Ineo 161 Ineo 210: Service Manual Theory of Operation

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Service Manual
Theory of Operation
ineo 161
ineo 210
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After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
• To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
2005/04 1.0 — Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision

Theory of Operation Ver. 1.0 Apr. 2005
CONTENTS
ineo 161
ineo 210
Outline
1. System configuration............................................................................................... 1
1.1 ineo 210 ................................................................................................................ 1
1.2 ineo 161 ................................................................................................................ 2
2. Product specification ............................................................................................... 3
2.1 Copier ................................................................................................................... 3
2.2 Fax Kit (FK-505): (Option) .................................................................................... 6
Outline
3. Cross sectional view................................................................................................ 7
4. Paper path............................................................................................................... 8
5. Copy process .......................................................................................................... 9
5.1 Copy Process Overview ....................................................................................... 9
Composition/Operation
5.2 Image Forming Process...................................................................................... 11
5.3 Drum Charging (Step 1) ..................................................................................... 11
5.4 Exposure Process (Step 2)................................................................................. 12
5.5 Developing Process (Step 3) .............................................................................. 12
5.6 Image Transfer Process (Step 4) ........................................................................ 13
5.7 Paper Separating Process (Step 5) .................................................................... 13
5.8 Fusing Process (Step 6) ..................................................................................... 14
5.9 PC Drum Cleaning Process (Step 7) .................................................................. 14
5.10 Charge Neutralizing Process (Step 8) ................................................................ 15
5.11 Image Transfer Roller Cleaning Process (Step 9)............................................... 15
5.12 Toner Recovery Process (Step 10)..................................................................... 16
6. Overall configuration ............................................................................................. 17
6.1 Timing Chart at Power ON.................................................................................. 17
6.2 Control Block Diagram ........................................................................................ 18
7. Scanner (IR) .......................................................................................................... 19
7.1 Construction ....................................................................................................... 19
7.2 Mechanism and Control for Moving the Scanner and Mirrors Carriage.............. 20
7.2.1 Scanner Moving Mechanism/Control .......................................................... 20
7.2.2 Operation .................................................................................................... 20
7.3 Original Size Detection ....................................................................................... 22
7.4 Determination of Original Size............................................................................ 23
7.4.1 For Inch area............................................................................................... 23
7.4.2 For Metric and China area .......................................................................... 23
7.4.3 For Latin America area (Inch) ..................................................................... 24
i
7.4.4 For Latin America area (Metric) .................................................................. 25

8. PH (Writing section) .............................................................................................. 26
ineo 161
ineo 210
8.1 Construction ....................................................................................................... 26

8.2 Operation............................................................................................................ 27
9. Imaging unit .......................................................................................................... 28
9.1 Construction ....................................................................................................... 28
9.2 Operation............................................................................................................ 29
9.3 PC Drum............................................................................................................. 30
9.4 Grounding of the PC Drum................................................................................. 30
Outline
10. PC Drum charging ................................................................................................ 31

11. Developing ............................................................................................................ 32
11.1 Developing Roller ............................................................................................... 32
11.2 Developing Bias.................................................................................................. 32
11.3 ATDC Sensor...................................................................................................... 33
11.4 ATDC Sensor Automatic Adjustment.................................................................. 33

12. Toner replenishing................................................................................................. 34
12.1 Toner Replenishing Mechanism ......................................................................... 34
12.2 Toner Replenishing Control ................................................................................ 35
12.3 T/C Recovery Mode ........................................................................................... 36
12.4 Toner Bottle Home Position Detection ................................................................ 37
13. Toner recovery ...................................................................................................... 38
14. Synchronizing roller section .................................................................................. 39
14.1 Construction ....................................................................................................... 39
14.2 Operation............................................................................................................ 40
14.3 Paper Dust Remover .......................................................................................... 40
15. Image transfer and paper separation section........................................................ 41
15.1 Image Transfer Section....................................................................................... 41
15.2 Paper Separation Section................................................................................... 41
16. Paper take-up........................................................................................................ 42
16.1 Construction ....................................................................................................... 42
16.2 Operation............................................................................................................ 43
16.2.1 Paper Separating Mechanism..................................................................... 44
16.3 Drawer in Position Detection .............................................................................. 45
16.4 Paper Empty Detection Mechanism ................................................................... 45
16.5 Paper Lifting Plate .............................................................................................. 46
16.6 Universal Tray Paper Size Detection Mechanism ............................................... 46
16.6.1 ON/OFF Positions of Paper Size Detecting Switches and Corresponding
Paper Size Detected47
16.7 Paper Take Up Control ....................................................................................... 48
16.7.1 Paper Take Up Retry Control ...................................................................... 48
ii
17. Manual bypass section.......................................................................................... 49

17.1 Operation ............................................................................................................ 49
ineo 161
ineo 210
17.2 Paper Detection Mechanism............................................................................... 49
17.3 Manual Feed Take Up Control ............................................................................ 50
18. Fusing unit section ................................................................................................ 51
18.1 Construction (for ineo 161) ................................................................................. 51
18.2 Construction (for ineo 210) ................................................................................. 52
18.3 Operation ............................................................................................................ 53
18.4 Fusing Roller Pressure Mechanism.................................................................... 53
Outline
18.5 Fusing Temperature Control (for ineo 161) ......................................................... 54
18.6 Fusing Temperature Control (for ineo 210) ......................................................... 55
18.7 PPM Control (ineo 161 Only).............................................................................. 56
19. Paper exit (for ineo 161) ........................................................................................ 57
19.1 Construction ....................................................................................................... 57
19.2 Operation ............................................................................................................ 57
20. Paper exit (for ineo 210) ........................................................................................ 58
20.1 Construction ....................................................................................................... 58
20.2 Operation ............................................................................................................ 58
21. Image stabilization system .................................................................................... 59
22. Others ................................................................................................................... 60
22.1 Fan Control ......................................................................................................... 60
22.1.1 Power Supply Section Cooling Mechanism................................................. 60
22.1.2 Fusing Section Cooling Mechanism............................................................ 61
iii
ineo 161
ineo 210
Outline
iv
Theory of Operation Ver. 1.0 Apr. 2005 1. System configuration
Outline
1. System configuration
ineo 161
ineo 210
1.1 ineo 210
2
1 3
Outline
11
5
4
12 13 14
6
15 7
16 17
8
9
10
4034F1E501DA
[1] Automatic Document Feeder (DF-502) [10] Copy Table (DK-703)*3

[2] Duplexing Document Feeder (DF-605) [11] Key Counter Kit
[3] Original Cover Kit (OC-504)*1 [12] 32MB Memory (EM-101)
[4] Job Separator (JS-503) [13] 64MB Memory (EM-102)
[5] Duplex Unit (AD-504) [14] Printer Controller (IC-205)
[6] Multiple Bypass (MB-501) [15] Network Interface Card (NC-502)
[7] Paper Feed Unit (PF-502)*2 [16] Internet Fax & Network Scan Kit (SU-502)
[8] Copy Desk (DK-701)*3 [17] Fax Kit (FK-505)
[9] Copy Desk (DK-702)*3 [18] Shifting Unit (SF-501) (Illustration none)
*1: Standard for the Chinese market

*2: One drawer PF-502 is standard for the Chinese market.
*3: 3rd area only
1
1. System configuration Theory of Operation Ver. 1.0 Apr. 2005
1.2 ineo 161

ineo 161
ineo 210
1 2
3
Outline
10 11 12
4
13 5
14 15
6
7
8
4035T1E501DA
[1] Automatic Document Feeder (DF-502) [9] Key Counter Kit

[2] Original Cover Kit (OC-504)*1 [10] 32MB Memory (EM-101)
[3] Job Separator (JS-503) [11] 64MB Memory (EM-102)
[4] Multiple Bypass (MB-501) [12] Printer Controller (IC-205)
[5] Paper Feed Unit (PF-502)*2 [13] Network Interface Card (NC-502)
[6] Copy Desk (DK-701)*3 [14] Internet Fax & Network Scan Kit (SU-502)
[7] Copy Desk (DK-702)*4 [15] Fax Kit (FK-505)
[8] Copy Table (DK-703)*4 [16] Shifting Unit (SF-501) (Illustration none)
*1: Standard
*2: One drawer PF-502 is standard for the Chinese market.
*3: 3rd area only
*4: Optional by dealer
2
Theory of Operation Ver. 1.0 Apr. 2005 2. Product specification
2. Product specification
2.1 Copier
ineo 161
ineo 210
Type Console/Desktop Type
Platen Stationary
Original Scanning System CCD Line Sensor
Photoconductor Organic Photoconductor
Copying System Electrostatic Dry Powdered Image Transfer to Plain Paper with a Laser
Resolution 600 × 600 dpi
Outline
Paper Feeding System Max. Six-way System
Exposure System Mirror Scanning
Developing System HMT System
Charging System Comb Electrode (1) DC Negative Corona with Scorotron System
Image Transfer System Roller Image Transfer
Paper Separating System Paper Separator Fingers and Charge Neutralizing Plate
Fusing System Heat Roller
Paper Discharging System Charge Neutralizing Brush
Max. Original Size A3
Copy Medium
Paper Feed Tray/1 Manual Bypass

Plain Paper (60 to 90 g/m2) ❍ ❍
Transparencies ❍ ❍
Type Thick Paper (91 to 157 g/m2) ❍ ❍
Postcards, Labels, and Envelopes ❍ ❍
Recycled Paper (60 to 90 g/m2) ❍ ❍
Width 90 × 297 mm* 90 × 297 mm
Size
Length 140 × 432 mm* 140 × 432 mm
✽ If the width set 297 mm, the max. length is to 420 mm.
If the length set 432 mm, the max. width is to 279 mm.
Multiple Copies 1 to 99
Warm-up Time ineo 210: 15 sec. or less (23 °C, Rated Voltage)
ineo 161: 30 sec. or less (23 °C, Rated Voltage)
First Copy Time 7 sec. or less (A4/Letter, Paper Feed Tray/1, full size mode)
3
2. Product specification Theory of Operation Ver. 1.0 Apr. 2005
Continuous Copy Speed (copies/min)

Zoom ratio ×1.000, Paper Feed Tray/1
ineo 161
ineo 210
Speed
Size
ineo 210 ineo 161
A3 12 10
A4 R 16 13
A4 21 16
B4 13 11
B5 23 18
Outline
B5 R 18 15
Letter 20 16
Letter R 17 14
11 × 17 11 10
Legal 14 12
11 × 14 14 12
Zoom Ratios
Full Size ×1.00

×0.81
×0.70
Reduction
×0.50
Fixed ×0.25
×1.15
×1.41
Enlargement
×2.00
×4.00
Variable ×0.25 to ×4.00 (in ×0.01 increments)
Lens Through Lens

Exposure Lamp Rare Gas Fluorescent Lamp
Power/Current Consumption
1250 W (ineo 210: 200 V area)

Max. Current Consumption 1200 W (ineo 210: 120 V area)
(full system) 1050 W (ineo 161: 200 V area)
1000 W (ineo 161: 120 V area)
5.5 A (ineo 210: 200 V area)
Current Consumption 10 A (ineo 210: 120 V area)
(full system) 4.5 A (ineo 161: 200 V area)
8.5 A (ineo 161: 120 V area)
Power Requirements 110 V, 120 V, 127 V, 220 V to 240 V, 50/60 Hz
4
Theory of Operation Ver. 1.0 Apr. 2005 2. Product specification
Environmental Conditions
Temperature 10 to 30 °C with a fluctuation of 10 °C or less per hour
ineo 161
ineo 210
Humidity 15 to 85 % RH with a fluctuation of 20 % RH or less per hour
Ambient Illumination 3000 lux or less
Levelness 1° or less
Copier Dimensions Width = 599 mm, Depth = 620 mm, Height = 487 mm (Copier Only)
Copier Mass 38 kg
<GDI Printer Functions>
Outline
Printing Speed ineo 210: 21 printed pages/min (A4, 300 dpi)
12 printed pages/min (A4, 600 dpi)
ineo 161: 16 printed pages/min (A4, 300 dpi)
12 printed pages/min (A4, 600 dpi)
Memory Shared with the copier
Interface IEEE 1284 (parallel), USB Revision 1.1 (except for Windows 95 and
Windows NT)
Printer Language GDI
Font Windows
Complying OS Windows XP (SP1 or later), Windows 2000 (SP3 or later), Windows NT
Workstation Version 4.0 (SP6a or later), Windows ME, Windows 98
(SP1), Windows 98 SE, and Windows 95 OSR2.5
Web Browser Internet Explorer 4.0 or later
5
2. Product specification Theory of Operation Ver. 1.0 Apr. 2005
2.2 Fax Kit (FK-505): (Option)

General
ineo 161
ineo 210
Compatibility G3
Scanning Resolution
TX Mode Resolution CD direction (dpi) FD direction (dpi)

STD 204 98
Memory TX FINE 204 196
S_FINE 204 392
Outline
STD 204 98
Non memory TX FINE 204 196
S_FINE 408 392
Line PSTN/ PBX

Data Transmission Rate 33.6 kbps (V.34 JBIG)
Coding Method MH/ MR/ MMR/ JBIG
Document Size CCD Scanning
- A3/11 × 17 (297 mm)
Sheet Through Scanning
- STD/FINE: Max. 297 mm width × 1,000 mm
- Super Fine: Max. 297 mm width × 900 mm
Internet fax Enable when the optional Internet Fax & Network Scan Kit SU-502 and
Network Interface Card NC-502 are installed.
Dialing
One touch dial 27 keys

Speed dial 200 fax numbers
Group dial 27 groups (50 destination/group)
Program dial 4 keys (No. 24 ~ 27)
Other dialing On-hook dial, Automatic redial, Manual redial, Chain dial, Combination dial
Transmission
Transmission mode ADF TX, Memory TX, Batch TX, Broadcast TX, Manual TX, Polling TX,
Quick Memory TX, Book TX, Relay initiate TX, Timer TX, Relay Broadcast
Receiving
Receiving mode Mailbox RX, Manual RX, Memory RX, Substitute RX, Polling RX
RX resolution 204 dpi × 98 dpi, 204 dpi × 196 dpi, 204 dpi × 392 dpi
Max. recording paper size A3/ 11 × 17
6
Theory of Operation Ver. 1.0 Apr. 2005 3. Cross sectional view
3. Cross sectional view
ineo 161
ineo 210
1
Outline
3
12
4
11
5
10 6
4034G502BA
[1] Automatic Document Feeder DF-502 [7] Paper Feed Unit PF-502 (Option)
(Option)
[2] Scanner [8] Copy Table DK-703 (Option)
[3] Job Separator JS-503 (Option) [9] Paper Feed Tray/1
[4] Fusing Unit [10] PH Unit
[5] Image Transfer Section [11] Imaging Unit
[6] Multiple Bypass MB-501 (Option) [12] Exit Section
7
4. Paper path Theory of Operation Ver. 1.0 Apr. 2005
4. Paper path
ineo 161
ineo 210
Outline
4034G503BA
8
Theory of Operation Ver. 1.0 Apr. 2005 5. Copy process
5. Copy process
5.1 Copy Process Overview
ineo 161
ineo 210
Outline
4034M544CA
1. PC Drum
• Made up of an aluminum pipe coated with a photoconductive layer, on which an electro-
static latent image is formed.
2. Drum Charging
• A uniform negative DC charge is deposited across the entire surface of the PC Drum.
3. Photoelectric Conversion
• A CCD sensor is used to convert the image data represented by light reflected off the
original to a corresponding electric signal which, in turn, is output to the IR image pro-
cessing section.
4. IR Image Processing
• The analog electric signal is converted to an 8-bit digital image signal (A/D conversion)
which, in turn, goes through appropriate corrections before being output to the PH image
processing section.
5. PH Image Processing
• After going through corrections, the digital image signal is converted to a corresponding
electric signal (D/A conversion), with which the laser is turned ON or OFF as necessary.
6. Laser Exposure
• The laser beam strikes the surface of the PC Drum, forming an electrostatic latent image.
7. Developing
• Toner negatively charged in the Developer Mixing Chamber is attracted onto the electro-
static latent image changing it to a visible, developed image.
• A developing bias (Vb) is applied to the Developing Roller to prevent toner from being
attracted onto those areas of the PC Drum which correspond to the background areas of
the original.
8. Paper Take-up
• Paper is supplied from the paper feed tray.
9. Bypass Paper Take-up
• Paper is supplied by way of the Manual Bypass, one sheet at a time.
• The optional Multiple Bypass (MB-501), when mounted on the copier, permits continu-
ous paper supply.
9
5. Copy process Theory of Operation Ver. 1.0 Apr. 2005
10. Image Transfer

• A DC positive charge is applied to the Image Transfer Roller to transfer the visible image
on the surface of the PC Drum onto the paper.
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11. Paper Separation

• The PC Drum Paper Separator Fingers remove paper from the surface of the PC Drum.
• The Charge Neutralizing Plate neutralizes any charge left on the paper.
12. Cleaning
• Residual toner on the surface of the PC Drum is scraped off.
• The toner is then recycled back to the Developing Unit.
13. Main Erase
• The surface of the PC Drum is irradiated with light and any surface potential remaining
there after cleaning is neutralized.
Outline
14. Paper Transport

• The paper is transported to the Fusing Unit.
15. Fusing
• The developed image is permanently fused to the paper by the combination of heat and
pressure applied by the Fusing Roller.
16. Paper Exit
• The paper is fed out onto the Exit Tray.
• The optional Job Separator (JS-503), when mounted on the copier, allows a specific tray,
in which paper is fed, to be selected according to the operating mode.
10
5.2 Image Forming Process
ineo 161
ineo 210
Step Process Function
Step 1 Drum charging Forms a charge layer on the surface of the PC Drum.
Forms an electrostatic latent image on the surface of
Step 2 Exposure
the PC Drum.
Changes the electrostatic latent image to a visible,
Step 3 Developing
developed image.
Transfers the toner image on surface of the PC Drum to
Step 4 Image transfer
paper.
Outline
Separates the paper, onto which the toner image has
Step 5 Paper separating
been transferred, from the surface of the PC Drum.
Step 6 Fusing Fuses the toner on the paper permanently.
Step 7 PC Drum cleaning Removes toner left on the surface of the PC Drum.
Neutralizes any residual charge left on the surface of
Step 8 Charge neutralizing
the PC Drum after the PC Drum cleaning process.
Removes toner sticking to the surface of the Image
Step 9 Image Transfer Roller cleaning
Transfer Roller after image transfer.
Recovers toner removed during the PC Drum cleaning
Step 10 Toner recovery
process.
5.3 Drum Charging (Step 1)

• A compact comb electrode is used for drum charging to reduce the amount of ozone pro-
duced and save space. The Drum Charge Corona deposits a charge evenly across the
entire surface of the PC Drum.
• The Scorotron system is used and the grid mesh provided between the corona wire and
the PC Drum ensures that a uniform charge is deposited across the entire surface of the
PC Drum.
Grid Mesh
PC Drum
Corona Wire
4034G505AA
11
5.4 Exposure Process (Step 2)

• The surface of the PC Drum is irradiated with light reflected off the original, which forms
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an electrostatic latent image.
PH Unit
Outline
4034G506AA
Laser Beam
5.5 Developing Process (Step 3)

• Toner is attracted onto the electrostatic latent image produced through the exposure pro-
cess, thereby forming a visible, developed image.
Toner
Developing Roller
4034G504AA
12
5.6 Image Transfer Process (Step 4)

• The Image Transfer Roller applies charge from the backside of the paper, thereby trans-
ineo 161
ineo 210
ferring toner on the surface of the PC Drum to the paper.
Charge Neutralizing Plate
Outline
Image Transfer Roller
Paper
4034G507AA
5.7 Paper Separating Process (Step 5)

• Employed is the paper separating system using curvature separation and mechanical
separation by means of the Paper Separator Fingers.
Paper Separator Finger
PC Drum
4034G508AA
13
5.8 Fusing Process (Step 6)

• The Fusing Unit consists of the Fusing Roller and the Fusing Roller/rt.
ineo 161
ineo 210
• The Fusing Roller is provided with two Fusing Heater Lamps, thereby shortening the
time required for warming-up and saving energy.
• The main heater, or the Fusing Roller Heater Lamp, heats the center of the Fusing
Roller. The sub heater, or the Fusing Roller Sub Heater Lamp, on the other hand, heats
both end portions of the Fusing Roller. The Fusing Roller Thermistor located at the cen-
tral portion controls the Fusing Roller Heater Lamp. The Fusing Roller Sub Thermistor
located in the rear control the Fusing Roller Sub Heater Lamp.
Outline
Fusing Paper Separator

Finger
Fusing Heater Lamp
Fusing Roller Fusing Roller/rt
Toner 4034G509AA
5.9 PC Drum Cleaning Process (Step 7)

• The Cleaning Blade scrapes residual toner off the surface of the PC Drum.
Residual Toner
Cleaning Blade
PC Drum
4034G510AA
14
5.10 Charge Neutralizing Process (Step 8)

• Any potential remaining on the surface of the PC Drum is neutralized by the Erase Lamp.
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Residual Potential
Outline
Erase Lamp
PC Drum
4030G511AA
5.11 Image Transfer Roller Cleaning Process (Step 9)

• A charge of the same polarity as that of toner (negative) is applied to clean the surface of
the Image Transfer Roller.
Toner
Potential
4034G512AA
15
5.12 Toner Recovery Process (Step 10)

• Toner scraped off by the Cleaning Blade is transported back to the Developing Unit by
ineo 161
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the Toner Recycling Coil.
Recycled Toner Agitating Blade

Outline
Recycled Toner Conveying Screw
PC Drum
4021M039AA
Recycling Duct
Recycling Coil
Cleaning Blade
4021M038AB
16
Theory of Operation Ver. 1.0 Apr. 2005 6. Overall configuration
6. Overall configuration
ineo 161
ineo 210
6.1 Timing Chart at Power ON
4034M537CA
17
6. Overall configuration Theory of Operation Ver. 1.0 Apr. 2005
6.2 Control Block Diagram

ineo 161
ineo 210
4034M538CA
18
Theory of Operation Ver. 1.0 Apr. 2005 7. Scanner (IR)
7. Scanner (IR)
7.1 Construction
ineo 161
ineo 210
1
9
8 2
5
6
4035M528AC
No. Name Function/System

1 Scanner Motor (M5) Drives the Scanner Assy and the 2nd/3rd Mirrors Carriage.
Converts light reflected off the mirror to a corresponding
2 CCD Board (PWB-J)
electric signal.
Detects the size of the original, validates the original size
3 Size Reset Switch (S5) detection and resets the size of the original according to
combination with the Original Cover Sensor.
Driven by the Scanner Motor to let light from the Exposure
4 Scanner Assy
Lamp hit against the original.
5 Exposure Lamp Irradiates the original with light.
Lets the light reflected off the original travel to reach the
6 2nd/3rd Mirrors Carriage
CCD Board.
Scanner Home Position Sensor
7 Detects the Scanner Assy at its home position.
(PC10)
Detects the size of the original, validates the original size
8 Original Cover Sensor (PC100) detection and resets the size of the original according to
combination with the Size Reset Switch.
9 Original Size Sensor 1 (UN2) Detects the size of the original.
19
7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2005
7.2 Mechanism and Control for Moving the Scanner and Mirrors
Carriage
ineo 161
ineo 210
7.2.1 Scanner Moving Mechanism/Control

• The Scanner is moved by the Scanner Motor at a given speed.
• The Scanner Home Position Sensor detects the Scanner at its home position.
• The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner. It thereby keeps
constant the optical path length between the original and the PC Drum.
7.2.2 Operation
<Marking copies through the Original Glass>
4034M547CA
1. The Scanner generally stands by at the shading position.

When the Original Cover or ADF is raised to an angle of 15° or more, the Scanner
moves to the original size detection position.
2. When the Original Cover or ADF is raised to an angle of less than 15° with an orig-
inal placed on the Original Glass (when the Original Cover Sensor is activated), the
lamp turns ON and the original size is detected.
3. When the Size Reset Switch is turned ON with the Original Cover or ADF fully low-
ered, the Scanner moves to the shading position to carry out shading.
4. If the Start key is not immediately pressed, the lamp goes out after the lapse of 11
sec. after it has turned ON.
5. If the Start key is pressed immediately and the lamp remains ON, the Scanner
starts a scan motion immediately.
6. After the original has been scanned, the Scanner makes a return motion and its
home position is detected. Then, the Scanner moves to, and stops at, the home
position.
20
<Making copiers using DF-502>
ineo 161
ineo 210
4034T2E501DA
1. When the original is loaded and the Start key pressed, the Scanner performs shad-
ing.
2. The Scanner then moves to the scanning position under the ADF glass.
The original is scanned as it is moved.
3. After the original has been scanned, the home position of the Scanner is detected.
Then, the Scanner moves to, and stops at, the home position.
21
7.3 Original Size Detection

• Original Size Sensor 1 and the CCD mounted in the optical section are used to detect
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the size of the original.
UN3 (Option)
UN2
4035M528AA
22
7.4 Determination of Original Size

• The Original Size Sensor is used to determine the size of the original.
ineo 161
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• Two size conversion patterns are available depending on the applicable marketing area.
Refer to the Field Service (CCD APS SIZE) for setting.
☞ 89
7.4.1 For Inch area

Pattern 1
Original Size
~144.7 ~220.9 ~221.0
Sensor mm mm mm
UN2 *UN3
Invoice
OFF – Letter R Letter
R
ON – Legal Legal 11×17
Pattern 2
Original Size
~143.9 ~153.0 ~187.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm~
UN2 *UN3
Invoice
OFF OFF A5 R B5 R A4 R Letter R B5 B5 Letter A4
R
ON OFF FLS FLS FLS FLS FLS FLS B4 11×17 A3
OFF ON Legal Legal Legal Legal Legal B4 B4 11×17 A3
ON ON Legal Legal Legal Legal Legal B4 B4 11×17 A3
✽ UN3 is an option.
7.4.2 For Metric and China area

Pattern 1
Original Size
~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~262.0 ~275.0 275.1
Sensor mm mm mm mm mm mm mm mm~
UN2 *UN3
OFF – A5 R B5 R 16K R A4 R B5 B5 16K A4
ON – FLS FLS FLS FLS FLS B4 8K A3
23
Pattern 2
Original
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Size
~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm mm mm~
UN2 *UN3
Invoice Letter
OFF OFF A5 R B5 R 16K R A4 R B5 B5 16K Letter A4
R R
ON OFF FLS FLS FLS FLS FLS FLS FLS B4 8K 11×17 A3
OFF ON Legal Legal Legal Legal Legal Legal B4 B4 8K 11×17 A3
ON ON Legal Legal Legal Legal Legal Legal B4 B4 8K 11×17 A3
✽ UN3 is an option.
7.4.3 For Latin America area (Inch)

Pattern 1
Original Size
~144.7 ~220.9 ~221.0
Sensor mm mm mm
UN2 *UN3
Invoice
OFF – Letter R Letter
R
ON – Legal Legal 11×17
Pattern 2
Original Size
~143.9 ~153.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
UN2 *UN3
Invoice
OFF OFF A5 R A4 R Letter R B5 B5 Letter A4
R
ON OFF FLS FLS FLS FLS FLS 11×17 11×17 A3
OFF ON Legal Legal Legal Legal 11×17 11×17 11×17 A3
ON ON Legal Legal Legal Legal 11×17 11×17 11×17 A3
24
7.4.4 For Latin America area (Metric)

Pattern 1
ineo 161
ineo 210
Original Size
~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~262.0 ~275.0 275.1
UN2 *UN3
OFF – A5 R B5 R 16K R A4 R B5 B5 16K A4
ON – FLS FLS FLS FLS FLS B4 8K A3
Pattern 2
Original Size
~143.9 ~153.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
UN2 *UN3
Invoice
OFF OFF A5 R A4 R Letter R B5 B5 Letter A4
R
ON OFF FLS FLS FLS FLS FLS 11×17 11×17 A3
OFF ON Legal Legal Legal Legal 11×17 11×17 11×17 A3
ON ON Legal Legal Legal Legal 11×17 11×17 11×17 A3
25
8. PH (Writing section) Theory of Operation Ver. 1.0 Apr. 2005
8. PH (Writing section)
8.1 Construction
ineo 161
ineo 210
4
4035M003AB
3

Allows the surface of the PC Drum to be irradiated with a laser
1 Polygon Motor (M1)
beam so that an image is formed.
Keeps constant the polarization angular velocity of the laser
2 fθ Lens
beam.
3 SOS Sensor Detects the timing at which the laser beam is emitted.
4 LD Board (PWB-B) -
26
Theory of Operation Ver. 1.0 Apr. 2005 8. PH (Writing section)
8.2 Operation
• When a laser beam strikes the Polygon Mirror, light reflected off the Polygon Mirror is
ineo 161
ineo 210
directed at the PC Drum by way of the lens and return mirror.
• The Polygon Mirror has seven faces, being turned at high speeds by the Polygon Motor.
• The SOS Mirror and SOS Sensor keep constant the timing, at which emission of a laser
beam is started for each main scanning line.
1
2
6
4035M004AD
5
[1] Polygon Motor (M2) [4] PC Drum

[2] fθ Lens [5] SOS Sensor
[3] SOS Mirror [6] LD Board (PWB-B)
27
9. Imaging unit Theory of Operation Ver. 1.0 Apr. 2005
9. Imaging unit
9.1 Construction
ineo 161
ineo 210
2
7
4034M539AA
6 5 4

PC Drum Paper Separator Fin- Mechanically separate the paper from the surface of the PC
1
gers Drum.
Forms an electrostatic latent image on the surface of the PC
2 PC Drum
Drum.
Toner is attracted onto the electrostatic latent image produced
3 Developing Roller through the exposure process, thereby forming a visible,
developed image.
4 1st Toner Conveying Roller
Convey toner in the Developer Mixing Chamber to the devel-
5 2nd Toner Conveying Roller
oping section.
6 3rd Toner Conveying Roller
The surface of the PC Drum is deposited with charge through
7 PC Drum Charge Corona
corona discharge from the PC Drum Charge Corona.
The Cleaning Blade scrapes residual toner off the surface of
8 Cleaning Blade
the PC Drum.
28
Theory of Operation Ver. 1.0 Apr. 2005 9. Imaging unit
9.2 Operation
• The Main Motor provides drive for the PC Drum, Developing Roller, and other mechani-
ineo 161
ineo 210
cal components.
3
4035M006AA
[1] Recycled Toner Conveying Screw [4] Developing Roller

[2] Recycled Toner Recycling Coil [5] Main Motor (M1)
[3] 2nd Toner Conveying Roller
29
9. Imaging unit Theory of Operation Ver. 1.0 Apr. 2005
9.3 PC Drum
• The PC Drum used in this copier is the organic photoconductor (OPC).
ineo 161
ineo 210
✽ The drum is a lamination of the Charge Transport Layer and Charge Generating Layer
coating an aluminum alloy base.
Handling Precaution
• The PC Drum of this type exhibits light fatigue after being exposed to light for a
long time, which results in its sensitivity being changed. Always, therefore, wrap
the drum in the PC Drum Cloth or a soft cloth immediately after it has been
removed from the copier. Utmost care should also be used when handling the PC
Drum to ensure that its surface is not contaminated.
(PC Drum Cross-Section)
Charge Generation Layer

PC Drum Charge Transport Layer
Aluminum Base
1167M007AA
1139M007AA
9.4 Grounding of the PC Drum

• The ground contact (Ground Plate) of the PC Drum is located on the inside on its left-
hand side. It remains in contact with the drum shaft at all times. When the Imaging Unit is
loaded in the copier, the drum shaft comes into contact with the Ground Plate of the PC
Drum. The potential on the surface of the PC Drum exposed to the laser beam is then
grounded through the Ground Plate to the frame of the copier.
PC Drum
Frame
4021M010AA
Ground Plate
30
Theory of Operation Ver. 1.0 Apr. 2005 10. PC Drum charging
10. PC Drum charging

• The surface of the PC Drum is deposited with charge through corona discharge from the
ineo 161
ineo 210
PC Drum Charge Corona.
• The grid mesh interposed between the corona wire and the PC Drum ensures that a uni-
form charge is deposited across the entire surface of the PC Drum.
• The corona unit has a comb electrode that discharges only toward the grid mesh. This
results in the amount of ozone produced being smaller than with the wire electrode.
Comb Electrode
4021M011AA
Grid Mesh
31
11. Developing Theory of Operation Ver. 1.0 Apr. 2005
11. Developing
11.1 Developing Roller
ineo 161
ineo 210
• The Developing Roller consists of an outer sleeve roller and an inner magnet roller.
• The roller conveys developer to the point of development.
• The developer (carrier and toner) in the Developer Mixing Chamber is conveyed onto the
point of development by the Toner Conveying Rollers and the Developing Roller.
Toner/Carrier PC Drum
1st Toner Conveying Roller Point of Development
Toner
2nd Toner Conveying Roller
Carrier
Developing Roller
4021M062AA
11.2 Developing Bias

• Vb (-DC, AC) is applied to the Developing Roller.
• Vb (-DC) is applied to prevent toner from sticking to the background of the image.
• Vb (AC) is applied to enhance good separation of toner from carrier.
• The amount of toner sticking to the surface of the PC Drum is varied according to the dif-
ference in potential between the voltage (Vi) on the surface of the PC Drum and
Vb (-DC).
✽ Large difference = A greater amount of toner sticks.
✽ Small difference = A smaller amount of toner sticks.
PC Drum
Developing Roller
Developing Bias
Terminal
4021M018AB
32
Theory of Operation Ver. 1.0 Apr. 2005 11. Developing
11.3 ATDC Sensor

• The ATDC Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Devel-
ineo 161
ineo 210
oper Mixing Chamber.
3rd Toner Conveying Roller Developing Roller

2nd Toner Conveying Roller
ATDC Sensor 1st Toner Conveying Roller
4021M019AA
11.4 ATDC Sensor Automatic Adjustment

• The reference value for the ATDC Sensor is automatically adjusted as detailed below
using the ATDC Sensor Automatic Adjustment mode.
With the copier set in the ATDC Sensor Automatic Adjustment mode, press the Start key.
The developer is mixed.
The ATDC Sensor converts the reference T/C (14 %) to a corresponding voltage
value and outputs it.
Does the output voltage fall within the range from 2.28 to 2.36 V?
YES NO
The voltage input to the ATDC Sensor The voltage input to the ATDC Sensor from
from the Master Board at this time is fixed the Master Board is varied.
as the reference voltage. 2.37 V or more: Decrease the voltage.
2.29 V or less: Increase the voltage.
33
12. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2005
12. Toner replenishing

12.1 Toner Replenishing Mechanism
ineo 161
ineo 210
• Toner is supplied from the Toner Bottle to the Developer Mixing Chamber.
1. The Toner Replenishing Motor (M6) turns the coupling, which turns the Toner Bot-
tle.
2. To regulate the amount of toner supplied from the Toner Bottle, there is a Metering
Chamber provided in the outer race of the coupling.
3. When the Toner Bottle turns, toner in the Metering Chamber drops.
4. Toner from the metering chamber is conveyed by the Toner Conveying Screw into
the Developer Mixing Chamber.
5. The Toner Conveying Screw is turned by the Toner Replenishing Motor (M6).
Coupling Toner Bottle

Metering
Chamber
4021M020AB 4034M527AA
Toner Replenishing
Motor (M6)
Toner Conveying Screw
4021M022AA
Developer Mixing Chamber
4021M023AA
34
Theory of Operation Ver. 1.0 Apr. 2005 12. Toner replenishing
12.2 Toner Replenishing Control

• Replenishing of the supply of toner is determined based on the T/C ratio and B/W ratio.
ineo 161
ineo 210
• If T/C is 14 % or more, toner replenishing is not carried out regardless of the B/W value.
• If T/C is less than 14 %, toner replenishing is determined according to the B/W value.
• Toner is replenished until T/C becomes 14 %.
T/C ratio (%) B/W ratio toner replenishing

More than 14 — not supplied
13.5 to 14 More than 2000 supplied
13 to 13.5 More than 1000 supplied
12.5 to 13 More than 500 supplied
12 to 12.5 More than 500 supplied
10 to 12 More than 0 supplied
Less than 7 Proceeds to the T/C recovery mode
✽ The greater the value of B/W in the table, the higher the B/W ratio (high image density
original).
35
12. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2005
12.3 T/C Recovery Mode

ineo 161
ineo 210
The machine enters the T/C recover mode when a T/C of 10 % or less is detected.
Toner is replenished for 90 sec.
T/C is recovered by 1 % or more. T/C is not recovered by 1 % or more,

or T/C is less than 12 %.
Toner is replenished for 60 sec.

T/C is recovered by 2 % or more, T/C is not recovered by 2 % or more,

or is 12 % or more. or T/C is less than 12 %.
Toner is replenished for 30 sec. to A toner-empty condition is detected.

complete the T/C recovery mode.
T/C is less than 8 %.
A toner-empty-stop condition results and

the initiation of any new copy cycle is pro-
hibited.
• A toner-empty condition is reset when the Front Cover is opened and closed after a T/C
of 10 % or more is detected with the supply of toner replenished.
• A toner-empty-stop condition is reset when the Front Cover is opened and closed after a
T/C of 8 % or more is detected with the supply of toner replenished. A toner-empty con-
dition results, however, if T/C falls within the range between 8 % and 10 % when the
Front Cover is opened and closed.
36
Theory of Operation Ver. 1.0 Apr. 2005 12. Toner replenishing
12.4 Toner Bottle Home Position Detection

• The Toner Supply Port is on the upper side whenever the Toner Bottle is at its home posi-
ineo 161
ineo 210
tion. The Toner Bottle Home Position Sensor (PC7) detects the Toner Bottle at its home
position.
Toner Supply Port
Toner Bottle Home Position
Sensor (PC7)
4021M024AA
37
13. Toner recovery Theory of Operation Ver. 1.0 Apr. 2005
13. Toner recovery

• The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum.
ineo 161
ineo 210
• The spent toner is conveyed through the Recycling Duct and eventually back to the
Developer Mixing Chamber.
• The following control is provided to prevent paper dust from being wedged between the
Cleaning Blade and the PC Drum. When the cumulative period of time through which the
PC Drum has been driven reaches a predetermined value, the PC Drum is turned back-
ward (by turning the Main Motor backward). Shoulder gears comprising two different
parts are provided on the copier. This ensures that the drive is transmitted only to the
Imaging Unit, but not any other parts, during backward rotation.
Cumulative Time Through Which PC Drum Has Been Driven PC Drum Backward Rotation Time
Approx. 330 sec. 50 ms
Spent Toner Conveying Screw 1
Spent Toner Conveying Screw 2
PC Drum
4021M039AA
Spent Toner Recycling Coil
Spent Toner Recycling Duct
Cleaning Blade
4021M038AB
Developer Mixing Chamber
38
Theory of Operation Ver. 1.0 Apr. 2005 14. Synchronizing roller section
14. Synchronizing roller section

14.1 Construction
ineo 161
ineo 210
• The Synchronizing Roller ensures that the paper is fed off from the transport section in
time with the exposure timing of the exposure section (PH).
1
5
3 4035M011AA

1 Synchronizing Roller
Transports the paper onto the developing section.
2 Transport Roller
Prevents paper dust from sticking to the surface of the
3 Paper Dust Remover
PC Drum.
Determines the condition of the paper being trans-
4 Synchronizing Roller Sensor (PC1) ported, thereby detecting a paper misfeed and paper
transport timing.
5 Synchronizing Roller Clutch (CL1) Controls drive of the Synchronizing Roller.
39
14. Synchronizing roller section Theory of Operation Ver. 1.0 Apr. 2005
14.2 Operation
• Drive from the Main Motor (M1) is transmitted through a gear train to the Synchronizing
ineo 161
ineo 210
Roller Clutch (CL1).
2
4035M012AA
[1] Main Motor (M1) [2] Synchronizing Roller Clutch (CL1)
14.3 Paper Dust Remover

• The Paper Dust Remover collects paper dust on the paper.
Paper Dust Remover
4035M012AA
40
Theory of Operation Ver. 1.0 Apr. 2005 15. Image transfer and paper separation section
15. Image transfer and paper separation section

15.1 Image Transfer Section
ineo 161
ineo 210
• A positive charge is applied to the Image Transfer Roller to transfer the toner image
formed on the surface of the PC Drum onto the paper.
• The charge applied to the Image Transfer Roller is varied according to the following con-
ditions to ensure that image transfer efficiency is stabilized.
• Paper Type: The amount of charge is made less for OHP film.
• Paper width: The smaller the paper width, the greater the amount of charge.
• B/W ratio of image: The lower the B/W ratio, the greater the amount of charge.
• A negative charge is applied to the Image Transfer Roller to return toner sticking to the
Image Transfer Roller to the PC Drum. It is performed in the following timings:
(At the start and end of a copy cycle; when the Power Switch is turned ON; when a mis-
feed or malfunction is reset)
15.2 Paper Separation Section

• Paper separation is accomplished through the curvature separation system that works
on the diameters of the PC Drum and the Image Transfer Roller.
Since the PC Drum has a small diameter, there is no likelihood that the paper will be
wound around the PC Drum. The paper is separated by its own weight.
• The Charge Neutralizing Plate neutralizes any charge left on the paper after image trans-
fer, thereby preventing discharge noise that could otherwise occur when the paper is
separated.
• The PC Drum Paper Separator Fingers properly separate from the surface of the PC
Drum thin paper or other type of paper that is hard to separate.
PC Drum Paper Separator Fingers
PC Drum
Charge Neutralizing Plate
4021M037AA
41
16. Paper take-up Theory of Operation Ver. 1.0 Apr. 2005
16. Paper take-up

16.1 Construction
ineo 161
ineo 210
3
2
1 4
6
4021M025AA
[1] Paper Size Detecting Board (PWB-I) [4] Feed Roller/1

[2] Paper Size Detecting Sensor (S11) [5] Separation Roller/1
[3] Paper Empty Sensor/1 (PC4) [6] Paper Lifting Plate
42
Theory of Operation Ver. 1.0 Apr. 2005 16. Paper take-up
16.2 Operation
• The Main Motor (M1) provides the drive for paper take-up operations.
ineo 161
ineo 210
• The drive is transmitted through the Paper Take-up Solenoid/1.
Main Motor (M1)
Paper Take-up Solenoid/1 (SL1)
Feed Roller
4021M027AA
43
16.2.1 Paper Separating Mechanism

• The coefficient of friction between the Feed Roller and Separation Roller is effectively
ineo 161
ineo 210
used to prevent double feed of paper.

When one sheet of paper is taken up:
The coefficient of friction on the front side of the sheet of paper taken up and fed through
the space between the Feed Roller and Separation Roller is the same as that on the back-
side of the sheet of paper, allowing the paper to be properly fed into the machine.
When two or more sheets of paper are taken up:

The coefficient of friction between the paper and the Separation Roller is greater than that
between the sheets of paper, which allows only the top sheet of paper to be fed into the
machine.
Feed Roller
Paper
Separation Roller
4021M060AB
44
16.3 Drawer in Position Detection

• When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor.
ineo 161
ineo 210
The copier then knows that the drawer has been slid in position.
Drawer Set Sensor (PC5)
4021M026AA
16.4 Paper Empty Detection Mechanism

• The Paper Empty Sensor detects a paper-empty condition in the drawer.
Paper Empty Sensor/1 (PC4)
1167M073AD
45
16.5 Paper Lifting Plate

• The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked
ineo 161
ineo 210
when the tray is slid into the unit.

• The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times.
Spring
Paper Lifting Plate

4021M063AA
16.6 Universal Tray Paper Size Detection Mechanism

• Both the width (in the crosswise direction) and length (in the feeding direction) of the
paper are detected and the copier CPU determines the paper size based on the combi-
nation of the two readings.
• The width (CD) of the paper is detected when the lever that is operatively connected to
the Edge Guide activates or deactivates the Paper Size (CD) Detection Sensor.
• The length (FD) of the paper is detected when the lever that is operatively connected to
the Trailing Edge Stop actuates or deactuates the switches on the Paper Size (FD)
Detection Board.
Paper Size Detecting Sensor (S11)

Paper Size Detecting Board (PWB-I)
1 2 3 4
4011M009AA
46
16.6.1 ON/OFF Positions of Paper Size Detecting Switches and Corresponding

Paper Size Detected
ineo 161
ineo 210
<For Metric>
Paper Size Detecting Board

PWB-I Paper Size Detecting
Paper Size
Sensor S11
SW1 SW2 SW3 SW4
– – – – – B4
– – – ON Activated A3
– – ON ON – A5 R
– – ON ON Activated A4
– ON – – – A5, postcards
– ON ON ON – A5 R
– ON ON ON Activated A4
ON – – ON – B5
ON ON ON – – A4 R
ON ON ON ON – B5 R
<For Inch>
Paper Size Detecting Board

PWB-I Paper Size Detecting
Paper Size
Sensor S11
SW1 SW2 SW3 SW4
– B4, Legal
– – – –
Activated B4, 11×14
– B5 R, Invoice R
– – – ON
Activated A3, 11×17
– – ON ON – A5 R, Invoice R
– – ON ON Activated A4, Letter
– ON – – – A5, Invoice
– ON ON ON – A5 R, Invoice R
– ON ON ON Activated A4, Letter
ON – – ON – B5, Invoice
ON ON ON – – A4 R, Letter R
ON ON ON ON – B5 R, Letter R
47
16.7 Paper Take Up Control

ineo 161
ineo 210
Start Key ON
Main Motor M1 ON
OFF
Paper Take-Up ON
Solenoid SL1 OFF
Synchronizing Roller H
Sensor PC1 L
4021M515CA
16.7.1 Paper Take Up Retry Control

• To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo-
rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given
period of time after the sequence has been started. The paper take-up sequence is then
performed again. These paper take-up sequences are repeated a given number of times.
No. of Paper Take-Up Retry Sequences

Paper Take-Up Retry 2
1st Paper Take-Up

Retry Sequence
Paper Take-Up ON
Solenoid SL1 OFF
Synchronizing Roller H
Sensor PC1 L
Successful paper take-up

4021M514CA
48
Theory of Operation Ver. 1.0 Apr. 2005 17. Manual bypass section
17. Manual bypass section

17.1 Operation
ineo 161
ineo 210
• Drive for bypass paper take-up is provided by the Main Motor (M1).
• The drive is transmitted through the Paper Take-up Solenoid/Bypass.
Main Motor (M1)
Paper Set Sensor/Bypass (PC2)
Paper Take-up Solenoid/Bypass (SL2)
4021M028AA
17.2 Paper Detection Mechanism

• The Sensor detects a sheet of paper on the Manual Bypass.
<When Paper is Present> <When Paper is not Present>
Paper Set Sensor/Bypass (PC2)
Paper
4021M061AA 4021M029AA
49
17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2005
17.3 Manual Feed Take Up Control

ineo 161
ineo 210
4034M539CA
50
Theory of Operation Ver. 1.0 Apr. 2005 18. Fusing unit section
18. Fusing unit section

18.1 Construction (for ineo 161)
ineo 161
ineo 210
• Heat and pressure from the Fusing Roller permanently fuse toner onto the paper.
5
3
4034M523BA
4
[1] Fusing Roller Heater Lamp (H1) [4] Fusing Roller Thermostat (TS1)
[2] Fusing Roller/rt [5] Fusing Roller Thermistor (TH1)
[3] Pressure Lever [6] Fusing Roller
51
18. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2005
18.2 Construction (for ineo 210)

• Heat and pressure from the Fusing Roller permanently fuse toner onto the paper.
ineo 161
ineo 210
1
2
8
4
4034M523CA
5, 6
[1] Fusing Roller Sub Heater Lamp (H2) [5] Fusing Roller Thermistor (TH1)
[2] Fusing Roller Heater Lamp (H1) [6] Fusing Roller Sub Thermistor (TH2)
[3] Fusing Roller/rt [7] Fusing Roller Thermostat
[4] Pressure Lever [8] Fusing Roller
52
18.3 Operation
• The Main Motor (M1) provides the drive for the Fusing Unit.
ineo 161
ineo 210
Main Motor (M1)
Fusing Roller/rt
Fusing Roller
4035M007AA
18.4 Fusing Roller Pressure Mechanism

• To provide a nip width between the rollers, a Pressure Spring is used functioning to press
the Fusing Roller/rt up against the Fusing Roller.
Fusing Roller/rt
Pressure Lever
Fusing Roller
4034M508BA
Pressure Spring
53
18.5 Fusing Temperature Control (for ineo 161)

• The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the
ineo 161
ineo 210
surface of the Fusing Roller.

• The Fusing Roller surface temperature is detected by using a thermistor that translates
the temperature to a corresponding electrical signal.
• If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater
Lamp is shut down.
<Temperature Control in Standby State>
Warm-up completed
4034M541CA
Machine Condition or Paper Type Mode 1 Mode 2 Mode 3

Standby 180 °C 180 °C → 170 °C 170 °C
Plain paper (width: 250 mm or more;
190 °C 190 °C → 170 °C 170 °C
length: less than 360 mm)
Plain paper (width: less than 250 mm) 180°C 180 °C → 165 °C 165 °C
Thick paper (width: 250 mm or more) 210 °C 210 °C → 190 °C 190 °C
Thick paper (width: less than 250 mm) 200 °C 200 °C → 190 °C 190 °C
OHP film (width: 250 mm or more) 180 °C 180 °C → 165 °C 165 °C
OHP film (width: less than 250 mm) 155 °C 155 °C 155 °C
54
18.6 Fusing Temperature Control (for ineo 210)

• The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the
ineo 161
ineo 210
surface of the Fusing Roller.
• The Fusing Roller surface temperature is detected by using a thermistor that translates
the temperature to a corresponding electrical signal.
• If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater
Lamp is shut down.
<Temperature Control in Standby State>
Warm-up completed
4034M507CA
Machine Condition or Paper Type Mode 1 Mode 2 Mode 3

Standby 180 °C 180 °C → 165 °C 165 °C
Plain paper (width: 221 mm or more) 180 °C 180 °C 180 °C
Plain paper (width: 220 mm or less) 180 °C 180 °C 180 °C
Thick paper (width: 201 mm or more) 200 °C 200 °C 200 °C
Thick paper (width: 200 mm or less) 200 °C 200 °C 200 °C
OHP film (width: 201 mm or more) 165 °C 165 °C 165 °C
OHP film (width: 200 mm or less) 165 °C 165 °C 165 °C
55
18.7 PPM Control (ineo 161 Only)

• If paper of a small size (width of 250 mm or less) or thick paper is used to run a multi-
ineo 161
ineo 210
copy cycle, the temperature on the edges of the Fusing Rollers tends to run high, mean-
ing that the temperature of the Fusing Rollers varies among different spots of the rollers.
• When the cumulative number of copies made through continuous copy cycles* exceeds
30, the paper take-up interval is made longer, thereby allowing the temperatures of the
Fusing Rollers at different spots to be uniform.
✽ Continuous copy cycle: Continuous copy cycles run with an interval of 2 min. or less
between cycles.
56
Theory of Operation Ver. 1.0 Apr. 2005 19. Paper exit (for ineo 161)
19. Paper exit (for ineo 161)

19.1 Construction
ineo 161
ineo 210
2
4035M008AB
[1] Main Motor (M1) [2] Exit Roller
19.2 Operation
• The Main Motor (M1) provides the drive for the exit section.
4035M009AC
57
20. Paper exit (for ineo 210) Theory of Operation Ver. 1.0 Apr. 2005
20. Paper exit (for ineo 210)

20.1 Construction
ineo 161
ineo 210
2
4034M545CA
[1] Duplex Unit Switchback Motor (M31) [2] Exit Roller
20.2 Operation
• The exit rollers are driven by the Duplex Unit Switchback Motor (M31).
4034M546CA
58
Theory of Operation Ver. 1.0 Apr. 2005 21. Image stabilization system
21. Image stabilization system

• The following image stabilization controls are provided to ensure stabilized copy image.
ineo 161
ineo 210
Purpose Means Control
The Vg/Vb control voltage is varied to bring Vg/Vb
to an appropriate level according to the following
settings.
To stabilize image Grid voltage (Vg) and devel- • Tech. Rep. Choice: ID Adjustment
density. oping bias (Vb) control • Tech. Rep. Choice: VG Adjustment
• User's Choice: Print Density
• SUPPLIES LIFE COUNT.
• Paper type
The image transfer output is varied to bring the
image transfer current to an appropriate level
To stabilize image Image transfer output con- according to the following conditions.
transfer. trol • Paper type
• Paper width
• B/W ratio of image
4034M540CA
59
22. Others Theory of Operation Ver. 1.0 Apr. 2005
22. Others
22.1 Fan Control
ineo 161
ineo 210
22.1.1 Power Supply Section Cooling Mechanism

• A cooling fan motor draws air from the area around the Power Supply Unit to the outside
to prevent the Power Supply Unit temperature from running high.
• The cooling fan motor is turned at full speed when the Main Motor turns and at a speed
reduction during other timings, thereby making the machine quieter without sacrificing
cooling performance.
Power Unit Cooling Fan

Motor (M4)
4034M535AA
60
Theory of Operation Ver. 1.0 Apr. 2005 22. Others
22.1.2 Fusing Section Cooling Mechanism

• A fan motor draws air from the area around the Fusing Unit to the outside to prevent the
ineo 161
ineo 210
machine interior temperature from running high. In addition, the fan motor pulls paper
being transported up through suction force to help stabilize paper transport.
• Ozone produced from the PC Drum Charge Corona is absorbed by the Ozone Filter from
the air drawn by a fan motor to the outside.
• The fan motor is turned at full speed during a print cycle and at a speed reduction during
other timings, thereby making the machine quieter without sacrificing cooling perfor-
mance.
Fusing Cooling Fan Motor (M3)
Ozone Filter
4034M521AA
61
22. Others Theory of Operation Ver. 1.0 Apr. 2005
ineo 161
ineo 210
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62

Ineo 161 Ineo 210: Service Manual Theory of Operation

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Ineo 161 Ineo 210: Service Manual Theory of Operation

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Dynamic balance

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2005/04 1.0 — Issue of the first edition

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7.4.4 For Latin America area (Metric) .................................................................. 25

8.1 Construction ....................................................................................................... 26

10. PC Drum charging ................................................................................................ 31

11.4 ATDC Sensor Automatic Adjustment.................................................................. 33

17. Manual bypass section.......................................................................................... 49

[1] Automatic Document Feeder (DF-502) [10] Copy Table (DK-703)*3

*1: Standard for the Chinese market

1.2 ineo 161

[1] Automatic Document Feeder (DF-502) [9] Key Counter Kit

Paper Feed Tray/1 Manual Bypass

Continuous Copy Speed (copies/min)

Full Size ×1.00

Lens Through Lens

1250 W (ineo 210: 200 V area)

Power Requirements 110 V, 120 V, 127 V, 220 V to 240 V, 50/60 Hz

Temperature 10 to 30 °C with a fluctuation of 10 °C or less per hour

<GDI Printer Functions>

2.2 Fax Kit (FK-505): (Option)

TX Mode Resolution CD direction (dpi) FD direction (dpi)

Line PSTN/ PBX

One touch dial 27 keys

3. Cross sectional view

10. Image Transfer

11. Paper Separation

14. Paper Transport

5.2 Image Forming Process

5.3 Drum Charging (Step 1)

5.4 Exposure Process (Step 2)

an electrostatic latent image.

5.5 Developing Process (Step 3)

5.6 Image Transfer Process (Step 4)

Charge Neutralizing Plate

5.7 Paper Separating Process (Step 5)

Paper Separator Finger

Image Transfer Roller

5.8 Fusing Process (Step 6)

Fusing Paper Separator

Fusing Heater Lamp

Fusing Roller Fusing Roller/rt

5.9 PC Drum Cleaning Process (Step 7)

5.10 Charge Neutralizing Process (Step 8)

5.11 Image Transfer Roller Cleaning Process (Step 9)

Image Transfer Roller

5.12 Toner Recovery Process (Step 10)

the Toner Recycling Coil.

Recycled Toner Agitating Blade

Recycled Toner Conveying Screw

6.2 Control Block Diagram

No. Name Function/System

7.2.1 Scanner Moving Mechanism/Control

1. The Scanner generally stands by at the shading position.

<Making copiers using DF-502>

7.3 Original Size Detection

the size of the original.

7.4 Determination of Original Size

7.4.1 For Inch area

7.4.2 For Metric and China area

7.4.3 For Latin America area (Inch)

7.4.4 For Latin America area (Metric)