Documente Academic
Documente Profesional
Documente Cultură
magicolor 2490MF
2006.07
Ver. 1.0
THEORY OF OPERATION TOTAL CONTENTS
Duplex Option
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 3
i
ii
SAFETY AND IMPORTANT WARNING ITEMS
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
(hereafter called the KMBT) strongly recommends that all servicing be performed only by
KMBT-trained service technicians.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.
Symbols used for safety and important warning items are defined as follows:
S-1
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.
KONICA MINOLTA brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.
Prohibited Actions
DANGER
• Using any cables or power cord not specified by KMBT.
S-2
SAFETY AND IMPORTANT WARNING ITEMS
WARNING
• Use power supply cord set which meets the following
criteria:
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
kw
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
S-3
SAFETY AND IMPORTANT WARNING ITEMS
1. Power Supply
WARNING
• Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock.
S-4
SAFETY AND IMPORTANT WARNING ITEMS
WARNING
• When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
If the power cord (inlet type) is not connected to the prod-
uct securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.
• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
S-5
SAFETY AND IMPORTANT WARNING ITEMS
Wiring
WARNING
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.
2. Installation Requirements
WARNING
• Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.
WARNING
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
S-6
SAFETY AND IMPORTANT WARNING ITEMS
Ventilation
CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Stability
CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
CAUTION
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure, using only the prescribed tools. Do not make any
adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect
the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
• The area around the fixing unit is hot.
You may get burnt.
S-7
SAFETY AND IMPORTANT WARNING ITEMS
WARNING
• Take every care when making adjustments or performing
an operation check with the product powered.
If you make adjustments or perform an operation check
with the external cover detached, you may touch live or
high-voltage parts or you may be caught in moving gears
or the timing belt, leading to a risk of injury.
Safety Checkpoints
WARNING
• Check the exterior and frame for edges, burrs, and other
damage.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
S-8
SAFETY AND IMPORTANT WARNING ITEMS
Safety Checkpoints
WARNING
• Check electrode units such as a charging corona unit for
deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.
S-9
SAFETY AND IMPORTANT WARNING ITEMS
Safety Checkpoints
WARNING
• Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
Handling of Consumables
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
CAUTION
• Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.
S-10
SAFETY AND IMPORTANT WARNING ITEMS
CAUTION
• Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
A risk of fire exists.
S-11
SAFETY AND IMPORTANT WARNING ITEMS
Semiconductor laser
Maximum power of the laser diode 10 mW
Maximum average radiation power(*) 7.5 µW
Wavelength 775 - 800 nm
*:Laser Aperture of the Print Head Unit
• This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.
• The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
4139P0C501AA
S-12
SAFETY AND IMPORTANT WARNING ITEMS
CAUTION
• Use of controls, adjustments or performance of procedures other than those spec-
ified in this manual may result in hazardous radiation exposure.
Semiconductor laser
Maximum power of the laser diode 10 mW
Wavelength 775 - 800 nm
All Areas
CAUTION
• Use of controls, adjustments or performance of procedures other than those spec-
ified in this manual may result in hazardous radiation exposure.
Semiconductor laser
Maximum power of the laser diode 10 mW
Wavelength 775 - 800 nm
Denmark
ADVARSEL
• Usynlig Laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion.
Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825 sik-
kerheds kravene.
Halvlederlaser
Laserdiodens højeste styrke 10 mW
Bølgelængden 775 - 800 nm
S-13
SAFETY AND IMPORTANT WARNING ITEMS
Finland, Sweden
VARO!
• Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle.
Älä katso säteeseen.
LOUKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
VAROITUS!
• Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa
altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.
Puolijohdelaser
Laserdiodin suurin teho 10 mW
Aallonpituus 775 - 800 nm
VARNING!
• Om apparaten används på annat sätt än i denna bruksanvisning specificerats, kan
användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laser-
klass 1.
Halvledarlaser
Den maximala effekten för laserdioden 10 mW
Våglängden 775 - 800 nm
VARNING!
• Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta
ej strålen.
Norway
ADVERSEL
• Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning,
kan brukeren utsettes for unsynlig laserstråling som overskrider grensen for laser
klass 1.
Halvleder laser
Maksimal effekt till laserdiode 10 mW
Bølgelengde 775 - 800 nm
S-14
SAFETY AND IMPORTANT WARNING ITEMS
or/and
4139P0E501DA
S-15
SAFETY AND IMPORTANT WARNING ITEMS
4139P0E503DA
S-16
SAFETY AND IMPORTANT WARNING ITEMS
S-17
SAFETY AND IMPORTANT WARNING ITEMS
High temperature
High voltage
4139P0E504DA
S-18
SAFETY AND IMPORTANT WARNING ITEMS
High voltage
4139P0E505DA
CAUTION:
• You may be burned or injured if you touch any area that you are advised not to
touch by any caution label. Do not remove caution labels. If any caution label has
come off or soiled and therefore the caution cannot be read, contact our Service
Office.
S-19
MEASURES TO TAKE IN CASE OF AN ACCIDENT
S-20
Composition of the service manual
This service manual consists of Theory of Operation section and Field Service section to
explain the main machine and its corresponding options.
Theory of Operation section gives, as information for the CE to get a full understanding of
the product, a rough outline of the object and role of each function, the relationship
between the electrical system and the mechanical system, and the timing of operation of
each part.
Field Service section gives, as information required by the CE at the site (or at the cus-
tomer’s premise), a rough outline of the service schedule and its details, maintenance
steps, the object and role of each adjustment, error codes and supplementary information.
The basic configuration of each section is as follows. However some options may not be
applied to the following configuration.
C-1
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Feeding direction
• When the long side of the media is parallel with the feeding direction, it is called short
edge feeding. The feeding direction which is perpendicular to the short edge feeding is
called the long edge feeding.
• Short edge feeding will be identified with [S (abbreviation for Short edge feeding)] on the
media size. No specific notation is added for the long edge feeding.
When the size has only the short edge feeding with no long edge feeding, [S] will not be
added to the media size.
<Sample notation>
C-2
SERVICE MANUAL THEORY OF OPERATION
®
magicolor 2490MF
Main Unit
2006.07
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
• To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
magicolor 2490MF
magicolor 2490MF main unit
Outline
1. System configuration............................................................................................... 1
2. Product specifications ............................................................................................. 2
2.1 Built-in controllers ................................................................................................. 4
Outline
2.2 Fax specifications ................................................................................................. 5
3. Center cross section ............................................................................................... 6
4. Paper path............................................................................................................... 7
5. Image creation process ........................................................................................... 8
Composition/Operation
Composition/operation
6. Overall composition............................................................................................... 11
6.1 Operation sequence ........................................................................................... 11
6.2 Control block diagram ......................................................................................... 12
7. Scanner section (IR section) ................................................................................. 13
7.1 Composition........................................................................................................ 13
7.2 Drive ................................................................................................................... 14
7.3 Operation ............................................................................................................ 15
7.3.1 IR unit open/close mechanism .................................................................... 15
7.3.2 Auto document feeder unit open/close........................................................ 17
7.3.3 Original size detection................................................................................. 17
8. Write section (PH section)..................................................................................... 18
8.1 Composition........................................................................................................ 18
8.2 Operation ............................................................................................................ 19
8.2.1 Outline......................................................................................................... 19
8.2.2 Laser exposure process.............................................................................. 19
8.2.3 Laser emission timing ................................................................................. 20
8.2.4 Laser emission area.................................................................................... 20
9. Cartridge section................................................................................................... 21
9.1 Composition........................................................................................................ 21
9.2 Drive ................................................................................................................... 22
9.3 Operation ............................................................................................................ 22
9.3.1 Drum cartridge (DC) life control .................................................................. 22
9.3.2 Toner cartridge (TC) life control .................................................................. 23
10. Photo conductor section........................................................................................ 24
10.1 Composition........................................................................................................ 24
i
Theory of operation ver. 1.0 July. 2006
10.3 Operation............................................................................................................ 25
10.3.1 Photo conductor drive mechanism ............................................................. 25
10.3.2 Photo conductor cleaning mechanism........................................................ 25
11. Charge corona section.......................................................................................... 26
11.1 Composition ....................................................................................................... 26
11.2 Operation............................................................................................................ 27
11.2.1 Charge corona unit ON/OFF control........................................................... 27
12. Developing section................................................................................................ 28
Outline
ii
Theory of operation ver. 1.0 July. 2006
magicolor 2490MF
15.3.2 Paper feed speed control ............................................................................ 53
15.3.3 Paper feed mechanism ............................................................................... 54
15.3.4 Double feed prevention mechanism............................................................ 55
15.3.5 Paper empty condition detection................................................................. 55
15.3.6 Paper feed retry function............................................................................. 55
16. Conveyance section/registration roller .................................................................. 56
16.1 Composition........................................................................................................ 56
16.2 Drive ................................................................................................................... 57
Outline
16.3 Operation ............................................................................................................ 57
16.3.1 Registration roller control ............................................................................ 57
16.3.2 OHP film detection ...................................................................................... 58
16.3.3 Size error detection control ......................................................................... 58
Composition/Operation
17. Fusing section ....................................................................................................... 59
17.1 Composition........................................................................................................ 59
17.2 Drive ................................................................................................................... 60
17.3 Operation ............................................................................................................ 60
17.3.1 Heating Roller drive control......................................................................... 60
17.3.2 Fusing temperature control ......................................................................... 62
17.3.3 Protection against abnormally high temperature ........................................ 66
17.3.4 PPM control ................................................................................................ 67
18. Paper exit section .................................................................................................. 68
18.1 Composition........................................................................................................ 68
18.2 Drive ................................................................................................................... 69
18.3 Operation ............................................................................................................ 69
18.3.1 Exit tray full detection .................................................................................. 69
19. Image stabilization control..................................................................................... 70
19.1 Overview............................................................................................................. 70
19.2 Operation ............................................................................................................ 71
19.2.1 Leak detection control ................................................................................. 71
19.2.2 AIDC Sensor LED intensity control ............................................................. 71
19.2.3 Reflectance measurement control .............................................................. 71
19.2.4 Control of the maximum amount of toner sticking....................................... 71
19.2.5 Laser intensity adjustment control .............................................................. 71
19.2.6 γ correction control ...................................................................................... 71
19.3 Operation timing ................................................................................................. 72
19.4 Operation flow..................................................................................................... 72
20. Other control ......................................................................................................... 73
20.1 Fan control .......................................................................................................... 73
iii
Theory of operation ver. 1.0 July. 2006
20.1.1 Construction................................................................................................ 73
magicolor 2490MF
iv
Theory of operation ver. 1.0 July. 2006 1. System configuration
Outline
magicolor 2490MF
1. System configuration
Machine front view
Outline
[1]
[2]
[3]
4139T2E562AA
1
2. Product specifications Theory of operation ver. 1.0 July. 2006
2. Product specifications
magicolor 2490MF
A. Type
Type Desktop
Printing system Semiconductor laser and electrostatic image transfer to plain paper
Exposure system 2 laser diodes and polygon mirror
PC drum type OPC (organic photo conductor)
Photoconductor
Blade cleaning system
cleaning
Scan resolution 600 x 600 dpi, 600 x 300 dpi
Outline
Print resolution 2400 x 600 dpi, 1200 x 600 dpi, 600 x 600 dpi
Copy resolution 600 x 600 dpi
Platen Stationary
Original scanning Scanning in main scanning direction with a CCD
Registration Rear left edge
Tray1: 200 sheets
Paper feeding system
Tray2: 500 sheets (Option)
Developing system Single-element developing system
Charging system DC comb electrode scorotron system
Image transfer
Intermediate transfer belt system
system
Paper separating
Curvature separation + charge-neutralizing system
system
Fusing system Roller fusing
Paper exit system Face down (Output tray capacity: 100 sheets)
2
Theory of operation ver. 1.0 July. 2006 2. Product specifications
B. Functions
magicolor 2490MF
Average: 45 seconds (100 V area)
Warm-up time Average: 49 seconds (200 - 240 V area)
(at ambient temperature of 23 °C/73.4 °F and rated source voltage)
Plain paper 126.78 mm/second
System speed Thick stock 63.39 mm/second
OHP film 42.26 mm/second
First-page-out time Full color 22 seconds or less: LetterS, A4S
(Plain paper)
Monochrome 13 seconds or less: LetterS, A4S
First copy time Full color 52 seconds (600 x 300 dpi scan)
Outline
(Plain paper)
Monochrome 23 seconds (600 x 300 dpi scan)
Copy / Print speed Full color 5 pages/minute
(Plain paper) Monochrome 20 pages/minute
Paper width: 92 to 216 mm (3 1/2 to 8 1/2 inch)
Custom paper sizes
Paper length: 148 to 356 mm (5 3/4 to 14 inch)
Plain paper (60 to 90 g/m2 / 16 to 24 lb)
Recycled paper (60 to 90 g/m2 / 16 to 24 lb)
Transparencies
Thick stock (91 to 163 g/m2 / 25 to 40 lb)
Media types Postcards
Envelopes
Letterhead
Label stock
Glossy stock
Plain paper and letterhead : 200 sheets
Transparencies, thick stock, postcards, labels stock,
Tray capacities
and glossy stock : 50 sheets
Envelopes : 10 sheets
C. Maintenance
D. Machine specifications
Voltage: AC 110 V to 127V -10% +6% (AC 120 V ± 10% only US/Canada)
Power requirements AC 220 to 240 V ± 10%
Frequency: 50 to 60 Hz ± 3 Hz
Max power consumption 1,100 W or less
528 (W) x 475 (D) x 531 (H) mm
Dimensions
20 3/4 (W) x 18 3/4 (D) x 21 (H) inch
33 kg (72 3/4 lb) or less
Weight
39 kg (86 lb) or less (include packing material)
During standby : 39 dB (A) or less
Operating noise During printing : 53 dB (A) or less
During copying : 57 dB (A) or less (with ADF)
3
2. Product specifications Theory of operation ver. 1.0 July. 2006
E. Operating environment
magicolor 2490MF
16 MB on LANB
Optional memory Not supported
Host (PC) interface USB device (High-speed mode 480 Mbps)
Camera direct interface USB Host (Full-speed mode 12 Mbps)
Interfaces
Network interface Ethernet 10/100 BaseT
PSTN line (Fax RX/TX) Telephone line jack/External device jack
OS Compatibility Windows 98SE/Me/2000/XP/Server 2003
NOTE
• These specifications are subject to change without notice.
4
Theory of operation ver. 1.0 July. 2006 2. Product specifications
magicolor 2490MF
Standard (203 dpi x 98 dpi)
Resolution Fine (203 dpi x 196 dpi)
Super fine (203 dpi x 392dpi)
Standard/Fine/Super fine
Halftone level
Half tone standard/Half tone fine/Half tone super fine
Receive Supported
Automatic reduction
Transmit Not supported
Compatibility ECM/Super G3
Outline
Modem speed V.34 (up to 33.6 Kbps)
Transmit speed 3 Second/page (at V.34)
Compression MH/MR/MMR/JBIG
Memory for receiving 4 MB for fax-RX (approx. 250 pages), (included in 32 MB NAND flash)
Remote setting Available via USB/Network
Paper size A4S, LegalS, LetterS
One touch dial 9 one-touch key on operation panel
Speed dial 100 fax numbers
Group dial 9 groups (50 destination stations for one group)
Functions Available maximum 125 stations.
Broadcast (One-touch dial 9 stations, speed dial 100 sta-
tions, full dial 16 stations)
Timer transmission, phone book, real time clock,
Other supported functions
auto redial, reduce/split, smoothing
5
3. Center cross section Theory of operation ver. 1.0 July. 2006
[11]
[10]
[1]
Outline
[9]
[2]
[8]
[7] [3]
[6]
[5]
[4]
4139T1C501AA
*: Option
6
Theory of operation ver. 1.0 July. 2006 4. Paper path
4. Paper path
magicolor 2490MF
<Machine right side view>
Outline
4139T1C502AA
4139T1C504AA
7
5. Image creation process Theory of operation ver. 1.0 July. 2006
[12] Fusing
Outline
4139T1C503AA
8
Theory of operation ver. 1.0 July. 2006 5. Image creation process
magicolor 2490MF
• Light reflected off the surface of the original is converted to a corre-
CCD (Photoelectric
[1] sponding electric signal by CCD and the resultant electric signal is sent
conversion)
to the image processing board.
Image processing • The intensity of the laser light is controlled based on the image signal
[2]
board transmitted to this board.
• The surface of the photo conductor is irradiated with the laser light and
[3] Laser exposure
an electrostatic latent image is thereby formed.
• The image projected onto the surface of the photo conductor is con-
[4] Photo conductor
verted to a corresponding electrostatic latent image.
Photo conductor • A negative DC charge layer is formed on the surface of the photo con-
[5]
charging ductor.
Outline
• The toner, negatively charged in the hopper, is attracted onto the elec-
trostatic latent image formed on the surface of the photo conductor. It is
[6] Developing thereby changed to a visible, developed image.
• A DC negative bias voltage is applied to the developing roller, thereby
preventing toner from sticking to the background image portion.
• A DC positive voltage is applied to the backside of the transfer belt,
[7] 1st image transfer thereby allowing the visible, developed image on the surface of the
photo conductor to be transferred onto the transfer belt.
• A DC positive voltage is applied to the backside of the paper, thereby
[8] 2nd image transfer allowing the visible, developed image on the surface of the transfer belt
to be transferred onto the paper.
• The paper, which has undergone the 2nd image transfer process, is
[9] Paper separation
neutralized.
Photo conductor • The residual toner left on the surface of the photo conductor is scraped
[10]
cleaning off.
• A charge is applied to the transfer belt. By potential difference, residual
[11] Transfer belt cleaning
toner on the surface of the transfer belt is collected for cleaning.
• Toner is permanently fused to the paper by the combination of heat and
[12] Fusing
pressure applied by the fusing roller.
9
5. Image creation process Theory of operation ver. 1.0 July. 2006
magicolor 2490MF
Outline
Blank Page
10
Theory of operation ver. 1.0 July. 2006 6. Overall composition
Composition/operation
magicolor 2490MF
6. Overall composition
6.1 Operation sequence
Print Request
Polygon Motor
Charge output
Composition/Operation
1st transfer output
Pressure/Retraction Solenoid
/Cleaning Blade (SD3)
C-TOD
4139T2E566AA
11
6. Overall composition Theory of operation ver. 1.0 July. 2006
CCD unit
Scanner motor IR
Auto
Operation document
Various IR sensors panel feeder
IR cooling f an motor
Image processing board (IPB) NCUB
IR unit open
/close sensor
Image processing LANB
DC power supply2
Composition/Operation
Duplex uni t
CPU
Paper pi ck-up/
transport
12
Theory of operation ver. 1.0 July. 2006 7. Scanner section (IR section)
magicolor 2490MF
7.1 Composition
4139T2C568AA
Composition/Operation
4139T2C502AA
Scanner unit
Scanner motor
4139T2C565AA
13
7. Scanner section (IR section) Theory of operation ver. 1.0 July. 2006
7.2 Drive
magicolor 2490MF
Composition/Operation
4139T2C566AA
14
Theory of operation ver. 1.0 July. 2006 7. Scanner section (IR section)
7.3 Operation
magicolor 2490MF
7.3.1 IR unit open/close mechanism
• The machine is provided with the IR unit open/close mechanism to allow the toner car-
tridge, drum cartridge, and other disposables to be replaced with new ones.
• Pulling the IR unit lock release lever will disengage the IR unit lock pawl, allowing the IR
unit to be opened.
The IR unit lock release lever is, however, locked to prevent the IR unit from being
opened when the auto document feeder unit is raised open. This is done to prevent the
machine from toppling over.
Composition/Operation
IR unit lock release lever
15
7. Scanner section (IR section) Theory of operation ver. 1.0 July. 2006
• Pulling the IR unit lock release lever will disengage the IR unit lock pawl, allowing the IR
unit to be opened.
• When the auto document feeder unit is raised open, the ADF lever is pushed upward to
lock the IR unit lock release lever, thus preventing the IR unit from being opened.
ADF lever
16
Theory of operation ver. 1.0 July. 2006 7. Scanner section (IR section)
magicolor 2490MF
• To prevent the auto document feeder unit from being raised or lowered when the IR unit
is opened or closed, the auto document feeder unit is secured to the IR unit when the IR
unit is to be opened or closed.
• When the IR unit lock release lever is pulled, the ADF lock lever is rotated through cou-
pling of gears. This causes the auto document feeder unit to be secured to the IR unit.
ADF lock lever
Composition/Operation
ADF in locked condition
4139T2C549AA
17
8. Write section (PH section) Theory of operation ver. 1.0 July. 2006
8.1 Composition
4139to2002c0
Composition/Operation
Semiconductor laser
4139T2C503AA
G2 lens
SOS sensor
SOS mirror
G1 lens
G2 lens (SOS lens)
4139T2C511AA
18
Theory of operation ver. 1.0 July. 2006 8. Write section (PH section)
8.2 Operation
magicolor 2490MF
8.2.1 Outline
• The surface of the photo conductor is irradiated with a laser light and an electrostatic
latent image is thereby formed.
• The polygon mirror has four faces. The machine uses a two-beam array LD to inhibit the
speed of the polygon mirror from increasing because of the decreased number of faces
the polygon mirror has as compared with the conventional models.
• The two-beam array LD consists of two LD elements arranged vertically. Two lines are
scanned with two laser beams emitted from these two LD elements through a single face
of the polygon mirror.
scan motion.
Photo Conductor Surface
Composition/Operation
Conductor
Direction of Rotation
Direction of Rotation
of Photo Conductor
G1 Lens
4139to2051e0
Photo Conductor
Semiconductor Laser
SOS Board
Polygon Motor
4139to2052e0
19
8. Write section (PH section) Theory of operation ver. 1.0 July. 2006
• When a ready signal is detected after the lapse of a given period of time after the print
cycle has been started, a laser ON signal is output from the print control board.
• The laser ON signal triggers the firing of each laser light which illuminates the SOS
board via the polygon mirror, G1 lens, return mirror, G2 lens (SOS lens), and SOS mirror.
This generates an SOS signal.
• This SOS (start of scan) signal unifies the timing at which the laser lights are irradiated
for each main scan line.
TOD) that is output from the image processing board and the length of the paper.
• The laser emission area is determined by the paper size. The area of 4 mm on both the
leading and trailing edges of the paper is, however, the void image area.
Void width: 4 mm
Void width: 4 mm
4138to2595c0
20
Theory of operation ver. 1.0 July. 2006 9. Cartridge section
9. Cartridge section
magicolor 2490MF
9.1 Composition
Drum Cartridge
4139to2053e0
Composition/Operation
Toner Cartridge
4139T2C504AA
4139to2054e0
21
9. Cartridge section Theory of operation ver. 1.0 July. 2006
9.2 Drive
magicolor 2490MF
Main Motor
Drum Cartridge
Photo Conductor
Developing Motor
Toner Cartridge
Composition/Operation
4139to2055e0
9.3 Operation
9.3.1 Drum cartridge (DC) life control
• The drum cartridge offers the following life controls: detecting a new DC and resetting the
life counter.
A. New DC detection
• The machine attempts to perform a new DC detection sequence when the power switch
is turned OFF and ON, or the front door is closed.
If no new DC is detected, the image stabilization sequence is not carried out.
• If a new DC is detected, the image stabilization sequence is carried out.
22
Theory of operation ver. 1.0 July. 2006 9. Cartridge section
magicolor 2490MF
A. Toner cartridge detection and new cartridge detection timing
• The machine attempts to perform a detection sequence when the front door is closed.
Composition/Operation
counter and dot counter reach the life value.
23
10. Photo conductor section Theory of operation ver. 1.0 July. 2006
10.1 Composition
Drum Cartridge
Photo Conductor
4139to2056e0
Composition/Operation
4139T2C505AA
Charge Generating Layer
4139to2057e0
10.2 Drive
Main Motor
Photo Conductor
4139to1058e0
24
Theory of operation ver. 1.0 July. 2006 10. Photo conductor section
10.3 Operation
magicolor 2490MF
10.3.1 Photo conductor drive mechanism
• The photo conductor is driven by the main motor.
• When the main motor is energized, it turns the drive gear, which in turn rotates the photo
conductor.
Composition/Operation
Cleaning Blade
4139to2059e0
25
11. Charge corona section Theory of operation ver. 1.0 July. 2006
11.1 Composition
Charge Corona
Composition/Operation
4139T2C505AA 4139T2C512AA
Grid mesh
Electrode
4139T2C513AA
26
Theory of operation ver. 1.0 July. 2006 11. Charge corona section
11.2 Operation
magicolor 2490MF
11.2.1 Charge corona unit ON/OFF control
• The grid voltage (Vg) applied to the grid mesh is controlled by image stabilization control.
Standby Position
Polygon Motor Energized
Belt Positioning
K Toner Developing Position Sensor Activated
Y M C K Y
Rack Motor (M2)
4139to2060e0
Composition/Operation
27
12. Developing section Theory of operation ver. 1.0 July. 2006
12.1 Composition
4139T2C559AA
Composition/Operation
4139T2C504AA
Developing motor
(M3)
4139T2C514AA
Photo conductor
Hopper Cleaning blade
Waste toner
Supply roller Agitating screw
Developing roller
Charge corona
Regulator blade/2nd
Agitating blade
Regulator blade/1st
4139T2C515AA 4139T2C516AA
28
Theory of operation ver. 1.0 July. 2006 12. Developing section
12.2 Drive
magicolor 2490MF
Main motor (M1)
Photo conductor
Composition/Operation
4139T2C517AA
4139T2C518AA
29
12. Developing section Theory of operation ver. 1.0 July. 2006
Developing bias AC
Developing bias DC
4139to2102e0
Hopper
Supply Roller
Developing Roller
Agitating Blade
Regulator Blade/2nd
Regulator Blade/1st
4139to2061e0
30
Theory of operation ver. 1.0 July. 2006 12. Developing section
magicolor 2490MF
• The developing bias voltage (Vb) is applied to the developing roller so that an adequate
amount of toner is attracted onto the surface of the photo conductor.
• To allow toner to fly to the photo conductor easily, DC (-) + AC developing bias voltage
(Vb) is applied to the developing roller during development. This AC component of the
developing bias voltage is applied only during development. At any time other than the
development, only the DC (-) component of the developing bias voltage is applied.
• The developing bias voltage (Vb) is supplied by the high voltage unit.
Composition/Operation
Regulator Blade Contact Points 4139to2062e0
Developing Roller
Photo Conductor
4139to2063e1
31
12. Developing section Theory of operation ver. 1.0 July. 2006
• The toner cartridge rack is mounted with four toner cartridges. The rack employs a rotary
system.
• Development of the image of each color of toner is performed by rotating the toner car-
tridge rack.
Y Toner K Toner
Cartridge Cartridge
C Toner
M Toner Cartridge
Composition/Operation
Cartridge
4139to2064e0 4139to1528c0
Rack Motor
4139T2C556AA
Rack Motor
4139to2065e0
32
Theory of operation ver. 1.0 July. 2006 12. Developing section
magicolor 2490MF
• The toner cartridge rack must be brought to a stop so that the toner cartridge of each
color of toner is located at its correct position. To accomplish this task, three stop posi-
tions are established: the standby (reference) position, the developing position, and the
cartridge replacement position.
• The standby position refers to the position at which the toner cartridge rack is stationary
when the machine is in the standby state. The toner cartridge rack is located at this
standby position when the machine completes a warm-up cycle or waits for a print com-
mand.
• The development position refers to the position at which the toner cartridge rack stops
during development of a specific color of toner.
• The cartridge replacement position refers to the position at which the toner cartridge rack
is stopped for replacement of the toner cartridge of a specific color of toner.
(1) Standby (reference) position
• The standby position is 45° before the developing position of the K toner cartridge.
Composition/Operation
C
K
M
Y 45˚
Standby Position
4139to2067e0
For developing of K
Photo Conductor
C C K
K
M 0˚
M Y
Y 45˚
Developing Position
4139to2068e0
33
12. Developing section Theory of operation ver. 1.0 July. 2006
• The cartridge replacement position is where the toner cartridge rack is rotated 70° from
the developing position.
For Developing of K
70˚
K
C K
Y
C
M Y M
4139to2069e0
Composition/Operation
C C K C K C
M K M K
Y M Y M Y Y
4139T2E567AA
34
Theory of operation ver. 1.0 July. 2006 12. Developing section
magicolor 2490MF
(1) Operation sequence
1. The toner cartridge rack is stationary at the standby position.
2. When a print request is received from the controller, the toner cartridge rack is
rotated to bring the Y toner cartridge to its developing position.
3. Development of Y is carried out.
4. When development of Y is completed, the toner cartridge rack is rotated to bring
the M toner cartridge to its developing position.
5. Development of M is carried out.
6. Similarly, the toner cartridge rack is rotated and development of C is carried out.
7. Similarly, the toner cartridge rack is rotated and development of K is carried out.
8. When the development of K is completed, the toner cartridge rack is rotated and
brought to a stop at the standby position.
C K Y K Y Y M
Composition/Operation
M K
Y C M C M K C
Y M M C C K C
M K
K C Y K M Y Y
35
12. Developing section Theory of operation ver. 1.0 July. 2006
• The toner cartridge rack stop position for each color of toner is detected by the rack
motor and the rack positioning sensor.
• The toner cartridge rack is provided with slits, each for a specific color of toner. When the
rack rotates, the rack positioning sensor is blocked and unblocked.
A specific stop position is detected when the rack positioning sensor is blocked and
unblocked.
Slits
Composition/Operation
Direction of Rotation of
the Toner Cartridge Rack
C
M K Toner Cartridge
Rack Standby
Rack Positioning Y Position
Sensor
K C M Y
36
Theory of operation ver. 1.0 July. 2006 12. Developing section
magicolor 2490MF
• To bring the toner cartridge rack to a stop at the corresponding developing position, the
rack is rotated from the standby position 45° through pulse control of the rack motor.
Composition/Operation
37
13. Image transfer section Theory of operation ver. 1.0 July. 2006
13.1 Composition
13.1.1 1st transfer section
Composition/Operation
4139to2019c0
4139T2C506AA
Driven roller
Transfer belt
Cleaning blade
38
Theory of operation ver. 1.0 July. 2006 13. Image transfer section
magicolor 2490MF
4139to2020c0
Composition/Operation
4139T2C506AA
Pressure/
Retraction slider
4139T2C521AA
39
13. Image transfer section Theory of operation ver. 1.0 July. 2006
13.2 Drive
magicolor 2490MF
13.3 Operation
13.3.1 Transfer belt cleaning mechanism
• To scrape residual toner off the surface of the transfer belt, there is a cleaning blade pro-
vided.
• The cleaning blade is pressed up against the transfer belt, thereby scraping residual
toner off the surface of the transfer belt.
• The toner collecting screw conveys toner scraped off by the cleaning blade onto the
drum cartridge.
Driven Roller
Cleaning Blade
4139to2074e0
40
Theory of operation ver. 1.0 July. 2006 13. Image transfer section
magicolor 2490MF
• In color printing, an image is formed on the transfer belt for each color of toner. The
cleaning blade is therefore provided with a pressure/retraction mechanism.
• In monochrome printing, no retraction sequence is carried out.
• The cleaning blade is normally in pressed contact with the transfer belt.
Composition/Operation
Lever
Pressure Cam
Main Motor
Retraction
Position Sensor
/Cleaning Blade
41
13. Image transfer section Theory of operation ver. 1.0 July. 2006
4139T2E571AA
Lever
Pressure Cam
4139to2077e0
42
Theory of operation ver. 1.0 July. 2006 13. Image transfer section
magicolor 2490MF
1. When the pressure/retraction solenoid/cleaning blade is energized in the condition,
in which the cleaning blade is retracted from the transfer belt, the pressure cam
rotates a half turn. This pushes the lever backward.
2. When the lever is pushed backward, the cleaning blade is returned. Then, the
cleaning blade is pressed against the transfer belt.
Pressure Cam
Lever
Composition/Operation
4139to2078e0
43
13. Image transfer section Theory of operation ver. 1.0 July. 2006
Image write start position for Image write start position for
a paper size greater than A4 a paper size of A4 or smaller
4139T2E575AA
(thus a total of four times to cover the four colors of toner). pressure/retraction control
with respect to the transfer belt is therefore provided for the 2nd transfer roller.
• In the standby state, the 2nd transfer roller is in a position retracted from the transfer belt.
A. Pressure/retraction operation
• The pressure/retraction operation is performed by the main motor, pressure/retraction
solenoid /2nd image transfer, and pressure/retraction clutch.
• When the pressure/retraction solenoid /2nd image transfer is energized, drive from the
main motor is transmitted to the pressure/retraction clutch.
Pressure/Retraction Solenoid /
2nd Image Transfer
Pressure/Retraction Clutch
4139to2079e0
44
Theory of operation ver. 1.0 July. 2006 13. Image transfer section
magicolor 2490MF
1. Drive from the main motor is transmitted to the drive gear.
2. Rotation of the drive gear is transmitted to the pressure/retraction clutch.
3. When the pressure/retraction solenoid /2nd image transfer is energized, the pres-
sure/retraction clutch rotates a half turn. This moves the pressure slider.
4. When the pressure slider is moved, ribs on the pressure slider push up the 2nd
transfer assy.
5. When the 2nd transfer assy is pushed up, the 2nd transfer roller is pressed up
against the transfer belt.
Pressure/Retraction Roller
2nd Transfer Assy Pressure/Retraction Solenoid/
2nd Image Transfer
Pressure Slider
Composition/Operation
Pressure/Retraction
Clutch
Ribs
2nd Image Transfer
4139to2080e0
Pressure Slider
Pressure/Retraction
Clutch
Ribs
2nd Transfer Roller
4139to2081e0
45
13. Image transfer section Theory of operation ver. 1.0 July. 2006
• DC positive and negative transfer bias voltages are alternately applied to the 2nd transfer
roller. This allows toner residue on the surface of the 2nd transfer roller to be transferred
back to the transfer belt, thus cleaning the 2nd transfer roller.
• The toner transferred back to the transfer belt is collected by the cleaning blade.
Transfer Belt
Composition/Operation
4139to2082e0
A. Operation timing
The 2nd transfer roller cleaning sequence is carried out under any of the following timings.
• Power switch is turned ON
• Cover is opened and closed
• A media error occurs during a print cycle.
• A paper empty condition occurs during a print cycle.
• A paper size error occurs during a print cycle.
4139T2E572AA
46
Theory of operation ver. 1.0 July. 2006 13. Image transfer section
magicolor 2490MF
• To neutralize the paper that has undergone the 2nd transfer process, a charge neutraliz-
ing cloth is provided for the guide plate after the 2nd transfer roller.
4139to2084e0
Composition/Operation
13.3.6 Belt positioning sensor
• When development takes place in this machine, the image of each color of toner is
formed on the surface of the transfer belt. The leading edge of the image of each color of
toner must therefore be aligned correctly with each other on the surface of the transfer
belt.
• The position of the transfer belt is detected when the belt positioning sensor detects
detection holes provided in the transfer belt.
• There are two detection holes provided in the transfer belt. The image write start position
is varied according to the paper size. For a paper size of A4 or smaller, the image write
start position is aligned with detection hole A. For a paper size greater than A4, detection
hole B serves as the reference for the image write start position.
Detection
Hole A
Detection
Hole B
47
13. Image transfer section Theory of operation ver. 1.0 July. 2006
• The ATVC, or auto transfer voltage control, is for optimizing the transfer output. A con-
stant current is made to flow through each of the transfer rollers. From the voltage
thereby detected, the resistance of each of the 1st transfer roller, 2nd transfer roller, and
transfer belt is measured. The ATVC then automatically adjusts the appropriate image
transfer output voltage to be applied to the 1st transfer roller and the 2nd transfer roller
during the print cycle.
48
Theory of operation ver. 1.0 July. 2006 14. Toner collecting section
magicolor 2490MF
14.1 Composition
Waste toner
conveyance unit
Composition/Operation
4139T2C507AA
Toner agitating
screw
4139T2C523AA
14.2 Drive
4139T2C524AA
49
14. Toner collecting section Theory of operation ver. 1.0 July. 2006
14.3 Operation
magicolor 2490MF
4139to2085e0
50
Theory of operation ver. 1.0 July. 2006 14. Toner collecting section
magicolor 2490MF
• A waste toner near full condition is detected using the output state of the waste toner
near full detect board/led.
• A waste toner near full condition is detected by letting the light emitted from the LED
mounted on the waste toner near full detect board/led travel through the light guide.
• To prevent false detection, the drum cartridge is provided with the toner agitating screw
that ensures that the waste toner is evenly stored.
Composition/Operation
Light Guide
4139to2086e1
51
15. Paper feed section Theory of operation ver. 1.0 July. 2006
15.1 Composition
4139T2C525AA
Composition/Operation
4139T2C508AA
Pick-up roller
52
Theory of operation ver. 1.0 July. 2006 15. Paper feed section
15.2 Drive
magicolor 2490MF
Main motor (M1)
Pick-up roller
Composition/Operation
Tray1 paper pick-up
solenoid (SD1) 4139T2C527AA
15.3 Operation
15.3.1 Paper feed control
53
15. Paper feed section Theory of operation ver. 1.0 July. 2006
• When the tray1 paper pick-up solenoid is energized, drive from the main motor is trans-
mitted to the pick-up roller via the paper pick-up clutch. The pick-up roller is thereby
rotated.
• At the same time, the lift cam is rotated, which raises the paper lift plate. This allows the
paper to be taken up and fed in by the pick-up roller.
Cam
4139to2101e0
4139to2089e0
54
Theory of operation ver. 1.0 July. 2006 15. Paper feed section
magicolor 2490MF
• The fixed separation pad system plus the claw stoppers are used for paper separation.
This ensures that only the first sheet of paper is taken up and fed in.
Pick-up Roller
Separation Pad
4139to2090e0
Claw Stoppers
Composition/Operation
15.3.5 Paper empty condition detection
• The tray1 paper empty sensor is located on the underside of tray1, detecting the paper
loaded in the tray.
• When there is paper loaded in the tray, the actuator drops into the tray, unblocking the
sensor light.
• When paper runs out, the actuator is raised, blocking the sensor light.
Actuator
4139to2091e0
55
16. Conveyance section/registration roller Theory of operation ver. 1.0 July. 2006
16.1 Composition
Conveyance
roller
4139T2C528AA
Composition/Operation
4139T2C509AA
Registration roller
Registration roller
solenoid (SD2)
56
Theory of operation ver. 1.0 July. 2006 16. Conveyance section/registration roller
16.2 Drive
magicolor 2490MF
Actuator
Registration sensor (PS1)
4139T2C530AA
Composition/Operation
16.3 Operation
16.3.1 Registration roller control
• The registration sensor detects whether or not the paper has reached the conveyance
section.
• Conveyance of paper is restarted by synchronizing the paper conveyed with the image.
• Since the conveyance roller and registration roller are synchronized with each other, no
loop is formed in the paper at the registration roller.
4139T2E574AA
57
16. Conveyance section/registration roller Theory of operation ver. 1.0 July. 2006
• To ensure that the paper of the correct type is being used, the OHP sensor detects the
type of the paper being conveyed.
• When the registration sensor is activated, the OHP sensor is also activated and the type
of paper being conveyed is determined if it is OHP film or any type other than OHP.
• If the OHP sensor is not deactivated, the machine determines that the paper is a type
other than OHP film. If the OHP sensor is activated, the machine determines that the
paper is OHP film.
• If the paper type specified by the controller when a print request is made does not match
the results of OHP sensor detection, the machine suspends the print cycle and displays
a corresponding message on the control panel.
OHP Sensor
Composition/Operation
Reflection Mirror
4139to2092e0 4139to2093e0
58
Theory of operation ver. 1.0 July. 2006 17. Fusing section
magicolor 2490MF
17.1 Composition
4139T2C567AA
Composition/Operation
Thermistor
4139T2C510AA Exit sensor (PS7)
Thermostat
Heater lamp
Pressure roller
Heating roller
4139T2C532AA 4139T2C531AA
59
17. Fusing section Theory of operation ver. 1.0 July. 2006
17.2 Drive
magicolor 2490MF
Fusing Motor
Heating Roller
Composition/Operation
4139to2094e0
17.3 Operation
17.3.1 Heating Roller drive control
A. Speed change control
• Drive for the heating roller is provided by the fusing motor.
• To prevent fusing failure, the fusing speed is changed in three steps according to the
media type.
B. Speed stabilization
• To prevent double transferred image or brush effect, the difference between the fusing
speed and paper transport speed during image transfer is corrected.
• The fusing speed is changed in two steps relative to the system speed, either at high
speed (which is +2% of the system speed) or low speed (which is -2.5% of the system
speed).
• The fusing motor is controlled to achieve this speed change in two steps.
60
Theory of operation ver. 1.0 July. 2006 17. Fusing section
C. Operation flow
magicolor 2490MF
1. The initial fusing speed is set to the low speed, thereby forming a loop in the paper
between the 2nd transfer roller and fusing rollers.
2. When the length of the loop formed in the paper becomes greater, the fusing paper
loop sensor is activated (blocked).
3. While the fusing paper loop sensor remains activated, the fusing speed is kept at
the high level.
4. When the fusing paper loop sensor is deactivated, the fusing speed is immediately
switched to the low level.
5. The sequence of these operations is repeated so that the fusing speed is changed
automatically according to the loop length. This effectively makes for the difference
between the fusing speed and paper conveyance speed during image transfer.
Composition/Operation
Fusing paper loop
sensor (PS8)
4139to1592c0 4139to1593c0
61
17. Fusing section Theory of operation ver. 1.0 July. 2006
• A thermistor is used to detect the surface temperature of the heating roller. The heater
lamp is then turned ON and OFF as necessary to achieve the set temperature.
㧔͠㧕
[*a]
185
180 [*b]
174
169
167
Composition/Operation
100
60
Approx. 45 sec.
Warm-up completed (approx.70 seconds for 100 V area) 4139T2E563AA
(approx.75 seconds for 200 V area)
62
Theory of operation ver. 1.0 July. 2006 17. Fusing section
magicolor 2490MF
Power Switch ON Copy/Print Start
Fusing Ready Temperature
100
Composition/Operation
60
Approx. 45 sec.
Warm-up completed (approx.70 seconds for 100 V area) 4139T2E564AA
(approx.75 seconds for 200 V area)
63
17. Fusing section Theory of operation ver. 1.0 July. 2006
A. Warm-up
magicolor 2490MF
• Control is provided until the heating roller temperature reaches 178 °C.
• This control is performed when the power switch is turned ON, a malfunction or paper
misfeed is reset, the energy saver mode is canceled, or the door is opened and closed.
B. In standby
• The fusing temperature in the standby state is prevented from being dropped.
• The control temperature in the standby state after the warm-up cycle which was started
with the heating roller temperature 60 °C or less is changed to that of the ordinary
standby after the lapse of a predetermined period of time.
*a: The fusing temperature in the standby state is changed if the standby state lasts for 20
min. or longer.
Machine interior temperature is less than 20 °C: 170 °C
Composition/Operation
Ordinary Temperature/humidity
Media type environment sensor less than 20 °C
(°C) (°C)
Plain paper (plain paper, letterhead) 169 174
Plain paper (plain paper, letterhead) 257 mm or less 169 174
Thick stock (thick stock, postcards, labels) 169
OHP 169
Envelopes 194*a
Glossy stock 169
64
Theory of operation ver. 1.0 July. 2006 17. Fusing section
magicolor 2490MF
• If the print cycle is started in a condition, in which the temperature/humidity sensor
detects 20 °C or more, control is returned back to one having a control temperature of
more than 60 °C after five printed pages have been produced.
Composition/Operation
Glossy stock - 190 190 185
65
17. Fusing section Theory of operation ver. 1.0 July. 2006
• The machine provides protection at three different stages to prevent abnormally high
temperature of the fusing Unit.
A. Soft protection
• If the thermistor detects a temperature exceeding a predetermined value, the malfunc-
tion code representing abnormally high temperature is displayed. At this time, the heater
lamp is turned OFF forcibly and the initiation of any new print cycle is prohibited (abnor-
mally high temperature detection control).
B. Hard protection
• If the CPU overruns and the output level of the CPU of the mechanical control board
becomes a HIGH or LOW level, and not a pulse output, and a predetermined tempera-
ture or higher is detected, a circuit within the mechanical control board turns OFF the
relay to shut down the power supply to the heater lamp.
C. Thermostat protection
• If neither the soft protection nor hard protection can detect an abnormally high tempera-
ture due to a defective thermistor or other reason, the thermostat operates at the speci-
Composition/Operation
fied temperature. This shuts down the power supply to the heater lamp, thus forcibly
turning it OFF.
5V
Mechanical Control Board
CPU
A/D
Heater Lamp
Thermistor
Heating Roller
Thermostat GND
Hard Protection
Fusing PressureRoller Circuit
FUSER WDT
Watchdog Circuit RESET
Triac Circuit
Heater Remote
ON/OFF
Power Switch
4139to2097e0
66
Theory of operation ver. 1.0 July. 2006 17. Fusing section
magicolor 2490MF
• PPM control is provided to prevent the temperature on edges of the heating roller from
increasing during a multi-print cycle using plain paper of a small size.
• The distance between sheets of paper is widened according to the number of printed
pages set to be produced and the paper length. This evens out the temperature of the
heating roller and thus stabilizes fusing performance of the printed toner image.
• To perform the PPM control, the number of printed pages per minute is established for
each paper size.
Length
Less than 210 mm 210 - 215 mm 216 - 256 mm 257 - 296 mm
139 mm or less 14 14 14 14
140 - 148 mm 18 18 14 14
Width
149 - 182 mm 19 18 14 14
183 - 210 mm 20 20 20 14
Composition/Operation
B. Monochrome low temperature environment
• The low temperature environment refers to the condition, in which the temperature/
humidity sensor detects a temperature of less than 20 °C.
Length
210 mm 211 - 216 mm 217 - 257 mm 258 - 297 mm
139 mm or less 12 12 12 12
140 - 148 mm 15 15 12 12
Width
149 - 182 mm 16 15 12 12
183 - 210 mm 17 17 17 12
C. Color environment
Length
210 mm 211 - 216 mm 217 - 257 mm 258 - 297 mm
139 mm or less 3 3 3 3
140 - 148 mm 5 5 3 3
Width
149 - 182 mm 5 5 3 3
183 - 210 mm 5 5 5 3
67
18. Paper exit section Theory of operation ver. 1.0 July. 2006
18.1 Composition
Composition/Operation
4139T2C558AA
4139T2C510AA
4139T2C552AA
68
Theory of operation ver. 1.0 July. 2006 18. Paper exit section
18.2 Drive
magicolor 2490MF
Fusing motor (M4)
Composition/Operation
4139T2C557AA
18.3 Operation
18.3.1 Exit tray full detection
• The exit tray is provided with a paper full detection system. When the exit tray full sensor
is unblocked, the corresponding message will be displayed on the control panel.
4139T2C553AA
69
19. Image stabilization control Theory of operation ver. 1.0 July. 2006
19.1 Overview
• To ensure that a stabilized output image is produced at all times, the following image sta-
bilization controls are provided.
IDC Sensor
1st Transfer Roller
Developing PC Charging
IN
Temperature/ OUT
humidity Sensor 4139T2E570AA
70
Theory of operation ver. 1.0 July. 2006 19. Image stabilization control
19.2 Operation
magicolor 2490MF
19.2.1 Leak detection control
• For the clearance between the photo conductor and developing roller, an optimum devel-
oping bias voltage is established that does not result in a leak image or uneven density.
Composition/Operation
19.2.4 Control of the maximum amount of toner sticking
• The developing bias setting value is adjusted to keep constant the amount of toner stick-
ing to the surface of the photo conductor with reference to the 100% solid image.
71
19. Image stabilization control Theory of operation ver. 1.0 July. 2006
Mode 1 Mode 2
Composition/Operation
Reflectance
AIDC intensity control
measurement control
γ correction control
4139to2099e0
72
Theory of operation ver. 1.0 July. 2006 20. Other control
magicolor 2490MF
20.1 Fan control
20.1.1 Construction
Exhaust
Composition/Operation
Power supply cooling
fan motor
Suction
Exhaust
Ozone filter
4139T2C554AA
73
20. Other control Theory of operation ver. 1.0 July. 2006
20.1.2 Control
magicolor 2490MF
<Half-speed conditions>
• At the end of a print cycle (half-speed rotation after the lapse of a predetermined period
of time of full-speed rotation)
• Half-speed rotation under any condition other than above
<Stop conditions>
• In energy saver mode
• The power supply cooling fan motor develops a malfunction
<Full-speed condition>
• While the main motor remains energized
<Stop conditions>
• The lapse of a predetermined period of time after the main motor has been deenergized
• Stop under any condition other than above
<Forced stop condition>
• A door is opened, a paper misfeed has occurred, or a malfunction has occurred.
<Half-speed conditions>
• At the end of a print cycle (half-speed rotation after the lapse of a predetermined period
of time of full-speed rotation)
• Half-speed rotation under any condition other than above
74
Theory of operation ver. 1.0 July. 2006 20. Other control
magicolor 2490MF
20.2.1 Composition
• The temperature/humidity sensor is used to detect the temperature of the inside of the
machine.
It is also used for image stabilization, transfer ATVC, and fusing temperature control.
Composition/Operation
Temperature/humidity
sensor (TEM/HUMS)
4139T2C555AA
75
20. Other control Theory of operation ver. 1.0 July. 2006
magicolor 2490MF
Composition/Operation
Blank Page
76
SERVICE MANUAL THEORY OF OPERATION
Auto Document
Feeder Unit
2006.07
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
• To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
Auto Document
Feeder Unit
Auto document feeder unit
Outline
1. Product specifications ............................................................................................. 1
Composition/operation
Outline
2. Composition ............................................................................................................ 3
3. Drive ........................................................................................................................ 4
4. Mechanical operations ............................................................................................ 5
4.1 Document take-up mechanism ............................................................................. 5
4.1.1 Document take-up mechanism ..................................................................... 5
Composition/Operation
4.1.2 Document separation mechanism................................................................. 6
4.2 Document transport/exit mechanism .................................................................... 7
4.2.1 Document transport mechanism ................................................................... 7
4.2.2 Document exit mechanism............................................................................ 8
4.3 Miscellaneous ....................................................................................................... 9
4.3.1 Document feeder raised/lowered position detection mechanism .................. 9
i
Auto Document
Composition/Operation Outline
Feeder Unit
ii
Blank Page
Theory of operation ver. 1.0 July. 2006
Theory of operation ver. 1.0 July. 2006 1. Product specifications
Outline
Auto Document
Feeder Unit
1. Product specifications
A. Type
B. Functions
Outline
Modes 1-sided mode
C. Paper type
1
1. Product specifications Theory of operation ver. 1.0 July. 2006
F. Machine specifications
G. Operating
• Conforms to the operating environment of the main unit.
NOTE
These specifications are subject to change without notice.
2
Theory of operation ver. 1.0 July. 2006 2. Composition
Composition/operation
Auto Document
Feeder Unit
2. Composition
4556T2C509AA
Composition/Operation
4556T2C505AA
Take-up roller
3
3. Drive Theory of operation ver. 1.0 July. 2006
3. Drive
Auto Document
Feeder Unit
Composition/Operation
4556T2C508AA
4
Theory of operation ver. 1.0 July. 2006 4. Mechanical operations
4. Mechanical operations
Auto Document
Feeder Unit
4.1 Document take-up mechanism
4.1.1 Document take-up mechanism
• The original detection sensor detects a document that has been properly loaded in the
document feeder.
• The document stopper establishes the leading edge position of the document loaded in
the document feeder. The stopper is lowered in the standby state and raised when the
document is taken up and fed in.
• The document stopper is raised and lowered in synchronism with the raising and lower-
ing motion of the pick-up roller.
• The pick-up roller and take-up roller turn to take up and feed the original properly.
• The pick-up roller transports the original up to the take-up roller.
• The main motor drives the pick-up roller and take-up roller through a gear train and the
paper feed clutch.
Composition/Operation
Original detection sensor (PS1)
5
4. Mechanical operations Theory of operation ver. 1.0 July. 2006
• Double feeding of paper is prevented using coefficient of friction between the take-up
Feeder Unit
Take-up roller
Composition/Operation
Single sheet feeding : The coefficient of friction on the front side of the paper fed between the take-
up roller and separator pad is equal to that on the backside of the paper.
This allows the take-up roller to transport the paper.
Multiple sheet feeding : The coefficient of friction between the paper and separator pad is greater
than that between sheets of paper. This allows only the first sheet of paper
to be transported by the take-up roller.
1382M009AA
6
Theory of operation ver. 1.0 July. 2006 4. Mechanical operations
Auto Document
4.2.1 Document transport mechanism
Feeder Unit
• The original that has been taken up blocks the paper feed sensor. The transport roller
turns to transport the original up to the document scanning position of the printer.
• The main motor drives the transport roller through a gear train.
Main motor (M1)
Composition/Operation
Transport roller
4556T2C503AA
7
4. Mechanical operations Theory of operation ver. 1.0 July. 2006
• The exit roller turns to feed the original out of the document feeder. During this
Feeder Unit
sequence, the original blocks the paper leading edge detection sensor and is fed onto
the document exit tray.
• The main motor turns the exit roller through a gear train.
8
Theory of operation ver. 1.0 July. 2006 4. Mechanical operations
4.3 Miscellaneous
Auto Document
4.3.1 Document feeder raised/lowered position detection mechanism
Feeder Unit
• There is a magnet provided in the document feeder, allowing the printer to detect the
position of the document feeder whether the document feeder is raised or lowered.
• This magnet attracts the original cover set switch provided on the printer side, thus acti-
vating the sensor. The printer will then detect the position of the document feeder.
Magnet
Composition/Operation
4556T2C510AA
Original cover set switch (SW4)
9
4. Mechanical operations Theory of operation ver. 1.0 July. 2006
Auto Document
Feeder Unit
Composition/Operation
Blank Page
10
SERVICE MANUAL THEORY OF OPERATION
Lower Feeder
Unit
2006.07
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
• To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
Outline
1. Product specifications ............................................................................................. 1
Composition/operation
Outline
2. Composition ............................................................................................................ 3
3. Drive ........................................................................................................................ 4
4. Mechanical operation .............................................................................................. 5
4.1 Conveyance drive mechanism.............................................................................. 5
4.2 Paper empty detection.......................................................................................... 6
Composition/Operation
4.3 Tray set detection.................................................................................................. 7
i
Theory of operation ver. 1.0 July. 2006
Lower Feeder Unit
Outline
Composition/Operation
Blank Page
ii
Theory of operation ver. 1.0 July. 2006 1. Product specifications
Outline
Outline
B. Paper type
C. Machine specifications
D. Operating environment
NOTE
• These specifications are subject to change without notice.
1
1. Product specifications Theory of operation ver. 1.0 July. 2006
Lower Feeder Unit
Outline
Blank Page
2
Theory of operation ver. 1.0 July. 2006 2. Composition
Composition/operation
4056T2C501AA 4056T2C509AA
Composition/Operation
Tray set detecting switch (SW1)
PF drive board (PFDB)
4056T2C502AA
3
3. Drive Theory of operation ver. 1.0 July. 2006
3. Drive
Lower Feeder Unit
Composition/Operation
4056T2C510AA
4
Theory of operation ver. 1.0 July. 2006 4. Mechanical operation
4. Mechanical operation
Composition/Operation
Paper Empty Sensor (S1)
4056T2E506AA
5
4. Mechanical operation Theory of operation ver. 1.0 July. 2006
• The paper empty sensor of the PF drive board detects a paper empty condition in the
lower feeder unit.
• When there is paper loaded in the lower feeder unit, the actuator is raised, which
unblocks the sensor.
• When there is no paper, the actuator drops into the slit in the paper lift plate, thus block-
ing the sensor.
6
Theory of operation ver. 1.0 July. 2006 4. Mechanical operation
Lever
Tray Set Detecting Switch (SW1)
OFF
Composition/Operation
ON
Switch Actuator
Tray 2
4056T2E508AA
7
4. Mechanical operation Theory of operation ver. 1.0 July. 2006
Lower Feeder Unit
Composition/Operation
Blank Page
8
SERVICE MANUAL THEORY OF OPERATION
Duplex Option
2006.07
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
• To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
Duplex Option
Duplex option
Outline
1. Product specifications ............................................................................................. 1
Composition/Operation
Outline
2. Composition ............................................................................................................ 3
3. Drive ........................................................................................................................ 4
4. Mechanical operations ............................................................................................ 5
4.1 Switchback mechanism ........................................................................................ 5
4.1.1 Switchback operation .................................................................................... 5
Composition/Operation
4.1.2 Paper exit roller drive coupling mechanism................................................... 6
4.1.3 Switchback motor control .............................................................................. 6
4.2 Transport and duplex paper take-up mechanism.................................................. 7
4.2.1 Transport and duplex paper take-up operation ............................................. 7
4.2.2 Duplex option transport motor control ........................................................... 7
4.2.3 Duplex option loop correction control............................................................ 7
4.3 2-sided printing method ........................................................................................ 8
4.3.1 Operations in 2-sided printing with a single sheet of paper resident
in the system................................................................................................. 8
4.3.2 Operations in 2-sided printing with two sheets of paper resident
in the system............................................................................................... 10
i
Theory of operation ver. 1.0 July. 2006
Duplex Option
Outline
Composition/Operation
Blank Page
ii
Theory of operation ver. 1.0 July. 2006 1. Product specifications
Outline
Duplex Option
1. Product specifications
A. Type
Outline
Document alignment Center
B. Paper type
C. Machine specifications
D. Operating environment
NOTE
• These specifications are subject to change without notice.
1
1. Product specifications Theory of operation ver. 1.0 July. 2006
Duplex Option
Outline
Blank Page
2
Theory of operation ver. 1.0 July. 2006 2. Composition
Composition/Operation
Duplex Option
2. Composition
4057T2C509AA
Composition/Operation
Transport roller 1
4057T2C501AA
Registration roller
4057T2C503AA
3
3. Drive Theory of operation ver. 1.0 July. 2006
3. Drive
Duplex Option
Transport roller 1
Registration roller
Composition/Operation
Transport roller 2
4057T2C504AA
4
Theory of operation ver. 1.0 July. 2006 4. Mechanical operations
4. Mechanical operations
Duplex Option
4.1 Switchback mechanism
4.1.1 Switchback operation
• The paper exit roller of the main unit is used to subject the 1-sided print to a switchback
sequence so that the 1-sided print is to be transported through the duplex option.
Composition/Operation
Exit sensor (PS7)
Paper exit roller
4057to2507c0
5
4. Mechanical operations Theory of operation ver. 1.0 July. 2006
• When the duplex option is mounted, the gear assy of the fusing unit is raised by the lead-
ing edge of the duplex option lever, thereby disconnecting drive from the machine (fusing
roller). The paper exit roller is driven by the duplex reverse motor.
4057to2508c0
6
Theory of operation ver. 1.0 July. 2006 4. Mechanical operations
Duplex Option
4.2.1 Transport and duplex paper take-up operation
• Drive for the duplex option is provided by the transport motor.
Transport roller 1
Transport motor (M1)
Registration roller
Composition/Operation
Transport roller 2
4057to2509c0
7
4. Mechanical operations Theory of operation ver. 1.0 July. 2006
Automatic 2-sided printing is not effective when the FD length is less than 276 mm.
4.3.1 Operations in 2-sided printing with a single sheet of paper resident in the
system
Operation 2
• Immediately before the 1-sided print leaves the paper exit
roller, the direction of rotation of the paper exit roller is 2
reversed and the 1-sided print is transported toward and
into the duplex option.
Operation 3
• The paper conveyed through the duplex option is tempo-
rarily stopped at the duplex take-up position.
• Any skew in the paper is corrected at the registration roller
before the paper is taken up and fed by the duplex option. 2
8
Theory of operation ver. 1.0 July. 2006 4. Mechanical operations
Operation 4
Duplex Option
• The main unit carries out the second print cycle to produce
the print image of the first page of the original on the other
side of the 1-sided print. 1 2
Operation 5
• While feeding the first 2-sided print out of itself, the main
2
unit carries out the first print cycle for the second sheet of
paper to produce the print image of the fourth page of the 1
4
original.
Composition/Operation
• Steps 2 through 5 are repeated.
4057T2E507AA
9
4. Mechanical operations Theory of operation ver. 1.0 July. 2006
4.3.2 Operations in 2-sided printing with two sheets of paper resident in the sys-
tem
Duplex Option
Operation 2
• Immediately before the first 1-sided print leaves the paper
exit roller, the direction of rotation of the paper exit roller is 2
reversed and the first 1-sided print is transported toward
and into the duplex option.
Composition/Operation
Operation 3
• The main unit carries out the first print cycle for the second
sheet of paper to produce the print image of the fourth
page of the original. 4
• At the same time, the first 1-sided print is transported 2
through the duplex option.
Operation 4
• The main unit produces the print image of the first page of
the original on the first 1-sided print that has been fed
through the duplex option. 1 2
• At the same time, the second sheet of paper is subjected 4
to a switchback sequence at the exit section and fed into
the duplex option.
• At the same time, the third sheet of paper is taken up and 6
fed into the main unit.
10
Theory of operation ver. 1.0 July. 2006 4. Mechanical operations
Operation 5
Duplex Option
• While feeding the first 2-sided print out, main unit produces
the print image of the 6th page of the original on the third 2
sheet of paper. 1
• The second sheet of paper waits at the duplex take-up
position until the third sheet of paper is subjected to a 6
switchback sequence. 4
Operation 6
• Immediately before the first 1-sided print leaves the paper
exit roller, the direction of rotation of the paper exit roller is 6
reversed and the first 1-sided print for the third sheet is 2
transported toward and into the duplex option. 1
• At the same time, the second sheet of paper is fed into the
main unit again. 4
Composition/Operation
Operation 7
• The main unit carries out the first print cycle for the second
sheet of paper to produce the print image of the third page
of the original. 2 3 4
• At the same time, the first 1-sided print for the third is 1
transported through the duplex option.
• At the same time, the forth sheet of paper is taken up and 6
fed into the main unit.
Operation 8
• While feeding the second 2-sided print out, main unit pro-
4
duces the print image of the 8th page of the original on the
fourth sheet of paper. 3 2
• The third sheet of paper waits at the duplex take-up posi- 1
tion until the fourth sheet of paper is subjected to a switch- 8
back sequence. 6
11
4. Mechanical operations Theory of operation ver. 1.0 July. 2006
• 2-sided printing of two A4 originals with two sheets of paper resident in the sys-
tem
Duplex Option
4057T2E508AA
12
© 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Printed in Japan
Use of this manual should be strictly supervised to
DD4139-A-TE1
avoid disclosure of confidential information.