User manual KONICA MINOLTA ST-723 - ST723/ST724 SERVICE MANUAL

SERVICE MANUAL Models ST-723/724 FEBRUARY 1999 CSM-ST723/724 KONICA BUSINESS TECHNOLOGIES, INC. ST-723/724 SERVICE MANUAL FEBRUARY 1999 Used on Konica Model 7823 IMPORTANT NOTICE Because of the possible hazards to an inexperienced person servicing this equipment, as well as the risk of damage to the equipment, Konica Business Technologies strongly recommends that all servicing be performed by Konica-trained service technicians only. Changes may have been made to this equipment to improve its performance after this service manual was printed. Accordingly, Konica Business Technologies, Inc., makes no representations or warranties, either expressed or implied, that the information contained in this service manual is complete or accurate. It is understood that the user of this manual must assume all risks or personal injury and/or damage to the equipment while servicing the equipment for which this service manual is intended. Corporate Publications Department © 2001, KONICA BUSINESS TECHNOLOGIES, INC. All rights reserved. Printed in U.S.A. CONTENTS GENERAL, MECHANICAL/ELECTRICAL 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 2. PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2 3. CROSS-SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3 4. DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-4 5. ELECTRICAL COMPONENTS LAYOUT . . . . . . . . . . . . . . . . . . . . M-5 6. OUTLINE OF OPERATION IN EACH MODE 6-1. INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. NON-SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. GROUP MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. SORT STAPLE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. MANUAL STAPLE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7. BIN MOVEMENT AT END OF COPY CYCLE . . . . . . . . . . . . 7. OPERATION OF EACH MECHANISM 7-1. PAPER TRANSPORT MECHANISM . . . . . . . . . . . . . . . . . . . 7-2. PAPER ALIGNING MECHANISM . . . . . . . . . . . . . . . . . . . . . . 7-3. BIN MOVING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. PAPER CLAMPING MECHANISM . . . . . . . . . . . . . . . . . . . . . 7-5. PAPER DETECTION AT STAPLING MECHANISM . . . . . . . 7-6. STAPLING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. SORTER SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. BIN EMPTY DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. OPERATION IN EACH MODE 8-1. NON-SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. GROUP MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. SORT STAPLE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-6 M-6 M-7 M-9 M-10 M-11 M-11 M-12 M-13 M-17 M-21 M-25 M-25 M-35 M-36 M-37 M-38 M-40 M-42 iii CONTENTS ... ...... TEST. MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1 DIS/REASSEMBLY, ADJUSTMENT 1. DISASSEMBLY/REASSEMBLY 1-1. REMOVAL OF EXTERIOR COVERS . . . . . . . . . . . . . . . . . . . 1-2. REMOVAL OF THE TRANSPORT GUIDE PLATE ASSY . . 1-3. REMOVAL OF THE BIN MOVING MOTOR M1 UNIT. . . . . . 1-4. REMOVAL OF PAPER CLAMP SOLENOID SL1 . . . . . . . . . 1-5. REMOVAL OF THE STAPLE UNIT . . . . . . . . . . . . . . . . . . . . 1-6. REMOVAL OF THE SORTER LOCK RELEASE LEVER . . . 1-7. REMOVAL OF THE BINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 D-2 D-3 D-4 D-4 D-5 D-6 2. ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9 TROUBLESHOOTING 1. MISFEED DETECTION/TROUBLESHOOTING PROCEDURES 1-1. MISFEED DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-2. TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . T-1 2. MALFUNCTION DETECTION/TROUBLESHOOTING PROCEDURES 2-1. MALFUNCTION DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . T-3 2-2. TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . T-5 xELECTRICAL WIRING DIAGRAM xELECTRICAL CIRCUIT DIAGRAM iv SAFETY PRECAUTIONS SAFETY PRECAUTIONS Installation Environment Safety considerations usually are directed toward machine design and the possibility of human error. In addition, the environment in which a machine is operated must not be overlooked as a potential safety hazard. Most electrical equipment is safe when installed in a normal environment. However, if the environment is different from what most people consider to be normal, it is conceivable that the combination of the machine and the room air could present a hazardous combination. This is because heat (such as from fusing units) and electrical arcs (which can occur inside switches) have the ability to ignite flammable substances, including air. When installing a machine, check to see if there is anything nearby which suggests that a potential hazard might exist. For example, a laboratory might use organic compounds which, when they evaporate, make the room air volatile. Potentially dangerous conditions might be seen or smelled. The presence of substances such as cleaners, paint thinners, gasoline, alcohol, solvents, explosives, or similar items should be cause for concern. If conditions such as these exist, take appropriate action, such as one of the following suggestions. · Determine that the environment is controlled (such as through the use of an exhaust hood) so that an offending substance or its fumes cannot reach the machine. Remove the offending substance. Install the machine in a different location. effect may be caused by altering any aspect of the machine's design. Such changes have the potential of degrading product performance and reducing safety margins. For these reasons, installation of any modification not specifically authorized by Konica Business Machines U.S.A., Inc., is strictly prohibited. The following list of prohibited actions is not all-inclusive, but demonstrates the intent of this policy. · · · · · · · · Using an extension cord or any unauthorized power cord adapter. Installing any fuse whose rating and physical size differs from that originally installed. Using wire, paper clips, solder, etc., to replace or eliminate any fuse (including temperature fuses). Removing (except for replacement) any air filter. Defeating the operation of relays by any means (such as wedging paper between contacts). Causing the machine to operate in a fashion other than as it was designed. Making any change which might have a chance of defeating built-in safety features. Using any unspecified replacement parts. General Safety Guidelines This copier has been examined in accordance with the laws pertaining to various product safety regulations prior to leaving the manufacturing facility to protect the operators and service personnel from injury. However, as with any operating device, components will break down through the wear-and-tear of everyday use, as will additional safety discrepancies be discovered. For this reason, it is important that the technician periodically performs safety checks on the copier to maintain optimum reliability and safety. The following checks, not all-inclusive, should be made during each service call: CAUTION: Avoid injury. Ensure that the copier is disconnected from its power source before continuing. · · · Look for sharp edges, burrs, and damage on all external covers and copier frame. Inspect all cover hinges for wear (loose or broken). Inspect cables for wear, frays, or pinched areas. · · The specific remedy will vary from site to site, but the principles remain the same. To avoid the risk of injury or damage, be alert for changes in the environment when performing subsequent service on any machine, and take appropriate action. Unauthorized Modifications Konica copiers have gained a reputation for being reliable products. This has been attained by a combination of outstanding design and a knowledgeable service force. The design of the copier is extremely important. It is the design process that determines tolerances and safety margins for mechanical, electrical, and electronic aspects. It is not reasonable to expect individuals not involved in product engineering to know what v SAFETY PRECAUTIONS · · · Ensure that the power cord insulation is not damaged (no exposed electrical conductors). Ensure that the power cord is properly mounted to the frame by cord clamps. Check the continuity from the round lug (GND) of the power cord to the frame of the copier -- ensure continuity. An improperly grounded machine can cause an electrically-charged machine frame. Applying Isopropyl Alcohol Care should be exercised when using isopropyl alcohol, due to its flammability. When using alcohol to clean parts, observe the following precautions: · · Remove power from the equipment. Use alcohol in small quantities to avoid spillage or puddling. Any spillage should be cleaned up with rags and disposed of properly. Be sure that there is adequate ventilation. Allow a surface which has been in contact with alcohol to dry for a few minutes to ensure that the alcohol has evaporated completely before applying power or installing covers. Safeguards During Service Calls Confirm that all screws, parts, and wiring which are removed during maintenance are installed in their original positions. · When disconnecting connectors, do not pull the wiring, particularly on AC line wiring and high voltage parts. Do not route the power cord where it is likely to be stepped on or crushed. Carefully remove all toner and dirt adhering to any electrical units or electrodes. After part replacement or repair work, route the wiring in such a way that it does not contact any burrs or sharp edges. Do not make any adjustments outside of the specified range. · · Summary It is the responsibility of every technician to use professional skills when servicing Konica products. There are no short cuts to high-quality service. Each copier must be thoroughly inspected with respect to safety considerations as part of every routine service call. The operability of the copier, and more importantly, the safety of those who operate or service the copier, are directly dependent upon the conscientious effort of each and every technician. Remember...when performing service calls, use good judgement (have a watchful eye) to identify safety hazards or potential safety hazards that may be present, and correct these problem areas as they are identified -- the safety of those who operate the copier as well as those who service the copier depend on it! · · · · vi GENERAL, M E C H A N ICAL/ ELECTRICAL 1 Type S P E C IFICATIONS : 10-Moving-Bin Sorter 10-Moving-Bin Sorter : Appendant to copier : 11 : Non-Sort Sort Group Sort Staple Manual Staple (ST-723) with Automatic Stapler (ST-724) Installation No. of Bins Modes *1 ST-724 only*2 ST-724 only *1: Not available for an ST-724 mounted together with an DF-723. *2: Available only for a system equipped also with an DF-723. In the Non-Sort Mode Copy Medium : Recommended paper weighing 60 to 90 g/m2 or 16 to 24 lbs., translucent paper, transparencies, heavy paper (91 to 157 g/m2 or 25 to 41 lbs.). : A5 lengthwise to A3, and A3 Wide or 5-1/2" × 8-1/2" to 11" × 17" and Full Bleed : Recommended paper : 1st Bin - 50 : 2nd to 10th Bin - 25/Bin (80 g/m2 or 22 lb.) : Transparencies: 10 (max. size: A4 or 8-1/2" × 11") : Other special paper: 10 Size Max. Capacity In the Sort/Group Mode Copy Medium : Recommended paper weighing 60 to 80 g/m2 or 16 to 22 lbs. Size : A5 lengthwise to A3, 5-1/2" × 8-1/2" to 11" × 17" Max. Capacity : 25 sheets of 80 g/m2 or 22 lb. paper per Bin In the Sort Staple Mode Copy Medium : Recommended paper weighing 60 to 80 g/m2 or 16 to 22 lbs. Size : A4 to A3, 8-1/2" × 11" to 11" × 17" Max. Capacity : 25 sheets of 80 g/m2 or 22 lb. paper per Bin No. of Copies That Can : 2 to 25 copies of 80 g/m2 or 22 lb. paper be Stapled Power Requirement Power Consumption Dimensions : DC24V (supplied from copier) : 72W or less : Width - 400 mm or 15-3/4" Depth - 562 mm or 22-1/4" Height - 404 mm or 16" : ST-723 - 15.8 kg or 34-3/4 lbs. (excl. Mounting Bracket) ST-724 - 18.1 kg or 40 lbs. (excl. Mounting Bracket) : Same as copier Weight Environmental Requirements M-1 2 P A R T S IDENTIFICATION 1 2 3 4 7 10 9 6 3 5 4428M060AA 8 11 4428M061AA 1. 2. 3. 4. 5. 6. 7. Sorter Lock Release Lever Hookup Connector Sorter Lock Lever Drive Coupling Gear Transport Guide Plates Sorter Set Detector Stapler Cover (Cannot be opened on ST-723) 8. 1st to 10th Bins 9. Top Bin 10. Paper Aligning Bar (ST-724 only) 11. Mounting Bracket M-2 3 C R O S S -SECTIONAL VIEW 3 4 2 5 6 7 1 8 9 10 11 1st to 10th Bins Top Bin Spiral Cam Bin Empty Sensor LED Board PWB-B 5. Sorter Lock Release Lever 6. Bin Upper Limit Interlock Switch S1 1. 2. 3. 4. 7. Sorter Lock Lever 8. Sorter Exit Sensor PC2 9. Bin Lower Limit Interlock Switch S2 10. Bin Lower Limit Position Sensor PC4 11. Bin Empty Sensor PQ Board PWB-C M-3 4 D R IVE SYSTEM P3 P2 Belt 2 Belt 1 P1 G5 GP1 G4 G3 Belt 4 Belt 3 GP2 P5 P6 P4 G1 G2 Symbol Belt 1 Belt 2 Belt 3 Belt 4 Length 150 mm 918 mm 160 mm 150 mm Symbol G1 G2 G3 G4 G5 GP1 GP2 Gear/Pulley: No. of Teeth 25/15 36 37 34/16 30 12/60 23/19 Symbol P1 P2 P3 P4 P5 P6 Pulley: No. of Teeth 22 22 28 28 20 20 M-4 5 ELECTRICAL COMPONENTS LAYOUT SYMBOL PWB-A PWB-B PWB-C M1 M2 M3 M4 SL1 PC1 PC2 PC3 PC4 PARTS NAME Control Board Bin Empty Sensor LED Board Bin Empty Sensor PQ Board Bin Moving Motor Paper Clamp Motor Paper Aligning Motor Stapling Motor Paper Clamp Solenoid Bin Moving Pulse Sensor Sorter Exit Sensor Bin Positioning Sensor Bin Lower Limit Position Sensor SYMBOL PC5 PC6 PC8 PC10 S1 S2 S3 S4 PARTS NAME Paper Aligning Home Position Sensor Paper Clamp Home Position Sensor Paper Clamping Sensor Staple Empty Detecting Sensor Bin Upper Limit Interlock Switch Bin Lower Limit Interlock Switch Sorter Set Switch Stapler Home Position Detecting Switch ... ST-724 Only M-5 6 OUTLINE OF OPERATION IN EACH MODE 6-1. INITIAL OPERATION The following operations are performed sequentially when Sorter Set Switch S3 is first actuated after the Power Switch of the copier has been turned ON. ST-723 performs step only. The Paper Aligning Bar is detected at its home position. (For details, see p. M-14.) The Paper Clamp Unit is detected at its home position. (For details, see p. M-22.) A check is made to ensure that the Stapler Arm is at its home position. * If not at the home position, the Stapler Arm is moved to the home * position. (For details, see p. M-27.) The 1st Bin is detected at the reference position. (For details, see p. M-19.) 6-2. NON-SORT MODE When in the Non-Sort Mode, the ST-724/ST-723 feeds all copies out onto the 1st Bin. It feeds copies into the subsequent Bin as soon as the capacity of the current Bin is exceeded. (As soon as 25 copies have been fed into the 10th Bin, the Remove Copies Indicator on the copier control panel lights up and the copier inhibits the initiation of a new copy cycle.) Example: Making 80 copies No. of Copies Fed In 50 25 5 Bin 1st 2nd 3rd Outline of Operation Out of Copier Repeats for the no. of copies set to be made. Through ST-724/ST-723 Fed into 1st Bin Aligning End of Operation ... ST-724 only When the capacity of the current Bin is exceeded Bin Moving M-6 6-3. SORT MODE q When in the Sort Mode, the ST-724/ST-723 sorts copies into complete sets of originals, each set being fed out onto a Bin. Sorting is bi-directional: the copies of the odd-numbered originals are sorted in the sequence from the 1st Bin to 10th Bin (the Bins moving upward). Copies of the even-numbered originals are sorted in the sequence from the 10th Bin to 1st Bin (the Bins moving downward). Example: Making 10 Copies Each from 3 Different Originals Direction of Bin Moving for Copies of 1st Original Direction of Bin Moving for Copies of 3rd Original Copy Direction of Bin Moving for Copies of 2nd Original q When 25 copies have been fed out into the last Bin, the Remove Copies Indicator lights up on the copier control panel and the copier inhibits the initiation of a new copy cycle. If, however, the 6th and subsequent Bins are not used in the Sort Mode (i.e., the number of copies to be made has been set to 5 or less), the Remove Copies Indicator does not light up. Instead, the ST-724/ST-723 is automatically switched to the Auto Dual Mode and copying continues using the 6th and subsequent Bins until the Remove Copies Indicator lights up or the copy cycle is completed. Example: Making 3 Copies Each from 30 Different Originals Bin 1st 2nd 3rd 6th 7th 8th 26th to 30th 5 1st to 25th 25 Original No. of Copies Fed Out M-7 q When the Start Key is pressed with 11 or more set for the number of copies to be made, the number on the Multi-Copy Display is automatically changed to 10 and the ST-724/ST-723 operates in the Sort Mode. Outline of Operation Out of Copier Through ST-724/ST-723 Fed into Bin Aligning Bin Moving ... ST-724 only Repeats for the no. of copies set to be made. After the last copy has been aligned End of Operation M-8 6-4. GROUP MODE q When in the Group Mode, the ST-724/ST-723 separates copies made from a single original into groups, each group containing the same, or a different, number of copies. Example: Making 25 Copies Each from 3 Different Originals Bin 1st 2nd 3rd 4th 2nd Original 1st No. of Copies Fed Out 25 5 25 5 q If the settings on the copier control panel and other conditions require more than 10 Bins, during execution of the copy job, the copier stops the initiation of a new copy cycle and the Remove Copies Indicator lights up. If space remains available in the 10th Bin, the Start Key can be pressed again. All copies of the subsequent original or originals are now fed into the 10th Bin. However, as soon as the capacity of the 10th Bin is exceeded, the copier inhibits the initiation of the new copy cycle. Outline of Operation Out of Copier Repeats for the no. of copies set to be made. Through ST-724/ST-723 Fed into Bin Aligning ... ST-724 only At the end of the copy cycle for one original End of Operation Bin Moving M-9 6-5. SORT STAPLE MODE (ST-724 ONLY) q When in the Sort Staple Mode, the ST-724 automatically staples each of the copy sets sorted into each Bin (the sorting operation is the same as in the Sort Mode). q Stapling action occurs starting with the lowest Bin in use. (For instance, if 1st to 4th Bins are in use, the copy sets are stapled starting with the 4th Bin.) q If copies are to be sorted only into the 1st Bin (i.e., when making one copy each of two different originals), after both copies have been fed into the 1st Bin, the ST-724 moves the Bins to the 2nd Bin position and then back to the 1st Bin position before initiating the stapling action. q If the ST-724 is switched to the Auto Dual Mode during sorting, it cancels the stapling action and sets the ST-724 into the Sort Mode. Outline of Operation Out of Copier Through ST-724 Repeats for the no. of copies set to be made. Fed into Bin Aligning Bin Moving After the last copy has been aligned Bin Moving Clamping Stapling Bin Moving ... If the lowest Bin in ... use is not located to ... receive copies End of Operation q Stapling action is inhibited under any of the following conditions even if There is a copy or copies present in any of the Bins when the Power Switch is turned ON and the copy cycle is initiated without having removed it. The copy cycle is initiated with copies made in a preceding Non-Sort cycle still in the Bins. The copy cycle is initiated with paper inserted into the Bin externally. There is only one copy in the Bin after sorting. Copies with different crosswise lengths are in the Bins. The copy set is not properly conveyed to the stapling position because of a clamping or other failure (in which case, the ST-724 goes on to staple the copy set in the next Bin). the copy cycle has been initiated in the Sort Staple Mode: M-10 6-6. MANUAL STAPLE MODE (ST-724 ONLY) The following two different operations are possible in the Manual Staple Mode. · When the Manual Staple Key on the copier control panel is pressed after copies have been made in the Sort or Group Mode, the ST-724 staples together two or more copies in a Bin. (The stapling action and stapling inhibiting conditions are the same as those in the Sort Staple Mode.) · When there are no copies in any of the Bins, the ST-724 can staple together sheets of paper inserted into the 1st Bin by hand when the Manual Staple Key on the copier control panel is pressed. At this time, the ST-724 performs no aligning action. Operation Press the Manual Staple Key. Clamping Stapling End of Operation No stapling action occurs if the sheets of paper have not properly been conveyed to the stapling position because of a clamping or other failure. 6-7. BIN MOVEMENT AT END OF COPY CYCLE If the 1st Bin is not located to receive copies at the end of a copy cycle, the Bins are moved so that the 1st Bin will be located to receive copies 2 sec. after copies have been removed from the Bins. This sets the ST-724/ST-723 M-11 7 O P E R A T I O N O F E A C H M E C H A N ISM 7-1. PAPER TRANSPORT MECHANISM q Paper Path The paper fed out of the Copier by the Exit Roller in the copier is fed directly onto the Transport Roller in the ST-724/ST-723. The Transport Roller turns to feed the paper almost straight into the Bin. During this time, Sorter Exit Sensor PC2 is unblocked ( H ) as the leading edge of the paper moves past it and blocked ( L ) as the trailing edge of the paper moves past it. The paper path is constant, as shown below, regardless of the operating mode selected for use. Light Blocking Plate PC2 Paper Copier PC2 Transport Roller Exit Roller in Copier q Transport Roller Drive The Transport Roller is driven by the Drive Coupling Gear Assy which receives drive from the Exit Roller Drive Gear inside the copier (or Duplex Unit). This means that the Transport Roller turns in phase with the paper take-up drive of the copier. = Viewed from Rear of System = Transport Roller Pulley Copier or Duplex Unit ST-724/ST-723 Drive Coupling Gear Assy Drive Coupling Gear Assy Timing Belt Transport Roller Pulley Exit Roller Drive Gear M-12 7-2. PAPER ALIGNING MECHANISM (ST-724 ONLY) q The Paper Aligning Mechanism presses the copies fed into the Bins up against the Aligning Reference Plate so that they can be aligned in the crosswise direction. This mechanism will operate only with B5 Lengthwise, 8" × 10" Lengthwise or greater size. q The copies are aligned by the Paper Aligning Bar which is moved by Paper Aligning Motor M3 turning forward or backward. The movement of the Paper Aligning Bar differs depending on the paper size. Paper Aligning Home Position Sensor PC5 Spiral Shaft M3 M3 Turning Forward Paper Aligning Bar M3 Turning Backward Aligning Reference Plate q Paper Aligning Motor M3 Paper Aligning Motor M3 is a two-phase stepping motor. The output pulses from pins 12 to 15 of IC1A are applied via IC6A and IC9A to M3 to control the direction and distance of movement of the Paper Aligning Bar. Each output pulse from IC1A turns M3 one angular increment, or a step, which is 7.5°. This is equivalent in the movement of the Paper Aligning Bar to approx. 0.3 mm. The number of output pulses from IC1A therefore controls the distance of movement of the Paper Aligning Bar. The output sequence of pulse signals (steps 1, 2, 3, and 4 or steps 4, 3, 2, and 1), on the other hand, determines the direction of rotation of M3. IC1A (Pin No.) 1 12 13 14 15 Output Sequence L H H L 2 L H L H Step 3 H L L H 4 H L H L M3 Turning Forward M3 Turning Backward M-13 q Paper Aligning Bar Home Position Detection The home position of the Paper Aligning Bar is where the Light Blocking Plate fitted to the Paper Aligning Bar has just blocked Paper Aligning Home Position Sensor PC5 ( L ). This position serves as the reference point, based on which the number of output pulses from IC1A is calculated for different paper sizes. Operation When Paper Aligning Bar is Detected at its Home Position M3 is turned backward until PC5 is blocked. M3 is turned forward until PC5 is unblocked. M3 is turned backward by one pulse until PC5 is blocked, at which time M3 is deenergized. (See NOTE below.) M3 is turned forward until PC5 is unblocked. M3 is turned backward by one pulse until PC5 is blocked, at which time M3 is deenergized. (See NOTE below.) NOTE: CPU checks whether PC5 is blocked or unblocked each time M3 is energized for one pulse. The home position of the Paper Aligning Bar is detected under any of the following timings: · When Sorter Set Switch S3 is turned ON. · At the end of each mode (when the last copy has been aligned). M-14 q Outline of Paper Aligning Bar Operation Home Position Standby Position ... ... The Bar is located near, but not in contact with, the copy. (See NOTE below.) ... ... The Bar presses the copy up against the Aligning Reference Plate. (See NOTE below.) Aligning Position Home Position NOTE: Varies for different paper sizes. During a multi-copy cycle, the Paper Aligning Bar repeatedly Sizes Predetermined No. of Pulses Paper Size A3 11" × 17" 8-1/2" × 11"L A4L From Home to Standby Position 0 11 137 139 From Standby to Aligning Position 51 62 188 190 L: Lengthwise moves between the standby and aligning position until it completes aligning the last copy. The Paper Aligning Bar returns to the home position when it has completed aligning the last copy. q Number of Pulses (Paper Aligning Bar Movement) for Different Paper M-15 q Aligning Operation Paper Aligning Bar at home position 60 msec. after Sorter Exit Sensor PC2 has been unblocked ( H ) as the leading edge of the copy fed out of the copier reaches it Paper Aligning Motor M3 turns forward for the predetermined number of pulses corresponding to the paper size, thereby moving the Paper Aligning Bar to the standby position. 270 msec. after PC2 has been blocked ( L ) as the trailing edge of the copy moves past it M3 turns forward for the predetermined number of pulses, which moves the Paper Aligning Bar to the aligning position to align the copy. 60 msec. later In a multi-copy cycle In a single-copy cycle or at the end of aligning the last copy M3 turns backward and the Paper M3 turns backward for the Aligning Bar is detected at its home predetermined number of pulses to return the Paper Aligning Bar to position. the standby position. M-16 7-3. BIN MOVING MECHANISM q The Top Bin and 1st to 10th Bin are all held in position by the grooves in the Side Plate and those in the Spiral Cams. When the Spiral Cams are turned one complete turn by Bin Moving Motor M1, all Bins and Top Bin are at once moved up or down (depending on the turning direction of the Spiral Cam) one Bin position along the grooves in the Spiral Cams. Top Bin Bin Upper Limit Interlock Switch S1 1st to 10th Bin Bin Lower Limit Interlock Switch S2 M1 Bin Moving Pulse Sensor PC1 4428M063AA Bin Lower Limit Position Sensor PC4 Bins Moving Up Bins Moving Down Spiral Cam Pressure Roll Drive Transmitting Belt M1 S1 S2 PC4 PC1 Bin Positioning Sensor PC3 Light Blocking Plate M-17 q Bin Moving Motor M1 Bin Moving Motor M1 is a DC motor. The outputs from pins 5 and 6 of IC1A are applied via IC7A and IC10A to M1. This energizes or deenergizes M1 and controls the direction of M1 rotation. IC1A-5 L H H IC1A-6 H L H Direction of M1 Rotation Forward (Bins Moving Up) Backward (Bins Moving Down) Deenergized If M1 is turned at its maximum speed, Bins vibrate heavily as they move, resulting in a greater noise. M1 speed is controlled by pulse width modulation, or PWM, which varies the width of pulses applied to M1, thereby changing the average voltage applied to M1. The M1 shaft is fitted with a Pulse Disk and Bin Moving Pulse Sensor PC1 is used to convert the M1 shaft speed to pulse signals. The CPU knows the shaft speed by means of the pulse frequency. Based on the output from PC1, the M1 drive pulses are controlled, thereby minimizing vibration as it occurs during Bin moving. This contributes to quieter operation. Pulse Disk M1 PC1 PC1 M-18 q Bin Home Position Detection The home position of the Bins is where the 1st Bin is located to receive copies fed out of the copier. Movement of each Bin is controlled with this position as the reference. The Bin home position is detected by Bin Positioning Sensor PC3 and Bin Lower Limit Position Sensor PC4. PC3 is blocked ( L ) and unblocked ( H ) by a Light Blocking Plate which turns in phase with the Spiral Cam. It is unblocked when any of the Bins is located to receive the copy. PC4 is normally kept blocked ( L ) by a Light Blocking Plate. However, when the 1st Bin is located lower than the level to receive the copy, the 10th Bin pushes the Light Blocking Plate, which unblocks PC4 ( H ). Spiral Cam 10th Bin PC4 PC3 4428M021AA Light Blocking Plate Senses that any of the Bins is located to receive a copy. Light Blocking Plate Operation at Bin Home Position Detection M1 is turned backward until PC4 is unblocked. M1 is turned forward and is deenergized as soon as PC3 is unblocked. (This is where the 1st Bin receives the copy.) 4428T01MCA · Sorter Set Switch S3 is turned ON for the first time after the Power The Bin home position is detected under the following timing: Switch of the copier has been turned ON. q Bin Moving Control After the Bin home position is detected, at which time the 1st Bin is located to receive the copy, movement of the Bins is controlled by the direction of M1 rotation and the number of times PC3 is blocked and unblocked. M-19 q Bin Upper Limit Interlock Switch S1 and Bin Lower Limit Interlock Switch S2 For a mechanical or electrical failure, Bin Moving Motor M1 can keep on turning even when it should remain stationary. Bin Upper Limit Interlock Switch S1 and Bin Lower Limit Interlock Switch S2 are installed to shut down the DC24V power supply to M1, thereby bringing it to a stop if such trouble occurs. Bin Upper Limit Interlock Switch S1 If, during the upward motion of the Bins, the Bins continue moving upward above the upper limit position (which is where the 10th Bin is located to receive the copy), the Actuator is swung by the Top Bin as shown on the left, actuating S1 to cut off the power supply to M1. Actuator Top Bin 1st Bin S1 Bin Lower Limit Interlock Switch S2 S2 10th Bin PC4 If, during the downward motion of the Bins, the Bins continue moving downward, having moved past the level which unblocks Bin Lower Limit Position Sensor PC4, the Light Blocking Plate of PC4 actuates S2 as shown on the left, thus shutting down the power supply to M1. Light Blocking Plate q Purpose of Installation of Top Bin The paper this machine handles is mainly colored copies. Colored copies tend to develop a slight face curl and, as a result, the copies fed out into the1st Bin in the Sort mode can be misaligned with each other in the bin. (With the 2nd Bin and lower, the copies fed into each bin are held by the immediately upper bin and therefore the curl is minimized in the copies.) The Top Bin in this machine therefore functions to keep the copies down as they are fed into the 1st Bin. M-20 7-4. PAPER CLAMPING MECHANISM (ST-724 ONLY) q The Paper Clamp Unit uses its jaws to clamp the copy set in the Bin and moves it to the stapling position. After the copy set has been stapled together, the jaws return it back to the Bin. Jaws Paper Clamp Solenoid SL1 Paper Clamp Motor M2 Paper Clamp Home Position Sensor PC6 q The paper clamping operation consists of, (1) the Paper Clamp Unit being moved between the home position (which is the stapling position) and the clamping position by Paper Clamp Motor M2, and (2) the Jaws of the Paper Clamp Unit clamping and unclamping the copy set as Paper Clamp Solenoid SL1 is energized and deenergized. q Paper Clamp Motor M2 A DC motor is used as Paper Clamp Motor M2. The output from pin 17 of IC1A energizes or deenergizes M2 which turns in one direction only. IC1A-17 L H M2 Energized Deenergized M-21 q Moving Mechanism and Position Detection of Paper Clamp Unit The Paper Clamp Unit is supported by four Rolls which run along the Rails fitted to the Front Frame. Installed under the Paper Clamp Unit is a Cam Slider, in which a Cam coupled to the drive shaft of M2 is fitted. When M2 is energized to turn the Cam one turn, the Paper Clamp Unit moves from home to the clamping position and then back to home position. Rail Rolls Rail Cam Slider Cam Light Blocking Plate M2 4428M026AA Cam Slider Cam PC6 Paper Clamp Home Position Sensor PC6 detects the Paper Clamp Unit at its home (stapling) position and clamping position. PC6 is blocked ( L ) and unblocked ( H ) by a semicircular Light Blocking Plate that turns in phase with the Cam. The home position and clamping position are detected by the Blocking Edge and Unblocking Edge of the Plate. The Blocking Edge is where PC6 is just blocked, which is the home position. The Unblocking Edge is where PC6 is just unblocked, which is the clamping position. Home Position Paper Clamp Unit Moving from Home to Clamping Position Paper Clamp Unit Moving from Clamping Clamping Position to Home Position PC6 4428M028AA 4428M029AA 4428M030AA 4428M031AA Blocking Edge Being Blocked Unblocking Edge Being Unblocked M2 is energized under the following timing to detect the home position of the Paper Clamp Unit: · Sorter Set Switch S3 is turned ON for the first time after the Power Switch of the copier has been turned ON. M-22 q Paper Clamping Mechanism As Paper Clamp Motor M2 turns, the Paper Clamp Unit moves to the paper clamping position. Paper Clamp Solenoid SL1 is then energized. When SL1 is energized, it moves the Lower Jaw upward by way of the Lower Arm. At the same time, the Upper Arm which is in gear with the Lower Arm pushes the Upper Jaw down. This results in the Upper and Lower Jaws clamping the copy set. In addition, Pin A of the Lower Jaw hooks catch B of the Aligning Reference Plate. This is done to move the Aligning Reference Plate, together with the copy set, to the stapling position. SL1 is deenergized when the Paper Clamp Unit moves back again to the clamping position after stapling. When SL1 is deenergized, the Jaws are returned back to the original position via the Upper and Lower Arms by the torsion spring fitted to the Lower Arm. (The Aligning Reference Plate is returned to the original position by torsion springs C and D fitted to it, as the Paper Clamp Unit moves to the paper clamping position.) Home Position (Before Operation) At Clamping C Upper Jaw Aligning Reference Plate Lower Jaw D Upper Arm Gear Coupling Lower Arm Torsion Spring A B SL1 M-23 q Paper Clamping Operation Paper Clamp Unit at home position Paper Clamp Motor M2 is energized to move the Paper Clamp Unit toward the clamping position. M2 is deenergized as the Unblocking Edge of the Light Blocking Plate reaches Paper Clamp Home Position Sensor PC6. 70 msec. later Paper Clamp Solenoid SL1 is energized and the Jaws clamp the copy set. 70 msec. later M2 is energized to move the Paper Clamp Unit toward the stapling position. M2 is deenergized as the Blocking Edge of the Light Blocking Plate reaches PC6. 70 msec. later (The copy set is stapled together. ... See 7-6. STAPLING MECHANISM.) 75 msec. later M2 is energized to move the Paper Clamp Unit toward the clamping position. M2 is deenergized as the Unblocking Edge of the Light Blocking Plate reaches PC6. 70 msec. later SL1 is deenergized and the Jaws open to unclamp the stapled copy set. 70 msec. later M2 remains energized until the Blocking Edge of the Light Blocking Plate reaches PC6, allowing the Paper Clamp Unit to return to the home position. M-24 7-5. PAPER DETECTION AT STAPLING MECHANISM (ST-724 ONLY) In the beginning of a stapling sequence, the copy set in the Bin is moved to the stapling position by the Paper Clamp Unit. Paper Clamping Sensor PC8 is used to check to see whether the copy set has been properly moved to the stapling position before each stapling action occurs. If PC8 is not blocked ( H ) by the copy set even when the Paper Clamp Unit has moved to the stapling position because of a clamp failure or other reason, the stapling action for that particular Bin is canceled and the sequence is started for the stapling action for the next Bin. PC8 Copy Set 7-6. STAPLING MECHANISM (ST-724 ONLY) q The Staple Unit has a Stapler Arm that is moved up and down by Stapling Motor M4 to drive a staple into the copy set. Stapler Home Position Detecting Switch S4 Plunger Guide Staple Forming Mechanism Stapler Arm M4 Knob Staple Cartridge Stapling Table Reverse Feed Check Paper Clamping Sensor PC8 4428M034AA M-25 q Stapling Motor M4 Stapling Motor M4, a DC motor, is energized or deenergized by the output from pin 20 of IC1A. It turns in one direction only. IC1A-20 L H q Stapler Arm Moving Mechanism M4 Energized Deenergized A cam slot is cut into the Stapler Arm, which the Roll on Gear D fits in. When Stapling Motor M4 is energized to turn Gear D one complete turn through a gear train of Gears A, B, and C, the Roll on Gear D causes the Stapler Arm to move through the upper and lower limit positions once. Upper Limit Position (Home Position) M4 Stapler Arm Gear A In Downward Stroke Gear B Gear C Roll Gear D Cam slot In Upward Stroke Lower Limit Position M-26 q Stapler Arm Home Position Detection The home position of the Stapler Arm is detected by Stapler Home Position Detecting Switch S4 which is actuated and deactuated by part A of the Plunger Guide fitted to the Stapler Arm. The output from S4 is applied to pin 1 of IC1A. S4 At Home Position When Arm Moves ON OFF IC1A-1 L H At Home Position Stapler Arm S4 A When Arm Moves S4 Pushbutton Plunger Guide S4 Plunger Guide S4 Pushbutton S4: ON S4: OFF A check is made to make sure if the Stapler Arm is at the home position under the following timing. If the Stapler Arm is not detected at its home position (S4 is deactuated), Stapling Motor M4 is energized and, when S4 is actuated, is deenergized. (This is the sequence of operation to detect the home position of the Stapler Arm.) · Sorter Set Switch S3 is turned ON for the first time after the Power Switch of the copier has been turned ON. M-27 q Staple Forming Mechanism The staple forming mechanism consists of the Guide Plate, Former, Driver, and Face Plate. Guide Plate (Front Sheath) Former Plunger Guide Body Bending Block A Driver Face Plate Staple Sheet 4428M037AA · The Guide Plate functions as a guide to hold the Former and Driver. The Bending Block of the Guide Plate serves as a stopper for the staple sheet being fed. The groove at A in the Bending Block holds the first, or front staple of the staple sheet. · The Former forms the front staple of the staple sheet held by the Bending Block into an inverted-U shape. · The Driver, fixed onto the Plunger Guide, separates the formed staple from the staple sheet and drives it into the copy set. · The Face Plate is fixed to the Body and presses the copy set down when the staple is driven into it. M-28 q Operation of the Staple Forming Mechanism Body Copy Set 1. As Stapling Motor M4 turns, the Stapler Arm moves downward. At this time the Body is pushed downward by the Plunger Guide. 2. The Body reaches the copy set and stops moving. At this time, the Face Plate presses the copy set downward. Plunger Guide Driver A 3. As the Stapler Arm (i.e. Plunger Guide) moves further downward, the Former is pushed by Claws A of the Driver and moves downward to form into an inverted-U the first staple of the staple sheet held in position by the Bending Block. 4428M039AA Former Bending Block Guide Plate Driver B A Driver Staple Sheet Bending Block Former Former 4428M040AA 4. Claws A of the Driver slide along protrusions B of the Guide Plate, slipping behind the Former. The tip of the Driver then reaches the first staple of the staple sheet. (At this time, the Bending Block is pushed in the direction of the arrow by the tip of the Driver, releasing the first staple.) Copy Set 5. The Former reaches the copy set and stops moving. The Driver Driver, on the other hand, moves further downward to separate the formed staple Former from the staple sheet and drives it into the copy set. (The staple driven into the Stapling copy set is bent by the Table Stapling Table. This completes the stapling action.) 4428M041AA M-29 Former Moves Upward As Driver Does So. Plunger Guide C Driver Former 6. The Stapler Arm (i.e. Plunger Guide) moves upward from the lower limit position. At this time, the Driver moves upward. 7. Since the protrusion of the Former fits into slot C in the Driver, the Former is moved upward as the Driver moves upward. Body Moves Upward As Driver and Former Do So. 8. Since the protrusion of the Former fits into rectangular hole D in the Face Plate, the Body also moves upward. D Face Plate Body S4 9. The Plunger Guide actuates Stapler Home Position Detecting Switch S4, which deenergizes M4. This completes the stapling action. Plunger Guide M-30 q Moving Stapler Arm Pivot Axis The lower limit position of the Stapler Arm varies depending on the number of sheets of paper to be stapled together. Since the Roll on Gear D fits into the cam slot in the Stapler Arm, however, the Stapler Arm at its cam slot end can move along only a given trajectory. The pivot axis of the Arm is therefore made movable, thereby compensating for the varying lower limit positions of the Arm depending on the number of sheets of paper to be stapled together. Pivot Axis Less Sheets of Paper More Sheets of Paper More Sheets of Paper Less Sheets of Paper Stapler Arm M-31 q Staple Feed Mechanism The staple sheet is fed one staple at a time onto the Bending Block by the Feed Spring fitted to the Feeder. Staple Feeding When a Staple Cartridge is placed in position, tension is applied to the Feeder in the direction of the arrow by the Cartridge, meaning that the Feeder is pressed against the Driver. Driver Feeder Cartridge Bending Block Feed Spring Staple Sheet When the Driver and Former move down as the Stapler Arm moves down, the protrusion of the Former pushes the Feeder back in the direction of the arrow, moving the Feed Spring one staple backward. (Because of the Reverse Feed Check of the Staple Cartridge, the staple sheet is not moved backward by the Feed Spring at this time.) Former Reverse Feed Check When the Stapler Arm moves up after a staple has been driven into the copy set, the Driver and Former move up. As a result, the Feeder is no longer pushed by the protrusion of the Former and, instead, it is again pushed toward the Driver. Since the Feed Spring moves in the direction of the arrow at this time, the staple sheet is fed one staple to the Bending Block. M-32 q Staple Sheet Empty Detection Staple Empty Detecting Sensor PC10 is used to detect whether there is a staple sheet or not in the Staple Cartridge. PC10 is a reflector-type photosensor. When there is a staple sheet, the light from PC10 LED is reflected by the staple sheet, turning ON the PC10 phototransistor. This results in a LOW signal being input to pin 62 of IC1A. If there is no staple sheet, the LED light is not reflected, which turns OFF the phototransistor. At this time, a HIGH signal is input to pin 62 of IC1A and the Add Staple Indicator lights up on the copier control panel. Staple Sheet Present Not Present IC1A-62 L H Staple Sheet