DP3500-4500 SM PDF

SERVICE MANUAL DIGITAL PLAIN PAPER COPIER
DP4500/3500
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Copyright TOSHIBA CORPORATION 2001 ALL RIGHTS RESERVED
GENERAL PRECAUTIONS REGARDING THE INSTALLATION AND SERVICE FOR THE COPIER DP4500/3500
The installation and service should be done by a qualified service technician. 1. Transportation/Installation When transporting/installing the copier, employ two persons and be sure to use the positions as indicated below. The copier is quite heavy and weighs approximately 73kg (161lb), therefore pay full attention when handling it.
Be sure to use a dedicated outlet with AC 115V or 120V/15A (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. The socket-outlet shall be installed near the copier and shall be easily accessible. 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, high-voltage transformer, IH control circuit, exposure lamp control inverter, inverter for the LCD backlight and power supply unit. Especially, the board of these components should not be touched since the electirc charge may remain in the condensers, etc. on them even after the power is turned OFF. Be sure not to touch rotating/operating sections such as gears, belts, pulleys, fan, etc. Be careful when removing the covers since there might be the parts with very sharp edges underneath. 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 :
Dispose of used batteries and RAM-ICs including lithium batteries according to the manufacturers instructions.
Attention :
Se dbarrasser de batteries et RAM-ICs uss y compris les batteries en lithium selon les instructions du fabricant.
Vorsicht :
Entsorgung des gebrauchten Batterien und RAM-ICs (inklusive der Lithium-Batterie) nach Angaben des Herstellers.
1. SPECIFICATIONS / ACCESSORIES / OPTIONS / SUPPLIES

1.1 Specifications
Values in [ ] are for DP3500 only when the specifications are different for the DP4500 and the DP3500. Copy process Type Original table Acceptable originals Indirect electrophotographic process (dry) Desktop type (console type when paper feed pedestal (PFP) and large capacity feeder (LCF) are installed) Fixed type (the left rear corner used as guide to place originals) Sheet, book and 3-dimensional object. The automatic document feeder (option) only accepts paper (64~80 g/m2/17~22 lb.) excluding carbon paper, pasted sheet and stapled sheet. Maximum size : A3/LD Copy speed
Paper supply Paper size A4, LT, B5 A4-R, B5-R, A5-R, LT-R, ST-R B4, LG A3, LD 24 [21] 21 [18] 24 [21] 21 [18] 21 [18] 21 [18] 24 [21] 21 [18] Bypass feeding Cassette 45 [35] 28 [25] Size specified 45 [35] 28 [25] Size not specified 21 [18] 21 [18] PFP 45 [35] 28 [25]
(Copies/min.)
LCF (only A4/LT) 45 [35]
* * *
means Cannot be used. The copy speeds in the above table are available when the originals are manually placed for single-side, multiple copying. When the automatic document feeder is used, the copy speed of 45 [35] sheets per minute is only available under the following conditions: Original/Mode: Number of sheets: Reproduction ratio: Single-side originals of A4/LT size. APS and automatic density are not selected. 45 [35] or more. 100%
December 2000 TOSHIBA TEC
1-1
DP4500/3500 SPECIFICATIONS
System copy speed (DP4500) Copy mode Single-sided originals Single-sided copies Single-sided originals Two-sided copies Two-sided originals Two-sided copies Two-sided originals Single-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. 34 39 41 19 28 30 17 25 28 19 30 35
The copy speeds in the table include the time for the first copy. They are available when the copy modes in the left-hand table are selected and 10 A4-sized originals are set in the automatic document feeder.
Copy paper
Size Cassette Duplex copy A3~A5R LD~ST-R PFP LCF A4, LT Bypass copy Remarks A3~A5-R, LD~ST-R (Non-standard or userspecified sizes can be set.) 64~80 g/m2,17~22lb (Continuous feeding) 50~209 g/m2, 14~55 lb (Single paper feeding) Tracing paper, labels, Special types of paper OHP film (thickness: 80m must be recommended or thicker) by Toshiba
Weight
64~80g/m2, 17~22 lb.
Special paper
First copy time .................. 3.9 seconds or faster (A4/LT, upper cassette, 100%, original placed manually) Warming-up time ................ Approx. 30 seconds (standalone, temperature: 20C) Multiple copying ................. Up to 999 copies; set number entered with digital keys Reproduction ratio .............. Actual ratio: Zooming: Resolution/Gradation ......... Read: ......... Write: 1000.5% 25~400% in increments of 1% (25~200% when using the RADF) 600 dpi Equivalent to 2400 dpi x 600 dpi (primary scanning only : 4 division smoothing) Eliminated image width ...... Leading/trailing edges: 2.01.0 mm, Side edges: 2.02.0 mm
1-2
Paper feeding ..................... Automatic feeding:
Copier cassettes2 cassettes (paper stack height 60.5 mm, equivalent to 550 sheets; 64 to 80 g/m2 (17 to 22 lb.)) PFPOptional (One cassette or two: paper stack height 60.5 mm: equivalent to 550 sheets; 64 to 80 g/ m2 (17 to 22 lb.)) LCFOptional (Paper stack height 137.5 mm x 2: equivalent to 2500 sheets; 64 to 80 g/m2, 17 to 22 lb.)
Bypass feeding:
(Paper stack height 11 mm : equivalent to 100 sheets; 64 to 80 g/m2, 17 to 22 lb.)
Capacity for originals in the automatic document feeder (Optional) ................. A3~A5-R, LD~ST-R : 100 sheets Automatic duplexing unit ... Stackless, Switchback type Toner supply ...................... Automatic toner density detection/supply Toner cartridge replacing method Density control .................. Automatic density mode and manual density mode selectable in 11 steps Weight ............................... Approx. 73 kg, 161 lb Power requirements ........... AC 115V/15A, AC 220 240V/10A Power consumption ........... 2.0 kW or less (115V series, 200V series) Electric power is supplied to the automatic document feeder, finisher, PFP and LCF through the copier. Total counter ...................... Electronic counter
1-3
Dimensions of copier ......... See the figure below (W660 x D673 x H739 mm)
67
73 9
660
1-4
1.2 Accessories
Unpacking/setup instructions Operators Manual PM sticker Setup report Customer satisfaction card Developer material Toner cartridge Operators Manual pocket Power cable Preventive maintenance check list Toner bag symbol sticker Warranty sheet 1 pc. 1 pc. (not available for MJD) 1 pc. (for MJD) 1 set. (for NAD and MJD) 1 pc. (for MJD) 1 pc. (not available NAD and MJD) 1 pc. (not available NAD and MJD) 1 pc. 1 pc. 1 pc. (for MJD) 1 pc. (for MJD) 1 pc. (for NAD)
* Machine version NAD: North America MJD: Europe AUD: Australia ASD: Asia
1-5
1.3 Options
Platen cover Automatic document feeder (RADF) Paper feed pedestal (PFP) Cassette module Large capacity feeder (LCF) Finisher Hole punch unit Staple cartridge Key copy counter, key copy counter socket Work table Damp heater kit Desk(H) Desk(L) System controller Option for system controller KA-1600PC MR-3012 KD-1009 MY-1017 KD-1010 MJ-1011 (for DP3500), MJ-1012, MJ-1013 MJ-6001 STAPLE-1600, STAPLE-600, STAPLE-700 MU-8, MU-10 KK-3500 MF-3500U, MF-3500E MH-1600H MH-1600L GL-1010, GL-1010E GC-1090 (Extended memory) GB-1040 (PC-Fax) GB-1060 (Scan/E-mail Print) SC-2-TKRING-NIC (TokenRingNIC) GF-1100 (I/F board for protocol converter) Printer controller Option for printer controller GA-1040 GC-1080 (Extended memory) GB-1070 (CWS) GB-1080 (FreeForm) GB-1090 (DocBuilderPro) GE-1020 (PS3 without HDD) GE-1030 (PS3 with HDD) Fax unit Option for fax unit GD-1080NA/EU/TW/AU GD-1090NA/EU (2nd line unit)
1.4 Supplies
Toner Toner bag PS-ZT3500, PS-ZT3500E, PS-ZT3500D PS-TB3500, PS-TB3500E
1-6
1.5 System List
Finisher MJ-1011 Automatic document feeder (RADF) MR-3012 Platen cover KA-1600PC
Staple cartridge STAPLE-1600
Finisher MJ-1012
Work table KK-3500
Staple cartridge STAPLE-700 Finisher relay unit
Finisher MJ-1013
Key copy counter socket MU-10 Key copy counter MU-8
1-7
Hole punch unit MJ-6001
Staple cartridge STAPLE-600
Cassette module MY-1017
Paper feed pedestal (PFP) KD-1009
Large capacity feeder (LCF) KD-1010
1-8
2. OUTLINE OF THE MACHINE

2.1 Sectional View
5 7
1 8 9 10
57 58 56 52 50 48 49 51 33 39 36 38
55
59 54 53 47 37 32 31 35 34 62
66
40
41
60 29 63 30 61 26 27 25 24
65 43 42 45 44 46
11
28 22
23
18 21 20 19
12
13
14,15,16 17
2-1
DP4500/3500 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
Original glass Exposure lamp Inverter Mirror-1 Mirror-2 Mirror-3 Carriage home position sensor Lens CCD drive PC board Scanner control PC board Laser optical unit Cassette Cassette tray Paper-empty sensor Paper-stock sensor Tray-up sensor Cassette pickup roller Cassette feed roller Cassette separation roller Transport roller Lower feed sensor Upper feed sensor Bypass tray Bypass guide Bypass pickup roller Bypass paper sensor Bypass feed roller Bypass separation pad Registration sensor Registration roller Drum Separation finger for drum Main charger
34 35 36 37 38 39 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
Transfer guide Transfer/separation charger Cleaning blade Recovery blade Toner recovery auger Discharge lamp Toner cartridge Toner motor Developer sleeve (magnetic roller) Doctor blade Mixer-1 Mixer-2 Auto-toner sensor Fuser unit entrance guide Fuser roller IH coil Fuser roller thermostat Fuser roller thermistor Separation finger for fuser roller Pressure roller Cleaning roller Separation finger for pressure roller Exit finger Fuser unit cover Exit roller ADU upper transport roller ADU middle transport roller ADU lower transport roller ADU entrance sensor ADU exit sensor Paper receiving tray Drum thermistor Humidity sensor
2-2
2.2 Location of Electrical Parts

[A] Arrangement of Various Units
Scanner unit
System unit
Laser unit
ADU
Rear side
Main unit
2-3
[B] Scanner unit (B-1) Motor
M1
Rear side
(B-2) Sensors and switches
S4
S3
S2
S10 S27 S1 S5 S6 Rear side
*A4 series : S1 to 5 are installed. LT series : S1 to 3 and S6 are installed.
2-4
(B-3) PC boards
SDV
CCD
Rear side
SLG
(B-4) Others
DHM
EXP INV
DHL
Rear side
2-5
[C] System unit
LGC
SYS
HDD
Rear side
Fax Printer
FAX NCU-US NIC HDD-PRT PRT
MDM
System controller
BRG
CPU CD-ROM
FAN-SC PWR-SC
HDD-SC
2-6
[D] Laser unit
M3 M2 LDR
POL SNS
Rear side
[E] ADU
S24
ADU
S22 S23 CLT1 M4
Rear side
2-7
[F] Main unit (F-1) Motors and fans
M14 M10 M13
M6 M11 M15 M12
M7
M5
Rear side M8
(F-2) PC boards and AC parts

S7 S8 IHCOIL ACC
FUSE
THERM1
DHC DHD
IH
Rear side
2-8
(F-3) DC parts except motors and PC boards
S26 S11 S9 THMS1 THMS2 THMS-D S12 S13 S14 HVT S30 S31
ERS
S20 S18 S29 CLT7 S15 S21 S19 S25 CLT4 S27
S28 CLT5 S17 CLT3 CLT6
S16 CLT2
Rear side
2-9
2.3 Symbols and Functions of Various Components

<P-I> indicates page and item number in the parts list.
(1) Motors
Symbol M1 SCAN-MOT Scanner motor Name <P12-I9> Function Drives the carriages. Cools down the system controller unit. [Optional] Drives the polygonal mirror. <P7-I28> Cools down the laser optical unit. Remarks (B-1) [C] [D] [D] [E] (F-1) (F-1) (F-1) (F-1) (F-1) (F-1) (F-1) (F-1) (F-1) (F-1)
FAN-SC FAN-534 System controller cooling fan M2 M3 M4 M5 M6 M7 M8 M10 M11 M12 M13 M14 M15 M/DC-POL-320 Polygonal motor FAN-DC-320 Laser unit fan ADU-MTR ADU motor MAIN-MTR Main motor EXIT-MTR Exit motor TNR-MTR Toner motor T-UP-MTR Tray-up motor SP-FAN Sub-separation fan EXIT-FAN Exhaust fan IH-FAN IH control board cooling fan MID-FAN Middle cooling fan FUSER-FAN Fuser unit cooling fan DEV-FAN Developer unit cooling fan
<P32-I18> Drives the ADU. <P11-I26> Drives the drum, developer unit and fuser unit. <P6-I11> <P27-I9> <P4-I22> <P10-I2> <P10-I2> <P8-I3> <P8-I3> Drives the exit roller. Supplies the toner. Drives the cassette tray upward. Assists the paper separation by suction. For exhaustion. Cools down the IGBT for fuser control. Cools down the drum and cleaner unit.
<P29-I13> Cools down the fuser unit. <P6-I33> Cools down the developer unit.
2 - 10
(2) Sensos and switches

Symbol S1-6 S10 S27 S22 S23 S24 S7 S8 S9 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S25 S26 S27 S28 Name APS1-6 <P9-I17,18> Automatic original detection sensor HOME-SW <P9-I22> Carriage home position switch PLTEN-SNR <P12-I15> Platen sensor ADU-TRU-SNR <P32-I31> ADU entrance sensor ADU-TRL-SNR <P32-I31> ADU exit sensor ADU-SET-SW <P32-I43> ADU opening/closing switch MAIN-SW <P5-I10> Main switch DOOR-SW <P5-I7> Front door switch EXIT-SNR <P30-I21> Exit sensor TNR-SW <P27-I23> Toner cartridge detection switch SNR-ATC <P25-I19> Auto-toner sensor RGST-SNR <P18-I11> Registration sensor FED-U-SNR <P18-I11> Upper feed sensor FED-L-SNR <P18-I5> Lower feed sensor NEMP-U-SNR <P13-I27> Upper cassette paper-stock sensor NEMP-L-SUR <P13-I27> Lower cassette paper-stock sensor EMP-U-SNR <P13-I27> Upper cassette paper-empty sensor EMP-L-SNR <P13-I27> Lower cassette paper-empty sensor TOP-U-SNR <P13-I27> Upper cassette tray-up sensor TOP-L-SNR <P13-I27> Lower cassette tray-up sensor CST-COVER-SW <P5-I19> Side door switch F-COV-SW <P5-I7> Front cover switch CST-U-SW <P4-I5> Upper cassette detection switch CST-L-SW <P4-I5> Lower cassette detection switch Function Detects the size of originals. Detects the home position of the carriage. Detects if the platen cover is opened/closed. Detects paper in the paper entrance area of the ADU. Controls paper transport in the ADU. Detects if the ADU is opened/closed. Shuts off the AC power to the copier. Interlock switch to shut off the AC power when the front cover is opened. Detects paper in the paper exit area. Detects the toner cartridge. Detects the toner density. Detects if paper has reached the registration roller. Detects paper misfeeding. Detects paper misfeeding. Informs that the upper cassette is almost empty. Informs that the lower cassette is almost empty. Detects presence/absence of paper in the upper cassette. Detects presence/absence of paper in the lower cassette. Detects if the upper cassette tray has been lifted to the upper limit. Detects if the lower cassette tray has been lifted to the upper limit. Detects if the the side door is opened/ closed. Detects if the front cover is opened/closed. Detects if the upper cassette is installed. Detects if the lower cassette is installed. Remarks (B-2) (B-2) (B-2) [E] [E] [E] (F-2) (F-2) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3) (F-3)
2 - 11
Symbol S29 S30 S31
Name SFB-SNR <P17-I25> Bypass paper sensor T-FUL-SNR <P11-I28> Toner bag full detection sensor HUMI-SNR <P7-I25> Humidity sensor
Function Detects presence/absence of paper in the bypass tray . Detects if the toner bag is full. Detects humidity inside the copier.
Remarks (F-3) (F-3) (F-3)
(3) Electromagnetic spring clutches

Symbol CLT1 CLT2 CLT3 CLT4 CLT5 CLT6 CLT7 ADU-CLT ADU clutch FED-U-CLT Upper cassette feed clutch FED-L-CLT Lower cassette feed clutch RGST-CLT Registration clutch TR-L-CLT Transport clutch (low speed) Name <P32-I16> <P13-I14> <P13-I14> <P18-I31> <P14-I20> Drives ADU. Drives the pickup roller for the upper cassette. Drives the pickup roller for the lower cassette. Drives the registration roller. Transport paper from the registration area. Transport paper up to the registration area. Drives the bypass pickup roller. Function Remarks [E] (F-3) (F-3) (F-3) (F-3) (F-3) (F-3)
TR-H-CLT <P14-I16> Transport clutch (high speed) SFB-CLT Bypass feed clutch <P16-I17>
(4) Heaters and lamps

Symbol EXP DHM DHL DHD DHC IHCOIL ERS Name LP-EXPO-50K-320 Exposure lamp DNP-HTR Damp heater DNP-HTR Damp heater D-HTR-L Lower damp heater D-HTR-CST Cassette damp heater IH-COIL IH coil LP-ERS Discharge lamp <P20-I2> <P9-I8> <P9-I30> <P26-I7> <P4-I34> <P30-I23> <P24-I33> Function Exposes the original with light. Prevents condensation in the scanning area (for mirrors). Prevents condensation in the scanning area (for lens). Keeps the drum and transfer/separation charger warm. Prevents condensation in the cassettes. Heats up the fuser roller. Removes the residual charge from the drum surface. Remarks (B-4) (B-4) (B-4) (F-2) (F-2) (F-2) (F-3)
2 - 12
(5) PC boards
Symbol SLG CCD SDV SYS LGC FAX MDM Name PWA-F-SLG-320 <P9-I13> Scanner control PC board (SLG board) PWA-F-CCD-320 CCD drive PC board (CCD board) Function Controls the scanner section. Controls pre-processing of the CCD image data. Remarks (B-3) (B-3) (B-3) [C] [C] [C] [C] [C] [C] [C] [C] [C] [D] [D] [D] [E] (F-2) (F-2)
PWA-F-SDV-320 <P12-I22> Controls the scanner motor. Scanner motor drive PC board (SDV board) PWA-F-SYS-320 <P7-I18> System PC board (SYS board) PWA-F-LGC-320 Logic PC board (LGC board) PWA-F-FAX-527 Fax control board <P7-I19> <P1-I11> General control of the copier and data processing. General control of the copier Controls the fax function. [Optional] Controls dialing for the analog circuit (2nd circuit) [Optional] Controls dialing for the analog circuit (2nd circuit) [Optional] Controls the printer function. [Optional] Connects the printer with the network. [Optional] Connects the system controller with the copier. (PCI to PCI bridge board) [Optional] Controls the system controller. [Optional] Drives the laser diode. Drives the polygonal motor. Detects the laser beam position. <P32-I30> <P31-I2> <P6-I36> Drives the ADU. Controls the IH of the fuser unit. Prevents over-current being supplied to the damp heaters.
PWA-F-MDM-528 <P2-I15> Telephone circuit control board
NCU-US PWA-F-NCU-US <P1-I12> Telephone circuit control board PRT NIC BRG CPU LDR POL SNS ADU IH FUSE PWA-F-PRT-533 Printer control board NIC Network board PWA-F-BRG-534 Bridge board PWA-F-SBC-534 System controller CPU board PWA-F-LDR-320 Laser drive PC board (LDR board) M/DC-POL-320 Polygonal motor drive board PWA-F-SNS-320 H-Sync detection PC board PWA-F-ADU-320 ADU board PS-IH-320 IH control board PWA-F-FUS Fuse PC board
(6) Transformer
Symbol HVT Name PS-HVT-320 High-voltage transformer <P4-I29> Function Generates the voltage for the following: main charger wire main charger grid developer bias transfer charger wire separation charger wire transfer guide bias
2 - 13
Remarks (F-3)
(7) Others
Symbol INV HDD HDD -PRT INV-EXP-50K-320 Lamp inverter HDD Hard disk OPTION-HDD-533 Hard disk (for printer) Name <P20-I3> <P7-I15> Function Controls the exposure lamp. Stores the image data. Extends the functions of the printer. [Optional] A part of the system controller. Reads the data. [Optional] Sub-memory for the system controller. [Optional] Power supply for the system controller [Optional] Provides the electrical power. Prevents the over-heating of the fuser unit. Detects the surface temperature of the drum. Detects the surface temperature of the center area of the fuser roller. Detects the surface temperature of the ends of the fuser roller. Remarks (B-4) [C] [C] [C] [C] [C] (F-2) (F-2) (F-3) (F-3) (F-3)
CD-ROM CD-ROM-534 CD-ROM drive HDD -SC PWR -SC ACC HDD-534 Hard disk (for system controller) PS-534 Power supply for system controller PS-ACC-320 Switching power supply <P6-I26> <P28-I9> <P25-I29> <P28-I10> <P28-I10>
THERM1 THERMO-HTR Thermostat THMS-D THMS-DRM Drum thermistor THMS1 THMS2 THMS-HTR Fuser roller center thermistor THMS-S-HTR Fuser roller side thermistor
2 - 14
PWA-F-SYS-320
RADF
Serial-I/F
System
3.3V
66M
PWA-F-SLG-320
80
20MHz
3.3V SDRAM-BUS 32/16
Total: 32MB
CCD
20MHz 20MHz
SDRAM
5VI/F
64MBx4 16
5V
SRAM 256KB 16
5Vtorelant
TX3927 CPU
Total: 4MB FROM 16MBx2 FROM 4MB TMP95C063 16bit 20M
S-CPU
8
32bit-RISC Speed:133MHz 8.3M LAN Printer 8 BT

5VI/F
Amp
40MHz
40MHz
Serial-I/F
SRAM 4MB
ASIC 40MHz (324BGA)
3.3V ROM-Bus
2.4 System Block Diagram
IDE I/F
32
5MHz
5V ADR/DAT-Bus
Serial-I/F Image Data
5MHz
3.3V ISA-Bus
ADR/DAT-Bus

System controller
A/D
40MHz
8 20M
5V
5V/3.3V
FAX board
3.3V
ASIC 33MHz (QFP176) 3.3V PCI-Bus

4
Image Data
PWA-F-CCD-320
HDD 8 32
5V
SCN_MT DRIVER 2 or 3
5V
5V
3.3V
ASIC 33MHz/66MHz (352BGA)

66MHz
DRAM SDRAM 32MB DRAM 64Mbit SDRAM 32MB 64MB
Total:32MB
EPROM 4MBx2
Scanner
PWA-F-DLM-320
LCD
2 - 15
RTC NVRAM 8KBx8 EPROM 16MBx2 PWA-F-DLS-320 68
CLR/STP
ASM-F-PNL-320
Serial-I/F
5V 5V 5V 3.3V 3.3V
EWS ASIC Debug

3.3V 3.3V
R R
PFP
LCA301 ASIC
FROM 4MB 8M SRAM 256KB 16 NVRAM 8KBx8
8bit D/A
PWA-F -LDR-320
3.3V
PWA-F -ADU-320
LVDS
59MHz/4-divided
ASIC ASIC 40MHz (208QFP) Image Data
LD
ADU
5V
Finisher
M-CPU
TMP95C063F 16bit
5V
IPC PWA-F-LGC-320
20M
(skt) 59M 20M EPROM 4MBx2
Laser Beam Sensor
Printer
PWA-F-DLM-320
2.5 Installation and Removal of Covers and PC board

2.5.1 Installation and removal of covers [A] Front cover (1) Open the front cover. (2) Pull up the hinge pins on the left and the right, then extract them. (3) Remove the front cover.
Hinge pin Front cover
[B] Front side right cover (1) Pull out the upper cassette. (2) Open the front cover, bypass unit and ADU. (3) Remove 2 screws. (4) Remove the front side right cover.
Front side right cover
ADU
Bypass unit
[C] Feed side front hinge cover (1) Pull out the upper and lower cassettes. (2) Remove 2 screws and take off the feed side front hinge cover.
Feed side front hinge cover
[D] Feed side rear hinge cover (1) Remove 2 screws and take off the feed side rear hinge cover.
Feed side rear hinge cover
2 - 16
[E] Feed side upper cover (1) Open the bypass unit, ADU, jam access cover and fuser unit cover. (2) Remove 2 screws. (3) Slide the feed side upper cover to the left to take it off.
Jam access cover ADU Fuser unit cover Feed side upper cover
[F] Feed side lower cover (1) Remove the feed side rear hinge cover. (2) Open the bypass feed unit and ADU. (3) Remove 2 screws and take off the feed side lower cover.
Feed side lower cover
[G] Rear side upper cover (1) Remove 4 screws and take off the rear side upper cover. [H] Rear side lower cover (1) Remove 2 screws. (2) Slide the rear side lower cover to the right to take it off.
Rear side lower cover Rear side upper cover
[I] Receiving tray (1) Open the front cover. (2) Remove 2 screws. (3) Slide the receiving tray upwards to the left to take it off.
Receiving tray
2 - 17
[J] Tray back cover (1) Remove the receiving tray. (2) Take off the feed side upper cover. (3) Remove 2 screws. (4) Slide the tray back cover to the left and take it off.
Tray back cover
[K] Left cover (1) Remove 3 screws and take off the left cover.
Left cover
[L] Option cover (1) Slide the cover in the direction of the arrow and take it off. [M] Exit side rear cover (1) Take off the rear side upper/lower covers. (2) Loosen the screws of the receiving tray and left cover. (3) Remove 4 screws and take off the exit side rear cover.
Option cover Rear side upper cover
Receiving tray
Rear side lower cover Exit side rear cover
Left cover
2 - 18
[N] Left top cover (1) Remove 2 screws. [O] Right top cover (1) Remove 4 screws.
[N] [N]
Rear top cover

[P] [P] [O] [O]
Left top cover

[O]
Right top cover
[O] [Q]
[P] Rear top cover (1) Loosen the screws of the left top cover and right top cover. (2) Remove 2 screws. [Q] Front top cover (1) Loosen the screws of the left top cover. (2) Loosen the screws of the right top cover. (3) Remove 3 rubber screw caps. (4) Remove 3 screws. [R] Control panel lower cover (1) Loosen the screws of the left top cover. (2) Loosen the screws of the right top cover. (3) Remove 3 screws.
Control panel lower cover
[Q] [Q]
Front top cover
2 - 19
2.5.2 Installation and removal of PC board [A] Logic PC board (LGC board) (1) Remove the paper receiving tray and left cover. (2) Remove 7 screws and take off the stay.
Stay
(3) Remove 4 screws and take off the plate cover of the system unit.
Plate cover
Laser unit fan
(4) Disconnect 14 connectors, remove 2 screws and detach 2 lock supports. Take out the logic PC board Note: When installing the logic PC board, connect it securely with the system PC board.
Lock support
Logic PC board
[B] System PC board (SYS board) (1) Remove the logic PC board. (2) Take off the rear side upper/lower covers and exit side rear cover. (3) Remove 7 screws. Take off the plate cover of the rear side of the system unit.
2 - 20
(4) Disconnect 4 connectors and remove 6 screws. Take off the system PC board.
[Rear side]
Connector
System PC board
[Front side]
System PC board
Connector
[C] Hard disk (HDD) (1) Take off the logic PC board. (2) Disconnect 2 connectors and remove 4 screws. Take out the hard disk with the metal plate attached. (3) Remove 4 screws and take the hard disk apart from the metal plate.
Connector
HDD
[D] Scanner control PC board (SLG board) (1) Take off the right top cover. Remove the original glass. (2) Remove 7 screws and disconnect one connector. Take off the lens cover.
Lens cover Connector
2 - 21
(3) Disconnect 9 connectors and remove 4 screws. Take out the scanner control PC board.
Scanner control PC board
[E] High-voltage transformer (1) Take off the rear side lower cover. (2) Disconnect 7 connectors, remove one screw and detach 3 lock supports. Take off the high-voltage transformer.
High-voltage transformer
Lock support
Note: Connect the connectors as shown in the figure below.

Harness: white/connector: white (tranfer bias output) Harness: red/connector: red (transfer charger output) Harness: black/connector: blue (separation charger output)
Harness: white/connector: blue (developer bias output)
Input connector
Harness: red/connector: red (Main charger output) Harness: white/connector: white (Main charger grid output)
2 - 22
[F] Switching power supply (1) Take off the left cover and rear side lower cover. (2) Disconnect one connector from the rear side.
[Rear side]
Connector
(3) Disconnect 5 connectors and remove 2 screws. Pull out the switching power supply.
[Exit side]
Connector
Do not disconnect this connector having 3 connector pins.
2 - 23
2 - 24
3. COPY PROCESS
3.1 General Description of Copying Process
(2) Original exposure Xenon lamp 20 W (10) Cleaning

Paper discharge (9) Fusing

Induction heating method
(3)
700~1300W
Data reading(scanning)
(11) (1)
Discharge LED array Wavelength 660 nm x14 pcs
CCD
600 dpi,7450 pixel
Charging
(8) Separation

+ + +
790V (grid voltage)

Image processing
(4)
Data writing
Semiconductive laser Pw=4.0 nJ/mm2

+ + +
ACH C L DC
4.8kV 4.5kV 2.9kV -100V
1kHz (7) Transfer H 286A C 286A L 137A Transfer bias DC+580V
+ + + +
(5)
Development Magnetic roller Bias 550VDC +150VDC
(6) Toner
Carrier
Bypass feeding (100 sheets)

Cassette feeding (upper/lower) (550 sheets)
PFP (upper/lower) (550 sheets) or LCF (1250 sheets x 2)
(1) Charging: Applies negative charge on the surface of the photoconductive drum. (2) Original exposure: Converts images on the original into optical signals. (3) Data reading: The optical signals are converted into electrical signals. (4) Data writing: The electrical signals are converted into light signals (laser emission) which exposes the surface of the photoconductive drum. (5) Development: Negatively-charged toner adheres to the photoconductive drum and forms visible image.
(6) Transfer bias: Improves transfer efficiency. (7) Transfer: Transfers the visible toner image on the photoconductive drum onto paper. (9) Separation: Separates paper with the toner image from the photoconductive drum. (9) Fusing: Fuses the toner image onto the paper by applying heat and pressure. (10) Cleaning : Scrapes off the residual toner from the drum. (11) Discharge LED array: Eliminates the residual negative charge from the surface of the photoconductive drum.
DP4500/3500 COPY PROCESS
3-1
3.2 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 photoconductor has the following property: when it is exposed to light, the electrical resistance it posSurface potential (V) Photoconductive layer Base Structure of the photoconductive drum (Example of OPC)
sesses increases or decreases according to the strength of the light. Example: Strong light Resistance is decreased (works as a conductor.) Weak light Resistance is increased (works as an insulator.) [Formation of electrostatic latent image] In the processes of charging, data reading, data writing, discharging described later, negative potential of the areas on the drum corresponding to black areas of the original are eliminated, while the areas on the drum corresponding to white areas retains the negative charge. As this image on the drum formed by the negative potential is not visible, it is called an electrostatic latent image.
Time (t)
0
Black 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 the process to apply charge evenly on the drum surface. The charger wire produces negative corona discharge is controlled by the grid, allowing the drum surface to be evenly charged with the negative potential. The surface potential on the drum is determined by the grid potential and is controlled to a certain value by the grid control circuit.
High-voltage transformer Grid control circuit Drum rotation
3-2
(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 into electrical signals (image signals), which are then sent to the image processing section.
Image processing section CCD
(Example) CCD light receiving amount Blight Value of image signals to be output 255 Difference between "blight " and "dark" is divided into 256 steps. Dark
(4) Data writing Data writing is the process of converting the image signals sent from the image processing section into optical signals and exposing the drum surface with the light. Semiconductive laser element converts image signals sent from the image processing section into optical signals (laser emission) to expose the drum surface and form an electrostatic latent image on it.
Photoconductive drum Image processing section
3-3
Laser drive board
Polygonal mirror Semiconductive laser element
(5) Development Development is the process of making the electrostatic latent images visible to the eye (visible images).
Drum
Developer material is supplied to the photoconductive drum surface by the magnetic roller. The toner in the developer material adheres 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 method).
Magnetic roller
Magnet Magnetic roller Toner Carrier (always attracted onto the magnet) Toner
Bias voltage 550 VDC
Toner Photoconductive drum
Photoconductive layer Aluminum base
White background
Half tone
Solid
White background
The () potential of the photoconductive drum is higher than the developer bias. 750 600V
Image not developed Bias potential
550 400V
Image developed by toner

300V
The () potential of the photoconductive drum is lower than the developer bias.
200V
100V
3-4
Switching of developer bias polarity With the area which has no negative change, background fogging is decreased by switching the bias to the positive polarity (approx. +150V). Developer material The developer material consists of a mixture of the toner and carrier. The toner is charged to the negative polarity and the carrier to positive polarity due to the friction with each other caused by mixing. Toner : Mainly consists of the resin and carbon. Carrier : Consists of the ferrite and resin coating on its surface to provide consistent frictional electrification.
[Carrier] 30~100m Resin (90~95%) [Toner] 5~20m Ferrite
Carbon (5~10%)
Note: If the developer material is used for a long time (beyond its normal life span), the toner is caked onto the carrier. The carriers (charging) performance is lowered. Symptom: 1. Image density is lowered. 2. Toner scattering occurs. 3. Background fogging occurs. Solution: Replace the developer material.
No frictional electrification occurs on the area where the toner is caked on. Toner Carrier
Magnetic roller - Magnetic brush development The south and north poles are arranged inside the magnetic roller as shown in the right figure. The developer material forms a brush-like fluff which contacts the photoconductive drum surface. This is caused by the magnetic force lines between the south and north poles.
December 2000 TOSHIBA TEC 3-5 DP4500/3500 COPY PROCESS
Photoconductive drum
N
S
Magnetic roller
Magnetic force line
Additional Explanation The life of the toner cartridge (number of copies) varies depending on the following conditions. 1. Coverage of originals (printing image ratio of the original size) and density of original background 2. Size and density of originals 3. The existence of solid black when making copies (when a book is copied and the original cover is partially opened) 4. Temperature and humidity in the room when making copies 5. Copy density and image quality mode As indicated in the figure below, the life of the toner cartridge varies depending on the copy mode and coverage of originals.
Type of originals
20,000
15,000
A.
10,000
5,000
B.
C.
3-6
(6) Transfer Transfer is a process of transfering the toner image (visible image) formed on the drum surface onto paper. Method: A paper passing the side of the drum is charged to the opposite polarity to the toner's by the corona discharge of the transfer charger. The toner moves from the drum surface onto the paper. * For smooth transfer In the transfer bias processing of this copier, bias voltage (+580VDC) is applied to the pre-transfer guide to prevent the charge produced by the transfer charger from flowing into the pre-transfer guide through the paper. The corona discharge applied to the paper is normally 286A DC. However, to improve transferability at the trailing edge of the paper, lower output (137A DC) is applied to the part 10 mm from the trailing edge. (7) Separation Separation is the process of separating paper which is temporalily adhering to the drum due to the static electricity during the transfer process. Method: Apply AC voltage to which the negative DC bias is added to the separation charger. The positive charge on the paper is decreased. The static electricity (adherence power) between the paper and drum becomes weak. The paper is separated from the drum by its own stiffness and absorption by the fan.
Separation charger Direction of transportation Drum rotation Toner Drum rotation Transfer charger Direction of transportation Transfer charger Drum Paper
Suction fan (Sub-separation fan)
3-7
Absorbing
* Output is controlled as follows to realizes the desirable separability and transferability.

Paper position against transfer point From leading edge to 10 mm from leading edge From 10 mm from leading edge to 17 mm from trailing edge From 17 mm from trailing edge to trailing edge Separation output (H) 4.8kV AC/100 V DC (C) 4.5kV AC/100 V DC (L) 2.9kV AC/100 V DC
Separation finger
Paper may not be separated from the drum surface because of moisture or malfunction of the transfer/separation charger. As the result, the paper gets into the cleaner and causes jamming. To prevent this, a separation finger is used to forcibly separate the paper which was left around the drum.
Drum rotation Separation charger Paper movement
(8) Fusing Fusing is the process of melting the toner on the paper and fixing it firmly on the paper. Method : The melting point of the toner (main ingredient : resin) is 100~110C. (Heat) Toner is melted by the heat of the surface of the fuser roller.
Fuser roller Pressure
+
(Pressure) The pressure roller is pressed against the fuser roller by the springs to increase the adherence of the melted toner onto the paper. Heat and pressure are applied to the paper when it passes between the fuser roller and pressure roller. || (Fusing) The toner is fused on the paper.
IH coil Fuser roller Separation finger
Paper
Separation finger
(Pressure)
Pressure roller
Paper movement
3-8
(9) Cleaning Cleaning is the process of removing the residual toner from the photoconductive drum. The edge of the urethane rubber cleaning blade is pressed against the photoconductive drum surface to scrape off the residual toner on it. The toner is then caught by the recovery blade. (10) Discharging Discharging is the process of eliminating the negative charge remaining on the photoconductive drum before the next charging process. If the residual charge is not eliminated, the following phenomenon occurs:
Photoconductive drum Discharge LED array Drum rotation Cleaning blade Recovery blade
Uneven charge is applied to the drum during the next copying. The next copy will have a double image. (The preceding image appears.) Solution : The entire surface of the photoconductive drum is illuminated with light by the discharge LED array. The photoconductive drum becomes electrically conductive. All of the negative charge remaining on the photoconductive drum is conducted to the ground. Preparation for the next copying is completed.
Ground
3-9
3.3 Comparison with 3580

Process 1. Photoconductive drum (1) Sensitivity (2) Surface potential 2. Charging 3580 OD-2460 (OPC 60) Highly sensitized/durable drum (Grid voltage 736 V) Scolotron method (constant current) Adjustable grid output (constant voltage) 3. Data writing (1) Light source (2) Light amount 4. Development (1) Magnetic roller (2) Auto-toner (3) Toner supply (4) Toner-empty detection (5) Toner (6) Developer material (7) Developer bias Semiconductive laser (adjustment not required) 3.5 nJ/mm2 One magnetic roller Magnetic bridge-circuit method Toner cartridge Density detection method T-3580, T-3580E, T-3580D D-3580 DC510V Adjustable output (during printing) DC+150V (fixed) (others) 5. Transfer bias 6. Transfer 7. Separation Adjustment not required Adjustable output (constant current) AC:Adjustable output (constant current) DC:Adjustment not required 8. Discharge before cleaning AC:Adjustable output (constant current) DC:Adjustment not required 9. Discharge (1) Discharging position (2) Discharge lamp 10. Cleaning (1) Method (2) Recovered toner 11. Fusing (1) Method Cleaning blade Cannot be reused Same as 3580 Same as 3580 Exposure after cleaning Red LED Same as 3580 Same as 3580 Not available DP4500/3500 OD-3500 (OPC 60) Same as 3580 750 V (grid voltage 790V) Same as 3580 Same as 3580
Same as 3580 4.0 nJ/mm2 Same as 3580 Same as 3580 Same as 3580 Same as 3580 T-3500, T-3500E, T-3500D D-3500 DC550V Adjustable output (during printing) DC+150V (fixed) (others) Same as 3580 Same as 3580 Same as 3580
Long-life fuser roller method Same as 3580 Fuser roller: Fuser roller: Coated with fluoroplastic (40) Coated with fluoroplastic (40) Pressure roller: PFA tube roller (35) Pressure roller: PFA tube roller (30) Cleaning roller for fuser roller (20) Cleaning roller for pressure roller (14) Cleaning felt roller for fuser roller (18) Halogen lamp (Lamp-heating method) IH coil (Induction-heating method) Turned ON/OFF by thermistor Same as 3580
(2) Cleaning (3) Heater
3 - 10
4. GENERAL OPERATION
4.1 Overview of Operation
Operation of copier Operation during initializing, pre-running and standby status Cassette feed copying by START key Copying operation Bypass feed copying Interrupt copying
4.2 Description of Operation

4.2.1 Warming-up (1) Initialization Power is turned ON. The IH coil comes ON. Set number 1 and WAIT WARMING UP are displayed The fan motors are turned ON. Initialization of the scanner system ~ The carriages move to the home position. ~ The carriages move to the peak detection position. ~ The exposure lamp is turned ON. ~ Peak detection (white color is detected by the shading correction plate) ~ The exposure lamp is turned OFF. Set number 1 and READY (WARMING UP) are displayed. (2) Pre-running operation The pre-running operation is started when the temperature of the fuser roller reaches a certain temperature. The fuser roller is rotated. The drum is rotated. ~ The main motor is turned ON. Initialization of laser optical system ~ The polygonal motor rotates at a low speed. Initialization of feeding system ~ Cassette trays go up. The pre-running operation is stopped after five seconds. (3) When the temperature of the fuser roller becomes sufficient for fusing: Set number 1 and READY are displayed.
4-1
DP4500/3500 GENERAL OPERATION
4.2.2 Standby state (ready for copying) Keys on the control panel operable When no key is pressed for a certain period of time: ~ Set number 1 and reproduction ratio 100% are displayed. The copier returns to the normal standby state. 4.2.3 Cassette feed copying (1) Press START key READY changes to COPYING. The exposure lamp is turned ON. The scanner motor is turned ON carriages -1 and -2 move forward. The main motor and exit motor are turned ON. ~ The drum, fuser unit, developer unit and exit roller are driven. (2) Cassette paper feeding The main charger, developer bias and discharge lamp are turned ON. The fans rotate at high speed. Feed clutch is turned ON. ~ The pickup roller, feed roller, separation roller and transport roller start to rotate. Paper reaches the upper feed sensor. ~ The upper feed sensor is turned ON. Paper reaches the registration roller. ~ The registration sensor is turned ON and aligning is performed. The feed clutch is turned OFF after a certain period of time. (3) After the carriage operation: The registration clutch is turned ON after a certain period of time paper is transported to the transfer section. The copy counter operates. (4) After the registration clutch is turned ON: The transfer charger is turned ON after a certain period of time. (5) Completion of scanning The scanner motor is turned OFF. The exposure lamp is turned OFF. The registration clutch is turned OFF (after the trailing edge of the paper passed the registration roller). READY (PRINTING) is displayed. (6) Paper discharging The exit sensor detects the trailing edge of the paper. The main charger, developer bias and discharge lamp are turned OFF. The main motor and exit motor are turned OFF. The drum, fuser unit and developer unit are stopped. The fans return to the standby rotation. READY is displayed and the copier enters the standby mode.
DP4500/3500 GENERAL OPERATION 4-2 December 2000 TOSHIBA TEC
(ms) 0
500 458 1658 1714 2296
1000
1500
2000
2500
3000
3500
4000
4500
5000
Scanner motor fwd. 6
154 1710 4156 402 2066 2246 1306 1284 2280 3908 2316
rev.
154
Exposure lamp
Main motor
Upper cassette feed clutch
0 18
246 366
Upper feed sensor
Timing in case of copying one A4 sized sheets fed from the upper cassette
4-3
Registration sensor
Registration clutch
MVDEN signal
Main charger
0 228 1398 2394 4156 4296
Developer bias
Discharge lamp
0 2278 3378
4296
Exit sensor
4.2.4 Bypass-feed copying (1) Insert some sheets of paper into the bypass tray. The bypass sensor comes ON. ~ READY FOR BYPASS FEEDING is displayed. The carriages move to the home position. (2) Press START key READY FOR BYPASS FEEDING changes to COPYING. The exposure lamp comes ON. The scanner motor ON Carriages -1 and -2 move forward. The main motor and exit motor are turned ON ~ The drum, fuser unit, developer unit and exit roller are driven. (3) Bypass feeding The main charger, developer bias and discharge lamp are turned ON. The fans rotate at high speed. The bypass feed clutch is turned ON. ~ The bypass pickup roller and feed roller start to rotate. ~ The bypass pickup roller is lowered. Aligning operation Paper reaches the registration roller. The bypass feed clutch is turned OFF after a certain period of time. (4) Hereafter, the operations (3) through (6) of 4.2.3. Cassette feed copying are repeated. 4.2.5 Interruption copying (1) Press the INTERRUPT key LED INTERRUPT is lit. Copying operation in progress is temporarily stopped, and the carriages -1 and -2 return to appropriate positions. JOB INTERRUPTED JOB 1 SAVED is displayed. Automatic density and reproduction ratio 100% are set. The set number remains the same. (2) Select the desired copy condition. (3) After the interruption copying is finished: PRESS INTERRUPT TO RESUME JOB 1 is displayed. LED INTERRRUPT goes OFF by pressing the INTERRUPT key, and the copier returns to the status before the interruption. READY TO RESUME JOB 1 is displayed. (4) Press START key The copying operation before the interruption is resumed.
4-4
4.3 Detection of Abnormality

When something abnormal occurs in the copier, the symbols corresponding to the type of abnormality are displayed. 4.3.1 Types of abnormality A) Abnormality cleared without turning off the door switch. (1) Add paper (2) Paper misfeed in bypass B) Abnormality not cleared without turning off the door switch. (1) Misfeed in copier (2) Add toner (3) Developer unit not installed properly (4) Dispose of used toner C) Abnormality not cleared without turning off the main switch. (1) Call for service 4.3.2 Description of abnormality A-1) Add paper [In case of the copier cassette or PFP cassette] (When cassette is not installed) Cassette not detected
Cassette is not installed or Cassette is installed but there is no paper in it:
No paper A signal is sent to the control circuit. Cassette in question flashes on the control panel. START key is disabled.
[In case of the copier cassette, PFP cassette or LCF cassette] (When cassette is installed) Based on the combination of the tray-up motor movement and the state of the tray-up sensor and paper-empty sensor, the CPU detects the presence/absence of paper.
4-5
When the power is turned ON or the LCF cassette is inserted (when the power is turned ON or copier cassette/PFP cassette is inserted), LCF performs initialization. Detects the presence/absence of paper Tray-up motor ON ~ The tray goes up At this time, the tray-up sensor and LCF empty sensor are OFF. If the tray-up sensor is not turned ON in a fixed time, the tray is in abnormal condition. Add paper is displayed regardless of presence/absence of paper. Cleared by turning ON and OFF the power Tray-up sensor is turned ON in a fixed time. ~ The tray-up motor stops. At this time, if the empty sensor is ON: It is judged that there is paper. At this time, if the empty sensor is OFF: It is judged that there is no paper. Cassette in question flashes on the control panel. When paper in the cassette gets short during copying, The tray-up sensor is turned OFF. The tray-up motor is turned ON. The tray goes up. The tray-up sensor is turned ON. The tray-up motor is stopped. The empty sensor is turned OFF during the copying in spite of the tray-up sensor being ON
It is judged that there is no paper. Cassette in question flashes on the control panel. The copying operation is stopped.
4-6
A-2) Paper misfeed in bypass ( ) During the bypass feeding The bypass feed clutch is turned ON. The registration sensor is turned ON. * The registration sensor is not turned ON in a fixed time (E12). Bypass misfeeding The bypass misfeeding symbol ( ) is displayed. The copying operation is disabled. Solution: The bypass paper sensor is turned OFF by removing the paper from the bypass tray. B-1) Misfeed in copier ( ) The exit sensor detects that the leading edge of paper is jamming. Registration clutch The registration clutch is turned ON. 1.056 sec. Exit sensor The exit sensor is turned ON. Timer If the exit sensor is not turned ON even though 1.056 seconds have elapsed, Paper jam (E01) The copying operation is stopped.
Registration clutch
ON
ON
1.056sec.
Paper jam (E01)
The exit sensor detects that the trailing edge Exit sensor of paper is jamming. The registration clutch is turned OFF. Timer 1.116 sec. The exit sensor is turned OFF. If the exit sensor is not turned OFF even though 1.116 seconds have elapsed, Paper jam (E02) The copying operation is stopped.
OFF
ON
1.116sec.
Paper jam (E02)
Immediately after the power comes ON Any of the sensors to detect a paper which is tranported on the transport path detects the presence of a paper (ON). Paper jam (E03)
4-7
The front cover is opened during copying. Paper jam (E41) The registration sensor detects that the leading edge of paper is jamming. The registration sensor is not turned ON in a fixed time after the leading edge of paper passed the transport roller. Paper jam (E12, E20, E21, E30, E33 and E3C) When paper is fed from the ADU: The registration sensor is not turned ON in a fixed time after the ADU clutch is turned ON. Paper jam (E11) When paper is transported into/from ADU: The ADU entrance/exit sensors do not detect the paper at the fixed timing. Paper jam (E51 or E52) When paper is fed from the main unit or PFP cassette: The registration sensor is not turned ON in a fixed time after the feed clutch is turned ON. Paper jam (E22, E31, E32, E34~E36, E3D and E3E: Error code defers depending on the paper source.)
4-8
B-2)
Add toner ( ) The toner density becomes low. The auto-toner sensor detects the absence of the toner. Control circuit Add toner displayed: the copying operation disabled. Solution: Open the front cover and replace the toner cartridge with a new one. Toner supplied copying operation enabled. Developer unit not installed properly The connector of the developer unit is disconnected. Developer unit not installed displayed. Solution: Connect the connectors of the developer unit and close the front cover.
B-3)
B-4)
Dispose of used toner ( ). The toner bag becomes full of toner. The toner recovery auger moves towards the rear of the copier: the toner bag full detection sensor is turned ON. Dispose of used toner is displayed.
When the toner bag full detection sensor is turned ON. Copying operation is disabled after the sheet which is being copied is discharged in the paper receiving tray. Solution: Replace the toner bag with a new one. C-1) Call for service An error code is displayed instead of the set number by pressing the CLEAR/STOP key and 8 key simultaneously when Call for service is flashing. Refer to the error code table in the Service Handbook.
4-9
4.4 Flow Chart

4.4.1 Immediately after the power is turned ON
Main switch ON
DC power ON Restart
YES Cover is open? NO IH coil ON
YES
Registration sensor ON? NO
Scanner motor ON
YES
Exit sensor ON? NO
Home position detected? YES
NO
2.5 seconds elapsed? YES Call for service
NO
YES
ADU entrance/exit sensors ON? NO
NO
Peak detected? YES C27 C28
Call for service C26
YES
Upper feed sensor ON? NO
YES
Lower feed sensor ON? NO
Paper jam E03
4 - 10
Temperature of the fuser roller ready for pre-running?
NO
YES Thermistor broken? YES Call for service NO

Fuser roller reached ready temp.?
Main motor ON Polygonal motor ON Tray-up motor ON
NO
IH coil broken? YES Call for service C44
NO
Polygonal motor in abnormal condition?
NO
IH error YES Call for service C47 C48 C49
NO
YES Call for service CA1
C41 C43
YES
Main motor OFF
B READY
4 - 11
4.4.2 Automatic paper feed copying

Press START key
Developer bias ON Main motor ON Main charger ON Exit motor ON Discharge lamp ON
Processing system control
Transport system control
Scanner system control
Polygonal motor normal rotation? YES
NO Call for service CA1
Laser ON
Feed clutch ON
Exposure lamp ON
Transfer charger ON
Feed clutch OFF
Carriages move forward
Registration clutch ON Counter ON/OFF Transfer charger OFF
Carriages stopped
Exposure lamp OFF
Registration clutch OFF NO H-Sync OK? Call for service CA2 NO YES NO Carriages move backward
Remaining set number=0?
Carriages stopped Scanner system control completed NG
Remaining set number=0?
YES
YES Laser OFF Exit sensor detected leading edge of paper? OK Processing system control completed
Paper jam E01

C
4 - 12
Paper jam E02
NG
Exit sensor detected trailing edge of paper? OK
Main charger OFF Discharge lamp OFF Developer bias OFF Exit motor OFF
Drum rotation reversed
Main motor OFF
Standby
4 - 13
4 - 14
5. DISPLAY UNIT
5.1 Control Panel and Display Panel
The display unit consists of key switches and touch-panel switches to operate the copier and select various modes, and LEDs and an LCD to display the state of the copier or the messages. When the operators attention is reguired, graphic symbols appear with messages explaining the condition of the copier in the LCD panel.
PRINTER/ NETWORK COPY
FAX
MAIN POWER
POWER DATA ERROR

ABC
MEMORY RX
1 2
DEF
INTERRUPT
1
GHI
2
JKL
3
MNO
FUNTION CLEAR
4
PQRS
5
TUV
6
WXYZ
FC
CLEAR/STOP
8 0
C/
START
JOB STATUS
MONITOR//PAUSE
HELP
Control panel
5-1
DP4500/3500 DISPLAY UNIT
5.2 Items Shown on the Display Panel
C Fig. 5.2-1
G J
D H
Fig. 5.2-2
5-2
5.2.1 Display during normal copying

No. 1 Message WAIT WARMING UP State of copier Scanner warming up - Displayed when the power is turned ON until the copier becomes ready to start scanning. 2 READY(WARMING UP) Ready for scanning - The set number 1 is displayed. Press - The copier is ready for scanning and waiting the digital key to change the number. for operator to select the copying conditions. - The number is reset to 1 by pressing - Returns to default setting if no key is pressed the CLEAR/STOP key. - Bypass feed copying is enabled. within 45 seconds. 3 READY - The set number 1 is displayed. Press Ready for copying - The copier is ready for copying and waiting for the digital key to change the number. the operator to select the copying conditions. - The number is reset to 1 by pressing - Returns to default setting if no key is pressed the CLEAR/STOP key. within 45 seconds. 4 5 6 COPYING Saving energy - press START Place next original Press START to copy The original is being scanned - Displayed by pressing the START key. The copier is in the energy saver mode - Bypass feed copying is enabled. - After scanning is completed, the copier becomes ready for the next scanning. - Can be cleared by pressing the START key or FUNCTION key. Note - The set number 1 and the reproduction ratio 100% are displayed when the power is turned ON.
- Displayed for SADF and manually Ready for the next original - Displayed by pressing the [Next original; placed originals. YES] icon. Power is OFF - Nothing is displayed in the display panel. - Power LED is lit in red. Ready for scanning - The copier is ready for scanning and waiting for the operator to select the copying conditions. Background printing is in progress - Press the POWER key.
READY (PRINTING)
- Since background printing is in progress, the scanned image is not output immediately. - Printing is resumed by adding paper to the cassette.
READY (ADD PAPER)
Ready for scanning - The copier is ready for scanning and waiting for the operator to select the copying conditions. Paper in the cassette has run out during printing
10 READY (FINISHER FULL)
- Printing is resumed by removing Ready for scanning - The copier is ready for scanning and waiting paper from the finisher. for the operator to select the copying conditions. The finisher is full of paper
11 READY (HOLE PUNCH DUST FULL)
- Printing is resumed by removing Ready for scanning - The copier is ready for scanning and waiting punching dust from the dust box. for operator to select the copying conditions. The punching dust box is full
5-3
No.
Message
State of copier
Note
12 READY (SADDLE STITCH TRAY FULL) 13 READY (SET CORRECT CASSETTE) 14 READY (ADDING TONER)
Printing is resumed by removing paper Ready for scanning - The copier is ready for scanning and waiting from the saddle stitcher unit. for the operator to select the copying conditions. The saddle stitcher is full of paper - Printing is resumed by changing Ready for scanning - The copier is ready for scanning and waiting the setting for cassette selection, for the operator to select the copying conditions. Cassette not installed during printing Ready for scanning - The copier is ready for scanning and waiting for the operator to select the copying conditions. The toner is being added from the cartridge then pressing the START key. - Printing is resumed automatically when the toner supply is completed.
15 READY (INSIDE TRAY FULL)
Ready for scanning - The copier is ready for scanning and waiting for the operator to select the copying conditions. The receiving tray is full of papers
- Printing is resumed automatically when the paper is removed from the receiving tray.
16 READY (CHECK STAPLER)
Ready for scanning - The copier is ready for scanning and waiting for the operator to select the copying conditions. The finisher unit runs out of the staples. Ready for scanning - The copier is ready for scanning and waiting for the operator to select the copying conditions. The saddle stitcher unit runs out of the staples
- Printing is resumed automatically when the staple cartridge is replaced with a new one. - Printing is resumed automatically when the staple cartridge is replaced with a new one.
17 READY (CHECK SADDLE STITCH STAPLER)
Ready for scanning 18 READY (USE GENUINE TOSHIBA - The copier is ready for scanning and TONER) waiting for the operator to select the copying conditions. Toner other than Toshibas has been used 19 ENTER DEPARTMENT CODE The copier is waiting for the operator to enter the department code. - Displayed when the department management function has been used.
The display is made to disappear by using the toner provided by Toshiba.
The copier becomes ready to start copying when the correct department code is entered.
5-4
5.2.2 Display in the abnormal condition

No. 20 21 Message Add paper Add toner Press HELP/INFO Abnormal state and indication in display panel Paper run out [Fig.5.2-1 A] - The cassette with no more paper flashes. Toner run out [Fig.5.2-2 B] - The toner cartridge is empty. - The message is displayed and the copier is stopped. 22 Set key copy counter Key copy counter not installed [Fig.5.2-1 C] - Insert the key copy counter (option). - The key copy counter was pulled out when copier was ready for scanning. - When the key copy counter is pulled out after the START key is pressed, the copier is stopped as soon as the copying is finished. 23 24 Paper misfeed in bypass Misfeed in copier Press HELP/INFO 25 Misfeed in copier Press HELP/INFO 26 Misfeed in doc. feeder Press HELP/INFO 27 Misfeed in finisher Press HELP/INFO 28 Misfeed in duplexer Press HELP/INFO Call for service Time for periodic maintenance CHECK PAPER IN LCF 32 Dispose of used toner Paper jam in the ADU [Fig.5.2-2 I] Paper jam in the finisher [Fig.5.2-2 H] - Press the HELP/INFO key and remove the paper following the messages shown on the display panel. - Press the HELP/INFO key and remove the paper following the messages shown on the display panel. 29 30 Motors, sensors, switches, etc. do not work - Turn OFF the power and solve the problem, then turn ON the power again. properly. [Fig.5.2-2 J] PM cycle - Time for maintenance - Copying is possible 31 Paper misloading in LCF - Paper is not stacked up correctly. Toner bag full - The toner bag is full of used toner. The copier stops its operation. [Fig.5.2-2 K] - Replace the toner bag with a new one and close the front cover. - Maintenance and inspection are performed by a qualified service technician. - Set the paper correctly. Misfeeding of cassette paper [Fig.5.2-2 F] - Paper fed from the cassette does not reach the feed sensor in a fixed time. Original jam [Fig.5.2-2 G] - Original jamming in ADF Bypass paper jam [Fig.5.2-2 D] - Paper jam at the bypass tray Paper jam in the copier [Fig.5.2-2 E] - Remove the paper from the bypass tray. - Press the HELP/INFO key and remove the paper following the messages shown on the display panel. - Press the HELP/INFO key and remove the paper following the messages shown on the display panel. - Open the jam-access cover and ADF unit to remove the original. Solution - Add paper to the cassette. - Select a different cassette. - Replace the toner cartridge and close the front door.
5-5
Operation -
State of copier
START key
C/S key
Digital keys
Cassette selection
INTERRUPT key
POWER key
Bypass feeding
Touch panel
FUNCTION key
CONDITION key
Scanner warming up
Printer warming up
Ready for copying
Printing -
Scanning
Paper run out
Toner empty -
Key copy counter not inserted (optional)
Paper misfeed in bypass copying
Paper jammed inside the machine
Service call indicated
5.3 Relation between Copier State and Operators Action
5-6
Ready for interrupt copying
In energy saver mode
Power OFF
: Operation enabled
- : Operation disabled

5.4.1 Dot matrix LCD circuit (1) Structure
(320 x 240)
The DSP-LCD-320 is an STN blue mode transmissive type LCD with a 320 x 240-dot display capacity. It consists of a driver LSI, frame, printed circuit board, and lateral type CFL backlight. *STN:Super Twisted Nematic (2) Block diagram
XSCL UD0 UD1 UD2 UD3 IC1 WF 80 IC2 80 IC3 80 IC4 80
IC5 LP LCDEN IC6
80
80
LCD PANEL 320 x 240 DOTS
VDD GND V0 VEE
Power supply
IC7
80
5-7
(3) LCD drive operation The following describes the drive operation to display the message READY.
PWA-F-SYS-320 PWA-F-SYS-300
GA (c) (c) LCD controller (d) R A M SYS CPU (b)
(a) PROM
LED driver
(d)
(a) The SYS CPU requests the PROM data to display READY. (b) The PROM outputs data to display the message to the SYS CPU. (c) The SYS CPU writes the data to be displayed on the LCD into the RAM. (d) The LCD controller/driver reads the display data from the RAM, and outputs the data to the LCD.
LED
LCD
KEY CPU
Key switches and touch panel

PWA-F-DSP-300 PWA-F-DSP-320
(4) Data Transmission

1/tF FRAME 240 LOAD 1 2 240 1 2 240 1 2 1/tF
FRAME
LOAD CP D0-D3
CP x(320/4) pulses
5-8
5.4.2 LED display circuit (1) Method of LED display ex) Displaying COPY .
5VL
Current
LDON0
"L" 17 D7 R6 IC8(7932)
"L"
Q3
(COPY) LED5
The transistor is turned ON when the LDON 0 signal becomes L level. Also, when IC8-17pin (D7) changes to L, the current flows from 5VL via the transistor to LED5 (COPY) to turn ON LED5 (COPY). Conditions to turn ON the LED (a) The transistor (Q3) connected to the LED anode is ON. (b) The output from the cathode side of the LED is L level. The LED is turned ON when (a) and (b) are satisfied.
5-9
5.5 Disassembly and Replacement

[A] Control panel (1) Take off the front side right cover, front top cover and control panel lower cover. (2) Disconnect one connector and remove 5 screws. Take off the control panel unit.
Control panel unit
(3) Remove 6 screws and take off the 3 brackets. (4) Disconnect 6 connectors and remove 2 screws. Release 6 lock supports and take off the DSP board.
Connector
DSP board Lock support
Lock support
(5) Remove 4 screws and take off the LCD board. (6) Remove 11 screws and take off the KEY board.
KEY board
LCD
5 - 10
6. IMAGE PROCESSING
6.1 General Description
The following diagram shows the process from scanning of the original to data writing on the photoconductive drum surface of the digital copier. ASIC stands for Application Specific IC, meaning an IC designed for a particular use.
Scanning section Image processing section Writing section
Original
System board [SYS] Original glass
Scanning/ image processing section [CCD]
Scanning control section [SLG]
Image processing/ writing control section [LGC]
Laser drive board [LDR] Polygonal motor drive board [POL]
Semiconductive laser element

Photoconductive drum
The followings are the boards used for image processing.

Board CCD board (PWA-F-CCD-320) LGC board (PWA-F-LGC-320) Number of ASIC 1 Function High-quality image processing, image memory editing, editing processing, gamma correction, gradation processing, external output system interface Smoothing processing, external input system interface, image area control, laser related control
6-1
DP4500/3500 IMAGE PROCESSING
6.2 Image Processing Circuit

6.2.1 General description The image of an original placed on the original glass is scanned by the carriage. The CCD (Charge Coupled Device) reads the optical image signals and converts them into the electrical signal. The electrical signals then undergo the analog-to-digital conversion and are changed into digital signal. The shading correction (correction of variance in CCD elements and the light source) is performed on the digital signal, then it is output as an image signal from the scanning section. The image processing section inputs this image signal from the scanning section and applies various types of image processing on it, then sends the output result to the writing section. Images are processed by the CCD board (PWA-F-CCD-320), SLG board (PWA-F-SLG-320) and LGC board (PWA-F-LGC-320) in this copier. (1) Image processing circuit on the CCD board One image processing ASIC is mounted on the CCD board, realizing the following functions: <Functions> High-quality image processing, image memory editing, edit processing, gamma correction, gradation processing and external output system interface (2) Image processing circuit on the LGC board One image processing ASIC is mounted on the LGC board, realizing the following functions: <Functions> Smoothing processing, external input system interface, image area control and laser related control
6-2
6.2.2 Configuration The following diagram shows the image processing section of this copier.
CCD board (PWA-F-CCD-320)
CCD
A/D conversion
Image processing section
Image processing ASIC for Scanner section Shading correction High-quality image processing Image memory editing Editing processing Gamma correction Gradation processing External output system interface
SLG board (PWA-F-SLG-320) Scanner CPU Scanning control LGC board (PWA-F-LGC-320) Image processing ASIC for Printer sction Smoothing processing External input system interface Image area control Laser related control Main CPU Laser writing control SYS board (PWA-F-SYS-320) Sorting, group copy, magazine copy, single side reduction/conjunction, double side reduction/ conjunction, image composition, date insertion, sheet insertion mode, etc.
Laser drive board (PWA-F-LDR-320) Laser drive
: Image data flow
Fig. A. Configuration of the image processing section

December 2000 TOSHIBA TEC 6-3 DP4500/3500 IMAGE PROCESSING
6.3 CCD Board (PWA-F-CCD-320)

6.3.1 Features (1) The image processing ASIC on the CCD board is controlled by the CPU on the SLG board. (2) The image processing ASIC on the CCD board realizes the following functions: High-quality image processing Image memory editing Editing processing Gamma correction Gradation processing External output system interface
6.3.2 Functions of image processing circuit An image processing ASIC mounted on the CCD board realizes the following functions: (1) High-quality image processing (a) Range adjustment This function converts the image signals into a density range, and adjusts it so that it is suited to each original image. It is possible to eliminate undesirable background density when an original with a certain level of density on the background, for example a newspaper, is copied. <Example>
Dynamic range Large After range adjustment Background Large Extended dynamic range
No. of pixels
Small
Small
Text Density Low High
No. of pixels
Density Low High
Histogram
6-4
(b) Filtering This function is enabled by a low-pass filter circuit and a high-pass filter circuit. Low-pass filter circuit This circuit removes image noise and electrical noise, decreases moire, and realizes high reproductibility of original by applying an averaging operation on the image signal of the targeted pixel and those of the pixels positioning next to it. <Example> The density of the targeted pixel position is x. The density of the pixel positions at the front and back of the targeted pixel are a and b respectively, x is converted to x through low pass filtering. When the matrix is (3 x 1):
x =
a+b+x 3
The above averaging operation is performed for all the pixel positions to accomplish the high reproducibility of the original. The following is when low pass filtering is applied on the primary scanning pixel.
Density After low-pass filtering
Density
0 1 2 3 4 5 6 7 8 9
Primary scanning pixel positions
0 1 2 3 4 5 6 7 8 9
Primary scanning pixel positions
(b) High-pass filter circuit The change of the density at the character outline becomes smooth when an original, such as text, with a great difference in density between the pixels placed next to one another is optically scanned and output from the CCD. This is caused by the characteristic of the lens and other factors. In this copier, the process such as the edge enhancement, is applied on the targeted pixel and the pixels around it to eliminate this phenomenon and realize high reproductibility of the original.
Solid black area Low contrast area Original
Image signal
After correction
6-5
(2) Image memory editing This function performs editing such as enlargement/reduction, mirror imaging, etc. using the line memory. Pixel data for one line in the primary scanning direction are stored in the line memory and the memory is renewed at each line. (a) Enlargement/reduction The enlargment/reduction is accomplished by using the line memory control function in the process of the image processing operation. <Example> Enlargement
100% 1 2 3 4 5 6 7 8 9 10
200%
<Example>
Reduction
100% 1 2 3 4 5 6 7 8 9 10
50%
(b) Mirror imaging This is accomplished by reading and outputting data from its end. (3) Edit processing This function performs trimming, masking and negative/positive reversing. (a) Trimming Using rectangular area signals, the image signals inside the rectangular area are left and the other image signals outside the area are eliminated. (b) Masking Using rectangular area signals, the image data inside the rectangular area are erased. (c) Negative/positive reversing This function reverses the entire data from negative to positive or vice versa.
6-6
(4) Gamma correction This function corrects the input/output characteristics of the scanner/printer and adjusts the image signals so that their input/output characteristics match with the copy mode. (5) Gradation processing This function works for genuine reproduction of halftone image such as photographs. (6) External output system interface This function controls the output of the output interface between the CCD board and the SYS board (PWA-F-SYS-320).
6-7
6.4 LGC Board (PWA-F-LGC-320)

6.4.1 Features (1) The image processing ASIC on the LGC board is controlled by the CPU on the LGC board. (2) The image processing functions of the LGC board realizes the following functions: Smoothing processing External input system interface Image area control Laser related control
6.4.2 Functions of image processing circuit An image processing ASIC mounted on the LGC board enables the following functions: (1) Smoothing processing This function removes jagginess and smoothes character outline of the text images input from the external input system interface, and output them. (2) External input system interface This function controls the input interface between the LGC board and the SYS board (PWA-F-SYS320). (3) Image area control This function sets the effective image area of four directions for the image to be output. (4) Laser related control This function controls the APC (Auto Power Control).
6-8
6.5 Scanning Section

Light reflected from original surface is directed to the CCD which performs the photovoltaic conversion, and the optical image data are converted into an electrical signal. This analog signal undergoes the A/D conversion processing and is changed into a digital signal. The signal then undertakes various corrective processes necessary for image formation.
CCD
Signal amplification
A/D conversion
Shading correction
Next stage
(1) Photovoltaic conversion The CCD elements convert the optical signal into electrical signal. ( (2) Signal amplification Amplifies the electrical signals converted in the CCD. (3) A/D conversion Converts the analog signal into the digital signal. (4) Shading correction The shading correction is applied on the signal read by CCD. (
Chapter 7.6.1)
Chapter 7.6.2)
6.6 Writing Section

The image signal processed by the LGC board is processed by the ASIC for writing control and laser drive board. The laser is controlled based on the signal, writing data on the drum. (1) Setting the effective image area ........................ Top, bottom, left and right margins (2) Horizontal synchronization signal (H-Sync) ....... The reference clock signal in the printer section clock generation section synchronized with the H-Sync and its signal. (3) Laser drive section ........................................... ON/OFF control of the semiconductive laser and APC (Auto Power Control) control.
6-9
6 - 10
7. SCANNER
7.1 Function
In the scanning section of this copier, the surface of an original is irradiated with a direct light and the reflected light is led through mirrors, lens and slit to the CCD where the optical-to-electrical conversion is performed, converting the optical image data into an electrical signal. This analog signal is changed to a digital signal, and then undertakes various corrective processes necessary for image formation. After that, an arithmetic operation is performed on the digital signal, which is then sent to the data writing section.
Exposure lamp Reflector
Shading correction plate Carriage-1 Rail for carriage-1 Original glass Drive pulley
Carriage-2
Rail for carriage-2
Lens CCD sensor CCD board SLG board
7-1
DP4500/3500 SCANNER
7.2 Construction
The construction and purpose of the scanning system are described in this section. (1) Original glass This is the glass on which originals to be copied are placed. The light from the exposure lamp is irradiated to the original through this glass. (2) Carriage-1 The carriage-1 consists of the exposure lamp, lamp inverter, reflector, mirror-1, etc. It is driven by the scanner motor and scans the original on the glass.
Reflector
Lamp inverter
Mirror-1
a. Exposure lamp This lamp is the light source to irradiate the original on the glass (one 20W Xenon lamp). b. Lamp inverter Controls lighting of the Xenon lamp. c. Reflector This is a plate to direct the light from the exposure lamp efficiently to the surface of the original on the glass.
Original Original glass Exposure lamp
Reflector
Mirror-1
DP4500/3500 SCANNER
7-2
d. Mirror-1 This mirror directs the light reflected from the original to the mirror-2 described later. (3) Carriage-2 The carriage-2 consists of mirror-2, mirror -3, etc. and directs the reflected light from the mirror-1 through mirrors-2 and -3 to the lens. This carriage is driven by the scanner motor as the carriage-1, at half the scanning speed of carriage-1 (the scanning distance is also half that of carriage-1).
Mirror-2
Mirror-3
7-3
DP4500/3500 SCANNER
(4) Lens unit The light reflected from mirror-3 is led to the CCD placed at the focal point of the lens which is fixed in position. (5) CCD drive PC board Processes such as the signal amplification, signal integration, A/D conversion and shading correction are applied on the electrical signal which was converted by the CCD.
CCD drive PC board
Lens unit
(6) Automatic original detection sensor The size of the original placed on the glass is instantly detected using the automatic original detection sensors (APS sensor) fixed on the base frame without carriage-1 having to move.
DP4500/3500 SCANNER
7-4

7.3.1 Scanner motor
Carriage wire
Scanner motor
Carriage-1 Pulley for carriage-2 20
Idler pulley 20
Motor pulley 2GT-Z21 Wire winding-up pulley/motor speed-reduction pulley 39/2GT-Z63
Idler pulley 20
Carriage-2 CRG2
(a) Scanning an original placed on the original glass This motor drives the carriages-1 and -2 through the timing belt and carriage wire. The scanner motor first drives carriages-1 and -2 to their respective home positions. The home positions are detected when carriage-1 passes the home position sensor. When the START key is pressed, both carriages start to move and scan the original on the glass. (b) Scanning an original placed on the ADF Carriage-1 stays at the shading position during the shading correction, and at the scanning position during the scanning operation.
7-5
DP4500/3500 SCANNER
Vcc2 6 7 5 4 3 2
DP4500/3500 SCANNER
current chopper method.
Vref
AB
BB
M1
Switching current fraction ratio Phase counter
M2
Excitation mode setting
CWB 10
Generation of pseudo sine wave
CLOCK 11
Switching pulse ON/OFF detection
M3 12
7.3.2 Two-phase motor drive circuit (fixed-current type)
The scanner motor is driven by the stepping motor driver IC-STK672-080 (IC1) with the unipolar fixed
7-6
RESET 13
Generation of phase excitation signal
Mol 14
Excitation status monitor
ENABLE 15
Generation of reference clock PWM control
CR oscillation
1 PG SUB
J19 1 6 2 3 4 J5 +24V B10 DG SCNEN-0A SCNDR-0A SCNRST SCREF-0A SCNMD3-0A SCNMD2-0A SCNMD1-0A SCNCK-0A GND VDD DG +24V PWA-F-SLG B9 B8 B7 B6 B5 B4 B3 B2 B1 A4 A3 A2 A1 +24V DG J18 13 6 11 8 7 6 5 4 3 2 4 5 5
SCN-MOT
Cut off output

Set motor rotation direction
Reset
Voltage to set value for motor current
Excitation mode setting (3) Excitation mode setting (2) Excitation mode setting (1) CLK input
GND VDD DG +24V
1 9 10 12 14 PWA-F-SDV
Circuit diagram Input signals

The motor is rotated by setting the number of pulses. SCNCK-0A CLK input Input * The internal circuit of the motor driver works when the first pulse becomes ON and the last pulse becomes OFF. The direction of the motor rotation is determined by the setting level of signal SCNDR-0A Sets the direction of motor rotation HClockwise direction (as seen from the output shaft) Input LCounterclockwise direction (as seen from the output shaft) Note: When SCNMD3-0A is L, do not change the rotation direction within 6.25s before the first pulse of the SCANCK-0A becomes ON and after the last pulse becomes OFF. SCNEN-0A Cuts OFF the drive output SCNREF-0A Voltage to set value for the motor current SCNMD1,2,3 Sets the exicitation Input -0A mode (1)(3) Input H Normal operation (The motor has been excited.) Input LExcitation drive output is forcibly shut OFF (the motor has not been excited). Motor wire current value is set in the range of 0 to 2.25 (A)/phase by applying the analog voltage 0 to 5 (V). Sets the excitation mode. Note: Do not change the setting wihin 5s after the first pulse becomes ON and the last pulse becomes OFF. Internal circuit of the driver is initialized by setting the motor to L SCNRST Reset Input level (pulse interval: 10s or more). The motor drive circuit is automatically reset when the power is turned ON.
December 2000 TOSHIBA TEC 7-7 DP4500/3500 SCANNER
7.4 Control of Exposure Lamp

7.4.1 General description Control circuit of the exposure lamp consists of the following three blocks: (1) Lighting device for the Xenon lamp (Inverter) Turns the exposure lamp ON/OFF. (2) CCD sensor circuit This circuit works to the convert the reflected light amount from the original surface and the shading correction plate to the electrical signals. The reflected light amount from the shading correction plate is read to control the exposure amount. (3) Image processing circuit The output signals from the CCD are digitized and the image processing such as gamma correction and shading correction is applied to them.
Original
Shading correction plate
Exposure lamp (Xenon lamp)
Lighting device for Xenon lamp (Inverter)
PWA-CCD
CCD sensor
PWA-CCD PWA-SLG A/D Image processing circuit

Scanner Main CPU CPU IC37
Construction of exposure lamp control circuit
DP4500/3500 SCANNER
7-8
7.4.2 Exposure lamp External electrode type Xenon fluorescent lamp is used as an exposure lamp in this copier. (1) Structure The fluorescer is applied to the inside surface of the lamp pipe (except for a part which serves as an opening) which is filled with the Xenon gas. A pair of the external electrodes covered by film with adhesive agent is attached around the pipe.
Adhesive agent Xenon gas Fluorescer PET film Aluminum tape electrode Glass valve
(2) Behavior inside the lamp The electron inside the pipe is led to the electric field by applying voltage to the pair of the external electrodes, and the discharge is started. The electrons then flow and clash with the Xenon atoms inside the pipe to excite them and allow them to generate ultraviolet rays. This ultraviolet rays convert the fluorescer into visible light.
(7) (2) (5) (4) (3)
(6)
(1)
(8)
(1)Electrode (2)Electron (3)Xenon atom (4)Ultraviolet ray (5)Fluorescer (6)Visible light (irradiated from the opening to outside the pipe) (7)Opening (8)Harness
7-9
DP4500/3500 SCANNER
7.4.3 Control circuit for the exposure lamp
+5VSW VDD E EXPON0

HCT00 IC10 HCT00 IC10
Xenon lamp
B C R92: 330 EXPON0A
P24
WDTOUT P23
WDTOUT0 WDTEN0
HCT00 IC10 HC14 IC9
Q2: RN2401
Lighting device for Xenon lamp
Scanner CPU
IC1 PWAFSLG320
Working conditions WDTOUT -0 H H L H WDTEN-0 H H X L EXPON-0 (Lamp drive signal) H L X X +5VSW ON ON OFF OFF Q2 OFF ON OFF OFF Xenen lamp OFF ON OFF OFF State of copier Normal operation Scanner CPU overdriving Call for Service
DP4500/3500 SCANNER
7 - 10
7.5 General Description of CCD Control

7.5.1 Opto-electronic conversion A CCD (charge-coupled device) is used to produce an electrical signal corresponding to the reflected light amount from the original. The CCD is a one-chip opto-electronic conversion device, comprised of several thousand light-receiving elements arranged in a line; each one of them is a few microns square. This model is equipped with a CCD which has 7,450 light-receiving elements. Each element of the light-receiving section consists of the semiconductive layers P and N. When the light irradiates the element, the light energy produces a (-) charge in the layer P; the amount of the charge produced is proportional to the energy and irradiating time. The charges produced in the light-receiving section are then sent to the transfer section where they are shifted by the transfer clock from left to right as shown in the figure below, and are finally output from the CCD. At this time, to increase the transfer speed of the CCD, image signals in the even-number and odd-number elements are separated and output in parallel via two channels.
Transfer clock Transfer section
1 2 3 4 7447 7448 7449 7450
Light energy layer N layer P Details of light receiving element
Light receiving section Transfer section Shift register Transfer clock
[Principle of the opto-electronic conversion by CCD]
7.5.2 Shading correction Signal voltages read by the CCD have the following characteristics. (1) Light source has variation in its light distribution. (2) Since the light beam reflected from the original is converged using a lens, the light path is the shortest at the center of the CCD and the longest at ends. This causes difference in the amount of light reaching the CCD (i.e. the light amount is maximum at the CCD center, gradually decreases toward ends). (3) Each of the 7,450 elements varies in the opto-electronic conversion efficiency. These variations need to be corrected and this correction is referred to as shading correction. Based on the black and white data obtained in advance, a normalization process using the following formula is applied to the raw image data to correct lighting variance and element variation of the image data. I=k k S K W (S K) (W K) : : : : Coefficient Image data before correction Black data (stored in black memory) White data (stored in white memory)
7 - 11
DP4500/3500 SCANNER
7.6 Automatic Original Size Detection Circuit

This circuit detects the size of original (standard sizes only) using the reflection type photosensors arranged on the base frame of the scanner unit. 7.6.1 Principle of original size detection The reflection type photosensors are placed on the base frame of the scanner unit as shown in the Fig. 7.6.1. Each sensor consists of an infrared light emitting diode (LED) on the light emitting side, and a phototransistor on the light receiving side. When there is an original on the original glass, light beams from the LEDs are reflected by the original and led to the phototransistors. This means that the size of the original is detected by checking which phototransistors are turned on or are not.
[A4 Series] Original glass Original Original [LT Series] Original glass
APS-5 APS-2 APS-3 APS-4 APS-1 APS-2 APS-3 APS-1
APS-6
Fig. 7.6-1 7.6.2 Process of original size detection (1) When the copier is in the original size detection mode, the carriage-1 is set at its home position. (2) When the platen cover is opened, the sensors receive the light reflected from the original and if one of the matrix conditions shown in (4) for original sizes is satisfied, the size of the original is instantly detected. (3) The output signal from each sensor is input to the CPU on the scanner control PC board to determine the size of the original.
[A4 Series]
APS-5 33 P81 VDD VDD
[LT Series]
APS-6
33
P81
APS-4
32
P80 APS-3
30 P96
Reflection type photosensor
APS-3
30
P96
Reflection type photosensor

29
APS-2
29 P95
APS-2
P95
APS-1
28
P94
APS-1
28
P94
GND
PWA-SLG
GND
PWA-SLG
Fig. 7.6.2 Original size detection circuit

DP4500/3500 SCANNER 7 - 12 December 2000 TOSHIBA TEC
[A4 Series]
A5
B5
A4
APS5
APS1
A5R
B5R
APS2
A4R B4
APS4
APS3
A3
[LT Series]
ST
LT
APS6
APS1
STR
APS2
LTR
APS3
LG
LD
Fig.7.6.3 Sensor detection points

December 2000 TOSHIBA TEC 7 - 13 DP4500/3500 SCANNER
(4) Original size is determined by the combination of the presense/absence of signals which are output at each detection point. The combination chart for size determination of A4 series and LT series are as follows.
[A4 Series] Size judgement A3 A4 B4 B5 A4-R A5 B5-R A5-R [LT Series] Size judgement LD LT LG LT-R ST ST-R Code 1 0 Output signal H L APS-1 0 0 0 0 1 0 Original Absent Present APS-2 0 0 0 0 0 1 APS-3 0 0 1 1 1 1 APS-6 0 1 0 1 1 1 APS-1 0 0 0 1 0 1 0 0 APS-2 0 0 0 0 0 0 1 1 APS-3 0 0 0 0 1 1 1 1 APS-4 0 0 1 1 1 1 1 1 APS-5 0 1 0 1 0 1 0 1
* When the platen sensor is OFF; The following points are determined by output signals from the APS sensors Size (The combination of the signals satisfy the above chart) : Size is displayed on the control panel and an appropriate paper and reproduction ratio are selected. Size retention (The combination of the signals do not satisfy the above chart) : Retains the latest original size recognized (or no original state) until a new paper size is recognized. No original (output from all the sensors are 1.) : Reproduction ratio and paper size are not selected. Size change is always observed and detected. Carriage-1 stays at the standby position even if the reproduction ratio changes corresponding to the change of the original size. * When the platen sensor is ON; Retains the latest original size (or no original state) recognized right before the platen sensor is turned ON regardless of the state of the APS sensor output signals.
DP4500/3500 SCANNER
7 - 14
About reflection type photosensor The reflection type photosensor is comprised of an infrared light emitting diode and a phototransistor. It uses the pulse modulation to detect an original.
Original
8sec 130sec LED
Phototransistor
The light emitting diode is driven by a pulse having a 130-sec cycle and an 8-sec ON time. When the phototransistor receives the same signal as this pulse, it is determined that there is an original. The pulse modulation is performed inside the reflection type phototransistor.
7 - 15
DP4500/3500 SCANNER

[A] Original glass (1) Take off the right top cover. (2) Remove the original glass.
Original glass
[B] Lens cover

Lens cover
(1) Remove the original glass. (2) Remove the rear top cover. (3) Remove 7 screws and disconnect one connector. Take off the lens cover.
Connector
[C] Automatic original detection sensor (APS sensor) (C-1) A4 series (1) Remove the original glass. (2) Disconnect one connector and remove one screw. Take off 5 APS sensors.
APS sensor
(C-2) LT series (1) Remove the original glass and lens cover. (2) Disconnect one connector and remove one screw. Take off 4 APS sensors.
APS sensor
DP4500/3500 SCANNER
7 - 16
[D] Exposure lamp (1) Take off the left, rear and front top covers. (2) Disconnect the connector of the exposure lamp and release the harness from the clamp.
Connector
Clamp
(3) Move carriage-1 to the position where both sides of the frame are cut out. Remove one screw and take off the exposure lamp.
Exposure lamp
[E] Lens unit (1) Remove the original glass and lens cover. (2) Disconnect 2 connectors and remove 2 screws. Take off the lens unit.
Lens unit
Connector
Note: 1. When installing the lens unit, fix it while it is pushed in the direction of the white arrow. 2. Refer to 2.7.2 Lens unit in the Service Handbook to adjust the magnification ratio of the lens. 3. When replacing the lens unit, do not touch the screws shown with the arrows.
[Rear side]
[Front side]
7 - 17
DP4500/3500 SCANNER
4. Handle the unit with care. Do not touch the adjusted area and lens. (Hold the unit as the right figure.)
Rear side Lens
Adjusted area Front side
[F] Scanner motor (1) Remove the rear side upper cover. (2) Disconnect one connector. (3) Detach the spring. (4) Remove 2 screws and take off the scanner motor with the bracket attached.
Spring
Connector
Scanner motor
Note: When installing the motor, take the following procedure. 1. Fix the bracket to the frame temporarily. 2. Attach the tension spring to the bracket and tighten the screws to fix the bracket on the frame while the bracket and spring are balanced.
[G] Carriages-1 and -2 (1) Remove 2 screws and take off the plate springs of the front and rear sides. Remove the ADF original glass.
ADF original glass
Plate spring
DP4500/3500 SCANNER
7 - 18
(2) Move the carriages to the exit side. (3) Remove 2 screws and take off the brackets fixing the carrage-1 to the wire.
(4) Remove the square sticker fixing the lamp cable to the base and disconnect the connector of the lamp cable from the SLG board.
SLG board Connector
Lamp cable
Sticker
(5) Take off carriage-1 while inclining it.
Carriage-1
(6) Take off mirror-1. (7) Remove 2 screws and take off the inverter board.
Inverter board
Mirror-1
7 - 19
DP4500/3500 SCANNER
(8) Attach the wire holder jigs to the pulleys to prevent the wires from loosening. Note: Refer to 2.7.1 Adjustment of the carriages in the Service Handbook for the direction of the wire holder jig when it is attached.
Wire holder jig
Pulley
(9) Detach the tension springs of the front and rear sides. (10)Remove the carriage wires.
Tension spring
Carriage wire
(11)Take off carriage-2 while its corner is pushed into the window of the rail and inclining the carriage.
Window
Carriage-2
(12)Take off mirrors-2 and -3.

Mirror-2
Mirror-3
DP4500/3500 SCANNER
7 - 20
[H] Platen sensor (1) Disconnect one connector. Release the latches and remove the platen sensor.
Platen sensor
[I] Home position sensor (1) Disconnect one connector. Release the latches and remove the home position sensor.
Home position sensor
[J] Damp heater (1) Remove the original glass, rear top cover and lens cover. (2) Remove one connector from the lens cover. Remove 2 screws and take off the damp heater for the lens.
Lens cover
Damp heater for the lens
Connector
(3) Release the harnesses from 2 clasps and one clamp and disconnect one connector.
Connector
Clamp
December 2000 TOSHIBA TEC 7 - 21
Clasp
DP4500/3500 SCANNER
(4) Move the carriages to the feed side. Remove 2 screws. Slide the damp heater for the mirrors to the rear side and take it off.
Damp heater for the mirrors
DP4500/3500 SCANNER
7 - 22
8. LASER OPTICAL UNIT

The laser optical unit radiates the laser beam onto the photoconductive drum responding to the digital image signals sent from the scanner, printer controller, etc. to create a latent image. The image signal is converted into the light emission signal of the laser diode on the laser drive board, then radiated on the drum through the optical elements such as the cylinder lenses, polygonal mirror and f lens. The unit must not be disassembled in the field as it is very sensitive to dust and finely adjusted at the factory.
8-1
DP4500/3500 LASER OPTICAL UNIT
Laser diode Laser emission unit Polygonal motor Finite focus lens Polygonal mirror Laser drive board Front Aperture Cylinder lens Paper exit f lens-1
H-Sync detection PC board
Polygonal motor drive board Rear f lens-2
Slit glass (for outgoing laser beam)
H-Sync returning mirror
[Laser Optical Unit]
Paper exit Front
Rear
[Appearance]
8-2
8.2 Structure
(1) Laser emission unit This unit consists of the laser diode, finite focus lens and aperture. a. Laser diode This laser diode features low droop, small laser variation and low threshold current. The aperture determines the shape of the laser beam at the laser emission position. The laser diode radiates the laser beams responding to the laser emission control (ON/OFF) signals from the laser drive PC board. The laser beams which passed through the finite focus lens are focused on the drum surface. b. CAUTION The beam of the semiconductive laser is very weak (about 5 mW), but the focused parallel rays create great energy which is hazardous. Some components of the laser optical unit are made of metal. However there is no danger of laser leakage during the normal operation, since the unit is in a sealed container. Note: The laser beam is not visible. Pay the closest attention when handling the laser unit components or performing operations such as adjustment of the beam. This kind of operation which is very dangerous must only be performed only by specially trained staff. The warning label shown below is attached inside of the front cover.
DANGER INVISIBLE LASER RADIATION WHEN OPTICAL UNIT OPEN OR DRUM UNIT REMOVED
AND INTERLOCK DEFEATED. AVOID DIRECT EXPOSURE TO BEAM.
>PS<
VORSICHT UNSICHTBARE LASERSTRAHLUNG, WENN DIE ABDECKUNG GEFFNET ODER

DIE TROMMEL ENTFERNT UND DIE VERRIEGELUNG UNWIRKSAM GEMACHT WIRD. NICHT DIREKT DEM STRAHL AUSSETZEN.
DANGER RAYON LASER INVISIBLE LORSQUE LE BLOC OPTIQUE EST OUVERT, LE

TAMBOUR RETIRE ET LE VERROUILLAGE HORS D'USAGE. EVITER L'EXPOSITION DIRECTE AU RAYON.
PELIGRORADIACION INVISIBLE DE LASER CUANDO LA UNIDAD OPTICA ESTA ABIERTA O LA UNIDAD

DEL CILINDRO ES RETIRADA Y CUANDO EL INTERRUPTOR DE SEGURIDAD ESTA DESACTIVADO. EVITE EXPOSICION DIRECTA AL RAYO.
[CAUTION] Do not put the tools near the path of the laser beam. Take off your watch, rings, bracelets, etc. when handling the unit.
8-3
(2) Polygonal mirror motor unit This unit consists of the polygonal mirror, polygonal mirror motor and polygonal mirror cover. a. Polygonal mirror motor This motor rotates the polygonal mirror at high speed. The DC motor controls the rotation speed of the mirror motor as follows: During standby During copying b. Polygonal mirror The laser beams emitted from the laser diode are reflected by this mirror. As the polygonal mirror is rotated by the polygonal mirror motor, the reflected laser light moves in sync with the rotation. The direction of this movement is the primary scanning direction of the image. One scan is performed on one plane of the polygonal mirror. As the polygonal mirror has eight planes, eight scans are performed in one rotation of the polygonal mirror. c. Polygonal mirror cover The polygonal mirror cover reduces the windage loss and noise, prevents adhesion of foreign objects on the mirror surface and releases heat.
(C)
Laser light
(A)
Drum
: 10,000 rpm (approx.) : 38,000 rpm (approx.)

(B)
Laser light
Drum
Laser light
Drum
Fig. 8.2-1
One scan is completed by completion of steps (A) through (C). One scan is performed on one plane of the polygonal mirror. Eight scans can be made with one rotation of the polygonal mirror.
8-4
(3) f lenses -1 and -2 These two lenses perform the following corrections on the laser beams reflected by the polygonal mirror.
a. Uniform-velocity scanning Since the polygonal mirror is rotating at a uniform velocity, the laser beam reflected from the mirror scans over the drum surface at the same angle; namely, the pitch between the dots on the drum is wider at both ends than at the center of the scanning range. The f lenses correct this difference, making all the dot-to-dot pitches equal on the drum surface.
Drum
Wider
Narrower
Lens-1
Lens-2 Same intervals
Fig. 8.2-2
b. Face tilt correction The reflecting face of the polygonal mirror is tilted slightly to one side against the perfect vertical. The f lenses correct the displacement of the laser beam on the drum (against the horizontal direction) which occurs due to the tilt of the reflecting face. c. Sectional shape of laser beam The shape of the laser beam spotted on the drum is adjusted. (4) H-Sync detection PC board
Mirror plane is tilted.
Deviation
Fig. 8.2-3
The laser light started to be scanned by one of the reflected faces of the polygonal mirror is reflected by the H-Sync detection mirror and goes into the PIN diode on the H-Sync detection PC board. The primary scanning synchronizing signal is generated based on this incomming laser light.
8-5
(5) Laser Drive Board This control board has the following functions: a. b. c. APC control function (corrects disparity of the laser intensity caused by temperature) Laser ON/OFF function Function to generate the primary scanning synchronizing signals
(6) Slit glass The slit glass is located where the laser beams are output from the laser optical unit, and it protects the unit from dust.
8-6
8.3 Laser Diode

The laser used in this copier is a AlGaAs type semiconductive laser. It is oscillated in the single-horizontal mode and its wavelength is approx. 785 nm. This semiconductive laser outputs 5mW with a standard DC power supply. Laser intensity is controlled using the output from the PIN diode for light output monitoring in the semiconductive laser. The relation between the current and optical output of the semiconductive laser is as shown on the
Optical Output (mW)
right. Light emission is started when the forward current reaches or becomes greater than the threshold current, and outputs the monitor current which is proportioned to the optical output. The threshold current and monitor current vary depending on each semiconductive laser due to their individual characteristic. The optical output has to be adjusted to maintain a constant value. Since the optical output of the semiconductive laser is decreased when the temperature of the laser rises, the APC control needs to be performed to maintain a constant optical output.
High temp. Regulation
Low temp.
Forward current Monitor current Current (mA)
Threshold current
Fig. 8.3-1
Power source
Semiconductive laser Laser power comparison circuit Laser driver circuit
Constant optical output
Monitor efficiency regulation circuit
Monitor output
Fig. 8.3-2 Block diagram
Fig. 8.3-2 shows a block diagram of the semiconductive laser control circuit. The semiconductive laser performs monitor efficiency regulation (a process to control the monitor current for the light amount), and laser itself is adjusted to output initially an emission of approx. 2.11mW (421 W on the drum surface). The regulated voltage of the monitor output is fed back to the laser power comparison circuit. This monitor output voltage is compared with the laser power voltage set for the control circuit for every scanning. The laser driver circuit increases the forward current if the laser power is insufficent and drecreases the current when the power is excessive to maintain a constant optical output.
8-7

[A] Laser unit fan (1) Take off the rear side upper/lower covers, receiving tray, exit side rear cover (with the option cover attached) and left cover. (2) Remove 7 screws and take off the stay.
Stay
(3) Remove 4 screws and take off the plate cover of the system unit. (4) Disconnect one connector and remove 2 screws. Take off the laser unit fan. [B] Laser optical unit (1) Remove 2 screws and take off the bracket.
(3) (3)
Plate cover (3) (4) (3)
[B] (1) (4)
[B] (1) Bracket
Laser unit fan
(2) Remove 4 fixing screws at the front side and 3 at the rear side of the system unit.
[Front side]
[Rear side]
8-8
(3) Disconnect all connectors of the logic PC board and 2 of the system PC board. (4) Release all harnesses from the clamps.
System PC board
Connectors of system PC board
Logic PC board
(5) Remove one binding band at the rear side.

Binding band
(6) Pull out the system unit in the direction of the arrow.
System unit
8-9
(7) Remove the 3 fixing screws of the laser optical unit. (8) Take out the laser optical unit. Notes: 1. The laser optical unit should be placed with the motor facing upwards and not impressing any load on it. 2. Do not leave fingerprints or stains on the slit glass. 3. The laser optical unit is a precise apparatus. Pay close attention not to make any impact or vibration on it. 4. The laser optical unit is precisely adjusted and very sensitive to dust and stains. Do not disassemble the unit in the field.
[Fixing screws of laser optical unit]
8 - 10
9 PAPER FEEDING SYSTEM

9.1 Functions
The purpose of this system is to pick up paper from the cassette or bypass tray and send it to the transfer section. The paper feeding system mainly consists of the pickup roller, feed roller, separation roller, transport roller, registration roller, bypass paper sensor, paper-empty sensor, paper-stock senser, feed sensor, registration sensor and the drive system for these components. (1) Pickup roller This roller moves up and down to draw out a sheet of paper from the bypass tray or the cassette and send it to the feed roller. (2) Feed roller This roller is mounted against the separation roller. It transports the paper from the pickup roller to the registration roller. (3) Separation roller This roller is mounted against the feed roller. When two sheets of paper or more are sent from the pickup roller, the load of the torque limiter of the separation roller is greater than the frictional force between the sheets. As the result, the separation roller is stopped and the lower sheet of paper is not advanced any further. When only one sheet of paper is sent from the pickup roller, the separation roller is forced to rotate following the feed roller. (4) Separation pad This pad is mounted against the bypass feed roller. When two sheets of paper or more are sent from the bypass pickup roller, the friction between the separation pad and the paper is greater than that between the sheets. Therefore, the sheet(s) other than the paper at the top is(are) not transported any further. When only one sheet is sent from the bypass pickup roller, the paper is transported forward due to the friction between it and the bypass feed roller. (5) Transport roller This roller transports the paper sent from the feed roller to the registration rollers. (6) Registration roller Paper sent from the feed roller is pushed against the registration rollers, which align its leading edge. The registration rollers then rotate to transport the paper to the transfer section.
9-1
DP4500/3500 PAPER FEEDING SYSTEM
The following is the sensors which detect the presence/absence of paper and the position of the paper being transported, to control the ON/OFF of the rollers. (7) Bypass paper sensor This sensor detects if paper is set in the bypass tray. If it is, bypass feeding is performed in preference to cassette feeding. (8) Paper-empty sensor This is a emission type sensor and detects the presence/absence of paper in the cassette using an actuator. When there is no paper in the cassette, the actuator blocks the light path of the sensor, and the sensor determines that there is no paper. (9) Paper-stock sensor This is a emission type sensor which detects the amount of paper remaining in the cassette using an actuator. When the remaining paper is almost finished and has become around 100 sheets, the actuator blocks the light path of the sensor to notify that the paper quantity is getting less. (10) Feed sensor This sensor detects if the leading edge or trailing edge of the paper passed the feed roller. It also detects jams such as paper misfeeding. (11) Registration sensor This sensor detects that the leading edge of the paper has reached the registration roller and the trailing edge of the paper has passed the registration roller.
9-2
13 14
12 4 6 15 5
11
8 10
16
Sectional view of paper feeding section (Front side)
No. 1 2 3 4 5 6 7 8
Name Bypass separation pad Bypass feed roller Bypass pickup roller Upper cassette separation roller Upper cassette feed roller Upper cassette pickup roller Transport roller Lower cassette separation roller
No. 9 10 11 12 13 14 15 16
Name Lower cassette feed roller Lower cassette pickup roller Bypass paper sensor Registration sensor Registration roller (rubber roller) Registration roller (metal roller) Upper feed sensor Lower feed sensor
9-3
20
(G27/G18)
(Clutch/G28) (G40/G34) (Clutch/ G28) (G20/G25)
17
(G23) (G21) (G24/G30)
(G31/G38)
(G35)
(G27/G21) (Clutch/G28) (G34)
18
(G33) (Clutch/ G28)
(G35)
(Clutch/G35)
(G33)
21
19
Paper feeding section drive system (Rear side)
No. 17 18 19 20 21
Name Bypass feed clutch Transport clutch (low speed) Transport feed clutch (high speed) Upper cassette feed clutch Lower cassette feed clutch
9-4
9.2 Description of Operations

9.2.1 Operation of bypass pickup roller
Feed roller Lever spring
Pickup lever
Pickup roller
Pickup arm Spring clutch
When driving force is applied to the feed roller, the rotational force is transmitted to the pickup lever via the spring clutch, and the pickup arm falls by its own weight. At this time, the pickup lever is stopped when the spring clutch contacts with the stopper. When the driving force is removed from the feed roller, the pickup lever and pickup arm are lifted up by the force of the lever spring. 9.2.2 Operation of cassette pickup roller
Insertion direction
Pickup roller
Lever (a)
A Spring (b)
Roller holder
When the cassette is inserted, the protrusion at the rear side of the cassette turns the lever (a) up in the direction of the arrow A. The pickup roller and roller holder are then lowered by the spring (b).
9-5
9.2.3 Separation of paper This model is equipped with a separation roller which works to prevent multiple paper feeding. The separation roller unit consists of the feed roller, separation roller, spring joint, etc., as shown in the right figure. The feed roller is rotated by the feed clutch in the direction of the arrow ( the pickup roller rotation. The figure at lower right shows how duplicate feeding is prevented: Since the friction between two sheets is small, the lower sheet is stopped by the separation roller and is not transported any further while the upper sheet is transported by the feed roller in the direction of the arrow ( ).
Separation roller Feed roller
) at the same timing as

Spring joint
[Example] When only one sheet enters between the rollers: Since the transporting force of the feed roller is greater than the braking force of the separation roller, the separation roller is forced to rotate following the feed roller, making the sheet go forward to the registration roller. When two sheets enter between the rollers at the same time: Since the transporting force of the feed roller and the breaking force of the separation roller are greater than the frictional force between two sheets, the paper A is transported in the direction of the arrow ( ) and the paper B is braked by the separation roller and is not transported any further.
Separation roller A B Feed roller
9-6
9.2.4 General operation [A] From power ON to standby status (1) When the copier is turned ON, the tray-up motor starts to rotate forward and the upper cassette tray starts to rise. When the tray-up sensor is turned ON (L H), the tray-up motor is turned OFF causing the tray to stop. At this time, if the empty sensor is OFF (L), it is judged that there is no paper in the cassette. If the empty sensor is ON (H), there is paper in the cassette. The tray stops at raised position regardless of the presence/absence of paper. The tray-up motor then starts to rotate in reverse and the lower cassette tray starts to rise. The lower cassette tray is stopped in the same manner as the upper cassette tray, and the empty sensor detects if there is paper in the cassette. (2) If the cassette is not completely inserted when the copier is turned ON, the tray in that cassette does not rise. When the cassette is inserted completely, the tray is raised and checks the presence/absence of paper. (3) If either of the feed sensors is ON (meaning there is paper on the transport path) when the copier is turned ON, it is determined that a paper jam has occurred and no operation is enabled until the jammed paper is removed. [B] Standby status (1) After the tray is moved up to check the presence/absence of paper as described above, the copier enters the standby state. In the standby mode, the tray remains at the raised position. (2) When a cassette is inserted or removed in the standby state, the tray is raised again and checks the presence/absence of paper. [C] Bypass feeding The bypass paper sensor detects paper in the bypass tray. The bypass feed clutch is turned ON, and then the bypass pickup roller and bypass feed roller are rotated. The bypass pickup roller is lowered to start feeding the paper. The leading edge of the paper turns the registration sensor ON and the paper is aligned by the registration rollers. The bypass feed clutch is turned OFF, causing the bypass pickup roller and bypass feed roller to stop rotating. The bypass pickup roller moves up. The registration clutch is turned ON, and the paper is transported to the transfer section.
9-7
[D] Cassette feeding (D-1) Lower cassette The feed clutch and transport clutch (high speed) are turned ON, and the pickup roller, feed roller and the transport roller are rotated to start feeding paper. The leading edge of paper turns ON the lower feed sensor. The feed clutch and transport clutch (high speed) are then turned OFF and back ON. The leading edge of the paper turns ON the registration sensor and the paper is aligned by the registration rollers. The feed clutch and transport clutch (high speed) are turned OFF causing the pickup roller, feed roller and transport roller to stop rotating. The registration clutch and transport clutch (low speed) are turned ON, and the paper is transported to the transfer section. (D-2) Upper cassette The feed clutch is turned ON and the pickup roller and feed roller start to rotate to start feeding the paper. The leading edge of paper turns ON the registration sensor, and the paper is aligned by the registration rollers. The feed clutch is turned OFF causing the pickup roller and feed roller to stop rotating. The registration clutch is turned ON, and the paper is transported to the transfer section.
9-8
9.3 Drive Circuit of Tray-up Motor

Tray-up motor (T-UP-MTR) Block diagram of TA8428 : Driven by IC44 (upper/lower cassettes) (LGC: TA8428)
Thermal shutdown overcurrent protection circuit
Control logic
1 IN1
2 IN2
3 M(+)
4 GND
5 M()
6 N.C. (Not used)
7 VCC
IN1 and IN2 are input terminals to receive the signals from the microcomputer. The control logic, based on the signals from the microcomputer, controls the rotation direction and ON/OFF of the motor.
Input IN1 H L H L IN2 H H L L L L H Output M (+) M () L H L
Remarks BRAKE CCW (upward) CW (downward)
OFF (high impedance) STOP
9-9

[A] Bypass feed unit (A-1) Bypass feed unit (1) Remove the feed side rear hinge cover. (2) Disconnect one connector and release the harness from the clamp.
Connector
Clamp
(3) Remove 2 screws. Release 2 hooks while the bypass feed unit is lifted up, then take it off toward you.
(A-2) Paper size detection board (1) Release the harnesses from 3 clamps and disconnect one connector. (2) Remove 2 screws and take off the hinge unit.
Hinge unit
Clamp
Connector
(3) Detach the bypass tray from the protrusion at the fulcrum of the frame.
Fulcrum
Bypass tray
9 - 10
(4) Remove 3 screws and release 4 latches. Take off the bypass tray upper cover.
Latch Bypass tray upper cover
Latch
(5) Remove one screw and plate spring. (6) Remove one screw (indicated with a white arrow) from the back, then take off the bracket.
Bracket
Plate spring
(7) Disconnect one connector and remove one screw. Take off the paper size detection board.
Paper size detection board Connector
Note: When reassembling the bracket, make sure that the pointer of the bracket is positioned as it was before the disassembly.
Pointer
9 - 11
(A-3) Separation pad (1) Remove 4 screws and take off the bracket.
Bracket
(2) Pull the separation pad in the direction of the arrow to remove it from the bracket. Detach the spring and then take off the pad.
Separation pad
Spring
(A-4) Bypass feed roller (1) Remove one screw and take off the front side paper guide. (2) Remove one clip and take off the bypass feed roller together with the one-way clutch.
(A-5) Bypass feed cover (A-4)
(A-5) Bypass pickup roller (1) Remove 2 screws and take off the bypass feed cover. (2) Remove one clip and pull out the shaft in the direction of the arrow. Detach the timing belt, and take off the bypass pickup roller.
Bypass feed roller One-way clutch
Clip
(A-5)
Front side paper guide
Shaft
Timing belt Clip Bypass pickup roller
9 - 12
Notes: Pay attention to the following when assembling the bypass feed roller and pickup roller. 1. Put the timing belt securely around the pulley. Make sure that the belt is also put on the belt tensioner. 2. Put the timing belt on the bypass pickup roller correctly. 3. Attach the clip in the groove on the shaft securely. 4. Make sure that there is no dirt or oil staining on the surface of the timing belt, pulley and rollers. 5. Pay attention to the direction of the bypass pickup roller and feed roller when they are installed.
Separation pad Pickup roller Feeding direction Feed roller
(A-6) Bypass paper sensor (1) Release the harness from the 2 clamps. Remove one screw and take off the sensor bracket. (2) Disconnect the connector. Release the latches and take off the bypass paper sensor.
Bypass paper sensor Connector Clamp
9 - 13
(A-7) Bypass feed clutch (1) Release the harness from the 2 clamps and disconnect the connector. Remove the E-ring.
Clamp
Connector E-ring
(2) Remove 4 screws. Take off the bypass feed roller unit sliding it in the direction of the arrow.
Bypass feed roller unit
(3) Remove one E-ring and loosen one setscrew. Take off the bypass feed clutch. Note: When assembling the bypass feed clutch, push it against one end (feed roller unit side) of the groove on the shaft.
Groove
E-ring Setscrew Feed clutch
9 - 14
[B] Lower feed sensor (1) Remove the feed side lower cover. (2) Open the jam access cover, and take out the transfer/separation charger. ( (3) Disconnect 3 connectors. (4) Disconnect the fan connector of the front side while the jam access cover unit is lifted up and moved slightly in the direction of the arrow, then take off the jam access cover unit. Note: Make sure that the harnesses are securely caught under the hooks when the connectors of the transfer/separation charger are connected. Chapter 11.5)
Fan connector
Connector
Hook
Black Red
Red (in a black tube)
(5) Remove one screw and take off the terminal cover, then disconnect the connector.
Terminal cover
Connector
(6) Remove 3 screws. Slide the transport guide unit to the rear side and take it off from the front side.
Transport guide unit

December 2000 TOSHIBA TEC 9 - 15 DP4500/3500 PAPER FEEDING SYSTEM
(7) Disconnect the connector. Release the latches and remove the lower feed sensor.
Connector
Lower feed sensor
[C] Registration sensor and upper feed sensor (1) Remove the front side right cover. (2) Release the latch from the shaft, and take off the jam release knob. (3) Disconnect one connector, remove one clamp and 2 screws. Take out the pre-registration guide from the front side.
Front side right cover
Jam release knob
Clamp
Pre-registration guide
Connector
(4) Remove one screw and take off the registration sensor with the bracket attached. (5) Disconnect the connector. Release the latches and remove the registration sensor. (6) Disconnect the connector. Release the latches and remove the upper feed sensor. Note: Do not damage or deform the roller rests when installing/removing the pre-registration guide.
Upper feed sensor Roller rest Registration sensor Bracket
Roller rest
9 - 16
[D] Registration roller (1) Disconnect one connector and loosen one setscrew. Remove the rear side registration clutch. ( Chapter 10.4) Chapter 11.5) (2) Remove the cleaner unit. (
[Front side]
(4) Spring
(3) Remove the E-rings from the front and rear sides (one each). Slide the registration roller (rubber roller) to the rear side and take it off from the front side. (4) Remove the E-rings and detach the springs from the front and rear sides (one each). Take off the registration roller (metal roller).
(3) E-ring [Rear side] (3) E-ring (4) Spring Registration roller (4) E-ring
(4) E-ring
[E] Tray drive unit (1) Remove 6 screws and disconnect one connector. Take off the tray drive unit with the metal sheet attached. (2) Remove 4 screws and take the tray drive unit apart from the metal sheet.
(2) (1)
Connector
(1) (1) (2) (1)
(2) (2) (1)
(1)
(3) Turn the tray drive unit. Release 6 latches and remove the cover. Note: When removing the cover, be careful of the spring inside the tray drive unit pushing the cover.
Latch
Cover Latch
9 - 17
(4) Remove the tray-up motor. Note: When assembling the tray drive unit, match the gear bosses with the holes of the cover.
Boss Tray-up motor
[F] Transport clutch (1) Remove one E-ring and 3 screws. Take off the metal cover of the transport clutch. Note: Do not move the transport roller shaft when attaching the metal sheet cover. Fix the screws in the order of (a), (b)and (c). Open the side cover and check if the transport roller rotates smoothly after it was attached.
Transport roller shaft
(c)
(b)
Metal sheet cover

(a)
E-ring
(2) Remove the gears, disconnect the connectors and loosen the setscrews. Remove the transport clutches. Notes: 1. Remember that the upper and lower clutches are different in the diameter of their shafts. Upper clutch: 8mm Lower clutch: 6mm 2. Attach the clutches to the shafts referring to the figure on the lower right. [G] Cassette detection switch (1) Pull out the cassette. (2) Disconnect the connector. Release the latches and remove the cassette detection switch from the front side.
Gear
Connector
Cassette detection switch
Clutch
0~0.5mm
Shaft
9 - 18
[H] Cassette feeding unit (H-1) Cassette feeding unit (1) Remove the cassette. (2) Remove one screw and take off the cassette feeding unit sliding it to the front side.
Cassette feeding unit
(H-2) Tray-up sensor (1) Disconnect the connector. Release the latches and remove the tray-up sensor. (H-3) Paper-empty (1) Disconnect the connector. Release the latches and remove the paper-empty sensor. (H-4) Paper-stock sensor (1) Disconnect the connector. Release the latches and remove the paper-stock sensor. (H-5) Separation roller (1) Remove one screw and take out the separation roller holder. (2) Remove the lever from the holder. Take off the separation roller together with the shaft. (3) Remove the cover, arbor and clutch spring from the shaft. Take off the separation roller.
Separation roller
Feed clutch
Feed roller
Paperstock sensor Tray-up sensor Paper-empty sensor
Pickup roller
[Separation roller] Lever
Holder Arbor Spring
Cover Clutch spring Separation roller Shaft
Arbor
(H-6) Feed roller (1) Remove the clip and take off the feed roller. Notes: 1. The feed roller and pickup roller are the same component parts.
Spring
2. There is a spring clutch inside the feed roller. Remove the feed roller together with the gear. (H-7) Pickup roller (1) Remove the clip and take off the pickup roller. Note: There is a spring clutch inside the pickup roller. Remove the pickup roller together with the gear.
9 - 19
(H-8) Feed clutch (1) Disconnect one connector, detach one spring, remove 2 screws and loosen one setscrew. Take off the feed clutch.
Setscrew
Spring
Connector
9 - 20
10. DRIVE SYSTEM

The drive system drives the drum, developer unit, cleaner unit, fuser unit, transport roller, cassette feed roller and registration roller. The drive system is driven by the rotation of the main motor.
10.2 Functions
Drum drive ............................. Drives the drum by transmitting the rotation of the main motor through the gears to the drum flange gear. Developer unit drive ............... Drives the developer unit by transmitting the rotation of the main motor through the gears to the developer unit gears. Fuser unit drive ...................... Drives the fuser unit by transmitting the rotation of the main motor through the gears to the fuser unit gears. Cleaner unit drive ................... Drives the cleaner unit gear by the rotation of the drum flange gear. Registration roller drive .......... Drives the registration rollers by transmitting the rotation of the main motor through the gears and clutches. Transport roller drive .............. Drives the transport roller by transmitting the rotation of the main motor through the gears and clutches. Cassette feed roller drive ....... Drives the cassette feed roller by transmitting the rotation of the main motor through the gears and clutches.
Fuser unit drive gear Cleaner unit drive gear Main motor
(G50/G27) (G72/G30) (G27) (G36/G21)
(G10)
(G22) (G24) (G23)
(G25/G14)
Developer unit drive gear
(G23) (G33) (G28/G25) (G24) (G64/G30)
Registration roller drive unit
(G47)
(G25)
Feeding system drive gear
10 - 1
DP4500/3500 DRIVE SYSTEM
10.3 Main Motor

10.3.1 Main motor drive
FG pulse Phase V
Wave correction
Difference Phase comparator Voltage detection circuit
Reference frequency
(MAMCK) MAMPL
Speed comparator
+ Difference
Rotation control Lock protection circuit
Excitation phase switching section
Phase W Hall element A
Hall element B
Photointerruptor Phase U Hall element C
Control signal
MAMCW MAMBK MAMON
Rotor position detection
Main motor
(1) LGC outputs the control signals for the the main motor rotation. (MAMCW: Motor rotation direction setting, MAMON: Motor rotation command) (2) The excitation phase switching section excites each phase of the main motor The main motor is rotated. (3) Hall elements A, B and C detect the rotation position of the motor (rotor). (4) The excitation phase switching section switches the excitation of each phase. (By repeating (2) through (4), the motor keeps rotating.) (5) An FG pulse is generated by the FG pattern of the encoder attached to the main motor. (6) The FG pulse and the reference frequency from the LGC are compared in terms of the phase and speed, and the difference is added to the IC1. The fluctuations in the power supply voltage is also added to the value. (Signal generation) (7) In accordance with the signal obtained in the step (6), the excitation phase switching section changes the switching timing. i.e. The FG pulse and reference frequency are controlled to be equal. The main motor rotates at a fixed speed. (Locked range) (8) When the main motor enters the locked range, the excitation phase switching section outputs the MAMPL signal to the LGC. (L level) (9) When the MAMBK from the LGC becomes L level, the main motor is braked. When the MAMON signal becomes H level, the main motor is stopped.
10 - 2
10.3.2 Control signals (1) MAMCW signal (LGC MTR: Input) This is a signal to switch the direction of the main motor rotation. When this signal becomes L level, the main motor rotates counterclockwise as seen from the rear side, and drives the developer unit, drum, fuser roller, etc to the appropriate direction. (2) MAMPL signal (MTR LGC: Output) When the difference of the FG pulse cycle against the reference frequency is within 6.25%, it is specified that the motor is in a lock range (normal rotation), and this MAMPL signal becomes L level. At this time, the LED D4 is lit. (3) MAMCK signal (LGC MTR: Input) This is a reference clock signal to rotate the main motor at a fixed speed. (4) MAMBK signal (LGC MTR: Input) This is a signal to stop the main motor. When it becomes L level, the main motor is braked. (5) MAMON signal (LGC MTR: Input) This is a signal to turn ON/OFF the main motor. When it becomes L level, the motor is rotated. Signal level of the motor circuit Signal MAMCW MAMPL MAMCK MAMBK MAMON Brake OFF Motor OFF Level H CCW direction Abnormal rotation Level L CW direction Normal rotation Reference clock Brake ON Motor ON
* The signal names are for the connector J313(LGC).
10 - 3
10.4 Disassembly and Repalacement

[A] Main motor (1) Take off the rear side upper/lower covers. (2) Take off the developer unit cooling fan unit ( Chapter 11.5) (3) Disconnect one connector, remove 2 screws and release one lock support. Take off the main motor with the board attached.
Setscrew
Registration clutch
Connector Lock support
Connector
Main motor Arm
[B] Registration clutch (1) Disconnect one connector and remove one setscrew. Take off the registration clutch. [C] Gear unit (1) Remove 5 screws and disconnect 3 connectors. (2) Take off the gear unit while the arm is held up.
Connectors Connector
(3) Turn over the gear unit and remove 2 screws to unfix 2 terminals. Note: Do not bend the plate spring attached to the terminal when installing or removing the gear unit. (4) Remove one screw and disconnect one connector. Take off the toner bag full detection sensor with the bracket attached. (5) Remove the E-rings and take off the gears. Note: When assembling the gear unit, set the gears referring to the figure in the page 10-1, and pay attention to the position of each gear.
Plate spring
(4)
Toner bag full detection sensor
(3) (3)
10 - 4
[D] Drum drive gear Note: Do not loosen or remove the 3 red screws fixing the bracket of the drum drive gear.
Bracket
Drum drive gear
10 - 5
10 - 6
11. DRUM AREA

11.1 Configuration
The parts and units located around the drum and the drum itself are described in this section. This area mainly consists of the following. Cleaner unit Drum Main charger Cleaner Cleaning blade Toner recovery blade Toner recovery auger Transfer / separation charger Sub-separation fan / Exhaust fan Discharge lamp Toner bag / Toner bag full detection sensor Developer unit cooling fan / Middle cooling fan Drum thermistor
Toner recovery auger Cleaning blade Toner recovery blade Sub-separation fan
Discharge lamp Main charger
Exhaust fan
Drum thermistor
Separation charger
Transfer charger
Middle cooling fan
Drum
Transfer guide
[Sectional view of drum area]

December 2000 TOSHIBA TEC 11 - 1 DP4500/3500 DRUM AREA
11.2 Functions
(1) Drum The drum is made of a cylindrical aluminum base coated with thin film of organic photoconductive substance. The photoconductive object becomes insulative (the electrical resistance is high) when it is not exposed to the light and electrically conductive (the electrical resistance is low) when it is exposed to the light. This object is called a photoconductor. (2) Main charger The main charger consists of a metal rod with U-shaped section, insulated blocks at both ends of the rod and charger wire attached between them. When a high voltage is applied to the charger wire, the air around it is charged (ionized). The ionized air then flows into the drum causing it to be charged. This phenomenon is called corona discharge. Negative charge caused by the corona discharge is applied to the drum surface evenly in dark place. The main charger is equipped with a wire cleaner to clean the wire. (3) Cleaner (a) Cleaning blade This blade is pressed against the drum surface with a constant force by the pressure springs, and scrapes off the residual toner from the drum surface. (b) Recovery blade This blade catches the toner scraped off by the cleaning blade. (c) Toner recovery auger This auger carries the residual toner scraped off to the toner bag. (4) Transfer/separation charger (a) Transfer guide This guide guides the paper transported from the feeding unit to the transfer section. Positive (+) bias voltage is applied to the guide to prevent the transferability being lowered under conditions such as high humidity. (b) Transfer charger The transfer charger applies a charge (= positive charge) which is contrary to the charging polarity of the toner to the back of the paper. The toner image is transferred electrostatically on paper by performing this corona discharge.
DP4500/3500 DRUM AREA
11 - 2
(c) Separation charger After the transfer process, the corona discharge applies a bipolar charge (AC) on the back of the paper to separate the paper adhering to the drum surface. (5) Sub-separation fan This fan works to help the separation of paper from the drum surface by sucking the air from the back of the paper. (6) Discharge lamp Discharging is a process to decrease or eliminate the static electricity on the drum surface. The electrical resistance of the photosensitive layer is decreased by the light irradiation, and the residual charge on the drum surface is neutralized and eliminated (cleaned). The electrical potential of the drum surface is fixed to a certain amount before the drum is charged (The pre-exposure effect). (7) Toner bag The residual toner scraped off the drum surface by the cleaning blade is disposed in this bag. (8) Toner bag full detection sensor When the toner bag is full of used toner, the toner recovery auger in the cleaner is pushed back by the toner and blocks the light emission of this sensor, as the result, notifying that the toner bag is full.
11 - 3
11.3 Output Control Circuits of High-Voltage Transformer

11.3.1 Overview Generate the output control voltage Vc of the main charger, transfer/separation charger, transfer guide bias and developer bias. Convert Vc The current is output linearly. 11.3.2 Description of operations
PWA-F-LGC-320 PS-HVT-320
BC-RAM
Adjustment value
Main CPU
Gate array
Digital Analog data D/A converter
Vc
IC2 IC13 IC10
IC31
Main/ transfer/ separation/ chargers, developer bias and transfer guide bias
Output
Outputs the adjustment value of the main, transfer and separation chargers and developer bias in the BC-RAM to the main CPU. Outputs the control voltage data from the main CPU to the D/A converter. Converts to the analog data by the D/A converter. Outputs the control voltage Vc to the main, transfer and separation chargers, transfer guide bias and developer bias transformer. The main, transfer and separation chargers, transfer guide bias and developer bias transformer generate output current or voltage which is proportional to the control voltage Vc. * Adjustment of the control voltage Vc (change of adjustment data) is performed in the adjustment mode. * The output value of the transfer guide bias is fixed when the high-voltage transformer is shipped from the factory.
11 - 4
J311-14 HVSAV J311-17 HVTVR
Separation charger Transfer charger Developer bias Main charger
D/A converter Gate array

IC31
J311-19 HVDVR J311-21 HVMVR
MAIN CPU
IC10
BC-RAM
IC13
IC2
11 - 5
11.4 Drum Temperature Detection Circuit

(1) Purpose of the drum temperature detection circuit The amount of charge on the drum surface varies greatly with the surface temperature of the drum. This circuit detects the temperature of the drum surface, and the amount of charge on the drum surface is controlled to be constant based on the result. (2) Configuration of the drum temperature detection circuit
+5V
R38 0
TH R158 100 C47 R37 DRMTH-1 CPU
GND
GND
Drum temperature detection circuit
The voltage developed through R38, thermistor and R37 is input via an analog multiplexer (IC94) to the microcomputer as a temperature signal.
11 - 6

[A] Cleaner unit (1) Open the front cover and take out the toner bag and developer unit. ( cess cover. (3) Remove 2 screws and pull out the cleaner unit. Chapter 12.5) (2) Open the bypass feed unit, ADU and jam ac-
Cleaner unit
Jam access cover
Developer unit
[B] Main charger (B-1) Main charger (1) Pull out the cleaner unit. (2) Release the latches and pull out the main charger in the direction of the arrow. Note: Do not touch or damage the drum surface.
Latch
(B-2) Main charger grid (1) Push the terminal head at the front side to remove the grid. Note: Do not touch the mesh pattern of the grid.
Push
Grid
(B-3) Charger wire * Length: 363mm, tungsten wire; diameter 0.06mm
[Rear side] Terminal cover
[Front side]
(1) Remove the terminal covers of the front and rear sides.
11 - 7
(2) Remove the terminal, detach the spring and take off the wire. Notes: Be careful of the following when attaching the wire. 1. Put the wire in the V-grooves of the front and rear sides. 2. Do not twist the wire. 3. Do not touch the wire directly with your bare hands. (B-4) Wire cleaner (1) Release the lock at the front side of the wire cleaner. (2) Turn the wire cleaner in the direction of the arrow, and pull out the cleaning pad unit from the charger case window.
[Rear side] V-groove
[Front side]
Spring
Terminal
Lock
Charger case window
Wire cleaner
Cleaning pad
(3) Remove the cleaning pads. Note: When attaching the wire cleaner, send the wire cleaner to the rear side end and be sure that the 2 cleaning pads do not touch the wire.
Cleaning pad
[C] Drum (1) Pull out the cleaner unit and remove the main charger. (2) Release the latch and take off the cleaner stay.
Latch Cleaner stay
11 - 8
(3) Turn the lever to the left to release the lock. Pull out the drum shaft. (4) Take off the drum upward.
Lever
Drum gear
Notes: 1. Release the pressure of the cleaning blade using a jig before installing the drum. 2. Insert the jig into space made by pressing the blade holder as shown in the right figure. 3. Do not touch or damage the edge of the cleaning blade.
Space to insert the jig
[D] Cleaner (D-1) Cleaning blade (1) Pull out the cleaner unit. Remove the main charger and the drum. (2) Remove 2 screws. Note: Do not touch or damage the edge of the cleaning blade. (D-2) Recovery blade (1) Remove the recovery blade. Notes: 1. When attaching the recovery blade, clean the frame of the cleaner side and make sure not to deform the blade. 2. Attach the recovery blade while it is pushed against the part with a difference in level on the surface of the frame. 3. Press the part sticking to the cleaner with the double-sided adhesive tape to attach the blade securely.
December 2000 TOSHIBA TEC 11 - 9
Cleaning blade
Recovery blade
(D-3) Separation finger (1) Remove 3 separation fingers. Notes: 1. Remove the drum before replacing the separation fingers to prevent damaging the drum surface. 2. After the separation fingers are replaced, check if the pressurization of them is normal using your finger. [E] Transfer/separation charger (E-1) Transfer/separation charger (1) Open the bypass feed unit, ADU and jam access cover. (2) Release the latches and remove the transfer/ separation charger. Note: Do not deform the plate spring when the charger is attached. (E-2) Charger wires * Length: 353mm 2 tungsten wires: diameter 0.06mm (The transfer charger wire and separation charger wire are the same component parts.) (1) Remove the separation supporter. (2) Remove the terminal covers of the front and rear sides. (3) Remove the terminals, detach the springs and take off the wires. Notes: Be careful of the following when attaching the charger wires. 1. Put the wires in the V-grooves of the front and rear sides. 2. Do not twist the wires. 3. Do not touch the wires directly with your bare hands.
Terminal V-groove V-groove Separation supporter Terminal cover Plate spring Separation finger
Latch
[Front side] Spring
[Rear side]
11 - 10
[F] Exhaust fan and sub-separation fan (1) Open the jam access cover. (2) Take off the transfer/separation charger. (3) Remove 2 screws and take off the fan cover.
Fan cover
(4) Remove 3 screws and 3 washers. Disconnect 2 connectors and take off the exhaust fan and sub-separation fan. Note: Pay attention to the direction of the air flow when attaching the fan.
Sub-separation fan
Exhaust fan
FL
W O W O
FL
[G] Middle cooling fan (1) Open the front cover. Take out the toner bag, toner cartridge, developer unit and cleaner unit. (2) Take off the paper receiving tray and tray back cover. (3) Remove 4 screws and disconnect one connector. Take off the bracket and cover plate of the toner cartridge drive unit.
[Rear side]
Cover plate
[Front side]
Connector
Cover plate
Bracket
11 - 11
(4) Remove 2 screws and take off the toner bag holder.
Toner bag holder
(5) Take off the rear side upper and lower covers. (6) Disconnect the developer bias connector of the high-voltage transformer.
High-voltage transformer
Developer bias connector
(7) Remove one screw and take off the developer unit guide.
Developer unit guide
(8) Remove 2 screws and take out the middle cooling fan duct.
Middle cooling fan duct
11 - 12
(9) Remove 2 screws and take off the middle cooling fan. Note: Pay attention to the direction of the air flow when attaching the fan.
Middle cooling fan
[H] Developer unit cooling fan (1) Take off the rear side upper and lower covers. (2) Remove one screw and disconnect one connector. Take out the developer unit cooling fan unit.
Connector
Developer unit cooling fan unit
(3) Remove 2 screws and take off the duct cover.
Duct cover
(4) Remove the developer unit cooling fan.

Developer unit cooling fan
Note: Pay attention to the direction of the air flow when attaching the fan.
11 - 13
[I] Discharge lamp (1) Take out the developer unit and cleaner unit. (2) Remove one screw and disconnect one connector. Take out the discharge lamp unit.
Connector
(3) Remove the discharge lamp.
Discharge lamp
[J] Toner bag full detection sensor (1) Take off the rear side upper and lower covers. (2) Take out the developer unit cooling fan unit. (3) Take out the main motor, registration clutch and gear unit. ( Chapter 10.4) (4) Remove one screw and disconnect one connector. Take out the toner bag full detection sensor with the bracket attached. (5) Disconnect one connector. Release the latches and take out the toner bag full detection sensor.
Connector
Toner bag full detection sensor
Latch
Connector Toner bag full detection sensor
11 - 14
12. DEVELOPMENT SYSTEM

12.1 Configuration
Development system consists of the following unit and components. Toner cartridge/toner cartridge detection switch Humidity sensor Drive unit for toner cartridge Developer unit Developer material Mixers -1 and -2 Developer sleeve (magnetic roller) Doctor blade Auto-toner sensor Drum thermistor
Drum
Drum thermistor Mixer-2 Doctor blade
Developer sleeve
Mixer-1
Auto-toner sensor [Sectional view of developer unit]
12 - 1
DP4500/3500 DEVELOPMENT SYSTEM
12.2 Functions
(1) Toner cartridge/toner cartridge detection switch The toner cartridge is filled with toner. The toner motor drives the cartridge to supply the toner to the developer unit. The toner cartridge detection switch detects whether the toner cartridge is installed. (2) Drive unit for the toner cartridge The toner motor rotates to drive the toner cartridge. (3) Developer unit a. Developer material The developer material is made of a mixture of the carrier and toner. The carrier is an electrical conductive ferrite whose size is 30 to 100m. The toner is a resin particle whose size is 5 to 20m. The developer material needs periodic replacement since its quality is deteriorated by long use. b. Mixers-1 and -2 Friction is generated by mixing the developer material. The carrier is charged to (+) and the toner to (), and the image is formed on the drum surface by the static electricity caused by the friction. c. Developer sleeve (Magnetic roller) This is an aluminum roller with a magnet inside. The magnet works to suck the developer material and forms the magnetic brush. The magnet is fixed at a position and the sleeve around it is rotated. This rotation makes the magnetic brush of the developer sleeve sweep over the drum surface and perform development. d. Doctor blade Doctor blade controls the amount of the developer material transported by the developer sleeve so that the magnetic brush of the developer material contacts with the drum surface properly. e. Auto-toner sensor The carrier and the toner (toner density) in the developer material should be always fixed to a certain ratio to output normal images. The auto-toner sensor detects the inclusion ratio of the toner in the developer material by using a magnetic bridge circuit. When the quantity of toner gets short, the toner motor is driven to supply the toner from the toner cartridge.
12 - 2
12.3 Drive Circuit of Toner Motor

The toner motor (brush motor) is a motor to supply toner to the developer unit. The toner motor is driven by the transistor TA8428 (logic PC board: IC41). Circuit diagram of the toner motor
MAIN -CPU
G/A IC10 PD6
TD62385 IC28 1 TA8428 2 IC41 Toner motor 5 R344 3
IC13
PD7
Motor driver TA8428 (IC41) is connected with both ends of the motor wire. When the PD6(TNRMT-1A) of the G/A becomes L and PD7 (TNRMT-0A) becomes H levels, current flows into the motor wire and the motor is rotated. When both of PD6 (TNRMT-1A) and PD7 (TNRMT-0A) of the G/A become H level, the motor is braked and stopped. When both of PD6 (TNRMT-1A) and PD7 (TNRMT-0A) become L level, the motor waits for the next command (the motor is stopped).
12 - 3
12.4 Auto-Toner Circuit

12.4.1 General description (1) Function of the auto-toner circuit Detects the toner density in the developer material, and supplies toner when the density is lowered to a certain level. Detects that there is no toner left in the cartridge (toner-empty detection). (2) The auto toner circuit consists of the following: Auto-toner sensor Control section Toner motor Display : Detects the toner density. : Controls the toner density so that the toner in the developer material is fixed to certain ratio. : Supplies toner to the developer material. : Indicates toner-empty information.
Arithmetic and control unit

PWA-SYS
BC-RAM IC40
Control panel
GA IC30 CPU IC10
Display panel Toner cartridge

Toner motor
Toner
Control voltage signal
D/A converter
IC31 MB88347
PWA-LGC
GA IC10 LCA301
Auto-toner sensor
TA8428 IC41
MAIN CPU IC13 95C063F
Developer material
Developer unit
12 - 4
12.4.2 Function of auto-toner sensor (1) Function a. Initialization adjustment function At the first use of the copier or when the developer material is replaced with a new one. Automatically adjusts the output value of the auto-toner sensor responding to humidity (input value to the main CPU) for the toner density of the new developer material so that it stays in range of 2.35 to 2.45V. b. Stabilizing the toner density During the copying operation Maintains the toner density to a certain ratio as follows. Toner is consumed. The toner density is lowered. Change in the auto-toner sensor output responding to humidity is detected. The toner motor is driven. Toner is supplied from the toner cartridge to the developer unit. c. Toner-empty detection and recovery: Detects that there is no toner in the toner cartridge: The toner motor is driven. The auto-toner sensor output does not change. The toner density does not change. It is determined there is no toner in the cartridge (toner empty). Recovering from the toner-empty state: The toner motor is driven. Toner is supplied. The auto-toner sensor output changes. The toner density returns to normal value. The toner-empty state is cleared.
12 - 5
(2) Function of auto-toner sensor The auto-toner sensor consists of the following circuits: Drive winding Detection winding : A magnetic head (primary side) with a high-frequency magnetic field, which forms a magnetic circuit in the developer material. : Receives the change in the magnetic resistance of the developer material through the magnetic circuit (secondary side). DC conversion circuit : Converts a high-frequency output from the detection winding into a DC signal (auto-toner output VATS).
Magnetic resistance
Drive winding
(Developer material)
Detection winding
Auto-toner output DC To the main conversion CPU (LGC) circuit VATS
Magnetic circuit
When the toner density is low The ratio of the toner against the carrier in the developer material decreases. The magnetic resistance decreases. The detection output increases. The auto-toner output VATS increases. When the toner density is high The ratio of the toner against the carrier in the developer material increases. The magnetic resistance increases. The detection output decreases. The auto-toner output VATS decreases.
12 - 6
12.4.3 Adjustment using the humidity sensor Variation in the output of the auto-toner sensor due to humidity is corrected using the humidity sensor to maintain the toner density in the developer material at a certain amount. The feedback control function using the humidity sensor is applicable to the main charger grid, developer bias and laser power as follows. The feedback control function can be set in the setting mode [0] + [8]. : Function effective
Code setting 08/839=0 (default) 08/839=1 08/839=2 08/839=3
: Function ineffective
Control of the main charger grid, Control of the auto-toner outpout VATS developer bias and laser power
12 - 7

[A] Developer unit (1) Open the front cover and take out the toner bag. (2) Loosen one blue screw and disconnect one connector. Take out the developer unit.
Connector
[B] Developer material (B-1) Disposition of developer material (1) Remove the top cover. (Release the protrusions and latches, and slide the cover in the direction of the arrow to take out the cover.)
Protrusion
Latch
Protrusion
Top cover
(2) Incline the developer unit and remove the developer material from the part shown with the arrow.
(B-2) Filling developer unit with developer material (1) Remove the lid of the developer bottle and fill the developer unit with the developer material. (2) Rotate the gear at the rear side manually in the direction of the arrow to spread out the developer material over the developer sleeve. Note: Securely attach 4 latches and 2 protrusions at both sides of the cover when fixing the top cover.
DP4500/3500 DEVELOPMENT SYSTEM 12 - 8 December 2000 TOSHIBA TEC
[C] Guide roller (C-1) Front side (1) Remove the developer material. (2) Make a note of the position which the polarity adjustment lever is pointing at. (Mark the position if needed.)
Scale
Polarity adjustment lever
(3) Remove 3 screws and take off the front cover of the developer unit.
Front cover
(4) Remove one screw and take off the polarity adjustment lever. (5) Remove one E-ring and take off the guide roller. Note: Match the polarity adjustment lever with the previously marked position on the scale when assembling the guide roller.
Guide roller
E-ring
Polarity adjustment lever
(C-2) Rear side (1) Remove 2 screws and take off the metal plate.
12 - 9
(2) Remove one E-ring and 4 gears. (3) Take off the guide roller.
Guide roller
Gear
E-ring
[D] Auto-toner sensor (1) Dispose of the developer material. (2) Remove one screw and disconnect one connector. Take off the auto-toner sensor from the bottom side of developer unit.
Connector
[E] Drum thermistor (1) Take off the front cover of the developer unit. (2) Remove 2 screws and take off the developer sleeve cover.
Developer sleeve cover
(3) Remove one screw and disconnect one connector, and take off the drum thermistor.
Connector
12 - 10
[F] Developer sleeve (1) Dispose of the developer material. (2) Take off the developer sleeve cover. (3) Take out the guide rollers (front side and rear side). (4) Remove 2 screws from the front and rear sides. Take out the developer sleeve unit lifting up both sides of the shaft.
(5) Remove 4 screws and take off the doctor blade. (6) Take off the developer sleeve.
Doctor blade
Developer sleeve
(7) Replace the oil seal of the shaft at the rear side of the developer sleeve with a new one. ( Replacement of Oil Seal described later)
Oil seal
12 - 11
Note: 1. Make sure that the side seals (urethane seal) of the front and rear sides do not come out of the case when assembling the developer sleeve unit (see the figures below). 2. Make the gap adjustment of the doctorsleeve when assembling the doctor blade.
[Front] Side seal Side seal [Rear]
Toner scattering prevention sheet
Toner scattering prevention sheet [Rear side] [G] Mixer-1
[G] Mixer-1 (1) Dispose of the developer material. (2) Take out the developer sleeve unit. (3) Remove one E-ring at the rear side, the bushing (plastic) at the front side and the bushing at the rear side. Take off mixer-1. (4) Replace the bushings and the oil seals on the developer frame with new ones. ( Replacement of Oil Seal described later)
[H] Mixer-2 [G] Bushing [G] E-ring [Front side] [H] E-ring [H] Bearing
[H] Mixer-2 (1) Dispose of the developer material. (2) Remove one E-ring and the bushings (rubber) at the front side and the bearing at the rear side. (3) Remove one screw and take off the holder for mixer-2 at the front side. (4) Take off mixer-2. (5) Replace the oil seals on the holder and at the rear side of the developer unit frame. ( Replacement of Oil Seal described later)
[H] Mixer-2 [H] Bushing (rubber)
[H] Holder
12 - 12
[I] Drive unit for the toner cartridge (1) Take out the toner cartridge. (2) Take off the paper receiving tray and tray back cover. (3) Remove the metal cover of the toner cartridge drive unit. (4) Remove 2 screws and take out the drive unit for the toner cartridge.
12 - 13
<< Replacement of Oil Seals >> Locations of the oil seals used in this developer unit (5 in total) a. One at the rear side of the developer sleeve shaft b. Two at both sides of the shaft of mixer-1 c. Two at both sides of the shaft of mixer-2 Procedure for replacement of the oil seal 1. Stick something thin like a screwdriver into the depression of the oil seal to take it out.
2. Push in new oil seal in parallel with the frame of the developer unit or bushing of the mixer shaft paying attention to its direction.
(Bushing side)
Oil seal
(Inside of frame)
3. Apply grease (Alvania No.2; quantity like one grain of rice) evenly over the entire surface of the oil seal. Assemble the mixer and developer sleeve. Note: Wipe off excessive grease. 4. Apply grease (Alvania No.2; quantity like one or two grains of rice) on the entire surface of the shafts of the mixer and the developer sleeve evenly, and attach the bushings.
Grease Shaft Wipe off Grease
12 - 14
[J] Toner cartridge detection switch (1) Open the front cover. Take out the toner bag and toner cartridge. (2) Remove 2 screws and take off the toner cartridge cover.
Toner cartridge cover
(3) Remove 2 screws and disconnect one connector. Take off the toner cartridge detection switch unit.
Connector
Toner cartridge detection switch unit
(4) Remove 2 screws and disconnect 2 connectors. Remove the toner cartridge detection switch from the bracket.
Bracket
Toner cartridge detection switch
Connector
12 - 15
[K] Humidity sensor (1) Open the front cover and take out the paper receiving tray. (2) Remove 4 screws and take off the metal cover of the system unit.
Metal cover
Humidity sensor window
(3) Disconnect one connector of the humidity sensor. (4) Remove the humidity sensor in the direction of the arrow while the part of the holder indicated as A in the right figure is slightly lifted up.
Connector
Humidity sensor
12 - 16
13. FUSER UNIT/PAPER EXIT SECTION

The toner is fused by applying heat and pressure on the paper separated from the drum. The paper is then transported to the receiving tray through the paper exit section. The fuser unit consists of the IH coil, fuser roller, pressure roller, separation fingers, cleaning roller, thermistors, thermostat, exit rollers, exit sensor, etc.
Exit roller
Separation finger for the fuser roller
Separation finger for the pressure roller Exit sensor
Thermostat
Fuser unit cooling fan
Cleaning roller Thermistor Fuser roller IH coil Pressure roller
13.2 Operation
Heat and pressure are applied to the paper separated and transported from the drum to have the toner fused onto the paper. The fuser roller and pressure roller are pressed to each other with the spring at a certain pressure, and driven by the main motor. The fuser roller is rotated by the motor drive and it has an IH coil inside which does not rotate. After the fusing, the paper is separated smoothly from the fuser roller by the separation fingers. The temperature of the fuser roller is controlled by a thermistor in the temperature detecting section. Power supply to the IH coil is cut off by the thermostat when the temperature becomes abnormally high.
13 - 1
DP4500/3500 FUSER UNIT/PAPER EXIT UNIT
13.3 Functions
(1) IH coil (IH: Induction Heating) The IH coil is in the fuser roller and applies the induction heating to the fuser roller. The coil is fixed at a position and does not move when the fuser roller is rotating. (2) Fuser roller The fuser roller is made of the iron and induction-heated by the IH coil. The fuser roller is in contact with the below-mentioned pressure roller, and fusing is performed by passing the sheet of paper between these two rollers. At this time, the toner image on the paper faces the fuser roller. Toner is melted by the heat of fuser roller while the heat conductivity is improved by the pressure from the pressure roller, and the toner soaks into the fibers of the paper. The surface of the fuser roller is coated with the fluoroplastic to prevent the toner from adhering onto the roller ( the phonomenon called offset) and to help the separation of the toner from the fuser roller. (3) Pressure roller The pressure roller is made of the silicon sponge which is highly cohesive and always pressed against the fuser roller by springs. (4) Separation finger The separation fingers for the fuser and pressure rollers separate paper adhering to the fuser roller and pressure roller. (5) Cleaning roller A metal cleaning roller is attached in contact with the pressure roller to remove the toner and paper scraps sticking to the pressure roller. (6) Exit sensor This sensor detects the arrival of the leading edge or trailing edge of paper at the exit roller of the fuser unit. It is also used to detect paper jams in the fuser unit paper discharge area and of the trailing edge of the paper turned over for duplex copying. (7) Fuser roller center thermistor The thermistor detects the temperature of the fuser roller to maintain it within a certain temperature range (the actual temperature is around 180C) which is higher than the lower limit (the temperature which causes the poor fusing) and lower than the upper limit (the temperature which causes the toner offset). Thus, the thermistor controls the temperature of the fuser roller to turn on the IH coil when it is lower than the set temperature and turn it off when it is higher than that.
13 - 2
(8) Fuser roller side thermistor The temperature distribution of the fuser roller may differ significantly at the center area and end area in the lengthwise direction depending on the printing conditions. The side thermistor detects the temperature of the end area. This center and side thermistors control the temperature to cut off the power supply to the IH coil when either values detected by them exceeds the set temperature. (9) Thermostat The thermostat cuts off the power supply to the IH coil if the fuser roller becomes abnormally hot as a result of any problems such as thermistor malfunction. The thermostat for this copier is used to prevent abnormal operation. When the thermostat detects any abnormality, the thermostat must be replaced together with the other damaged parts in the fuser unit.
13 - 3
13.4.1 Configuraton
Side thermistor
Center thermistor
Fuser roller
Coil Thermostat Noise filter Drum thermistor Power code Breaker
13.4 Heater Control Circuit
Coil output AC N input

5V SW
13 - 4
Fuse Power supply for photocoupler Electric power setting Error signal
IH ON/OFF signal (L: ON)
Photocoupler
IH power source/ drive circuit
CPU
5V SW
Control circuit including CPU

IH
Temperature control circuit

LGC
AC line DC line
[Block diagram of fuser unit and IH control circuit]
13.4.2 Heating principle of IH heater High frequency magnetic field is generated by applying a current of high frequency to the heating coil (IH coil) in the fuser roller to produce the eddy current in the fuser roller. Resistance element of the fuser roller generates Joule heat with which the roller is heated when the eddy current flows in the fuser roller. The thermal efficiency is high because the fuser roller is directly heated by the heater.
Current flowing on the surface of the fuser roller
High frequency power source

A
IH coil High frequency Eddy current magnetic field
Current flowing inside the fuser roller
[Image of current flowing from A to B]
Control circuit for high-frequency current IH coil Smoothing circuit Fuser roller
C2 C1 D1 T1
Current input
(IGBT) Te1
IGBT drive
CPU
Monitoring input current
Voltage input
I/F circuit on LGC board
Monitoring input current
[Block diagram of high-frequency power supply]

December 2000 TOSHIBA TEC 13 - 5 DP4500/3500 FUSER UNIT/PAPER EXIT UNIT
Photocoupler
13.4.3 IH control circuit interface The IH control circuit uses a photocoupler as insulation against the secondary circuit. The interface signals are as follows.
No. J522-1 J522-2 J522-3 J522-4 J522-5 J522-6 J522-7 J522-8 Name of signal 5V PWR3 PWR2 PWR1 IH ON/OFF ERROR2 ERROR1 GND Host to IH IH to Host Thermistor monitoring feedback signal from host IH status signal (*Note) (ERROR2 ERROR1) Host to IH Direction Definition
(*Note) IH status signal When the temperature (due to insufficient cooling) of the switching element (IGBT) is abnormal: 10: Abnormal temperature, IH-FAN stopped After a certain period of time Error[C48] When the upper limit of the power voltage is abnormal: 00: Initializing After a certain period of time Error[C47] When the lower limit of the power voltage is abnormal: 00: Initializing After a certain period of time Error[C47] Defective circuits : 11 Abnormal circuit, defective coil Error[C49] Standby state after initialization: 01: Ready
13 - 6
13.4.4 Relation between system configuration and IH output

Energy System configuration Copier only Copier and ADF
(*1)
Automatically OFF OFF
Warming up time Approx. 30 sec. Approx. 40 sec.
Warming up 1300/1250W 1250/1200W

(*2)
Ready 700W
Copying saver mode 900W 700W
Copier, ADF(*1) and FIN
1250/1200W
Copier, ADF(*1) and FAX 1200/1100W(*2) or Copier, ADF(*1), FAX and PRT Copier, ADF(*1), FIN, FAX and PRT Copier, ADF
(*1)
1200/1100W
Approx. 45 sec.
and SC 1100/1100W Approx. 50 sec.
Copier, ADF(*1), FIN, FAX and SC
* FIN: Finisher, FAX: Fax unit, PRT: Printer unit, SC: System controller (*1) The electric power is lowered when a document fed from the ADF is scanned while the copier is warming up. (*2) AC power should be 100V when the copier is warming up (the lower the voltage, the longer the warming up time becomes). 13.4.5 Abnormality of IH control circuit IH output is stopped when the IH control circuit does not work properly. (1) When the power voltage of the copier is too high or too low IH output is stopped to protect the IGBT when the input voltage which is higher or lower than specified range is applied to the copier. This is an error [C47]. (2) When the AC is not applied to the IH control circuit The AC is not applied to the IH control circuit properly. This is an error [C47]. The same error occurs when the thermostat is activated (blown). (3) When the temperature of the IGBT is too high IGBT is forcibly cooled down by the fan as it becomes hot when the power is supplied to the IH control circuit. The error [C48] is occurs when the cooling operation is not sufficient and the IGBT gets too hot.
13 - 7
(4) The temperature detection sensor of the IH control circuit is malfunctioning The error [C49] occurs when the temperature detection sensor of the IH control circuit does not work properly. The same error code is displayed in case the IH coil is not connected properly.
13.4.6 Temperature detection section To keep the fuser roller temperature constant, the thermistors detect the temperature and control ON/OFF of the heater. Output from the thermistors is used to detect abnormality. (1) Relation between the thermistor output voltage and surface temperature of the fuser roller: Approx. 4.0V when the temperature is 200C, and approx. 0.5V when the temperature is 40C. Approx. 3.7V when the temperature is 180C, and approx. 3.9V when the temperature is 190C. (2) Control of the surface temperature of the fuser roller:
Warming-up
C
Ready (190C)
During copying (180C)
190 180
Temperature of fuser roller
OFF Heater ON
ON OFF ON OFF ON OFF
ON
OFF
ON
OFF
(3) Temperature control for both ends of the fuser roller During the multiple copying, the temperature of both ends of the fuser roller (areas where the paper does not pass) generally tends to become higher than that of the other areas (areas where the paper passes). The temperature of the ends is detected by the side thermistor, and when it reaches 250C, the heater is automatically turned OFF regardless of the temperature of the area where the paper passes. (4) Error detection during warming up (1) If the output voltage of the thermistor does not go over approx. 0.5V(40C) even a certain period of time has passed after the heater was turned ON, service call [C41] is displayed. (5) Error detection during warming up (2) If the output voltage of the thermistor does not go over approx. 3.2V(150C) after it exceeded 40C and a certain period of time has passed, service call [C44] is displayed.
13 - 8
(6) Error detecion during standby and copying Service call [C43] is displayed if the output voltage of the center thermistor becomes approx. 0.5V or lower for 0.5 sec. or longer. If the side thermistor is in this condition, service call [C45] is displayed. (7) Error detection during warming up (3) If the output voltage of the thermistor does not go over approx. 3.9V(190C) after it exceeded 150C and a certain period of time has passed, service call [C44] is displayed. (8) Thermistor/heater status counter control To enhance the safety of the fuser unit, the CPU provides the following protection: When the third [C41] error has occurred after two consecutive [C41] errors, even if the operator turns the power OFF and then back ON, the heater is not turned ON and error [C41] is displayed immediately. However, if the copier becomes ready normally with the thermistor/heater status counter 1 or below, the counter is cleared to 0. If the heater is not turned ON and any of the error codes [C41] to [C45] is still displayed even though the thermistor, thermostat and IH coil have been repaired and the power is turned ON, check the code 400 in the mode (08) to set the thermistor/heater status counter to 0. Reference * The thermistor/heater status counter never has values other than 0 ~ 19 entered. If the heater does not come ON and service call [C41] is displayed immediately after the power is turned ON, check the thermistor/heater status counter. If it is 2 or over, be sure to check the thermistor, thermostat and IH coil. Reset the counter to 0 (code 400 in the (08) mode) after repairing them, then turn ON the power. If the thermistor/heater status counter is 20 or over (e.g., 21), there is a possibility that data in BCRAM or BCRAM itself may have been ruined due to causes such as leakage from the chargers. Check the bias, high-voltage transformers and charge wires to see if any of them is defective, and also look through all the data in the BCRAM.
13 - 9
13.4.7 Detection of open-circuited thermistors A thermistor is a device whose resistance decreases when it detects high temperature. If the fuser roller thermistor is open-circuited, the control circuit determines that the fuser roller temperature is extremely low, and keep turning ON the IH coil. As the result, the fuser roller temperature rises, possibly activating the thermostat which is a safety protection device. To prevent this, CPU works to detect if the thermistor is open-circuited or not. * The following is a circuit diagram of the thermistor open-circuit detection circuit for the center thermistor. The same circuit is used for the side thermistor.
+5 R165 Resistor-1
Main CPU Center thermistor

HTRTH-
Resistor-2 R170
C125
Resistor-3 R174
The input voltage is obtained by dividing the resistor-1, thermistor, resistor-2 and resistor-3. The surface temperature of the fuser roller changes. The resistance of the thermistor changes. The input voltage changes. The main CPU detects this change of the input voltage to determine if the thermistor is abnormal or not.
13 - 10
13.4.8 Control for abnormal heater conditions The heater cannot be turned ON/OFF when trouble occured to the IH control circuit. In this case, the microcomputer detects abnormal temperature using the center and side thermistors, determines the corresponding error codes and counter values. The power is then turned OFF to protect the fuser unit in case the machine is 200V-series. (1) Temperature to be detected Abnormal temperature detected by the thermistors: Center thermistor: 230C Side thermistor: (2) Error code [C44] Call for service : Displayed when the keys [C/S] and [8] are pressed simultaneously. Counter value 9 (3) Operation of the machine The microcomputer stops the output of the heater, exposure lamp, control panel display and motor, then turns OFF the power in case the machine is 200V-series. (4) Corrective action [For 200V-series] Thermistors continue detecting the abnormal temperature even after the error codes and counter values are determined. Even if the power is turned ON by the operator, it is automatically turned OFF when the surface temperature of the fuser roller is still abnormal or higher than the temperature in (1). This behavior is repeated until the temperature becomes normal. Wait until the surface temperature of the fuser roller is lowered enough, and turn ON the power to check the counter value. [For 200V-series and other models] The copier is returned to the normal conditions by fixing the heater and setting the counter value of the setting code from 400 to 0. : Displayed by entering the code number 400 in the setting mode (08). 270C
13 - 11
13.5 Exit Motor Drive

The control circuit of the exit motor which works to drive the exit roller is shown below. The exit motor is a 4-phase control PM stepping motor. The motor is turned ON/OFF and the direction of its rotation is changed by controlling the timing of the pulse signal output (AABB).
+24A
EXTMA-0 EXTMB-0 CPU IC13 EXTMC-0 EXTMD-0 Motor driver IC35
A B A B
Exit motor
PWA-F-LGC-320
13 - 12

[A] Fuser unit (1) Remove 2 screws and take off the feed side upper cover. (2) Disconnect 2 connectors and 2 faston terminals. (3) Open the jam access cover. (4) Remove 2 blue screws and take out the fuser unit.
Connector and faston terminal (2 each)
Jam access cover
[B] Fuser unit cooling fan (1) Release the hooks near the hinges and take off the fuser unit cover.
Fuser unit cover
Hook
(2) Disconnect one connector, remove 2 screws and release 2 latches. Take off the fuser unit cooling fan.
Connector
Latch
(3) Release 2 latches and remove the fan cover. (4) Release the harness from the holder. Remove 4 screws and take off the fuser unit cooling fan.
Fan cover
Latch
13 - 13
[C] Exit sensor (1) Remove 2 screws and open the upper exit unit (2) Release the latches and remove the exit sensor cover.
Exit sensor cover Upper exit unit
(3) Disconnect the connector. Release the latches and remove the exit sensor.
Connector
Exit sensor
[D] Exit finger (1) Pull out the shaft and remove 8 exit fingers.
Exit finger
Shaft
[E] Separation finger for pressure roller (1) Remove 5 separation fingers for the pressure roller. [F] Separation finger for fuser roller (1) Remove 2 screws and take out the lower paper exit unit.
Separation finger for pressure roller
Lower paper exit unit
13 - 14
(2) Remove 6 separation fingers for the fuser roller.
Separation finger for fuser roller
[G] Cleaning roller (1) Remove one screw and take off the rear side cover.
13 - 15
(2) Remove the screws from the front and rear sides (2 each). Take off the stay of the pressure roller side.
[Rear side]
[Front side]
Stay
(3) Remove the E-ring. Take off the cleaning roller together with the bushings at the both sides.
E-ring
Bushing
Cleaning roller
13 - 16
[H] Pressure roller (1) Take off the pressure springs of the front and rear sides from the hooks.
Pressure spring
(2) Take off the pressure roller.
Pressure roller
[I] IH coil (1) Remove 2 screws and take off the front coil holder.
Front coil holder
(2) Remove one screw and take off the rear coil holder.
Rear coil holder
13 - 17
(3) Pull out the IH coil from the rear side.
IH coil
[J] Fuser roller (1) Remove the grip ring of the front side. (2) Remove the E-ring of the rear side and take off the gear A. (3) Remove the grip ring and gear of the rear side. (4) Take off the fuser roller. Notes: 1. Do not deform the thermistor when installing the fuser roller. 2. Pay attention to the direction of the gear (the position of a square protrusion on the inner face of the gear) when attaching it.
[Front side]
Grip ring Fuser roller
[Rear side]
Fuser roller Gear Grip ring
Outer edge (Grip ring side)
Gear A
Inner edge (Bearing side) Protrusion
13 - 18
[K] Thermistor (1) Remove one screw and take off the center thermistor. (2) Remove one screw and take off the side thermistor. Note: Do not deform or damage the thermistors and frame (metal sheet) when fixing the thermistors. [L] Thermostat (1) Remove 2 screws and take off the thermostat. Notes: 1. Give attention to the order to fix the thermostat terminal and harness terminal when fixing the thermostat with a screw. 2. Adjust space between the fuser roller and thermostat by tightening/loosening the screw A while the pressure roller is pressed against the fuser roller to make the space fall within 1.5 to 1.9mm.
Screw A Harness terminal Screw Thermostat Side thermistor Center thermistor Thermostat
[M] IH control board cooling fan (1) Take off the rear side upper and lower covers. (2) Disconnect one connector and remove 2 screws. Take off the IH control board cooling fan together with the sheet metal. (3) Remove 2 screws and take the IH control board cooling fan apart from the sheet metal. Note: Pay attention to the direction of the air flow from the fan when installing it.
IH control board cooling fan
Connector
13 - 19
[N] IH control board (1) Disconnect 4 connectors and remove 9 screws. Take off the IH control board.
IH control board Connector [O]
[O] Exit motor (1) Remove 2 screws and take off the case of the IH control board (Slide the case to the right to detach the hooks, then take off the case). Note: If the IH control board is not replaced with new one, the board does not have to be separated from the case. (2) Disconnect one connector and remove 2 screws. Take off the exit motor behind the sheet metal with the bracket attached.
Connector [O]
Exit motor
(3) Remove 2 screws and take off the exit motor.
13 - 20
14. AUTOMATIC DUPLEXING UNIT (ADU)

The Automatic Duplexing Unit (ADU) is a unit which automatically makes a copy on both sides of a sheet of paper. The switchback method is adopted for the ADU of this model. The sheet of paper is switchbacked right after the copying operation (fusing process) on one side is completed, and the reversed paper is transported to the registration section to be copied on another side. The ADU mainly consists of the transport rollers and their drive system, paper transport guide and the ADU entrance/exit sensors.
Exit gate
Paper guide Upper transport roller
Entrance guide
ADU entrance sensor
Middle transport roller
ADU motor
ADU exit sensor
Exit guide Lower transport roller
14 - 1
DP4500/3500 AUTOMATIC DUPLEXING UNIT
14.2 Description of Operations

The back side copying (data for the back side of a paper is recorded) is performed by first selecting the duplex copying mode and pressing the START key. When the trailing edge of the paper passes the exit gate, the paper is switchbacked and transported to the ADU (the exit gate is closed by its own weight) then to the registration section, and the front side copying (data for the front side of the paper is recorded) is performed. The paper passes through the exit gate again and is transported to the paper receiving tray to complete duplex copying. There are three kinds of jams which are related to the ADU. E51: The ADU entrance sensor does not come ON within a fixed time after the switchback operation has been started in the ADU. E52: The ADU exit sensor does not come ON within a fixed time after the ADU entrance sensor has become ON. E11: The registration sensor does not come ON within a fixed time after the ADU has started feeding paper into the main unit. The error [E43] occurs if the ADU is opened during duplex copying. The ADU motor and ADU clutch are stopped at this time. If the copying operation is interrupted or stopped for some reason other than jam or service call, the process in progress on a sheet of paper is completed and the sheet is discharged into the paper receiving tray. The operation of the duplex copying varies depending on the size of the paper: Single-sheet circulation and Double-sheet circulation. The figure on the following pages show the duplex copying operation when documents from page one to four are copied. The numbers in the figure indicate the page numbers.
14 - 2
(a) Single-paper circulation With sheets of paper other than A4/LT size, duplex copying (back-side copying front-side copying) is performed for a single sheet of paper as shown below.
14 - 3
(b) Double-sheet circulation With A4/LT sized paper, duplex copying is performed for two sheets of paper at a time as shown below. The sheets are processed in the following order. Back side of the 1st sheet back side of the 2nd sheet front side of the 1st sheet front side of the 2nd sheet
14 - 4
In the main unit

2236 3320 4460 5532 7650 8716 8962 10040 11264 12344 13470 14538

2204 2394 4420 5632 7606 7726 8926 9278 11224 12356 13430 2018 2226 4236 5900 8738 1262 2272 3480 4490 6670 7680 7982 8992 10288 11298 12494 13504 2032 2268 2300 2430 5718 5942 7642 7762 4382 5304 6602 7910 11122 12030 4970 6916 7580 10534 11696 12740 4560 5708 7096 8060 9010 9354 11282 12432 3826 6640 7036 8060 9010 9354 10558 12432
Exit sensor
326
Registration sensor Upper cassette feed sensor Registration clutch
204
Transport clutch (low speed)
362
Timing chart for duplex copying on 3 A4 sized sheets fed from the upper cassette
14 - 5
In the ADU ADU entrance sensor
ADU exit sensor
ADU clutch
ADU motor
In the main unit
Exit sensor
975 3035 6445 8500
Registration sensor
1920 0 1980 5485 5345 7380 7465
DP4500/3500 AUTOMATIC DUPLEXING UNIT 4110 4690 6000 6680 4270 5425 5485 6860 3550 5425 5485 6860
Registration clutch
Timing chart for duplex copying on one A3 sized sheet fed from the upper cassette
14 - 6
In the ADU
ADU entrance sensor
ADU exit sensor
ADU clutch
ADU motor
14.3 Drive of ADU

When the ADU motor rotates in the direction A, the upper transport roller is rotated driven by the gears and belt. The ADU clutch is then turned ON, allowing the middle transport roller and lower transport roller to rotate.
Upper transport roller
ADU motor
A Middle transport roller
ADU clutch
Lower transport roller
14 - 7
14.4 Flow Chart

Exit motor reverse rotation ON 400msec. elapses
ADU motor ON
ADU entrance sensor ON?

Yes
No
ADU transport jam (E51)
32msec. elapses (A sheet is transported to the position where the sheets are stopped first.)
The trailing edge of the first sheet turned ON the ADU exit sensor? Yes
No
ADU motor stopped
ADU motor ON
ADU clutch ON
ADU exit sensor ON?
No
Yes
ADU transport jam (E52)
400msec. elapses
14 - 8
ADU paper feeding command signal received

Yes
No
ADU motor stopped ADU clutch OFF
ADU motor/clutch ON
ADU feeding operation started
Registration sensor ON?

Yes
No
ADU misfeeding (E11)
Registration proceeded Registration operation completed ADU motor stopped ADU clutch OFF
Next paper is ready for the registration
14 - 9

[A] ADU (1) Remove the feed side rear hinge cover and feed side front hinge cover. (2) Open the ADU. (3) Disconnect one connector and remove one screw fixing the ground wire. Remove the pin. (4) Slide the ADU to the rear side and take it off.
Connector Pin
[B] ADU inside cover (1) Remove 2 screws and take off the ADU inside cover (front). (2) Remove 2 screws and take off the ADU inside cover (rear).
ADU inside cover (rear)
ADU inside cover (front)
[C] ADU opening/closing switch (1) Disconnect the connector. Release the latches and take off the ADU opening/closing switch.
ADU opening/ closing switch
[D] ADU cover (1) Remove 4 screws and take off the ADU cover. Note: Make sure to attach the ADU opening/closing switch when attaching the ADU cover.
14 - 10
[E] Paper guide (1) Detach the fulcrum at the rear side from the frame. Take off the paper guide.
Fulcrum
(2) Release the hook springs and remove the pinch rollers (6 each). (3) Remove 2 screws and take off 2 pressure plate springs.
Pressure plate spring Pinch roller
Hook spring
[F] Latches (1) Remove the spring. (2) Remove one screw and take off the front latch.
Front latch
Spring
(3) Remove the screw and take off the rear latch.
Rear latch
14 - 11
[G] Opening/closing lever (1) Remove 2 screws and take off the opening/closing lever.
Opening/closing lever
[H] ADU entrance sensor and ADU exit sensor (1) Disconnect the connector. Release the latches and remove the ADU entrance sensor. (2) Disconnect the connector. Release the latches and remove the ADU exit sensor.
ADU entrance sensor
ADU exit sensor
[I] ADU board (1) Remove 4 screws and take off the bracket. Disconnect one connector of the harness connected with the ADU board from the bracket.
Bracket
(2) Disconnect 5 connectors. Release 4 lock supports and take off the ADU board. [J] ADU motor (1) Remove 2 screws and take off the ADU motor.
ADU motor Lock support ADU board
14 - 12
[K] ADU drive unit (1) Remove 3 screws and take off the gear unit.
Gear unit
(2) Remove 2 E-rings and take off 3 gears.
E-ring
(3) Disconnect one connector. Loosen one setscrew and take off the ADU clutch.
Connector
Setscrew
[L] ADU transport rollers and entrance/exit guides (L-1) Upper transport roller (1) Remove 4 screws and take off the bracket.
14 - 13
(2) Remove the clip of the front side. (3) Remove the clip, pulley, fixing pin and belt of the rear side. (4) Remove 2 bushings and take off the upper transport roller.
[Front side]
Clip (L-1) Bushing (L-1) (L-3)
(L-3)
Clip (L-2) Pulley (L-2) Bushing (L-2)
(L-2) Middle transport roller (1) Remove the clip, pulley, fixing pin and belt of the front side. (2) Remove the clip of the rear side. (3) Remove 2 bushings and take off the middle transport roller. (L-3) Entrance guide (1) Remove 4 screws (2 each for front and rear sides) and take off the entrance guide.
Clip (L-1) [Rear side] Fixing pin (L-1) Bushing (L-1) (L-3) (L-3) Pulley (L-1) Fixing pin (L-2)
Entrance guide
Bushing (L-2) Clip (L-2)
(L-4) Lower transport roller (1) Remove the clip, pulley, fixing pin and belt of the front side. (2) Remove the clip of the rear side. (3) Remove 2 bushings and take off the lower transport roller. (L-5) Exit guide (1) Remove 3 screws (2 for the front side and 1 for the rear side) and take off the exit guide.
[Front side]
Fixing pin (L-4)
(L-5)
Bushing (L-4)
(L-5)
Exit guide
Pulley (L-4) [Rear side]
Clip (L-4)
(L-5)
Bushing (L-4)
Clip (L-4)
14 - 14
15. POWER SUPPLY UNIT

15.1 Configuration
The power supply unit consists of an AC filter and insulation type DC output circuits. (1) AC filter Eliminates noise from the outside and prevents noise generated by the copier from leaking to the outside. (2) DC output circuits The DC outputs are roughly divided into three lines of outputs: a. System line b. Main line : Power supply used around-the-clock mainly for the SYS/FAX board. This line outputs three voltage (+3.3V, +5.1V, +12V) which start up when the main switch is turned ON. : Power supply used in the entire machine during image forming process. This line outputs four voltage (+3.3V, +5.1V, +12V and -12V) which are started up by the signals from the SYS board. c. Door switch line : Power supply used in the entire machine during image forming process, being supplied via the door switch. This line outputs two voltage (+5V and +24V) which start up when the door switch is turned ON and with the signals from the SYS board.
15 - 1
DP4500/3500 POWER SUPPLY UNIT
15.2 Operation of DC Output Circuits

(1) Start of operation When the main switch of the copier is turned ON, AC power is supplied to the switching regulator-1 (REG 1) to start up three output voltage of the system line. System CPU is then activated to output the power control signal (PWR-EN: L level), and four output voltage of the main line are started up. If the door switch of the copier is ON (the door is closed) at this time, AC power is supplied to the switching regulator-2 (REG 2) to start up two output voltage of the door switch line. (2) Stop of operation When the main switch of the copier is turned OFF, the power-OFF signal (PWR-DN) is output (Hi-Z: High impedance) after the instantaneous outage insurance time (20 msec. at least) has elapsed. After the power-OFF signal has been output, the regulator-1 (system line and main line) retains the rated voltage for the minimum retaining time (15 msec. at least, depending on the AC input and load capacity), then starts to drop the voltage. (3) Output protection Each output system includes an over-current protection circuit (which has the fuse protecion and the series regulator internal protection functions) and an over-voltage protection circuit (does not cover the voltage 12V of the system/main lines). These circuits prevent the abnormal operation or damage to the secondary circuit caused by over-current due to shorted load or over-voltage due to short-circuit between different voltages. When the protection circuit is activated, remove the causes such as short-circuits (replace the fuse if it is blown), and turn ON the power again to clear the circuit. Occasionally it may not cleared when the power is turned back ON too soon (within 30 seconds).
15 - 2
15.3 Output Channel

The following are 3 output channels which are not linked with the door switches. (1) 3.3V 3.3VA 3.3VB 3.3VC 3.3VD : Pin 1, J412 Output to the LGC board : Pins 1, 2 and 3, J413 Output to the SYS board : Pin 1, J414 Output to the SLG board and CCD board via SLG board : Pin 4, J413 Output to the SYS board (2) 5.1V 5.1VA 5.1VB 5.1VC 5.1VD 5.1VE 5.1VF : Pins 3 and 4, J412 Output to the LGC board : Pins 17, 18, 19 and 20, J413 Output to the SYS board : Pin 21, J413 Output to the SYS board : Pins 3 and 4, J414 Output to the SLG board, SDV/CCD board (via SLG board) and FUS board : Pin 5, J414 Output to the RADF and finisher : Pin 6, J414 Output to the RADF and finisher (3) 12V 12VA -12VA 12VB 12VC : Pin 24, J413 Output to the SYS board : Pin 26, J413 Output to the SYS board : Pin 25, J413 Output to the SYS board : Pin 11, J414 Output to the SLG board and CCD board via SLG board
15 - 3
The following are 2 output channels which are linked with the door switches. (1) 5.1V 5.1VG : Pin 5, J416 Output to the LGC board (2) 24V 24VC 24VD 24VE 24VF 24VG : Pin 1, J415 Output to the SLG board and SDV board via SLG board : Pin 2, J415 Output to the RADF and finisher : Pin 3, J415 Output to the RADF and finisher : Pin 1, J416 Output to LGC board (MOT, FAN, ADU and CLT) : Pin 2, J416 Output to LGC board (MOT, FAN, relay unit and high-voltage transformer) <<Output connector>> Not linked with the door switches J412 J413 J414 for the LGC board for the SYS board for the SLG board, SDV board, RADF and finisher
Linked with the door switches J415 J416 for the SLG board, SDV board, RADF and finisher for the LGC board, MOT, FAN, ADU, CLT, relay unit and high-voltage transformer
15 - 4
IH
Breaker
Noise filter
Main switch
F1 Noise filter REG2 F3 F4 F5 F6
5.1VG 24VC (SCN) 24VD (RADF/FIN) 24VE (RADF/FIN) 24VF 24VG
PWR-EN PWR-DN
Switching power supply Door switch
F7
3.3VA/5.1VA (M) F2 Noise filter REG1 3.3VB.D/5.1VB, C (SYS) 3.3VC/5.1VD (SCN) 5.1VE, F (RADF/FIN) 12VA, B (SYS) 12VA (SYS) 12VC (SCN)
[Configuration of power supply unit]
15 - 5
ON
(Instantaneous outage)
AC input
Max. 20ms OFF
120ms or lower Hi-Z (High impedance) PWR-DN signal (L)
20ms or higher
500ms or lower
50ms or higher
System line output (with rated load)
Lower limit of each rated voltage or higher
PWR-EN signal (L)
Hi-Z (High impedance)
200ms or lower
200ms or lower
Main line output Door switch line output (with rated load)
Lower limit of each rated voltage or higher
[Sequence of power supply]
15 - 6
16. PC BOARDS
(1) PWA-F-SYS-320
16 - 1
DP4500/3500 PC BOARDS
(2) PWA-F-LGC-320
16 - 2
(3) PWA-F-SLG-320
(4) PWA-F-CCD-320
16 - 3
(5) PWA-F-SDV-320
(6) PWA-F-LDR-320
(7) PWA-F-SNS-320
16 - 4
(8) PWA-F-ADU-520-3
(9) PWA-F-FUS-320
16 - 5
16 - 6

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SERVICE MANUAL DIGITAL PLAIN PAPER COPIER

Copyright TOSHIBA CORPORATION 2001 ALL RIGHTS RESERVED

1. SPECIFICATIONS / ACCESSORIES / OPTIONS / SUPPLIES

December 2000 TOSHIBA TEC

64~80g/m2, 17~22 lb.

December 2000 TOSHIBA TEC

Paper feeding ..................... Automatic feeding:

(Paper stack height 11 mm : equivalent to 100 sheets; 64 to 80 g/m2, 17 to 22 lb.)

December 2000 TOSHIBA TEC

December 2000 TOSHIBA TEC

December 2000 TOSHIBA TEC

December 2000 TOSHIBA TEC

1.5 System List

December 2000 TOSHIBA TEC

Staple cartridge STAPLE-1600

Work table KK-3500

Staple cartridge STAPLE-700 Finisher relay unit

Key copy counter socket MU-10 Key copy counter MU-8

Hole punch unit MJ-6001

Staple cartridge STAPLE-600

Cassette module MY-1017

Paper feed pedestal (PFP) KD-1009

Large capacity feeder (LCF) KD-1010

December 2000 TOSHIBA TEC

2. OUTLINE OF THE MACHINE

December 2000 TOSHIBA TEC

DP4500/3500 OUTLINE OF THE MACHINE

DP4500/3500 OUTLINE OF THE MACHINE

December 2000 TOSHIBA TEC

2.2 Location of Electrical Parts

December 2000 TOSHIBA TEC

DP4500/3500 OUTLINE OF THE MACHINE

[B] Scanner unit (B-1) Motor

(B-2) Sensors and switches

S10 S27 S1 S5 S6 Rear side

*A4 series : S1 to 5 are installed. LT series : S1 to 3 and S6 are installed.

DP4500/3500 OUTLINE OF THE MACHINE

December 2000 TOSHIBA TEC

December 2000 TOSHIBA TEC

DP4500/3500 OUTLINE OF THE MACHINE

[C] System unit

DP4500/3500 OUTLINE OF THE MACHINE

December 2000 TOSHIBA TEC

[D] Laser unit

S22 S23 CLT1 M4

December 2000 TOSHIBA TEC

DP4500/3500 OUTLINE OF THE MACHINE

[F] Main unit (F-1) Motors and fans

M14 M10 M13

M6 M11 M15 M12

(F-2) PC boards and AC parts

DP4500/3500 OUTLINE OF THE MACHINE

December 2000 TOSHIBA TEC

(F-3) DC parts except motors and PC boards

S28 CLT5 S17 CLT3 CLT6

December 2000 TOSHIBA TEC

DP4500/3500 OUTLINE OF THE MACHINE

2.3 Symbols and Functions of Various Components

DP4500/3500 OUTLINE OF THE MACHINE

December 2000 TOSHIBA TEC

(2) Sensos and switches

December 2000 TOSHIBA TEC

DP4500/3500 OUTLINE OF THE MACHINE