Basic Copier PDF

Basic copier for Service Master

Last Modified: 10/07/2001
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Technical Tr aining Centr e www.get-u-wice.co m
Ricoh Europe B.V.

Technical Training Centre 1 www.get-u-wice.com

Short Description
This basic copier module is the starting point for
a new employee, to start his career as a service
technician. The module contains the basic
technologies that used in the copy process for
analog and digital copiers.
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Objectives
After com pletion of this training a serv ice technician:
Is familiar with the user feature s of a copier
Understand the copiers jargon/terminology
Ha s a good understanding about the basic technologies of
a copier
Can do installation, including options
can print a SMC sheet
can determine the firmware version
can do a firmware upgrade
Can do maintenance
Can do troubleshooting
Can do adjustments
Can report to the product specialist
Knows how to u se a Service Manual
Can follow product training for engines
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Course Overview
1. Copy paper
2. Copier
3. User Training
4. Options / Installation
5. Advanced copier technology
6. Service
7. Information Flow
8. Specifications
This training module tells about the copy process. First, it is important to know what a
user can do with a copier. After this, the module gives an answer on what happens
inside that copy machine. From scanning the original, it says how the toner particles
come onto the right location on the copy and why the toner sticks to the paper. What is
the difference between an analog and a digital copier? It also describes the paper path
trough the machine.
Besides knowing how the copier works, the engineer must know what to do at the
customers. With help of some tools and manuals, he must be able to keep the copier
running, with good copy quality. Copiers need maintenance after a periodic number of
copies, just like cars after some kilometers. If the copy quality is bad, you might adjust
the machine. If the machine is broken, you might repair it.
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Requirements
Computer based training:
Windows PC Or
Macintosh
Hands on:
Digital black and white copier, ADF/ARDF,
Finisher
Training materials
Computer based training:

Windows PC:
Intel 486 processor, minimum 66 MHz (Intel Pentium-processor recommended)
Windows 95/98/NT
Double-speed CD ROM or better
Minimum 16 Mb of free RAM
Color display recommended
Soundcard recommended
Macintosh:
Power Macintosh recommended
Mac OS 7.6 or higher (previous Mac OS needs the thread manager)
Double speed CD ROM or better
Minimum 16 Mb of free RAM
Color display recommended
Hands on:
Later in this training module we need this requirements to do some exercises.
The exercises in this module are generated for a generic copier with ADF and finisher.
However it is possible that not all exercises can be done on all machine’s, because
some functions are not available, in that case skip that part of the exercise.
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Pre-requisites
Basic electronic skills
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Training Materials
Main Document
Maincopier.ppt
Downloads
Basiccopier.exe
CBT
Operating Instructions
Main Document
Maincopier.ppt
¾ PowerPoint presentation with notes pages of the main document
Downloads
Basiccopier.exe
¾ Self extractable pdf file containing:
main document notes pages
core technology manual pages for basic copier
Exercises
CBT
Copier technology Technical Training Tool (Basic copier CBT)
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Exam
Yes, WICE Multiple choice exam
Name of the exam: Basic copier exam
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1. Copy paper
Study the Copy Pa per section of the Copier Computer
Based Traini ng CD.
1. Copy Pap er
Study the Copy Paper section of the Copier Computer Based Training CD.
Make sure that you understand:
Paper sizes
Paper weight
Paper gain
Paper curl
Front and back sides of paper
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2. Copier
Study the Copier section of the Copier Computer Based
Training CD.
2. Copier
Study the Copier section of the Copier Computer Based Training CD.
Make sure that you first have to start with the analogue copier and that you understand:
Copy process overview
A closer look
¾ Scanning
Scanning
Absorbing
Exposure to photoconductor
Lens
Enlargement
Reduction
¾ Photoconductor
Types
Layers
¾ Toner on latent image
Charge
Exposure
Development
Transfer
Separation
Cleaning
Quenching
¾ Transfer to paper
Friction
FRR
Registration
¾ Fusing
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After you finished the analogue copier continue with the digital copier and make sure
that you understand:
Scanning
Shading
¾ White shading
¾ Black level correction
Laser exposure
Development
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3. User Training
3. Use r Training
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User Training Content
Introduction
Operation panel
User tools
Basic functions
Other functions
3. Use r Training
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Introduction
All functions and features on copiers can be
used to change the output
For example the original’s are simplex but the
output is duplex with a staple.
3. Use r Training
This part of the module will explain most common used functions and features on
copiers.
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Different Levels
Normal
User tools
Service mode
3. Use r Training
Normal
Every user can use the machine for copying
User tools
In the user tools items can be changed for example date and time.
In the user tools there is a special function called key operator tools, this is a kind of
administration tool.
A password can be programmed that not all users can access the key operator user
tools.
Service mode
The service mode is for the technician.
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Scanning
The original can be placed on the platen glass or
ADF (automatic document feeder)
With an ARDF (automatic reverse document
feeder) scanning can be done on both side’s of
the original
3. Use r Training
The ADF can hold a lot of documents to scan it all together.

The number of documents that can be put in the ADF depends on the copier model.
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Imaging
The image process can be changed
Image density
Enlarge / reduce
Photo mode / text mode
Positive / negative
Image repeat (more image’s on one sheet)
Poster mode
3. Use r Training
After the scanning process the images are stored in memory and can be processed with
the settings (see above) selected by the user.
All these processes are done on a digital way.
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Paper Selection
Input selection
Paper size
Which tray
Orientation
Output selection
Which output bin
3. Use r Training
Paper size
On the operation panel you can be defined which paper tray will be used for the copy
job.
If a paper tray is filled with A3 sized paper and an other tray is filled with A4 sized paper,
we can make a selection which paper size can be used.
Which tray
All tray’s can be selected.
In case of thick paper or an other size the bypass tray can be used.
The bypass is not meant for large amount of paper.
Orientation
The A4 size paper can be stored in 2 way’s LEF (long edge feed) and SEF (short edge
feed).
If the paper tray’s are filled with A4 LEF and with A4 SEF, the selection for orientation
can be made.
Output selection
If there are more output bins there can be a selection for which one.
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Function Select
Number of copies
Simplex / Duplex
Booklet / Magazine
Simplex Duplex Booklet/Magazine
3. Use r Training
When starting a copy job we can select the number of copies.

Simplex or duplex is done by putting the right image on the front side or the front and
back side of the paper.
Booklet or magazine is a combination of 4 images on one sheet of paper.
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Finisher options
Punch
Staple
Sort
Stack
Staple Punch
1 2 3 1 2 3 1 2 3
Sorting stacking
3. Use r Training
To select punch or staple the option should be installed in the finisher.

Sort
Sorting will create a number of sets start from the first to the last page on the same way
as your originals.
When staple is selected sort is also selected automatically.
Stack
Stacking will make it easier to separate the copied sets.
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Key Layout
Example of a n opera tion panel.

Each button w ill be explained at the follow ing slides
3. Use r Training
Each model has it’s own operation panel layout however the symbols that are used are
the same.
The way of selecting a function can be different, in that case see your operating
instruction for your machine.
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Screen Contrast

Screen adj ust knob
3. Use r Training
To adjust the screen for a good clear view turn this knob.
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Indicators
Indicators show s errors or s tatus
3. Use r Training
These indicators can be different on a other copier models.

These indicators will show you the following: (starting from the top left)
Staples empty, Toner empty, Paper empty
Maintenance needed, cover not closed, Paper jam
Communicating (not used for standard copier)
Receiving a file (not used for standard copier)
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User Tools/Counter
User tools / counter key
3. Use r Training
Two functions for this button.

To access the user tools and to access the counter (how many copies are made).
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Functions
Copy mode
Document server mode
Facsimile mode
Printer mode
Scanner mode
3. Use r Training
At this moment we are only discussing a standard copier.

For a lot of copiers there are option’s available for example a fax option.
By selecting one of these buttons, the selection for that option can be made.
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Display
Used for input and output.
3. Use r Training
This is an example of a display.

The display is used for output and input.
Input
All selection can be made by touching the right items on the screen.
Output
All information will be displayed, like settings, errors etc.
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More Buttons
Check Modes Energy Saver

Program
Clear modes Interrupt
3. Use r Training
Check Modes Key

Press to check the entered copy job settings.
Program Key
Press to select the program mode.
Clear Modes Key
Press to clear all selected copy job settings.
Energy Saver Key
Press to switch to and from Energy Saver Mode.
Interrupt Key
Press to make interrupt copies during a copy run.
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Power
Main Pow er Indicator

On Indicator
Operation Sw itch
3. Use r Training
Main Power Indicator

Indicates if the main power is turned on.
If a printer or a fax option is installed, the main power should never be switched off.
For example the machine Main power switch is off and someone is sending you a fax
message, the fax won’t be received because the machine is switch off.
On Indicator
The on indicator will be lit if the machine is switched on for operation.
If the indicator is blinking it means that the machine is doing something for example
reading/writing the hard disk.
If this indicator is blinking never touch the main power switch, because it can damage
your machine.
Operation switch
This switch is used the switch off and on the machine.
If the machine is switched off it still can be used for printing and receive fax messages.
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Number Keys
Number ke ys
3. Use r Training
Number Keys
With the number keys you can enter the number of copies required.
In case of a Multifunctional product they are also used to enter the numbers for faxing.
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Start / Stop / Sample
Sample Copy
Start

Clear / Stop
3. Use r Training
Sample copy button

Used to see if the output is correct.
If the sample copy is approved the keypad can be used to set the number of copies.
Start button
Pressing the start button it will start your copy job.
Clear / Stop button
Clear to delete a entered number
Stop to stop a copy process in progress
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Exercise
Do the exercise user functions
3. Use r Training
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User Tools
User Tools
special settings can be done.
System settings
Timer settings
Key operator tools
Copier settings
Density
Margin’s
3. Use r Training
User tools
From the first screen a selection can be made for system settings, copier settings,
printer settings, scanner settings and counter.
System settings
In the system settings a lot of items can be changed that are related to the system for
example date and time.
The key operator tool can be accessed from the system settings.
For example to change user code’s.
The key operator tool can be password protected.
Copier settings
All items that are related to the copier process can be changed here.
For example density and margin’s
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4. Options / Installation
4. Options/Installation
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Options
Examples
Finisher
Paper bank
Duplex unit
Interfaces
Mailbox
Other
Each device can have options installed. Details about what options can be installed and
it’s functions are explained in the Operating Instructions coming with the device.
Setup Guide
Provides information about setting up the device and its options. This manual is
provided as a printed manual, and also as a PDF file on the CD-ROM labelled
"Operating Instructions".
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Installation
The installation procedure is described in the
Service Manual
Requirements
The installation chapter starts with requirements like:
Environment
Machine level
Minimum space
Power
Options
In case of installing options there could be a logical order.
Some times you will find a installation flow chart for this order.
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5. Advanced Copier Technology
5. Advan ced Copie r Te chnology
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Core Technology Manual
Core Tec hnology Manual
topics
Serv ice Manual CD’s
For several topics in this advanced copier technology chapter there will be referred to
the Core Technology Manual (CTM).
The CTM can be found on the Service Manual CD ROM’s.
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Advanced copier technology content
5.1 Handling paper
5.2 Photocopying processes
5.3 Digital processes
5.4 Process control
5.5 Standard Components
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5.1 Handling paper
Paper feed
Paper feed methods
Paper tray
By pass
Paper size detection
Paper end detection
Registration
Paper transport
Duplex
Misfeed detection
5.1 Adv anc ed Copier T echnology > Handling Pape r
Study the CTM > Handling paper and make sure that you understand:
Paper feed
Paper feed methods
Paper tray
By pass
Paper end detection
Registration
Paper transport
Duplex
Misfeed detection
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Paper feed
Paper feed is the separation of a single sheet of
paper from a paper source—usually a stack of
paper in a cassette or tray—and moving it into
the machine.
CTM > Handling Paper > Paper Feed
There are several key factors involved with handling paper in office machines (copiers,
printers, faxes, whatever). First, there has to be a stock of paper from which to feed,
which implies some kind of holder—a tray, a cassette, or a roll—which positions the
paper properly for feeding. Second, there has to be a method of separating a single
sheet from the source; this is referred to as paper feed. Finally, most machines use
sensors to detect paper size and detect the presence or absence of paper.
After paper is fed into a machine, it must be transported to a registration mechanism,
then to an imaging section where the image is transferred to the paper. Finally the paper
passes through an image fusing section and exits the machine.
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Paper feed methods
Feed and Rev erse Roller Feed roller
Pick-up roller
(FRR)
Friction Pad
Reverse roller
Feed roller
Friction pad
Feed and Reverse Roller (FRR)

The FRR feed mechanism consists of a pick-up roller, a feed roller, and a
reverse roller.
Friction Pad
The friction pad mechanism has two principle components—the paper feed roller
and a friction pad.
CBT reference > Copier > Analogue copier > A closer look > Transfer to paper
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Paper tray
A paper tray is a non-removable drawer or bin
that is permanently built into or attached to the
machine.
500 _she et_t ray .tif 170 0_sh eet _tr ay.tif
Paper Tray
A paper tray is a non-removable drawer or bin that is permanently built into or attached
to the machine. The capacity of paper trays varies considerably; smaller trays typically
hold 250 to 500 sheets of paper, but large capacity trays hold a paper stock of 1000 or
more sheets.
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By pass
odd paper sizes
stiff feed stock such as
post car ds or O HP
transpare ncies
By-pass Feed Tray

Most copiers and multifunction machines incorporate a fold-out by-pass feed table. By-
pass feed is useful for casual copying on odd paper sizes. Also, on most machines, the
by-pass feed tray provides a straight paper path that is suitable for stiff feed stock such
as post cards or OHP transparencies.
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Sw itch Com bina tion
Paper Size Dial
For many copy processes, operation timing depends on paper size. Machines can
detect paper size in a number of different ways. Here are some common ones.
Switch Combination
¾ The illustration at the top right shows a paper size detection mechanism
commonly used with cassettes and smaller paper trays.
Paper Size Dial
¾ Some paper trays use a dial to change paper size (bottom right).
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Paper end detection
typical paper end
detection mecha nism for a
small paper tra y
Paper End Feeler Paper End Sensor
Cutout Lever
The illustration to the right shows a typical paper end detection mechanism for a small
paper tray.
When the paper tray runs out of paper, the paper end feeler drops into the cutout in the
tray bottom plate, and the paper end actuator activates the paper end sensor.
The paper end actuator is in contact with a lever. When the tray is drawn out, the lever
turns as shown by the arrow and pushes up the actuator. As a result, the feeler rotates
upwards. This mechanism prevents the feeler from getting damaged by the paper tray
body.
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Registration
Registra tion Using A
Stopper
Registra tion Using Rollers
There is often some slippage during paper feed. As a result, paper cannot be
transported directly to the image transfer or printing position, because the image position
on the paper would not be stable. After paper feed starts, its transport timing requires
adjustment to match it with the imaging process timing. This alignment is called “image
registration” or just “registration”. Generally the registration process also removes any
skew that the paper may have acquired during paper feed.
Here are some common ones.
Registration Using A Stopper
¾ Some machines use a stopper to delay the paper at the registration rollers.
It allows a simplified drive mechanism where the registration rollers are not
stopped during feeding. This method is used mainly with low speed
machines.
Registration Using Rollers
¾ Most copiers and printers use registration rollers to match the paper timing
to the image and remove skew.
CBT reference > Copier > Analogue copier > A closer look > Transfer to paper
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Paper transport
Roller Tra nsport
Belt + Vacuum Tra nsport
Roller Transport
The illustration to the right shows a typical vertical transport mechanism that is used in
several models.
Belt + Vacuum Transport
Many photocopiers use a combination of belts and vacuum fans to transport paper from
the drum to the fusing unit. The vacuum holds the paper firmly against the transport
belts. This method has the advantage of holding the paper secure to prevent vibrations
or slippage that might disturb the as yet unfused toner image.
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Duplex
Single sheet
Stack
Mechanism in a Photocopier that allows the machine to feed a sheet of paper twice
through the machine to enable automatic duplex copying.
Duplexing mechanisms can take many forms. However, they have the following things in
common.
They all have some way of sending copies or prints to the duplex mechanism.
This is usually accomplished by a “junction gate”, which redirects the paper as it
exits from the fusing unit.
There is a mechanism that turns the paper over (reverses it) so that it is ready to
receive an image on the reverse side. This can occur before the paper enters the
duplex tray or after it exits the duplex tray.
Duplexing systems in most machines also have the following mechanisms.
There is a tray to hold the sheets of paper to be duplexed. Usually, it is simply
"called the “duplex tray”.
There is a mechanism, usually called a jogger, to align the sheets of paper in the
duplex tray.
There is a paper feed mechanism employing one of the standard paper
separation techniques.
Conclusion:
There is are 2 different duplexing methods.
First one is stack, where paper is gathered in a tray and fed back into the machine in
reverse position.
Second one is single sheet duplex (interleave duplexing), where paper is not gathered
but directly reversed in a tray and fed back into the machine.
Next slide will give you an example of the interleave duplexing.
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Interleave Duplexing
Memory needed
Productiv ity increased
Decrease w ear on originals
Some digital machines have a lot of RAM and a large capacity hard disk that can store
many pages. This allows a different method of Duplexing called “interleave Duplexing”,
in which sheets are not stacked. Instead, in interleave Duplexing, sheets are
continuously fed through the machine and the correct image is selected from memory or
disk depending on which sheet and side is in the imaging section.
This type of mechanism allows more than one page to be processed at once, and it
increases the productivity of duplex imaging, especially when making multiple duplex
copies. Also, in the case of making copies from paper originals, it decreases the cycling
of and the wear on originals.
The example shows a 14-page copy. The large numbers in the illustration show the
order of pages. The small numbers in circles show the order of sheets of copy paper (if
shaded, this indicates the second side).
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Misfeed detection
photo i nterr upters
unaffected by the Phototransistor
reflectivity or
transpa rency
LED Paper
Misfeed Detection
Office machines that print images on paper (copiers, fax, laser printers, etc.) have to
detect paper Misfeed and jams and take appropriate action. One or more sensors
placed along the paper path accomplish Misfeed detection. Typically, photo interrupters
with feeler actuators are used for Misfeed detection because they are unaffected by the
reflectivity or transparency of the feed stock.
The number of Misfeed detectors used depends on the length and complexity of the
paper path
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5.2 Photocopying processes
Charge
Exposure
Development
Image Transfer And Paper Separation
Cleaning
Quenching
Fusing
5.2 Adv anc ed Copier T echnology > Photocopying Proc es se s
Study the CTM > Photocopying processes and make sure that you understand:
Charge
Exposure
Development
Cleaning
Quenching
Fusing
1. CBT reference > Copier > Analogue copier > A closer look > Toner on Latent Image
2. CBT reference > Copier > Digital copier
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Overview
1. Char ge
1 2
2. Exposure
6
3. Dev elopment
4. Image Trans fer And Paper
Separation
5
5. Cleaning
6. Quenchi ng
3
7. Fusing
Fusing section 7
4
CTM > Photocopying Processes
In this slide you can see an overview of the process around the drum.
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Charge
Cor ona Charge
Char ge Roller Method
CTM > Photocopying Processes > Charge
Charge refers to the application of a uniform electrostatic charge to a photoconductor in

darkness. At present, two kinds of electrostatic charge methods are widely used.
The most common is the corona electrostatic charge method (non-contact type), which
takes advantage of the corona discharge produced when a high voltage is applied to a
fine wire.
The other is the electrostatic charge roller method (contact type), which provides an
electrostatic charge by applying a high voltage to a roller and contacting the roller to the
photoconductor.
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Exposure
Analog Machines
Digital Machines
CTM > Photocopying Processes > Exposure
Exposure refers to a process where light is applied to a photoconductor to create a

latent reverse image on in the form of a charge pattern on the surface of the
photoconductive material. Depending on the brightness of the image, the electric
potential on the photoconductor's surface is attenuated; thus, forming an electrostatic
latent image
In general you can say that we use three main exposure methods
flash exposure
strip exposure (sometimes called slit exposure)
laser exposure (covered in the Digital Processes chapter)
Analog Machines
An exposure lamp illuminates the original. Mirrors reflect light from the original directly
onto the photoconductor. This light writes a latent image on the photoconductor. This
image is then developed with toner and transferred to the copy paper.
Digital Machines
The big difference with scanners in digital machines is that the light reflected from the
original does not pass directly to the photoconductor.
The light is reflected onto a light-sensitive element, such as a CCD (Charge Coupled
Device). This device converts the light into an analog electrical signal. Circuits inside the
machine convert this signal into a digital signal. This signal then passes to a laser diode,
which emits a laser beam to write a latent image on the photoconductor.
So, in a digital machine, there is a lot of electronics between the light reflected off the
original and the light arriving at the photoconductor.
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Development
dual-component development method
single-component development method
CTM > Photocopying Processes > Development

Development systems are divided into:
dual-component development method
single-component development method (mono-component)
Dual-component
The two-component development process uses developer made of mixed toner and
carrier. These two components rub against each other in the development unit and take
on opposite charges.
The charged latent image areas of the drum attract the charged toner particles.
Advantages
Achieves high speed development
Allows relatively wide scope in terms of accuracy
Disadvantages
The development section is complex and large
Deterioration of developer over time (difficult to achieve maintenance free
operations)
Requires toner concentration control
Mono-component
The mono-component development process uses toner only (no carrier). Mono-
component development systems are used mainly in small photocopiers with a low copy
rate.
Advantages:
Development unit structure is simple and compact.
Toner density control is unnecessary.
Disadvantages:
Unsuitable for high speed developing
Suitable for low-volume copying only because the development unit parts wear
out relatively quickly.
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A. Pre-trans fer
B. Image Trans fer
C. Paper Separation
CTM > Photocopying Processes > Image Transfer & Paper

Separation
The transfer and separation process can be broken down into three areas:
Pre-transfer
Just before the image transfer process starts, guides direct the paper against the
photosensitive surface of the drum (or belt). The mechanism is structured so that the
transfer charge does not reach this area, and therefore, the paper can achieve complete
contact with the photoconductor before image transfer starts.
Image Transfer
This is the area where the image is actually transferred from the photoconductor to the
paper. Generally, an electrostatic charge is applied to the back of the paper to pull the
oppositely charged toner from the photoconductor to the paper.
Paper Separation
The paper separates from the photoconductor after the toner image is transferred. This
is usually achieved by applying an ac corona to the back of the paper to eliminate the
previously applied transfer charge. Pick-off pawls are also used to physically separate
paper of low stiffness from the drum.
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Cleaning
Cleaning blades
Cleaning br ushes
Counter Blade
Cleaning Brush
CTM > Photocopying Processes > Cleaning
Cleaning refers to the process of removing any toner remaining on the photoconductor
(drum or OPC belt) after the imaging process is complete to prepare the photoconductor
for the next copy/print cycle. The cleaning step also removes any paper dust on the
photoconductor surface.
Cleaning is necessary before a new copy cycle or print cycle can start. If the cleaning
step were not included in the copy process, the background of images would become
progressively darker and dirtier.
All cleaning systems use a cleaning blade or a cleaning brush or both. Additionally, all
cleaning systems have a mechanism for collecting and storing (or recycling) the
collected toner.
The most common cleaning systems use blades, and these are further divided into
trailing-blade cleaning and counter-blade cleaning systems.
Cleaning brushes all rotate in contact with the photoconductor. There are also two types
of cleaning brushes—fiber brushes and magnetic brushes.
Some cleaning systems also use a corona (pre-cleaning corona) to prepare the drum
and toner for cleaning.
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Quenching
eliminates any residual
electric charge remaining
on the photoconductor
after the cleaning process
CTM > Photocopying Processes > Quenching
Quenching is the process that eliminates any residual electric charge remaining on the
photoconductor after the cleaning process. Quenching prepares the photoconductor for
the charge step of the next copy or print cycle.
Several different methods are used to quench the photoconductor. The most common
method is photo quenching using a lamp. Some machines use a combination of a dc
corona and photo quenching. A few machines use an ac corona for quenching. The
choice of quenching method depends on the type of photoconductor used and the
details of the other steps of the copy process.
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Fusing
Hot roller
Pressure roller
Fusing lamp
Stripper paw ls
Fusing lamp
Hot Roller Press ure Roller
Stripper Pawls
CTM > Photocopying Processes > Fusing
After the image transfer and paper separation steps, the image must be bound or “fixed”
to the paper. Modern photocopiers and other machines (fax, printer) that use
photocopier imaging processes, use resin based toners. To form a stable permanent
image, the toner is heated to cause it to melt and soften. Simultaneously, pressure is
applied to cause the toner to fuse with the fibers of the paper.
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5.3 Digital processes
Digital scanning
Image processing
Scanner gamma correction
Photo mode smoothing
Moiré
Grayscale processing
Binary picture processing
Image rotation
Printing
5.3 Adv anc ed Copier T echnology > Digital Proc es se s
Study the CTM > Digital Processes and make sure that you understand:
Digital scanning
Image processing
¾ Scanner gamma correction
¾ Photo mode smoothing
¾ Magnification and Reduction
¾ Moiré
¾ Grayscale processing
¾ Binary picture processing
¾ Image rotation
Printing
CBT reference > Copier > Digital copier
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Digital Scanning
Analog Machines
Digital Machines
CTM > Digital Processes > Digital Scanning

Earlier in this module we already explained the difference between the analog and digital
scanner.
Analog Machines
An exposure lamp illuminates the original. Mirrors reflect light from the original directly
onto the photoconductor. This light writes a latent image on the photoconductor. This
image is then developed with toner and transferred to the copy paper.
Digital Machines
The big difference with scanners in digital machines is that the light reflected from the
original does not pass directly to the photoconductor.
The light is reflected onto a light-sensitive element, such as a CCD (Charge Coupled
Device). This device converts the light into an analog electrical signal. Circuits inside the
machine convert this signal into a digital signal. This signal then passes to a laser diode,
which emits a laser beam to write a latent image on the photoconductor.
So, in a digital machine, there is a lot of electronics between the light reflected off the
original and the light arriving at the photoconductor.
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Image processing
Image processing describes how digital machines convert the image from a scanned
original into digital data. Image processing use techniques for processing the digital
data, so that the printout is as close to the original as possible.
For example, techniques used to process a business letter will be different from those
used to process an original containing photographs.
Each model implements these techniques in different ways, and some models do not
implement all the techniques.
The techniques used by black-and-white machines and color machines are different, but
these kind of details will be explained in the product trainings.
The CTM will explain all of the techniques in detail.

For this training module we only discuss some of them.
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Scanner gamma correction
relationshi p be tw een
original ima ge density a nd
analog circui t output
shoul d be linear as show n
in the upper diagram.
How ev er, in reality, it is
more like that s how n in
the low er diagram.
Scanner Gamma Correction

Scanner gamma correction corrects the data to compensate for the characteristics of the
scanner (e.g., CCD response, scanner optics). This ensures that the various shades in
the gray scale from black to white on the copy match those on the original.
The relationship between original image density and analog circuit output should be
linear as shown in the upper diagram. However, in reality, it is more like that shown in
the lower diagram.
Gamma correction corrects the data for this deviation, as shown by the arrows in the
lower diagram.
In some machines, the gamma curve can be changed with a service mode.
Also, some machines automatically adjust the gamma curve depending on the image
density setting selected by the user.
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To make a softer image
Text Mode
Photo Mode

There are some different processes that use the name 'smoothing'. Photo mode is to
make a softer image.
Smoothing smoothes the contrast between adjacent pixels, giving better reproduction for
photos. Because of this, it will not normally be used in text mode.
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Moiré
The m oiré pattern typically appears w hen the CCD pixel

density is a mul tiple of the density of the regular lines on
the ori ginal.
Moiré
When one pattern is imposed over another sometimes they interfere with each other and
form a third pattern called a moiré pattern. In our products, MTF processing is a major
cause of moiré patterns.
The photos show the result of moiré.
The moiré pattern typically appears when the CCD pixel density is a multiple of the
density of the regular lines on the original.
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uses many shades for
instance 64 or 256.
64 Grays cales 256 Grayscal es

Grayscale Processing
The human eye can discern up to about 200 different levels, or shades, of gray. A lot of
digital copiers can create 256 gray levels: 0 through 255.
Compare the right and left halves of the images, to see the difference if you have more
grayscales available.
Grayscale processing uses many shades of gray to reproduce continuous tone originals,
such as those containing photographs. A black and white photograph contains an
unlimited number of shades of gray, but digital copiers and printers can normally only
output a few shades, normally 64 or 256.
If grayscale processing is used, the result is a multi-bit per pixel stream of digital data.
For example, if there are 256 shades of gray, there are eight bits per pixel.
00000000 11111111
0 255
Note that grayscale processing needs a lot of memory. At eight bits per pixel (256
shades of gray), an A4 or LT page needs about 14 megabytes, without compression.
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Binary picture processing
One bit output
White or
Black
Binary Picture Processing

In binary picture processing, the output data is one-bit only. There are no shades of
gray. the output is black or white only.
The multi-bit per pixel data stream has to be reduced to single-bit data. To do this, a
threshold level is used. If a pixel has a value that is brighter than the threshold, it
becomes a white pixel. If it is darker than the threshold, it becomes a black pixel.
The threshold can usually be adjusted, and it often varies depending on modes selected
at the operation panel. The example on the slide shows how the threshold level affects
the output.
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Image rotation
Image Rotation
If the machine has paper of the same size as the original but different orientation, the
image will be rotated by 90 degrees in memory before printing. The machine must have
enough working memory to do this. The amount of memory required for a certain paper
size depends on the image resolution and the number of bits per pixel.
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Printing
CTM > Digital Processes > Printing
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The Latent Image
The diagram show s the
typical optical
components of a laser
printer
CTM > Digital Processes > Printing

CBT reference > Copier > Digital copier > Laser Exposure
The Latent Image

Exposure of the photoconductor to the laser beam creates the latent image. A rotating
mirror moves the laser beam across the photoconductor to make the main scan while
photoconductor rotation controls the sub-scan.
The diagram shows the typical optical components of a laser printer.

A: Laser Diode Unit
B: F theta Lenses
C: BTL (Barrel Toroidal Lens)
D: Drum Mirror
E: Laser Synchronization Detector Board-2
F: Laser Synchronization Detector Board-1
G: Polygon Mirror Motor
H: Cylindrical Lens
I: OPC Drum
J: Toner Shield Glass
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5.4 Process control
Basic concepts
OPC digital systems
5.4 Adv anc ed Copier T echnology > Proc es s Control
Study the CTM > Process Control and make sure that you understand:
Basic concepts
OPC analog systems
OPC digital systems
OPC analog systems is not explained in this module, but is necessary as basic
knowledge to understand process control.
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Basic Concepts
In this section we will take an overall look at
process control.
Machine conditions that process control
compensates for:
Dirty optics
Exposure lamp deterioration
Dirty charge corona wire/grid
Change of drum sensitivity
Deterioration of developer
Process control is a system that automatically changes machine processes to

compensate for changes in the environment or the machine condition. The objective of
process control is to stabilize the quality of image output. The practical result is a
decrease in the frequency of service calls, thus increasing customer satisfaction and
decreasing service cost.
To maintain good copy quality, a lot of machines do process control data initial setting
just after the main switch is turned on.
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Latent Image & Image Density Control
CTM > Process Control > Basic concepts
This illustration represents a copier model that uses two process control methods. One
compensates for variation in the drum potential (latent image control) and the other
controls the toner concentration and toner supply amount (image density control).
All process control components affect one or the other (or both) of these methods.
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Latent Image Control
VO Drum potential j ust after chargi ng the

drum.
VD (Dark Potential ) Drum potential j ust after exposi ng the
black patter n (V D pattern)
VL (Li ght Potential ) Drum potential j ust after exposi ng the
w hite patter n (V L pattern)
VR (Residual Drum potential j ust after the exposure of
Voltage ) the erase lamp.
The figure in the slide shows the changes of the drum potential during the copy process.
The following list explains the meaning of some of the terms and abbreviations used
when describing process control.
VO (Original Potential)
The drum potential after the drum is charged.
VD (Dark Potential)
The drum potential in black image areas after exposure. Standard VD is the
potential measured after exposing a black pattern.
VL (Light Potential)
The drum potential in white image areas after exposure. Standard VL is the
potential measured after exposing a white pattern.
VR (Residual Voltage)
The drum potential after the drum has been exposed by the erase lamp.
Potential Sensor
A sensor used to measure the strength of the charge on the OPC drum surface
(drum potential).
VL Pattern
A standard white pattern used for reference. On some machines the VL pattern
is actually a light gray tone rather than pure white.
VD Pattern
A standard black pattern used for reference.
ID Sensor
A photosensor that measures the image density (reflectivity) of the drum and of a
test pattern (ID sensor pattern). The output of this sensor is used to control toner
supply.
ID Sensor Pattern
A standard pattern that is exposed and developed for sensing by the ID sensor.
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VSG
The ID sensor output when checking the erased drum surface.
VSP
The ID sensor output when checking the ID sensor pattern image.
VLAMP
Exposure lamp voltage.
VB or VBB
Development bias.
TD Sensor
Toner density sensor—it measures the concentration of toner in the developer.
VREF
A targeted control reference for the TD sensor. When VTD becomes too low,
toner is added to the developer to bring VTD back to the VREF value.
VTD, VT, or VOUT
The output voltage of the TD sensor.
V Sensor
A reflective photosensor similar to the ID sensor that is used to indirectly
measure the drum potential. It was used prior to the development of the potential
sensor system and will be found in earlier models using process control.
VG or VGRID
Charge corona grid potential.
VH (Halftone Potential)
A standard halftone drum potential. This value is used for laser power
adjustment in the process control system of some digital products.
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Image Density Control
Toner density sens or (TD
sensor)
Image density sens or (I D
sensor)
ID Sensor TD Sensor
Data from the TD sensor is used to keep the toner concentration in the developer at a
constant level. However, the image on the OPC drum varies due to the variation of toner
chargeability (influenced by the environment) even if the toner concentration is constant.
By the ID sensor compensation, toner concentration is changed to keep the image
density on the OPC drum constant.
The following items are controlled to maintain a constant copy image density:
Toner supply clutch on time
Toner supply level data (VREF) of the TD sensor
NOTE:
Some machines do not have a TD sensor and use only an ID sensor for image density
control.
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OPC digital systems
CTM > Process Control > OPC Digital Systems
This training module will mainly focus on digital copiers, but all detail about OPC’s for
analog systems is explained in the CTM.
CTM > Process Control > OPC Analog Systems
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Overview
The drum potential will gradually change because
of the following factors:
Dirty optics or exposure glass
Dirty charge corona casing and grid plate
Changes in drum sensitivity
In this OPC digital systems chapter we explain process control based on the model
A229 (Aficio650 or SP5).
For detail about the different process control descriptions you have to refer to the
machines Service Manual and Product trainings.
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Process Control Data Initial Setting
The following is done during process control
initial setting:
1. Potential Sensor Calibration (Latent Image
Control)
2. Vsg Adjustment (Image Density Control)
3. Vg (Grid Voltage) Adjustment (Latent Image
Control)
4. LD Power Adjustment (Latent Image Control)
5. Vref Update (Image Density Control)
Process Con trol
Laten t Image Im age Dens ity

Co ntrol Con trol
Potential Sensor VG Adju stment LD Power Adj. Vsg Adju stme nt Vref Update
Calibration (VD Co rrection) (VH Correctio n) (ID Sens . Cal.)
To maintain good copy quality, the machine does Process Control Initial Setting just
after the main switch has been turned on.
NOTE:
In most cases it is done if the fusing temperature is less than 100 °C and auto process
control is enabled on the machine.
Next slides will describe these steps in more detail.
Processes 1, 3, and 4 in the above list compensate for changes in drum potential.
Processes 2 and 5 are for toner density control.
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Drum Potential Sensor Calibration
(Latent I mage Control)
RA101
-200/-700
RA102
To correct for environmental conditions
The drum potential sensor detects the electric potential of the drum surface.
Since the output of the sensor is affected by environmental conditions, such as
temperature and humidity, the sensor needs recalibration at times. This is done during
process control initial setting.
The development power pack has two relay contacts. Usually RA102 grounds the drum.
However, to calibrate the sensor, RA102 and RA101 switch over and apply the power
pack output voltage to the drum shaft.
The machine automatically calibrates the drum potential sensor by measuring the output
of the sensor when –200V and –700V are applied to the drum. From these two readings,
the machine can determine the actual drum potential from the potential sensor output
that is measured during operation.
During calibration, if the rate of change in drum potential sensor response to applied
voltage is out of the target range, a SC (Service Call) is logged and auto process control
turns off. The VG and LD power adjustments are skipped; VG is set to a value stored in
a SP (Service Program) mode, and LD power is also set to a value stored in a SP mode.
Exercise:
Check with help of the Service Manual the following problem
Drum Potential Sensor Error
See the result in the manual and compare with the result underneath
Definition D
¾ The SC history is updated. The machine can be operated as usual.
¾ The SC will not be displayed. All that happens is that the SC history is
updated.
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Vsg Adjustment
(Image Density Control )
Y During the process control initial setting or by SP, the

ID sensor output is calibrated by changing the LED
light intensity
Vsg adjustment calibrates the ID sensor output for a bare drum to a standard value. It
does this by changing the intensity of the light shining on the drum from the sensor. This
is done automatically during process control initial setting, and it can also be done
manually with an SP mode selection.
If the ID sensor output cannot be adjusted to within the standard, a SC is logged and
toner density control is done using the TD sensor only.
Later in this module we will explain more detail about the ID sensor when Image Density
control is explained.
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New Drum
Drum
Potential VD
-900V
Gradations
-300V
VH
VR
Light Original Density Dark
The relationship between the drum potential and the original density is illustrated in the
characteristic. In this example the drum potential of a new drum is 600 Volts. This
means that with this drum potential we have the maximum density from white to solid
black.
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Vg Adjustment (VD Correction)
The Potential on unexposed areas of the drum (VD) gradually

changes during drum life
Charge/Grid
P.P
VG
SBICU
VD Must be constant
(Target= -900V + 10V)
The potential on unexposed areas of the drum (VD) gradually changes during drum life.
To keep VD constant, the grid voltage (VG) is adjusted during process control initial
setting.
The SBICU checks VD using the drum potential sensor. If it is not within the target range
(-900V +– 10V), the SBICU adjusts VG (Grid Voltage) through the Charge/Grid power
pack to get the correct target voltage.
For details of how the machine determines an abnormal sensor detection see the
service manual of the copier.
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Older Drum
Drum
Potential VD
-900V
VD’
VH’
-300V
VH After many copies
New drum
VR’
VR
The relationship between the drum potential and the original density is illustrated in the
characteristic. To get consistent copy quality throughout the drum’s life, this relationship
must be maintained. Since this relationship changes due to various factors to the one
represented by the red dotted line, compensation is required. Factors causing these
changes occur in the optics and charge sections and in drum sensitivity. The residual
voltage (VR) cannot be compensated even if exposure lamp voltage is increased.
Therefore, the VR change has to be compensated by other means.
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VG Adjustment
Drum
Potential VD
-900V
VG Adjust
VD’
VH’
-300V
VH
VR’
VR
The drum potential tends to lower during drum life due to a decrease in the drum’s
capacity to carry a charge.
The main control board measures VD through the drum potential sensor and adjusts it to
a target value by adjusting the grid bias voltage (VGRID). This is illustrated with the blue
dotted line.
Now that VD is back to normal you can see that VH is not correct, so the drum potential
range is less than the 600 Volts which we had with a new drum.
The next adjustment is to bring VH back.
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LD Power Adjustment (VH Correction)
LDDR
SBICU
VH Must be constant
(Target= -300V + 20V)
This adjustment uses the drum potential sensor to keep the ID sensor pattern at the
same density, so that VREF will be updated correctly (see some slides later). The VH
pattern is developed using the current LD power (the density is the same as the ID
sensor pattern).
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LD Power Adjustment
Drum
Potential VD
-900V
VD’
LD Adjust
-300V
VH
VR’
VR
The drum potential sensor detects the potential on the VH pattern. The LD power is
adjusted until VH becomes –300V +–20V. This is done only during process control initial
setting.
For details of how the machine determines an abnormal sensor detection please refer to
the Service Manual.
Now that the latent image is controlled the next thing which has to be done is the Image
Density Control with help of the TD & ID sensors.
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Toner Density Sensor
7
Sensor output [V]
6
4
Vref
1
0 1 2 3 4 5
Toner weight [wt %]
Developer consists of carrier particles (iron) and toner particles (resin and carbon).
Inside the development unit, developer passes through a magnetic field created by coils
inside the toner density sensor. When the toner concentration changes, the voltage
output by the sensor changes accordingly.
When new developer with the standard toner concentration is installed, developer initial
setting must be performed by using an SP mode.
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Toner Supply Criteria
7
Sensor output [V]
6 VTD > Vref (Toner WT% is small)
Increase toner supply
5
4
Vref
3
VTD < Vref (Toner WT% is large )
2 Decrease toner supply
1
0 1 2 3 4 5
Toner weight [wt %]
At every copy cycle, toner density in the developer is detected. The sensor output
voltage (VTD) during the detection cycle is compared with the toner supply level voltage
(VREF).
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Toner Density Control
T oner Supply Clutch On T ime
Calculation
Pixel Count GAIN
T D Sensor
Output (V TD )
VT Reference
Voltage (VREF)
(New VREF)
VT Reference
Voltage Update
VREF Update
ID Sensor Output
(V SP /VSG)
T D Sensor Initial
Setting (VREF)
To stabilize toner concentration, toner supply amount (toner supply clutch on time) is
controlled by referring to VREF and VTD. The toner supply amount is calculated at
every copy.
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Vref Update
(Image Density Control )
Y To sta bilize the concentration
of toner i n the dev elopment T oner Supply Clutch On T ime
unit Vre f is updated using Calculation
Vsp/Vsg and V TD
Pixel Count GAIN
T D Sensor
Output (V TD )
VT Reference
Voltage (VREF)
(New VREF)
VT Reference
Voltage Update
V REF Update
ID Sensor Output
(VSP /VS G)
T D Sensor Initial
Setting (VREF)

Earlier in this module we already explained that during process control initial setting the
ID sensor is calibrated with help of the Vsg adjustment.
The image on the OPC drum changes due to variation of toner chargeability (influenced
by the environment) even if the toner concentration is constant. The image density
sensor (ID sensor) directly checks the image on the OPC drum and shifts VREF data to
keep the image on the OPC drum constant.
VSG and VSP are checked by the ID sensor.
There is no ID sensor pattern in the optics, however, a pattern image is made on the
OPC drum by the charge corona unit and the erase lamp.
Y VSG is the ID sensor output when checking the erased drum surface.
Y VSP is the ID sensor output when checking the ID sensor pattern image.
To compensate for any variation in light intensity from the sensor LED, the reflectivity of
both the erased drum surface and the pattern on the drum are checked.
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5.5 Standard Components
Y Light Sources
Y Sensors and Switches
Y Clutches, Motors, And Solenoids
Y Consumables
5.5 Adv anc ed Copier T echnology > Standa rd Compon ents
Study the CTM > Standard Components and make sure that you understand:
Y Light Sources
Y Semiconductor Components
Y Sensors and Switches
Y Clutches, Motors, And Solenoids
Y Other Electrical components
Y Consumables
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6. Service
6. Servi ce
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Service Manual
CD ROM
Hard Copy
6. Servi ce
What is the best way to use the service manual CD ROM’s.

How to View Files
All the technical documents on this disk are in the portable document format
(PDF). To view them you must install either Adobe Acrobat Reader or Adobe
Acrobat Exchange on your computer. You will find a version of Acrobat
Reader for Windows in the RDR_SRCH directory of this disk. Please install it if
you haven't already.
There are two ways to quickly find the documents that you want on this disk. You
can use the main contents file (CONTENTS.PDF) or use the full-text search
function. (You will find more detail about this in the readme file on the CD ROM.)
Using the Contents File

Just open CONTENTS.PDF (in the "Contents" folder). It is arranged according to
product or product family and has links to all the technical documents on this disk.
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Tools
Special Tools (Serv ice Manual)

Part Number
De scription
Q’ty
6. Servi ce
The chapter Special tools and Lubricants is always a topic described in the Service
Manual. It will give an overview of the part numbers of the tools.
A description gives you more detail about the tools.
Next slide will explain more detail about the test chart which you see in the tools table.
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Test chart
The follow ing new test
chart is released for B/ W
copiers.
6. Servi ce
Check the next page to have a better look at the test chart.
Part Number Description A2929500 Test Chart – S5S (10 pcs/set)
A: Leading edge registration (Max. A3/DLT size copier)

B: Side-to- Side registration / Skew (Max. A3/DLT size copier)
C: Leading edge registration (Max. A4/LT size copier)
D: Side-to- Side registration / Skew (Max. A4/LT size copier)
E: Jitter (Max. A3/DLT size copier)
F: White line(s) in half tone area (Max. A3/DLT size copier)
G: White line(s) (Max. A3/DLT size copier)
H: Main scan / horizontal magnification (Max. A3/DLT size copier)
I: Sub scan / vertical magnification (Max. A3/DLT size copier)
J: Solid black area
K: Photo image
L: Scanning bit error (Max. A3/DLT size copier)
N: Letter
M: Uneven image density (Max. A3/DLT size copier)
O: Jitter (Max. A4/LT size copier)
P: Uneven image density (Max. A4/LT size copier)
Q: White line(s)
R: Sub scan / vertical magnification (Max. A4/LT size copier)
S: Scanning bit error (Max. A4/LT size copier)
T: Main scan / horizontal magnification (Max. A4/LT size copier)
U: White line(s) in half tone area (Max. A4/LT size copier)
V: ID balance of solid black areas
W: Resolution
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Troubleshooting
Y Service Manual
Y Operating Instructions
6. Servi ce
The Service Manual will explain all the necessary detail about troubleshooting
procedures for the device.
Also Operating Instruction sometimes have a chapter related to troubleshooting. In case
the problems are more complicated and solutions are not given by any of these
manuals, contact a Product Specialist in your organisation.
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Maintenance
Y Service Manual
6. Servi ce
The Service Manual and Parts Catalogue will explain all the necessary detail about
Preventive Maintenance for the device.
It is even possible that devices are customer maintainable, in this situation there is also
an Operating Instruction (maintenance guide) available.
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Firmware
6. Servi ce
There are different ways to upgrade the firmware, this depends on the product.
Some examples of firmware upgrade procedures are:
Y EEPROM
Y Via the network
Y Flash memory card
Y Other
EEPROM
Electrically Erasable Programmable Read-Only Memory. An EEPROM is a special type
of PROM that can be erased by exposing it to an electrical charge. Like other types of
PROM, EEPROM retains its contents even when the power is turned off. Also like other
types of ROM, EEPROM is not as fast as RAM.
EEPROM is similar to flash memory (sometimes called flash EEPROM). The principal
difference is that EEPROM requires data to be written or erased one byte at a time
whereas flash memory allows data to be written or erased in blocks. This makes flash
memory faster.
PROM
Programmable Read-Only Memory. A PROM is a memory chip on which data can be
written only once. Once a program has been written onto a PROM, it remains there
forever.
RAM
Random Access Memory, a type of computer memory that can be accessed randomly;
that is, any byte of memory can be accessed without touching the preceding bytes. RAM
is the most common type of memory found in computers and other devices, such as
printers, they lose their contents when the power is turned off.
There are two basic types of RAM:
Y dynamic RAM (DRAM)
Y static RAM (SRAM)
ROM
Read-Only Memory, computer memory on which data has been prerecorded. Once data
has been written onto a ROM chip, it cannot be removed and can only be read.
Unlike RAM, ROM retains its contents even when the computer is turned off. ROM is
referred to as being nonvolatile, whereas RAM is volatile.
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Getting a source file
Notes database
Software Di stribution
Database
Interne t
www.ricoh-suppo rt.com
6. Servi ce
To get more information about how to deal with procedures and logins, your Service
Manager has all the details.
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Desktop Computer
Y Application software is required (SWAPFTL)
+
6. Servi ce
Y SwapFTL software allows a flash memory card to be used as an intermediate

medium between a flash ROM (or RAM) on the machine and a Windows 95
based computer.
The basic procedure is as follows:
1. You receive ROM firmware files from a database either via network or via
physical medium, and save them onto your computer’s local hard disk. A
computer can work as a flash memory card programmer after a SwapBox and
SwapFTL software is installed.
2. You program the ROM file to a flash memory card using this software.
3. You carry the programmed card to a machine site and download the ROM data
from the card to the machine’s internal flash ROM. The 4MB flash memory card
that is customized for this application is available as a special tool. You cannot
use other types of flash memory cards.
4. After downloading ROM data to one machine, you can use the same card with
another machine of the same type.
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Laptop
Y Application software is required (SWAPFTL)
6. Servi ce
SWAPFTL is an application designed for the Swapbox hardware, that means that the
software on a laptop with his own card interface (called PCMCIA slot) can have
problems. Refer to the SwapBox & SwapFTL Service Manual for more detail about this.
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Download to a machine
Y Plug the card into the card slot
6. Servi ce
The procedure to download firmware to the machine is depending on the type of

product.
This procedure is always described in the machines Service Manual.
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7. Information Flow
Y Service Manuals
Y Parts Catalogues
Y Modification Bulletin
Y Ricoh Technical Bulletin
Y Ricoh Technical Tip
7. Information Flow
It is very important that the information flow is known in the organisation.

Some information which should be available:
Y Service Manuals
Y Parts Catalogues
Y Technical Bulletins and Notes (CD or hardcopy)
Y Other relevant service related information
For Ricoh distributors there is a document called Customer Service Policy.

In this policy, you will find guidelines and procedures you may require when servicing a
product.
Your service manager knows all about this document.
Ricoh Europe B.V.


Service Manuals
The Serv ice Manual
consists of:
machine description
detailed installation
and service inst ructions
and service tables for
maintenance.
7. Information Flow
The Service Manual consists of:

Y machine description
Y detailed installation
Y and service instructions and service tables for maintenance.
Ricoh Europe B.V.


Parts Catalogues
Landscape la yout
The Parts Catalogue
contai ns:
all parts
part numbers
part descriptions
exploded views of the
machines.
7. Information Flow
As you can see in the slide the layout of the PC is landscape. That means that the top
page shows the part layout and the bottom page shows the details.
The Parts Catalogue contains:
Y all parts
Y part numbers
Y part descriptions
Y exploded views of the machines.
The Service Manuals and Parts Catalogues are issued on a CD ROM. There is a
standard annual fee for the CD ROM and a new update will be sent every 3 (three)
months. If your organisation does not make use of them, then you have to make use of
the hardcopy.
Earlier we discussed that for maintenance the Service Manual and Parts Catalogue are
used to explain all the necessary detail about Preventive Maintenance for the device. In
the PC there is a topic called PM Parts Index, this will give you a nice overview of all the
PM parts for the Machine.
Example:
Ricoh Europe B.V.


Modification Bulletin (MB)
Issued w hen any
modi fication is applied to
a product.
7. Information Flow
A Modification Bulletin (MB) will be issued when any modification is applied to a product.
Part number change, interchange ability, reason for modification and the serial number
of the machine will be provided.
This information can be found on the Technical Documentation database in Lotus Notes
which is normally only used by a product specialist, but the MB’s will also be provided on
the Service Manuals CD ROM’s for each product.
Example:
Ricoh Europe B.V.


Ricoh Technical Bulletin (RTB)
A Ricoh Technical Bulletin
is issued w hen technical
infor mati on is require d in
the field.
7. Information Flow
A Ricoh Technical Bulletin is issued when technical information such as troubleshooting,

modification kits and the latest manual information is required in the field. This
information can be found on the Technical Documentation database in Lotus Notes
which is normally only used by a product specialist, but the RTB’s will also be provided
on the Service Manuals CD ROM’s for each product.
Example:
Ricoh Europe B.V.


Click here for Bulletins
Click here for bulleti ns:

MB’s
RTB’s
7. Information Flow
How to find bulletins.

On the Service Manuals CD ROM’s you can select a product, after you selected a
product there is a possibility to click on bulletins (red text).
Now you have all the MB’s and RTB’s for the selected product in view.
Ricoh Europe B.V.


Ricoh Technical Tip (RTT)
A Ricoh Technical Tip w ill
be issued w hen addi tional
infor mati on in the fiel d is
necessary.
7. Information Flow
A Ricoh Technical Tip will be issued when additional information in the field is
necessary. This information can be found on the Technical Documentation database in
Lotus Notes which is normally only used by a product specialist, RTT’s are NOT
provided on the Service Manuals CD ROM’s.
Ask your instructor or product specialist if this information is distributed in your
organisation.
Example:
Ricoh Europe B.V.


8. Specifications
Y Service Manual
8. Specific ations
The Service Manual will explain all the necessary detail about Specifications for the
device. Normally this is divided in several topics like for instance:
Y General Specifications
Y Machine Configuration
Y Optional Equipment
Also Operating Instructions have a chapter related to Specifications.
Ricoh Europe B.V.


End
Ricoh Europe B.V.


Basic Copier module
for service master
Exercise Functions and features
Functions and Features

1 Objective
'Operate a copy machine
'Understand basic and advanced functions
'Operating Instructions
2 Required materials
'1 copier with ADF and Finisher
'Operating Instructions
'Test charts
3 Overview
1 OBJECTIVE........................................................................................................................................................................................................1
2 REQUIRED MATERIALS............................................................................................................................................................................1
3 OVERVIEW.........................................................................................................................................................................................................1
4 INTRODUCTION .............................................................................................................................................................................................2
5 IMAGING .............................................................................................................................................................................................................2
5.1 IMAGE DENSITY ............................................................................................................................................................................................2
5.2 ENLARGE / REDUCE ....................................................................................................................................................................................2
5.3 PHOTO MODE / TEXT MODE.......................................................................................................................................................................2
5.4 POSITIVE / NEGATIVE .................................................................................................................................................................................2
5.5 IMAGE REPEAT / POSTER MODE................................................................................................................................................................3
6 PAPER SELECTION.......................................................................................................................................................................................3
6.1 INPUT SELECTION ........................................................................................................................................................................................3
6.2 OUTPUT SELECTION ....................................................................................................................................................................................3
7 OUTPUT SELECTIONS................................................................................................................................................................................3
7.1 SAMPLE COPY ...............................................................................................................................................................................................3
7.2 SIMPLEX / DUPLEX ......................................................................................................................................................................................4
7.3 BOOKLET / MAGAZINE ...............................................................................................................................................................................4
8 FINISHING OPTIONS....................................................................................................................................................................................4
8.1 PUNCH ............................................................................................................................................................................................................4
8.2 STAPLE ...........................................................................................................................................................................................................4
8.3 SORT................................................................................................................................................................................................................4
8.4 STACK .............................................................................................................................................................................................................5
Ricoh Europe B.V. Last Modified 06-07-2001

Technical Training Centre
www.get-u-wice.com PAGE 1
4 Introduction
These exercises will help to have a better understanding on how to operate a copier.
These exercises can be done on a standard digital copier but the ADF and Finisher should be installed
to get a better overview of all functions.
It is possible that not all functions are available on your copier, in that case move to the next exercise.
5 Imaging
5.1 Image density
Put an original in the ADF.

Change the image density to the lightest position.
Make a copy.
Put the same original in the ADF.

Change the image density to the darkest position.
Make a copy.
Compare the two copies and see the difference.

To go back to default settings press the cancel button, now your machine settings are back to default.
5.2 Enlarge / Reduce
Put an A4 original on the platen glass.

Select 141% enlargement.
Select A3 from the paper tray and make a copy.
Q1: Does the copy fit on the A3? …………………
Put the just copied A3 on the platen glass.

Select 70% reduction.
Select A4 from the paper tray and make a copy.
Q2: Does the copy fit to A4? …………….
Q3: What is the biggest enlargement setting on your machine? …………………
5.3 Photo mode / Text mode
Put an Original with a photo on the platen glass.

Select photo and make a copy.
Select text and make a copy.
Q4: Which setting is better for copying photo’s, photo or text mode? ……………………………
Q5: What will happen if you select photo mode with a text original? ………………………….
5.4 Positive / Negative
Put an original on the platen glass.

Select Photo mode.
Select positive/negative and make a copy.
Change the density to the darkest position and make a copy again.
Q6: Why is the density setting reversed? ………………….
PAGE 2
5.5 Image repeat / Poster mode
Put an original on the platen glass.

Select 4 pages on 1 sheet and make a copy.
With poster mode the machine will enlarge your image.
If you put all the copies together you get a poster.
6 Paper Selection
6.1 Input Selection
Default the machine is set on Auto paper select.

When an original is placed on the platen glass or ADF the machine will scan its size.
If the original size is known, the right paper from the tray will be selected automatically.
Put an A4 original LEF on the platen glass or ADF.

Select A3 and make a copy.
Put an A4 original LEF on the platen glass or ADF.

Select a paper tray with A4 SEF and make a copy.
Q7: Is the complete image copied or do you miss a part of the image? ………………….
Put an A4 original SEF on the platen glass or ADF.

Select A4 LEF and make a copy.
Put an A4 original SEF on the platen glass or feeder.

Select auto paper select and make a copy.
Q9: Which paper tray did the machine use? ……………….
Put an A4 sheet into the bypass tray.

Put an original on the platen glass or ADF.
Select bypass tray and make a copy.
Q11: Can the machine detect the paper size from the bypass automatically? ……………………
6.2 Output Selection
When a finisher is installed you can select more output bins.

Select the internal tray for the output and make a copy.
Do the same but select a finisher output bin.
Q12: Where did you find these setting? …………………………………….
7 Output Selections
7.1 Sample copy
On the keypad you select the number of copies.

Select 3 copies on the keypad.
Press the sample copy button.
Q13: How many copies are being made? ………………….
The machine will ask print or suspend select print, select print.
Q14: How many copies did come out in total? …………….
PAGE 3
7.2 Simplex / Duplex
The machine wants to know if the original is simplex or duplex.

You can only scan duplex originals when an ARDF is installed.
For the output we can select simplex or duplex.
Put 4 originals in the ADF.
Select for the output duplex and press the start button.
Check if the copies are duplex.
7.3 Booklet / Magazine
The words booklet and magazine do have the same meaning.

The only difference is how to combine the sheets to make a book.
With booklet/magazine it is possible to create a complete book.
After printing we need to do something extra, fold and staple (saddle stitching).
Our machine is not capable to do this operation.
Put 4 numbered (1,2,3,4) A4 originals in the ADF.

Select booklet/magazine and press the start button.
Fold the A3 copy and check that the numbers are in the right order.
Try to make your own magazine.

Place your originals 2 by 2 next to each other on the platen glass.
Select duplex and select the A3 paper tray and press the start button to scan the first two pages.
Now put the other 2 originals on the platen glass and press the start button.
Q15: In which order do you have to put your originals to get the correct page numbering? ……….
8 Finishing Options
8.1 Punch
The punch hole will be made during the paper transportation in the finisher.
The holes will always be on the correct side of the paper unless if you select simplex or duplex.
Put 2 originals in the ADF select duplex and punch.

Press the start button and check if the punch holes are made.
8.2 Staple
Stapling is done in the finisher.

Put two originals in the ADF, select staple and press the start button.
Q16: Will you get a staple if you put only 1 original in the ADF? ……………….
Q17: Is it possible to select staple and punch for the same copy job? ………………….
Q18: If you select staple the sort function will be selected also, why? ………………………
8.3 Sort
Put 3 A4 originals into the ADF.

Check that the paper selection is set to auto.
Select 1 set to copy and press the start button.
Q19: Has the output the same order as the originals? ……………………
Put the same 3 A4 originals into the ADF.

Select 3 sets to copy and press the start button.
Q20: Is the output order still the same as the originals? ………………
Q21: Which function must be selected to get the same order as the originals? ………………
PAGE 4
8.4 Stack
On almost all machines stack is selected automatically if you select sort.
Put 3 originals in the ADF, select stack and press the start button.
Check the output.
End of this exercise.
PAGE 5
Te c h n i c a l Tr a i n i n g M a n u a l
C o p i e r
C o p y P a p e r
G l o s s a r y
2
C o p i e r
Analogue copier
• Copy process overview
• A closer look
Digital copier
• Scanning
• Shading
• Laser Exposure
• Development
3
C o p i e r
Analogue copier
• A closer look
4
C o p i e r
Analogue copier
Step 1 Scanning
An original document is • Copy process overview
placed on the platen glass.
A bright light illuminates the • A closer look
original, and its image is
reflected through the
optical system towards the
photoconductor’s surface.
Step 1
Step 2 Photoconductor
In the dark, the photoconductor receives an electrostatic
charge. This electrostatic charge remains on the photocon-
ductor until it is exposed to light. The charge disappears
on places where light reflected from the original reaches
the photoconductor. Darker parts of the original reflect less
light and there the electrostatic charge will remain on the
photoconductor as the latent image.
Step 2
Step 3 Toner on latent image

After exposure, the remaining charge on the photoconduc-
tor will attract toner when the charged areas pass the
development unit.
Step 3
Step 4 Transfer to paper

The paper is fed through the machine and is synchronised
with the image on the photoconductor.
The toner on the photoconductor is transferred to the paper
by an electrostatic charge applied to the back of the paper.
Step 4
Step 5 Fusing
Paper is fed between two rollers and a combination of
heat and pressure permanently melts the toner into the
copy paper.
Step 5
5
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Process around the photoconductor •
Paper feed and registration •
Fusing •
A. Scanning
The original document is placed on the platen glass
either by hand or automatically via a document feeder.
B. Absorbing
The exposure lamp illuminates the original. Light areas
on the original reflect light, and dark areas absorb light.
C. Exposure to photoconductor
The light reflected from the exposed original now must travel
through the optical system. Light areas remove the charge
from the photoconductor surface. Dark areas leave the
charge in place. The difference in charge creates an electro-
static copy of the original image, also known as the latent
image, on the photoconductor.
6
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Fusing •
D. Lens
The lens gathers and focuses the reflected light onto the
photoconductor surface. It is situated in the middle of the
optical path for making copies that are the same size as
the original.
E. Enlargement
The image is enlarged if the lens is positioned closer to
the original. This action enlarges the image over the width
of the photoconductor. In order to enlarge the image around
the entire photoconductor, the copier reduces scanner speed
while maintaining the same photoconductor speed. The third
scanner is moved to keep the image in focus on the photo-
conductor.
E
F. Reduction
The image is reduced if the lens is positioned further away
from the original. This action reduces the image over the
width of the photoconductor. In order to reduce the image
around the entire photoconductor, the copier increases
scanner speed while maintaining the same photoconductor
speed. The third scanner is moved to keep the image in
focus on the photoconductor.
7
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Fusing •
A photoconductor is made of light-sensitive material.

In the dark it acts as an isolator, keeping the charge by not
allowing any electric flow. When exposed to light, the photo-
conductor acts as a conductor and loses the electric charge.
Non-image areas on the original reflect light onto the photo-

conductor, discharging that area. Such areas will not attract
toner. Image areas on the original do not reflect light onto
the photoconductor and, thus, attract toner.
Photoconductors come in the form of belts and drums.

There are two types:
- Selenium photoconductors are positively charged and

Belt attract negatively charged toner.
- OPC (Organic Photo Conductor) photoconductors are

negatively charged and attract positively charged toner.
OPCs are safer to handle than other varieties, some of
which are made from toxic materials.
The type of photoconductor most widely used with

Drum Ricoh copiers is a cylindrical OPC drum.
8
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Fusing •
A combination of layers forms the photoconductor.

Substrate The main layers of the photoconductor are the:
1. Substrate
Under layer 2. Under layer
3. Charge generation layer
4. Charge transfer layer
Charge generation layer
The Substrate is the base for the other layers and is
Charge transfer layer made of aluminium. It is a good conductor and provides
the electrical grounding for the photoconductor.
The Under layer is a super-thin layer that maintains a

charge by preventing electrons from moving too easily to
the Substrate, giving the base a better grip on the next layer.
The Charge generation layer isolates the charge build-up in

the Charge transfer layer in the dark, but when exposed to
light it conducts the charge to the grounded Substrate.
The Charge transfer layer is very similar to the Under layer

because it, too, prevents electrons from moving too easily
to the Charge generation layer. In addition, it acts as a trap
for the electrostatic charge.
9
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Process around the photoconductor • CHARGE
EXPOSURE
Paper feed and registration • DEVELOPMENT
TRANSFER
Fusing • SEPARATION
CLEANING
QUENCHING
Process around the photoconductor

When copying, several processes take place. The process
around the photoconductor is a crucial element of the copy-
ing procedure. The following are the key components of this
process explained in more detail.
10
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Process around the photoconductor • A CHARGE
EXPOSURE
TRANSFER
CLEANING
QUENCHING
A. Charge
A1
The charge circuit applies a uniform charge to the photocon-
A1 ductor surface. Most copiers use a high negative DC voltage
brought into contact with the air by a very thin, un-insulated
wire called a corona wire.
A2
When high negative voltages are applied to the corona wire,
the air around the wire becomes negatively charged. A nega-
tive voltage on the corona wire means there is an excess of
electrons on it. The corona wire releases some electrons to
the air molecules around the corona wire. These negatively
A2 charged air molecules are known as negative ions.
When a negative ion approaches the Charge transfer layer,
an electron is released to this layer. At this time, the Charge
transfer layer receives a negative charge. Since the OPC
photoconductor does not conduct in the dark, this layer
remains charged until exposed to light. A charge fan makes
sure the ions evenly charge the photoconductor.
A2
A3
A grid is used to control the amount of charge that reaches
the photoconductor. Whereas a very high voltage on the
corona wire is needed to create ions, the charge needed
on the photoconductor is much lower. A grid bias voltage
ensures that a certain amount of charge reaches the
photoconductor, and the excessive charge is conducted
to ground.
A3
A4
Some photoconductors are charged with the help of a
conductive charge roller. The charge roller directly charges
the photoconductor.
A4
11
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
B EXPOSURE
TRANSFER
CLEANING
QUENCHING
B. Exposure
During exposure, the charged photoconductor is exposed to

light reflected from the original.
Light areas remove the charge from the surface. Dark areas
leave the charge in place. The differences in charge create
an electrostatic copy of the original image on the photocon-
ductor, also known as the latent image.
Besides white and dark areas there are also many shades of
grey. These areas partly discharge the photoconductor. This
means these areas attract toner in proportion to the density
of the original.
12
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
EXPOSURE
Paper feed and registration • C DEVELOPMENT
TRANSFER
CLEANING
QUENCHING
C. Development
In the development stage, toner is transferred to the latent

image on the photoconductor. The latent image is developed
when negatively charged areas attract positively charged toner.
There are two basic types of development:
1. Mono-component development
2. Dual-component development
Mono-component development
Mono-component developer consists only of toner. The toner
itself consists of resin and ferrite. Ferrite gives the toner
magnetic characteristics. The toner comes into contact with
the latent image on the photoconductor surface, and the
charged areas attract toner.
Dual-component developer
Most copiers use a dual-component development system.
The first component is carrier, an iron-based material that is
attracted to magnets in the development roller. Carrier stays
Toner and Carrier
in the development unit during the copy process. The second
component is toner. Toner is the fine powder that gives the
image its color.
Inside the development unit toner and carrier are mixed
together to form developer.
The mixing action gives the toner a positive electrical charge,
which allows the toner to be attracted to the negative latent
image.
During development the photoconductor comes in contact

with the developer on the development roller. The carrier
stays in the development unit and the toner is attracted to
Mono-component
the latent image. The ratio of toner to carrier must be kept at
a proper level to maintain constant copy quality.
Dual-component
13
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
EXPOSURE
D TRANSFER
CLEANING
QUENCHING
D. Transfer
The transfer function moves the toner from the developed

image on the photoconductor surface to the passing
copy paper.
As paper is fed past the photoconductor a high charge

is applied to the back of the copy paper. This charge is
stronger then the latent image on the photoconductor
and attracts toner onto the paper.
There are two ways to charge the paper:
1. By using a transfer corona
2. By using a transfer belt
14
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
EXPOSURE
TRANSFER
Fusing • E SEPARATION
CLEANING
QUENCHING
E. Separation
After transferring the image from the photoconductor to the

passing paper, the paper must be separated from the photo-
conductor surface and transported to the fusing unit.
A separation corona applies an AC current to the paper to

neutralise the paper charge. If a transfer belt is used a sepa-
ration corona is not necessary.
With the force of attraction neutralised, the paper’s own

stiffness usually separates it from the photoconductor.
Pick-off pawls mechanically separate the paper from the

photoconductor if electrical separation was unsuccessful.
Pick-off pawl
Separation Corona
15
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
EXPOSURE
TRANSFER
F CLEANING
QUENCHING
F. Cleaning
After transfer and separation we finally have something that

looks like a copy. Nearly all the toner has transferred to the
paper, but a very small amount remains on the photoconduc-
tor and must be removed by the cleaning system.
A rubber-cleaning blade contacts the photoconductor surface.

The remaining toner is gently scraped off the photoconductor
surface by the cleaning blade. Sometimes a cleaning brush
is used in combination with a cleaning blade.
16
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
EXPOSURE
TRANSFER
CLEANING
G QUENCHING
G. Quenching
After cleaning, the toner is gone but the latent image is still
there. At this point the charge is slightly weaker than it was
immediately after exposure, but it is still strong enough to
pick up toner during development. Light from the quenching
lamp discharges any electrical potential on the photoconduc-
tor’s surface.
17
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Fusing •
Paper feed and registration
There are different systems used to feed paper through a

copier. All paper-feed systems are based on the different
friction between feeding system and paper.
When the feed roller starts feeding the top sheet into the
copier, sometimes the sheet underneath sticks to it. The top
sheet has to be separated from the bottom sheets.
The two most common feed systems are:
1. A feed roller and a friction pad
2. The Feed and Reverse Roller system (FRR)
A (friction)
A cork friction pad is used to hold the bottom sheet back
while just the top sheet is fed. The friction between the cork
pad and the bottom sheet is larger then the friction between
the sheets of paper.
B (FRR)
A
The feed and reverse roller system uses three rollers. The
pick-up roller feeds the sheet of paper. The reverse roller is
driven in reverse through a slip clutch. The reverse roller will
feed the bottom sheet back because the friction of the slip
clutch is larger than the friction between the sheets of paper.
If there is only one sheet between the feed and the reverse
roller, the clutch will slip and the reverse roller will rotate in
the feed direction.
Transfer roller Pick-up roller
Reverse roller
18
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Fusing •
C (Registration)
The registration rollers have two functions. The first is to
correct for skew. Skew means that the paper’s leading edge
is not parallel to the drum. The feed rollers push the paper
against the registration rollers and create a buckle, causing
the leading edge of the paper to align with the registration
rollers. The second function of the registration rollers is to
align the paper with the image on the photoconductor.
The registration rollers start to feed the paper when the reg-
istration clutch is energised. The copier’s electronic circuits
control the clutch.
19
C o p i e r
Analogue copier
Scanning •
Photoconductor •
• A closer look
Fusing •
Fusing
Paper is fed into the fusing section between a hot roller and
a pressure roller to fuse the toner into the paper. At power
up the CPU turns on the fusing lamp, warming the hot roller.
The lamp is turned on and off to maintain the proper temper-
ature based on the signal of a thermistor.
A thermofuse gives back-up protection against overheating.
When the front cover is opened, safety interlock switches
shut off the power to the fusing unit.
20
C o p i e r
Digital copier
A digital scanner and a laser printer are the two

fundamental elements of a digital copier. The
digital copying process consists of four steps.
First, a document is scanned to a Charge There are several important differences
Coupled Device (CCD). Next, the analogue between analogue and digital copying. To begin
information from the CCD is converted into digi- with, digital copiers are capable of more features
tal information. The digital information is then than analogue copiers. Once the document is
sent by the Image Processing Unit (IPU) to the turned into digital information, various image
laser for writing on the photoconductor. quality-related and sorting features are possible.
Another difference is in the development
process. Analogue copiers use positive toner
that is attracted to a negatively charged latent
image, whereas digital copiers contain nega-
tive toner that is attracted to a less-negative
latent image.
21
C o p i e r
Digital copier
• Scanning
• Shading
• Laser Exposure
• Development
22
C o p i e r
Digital copier
• Scanning
• Shading
• Laser Exposure
• Development
Step 1
During scanning the original document is illuminated by
an exposure lamp. To scan the original, either the docu-
ment or the lamp must be moving. In most digital copiers
the document remains stationary on the exposure glass
during scanning.
Step 2
Some machines use a stationary scanner and the docu-
ment is moved past the exposure lamp during scanning.
Step 3
Light from the original is reflected through mirrors and
a lens to a Charge Coupled Device (CCD). The CCD
is a row of small photocells also referred to as picture
elements, or pixels. They convert the light reflected from
the original into an electric charge.
Step 4
The charges are stored as a separate voltage level for
each pixel. These voltages are output serially from the
CCD as analogue image signals. These signals are
amplified and converted from analogue to digital.
Each electric charge from the CCD is converted into
a digital value based on its voltage level.
4
23
C o p i e r
Digital copier
• Scanning
• Shading
• Laser Exposure
• Development
Step 5
The digital signal is sent to the Image Processing Unit
(IPU). The signal can be manipulated to perform features
that are not possible on analogue machines. Digital
processing is also used to compensate electronically
for limitations of various components.
Two examples are smoothing, which enhances reproduc-

tion of greyscales, and the Modulation Transfer Function
MTF
(MTF) which improves fine details.
Features
Smoothing
24
C o p i e r
Digital copier
• Scanning
• Shading
• Laser Exposure
• Development
In digital copiers, Auto Shading must be performed before

an original document is scanned.
Auto Shading compensates for variations in the output of
each individual photocell. Such variations are caused by
the different sensitivities of individual photocells, optical
distortions and the fact that the fluorescent lamp is brighter
at its centre than it is at its ends.
There are two Auto Shading processes:

1. White Shading
2. Black Level Correction
White shading and Black Level Correction eliminate distor-

tions by ensuring that the signals received from every
photocell in the CCD contain only image data.
White shading is performed with the exposure lamp on.

Light reflected from the white reference plate generates a
charge in every photocell. The CCD outputs are adjusted
to the same white level during white shading. This correction
is stored in RAM, and the output of the photocell is modified
during every main scan.
Black Level Correction is done with the lamp off. Since no

light is being reflected to the CCD, all photocells should
generate zero volts. Black Level Correction stores in RAM
the voltage level of any photocell that generates a charge.
That voltage level will be subtracted from the output of the
photocell during each main scan.
25
C o p i e r
Digital copier
• Scanning
• Shading
• Laser Exposure
• Development
Based on the digital image data, the laser diode turns on

and off to illuminate areas of the photoconductor via a rotat-
ing polygon mirror and lenses. Each surface of the polygon
mirror reflects one horizontal line, or main scan, of the laser
across the photoconductor’s surface. The polygon mirror is
driven at a very high speed.
The charge is reduced on the illuminated areas of the pho-

toconductor. The pattern of low and high voltages on the
photoconductor is referred to as the latent image.
In analogue copiers the non-image areas are exposed to

light. In digital copiers the image areas are exposed. This
is called write-to-black. In digital copiers toner has a high
negative charge. The negative toner is transferred to the
discharged areas of the drum.
The laser also hits a synchronisation detector. This gives

the starting signal to write the data to the photo conductor.
The laser light is kept in focus by a lens between the polygon

mirror and the photoconductor’s surface. The f-theta lenses
assure proper spacing of the pixels on the photoconductor.
Lighter or darker shades of grey are produced by changing
both the laser power and the time the laser stays on for
each pixel.
26
C o p i e r
Digital copier
• Scanning
• Shading
• Laser Exposure
• Development
The areas exposed by the laser attract toner. The toner

used in digital copiers is negatively charged and is attracted
to the areas discharged by the laser because they are
more positive.
27
C o p y p a p e r
Paper sizes
Paper weight
Paper grain
Paper curl
Front and back

sides of paper
28
C o p y p a p e r
Paper sizes
Metric Paper
Letter Paper
There are two main paper sizes:

Metric paper and Letter paper.
• Metric paper has two sizes: A size and B size.
An example of A size paper is A3.

An A3 sheet is 297 by 420 millimeters.
An A3 sheet is the same size as two A4 sheets.
An example of B size paper is B4.

The size of a B4 sheet is 257 by 364 millimeters.
A B5 sheet is half the size of a B4 sheet.
A
size
B
size
dA4
210 mm
297 mm
d B4
257 mm
364 mm
A5 148.5 mm B5 182 mm
A3 297 mm
A5 B5
420 mm 210 mm
257 mm
• Letter paper is defined in inches.

letter 11 inch A letter sheet of paper is 8.5 by 11 inches
and is wider than A4.
Double Letter or Ledger is 11 by 17 inches.
8.5 inch
Legal size is 8.5 x 14 inches.
Double letter 11 inch
17 inch
29
C o p y p a p e r
Paper weight
Paper weight is specified in grams per square meter (g/m2)

or in pounds (lb). For example, 100 gram paper weighs 100
grams per square meter; 20 lb paper means that 500 sheets
of paper weighs 20 pounds. Plain paper copiers normally
use 20 lb paper in North America and the U.K., and 80 gram
paper in most other places. Colour copiers commonly use 24 lb
paper in North America and the U.K., and 100 gram paper in
most other places.
500 sheets
100 grams
1 meter
1 meter
30
C o p y p a p e r
Paper grain
The direction of fibers in the paper is known as the grain and

is either along the long edge of the paper or along the short
edge of the paper. Paper is stiff along the direction of the grain.
Grain along the long edge of the paper is called long grain.
Grain along the short edge of the paper is called short grain.
The paper grain should be in the same direction as the paper
feed because then it easily separates from the photoconductor.
To check the grain, fold a piece of paper. Once it is folded,

open it and check the back of the paper. If the paper is folded
in the same direction as the paper grain, the folded line is a
clear line. If not, it is a wrinkled line.
Fibers
f
31
f
C o p y p a p e r
Paper curl
Excessive paper curl can cause paper jams, separation

problems and mis-feeds. Paper curl also limits the amount
of paper that can be stacked on the exit tray or sorter.
There are several causes for paper curl. Humidity causes

paper curl because of moisture. The fusing stage also
causes heat curl because of high temperatures.
To check paper curl direction, moisten a piece of paper.

The fibers become thicker when exposed to humidity, meaning
the paper will stay straight in the direction of the grain and
curl on the sides.
32
C o p y p a p e r
Front and back sides of paper
There are some differences between the front and back

sides of paper. A higher density of fibers makes the surface
of the front side smoother. The higher density also causes
the front side to expand more compared to the back.
The arrow on the paper package shows the side of paper

that should receive the image.
Paper
Paper
33
G l o s s a r y
AGITATOR
a type of mechanical mixing device; used in copiers in the toner supply to keep toner particles separated;
also used in the development unit to combine toner and carrier, creating two-component developer.
ALTERNATING CURRENT (AC)

a type of electrical flow (current) which reverses its direction of travel according to some regular cycle.
ALUMINIUM OXIDE
a chemical combination of aluminium and oxygen; used as an intermediate layer between the structural
aluminium base and the light-sensitive selenium layer in selenium photoconductors, providing a better
bond than is possible between selenium and metallic aluminium.
AMORPHOUS SILICON
a photoconductive material used in some copiers; it offers a durable surface, is highly sensitive to light,
and can produce copies with excellent resolution.
ANALOGUE METER
an electronic instrument used to measure electrical voltage, current or resistance, which displays an individ-
ual reading using a needle that moves along a calibrated scale; good for detecting transients or “spikes” in
current flow. (See also DIGITAL METER)
AUGER
a screw-type mechanical transport device used to move bulk materials in many different applications; relies
on a large screw with deep, wide-pitched threads turning inside a close-fitting cylinder-the threads act like
an endless scoop or wedge to lift material from one end of the cylinder to the other; used in some copiers to
transport used toner from the cleaning unit to the development unit for reuse or to a used toner storage area.
BIAS
an electrical signal applied to a given component to achieve a specific controlling effect over that component's
performance; AC and DC bias signals of widely differing voltages, currents and frequencies are commonly used
in tape recorders, radios and copiers.
BIAS CIRCUIT
used in a copier's development system to control image density and prevent toner background on copies;
creates a certain amount of electrical attraction at the surface of the development roller, thereby controlling
the amount of toner which transfers to the latent image.
BASE BOARD
part of the OPC which develops the counter charge to the charge developed on the Charge Transfer Layer (CTL);
made of either aluminium drum, nickel or polyester film.
BIAS ROLLER
used in a copier's cleaning system to apply an electrical charge to the cleaning brush; this charge helps the
brush loosen toner particles more effectively than it could with mechanical action alone.
(See also CLEANING BRUSH)
BLOCK DIAGRAM
a kind of electronic map that divides a system into a number of functional “blocks”; it shows all the intercon-
nections among the blocks, but generally does not show detail inside them.
BOND
a category of papers consisting of many individual types; most bond papers are suitable for use in
plain-paper copiers.
BRIGHTNESS
the quality of light that refers to its ability to carry more or less energy- the brighter the light, the more energy
is involved; also referred to as intensity.
34
G l o s s a r y
CARRIER
one of the components of two-component developer; carrier consists of tiny iron-based beads; the beads
attract toner particles through a triboelectric charge and transport them to the photoconductor during the
development process. (See also TRIBOELECTRIC CHARGE)
CENTRAL PROCESSING UNIT (CPU)

a microprocessor chip or other Very Large Scale Integrated Circuit (VLSI), used as the primary control
and information processing device in a sophisticated electronic system; CPU chips are commonly found
in personal computers, fax machines and copiers.
CHARGE
the first step in the copy process; during the charge process, an even electrical charge is applied to the
photoconductor, preparing it to receive the image of an original during exposure; usually accomplished
with a corona unit.
CHARGE COUPLED DEVICE (CCD)

a solid-state component made from a number of very small light-sensitive elements; the amount of light
falling on each element produces an electrical signal of corresponding strength; CCDs are used in laser-
based copiers, fax machines and some television cameras.
CHARGE GENERATION LAYER (CGL)

part of the OPC which generates the charge from the absorption of light; generally made of azo pigments and
plastic binders (Analogue and digital OPCs have different colour pigments; in analogue OPCs the pigment is
a dark blue color; digital OPCs have a green pigment.)
CHARGE TRANSFER LAYER (CTL)

one of the layers of the OPC; the charge generated in the Charge Generation Layer (CGL) is transmitted through
this layer to the surface of the photoconductor; generally made of organic additives and a plastic binder.
CLEANING
that step in the copy process during which residual toner particles, those left behind after image transfer, are
removed from the photoconductor; relies on mechanical systems to remove toner from the surface, and either
contain it for disposal or recycle it in the development unit. (See also QUENCHING)
CLEANING BLADE
the secondary element in a copier's cleaning system; after a copy has been made, the cleaning blade acts like a
windshield wiper, riding along the surface of the photoconductor to scrape off all remaining toner particles.
CLEANING BRUSH
the primary element in a copier's cleaning system; after a copy has been made, the round cleaning brush
removes most of the residual toner from the surface of the photoconductor. (See also BIAS ROLLER)
CLUTCH
a control device for rotational movement; a clutch will either be engaged, locking its components together and
transferring rotation, or disengaged, letting its components turn separately and preventing the transfer of rotation.
CLUTCH, MAGNETIC
a type of clutch which contains its own electromagnetic actuator; when the clutch’s coil is energised, two
metal plates are pulled together and transmit rotation to a given component-when not energised, the two
plates are separated by a spring, and no rotation is transmitted.
CLUTCH, SPRING
a popular clutch for copier applications; its internal components are normally held together by a spring
connected to an external sleeve, and rotation is transmitted to a given component-when the sleeve is kept
from turning, the spring expands, releasing one internal component and preventing the transfer of rotation.
35
G l o s s a r y
CORONA UNIT
a copier component that uses a high electrical voltage to create a localised electrical field of charged ions;
various kinds of corona units are used at different points in the copy process.
CORONA WIRE
a thin wire, usually made from tungsten and coated with gold or carbon; mounted inside a corona unit, it
carries the high voltage needed to generate an electrical field for a specific copier application.
CORONA, CHARGE
a corona unit used for the first step in the copy process, to apply an even high-voltage charge to the photo-
conductor; usually ventilated by a blower to help distribute ions during charging.
CORONA, PRE-CLEANING
a corona unit used at the end of the copy process; it creates an electrical field that reduces the charge on
the photoconductor before mechanical cleaning, making it easier to remove leftover toner.
CORONA, QUENCHING
a corona unit used at the end of the copy process; it creates an electrical field to help remove latent image
charge on the photoconductor after mechanical cleaning, preparing the surface for the next copy cycle;
always used in conjunction with a quenching lamp.
CORONA, SEPARATION
a corona unit used immediately after Transfer; it creates an electrical field which releases the paper, together
with the developed toner image, from the photoconductor.
CORONA, TRANSFER
a corona unit used immediately after Development; it creates an electrical field which pulls the developed
toner image away from the latent image on the photoconductor, transferring it to a sheet of paper.
CROSS MIXING
the process by which toner and carrier are mixed together inside a copier; also creates and distributes the
triboelectric charge that binds the toner to the carrier particles.
CURRENT
the rate of flow of electricity through a conductor; current is measured in Amperes, or Amps.
DEVELOPER, MONO-COMPONENT
a special toner formulation that has both magnetic and electrical properties; functions without carrier.
DEVELOPER, TWO-COMPONENT
the most popular developer formulation; uses tiny, magnetic carrier beads to deliver much smaller toner
particles to the photoconductor during the development process.
DEVELOPMENT
that step in the copy process which first produces a visible image on the photoconductor; during development,
toner is applied to the photoconductor, where it is electrically attracted to the latent image formed during exposure.
DEVELOPMENT ROLLER
part of a copier's development system; relies on some combination of magnetism, triboelectric charge and/or
bias voltage to apply toner to the latent image on the photoconductor.
DIFFUSION TRANSFER
a photographic technique that uses a camera to produce an image on a special light-sensitive master; the
master is chemically developed and pressed against a transfer sheet, on which is produced a single high-quality
copy of the original.
36
G l o s s a r y
DIGITAL METER
an electronic instrument used to measure electrical voltage, current or resistance, which displays an individual
reading as numerals on a LCD or LED display; good for showing specific measurements of circuit parameters
with a high degree of accuracy. (See also ANALOGUE METER)
DIRECT CURRENT (DC)

a type of electrical flow (current) which maintains a constant direction of travel according to a fixed polarity-
DC flow is always from negative to positive.
DOCTOR BLADE
part of a copier's development system; limits the thickness of developer picked up by the development roller,
by scraping off the excess as the roller turns; its precise position over the roller determines the height of the
magnetic brush. (See also MAGNETIC BRUSH)
DOCMENT FEEDER, AUTOMATIC (ADF)

a motorised device that allows automatic feeding, alignment and stacking of multiple originals, greatly improving
the overall efficiency of photocopying; also known as an Automatic Document Handler (ADH).
DUPLEX UNIT
a paper-handling device that permits the making of two-sided copies without manual intervention by the user;
available through the installation of a peripheral duplex unit on mid-size copiers, duplexing is a standard feature on
most high-volume machines.
E-STAT
an early electrostatic copy process; uses electrical charges to form and develop an image directly on chemically-
treated, light-sensitive paper, using no intermediate photoconductor.
EDITOR BOARD
a sophisticated copier peripheral that lets the user manipulate the latent image on the photoconductor;
controls a group of erase lamps to remove selected parts of the image before development.
ELECTRICITY
a form of energy consisting of electrons travelling at close to the speed of light in a suitable conductor,
or present as a static field around an electrified object; can produce such effects as attraction, repulsion,
heating and illumination.
ELECTRON
the smallest subatomic particle, existing in orbit around a nucleus composed of protons and neutrons;
an atom normally has the same number of electrons as it has protons; when the number of electrons is either
higher or lower than normal, the atom gains an electrical charge and is said to be “ionised”. (See also ION)
ELECTROSTATIC CHARGE
an electrical phenomenon in which a static (non-flowing) charge is created on an object or material by
the presence of an electrical field; such a field is typically composed of ionised atoms and molecules
spread out some distance from a source of electrical power. (See also ION, ELECTRON)
ERASE LAMP
a component which removes certain parts of the latent image after exposure; after considering reproduction
ratio and paper size, the main control board turns on specific sections of the erase lamp to remove the
charge from the photoconductor outside the desired image area.
EXIT ROLLERS
part of a copier's paper feed system; a set of two rollers which push a finished copy from the fusing system
into the exit or "copy" tray, outside the machine.
EXPOSURE
that step in the copy process that produces an invisible “latent” image on the photoconductor; can use lenses,
mirrors, light guides and other components to produce a sharp and accurate copy.
37
G l o s s a r y
EXPOSURE LAMP
part of a copier's exposure and optical systems; provides the necessary illumination to create a reflected
image from an original, which in turn creates an electrical latent image on the photoconductor; can be a
quartz-halogen incandescent, fluorescent, or xenon flash design.
FEED ROLLER
the first roller to handle paper in a copier's paper feed system; pulls individual sheets from a paper supply,
feeding them into the copier where they are passed to other rollers in the paper path.
FIBER OPTIC
a flexible glass or plastic fiber designed to conduct light like a wire conducts electricity; also refers to components
and systems which utilise such fibers as an integral part of their function, as in “a fiber optic lens”; used in the
exposure systems of some copiers. (See also LIGHT GUIDES)
FOCAL LENGTH
the characteristic of a lens that determines the distance at which it produces a sharply focused image;
also determines the size of that image.
FOCUS
the characteristic of a lens or optical system that describes its ability to produce a clear and sharply defined
image; also refers to the adjustment of a lens or optical system to produce such an image.
FRICTION
a mechanical effect which causes surfaces in direct contact to resist moving in relation to each other; enables
an object whose surface is in contact with another object to affect that object's motion, even though the two
surfaces are not actually attached to each other; an important consideration in copier paper feed systems.
FRONT SURFACE MIRROR

part of the exposure system in most copiers; coated with metallic reflective material on the side facing into
the optical path, enabling them to produce sharp, high-resolution reflections suitable for optical use.
FUSING
that step in the copy process that bonds toner to a sheet of paper; uses heat and pressure to melt toner and
force it into the paper surface, creating a copy that meets or exceeds the durability of the original.
FUSING LUBRICATION SYSTEM

part of a copier's fusing system, needed to keep toner from sticking to the fusing rollers; uses an absorbent
pad and a blade to coat the rollers with silicone oil.
GRAY SCALE
a row of small test patches showing a full range of image density, from solid black to paper white, usually in five
to ten steps; printed on a copier test chart as a gauge of a machine's side-to-side and overall image density.
GRID PLATE
part of the charging system in copiers that use an Organic photoconductor (OPC); OPCs are more sensitive to
high voltage charges, so the grid plate acts as a regulator between the OPC surface and the charge corona.
HOT ROLLER
the part of a copier's fusing system that contains the fusing heat source, usually an incandescent lamp;
the hot roller is usually made of Teflon, and works in conjunction with the pressure roller.
IMAGE DENSITY
the quality of an original or copy that describes its relative lightness or darkness; high image density refers
to a very dark copy, low image density refers to a very light copy.
38
G l o s s a r y
IMAGE DENSITY CONTROL

the system in a copier that compensates for the variation in reflectivity among different originals; some adjust
the brightness of the exposure lamp, others regulate toner transfer during development, by adjusting a bias
circuit; in either case, image density controls can be manual, automatic or both.
ION
an atom or molecule that has other than its normal number of electrons, causing it to have an electrical
charge; an atom that gains excess electrons has a negative charge and is known as a negative ion-an atom
that loses electrons has a positive charge: a positive ion; a localised cloud of ions constitutes an electrical
field. (See also ELECTRON)
JITTER BANDS
long bands of fine dots or lines printed on a copier test chart as a gauge of “jitter”, unsteady scanner or paper
movement; white bands across the jitter bands indicate a sticking scanner-black bands mean unsteady paper
movement during transfer.
LARGE CAPACITY PAPER TRAY

a copier peripheral; holds a much greater amount of paper than a standard tray, thereby enabling the copier
to run for longer periods without the supply being refilled; typically holds between 500 and 3,000 sheets.
LASER
an acronym for Light Amplification through Stimulated Emission of Radiation, which refers to a device that
produces an extremely accurate beam of coherent light; used in some copiers to “write” an image on the
photoconductor, instead of reflecting and focusing one with conventional optics; very effective for producing
a visual pattern from electronic information.
LATENT IMAGE
a photographic term which refers to an undeveloped image on a piece of film; in xerography, it refers to
the invisible, electrostatic image formed on the photoconductor during exposure.
LATERAL REVERSAL
an optical effect in which left and right perspectives are reversed, commonly perceived in the reflections from
mirrors; a “mirror image” effect.
LEAD EDGE
the edge of a sheet of copy paper which first contacts the latent image on the photoconductor; the “front
edge” of a copy as it travels trough the paper path.
LEAD EDGE ERASE

the removal of that portion of a latent image which corresponds to a narrow strip along the lead edge of the
copy, usually no more than 5 mm wide; achieved through the action of an erase lamp immediately after the
exposure process, to prevent a dark line from the edge of the original document from appearing on the copy.
LIGHT GUIDES
bundles of glass or plastic optical fibers used in some copiers instead of a lens-and-mirror optical system;
light guides are effective for exposure in a moving-platen copier, but are unsuitable for use with a moving
scanner.
LIGHT SHOCK
a condition that occurs in a photoconductor that has had prolonged exposure to ambient room light; can
sometimes be corrected by a period of recovery time in darkness, but in severe cases can render the photo-
conductor permanently insensitive to light.
LIQUID TONER TRANSFER (LTT)

a process whereby the photoconductor drum is immersed in a shallow bath of liquid developer, from which
toner particles are attracted to the latent image; the particles in liquid toner are much smaller than those in
dry toner, providing higher resolution on copies.
39
G l o s s a r y
MAGNETIC BRUSH
a localised concentration of two-component developer formed on the surface of a development roller by magnetic
fields; brushes developer over the photoconductor during the development process, so that toner particles in the
brush can be attracted to the latent image.
MAGNETIC FIELD
a localised area of influence surrounding a magnet or electric current, which manifests itself as a force
on nearby magnetic or other iron-based objects; attracts all iron-based objects; attracts or repels magnetic
objects depending on their orientation to the field.
MAGNIFICATION LINES
two lines of an identical specified length, one vertical and one horizontal, printed on a copier test chart;
used to check the vertical and horizontal magnification of a copier’s optical system.
MAIN CONTROL BOARD

a printed circuit board containing the most important components in a copier's electronic control system,
including the Central Processing Unit, and factory-programmed instructions stored on a Read Only Memory
chip; the main board is linked to other parts of the control system with a number of multi-wire connectors.
MOVING PLATEN
a type of scanning optical system in which originals are placed on a glass document surface (the platen)
which moves across a fixed exposure slit and lamp during an exposure; found only on relatively small,
low-speed copiers.
MOVING SCANNER
a type of scanning optical system in which originals are placed on a fixed glass document surface, under
which is a moving lamp and mirror assembly (the scanner)-this scanner moves under the original during an
exposure; found on most medium-to-high speed copiers; this design is also known as “fixed platen” scanning.
MULTIMETER
an instrument designed to take a variety of electrical measurements for virtually any type of equipment;
sometimes called a Volt-Ohm Meter or VOM. (See also ANALOGUE METER, DIGITAL METER)
ORGANIC PHOTOCONDUCTOR
a type of photoconductor based on certain organic chemicals, rather than metallic elements like selenium
or silicon; requires negative charging before exposure; is generally non-toxic, enabling it to be handled and
disposed of more easily than selenium types.
OVER-TONING
a condition that occurs when a copier’s toner supply system is delivering too much toner to the development
unit; the excess toner builds up inside the copier, especially around the photoconductor and paper path.
PADDLE ROLLER
found in a copier’s development unit; pushes charged developer (a mix of toner and carrier) against the
development roller, which picks up the developer through magnetic attraction and brushes it over the latent
image.
PAPER CURL
the characteristic of paper that makes it tend to curve slightly in one direction, due to its original placement on
a large roll during the manufacturing process; in a copier, paper should always be loaded with the curl away
from the photoconductor drum.
PAPER FEED SYSTEM

the various rollers, belts, sensors and control devices that are responsible for moving sheets of paper through
the copier; begins with the paper supply, and ends with the exit tray or sorter that holds the finished copies.
40
G l o s s a r y
PARALLEL CIRCUIT
a type of electrical connection in which components each have a direct, independent path to a power source.
(See also SERIES CIRCUIT)
PHOTOCONDUCTOR
a special material that reacts in certain ways to light and electricity, acting as an insulator in darkness and as
a conductor when exposed to light; selenium is the most popular photoconductive material used in modern
copiers, although other organic and inorganic compounds are also used.
PHOTOINTERRUPTERS
electronic sensors that have a photocell and a Light Emitting Diode (LED) on either side of a small gap;
when a tab on a moving component enters the gap, it blocks the light from the LED, shutting of the photocell
and signalling the component's position to the copier's Main Control Board.
PICK-OFF PAWLS
part of a copier's separation system; providing a mechanical separation method, pick-off pawls ride along
the surface of the photoconductor to peel off any paper not removed electrically by the separation corona.
POINT-TO-POINT DIAGRAM
a kind of electronic map, specially designed for troubleshooting equipment with replaceable circuit boards;
combines features of a schematic drawing and a block diagram, concentrating on connections to and from
different components.
POLARITY
the quality of electricity that describes its tendency to exist in either a positive or negative state; in most
electrical circuits, polarity determines the direction of current flow; in electrostatic charges, polarity indicates
the charge of ions which make up an electrical field, and therefore determines the polarity of materials which
can be attracted by that field-a charge of a given polarity always attracts materials of the opposite polarity.
POWER
the quality of electricity that measures its ability to perform work; also the specification of an electrical component
that measures the amount of energy it consumes; power is measured in Watts.
POWER PACK
a copier component that produces a very high DC or AC voltage needed to create an electrical field for a specific
part of the copy process; power packs are required for the charge, development, transfer and separation processes,
and sometimes for cleaning; power pack output will vary in different copiers but is usually about 5,000 Volts.
PRE-TRANSFER LAMP
used in some copiers to reduce the charge of the latent image after development, weakening its attraction
just enough to assure a clean transfer; also prevents toner particles from being attracted back to the photo-
conductor during separation.
PRESSURE ROLLER
part of a copier's fusing system; during fusing, toner is forced into the surface of the paper by two rollers-the
pressure roller and the hot roller; the pressure roller is usually made of silicon rubber, to help it withstand heat
and provide a good grip on the paper. (See also HOT ROLLER)
QUENCHING CORONA
found in the cleaning and quenching system in some high-speed copiers; near the end of a copy cycle,
it creates an electrical field which partially neutralises the pre-cleaning corona's charge on the photoconductor;
always used in conjunction with a quenching lamp.
QUENCHING LAMP
performs the last process in a copy cycle: returning the photoconductor to an electrically neutral condition;
shines light on the surface of the photoconductor to remove the latent image, after the leftover toner has
been removed by a cleaning brush and cleaning blade.
41
G l o s s a r y
RAG CONTENT
a paper specification which indicates a certain amount of cotton fiber combined with the wood pulp from
which the paper was made; some more expensive copy papers have a 25% rag content.
REFLECTION
that quality of light that describes its tendency to strike an object and bounce off at a predictable angle-the
angle of the incidence always equals the angle of reflection; mirrors are used in most copier exposure sys-
tems to control light by reflecting it in different directions.
REFRACTION
that quality of light that describes its tendency to bend as it passes through a transparent material; a lens is
used in most copiers to focus an image by bending its individual light rays a specific amount in the desired
direction.
REGISTRATION
the process by which paper is lined up properly with the developed image on the photoconductor; registration
is usually accomplished with a system of rollers, mechanical guides and electronic sensors.
REGISTRATION MARKS
printed at the top and side of a copier test chart as a gauge of paper alignment and copier erase margins;
consist of thin parallel lines that will show if the paper is improperly meeting the latent image on the photo-
conductor.
REGISTRATION ROLLERS
part of a copier’s paper feed system; a pair of rollers which align a sheet of paper with the latent image, and
then feed the sheet toward the photoconductor at the correct time during the copy cycle.
REGISTRATION SENSOR
part of a copier's paper feed system; an electronic sensor mounted in the paper path just before the registration
rollers; alerts the copier’s control system when a sheet of paper approaches the rollers, so that they can be
stopped before the sheet contacts them.
RELAY ROLLERS
part of a copier's paper feed system; used in machines with long or complex paper paths simply to move
sheets from one area to another-they have no special copy-related function.
REPRODUCTION RATIO
an optical specification that determines the relationship between original size and copy image size; a one-
to-one reproduction ratio indicates that original and copy have the same image size; can be varied in some
copiers to produce enlarged and reduced copies.
RESISTANCE
that quality of an electrical conductor that measures the degree to which it opposes a flow of electricity;
resistance is measured in Ohms.
RESOLUTION BARS
printed on copier test chart as a gauge of the overall sharpness of a machine's optical system; should be
clearly visible on copies as individual lines.
SCANNER
part of the exposure system in a moving scanner copier; these exposure systems have two scanners-
the first consists of a light-weight metal frame containing one mirror and the exposure lamp-the second
has a similar frame and two mirrors; both scanners move along guide rails during an exposure, and reflect
the image between them during the scan to maintain a constant optical distance from the original to the lens.
SCHEMATIC DIAGRAM
the most traditional and detailed type of electronic map; shows every circuit no matter how complex,
and every component, no matter how small.
42
G l o s s a r y
SELENIUM DRUM
the most popular photoconductor design; consists of a hollow aluminium cylinder coated with several layers
of material: aliminium oxide, selenium and selenium oxide; the selenium layer provides the key photoconductive
property of having high electrical resistance in the dark, and low resistance when exposed to light; the drum shape
allows the surface to interact easily with other copier components.
SEPARATION
that step in the copy process during which the paper and toner are separated from the photoconductor;
usually accomplished by a separation corona unit, sometimes assisted by mechanical pick-off pawls.
SEPARATION PAD
a cork pad used to provide friction for separation sheets of paper during an unwanted multiple-feed; found in
a copier's paper feed system, and also in Automatic Document Handlers.
SERIES CIRCUIT
a type of electrical connection in which components share a common path to a power source.
(See also PARALLEL CIRCUIT)
SERVO MOTOR
used in many copiers to move scanners in the optical system; servo motors emit a specific number of electrical
pulses with each revolution, allowing a control circuit to monitor and regulate their speed.
SETTING POWDER
a dry lubricant powder applied to new photoconductors immediately before installation; during initial operation,
the powder protects the surface from scratches which might result from contact with other copier components.
SOLENOID
a simple electrical control device, consisting of a hollow electromagnet and a metal plunger; when the magnet
is energised the metal plunger is pulled inside it, triggering whatever mechanism is attached.
SORTER
a paper handling device that feeds finished copies into multiple output bins; can produce “sets” of collated
copies, which match the order of the original documents, or count out “stacks” of single copies.
STEPPER MOTOR
a type of electric motor designed to be controlled in individual steps which are portions of a full rotation, each
step as small as one degree of arc; often used to adjust lens position in copiers with variable reproduction
ratio, a stepper motor’s design allows for extremely precise lens placement and easy electronic control.
STRIPPER FINGERS
part of a copier's fusing system; stripper fingers ride along the surface of the hot roller, and peel off copies
that stick to the roller despite the roller's lubrication.
TELLURIUM
a material used as an additive in selenium-based photoconductors; hardens the photoconductor's surface
and improves its ability to copy blue image areas.
TEST-CHART
a specially designed copier original, with printed gauges used to assess many aspects of copy quality.
THERMISTOR
a heat-sensitive electronic component, used in a copier’s fusing system; indicates changes in temperature by
varying its electrical resistance, allowing the main control board to monitor and regulate the fusing temperature.
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G l o s s a r y
THERMOFAX
a copying system based on heat; in Thermofax, an original is created with heat absorbing ink; this original is
then exposed to high temperatures, making it hot enough to burn an image of itself into special heat-sensitive
paper; an early process, it is now used only for making overhead projector transparencies.
THERMOSWITCH
an electrical control device used in copiers as a form of overheat protection for the exposure system;
if the thermoswitch is exposed to a certain high temperature, it opens and shuts off the exposure lamp;
after sufficient cooling has taken place, the switch closes and operation may continue.
TONER
the “ink” of an electrostatic copier which forms the actual image on finished copies; made from resin and a
solid lubricant combined with carbon or a coloured pigment; toner is not magnetic, but is bound to carrier
particles by a triboelectric charge, creating two-component developer. (See also TRIBOELECTRIC CHARGE)
TONER-END SENSOR
part of a copier’s development system; an electronic sensor which monitors the level of toner in the toner
supply-when the sensor detects a predetermined “low-toner” condition, it signals the control system, which
then lights a corresponding indicator on the machine's operation panel; usually detects two different toner
levels: “low” and “too low to continue operation”.
TONER-OVERFLOW SENSOR
part of a copier’s cleaning system; an electronic sensor which monitors the level of toner in the used-toner
storage tank-when the sensor detects a predetermined “used-toner tank full” condition, it signals the control
system, which then lights a corresponding indicator on the machine’s operation panel; usually detects two
different toner levels: “full” and “too full to continue operation”.
TONER SHIELD GLASS

a piece of ordinary glass used in copiers as a “window” in the exposure slit; allows light to reach the photo-
conductor, but keeps toner from contaminating the optical system.
TONER-ADD SYSTEM
a combination of electronic and mechanical components that monitors the average density of toner on
the photoconductor, and adds toner to the development unit whenever the density falls too low.
TRANSFER
that step in the copy process in which toner, held by the latent image on the photoconductor, is transferred
to a blank sheet of paper, thereby creating a copy; is usually accomplished with a Transfer Corona Unit.
TRANSPORT
the primary job of a copier’s paper feed system: moving sheets of paper from the supply, through
the machine, and out into the exit tray; accomplished with a variety of rubber belts and rollers.
TRAPPING LAYER
the surface layer of a selenium photoconductor, composed of selenium oxide; receives and traps an electrostatic
charge on the surface as long as the photoconductor is in darkness.
TRIAC
an electrical control device, similar to a transistor but able to control very high power levels directly; used to
regulate exposure lamp and fusing lamp voltages in most copiers.
TRIBOELECTRIC CHARGE
a type of static charge that builds up when certain materials are rubbed together; a triboelectric charge is
used to attract toner to carrier in a two-component developer system.
UNDER-TONING
a condition that occurs when a copier’s toner-supply system is delivering too little toner to the development
unit; can lead to carrier abrasion, which may damage the photoconductor and shorten the useful life of the
carrier particles.
44
G l o s s a r y
VERIFAX
an early copying system developed by Eastman Kodak Company; photographed an original using a “master”
which was chemically developed into an image of hard areas and sticky areas; the developed material was
then pressed against special paper-the sticky areas adhered to the paper, producing about ten copies from
every master.
VOLTAGE
that quality of electricity that measures the force with which it moves through a conductor; also known as
Electro-Motive Force (EMF), voltage is measured in Volts.
XEROGRAPHY
the indirect electrostatic copying system which is the basis of all modern plain paper copiers; patented in
1939 by Chester Carlson, Xerography comes from the Greek words for “dry writing”.
45

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Basic copier for Service Master

Basic copier for Service Master

Last Modified: 10/07/2001

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Computer based training:

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Name of the exam: Basic copier exam

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The ADF can hold a lot of documents to scan it all together.

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Simplex Duplex Booklet/Magazine

When starting a copy job we can select the number of copies.

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To select punch or staple the option should be installed in the finisher.

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 Example of a n opera tion panel.

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 Indicators show s errors or s tatus

These indicators can be different on a other copier models.

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 User tools / counter key

Two functions for this button.

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At this moment we are only discussing a standard copier.

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 Used for input and output.

This is an example of a display.

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 Check Modes Energy Saver

Check Modes Key

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 Main Pow er Indicator

Main Power Indicator

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Sample copy button

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Do the exercise user functions

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5. Advanced Copier Technology

5. Advan ced Copie r Te chnology

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5. Advan ced Copie r Te chnology

Example of a n opera tion panel.

Indicators show s errors or s tatus

User tools / counter key

Used for input and output.

Check Modes Energy Saver

Main Pow er Indicator