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IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off. 4. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 5. If the start key is pressed before the copier completes the warm-up period, keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed. 6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands.
HEALTH SAFETY CONDITIONS
1. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. 2. The RAM board on the main control board has a lithium battery which can explode if replaced incorrectly. Replace the battery only with an identical one. The manufacturer recommends replacing the entire RAM board. Do not recharge or burn this battery. Used batteries must be handled in accordance with local regulations.
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate the toner bottle or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductor according to local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations. 4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.
A204/A206/A207/A208/A210/A211 COPIER SERVICE MANUAL
The A204 copier is based on the A153 copier. The A206 copier is based on the A155 copier. The A207 copier is based on the A156 copier. The A208 copier is based on the A157 copier. The A210 copier is based on the A159 copier. The A211 copier is based on the A160 copier. Only the differences from the base copiers are described in the following pages. Therefore, this documentation should be treated as an insert version of the base copier's service manual, although it has a separate binder. It should always be utilized together with the base copier's service manual.
31 March 1997
SPECIFICATIONS
NOTE: Only items marked with V are different from A153, A155, A156, A157, A159, and A160 copiers. Configuration: Copy Process: Originals: Original Size: Copy Paper Size: Desktop Dry electrostatic transfer system Sheet/Book Maximum: A3/11" x 17" Maximum: A3/11" x17" (Paper trays) Minimum: A5/81/2" x 51/2" sideways (Paper trays) A4/11" x 81/2" sideways (LCT) A6/51/2" x 81/2" lengthwise (By-pass) Maximum: A3/11" x 17" Minimum: A5/81/2" x 51/2" (sideways) Paper tray: 52 ~ 128 g/m2, 14 ~ 34 lb By-pass: 52 ~ 157 g/m2, 14 ~ 42 lb LCT: 52 ~ 128 g/m2, 14 ~ 34 lb Duplex copying: 64 ~ 105 g/m2, 17 ~ 24 lb 4 Enlargement and 6 Reduction
A4/A3 Version 200% 141% 122% 115% 100% 93% 82% 75% 71% 65% 50% LT/DLT Version 200% 155% 129% 121% 100% 93% 85% 77% 74% 65% 50%
Duplex Copying: V Copy Paper Weight:
Reproduction Ratios:
Enlargement Full size
Reduction
1
Copier
1. SPECIFICATIONS
SPECIFICATIONS
31 March 1997
Power Source:
120 V/60 Hz: More than 12 A (for North America) 220 V ~ 240 V/50 Hz: More than 7 A (for Europe) 220 V/50 Hz: More than 7 A (for Asia) 110 V/60 Hz: More than 13 A (for Taiwan) 220 V/60 Hz: More than 7 A (for Saudi Arabia, Philippines)
V Power Consumption:
A204, A206, and A207 copiers Copier Only Full System 1.35 kW 1.40 kW 1.15 kW 1.21 kW 1.21 kW 1.23 kW 0.18 kW 0.20 kW A208, A210, and A211 copiers Copier Only Full System 1.35 kW 1.40 kW 0.90 kW 1.00 kW 0.98 kW 1.00 kW 0.16 kW 0.18 kW
Maximum Copying Warm-up Stand-by
NOTE: Full System Copier + ARDF (A663) + Paper Tray Unit (A549) + 20 Bin S/S (A664) V Noise Emission:
A204, A206, and A207 copiers Copier Only 1. Sound Pressure Level Operator position 64 dB (A) Standard position 59 dB (A) 2. Sound Power Level Copying 70 dB (A) Stand-by 42 dB (A) A208, A210, and A211 copiers Copier Only 63 dB (A) 58 dB (A) 69 dB (A) 43 dB (A)
NOTE: The above measurements were made in accordance with ISO 7779.
2
31 March 1997
SPECIFICATIONS
Dimensions:
A204 copier A208 copier A206 and A207 copiers A210 and A211 copiers Width 1,030 mm (40.6") 900 mm (35.5") 1,258 mm (49.6") 1,128 mm (44.5") Depth 655 mm (25.8") 655 mm (25.8") 655 mm (25.8") 655 mm (25.8") Height 606 mm (23.9") 606 mm (23.9") 606 mm (23.9") 606 mm (23.9")
Measurement Conditions 1) With by-pass feed table closed 2) With platen cover and copy tray attached 3) With LCT cover closed V Weight:
A204 copier A206 copier A207 copier A208 copier A210 copier A211 copier Weight NA 70 kg (154.3 lb) 78 kg (172.0 lb) 81 kg (178.6 lb) 69 kg (152.1 lb) 77 kg (169.8 lb) 79 kg (174.2 lb) EU 73 kg (160.9 lb) 81 kg (178.5 lb) 84 kg (185.2 lb) 72 kg (158.7 lb) 80 kg (176.4 lb) 82 kg (180.7 lb)
Zoom:
From 50% to 200% in 1% steps
V Copying Speed (copies/minute):
A4 sideways/ 11" x 81/2" 40 32 A3/11" x 17" 22/21 17/16 B4/81/2" x 14" 25 19
A204, A206, and A207 copiers A208, A210, and A211 copiers
V Warm-up Time:
A204, A206, and A207 copiers: Less than 250 seconds (20°C) A208, A210, and A211 copiers: Less than 110 seconds (20°C)
V First Copy Time:
Paper Feed Station 1st Tray 2nd Tray By-pass LCT A4/11" x 81/2" (sideways) A204, A206, and A207 copiers A208, A210, and A211 copiers 4.4 s (except for A207) 4.9 s (except for A211) 4.9 s 5.4 s 4.4 s 4.7 s 4.4 s 4.9 s
NOTE: In A207 and A211 copiers, the 2nd tray in the above table is called the 1st tray.
3
Copier
SPECIFICATIONS
31 March 1997
Copy Number Input: Manual Image Density Selection: Automatic Reset:
Ten-key pad, 1 to 999 (count up or count down) 7 steps 1 minute is the standard setting; it can be changed to a maximum of 999 seconds or no auto reset by SP mode.
V Copy Paper Capacity:
A204 copier A206 copier A207 copier A208 copier A210 copier A211 copier Paper Tray About 500 sheets x 2 About 500 sheets x 2 About 500 sheets x 1 About 500 sheets x 2 About 500 sheets x 2 About 500 sheets x 1 By-pass Feed About 40 sheets About 40 sheets About 40 sheets About 40 sheets About 40 sheets About 40 sheets LCT -- About 1,000 sheets About 1,000 sheets -- About 1,000 sheets About 1,000 sheets
- 500 sheets or less than 53 mm stack height NOTE: Paper tray By-pass feed 40 sheets or less than 4 mm stack height LCT - 1,000 sheets or less than 120 mm stack height Duplex Tray Capacity [A207/A211]: Toner Replenishment: V Optional Equipment: 50 sheets (30 sheets for A3/11"x17" 81 ~ 105g/m2, 21.5 ~ 27.9 lb paper) Cartridge exchange (415 g/cartridge)
· Platen cover · Document feeder · Paper tray unit with two paper trays · Paper tray unit with three paper trays · 10 bin micro sorter (for A208, A210, and A211 · · · · ·
· ·
copiers) 20 bin mini sorter 10 bin sorter stapler 20 bin sorter stapler 20 bin multi-position sorter stapler Sorter adapter (required when installing 20 bin mini sorter, 10 bin sorter stapler, 20 bin sorter stapler, or 20 bin multi-position sorter stapler for A208, A210, and A211 copiers) Key counter Tray heater
4
31 March 1997
SPECIFICATIONS
· Optical anti-condensation heater
(only for LT/DLT version) · ADS sensor for particular types of red original
·
Specifications are subject to change without notice.
5
Copier
· Original length sensor for 11" x 15" size paper
MACHINE CONFIGURATION
31 March 1997
2. MACHINE CONFIGURATION
2.1 COPIER
A204V500.wmf
6
31 March 1997
MACHINE CONFIGURATION
2.2 OPTIONAL EQUIPMENT
Copier
A204V501.wmf
7
MECHANICAL COMPONENT LAYOUT
31 March 1997
3. MECHANICAL COMPONENT LAYOUT
A207 copier 5 6 7 8 9 10 11
4 3 2 1 38 37 36 35 34 33 32 31 30
12 13 14 15 16 17 18 19 20
21 22 29 28 27 26 25 24 23
A204V502.wmf
The fusing unit has been changed. (See Detailed Descriptions for more information.) NOTE: 1) The A204 copier is the same as the A207 copier except that the A204 does not have a duplex tray or an LCT. 2) The A206 copier is the same as the A207 copier except that the A206 does not have a duplex tray.
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31 March 1997
MECHANICAL COMPONENT LAYOUT
A211 copier
5
6
7
8
9
10
11
4 3 2 1 38 37 36 35 34 33 32 31
12 13 14 15 16 17 18 19 20
21 30 29 28 27 26 25 24 23
A204V503.wmf
22
The paper tray unit has been changed from the corner separation system to the FRR feed system. NOTE: 1) The A208 copier is the same as the A211 copier except that the A208 does not have a duplex tray or an LCT. 2) The A210 copier is the same as the A211 copier except that the A210 does not have a duplex tray.
9
Copier
MECHANICAL COMPONENT LAYOUT
31 March 1997
1. 3rd Mirror 2. 2nd Mirror 3. 1st Mirror 4. Exposure Lamp 5. Lens 6. Quenching Lamp 7. Drum Cleaning Blade 8. Drum Charge Roller 9. 6th Mirror 10. OPC Drum 11. Erase Lamp 12. 4th Mirror 13. 5th Mirror 14. Toner Supply Unit 15. Pre-transfer Lamp 16. Development Unit 17. Registration Rollers 18. Feed Roller 19. Pick-up Roller
20. Separation Roller 21. Large Capacity Tray 22. Vertical Transport Rollers 23. Paper Feed Roller 24. Friction Pad 25. Duplex Friction Roller 26. Duplex Feed Roller 27. Jogger Fence 28. Transfer Belt 29. Transfer Belt Cleaning Blade 30. Lower Paper Tray 31. End Fence 32. Entrance Rollers 33. Pick-off Pawls 34. Pressure Roller 35. Hot Roller 36. Junction Gate 37. Hot Roller Strippers 38. Exhaust Fan
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31 March 1997
ELECTRICAL COMPONENT DESCRIPTIONS
Refer to the electrical component layout and the point to point diagram on the waterproof paper in the pocket for symbols and index numbers. V : New or modified components
Symbol Name Printed Circuit Boards Main Control PCB1 PCB2 PCB3 PCB4 PCB5 PCB6 PCB7 PCB8 PCB9 PCB10 PCB11 Function Index No.
Controls all copier functions both directly or through other control boards. AC Drive Provides ac power to the exposure lamp and fusing lamps. DC Power Supply Provides dc power. Main Motor Control Controls the rotation of the main motor. CB High Voltage Supply Supplies high voltage to the drum charge roller and development roller. T High Voltage Supply Supplies high voltage to the transfer belt. Operation Panel Controls the LED matrix, and monitors the key matrix. Noise Filter (220 ~ 240 Removes electrical noise. V machines only) Duplex Control Controls the operation of the duplex tray. (Duplex machines only) Liquid Crystal Display Controls the guidance display and displays (A207 machines only) guidance for machine operation. LCT Interface Interfaces the LCT control signal between (LCT machines only) the main board and the LCT.
13 11 10 94 1 52 3 8 60 6 100
Motors M1 M2
Main Toner Bottle Drive Upper Tray Lift (Non-duplex machines only) Lower Tray Lift LCT Lift (LCT machines only) Optics Cooling Fan 1 Optics Cooling Fan 2 Exhaust Fan 1
V M3
V M4 M5 M6 V M7 M8
Drives the main unit components. Rotates the toner bottle to supply toner to the toner supply unit. Raises the bottom plate in the upper paper tray. V A204/206/208/210: M3 and M4 are combined into one unit Raises the bottom plate in the lower paper tray. Lifts up and lowers the LCT bottom plate. Removes heat from the optics unit. Removes heat from the optics unit. V A208/210/211 now have two fans. Removes the heat from around the fusing unit.
85 76
95
83 97 92 93 87
11
Copier
4. ELECTRICAL COMPONENT DESCRIPTIONS
ELECTRICAL COMPONENT DESCRIPTIONS
31 March 1997
Symbol M9 M10 M11 M12 M13 M14 M15 M16 V M17
Name Exhaust Fan 2 (A204/A206/A207 machines only) Scanner Drive 3rd Scanner Drive Lens Vertical Drive Lens Horizontal Drive Duplex Feed (Duplex machines only) End Fence Jogger (Duplex machines only) Side Fence Jogger (Duplex machines only) DC Board Cooling Fan Motor (A204/A206/A207 N. American models)
Function Removes the heat from around the fusing unit. Drives the 1st and 2nd scanners (dc stepper motor). Drives the 3rd scanner (dc stepper motor). Shifts the lens vertical position. Shifts the lens horizontal position. Drives the feed roller and moves the bottom plate up and down. Drives the end fence jogger to square the paper stack. Drives the side fence jogger to square the paper stack. Removes heat from the dc power supply board.
Index No. 88 90 75 84 74 55 58 57 86
Sensors S1 S2 S3 By-pass Feed Paper Informs the CPU what width paper is in the Width by-pass feed table. By-pass Feed Paper End Informs the CPU that there is no paper in the by-pass tray. Upper Tray Paper End Informs the CPU when the upper paper (Non-duplex machines tray runs out of paper. only) Upper Relay Detects the leading edge of paper from the upper tray to determine the stop timing of the upper paper feed clutch, and detects misfeeds. Upper Tray Upper Limit Detects the height of the paper stack in the (Non-duplex machines upper paper tray to stop the upper tray lift only) motor. V A208/210/211 have the components needed for an FRR mechanism. Lower Tray Paper End Informs the CPU when the lower paper tray runs out of paper. Lower Relay Detects the leading edge of paper from the lower paper tray to determine the stop timing of the lower paper feed clutch, and detects misfeeds. Lower Tray Upper Limit Detects the height of the paper stack in the lower paper tray to stop the lower tray lift motor. V A208/210/211 have the components needed for an FRR mechanism. 26 30 48
S4
105
V S5
28
S6
49
S7
104
V S8
29
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31 March 1997
ELECTRICAL COMPONENT DESCRIPTIONS
Symbol S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21
Name LCT Lower Limit (LCT machines only) LCT Paper End (LCT machines only) LCT Upper Limit (LCT machines only) Registration
Image Density (ID) Toner Density (TD) Lens Horizontal HP Lens Vertical HP Scanner HP 3rd Scanner HP Original Length-2
Function Index No. Sends a signal to the CPU to stop lowering 98 the LCT bottom plate. Informs the CPU when the LCT runs out of 99 paper. Sends a signal to the CPU to stop lifting 25 the LCT bottom plate. Detects the leading edge of the copy paper to determine the stop timing of the paper 27 feed clutch, and detects misfeeds. Detects the density of various patterns on 47 the drum during process control. Detects the toner concentration inside the 50 development unit. Informs the CPU that the lens is at the 36 horizontal home position. Informs the CPU that the lens is at the 19 full-size position. Informs the CPU when the 1st and 2nd 14 scanners are at the home position. Informs the CPU when the 3rd scanner is 23 at the home position. 20 42 15
S22 S23 S24 S25 S26
S27 S28
Detects the length of the original. This is one of the APS (Auto Paper Select) sensors. Fusing Exit Detects misfeeds. Platen Cover Informs the CPU whether the platen cover is up or down (related to APS/ARE functions). ARE: Auto Reduce and Enlarge Toner End Instructs the CPU to add toner to the toner supply unit, and detects toner end conditions. Auto Response Returns the operation panel display and exits from the energy saver mode. Transfer Belt Contact HP Informs the CPU of the current position of both the transfer belt unit and the drum charge roller unit. Auto Image Density Detects the background density of each (ADS Sensor) original in ADS mode. Original Width Detects the width of the original. This is one of the APS (Auto Paper Select) sensors. Original Length-1 Detects the length of the original. This is one of the APS (Auto Paper Select) sensors. Duplex Paper End Detects paper in the duplex tray. (Duplex machines only)
51 40 22 12 41
18 53
13
Copier
ELECTRICAL COMPONENT DESCRIPTIONS
31 March 1997
Symbol S29 S30 S31 S32 S33
Name Duplex Turn (Duplex machines only) Duplex Entrance (Duplex machines only) Side Fence Jogger HP (Duplex machines only) End Fence Jogger HP (Duplex machines only) Original Length (Option for N. American models)
Function Detects the trailing edge of the copy paper to determine the jogging timing, and detects misfeeds. Detects misfeeds. Detects the home position of the duplex side fence jogger. Detects the home position of the duplex end fence jogger. Detects original length for 11" x 15" paper.
Index No. 54 59 56 61 21
Switches SW1 SW2 By-pass Feed Table Tray Down (LCT machines only) Upper Tray Paper Size (Non-duplex machines only) Detects whether the by-pass feed table is open or closed. Sends a signal to the CPU to lower the LCT bottom plate. Determines what size of paper is in the upper paper tray, and detects when the tray has been closed. V The upper tray switch has been eliminated. Determines what size of paper is in the lower paper tray, and detects when the tray has been closed. V The lower tray switch has been eliminated. Detects whether the vertical guide is open or not. Detects whether the LCT cover is open or not. Cuts the dc power line of the LCT lift motor. Supplies power to the copier. Cuts the ac power line and detects whether the front door is open or not. Cuts the ac power line and detects whether the exit cover is open or not. 32 102
V SW3
24
Lower Tray Paper Size V SW4
33
SW5 SW6 SW7 SW8 SW9 SW10
Vertical Guide Set (Non-LCT machines only) LCT Cover-1 (LCT machines only) LCT Cover-2 (LCT machines only) Main Front Cover Safety Exit Cover Safety (A211 machines only)
31 103 101 39 38 45
Magnetic Clutches Toner Supply CL1 CL2 Development
Turns the toner supply roller to supply toner to the development unit. Drives the development roller.
69 68
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31 March 1997
ELECTRICAL COMPONENT DESCRIPTIONS
Symbol CL3 CL4 CL5 CL6 CL7 CL8 Solenoids
91 70 71 73 81 82
Registration By-pass Feed Relay Upper Paper Feed (Non-duplex machines only) Lower Paper Feed
Starts paper feed from the lower paper tray.
SOL1
SOL2 SOL3
LCT machines: LCT/By-Pass Pick-up Solenoid Non-LCT machines: By-pass Pick-up Solenoid Junction Gate (Duplex machines only)
Picks paper up from the by-pass feed table. When paper is fed from the LCT, this solenoid assists SOL3.
72
Moves the junction gate to direct copies to the duplex tray or to the paper exit. Picks up paper from the LCT. Controls the up/down movement of the pick-up roller in the upper paper tray. V A208/210/211 have the components needed for an FRR mechanism. Controls the up/down movement of the pick-up roller in the lower paper tray. V A208/210/211 have the components needed for an FRR mechanism. Controls the up-down movement of the separation roller in the upper paper tray feed station. V A208/210/211 have the components needed for an FRR mechanism. Controls the up-down movement of the separation roller in the lower paper tray feed station. V A208/210/211 have the components needed for an FRR mechanism.
89 96
LCT Pick-up (LCT machines only) Upper Tray Pick-up (Non-duplex machines V SOL4 only) Lower Tray Pick-up V SOL5 Upper Tray Separation (Non-duplex machines V SOL6 only)
77
79
78
Lower Tray Separation V SOL7
80
Lamps Exposure V L1 Applies high intensity light to the original for exposure. V Modified - see the "Optics" section for details. 16
15
Copier
Name Transfer Belt Contact
Function Controls the touch and release movement of both the transfer belt unit and the drum charge roller unit. Drives the registration rollers. Starts paper feed from the by-pass feed table or LCT. Drives the relay rollers. Starts paper feed from the upper paper tray.
Index No.
ELECTRICAL COMPONENT DESCRIPTIONS
31 March 1997
Symbol V L2
Name Main Fusing
Secondary Fusing V L3 Pre-transfer L4 Quenching L5 Erase L6
Function Index No. Provides heat to the central area of the hot roller. 62 V Modified - see the "Fusing" section for details. Provides heat to both ends of the hot roller. 63 V Modified - see the "Fusing" section for details. Reduces the charge remaining on the drum surface before transfer. 4 Neutralizes any charge remaining on the drum surface after cleaning. After exposure, this eliminates the charge on areas of the drum that will not be used for the image.
5
2
Heaters Drum H1 Turns on when the main switch is off to keep the temperature around the drum charge roller at a certain level. Also prevents moisture from forming around the drum. Optics Anti-condensation Turns on when the main switch is off to (option) prevent moisture from forming on the optics. Lower Tray (option) Turns on when the main switch is off to keep paper dry in the lower paper tray.
35
H2 H3
43 34
Thermistors Main Fusing TH1 V TH2 TH3 TH4 Secondary Fusing (A208/A210/A211 machines only) Optics Drum Charge
Monitors the temperature at the central area of the hot roller. Monitors the temperature at the ends of the hot roller. V A204/206/207 have only one thermistor. Monitors the temperature of the optics cavity. Monitors the temperature of the drum charge roller.
66 67 44 46
Thermofuses Main Fusing TF1 V TF2 Secondary Fusing (A208/A210/A211 machines only)
Provides back-up overheat protection in the fusing unit. Provides back-up overheat protection in the fusing unit. V A204/206/207 have only one thermofuse.
65 64
16
31 March 1997
ELECTRICAL COMPONENT DESCRIPTIONS
Symbol TF3
17
Counters CO1 CO2 Total Key (option) Keeps track of the total number of copies made. Used for control of authorized use. The copier will not operate until it is installed. 37 N/A
Others CB1 TR1 CC1 Circuit Breaker (220 ~ 240 V machines only) Transformer (220 ~ 240 V machines only) Provides back-up high current protection for electrical components. Steps down the wall voltage to 100 Vac. This has been eliminated from all models. 9 7
17
Copier
Name Exposure Lamp
Function Opens the exposure lamp circuit if the 1st scanner overheats.
Index No.
PAPER FEED DRIVE LAYOUT
31 March 1997
5. PAPER FEED DRIVE LAYOUT
5.1 A204/A206/A207/A208/A210/A211
1
3
2
A204V504.wmf
Since A208, A210, and A211 have been changed to the FRR feed system, all models carry the same type of drive layout. 1. Upper Paper Feed Clutch Gear (A207/A211 only) 2. Lower Paper Feed Clutch Gear 3. Relay Clutch Gear
18
31 March 1997
PROCESS CONTROL
6.1 HALFTONE MODE
This mode is newly added. If the user selects the halftone mode function on the operation panel, the machine reduces the size of the exposure lamp voltage, development bias, and the drum charge voltage by the changes shown below. · Exposure Lamp Voltage: 1.0 V
· Development Bias: +80 V · Drum Charge Voltage: +300 V
6.2 ADS CORRECTION
V Five possible corrections can be selected from, where the base copier has only three. ADS correction
ADS Density SP5-106 Setting Copy Density Darkest V0 1 Darker 2 Normal 3 Lighter Lightest V4 Development Bias Correction Voltage 816 x (AR 0.85) + 60 816 x (AR 0.75) 816 x (AR 0.85) 816 x (AR 0.95) 816 x (AR 0.85) 60
Where AR (ADS Ratio) = VADS (original)/VADS (pattern)
19
Copier
6. PROCESS CONTROL
PROCESS CONTROL
31 March 1997
6.3 TONER SUPPLY CONTROL DURING COPYING
V The amount of toner supplied per unit of time (TS) has been changed from the base copier. Toner clutch on time is calculated by the following formula. Toner CL on time [ms] = where: S AT = = = TSC = V TS = = = S x AT x TSC / 100 TS (Formula 1)
Copy paper size [cm2] Amount of toner developed on the latent image per unit area 0.7 [mg/cm2] (constant) Toner supply coefficient [%] Amount of toner supplied per unit of time 0.217 [mg/ms] (for A204, A206, and A207 copiers) 0.183 [mg/ms] (for A208, A210, and A211 copiers)
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31 March 1997
PROCESS CONTROL
6.4 VR PATTERN CORRECTION
V The values in the ID correction column of the table have been changed. VR correction
±0 V 74 ~ 100 VRP/VRG 53 ~ 73 x 100 (%) 41 ~ 52 31 ~ 40 0 ~ 30 ID Correction 40 V 80 V 68 ~ 100 50 ~ 67 37 ~ 49 26 ~ 36 0 ~ 25 62 ~ 100 43 ~ 61 26 ~ 42 19 ~ 25 0 ~ 18 Drum Charge Roller Correction Voltage ±0 V 40 V 80 V 120 V 160 V Development Bias Correction Voltage ±0 V 40 V 80 V 120 V 160 V
For example, taking the ID correction to be zero for now, if VRP/VRG is 45%, the drum charge and development bias corrections will both be 80 V. VR correction also depends on the current VSP pattern ID correction that is being used. If development bias has been increased by ID correction, the VR correction may be smaller in some cases to take this into account. This is shown by both the table above and the following diagram.
160 V V R Correction Voltage
120 V
ID correction 0 V 40 V 80 V
80 V
40 V
0 V
10 Drum residual voltage largel
20
30
40
50
60
70
80
90
100
V R P /V R G (%)
Drum residual voltage small
A204D505.wmf
Using the same example to illustrate this, but with an ID correction of 80 V, the corrections will both be 40 V this time.
21
Copier
PROCESS CONTROL
31 March 1997
6.5 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS
If any sensor errors occur under detect supply mode, toner supply mode is changed automatically as shown below.
Fallback Toner Supply Mode ID Sensor When ID sensor output Fixed Supply Mode Adjustment Error cannot be adjusted to 4.0 ± 0.2 V Fixed Supply Mode Abnormal ID Sensor If VSP > 2.5 V during VSP detection. (VSP) Fixed Supply Mode Abnormal ID Sensor If VSG < 2.5 V during VSG detection (VSG) TD Sensor When TD sensor Fixed Supply Mode Adjustment Error output cannot be adjusted to 2.5 ± 0.1 V TD Sensor (VT) If VT > 4.0 V or VT < Fixed Supply Mode Measurement Error 0.3 V during VT detection. Drum Charge Temperature detected Fixed Supply Mode Thermistor Error by the drum charge thermistor is below 0°C or above 60°C Temperature detected TD Sensor Supply V Abnormal Drum Mode Charge Thermistor by the drum charge thermistor is between Output 0°C and 14°C Error Abnormal Condition Display on Operation Panel None
None
Manual ID level or ADS indicator blinks Manual ID level or ADS indicator blinks None
None
NOTE: No indication is displayed under the "abnormal drum charge thermistor output" condition, because the machine soon recovers due to the heat inside the machine.
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31 March 1997
PROCESS CONTROL
6.6 TEMPERATURE CORRECTION
Copier
[A]
A204D506.wmf
V The temperature correction has changed as explained below. Also, the machine no longer does the drum rotation time correction. The temperature correction difference between the A204, A206, and A207 copiers and the A208, A210, and A211 copiers is a result of the difference in copy processing speed (240 mm/s for the A204, A206, and A207 copiers, compared with 200 mm/s for the A208, A210, and A211 copiers). The new drum charge roller needs only about half the correction voltage used for the base copier. Also, the level of correction needed for the lowest temperature point (5°C) is about the same as the normal room temperature point for the base copier [A]. In the base machine, rotation time correction was only needed for low temperatures where the temperature correction was large. In the new machines, the temperature correction is never greater than 300 V, so the rotation time correction has been eliminated.
23
PROCESS CONTROL
31 March 1997
The temperature corrections are as shown below. · Temperature Correction (Copying) - Base drum charge voltage = 1,500 V · Temperature Correction (VSP Pattern) - Base drum charge = 1,370 V A204, A206, and A207
Drum Charge Roller Temperature (°C) 35.0 T 28.0 T < 35.0 10.0 T < 28.0 T < 10.0 Temperature Correction VSP Pattern Copying +53 83.5 + 3.9T 217.6 + 8.7T 130.0 57.0 211.0 + 4.4T 410.0 + 11.5T 295.0
A208, A210, and A211
Drum Charge Roller Temperature (°C) 35.0 T 29.0 T < 35.0 10.0 T < 29.0 T < 10.0 Temperature Correction VSP Pattern Copying +47 51.0 + 2.8T 199.1 + 7.9T 120.0 61.0 173.0 + 3.2T 355.5 + 9.5T 260.0
24
31 March 1997
PROCESS CONTROL
6.7 TONER END RECOVERY
If the front cover switch or the main switch is turned off and on during a toner near-end/end condition, the machine will perform the toner end recovery procedure as shown on the flow chart on the next page. For the base copier, the toner end sensor checked for toner for a total of 10 seconds. The check stops when the toner supply clutch stops transporting toner. For the A204 series, the toner sensor checks for toner for a total of 14 seconds, stopping 2 seconds after the toner supply clutch stops. When the toner supply clutch stops, any toner present is likely to drop into the development unit, which will be detected during the final 2 seconds of detection time. This will decrease the chances of a mis-detection when a new toner bottle has been installed by the customer.
Copier
Toner Supply Clutch A153/A155/A156/ A157/A159/A160 Toner End Sensor
ON OFF ON OFF 10
2
Toner Supply Clutch A204/A206/A207/ A208/A210/A211 Toner End Sensor
ON OFF 5 2 5 2
ON OFF
2
A204D516.wmf
25
PROCESS CONTROL
31 March 1997
Toner End Condition Yes Front Cover Switch or Main Switch Turned OFF/ ON? Yes Drum Drive, Development Clutch, Toner Supply Clutch, Toner Bottle Drive Motor Turn On. t = 0s.
t 2s Yes
No
No Toner End Detection. Is Toner Present? Yes Components Turn Off. Toner End/Near End Condition is Canceled. No t 5s Yes
Drum Drive, Development Clutch, Toner Supply Clutch, Toner Bottle Drive Motor Turn Off.
Yes No Toner Supply Clutch, Toner Bottle Drive Turn Off. t 14s
No t 7s No Yes Yes Components Turn Off. Toner End/Near End Condition is Canceled. Toner End Detection. Is Toner Present?
Toner End Detection. Is Toner Present? Yes
No
Toner Supply Clutch, Toner Bottle Drive Turn On.
Components Turn Off. Toner End/Near End Condition is Canceled.
No Toner End Detection. Is Toner Present? Yes No t 12s Yes
Components Turn Off. Toner End/Near End Condition is Canceled.
A204D515.wmf
26
31 March 1997
PROCESS CONTROL
6.8 SUMMARY
NOTE: Only items marked with V are different or reviewed from A153, A155, A156, A157, A159, and A160 copiers. A summary of process control and correction timing is shown below.
Correction Manual ID correction Reproduction ratio correction V Halftone mode Electrical Component Operation panel Operation panel Sensor Output Used -- Correction Timing Forced Correction -- Automatic Correction Every copy in manual ID mode Every copy in reduce/enlarge mode Every copy in halftone mode Corrected Value · Lamp voltage · Dev. bias Development bias
--
--
Operation panel
--
--
· Lamp voltage · Dev. bias · Drum charge roller voltage Development bias
--
ADS correction
ADS sensor
VADS (pattern) VADS (original) New exposure
lamp, ADS sensor, after SP4-001 (Exposure lamp voltage adjustment) or optics cleaning
· ADS Mode: Once per original (ARDF mode), or once when the key is pressed (Platen mode)
Every 1,000 copies · VADS (pattern) is stored
ID correction and Toner density control
VSG ID sensor VSP TD sensor VT
New drum, ID sensor or ID sensor cleaning When the developer is changed
At the start of each copy job About every 10 copies Every copy
· Dev. bias · Toner supply clutch ON time
VR correction
ID sensor
VRP, VRG
New drum or ID After every 1,000 sensor replacement copies New drum, exposure lamp or after SP4-001 (Exposure lamp voltage adjustment) Every copy --
· Drum charge roller voltage · Dev. bias Lamp voltage
VL correction
ID sensor
VLP, VLG
V Temperature correction
Drum charge roller thermistor
T: (temperature)
Drum charge roller voltage
27
Copier
Development bias, drum charge voltage, and exposure lamp voltage
NOTE: Only items marked with V are different from A153, A155, A156, A157, A159, and A160 copiers.
The following table shows how process control affects development bias, drum charge, and exposure lamp voltages for various machine operations.
Drum Charge Voltage [V] Vexp + VL correction Exposure Lamp Voltage [V]
PROCESS CONTROL
Mode
ADS mode
Copying (1500) + + V Halftone Mode + C VR V Temperature + correction correction Vexp +
ID Level 1~6
Development Bias [V] Reproduction VR +B (240) + ADS correction + + ratio correction correction Reproduction VR Manual ID + + (240) + ratio correction correction correction
Manual ID mode
VL Manual ID + correction correction + V Halftone Mode
ID Level 7
+ V Halftone Mode + B Reproduction VR Lightest ID level + + (240) + ratio dev.bias correction correction
+ V Halfotone Mode + B (V 1370) + (1500) + +C 0 0 Vexp + V Temperature + CP correction 0 0 Vexp Vexp + VL correction 0 VL correction
28
VSP Pattern Detection
(300) + BP + ID correction
VR Pattern Detection VL Forced VL Pattern Detection Detection VL Detection
VR V Temperature + correction correction
Non Image Area
0 VR BL + + VBL (ID) correction VR + VBL (ID) BL + (25) + correction VR (200) + + VBL (ID) correction
Auto ADS Gain Adjustment
0
31 March 1997
NOTE: B = Development bias adjustment factor, selected with SP2-201-001. BP = Correction to the development bias used for making for VSP patterns, selected with SP2-203. BL = The value of the development bias that was reached during the most recently performed forced VL detection routine. VBL (ID) = ID compensation factor based on the current ID correction used for making VSP patterns. C = Correction to the drum charge voltage, selected with SP2-001. CP = Correction to the drum charge voltage for maknig VSP patterns, selected with SP2-003. Vexp = Exposure lamp voltage, selected with SP4-001.
31 March 1997
DRUM
7.1 DRUM CHARGE ROLLER CLEANING
V The cleaning interval and the cleaning time have been changed. The drum charge roller cleaning routine is executed at the following intervals: 1) For 2 seconds at the end of every job 2) V For 5 seconds after the copy job interval set by SP2-901. SP2-901 setting: 0: Every 1,000 copies (5 seconds) 1: Every 500 copies (5 seconds) [V new default] 2: Every 200 copies (5 seconds) 3: Every 100 copies (5 seconds) The effect of the change in the default setting is to do the cleaning more frequently.
29
Copier
7. DRUM
OPTICS
31 March 1997
8. OPTICS
8.1 OVERVIEW
8.1.1 Halogen Lamp V The specifications of the halogen lamp have been changed as follows. Note that the A204/A206/A207 models are faster, so they need more light during exposure.
A204/A206/A207 A208/A210/A211 115 V Machines 97 V 310 W V 97 V 200 W 230 V Machines 85 V 310 W V 85 V 280 W
V The halogen lamps installed in the A208/A210/A211 are the same as for the A153/A155/A156 copiers
8.1.2 Toner Shield Glass V The shield glass by the green filter above the drum has been removed (it is no longer needed). 8.1.3 Optics Cooling Fans V The optics cooling fan specifications have changed. Both models now have two fans; this is because the cpm for the A207/A210/A211 models has been increased from the previous models (27 32). Also the rotating speed has been changed as follows:
Rotating speed Rotating temperature Number of fans A204/A206/A207 3,450 rpm 45°C 2 A207/A210/A211 V 3,200 rpm 45°C 2
V The rotating speed of 3,200 rpm is as same as for the A153/A155/A156 copiers.
8.2 SCANNER DRIVE
V The scanner drive speeds have changed as follows. The first scanner drive speed in full size mode is: 240 (mm/s) for A204/A206/A207 copiers 200 (mm/s) for A208/A210/A211 copiers The first scanner drive speed for a selected reproduction ratio is: 240/M (mm/s) for A204/A206/A207 copiers 200/M (mm/s) for A208/A210/A211 copiers NOTE: M = Selected reproduction ratio (0.5 ~ 2.0)
30
31 March 1997
OPTICS
8.3 ADS SAMPLING DURING COPYING
Copier
A204D511.wmf
V The position of the sampling area has been changed (in the base copier, it was 60 mm from the edge and 38 mm wide).
31
PAPER FEED AND REGISTRATION
31 March 1997
9. PAPER FEED AND REGISTRATION
9.1 OVERVIEW
- A204/206/207/208/210/211 -
[C]
[A] [B]
A204D512.wmf
V All of the above-mentioned models use the FRR system. This model has three paper feed stations: the large capacity tray feed station [A] (LCT machines only), the upper paper tray feed station (non-duplex machines only), and the lower paper tray feed station [B]. The LCT holds 1,000 sheets of paper. The upper and lower paper trays are drawer trays that hold 500 sheets of paper. Paper can also be fed using the by-pass feed table [C], which uses the feed mechanism of the LCT feed station. The by-pass feed table can hold 40 sheets of paper. All feed stations use the FRR feed system. The top sheet of paper separates from the stack and is fed to the relay rollers, then to the registration rollers. There are two relay sensors, one located just under each set of relay rollers. These sensors are used for paper jam detection.
32
31 March 1997
IMAGE FUSING (A204/A206/A207 COPIERS)
10.1 OVERVIEW
13 12 11 3 1 2
4 5
6
10
9
8
7
A204D513.wmf
V 1. Thermofuse V 2. Oil Supply Roller V 3. Oil Supply Roller Cleaning Brush V 4. Main Fusing Lamp 5. Pressure Springs V 6. Hot Roller
7. Pressure Roller 8. Cleaning Roller V 9. Secondary Fusing Lamp 10. Fusing Exit Rollers 11. Fusing Exit Sensor 12. Hot Roller Strippers (7 pcs) V 13. Thermistor
The fusing unit for the A204/206/207 has several new features, which are described in the following pages. NOTE: The fusing unit for the A208/210/211 is the same as the fusing unit for the A153/155/156 except for the drawer connector (the shape for changed), and uses the same parts (hot roller, etc).
33
Copier
10. IMAGE FUSING (A204/A206/A207 COPIERS)
IMAGE FUSING (A204/A206/A207 COPIERS)
31 March 1997
10.2 OIL SUPPLY MECHANISM
[B]
[C]
[D] [A]
A204D517.wmf
The oil supply is necessary for a 40 cpm copier. An oil supply roller [A] is installed above the hot roller [B]. It is always in contact with the hot roller, and applies a light coat of silicone oil as the roller rotates. The oil supply roller is made of paper soaked with silicone oil wrapped around the shaft, and covered with PTFE (polytetra fluoroethylene) tube. As the temperature of the hot roller rises, the PTFE tube contracts and squeezes the oil-soaked paper, and the oil comes out through the coating. The oil supply roller cleaning brush [C] under the oil supply roller removes the toner and paper dust accumulated on the oil supply roller. The oil supply roller shaft is installed on a one-way bushing [D], to prevent collected toner from returning to the hot roller surface by the customer operating the fusing knob manually in the reverse direction.
34
31 March 1997
IMAGE FUSING (A204/A206/A207 COPIERS)
10.3 FUSING LAMP CONTROL
Copier
A204D514.wmf
There are two fusing lamps in the hot roller: the main fusing lamp (800 W) [A] and the secondary fusing lamp (350 W) [B]. The main fusing lamp has a much higher wattage that the one in the base copier, because it is the only lamp that is used during copying to control the operating temperature of the fusing unit (185°C). The secondary fusing lamp is only used in the following conditions to help achieve a faster warm-up time. · When the main switch is turned on · When exiting from the energy saver mode The new hot roller's metal core is thicker than the base copier's hot roller's. The new roller holds heat much better, to allow multicopying at the higher cpm of this model without the hot roller temperature dropping too far. However, it takes a lot longer to warm up after switching on (see the Warm-up Time in the Specifications section). The temperature is only monitored at the center; there is only one fusing thermistor. There is also only one thermofuse.
35
IMAGE FUSING (A204/A206/A207 COPIERS)
31 March 1997
When the main switch turns on, the CPU checks the mains frequency for 500 ms; this is done in case phase control mode is selected later. Then the CPU turns on the main fusing lamp. After 3 more seconds, the secondary fusing lamp is turned on. This delay reduces the surge current after the main switch is turned on. Both lamps are turned on to raise the temperature of the hot roller's surface. When the thermistor detects the operating temperature (185°C), the copier turns off the secondary fusing lamp, and starts fusing idling for 100 seconds to warm up the hot roller completely and evenly (the roller has a thicker metal core), and to distribute the oil. During fusing idling, the temperature is kept at 185°C. When fusing idling is finished, the copier enters the ready condition. The CPU keeps the temperature at 185°C by turning off and on the main fusing lamp. The lamp is turned off at 190°C, and on at 180°C. If the fusing lamp turns on while the exposure lamp is on, the power supplied to the exposure lamp may fluctuate, possibly degrading the copy quality. To prevent this, in this machine, the fusing lamp can either stay off or change from on to off while the exposure lamp is on. There are two types of fusing unit control: on/off control, and phase control. The mode can be selected with SP1-104.
36
31 March 1997
INSTALLATION
11.1 COPIER ACCESSORY CHECK
Check the accessories against the following list: Description Q'ty
1. Paper Size Decal.............................................................. 1 2. Symbol Explanation Decal (except for the A207 copier) ............................................. 1 3. Optional Zoom Function Decal ......................................... 1 4. Optional Margin Adjustment Function Decal .................... 1 5. Combine Originals Explanation Decal (except for the A207 copier) ............................................. 1 6. Receiving Tray.................................................................. 1 7. Operating Instructions (except for -27 machines) ............ 1 8. User Survey Card (-17 machines only) ............................ 1 9. New Equipment Condition Report .................................... 1 10. Cushion ............................................................................ 1
37
Copier
11. INSTALLATION
INSTALLATION
31 March 1997
11.2 COPIER INSTALLATION PROCEDURE
CAUTION Rating Voltage for Peripherals Make sure to plug the cables into the correct sockets.
A204I516.wmf
38
31 March 1997
INSTALLATION
A204/A206/A207 copiers
Copier
[C]
[A] [F] A206/A207/A210/A211 copiers
[B]
A204I500.wmf
[E] [D]
A208/A210/A211 copiers [C]
A204I501.wmf
[A] [F]
[B]
A204I502.wmf
[E]
NOTE: 1) Never lift the machine by holding the LCT, or the LCT will break. 2) Keep the shipping retainers after installing the machine. They will be reused if the machine is moved to another location in the future. 3) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage. It is most important to put back the scanner lock pin when transporting this copier. If not, skewed image may result. 1. Remove the scanner lock pin [A] and red tag [B] as shown. 2. Remove the strips of tape and the sheet of paper [C]. Also, for A206/207/A210/A211 copiers, remove the strip of tape on the LCT [D]. 3. Pull out the paper tray [E], and remove the strips of tape and the bottom plate stopper [F]. Then install the paper tray in the copier (1 tray for duplex machines and 2 trays for non-duplex machines).
39
INSTALLATION
31 March 1997
A207 copier [H] [F] [C] [B]
[I]
[A]
[D] [G] [F]
[B]
[E]
A204I503.wmf
A211 copier [H] [C] [F] [B]
[I] [A] [D] [G] [B] [F] [E]
A204I504.wmf
4. A207/A211 copiers only: 1) Pull out the duplex tray [A] and remove the strips of tape [B]. 2) Remove the guide roller stopper [C] and a sheet of paper [D]. 3) Open the upper duplex guide plate [E] and remove the strips of tape [F]. 4) Open the lower duplex guide plate [G], and remove the styrofoam support [H] and the sheet of paper [I]. 5) Install the duplex tray in the copier.
40
31 March 1997
INSTALLATION
[A]
[B] [B]
A204I505.wmf
[F]
A208/A210/A211 copiers [G] [A] [E]
[D]
A204I506.wmf
[B]
A204I507.wmf
5. Open the front cover and swing out the toner bottle holder [A]. 6. Remove the strips of tape [B]. 7. Remove the switch actuator lock bracket [C] as shown. 8. Turn the "A1" lever [D] counterclockwise to lower the transfer belt unit. Then remove the cushion sheet [E]. 9. Remove the blade release wedge [F] together with the pick off pawl release mylar [G]. 10. Return the "A1" lever to the set position.
41
Copier
A204/A206/A207 copiers [C]
INSTALLATION
31 March 1997
[D]
[C] [B] [A]
A204I508.wmf
[H]
[F]
[E]
[G]
A204I509.wmf
11. Remove the knob screw [A]. 12. Swing out the bottle holder [B] and pull down the lock lever [C]. Then slide out the bottle holder assembly [D] and swing out the bottle holder assembly [D]. 13. Remove the knob screw [E] and disconnect the white connector [F]. 14. Pull down the development unit lock lever [G] from under the plate and pull out the development unit [H]. Then place it on a clean sheet of paper.
42
31 March 1997
INSTALLATION
[B]
Copier
[A]
[F] [E]
A204I510.wmf
[C]
[D]
A204I511.wmf
15. Disconnect the connector [A] and separate the toner supply unit [B] from the development unit (2 screws). 16. Pour about half a pack of developer [C] into the development unit. Then rotate the outer gear [D] as shown to distribute the developer evenly. Then pour in all the remaining developer and rotate the gear again. NOTE: To prevent the developer from spilling, do not rotate the gears in the other direction. 17. Remount the toner supply unit on the development unit (2 screws) and connect the white connector. NOTE: Make sure that the positioning rib [E] sits in the groove [F]. 18. Install the development unit in the copier (1 knob screw and 1 connector).
43
INSTALLATION
31 March 1997
[A]
[C] [D] [B]
A204I512.wmf
19. Swing in the bottle holder assembly [A] so that the toner bottle holder [B] and the slide rail [C] are aligned straight. IMPORTANT: Do not swing the bottle holder fully into the machine before doing step 20. 20. Slide the bottle holder assembly in as described below: 1) Slide the bottle holder assembly into its lock position while pressing down the bottle holder lock lever [D]. 2) When the bottle holder assembly reaches its lock position, push up the bottle holder lock lever so that the knob screw holes are aligned. 3) Secure the bottle holder lock lever with the knob screw. NOTE: Do not swing the bottle holder assembly all the way into its original position in the machine without sliding and locking it into position exactly as described above. Otherwise, the assembly will be damaged. 21. Install a toner bottle by following the instructions placed on the reverse side of the front cover. 22. Swing in the toner bottle holder to its original position and close the front cover. 23. Plug in the copier and turn on the main switch.
44
31 March 1997
INSTALLATION
24. Enter SP mode as follows: 1) Press the key. 2) Enter "107" using the numeric keys. 3) Hold down the key for more than 3 seconds.
NOTE: When SP mode is selected, "1" blinks in the 3rd digit of the copy counter, the Auto Image Density indicator starts blinking, and the reduce/enlarge indicator turns off. 25. Perform the "TD sensor initial setting" SP mode as follows: 1) Enter "2" and press the key. 2) Enter "214" and press the key. 3) Press the key. NOTE: The machine will automatically stop when TD sensor initial setting is completed. (It takes about 2.5 minutes.) Then perform the "Compulsory toner supply" SP mode as follows: 1) Press the key twice. 2) Enter "2" and press the key. 3) Enter "207" and press the key. 4) Press the key.
A204I513.wmf
NOTE: The machine will automatically stop when compulsory toner supply is completed. (It takes about 30 seconds.) 5) Compulsory toner supply must be performed twice in order to supply enough toner to the toner hopper, so press the key again. 26. A207 copier only: Select the proper language for the guidance display as follows: 1) Press the key twice. 2) Enter "5" in the 3rd digit of the copy counter and press the key. 3) Enter "910" and press the key. 4) Enter the number for the desired language in the three-digit indicator and press the key. 1: English 2: French 3: German 4: Italian 5: Spanish 6: Swedish 7: Portuguese 8: Danish 9: Norwegian 10: Finnish 11: Dutch
27. Press the
key three times to exit SP mode.
45
Copier
INSTALLATION
31 March 1997
[A]
[B]
[C]
A204I518.img
A204I514.wmf
A204I517.wmf
28. Pull out the paper tray and load paper into it. (The paper size and direction for each tray should be as specified by the customer.) NOTE: The side and rear fences should be properly positioned. 29. Select the appropriate paper size for the paper trays in the main body by sliding the paper size slider into the correct position (see section 2.3.2 in the base copier manual, "Paper size selection for the copier paper trays" for details). 30. When a paper tray unit is installed: Enter the proper paper size for each paper tray by following the procedure shown in section 2.3 in the base copier manual, "Paper Size Selection" and in "Service Tables SP5-019: Paper Size Setting". 31. Load paper into the paper trays and the copy tray. 32. Attach the appropriate paper size decals [A] to the paper trays. Also (A207/A211 copiers only), attach the duplex decal to the duplex tray. NOTE: Paper size decals are used also for the paper tray unit. Save the remaining decals for use with the paper tray unit. 33. Attach the cushion [B] at the center of the LCT upper stay [C] as shown. NOTE: Make sure that the edge of the cushion is aligned with the line where the stay is bent at a slight angle.
46
31 March 1997
INSTALLATION
[C] [D]
[B]
A204I515.wmf
34. Install the optional platen cover [A] as follows if necessary: 1) Install 2 stud screws [B] on the top cover as shown. 2) Position the platen cover bracket [C] on the stud screws and slide it to the left. 35. All models except the A207: Attach the symbol explanation decal [D] to the top cover as shown. (If the ARDF will be installed, stick the decal on the ARDF exit cover. Refer to the ARDF installation procedure.) 36. Check the copy quality and machine operation.
47
Copier
[A]
INSTALLATION
31 March 1997
11.3 AUTO REVERSE DOCUMENT FEEDER (A663) ACCESSORY CHECK
Check the accessories against the following list: Description Q'ty
1. New Equipment Condition Report (Multi-language) ......... 1 2. Installation Procedure (English)........................................ 1 3. Stud Screw ....................................................................... 2 4. Philips Screw with Flat Washer - M4 x 10 ........................ 2 5. Sponge Retainer............................................................... 1
48
31 March 1997
INSTALLATION
[A]
[A]
[B]
A663I500.wmf
[E] [D]
[E] [I] [H]
A663I501.wmf
[F]
[C]
[G]
A663I502.wmf A663I503.wmf
CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape [A]. 2. Attach the sponge retainer [B] to the top cover of the copier as shown. 3. Tighten the two stud screws [C]. 4. Mount the ARDF by aligning the holes [D] in the ARDF and the stud screws [C], then slide the ARDF to the front as shown. NOTE: When mounting the ARDF, hold it by hand as shown in the illustration. Holding it in another way may damage the ARDF. 5. Screw the two stud screws [E] into the holes [F] and tighten them. 6. Connect the connectors [G] into the socket on the rear of the copier. 7. Attach the symbol explanation decal [H] and the combine originals explanation decal [I] to the ARDF as shown (except for the A207 copier).
49
Copier
11.4 AUTO REVERSE DOCUMENT FEEDER (A663) INSTALLATION PROCEDURE
INSTALLATION
31 March 1997
11.5 20-BIN SORTER STAPLER (A664) ACCESSORY CHECK
Check the accessories against the following list: Description Q'ty
1. Front Connection Bracket................................................. 1 2. Rear Connecting Bracket ................................................. 1 3. Cushion ............................................................................ 2 4. Entrance Guide Mylar for A204/A206/A207 copiers ....... 1 5. Entrance Guide Mylar for A208/A210/A211 copiers ....... 1 6. Proof Tray ........................................................................ 1 7. Caster Stopper ................................................................. 2 8. Relay Guide ..................................................................... 1 9. Philips Pan Head Screw - M4 x 12 ................................... 4 10. Philips Pan Head Screw - M4 x 6 ..................................... 2 11. New Equipment Condition Report (Multi-language) ......... 1 12. Staple Position Decal ....................................................... 1 13. Installation Procedure (English)........................................ 1
50
31 March 1997
INSTALLATION
[B] [A] [A]
[A] [B] [B] [A]
A664I500.wmf
[A]
[A]
[D]
A664I501.wmf
[E]
[C]
A664I502.wmf
CAUTION Unplug the copier power cord before starting the following procedure.
NOTE: 1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to another location. 2) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage. 3) A sorter adapter (A568) is required to install this sorter stapler in the A208/A210/A211 copiers. Before installing this sorter stapler, please install the sorter adapter. 1. Remove the strips of tape [A] and the cushions [B]. 2. Open the front door and remove the inner cover [C] (3 screws). 3. Remove the strips of tape [D] and remove the cushion [E]. Then re-install the inner cover [C].
51
Copier
11.6 20-BIN SORTER STAPLER (A664) INSTALLATION PROCEDURE
INSTALLATION
31 March 1997
A204/A206/A207 copiers
A208/A210/A211 copiers
[B] [C] [C]
[B]
[A]
A664I503.wmf
[A]
A664I504.wmf
A204/A206/A207 copiers
A208/A210/A211 copiers
[D]
[D]
[E] [E] [D]
A664I505.wmf
[D]
A664I506.wmf
4. Remove the two M4 x 8 round head screws [A] from the left cover of the copier. 5. Install the front connecting bracket [B] (2 screws M4 x 12) and the rear connecting bracket [C] (2 screws M4 x 12) on the copier. 6. Attach the entrance guide mylar [D] to the copier exit area, as shown. NOTE: 1) The entrance guide mylar differs depending on the model. 2) Align the edge [E] of the cover and the mylar.
52
31 March 1997
INSTALLATION
[A]
[C]
[D]
[B] [G]
A664I507.wmf
[H]
[E] [F]
A664I508.wmf
7. Attach the two cushions [A] as shown. 8. Install the relay guide [B] (2 screws M4 x 6). 9. Open the front door of the sorter stapler and remove the screw [C] securing the locking lever [D], then lower the locking lever. 10. Align and press the sorter stapler against the copier and secure them by raising the locking lever [E]. 11. Secure the locking lever (1 screw [F]). 12. Install the proof tray [G]. 13. Connect the connectors [H] to the sockets at the rear of the copier.
53
Copier
INSTALLATION
31 March 1997
[A]
A664I509.wmf
14. If the gap between the top of the sorter stapler and the copier is too great, adjust it by placing caster stoppers [A]. 15. Plug in the copier. 16. Turn on the main switch of the copier and test the operation of the sorter stapler. NOTE: The copier automatically recognizes that the sorter stapler has been installed.
54
31 March 1997
INSTALLATION
11.7 20-BIN SORTER STAPLER (A658) ACCESSORY CHECK
Check the accessories against the following list: Description Q'ty
Copier
1. Staple Position Decal ....................................................... 1 2. Chain ................................................................................ 1 3. Cap Remover ................................................................... 1 4. Philips Pan Head Screw - M4 x 14 ................................... 5 5. New Equipment Condition Report (Multi-language) ......... 1 6. Installation Procedure (English)........................................ 1 7. Stepped Screw ................................................................. 1
55
INSTALLATION
31 March 1997
11.8 20-BIN SORTER STAPLER (A658) INSTALLATION PROCEDURE
[A]
A658I500.wmf
A658I501.wmf
[C] [D] [B]
A658I508.wmf
CAUTION Unplug the copier power cord before starting the following procedure. When handling the sorter stapler, make sure to hold the parts shown [A]. Otherwise, the resulting damage may cause paper jams at the entrance.
NOTE: 1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to another location. 2) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage. 3) A sorter adapter (A568) is required to install this sorter stapler in the A208/A210/A211 copiers. Before installing this sorter stapler, please install the sorter adapter. 1. Remove the strips of tape and the shipping retainers as shown. 2. Open the front door [B] and remove the cardboard [C] and the strip of tape [D] from the staple unit. Close the front door.
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INSTALLATION
[A]
A658I502.wmf
[C]
[B]
A658I503.wmf
3. Remove the two plastic caps [A] from the copier left cover with nippers. 4. By releasing the open lever [B] of the sorter stapler, remove the sorter stapler mounting frame [C], as shown.
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Copier
INSTALLATION
31 March 1997
[C]
[E]
[F] [B]
[A] [G] [D]
A658I504.wmf
A658I505.wmf
[H]
A658I506.wmf
5. Remove the M4 x 8 round head screws (2 screws [A] for the A204/A206/A207 copiers, 3 screws [A] and [B] for A208/A210/A211 copiers) from the left cover of the copier. 6. Mount the sorter stapler mounting frame [C] on the copier as shown (4 screws M4 x 14 and 1 stepped screw [D]). NOTE: When hooking the sorter stapler mounting frame on the left side of the copier, make sure that the positioning hooks [E] on the frame are properly inserted in the positioning holes [F] in the copier. 7. Install the sorter stapler [G] on the frame (2 hinge pins at the rear) as shown. 8. Tighten the M4 x 14 screw [H]. NOTE: This screw prevents the sorter stapler from falling down.
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INSTALLATION
[A]
[B] [D]
Copier
[C]
A658I507.wmf
9. Connect the cable [A] and the optic cable [B]. 10. Install the chain [C] as shown. 11. Attach the staple position decal [D], as shown. 12. Plug in the copier. 13. Turn on the main switch of the copier and test the operation of the sorter stapler. NOTE: The copier automatically recognizes that the sorter stapler has been installed.
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SERVICE PROGRAM MODE
31 March 1997
12. SERVICE PROGRAM MODE
12.1 SERVICE PROGRAM MODE TABLE
1. Items written in bold italic letters are newly added service programs. 2. Items written in bold are modified service programs. 3. A "" after the mode name means that copies can be made while in this SP mode. 4. A "" after the setting in the "Settings" column means that the actual factory setting for this is written on the data sheet in the front cover. 5. A "°" before the mode number means that this mode can be accessed by sales representatives ( ). 6. A "·" before the mode number means that this mode can be accessed by users using a UP mode ( ). See "UP Mode/SP Mode Cross Reference Table". 7. In the Function column, comments (extra information) are in italics. 8. In the Settings column, the default values are printed in bold letters. 9. "RDS" means Remote Diagnostic System (not available in these models) "CSS" means Customer Support System (only available in Japan) 10. Type 1 = A204, A206, and A207 copiers Type 2 = A208, A210, and A211 copiers
12.1.1 Quick Reference The following is a quick reference list of the SP Modes.
Mode No. Function Paper Feed/Paper Transport/Fusing 1-001 Registration 1-003-xxx Paper Feed Timing 1-008 Misfeed Detection 1-103 Fusing Idling °1-104 Fusing Temperature Control 1-105-xxx Fusing Temperature Adjustments 1-106-xxx Fusing Temperature Display 1-108 Forced Start 1-801 CPM Down Select 1-902 Jogger Span Adjustment (Side Fence) 1-905 Jogger Span Adjustment (End Fence)
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Mode No. Around the Drum 2-001 2-002-xxx 2-003 2-101-xxx 2-201-xxx 2-203 2-206-xxx 2-207 2-208-001 2-208-002 2-208-003 2-214 2-215-xxx 2-220 2-222 2-301-xxx 2-801 2-802 2-812 2-901 2-902 Process Control 3-001 3-002 3-103-xxx 3-105 3-106 3-107 3-111 3-112 3-123 3-801 3-901 3-902 Optics 4-001 °4-002 4-008 4-011-xxx
Function Drum Charge Voltage Adjustment (for copying) Drum Charge Voltage Display Drum Charge Voltage Adjustment (for making VSP patterns) Leading/Trailing Edge Erase Margin Adjustment Development Bias Adjustments Development Bias Adjustment (for making VSP patterns) Development Bias Display Forced Toner Supply (shown as "Compulsory Toner Supply" on the display) Toner Supply Mode Selection Toner Supply Ratio (TD Sensor Supply Mode) Toner Supply Ratio (Fixed Supply Mode) TD Sensor Initial Setting TD Sensor Output Display TD Sensor Initial Output Display Toner Supply Ratio (Detect Supply Mode) Transfer Current Adjustments Factory Use Only: Do not change the settings. Developer Agitation Drum Charge Roller Temperature Drum Reverse Rotation Adjustment Drum Charge Roller Cleaning Interval Not used
ID Sensor Initial Setting ID Sensor Initial Setting Display ID Sensor Output Display Forced VL Detection Initial VLP/VLG Display Current VLP/VLG Display Current VRP/VRG Display Forced VR Detection Drum Initialize Auto Process Control Mode Selection Free Run (Exposure Lamp Off) Forced Process Control
Exposure Lamp Voltage Adjustment Exposure Lamp Voltage Display Vertical Magnification Adjustment Lens Horizontal HP Adjustments
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Mode No. 4-013 4-101 4-102 4-103 4-201 4-202 4-203 4-301 4-302 4-303 4-901 ·°4-902 Operation ·°5-001 ·°5-002 ·°5-003 ·°5-004 ·°5-013 ·°5-017 ·°5-019-xxx ·°5-021-xxx ·°5-022-xxx ·°5-101 ·°5-102 ·°5-103 °5-104 ·°5-106 ·°5-107-xxx ·°5-108 ·°5-110 °5-113 5-115 °5-121 ·°5-122-xxx 5-127 ·°5-305-001 °5-305-002 °5-401 ·°5-402 ·°5-404-xxx ·°5-405 ·°5-407-xxx
Function Scanner Free Run Horizontal Magnification Adjustment Lens Error Correction Focus Adjustment Auto ADS Gain Adjustment ADS Initial Gain Display ADS Actual Gain Display APS Sensor Function Check Optional APS Sensor (LT version only) APS A5/HLT Detection APS Size Priority (for F4 size) APS 8 k/16 k Detection (A4 versions only)
All Indicators ON Feed Station Priority Selection APS Priority Selection ADS Priority Selection Counter Up/Down Selection Maximum Copy Quantity (Copy Limit) Paper Size Set Duplex Priority Selection (Energy Star) Energy Star Selection Auto Reset Time Setting Auto Energy Saver Time Setting Auto Tray Shift A3/DLT Double Count Image Density Level Correction (ADS Correction) Image Shift Margin Adjustment Edge Erase Margin Adjustment Center Erase Margin Adjustment Coin Lock Installation Duplex Image Shift (Back Side Margin) T/C (Total Counter) Count Up Timing OHP Slip Sheet Mode Selection APS Detection Auto Shut Off Time Setting Auto Shut Off Selection User Code Mode User Code Counter Check User Code Counter Clear User Code Number Setting User Code Number Clear
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SERVICE PROGRAM MODE
Mode No. °5-408 ·°5-410 °5-501-001 °5-501-002 5-504 5-505 °5-507 5-801 5-802-xxx 5-803 5-804 °5-810 5-811 °5-812 °5-816 5-817 °5-905 ·°5-906 ·°5-907 ·°5-908 ·°5-909 ·°5-910 Peripherals ·°6-001 °6-003 °6-005 6-006-xxx 6-009 ·°6-010 ·°6-011 °6-101 °6-102 °6-104 6-105-xxx 6-107 Counters °7-001 °7-002 °7-003
Function Number of Registered User Codes Display User Code Reset Time Setting PM Interval Setting PM Interval Setting (PM Alarm Mode Setting) Used in Japan only. Do not change the factory setting. Used in Japan only. Do not change the factory setting. Used in Japan only. Do not change the factory setting. Memory All Clear Free Run Mode Input Check Mode Output Check Mode SC Reset Used in Japan only. Do not change the factory setting. Telephone Number Input (A207 copier only) Used in Japan only. Do not change the factory setting. Used in Japan only. Do not change the factory setting. APS A4/LT Sideways Priority Manual Staple Reset Time Setting Cover Mode Selection Image Shift/Erase Selection 10 key Zoom/Size Magnification Guidance Language Setting (A207 copier only)
SADF Auto Reset Time Setting Auto Sort Selection Blank Copy for Last Odd Originals in Duplex DF Registration Adjustment DF Free Run with Paper Auto APS Select (DF) Thick/Thin Original Mode Selection Sorter Installation Sorter Stack Limit Staple Sheet Limit Staple Position Adjustment Sorter Free Run Mode
Total Operation Time Display Total Original Counter Display Copy Charge Counter for RDS/CSS Display This is for use with features that are available only in Japan. However, it does show how many originals have been copied (total of DF mode + platen mode).
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Copier
SERVICE PROGRAM MODE
31 March 1997
Mode No. °7-004 °7-101-xxx °7-203 °7-204-xxx °7-205 °7-206 °7-301-xxx °7-401 °7-402 °7-501 °7-502 °7-503 °7-504-xxx °7-505-xxx °7-801-xxx °7-803 °7-804 °7-807-001 °7-807-002 °7-807-003 °7-808 °7-810 °7-811 °7-816-xxx
Function Initial Copy Counter Setting for RDS/CSS Display Thi