drives the Retraction Lever
• Drives the AIDC Sensor Lever
[5] AIDC Sensor Cover
• Protects the AIDC Sensor
2-63
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AIDC Sensor
11.1.1 Drive
Main Unit Theory of Operation
[4]
[3]
[1]
[2]
4138to2083c0
[1] Pressure/Retraction Clutch/2nd Image
Transfer (CL5)
[3] AIDC Sensor Cover
[4] AIDC Sensor Lever
[2] Retraction Cam
11.2 Operation
11.2.1
Toner density detection control
• A reflective sensor is used for the AIDC Sensor that detects the amount of toner sticking
to the surface of the Transfer Belt. Image stabilization is performed based on the value
detected.
• The detection pattern (toner image) produced on the surface of the Transfer Belt is irradi-
ated with light emitted by the LED of the sensor.
• The photodiode of the sensor detects the light reflected off the toner pattern on the sur-
face of the Transfer Belt.
Photodiode
Transfer Belt surface
LED
AIDC Sensor
4138to2085c0
4138to2084c0
• A voltage corresponding to the intensity of the light reflected off the toner pattern is out-
put to the Mechanical Control Board (PWB-A).
Amount of toner
sticking
Intensity of light
reflected
Output
Large
Small
Small
Great
Low
High
2-64
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Main Unit Theory of Operation
AIDC Sensor
• Changes in various types of characteristics due to change with time of the AIDC Sensor
(deteriorated LED, dirty sensor surface), part-to-part variations in the sensors, and
change of environment affect the AIDC Sensor output corresponding to the clear Trans-
fer Belt surface. To correct fluctuations in the output, the sensor LED intensity is adjusted
so as to keep constant the AIDC Sensor output value.
• The AIDC Sensor calibration control may be either the simplified check or complete cor-
rection.
• The AIDC Sensor calibration is controlled integrally with other control items by the image
stabilization control.
• The AIDC Sensor calibration control is performed when there is a request made for exe-
cution of image stabilization sequence.
☞
2-120
A. Simplified correction control
1. The offset voltage of the AIDC Sensor is calculated.
2. A simplified detection pattern of each color of toner is produced on the surface of the
Transfer Belt.
3. The LED is illuminated with the intensity value set last to let the AIDC Sensor detect the
output value.
4. If the output value is a predetermined value or more, the intensity value set last
becomes the current setting value.
5. If the output value is less than the predetermined value, the control proceeds to the
complete correction.
Start
Calculate the offset voltage.
Check the output value based on
the previously set intensity value.
Less than reference value
Reference value
Reference value or more
Define the previously set intensity
Complete correction control
value as the set intensity.
End
4138to2139e0
2-65
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AIDC Sensor
Main Unit Theory of Operation
B. Complete correction control
1. The offset voltage of the AIDC Sensor is calculated.
2. A complete detection pattern of each color of toner is produced on the surface of the
Transfer Belt.
3. The LED is illuminated with each of the specified intensity values and the output value
for each LED intensity value is detected using the AIDC Sensor.
4. The intensity setting value is calculated from the output value detected.
Start
Calculate the offset voltage.
Check the output value based on
the specified intensity value.
Calculate the set intensity value
using the output value detected.
End
4138to2140e0
11.2.3
AIDC Sensor shutter mechanism
• Since the AIDC Sensor is installed below the Transfer Belt, it can be dirtied with toner or
other foreign matter. A shutter mechanism is therefore provided above the AIDC Sensor
to prevent it from being dirtied.
• The shutter is opened or closed in synchronism with the pressure or retraction motion of
the 2nd Transfer Roller. When the 2nd Transfer Roller is pressed, the Pressure Cam
pushes up the Sensor Lever, which opens the shutter above the AIDC Sensor.
• When the 2nd Transfer Roller is released, the shutter above the AIDC Sensor is closed
by the tension of a spring.
Shutter
Pressure Cam
4138to2551c0
4138to2577c0
Pressure Cam
2-66
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Main Unit Theory of Operation
Media Feed Section (magicolor 5430 DL)
12. Media Feed Section (magicolor 5430 DL)
12.1 Composition
[6]
[1]
[2]
4138to2598c0
[3]
[4]
[5]
4138to2056c0
[9]
[10]
[8]
[11]
[7]
4138to2057c1
Key
[1] Tray 1 Feed Roller
Tray 1 Separation Roller
Name
Function/system
• Takes up and feeds media from Tray 1
• Separates media in Tray 1
• Small-diameter roller with a torque limiter
[2]
[3] Edge Guide Plate
• Aligns the edges of the media stack in Tray 1
[4] Size Detection Board
[5] Trailing Edge Guide Plate
[6] Empty Sensor Actuator
• Detects the length of the media loaded in Tray 1
• Aligns the trailing edges of the media stack in Tray 1
• Detects the media level in Tray 1
Paper Level Indicator Lever
[7]
• Indicates the level of the media still available for use in
Tray 1
[8] Paper Size Switch (S5)
• Detects the media length in Tray 1
Tray 1 Paper Feed Clutch (CL1)
[9]
• Transmits drive from the Intermediate Transport Motor
(M3) to the Tray 1 Feed Roller
[10] Tray 1 Paper Empty Sensor (PC1)
Paper Lift Plate
• Detects the media level in Tray 1
• Surface on which the media stack is placed in Tray 1
• Maximum media capacity
[11]
Plain paper: 250 sheets
Thick stock, OHP film, postcards, and labels: 20 sheets
Envelopes: 10 sheets
2-67
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Main Unit Theory of Operation
Media Feed Section (magicolor 5430 DL)
12.3 Operation
12.3.1
Paper Lift Plate mechanism
• The Paper Lift Plate is pressed down into the locked position (so the media can be
loaded).
• A stack of media is loaded and then the tray is slid into the machine. This causes the
Lock Release Lever to unlock the Paper Lift Plate.
• The Paper Lift Plate (media stack) is pressed against the Feed Roller.
• The Paper Lift Plate (media stack) is pressed upward by the springs at all times.
Feed Roller
Spring
Paper Lift
Plate
Lock Release
position
Paper Lift
Plate
4138to2087c0
4138to2088c0
12.3.2
Media separation mechanism
• Drive from the Intermediate Transport Motor (M3) is transmitted through the Tray 1 Paper
Feed Clutch (CL1) to turn the Feed Roller.
• The Feed Roller rotates to take up and feed media into the machine.
• Double-feeding of media is prevented by the Separation Roller provided with a torque
limiter.
Feed Roller
Intermediate Transport Motor (M3)
Feed Roller
Separation
Roller
4138to2089c0
4138to2058c0
2-69
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Media Feed Section (magicolor 5430 DL)
12.3.3 Media feed control
Main Unit Theory of Operation
• Drive from the Intermediate Transport Motor (M3) is transmitted through the Tray 1 Paper
Feed Clutch (CL1) to turn the Feed Roller, thereby taking up and feeding the media.
• The media taken up and fed in is conveyed onto the Synchronizing Roller.
• The media is pressed against the stationary Synchronizing Roller so that a loop is
formed in the media. The Feed Roller is then stopped. The loop thus formed in the media
corrects any mechanical skew in the media.
• The Synchronizing Roller is started [Synchronizing Roller Clutch (CL2)] in synchronism
with the Sub Scan Print Start signal (/TOD) of the controller to convey the media.
• At the same time that the Synchronizing Roller is started [Synchronizing Roller Clutch
(CL2)], the Feed Roller is started again so that the media is conveyed further (this is
done to reduce load otherwise placed on the media feed section when the media is con-
veyed).
• As the trailing edge of the media reaches a point immediately before the Feed Roller, the
Feed Roller is stopped.
Intermediate Transport Motor (M3)
Tray 1 Paper Feed Clutch (CL1)
Synchronizing Roller Sensor (PC4)
Synchronizing Roller Clutch (CL2)
Sub Scan Print Start signal (/TOD)
4138T2E006DA
12.3.4
Media supply level detection control
• There is a window in the front cover of the cassette for indicating the media supply level.
• When the Paper Lift Plate goes up, a red lever appears in the window. The lower the level
of the media stack, the more the red portion is visible.
Lever Indica-
tor indicating
the media
supply level
A media empty
condition
4138to2090c0
Lever
When media is
loaded
4138to2091c0
2-70
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Main Unit Theory of Operation
Media Feed Section (magicolor 5430 DL)
12.3.5 Media empty condition detection control
• The media empty message (TRAY1 EMPTY) is displayed on the panel when the Empty
Sensor Actuator unblocks the Tray 1 Media Empty Sensor (PC1).
• No mechanism is provided for detecting a media near-empty condition. The media sup-
ply level indicator serves this purpose.
When media
is loaded
Tray 1 Paper Empty Sensor (PC1)
Empty Sensor
Actuator
4138to2092c0
A media empty
condition
Paper Lift Plate
4138to2124c0
12.3.6
Edge Guide Plate
• The Edge Guide Plate can be slid to the exact size in the width direction of the media to
be loaded.
Edge Guide Plate
4138to2093c0
12.3.7
Trailing Edge Guide Plate
• The Trailing Edge Guide Plate can be slid to the exact size in the length direction of the
media to be loaded.
Trailing Edge Guide Plate
4138to2094c0
2-71
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Media Feed Section (magicolor 5430 DL)
12.3.8 Media size detection control
Main Unit Theory of Operation
• The Paper Size Switch (S5) detects the length size (FD) of the media.
1. The Size Detection Board turns as the Trailing Edge Guide Plate is moved.
2. When the tray is slid into the machine, the Size Detection Board pushes the actuator of
the Paper Size Switch (S5) mounted to the machine frame, thus turning ON the switch.
3. The combination of ON/OFF positions of the sub-switches of the Paper Size Switch
(S5) determines the specific media size that can be either one of the seven different
sizes.
4. If the tray is not slid into position, all of the sub-switches are OFF and the message
“TRAY1 NOT ATTACHED” appears.
Tray 1 Paper Size Switch
Media size
SW1
ON
SW2
OFF
ON
SW3
OFF
OFF
ON
A4
11” (Letter)
10” (Executive)
B5
OFF
ON
OFF
ON
ON
OFF
ON
OFF
ON
ON
Postcards
Nonstandard size
Tray open
ON
ON
OFF
OFF
OFF
Paper Size Switch (S5)
Actuator
Size Detection
Board
Trailing Edge Guide Plate
4138to2095c0
12.3.9
Media misfeed detection control
• If the Synchronizing Roller Sensor (PC4) is not activated within a predetermined period
of time after a media feed sequence has been started, the machine determines that
there is a media misfeed. It then gives the message “MEDIA JAM TRAY1” on the panel.
• The media misfeed display can be reset by opening and closing any of the doors.
2-72
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Main Unit Theory of Operation
Media Feed Section (magicolor 5440 DL/5450)
13. Media Feed Section (magicolor 5440 DL/5450)
NOTE
• Be sure to note that the feed tray located immediately under the printer is named
differently depending upon the printer model.
TRAY1
TRAY2
magicolor 5430 DL/5440 DL
magicolor 5450
• Throughout this manual, this tray is referred to as TRAY1, its magicolor 5430 DL/
5440 DL name.
13.1 Composition
[1]
[5]
[2]
4138to2603c0
[3]
[4]
4138to2056c0
[8]
[9]
[7]
[10]
[6]
4138to2600c1
Key
[1] Tray 1 Feed Roller
Tray 1 Separation Roller
Name
Function/system
• Takes up and feeds paper from Tray 1
• Separates paper in Tray 1
• Small-diameter roller with a torque limiter
[2]
[3] Edge Guide Plate
• Aligns the edges of the paper stack in Tray 1
• Aligns the trailing edges of the paper stack in Tray 1
• Detects the length of paper in the Tray1
[4] Trailing Edge Guide Plate
[5] Empty Sensor Actuator
2-73
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Media Feed Section (magicolor 5440 DL/5450)
Main Unit Theory of Operation
Function/system
Key
[6]
Name
Paper Level Indicator Lever
• Indicates the level of the paper still available for use in
Tray 1
[7] Paper Size Switch (S5)
• Detects the presence of the Tray1
Tray 1 Paper Feed Clutch (CL1)
[8]
• Transmits drive from the Intermediate Transport Motor
(M3) to the Tray 1 Feed Roller
[9] Tray 1 Paper Empty Sensor (PC1)
• Detects the paper level in Tray 1
Paper Lift Plate
[10]
• Surface on which the paper stack is placed in Tray 1
• Maximum paper capacity
Plain paper: 500 sheets
13.2 Drive
[1]
[2]
[3]
4138to2058c0
[1] Intermediate Transport Motor (M3)
[2] Tray 1 Paper Feed Clutch (CL1)
[3] Tray 1 Feed Roller
13.3 Operation
13.3.1
Paper Lift Plate mechanism
• The Paper Lift Plate is pressed down into the locked position (in which the paper is
loaded in position).
• Load a paper stack and then slide the tray into the machine. This causes the Lock
Release Lever to unlock the Paper Lift Plate.
• The Paper Lift Plate (paper stack) is pressed against the Feed Roller.
• The Paper Lift Plate (paper stack) is pressed upward by the springs at all times.
Paper Lift Plate
Paper Lift Plate
Lock Release Lever
Feed Roller
Spring
4138to2606c0
4138to2605c0
2-74
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Main Unit Theory of Operation
13.3.2 Paper separation mechanism
Media Feed Section (magicolor 5440 DL/5450)
• Drive from the Intermediate Transport Motor (M3) is transmitted through the Tray 1 Paper
Feed Clutch (CL1) to turn the Feed Roller.
• The Feed Roller rotates to take up and feed paper into the machine.
• Double-feeding of paper is prevented by the Separation Roller provided with a torque lim-
iter.
Feed Roller
Intermediate Transport Motor (M3)
Feed Roller
Separation
Roller
4138to2089c0
4138to2058c0
13.3.3
Paper feed control
• Drive from the Intermediate Transport Motor (M3) is transmitted through the Tray 1 Paper
Feed Clutch (CL1) to turn the Feed Roller, thereby taking up and feeding the paper.
• The paper taken up and fed in is conveyed onto the Synchronizing Roller.
• The paper is pressed against the stationary Synchronizing Roller so that a loop is formed
in the paper. The Feed Roller is then stopped. The loop thus formed in the paper corrects
any mechanical skew in the paper.
• The Synchronizing Roller is started [Synchronizing Roller Clutch (CL2)] in synchronism
with the Sub Scan Print Start signal (/TOD) of the controller to convey the paper.
• At the same time that the Synchronizing Roller is started [Synchronizing Roller Clutch
(CL2)], the Feed Roller is started again so that the paper is conveyed further (this is done
to reduce load otherwise placed on the paper feed section when the paper is conveyed).
• As the trailing edge of the paper reaches a point immediately before the Feed Roller, the
Feed Roller is stopped.
Intermediate Transport Motor (M3)
Tray 1 Paper Feed Clutch (CL1)
Synchronizing Roller Sensor (PC4)
Synchronizing Roller Clutch (CL2)
Sub Scan Print Start signal (/TOD)
4138T2E006DA
2-75
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Media Feed Section (magicolor 5440 DL/5450)
13.3.4 Paper supply level detection control
Main Unit Theory of Operation
• There is a window in the front cover of the cassette for indicating the paper supply level.
• When the Paper Lift Plate goes up, a red lever appears in the window. The lower the level
of the paper stack, the more the red portion is visible.
Lever Indicator indicating the paper supply level
A paper empty condition
4138to2607c0
4138to2091c0
Lever
When paper is loaded
13.3.5
Paper empty condition detection control
• The paper empty message “TRAY1 EMPTY (magicolor 5440)” or “PAPER EMPTY
TRAY2 (magicolor 5450)” is displayed on the panel when the Empty Sensor Actuator
unblocks the Tray 1 Paper Empty Sensor (PC1).
• No mechanism is provided for detecting a paper near-empty condition. The paper supply
level indicator serves this purpose.
When media
is loaded
Tray 1 Paper Empty Sensor (PC1)
Empty Sensor
Actuator
4138to2092c0
A paper empty
condition
Paper Lift Plate
4138to2124c0
2-76
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Main Unit Theory of Operation
13.3.6 Edge Guide Plate
Media Feed Section (magicolor 5440 DL/5450)
• Set the appropriate Edge Guide Plate which corresponds to the width of the media to be
loaded (A4 or 81/2).
• No mechanism is provided for detecting the media size.
Lock Plate
Lock Plate
Edge Guide Plate
4138to2613c0
Positioning Pin
4138to2609c0
A4 Position
8 1/2 Position
Lock plate
Lock Plate
4138to2610c0
4138to2611c
13.3.7
Trailing Edge Guide Plate
• Set the appropriate Trailing Edge Plate which corresponds to the length of the media (A4
or 11). The size detection function is not equipped.
• No mechanism is provided for detecting the media size.
Lock Lever
Positioning Plate
Trailing Edge
Guide Plate
4138to2612c0
4138to2609c0
11
A4
Position
Position
A4
11
A4
11
4138to2614c0
2-77
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Media Feed Section (magicolor 5440 DL/5450)
Main Unit Theory of Operation
13.3.8
Tray detection control
•
Detects the Tray presence with the Paper size switch (S5).
1. Setting the Tray to the printer will make the detecting plate press and turn ON the actu-
ator for the Paper size switch (S5) mounted on the Copier frame.
2. The switch will be OFF if the Tray is not properly set, and “TRAY1 DRAWER OPEN
(magicolor 5440 DL)” or “PAPER EMPTY TRAY2 (magicolor 5450)” will be displayed.
Paper Size Switch (S5)
Tray Detection
Plate
Actuator
Tray Detection Plate
4138to2615c0
4138to2616c0
13.3.9
Media misfeed detection control
• If the Synchronizing Roller Sensor (PC4) is not activated within a predetermined period
of time after a paper feed sequence has been started, the machine determines that there
is a media misfeed. It then gives the message “MEDIA JAM TRAY1 (magicolor 5440 DL)”
or “PAPER JAM TRAY2 (magicolor 5450)” on the panel.
• The media misfeed display can be reset by opening and closing any of the doors.
2-78
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Main Unit Theory of Operation
Manual Feed Section (magicolor 5440 DL/5450)
14. Manual Feed Section (magicolor 5440 DL/5450)
NOTE
• Be sure to note that the feed tray located on the right side of the printer is named
differently depending upon the printer model.
magicolor 5430 DL/5440 DL
magicolor 5450
MANUAL FEED TRAY
TRAY1
• Throughout this manual, this tray is referred to as MANUAL FEED TRAY, its
magicolor 5430 DL/5440 DL name.
14.1 Composition
[5]
[4]
[1]
[6]
[2]
[3]
4138to2601c0
4138to2604c0
[1]
[2]
[7]
[6]
[3]
[5]
[4]
4138T2C001DB
Key
Name
Function/system
[1] Empty Sensor Actuator
• Detects the media level in Manual Feed Tray
Manual Feed Tray Paper Empty Sen-
sor (PC3)
[2]
[3]
• Detects the media level in Manual Feed Tray
Edge Guide Plate
• Aligns the edges of the media stack in Manual Feed
Tray
2-79
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Manual Feed Section (magicolor 5440 DL/5450)
Main Unit Theory of Operation
Function/system
Key
[4]
Name
Manual Feed Tray Separation Roller • Separates media in Manual Feed Tray
• Small-diameter roller with a torque limiter
[5] Manual Feed Tray Feed Roller
Paper Lift Plate
• Takes up and feeds media from Manual Feed Tray
• Surface on which the media stack is placed in Manual
Feed Tray
• Maximum paper capacity
Plain paper: 100 sheets
[6]
Thick stock, OHP film, postcards, and labels: 20 sheets
Envelopes: 10 sheets
Manual Feed Tray Paper Feed Clutch • Transmits drive from the Intermediate Transport Motor
(CL3) (M3) to the Manual Feed Tray Feed Roller.
[7]
14.2 Drive
[2]
[1]
[3]
4138T2C002DB
[1] Intermediate Transport Motor (M3)
[3] Manual Feed Tray Feed Roller
[2] Manual Feed Tray Paper Feed Clutch (CL3)
2-80
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Main Unit Theory of Operation
Manual Feed Section (magicolor 5440 DL/5450)
14.3 Operation
14.3.1
Paper Lift Plate mechanism
• The Paper Lift Plate will be locked under the Paper Lift Plate Lock Lever by pressing it
down (in which the media is loaded in position). The Paper Lift Plate Lock Lever will be
pressed to the Feed Roller.
• The Paper Feed Clutch will rotate the Feed Roller to activate the Lock Release Lever
pressed to the Feed Roller, and the Paper Lift Plate will be unlocked.
• The Paper Lift Plate (media stack) is pressed against the Feed Roller.
• The Paper Lift Plate (media stack) is pressed upward by the springs at all times.
Feed Roller
LOCK POSITION
Paper Lift Plate
Spring
Paper Lift Plate Lock Lever
LOCK RELEASE POSITION
4138to2617c0
2-81
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Manual Feed Section (magicolor 5440 DL/5450)
14.3.2 Media separation mechanism
Main Unit Theory of Operation
• Drive from the Intermediate Transport Motor (M3) is transmitted through the Manual
Feed Tray Paper Feed Clutch (CL3) to turn the Feed Roller.
• The Feed Roller rotates to take up and feed media into the machine.
• Double-feeding of media is prevented by the Separation Roller provided with a torque
limiter.
Feed Roller
Intermediate Transport Motor (M3)
Feed Roller
Separation
Roller
4138T2C002DB
4138to2618c0
14.3.3
Media feed control
• Drive from the Intermediate Transport Motor (M3) is transmitted through the Manual
Feed Tray Paper Feed Clutch (CL3) to turn the Feed Roller, thereby taking up and feed-
ing the media.
• The media taken up and fed in is conveyed onto the Synchronizing Roller.
• The media is pressed against the stationary Synchronizing Roller so that a loop is
formed in the media. The Feed Roller is then stopped. The loop thus formed in the media
corrects any mechanical skew in the media.
• The Synchronizing Roller is started [Synchronizing Roller Clutch (CL2)] in synchronism
with the Sub Scan Print Start signal (/TOD) of the controller to convey the media.
• At the same time that the Synchronizing Roller is started [Synchronizing Roller Clutch
(CL2)], the Feed Roller is started again so that the media is conveyed further (this is
done to reduce load otherwise placed on the media feed section when the media is con-
veyed).
• As the trailing edge of the media reaches a point immediately before the Feed Roller, the
Feed Roller is stopped.
Intermediate Transport Motor (M3)
Manual Feed Tray Paper Feed
Clutch (CL3)
Synchronizing Roller Sensor (PC4)
Synchronizing Roller Clutch (CL2)
Sub Scan Print Start signal (/TOD)
4138T2E007DA
2-82
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Main Unit Theory of Operation
Manual Feed Section (magicolor 5440 DL/5450)
14.3.4 Media empty condition detection control
• A media empty condition is detected when the Empty Sensor Actuator unblocks the
Manual Feed Tray Paper Empty Sensor (PC3).
• No mechanism is provided for detecting a media near-empty condition. The media sup-
ply level indicator serves this purpose.
When media
is loaded
Paper Lift Plate
Empty Sensor Actuator
Manual Feed Tray Paper Empty Sensor (PC3)
4138to2619c0
A media empty
condition
4138to2620c0
14.3.5
Edge Guide Plate
• The Edge Guide Plate can be slid to the exact size in the width direction of the media to
be loaded.
• No mechanism is provided for detecting a media size.
Edge Guide Plate
4138to2621c0
2-83
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Manual Feed Section (magicolor 5440 DL/5450)
14.3.6 Media misfeed detection control
Main Unit Theory of Operation
• If the Synchronizing Roller Sensor (PC4) is not activated within a predetermined period
of time after a media feed sequence has been started, the machine determines that
there is a media misfeed. It then gives the message “MEDIA JAM MANUAL FEED TRAY
(magicolor 5440 DL)” or “PAPER JAM TRAY1 (magicolor 5450)” on the panel.
• The media misfeed display can be reset by opening and closing any of the doors.
2-84
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Main Unit Theory of Operation
Conveyance Section
15. Conveyance Section
15.1 Composition
4138to2096c0
4138to2037c1
[1]
[2]
[3]
[4]
[5]
[8]
[6]
[7]
4138to2097c0
Key
[1]
Name
Function/system
Paper Loop Sensor (PC6)
• Detects the length of the loop in the media conveyed
from the 2nd Transfer Roller
Charge Neutralizing Cloth
2nd Transfer Roller
• Neutralizes the media that has undergone the 2nd
transfer process
[2]
[3]
• Transfers the images in four colors of toner on the
Transfer Belt to the media
Synchronizing Roller
• Conveys the media fed from the Feed Roller to the
transfer section
• Synchronizes the media fed from the Feed Roller with
the image
• Corrects any skew in the media fed from the Feed
Roller
[4]
[5]
Synchronizing Roller Clutch (CL2)
• Transmits the drive from the Intermediate Transport
Motor (M3) to the Synchronizing Roller
2-85
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Conveyance Section
Main Unit Theory of Operation
Function/system
Key
[6]
Name
Synchronizing Roller Sensor (PC4)
• Detects the leading edge of the media fed from the
Feed Roller
[7] Temperature/humidity Sensor (HS1)
• Detects temperature and humidity inside the machine
OHP Sensor (PC7)
[8]
• Identifies the type of the media fed from the Feed
Roller
15.2 Drive
[1]
[5]
[6]
[4]
[2]
4138to2098c0
[3]
[1] 2nd Transfer Roller
[4] Synchronizing Roller
[2] Pressure/Retraction Clutch/2nd Image
Transfer (CL5)
[5]
Synchronizing Roller Clutch (CL2)
[3] Transfer Belt Driver Roller
[6] Intermediate Transport Motor (M3)
2-86
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Main Unit Theory of Operation
Conveyance Section
15.3 Operation
15.3.1
Conveyance speed control
• The Intermediate Transport Motor (M3) provides drive for the conveyance section.
• The conveyance speed is variable in three steps and the appropriate one is selected
according to the media type and print mode as detailed below.
Media type/print mode
Conveyance speed
1 (standard)
Reason
Plain paper
Thick stock, envelopes, postcards, label OHP film
(monochrome print)
To ensure good fusing
performance
1/2 (one-half speed)
1/3 (one-third speed)
To ensure good light
transmission performance
OHP film (color print)
• For the first print, the machine makes the above decision before starting a print/media
feed sequence and, based on the established speed, starts the print/media feed
sequence.
15.3.2
Synchronizing Roller control
• When the media taken up and fed in by the Feed Roller reaches the Synchronizing
Roller, a loop is formed in the media and media conveyance is temporarily stopped. Con-
veyance skew is corrected by this loop.
• The Synchronizing Roller Sensor (PC4) detects whether or not the media has reached
the Synchronizing Roller.
• The media fed in is synchronized with the image before media conveyance is restarted.
A. Media detection control
• When the media fed from the Feed Roller pushes up the actuator of the Synchronizing
Roller Sensor (PC4), the sensor is unblocked. With this event occurring, the machine
determines that the media has reached the position before the Synchronizing Roller.
Synchronizing Roller
Paper (fed from Duplex)
Actuator
Synchronizing Roller Sensor
(PC4)
4138to2099c0
Media (from Tray 1/2/3)
2-87
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Conveyance Section
Main Unit Theory of Operation
15.3.3 Control of loop formed before Synchronizing Roller
• Media conveyance is stopped after the lapse of a predetermined period of time after the
leading edge of the media fed from the Feed Roller has reached the Synchronizing
Roller. This forms a loop in the media.
• The loop in the media corrects skew in the media.
Synchronizing Roller
Media
4138to2100c0
A. Media conveyance temporary stop control
• <Media conveyance stop>
A given period of time after the Synchronizing Roller Sensor (PC4) has detected the
leading edge of the media, media conveyance in the media feed/conveyance section is
stopped.
• <Restart>
Media conveyance in the media feed/conveyance section is restarted in synchronism
with the Sub Scan Print Start signal (/TOD) of the controller.
Paper Feed Section Paper Conveyance
ޓ ꢀ Conveyance Section Paper Conveyance
Synchronizing Roller Sensor (PC4)
Synchronizing Roller Clutch (CL2)
Sub Scan Print Start signal (/TOD)
4138T2E008DA
2-88
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Main Unit Theory of Operation
Conveyance Section
B. Synchronizing Roller Clutch (CL2) control
• In synchronization with the leading edge of the image [the Sub Scan Print Start signal (/
TOD) of the controller] after the leading edge of the media has reached the Synchroniz-
ing Roller and a loop has been formed in the media, the Synchronizing Roller Clutch
(CL2) is energized to start turning the Synchronizing Roller.
• After the lapse of a predetermined period of time after the Synchronizing Roller Sensor
(PC4) has been deactivated by the media, the Synchronizing Roller Clutch (CL2) is de-
energized to stop the Synchronizing Roller.
Synchronizing Roller Sensor (PC4)
Synchronizing Roller Clutch (CL2)
Sub Scan Print Start signal (/TOD)
4138to2150e0
15.3.4
Control of loop formed before 2nd transfer
• A loop is formed in the media by the difference between the 2nd Transfer Roller media
conveyance speed (1.000) and the Synchronizing Roller media conveyance speed
(1.006).
• The loop formed in the media absorbs effect from the Synchronizing Roller side, thus
preventing it from being transferred to the 2nd transfer section.
2nd Transfer Roller
2nd Transfer Roller
4138to2101c0
Media
2-89
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Conveyance Section
15.3.5 Control of loop formed before fusing section
Main Unit Theory of Operation
• The difference between the fusing speed and media conveyance speed is corrected to
prevent double transferred images and brush effects from occurring.
• The Paper Loop Sensor (PC6) detects the length of the loop formed in the media
between the 2nd Transfer Roller and the Fusing Pressure Roller. The fusing speed is
then varied according to the length of the loop detected. By varying the fusing speed, any
effects from the Fusing Pressure Roller side (part-to-part variations, change of parts over
time) are prevented from being transferred to the 2nd transfer section.
• No loop control is provided to perform the fusing process at high speeds when envelopes
are used (to prevent wrinkles).
☞
2-100
• Fusing deceleration (low speed):
When the media loop length is small, the actuator of the Paper Loop Sensor (PC6) is
pushed up a small amount and the sensor is unblocked. When the sensor is unblocked,
the fusing speed is decelerated (-1.36%).
• Fusing acceleration (high speed):
When the media loop length is large, the actuator of the Paper Loop Sensor (PC6) is
pushed up a large amount and the sensor is blocked. When the sensor is blocked, the
fusing speed is accelerated (+1.64%).
Fusing deceleration
Fusing acceleration
Fusing Pressure
Roller
Actuator
Paper Loop Sensor
4138to2069c2
2nd Transfer Roller
4138to2069c1
2-90
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Main Unit Theory of Operation
15.3.6 Media neutralization
Conveyance Section
• The Charge Neutralizing Cloth neutralizes any charge left in the media after the 2nd
transfer process.
• The charge residue is grounded through the Charge Neutralizing Cloth to the machine
frame.
Charge Neutralizing
Cloth
4138to2102c0
Media
2nd Transfer Roller
15.3.7
OHP film detection control
• To prevent incorrect prints on OHP film, the type of the media being conveyed is detected
by the OHP Sensor (PC7).
• The OHP detection is made after the loop has been formed in the media before the Syn-
chronizing Roller.
• If the output voltage of the OHP Sensor (PC7) is less than a predetermined value, the
machine considers that the media is a type other than OHP film. If the output voltage is
the predetermined value or more, the machine determines that the media is OHP film.
Synchronizing Roller
Prism
Sensor
Prism
Sensor output
LED Remote
4138to2583e0
4138to2103c1
OHP Sensor (PC7)
• If the media type setting does not match the results of OHP detection, the machine sus-
pends the print cycle and displays the message “SIZE/TYPE ERROR (magicolor 5430
DL/5440 DL)” or “PAPER ERROR (magicolor 5450)” on the panel.
• The media that has caused type error is fed out of the machine after going through the
2nd transfer and fusing processes. The subsequent sheets of media are subjected to the
following operation.
2-91
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Conveyance Section
Main Unit Theory of Operation
Media state
Feed operation
Print operation
Exit operation
Media
Print
Feed
“TYPE ERROR” media
Yet to be printed
Feed
Suspend
Feed
Print
Suspend
Print
Exit
Suspend
Exit
Yet to be
fed
Printed
Yet to be printed
Printed
Subsequent
sheets
Feed
Print
Exit
Fed
Feed
Print
Exit
15.3.8
Media size error detection control
• To prevent incorrect printed pages, the size of the media being conveyed is detected
using the Synchronizing Roller Sensor (PC4) and Lower Feeder Paper Feed Sensor
(PC3 PF: option).
• The length of the media is detected based on the value calculated using the period of
time that begins when the sensor is activated and ends when it is deactivated for each
media source.
• For the Lower Feeder Unit, even if the Lower Feeder Paper Feed Sensor (PC3 PF) does
not detect a media size error, the downstream Synchronizing Roller Sensor (PC4) makes
an error check again.
Media source
Tray 1
Media length detection sensor
Starting point
Ending point
Synchronizing Roller Sensor (PC4)
Synchronizing
Roller Clutch (CL2)
energized
PC4 deactivated
Lower Feeder Unit
(Tray 2)
Lower Feeder Paper Feed Sensor
(PC3 PF: Tray 2)
PC3 PF activated PC3 PF deacti-
vated
Synchronizing Roller Sensor (PC4)
CL2 energized
PC4 deactivated
Lower Feeder Unit
(Tray 3)
Lower Feeder Paper Feed Sensor
(PC3 PF: Tray 3)
PC3 PF activated PC3 PF deacti-
vated
Lower Feeder Paper Feed Sensor
(PC3 PF: Tray 2)
PC3 PF activated PC3 PF deacti-
vated
Synchronizing Roller Sensor (PC4)
No media length is detected.
CL2 energized
PC4 deactivated
Duplex Unit
• If there is a mismatch between the media size setting and the results of media size
detection, the machine suspends the print cycle and displays the message “SIZE/TYPE
ERROR (magicolor 5430 DL/5440 DL)” or “PAPER ERROR (magicolor 5450)” on the
panel.
• The media that has caused size error is fed out of the machine after going through the
2nd transfer and fusing processes.
• The subsequent sheets of media are subjected to the following operation.
Media state
Feed operation
Print operation
Exit operation
Media
Print
Size error media
Yet to be printed
Printed
Feed
Feed
Suspend
Feed
Print
Suspend
Print
Exit
Suspend
Exit
Yet to be
fed
Subsequent
sheets
Yet to be printed
Printed
Feed
Print
Exit
Fed
Feed
Print
Exit
2-92
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Main Unit Theory of Operation
Conveyance Section
• The size error display can be reset when the Power Switch is turned OFF and ON, or by
a reset command (media size error reset).
• If a media size error is detected during 2-sided printing, the machine determines that
there is a media misfeed and stops operating.
15.3.9
Conveyance system media misfeed detection control
• A specific sensor is assigned for each section of the conveyance system to detect a
media misfeed that could occur along the path.
• When a media misfeed is detected, the machine suspends the print cycle and gives the
message “MEDIA JAM (magicolor 5430 DL/5440 DL)” or “PAPER JAM (magicolor 5450)”
on the panel. The machine thereafter attempts to detect any sheet of media left inside it.
Exit Sensor (PC8)
Paper Loop Sensor (PC6)
Duplex Unit Feed Sensor
(PWB-E-DU)
Synchronizing Roller/
Synchronizing Roller Clutch
(CL2)
Synchronizing Roller Sensor (PC4)
Lower Feeder Paper Feed
Sensor (PC3 PF)
4138to2104c1
Misfeed type
Misfeed detection starting point
Misfeed detection condition
PC4 not activated
Misfeed at vertical con- Lower Feeder Paper Feed Sensor
veyance section
(PC3 PF: Tray 2) activated
PC3 PF: Tray 2 not deactivated
PC4 not activated
Lower Feeder Paper Feed Sensor
(PC3 PF: Tray 3) activated
PC3 PF: Tray 3 not deactivated
PC4 not deactivated
Misfeed at 2nd transfer
section
Synchronizing Roller Sensor (PC4)
activated
PC8 not activated
Synchronizing Roller Clutch (CL2)
activated
PC4 not deactivated
Misfeed at exit/fusing
section
Exit Sensor (PC8) activated
PC8 not deactivated
Exit Sensor (PC8) deactivated
Duplex Unit Feed Sensor activated
PWB-E-DU not activated
PC4 not activated
Misfeed at Duplex Unit
PWB-E-DU not deactivated
2-93
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Conveyance Section
Main Unit Theory of Operation
• The “MEDIA JAM (magicolor 5430 DL/5440 DL)” or “PAPER JAM (magicolor 5450)” dis-
play is reset when all doors are closed after any of the doors has been open. At the same
time, the information on media left is cleared. Thereafter, the machine attempts to detect
any sheet of media left inside it again.
15.3.10 Control of detection of media left in conveyance system
• Any sheet of media left inside the machine is checked when the Power Switch is turned
ON or a door is opened and closed.
A. Sensor activation detection
• The machine checks sensors sequentially and, if a sensor is found to be activated, deter-
mines that there is a sheet of media left there inside the machine. Then, the machine
gives the message of “MEDIA JAM (magicolor 5430 DL/5440 DL)” or “PAPER JAM
(magicolor 5450)” on the panel.
• If all sensors are found to be deactivated, the machine proceeds to the step of “detection
of media left between sensors along 1-sided conveyance path.”
B. Detection of media left between sensors along 1-sided conveyance path
• The Paper Exit Roller, Fusing Pressure Roller, and Synchronizing Roller are turned in the
direction of feeding media out of the machine.
• If the Exit Sensor (PC8) is activated, the machine determines that there is a sheet of
media left and gives the message “MEDIA JAM TRANSFER ROLLER (magicolor 5430
DL/5440 DL)” or “PAPER JAM VERTICAL TRANS (magicolor 5450)” on the panel.
C. Detection of media left between sensors along 2-sided conveyance path
• If the machine detects that the Duplex Unit Feed Sensor on the Duplex Board (PWB-E
DU) is activated, it determines that there is a sheet of media left and gives the message
“MEDIA JAM DUPLEX UPPER (magicolor 5430 DL/5440 DL)” or “PAPER JAM
DUPLEX1 (magicolor 5450)” on the panel.
• If the machine detects that the Synchronizing Roller Sensor (PC4) is activated, it deter-
mines that there is a sheet of media left and gives the message “MEDIA JAM DUPLEX
LOWER (magicolor 5430 DL/5440 DL)” or “PAPER JAM DUPLEX2 (magicolor 5450)” on
the panel.
2-94
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Main Unit Theory of Operation
Conveyance Section
15.3.11 Control of detection of media left in machine upon stoppage of media
conveyance
• When media conveyance is stopped due to a media misfeed, a malfunction, an opened
door, or a unit closure failure, the machine checks for media left inside it.
• If a media misfeed occurs, the machine performs the following detection procedures 1 to
3.
• If there is a malfunction, an open door, or a unit closure failure, the machine carries out
the detection procedures 2 and 3.
1. The machine sets the remaining media information according to the cause of the media
misfeed as it occurs.
Cause of media misfeed
Misfeed at vertical conveyance section
Misfeed at Tray 1 media feed section
Misfeed at Tray 2 media feed section
Misfeed at Tray 3 media feed section
Misfeed in Duplex Unit media feed section
Misfeed in 2-sided conveyance section
Misfeed at 2nd transfer section
Remaining media information
Media left at vertical conveyance section
Media left at Tray 1 media feed section
Media left at Tray 2 media feed section
Media left at Tray 3 media feed section
Media left in Duplex Unit media feed section
Media left in Duplex conveyance section
Media left at 2nd transfer section
Media left at Tray 2 media feed section (when media is
fed from Tray 2)
Misfeed at exit/fusing section
Media left at exit/fusing section
2. If media information is left inside the Mechanical Control Board when a media misfeed,
the media that is left inside it based on the actual media location and other data avail-
able from the media information. If the machine determines that there is media left, it
gives the “MEDIA JAM” or “PAPER JAM” message corresponding to the location of the
media left.
3. The machine detects media left using sensors (by performing the same control as in
the control of detection of media left).
15.3.12 Temperature/humidity Sensor
• The Temperature/humidity Sensor detects temperature and humidity inside the machine.
• The detected data are used for image stabilization control, ATVC control, and transfer
output control.
☞
2-118, 2-40, 2-52
Temperature/Humidity
Sensor (HS1)
4138to2580c0
2-95
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Fusing Section
Main Unit Theory of Operation
16. Fusing Section
16.1 Composition
4138to2065c0
4138to2066c0
[20]
[19]
[1]
[2]
[3]
[4]
[18]
[17]
[16]
[15]
[14]
[5]
[6]
[13]
[7]
[8]
[9]
[12]
[11]
[10]
4138to2067c2
Key
[1]
Name
Exit Sensor (PC8)
Function/system
• Detects the media conveyed from the Fusing Pressure
Roller and Fusing Belt
Fusing Pressure Roller Pressure
Selector Dial
• Used to select the pressure of the Fusing Pressure
Roller in two steps (normal mode and envelope mode)
[2]
[3] Upper Paper Separator Claw
[4] Lower Paper Separator Claw
• Separates the media from the roller
• Prevent the media from winding around the roller
Fusing Pressure Roller Thermistor
[5] (TH2)
• Controls the temperature of the Fusing Pressure
Roller
• Non-contact type
Fusing Pressure Roller Heater Lamp • Heats the Fusing Pressure Roller
(H2) • Prevents the surface temperature of the Fusing Belt
[6]
from being decreased
• Heater lamp: 300 W
2-96
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Main Unit Theory of Operation
Fusing Section
Key
[7]
Name
Function/system
Fusing Pressure Roller
• Applies pressure to the toner to fuse it into the media
• Toner is fused by the Fusing Pressure Roller and Fus-
ing Belt
Fusing Pressure Roller Thermostat
[8] (TS2)
• Detects an abnormally high temperature of the Fusing
Pressure Roller
• Non-contact type
Fusing Entrance Guide Plate
• Guides the media between the Heating Roller and
Fusing Pressure Roller
[9]
Fusing Motor (M4)
Heating Roller
• Drives the Fusing Pressure Roller and Paper Exit
Roller
[10]
• Heated to a required temperature by the heater lamp
provided inside this roller
[11]
• Supplies the Fusing Belt with heat
Heating Roller Heater Lamp (H1)
Heating Roller Thermistor (TH1)
Heating Roller Thermostat (TS1)
• Heats the Heating Roller
• Heater lamp: 700 W
[12]
[13]
• Controls the temperature of the Heating Roller
• Type in contact with the roller
• Detects an abnormally high temperature of the Heat-
ing Roller
• Type in contact with the roller
[14]
[15]
Fusing Belt
• Applies heat to the toner to fuse it into the media
• Toner is fused by the Fusing Pressure Roller and Fus-
ing Belt
Fusing Pad
• Presses the Fusing Belt against the Fusing Pressure
Roller
[16]
[17]
[18]
Paper Size Sensor (PC23)
Paper Exit Roller
• Detects the size of the media conveyed from the Fus-
ing Pressure Roller and Fusing Belt
• Feeds the media conveyed from the Fusing Pressure
Roller and Fusing Belt out into the Exit Tray
Paper Holding Plate
• Guides the media fed out of the machine into the Exit
Tray
• Prevents the trailing edge of the media from failing to
clear the Exit Roller
• It also serves as the actuator of the Paper Full Sensor
(magicolor 5450 only)
[19]
[20]
Paper Full Sensor (PC20)
• Detects load capacity full of the media fed to the print
tray (magicolor 5450 only)
2-97
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Fusing Section
Main Unit Theory of Operation
16.2 Drive
[5]
[1]
[2]
[3]
[4]
4138to2105c0
[1]
[4]
[2]
[3]
4138to2068c0
[5]
[4]
4138to2074c0
[1] Fusing Pressure Roller
[2] Fusing Belt
[4] Fusing Motor (M4)
[5] Paper Exit Roller
[3] Heating Roller
2-98
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Main Unit Theory of Operation
Fusing Section
16.3 Operation
16.3.1
Fusing Pressure Roller pressure selection mechanism
• The pressure applied by the Fusing Pressure Roller is selected appropriately to prevent
media wrinkles during printing of envelopes.
• A pressure selection mechanism is provided to vary the pressure in two steps.
• The pressure is selected by placing the Pressure Selector Dial in either of the two posi-
tions that are 180 degrees apart from each other.
• Placing the dial in the appropriate position selects the corresponding pressure applied by
the Fusing Pressure Roller to the Fusing Pad.
• Place the dial in the top position when printing is to be done on plain paper or a similar
type of media (for a high pressure).
• Place the dial in the bottom position when printing is to be done on envelopes (for a low
pressure).
• Whenever printing on envelopes, the Pressure Selector Dial must be placed in the appro-
priate position. When the print cycle using envelopes is completed, be sure to place the
dial back in the original position.
• If the print cycle is started without first selecting the appropriate position of the dial, enve-
lopes are very likely to be wrinkled, and the image could be poorly fused on plain paper
and similar media.
Pressure Selector Dial
Fusing Pad
Fusing Pressure Roller
4138to2106c0
16.3.2
Fusing Pressure Roller drive control
A. Fusing speed selection control
• The Fusing Motor (M4) provides drive for the fusing section.
• The appropriate fusing speed is selected from among three options according to the
media type and print mode to prevent fusing failure.
Media type/print mode
Fusing speed
1 (standard)
Reason
Plain paper
Thick stock, envelopes, postcards, label OHP film
(monochrome print)
To ensure good fusing
performance
1/2 (one-half speed)
1/3 (one-third speed)
To ensure good light
transmission performance
OHP film (color print)
• The Fusing Motor (M4) is turned at 1/3 of the normal speed during a warm-up cycle.
• The Fusing Motor (M4) is turned at half the normal speed when a print request is
received.
2-99
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Fusing Section
Main Unit Theory of Operation
• The fusing speed is not changed during a single job.
• When the last piece of media for that particular job moves past the Paper Exit Roller, the
B. Fusing speed control (control of loop before fusing)
• To prevent double transferred images and brush effects from occurring, the difference
between the fusing speed and the media conveyance speed during image transfer is cor-
rected.
• The Paper Loop Sensor (PC6) detects the length of the loop formed in the media
between the 2nd Transfer Roller and the Fusing Pressure Roller. The fusing speed is
then varied according to the length of the loop detected. By varying the fusing speed, any
effects from the Fusing Pressure Roller side (part-to-part variations, change of parts over
time) are prevented from being transferred to the 2nd transfer section.
• No loop control is provided to perform the fusing process at high speeds when envelopes
are used (to prevent wrinkles).
☞
2-90
• Fusing deceleration (low speed):
When the media loop length is small, the actuator of the Paper Loop Sensor (PC6) is
pushed up a small amount and the sensor is unblocked. When the sensor is unblocked,
the fusing speed is decelerated (-1.36%).
• Fusing acceleration (high speed):
When the media loop length is large, the actuator of the Paper Loop Sensor (PC6) is
pushed up a large amount and the sensor is blocked. When the sensor is blocked, the
fusing speed is accelerated (+1.64%).
Fusing deceleration
Fusing acceleration
Fusing Pressure
Roller
Actuator
Paper Loop Sensor
4138to2069c2
2nd Transfer Roller
4138to2069c1
2-100
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Main Unit Theory of Operation
• Operation timing
Fusing Section
1. The Fusing Motor (M4) is turned at low speed when the leading edge of the media
reaches a point before the roller pressure point.
2. When it is detected that the Paper Loop Sensor (PC6) is unblocked, the Fusing Motor
(M4) is turned at high speed. Regardless of the condition of the Paper Loop Sensor
(PC6), the Fusing Motor (M4) is kept turned at high speed for a predetermined period
of time after the motor speed has been switched to the high level.
3. When it is detected that the Paper Loop Sensor (PC6) is blocked, the Fusing Motor
(M4) is turned at low speed. Regardless of the condition of the Paper Loop Sensor
(PC6), the Fusing Motor (M4) is kept turned at low speed for a predetermined period of
time after the motor speed has been switched to the low level.
4. The operations of steps 2 and 3 above are repeated.
trol is terminated and thereafter the Fusing Motor (M4) is turned at the normal speed.
C. Fusing Pressure Roller deformation prevention control
• To prevent the Fusing Pressure Roller from being deformed, the Fusing Pressure Roller
is forcibly turned if it is left idle for a predetermined period of time.
• Operation timing
1. If the machine remains in the standby state for more than 13 hours, the Fusing Motor
(M4) is turned at 1/3 speed for 1 sec.
2. If the machine remains in the Power Save mode for more than 14 days, a single refer-
ence temperature adjustment is performed [during which the Fusing Cooling Fan Motor
(M11) is also turned] and thereafter the Fusing Motor (M4) is turned at 1/3 speed for 1
sec.
☞
2-110
D. Media exit detection control
• The Exit Sensor (PC8) detects the media conveyed from the Fusing Belt and Fusing
Pressure Roller.
• The leading edge of the media pushes up the Exit Sensor actuator. When the actuator
blocks the Exit Sensor (PC8), the machine determines that the media has reached the
exit point.
• The Exit Sensor is placed right after the Fusing Pressure Roller in order to detect the
media jam and prevent the media from being wound to the Fusing Pressure Roller.
Actuator
Paper Size Sensor (PC8)
4138to2108c0
2-101
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Fusing Section
Main Unit Theory of Operation
E. Media width detection control
• The Paper Size Sensor (PC23) detects the width of the media being conveyed.
(A4 width) or more, the leading edge of the media pushes up the actuator of the sensor,
thus blocking the sensor. When the sensor is blocked, the machine considers that the
width of the media is equivalent to A4 width or more.
• If the width of the media that has moved past the Paper Size Sensor (PC23) is less than
210 mm (A4 width), the actuator of the sensor is not moved and the sensor is left
unblocked. When the sensor is unblocked, the machine considers that the width of the
media is a small size (B5 size or less).
• For media size detection, the machine recognizes the media size using the media size
setting made in the controller and determines it after the media has actually been fed
through. The media size detection results are used in the “PPM control,” to be described
later.
☞
2-111
Paper Size Sensor (PC23)
Actuator
4138to2107c0
2-102
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Main Unit Theory of Operation
Fusing Section
F. Detection of media full in the exit tray (magicolor 5450 only)
• The Paper Full Sensor (PC20) detects the load capacity of output media in the Exit Tray.
• When the Paper Holding Plate is low, the edge of the Paper Holding Plate shades the
Paper Full Sensor (PC20.)
• When printing starts, the output media pushes up the Paper Holding Plate and the edge
of the Plate activates the Paper Full Sensor (PC20.)
• After all media is discharged, the Paper Holding Plate goes down and the edge of the
Plate shades the Paper Full Sensor (PC20.) If the sensor is shaded, the printed media is
judged to not have reached the maximum load capacity yet.
• After all media is discharged, if the output media in the Exit Tray keeps the Paper Holding
Plate up and the Paper Full Sensor (PC20) remains activated, the printed media is
judged to have reached the maximum load capacity, and the operation panel displays the
message “OUTPUT FULL REMOVE PAPER.”
• If the sensor detects that the Exit Tray is full, printing is stopped.
• The message “OUTPUT FULL REMOVE PAPER” is removed when the output media is
removed from the Exit Tray, which again shades the Paper Full Sensor (PC20).
Paper Full Sensor (PC20)
When the tray is empty
Paper Holding Plate
Exit Tray
When media is loaded
4138T2C003DA
Media
4138T2C004DA
When the tray is full
Media
4138T2C005DA
2-103
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Fusing Section
Main Unit Theory of Operation
G. Print start wait control
• To ensure good fusing performance for the first print, the print start timing is retarded.
• The control also prevents the media from sticking during printing on OHP film in the color
mode.
• <Operation>
The print start timing is retarded using the value of either one of the two wait periods,
whichever is longer, calculated under the following two conditions.
1. Using the data provided by the Temperature/Humidity Sensor (HS1) and other sensors,
the period of time that begins when the print control (print start timing control) is started
and ends when the first sheet of media reaches the Fusing Belt is calculated.
2. If the first print is produced on OHP film in the color mode, the wait time is calculated to
ensure that the media interval is the specified value.
16.3.3
Fusing temperature control
• To fuse the toner image on the media (image yet to be permanently fixed) properly into
the media, the Heater Lamps are turned ON and OFF as necessary to bring the fusing
temperature to an appropriate level.
• Thermistors are used to detect the surface temperatures of the Heating Roller and Fus-
ing Pressure Roller. The Heater Lamps are then turned ON and OFF as necessary to
achieve the set temperature.
• The control temperature in the print command wait state is called the standby tempera-
ture, while that for permanently fix the toner image on media into the media is called the
print temperature.
2-104
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Main Unit Theory of Operation
16.3.4 Fusing temperature control management
Fusing Section
• The appropriate type of temperature control is provided according to the machine status.
Reset
Heater OFF
Warm-up control
Post-warm-up control
Wait control
Print control
Post-print cycle control
4138to2138e0
A. Conditions enabling shift to warm-up control
• The Power Switch is turned ON.
• A malfunction or media misfeed is reset.
• The machine leaves the Power Save mode.
• A door is closed.
B. Condition enabling shift to post-warm-up control
• At the end of the warm-up control (no print request)
C. Conditions enabling shift to wait control
• At the end of the warm-up control (no print request)
• At the end of the post-print cycle control
D. Condition enabling shift to print control
• A print request is accepted.
E. Condition enabling shift to post-print cycle control
• At the end of the print control
F. Condition enabling shift to heater OFF control
• A malfunction or media misfeed occurs.
• A Power Save mode signal is received.
2-105
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Fusing Section
16.3.5 Warm-up control
Main Unit Theory of Operation
• Control is provided until the Heating Roller reaches the predetermined level.
• The Power Save mode is not accepted during a warm-up cycle.
A. Control start timing
• The Power Switch is turned ON.
• A malfunction or media misfeed is reset.
• The machine leaves the Power Save mode.
• A door is closed.
B. Control termination timing
• A malfunction or media misfeed is reset.
• A door is opened.
C. Control start decision
• If the information provided by the Temperature/Humidity Sensor (HS1) is less than a pre-
determined value, the low temperature start control is provided.
• If the information provided by the Temperature/Humidity Sensor (HS1) is the predeter-
mined value or more, the ordinary start control is provided.
D. Low temperature start control
1. The “single reference temperature adjustment” is started with the target temperature of
the Heating Roller Heater Lamp set at 80°C + correction value. At the same time, the
“single reference temperature adjustment” is started with the target temperature of the
Fusing Pressure Roller Heater Lamp set at 10°C.
2. The control proceeds to “ordinary start control” after the lapse of a predetermined
period of time after the Heating Roller temperature has reached the target value.
3. The control proceeds to “heater OFF control” if an event of control termination timing
occurs during control.
OFF
Fusing Motor (M4)
ON
HI
LOW
HI
Heating Roller Heater Lamp
(H1) Remote
Temperature control
Temperature control
Temperature control
Fusing Pressure Roller
Heater Lamp (H2) Remote
Temperature control
LOW
Temperature (°C)
Heating Roller
170 + ǩ
Fusing
Pressure Roller
165
150
80 + ǩ
10
Fusing Unit rollers
and belt start
Fusing Ready
Warm-up start
4138to2144e0
Warm-up cycle control diagram during low temperature start
2-106
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Main Unit Theory of Operation
Fusing Section
E. Ordinary start control
1. The “single reference temperature adjustment” is started with the target temperature of
the Heating Roller Heater Lamp set at 170°C + correction value. At the same time, the
“single reference temperature adjustment” is started with the target temperature of the
Fusing Pressure Roller Heater Lamp set at 150°C.
2. If the Heating Roller temperature reaches a level of 120°C or more, both the Fusing
Pressure Roller and Fusing Belt are turned at the specified speed. Or, when a prede-
termined period of time elapses, the Fusing Pressure Roller and Fusing Belt are turned
at the specified speed.
3. If the control has proceeded from “low temperature start control,” the Fusing Pressure
Roller and Fusing Belt are turned at the specified speed.
4. If the Heating Roller temperature becomes 165°C or more and the Fusing Pressure
Roller temperature becomes 70°C or more after the lapse of a predetermined period of
time after the Fusing Unit rollers and belt have been rotated, the “fusing Ready” state is
set.
5. If a print request is received after the “fusing Ready” state, the control proceeds to
“print control (print start control).”
6. If the Heating Roller temperature becomes 170°C + the correction value or more, the
control proceeds to “post-warm-up control.”
7. The control proceeds to “heater OFF control” if an event of control termination timing
occurs during control.
OFF
Fusing Motor (M4)
ON
HI
LOW
HI
Heating Roller Heater Lamp
(H1) Remote
Temperature control
Temperature control
Fusing Pressure Roller
Heater Lamp (H2) Remote
LOW
Temperature (°C)
Heating Roller
170 + ǩ
165
Fusing
Pressure Roller
150
120
Warm-up start
Fusing Unit rollers
and belt start
Fusing Ready
4138to2565c0
Warm-up cycle control diagram during ordinary start
2-107
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Fusing Section
16.3.6 Post-warm-up control
Main Unit Theory of Operation
• After the warm-up cycle has been completed, the Fusing Pressure Roller and Fusing
Belt are turned to achieve a uniform temperature.
• If the Heating Roller and the Fusing Pressure Roller have reached their respective
required temperatures, the machine considers that the Fusing Unit rollers and belt have
reached the specified temperatures. It then terminates the post-warm-up control
sequence.
A. Control start timing
• At the end of the warm-up control (no post-warm-up control sequences are performed if
a print request is received)
B. Control termination timing
• A predetermined period of time elapses after the post-warm-up control has been started.
• The temperature of the Heating Roller reaches 170°C + correction value and that of the
Fusing Pressure Roller reaches 150°C or more.
• A Power Save mode signal is received.
C. Control operation timing
1. The Fusing Pressure Roller and Fusing Belt are turned at the specified speed.
2. The “ripple prediction temperature adjustment” is started with the target temperature of
the Heating Roller Heater Lamp set at 170°C + correction value. At the same time, the
“ripple prediction temperature adjustment” is started with the target temperature of the
Fusing Pressure Roller Heater Lamp set at 150°C.
3. Rotation is stopped after the lapse of a predetermined period of time after the post-
warm-up control has been started and the control proceeds to “wait control.” Or, if the
temperatures of the Fusing Pressure Roller and Fusing Belt have reached the specified
levels, rotation is stopped and the control proceeds to “wait control.”
4. If a print request is received during the control, the control proceeds to “print control.”
5. If a malfunction or media misfeed occurs during control, the control proceeds to “heater
OFF control.”
16.3.7
Wait control
• Control is provided to ensure that the temperatures at different parts of the Fusing Unit
reach a constant level during the wait state.
A. Control start timing
• At the end of the post-warm-up control
• At the end of the post-print cycle control (print start control)
B. Control termination timing
• A print request is received.
• A malfunction or media misfeed occurs.
• A Power Save mode signal is received.
C. Control operation timing
1. The “hysteresis temperature adjustment” is started with the target temperature of the
Heating Roller Heater Lamp set at 170°C + correction value. At the same time, the
“hysteresis temperature adjustment” is started with the target temperature of the Fus-
ing Pressure Roller Heater Lamp set at 150°C.
2. If a print request is received during the wait state, the control proceeds to “print control.”
3. If a malfunction or media misfeed occurs or a Power Save request is made during the
wait state, the control proceeds to “heater OFF control.”
2-108
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Main Unit Theory of Operation
16.3.8 Print control
Fusing Section
• To ensure a good fixing level and light transmission performance of the OHP film, the
fusing speed, Fusing Pressure Roller temperature, and Fusing Belt temperature are
controlled.
A. Control start timing
• A print request is received.
B. Control termination timing
• A malfunction or media misfeed occurs.
C. Control operation timing
1. The Fusing Pressure Roller and Fusing Belt are turned at the specified speed.
2. The “single reference temperature adjustment” is started with the target temperature of
the Heating Roller Heater Lamp set at 170°C + correction value. At the same time, the
“single reference temperature adjustment” is started with the target temperature of the
Fusing Pressure Roller Heater Lamp set at 150°C.
3. If the temperature of the Heating Roller reaches the target value, the control of the
Heating Roller Heater Lamp proceeds to the “hysteresis temperature adjustment.” If the
temperature of the Fusing Pressure Roller reaches the target value, the control of the
Fusing Pressure Roller Heater Lamp proceeds to the “ripple prediction temperature
adjustment.”
4. When the leading edge of the first sheet of media moves past the Synchronizing Roller,
the Fusing Pressure Roller and Fusing Belt are turned at the specified speed corre-
sponding to the type of the media.
5. If there is another sheet of media to be printed when the trailing edge of the preceding
sheet of media moves past the Fusing Pressure Roller/Fusing Belt, the Heating Roller
Heater Lamp temperature, Fusing Pressure Roller Heater Lamp temperature, and the
fusing speed are changed to the settings that correspond to that particular piece of
media.
6. After the trailing edge of the last sheet of media moves past the Exit Roller, the control
proceeds to “post-print cycle control.”
7. If a malfunction or media misfeed occurs during a print cycle, the control proceeds to
“heater OFF control.”
2-109
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Fusing Section
16.3.9 Post-print control
Main Unit Theory of Operation
• To prevent the fusing temperature from rising after the print cycle has been run, a step-
wise control is provided using an intermediate temperature between the print tempera-
ture and the wait temperature.
A. Control start timing
• There is no new print request received when the trailing edge of the last sheet of media
has moved past the Exit Roller.
B. Control termination timing
• A predetermined period of time elapses after the post-print cycle control has been
started.
• A print request is received.
• A door is opened, or an error or malfunction occurs.
C. Control operation timing
1. The Fusing Pressure Roller and Fusing Belt are turned at the specified speed.
2. The “ripple prediction temperature adjustment” is started with the target temperature of
the Heating Roller Heater Lamp set at 160°C + correction value. At the same time, the
“ripple prediction temperature adjustment” is started with the target temperature of the
Fusing Pressure Roller Heater Lamp set at 140°C.
3. The Fusing Pressure Roller and Fusing Belt are stopped after the lapse of a predeter-
mined period of time after the post-print cycle control has been started.
4. The control proceeds to “wait control” after the lapse of another predetermined period
of time after the post-print cycle control has been started.
5. The control proceeds to “print control” if a print request is received during the post-print
cycle control.
6. The control proceeds to “heater OFF control” if a malfunction or media misfeed occurs
during the post-print cycle control.
16.3.10 Heater OFF control
• Heater control is suspended when a malfunction or media misfeed occurs or a Power
Save mode signal is received.
A. Control start timing
• A door is opened or an error or malfunction occurs.
• A Power Save mode signal is received.
B. Control termination timing
• All of the following events are reset: an open door, an error or malfunction that has
occurred, a Power Save mode signal that has been received.
C. Control operation details
1. A request for heater forced turning OFF control is made for heater control.
2. A request is made for stopping rotation of the Fusing Pressure Roller and Fusing Belt.
2-110
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Main Unit Theory of Operation
Fusing Section
16.3.11 Heater control
A. Single reference temperature adjustment
• The heater is turned ON or OFF using a target temperature value.
B. Hysteresis temperature adjustment
• The heater is turned ON or OFF with a certain allowance given for the threshold value of
turning ON or OFF the heater.
C. Ripple prediction temperature adjustment
• The heater is turned ON or OFF by determining whether the temperature is on the
increase or decrease within a set temperature range.
16.3.12 PPM control
• When a multi-print cycle is run, the temperature of the Fusing Pressure Roller and the
Fusing Belt decrease, resulting in the fusing performance of the printed image being
degraded.
To prevent this problem, fusing performance is estimated based on the surface tempera-
ture of the Fusing Pressure Roller; the distance between sheets of media is widened
according to the media length and fusing speed, thereby allowing the Fusing Pressure
Roller and the Fusing Belt to recover the required temperature; the fusing performance of
the printed toner image is thus ensured.
• If a multi-print cycle is run using media of a small size, a difference is produced in tem-
moves past) and the edges of the roller/belt (where no part of the media moves past).
Since the thermistor is located at the center portion, the machine determines that there
is a drop in roller temperature and turns ON the heater to increase the roller temperature.
This also heats the edges of the roller, at which a high temperature is still maintained.
This increases the overall temperature.
To inhibit this situation, the distance between sheets of media is widened and the tem-
perature of the Fusing Pressure Roller and Fusing Belt is thereby made uniform.
A. Control start timing
• In an ambience of low temperature and low humidity
• In an ambience of high temperature and high humidity
• Media of a small size is detected through media width detection control.
☞
2-102
• The Heating Roller temperature becomes lower than a predetermined level.
• Media of a small size is detected through media width detection control.
B. Control termination timing
• The control proceeds to “wait control” or “heater OFF control” during the PPM control.
• The media that requires no PPM control is fed through during PPM control.
2-111
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Fusing Section
Main Unit Theory of Operation
16.4 Malfunction detection
16.4.1
Fusing Unit malfunctions
• The following table lists the seven types of malfunctions as they relate to the Fusing Unit.
Malfunction code
0060
Description
Fusing Motor abnormal rotation
Warm-up failure
Defective component
Fusing Motor (M4)
Heating Roller Heater Lamp (H1)
Open-circuited thermistor (incorrect
installation)
0500
Heating Roller Thermistor (TH1)
Abnormal temperature increase rate
Warm-up failure
Fusing Pressure Roller Heater Lamp (H2)
Fusing Pressure Roller Thermistor (TH2)
0501
Open-circuited thermistor (incorrect
installation)
0510
0511
0520
0521
Abnormally low temperature
Abnormally low temperature
Abnormally high temperature
Abnormally high temperature
Heating Roller Heater Lamp (H1)
Fusing Pressure Roller Heater Lamp (H2)
Heating Roller Heater Lamp (H1)
Fusing Pressure Roller Heater Lamp (H2)
16.4.2
Fusing Motor abnormal rotation detection control
• The condition of the Fusing Motor (M4) while it is rotating is monitored and, if an abnor-
mal rotation is detected, “Fusing Motor abnormal rotation 060” is displayed.
A. Detection operation
• The machine determines that the Fusing Motor (M4) is in a good rotating condition if the
motor maintains a steady-state rotating condition continuously for a predetermined
period of time or more during its stable rotation.
• The Fusing Motor is considered to be abnormal if it fails to rotate in a steady state even
after the lapse of a predetermined period of time during its stable rotation.
• The Fusing Motor is considered to be abnormal if a Fusing LOCK signal is not detected
even after the lapse of a predetermined period of time after the machine has determined
that the motor rotates in a steady state.
2-112
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Main Unit Theory of Operation
16.4.3 Warm-up failure detection control
Fusing Section
• The temperatures of the Heating Roller and Fusing Pressure Roller are monitored using
the Heating Roller Thermistor (TH1) and Fusing Pressure Roller Thermistor (TH2) during
a warm-up cycle. If an abnormal rise in temperature is detected, “warm-up failure 0500/
0501” is displayed.
A. Detection start timing
• At the start of the warm-up control
• At the start of the low temperature start control
• During rotation under the Fusing Pressure Roller deformation prevention control
B. Detection termination timing
• At the end of the warm-up control
• At the end of the low temperature start control
• At the end of the Fusing Pressure Roller deformation prevention control
• The detection reference temperature for the above control is reached.
C. Detection condition
• The temperatures of the Heating Roller and Fusing Pressure Roller do not reach the
control temperatures within a predetermined period of time after the warm-up control has
been started.
16.4.4
Abnormally low temperature detection control
• The temperatures of the Heating Roller and Fusing Pressure Roller are monitored using
the Heating Roller Thermistor (TH1) and Fusing Pressure Roller Thermistor (TH2) after
the warm-up cycle. If an abnormally low temperature is detected, “abnormally low tem-
perature 0510/0511” is displayed.
A. Detection start timing
• At the completion of the warm-up cycle
B. Detection termination timing
• A malfunction or media misfeed occurs.
• A door is opened.
C. Detection condition
• The temperatures of the Heating Roller and Fusing Pressure Roller remain below a pre-
determined level for a predetermined period of time or more.
2-113
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Fusing Section
Main Unit Theory of Operation
16.4.5 Abnormally high temperature detection control
• The temperatures of the Heating Roller and Fusing Pressure Roller are monitored using
the Heating Roller Thermistor (TH1) and Fusing Pressure Roller Thermistor (TH2) while
the machine remains active. If an abnormally high temperature is detected, “abnormally
high temperature 0520/0521” is displayed.
A. Detection start timing
• The Power Switch is turned ON.
B. Detection termination timing
• The Power Switch is turned OFF.
C. Detection conditions
• The temperature detected by the Heating Roller Thermistor (TH1) becomes 230°C or
more.
• The temperature detected by the Heating Roller Thermistor (TH1) is 220°C or more and,
at the same time, the temperature gradient for a 1-sec. period exceeds 11°C.
• The temperature detected by the Fusing Pressure Roller Thermistor (TH2) becomes
196°C or more during a predetermined period of time after a door has been opened or
an error or malfunction has occurred.
• The temperature of the Fusing Pressure Roller (after correction) becomes 220°C or
more.
16.4.6
Open-circuited Heating Roller Thermistor (incorrect installation) detection
control
• The temperature detected by the Heating Roller Thermistor (TH1) during a warm-up
cycle is monitored and, if an abnormal temperature is detected, “warm-up failure 0500” is
displayed.
A. Detection start timing
• At the start of the low temperature start control
• At the start of the warm-up control
B. Detection termination timing
• The temperature detected by the Heating Roller Thermistor (TH1) reaches the control
temperature (warm-up control temperature).
• A predetermined period of time elapses after the start of control.
C. Detection conditions
• The temperature detected by the Heating Roller Thermistor (TH1) increases by less than
3°C for the period of time that begins when the low temperature start control is started
and ends when 2 sec. elapse thereafter.
• The temperature detected by the Heating Roller Thermistor (TH1) increases by less than
7°C for the period of time that begins when the low temperature start control is started
and ends when 3 sec. elapse thereafter.
• The difference between the maximum and minimum temperatures detected by the Heat-
ing Roller Thermistor (TH1) for the 3-sec. period after the warm-up cycle has been
started is less than 5°C.
• The difference between the maximum and minimum temperatures detected by the Heat-
ing Roller Thermistor (TH1) for the 3-sec. period after the warm-up cycle has been
started is 50°C or more.
2-114
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Main Unit Theory of Operation
Fusing Section
16.4.7
Open-circuited Fusing Pressure Roller Thermistor (incorrect installation)
detection control
• The temperature detected by the Fusing Pressure Roller Thermistor (TH2) during a
warm-up cycle is monitored and, if an abnormal temperature is detected, “warm-up fail-
ure 0501” is displayed.
A. Detection start timing
• A detection sequence is started when the following three conditions are met:
1. At the start of the warm-up control
2. The fusing rollers are turning.
3. The temperature detected by the Heating Roller Thermistor (TH1) is higher than the
correction temperature of the Fusing Pressure Roller.
• If the temperature detected by the Heating Roller Thermistor (TH1) is lower than the cor-
rection temperature of the Fusing Pressure Roller, the internal state in the middle of the
detection sequence is reset and, if the detection conditions are met again, the sequence
is started anew.
B. Detection termination timing
• The temperature of the Fusing Pressure Roller after correction reaches the warm-up
control temperature -3°C (147°C).
• At the end of the warm-up control or post-warm-up control
C. Detection conditions
• The temperature detected by the Heating Roller Thermistor (TH1) after the lapse of 21
sec. after the start of detection sequence does not increase by 3°C or more as compared
with that at the start of the sequence when the Fusing Pressure Roller correction temper-
ature is less than 147°C.
• The temperature after each period of 1 sec. does not increase by 3°C or more as com-
pared with that 21 sec. ago after the detection sequence.
16.4.8
Abnormal temperature increase rate detection control
• The temperature of the Heating Roller is monitored using the Heating Roller Thermistor
(TH1) during a warm-up cycle. If an abnormal temperature increase rate is detected,
“warm-up failure 0500” is displayed.
A. Detection start timing
• The temperature of the Heating Roller is less than the specified level during the warm-up
control.
B. Detection termination timing
• The temperature of the Heating Roller reaches the specified level during the warm-up
control.
C. Detection conditions
1. The temperature of the Heating Roller at the start of the detection is recorded.
2. The temperature of the Heating Roller 1 sec. after the recording is compared with that
recorded.
3. The malfunction is detected if the difference in temperature exceeds 11°C.
4. If the temperature difference is 11°C or less, the current Heating Roller temperature is
recorded and then the detection operation is repeated starting with step 2.
2-115
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Fusing Section
Main Unit Theory of Operation
16.4.9 Protection against abnormally high temperature
• The machine provides protection at three different stages to prevent abnormally high
temperature of the Fusing Unit.
1. Soft protection
2. Hard protection
3. Thermostat protection
A. 1st stage: soft protection
• If the Heating Roller Thermistor (TH1) and the Fusing Pressure Roller Thermistor (TH2)
detect a temperature exceeding a predetermined value, the malfunction code represent-
ing abnormally high temperature is displayed. At this time, the Heater Lamps are turned
OFF forcibly and the initiation of any new print cycle is prohibited (abnormally high tem-
perature detection control).
B. 2nd stage: hard protection
• The following hard protection control is provided if the CPU overruns and becomes
unable to detect an abnormally high temperature.
1. The Heating Roller Thermistor (TH1) and Fusing Pressure Roller Thermistor (TH2)
detect a temperature exceeding a predetermined value.
2. The Remote signal for the corresponding Heater Lamp of the Low Voltage Unit (LV) is
forcibly turned OFF through the Mechanical Control Board (PWB-A).
3. The triac on the Lower Voltage Unit (LV) is turned OFF to shut down the power supply
to the corresponding Heater Lamp.
4. The Heater Lamp is forcibly turned OFF.
5. The temperature detected by the Heating Roller Thermistor (TH1) and Fusing Pressure
Roller Thermistor (TH2) is decreased to a level below the predetermined value.
6. The Remote signal forcible OFF of the corresponding Heater Lamp is reset so that
power supply to the Heater Lamp is resumed. This operation is repeated until the CPU
recovers to be able to detect the abnormally high temperature condition. This control
allows the power supply to the corresponding Heater Lamp to be shut down before the
thermostat operates, inhibiting the Fusing Unit from being damaged.
2-116
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Main Unit Theory of Operation
Fusing Section
C. 3rd stage: Thermostat protection
• If neither the soft protection nor hard protection can detect an abnormally high tempera-
ture due to a defective thermistor, the Heating Roller Thermostat (TS1) and Fusing Pres-
sure Roller Thermostat (TS2) operate at the specified temperature. This shuts down the
power supply to the Heating Roller Heater Lamp (H1) and Fusing Pressure Roller Heater
Lamp (H2), thus forcibly turning them OFF.
Fusing Unit
Thermostat
Thermistor
Heating Roller Heater Lamp
Fusing Pressure Roller
Heater Lamp
Lower Voltage
Unit (LV1)
Heater
REM
Relay
Mechanical Control Board
(PWB-A)
4138to2109c0
Power Switch
L
N
2-117
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Image Stabilization Control
Main Unit Theory of Operation
17. Image Stabilization Control
• To ensure that a stabilized output image is produced at all times, a comprehensive con-
trol is provided for the developing bias voltage, laser light intensity, registration correction,
gamma correction, and other parameters.
• Image stabilization control may be divided into two types: complete and full correction
control. The following explain specific details of each type of control.
17.1.1
Complete correction control
• Controls 1 through 6 below are collectively called the “complete correction control.”
• For details of each of these controls, see the relevant page.
Control name
Purpose
AIDC Sensor calibra-
tion control
Changes in various types of characteristics due to change with time of
the AIDC Sensor (deteriorated LED, dirty sensor surface), part-to-part
variations in the sensors, and change of environment affect the AIDC
rect fluctuations in the output, the sensor LED intensity is adjusted so as
to keep constant the AIDC Sensor output value.
☞
2-65
1
2
3
4
Developing bias Vpp
control
each Toner Cartridge, a leak image (background leak, image area leak)
results. If Vpp is excessively low, halftone reproducibility becomes poor.
This control detects a Vpp range, in which no image failure occurs, to set
the optimum Vpp.
☞
2-33
Developing bias duty
control (control of the
maximum amount of
toner sticking to the
Transfer Belt)
the solid image.
☞
2-34
Laser light intensity con- To correct the target level of fluctuations in fine line reproduction and
trol
☞
reverse image (white on black) reproduction that occur due to variations
in photo conductor electrostatic characteristics, developing characteris-
tics, and transfer characteristics (part-to-part variations, environment,
durability).
2-6
Gamma characteristics To correct the tone by using the AIDC Sensor to measure the density of
detection control
a gradation pattern produced on the Transfer Belt and sending the
results of the measurement to the controller.
5
6
☞
2-35
Registration correction To correct incorrect color registration that occurs due to variations in
control
parts of the machine used for regulating different drawing positions.
☞
2-6
2-118
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Main Unit Theory of Operation
17.1.2 Simplified correction control
Image Stabilization Control
plete correction control is executed.
Control name
Purpose
AIDC Sensor offset value check
To check the low gain output value and offset voltage value of
the AIDC Sensor when the shutter is closed.
1
2
☞
2-65
Check of AIDC Sensor output cor- To check the low gain output value of the AIDC Sensor using
responding to clear Transfer Belt
surface
the intensity value set last for the clear Transfer Belt surface
on which no toner sticks.
☞
2-65
Vpp check) ment value taken last.
3
4
5
6
☞
2-33
Developing bias duty control (con- To correct the amount of toner based on the measurement
trol of the maximum amount of
toner sticking to the Transfer Belt)
value taken last.
☞
2-34
Laser light intensity control (simpli- To correct based on the measurement value taken last.
fied correction control)
☞
2-6
Registration correction control
(simplified control)
To correct incorrect color registration that occurs due to varia-
tions in parts of the machine used for regulating different
drawing positions. The simplified control uses a simplified
registration pattern to make the correction.
☞
2-6
2-119
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Image Stabilization Control
17.1.3 Image stabilization control execution request
Main Unit Theory of Operation
• A request for execution of the complete correction control or simplified correction control
is made at the following timing.
Stabilization request
detection timing
Stabilization request timing
When a new TC is detected
Execution processing
Upon
replace-
When the Power Switch is
turned ON
Complete correction
control
ment of unit
When the Transfer Belt Unit is When the Front/Right Door is Complete correction
*1
closed
control
replaced
By machine When the Power Switch is
Power the Switch is turned
ON
Simplified correction
control
status
turned ON
When there is a change in
environmental conditions
from those when the last sta-
bilization sequence was exe-
cuted
At the end of a job
At the end of a print cycle of At the end or during a job
*2
given conditions
When a malfunction is reset • When the Power Switch is
turned ON
• When the Front/Right Door
is closed
When simplified correction
control is executed
After simplified correction
control is executed
Gamma correction con-
trol, registration correction
control, or complete cor-
rection control
When the temperature of the Always
print head unit changes over
the specified range from the
one at the previous stabiliza-
tion.
Register adjustment
control
User
selection
When Engine/Engine Ser-
vice/Calibration is selected
When Engine/Engine Ser-
vice/Calibration is selected
Complete correction
control
*1: Since the machine is not provided with a function that detects a new Transfer Belt Unit,
Engine/Engine Service/Calibration must be selected and complete correction control
executed whenever the unit has been replaced with a new one.
*2: See the following for the conditions that enable execution of the stabilization control at
the end of a print cycle of given conditions.
17.1.4
Conditions enabling execution of stabilization control at the end of a print
cycle of given conditions
• The time equivalent to the number of printed pages produced by each TC is counted
after the execution of the last image stabilization sequence.
• The equivalent time counter of all TCs is reset after the execution of the image stabiliza-
tion sequence.
A. Calculation of equivalent printed page time
• The period of time through which the Developing Unit is driven is used for the equivalent
printed page time.
• Half of the Developing Unit driving time involved with 2P/J is one printed page time.
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Main Unit Theory of Operation
17.1.5
Image Stabilization Control
Combination and execution sequence of different sub-controls
Simplified Individual Individual Complete correc-
Control name
control
control 1
control 2
tion control
AIDC Sensor calibra-
tion control
Simplified correc-
tion control
(check)
➀
☞
2-65
Complete correc-
tion control
➀
Developing bias Vpp
control
Simplified correc-
tion control
(check)
➁
➂
☞
2-33
Complete correc-
tion control
➁
Developing bias duty
control (control of the
maximum amount of
toner sticking to the
Transfer Belt)
Simplified correc-
tion control
tion control
➂, ➄
☞
2-34
Laser light intensity
control
Simplified correc-
tion control
➃
☞
2-6
Complete correc-
tion control
➃, ➅
Gamma correction control
➀
➆
☞
2-35
Registration correction Simplified correc-
➄
control
tion control
☞
2-6
Complete correc-
tion control
➀
➇
2-121
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Image Stabilization Control
Main Unit Theory of Operation
17.2 Operation flow of image stabilization control upon replace-
ment of unit
When a new Transfer Unit or a new TC is installed
(complete correction control)
Start
Transfer Belt cleaning control,
2nd transfer cleaning control
Transfer ATVC control
AIDC offset processing
AIDC intensity control
Vpp control
Max. amount of toner
sticking control I
Laser light intensity control I
Max. amount of toner
sticking control II
Laser light intensity control II
Gamma correction control
Registration control
End
4138to2129e0
2-122
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Main Unit Theory of Operation
Miscellaneous
18. Miscellaneous
18.1 Fan control
18.1.1
Composition
[1]
[1], [2]
[2]
[3]
4138to2111c0
[3]
4138to2110c0
Key
[1]
Name
Function/system
Fusing Cooling Fan Motor (M11)
• Discharges heat generated from the interior parts
(including the Low Voltage Unit, Fusing Unit, Toner
Cartridges/K, and motor drives) from the machine to
prevent the interior temperature from rising
inordinately.
• Air passageway is formed on top of the Low Voltage
Unit, in the duct inside the Toner Cartridge rail, and
below the print head housing. No air flows through
areas around the Toner Cartridges. This effectively
prevents toner from scattering.
LV Cooling Fan Motor (M10)
• Discharges heat generated from the interior parts
(including the Low Voltage Unit, intermediate transfer
belt section, Toner Cartridges/C, M, Y, and motor
drives) from the machine to prevent the interior tem-
perature from rising inordinately.
[2]
[3]
Ozone Ventilation Fan Motor (M12)
• Discharges heat generated from the print head from
the machine to prevent the print head temperature
from becoming inordinately high.
• Removes ozone produced from the Toner Cartridges
and charging section.
• Air passageway is formed on top of the Low Voltage
Unit, in the duct inside the Toner Cartridge rail, and
below the print head housing. No air flows through
areas around the Toner Cartridges. This effectively
prevents toner from scattering.
2-123
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Miscellaneous
Main Unit Theory of Operation
18.1.2
Control
A. LV Cooling Fan Motor (M10) control
<Full speed rotation conditions>
• For the period of time that begins when the warm-up cycle is started and ends when a
predetermined period of time elapses after the warm-up cycle has been completed.
• For the period of time that begins when the Intermediate Transport Motor (M3) is ener-
gized and ends when a predetermined period of time elapses after the motor is de-ener-
gized.
• For the period of time during which the Fusing Pressure Roller deformation prevention
control is performed
<Half speed rotation conditions>
• The motor runs at a half speed during any time other than above.
• The motor runs at a half speed only when printing in monochrome mode without a
Duplex Option or optional Lower Feed Unit (magicolor 5440 DL/5450 only).
<Stop conditions>
• Stopped in the Power Save mode. The motor is, however, run while the Ozone Ventilation
Fan Motor (M12) is running and stopped after the Ozone Ventilation Fan Motor (M12)
has been stopped. At this time, the motor is run at full speed for a predetermined period
of time after the Intermediate Transport Motor (M3) has been stopped and is run at half
speed thereafter.
<Forced stop condition>
• A door is opened or a malfunction occurs, but not when an error occurs.
B. Fusing Cooling Fan Motor (M11) control
<Full speed rotation conditions>
• For the period of time that begins when the Intermediate Transport Motor (M3) is
energized and ends when a predetermined period of time elapses after the motor is
de-energized.
<Half speed rotation conditions>
• The motor runs at a half speed during any time other than above.
<Stop conditions>
• Stopped in the Power Save mode. The motor is not, however, stopped for a predeter-
mined period of time after the Intermediate Transport Motor (M3) is de-energized.
<Forced stop condition>
• A door is opened or a malfunction occurs, but not when an error occurs.
C. Ozone Ventilation Fan Motor (M12)
<Full speed rotation conditions>
• At the start of a warm-up cycle
• The Intermediate Transport Motor (M3) is energized.
<Stop conditions>
• A predetermined period of time elapses after a warm-up cycle is completed
• A predetermined period of time elapses after the Intermediate Transport Motor (M3) is
de-energized
• Stopped in the Power Save mode. The motor is not, however, stopped for a predeter-
mined period of time after a predrive or a print cycle is completed.
<Forced stop condition>
• A door is opened or a malfunction occurs, but not when an error occurs.
2-124
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THEORY OF OPERATION
SERVICE MANUAL
Lower Feeder Unit
2005.04
Ver. 2.0
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Lower Feeder Unit Theory of Operation
I
Outline
1.
Product specifications ..........................................................................................1-1
1.1 Type ...................................................................................................................1-1
1.2 Paper type .........................................................................................................1-1
1.3 Machine specifications.......................................................................................1-1
1.4 Operating environment ......................................................................................1-1
1.
2.
3.
Overall composition..............................................................................................2-1
Drive.....................................................................................................................2-3
Operations............................................................................................................2-3
3.1 Paper feed control..............................................................................................2-3
3.1.1 Paper Lift Plate mechanism..........................................................................2-3
3.1.3 Paper separation mechanism.......................................................................2-5
3.1.4 Paper detection mechanism .........................................................................2-5
3.1.5 Paper supply level detection control .............................................................2-6
3.1.6 Paper empty condition detection control.......................................................2-6
3.1.7 Edge Guide Plate .........................................................................................2-7
3.1.8 Trailing Edge Guide Plate.............................................................................2-7
3.1.9 Paper size detection control .........................................................................2-8
3.1.10 Paper reference position adjustment mechanism.........................................2-9
3.1.11 Paper misfeed detection control ...................................................................2-9
i
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Lower Feeder Unit Theory of Operation
ii
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Lower Feeder Unit Theory of Operation
Product specifications
I Outline
1. Product specifications
1.1 Type
Name
Add-on 500-sheet paper feed cassette
Type
Front-loading type
Desk type
Installation
Paper Feeding System Paper separation by a small-diameter roller with torque limiter
Document Alignment Center
1.2 Paper type
Paper Size
Paper Type
B5/A4/Letter/Executive/Government Legal/Letter Plus
2
• Plain paper: 60 to 90 g/m (16 to 24 lb)
2
• Recycled paper: 60 to 90 g/m (16 to 24 lb)
Capacity
500 sheets
1.3 Machine specifications
DC 24 V 10% (supplied from the main unit)
Power Requirements
DC 5 V 5%
Max. Power
Consumption
16 W
448 mm (W) × 520 mm (D) × 111.5 mm (H)
17.6 inch (W) × 4.4 inch (D) × 20.5 inch (H)
Dimensions
Weight
Approx. 6.5 kg (14.25 lb)
1.4 Operating environment
Temperature
Humidity
10° to 30° C/50° to 95° F (with a fluctuation of 10° C/h (18° F/h))
15% to 85% (with a fluctuation of 20%/h)
Note
• These specifications are subject to change without notice.
1-1
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Product specifications
Lower Feeder Unit Theory of Operation
1-2
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Overall composition
Lower Feeder Unit Theory of Operation
Function/system
Key
Name
• Surface on which the paper stack is placed
[1] Paper Lift Plate
• Maximum paper capacity
Plain paper: 500 sheets
• Open to clear a sheet of misfed paper from the Lower
Feeder Unit.
[2] Lower Feeder Unit Right Door
[3] Auxiliary Guide
• Guides the paper conveyed toward the machine.
• Covers the Vertical Conveyance Roller.
• If two Lower Feeder Units are installed, remove the
Auxiliary Guide on the side of Tray 3.
• Indicates the level of the paper still available for use in
the Lower Feeder Unit.
[4] Paper Level Indicator Lever
[5] Trailing Edge Guide Plate
[6] Edge Guide Plate
• Aligns the trailing edges of the paper stack in the
Lower Feeder Unit.
• Aligns the edges of the paper stack in the Lower
Feeder Unit.
• Conveys the paper fed in from the Lower Feeder
Paper Feed Roller into the inside of the machine.
[7] Vertical Conveyance Roller
• Separates paper in the Lower Feeder Unit.
• Small-diameter roller with a torque limiter
[8] Lower Feeder Separation Roller
[9] Lower Feeder Paper Feed Roller
[10] Lower Feeder Motor (M1 PF)
• Feeds paper from the Lower Feeder Unit.
• Drives the Lower Feeder Paper Feed Clutch (CL1 PF)
and Vertical Conveyance Roller.
Lower Feeder Paper Feed Clutch
(CL1 PF)
• Transmits drive from the Lower Feeder Motor (M1 PF)
to the Lower Feeder Paper Feed Roller.
[11]
Lower Feeder Paper Feed Sensor
Actuator
[12]
• Detects the paper fed in from the Lower Feeder Unit.
• Detects the paper fed in from Tray 3 when two Lower
Feeder Units are installed.
Lower Feeder Paper Feed Sensor
(PC3 PF)
[13]
[14] Size Detection Board
• Detects the length of the paper loaded in the Lower
Feeder Unit.
Lower Feeder Paper Size Switch
[15]
(S1 PF)
[16] Empty Sensor Actuator
• Detects the paper still available for use in the Lower
Feeder Unit.
Lower Feeder Paper Empty Sensor
[17]
(PC1 PF)
2-2
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Lower Feeder Unit Theory of Operation
Drive
2. Drive
[1]
[5]
[3]
[4]
[2]
4537to2502c0
[1] Vertical Conveyance Roller
[4] Lower Feeder Motor (M1 PF)
[5] Lower Feeder Paper Feed Clutch (CL1 PF)
[2] Lower Feeder Separation Roller
[3] Lower Feeder Paper Feed Roller
3. Operations
3.1 Paper feed control
3.1.1
Paper Lift Plate mechanism
• The Paper Lift Plate is pressed down into the locked position (in which the paper is
loaded in position).
• Load a paper stack and then slide the tray into the machine. This unlocks the Paper Lift
Plate.
• The Paper Lift Plate (paper stack) is pressed against the Feed Roller.
• The Paper Lift Plate (paper stack) is pressed upward by the springs at all times.
Springs
Lock Release Lever
4138to2113c0
4138to2114c0
Paper Lift Plate
2-3
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Operations
Lower Feeder Unit Theory of Operation
3.1.2 Feed Roller/Vertical Conveyance Roller control
• The Feed Roller and Vertical Conveyance Roller are rotated, which feeds paper from the
Lower Feeder Unit and conveys it further into the inside of the machine.
1. The Lower Feeder Motor (M1 PF) is energized to turn the Vertical Conveyance Roller.
2. The Lower Feeder Paper Feed Clutch (CL1 PF) is energized to turn the Feed Roller.
3. The paper is fed in by the Feed Roller.
4. The paper fed in by the Feed Roller is conveyed onto the Synchronizing Roller of the
machine by the Vertical Conveyance Roller.
5. When the Lower Feeder Paper Feed Sensor (PC3 PF) is activated and then the paper
is conveyed onto a predetermined point in the paper path, the Lower Feeder Paper
Feed Clutch (CL1 PF) is de-energized, thus bringing the Feed Roller to a stop. The Ver-
tical Conveyance Roller thereafter takes charge of conveying paper further.
6. When the trailing edge of the last sheet of paper moves past the Synchronizing Roller
Sensor (PC4), the Lower Feeder Motor (M1 PF) is de-energized to bring the Vertical
Transport Roller to a stop.
Lower Feeder Paper
Feed Clutch (CL1 PF)
Vertical Transport Roller
Feed Roller
Separation Roller
Lower Feeder Motor
4537to2502c1
(M1 PF)
Energized
Lower Feeder Motor
(M1 PF)
De-energized
Lower Feeder Paper Feed
Clutch (CL1 PF)
Energized
De-energized
Lower Feeder Paper Feed
Sensor (PC3 PF)
Unblocked
Blocked
4537to2001c0
2-4
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Lower Feeder Unit Theory of Operation
3.1.3 Paper separation mechanism
Operations
• A Separation Roller provided with a torque limiter is used to prevent double feeding of
paper.
Feed Roller
Separation Roller
4138to2115c0
3.1.4
Paper detection mechanism
• The Lower Feeder Paper Feed Sensor (PC3 PF) detects the paper fed in by the Feed
Roller.
• When two Lower Feeder Units are installed, the sensor detects the paper fed off from
Tray 3.
• When the Lower Feeder Paper Feed Sensor actuator unblocks the Lower Feeder Paper
Feed Sensor (PC3 PF), the machine considers that the paper has reached the sensor
position.
Actuator
Lower Feeder Paper Feed Sensor (PC3 PF)
Paper (Tray 1)
4138to2116c0
Paper (Tray 2/3)
2-5
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Operations
3.1.5 Paper supply level detection control
Lower Feeder Unit Theory of Operation
• There is a window in the front cover of the cassette for indicating the paper supply level.
• When the Paper Lift Plate goes up, a red lever appears in the window. The lower the level
of the paper stack in the tray, the more red that is visible.
Lever Indicator
indicating the
paper supply
level
Paper Lift Plate
A paper empty
condition
4138to2117c0
When paper
is loaded
Lever
4138to2118c0
3.1.6
Paper empty condition detection control
• The paper empty message is displayed on the panel when the Empty Sensor Actuator
unblocks the Lower Feeder Paper Empty Sensor (PC1 PF).
• No mechanism is provided for detecting a paper near empty condition. The paper supply
level indicator serves this purpose.
Actuator
When paper
is loaded
Lower Feeder Paper
Empty Sensor (PC1 PF)
Paper
A paper empty
condition
4138to2119c0
Paper Lift Plate
2-6
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Lower Feeder Unit Theory of Operation
3.1.7 Edge Guide Plate
Operations
• The Edge Guide Plate can be slid to the exact size in the width direction of the paper to
be loaded (A4, B5, 8/12).
Edge Guide Plate
4138to2120c0
3.1.8
Trailing Edge Guide Plate
• The Trailing Edge Guide Plate can be slid to the exact size in the length direction of the
paper to be loaded (14 inch, 13 inch, 127/10 inch, A4, 11, 101/2 inch, B5).
Trailing Edge Guide Plate
4138to2121c0
2-7
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Operations
3.1.9 Paper size detection control
Lower Feeder Unit Theory of Operation
• The Lower Feeder Paper Size Switch (S1 PF) detects the length size (FD) of the paper.
1. The Size Detection Board turns as the Trailing Edge Guide Plate is moved.
2. When the tray is slid into the machine, the Size Detection Board pushes the actuator of
the Lower Feeder Paper Size Switch (S1 PF) installed to the machine frame, thus turn-
ing ON the switch.
3. The combination of ON/OFF positions of the sub-switches of the Lower Feeder Paper
Size Switch (S1 PF) determines the specific paper size that can be either one of the
seven different sizes.
4. If the tray is not slid into position, all of the sub-switches are OFF and the message
“DRAWER OPEN TRAY X” appears.
Lower Feeder Paper Size Switch
Paper size
SW1
OFF
ON
SW2
ON
SW3
ON
Legal (8.5” × 14”)
ON
ON
Government Legal Letter Plus
ON
ON
OFF
OFF
ON
A4
Letter (8.5” × 11”)
B5
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
Executive
OFF
OFF
Lower Feeder Unit not installed
Lower Feeder Paper Size Switch (S1 PF)
Actuator
Size Detection Board
Trailing Edge Guide Plate
4138to2122c0
2-8
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Lower Feeder Unit Theory of Operation
3.1.10 Paper reference position adjustment mechanism
Operations
• The Edge Guide Plate can be moved to allow the print start reference position for the
paper to be adjusted.
1. Through a hole in the Paper Lift Plate on top of the tray, loosen two screws that secure
the Edge Guide Plate.
2. Accessing the tray from its bottom surface, loosen two screws that secure the Refer-
ence position Adjusting Plate.
3. Slide the Reference position Adjusting Plate as necessary as indicated on the scale.
4. From the bottom surface of the tray, tighten the two screws that secure the Reference
position Adjusting Plate.
5. Through the hole in the Paper Lift Plate on top of the tray, tighten the two screws that
secure the Edge Guide Plate.
Paper Lift Plate
Edge Guide Plate fixing
screws
4138to2125c0
Adjustment scale
Reference position
Adjusting Plate
4138to2123c0
Reference Position Adjusting Plate fixing screws
3.1.11
Paper misfeed detection control
• If the Lower Feeder Paper Feed Sensor (PC3 PF) is not activated within a predetermined
period of time after a paper feed sequence has been started, the machine determines
that there is a paper misfeed. It then displays a paper misfeed message on the panel.
• The paper misfeed display can be reset by opening and closing any door.
2-9
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Operations
Lower Feeder Unit Theory of Operation
2-10
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THEORY OF OPERATION
SERVICE MANUAL
Duplex Option
2005.04
Ver. 2.0
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Duplex Option Theory of Operation
I
Outline
1.
Product specifications ..........................................................................................1-1
1.1 Type ...................................................................................................................1-1
1.2 Paper type .........................................................................................................1-1
1.3 Machine specifications.......................................................................................1-1
1.4 Operating environment ......................................................................................1-1
1.
2.
3.
4.
Overrall composition.............................................................................................2-1
Center cross section ............................................................................................2-2
Drive system ........................................................................................................2-3
Mechanical operations .........................................................................................2-4
4.1 Reversing mechanism .......................................................................................2-4
4.1.1 Reversing operation......................................................................................2-4
4.1.2 Paper exit roller drive coupling mechanism ..................................................2-4
4.1.3 Reverse Motor Control..................................................................................2-4
4.2 Conveyance and duplex paper feed mechanism...............................................2-5
4.2.1 Coveyance and duplex paper feed operation ...............................................2-5
4.2.2 Duplex Unit Conveyance Motor Control........................................................2-5
4.3 2-sided printing method.....................................................................................2-6
4.3.1 Operations in 2-sided printing with a single sheet of paper resident
in the system ...............................................................................................2-6
4.3.2 Operations in 2-sided printing with two sheets of paper resident
in the system ...............................................................................................2-8
i
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Duplex Option Theory of Operation
ii
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Duplex Option Theory of Operation
Product specifications
I Outline
1. Product specifications
1.1 Type
Name
Duplex Unit
Type
Reversing and Circulating Duplex Unit
Mounted on the right side door of the main unit
Installation
Document Alignment Center
1.2 Paper type
2
2
Paper Type
Paper Size
Plain paper
A4, B5T, Letter, Legal
60 g/m to 90 g/m (16 lbs to 24 lbs)
1.3 Machine specifications
DC 24 V 10% (supplied from the main unit)
DC 5 V 5% (supplied from the main unit)
Power Requirements
Max. Power
Consumption
17 W
394 mm (W) × 320 mm (D) × 58 mm (H)
15.5 inch (W) × 12.6 inch (D) × 2.3 inch (H)
Dimensions
Weight
Approx. 1.8 kg (4.0 lb)
1.4 Operating environment
Temperature
Humidity
10° to 30° C/50° to 86° F (with a fluctuation of 10° C/h (18° F/h))
15% to 85% (with a fluctuation of 20%/h)
Note
• These specifications are subject to change without notice.
1-1
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Product specifications
Duplex Option Theory of Operation
1-2
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Center Cross Section
Duplex Option Theory of Operation
2. Center Cross Section
[2]
[1]
[4]
[3]
[1] Duplex Option Conveyance Roll 1
[2] Duplex Option Conveyance Roller 1
[3] Duplex Option Conveyance Roller 2
[4] Duplex Option Conveyance Roll 2
2-2
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Mechanical Operations
Duplex Option Theory of Operation
4. Mechanical Operations
4.1 Reversing mechanism
4.1.1
Reversing operation
• The 1-sided printed page is subjected to a reversing operation performed by the Exit
Roller in the machine and conveyed into the Duplex Option.
Conveyed into the Duplex Option
Exit Roller
4.1.2
Paper exit roller drive coupling mechanism
• When the Duplex Option is mounted, the leading edge of the Duplex Option Lever raises
the Idle Lever, thus disconnecting the drive from the machine. The Exit Roller is driven by
the Duplex Reverse Motor.
Duplex Reverse
Motor (M2 DU)
Idle Lever
Duplex Option Lever
Exit Roller
4.1.3
Reverse Motor Control
• The signal output from the Duplex Board is used to control rotation of the Duplex
Reverse Motor.
2-4
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Duplex Option Theory of Operation
Mechanical Operations
4.2 Conveyance and duplex paper feed mechanism
4.2.1
Conveyance and duplex paper feed operation
• The Duplex Conveyance Motor provides the drive for the Duplex Option.
Duplex Option Conveyance Roller 1
Duplex Conveyance
Motor (M1 DU)
Duplex Option Conveyance Roll
Duplex Option Conveyance Roll
Duplex Option Conveyance Roller 2
4.2.2
Duplex Option Conveyance Motor Control
• The signal output from the Duplex Board is used to control the rotation of the Duplex
Conveyance Motor.
2-5
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Mechanical Operations
Duplex Option Theory of Operation
4.3 2-sided printing method
• The following two types of 2-sided printing methods are available.
2-sided printing with a single sheet of paper resident in
the system
2-sided printing method
2-sided printing with two sheets of paper resident in the
system (for Letter and smaller sizes)
4.3.1
Process of 2-sided printing with a single sheet of paper resident in the
system
Operation 1
Exit Roller
• A sheet of paper is fed in and the image of the
second page of the print job is printed.
2
Operation 2
• Just before the 1-sided printed page moves
past the Exit Roller, the direction of rotation of
the Exit Roller is reversed and the 1-sided
printed page is conveyed into the Duplex
Option.
2
Operation 3
• The 1-sided printed page being transported
through the Duplex Option is stopped briefly
and then fed into the machine.
2
2-6
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Duplex Option Theory of Operation
Mechanical Operations
Operation 4
• The image of the first page of the print job is
printed on the 1-sided printed page fed out of
the Duplex Option.
1
2
Operation 5
2
• As the 2-sided printed page is being fed out of
the machine, the image of the fourth page of
the print job is printed on the second sheet of
paper.
1
4
• Steps 2 through 5 are repeated until all pages of the job are printed.
2-7
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Mechanical Operations
Duplex Option Theory of Operation
4.3.2 Process of 2-sided printing with two sheets of paper resident in the system
Operation 1
Exit Roller
• The first sheet of paper is fed in and the
image of the second page of the print job is
printed.
2
4538to2502c1
Operation 2
• Just before the 1-sided printed page moves
past the Exit Roller, the direction of rotation of
the Exit Roller is reversed and the first 1-sided
printed page is conveyed into the Duplex
Option.
2
• The second sheet of paper is fed alongside.
4538to2513c1
Operation 3
• The first 1-sided printed page is conveyed
through the Duplex Option.
• The image of the fourth page is printed on the
second sheet of paper fed alongside.
4
2
4538to2514c1
2-8
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Duplex Option Theory of Operation
Mechanical Operations
Operation 4
• Immediately before the second sheet of paper
exits the feed roller, the rotating direction of
the feed roller changes and the second sheet
of paper is transported into the Duplex
Option.
4
2
• The first sheet of paper is fed alongside
again. The second sheet of paper is fed
4538to2515c1
Operation 5
• The image of the first page is printed on the
first sheet of paper as it is fed again.
4
1
2
4538to2508c1
Operation 6
2
• The image of the third page is printed on the
second sheet of paper as the first sheet of
paper is discharged.
1
• The third sheet of paper is fed alongside.
3
4
4538to2509c1
Operation 7
4
3
• As the second sheet of paper is fed out of the
machine, the image of the sixth page of the
print job is printed on the third sheet of paper.
2
1
• Steps 6 through 7 are repeated until all pages
of the job are printed.
6
2-9
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