Theory of Operation Bizhub 163 - 211 - 220

SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
THEORY OF OPERATION TOTAL CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1 IMPORTANT NOTICE ................................................................................................S-1 DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1 SAFETY WARNINGS .................................................................................................S-2 WARNING INDICATIONS ON THE MACHINE ........................................................S-18 MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-19 Composition of the service manual ................................................................................. C-1 Notation of the service manual ....................................................................................... C-2
bizhub 163/211/220 main body

Outline ............................................................................................................................ 1 Composition/Operation ................................................................................................. 11
DF-605/MK-501
Outline ............................................................................................................................ 1 Composition/Operation ................................................................................................... 5
DF-502
AD-504
PF-502
MB-501
JS-503
SF-501
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 3
ii
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the safety and important warning items described below to understand them before doing service work.
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.
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION

In this Service Manual, each of three expressions DANGER, WARNING, and CAUTION is defined as follows together with a symbol mark to be used in a limited meaning. When servicing the product, the relevant works (disassembling, reassembling, adjustment, repair, maintenance, etc.) need to be conducted with utmost care. DANGER: Action having a high possibility of suffering death or serious injury WARNING: Action having a possibility of suffering death or serious injury CAUTION: Action having a possibility of suffering a slight wound, medium trouble, and property damage Symbols used for safety and important warning items are defined as follows:
:Precaution when servicing the product. :Prohibition when servicing the product. :Direction when servicing the product.
General precaution General prohibition General instruction
Electric hazard High temperature
Do not touch with wet hand Unplug
Do not disassemble Ground/Earth
S-1
MEASURES TO TAKE IN CASE OF AN ACCIDENT

1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage. 2. If a report of a serious accident has been received from a customer, an on-site evaluation must be carried out quickly and KMBT must be notified. 3. To determine the cause of the accident, conditions and materials must be recorded through direct on-site checks, in accordance with instructions issued by KMBT. 4. For reports and measures concerning serious accidents, follow the regulations specified by every distributor.
S-19
Blank Page
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 customers 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. <Theory of Operation section> OUTLINE: Explanation of system configuration, product specifications, unit configuration, and paper path COMPOSITION/OPERATION: Explanation of configuration of each unit, operating system, and control system
<Field Service section> GENERAL: MAINTENANCE: Explanation of system configuration, and product specifications Explanation of service schedule, maintenance steps, service tools, removal/reinstallation methods of major parts, and firmware version up method etc. ADJUSTMENT/SETTING: TROUBLESHOOTING: APPENDIX: Explanation of utility mode, service mode, and mechanical adjustment etc. Explanation of lists of jam codes and error codes, and their countermeasures etc. Parts layout drawings, connector layout drawings, timing chart, overall layout drawing are attached.
C-1
Notation of the service manual

A. Product name In this manual, each of the products is described as follows: (1) bizhub 163/211/220: (2) Microsoft Windows 98: Microsoft Windows Me: Microsoft Windows NT 4.0: Microsoft Windows 2000: Microsoft Windows XP: Main body Windows 98 Windows Me Windows NT 4.0 or Windows NT Windows 2000 Windows XP Windows 98/Me Windows NT 4.0/2000 Windows NT/2000/XP Windows 98/Me/ NT/2000/XP
When the description is made in combination of the OSs mentioned above:
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 paper 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 paper 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 paper size. <Sample notation>
Paper size A4 A3 Feeding direction Long edge feeding Short edge feeding Short edge feeding Notation A4 A4S A3
C-2
SERVICE MANUAL
THEORY OF OPERATION
2007.04 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 corresponding 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.
2007/04 Date
1.0 Service manual Ver.
Revision mark
Issue of the first edition Descriptions of revision
Theory of Operation Ver. 1.0 Apr. 2007

bizhub 163/211/220
CONTENTS bizhub 163/211/220 main body Outline

1. 2. 2.1 3. 4. 5. System configuration............................................................................................... 1 Product specification ............................................................................................... 3 Fax kit (FK-506): (Option) ..................................................................................... 6 Cross sectional view................................................................................................ 7 Paper path............................................................................................................... 8 Copy process .......................................................................................................... 9
Composition/Operation
6. 6.1 6.2 7. 7.1 7.2 7.3 Overall configuration ............................................................................................. 11 Timing Chart at Power ON.................................................................................. 11 Control Block Diagram ........................................................................................ 12 Scanner (IR) .......................................................................................................... 13 Composition........................................................................................................ 13 Drive ................................................................................................................... 14 Operation ............................................................................................................ 15 Scanner Moving Mechanism/Control .......................................................... 15 Original Size Detection ............................................................................... 16 Determination of Original Size .................................................................... 17 For Metric, China and Latin America (Metric) areas ................................... 20
7.3.1 7.3.2 7.3.3 7.3.4 8. 8.1 8.2 9. 9.1 9.2 10.
PH (Writing section) .............................................................................................. 21 Composition........................................................................................................ 21 Drive ................................................................................................................... 22 Imaging unit........................................................................................................... 23 Construction ....................................................................................................... 23 Operation ............................................................................................................ 24 PC Drum ............................................................................................................... 25
10.1 Composition........................................................................................................ 25 10.2 Drive ................................................................................................................... 25 10.3 Operation ............................................................................................................ 26 10.3.1 11. Grounding of the PC Drum ......................................................................... 27 PC Drum charging................................................................................................. 28
11.1 Composition........................................................................................................ 28 11.2 Operation ............................................................................................................ 28 12. Developing ............................................................................................................ 29
Outline

bizhub 163/211/220
12.1 Composition ....................................................................................................... 29 12.2 Drive ................................................................................................................... 29 12.3 Operation............................................................................................................ 30 12.3.1 12.3.2 12.3.3 12.3.4 13. Developing Roller........................................................................................ 30 Developing Bias .......................................................................................... 30 TCR Sensor ................................................................................................ 31 TCR Sensor Automatic Adjustment ............................................................ 31
Toner replenishing................................................................................................. 32
Outline
13.1 Composition ....................................................................................................... 32 13.2 Drive ................................................................................................................... 32 13.3 Operation............................................................................................................ 33 13.3.1 13.4.1 13.4.2 14. Toner Replenishing Mechanism.................................................................. 33 T/C Recovery Mode.................................................................................... 35 Toner Bottle Home Position Detection ........................................................ 36 13.4 Toner Replenishing Control ................................................................................ 34
Image transfer and paper separation section........................................................ 37
14.1 Composition ....................................................................................................... 37 14.2 Drive ................................................................................................................... 37 14.3 Operation............................................................................................................ 38 14.3.1 14.3.2 15. Image Transfer Section ............................................................................... 38 Paper Separation Section ........................................................................... 38
Toner recovery ...................................................................................................... 39
15.1 Composition ....................................................................................................... 39 15.2 Drive ................................................................................................................... 39 15.3 Operation............................................................................................................ 40 16. Paper feed............................................................................................................. 41 16.1 Composition ....................................................................................................... 41 16.2 Drive ................................................................................................................... 42 16.3 Operation............................................................................................................ 43 16.3.1 16.3.2 16.3.3 16.3.4 16.3.5 16.3.6 16.3.7 16.3.8 17. Paper Separating Mechanism..................................................................... 43 Drawer in Position Detection....................................................................... 43 Paper Empty Detection Mechanism............................................................ 44 Paper Lifting Plate....................................................................................... 44 Universal Tray Paper Size Detection Mechanism ....................................... 45 ON/OFF Positions of Paper Size Detecting Switches and Corresponding Paper Size Detected .......................................................... 46 Paper feed Control...................................................................................... 47 Paper feed Retry Control ............................................................................ 47
Manual bypass section.......................................................................................... 48
ii

bizhub 163/211/220 Composition/Operation Outline
17.1 Composition........................................................................................................ 48 17.2 Drive ................................................................................................................... 48 17.3 Operation ............................................................................................................ 49 17.3.1 17.3.2 18. Paper Detection Mechanism ....................................................................... 49 Manual Feed Take Up Control..................................................................... 50
Registration roller section...................................................................................... 51
18.1 Composition........................................................................................................ 51 18.2 Drive ................................................................................................................... 51 18.3 Operation ............................................................................................................ 52 18.3.1 19. Paper Dust Remover................................................................................... 52 Fusing unit section ................................................................................................ 53
19.1 Composition (for bizhub 163).............................................................................. 53 19.2 Composition (for bizhub 211/220)....................................................................... 54 19.3 Drive ................................................................................................................... 55 19.4 Operation ............................................................................................................ 55 19.4.1 19.4.2 19.4.3 19.4.4 20. Fusing Roller Pressure Mechanism ............................................................ 55 Fusing Temperature Control (for bizhub 163) ............................................. 56 Fusing Temperature Control (for bizhub 211/220) ...................................... 57 PPM Control (bizhub 163 Only) .................................................................. 58
Paper exit (for bizhub 163) .................................................................................... 59
20.1 Composition........................................................................................................ 59 20.2 Drive ................................................................................................................... 59 21. Paper exit (for bizhub 210/220) ............................................................................. 60 21.1 Construction ....................................................................................................... 60 21.2 Operation ............................................................................................................ 60 22. 23. Image stabilization system .................................................................................... 61 Others ................................................................................................................... 62 23.1.1 23.1.2 Composition ................................................................................................ 62 Operation .................................................................................................... 63 22.1 Composition........................................................................................................ 61 23.1 Fan Control ......................................................................................................... 62
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bizhub 163/211/220 Composition/Operation Outline
Blank Page
iv
1. System configuration
bizhub 163/211/220 [8] [9]
A08EE501AA
Outline
[2] [3] [4]
1/2 System front view
[12] [6] [1] [13] [7]
[14] [11]
[10]
[1] [2] [3] [4] [5] [6]
bizhub 163/211/220 *1 Original cover (OC-504) *2 Automatic document feeder (DF-502) Reverse automatic document feeder (DF-605) *3 Shift tray (SF-501) Automatic duplex unit (AD-504) *3 *5
[8] [9] [10] [11] [12] [13]
Paper feed unit (PF-502) Desk (DK-703) Desk (DK-702) Desk (DK-701) Job separator (JS-503) Key counter mount kit 1 (previous models for minolta.) Key counter mount kit 2 (previous models for konica) Mechanical counter (MC-503)
[7]
Multi bypass tray (MB-501) *4
[14]
*1: The standard bizhub 220 configuration is the main body plus 1-drawer paper feed unit. *2: Standard only on the bizhub 163 and bizhub 211/220 for china *3: To be mountable only on bizhub 211/220 *4: Standard only the main body for china (but separately packaged upon shipment from factory) *5: Standard only on bizhub 220 (but separately packaged upon shipment from factory)
Outline
[5]
bizhub 163/211/220
2/2 System rear view
[4]
[3]
[1]
[2]
Outline
A08EE502AA
[1] [2]
Expanded memory unit (EM-103) Fax kit (FK-506)
[3] [4]
Image controller (IC-206) * Network interface card (NC-503) *
* It is not possible to mount these units at the same time.
2. Product specification
bizhub 163/211/220
x 1.00 x 0.250, x 0.500. x 0.700, x 0.810 x 1.150, x 1.410, x 2.000, x 4.000 x 1.00 x 0.250, x 0.500, x 0.640, x 0.780 x 1.210, x 1.290, x 2.000, x 4.000
2.
Type Platen
Product specification
Console/desktop type Stationary CCD line sensor Organic photoconductor Electrostatic dry powdered image transfer to plain paper with a laser 600 600 dpi
A. Copier
Original scanning system Photoconductor Copying system Resolution Paper feeding system Exposure system Developing system Charging system Image transfer system Paper separating system Fusing system Paper discharging system
Mirror scanning HMT system Comb electrode DC negative corona with scorotron system Roller image transfer Paper separator fingers and charge neutralizing plate Heat roller Charge neutralizing brush
B. Functions
Types of original Max. original size Multiple copies Sheets, books, and three-dimensional objects A3 or 11 17 1 to 99 15 sec. or less: bizhub 211/bizhub 220 30 sec. or less: bizhub 163 (when the auxiliary power switch is turned ON from a stabilized state, in which the main power switch is ON and auxiliary power switch is OFF, with the rated power source voltage and at a room temperature of 23C) Leading edge: 4 mm (1/4 inch), trailing edge: 4 mm (1/4 inch), Rear edge: 4 mm (1/4 inch), front edge: 4 mm (1/4 inch) Scan through glass: 7 sec. or less ADF scan: 11 sec. or less (Values in conditions of paper fed from tray 1 at a room temperature of 23C and with a rated power source) 93 mm/s 21 cpm or more (bizhub 211: metric areas) Copying speed for multi-copy cycle (A4, 8-1/2 x 11) 22 cpm or more (bizhub 220) 20 cpm or more (bizhub 211: inch areas) 16 cpm or more (bizhub 163) Full size Fixed zoom ratios (Europe, china) Fixed zoom ratios (Latin america areas for inch) Reduction Enlargement Full size Reduction Enlargement
Warming-up time
Image loss
First copy time (A4, full size) Processing speed
Outline
Max. six-way system
bizhub 163/211/220
Full size Fixed zoom ratios (Latin america area for Reduction metric) Enlargement Variable zoom ratios Paper size used 0.250 to 4.000 Tray 1 Manual bypass Plain paper/recycled paper Paper capacity (Tray 1)

x 1.00 x 0.250, x 0.500, x 0.700, x 0.780 x 1.150, x 1.410, x 2.000, x 4.000 in 0.001 increments A3 to A5S, Letter, LedgerS, 11 x 14, LegalS, Invoice, 8K, 16K, FLS 250 sheets 20 sheets 10 sheets 1 sheets
Special paper (thick paper, overhead projector transparencies, postcards, label sheets) Envelopes
Outline
Paper capacity (Manual bypass)
Plain paper/recycled paper/special paper
C. Paper
Tray1 Plain paper (60 to 90 g/m2) Transparencies Type Thick Paper (91 to 157 g/m2) Postcards Labels Envelopes Size Width Length Paper feed unit Manual bypass *1 *1 *1 *1 *1 *1
(250 sheets) (20 sheets) (20 sheets) (20 sheets) (20 sheets) (10 sheets) 140 to 432 mm *2
90 to 297 mm *2 182 to 297 mm *2 90 to 297 mm *2
*1: Capacity of manual bypass: 1 sheet *2: If the width set 297 mm, the max. length is to 420 mm. If the length set 432 mm, the max. width is to 279 mm. D. Maintenance
300,000 prints or 5 years, whichever is earlier (bizhub 211/bizhub 220) 240,000 prints or 5 years, whichever is earlier (bizhub 163)
Machine durability
Theory of Operation Ver. 1.0 Apr. 2007 E. Machine specifications

Power requirements Voltage Frequency
bizhub 163/211/220
AC100 V, AC120V, AC220-240V 50/60 Hz 100/110/120 area 1000 W 10% or less 1050 W 10% or less 940 W 10% or less 1100 W 10% or less 1200 W 10% or less 1350 W 10% or less 1250 W 10% or less
bizhub 163 Max power consumption bizhub 211/220
127/230 area 220 area 240 area 110/120/220 area 127/240 area 230 area
599 (W) x 620 (D) x 520 (H) mm *1 Dimensions 760 (W) x 620 (D) x 604 (H) mm *2 (bizhub 220 for China) 760 (W) x 620 (D) x 520 (H) mm *2 (bizhub 163 for China) Space requirements Mass 998 (W) x 665 (D) mm (bizhub 211/220) 998 (W) x 620 (D) mm (bizhub 161) 89 kg (when fully equipped)
*1: Including the original cover *2: Including MB-501 and original cover F. Operating environment
Temperature Humidity 10 to 30C (with a fluctuation of 10C or less per hour) 15 to 85% (with a fluctuation of 10%/h)
G. Built-in controllers
Printing Speed bizhub 211: 21 printed pages/min (A4, 300 dpi) 12 printed pages/min (A4, 600 dpi) bizhub 163: 16 printed pages/min (A4, 300 dpi) 12 printed pages/min (A4, 600 dpi) Memory Interface Printer language Font Complying OS Shared with the copier USB revision 2.0 compatible GDI Windows Windows XP (SP2 or later), Windows 2000 (SP4 or later), Windows ME, Windows 98 SE
Outline
bizhub 163/211/220
2.1
Fax kit (FK-506): (Option)

G3 General subscriber telephone line, NCC each line Direct connection (using a modular jack) 33.6, 31.2, 28.8, 26.4, 24.0, 21.6, 19.2, 16.8, 14.4, 12.0, 9.6, 7.2, 4.8, 2.4 kbps (automatic switching) 3 seconds *1 8 dots/mm x 3.85/7.7/15.4 lines/mm, 16 dots/mm x 15.4 lines/mm *2 Maximum A3 (Ledger), banner documents (maximum 1000 mm (39-1/4 inches)) possible Metric: A3, B4, A4, B5, A5 Inch: Invoice (8-1/2 x 5-1/2), Letter, Legal (8-1/2 x 14), Ledger (11 x 17) With built in memory (5 MB): 280 pages With expanded memory (64 MB): 1,024 pages *With standard A4-size documents MH / MR / MMR / JBIG
Transmission mode Compatible wiring Connection method Transmission speed Transmission time Scanning density
Outline
Document size Print paper size Scanning storage
Compression encoding format
*1: This is the speed for transmitting an A4-size, or Letter-size document containing approximately 700 characters at high-speed (33.6 kbps) using the standard resolution (8 dots/mm x 3.85 lines/mm (200 dpi x 100 lpi)). The transmission time for only the image information and the communication control time are not included. In addition, the actual transmission time differs depending on the contents of the document, the recipients fax machine and the condition of the wiring. *2: Real-time transmission is supported only with the document feeder.
3. Cross sectional view

bizhub 163/211/220
2 3 4 5 6 7 8
4034G502BA
3.
Cross sectional view

1
12
11
10
[1] [2] [3] [4] [5] [6]
Automatic document feeder DF-502 (Option) Scanner Job separator JS-503 (Option) Fusing unit Image transfer section Multiple bypass MB-501 (Option)
[7] [8] [9] [10] [11] [12]
Paper feed unit PF-502 (Option) Copy table DK-703 (Option) Paper feed tray/1 PH unit Imaging unit Exit section
Outline
4. Paper path
bizhub 163/211/220
4.
Paper path
Outline
4034G503BA
5. Copy process
bizhub 163/211/220
[13] Fusing [11] Cleaning [10] Paper Separation [9] Image Transfer [8] Paper Feed
A08EE568AA
5.
Copy process
[1] Photoelectric Conversion [2] IR Image [14] Paper Exit
Processing
[3] PH Image
Processing
[6] Laser Exposure
[5] Drum Charging [7] Developing
[1]
Photoelectric Conversion
A CCD sensor is used to convert the image data represented by light reflected off the original to a corresponding electric signal which, in turn, is output to the IR image processing section. The analog electric signal is converted to an 8-bit digital image
IR Image [2] Processing
signal (A/D conversion) which, in turn, goes through appropriate corrections before being output to the PH image processing section.
After going through corrections, the digital image signal is con-
[3]
PH Image Processing
verted to a corresponding electric signal (D/A conversion), with which the laser is turned ON or OFF as necessary.
Made up of an aluminum pipe coated with a photoconductive
[4] PC Drum [5] Drum Charging [6] Laser Exposure
layer, on which an electrostatic latent image is formed.

A uniform negative DC charge is deposited across the entire
surface of the PC Drum.

The laser beam strikes the surface of the PC Drum, forming an
electrostatic latent image. Toner negatively charged in the Developer Mixing Chamber is attracted onto the electrostatic latent image changing it to a visible, developed image. A developing bias (Vb) is applied to the Developing Roller to prevent toner from being attracted onto those areas of the PC Drum which correspond to the background areas of the original.
Paper is supplied from the paper feed tray. A DC positive charge is applied to the Image Transfer Roller to
[7] Developing
[8] Paper Feed [9] Image Transfer
transfer the visible image on the surface of the PC Drum onto the paper.
Outline
[12] Main Erase
[4] PC Drum
5. Copy process
bizhub 163/211/220
The PC Drum Paper Separator Fingers remove paper from the surface of the PC Drum. [10] Paper Separation The Charge Neutralizing Plate neutralizes any charge left on the paper.
[11] Cleaning [12] Main Erase [13] Fusing
Residual toner on the surface of the PC Drum is scraped off.

The toner is then recycled back to the Developing Unit. The surface of the PC Drum is irradiated with light and any sur-
face potential remaining there after cleaning is neutralized.

The developed image is permanently fused to the paper by the
combination of heat and pressure applied by the Fusing Roller. The paper is fed out onto the Exit Tray. The optional Job Separator (JS-503), when mounted on the copier, allows a specific tray, in which paper is fed, to be selected according to the operating mode.
Outline
[14] Paper Exit
10
6. Overall configuration
bizhub 163/211/220
A08EE569AA
6.
6.1
Overall configuration
Timing Chart at Power ON
Power unit cooling fan motor (FM2)
11
Fusing cooling fan motor (FM1)
6. Overall configuration
bizhub 163/211/220
6.2
Control Block Diagram
Operation Panel
IR
CCD
MFP board (MFPB) EM-103
Document related option
FAXB NC-503 or IC-206
NCUB
Paper Exit Source Option PH High voltage unit Paper Source Option Printer control board (PRCB) PU
Process (Motor, Sensor, DC Power) Control System Line Image Bus Line
A08EC506AA
12
7. Scanner (IR)
bizhub 163/211/220
A08EC579AA
7.
7.1
Scanner (IR)
Composition
A08EC508AA
Original size sensor 1 (PS101) Original cover sensor (PS8) Scanner home position sensor (PS100) Original cover set switch (S6) Scanner motor (M5) CCD board (CCDB)
Scanner Assy
Exposure Lamp 2nd/3rd Mirrors Carriage

A08EC514AA
13
7. Scanner (IR)
bizhub 163/211/220
7.2
Drive
A08EC515AA
14
7. Scanner (IR)
bizhub 163/211/220 Composition/Operation
A08EE572AA
7.3
7.3.1
Operation
Scanner Moving Mechanism/Control
The Scanner is moved by the Scanner Motor at a given speed. The Scanner Home Position Sensor detects the Scanner at its home position. The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner. It thereby keeps constant the optical path length between the original and the PC Drum. A. Operation <Marking copies through the Original Glass>
1. The Scanner generally stands by at the shading position. When the Original Cover or ADF is raised to an angle of 15 or more, the Scanner moves to the original size detection position. 2. When the Original Cover or ADF is raised to an angle of less than 15 with an original placed on the Original Glass (when the Original Cover Sensor is activated), the lamp turns ON and the original size is detected. 3. When the Size Reset Switch is turned ON with the Original Cover or ADF fully lowered, the Scanner moves to the shading position to carry out shading. 4. If the Start key is not immediately pressed, the lamp goes out after the lapse of 11 sec. after it has turned ON. 5. If the Start key is pressed immediately and the lamp remains ON, the Scanner starts a scan motion immediately. 6. After the original has been scanned, the Scanner makes a return motion and its home position is detected. Then, the Scanner moves to, and stops at, the home position.
15
7. Scanner (IR)
bizhub 163/211/220
<Making copiers using DF-502>
A08EE578AA
1. When the original is loaded and the Start key pressed, the Scanner performs shading. 2. The Scanner then moves to the scanning position under the ADF glass. The original is scanned as it is moved. 3. After the original has been scanned, the home position of the Scanner is detected. Then, the Scanner moves to, and stops at, the home position. 7.3.2 Original Size Detection
Original Size Sensor 1 and the CCD mounted in the optical section are used to detect the size of the original.
PS102 (Option) PS101
A08EE570AA
16
Theory of Operation Ver. 1.0 Apr. 2007 7.3.3 Determination of Original Size
7. Scanner (IR)
The Original Size Sensor is used to determine the size of the original. Two size conversion patterns are available depending on the applicable marketing area. Refer to the Field Service (CCD APS SIZE) for setting. (1) Size Detection (Standard) <For Inch and Latin America (Inch) areas> Pattern 1
Original Size Sensor PS101 *PS102 OFF ON Invoice S Legal S Letter S Legal S Letter 1117 S ~144.7 mm ~220.9 mm ~221.0 mm
Pattern 2
Original Size Sensor PS101 *PS102 OFF ON OFF ON OFF OFF ON ON Invoice S FLS S A5 S FLS S B5 S FLS S A4 S FLS S Letter S FLS S B5 FLS S B4 S B4 S B5 B4 S B4 S B4 S Letter 1117 S 1117 S 1117 S A4 A3 A3 A3 ~143.9 mm ~153.0 mm ~187.0 mm ~213.0 mm ~220.9 mm ~225.0 mm ~262.0 mm ~284.4 mm 284.5 mm~
Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S
*: PS102 is an option.
17
7. Scanner (IR)
bizhub 163/211/220
<For Metric, China and Latin America (Metric) areas> Pattern 1

Original Size Sensor PS101 OFF ON *PS102 A5 S FLS S B5 S FLS S 16K S FLS S A4 S FLS S B5 FLS S B5 B4 S 16K 8K S A4 A3 ~153.0 mm ~187.0 mm ~200.0 mm ~215.0 mm ~225.0 mm ~262.0 mm ~275.0 mm 275.1 mm~
Pattern 2
Original Size Sensor PS 101 *PS 102 Invoice S A5 S B5 S 16K S A4 S Letter S B5 B5 B4 S B4 S B4 S 16K 8K S 8K S 8K S Letter 1117 S 1117 S 1117 S A4 A3 A3 A3 ~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5 mm mm mm mm mm mm mm mm mm mm mm~
OFF OFF ON OFF ON
OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S ON ON Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S B4 S B4 S
18
Theory of Operation Ver. 1.0 Apr. 2007 (2) Size Detection (When FLS/LEGAL Change is selected) For Inch and Latin America (Inch) areas Pattern 1
Original Size Sensor PS101 *PS102 OFF ON Invoice S FLS S Letter S FLS S Letter 1117 S ~144.7 mm ~220.9 mm ~221.0 mm
7. Scanner (IR)
bizhub 163/211/220
~262.0 mm ~284.4 mm 284.5 mm~ B4 S B4 S B4 S 1117 S 1117 S 1117 S A3 A3 A3
Pattern 2
Original Size Sensor PS101 *PS102 ~143.9 mm Invoice S FLS S ~153.0 mm ~187.0 mm ~213.0 mm ~220.9 mm ~225.0 mm
ON OFF ON
OFF ON ON
FLS S
FLS S
FLS S
FLS S
FLS S B4 S B4 S
Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S
*: UN3 is an option.
19
OFF
OFF
A5 S
B5 S
A4 S
Letter S
B5
B5
Letter
A4
7. Scanner (IR)
bizhub 163/211/220
7.3.4 Pattern 1
For Metric, China and Latin America (Metric) areas
Original Size Sensor PS101 OFF ON *PS102 A5 S B5 S 16K S A4 S B5 B5 B4 S 16K 8K S A4 A3 ~153.0 mm ~187.0 mm ~200.0 mm ~215.0 mm ~225.0 mm ~262.0 mm ~275.0 mm 275.1 mm~
Legal S Legal S Legal S Legal S Legal S
Pattern 2
Original Size Sensor PS 101 *PS 102 Invoice S A5 S B5 S 16K S A4 S Letter S B5 B5 B4 S B4 S B4 S 16K 8K S 8K S 8K S Letter 1117 S 1117 S 1117 S A4 A3 A3 A3 ~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5 mm mm mm mm mm mm mm mm mm mm mm~
OFF OFF ON OFF ON
OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S ON ON Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S B4 S B4 S
20
8. PH (Writing section)
bizhub 163/211/220
A08EC580AA
8.
8.1
PH (Writing section)
Composition
A08EC508AA
Polygon Motor
f Lens
LD Board
SOS Sensor
A08EC516AA
21
8. PH (Writing section)
bizhub 163/211/220
8.2
Drive
When a laser beam strikes the Polygon Mirror, light reflected off the Polygon Mirror is directed at the PC Drum by way of the lens and return mirror. The Polygon Mirror has seven faces, being turned at high speeds by the Polygon Motor. The SOS Mirror and SOS Sensor keep constant the timing, at which emission of a laser beam is started for each main scanning line.
Polygon Motor
f Lens SOS Mirror
PC Drum
LD Board
SOS Sensor
A08EC526AA
22
9. Imaging unit
bizhub 163/211/220
A08EC581AA
9.
9.1
Imaging unit
Construction
A08EC509AA
Cleaning Blade
PC Drum Paper Separator Fingers
PC Drum Charge Corona
PC Drum
Developing Roller
3rd Toner Conveying Roller
1st Toner Conveying Roller 2nd Toner Conveying Roller
A08EC517AA
23
9. Imaging unit
bizhub 163/211/220
9.2
Operation
The Main Motor provides drive for the PC Drum, Developing Roller, and other mechanical components.
A08EC562AA
24
19. Fusing unit section

bizhub 163/211/220
19.2 Composition (for bizhub 211/220)

Sub Heater Lamp) Heater Lamp
Fusing Roller/rt
Fusing Roller
Thermostat
Pressure Lever
A08EE571AA
Thermistor (TH1) Thermistor (TH2)
54

bizhub 163/211/220
Fusing Roller/Rt
A08EC549AA
19.3 Drive
The main motor (M1) provides the drive for the fusing unit.
Main motor (M1)
Fusing roller
19.4 Operation
19.4.1 Fusing Roller Pressure Mechanism To provide a nip width between the rollers, a Pressure Spring is used functioning to press the Fusing Roller/Rt up against the Fusing Roller.
Fusing Roller/Rt
Pressure Lever
Fusing Roller
Pressure Spring
A08EC550AA
55

bizhub 163/211/220
19.4.2
Fusing Temperature Control (for bizhub 163)
The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the surface of the Fusing Roller. The Fusing Roller surface temperature is detected by using a thermistor that translates the temperature to a corresponding electrical signal. If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater Lamp is shut down.
<Temperature Control in Standby State>
Warm-up completed
A08EE574AA
Machine Condition or Paper Type Standby Plain paper (width: 250 mm or more; length: less than 360 mm) Plain paper (width: less than 250 mm) Thick paper (width: 250 mm or more) Thick paper (width: less than 250 mm) OHP film (width: 250 mm or more) OHP film (width: less than 250 mm)
Mode 1 180 C 190 C 180C 210 C 200 C 180 C 155 C
Mode 2 180 C 170 C 190 C 170 C 180 C 165 C 210 C 190 C 200 C 190 C 180 C 165 C 155 C
Mode 3 170 C 170 C 165 C 190 C 190 C 165 C 155 C
56
Theory of Operation Ver. 1.0 Apr. 2007 19.4.3 Fusing Temperature Control (for bizhub 211/220)

A08EE576AA
The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the surface of the Fusing Roller. The Fusing Roller surface temperature is detected by using a thermistor that translates the temperature to a corresponding electrical signal. If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater Lamp is shut down.
<Temperature Control in Standby State>
Warm-up completed
Machine Condition or Paper Type Standby Plain paper (width: 221 mm or more) Plain paper (width: 220 mm or less) Thick paper (width: 201 mm or more) Thick paper (width: 200 mm or less) OHP film (width: 201 mm or more) OHP film (width: 200 mm or less)
Mode 1 180 C 180 C 180 C 200 C 200 C 165 C 165 C
Mode 2 180 C 165 C 180 C 180 C 200 C 200 C 165 C 165 C
Mode 3 165 C 180 C 180 C 200 C 200 C 165 C 165 C
57

bizhub 163/211/220
19.4.4
PPM Control (bizhub 163 Only)
If paper of a small size (width of 250 mm or less) or thick paper is used to run a multicopy cycle, the temperature on the edges of the Fusing Rollers tends to run high, meaning that the temperature of the Fusing Rollers varies among different spots of the rollers. When the cumulative number of copies made through continuous copy cycles * exceeds 30, the paper take-up interval is made longer, thereby allowing the temperatures of the Fusing Rollers at different spots to be uniform. * Continuous copy cycle: Continuous copy cycles run with an interval of 2 min. or less between cycles.
58
20. Paper exit (for bizhub 163)

bizhub 163/211/220
A08EC593AA
20. Paper exit (for bizhub 163)

20.1 Composition
A08EC560AA
20.2 Drive
The main motor (M1) provides the drive for the exit section.
Exit Roller Main motor (M1)
A08EC553AA
59
21. Paper exit (for bizhub 210/220)

bizhub 163/211/220
21. Paper exit (for bizhub 210/220)

21.1 Construction
A08EC593AA
A08EC560AA
21.2 Operation
The exit rollers are driven by the switchback motor (M3).
Exit Roller
Switchback motor (M3)

A08EE575AA
60
22. Image stabilization system

22. Image stabilization system

22.1 Composition
The following image stabilization controls are provided to ensure stabilized copy image.
Purpose Means Control
To stabilize image density.
The Vg/Vb control voltage is varied to bring Vg/Vb to an appropriate level according to the following settings. Grid voltage (Vg) and devel- Tech. Rep. Choice: ID Adjustment oping bias (Vb) control Tech. Rep. Choice: VG Adjustment User's Choice: Print Density SUPPLIES LIFE COUNT. Paper type The image transfer output is varied to bring the image transfer current to an appropriate level according to the following conditions. Paper type Paper width B/W ratio of image
To stabilize image transfer.
Image transfer output control
A08EE577AA
61
23. Others
bizhub 163/211/220
23. Others
23.1 Fan Control
23.1.1 Composition
Power unit cooling fan motor (FM2)

A08EC555AA
Ozone Filter
A08EC556AA
62
Theory of Operation Ver. 1.0 Apr. 2007 23.1.2 Operation
23. Others
A. Function
Motor Name Control Conditions
A fan motor draws air from the area around the Fusing Unit to the outside to prevent the machine interior temperature from running high. In addition, the fan motor pulls paper being transported up through suction force to help stabilize paper transport. Ozone produced from the PC Drum Charge Corona is absorbed by the Ozone Filter from the air drawn by a fan motor to the outside. The fan motor is turned at full speed during a print cycle and at a speed reduction during other timings, thereby making the machine quieter without sacrificing cooling performance.
A cooling fan motor draws air from the area around the Power Supply Unit to the outside to prevent the Power Supply Unit temperature from running high. Power unit cooling fan motor (FM2) The cooling fan motor is turned at full speed when the Main Motor turns and at a speed reduction during other timings, thereby making the machine quieter without sacrificing cooling performance. B. Fan control
Motor Name Control Control Conditions
During a print cycle (full speed rotation after the lapse Full speed of a given period of time after the start of the print cycle) Fusing cooling fan motor (FM1) Half speed rotation after the lapse of a given period of time after the end of the print cycle Half speed Half speed rotation at any timing other than the full speed and stop control Stop When a malfunction occurs When the right door is open
Full speed When power is turned ON or Sleep is canceled Power unit cooling fan motor (FM2) Stop Half speed rotation if the main motor (M1) is deenergized after the lapse of a given period of time after the full speed rotation
63
23. Others
bizhub 163/211/220
Blank Page
64
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
DF-605/MK-501 Outline
1. 2. 2.1 2.2 Product specifications ............................................................................................. 1 Paper Feed Path ..................................................................................................... 4 In 1-sided mode .................................................................................................... 4 In 2-sided mode .................................................................................................... 4
3. 4. 5. 5.1 5.2 5.3 Composition ............................................................................................................ 5 Operation ................................................................................................................ 7 Document pick-up mechanism ............................................................................. 7 Pick-up operation .......................................................................................... 7 Document feed/transport mechanism................................................................... 8 Raised/lowered position detecting mechanism................................................... 12 Document size detection............................................................................. 12 Raised/lowered position detection .............................................................. 12 5.1.1
Drive ........................................................................................................................ 6
5.3.1 5.3.2
Outline
DF-605/MK-501
CONTENTS
Outline
DF-605/MK-501
Blank Page
ii
1. Product specifications
1.
Name
Product specifications
Reverse automatic document feeder Paper feed Paper feed from top of stack Switch back system Straight exit system
A. Type
Type
Turnover Paper exit
Installation Document alignment Document loading
Screw cramp to the main unit Center Left image side up
B. Functions
Modes 1-sided mode / 2-sided mode
C. Paper
1-Sided mode 35 to 128 g/m2 (9.25 to 34 lb) 2-Sided mode 50 to 128 g/m2 (13.25 to 34 lb) 1-Sided / 2-Sided Mode 50 to 128 g/m2 (13.25 to 34 lb) 1-Sided mode 35 to 128 g/m2 (9.25 to 34 lb) 2-Sided mode 50 to 128 g/m2 (13.25 to 34 lb)
Standard mode Plain paper Mixed original detection mode Plain paper FAX mode Plain paper
Type of document
Detectable document size*1 Capacity
Metric area B6S to A3 Inch area 5 1/2 8 1/2S / 5 1/2 8 1/2 to 11 17 80 sheets (80 g/m2) or load height of 11 mm or less.
*1: For the combined original detection mode, refer to the mixed original detection enabled size combination table.
Outline
DF-605/MK-501
Outline
1. Product specifications D. Paper feed prohibited originals If fed, trouble occurrence will be highly possible.
Type of original Original that is stapled or clipped. Book original Original weighing less than 35g/m2 or 129g/m2 or more Torn original
DF-605/MK-501
Possible trouble Feed failure, damage to the original, or drive failure due to clip clogging Feed failure, damage to the original, or drive failure Feed failure Feed failure, damaged sheet Original misfeed due to dog-ear or skew Feed failure Feed failure Feed failure Damaged sheet Patched part folded or torn sheet, Sheets misfed
Outline
Highly curled original (15 mm or more) OHP transparencies Label Sheet Offset master Sheets clipped or notched Sheets patched
E. Paper feed not guaranteed originals If fed, paper feed will be possible to some extent but trouble occurrence will be possible.
Type of original Sheets lightly curled (Curled amount: 10 - 15 mm) Heat sensitive paper Coated paper (Ink Jet paper) Translucent paper Paper immediately after paper exit from the main unit Possible trouble Dog-eared, exit failure Edge folded, exit failure, transport failure Take-up failure, transport failure Take-up failure, transport failure Take-up failure, transport failure
Paper with many punched holes (e.g., loose leaf) limited Multi-page feed due to flashes from holes to vertical feeding Sheets with 2 to 4 holes Sheets two-folded or Z-folded Sheets with rough surface (e.g., letterhead) Sheets folded Transport failure Transport failure, image deformation Take-up failure Image deformation, multi-page feed, take-up failure
Theory of Operation Ver. 1.0 Apr. 2007 F. Mixed original feed chart For Metric
Max. original size Mixed original size 297 mm A3 A4 B4 B5 A4S A5 B5S A5S B6S 297 mm A3 OK OK OK OK OK* NG NG NG NG A4 OK OK OK OK OK* NG NG NG NG 257 mm B4 OK OK OK OK OK* NG NG B5 OK OK OK OK OK* NG NG
210 mm A4S OK OK OK NG NG A5 OK OK OK NG NG
182 mm 148 mm B5S OK OK NG A5S -
257 mm
210 mm 182 mm 148 mm 128 mm
OK OK
For Inch
Max. original size Mixed original size 11 11 x 17 8.5 x 11 8.5 x 14 8.5 x 11S 8.5 x 5.5 8.5 x 5.5S 11 x 17 OK OK OK* OK* NG NG 11 8.5 x 11 OK OK OK* OK* NG NG 8.5 x 14 OK OK OK NG 8.5 8.5 x 11S OK OK OK NG 5.5 x 8.5 OK OK OK NG 5.5 8.5 x 5.5S OK
8.5
5.5
OK NG *
Mixed original feed available (Tilted with in 1.5% or less) NO. mixed original feed Can not set original Tilted with in 2% or less is 80%
G. Machine specifications
DC 24 V (supplied from the main unit) Power Requirements DC 5 V (generated within the Automatic Document Feeder) DC 3.3 V (supplied from the main unit) Max. Power Consumption Dimensions Weight 48 W or less 582 (W) x 558 (D) x 145 (H) mm 23 inch (W) x 20.5 inch (D) x 5.75 inch (H) 10 kg (22 lb) or less
H. Operating Conforms to the operating environment of the main unit. NOTE These specifications are subject to change without notice.
Outline
DF-605/MK-501
2. Paper Feed Path
DF-605/MK-501
2.
2.1
Paper Feed Path

In 1-sided mode
Outline
3: Exit 2: Transport and turnover 1: Feed (scanning the 1st side)
4344T1C501AA
2.2
In 2-sided mode
2: Transport and switchback
6: Exit
4: Transport and switchback 1: Feed (scanning the 1st side) 3: Transport and turnover (scanning the 2nd side) 5: Transport
4344T1C502AA
3. Composition
3.
Composition
Document feed section
Conveyance section
Switchback section
Document exit section

4344T2C501AA
DF-605/MK-501
4. Drive
DF-605/MK-501
4.
Drive
Paper feed motor (M1-ADF)
Transport motor (M2-ADF)
4344T2C502AA
5. Operation
5.1
Document pick-up mechanism
The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separation Roller, and this section is driven by the Paper Feed Motor. 5.1.1 Pick-up operation
When the Start key is pressed, the Paper Feed Motor starts turning backward, causing the Pick-Up Roller to lower and start turning at the same time. At the same time, the Feed Roller starts turning. The Pick-Up Rollers are in the raised position when in the standby state and in the lowered position during feeding.
Paper feed motor (M1-ADF) Pick-Up Roller
Feed Roller
Separation Roller
4344T2C503AA
DF-605/MK-501
5.
Operation
5. Operation
5.2
DF-605/MK-501
Document feed/transport mechanism
When the document reaches the Registration Sensor, the Feed Roller starts turning forward and, at the same time that the Pickup Roller goes up, drive is then supplied to the Registration Roller. When the Transport Motor starts turning forward, the two Transport Rollers and the Exit/ Turnover Roller feed the document toward the exit direction.
Parts Direction of Rotation Backward rotation Forward rotation Backward rotation Forward rotation Details The Pickup Rollers lower and start turning and the Feed Roller turns. The Registration Roller turns. The Transport Roller and Exit/Turnover Roller turn in the direction to turn over the original. The Transport Roller and Exit/Turnover Roller turn in the direction to feed the original out.
Paper Feed Motor (M1-ADF)
Transport Motor (M2-ADF)
Transport motor (M2-DF)
Paper feed motor (M1-DF)
Exit/Turnover Roller
Registration Roller Transport Roller
4344T2C504AA
Theory of Operation Ver. 1.0 Apr. 2007 A. Operation flow in the 1-sided mode
5. Operation
Original Detection Sensor
Exit
Scanning the 1st side
Exit/Turnover Sensor
4344T2C506AA
1. When the Start key is pressed, the Paper Feed Motor starts turning backward, causing the Pick-Up Roller to lower and start a paper take-up sequence. 2. The scanning of the 1st side is started after the lapse of a given period of time after the Original Detection Sensor has been activated by the leading edge of the original. 3. The original is transported for a given period of time after the trailing edge of the last page of the document has deactivated the Exit/Turnover Sensor. It is then fed into the Exit Tray and the Transport Motor is deenergized.
DF-605/MK-501
5. Operation
B. Operation flow in the 2-sided mode 1. When the Start key is pressed, the Paper Feed Motor starts turning backward, causing the Pick-Up Roller to lower and start feeding the 1st page of the document. The scanning of the 1st side is started after the lapse of a given period of time after the Original Detection Sensor has been activated by the leading edge of the 1st page. The Transport Motor is deenergized to stop the original after the lapse of a given period of time after the trailing edge of the 1st page has deactivated the Exit/Turnover Sensor.
Original Detection Sensor
DF-605/MK-501
Stop
Scanning the 1st side
Exit/Turnover Sensor
4344T2C506AA
2. The Transport Motor is turned backward to turn over the original. After the Registration Roller, the Transport Motor is turned forward to allow the Scanner to scan the backside of the 1st page. 3. After the transport sequence for turnover has been started, the Exit Roller Retraction Solenoid is energized so that the Exit/Turnover Roller is retracted.
Turnover Stop
Scanning the 2nd side

4344T2C505AA
10
5. Operation
Turnover Exit
Scanning the 2nd side

4344T2C505AA
11
DF-605/MK-501
4. To ensure that pages of the document are in the proper order, the page is turned over again before being ejected into the Exit Tray.
5. Operation
5.3
DF-605/MK-501
Raised/lowered position detecting mechanism

Document size detection
5.3.1
The 15 degree Open Detection Mechanism enables the main unit to detect the document size when the DF is used as the Original Cover of the main unit, there is the Lever Actuator provided in the DF body that blocks or unblocks a sensor to initiate a reconfirmation of the original size as read by the original size detection sensors. 5.3.2 Raised/lowered position detection
The Raised/Lowered Position Detection Mechanism uses a magnet installed in the DF body to allow the main unit to know that the DF is raised or lowered. This magnet actuates the Original cover set switch on the main unit to perform this operation.
Original cover set switch (S6)
4344T2C508AA
12
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
Revision mark: To indicate clearly a section revised, show to the left of the revised section. A number within represents the number of times the revision has been made. To indicate clearly a section revised, show in the lower outside section of the corresponding page. A number within represents the number of times the revision has been made. NOTE s and mechanism may be subject to change for
2. Multiple Bypass (MB-501)
2.2
MB-501
Drive
Drive for bypass paper feed is provided by the Main Motor (M1). The drive is transmitted through the Paper feed Solenoid.
Main motor (M1)
Feed Roller
Paper feed solenoid (SD1)
Paper empty sensor (PS1)

4687C503AA
2.3
2.3.1
Operation
MB-501 Composition/Operation
4687C504AA
Paper Feed Mechanism
The Paper Lifting Plate is raised to press the paper stack on the tray up against the Feed Roller. The Paper Lifting Plate is raised and lowered in time with a paper feed sequence. The ascent and descent motion of the Paper Lifting Plate is accomplished when the drive from the motor is transmitted to the cam through a solenoid to rotate the cam.
Drive from Main Motor Paper feed solenoid (SD1)
Feed Roller
Cam
<Ascent/Descent Motion> Main Motor (M1) is energized. Feed Roller is turned. Paper feed solenoid (SD1): Energized Cam: Rotates Tray: Raised Paper feed solenoid (SD1): Deenergized Paper take-up Paper feed solenoid (SD1): Energized Cam: Rotates Tray: Lowered Paper feed solenoid (SD1): Deenergized
4687C505AA
Feed Roller Paper Cam
2. Multiple Bypass (MB-501) 2.3.2

MB-501
Paper Empty Detection Mechanism
The Paper Empty Sensor detects a sheet of paper on the Multiple Bypass.
<When Paper is Present> Paper feed solenoid (SD1) <When Paper is not Present>
Paper
4687C506AA
2.3.3
Paper Feed Control
4687E507AA
Theory of Operation Ver. 1.0 Apr. 2007 2.3.4 Paper Feed Retry Control
To minimize the occurrence of a paper misfeed, the paper feed sequence is temporarily halted if the paper fails to reach the Registration Roller Sensor within a given period of time after the sequence has been started. The paper feed sequence is then performed again. These paper feed sequences are repeated a given number of times.
No. of Paper Feed Retry Sequences Paper Feed Retry 2
MB-501
MB-501
Blank Page
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS JS-503 Outline

1. Product specification ............................................................................................... 1
JS-503
2. 2.1 2.2 Job Separator (JS-503) ........................................................................................... 3 Construction ......................................................................................................... 3 Operation .............................................................................................................. 4 Tray Selecting Mechanism ............................................................................ 5
Composition/Operation Outline
2.2.1 2.2.2 2.2.3
Tray-Full Detecting Mechanism..................................................................... 6 Job Tray Paper Detecting Mechanism........................................................... 6
Outline
JS-503
Blank Page
ii
Outline
A. Type
Type Installation Paper storage system Add-on drawer Built into the exit section of the copier Moving drawer system
B. Paper
Upper drawer Plain paper (60 to 90 g/m2) OHP film Thick paper (91 to 157 g/m2) Postcards, labels, and envelopes 100 sheets (A4S), Recycled paper (60 to 90 g/m2) 50 sheets (other than A4S) Load height up to 22 mm 150 sheets (A4S), 75 sheets (other than A4S) 10 sheets 20 sheets 100 sheets (A4S), 50 sheets (other than A4S) Load height up to 22 mm Lower drawer 150 sheets (A4S), 75 sheets (other than A4S)
C. Machine specifications
Power requirements Power consumption DC24 V, DC5 V (supplied from the copier) 24 W or less
D. Operating environment Conforms to the operating environment of the main body. NOTE These specifications are subject to change without notice.
Outline
JS-503
1.
Product specification
Outline
JS-503
Blank Page
2. Job Separator (JS-503)
2.1 Construction
JS-503
4689C507AA
2.
Job Separator (JS-503)
4689C501AA
Paper empty sensor (PS4) JS drive board (JSDB) Job Tray
Paper full sensor (PS3)
Paper detecting board (PSDB)
Bin switching motor (M1) Lower home position sensor (PS2) Upper home position sensor (PS1)
4688C510AA
2.2
JS-503
Operation
The Main Motor (M1) provides drive for the Job Separator.
Paper detecting board (M1) Job Tray
4689C502AA
Theory of Operation Ver. 1.0 Apr. 2007 2.2.1 Tray Selecting Mechanism
The paper is fed out into either the Exit Tray of the copier or the Job Tray. The active tray is selected according to the operating mode (either the fax, copier, or printer mode). The Exit Tray of the copier is for the copier. The Job Tray is, on the other hand, for the fax and printer. The corresponding tray is selected through the operation of the motor and sensor as shown below.
<When feeding paper into the Exit Tray: Copier>
Upper home position sensor (PS1): Activated Bin switching motor (M1)
Paper
4021M046AB
4689C503AA
(M1: Backward Rotation)
<When feeding paper into the Job Tray: fax/printer> Lower Home position sensor (PS2): Activated
Paper
Job Tray
4689C504AA
JS-503
2. Job Separator (JS-503) 2.2.2

JS-503
Tray-Full Detecting Mechanism
Tray-full detection is valid only when paper is fed into the Job Tray (Job Tray in the lowered position). A tray-full condition is detected when the sensor is blocked for a continuous given period of time (approx. 20 sec.).
Paper full sensor (PS3) Paper
Job Tray Exit Roller
4689C505AA
2.2.3
Job Tray Paper Detecting Mechanism
If paper is fed into the Job Tray when the machine is in a mode in which paper is fed into the Exit Tray (Job Tray in the raise position), the indicator lamp on the Paper Detecting Board lights to warn the user that there is paper in the Job Tray. A sensor is provided for detecting paper in the Job Tray.
<When Paper is Present> Paper empty sensor (PS4) Paper Paper detecting board (PSDB) Job Tray
<When Paper is not Present>
4689C506AA
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS SF-501 Outline

1. Product specifications ............................................................................................. 1
SF-501
2. 2.1 2.2 SHIFTING UNIT (SF-501) ....................................................................................... 3 Composition.......................................................................................................... 3 Operation .............................................................................................................. 4 Exit Position Shifting Mechanism .................................................................. 4
Composition/Operation Outline
2.2.1
Outline
SF-501
Blank Page
ii
Outline
A. Machine specifications
Shifting amount Paper capacity Power consumption 28 mm 250 sheets Less than 63 W
NOTE These specifications are subject to change without notice.
Outline
B. Operating environment Conforms to the operating environment of the main body.
SF-501
1.
Product specifications
Outline
SF-501
Blank Page
2. SHIFTING UNIT (SF-501)
2.1 Composition
SF-501
4690C505AA
2.
SHIFTING UNIT (SF-501)
4690C502AA
SF drive board (SFDB)
Home sensor (PS1)
Shift motor (M1)
4690C501AA
2. SHIFTING UNIT (SF-501)
2.2
SF-501
Operation
Exit Position Shifting Mechanism
2.2.1
Paper is fed into the Shifting Unit along a straight path or shifted from the reference straight path position. This exit position shifting mechanism allows different finishing functions offered by the machine (Non-Sort, Sort, and Group) to be effected. <Straight Feeding> The paper that travels along a straight path is fed straight into the Shifting Unit without being shifted sideways as the Exit Roller turns.
Exit Roller
Paper
4690C503AA
<Shifted Feeding> When the trailing edge of the paper transported to the exit section moves past the Fusing Roller, the Shift Motor is energized to move the Transport Roller sideways. The paper is fed into the Shifting Unit as it is shifted sideways. The Exit Roller is moved sideways by turning the motor forward or backward. The Exit Roller is detected at its home position by a sensor.
Shift motor (M1)
Paper
Home sensor (PS1)
Exit Roller
4690C504AA
2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Use of this manual should be strictly supervised to avoid disclosure of confidential information. Printed in Japan DDA09A-M-TE1

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2007.04 Ver. 1.0

THEORY OF OPERATION TOTAL CONTENTS

bizhub 163/211/220 main body

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION

General precaution General prohibition General instruction

Electric hazard High temperature

Do not touch with wet hand Unplug

Do not disassemble Ground/Earth

MEASURES TO TAKE IN CASE OF AN ACCIDENT

MEASURES TO TAKE IN CASE OF AN ACCIDENT

MEASURES TO TAKE IN CASE OF AN ACCIDENT

Composition of the service manual

Notation of the service manual

When the description is made in combination of the OSs mentioned above:

2007.04 Ver. 1.0

1.0 Service manual Ver.

Issue of the first edition Descriptions of revision

Theory of Operation Ver. 1.0 Apr. 2007

CONTENTS bizhub 163/211/220 main body Outline

7.3.1 7.3.2 7.3.3 7.3.4 8. 8.1 8.2 9. 9.1 9.2 10.

Theory of Operation Ver. 1.0 Apr. 2007

Image transfer and paper separation section........................................................ 37

Toner recovery ...................................................................................................... 39

Manual bypass section.......................................................................................... 48

Theory of Operation Ver. 1.0 Apr. 2007

Registration roller section...................................................................................... 51

Paper exit (for bizhub 163) .................................................................................... 59

Theory of Operation Ver. 1.0 Apr. 2007

Theory of Operation Ver. 1.0 Apr. 2007

1/2 System front view

[12] [6] [1] [13] [7]

[1] [2] [3] [4] [5] [6]

[8] [9] [10] [11] [12] [13]

Multi bypass tray (MB-501) *4

Theory of Operation Ver. 1.0 Apr. 2007

2/2 System rear view

Expanded memory unit (EM-103) Fax kit (FK-506)

Image controller (IC-206) * Network interface card (NC-503) *

* It is not possible to mount these units at the same time.

Theory of Operation Ver. 1.0 Apr. 2007

First copy time (A4, full size) Processing speed

Max. six-way system

Theory of Operation Ver. 1.0 Apr. 2007

Paper capacity (Manual bypass)

Plain paper/recycled paper/special paper

90 to 297 mm *2 182 to 297 mm *2 90 to 297 mm *2

Theory of Operation Ver. 1.0 Apr. 2007 E. Machine specifications

bizhub 163 Max power consumption bizhub 211/220

Theory of Operation Ver. 1.0 Apr. 2007

Fax kit (FK-506): (Option)

Document size Print paper size Scanning storage

Compression encoding format

Theory of Operation Ver. 1.0 Apr. 2007

3. Cross sectional view

Cross sectional view

[1] [2] [3] [4] [5] [6]

[7] [8] [9] [10] [11] [12]

Theory of Operation Ver. 1.0 Apr. 2007

Theory of Operation Ver. 1.0 Apr. 2007

[5] Drum Charging [7] Developing

90 to 297 mm 2 182 to 297 mm 2 90 to 297 mm *2