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Aficio AP3800C Service Manual

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Model J P1c
(Machine Code: G082)
SERVICE MANUAL
April, 2002
Subject to change

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Summary of Contents for Aficio AP3800C

  • Page 1 Model J P1c (Machine Code: G082) SERVICE MANUAL April, 2002 Subject to change...
  • Page 2 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the printer power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components.
  • Page 3 SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor in accordance with local regulations. (These are non-toxic supplies.) 3.
  • Page 4 Trademarks ® Fiery is a registered trademark of Electronics for Imaging, Inc. ® ® ® Microsoft , Windows , and MS-DOS are registered trademarks of Microsoft Corporation in the United States and /or other countries. ® PostScript is a registered trademark of Adobe Systems, Incorporated. ®...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. INSTALLATION ................1-1 1.1 INSTALLATION REQUIREMENTS ............1-1 1.1.1 ENVIRONMENT ................1-1 1.1.2 MACHINE LEVEL ................1-1 1.1.3 MACHINE SPACE REQUIREMENT..........1-2 1.1.4 POWER REQUIREMENTS ..............1-2 1.2 OPTIONAL UNIT COMBINATIONS ............1-3 1.3 INSTALLATION FLOW CHART ..............1-4 1.4 MACHINE INSTALLATION ...............1-5 1.5 OPTIONAL UNIT INSTALLATION.............1-7 1.5.1 LIST OF OPTIONS ................1-7 Note for Transporting the Machine ............1-7...
  • Page 6 5.4.5 ERROR RECOVERY................5-9 5.5 CONTROLLER SELF-DIAGNOSTICS ............5-10 5.5.1 OVERVIEW ..................5-10 5.6 USER PROGRAM MODE ...............5-11 6. DETAILED SECTION DESCRIPTIONS ........6-1 6.1 CONTROLLER ..................6-1 6.1.1 BLOCK DIAGRAM AND FUNCTIONS ..........6-1 Components ..................6-1 Networking....................6-2 IX ASIC ....................6-2 Engine Video Interface................6-2 Hard Disk Drive..................6-2 Memory....................6-3 Options ....................6-4 6.1.2 BOARD LAYOUT ................6-5...

  • Page 7: Installation

    26 April, 2002 INSTALLATION 1. INSTALLATION 1.1 INSTALLATION REQUIREMENTS 1.1.1 ENVIRONMENT 1. Temperature Range: 10°C to 32°C (50°F to 89.6°F) 2. Humidity Range: 15% to 80% RH 3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight) 4.

  • Page 8: Machine Space Requirement

    INSTALLATION REQUIREMENTS 26 April, 2002 1.1.3 MACHINE SPACE REQUIREMENT Place the machine near the power source, providing clearance as shown. 575mm (23") A: Over 460 mm (18") B: Over 100 mm (4") C: Over 550 mm (22") D: Over 700 mm (28") G082I801.WMF 1450mm (57") G082I802.WMF...

  • Page 9: Optional Unit Combinations

    26 April, 2002 INSTALLATION 1.2 OPTIONAL UNIT COMBINATIONS Item Options Alternative Required PFU (1 Tray) Items 2, 3 PFU (2 Trays) Items 1, 3 Items 1, 2 • Item 7 Two-tray finisher Item 6 • Item 1, 2 or 3 3 types of punch kit Item 4 Four-bin mailbox...

  • Page 10: Installation Flow Chart

    INSTALLATION FLOW CHART 26 April, 2002 1.3 INSTALLATION FLOW CHART The following flow chart shows how to install the optional units more efficiently. Unpack the printer. Will the paper feed unit or LCT be installed? Place the printer on the paper feed unit or LCT. Install the paper feed unit or LCT.

  • Page 11: Machine Installation

    26 April, 2002 INSTALLATION 1.4 MACHINE INSTALLATION Refer to the Operating Instructions for details. If the customer has a service contract, change the settings of the following SP modes depending on the contract type. Item SP No. Function Default Meter charge SP5-930-1 Specifies whether the meter charge mode is enabled or disabled.
  • Page 12 MACHINE INSTALLATION 26 April, 2002 Item SP No. Function Default Counter reset SP7-825-1 Resets the counters to 0. Important: This must be done at installation after all the above settings have been finished. The negative counters used in meter charge mode will be reset to zero.

  • Page 13: Optional Unit Installation

    26 April, 2002 INSTALLATION 1.5 OPTIONAL UNIT INSTALLATION 1.5.1 LIST OF OPTIONS The available options are listed below. Except for the punch unit and DIMM memories, installation is explained in the Operating Instructions. • Paper Feed Unit (500 sheets x 1) •...

  • Page 14: Dimm Memory Installation

    OPTIONAL UNIT INSTALLATION 26 April, 2002 1.5.2 DIMM MEMORY INSTALLATION G082I902.WMF G082I901.WMF CAUTION Make sure no data is coming into the machine. Turn the main switch off before removing the controller box. 1. Remove the controller box [A] (! x 2). 2.

  • Page 15: Punch Unit Installation

    26 April, 2002 INSTALLATION 1.5.3 PUNCH UNIT INSTALLATION ☛ G060 Printer Service Manual, Section 1: Installation.

  • Page 16: Preventive Maintenance

    26 April, 2002 PREVENTIVE MAINTENANCE 2. PREVENTIVE MAINTENANCE ☛ G060 Printer Service Manual, Section 2: Preventive Maintenance. NOTE: LED behavior is different from the G060 printer as follows. PRODUCT NEAR END CONDITION END CONDITION G082 Printer Blinking Lighting G060 Printer Lighting Lighting...

  • Page 17: Replacement And Adjustment

    26 April, 2002 CONTROLLER 3. REPLACEMENT AND ADJUSTMENT 3.1 CONTROLLER NOTE: After replacing the controller, remove the NVRAM, HDD, DIMM, BIOS ROM, and battery on the old board and install them on the new board. 1. Controller box [A] (! x 2) 2.

  • Page 18: Controller Psu

    CONTROLLER PSU 26 April, 2002 3.2 CONTROLLER PSU 1. Controller box [A] (! x 2) 2. Controller cover [B] (! x 18, " x 2) G082R101.WMF 3. Controller PSU [C] (! x 4, " x 1) G082R104.WMF 3.3 PRINTER ENGINE ☛...

  • Page 19: Trouble Shooting

    26 April, 2002 CONTROLLER SELF-DIAGNOSTICS ERRORS 4. TROUBLE SHOOTING 4.1 CONTROLLER SELF-DIAGNOSTICS ERRORS When a controller self-diagnostic error occurs, the error code number is displayed on the operation panel LCD and booting up stops. After pressing “Enter” key, the machine will continue to boot up. Error Possible Cause/ Symptom...

  • Page 20: Internal Error

    INTERNAL ERROR 26 April, 2002 Error Possible Cause/ Symptom Code Required Action Disk Identify 1. Turn the main switch off and on. 2. Replace the memory. Can't identify drive 3. Replace the controller. Disk Read/Write Test Drive has retry errors Disk Read Capability Test Can't read from drive Disk Write Capability Test...

  • Page 21: Service Tables

    26 April, 2002 SERVICE PROGRAM MODE 5. SERVICE TABLES 5.1 SERVICE PROGRAM MODE CAUTION Before accessing the service menu, do the following: Confirm that there is no print data in the printer buffer (the Data In LED must not be lit or blinking). If there is some data in the buffer, wait until all data has been printed.

  • Page 22: Accessing The Required Program

    SERVICE PROGRAM MODE 26 April, 2002 Accessing the Required Program Use the “Up/Down arrow” keys to scroll through the menu listing. 1. Service: Controller service modes 2. Engine: Engine service modes 3. End: Exit service mode To select an item, press the right-arrow key.

  • Page 23: Printer Controller Service Mode

    26 April, 2002 PRINTER CONTROLLER SERVICE MODE 5.2 PRINTER CONTROLLER SERVICE MODE 5.2.1 SERVICE MODE MENU (“1. SERVICE") Mode No. Function / [ Setting ] (Class 1 and 2) [Clear Setting] Clear Setting Initializes settings in the “System” menu of the user mode.

  • Page 24: Printer Engine Service Mode

    PRINTER ENGINE SERVICE MODE 26 April, 2002 5.3 PRINTER ENGINE SERVICE MODE ☛ G060 Printer Service Manual, Section 5.3: Printer Engine Service Mode.

  • Page 25: Firmware Update Procedure

    26 April, 2002 FIRMWARE UPDATE PROCEDURE 5.4 FIRMWARE UPDATE PROCEDURE 5.4.1 TYPE OF FIRMWARE There are three types of firmware as shown below. Type of firmware Function Location of firmware BCU Flash ROM 1. Main Printer engine control Printer Engine BCU Flash ROM 2.

  • Page 26: Firmware Upgrade

    FIRMWARE UPDATE PROCEDURE 26 April, 2002 5.4.4 FIRMWARE UPGRADE CAUTION 1. Open the front cover whenever updating the firmware. 2. Do not turn off the machine while downloading the firmware. Upgrading Printer Firmware To upgrade the firmware, you must connect the printer to your PC with the Ethernet cross cable.
  • Page 27 26 April, 2002 FIRMWARE UPDATE PROCEDURE Preparation on the PC 1. Set the TCP/IP address for your PC (e.g. 133.139.157.010). NOTE: NOTE: Do not use the IP address of the printer. 2. Set the Subnet Mask (e.g. 255.255.255.0). 3. Reboot the PC. Upgrade Procedure 1.
  • Page 28 FIRMWARE UPDATE PROCEDURE 26 April, 2002 Updating the lpr Command Preparation on the printer 1. Turn the main switch on. 2. Wait until Ready is displayed. Ready G082S910.WMF 3. Print out Configuration Page in case you need to refer to the current settings. 4.

  • Page 29: Error Recovery

    26 April, 2002 FIRMWARE UPDATE PROCEDURE 4. Wait until the Data In LED blinks. 5. Check that the massages Upgrading Upgrading System System Do Not Power Off Do Not Power Off displayed. NOTE: Do NOT turn the main switch off before the messages disappear.

  • Page 30: Controller Self-Diagnostics

    CONTROLLER SELF-DIAGNOSTICS 26 April, 2002 5.5 CONTROLLER SELF-DIAGNOSTICS 5.5.1 OVERVIEW There are two types of self-diagnostics for the controller. • Power-on self-diagnostics: The machine automatically starts the self-diagnostics just after the power has been turned on. • SC detection: The machine automatically detects SC conditions at power-on or during operation.

  • Page 31: User Program Mode

    26 April, 2002 USER PROGRAM MODE 5.6 USER PROGRAM MODE Press the “Menu” key to scroll through the menu listing. User Mode Tree USER MODE READY COUNTER CHECK AND PRINT SECURE PRINT PRINT MENU TRAY SETUP MENU RESETS SYSTEM SETUP PRINTER SETUP PS SETUP PCL SETUP...

  • Page 32: Detailed Section Descriptions

    26 April, 2002 CONTROLLER 6. DETAILED SECTION DESCRIPTIONS 6.1 CONTROLLER 6.1.1 BLOCK DIAGRAM AND FUNCTIONS Intel Pentium III Intel 440 BX PC100 SDRAM 700 MHz NVRAM North Bridge Memory EFI ASIC Ethernet Chip (VXMCT) Controller EFI ASIC (VXMCT) PCI BUS South Bridge BIOS EFI ASIC...

  • Page 33: Networking

    CONTROLLER 26 April, 2002 Networking The standard networks and cabling configuration includes: • Ethernet 10BaseT (Unshielded Twisted Pair) • Fast Ethernet 100Base-TX (Unshielded Twisted Pair) IX ASIC Increases the speed of I/O functions including: • Parallel Port • Peripheral Control Engine Video Interface The engine interface’s responsibilities include: •...

  • Page 34: Memory

    26 April, 2002 CONTROLLER Memory The dynamic memory used for System and Frame Buffer memory PC100 Synchronous DRAM in 168 pin DIMMs. Non-Volatile Memory There are three types of nonvolatile memory used on this machine: The 256KB Flash Memory contains the BIOS data, the 16MB Flash Memory contains the diagnostics and drivers to support firmware update, and the NVRAM contains various parameters such as SP and UP Mode data.

  • Page 35: Options

    CONTROLLER 26 April, 2002 Compression The Fiery uses ECT compression to optimize the use of memory by reducing file sizes using proprietary techniques. This step allows the Fiery to store many more pages in the frame buffer than would be available normally. Options The printer will be available with the following types of options: •...

  • Page 36: Board Layout

    26 April, 2002 CONTROLLER 6.1.2 BOARD LAYOUT SDRAM Slot SDRAM SDRAM Slot SDRAM North Bridge NVRAM ASIC (VXMCT) ASIC (VXMCT) ASIC (VXMCT) IEEE 1284 ASIC ASIC (IX) (VXMCT) Network I/F (RJ-45) South Bridge Lithium Battely Strata BIOS Flash G082D902.WMF...

  • Page 37: Print Data Processing

    CONTROLLER 26 April, 2002 6.1.3 PRINT DATA PROCESSING IO/Print/ Video Drivers Connectivity PDLs Compression Page Mgr Device Mgr PostScript generation Page Ethernet parsing Compression PostScript Spooling, PDL Finishing, Decomp, switching Engine loading Video PJL parsing Page Parallel PCL 5e/5c Compression generation G082D904.WMF The key roles of each part of the print system are outlined below.

  • Page 38: Built-In Color Management

    26 April, 2002 CONTROLLER 6.1.4 BUILT-IN COLOR MANAGEMENT This controller has a full complement of built-in color management technologies. Component Description Location/Platforms PostScript color CRDs optimized for photos, graphics, Controller firmware rendering presentation objects; (HDD) dictionaries plain paper/transparency media types (CRDs) Press simulation Lookup tables to simulate density...

  • Page 39: Printer Engine

    PRINTER ENGINE 26 April, 2002 6.2 PRINTER ENGINE ☛ G060 Printer Service Manual, Section 6: Detailed Section Descriptions.

  • Page 40: Specifications

    26 April, 2002 SPECIFICATIONS SPECIFICATIONS 1. GENERAL SPECIFICATIONS Configuration: Desktop Print Process: Dry electrostatic transfer system Printer Languages: PCL5c: CLJ5 class compatible Adobe PostScript 3 (Genuine): Interpreter 3011.103 Resolution: PCL5c : 600 x 600 dpi : 600 x 600 dpi, 1200 x 1200 dpi Gradation 1 bit/pixel Printing speed:...
  • Page 41 SPECIFICATIONS 26 April, 2002 Print Paper Size: (Refer to “Supported Paper Sizes”.) Minimum Maximum Tray 1 A4/8 " x 11" (LEF) Tray 2 A5 (LEF)/8 " x 11" A3/11" x 17" By-pass 90 x 148 mm 305 x 458 mm/12" x 18" Optional Tray A5 (LEF)/8 "...

  • Page 42: Supported Paper Sizes

    26 April, 2002 SPECIFICATIONS 1.1 SUPPORTED PAPER SIZES 1.1.1 PAPER FEED North America Europe/Asia By-pass Paper Size (W x L) Tray Tray Tray Tray 1 Tray 1 2/3/4 2/3/4 A3 W 12" x 18" A3 SEF 297 x 420 mm A4 SEF 210 x 297 mm A4 LEF...

  • Page 43: Paper Exit

    SPECIFICATIONS 26 April, 2002 1.1.2 PAPER EXIT Internal Tray External Tray 4-bin Paper Size (W x L) Finisher Duplex Mailbox (Face Down) (Face Up) A3 W 12" x 18" A3 SEF 297 x 420 mm A4 SEF 210 x 297 mm A4 LEF 297 x 210 mm A5 SEF...

  • Page 44: Software Accessories

    26 April, 2002 SPECIFICATIONS 2. SOFTWARE ACCESSORIES The printer drivers and utility software are provided on one CD-ROM. An auto-run installer allows you to select which components to install. 2.1 PRINTER DRIVERS Printer Windows Windows Windows NT4.0 Macintosh Language 95/98/ME 2000/XP PCL 5c NOTE: 1) The printer drivers for Windows NT 4.0 are only for the Intel x86...

  • Page 45: Machine Configuration

    SPECIFICATIONS 26 April, 2002 3. MACHINE CONFIGURATION G082V900.JPG Machine Item Remarks Code Main Unit G060 Options Requires the duplex unit and one of the three paper feed options. Finisher G565 Finisher and mailbox cannot both be installed. Finisher and mailbox cannot both be Four-bin Mailbox G566 installed.

  • Page 46: Optional Equipment

    26 April, 2002 SPECIFICATIONS 4. OPTIONAL EQUIPMENT 4.1 500-SHEET TRAY Paper Size: Maximum: A3/11" x 17" (SEF) Minimum: A5 (LEF)/8 " x 11" Paper Weight: 60 to 105 g/m (16 to 28 lb.) Tray Capacity: 500 sheets (80 g/m , 20 lb.) Paper Feed System: FRR system Paper Height Detection:...

  • Page 47: Two-Tray Finisher & Punch Unit

    SPECIFICATIONS 26 April, 2002 4.4 TWO-TRAY FINISHER & PUNCH UNIT Print Paper Size: No punch mode: A3/11" x 17" to A5 (LEF)/8 " x 11" Punch mode: 2 holes: A3/11" x 17" to A4/8 " x 11" (SEF) A4/8 " x 11" to A5 (LEF) 3 holes: A3, B4, 11"...

  • Page 48: Four-Bin Mailbox

    26 April, 2002 SPECIFICATIONS Staple replenishment: Cartridge (5000 staples) Power consumption: 48 W Dimensions (W x D x H): 680 x 620 x 1030 mm (26.8" x 24.4" x 40.6") Weight Without punch unit: 53 kg (116.9 lb.) With punch unit: 55 Kg (121.3 lb.) 4.5 FOUR-BIN MAILBOX 4 bins...

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