No.

Component

Function

Boards (PCB)

PCB1

Main Board

The main board that controls the finisher

PCB2

Booklet Stapler Board

A separate board that controls booklet finishing.

PCB3

Punch Unit Board

The board that controls the punch unit.

Motors

M1

Finisher Entrance Motor

Drives 1) the finisher entrance rollers, 2) and the punch waste transport belt of the punch unit.

M2

Upper Transport Motor

Drives the paper feed rollers that feed paper 1) to the proof tray, 2) straight-through to the upper tray, 3) the pre-stack tray entrance roller.

M3

Lower Transport Motor

Drives paper feed rollers forward and reverse in the pre-stack tray for the switchback, and drives the other rollers in the lower transport area.

M4

Upper/Proof Tray Exit Motor

Drives 1) proof tray exit rollers, 2) extension and retraction of the stacking sponge roller, 3) upper tray exit rollers.

M5

Feed Out Belt Motor

Drives the feed out belt that moves the stapled stacks out of the stapling tray after stapling.

M6

Corner Stapler Movement Motor

Moves the corner stapler horizontally on a steel rod to position the stapler at the stapling position at 1) the front, 2) the rear (straight stapling), 3) the rear (diagonal stapling), or 4) the front and rear for double stapling.

No.

Component

Function

M7

Paper Position Sensor Slide Motor

Drives the movement of the paper position slide that holds the paper position sensor (S3) that detects the position of the paper.

M8

Clamp Roller Retraction Motor

Drives a large cam that alternately clamps and unclamps the clamp retraction roller, the idle roller of the clamp roller pair. When these rollers are clamped, they are part of the paper feed path and feed the stack toward the bottom fence of the fold unit. When the idle roller is retracted, the stacks falls a very short distance (3 mm) onto the fold unit bottom fence below. These rollers remain unclamped while the bottom fence positions the stack for folding and while the stack is folded by the fold rollers.

M9

Punch Movement Motor

Drives the front/back movement of the punch unit to position it correctly for stapling the paper below.

M10

Stacking Sponge Roller Motor

Rotates the stacking roller that drags each sheet back against the end fence to jog the bottom of each sheet after feed out to the upper tray.

M11

Fold Plate Motor

Drives the fold plate that pushes the center of the stack into the nip of the fold rollers to start the fold.

M12

Fold Roller Motor

Rotates forward and drives the fold rollers that fold the stack and feed it out of the fold unit, reverses to feed the fold once more into the fold unit, and then rotates forward again to feed the fold out of the fold unit.

M13

Corner Stapler Rotation Motor

Swivels the corner stapler and positions it so the staple fires at an oblique angle at the rear corner of the paper stack.

M14

Positioning Roller Motor

Drives the positioning roller in the stapling tray.

M15

Jogger Fence Motor

Drives the jogger fences in the stapling tray to jog both sides of the stack before stapling.

No.

Component

Function

M16

Fold Unit Bottom Fence Lift Motor

Raises the bottom fence and stops when the center of the vertical stack is opposite the edge of the horizontal fold blade. The distance for raising the blade is prescribed as one-half the size of the paper selected for the job. For large paper, (A3, B4) the bottom fence first lowers the stack 10 mm below the fold position, and then raises it to the fold position.

M17

Stack Junction Gate Motor

Drives the large cam that operates the stack junction gate at the top of the stapling tray. When this gate is open, it directs the ascending stack to the upper tray if it has been corner stapled, or if it is closed the gate turns the booklet stapled stack down so it falls onto the bottom fence of the folding unit.

M18

Shift Roller Motor

Drives the shift roller that operates in shift mode to stagger document sets as they feed out to the upper tray (making them easier to separate).

M19

Exit Guide Plate Motor

Drives the mechanism that raises and lowers the exit guide plate.

M20

Corner Stapler EH530

This is the roving corner stapler, mounted on a steel rail that staples 1) at the front, 2) at the rear (straight staple), 3) at the rear (diagonal staple), and 4) font and rear (two staples).

M21

Upper Tray Lift Motor

Raises and lowers the upper tray during feed out to keep the tray at the optimum height until it is full.

M22

Booklet Stapler EH185R: Front

Booklet stapler. Staples paper stacks in the center before they are folded.

M23

Booklet Stapler EH185R: Rear

Booklet stapler. Staples paper stacks in the center before they are folded.

M24

Punch Drive Motor

Fires the punches that punch the holes in the paper.

No.

Component

Function

Sensors

S1

Finisher Entrance Sensor

Provides two functions: (1) Detects paper entering the finisher from the copier, and (2) Signals a jam if it detects paper at the entrance when the copier is switched on.

S2

Pre-stack Tray Exit Sensor

Detects 1) paper fed from the pre-stack tray to the stapling tray, and detects 2) paper in the pre-stack when the copier is switched on. (This sensor performs no timing function. The entire flow of paper through the

pre-stacking mechanism is controlled by motor pulse counts.)

S3

Paper Position Sensor

The photosensor that detects the edge of the paper and sends this information to the punch unit board where it is used to position the punch for punching the holes in the paper.

S4

Punch Hopper Full Sensor

1) A photosensor that detects and signals that the punch hopper is filled with punch waste and needs emptying, and 2) confirms the presence of the punch hopper and signals an error if it is missing or not installed completely.

S5

Shift Roller HP Sensor

Located near the shift roller motor, controls the

front-to-back movement of the shift roller as shifts paper during straight-through feed.

S6

Upper Tray Exit Sensor

A flat, photo sensor located inside the guide plate, detects the leading edge and trailing edge of the paper as it feeds out to the upper tray during straight-through jobs (with and without stapling). When paper is fed to the upper tray, at the paper output slot this sensor signals an error when it detects (1) paper has failed to leave the paper exit (lag error), (2) detects paper has failed to arrive at the paper exit (late error), (3) detects paper is in the exit slot when the machine is turned on.

No.

Component

Function

S7

Exit Guide Plate HP Sensor

Controls the vertical movement of the control exit

guide . The guide plate is in the home position when the guide plate is down and the actuator interrupts the sensor gap.

S8

Upper Tray Paper Height Sensor (Staple Mode)

This is the upper sensor of the upper/lower paper height sensor pair that controls the lift of the upper tray. This sensor detects the paper height of the stack in the upper tray when the copier is operating in the staple mode.

S9

Upper Tray Paper Height Sensor (Non-Staple Mode)

This is the lower sensor of the upper/lower paper height sensor pair that controls the lift of the upper tray. When the machine is switched on, the upper tray rises until the actuator on the tray triggers this sensor to switch off the upper tray lift motor.

S10

Proof Tray Exit Sensor

This sensor detects and times the feeding of paper to the proof tray. It also detects whether paper is present at the proof tray exit when the copier is switched on.

S11

Proof Tray Full Sensor

The top of the stack in the proof tray increases until it nudges the feeler of this sensor. The sensor then signals that the proof tray is full and the job halts until some paper is removed from the proof tray.

S12

Upper Tray Limit Sensor

This sensor controls the position of the upper tray 1) during straight-through feed out, 2) during shift feed out,

3) when the machine is turned on. The machine obeys the signal of whichever sensor is actuated first.

An actuator attached to an arm triggers this sensor. The tip of the same arm depresses the upper tray limit switch If the sensor fails, the tip of the arm will activate the upper tray limit microswitch (SW2) and stop the lift of the upper tray.

Note: When the machine is turned on, the upper tray position is controlled by either this sensor or the upper tray paper height sensor (S9).

No.

Component

Function

S13

Stacking Roller HP Sensor

Controls the forward and back motion of the stacking roller (a sponge roller) located at the output slot of the upper tray. The sponge roller drags each ejected sheet back against the end fence of the upper tray to keep the bottom of the stack aligned.

S14

Stapling Tray Paper Sensor

A photo sensor that detects whether paper is in the stapling tray. When this sensor detects paper, the bottom fence motor raises or lowers the bottom fence to position the selected paper size for booklet stapling.

S15

Jogger Fence HP Sensor

Detects the home position of the jogger fences. When the actuator on the jogger fence interrupts this sensor, the jogger fence is in its home position and the jogger fence motor (M15) stops.

S16

Stack Feed-Out Belt HP Sensor

Controls the position of the stack feed-out pawl on the stack feed-out belt. Once the actuator on the feed belt nudges the feeler of this sensor near the top of the stapling unit, the feed out belt motor (M5) remains on for the time prescribed to position the pawl at the home position to catch the next stack.

S17

Corner Stapler HP Sensor

Located at the front the stapling tray and mounted above the steel rod where the corner stapler travels, this sensor detects the home position of the corner stapler. The corner stapler is in its home position when the actuator on the corner stapler unit interrupts this sensor.

S18

Stapler Rotation HP Sensor

Controls the angle of the position of the corner stapler during oblique stapling.

No.

Component

Function

S19

Upper Tray Full Sensor (B804/B805)

B804: When the actuator on the side of the upper fence enters the gap of this sensor, the sensor signals that the upper tray is at its lowest position (full) and stops the job.

B805: One of two upper tray full sensors. This is the higher tray full sensor for A3 and other heavy paper. The other upper tray full sensor (20) is for lighter paper.

S20

Upper Tray Full Sensor (B805 only)

B804: This sensor is not used on the booklet finisher. There is only one upper tray full sensor (S18).

B805: One of two upper tray full sensors. This is the lower tray full sensor for A4 and smaller paper. The other upper tray full sensor (19) is for larger paper.

S21

Punch Unit HP Sensor

Switches off the punch movement motor when the punch unit returns to its home position. Pulse counts determine where the punch unit pauses for punching and reversing.

S22

Paper Position Side HP Sensor

Controls the movement of the paper position detection unit. Switches on when the horizontal detection unit is at the home position (HP is the reference point).

S23

Punch HP Sensor

Detects the home position of the punch unit and controls the vertical movement of the punches when they fire.

S24

Punch Encoder Sensor

When the punch mode is selected for the job (2-hole, 3-hole, etc.), the machine controls the operation of the punch drive (M24) motor which drives a small encoder shaped like a notched wheel. This wheel is rotated forward and reverse precisely to select which punches are moved up and down during the punch stroke.

No.

Component

Function

S25

Clamp Roller HP Sensor

Controls the movement of the clamp retraction roller (the idle roller of the clamp roller pair).

S26

Fold Unit Entrance Sensor

Detects 1) the leading edge of the stack during booklet stapling, and 2) also used to signal an alarm if a paper is detected at the entrance of the fold unit when the copier is turned on.

S27

Stack Junction Gate HP Sensor

Controls the opening and closing of the stack junction gate. Switches on when the stack junction gate is open and at the home position.

S28

Fold Bottom Fence HP Sensor

Controls the movement of the bottom fence in the folding unit using pulse counts based on the size of the paper selected for the job to position the stack correctly for feeding.

S29

Fold Plate HP Sensor

Along with the fold plate cam HP sensor (S30) this sensor controls the movement of the fold plate . The fold plate has arrived at the home position when the edge of the plate enters the gap of this sensor.

S30

Fold Plate Cam HP Sensor

Along with the fold plate HP sensor (S29), this sensor controls the movement of the fold plate. The actuator mounted on the end of the roller that drives the folder plate forward and back makes three full rotations, i.e. the actuator passes the sensor gap twice and stops on the 3rd rotation and reverses. This accounts for the left and right movement of fold plate.

S31

Fold Unit Exit Sensor

1) Detects the folded edge of the stack as it feeds out from the nip of the fold rollers, stops the rollers, and reverses them so the fold feeds back into the nip, 2) when the folded booklet finally emerges from the nip of the fold rollers, detects the leading and trailing edge of the booklet to make sure that it feeds out correctly.

No.

Component

Function

S32

Stack Present Sensor

This sensor determines whether a there is paper at the turn junction gate when the machine is turned on. If a stack is present, this triggers a jam alert. (This sensor performs no dynamic function such as pulse counting, etc. It only detects whether paper is at the top of the folding unit when power its turned on.)

S33

Lower Tray Full Sensor - Rear

This rear sensor is the lower sensor of the lower tray full sensor pair. Two actuators are attached to the actuator arm that touches the top of stapled and folded booklets as they feed out. The on/off combinations of the two sensors are used to detect when the tray is full and stop the job. (The lower tray is stationary. At tray full, the job halts until booklets are removed from the lower tray.)

S34

Lower Tray Full Sensor - Front

This front sensor is the higher sensor of the lower tray full sensor pair. Two actuators are attached to the actuator arm that touches the top of stapled and folded booklets as they feed out. The on/off combinations of the two sensors are used to detect when the tray is full and stop the job. (The lower tray is stationary. At tray full, the job halts until booklets are removed from the lower tray.)

Solenoids

SOL1

Proof Junction Gate Solenoid

Opens and closes the proof tray junction gate. When the solenoid switches on, it opens the gate and paper is diverted to the proof tray. When this gate is closed, the paper goes straight to the upper tray. I

SOL2

Stapling Tray Junction Gate Solenoid

Directs paper to the stapling tray. When this solenoid is on, paper feeds straight through. When this solenoid is off, paper feeds to the stapler tray below.

No.

Component

Function

SOL3

Positioning Roller Solenoid

Engages the stapler transport motor and the positioning roller of the stapling tray. The positioning roller pushes each sheet down against the bottom fence to align the bottom the stack for stapling. (The jogger fences align the sides.)

SOL4

Stapling Edge Pressure Plate Solenoid

Operates the pressure plate of the stapling unit. The pressure plate presses down the edge of stack in the stapling tray so it is tight for stapling.

SOL5

Booklet Pressure Roller Solenoid

When the paper stack in the stapling tray feeds to the folding unit, this solenoid turns on and operates the roller that pushes on the surface of the stack to flatten it.

Switches

SW1

Front Door Safety Switch

The safety switch that cuts the dc power when the front door is opened.

SW2

Upper Tray Limit SW

A micro-switch that cuts the power to the upper tray lift motor when the upper tray reaches its upper limit. This switch duplicates the function of the upper tray limit sensor (S12) and stops the upper tray if S12 fails.