In this device, there are two types of toner near end status.

The detection conditions and detection operation for each status are shown in the following table.

Control overview

Status

Control panel message

Detection conditions

Estimated toner end

SP3-101-001 to 004="2"

Control panel banner display:

'Toner Cartridge is almost empty. Prepare toner cartridge replacement(s).'

If the residual amount in the toner cartridge falls below SP3-110-001 to 004 (Near End Thresh) (Default: K 65g, CMY 45g)

The lesser of the "toner residual amount computed from the toner supply motor drive time" and the "toner residual amount computed from the pixel count" is taken as the toner residual amount.

Definite toner near end

SP3-101-001 to 004="1"

Control panel banner display:

'Toner Cartridge is empty.

Printing will be suspended soon.

Replace the cartridge.'

If "the toner cartridge residual amount falls below specification" and "the toner end sensor in the sub-hopper has detected toner end"

Remarks:

When toner end is detected, to use up all the toner in the cartridge, the toner cartridge is rotated for 5 seconds (full use control).

After no toner is detected again, the status becomes definite toner near end.

Toner end

Control panel pop-up display (alert screen):

'Toner has been depleted.

Replace Toner Cartridge.'

Toner end is defined by the following conditions (1) or (2):

(1) Determination by number of sheets and pixel count

(After definite toner near end, count is begun).

(2) Determination by Vt output

(not related to definite toner near end)

Control details

Estimated toner near end
  • The toner residual amount Z (SP3-102-021 to 024) is taken as the lesser of the toner residual amount Z1 computed from the toner supply motor drive time (SP3-102-001 to 004) and the toner residual amount Z2 computed from the pixel count (SP3-102-011 to 014).
  • If the condition, toner residual amount Z (SP3-102-021 to 024) < near end residual amount threshold value (SP3-110-001 to 004) is satisfied, this is taken as the estimated toner near end.
Definite toner near end

Preconditions

  • The toner residual amount Z (SP3-102-021 to 024) is taken as the lesser of the toner residual amount Z1 computed from the toner supply motor drive time (SP3-102-001 to 004) and the toner residual amount Z2 computed from the pixel count (SP3-102-011 to 014).
  • If the condition, toner residual amount Z (SP3-102-021 to 024) < sensor near end residual amount threshold value (SP3-120-001 to 004) is satisfied, toner end sensor detection is begun to determine the definite end. (When the toner residual amount is more than the threshold value, determination by the toner end sensor is not performed).

Sensor detection

  • The toner end sensor detects the sensor output every 200 ms while the polygon motor is ON, and determines whether toner is present or not from the latest 10 counts.
  • The determination result is stored in the "no toner counter (SP3-121-001 to 004)".
    To prevent clearing due to erroneous detection, the counter is reset if the toner end sensor detects "toner remaining" 4 times in a row.
  • If the condition "no toner counter (SP3-121-001 to 004) > sensor near end determination threshold value (SP3-122-001 to 004) is satisfied, full use control which rotates the toner bottle for a certain time (SP3-163-001) is performed, and toner presence/absence determination by the toner end sensor is performed again.
  • If no toner is detected after full use control determination, it is taken as definite toner near end.

Operation after changing status to definite toner near end

  • After changing the status to definite toner near end, sheet counter and pixel counter increment is begun to detect toner end.
    SP3-133-011 to 014 (TE Detect :Set Page Cnt:K, C, M, Y)
    SP3-133-031 to 034 (TE Detect :Set Pxl Cnt:K, C, M, Y)

Operation during definite toner near end

  • When the toner supply motor drives and the toner end sensor detects no toner, the toner bottle drive motor drives for 2 seconds.
  • If "toner remaining" is detected 4 times in a row, according to the ID chip data on the toner bottle SP3-101-001 to 004 (Toner Status :Disp) display "10" or "2" (estimated toner end).
  • When it comes under the condition of Toner End Pattern (1) and (2) (mentioned below), the status becomes toner end.
  • After the toner bottle is replaced during definite toner near end, the judgement of toner end is not done until the toner bottle motor drives for 40 or more seconds totally.
Toner end

Toner End Pattern (1): Determination by paper sheet counter/pixel counter

  • The total sheet counter and pixel counter values after definite toner near end are compared with the threshold values.
  • If the following "(evaluation method A=TRUE) and (evaluation method B=TRUE) or (evaluation method C=TRUE)" is satisfied, it is determined as toner end.

Determination method A: Sheet counter (SP3-133-011 to 014) > Sheet counter threshold value (min)

Determination method B: Sheet counter (SP3-133-011 to 014) > Sheet counter threshold value (max)

Determination method C: Pixel counter (SP3-133-031 to 034) > Pixel counter threshold value

Toner End Pattern (2): Determination by Vt output

  • When the deviation between the TD sensor output value and TD sensor target value has become large, it is taken as toner end.
  • After definite toner end has been determined

The difference between the output of the TD sensor (Vt: SP3-210-001 to 004) and the target value of the TD sensor (Vtref: SP3-230-001 to 004) is computed as the delta Vt, and values of the delta Vt larger than the threshold value (SP3-131-001) are integrated as "sigma delta Vt" (SP3-132-001 to 004).

If the integration value of "sigma delta Vt" is larger than the threshold value (SP3-132-002), it is determined to be toner end.

  • Before definite toner near end is determined (bottle full or estimated toner near end)

The computation is done in the same way as for definite toner near end, but separate values for the delta Vt threshold value and "sigma delta Vt" threshold value are used.

The delta Vt threshold value before NE: SP3-131-011

The "sigma delta Vt" threshold value before NE: SP3-131-012