Star Micronics WinType 4000 Technical Manual

WinType 4000

T

ECHNICAL MANUAL

[ SECOND EDITION ]

LASER PRINTER

NOTICE

form whatsoever, without STAR’s express permission, is forbid-

den.

• The contents of this manual are subject to change without notice.

• All efforts have been made to ensure the accuracy of the contents

of this manual at the time of going to press. However, should any

errors be detected, STAR would greatly appreciate being in-

formed of them.

• The above notwithstanding, STAR can assume no responsibility

for any errors in this manual.

Trademark acknowledgments

Windows

: Microsoft Corporation

INTRODUCTION

1

2

3

4

5

6

This manual describes the WinType 4000 laser printer.

It is intended for use as a reference when performing maintenance procedures.

This manual is prepared for use at a technical level and is not for the general user.

This manual is divided into the following sections:

Chapter 1 General Specifications

Specifications, safety information

Chapter 2 Theory of Operation

A description of the principles of the electrical and mechanical systems and their functions

Chapter 3 Parts Replacement and Adjustments

Explanation of disassembly, reassembly, and adjustment procedures

Chapter 4 Maintenance Guide

Contains an overview of steps for recovering from a breakdown, connector layout diagrams, wiring

connections, and other information useful in maintenance operations.

Chapter 5 Troubleshooting

Contains breakdown analysis procedures used when repairing breakdowns.

Chapter 6 Parts List

Illustrations showing disassembly diagrams, part numbers and part names

* In this manual, MCU PWB is the abbreviation for Main Control Unit Printed Wiring Board.

1

CHAPTER 1

GENERAL SPECIFICATIONS

1. GENERAL SPECIFICATIONS................................................................................3

2. SAFETY INFORMATION........................................................................................6

2-1. Power Supply .......................................................................................................... 6

2-2. Drive Parts............................................................................................................... 6

2-3. Safety Devices ........................................................................................................ 6

2-4. Laser safety............................................................................................................. 7

3. PRINTER COMPONENTS......................................................................................8

– 2 –

GENERAL SPECIFICATIONS

– 3 –

GENERAL SPECIFICATIONS

1. GENERAL SPECIFICATIONS

Engine

Printing process Electro-photographic

Resolution 300 x 300 dpi (Smoothing off)

600 dpi class (Smoothing on)

Exposure Semi-conductor laser beam scanning

Fixing Thermal fusing using heated rollers

Printing speed

Warm-up time 45 seconds or less after power on at 22°C (72°F)

(115 volts or 220 volts)

Time for first print 20.5 seconds for Letter paper

21.1 seconds for A4 paper

Continuous printing speed Min. 4 pages per minute for Letter or A 4 size paper

Printable area 4mm in from the edge of the paper on all sides

Paper feed

Input tray Capacity: 100 sheets of standard paper, 30 overhead (OHP) trans-

parencies, 30 label sheets or 10 envelopes

Paper weight: From 60 g/m

2

(16 lb.) – 135 g/m

2

(36 lb.)

Output tray Face down

Capacity: Approximately 50 sheets

Printing materials

Standard paper XEROX 4024 DP 20 lb 8.5" x 11" cut sheet paper (US)

Special printing OHP film: 8.5" x 11" XEROX, PN 3R2780 (US)

materials A4 XEROX, PN 3R91330 (Europe)

Label: 8.5" x 11" XEROX, PN 3R4469 (US)

A4 XEROX, PN 3R97408 (Europe)

Envelope: Com-10 Monroe Brand, Monarch Monroe Brand

– 4 –

GENERAL SPECIFICATIONS

Toner cartridge

The toner cartridge consists of an OPC drum, developing roller and blades,

primary charge roller, drum cleaner and high definition black toner.

Toner save mode Off/Dark/Medium/Light

Mode Yield

Off Approx. 4000 pages

Dark Approx. 5000 pages

Medium Approx. 5700 pages

Light Approx. 8000 pages

Mean printing life Starter cartridge: 4000 sheets at 5% paper coverage

Replacement cartridge: 4000 sheets at 5% paper coverage

Power specifications

Input line voltage/ For US Voltage Frequency

frequency Min.: 90V 47Hz

Normal: 100/120V 50/60Hz

Max.: 132V 63Hz

For Europe and Asia/Pacific

Voltage Frequency

Min.: 198V 4 7Hz

Normal: 220/240V 50/60Hz

Max.: 264V 63Hz

Power consumption Maximum power consumption when warming-up and printing is as

follows

100/120V Less than 400W (less than 3A)

220/240V Less than 400W (less than 2A)

Environmental specifications Energy Star Compliant

Temperature, humidity Print engine with toner cartridge:

and altitude Operating: 5 – 35°C (41 – 95°F) at 15 – 85% RH (no conden-

sation)

Non-operating: 20 – 40°C (60 – 104°F) at 5 – 95% RH (no conden-

sation)

0 – 2,500 meters (0 – 8,200 feet)

Print engine without toner cartridge:

Non-operating: 20 – 40°C (60 – 104°F) at 5 – 95% RH (no conden-

sation)

0 – 15,000 meters (0 – 49,200 feet)

Acoustic noise Printing: 48 dB (A) or less

Warm up: 38 dB (A) or less

In accordance with ISO 7779

Dust emission Less than 0.1mg/m

3

concentration: Measured in accordance with Mass Measurements Method

– 5 –

GENERAL SPECIFICATIONS

Reliability specifications

MPBF Recommended usage: Average 2,000 pages per month

Maximum 10,000 in any one month

MPBF: 60,000 pages

MTTR Within 30 minutes

Jam ratio 1/1000 using recommended paper

1/100 using special printing materials

Double feed ratio 1/1000 using recommended paper

1/100 using special printing materials

Life 100,000 pages or 5 years

Dimensions 330mm x 235mm x 265mm

(13.0 in. x 9.25 in. x 10.4 in.)

Weight 6.5 kg. (14.3 lbs.) without toner cartridge

7.5 kg. (16.5 lbs.) with toner cartridge

Controller

I/F High speed bi-directional parallel interface

Panel 2 LED lamps (Ready and Error)

Software

Windows Direct (GDI) mode Provides fast, WYSIWYG output from Windows (GDI) mode applica-

tions

PCL mode Provides compatibility with the popular printer languages used in the

LaserJet II series. Both Windows applications and DOS applications

running under Windows can use PCL emulation mode for printing.

PostScript mode Provides compatibility with the sophisticated PostScript language. Both

Windows applications and DOS applications running under Windows can

use PostScript emulation mode for printing.

Paper size

Paper sizes available A4, Letter, Legal, A5, Executive, B5, Com 10, C5, DL, Monarch

in GDI mode

Paper sizes available in A4, Letter, Legal, Executive, Com 10, C5, DL, Monarch

PCL4 emulation

Paper sizes available in A4, Letter, Legal, A5, Executive, B5, Com 10, C5, DL, Monarch

PostScript emulation

– 6 –

GENERAL SPECIFICATIONS

2. SAFETY INFORMATION

In order to prevent accidents from occurring while maintenance is being carried out, all warnings and precautions should

be strictly observed while work is being carried out. Never attempt any kind of dangerous procedure when servicing this

machine.

The precautions noted below only cover a few of the situations which could foreseeably occur during maintenance

operations. Please make sure every safety precaution is observed while work is being carried out.

2-1. Power Supply

In order to prevent electrical shock, burns, damage to the equipment and other problems, always make sure the power

supply is turned off and the power supply cable has been unplugged before maintenance work is carried out.

If the power must be left on in order to measure voltage or for other reasons, make sure sufficient precautions are taken

to prevent electrical shock, and follow the procedures laid down in this manual.

2-2. Drive Parts

Inspection of drive section parts such as sprockets and gears should be carried out using a hand crank.

DANGER: Never inspect these parts while the equipment is in operation!

2-3. Safety Devices

Thorough consideration should be given to safety devices designed to prevent accidents (fuses, interlock switches, etc.)

as well as those handled by the user in the course of operating the equipment (covers, panels, etc.), in order to make sure

they fulfill their function as safety equipment.

DANGER: In order to prevent exposure to the laser beam contained in the printer, the following precautions must

always be strictly observed.

Exposure to the laser beam can result in blindness.

• Never open a cover (ROS assembly) that has the label shown in figure 1-3 on it.

• When disassembling and adjusting the equipment, always make sure the power supply has been

turned off first.

• This equipment is provided with a two-stage safety switch function, so that it can be operated even

with the covers removed, by pressing the interlock switch. When using this method of operation, never

short the other switch at the same time (the second switch is pressed when the actuator at the back of

the EP toner cartridge attachment section is pressed).

• When servicing the printer’s optical system, be careful not to place screwdrivers or other reflective

objects in the path of the laser beam.

Be sure to take off accessories, such as watches and rings, before working on the printer. A reflected

beam, though invisible, can permanently damage your eyes.

Because the laser beam is invisible, be especially careful when servicing the optical system.

Figure 1-1 Itnerlock switch location

Itnerlock switch

– 7 –

GENERAL SPECIFICATIONS

2-4. Laser safety

This printer is certified as a Class 1 laser product. This means that this laser product does not emit harmful laser beams.

This printer emits a Class 3B laser beam, but the beam is entirely enclosed within a protective case and an external cover,

and cannot escape from the printer while the printer is in use.

CLASS 1 LASER PRODUCT.

LUOKAN 1 LASERLAITE.

KLASS 1 LASER APPARAT.

CLASS 3B LASER

WAVE LENGTH 780nm (INVISIBLE)

RATED POWER 5mW

LUOKAN 3B LASER

AALLONPITUUS 780nm (NÄKYMÄTÖN)

TEHO 5mW

Figure 1-3 Caution Label

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso

säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser Klasse 1

Laser de Classe 1

Láser Clase 1

Laser Luokan 1

Laser Klass 1

Figure 1-2 Class 1 Label

– 8 –

GENERAL SPECIFICATIONS

3. PRINTER COMPONENTS

Figure 1-4 External Dimensions Figure 1-5 Rear View

Figure 1-6 Front View

Power release lever

Power switch

Extension bar and

paper support extender

Upper paper tray

330 mm

235 mm

265 mm

Ventillation fan outlet

Front cover

Output paper

extender

Output tray

Ready LED lamp

(Green)

Error LED lamp

(Orange)

Power switch Power card socket

Parallel interface

connector

2

CHAPTER 2

THEORY OF OPERATION

1. PRINTING PROCESS...........................................................................................11

2. PAPER TRANSPORTATION ...............................................................................14

3. FUNCTIONS OF THE MAIN PARTS....................................................................15

3.1 Covers.................................................................................................................... 15

3.2 Feeder & Drive ...................................................................................................... 15

3.3 Fuser & Paper Exit................................................................................................ 17

3.4 Photographics & ROS .......................................................................................... 19

3.5 Electrical................................................................................................................ 21

– 10 –

THEORY OF OPERATION

– 11 –

THEORY OF OPERATION

1. PRINTING PROCESS

The printing process for this system consists of the repetition of the following five basic steps:

Charging Scanning exposure Developing FusingTransfer

(Separation)

(Cleaning)

CM blade

Heat roller

Fuser assembly

Pressure roller

BTR

Drum

Magnetic roller

Ros assembly

BCR

Figure 2-1 Printing Process

: Laser beam

: Paper path

– 12 –

THEORY OF OPERATION

• Description of the Printing Process

Step Details

Charging

The surface of the rotating drum in the EP toner cartridge is uniformly negatively charged

by the electric charge from the BCR (Bias Charge Roller).

The ROS assembly scans the exposure by converting the image signal from the MCU PWB

into an optical signal (laser beam) and directs the laser beam onto the drum.

Scanning Exposure When an image is present, a laser is emitted and the laser beam is irradiated onto the surface

of the drum causing the irradiated area to be set to a neutral charge, thus enabling an

invisible latent electrostatic image to be formed on the drum’s surface.

The latent electrostatic image on the drum’s surface attracts toner from the surface of the

magnetic roller in the EP toner cartridge, forming a visible image on the surface of the drum.

Developing

The magnet inside the magnetic roller causes the toner, which also has magnetic properties,

to adhere to the roller while the friction between the rotating magnetic roller and the CM

blade (Charge Metal Blade) negatively charges the toner, so that a thin layer of toner is n

the surface of the magnetic roller.

Transfer

A positive charge is applied to the back of the paper by the BTR (Bias Transfer Roller)

causing the toner on the drum’s surface to be transferred to the paper.

Applying a positive charge to the back of the paper causes the paper itself to be positively

charged, so that the paper adheres to the drum

(Separation)

The firmness of the paper causes the paper with the toner affixed to it to be separated from

the drum.

Fusing

The heat from the heat roller heated by the heat rod and the pressure from the pressure roller

causes the toner to be fused to the paper in the fuser assembly.

(Cleaning)

Any residual toner remaining on the drum after the transfer step is scraped off by the

cleaning blade which is in contact with the drum’s surface.

–350V

0

–V

–350V

0

–V

–350V

0

–V

–210V

(Developing bias)

Laser beam

Scanning Exposure DevelopingCharging

Toner image

(Visible image)

Electrostatic latent

image (Invisible image)

Drum’s surface

Voltage

Figure 2-2 Printing Process (Drum’s Surface)

– 13 –

THEORY OF OPERATION

Cleaning blade

BCR

AC Bias: 1.6kVp-p

(f=2.4kHz)

DC Bias: –210V

Laser beam

Toner

DC Bias

(+): 250V~2600V

(0.5µA~1.6µA)

(–): –700V

Magnetic roll

AC Bias: 200µA

(f=160Hz)

DC Bias: –350V

Paper

Eliminator

Pressure roll

BTR

Drum

( 30mm)

CM blade

Toner

17.28

Heat roll

17

Transfer

Scanning Exposure

152˚C 140˚C

158˚C 150˚C

Separation

While the lamp

flashes

six times

After the lamp

flashes

the sixth time

Developing

Charging

Heat roll

Figure 2-3 Printing Process (Seven Steps)

– 14 –

THEORY OF OPERATION

- - -

: Transport path of the paper

Input tray assembly

Feeder assembly

Heat roller

Pinch roller

Exit roller

Delivery tray assembly

Fuser assembly

Pressure roller

Drum

BTR

Feed roller

Figure 2-4 Paper Transportation

2. PAPER TRANSPORTATION

The following diagram shows the order in which paper passes over the rollers.

Paper that is inserted is automatically fed.

Paper is supplied and transported by the feed roller.

Paper is transported by the drum and BTR assembly.

Paper is transported by the heat roller and pressure roller.

Paper is discharged by the exit roller in the fuser assembly and the pinch roller in the

fuser top cover assembly.

– 15 –

THEORY OF OPERATION

3. FUNCTIONS OF THE MAIN PARTS

The main parts are briefly described and illustrated as follows. In order to remain consistent with the parts list, parts are

divided into the following five sections based on their type.

1 Covers

2 Feeder & Drive

3 Fuser & Paper Exit

4 Photographics & ROS

5 Electrical

3.1 Covers

This consists of the printer, four covers and two trays.

(Refer to Chapter 6, Parts List)

3.2 Feeder & Drive

• Input Tray Assembly

Regular (cut sheet) paper, envelopes can be fed into the printer from this tray.

Slide the left and right paper guides to hold the paper in place.

• Feed Roller Assembly

This assembly consists of the feed roller and the feed clutch. After the spring clutch in the feed clutch has been set by

the movement of the feed solenoid, the feed roller assembly rotates driven by the drive assembly and the feed rollers

feed the paper into the printer from the input tray assembly.

One full rotation of the feed roller assembly causes the spring clutch to be released by the feed solenoid and disables

the drive assembly from transmitting a driving signal.

• Feed Solenoid

The feed solenoid controls the operations (rotation and stop) of the feed roller assembly.

• Pre-regi. Sensor

This sensor detects whether paper is sent by the paper set lever based on changes in the position of the regi. actuator

and sends a signal to the MCU PWB.

• MCU PWB

The MCU PWB controls the regi. solenoid, rotates the feed roller assembly and feeds the paper into the printer with

the paper set lever. After receiving the signal from the regi. sensor, the MCU PWB instructs the EP toner cartridge to

generate the image.

(Refer to section 3.5 Electrical System. Illustrations of the parts described above are shown in Chapter 6, Parts List

PL5.)

• Drive Assembly

The drive assembly consists of the main motor and the gear that transmits the driving force. This assembly transmits

a driving force by rotating the main motor.

– 16 –

THEORY OF OPERATION

Feed clutch

Feed solenoid

Feed roller assembly

Paper set lever

Retard pad

Pre-regi. sensor

Figure 2-5 Feeder & Drive

Drive assembly

Main motor

Paper set lever

Input tray assembly

Feed roller

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Star Micronics WinType 4000 Technical Manual

Star Micronics WinType 4000 Technical Manual

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