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SERVICE HANDBOOK DIGITAL COLOR COPIER
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FC-22
Copyright TOSHIBA CORPORATION 2000 ALL RIGHTS RESERVED
GENERAL PRECAUTIONS REGARDING THE INSTALLATION AND SERVICE FOR THE COPIER FC-22
The installation and service should be done by a qualified service technician. 1. Transportation/Installation · When transporting/installing the copier, move it by the casters while lifting the stoppers. The copier is quite heavy and weighs approximately 200 kg (441 lb), therefore pay full attention when handling it. · Be sure to use a dedicated outlet with AC 115V or 120V/20A (220V, 230V, 240V/10A) or more for its power source. · The copier must be grounded for safety. Never ground it to a gas pipe or a water pipe. · Select a suitable place for installation. Avoid excessive heat, high humidity, dust, vibration and direct sunlight. · Also provide proper ventilation as the copier emits a slight amount of ozone. · To insure adequate working space for the copying operation, keep a minimum clearance of 80 cm (32") on the left, 80 cm (32") on the right and 10 cm (4") in the rear. 2. Service of Machines · Basically, be sure to turn the main switch off and unplug the power cord during service. · Be sure not to touch high-temperature sections such as the exposure lamp, the fuser unit, the damp heater and their periphery. · Be sure not to touch high-voltage sections such as the chargers, the transfer belt and the highvoltage transformer. · Be sure not to touch rotating/operating sections such as gears, belts, pulleys, fan, etc. · When servicing the machines with the main switch turned on, be sure not to touch live sections and rotating/operating sections. Avoid exposure to laser radiation. · Use suitable measuring instruments and tools. · Avoid exposure to laser radiation during servicing. - Avoid direct exposure to the beam. - Do not insert tools, parts, etc. that are reflective into the path of the laser beam. - Remove all watches, rings, bracelets, etc. that are reflective. 3. Main Service Parts for Safety · The breaker, door switch, fuse, thermostat, thermofuse, thermistor, etc. are particularly important for safety. Be sure to handle/install them properly. 4. Cautionary Labels · During servicing, be sure to check the rating plate and the cautionary labels such as "Unplug the power cord during service", "Hot area", "Laser warning label" etc. to see if there is any dirt on their surface and whether they are properly stuck to the copier.
5.
Disposition of Consumable Parts/Packing Materials · Regarding the recovery and disposal of the copier, supplies, consumable parts and packing materials, it is recommended to follow the relevant local regulations or rules.
6.
When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise noted in this manual or other related documents. Be careful not to reassemble small parts such as screws, washers, pins, E-rings, star washers in the wrong places.
7. 8.
Basically, the machine should not be operated with any parts removed or disassembled. Precautions Against Static Electricity · The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband, because the ICs on it may become damaged due to static electricity. Caution: Before using the wristband, pull out the power cord plug of the copier and make sure that there are no uninsulated charged objects in the vicinity.
Caution Vorsicht
: :
Dispose of used RAM-ICs (including lithium battery) according to the manufacturer's instructions. Entsorgung des gebrauchten RAM-ICs (inklusive der Lithium-Batterie) nach Angaben des Herstellers.
In this manual, colors are sometimes shown in abbreviations as below: Yellow : Y ; Magenta : M ; Cyan : C ; Black : K
1. SPECIFICATIONS · ACCESSORIES · OPTIONS · SUPPLIES
1.1 Specifications
· Copy process · Type · Original table · Acceptable originals Indirect electrophotographic process (dry) Console type Fixed table (the left rear corner used for Standard original placement) Type: Sheets, books and 3-dimensional objects. However, the automatic document feeder only accepts sheets of paper (64~90 g/m2, or 17~24 lb.), excluding carbon paper, pasted sheets and stapled sheets. Size : A3/LD max. · Copy speed
Paper supply Cassette Paper size A4, LT B5, A5-R, ST-R A4-R, B5-R, LTR B4, LG A3, LD OHP sheets (A4, LT) Full bleed (12" x 18") 22 22 17 14 12 4 Bypass feeding Size specification Size specification YES NO 18 12 18 12 15 12 14 12 12 12 4 12 12
(Copies/min.)
LCF 22
* * * *
The copy speed is the same in both color and black modes. "" shows "Not usable". The copy speeds listed are available when originals are manually placed for single-side, multiple copying. When the document feeder is used, the copy speed of 22 sheets per minute is only available under the following conditions: · Original/Mode: Single-side originals of A4/LT size, not select auto color, APS, automatic density and advance image enhancement mode · Number of sheets set: 22 or over. · Paper feeding: · Reproduction ratio: LCF Actual ratio
*
Reverse side copying speed of the automatic duplexing unit (When specific paper size is selected) A4, B5, A5-R, LT, ST-R: 22 sheets/min. A4-R, B5-R, LT-R: B4, LG: A3, LD: 17 sheets/min. 14 sheets/min. 12 sheets/min.
1-1 FC-22 SPECIFICATIONS
January 2000 © TOSHIBA TEC
*
System copy speed Copy mode Single-sided originals Single-sided copies Single-sided originals Two-sided copies Two-sided originals Two-sided copies Two-sided originals Two-sided copies 1 set 3 sets 5 sets 1 set 3 sets 5 sets 1 set 3 sets 5 sets 1 set 3 sets 5 sets Copies/min. 16 19 20 4 9 12 4 9 12 12 17 19
*
Any of the left copy speeds includes the first copy time and is available when the corresponding copy mode is used and 10 A4-sized originals are set in the automatic document feeder. These values are attained in full color mode copying.
*
· Copy paper Cassette Duplex copy LCF A3~A5R A4, LT LD~ST-R 64~90g/m2, 17~24 lb. Bypass copy Remarks A3~A5-R Irregular or LD~ST-R arbitrary sizes can be set. 64~209g/m2 17~110 lb. index Recommended OHP film
Size Weight Special paper
· First copy time .................. Approx. 10 seconds or under (A4/LT, the first cassette, 100%) · Warming-up time ............... Approx. 9 minutes · Multiple copying ................ Up to 999 copies;entry by digital keys · Reproduction ratio ............. Actual ratio: Zooming: · Resolution/Gradation Read: Write: · Excluded image width 100±0.5% 25~400% in increments of 1% 600 dpi/256 gradation Corresponding to 9600 dpi x 600 dpi (primary scanning only : 16 division smoothing) Leading edge: 5.0±2.0 mm, Trailing edge: 2.5±2.0 mm Side edge: 2.0±2.0 mm to 4 pieces by installing optional cassettes) LCFOptional (Stack height 165 mm : Equivalent to 1500 sheets of 80 g/m2, 20 lb.) Bypass feeding: (Optional automatic document feeder) (Stack height 8 mm : Equivalent to 50 sheets of 80 g/m2, 20 lb.) B4, Folio, LG, Comp: A3, LD:
FC-22 SPECIFICATIONS 1-2
· Paper feeding .................... Automatic feeding: Copier's cassettes2 pieces standard (expandable up
· Capacity for originals ....................................... A4, A4-R, B5, B5-R, A5-R, LT, LT-R, ST-R: 50 sheets 35 sheets 25 sheets
January 2000 © TOSHIBA TEC
· Stacking capacity of sheets ... Paper weight 64~80 g/m2, 17~22 lb.: 50 sheets (Optional automatic duplexing unit) Paper weight 81~90 g/m2, 23~24 lb.: 40 sheets · Toner supplying ...................... Automatic toner-density detection and supply Toner cartridge replacing method · Density control ....................... Automatic density mode and manual density mode selectable in 11 steps · Weight .................................... Approx. 200 kg · Power requirements ............... AC 115V/16A, AC 220 240V/9A · Power consumption................ 2.0 kW or less (115V series, 200V series) The automatic document feeder, automatic duplexing unit and LCF are supplied with electric power through the copier. · Total counter........................... Mechanical counter (7 digit) · Dimensions ............................ See the figure below (W845 x D750 x H1000 mm)
*
1000 mm
750 mm 845 mm
January 2000 © TOSHIBA TEC
1-3
FC-22 SPECIFICATIONS
1.2 Accessories
Setup instructions Operator's manual Color copy guide PM sticker Setup report CS card Drum Operator's manual pocket Detouchable code Copy receiving tray Preventive maintenance check list Toner bag symbol sticker Warrantee sheet DF level up kit Cassette size plate for OHP film 1 pc. 1 pc. (not available for MJD) 1 pc. (not available for MJD) 1 pc. (for MJD) 1 set. (for NAD and MJD) 1 pc. (for MJD) 4 pcs. 1 pc. 1 pc. (for ASD, AUD and MJD) 1 pc. 1 pc. (for MJD) 1 pc. (for MJD) 1 pc. (for NAD) 1 pc. 1 pc.
* Machine version NAD: North America MJD: Europe AUD: Australia ASD: Asia
FC-22 SPECIFICATIONS
1-4
January 2000 © TOSHIBA TEC
1.3 Options
Platen cover Automatic document feeder (RADF) Automatic duplexing unit (ADU) Cassette module Slot cover Large capacity feeder (LCF) LCF kit 20-bin staple sorter Installation kit for staple sorter Staple cartridge External printer controller (Fiery Z4) Built-in printer controller (Fiery X4e) Video I/F kit for external controller connection Control panel kit for built-in controller Key copy counter Work table Work table kit AI board Damp heater kit Operator's manual (English, French, German, Spanish, Italian) Color copy guide (English, French, German, Spanish, Italian) GUIDE FC22 KA-2060PC MR-3006A, MR-3006E MD-5007, MD-5007N MY-1011, MY-1011N KE-FC22 MP-1501 KN-FC22L01 MG-2014 KN-FC22S01 STAPLE-400 KR-7037 KR-7038 KR-8005 KR-8006 MU-8, MU-10 KK-2460 KN-FC22W01 KR-2030 MF-FC22U, MF-FC22E MANUAL FC22
1.4 Replacement Units/Supplies
(1) Replacement units Electrophotographic processing unit (EPU) Transfer belt unit (TBU) Fuser unit Oil roller cartridge (2) Supplies Toner Y (Yellow) Toner M (Magenta) Toner C (Cyan) Toner K (Black) Toner bag PS-ZTFC22Y, PS-ZTFC22EY PS-ZTFC22M, PS-ZTFC22EM PS-ZTFC22C, PS-ZTFC22EC PS-ZTFC22K, PS-ZTFC22EK PS-TBFC22, PS-TBFC22E EPU-FC22 TR-BLT-FC22 FUSER-FC22-115/127/200 OIL-CTRG-FC22
January 2000 © TOSHIBA TEC
1-5
FC-22 SPECIFICATIONS
AI board KR-2030 Platen cover KA-2060PC
1.5 System List
Installation kit for staple sorter KN-FC22S01
Cassette (Standard) Cassette (Standard)
LCF kit KN-FC22L01
FC-22 SPECIFICATIONS
Control panel kit for built-in controller KR-8006 Automatic document feeder MR-3006A, MR-3006E
Built-in printer controller (Fiery X4e) KR-7038 Key copy counter MU-8, MU-10
Work table KK-2460 Work table kit KN-FC22W01
Staple cartridge STAPLE-400
20-bin staple sorter MG-2014
1-6
Large capacity feeder MP-1501
Cassette module MY-1011, MY-1011N
External printer controller (Fiery Z4) KR-7037 Slot cover KE-FC22 Automatic duplexing unit MD-5007, MD-5007N Video I/F kit for external controller connection KR-8005
January 2000 © TOSHIBA TEC
2. OUTLINE OF THE MACHINE
2.1 Sectional View [A] Front view (The drive system is illustrated in [B] and [C])
13 4 3 1 2 5 12 63 55 43 19 8 59 6 27 7 23 35 62 34 26 61 33 25 42 18 9 41 17 21 60 40 11 16 56 32 20 28 24 14 126, 127
54 58 22 53 57 10 52
114 113
15
109 105 103 107 119 118 120 117 108 121 104 106 110 115 116 122 123 125
83 64 65 66 67 111 112 69 47 39 50 76 30 45 37 48 74 51 77 31 46 38 49 75 29 44 36 68 78 80 81 82 85 102 73 71 101 86 88 72 79 102 101 91 92 90 95 94 93 102 101 87 84
70
89
124 102 101
January 2000 © TOSHIBA TEC
2-1
FC-22 OUTLINE OF THE MACHINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
Carriage 1 Exposure lamp Reflector Mirror 1 Thermostat Carriage 2 Mirror 2 Mirror 3 Lens CCD PC board Scanner control board Original glass Carriage fan SCM fan SIC fan Drum Y Drum M Drum C Drum K Developer sleeve (Magnetic roller) Y Developer sleeve (Magnetic roller) M Developer sleeve (Magnetic roller) C Developer sleeve (Magnetic roller) K Upper mixer Y Upper mixer M Upper mixer C Upper mixer K Lower mixer Y Lower mixer M Lower mixer C Lower mixer K Doctor blade Y Doctor blade M Doctor blade C Doctor blade K Scattered toner recovery roller Y Scattered toner recovery roller M Scattered toner recovery roller C Scattered toner recovery roller K
2-2
40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78
Cleaning blade Y Cleaning blade M Cleaning blade C Cleaning blade K Recovery blade Y Recovery blade M Recovery blade C Recovery blade K Toner recovery auger Y Toner recovery auger M Toner recovery auger C Toner recovery auger K Discharge LED Y Discharge LED M Discharge LED C Discharge LED K Main charger Y Main charger M Main charger C Main charger K Charger wire cleaner Y Charger wire cleaner M Charger wire cleaner C Charger wire cleaner K Image quality sensor Color registration sensor Transfer belt Transfer belt drive roller Transfer belt cleaning blade Transfer belt recovery blade Transfer belt toner recovery auger Suction charger Transfer belt contact/release motor Transfer belt driven roller Transfer roller Y Transfer roller M Transfer roller C Transfer roller K Transfer belt push-up mechanism
January 2000 © TOSHIBA
FC-22 OUTLINE OF THE MACHINE
79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122
Transfer transformer Registration roller Registration switch Bypass pick-up roller Bypass feed roller Bypass separation pad Bypass tray 1st cassette pick-up roller 1st cassette feed roller 1st cassette separation roller 1st cassette tray 1st cassette 2nd cassette pick-up roller 2nd cassette feed roller 2nd cassette separation roller 2nd cassette tray 2nd cassette Transport roller Cassette feed jam sensor Upper fuser roller Lower fuser roller Upper fuser lamp Lower fuser lamp Upper separation fingers Lower separation fingers Upper thermostat Lower thermostat Upper fuser roller thermistor Lower fuser roller thermistor Upper oil roller Upper cleaning roller Lower oil roller Lower cleaning roller Fuser unit exit roller Exit roller Exit sensor ADU/exit switching gate ADU transport roller 1 ADU transport roller 2
2-3
123 124 125 126 127
ADU transport roller 3 Toner bag Used toner transport unit (main unit side) OHP edge sensor OHP center sensor
January 2000 © TOSHIBA TEC
FC-22 OUTLINE OF THE MACHINE
[B] Front drive system
12 8 4 11 7 3 10 6 2 9 5 1
15
14
16 17 19 18
13
1 2 3 4 5 6 7 8 9 10
Toner motor Y Toner motor M Toner motor C Toner motor K Upper mixer Y Upper mixer M Upper mixer C Upper mixer K Lower mixer Y Lower mixer M
2-4
11 12 13 14 15 16 17 18 19
Lower mixer C Lower mixer K Wire cleaner drive unit Y Wire cleaner drive unit M Wire cleaner drive unit C Wire cleaner drive unit K Transfer belt contact/release motor Transfer belt home position switch Transfer belt limit switch
FC-22 OUTLINE OF THE MACHINE
January 2000 © TOSHIBA
[C] Rear drive system
4
2
1
3
49
5
10 11
12 13
19
39
38
40
23 22
42 26 25 24 36 21 14 6 15 7 16 8 17 9 18 20 37 27,28 50 45 36 30,31 29 48 47 32 46 44 46 43 46
41
36
36
January 2000 © TOSHIBA TEC
2-5
FC-22 OUTLINE OF THE MACHINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 36 37 38 39 40 41
Scan motor Drive belt Drive pulley Driven pulley Carriage drive wire Drum motor Y (drum Y) Drum motor M (drum M) Drum motor C (drum C) Drum motor K (drum K) Color developer motor Color developer drive belt Black developer motor Black developer drive belt Developer sleeve (magnetic roller) Y Developer sleeve (magnetic roller) M Developer sleeve (magnetic roller) C Developer sleeve (magnetic roller) K Used toner transport unit (EPU side) drive belt Transfer belt motor Transfer belt drive roller Registration roller Registration clutch Paper feed motor Feed path clutch Bypass feed roller Bypass feed clutch 1st cassette feed roller 1st cassette feed clutch 1st cassette tray-up motor unit 2nd cassette feed roller 2nd cassette feed clutch 2nd cassette tray-up motor unit Transport roller Fuser motor Upper fuser roller Upper cleaning roller Fuser exit roller Exit roller
2-6
42 43 44 45 46 47 48 49 50
Paper exit gate solenoid ADU transport roller 1 ADU transport roller 2 ADU transport roller 3 ADU transport drive belt Used toner transport motor Used toner transport unit (main unit side) drive belt Document motor Developer removal shutter open/close motor
FC-22 OUTLINE OF THE MACHINE
January 2000 © TOSHIBA
2.2 Location of Electrical Parts
[A] Arrangement of Various Units
Scanner unit
Laser optical unit
Processing unit Fuser unit Transfer/transport unit
Main unit
Rear side
January 2000 © TOSHIBA TEC
2-7
FC-22 OUTLINE OF THE MACHINE
[B] Scanner unit (B-1) Motors
M4 M3
M1
M2
Rear side
(B-2) Sensors and switches
[A4 series]
SEN2
APS-1, 2, 3 APS-R APS-C SEN1
Rear side [LT series]
APS-R APS-C SEN2 APS-1 APS-3 SEN1
Rear side
FC-22 OUTLINE OF THE MACHINE 2-8 January 2000 © TOSHIBA
(B-3) PC boards
FUS-SCN CCD DH1-1 SDV DH1-2
SCM
Rear side
(B-4) Others
THM02
EXP
LRG
Rear side
January 2000 © TOSHIBA TEC
2-9
FC-22 OUTLINE OF THE MACHINE
[C] Laser optical unit (C-1) Motors
M12
M13
M14
M11
Rear side
(C-2)PC boards
RLY
LDR-Y LDR-M LDR-C OPT LDR-K
Rear side
FC-22 OUTLINE OF THE MACHINE
2 - 10
January 2000 © TOSHIBA
[D] Processing Unit (D-1) Motors
M19 M20 M21 M22
Rear side
(D-2) Sensors, switches, thermistors and lamps
SW5-Y SW5-C SW5-M SW5-K ERS-Y THM1-M THM1-K THM1-Y THM1-C ERS-M ERS-C ERS-K
Rear side
SEN11-Y
SEN11-C SEN11-K
SW6-M SW6-K SW6-Y SW6-C
SEN11-M
January 2000 © TOSHIBA TEC 2 - 11
FC-22 OUTLINE OF THE MACHINE
[E] Transfer/transport unit (E-1) Motors, thermostats and heaters
M24
DH3-2
DH3-1
THMO1
Rear side
(E-2) Switches, PC boards and fuses
HVT-TB SW9 SW10
FUS-TBU
Rear side
FC-22 OUTLINE OF THE MACHINE
2 - 12
January 2000 © TOSHIBA
[F] Fuser unit
THMO3 THM2
LAMP1
THM3
THM4 THMO4
THM5 LAMP2
Rear side
[G] Main unit (G-1) Motors
M15 M16 M17 M18
M5 M6 M8 M27 M25 M34 M28 M35 M23 M10 M9 M29 M30 M31 M26 M7 M32 M33
Rear side
January 2000 © TOSHIBA TEC 2 - 13 FC-22 OUTLINE OF THE MACHINE
(G-2) Switches, clutches and solenoids
SW7-M SW7-Y SW7-K SW13
SW7-C
SW14 SW12 SW15
SW4 CL2 SW2-1 SW3 CL1 CL4 CL3-1
SOL2
SW2-2 SOL1
CL3-2
Rear side
(G-3) Sensors
SEN10 SEN8 SEN17 SEN7
SEN9 SEN4 SEN6-1 SEN3-1 SEN6-2 SEN3-2 SEN6-3 SEN5-1 SEN5-2
SEN16-F SEN15 SEN12
SEN16-R
SEN13
SEN18 SEN6-4 SEN14
Rear side
FC-22 OUTLINE OF THE MACHINE 2 - 14 January 2000 © TOSHIBA
(G-4) PC boards
Control panel
KEY DSP PNL
MTH SIC IMC
HVT-M-C HVT-M-M HVT-M-K HVT-M-Y
LGC
Rear side
(G-5) Others
PS INL PWC
SSR-L
NFL SSR-U BR
Rear side
January 2000 © TOSHIBA TEC 2 - 15
FC-22 OUTLINE OF THE MACHINE
2.3 Symbols and Functions of Various Devices
(1) Motors Symbol M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 SCN-MOT Scan motor DCM-MOT Document motor CRG-FAN (Fan, 80 square) Carriage fan motors SCM-FAN (Fan, 60 square) SCM fan motor IN-FAN (Fan, 60 square) SIC fan motor OUT-FAN (Fan, 60 square) SIC fan motor PU-FAN (Fan, 80 square) Ozone exhaust fan motor EX-FAN (Fan, 80 square) Fuser-unit exhaust fan motor POW-FAN (Fan, 80 mm square) Power-unit fan motor USTN-MOT Used toner transport motor POL-MOT Polygonal motor Y-TILT-MOT Tilt motor Y M-TILT-MOT Tilt motor M C-TILT-MOT Tilt motor C Y-TNR-MOT Toner motor Y M-TNR-MOT Toner motor M C-TNR-MOT Toner motor C K-TNR-MOT Toner motor K
FC-22 OUTLINE OF THE MACHINE 2 - 16 January 2000 © TOSHIBA
Name
Function Scans the carriages. Drives the original-width indicator. Cool the surroundings of the carriages. (2 pcs.) Cools SCM PC boards. Cools the SIC PC boards (suction). Cools the SIC PC boards (exhaust). Exhausts the ozone of copier. Cools the fuser unit. Cools the power unit. Transports used toner to the toner bag. Drives the polygonal mirror. Drives the parallel adjustment controls of the laser optical system (Y). Drives the parallel adjustment controls of the laser optical system (M). Drives the parallel adjustment controls of the laser optical system (C). Supplies toner (Y). Supplies toner (M). Supplies toner (C). Supplies toner (K).
Remarks (B-1) (B-1) (B-1) (B-1) (G-1) (G-1) (G-1) (G-1) (G-1) (G-1) (C-1) (C-1) (C-1) (C-1) (G-1) (G-1) (G-1) (G-1)
Symbol M19 M20 M21 M22 M23 M24 M25 M26 M27 M28 M29 M30 M31 M32 M33 M34 M35 Y-CLN-MOT
Name Wire cleaner drive motor Y M-CLN-MOT Wire cleaner drive motor M C-CLN-MOT Wire cleaner drive motor C K-CLN-MOT Wire cleaner drive motor K USSHT-MOT Developer removal shutter open/close motor LIFT-MOT Transfer belt contact/release drive motor FED-MOT Paper feed motor K-DEV-MOT Black developer motor C-DEV-MOT Color developer motor Y-DRM-MOT Drum motor Y M-DRM-MOT Drum motor M C-DRM-MOT Drum motor C K-DRM-MOT Drum motor K TRB-MOT Transfer belt motor FS-MOT Fuser motor TR1-MOT 1st cassette tray-up motor TR2-MOT 2nd cassette tray-up motor
Function Drives the main charger-wire cleaner (Y). Drives the main charger wire cleaner (M). Drives the main charger wire cleaner (C). Drives the main charger wire cleaner (K). Opens/closes the shutter to remove the used developer material. Drives to contact/release the transfer belt to/from the drums Y, M and C. Drives the paper feed roller and bypass feed roller. Drives the black developer unit. Drives the color developer units. Drives the drum (Y). Drives the drum (M). Drives the drum (C). Drives the drum (K). Drives the transfer belt. Drives the fuser unit. Drives the 1st cassette tray upward. Drives the 2nd cassette tray upward.
Remarks (D-1) (D-1) (D-1) (D-1) (G-1) (E-1) (G-1) (G-1) (G-1) (G-1) (G-1) (G-1) (G-1) (G-1) (G-1) (G-1) (G-1)
January 2000 © TOSHIBA TEC
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FC-22 OUTLINE OF THE MACHINE
(2) Solenoids Symbol SOL1 EXGAT-SOL Paper-exit gate solenoid SOL2 TLCV-SOL Drives the shutter for protecting the (G-2) Image quality sensor shutter solenoid image quality sensor. (3) Electromagnetic spring clutches Symbol CL1 CL2 RGST-CLT Registration clutch FDPS-CLT Feed path clutch CL3-1 CSFD-CLT (for 1st cassette) CL3-2 CSFD-CLT (for 2nd cassette) Feed clutch CL4 MNFD-CLT Bypass feed clutch (4) Switches and thermostats Symbol Name Function Detects the paper size of the cassette. Remarks (G-2) Drives the bypass pick-up roller. (G-2) Drives the cassette pick-up roller. (G-2) Drives the paper feed unit. (G-2) Name Function Drives the registration roller. Remarks (G-2) Name Function Drives the ADU/exit switching gate. Remarks (G-2)
SW2-1 CSPS-SW (for 1st cassette) SW2-2 CSPS-SW (for 2nd cassette) Paper-size switch SW3 SW4 UTCV-SW Side door open/close switch MNCV-SW Bypass unit open/close switch SW5-Y CLHOM-SW (Y) SW5-M CLHOM-SW (M) SW5-C CLHOM-SW (C) SW5-K CLHOM-SW (K) Wire cleaner home position switch SW6-Y CLLM-SW (Y) SW6-M CLLM-SW (M) SW6-C CLLM-SW (C) SW6-K CLLM-SW (K) Wire cleaner limit switch
Detects if the side door is open or closed. Detects if the bypass unit is open or not. Detects the home position of the main charger wire cleaning pad.
(G-2) (G-2) (D-2)
Detects the limit position of the main charger wire cleaning pad.
(D-2)
FC-22 OUTLINE OF THE MACHINE
2 - 18
January 2000 © TOSHIBA
Symbol
Name or not.
Function Detects if the developer cartridge is set
Remarks (G-2)
SW7-Y DVCR-SW (Y) SW7-M DVCR-SW (M) SW7-C DVCR-SW (C) SW7-K DVCR-SW (K) Developer cartridge detection switch SW9 SW10 SW12 SW13 SW14 SW15 TBUHOM-SW Transfer belt home position switch TBULM-SW Transfer belt limit switch EXDR-SW FRNCV-SW LEFCV-SW MAIN-SW Main switch THMO1 THERMO Thermostat THMO2 THERMO-SCN-310 Thermostat THMO3 THERMO-FU-310 (U) Upper fuser roller thermostat THMO4 THERMO-FU-310 (L) Lower fuser roller thermostat
Detects the home position of the transfer belt. Detects the limit when the transfer belt is released from drums Y, M and C. Detects if the paper-exit unit is open or Interlock switch to shut off the AC power Interlock switch to shut off the AC power Shuts off the AC power to the copier. Turns the drum damp heater ON/OFF. Prevents the exposure lamp from overheating. Prevents the upper fuser roller from over-heating. Prevents the lower fuser roller from overheating.
(E-2) (E-2) (G-2) (G-2) (G-2) (G-2) (E-1) (B-5) [F] [F]
Paper-exit unit open/close switch closed. Front cover switch (front door switch) when the front cover is open. Paper-exit unit switch (left door switch) when the paper-exit unit cover is open.
January 2000 © TOSHIBA TEC
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FC-22 OUTLINE OF THE MACHINE
(5) Sensors and thermistors Symbol APS-C APS-C APS-R APS-R Automatic original detection sensor APS-1 APS-1 APS-3 APS-3 APS-C APS-C APS-R APS-R Automatic original detection sensor CCD SEN1 SEN2 CCD-SEN CCD sensor HP-SEN Carriage home position sensor PLTEN-SEN Platen sensor SEN3-1 CSPEN-SEN (for 1st cassette) SEN3-2 CSPEN-SEN (for 2nd cassette) Cassette paper-empty sensor SEN4 MNPEN-SEN Bypass paper sensor SEN5-1 CSLIM-SEN (for 1st cassette) SEN5-2 CSLIM-SEN (for 2nd cassette) Cassette tray-up limit sensor SEN6-1 CSJAM-SEN (for 1st cassette) SEN6-2 CSJAM-SEN (for 2nd cassette) SEN6-3 CSJAM-SEN (for 3rd cassette) SEN6-4 CSJAM-SEN (for 4th cassette) Cassette-feed jam sensor SEN7 SEN8 SEN9 OHPE-SEN OHP edge sensor OHPC-SEN OHP center sensor PWA-F-SFB Bypass paper-width sensor SEN10 RGST-SEN Registration sensor Detects the paper width of the bypass tray. Detects if paper has reached the registration roller or not. (G-3) (G-3) Detects if paper or OHP is set. (G-3) Detects if paper or OHP is set. (G-3) Detects if there is paper in the bypass tray or not. Detects paper inside the cassette as well as detecting if the cassette tray is at its upper limit. Detects paper misfeeding. (G-3) (G-3) (G-3) Detects if the platen cover is open or closed. Detects if there is paper in the cassette or not. (G-3) (B-2) Detects the carriage home position. (B-2) Reads out information on originals. (B-3) Detects the size of original documents. (LT series) (B-2) Name (A4 series) Function Detects the size of original documents. Remarks (B-2)
APS-1,2,3 APS-1, 2, 3 (3-beam)
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Symbol
Name
Function Detects the toner density.
Remarks (D-2)
SEN11-Y ATTNR-SEN (Y) SEN11-M ATTNR-SEN (M) SEN11-C ATTNR-SEN (C) SEN11-K ATTNR-SEN (K) Auto-toner sensor THM1-Y DRM-THM (Y) THM1-M DRM-THM (M) THM1-C DRM-THM (C) THM1-K DRM-THM (K) Drum thermistor THM2 THM3 THM4 THM5 UHEC-THM UHEE-THM LHEC-THM LHEE-THM
Detects the surface temperature of the drum.
(D-2)
Detects the surface temperature in the Detects the surface temperature at the Detects the surface temperature in the Detects the surface temperature at the Detects paper in the paper exit area. Detects paper in the exit area of the ADU paper transport path. Detects if the used toner bag is full as well as detecting if it is set or not. Detects the amount of toner on the patch on the transport belt. Detects deviation in printed images.
[F] [F] [F] [F] (G-3) (G-3) (G-3) (G-3) (G-3)
Upper fuser roller thermistor (center) center of the upper fuser roller. Upper fuser roller thermistor (rear) rear of the upper fuser roller. Lower fuser roller thermistor (center) center of the lower fuser roller. Lower fuser roller thermistor (rear) rear of the lower fuser roller. SEN12 EXIT-SEN Exit sensor SEN13 ADUPS-SEN ADU path sensor SEN14 USFUL-SEN Toner bag limit sensor SEN15 TNLVL-SEN Image quality sensor SEN16-F POS-SEN (front) SEN16-R POS-SEN (rear) Color registration sensor SEN17 T&H-SEN Temperature/humidity sensor SEN18 USDSHP-SEN Developer removal shutter home position sensor Detects the temperature and humidity inside the copier. Detects the home position of the developer removal shutters. (G-1) (G-3)
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(6) Heaters and lamps Symbol EXP LRG Name EXPO-LAMP Exposure lamp PS-LRG-310 Lamp regulator DH1-1 DNP-HTR (for lenses) DH1-2 DNP-HTR (for mirrors) Damp heater DH3-1 DNP-HTR (paper feed side) DH3-2 DNP-HTR (paper exit side) Damp heater LAMP1 UP-LAMP Upper fuser lamp LAMP2 LOW-LAMP Lower fuser lamp ERS-Y ERAS-LED (Y) ERS-M ERAS-LED (M) ERS-C ERAS-LED (C) ERS-K ERAS-LED (K) Discharge LED lamp Removes residual charge on the drum surface. (D-2) Heats the lower fuser roller. [F] Heats the upper fuser roller. [F] Prevents condensation on the drum surface. (E-1) Prevents condensation in the scanner section. (B-3) Controls the exposure lamp. (B-4) Function Exposes the original. Remarks (B-4)
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(7) PC boards Symbol SIC Name PWA-F-SIC-310 SIC PC board LDR-Y PWA-F-LDR-310 (Y) LDR-M PWA-F-LDR-310 (M) LDR-C PWA-F-LDR-310 (C) LDR-K PWA-F-LDR-310 (K) Laser drive PC board (LDR board) OPT MTH LGC IMC RLY SCM CCD SDV DSP PNL KEY PWA-F-OPT-310 H-Sync signal detection PC board PWA-F-MTH-310 Mother board PWA-F-LGC-310 LGC PC board PWA-F-IMC-310 IMC PC board PWA-F-RLY-310 PWA-F-SCM-310 Scanner control PC board (SCM board) PWA-F-CCD-310 CCD PC board PWA-F-SDV-230 Scan motor drive PC board PWA-F-DSP-310 PWA-F-PNL-310 PWA-F-KEY-310 Control panel PC board DSP PC board PNL PC board KEY PC board (G-4) Controls the pre-processing of CCD image data. Controls the scan motor. (B-3) (B-3) Controls image processing and color registration. Relays between IMC and laser drive PC Controls the scanner section. (C-2) (B-3) (G-4) General control of the copier. (G-4) Relays between SIC and IMC. (G-4) Detects the position of laser beams. (C-2) Function Controls image processing and the control panel. Drives the lasers. (C-2) Remarks (G-4)
Laser relay PC board (RLY board) boards.
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(8) Transformers Symbol Name Function Produces high voltages for charging, development and discharging. Remarks (G-4)
HVT-M-Y PS-HVT-M-310 (Y) HVT-M-M PS-HVT-M-310 (M) HVT-M-C PS-HVT-M-310 (C) HVT-M-K PS-HVT-M-310 (K) Main high-voltage transformer HVT-TB PS-HVT-TB-310 Transfer transformer (9) Others Symbol SSR-U SSR (U) SSR-L SSR (L) Solid-state relay FUS-SCN PWA-F-FUS-351 (SCN) FUS-TBU PWA-F-FUS-351 (TBU) Fuse PC board PS PS-ACC-310JU (115V series) PS-ACC-310E (200V series) Switching power supply NFL FL-VU-220F (115V series) FILTER-ZSB2210 (200V series) Noise filter BR B-NK1D-110-20A (115v series) B-NRW10-10A-Y (200V series) Breaker INL PWC INLET-AP300-2A2 (200V series) Inlet CBL/P-152UC-1 (115V series) CBL/P-INLET-EUR (200V series) Power cable Name
Produces high voltages for transfer and suction.
(E-2)
Function Switches the upper and lower fuser lamps ON and OFF. Prevents over-current to damp heaters (scanner section, transfer/transport unit). Provides electrical power.
Remarks (G-5)
(B-3) (E-2) (G-5)
Cuts off noise.
(G-5)
Safety switch
(G-5)
Inlet Power cable
(G-5) (G-5)
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2.4 System Block Diagram
A/D Amp A/D
R
SCANNER IMAGE PROCESSING UNIT
Y/(R) M/(G)
CCD
Amp A/D
IMAGE PROCESSING UNIT
K B RGB
PWA-F-SIC-310
M(G) C(B) K
I/F PWA
A/D
G
C/(B)
Y(R)
Y(R) M(G) C(B) K
A/D Amp A/D
Fiery Color Printer Controller
PWA-F-SCM-310
PWA-F -PIF-310
ADF ADF DRAM 4MB
16
SIO
CPU
TMP95C063F (22MHz)
SIO
Device IO bus
IMAGE PROCESSING UNIT
32 SDRAM 8MB 16 EPROM 4MB
EPROM 4MB
DRV
PWA-F-LDR-310 LD
PWA-F-MAC-511 PRINTER IMAGE PROCESSING UNIT
16
PWA-F-RLY-310
DRV
PWA-F-LDR-310 LD
DRV Main Memory SDRAM (64MBx 2)
8
PWA-F-LDR-310 LD
CPU R4650 ASSP (100MHz)
DRV
32 27 Data Bus Address Bus
PWA-F-LDR-310 LD
SCANNER I/F(SIO)
OSC
PLL
PRINTER CONTROLLERI/F(SIO)
FlashROM 8MB
32 PCI Bus(33MHz)
Laser Beam Sensor PWA-F-OPT-310
SRAM 8KB
EPROM 1MB
Device IO bus
CPU
TMP95C063F 22MHz
PWA-F-IMC-310
MMF I/F( 14.4kbps)
ASIC (South bridge)
SIO
PRINTER I/F(SIO)
ASIC1
CPU
PWA-F-LGC-310
TMP95C063F 22MHz Device IO bus
Sorter
IPC
OPTION
LED Ctl LCD/Key I/F(SIO)
7 LCD 4 1 0
8 5 2
9 6 3
8
LCD Controller
ISA Bus
16
ASIC2
NVRAM+RTC (32KB)
SRAM 32KB
EPROM 4MB
NVRAM 32KB
ASIC3
SIO SIO
COPY
Control panel
ADU LCF
VRAM 32KB
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FC-22 OUTLINE OF THE MACHINE
2.5 Removal and Reinstallation of Covers, PC Boards and ROMs
2.5.1 Removal and reinstallation of covers [A] Right front cover (1) Open the right front cover. (2) Lift up 2 L-shaped pins out from the hinges. [B] Left front cover (1) Open the left front cover. (2) Lift up 2 L-shaped pins out from the hinges. [C] Middle inner cover (1) Draw out the processing unit. (2) Remove the middle inner cover (4 screws). [D] Right inner cover (1) Remove the right inner cover (3 screws). (2) Disconnect the connector of the temperature/ humidity sensor. [E] Left inner cover (1) Remove the left inner cover (4 screws). [F] Rear cover (1) Unscrew 9 screws. (2) Unlock the lower 3 hooks and remove the rear cover.
Left inner cover Left front cover
Right inner cover Right front cover
Middle inner cover
Hinges
Hinges
Processing unit
Hooks
[G] Feed-side upper cover (1) Open the bypass unit. (2) Remove the feed-side upper cover (4 screws). [H] Feed-side front and rear covers. (1) Remove the feed-side front cover (2 screws). (2) Remove the feed-side rear cover (3 screws).
Feedside front cover
Feedside upper cover Feedside rear cover
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[I] Exit-side upper cover (1) Shift the slide cover toward the rear to remove it. (2) Unscrew 3 screws and remove the exit-side upper cover. [J] Exit-side lower cover, front cover and rear cover, and paper-exit unit cover (1) Remove the exit-side lower cover (4 screws). (2) Remove the exit-side front cover (2 screws). (3) Remove the exit-side rear cover (2 screws). (4) Remove the paper-exit unit cover (6 screws).
Exit-side rear cover Exit-side front cover Paperexit unit cover Exit-side lower cover Exit-side upper cover Slide cover
[K] Right top cover (1) Remove the right top cover (3 screws).
Left top cover
Rear top cover
Right top cover
[L] Rear top cover (1) Remove the rear top cover (6 screws). [M] Left top cover (1) Remove the left top cover (3 screws).
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2.5.2 Removal of PC boards and ROMs This model is equipped with three PROMs and two flash ROMs (including one optional). Their loaded sites are as follows. SCM-ROM : SCM board (IC19) M-ROM IMC-ROM SYS-ROM AI-ROM : LGC board (IC56) : IMC board (IC30) : SIC board (IC90) : AI board (IC8) ; Optional
*SYS-ROM can be downloaded by FSMS with a personal computer. These ROMs can be removed and reinstalled in the following procedure if necessary. [A] LGC board/M-ROM (1) Remove the rear cover. (2) Disconnect 24 connectors. (3) Detach the M-ROM (IC56) on the LGC board. (4) Unscrew 2 screws, remove 4 lock supports and take out the LGC board.
M-ROM
Lock supports
[B] IMC board/IMC-ROM, SIC board/SYS-ROM and AI board/AI-ROM (1) Remove the feed-side upper cover and feedside upper inner cover (4 screws).
(2) Disengage the harness from 2 clamps. (3) Disconnect the connector from the fan. (4) Remove the metal shield cover (5 screws).
Clamps
Metal shield cover
FC-22 OUTLINE OF THE MACHINE 2 - 30 January 2000 © TOSHIBA TEC
(5) Disconnect 4 connectors of the SIC board, unscrew 2 screws and take out the SIC board with the AI board on it. (6) Detach the SYS-ROM (J190) from the SIC board. (7) Detach the AI-ROM (IC8) from the AI board. (8) Remove 4 lock supports and detach the AI board from the SIC board. (9) Disconnect 5 connectors of the IMC board, unscrew 2 screws and take out the IMC board. (10) Detach the IMC-ROM (IC30) from the IMC board.
AI board SIC board Lock supports AI-ROM SIC board SYS-ROM
IMC board
AI board SCM board
[C] SCM board (Scanner Control Board)/SCMROM (1) Remove the glass retainer (2 screws). (2) Remove the original glass. (3) Remove the right top cover (3 screws). (4) Remove the right top bracket (3 screws). (5) Remove the lens cover (9 screws and connector(s)). (6) Detach the SCM board, disconnecting 11 connectors and unscrewing 8 screws. (7) Detach the SCM-ROM (IC19) from the SCM board. * See Chapter 9 for the detail on the above procedure. [D] Main high-voltage transformer (1) Remove the rear cover. (2) Disconnect 5 connectors. (3) Unscrew 2 screws and remove the main highvoltage transformer together with its bracket. (4) Remove 2 screws and 2 lock supports and take out the main high-voltage transformer. * All 4 transformers should be removed using the same procedure.
SCM-ROM
Connectors
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[E] Switching power supply (1) Remove the rear cover. (2) Disconnect 8 connectors. (3) Unscrew 3 screws. (4) Take out the switching power supply.
Connectors Connector
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3. COPY PROCESS
3.1 Expression of Colors and 4-Step Copy Process
A variety of colors can be expressed by mixing the three primary colors : Yellow, magenta and cyan. Red can be created by mixing yellow and magenta; blue can be created by mixing magenta and cyan; green is created by mixing cyan and yellow; and mixing all the three primary colors allows you to obtain black.
Magenta Red Black Blue Cyan Green Yellow
With color copiers, a variety of colors are accomplished by mixing toners of the above three colors at proper ratios. However, there are no coloring agents available which exhibit ideal characteristics, so if you mix all the three colors made of available coloring agents, you cannot obtain a suitable black color. To improve the reproduction of black color, black toner is added to the mixture of the three colors. On this model, a 4-step copy process is employed to realize the color expression described above. In the 4-step copy process, four sets of the drum, developer unit, main charger, etc., corresponding to the four colors of yellow, magenta, cyan and black, are horizontally arranged along the paper path. Paper is passed through these units to allow the four colors to be overlaid for the appropriate expressions of colors.
[Three primary colors]
Main charger K
Main charger C
Main charger M
Main charger Y Developer unit Y
Developer unit K
Developer unit C
Developer unit M
Transfer belt
Drum K
Drum C
Drum M
Drum Y
January 2000 © TOSHIBA TEC
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FC-22 COPY PROCESS
3.2 General Description of Copying Process
Image processing
2
Original exposure Halogen lamp 180 W
3
Data reading (scanning) CCD
4
Data writing Semiconductor laser
600-dpi, 7500 pixel x 3 Pw=10.4 nJ/mm2
1
Charger (grid voltage) 550V (250~1000V) Toner Carrier
9
Discharge LED array Wavelength 660 nm x24 pcs
5
+ + + + + + + +
8
Conductive blade cleaning 700 VDC 1.0 kV/500 Hz AC
Photoconductive drum
Development Magnetic roller Bias 400 VDC (100 ~ 700) 1.2 kV/4kHz AC
7
Paper exit Fusing Heat roller 500 W x1, 400 W x1 (115V, 127V) 570 W x1, 460 W x1 (200V series)
++++
Bypass feeding Separation/transfer 700~1500 W (600~4800) (50 sheets) LCF feeding
6
(1500 sheets) Cassette feeding (600 sheets for each)
Charging: Places a negative charge on the surface of the photoconductive drum. Original exposure: Converts images on the original into optical signals. Data reading: The optical image signals are read into CCD and converted into electrical signals. Data writing: The electrical image signals are changed to light signals (by laser emission) which expose the surface of the photoconductive drum. Development: Negatively-charged toner is made to adhere to the photoconductive drum, producing a visible image.
Transfer/separation: Transfers the visible toner image onto paper, and separates the paper with the toner image from the photoconductive drum. Fusing: Fuses the toner image to the paper by applying heat and pressure. Conductive blade cleaning : While scraping off the residual toner from the drum, this blade also eliminates the (+) residual charge on the drum left after image transfer. Discharge LED array: Eliminates the residual () charge from the surface of the photoconductive drum.
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3.3 Details of Copying Process
(1) Photoconductive drum The photoconductive drum consists of two layers. The outer layer is a photoconductive layer made of an organic photoconductive carrier (OPC), and the inner layer is an aluminum conductive base in a cylindrical form. The photoconductive carrier has a special property: when it is exposed to light, the electrical resistance
Surface potential (V) Photoconductive layer Base Structure of the photoconductive drum (Example of OPC)
it possesses increases or decreases with the strength of the light. Example: · Strong incident light Decreases resistance (works as a conductor.) · Weak incident light Increases resistance (works as an insulator.) [Formation of electrostatic latent images] In the processes of charging, data reading, data writing, discharging described below, the areas on the drum corresponding to colored areas on the original are deprived of negative charge, while the areas on the drum corresponding to white areas retain negative charge, thus forming a negative charge image on the drum surface. As this negative charge image on the drum is not visible to the human eye, it is called an "electrostatic latent image."
Time (t)
0
Colored area of original
500
White area of original
1000
Discharge Charging process process
Electric potential of the photoconductive drum
Main charger
(2) Charging Charging is a process to apply some charge uniformly to the drum surface. The charger wire produces negative corona discharge, which is controlled by the grid so that the drum surface is uniformly charged with negative potential. The surface potential on the drum is determined by the grid potential and is controlled to a fixed value by the grid control circuit.
January 2000 © TOSHIBA TEC 3-3 FC-22 COPY PROCESS
Rotation of drum
High-voltage transformer
Grid control circuit
(3) Data reading (scanning) Data reading is the process of illuminating the original with light and converting the reflected light into electrical signals. The light reflected from the original is directed to the charge coupled device (CCD) and this optical image information is converted to electrical signals (image signals), which are then sent to the image processing section via the scanner control PC board. The CCD for color processing has RGB filters provided over its surface, which allow the CCD to read the light amount in the respective ranges of wavelength. The image data corresponding to the respective RGB colors is then sent to the image processing section.
(Example) CCD light receiving amount Light Value of image signals to be output 255 Image processing section CCD board Scanner control PC board
Dark
0
Difference between "light " and "dark" is divided into 256 steps.
(4) Data writing Data writing is the process of converting the image signals sent from the image processing section into light signals and exposing the drum surface with the light signal. Namely, the image signals sent from the image processing section are converted into optical signals (laser emission) by the semiconductor laser element, which are then used to expose the drum surface, thus forming an electrostatic latent image there.
Drum K
Image processing section
Laser drive PC board
Semiconductor laser element Polygonal mirror
Drum Y
Drum C
Drum M
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January 2000 © TOSHIBA TEC
(5) Development Development is the process of making the electrostatic latent images visible to the eye (visible image). Developer material is supplied to the photoconductive drum surface by means of a magnetic roller, allowing the toner in the developer material to adhere to the areas on the drum surface where the potential is lower than the developer bias which is applied to the magnetic roller (reverse development).
Drum Magnetic roller
Magnet Magnetic roller
Toner Carrier (always attracted onto the magnet) Toner
Bias voltage 400 VDC 1.2 kV/4 kHzAC
Toner Photoconductive drum
Photoconductive layer Aluminum base
White background
Half tone
Solid
White background
When the () potential of the photoconductive drum is higher than the developer bias.
600V
Image is not developed Bias voltage
400V
Image is developed by toner
300V
When the () potential of the photoconductive drum is lower than the developer bias.
200V
100V
0
January 2000 © TOSHIBA TEC
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FC-22 COPY PROCESS
· About developer material The developer material is comprised of a mixture of toner and carrier. The toner is charged to a negative polarity and the carrier to a positive polarity, due to the friction with each other caused by mixing. Toner : Mainly consists of resin and coloring. Carrier: Consists of ferrite, and over its surface resin coating to provide consistent frictional electrification.
Resin (90~95%) [Toner]
Coloring agent (5~10%)
5~20µm
Ferrite
30~100µm [Carrier]
Note: If the developer material is used for long periods of time (beyond its normal life span), toner will become caked onto the carrier. The carrier's (charging) performance is lowered. Result: 1. Image density is lowered. 2. Toner scattering occurs. 3. Background fogging occurs. Solution: Replace the developer material.
Where toner is caked, no frictional electrification occurs. Toner Carrier
· Magnetic roller - Magnetic brush development Inside magnetic rollers, the south and north poles are arranged as shown in the right figure. The deS
Lines of magnetic force
veloper material forms a brush-like fluff which contacts the photoconductive drum surface. This is caused by the lines of magnetic force between the south and north poles.
Photoconductive drum
N
S
Magnetic roller
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January 2000 © TOSHIBA TEC
(6) Transfer/separation · Transfer is the process of transcribing the toner image (visible image) formed on the photoconductive drum to the copy paper. 1. Transfer process A positive bias is applied to the transfer roller, causing the transfer belt to be positively charged. This in turn helps to form an electric field E between the transfer belt (positive) and the aluminum base of the photoconductive drum (grounded), thereby making the paper electrostatically polarized, as shown in the figure. An electrostatic attracting force occurs between the polarized charge (positive) on the upper surface of the paper and the toner (negative) on the photoconductive drum, thus making the toner image transferred to the paper. In the 4-step copy process of this model, images are transferred, in the order of Y M C K, onto the paper which is transported on the transfer belt.
Toner
Photoconductive drum
Transfer belt Paper
on toc o Ph ctive du m u dr base inum Alum ayer ive l duct n toco Pho
E Paper Transfer belt
Transfer roller
2. Separation process An electrostatic force occurs between the polarized charge (negative) on the underside of the paper and the transfer belt (positive), allowing the paper to be attracted to the belt and separated from the photoconductive drum.
January 2000 © TOSHIBA TEC
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FC-22 COPY PROCESS
(7) Fusing process Fusing is the process of melting the toner on the paper and fixing it firmly onto the paper. Method : The melting point of the toner (main component : resin) is 100~110°C. (Heat) Toner is melted by the heat emitted from the surfaces of both upper and lower fuser rollers.
Upper fuser roller Paper
Pressure Upper fuser roller Upper separation finger Upper fuser lamp Direction of paper movement
+
(Pressure) The lower fuser roller is pressed against the upper fuser roller by the springs to increase adherence of the melted toner to the paper. The paper is subjected to the heat and pressure when passing through both upper and lower fuser rollers. || (Fusing) The toner on the paper is fused to it.
(Pressure) Lower separation finger Lower fuser lamp Lower fuser roller
Surface potential of photoconductive drum
800V
(8) Conductive blade cleaning While eliminating the (+) charge on the photoconductive drum applied during the transfer stage, the conductive blade recovers the toner left on the drum
0
at the same time. · Elimination of transfer charge With this OPC photoconductive drum, (+) charge on their surface can not be eliminated optically. Therefore, () voltage is applied to the conductive blade, which is pressed against the drum, to eliminate the (+) charge applied at the transfer stage. · Cleaning The edge of the conductive blade is pressed against the photoconductive drum surface to scrape off residual toner from it. The toner thus removed is then caught by the recovery blade.
Recovery blade
FC-22 COPY PROCESS 3-8 January 2000 © TOSHIBA TEC
800V
Elimination of transfer Discharge Charging Transfer charge Conductive blade
Drum rotation
(9) Discharging process Discharging is the process of eliminating the () charge remaining on the photoconductive drum before the next charging process. If the charge remaining on the photoconductive drum is not eliminated, the following phenomena would occur: () charge remaining on the photoconductive drum surface causes uneven application of the charge for the next copying.
Ground Photoconductive drum Discharge LED array
The next copy will have a double image. (The preceding image will also be copied.) To prevent this : The entire surface of the photoconductive drum is flooded with light by the discharge LED array. The photoconductive drum becomes electrically conductive. All of the () charge remaining on the photoconductive drum is conducted away to ground (However, (+) charge is eliminated by the conductive blade as mentioned in (8)). Preparation for the next copying process is completed.
January 2000 © TOSHIBA TEC
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FC-22 COPY PROCESS
3.4 List of Copying Process Conditions
Process 1. Photoconductive drum (1) Sensitivity (2) Surface potential 2. Charging 3. Data writing (1) Light source (2) Light amount 4. Image control 5. Development (1) Magnetic roller (2) Auto-toner detection (3) Toner supply (4) Toner-empty detection (5) Toner OD-FC22 (OPC drum) (1) Highly sensitized drum (2) 550 V (grid voltage 600 V) Scolotron method 250~1000V (grid voltage) (adjusting by image quality control) (1) Semiconductor laser (adjustment not required) (2) 10.4 nJ/mm2 Image quality control by sensoring toner adhesion amount (1) One magnetic roller (2) Magnetic bridge-circuit method (3) Toner cartridge replacing method (4) Density detection method (5) T-FC22-K(black), T-FC22-Y(yellow), T-FC22-M(magenta), T-FC22-C(cyan) T-FC22E-K (black), T-FC22E-Y (yellow), T-FC22E-M (magenta) T-FC22E-C (cyan) (6) D-FC22-K(black), D-FC22-Y(yellow), D-FC22-M(magenta), D-FC22-C(cyan) (7) DC-400 V + AC 1.2 kV/4 kHz Transfer belt method Separation by electrostatic attraction of the transfer belt (1) Blade cleaning (2) Non-reusable (3) Simultaneous cleaning and discharging by the conductive blade LED array (red) (1) Long-life fuser roller system · Upper fuser roller: PFA tube roller (ø60) (Lamp rating : 500W (115V, 127V), 570W (200V series)) · Lower fuser roller: PFA tube roller (ø60) (Lamp rating : 400W (115V, 127V), 460W (200V series)) (2) Cleaning (2) Oil roller method · Upper oil roller (ø22) · Upper cleaning roller (ø19) · Lower oil roller (ø18) · Lower cleaning roller (ø16) FC-22
(6) Developer material (7) Developer bias 6. Transfer 7. Separation 8. Cleaning (1) Method (2) Recovered toner (3) Transfer charge removal 9. Discharge 10. Fusing (1) Method
(3) Fuser roller temperature control (3) ON/OFF control by thermistor (upper/lower roller independent temperature control) 11. System Control 12. Drive system Microcomputer control Units are controlled independently by separate DC motors.
FC-22 COPY PROCESS
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January 2000 © TOSHIBA TEC
4. GENERAL OPERATION
4. 1 Overview of Operation
Copier operation Operation during warming-up, pre-running and standby Automatic paper feed copying with the START key Copy operation Bypass paper feed copying Interrupt copying
4. 2 Description of Operation
4. 2. 1 Warming-up (1) Initializing operation · · · · · Power ON Fuser lamp ON Copy counter "1"/ "WAIT WARMING UP" displayed. Fan motors ON Initializing of the scanner system: ~ The carriage moves to and stops at its home position. ~ The carriage moves to the peak detection position. ~ The exposure lamp ON~Peak detection (white color detection based on the shading correction plate)~The exposure lamp OFF. ~ The original size indicator initializes, then displays the original size. · Initialization of the paper feeding system: ~ The tray of each cassette rises. ~ The guides of the ADU (automatic duplexing unit) detect their home positions, then move to their maximum-size position. · · Initialization of the laser optical system: ~ The polygonal motor rotates. Drum rotation: ~ Drum motors ON, transfer belt motor ON, color developer motor ON and black developer motor ON. · · Toner supply control: ~ If the toner density in any developer unit is lower than specified, the toner supply mode starts. Image quality control: ~ Test patterns are formed on the transfer belt, and based on their reflection factors, the optimal conditions are set. · · Others: ~ The main charger wire cleaners operate. Color registration control: ~ Test patterns are formed on the transfer belt and their signals are read to detect if toner is present or not. This information is used to correct registrational deviation of each color.
January 2000 © TOSHIBA TEC 4-1 FC-22 GENERAL OPERATION
(2) Pre-running operation When the fuser roller has reached a certain temperature, pre-running operation is performed. (If the fuser roller is already warm enough, this operation does not take place.) · The fuser motor rotates.
(3) When the fuser roller reaches a temperature capable of fusing: · · Fuser lamp OFF Copy counter "1" / "READY" displayed.
4. 2. 2 Standby state (ready for copying) · · · All keys on the control panel are operable. If no key is pressed for a certain period of time: ~Copy counter "1", reproduction ratio "100%" and other defaults are set. A fixed time after the warming-up has ended. ~Color registration control 4. 2. 3 Cassette feed copying (1) START key ON · · · · · · · Display: "READY""COPYING" In black copying, the transfer belt performs its release operation and the suction charger bias is turned ON. The main chargers, developer bias, discharge LEDs and cleaning blade bias are turned ON. The fan motors and polygonal motor rotate at high speed. The drum motors, transfer belt motor, fuser motor and developer motors rotate. The feed motor, feed path clutch and feed clutch for the selected cassette are turned ON: ~ The pick-up roller, feed roller, separation roller, and transport roller rotate. The jam sensor for the selected cassette is turned ON, which then turns the feed clutch OFF. A sheet of paper reaches the registration roller: ~ Aligning operation takes place. (3) Carriage operation · · · · Exposure lamp ONShading correction Scan motor ONCarriages 1 and 2 start moving forward. Registration motor ONTransports the paper to the transfer section. The copy counter operates. (2) Cassette paper feeding
(4) A fixed time after the carriage operation,
(5) A fixed time after the registration motor has been turned ON, toner supply operation is performed in the order of Y, M, C and K, and then the transfer roller bias is turned ON.
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January 2000 © TOSHIBA TEC
(6) Carriage scanning completion · · · · · · · Scan motor OFF Exposure lamp OFF Registration motor OFF (after the trailing edge of the paper has passed the registration roller) The trailing edge of the paper is detected by the exit sensor. The main chargers, developer bias and discharge LEDs are turned OFF. The drum motors, transfer belt motor, fuser motor and developer motors stop their operations. The fan motors and polygonal motor return to their standby rotations. "READY" is displayed and the copier goes into standby.
(7) Paper exit operation
January 2000 © TOSHIBA TEC
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FC-22 GENERAL OPERATION
Scan motor
Feed motor
FC-22 GENERAL OPERATION
Feed clutch
Drum motor (Y, M, C, K)
Transfer belt motor
Color developer motor
Black developer motor
Main charger wire/grid (Y, M, C, K)
Developer bias (Y, M, C, K)
Timing chart for copying two A4 sized sheets fed from the 2nd cassette
4-4
Transfer roller bias (Y)
Transfer roller bias (M)
Transfer roller bias (C)
Transfer roller bias (K)
Discharge LED
Cleaning blade bias
Registration sensor
Registration clutch
Exit sensor
January 2000 © TOSHIBA TEC
Fuser motor
4. 2. 4 Bypass feed copying (1) Insertion of paper in the bypass tray · · · · · · Bypass paper sensor ON: ~ "Ready for bypass feeding" is displayed. The carriage moves to its home position. "Reasy for bypass feeding""COPYING" display The main chargers, developer bias and discharge LEDs are turned ON. The fan motors rotate and polygonal motor rotates at high speed. The drum motors, developer motors, transfer belt motor and fuser motor rotate. The feed motor, feed path clutch and bypass feed clutch are turned ON: ~ The bypass pick-up roller lowers. ~ The bypass pick-up roller and bypass feed roller rotate. · · · Aligning operation When the paper arrives at the registration sensor, the bypass feed clutch is turned OFF. The paper arrives at the registration roller. (3) Bypass paper feed operation (2) Pressing of the START key
(4) Hereafter, the same operation as described in (3) to (6) of "4.2.3 Cassette feed copying" is performed. 4. 2. 5 Interruption copying (1) Pressing of the INTERRUPT key · · · · The INTERRUPT lamp is turned ON. The copying operation now in progress is stopped temporarily. Carriages 1 and 2 return to their preset positions. "Job interrupted job 1 saved" is displayed. The center step of manual density and the 100% reproduction ratio are set. The copy quantity does not change. (2) Selection of the desired copy modes (3) After interruption copying is finished, · · · "Press INTERRUPT to resume job 1" is displayed. Pressing the INTERRUPT key turns the INTERRUPT lamp OFF, returning the copier to the condition before the interruption. "Ready to resume job 1" is displayed. (4) Pressing the START key The copying operation before interruption is resumed.
January 2000 © TOSHIBA TEC
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FC-22 GENERAL OPERATION
4. 3 Detection of Abnormal Conditions
When an abnormal condition occurs, the symbol corresponding to the abnormality is displayed to alert the operator. 4. 3. 1 Types of abnormality A) Type that can be cleared without turning the door switch OFF: (1) Add paper (2) Paper misfeed in bypass (3) Set key copy counter B) Type that cannot be cleared without turning the door switch OFF: (1) Misfeed in copier (2) Install new toner cartridge (3) Replace toner bag C) Type that cannot be cleared without turning the main switch (SW17) OFF: (1) Call for service 4. 3. 2 Description of abnormalities A-1) Add paper [For the copier's cassette]( when it is not inserted) Detection of no cassette When the cassette is not inserted When the cassette is inserted but no paper is set in it No paper A signal is sent to the control circuit. "Add paper" symbol flashes. *The START key is not operable.
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January 2000 © TOSHIBA TEC
[For the copier's cassette](when it is inserted) Based on the combination of the cassette tray-up motor operation and the conditions of the cassette tray-up limit sensor and cassette paper empty sensor, the CPU detects the presence or absence of paper.
° When the power is turned ON or when the LCF door is opened/closed, the LCF performs initialization.
Detection of whether or not there is paper: Tray-up motor ON~The tray rises. At this time, both tray-up and LCF paper empty sensors are OFF. If the tray-up sensor is not turned ON in a fixed time: The tray is abnormal. Cleared by turning the power ON/OFF. If the tray-up sensor is turned ON in a fixed time: ~The tray-up motor stops rotating. At this time, if the empty sensor is ON:It is judged that there is paper. OFF:It is judged that there is no paper The tray lowers. "Add paper" symbol flashes.
° During copying, after paper has been fed, and the paper source becomes low:
The tray-up sensor is turned OFF. The tray-up motor is turned ONThe tray moves up. The tray-up sensor is turned ONThe tray-up motor stops.
° During copying, despite of the tray-up sensor being ON, if the paper empty sensor is turned OFF:
"Add paper" symbol flashes. The copying operation is stopped. It is judged that there is no paper.
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FC-22 GENERAL OPERATION
A-2) Paper misfeed in bypass (
)
° During bypass copying:
Bypass feed clutch is turned ON. *If the registration sensor is not turned ON in a fixed time (E12), Bypass misfeeding Bypass misfeed symbol ( The Copying operation is disabled. To clear: Remove the paper from the bypass tray. The bypass paper sensor is turned OFF. A-3) Set key copy counter ) is displayed.
° In the case of a copier equipped with a key copy counter (option), if this is pulled out:
"Set key copy counter" is displayed. The Copying operation is disabled.
° During copying, if the key copy counter is pulled out,
Copying is stopped after the paper being copied is finished and ejected.
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January 2000 © TOSHIBA TEC
B-1) Misfeed in copier (
)
° Leading-edge jam detection with the exit sensor(E01)
The registration clutch is turned ON. 5.724 sec. The exit sensor is turned ON. After 5.724 sec., if the exit sensor is not ON yet, Paper jam (E01) Copying operation is stopped.
Paper jam (E01) Exit sensor Timer
5.724 sec. ON
Registration clutch
ON
° Trailing-edge jam detection with the exit sensor(E02)
The registration clutch is turned OFF. 5.302 sec.* The exit sensor is tuned OFF. After 5.302 sec., if the exit sensor is not turned OFF yet, Paper jam (E02) Copying operation is stopped.
Paper jam (E02) Timer
5.302 sec.
Registration clutch Exit sensor
OFF
ON
° Immediately after the power is turned ON:
Paper jam (E03) The exit sensor detects paper (ON).
° During copying, the front cover is opened:
Paper jam (E41)
° During paper feeding from ADU, a fixed time after the feed clutch has been turned ON, the
cassette-feed jam sensor (1st cassette) is not turned ON, Paper jam (E11)
° During duplex copying, the ADU path sensor and ADU jam sensor do not detect paper:
Paper jam (E50~E52)
January 2000 © TOSHIBA TEC 4-9 FC-22 GENERAL OPERATION
° During paper feeding from the cassette or LCF, a fixed time after the feed clutch has turned
ON, the paper jam sensor is not turned ON, Paper jam (E13~E16, E19: depending on the paper sources) B-2) Install new toner cartridge ( Toner empty detection: Auto-toner mechanism Control circuit "Install new toner cartridge" is displayed: Copying is disabled To clear: Open the front cover and replace the toner cartridge. Toner supply operation: Copying is enabled B-3) Replace toner bag ( The toner bag limit sensor is turned ON. "Replace toner bag" is displayed. ) )
The toner density has become low:
The toner bag is filled with used toner to the limit.
° During copying, if the toner bag limit sensor is turned ON,
After ejecting the copy paper now in process, the copying operation is stopped. To clear: Open the front cover, replace with a new toner bag and then close the front cover. C-4) Call for service When the "Call for service" symbol is flashing, pressing the CLEAR key and "8" key simultaneously causes an error code to be shown on the copy quantity display. Refer to the error code table in the Service Handbook.
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January 2000 © TOSHIBA TEC
4. 4 Flowchart
4. 4. 1 Immediately after the power is turned ON
Main switch ON
DC power supply ON Restart YES Cover open? NO Any switch on transport path ON? NO YES
Paper jam Processing, transfer/transport, and fuser units all installed? YES Polygonal motor ON Fuser lamp ON Main charger wire cleaning performed Unit uninstalled
"E03"
NO
YES
Toner empty? NO
YES
Higher than pre-running start temp.? NO Pre-running start temp. reached? YES NO
Thermistor value changed within 120 sec. after initialization? YES
NO
B
A
Call for service
"C41"
January 2000 © TOSHIBA TEC
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FC-22 GENERAL OPERATION
A Pre-running operation starts.
NO
Toner empty? YES Toner supplied.
Image quality control starts.
Image quality control ended normally?
NO
YES B Color registration control starts.
Call for service
"CE1, CE2, CE4"
Color registration control ended normally?
NO
YES
Call for service
"CF1"
NO
Fuser rollers reached pre-run end temp.?
YES Pre-running operation finished.
NO
Fuser roller reached ready temp.? YES
READY
FC-22 GENERAL OPERATION