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HP 5100 vs. 5000 Differences

20 Sep, 2002 By: Bill Voelker imageSource

HP 5100 vs. 5000 Differences

now, most of you know that there is a new printer out to replace the HP 5000.
Appropriately named the HP 5100, it is an upgraded version of the 5000. At 21
pages per minute (ppm), it is 5 ppm faster then the 5000 and it also has a
faster processor speed at 300 MHz.

this likely prompts many questions such as:

  • What
    does it look like?

  • Is
    it the same engine?

  • Is
    it similar to the 5000?

  • Does
    it operate differently then the 5000?

  • What
    parts are compatible?

answers are, it looks just like the 5000 and has the same engine. It also
operates the same. The last question is a little more difficult. And that is
what this article will explain.

are quite a few part differences between the 5000 and the 5100. There is not a
combined 5000/5100-service manual. Therefore, it is important to use the
appropriate service manual for each machine. Remember, there is a speed
difference between these printers, so do not assume parts will or will not
interchange; look it up. In the meantime, here is a highlight of some of the
most common parts and their interchangeability. 


  • Formatters                      

  • DC

  • Power
    Supplies, 110v & 220v

  • Paper
    Handling PCA’s  

  • Laser

  • Main
    Gear Assy’s

  • Motors


  • Control

  • All
    Pickup Rollers

  • All
    Separation Pads

  • Feed
    Separation Rollers

  • Registration

  • Transfer

  • Feed

  • Upper
    and lower Delivery Rollers

the fusing assembly, read on. For all others, please see the manual.”

you notice, the fusing assemblies are not in the above list. This will take some
explanation. Hewlett Packard says they are not interchangeable, even though they
do physically fit in each other’s machine and appear to work. However, we have
to agree with HP. We tested both the 5000 fuser in the 5100 printer, and the
5100 fuser in the 5000 printer. Upon initial evaluation, no problem was apparent
until we started changing the fuser temperatures in the menu. This was when the
trouble became visible.

the 5100 fuser was installed in the 5000 and the fuser temperature was set to
high, a repetitive defect appeared down the page, as well as print on the
backside of the page. Upon further examination of the fuser, it appeared that
toner was sticking to the upper fixing film and to the lower pressure roller.
This only occurred during the above test. We also performed other tests and took
temperature readings of the paper as it exited the fuser with the following



set to low

set to low

Fuser: 200º F

Fuser: 185º F

Fuser: 211º F

Fuser: 186º F.

set to high

set to high

Fuser: 220º F

Fuser 207º F

Fuser: 250º F

Fuser 204º F

you can see, there was a significant temperature increase with the 5100 fuser in
the 5000, with the temperature set to high. The fuser gets too hot, causing
toner to stick to the fixing film, it then passes the toner onto the pressure
roller, after paper passes through. This would account for the toner on the back
of the page. Even when the temperature is set to low, the 5100 fuser runs
significantly hotter then the 5000 fuser.

difference in the fusing assemblies that we noticed was the resistance reading
of the thermistors. The 5000 fuser read 1.431 M W and the 5100 fuser read .368 M
W at the same room temperature. This may account for the difference in
temperatures of the paper coming out of the fuser.

With High Temperatures

The temperature readings above were taken with an infrared thermometer of the
paper just beyond the fuser delivery rollers, about one and a half inches past
the actual fusing point. With the 5000 fuser installed in the 5000 printer and
the fuser temperature set to low, the temperature of the paper was 200° F. We
know that the fusing temperature between the rollers is approximately 365º F at
this setting. With the fuser set to high in the same machine, the temperature of
the paper exiting the 5000 fuser was 220º F. We know that the fusing
temperature between the rollers is approximately 392º F.

when we install the 5100 fuser in the 5000 and set it to high, the paper
temperature of the paper goes to 250º F, what is the temperature at the fusing
point? If we add the 172º F to the paper temperature of 250º F, we got 422º
F- this would be a conservative temperature. Any way we look at it, the
temperature of the paper at the fusing point between the rollers will most
likely be above 430º F. At that temperature, the chance of a paper fire exists,
especially if you consider a paper jam in the fuser.

identify a 5000 fuser compared to a 5100, the notable differences of these
fusing assemblies are that the 5100 has a gray fuser film and the 21 tooth gear
is black. The 5000 has a brown fuser film and the 21-tooth gear is brown. See
figure 1.

if the 5100 fuser is installed in the 5000, it will function short term, but a
definite problem will occur. What about installing the 5000 fuser in the 5100?
It appears to work, but let’s consider the confusion factor on an upward
compatible part. Think of the technician down the road that checks the
resistance values of the fusing assembly using 5100 specifications, or a
competitor who tells the customer the wrong fuser has been installed. Another
thought is, how long will the 5000 fuser last in a 5100? These are all things we
must consider when we recommend part interchangeability. In this case, we
believe it is in your customers,’ as well as your own, best interest that
these fusers not be interchanged.

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