TSM 9800

Oc
Technical Service Manual
Oc 9800
Oc Codenumber: 0910330 Edition: 5
GB
ES DIGITAL PPC-2 (Oc 9700/9800 series) (Oc 705/710 + 850) (Oc 880) (Oc 965)
1.Photoconductor/Drum 001 002 003 004 005 006 Drum assy Carbon brush ASV compensation sensor Fan(s) Drum fan invertor NTC 5.Developing 161 Doctor blade 162 Spacing disk 163 Magnet roller 165 166 167 168 Gear(s) Toner Scraper mechanism Toner supply funnel
CAS-C
238 Mechanical connections 239 Electrical connections 240 Others 7.Cleaning/Discharging 241 242 243 244 246 Pin array Fan(s) High voltage supply LED(s) Ozone filter
029 Adjustments 030 PBA(s) 031 Motor(s) 037 038 039 040 Settings/Parameters Mechanical connections Electrical connections Others
189 Sensor(s) 190 PBA(s) 191 Motor(s) 197 198 199 200 Settings/Parameters Mechanical connections Electrical connections Others
247 Discharging unit assy 270 PBA(s) 277 278 279 280 Settings/Parameters Mechanical connections Electrical connections Others
2.Charging 041 Corona (pin array) 042 Fan(s) 046 Ozone filter 070 075 077 078 079 080 PBA(s) Power Supply Settings/Parameters Mechanical connections Electrical connections Others
6.Compact Transfer Transfuse 201 Fuse roller 202 Pressure roller 203 Cleaner(s) 205 206 207 208 209 Compressor Compressor control unit Cylinder(s) Valve(s) Hose(s) 9.Original Handling 321 322 323 324 348 349 350 351 Glass plate Gauge/feed roller Scanner lamp White original plate Switch(es) Sensor(s) PBA(s) Motors
4.Exposure 121 Printhead 136 137 138 139 Fan(s) Hose(s) Cooling unit/liquid NTC
210 Heater(s) 211 Bearing(s) 212 Output guide 217 Fuse roller Temperature sensor 218 Thermal switch(es) 219 Clutch(es)/Brake(s) 220 Solenoid(s) 227 Invertor pressure roller motor 228 Switch(es) 229 Sensor(s) 230 PBA(s) 231 Motor(s) 237 Settings/Parameters
353 Solenoid(s) 357 358 359 360 Settings/Parameters Mechanical connections Electrical connections Others
150 PBA(s) 155 Power supply 157 158 159 160 Settings/parameters Mechanical connections Electrical connections Others
10.Image-scanning 361 362 363 364 Scanning unit/Camera Scanner-engine cable Mirror Fan(s)
390 PBA(s) 397 Settings/Parameters
SYMPTOMS
1 2 3 4 5 6 7 8 9 General copy quality Image position/ deformation/ size Spots/ stripes/ pullution Fusing/ finishing (delivery) Jammed or damaged original or copy Total stop Control Noise/ odour/ damage/ others
ACTIONS
1 2 3 4 5 6 7 8 9 Replace (life time) Replace (defective) Install (missing part) Adjust,correct Repair/fix Clean/ dismount/ lubricate Replenish/ drain Instruct/ install -
ed.4, Februrary 1997, Code no. 0109.280
Confidential 1997 Oc-Nederland B.V., Venlo
ES DIGITAL PPC-2 (Oc 9700/9800 series)

398 Mechanical connections 399 Electrical connections 400 Others 11.Image processing 430 PBA(s) 437 438 439 440 Settings Mechanical connections Electrical connections Others 538 Switch(es) 539 Sensor(s) 540 PBA(s) 557 558 559 560 Settings/Parameters Mechanical connections Electrical Others
CAS-C
730 Static eliminator(s) 731 Mechanical switch(es) 732 Damper(s) 742 Fan(s) 745 747 748 749 750 751 752 753 754 757 758 759 760 Fuse(s) LED(s) Switch(es) Sensor(s) PBA(s) Motor(s) Clutch(es)/Brake(s) Solenoid(s) Power supply Settings/Parameters Mechanical connections Electrical connections Others
15.Paper Transport 564 Paper guide plates 565 Rollers 568 569 570 571 572 573 597 598 599 600 Switch(es) Sensor(s) PBA(s) Motor(s) Clutch(es)/Brake(s) Solenoid(s) Settings/Parameters Mechanical connections Electrical connections Others
12.Paper Roll Drawers 441 442 443 444 Paper spool(s) Feeding roller(s) Belt(s) Cutter
446 Gear(s) 447 Tensioner(s) 448 Drawer rails 468 469 470 471 472 473 477 478 479 480 Switch(es) Sensor(s) PBA(s) Motor(s) Clutch(es)/Brake(s) Solenoid(s) Settings/Parameters Mechanical connections Electrical connections Others
20.Interfacing Oc Host Interface HW/cables 771 772 773 774 775 Data cable Protocol convertor Interface failure Interface setting SCSI termination
18.Folding/Folding Output 681 685 686 687 688 689 690 700 701 702 703 704 705 710 711 712 713 717 718 719 720 Clutch(es)/Brake(s) Gear(s) Paper guide plate(s) Folding roller(s) Timing belt(s)/pulley(s) Feed rollers Folding flap Motor(s) Solenoid(s) Sensor(s) Static eliminators PBA(s) Power supply Punch unit Renforcement unit Receiving belt(s) Safety switch(es) Settings/Parameters Mechanical connections Electrical connections Others
Data emulation 776 Incorrect data 777 Unsupported command/file format 778 Incorrect or no output Controller 781 782 783 784 785 786 Memory Disk Fan(s) PBA(s) Software/firmware Power supply unit
13.Paper Sheet Feeding 481 Sheet feeding roller(s) 482 Belt(s) 483 Gear(s) 509 510 511 512 513 517 518 519 520 Sensor(s) PBA(s) Motor(s) Clutch(es)/Brake(s) Solenoid(s) Settings/Parameters Mechanical connections Electrical connections Others
790 Switch(es) 791 Controller settings 798 Mechanical connections 799 Electrical connections 800 Others 21.Host Software Oc Application SW 821 822 823 824 Oc JobDirector failure Oc JobDirector setting Oc PlotDirector failure Oc PlotDirector setting
14.Preheating 521 522 523 524 525 526 527 528 Paper guide cloth Paper driving rollers Heater(s) Liquid (-container) Thermal switch(es) Clutch(es)/Brake(s) Solenoid(s) Belt
19.Delivery 721 722 723 724 725 726 Paper guide plate(s) Timing belt(s)/pulley(s) Gear(s) Feed roller Bearing(s) Transport belts
ES DIGITAL PPC-2 (Oc 9700/9800 series)

825 Oc Reprostation failure 826 827 828 829 830 Oc Reprostation setting Oc ScanStation failure Oc ScanStation setting ScanStation Viewer failure ScanStation Viewer setting 952 Incorrect operation 953 Original 954 Exaggerated demands 960 Others Customers Environment 961 Humidity/Temperature 962 Main power supply 963 Host connection 970 Others Environment Supplies Customer SW/application 836 SW/application failure 837 SW/application setup 22.Control 841 842 843 844 845 846 847 848 849 Memory Relay(s) Line filter(s) Stepdown transformer Fuse(s) Copy counter Fan(s) Switch(es) Sensor(s) 980 Others Supplies Installation (problems)/ Integration/Instruction Use all other codes and: 981 Integration 982 Training/Instruction 991 Packing 992 Covers 993 Transport securities 995 Oc Application SW 996 Oc Drivers/Convertors/ SW 997 Customer SW/application 998 Others Installation/ Integration/Instruction 999 Complete system okay 971 972 973 974 Paper Specialities Toner (Cooling) Liquid
CAS-C
Oc Drivers & Convertors/SW 831 832 833 834 Oc Drivers SW failure Oc Drivers SW setup Oc Convertor SW failure Oc Convertor SW setup
855 PBA(s)/EPROM(s) 856 Power supplies 877 878 879 880 Settings/parameters Mechanical connections Electrical connections Others
23.Main Drive 881 882 883 884 909 910 911 912 913 917 918 919 920 Timing belt(s) Gear(s) Tensioner(s) Bearing(s) Invertor main drive motor PBA(s) Motor(s) Clutch(es)/Brake(s) Adjustments Settings/Parameters Mechanical connections Electrical connections Others
25.Customer/Environment/ Supplies/Installation/ Customer 951 No fault on arrival
Oc
Oc 9800
PREFACE
Contents
Preface
1 Copyright 101 2 TSM INFORMATION 102 3 GENERAL WARNINGS 104 4 NOTATION CONVENTIONS 105 5 FUNCTIONAL TEST 105 6 EDITION REVIEW 106 7 CURRENT STATUS SHEET 107 8 MODIFICATION / INFORMATION BULLETIN SURVEY 108 9 SAFETY DATA 108
Confidential 1999 Oc-Technologies B.V.
ed.5
Preface
TSM Oc 9800
Contents
Preface
1 Copyright
This publication is and remains the property of Oc-Technologies B.V.
The information it contains is confidential and is solely intended as a personal aid for service personnel in carrying out service activities on the Oc equipment described in this publication.
No part of this publication may be reproduced or be made public in any form or in any way whatsoever without the prior written permission of Oc-Technologies B.V.
1999 Oc-Technologies B.V.
ed.5
Preface 101
2 TSM INFORMATION
Why should you use the Technical Service Manual Oc 9800?
The TSM Oc 9800 is one of the tools you will need for your work. It will enable you to meet customer requirements better, quicker and in a clearly structured and accessible way. The TSM provides you with information you will require for installing and carrying out corrective and preventive maintenance on this machine.
At whom is the TSM Oc 9800 targeted?
This TSM has certainly not been written as a teach-yourself manual. During the Oc 9800 service training course you will learn to use and interpret the TSM in such a way that you can work quickly and efficiently. The service training course also gives you an opportunity to broaden your knowledge on how the machine functions. The TSM and service training course are closely linked. Participating in a service training course without using the TSM is just as incomplete as using the TSM without having learned how to use and interpret it in a service training course. The compilers of the TSM hope that you will find adequate information so that you can do your work quickly, correctly and with a continuing sense of satisfaction.
102
TSM Oc 9800
Preface
Feedback
Naturally, this TSM is always open to improvement. It is not unlikely that you may find imperfections and/or errors. Oc would be grateful if you would inform ITC (International Training Centre) in Venlo of any errors, imperfections or suggestions for improvement. You can do this as follows: This chapter contains a Document Change Request Form (DCRF). Copy this Form and enter any remarks you may have about this manual. Send the DCRF to the Technical Co-ordination department. This department will inform the International Training Centre-Service. The address is:
For the attention of:

Oc-Technologies B.V. Manager International Training Centre - Service Postbus 101 5900 MA Venlo
ed.5
Preface 103
3 GENERAL WARNINGS
We would like to draw your attention to the general warnings, summarised on this page. You will find specific warnings further on in the TSM in the descriptions of operations that have to be carried out in dangerous circumstances.
1 Avoid damaging PBA's via electrostatic discharges. You should wear the wrist-
band, code no. 7991.320 and use the antistatic mat, code no. 7991.322.
2 AVOID ELECTRIC SHOCKS!
Switch off the power supply to the machine and remove the mains plug from the wall socket if the machine does not need to be on when you are working on it.
3 AVOID MOVING PARTS!
When you remove the panels from the machine, make sure that you do not get your fingers caught between moving parts such as chains, cogs and gear belts.
4 This equipment must be earthed. 5 This equipment is not suitable for connecting to an IT-power system, often
used in stand-alone power systems (for instance offshore, mining). When in doubt consult your Technical Coordinator.
6 Always ensure that wall sockets and power switches are easily accessible. 7 A blown fuse does not guarantee a powerless situation. 8 When replacing a mains cable or mains plug, only use components which com-
ply with local regulations.
104
TSM Oc 9800
Preface
4 NOTATION CONVENTIONS
Wherever necessary, the following points for attention are indicated in this TSM.
Note:
A "Note" provides information that is essential for a correct functioning of the machine. It may also offer useful advice about its operation.
Warning:
A "Warning" provides information that can prevent the product (copy, original, the copier, etc.) from being damaged.
Caution:
A "Caution" provides information that prevents you from suffering personal injury.
Approx.: Whenever a measurement is indicated with the expression approximately or approx., non calibrated measuring instruments can be used. For code numbers of tools, jigs or measuring instruments please refer to the parts list.
5 FUNCTIONAL TEST
After every service do the following functional test:
s s s
Make a copy of a typical original used by the customer. Show the copy to the customer. The customer must agree that the machine is performing according to their expectations and within the machine specifications laid down in this Technical Service Manual.
ed.5
Preface 105
6 EDITION REVIEW
EDITION DATE ed.1 ed.2 ed.3 May 1995 April 1996 July 1996 CHAPTER All All Faults 01-Drum 09-Originals 20-Interface Installation Faults 19-Finishing 20-Interface 1-7 11-23 all SECTION All All All All (except Diagrams) All (except Diagrams) All (except Diagrams) All SDS All All (from on page 1001) Diagrams Diagrams all
ed.4
April 1997
ed.5
Februari 1999
including Information Bulletins 1002, 1003, 1008, 1010, 1012, 1013, 1015, 1016, 1018, 1023, 1026, 1030, 1041, 1043, 1044, 1045a, 1046, 1047, 1048, 1050, 1052, 1054, 1055. IB 1001 of the Folder. Modifiaction bulletins Engine 9801 -11, 13, 17, 25, 27, 28, 33, 34, 36, 37, 39. Scanner 9810-01 / 11, 39 Controller 9812 - 11, 39 Folder 06, 07 and 08
106
TSM Oc 9800
Preface
7 CURRENT STATUS SHEET

CHAPTER TOC SECTION
Preface
ed.5 TOC
ed.5 INS ed.5 CQ ed.5 E.F. ed.5 TOC ed.5 SDS ed.5 LAP ed.5
Installation
ed.5 TOC
Faults Functions 01 02 04
ed.5
TOC
DIAG SDS
ADJU DISA FUNC ELEC E.D.
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
TOC
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5
ed.5 ed.5
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
05 06 07 09 10 11 12 13 14 15 18 19 20 (1-999) 20 (1001-1999) 20 (2001-2999) 22 23 25
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
COP
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 CON ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
ed.5
ed.5
Preface 107
CHAPTER
TOC
SECTION
Preventive maint. Miscellaneous Parts list 9800 Parts list 976
ed.5 ed.5 ed.2 ed.1
ed.5 ed.5
ed.5
8 MODIFICATION / INFORMATION BULLETIN SURVEY

See MERLIN Database
9 SAFETY DATA
For information about safety data, see the User Manual Oc 9800.
108
TSM Oc 9800
Preface
o
Approved by
ITC DOCUMENTATION CHANGE REQUEST FORM

Country : Department : : Tel :
Requested by :
DOCUMENT TO BE CHANGED Manual : Edition :

Write brief description of the changes requested.
Chapter / Page
Changes
Please use print-script to fill-out this form for error free handling
Please attach extra pages if necessary

Technicians send this request form to : Technical Coordination please send this request form to :
SIGNED :
Technical Coordination Department
DATE :
Oc-Technologies B.V. Attn. of: Manager International Training Centre - Service P Box 101 .O. 5900 MA VENLO The Netherlands
110
TSM Oc 9800
Preface
Oc
Oc 9800
01 DRUM
Contents
Diagnostics
1 Faults
101
SDS
1 Drum
201
Adjustments
1 The ASV probe for the drum 2 ~DRU ASV test~ 302 3 Drum security 303
301
Dis-/assemblies
1 The drum cleaning position 401 2 Drum cleaning procedures 406 3 Drum replacement 411 4 Removal of the drum pulley 413 5 Grease procedure of the drum shaft end 414 6 Fast Drum cleaning procedure (time saving) 414 7 Drum reporting card 416
Functional description
1 Copy process 501 2 Photoconductor 502 3 Charging 502 4 Exposure 503 5 Developing 504 6 Compact Transfer transFuse 504 7 Discharging 505 8 General drum 505
Electrical description
1 Component locations 601 2 ASV measurement 603 3 Compensation voltage 604
ed.5
01 Drum
Diagrams
1 Drum (from engine 484) 701 2 Drum (up to engine 483) 702
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. DRUm 01000 - 01999 code display 01001 FE: ~DRUmFAN not rotating~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
01-2-02 DRUFANROTSE Possible cause Remark
ON OFF
01501 MRE: ~DRUFANTEMPSE open / short-circuit~

~
01-9-01 DRUFANTEMPSE (NTC)
R NTC = 100 Ohm 300 kOhm Yes
Possible cause
Remark
ADC value > 808
DRUFANTEMPSE defect (short-circuit) CPU_IO PBA defect disconnect 2201X4
ADC value < 144
Yes
DRUMFANTEMPSE defect (open circuit) Electrical connection DRUFANTEMPSE -> CPU_ IO PBA Electrical connection: * DRUMFANTEMPSE --> CPU_IO-PBA. * +5VAN signal of 2201X3, X4 X5 short circuit to earth CPU_ IO PBA defect
ed.5
01 Drum 101
01502 MRE: ~Drum temp.(erature). too high: DRUFANTEMPSE~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
01-4-01 DRUFANPWM
DRUFAN turning No
Possible cause
Remark
ON
DRUFAN defect Connection L2 -> DRUFANINV (green led off) Connection DRUFANPWM ->DRUFANINV DRUFANINV defect CPU_IO PBA defect
Yes
Environment temperature too high Air inlet blocked Cover panel air outlet wrongly mounted
Max. 32 C
01504 MRE: ~DRUMFAN not connected: DRUFANSW~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
01-2-01 DRUMFANSW Possible cause Remark
OFF
01X1 (DRUFANSW) not connected Connection CPU_IO PBA -> SSR PBA Connection SSR PBA -> 01X1 (DRUFAN) CPU_IO PBA defect SSR PBA defect
102
TSM Oc 9800
Diagnostics
01505 MRE: ~Too high positive ASV in stand-by~

Possible cause
Recently cleaned OPC drum Newly installed OPC drum

Action
Withdraw the developing unit 1 mm (e.g. put the developing unit in the lock position as done during transport use a screw M6 x 30mm) from the OPC drum and make 50 A0 white copies. Normally the positive charge disappears.
01506 MRE: "Too high negative ASV in stand-by"

Possible cause
bad contacts: polluted compensation voltage sliding contacts polluted sliding contact on magnet roller check carbon brush connectors OPC drum short-cut to ground polluted OPC drum SSR PBA ASV-probe
Action
Info test 01-9-03 Clean/check the respective sliding contacts Clean the drum
01507 MRE: "Too high positive ASV val. in run"

Possible cause
See error code 01505 Capacitor charge unit + charge unit

Action
Special test 01-6-03 See error code 01505
ed.5
01 Drum 103
01508 MRE: "Too high negative ASV val. in run"

Possible cause
See error code 01506 Incorrect system configuration (DOCMEM instead of SETMEM v.v.) Too low PHD light intensity setting Dirty PHD diaphragm Defective PHD
Actions
See error code 01506 Correct system configuration If the PHD is involved, it can be checked, when there is enough light in the environment, by removing of the engine back-cover; if the problem still occurs the PHD is not involved
01509 MRE: "ASV init. pulse not detected"

Possible cause
Drum has a short cut to ground Bad connection between ASV-probe and CPU-IO Bad connection between CPU-IO and SSR-PBA or SSR-PBA and OPC drum No 24V supply to ASV-probe Defective compensation voltage supply unit Defective ASV-probe CPU-IO defect
Actions
Remedy the drum short cut Check the concerning connections and the wiring Check/replace the concerning parts
104
TSM Oc 9800
Diagnostics
01901 SWAR: ~Drum temp.(erature) too low: DRUFANTEMPSE~

~
01-4-01 DRUFANPWM
Drumfan turning
Possible cause
Remarks
OFF
Yes No
DRUFANINV defect Environment temperature too low

Possible cause
Min. 17 C
CONDRI- 1st trans06-4-05 OUTDIAG fer step (06-6-07) activated CTFSTVA 1st
Remarks
transfer step ON OFF ON No No DRIVERS PBA defect CTFSTVA defect Pneumatic connection -> CTFSFVA
Listen
Pneumatic connection -> CTFSTVA -> CTFSTCYLL/R Connection CTFSTVA -> DRIVERS PBA CTFSTCYLL/R defect CTFCOMP defect
ed.5
01 Drum 105
106
TSM Oc 9800
Diagnostics
SDS
1 Drum
Test nr. Component Signal Description
Analysis info tests 30 ~Reset PE & handicaps~
see SDS
31 ~Log / res err & ser cnt~
see SDS
32
~Last error logging (OWAR/SWAR/ORE/MRE/PE/FE)~
last 15 errors 32.1 last errors (all) user mode 32.2 last system errors (MRE, PE, FE) user mode 32.3 last errors (all) service mode 32.4 last system errors (MRE, PE, FE) service mode
34 ~Error top 10 (OWAR/SWAR/ORE/MRE/PE/FE)~
34.1 absolute top ten (all) 34.2 absolute system top ten (MRE, PE, FE) 34.3 relative top ten (all) 34.4 relative system top ten (MRE, PE, FE)
35 ~Error counters > 0~
see SDS
36 ~Consumable counters~
see SDS
37 ~Parameters settings~
see SDS
38 ~Serv. / Mark. counters~
see SDS
ed.5
01 Drum 201
Test nr. Input tests 01-2-01 01-2-02
Component
Signal
Description
01M1
DRUm FAN SWitch DRUM FAN ROTation SEnsor
Drum fan switch ON = connection X01 correct. Drum fan rotation sensor ON/OFF when drum rotating
Output tests 01-4-01 01-4-02
01M1 01M2/01M3
DRUm FANPWM
Drum fan PWM ON = drumfan switched on
DRUm COLD- Drum cold process fans 1 and 2 activated PROCess FAN ON = fans activated Hardware diagnosis: CONDRIOUTDIAG DRUm ASV Drum ASV compensation voltage COMPensation ON = 100% PWM (> 35 V DC) PWM
01-4-03
Special tests 01-6-01 ~Make function warm~
Functions 01 (drum), 02 (corona), 05 (developing) and 07 (discharging) are in warm condition

01-6-02 ~Make function cold~
Functions 01 (drum), 02 (corona), 05 (developing) and 07 (discharging) are in cold condition

01-6-03 ~View last ASV error~
The ASV-compensation voltages and the ASV-probe samples will be averaged over the last two minutes. In case of an ASV error the averages as well as the highest and the lowest values will be time stamped and saved. If during the last minute the state of the machine has been changed (run to stand by v.v.), only the samples in the last state will be averaged and saved.
202
TSM Oc 9800
SDS
Test nr. 01-6-04
Component
Signal
Description ~View last ASV probe/volt. values~
The average and lowest/highest values of the ASV-compensation as well as the ASVprobe values over the last minuteduring copying.
Adjustment tests 01-07-01 ~OPC Wax Cleaning procedure
see OPC wax cleaning procedure on page 410

Consumable tests 01-8-01
01X1
~Drum (lm)~
Drum copy length meters (range 0 - 9999999 m)

Info tests 01-9-01
01R1 01B3
~DRUm FAN TEMPerature SEnsor (adc)~
Actual A/D value 0-1023

01-9-02 ~DRUm ASV COMP. Sensor (V/10)~
Actual output value of ASV sensor (range -100 ... + 100 V / 10)
01-9-03 System tests 43 ~Cut sheet length~ ~Drum 45V Comp. last value (V/10)~
(range 0 - 400)
Setting of necessary sheet length for adjustments checking

52 ~Black mode~
Solid black test pattern with framing

54 ~DRU ASV test~
Preventive check of drum deterioration
ed.5
01 Drum 203
204
TSM Oc 9800
SDS
Adjustments
1 The ASV probe for the drum
Aim:
To ensure that the DRUASVCOMPSE functions correctly. Check 1: Fluctuating indication to check if the ASV probe is still measuring. Check 2: Measurement check with the (grounded) adjustment plate.
Check: 1 1 Carry out SDS test 01-9-02 (DRUASVCOMPSE). 2 1st specification: The reading in the display must vary at least 1 digit
(+/- 0.1 V).

3 Continue with check 2.
Check: 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Switch off the machine. Open the top front cover. Remove the front cover. Remove the air tube at the left side. Disconnect the connector 05X1 from the developing unit. Pull out the developing unit as far as possible. Remove the DRUASVCOMPSE adjusting plate. Move the bar with the ASV probe on the left and right side to its top position. Clean the probe. Mount the adjusting plate over the ASV probe and check if the plate is connected to the ground wire. The adjusting plate must touch the plastic block and the rubber stopper must touch the probe. Push the developing unit into the machine, do not lock the unit. Mount the air tube in the machine and plug in the connector 05X1. Switch on the machine. Carry out SDS test 40, cold SDS. Carry out SDS test 01-9-02. 2nd specification: The reading in the display must vary between the values +10 and -10 (between -1V and +1V).
ed.5
01 Drum 301
Correction:
If one of both is incorrect:

1 Switch off the machine. 2 Replace the DRUASVCOMPSE with a new one. 3 Re-mount all parts to their initial position.
2 ~DRU ASV test~

Aim:
Preventive test to check if the drum quality will decrease in the near future and drum cleaning is needed. Two copies are made on +3 and -5 V compensation voltage added to the actual (value SDS test 01-09-02) compensation voltage.
Check: 1 2 3 4 5 6 7 8 9
Carry out SDS test 43. Enter the value 930. Push the start button. Select: roll width A0 (34/36), unfolded and 2 copies. Push the start button. Carry out SDS test 54 with 2 copies selected. Feed one sheet in landscape direction into the sheet feeder. Feed the other sheet in landscape direction into the sheet feeder. Specification: The copies must be background-free.
Correction:
If one of the copies contains background carry out 01 Drum Drum cleaning procedures on page 406.
302
TSM Oc 9800
Adjustments
3 Drum security
Aim:
To prevent that the drum is damaged by the housing of CTFFTEMPSE when the CTF unit is closed.
Check: 1 2 3 4 5
Remove the left and right side top covers. Remove the left and right side top covers. Carry out SDS test 40, COLD SDS. Carry out test 06-6-07. Activate step 4; display indicates: Transfer CTFSTVA: closed Transfuse CTFSFVA: closed Pressure CTFSPVA: high 6 Specification: The distance between the CTF support and the adjusting bolt at the left and right must be 1.5 -0 / +0.5 mm.
Correction: 1 Adjust at the left and right side the distance between the CTF support and the
adjusting bolt to 1.5 -0 / +0.5 mm.
CTF support
adjusting bolt
1.5 -0 / + 0.5
ed.5
01 Drum 303
304
TSM Oc 9800
Adjustments
Dis-/assemblies
1 The drum cleaning position
Caution: Close the drawers of the upper and lower paper rolls and the paper
sheet feeding section if opened.

Note: The drum is sensitive to direct sunlight and fluorescent lamps. Do not
expose the drum to light for longer than 30 minutes.

C
C D E
D E
1 Switch off the machine. 2 Open the top front cover (A). 3 Remove the covers in the following sequence: Note: Disconnect the earth wires from the covers.
B, the front cover C, the left and right top covers D, the left and right side top covers E, the left and right side upper front covers F,. the left and right side lower covers
ed.5
01 Drum 401
4 Release the drawer of the cold process unit at the left and right.
This will also release the print head.

05X1
release lever
5 Open the drawer of the cold process unit until it clicks into the first position. 6 Disconnect the connector 05X1(developing unit) at on the right side. 7 Remove the air supply tube of the DRUASV probe at the left side.
air supply tube
8 Disconnect the connector (01X2 (drum temperature sensor) on the right side
under the drum fan.

9 Disconnect the connector 01X1 (drum fan) on the right side under the drum fan 10 Disconnect the connector 01B2 (DRum fan rotation sensor) from the fan hous-
ing
402
TSM Oc 9800
Dis-/assemblies
11 Loosen on the right front side, 4 screws of the air outlet from the drum cooling
and push the air outlet downwards.

12 Remove the drum fan on the right side (3 nuts). 13 Disconnect on the left side the connector 01X5 (drum sliding contact) from the
air inlet.
14 Remove the air inlet on the left side (3 nuts). 15 Loosen the tension of the drum drive belt with the belt tensioner on the left side
(2 bolts 10 mm).
belt tensioner drum drive belt

16 Remove the drive belt from the drum drive gear. 17 Release the drum drive gear (red knob) and remove the drive gear.
see Removal of the drum pulley on page 413

18 Release the developing unit and pull it out completely. drum drive gear
red knob
ed.5
01 Drum 403
19 Set the drum lifting handle into the drum winding mechanism at the left. 20 Turn down the drum lifting brackets. lifting handle
storage position lifting bracket
21 Fit the drum lifting bushes on the drum shaft on both sides and then turn and
lock them with the knurled screw.

22 Loosen the nuts of the drum position holders (bolt 17 mm) at both sides until
they can be turned to the front.

nut 17 mm
drum lifting bushes
23 Turn the drum lifting handle until the drum reaches the top position. Note: Check that earth wires do not touch the drum when turning the drum to
the front.
404
TSM Oc 9800
Dis-/assemblies
24 Push manually the drum over the top position and turn the lifting handle oppo-
site direction to move the drum downwards until the lifting arms reach the end position. 25 Close the developing unit.
drum cleaning position
26 The drum is in the cleaning position.
Installation
see Installation procedure on page 412.
ed.5
01 Drum 405
2 Drum cleaning procedures

Caution: Close the drawers of the upper and lower paper rolls and the paper sheet feeding section if opened. Aim:
To make sure that the copy quality is increased. Tools for drum cleaning:
s s s s s s s s
1987994 Oc cleaner P (EUR) 1987798 Oc cleaner P (USA) 2831.001 plastic gloves 2813.013 waste bags 9714.529 cleaning towels 7991.283 remote control switch 1929.022 Oc cleaner K (EUR) 1929.023 Oc cleaner K (USA)
The Drum Cleaning procedure consists of three separate cleaning procedures which should be executed depending on the kind of drum pollution. - Local cleaning procedure - Overall drum cleaning procedure - OPC wax cleaning procedure. Examine the background carefully to carry out the right cleaning procedure. If there is no result by cleaning, the OPC drum must be replaced.
1 Local drum pollution.
The OPC Drum is just locally polluted for example by fused toner or talc. As a result the copy may be polluted with small black stains or stripes in white areas. In black areas on the copy white stains or stripes might be seen. The stains/stripes on the copy can be related to the stains/stripes on the drum (repeating every 62 cm on the copy). The stains/stripes can be cleaned locally on the drum with Oc cleaner K. If there is no sufficient result, carry out the Overall drum cleaning procedure.
2 Overall pollution on the OPC Drum. Note: If after accurate examination of the background on the copies is a result
of wax pollution on the drum, the drum needs to be cleaned according the OPC wax cleaning procedure
406
TSM Oc 9800
Dis-/assemblies
Due to dust, talc or other substances being liberated from the copy material, the OPC Drum will get an overall pollution. With the DRU-ASV test (SDS test 54)it is possible to check for future pollution possibilities of the drum surface. If the pollution is severe, it will cause background on the copies. Often this background can be related to copy material sizes. Oc Cleaner K and Oc cleaner P will be needed to clean the drum.
3 Overall pollution on the OPC drum by wax.
Wax from copy material will saturate the soft fuserroller and than transferred to the drum. To recognize this problem, see chapter FAULTS Recognizing wax pollution on page 1107
Local drum cleaning procedure.
Before executing this cleaning procedure verify the location on the drum where to clean.
1 Make 2 white copies by means of SDS test 43 "cut sheet length". 2 Select A0/36 roll width and 930 mm length. 3 Carry out SDS-test 52 (Black-mode) and make 2 copies to determine the loca-
tion of the pollution on the drum.

4 Switch off the machine. 5 Disconnect the connector 05X1 (Developing unit) and the air tube of the ASV
probe.
6 Slide out the developing unit completely. 7 Activate SDS-test 23-4-01(Main drive Motor). Note: Use the remote control switch in order to stop the main drive immedi-
ately if necessary.
8 Fold a cleaning towel in such a way that its surface is approximately 5 cm by
9 10 11 12 13
5 cm and moisten the towel with Oc cleaner K. When pressing in the towel no cleaner liquid should drip off. Press the wet cleaning towel against the rotating OPC Drum at the polluted place during 3 drum revolutions. Repeat this once again with a new wet cleaning towel. Press a new dry cleaning towel against the OPC Drum at the polluted place during 3 drum revolutions. Close the machine. Judge the result of the cleaning procedure by executing: s adjustment ~DRU ASV test~ on page 302. s SDS test 52 (Black-mode) : No white spots/stripes should be visible on the two black copies (cut sheet 930 mm long).
ed.5
01 Drum 407
14 If still white or black spots/stripes are visible on the copy repeat the local drum
cleaning procedure once again.
408
TSM Oc 9800
Dis-/assemblies
Overall drum cleaning procedure. 1 Carry out the dis-/assembly 1,The drum cleaning position on page 401. 2 Put on the plastic gloves. 3 Remove the loose toner on the drum using a dry cleaning towel. Rub the clean-
ing towel in straight lines over the total width of the drum.
4 Shake the bottle Oc cleaner P well before use. 5 Moisten a cleaning towel with Oc cleaner P and clean the drum. Note: Pay extra attention to the edges of the drum. Use frequently a new towel
with sufficient cleaner on it.

6 After cleaning the drum with Oc cleaner P the Oc cleaner P should be re-
moved from the drum. Use new cleaning towels and gloves to polish the drum.
7 Rub in straight lines over the total width of the drum to remove the Oc cleaner
8
9 10 11 12 13
14 15 16 17 18 19 20 21
P. The drum should get back its original colour and a smooth surface without flames. Clean the drum again with Oc cleaner K using new towels and gloves. Repeat this twice again with new towels. Dry the drum with new cleaning towels and gloves. Remount the drum in the machine and fan (right side) and air inlet (left side). Carry out adjustment 23 Main driveMain drive belt on page 975 Remount the developing unit. Unhook the 2 locking springs of the developing unit, slide the unit a few mm away from the drum and lock it in the transport position with 2 bolts (no toner is developed to the drum). Close the drawer of the cold process, do not mount the front cover. Carry out SDS test 43 and enter a value of 930. Push the start button. Select an A0(36) roll and make 10 copies. Place the developing unit in the locking position and hook the tension springs back again. Mount the front cover. Check adjustment 23 Main driveMain drive belt on page 975 again. Carry out adjustment ~DRU ASV test~ on page 302
Note: If background / ghost image is still visible:
the background can be caused by wax pollution, see chapter FAULTS. if a ghost image appears. Make 25 copies blank A0 copies. The gost image should disappear. 22 Carry out 04 Printhead adjustment ~Testprint adjust PHD~ (new drum or after cleaning the drum). on page 101.
s s
ed.5
01 Drum 409
OPC wax cleaning procedure
Aim:
To clean the wax from the drum surface. Wax from copy materials pollutes the drum surface and creates an analogue background on the copies.
Note: During this procedure the temperature of the drum raises up to 50C
(122F), to transport the melted wax to the CTF fuser roller. - The fuser roller must be replaced by a new roller before the cleaning action starts, otherwise the old saturated fuser roller will not accept the melted wax from the drum. - To prevent that the toner is fused on the hot drum, the developer section must be placed in the transport position.
Recognizing wax pollution
The typical background on the copies caused by wax are described in chapter FAULTS: see Wax pollution on page 1107. This text replaces the description:- 2.3.3 Solving problems cause by wax-, of the Information Bulletin no. 12.
1 Switch the machine off. 2 Replace the CTF fuser roller by a new roller, see chapter 06-CTF fuser roller
on page 178.
3 Position the developer unit a few millimetres away from the drum by opening
4 5
7 8
and closing the unit with the locking handles before and not behind the locking bolts. (The toner should not touch the drum.). Switch the machine on in SDS mode. Execute SDS test 01-7-01 OPC Wax Cleaning Procedure. When the machine is in warm condition, the test takes about 20 minutes to complete, inclusive the cooling down by the fan. When the test is finished, the screen will display: ~Test done~. Execute SDS test 43 ~Cut Sheet length~ 930 mm on A0/36 roll width and make 10 sheets. This action will clean the eventual remnants of the drum and the CTF unit. Switch off the machine. Reposition the developer unit.
410
TSM Oc 9800
Dis-/assemblies
3 Drum replacement
sheet feeding section if opened.

Note: The drum is sensitive to direct sunlight and fluorescent lamps. Do not
expose the drum to light for longer than 30 minutes.

1 Carry out points 1 up to and including 23 of The drum cleaning position on
page 401.
2 Open the manual feed table until it clicks into the first lock position. 3 Open the drum box. 4 Place the empty cover of the drum box upside down on the manual feed table. Note: Check that the drum is free to move to the front.
drum box cover
manual feed table
5 Push the drum over the top position and turn the lifting handle to move the
drum downwards into the drum box cover.

6 Cover the drum with a protection sheet. 7 Release the drum lifting bushes from the drum shaft and push them into the lift-
ing brackets.
8 Place the drum box cover with the drum on the floor.
ed.5
01 Drum 411
Installation procedure 1 Place the drum box with the new drum on the manual feed table. Note: The pin groove (wedge groove) must face to the left side. 2 3 4 5 6 7 8
.
Fit the lifting brackets to the drum shaft and lock them. Turn the lifting handle to move the drum out of the drum box. Remove the tape from the drum protection sheet. Remove the drum protection sheet from the drum. Remove the two foam blocks, preventing turning of the drum during transport. Turn the drum to the working position. Place the drum position holders (the spacers against the outside of the frame).
spacer
9 Remove from the drum the lifting bushes and lock them. 10 Turn the drum lifting mechanism to the neutral position. Note: points 10 and 11 must be carried out after mounting a new drum and when the drum gear was difficult to remove. 11 Clean the drum shaft at the drive side with a dry cloth. 12 Rub the shaft end evenly with MOLYCOTE-GN Plus (code 1988.856) using a 13 14 15 16
brush or cloth. Do not allow MOLYCOTE-GN Plus to get into your eyes. Remount all parts. Tighten the belt tensioner manually. Push the developing unit into the machine. Connect the air tube and connect the connector 05X1.
412
TSM Oc 9800
Dis-/assemblies
17 Close the drawer of the cold process unit and lock it. 18 Lock the print head. 19 Unhook the 2 locking springs of the developing unit, slide the unit a few mm
20 21 22 23 24 25 26
away from the drum and lock it in the transport position with 2 bolts (no toner is developed to the drum). Carry out the adjustment Main drive belt on page 975 function 23 Main drive. Carry out SDS test 42 (Service copy mode, machine is warming up). Carry out SDS test 43 and enter a value of 930. Push the start button. Select an A0 (36) roll and make 10 copies. Remove the 2 bolts and place the developing unit in the locking position and hook the tension springs back again. Carry out adjustment 04 ~Test print adjust PHD~ adjustment 1 or 2.
Note: Only when a new drum is installed:
27 Select SDS test 01-8-01. 28 Enter the value 0.
4 Removal of the drum pulley

Note: (Drum pulley removal toolkit 7991.581). 1 2 3 4 5
Remove the inlet pipe of the drum at main drive side. Remove the carbon and the brass plate from the drum pulley. Insert the disassembling tool (7991.528) in the shaft hole. Mount the metal plate (7093.204) with tapties (2111.275) on pulley. Screw the bolt (M8x40) (2121.148) in the hole, while the red position pin is lifted continuously, to remove the pulley from the shaft end.
Note: As an alternative you always can order a the large pulley remover, a
2-arm pulley remover (7991.527) with an arm reach of 200 mm.
ed.5
01 Drum 413
5 Grease procedure of the drum shaft end

Note: Only use Molycote-GN Plus (1988.856).
The procedure of greasing the drum shaft end with Molycote-GN Plus is part of the Preventive Maintenance Procedure. At least every 6 months this has to be done to avoid sticking of the pulley at the drum shaft. To prevent damages to pulley and drum shaft-end the kind of grease and the grease instruction is changed: do not use the grease Molycote TP42.
1 2 3 4
The procedure is as follows: Remove the pulley from the drum shaft-end. Remove all grease of the shaft end and from the inside of the pulley bush. Grease the drum shaft-end with Molycote-GN Plus. Grease the inside of the drum pulley.
6 Fast Drum cleaning procedure (time saving)

It is not anymore necessary to position the drum into the cleaning position: this procedure describes the way how to clean the drum inside the engine. Don't use the cleaner P, only use cleaner K. In case of heavy pollution on the drum you may use cleaner P. However, afterwards the drum must be cleaned heavily with cleaner K to remove residues of the cleaner P. Make some copies to judge the cleaning results. Tools for drum cleaning:
s s s s s s s s
1987994 Oc cleaner P (EUR) 1987798 Oc cleaner P (USA) 2831.001 plastic gloves 2813.013 waste bags 9714.529 cleaning towels 7991.283 remote control switch 1929.022 Oc cleaner K (EUR) 1929.023 Oc cleaner K (USA)
414
TSM Oc 9800
Dis-/assemblies
Drum Cleaning Instruction

1 2 3 4 5 6 7
Open the top cover. Remove the front cover. Open the drawer of the cold process unit, until it clicks in the first position. Remove the air supply tube of the DRU-ASV probe. Slide out the developing unit completely. Cover the cold process unit with a sheet of paper. Activate SDS-test 23-4-01.
Note: Use the remote control switch in order to stop the main drive immediately if necessary. The drum can also be rotated step by step using the remote control.
8 Fold a polishing cloth in such a way that its surface is approximately 5 cm by
5 cm and moisten the towel with Oc Cleaner K.

Note: Press the wet cleaning cloth against the rotating drum during 3 drum
revolutions.
9 10 11 12 13 14
Repeat this once again with a new wet cleaning towel. Press a new dry cleaning towel against the drum during 3 revolutions. Place the developing unit in the machine. Connect the air supply tube and connector 05X1. Close the drawer of the cold process unit, lock it and unlock the PHD. Remount the covers.
ed.5
01 Drum 415
7 Drum reporting card

To have a proper analysis of the returned drums it is important to register the cause of failing, reached lifetime, fail circumstances, etc. We emphasize the importance to fill in the drum reporting card completely and to return it with the belonging drum. Instruction: When the technician replaces a consumable (in this case: drum) he has to: 1 Take the new drum reporting card (packed together with the new drum. 2 Fill in at the reporting card: s drum number s machine type and serial number s country s the date of installation of the consumable
3 4 5 6
Store the new card in the engine After replacement: Take out the Drum reporting card of the removed drum. Fill in at the reporting card: s the date of removal of the consumable s consumable counter in lm s "Reason of removal" indicated with numbers s also mention the "Paper used by the customer
7 Pack the "old" card together with the removed drum and an example of a fault
copy and return it via the regular channels.
416
TSM Oc 9800
Dis-/assemblies
1 Copy process
There are 5 steps involved in the copy process around the drum:
developing roller
developing unit
drum fuser roller
exposure
charging discharging
1 2 3 4 5
Charging Exposure Developing Transfer Discharging The copy process steps are numbered in the sequence in which they occur.
ed.5
01 Drum 501
2 Photoconductor
The photoconductor is an organic photoconductor (OPC). The drum is an aluminium cylinder coated with two layers of photoconductive material. The first layer is the generation layer and the second is the transfer layer. The photoconductor can hold an electrical charge in the dark, because the layer has a high electrical resistance in the dark. The drum, which is insulated from the frame of the machine, is supplied with a variable compensation voltage (approx. 0 to 35 V) for obtaining a correct copy quality (no background). The ASV probe, mounted on the developing unit, measures the Apparent Surface Voltage of the drum after development.
3 Charging
The charge corona unit has 2 pin arrays. The pin arrays (supplied with a negative HV) will evenly charge the total width of the drum surface. The HV supply voltage for the pin array is a DC voltage of - 6.4 kV on which an AC voltage of 4.2 kV pp 13 kHz is superimposed. After charging, the drum has an Apparent Surface Voltage (ASV) of -130 V.
pin array
drum
502
TSM Oc 9800
4 Exposure
Exposure:
The digital information of an original is transferred via the image processing function to the print head. The light of the LEDs passes a SLA (self focusing lens array) to expose the drum. The printer is based on white writing with LEDs. This means that all white parts of the original are discharged on the drum by the LEDs of the printhead. Black parts (image areas) of the orig- SLA inal are not discharged on the drum. After the exposure function a latent (not visible) image remains on the drum surface.
Framing:
drum
cooling
LEDs
A second function of the printhead is framing in the length and width direction. Framing is necessary to prevent toner pollution in the system. Width direction framing Width framing is carried out between 2 copies. All LEDs of the printhead switch on and discharge the entire width of the drum. Length direction framing The remaining width of the drum (alongside the latent image) is discharged by switching on the outer LEDs of the printhead.
ed.5
01 Drum 503
5 Developing
The developing unit is filled with one component toner. Magnetic forces transport the toner to the developing roller. The doctor blade transfers a fixed amount of toner on the developing roller. The toner on the developing roller develops the latent image on the drum. The developing unit also removes residual toner (from the previous copy) from the drum. The developing unit therefore also acts as a cleaning unit.
developing roller doctor
drum
6 Compact Transfer transFuse

The transfer of the toner from the drum surface to the copy material is carried out in 2 steps. The first step is transfer of toner from the drum to the fuser roller. The second step is transfer and fusing (transfuse) of toner from the fuser roller to the copy material.
fuser roller
2nd step
1st step
504
TSM Oc 9800
7 Discharging
The discharge unit contains a pin array and a LED bar. The charged toner and the residual charge on the drum are discharged by the pin array and the LEDs. The pin array in the discharge unit is supplied by a DC voltage of - 3 kV on which an AC voltage of 3 kV is superimposed. The discharge LEDs are mounted on 3 PBAs (3 x 32 LEDs)
pin array Drum LEDs
8 General drum
Drum drive
The Main Drive motor (MADMO) drives the drum via a pulley and a toothed belt. The speed of the drum is 10 m / min. (32.8 ft/min.).
Drum cooling
The temperature of the drum must stay in between certain temperatures to ensure a good copy quality. This means that the air, through the drum, should stay between 30 and 43 C (109F). When the temperature of the air rises above 35 C (95F) a drum cooling fan (DRUFAN), located at the non drive side of the drum, starts turning and sucks air through the inside of the drum. Inside the drum a conic form is mounted to ensure an even cooling of the drum. The drum fan temperature sensor (DRUFANTEMPSE), located near the cooling fan, measures the temperature of the air in the outlet of the drum. The speed of the drum cooling fan is increased when the air temperature becomes higher. If 2 times a temperature above or equal to 43 C is detected by the temperature sensor the error code 01502, DRUFANTEMPSE too high, is generated. To prevent main damage on the drum and CTF rollers in case the drum cooling does not operate properly a safety circuit is added to the drum fan. This circuit contains a pulse disk mounted on the drum fan rotor and a sensor, if the sensor doesnt detect the rotation of the fan, a FE error 01001 is presented and the machine stops.
ed.5
01 Drum 505
ASV compensation
After discharging the drum a residual charge remains on the drum surface. The amount of the residual charge depends on: - The age of the drum (1 - 2 V / 10,000 lm). This value steadily increases but after approx. 50 length km it will remain stable. - Cleaning of the drum - Pollution of the drum The ASV compensation sensor measures the residual charge of the drum and places a compensation voltage on the drum. This prevents background on the copies and system pollution. The ASV compensation control is only able to compensate negative rest changes on the OPC drum
ASV errors 1 Initialisation.
After start-up, a software routine checks a number of ASV components for malfunctions. This is done during a complete drum rotation at stand-by speed. If the check fails, the error code 01509 is generated. 2 Positive charged drum. (Compensation is only possible with negative tension). Positive charge occurs due to function between the drum surface and the toner brush on the developer roller. This rest charge occurs only on new OPC drums and on recently cleaned drums. It doesnt occur on drums that have been running for a longer time. In run mode, this voltage is neutralized by the corona and discharge function. In stand by mode, this voltage is neutralized by switching on the discharge unit and the LEDs on this unit. The fans run a little time longer to remove the ozone. 3 Too high & too low value. The ASV value is monitored during constantly. If the value is too high or to low during a complete rotation of the drum, error code is generated. Stand-by mode ASV is < -9V or > +9V: error 01505 or 01506 Runmode ASV is < -9V or > +3V: error 01507 or 01508.
506
TSM Oc 9800
ASV probe
The ASV probe, mounted on the developing unit, measures the Apparent Surface Voltage on the drum behind the developing unit. The probe measures the ASV on one position, just outside the regular images, at 440 mm from the middle of the drum. When 914 mm (36) paper is used the measurement and compensation is carried out in the distance between two copies (10 cm).
ASV probe 36
A0 36
100 mm
DRUM
ASV Probe cleaning
The electrode of the probe is sensitive to pollution. An air pump (DRUASVCOMPPUMP) blows air through the probe housing over the electrode. The air keeps the electrode clean.
Drum replacement
The replacement drum can be a new drum or a recycled drum. Both drums are 100% tested at the production department regarding copy quality aspects. Therefore the copy quality for both recycled and new is fully guaranteed. It is possible that a certain pattern is viewed on the drum. This is not on the surface, but this is from the aluminium surface and can be seen through the transparent layer.
ed.5
01 Drum 507
508
TSM Oc 9800
1 Component locations
Drum DRUFANTEMPSE DRUFANMO
Sliding contact DRUFANROTSE DRUCOLDPROCFAN1+2
DRUASVPROBE
DRUASVCOMPSE
DRUASVCOMPPUMP
ed.5
01 Drum 601
DRUFANMO
DRUFANROTSE 01X1 and 01X2 01B2
DRUFANINV
602
TSM Oc 9800
2 ASV measurement
The Apparent Surface Voltage (ASV) is measured with a ASV probe. The probe is mounted on the developing unit. The ASV probe consists of: s Housing s Tuning fork s Piezo element s Electrode s DRUASVCOMPSE PBA
A tuning fork is mounted in a housing. On the upper side of the tuning fork a piezo element is mounted. If the piezo-element is supplied with a voltage the piezo element starts vibrating and so the tuning fork start vibrating. At the lower side of the tuning fork an electrode is mounted which moves in and out of the probe housing when the tuning fork is in vibration. The distance between the probe and drum is 2 mm. The measurement works as follows: Assume the residual drum ASV voltage (after charging by the corona and discharging by the printhead) on the drum is - 10 V and the probe housing voltage is 0 V. The piezo element is activated and the tuning fork start vibrating. The electrode moves in and out an electrical field. Depending on the field strength a voltage is generated in the electrode. The voltage on the probe housing is decreased (e.g. to -2 V). The electrode moves in a smaller electrical field and so the generated voltage in the electrode is also smaller. The probe housing voltage is decreased again. The measurement continues until there is no more voltage generated by the electrode. At this moment the probe housing voltage is the same as the residual drum ASV voltage on the drum. The measured residual ASV voltage is used to put a compensation voltage on the drum.
ed.5
01 Drum 603
Note: The ASV probe can be tested with adjustment The ASV probe for the
drum on page 301
3 Compensation voltage
The measured residual drum ASV voltage on the drum surface is between 0 and - 35 V. This would result in background on the copy. To avoid this background a positive compensation voltage is supplied to the drum via a carbon brush. The height of the compensation voltage is regulated with the DRUASVCOMPPWM signal. On the SSR-PBA, this signal is converted in a DC voltage DRUASVCOMP between 0 and +35 V, which is supplied to the drum via a single wire and a carbon brush sliding contact.
DRUASV PROBE (e.g. - 10 V)
DRUASV COMPSE DRUASV COMP PWM
Compensation voltage on sliding contact (e.g.+10V)
DRUASV COMPSE PBA 22Z2
CPU I/O L2 N2 SSR PBA
DRUASV COMP DRUM
Note: With adjustment ~DRU ASV test~ on page 302 its possible to check preventively if the drum quality is decreased and drum cleaning is needed.
604
TSM Oc 9800
1
22G1 CONSUPLV
G2 1 2 3 4 5 6 G3 1 2 3 4 +24V GND +24V GND +24V GND +5V GND +5V GND
2
X8 5 6 7 8 9 10 1 2 3 4 F4 4A F1 4A
3
22PBA5 DRIVERS
X11 31 +24V
4
22X12 1
5
01X6 1
6
DRUCOLDPROCFAN1
M
32 33
DRUCOLDPROCFAN1-B +24V
01M2 2 3 2 01X7 1
M
34 DRUCOLDPROCFAN2-B 01M3 4 2
DRUCOLDPROCFAN2
X5 7
CTFDOORSW
+24V 1 O6S1 2 1
PTRFRAMESW
2 15S1
22PBA1 CPU I/O

X13 1 2 3 5 X6 27 28 X11 12 X9 2 X5 1 2 3 +5V 1 DRUFANROTSE 2 GND 3 +5V +24V GND CONDRIINDIAG CONDRIOUTDIAG DRUCOLDPROCFAN DRUFANPWM 01B2 1 2 3 GND +24V X10 1 2 3 5 X6 27 28 X7 12 X11 12 7
8 X12 12
+24V-SW
CONEMS2-B 22K2-2A
15
+24V-SW
CONEMS2 22PBA4 SSR DRUM

X1 23 DRUASVCOMP 01X5 1 01X
F3 4A
23 20
+24V GND
X1 28 30
+5V ....+35V
01B1 DRUASVCOMPSE
05X1 6 7 8 B1 1 2 3
TP4
DRUFANROTSE
19 20 DRUASVCOMPSE GNDAN
D
1 +5VAN 01X2 1
DRUASVPROBE
COMPSUP
-T
-T
DRUFANTEMPSE
01R1
+45V
TP3
DRUFANTEMPSE
X9 9 7 8 12 10
CONSSRINDIAG +5V GND DRUASVCOMPPWM DRUFANSW
9 7 8 12 10 CONCONSUP X9 1 2 22X010 3 X8 3 6 4 1 F1 0.031A
X15 2
GND
01X1 9
DRUFANSW
1 DRUFANSW 8
22Z2
6 5 4 L2 N2
DRUASVCOMPPUMP
X2 12 L2S 05X2 1
M
1
01M4
11
N2S
4 8
2 6
N2 L2 L2-S N2-S
15
L2-S
01X1 5
01U1 DRUFANINV
14 N2-S U6 3 U6 1 U4 4 3 1 2 L2-S T3 T2 T1 E 6 4 3 1 2
M
3
01M1
2 22X003-2
DRUFANMO
F1 5A
G
GND DRUFANPWM
U2 1 2
H
ed.5
05X1 9 22X003-1
05X001
05X002 DEVROLLER
05X003 RESTASVREF
FROM ENGINE 484
TSM Oc 9800
01 Drum 701
1
22G1 CONSUPLV
2
22PBA5 DRIVERS
X8 5 6 7 8 9 10 1 2 3 4 F4 4A F1 4A 32 33 X11 31 +24V
3
22X12 1
5
01X6 1
M
DRUCOLDPROCFAN1-B +24V 2 3 2 01X7 1
DRUCOLDPROCFAN1
01M2
M
34 DRUCOLDPROCFAN2-B 4 2
DRUCOLDPROCFAN2
01M3
X5 7
CTFDOORSW
+24V 1 O6S1 2 1
PTRFRAMESW
2 15S1
22PBA1 CPU I/O

X13 1 2 3 5 X6 27 28 X11 12 X9 2 +5V GND +24V GND CONDRIINDIAG CONDRIOUTDIAG DRUCOLDPROCFAN DRUFANPWM GND +24V X10 1 2 3 5 X6 27 28 X7 12 X11 12 7
8 X12 12
+24V-SW
CONEMS2-B 22K2-2A
15
+24V-SW
CONEMS2 22PBA4 SSR
F3 4A
23 20
+24V GND
X1 28 30
X1 23
DRUASVCOMP
01X5 1
DRUM
01X
+5V ....+35V
01B1 DRUASVCOMPSE
05X1 6 X4 19 20 DRUASVCOMPSE GNDAN 7 8 B1 1 2 3
TP4
D
1 +5VAN 01X2 1
DRUASVPROBE
COMPSUP
-T
-T
DRUFANTEMPSE
01R1
+45V
TP3
DRUFANTEMPSE
X9 9 7 8 12 10
CONSSRINDIAG +5V GND DRUASVCOMPPWM DRUFANSW
9 7 8 12 10 CONCONSUP X9 1 2 F1 0.031A
X15 2
GND
01X1 9
DRUFANSW
1 DRUFANSW 8
22Z2
6 5 4 L2 N2 22X010 3 X8 3 6 4 1
X2 12
L2S
05X2 1
M
1
DRUASVCOMPPUMP
01M4
11
N2S
4 8
2 6
N2 L2 L2-S N2-S
15
L2-S
01X1 5
01U1 DRUFANINV
14 N2-S U2 3 U2 1 8 7 6 9 F1 5A L2-S T3 T2 T1 E 6 4 3 1 2
DRUFANMO
M
3
01M1
2 22X003-2 GND U1 4 5 2 3
G
GND DRUFANPWM
RUNFWD
H
ed.5
05X1 9 22X003-1
05X001
05X002 DEVROLLER
05X003 RESTASVREF
UP TO ENGINE 483
TSM Oc 9800
01 Drum 702
Oc
Oc 9800
02 CORONA
Contents
Diagnostics
1 Faults
101
SDS
1 CORona
201
Dis-/assemblies
1 Corona unit 401 2 Corona pin array 402 3 Corona fans 403
1 General 501 2 Air circulation 502
1 Component locations 601 2 High voltage supply unit 602 3 Corona fans 602
Diagrams
1 Corona
701
ed.5
02 Corona
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. CORona 02000 - 02999 code display 02501 MRE: ~CORona SUPply failure: (CORSUPER)~
02-6-05 CORSU CORSUP PER Possible cause 24 V present on 02G1 Remark
OFF
OFF
Yes
CORSUP defect (continuously ON) Connection CORSUPER -> CPU_IO PBA
OFF dis- Yes connect 2201X4 ON ON No
CPU_ IO PBA defect (CORSUPER) Connection 24 V DRIVER PBA -> CORSUP F3 DRIVERS PBA Other 24 V users on 2205X11
Yes
Connection CORSUP -> Pin arrays Connection backing CORona -> CORSUP Connection CPU_IO PBA -> CORSUP Connection CORSUPER -> CPU_IO PBA CORSUP defect (continuously off) Pin array disconnected / broken Polluted or humid isolation blocks
ed.5
02 Corona 101
02901 SWAR: ~Failure CORFAN (1-3): CORFANER~

02-4-01 CORFAN
CORFANER OFF
FANs turning (listen) No
Possible cause 24 V present on all fans
Remark
OFF
No
Connection CORFANER -> CPU_IO PBA CPU_IO PBA defect
OFF dis- Yes connect 2201X11 ON ON No
Yes
DRIVERS PBA defect Fuse F3 DRIVERS PBA defect 24 V DRIVERS PBA -> CORFAN 1, 2 or 3 Other 24 V users on 2205X11 DRIVERS PBA defect
No
Yes
Yes
CORFAN 1, 2 or 3 defect
102
TSM Oc 9800
Diagnostics
SDS
1 CORona
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
02 Corona 201
Component
Signal
Description
02G1 02M1 / 2 / 3
CORona SUPply ERror CORona FAN ERror
Corona supply error ON = corona supply switched off Corona fans error ON = fans not turning
Output tests 02-4-01
02M1/ 2 / 3
CORona FAN
~Corona fan~
ON = corona fans switched on Hard ware diagnoses CORFANER ON / OFF



02-6-05 ~CORona SUPply~
~CORSUP: OFF~ Hard ware diagnoses ~CORSUPER: ON/OFF~ Push the <start> button ~CORSUP: ON~ Hard ware diagnoses ~CORSUPER: ON/OFF~ During the test the drum and printhead are activated. Push the <start> button to switch the corona supply unit ON/OFF
Consumable tests 02-8-01 ~Corona pin array (lm)~
(range 0 ... 9999999 m) Norm 200000 m
202
TSM Oc 9800
SDS
Dis-/assemblies
1 Corona unit
Caution: Close the upper and lower paper roll drawer and the paper-sheet feeding section if opened. 1 2 3 4 5 6 7 8
Switch off the engine. Open the top front cover. Remove the front cover. Disconnect on the right side the connectors 22X5 and 0401X1 from the printhead. Disconnect on the left hand side the connector 22X4 from the printhead. Unlock on the left and right side the drawer of the cold process unit. Open the drawer of the cold process unit as far as possible. Lift the discharging unit and move it to the rear.
02X1
0201G2 HV 9 Disconnect 3 connectors (02X1, 0201G2 and the HV connector) at the right
from the corona unit.

10 Remove the corona unit.
ed.5
02 Corona 401
2 Corona pin array

Always replace both corona pin arrays.
1 2 3 4 5
Carry out dis-/assembly Corona unit on page 401. Place the corona unit on a flat surface. Remove the clear plastic covers on both sides. Release the tensioner of the corona pin array on the side without connector. Remove the corona pin arrays.
Note: Do not touch the corona pin array with your fingers.
Never clean the corona pin arrays. Installation

1 2 3 4 5 6
Mount the corona pin array on the side with connector. Guide it between the flat side of the supporting blocks. Install the other side and tension the spring. Remount the 2 plastic covers. Carry out SDS test 02-8-01. Enter the value 0.
Note: Dispose of the old corona pin array according to your local regulations to the local Oc organization.
402
TSM Oc 9800
Dis-/assemblies
3 Corona fans
Caution: Close the upper and lower paper roll drawers and the paper-sheet feeding section if opened. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Carry out dis-/assembly Corona unit on page 401. Remove on one side the metal side cover plate (4 screws). Remove the earth connection (1 screw). Remove the metal side cover plate. Remove 2 screws from the fan(s). Mount the side cover plate. Turn the unit. Remove the other side cover plate. Remove two screws from the fan(s). Remove the fan(s). Mount the fan(s) with two screws. Remount the side cover plate. Turn the unit. Remove the other side cover plate. Mount on the other side the fan(s). Remount the side cover plate.
ed.5
02 Corona 403
404
TSM Oc 9800
Dis-/assemblies
1 General
The function of the corona unit is to charge the drum electrically to a controlled even negative Apparent Surface Voltage (ASV) of about - 130 V. The corona section comprises:
pin array
backing plates pin arrays carbon filter
fans (3x)
The 2 pin arrays are positioned in the corona frame. The shape of the pin arrays is saw-tooth. The distance between each tooth is 4 mm. The 2 pin arrays are 2 mm staggered with respect to each other to achieve a uniform charging of the drum.The distance between the 2 arrays is 26 mm. The distance between the pin arrays and the drum is 26 mm. The distance between the pin array and the housing (backing) is 12 mm. A negative high voltage of - 6.4 kV DC superimposed with 4.2 kV AC are supplied to the pin arrays. The AC voltage is needed to create an even charging.
ed.5
02 Corona 501
2 Air circulation
The air inside the corona unit is nearly complete kept inside the unit. The circulation is a so-called turn around system.
carbon filter
fans 3x
To prevent pollution of the pin arrays, air is sucked towards the carbon filter. Pollution of the corona pin array results in less ASV and more background. Around the pin arrays ozone is produced. The ozone is changed to oxygen in the active carbon filter. The 3 fans suck the air from the pin arrays via the ozone filter. The lifetime of the carbon filter is machine lifetime.
502
TSM Oc 9800
Corona (COR)
CORSUP
CORFAN 1,2,3
ed.5
02 Corona 601
2 High voltage supply unit

The high voltage PBA supplies the charge corona pin arrays with a negative 6.4 kV DC nominal on which an 4.2 kV (peak - peak) AC 13 kHz is superimposed. The PBA is controlled by signal CORSUP from the CPU-IO PBA (22PBA1). The total corona current (It) is divided into the photoconductor current (Ip) and the backplate current (Ib). I(t) 1.2 = I (p) 0.11 + I (b) 1.09 [mA]. The Ip current charges the photoconductor to the required ASV. This current is kept constant. CORSUPER is the error detection signal.
3 Corona fans
The three corona fans are switched on / off with signal CORFAN signal. The error detection is done with the CORFANER signal.
602
TSM Oc 9800
1
22G1 CONSUPLV
2
X8 5 6 7 8 9 10 1 2 3 4 F4 4A X10 1 2 3 5 X7 17 11 X6 27 13 14 X11 15
3
22PBA5 DRIVERS
CORFAN1-B 22X5 28
4
02X1 1
5
02X3 1
M
16 F3 4A 18 19 CORFAN2-CORFAN3-B 3 31 4 5 2 02X5 1 17 CORFAN1-CORFAN2-B 2 30 2 3 2 02X4 1
CORFAN1
02M1
CORFAN2
02M2
M
22 CORFAN3-4 6 2
CORFAN3
02M3
22PBA1 CPU I/O
X13 1 2 3 5 X11 17 11 X6 27
+5V GND +24V GND CORFAN CORFANER
02G1 CORSUP
+24V GND 29 1 G1 1 4 G3 HV G2 1 CORPIN
02X9
02E1 02X7 02X8 02X2
CONDRIINDIAG
2 3 02X10
02X6
X4 14 15
CORSUP CORSUPER
13 14
2 3
H
ed.5 TSM Oc 9800 02 Corona 701
Oc
Oc 9800
04 PRINTHEAD
Contents
Diagnostics
1 Faults
101
SDS
1 PrintHeaD 201
Adjustments
1 ~Testprint adjust PHD~ (every service visit) 301 2 ~Testprint adjust PHD~ (new drum or after cleaning the drum). 3 Check Printhead 305
303
Dis-/assemblies
1 Cold process drawer 401 2 Replacing the printhead 402 3 Disassembly cooling unit 406 4 Installation cooling unit 407 5 Removal old cooling liquid 408 6 Preparation cooling unit for transport 408 7 Refilling liquid 408 8 Liquid pump 409
1 General 501 2 Printhead 502 3 Framing 503 4 Cooling 504
601
Diagrams
1 Printhead
701
ed.5
04 Printhead
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. PrintHeaD 04000 - 04999 code display 04101 PE: ~PHD temp. too high: PHDTEMPSE~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
.
04-4-01 PHDFAN
CONDRI
OUTDIAG OFF ON
PHDFAN turning No No
Possible cause
Remarks
ON
PHDFAN blocked / defect PHDFAN defect Connection 24 V DRIVER PBA -> PHDFAN Fuse F1 DRIVERS PBA defect Connection PHDFAN -> DRIVERS PBA
Yes
Obstruction / leakage cooling channels printhead PHDPUMP defect Air passage heat exchanger blocked / polluted
ed.5
04 Printhead 101
04501 MRE: ~PrintHeaD supply fail: (PHDSUPER)~

04-4-02 PHDSUP
PHDSUPER OFF
Possible cause
Remarks
OFF
PHDSUP defect Connection PHDSUPER -> CPU_IO PBA
OFF disconnect CPU_IO PBA defect (PHDSU2201X11 PER) ON ON PHDSUP defect Connection CONSUPPLV (400 V DC) -> PHDSUP Connection CPU_IO PBA -> PHDSUP Connection PHDSUPER -> CPU_IO PBA
102
TSM Oc 9800
Diagnostics
04901 SWAR: ~PHDTEMPSE open / short circuit~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
04-9-01 PHDTEMPSE
R NTC = 0.1 - 300 Possible cause kOhm Yes PHDTEMPSE defect (short circuit) CPU_IO PBA defect (disconnect 2201X4) DATA_RECEIVER PBA defect (disconnect 0401X3)
Remarks
ADC value > 808
ADC value < 160
Yes
PHDTEMPSE defect (open circuit) Connection PHDTEMPSE -> DATA_RECEIVER PBA
Connection DATA RECEIVER PBA -> CPU_IO PBA + 5VAN signal of 2201X3, X4, X5 (short circuit to earth) CPU_IO PBA DATA_RECEIVER PBA defect
ed.5
04 Printhead 103
04902 SWAR: ~PHD temp. too high: PHDTEMPSE~
Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
04-4-01 PHDFAN
CONDRIOUTDIAG OFF ON
Possible cause PHDFAN turning
Remark
ON
No No
PHDFAN blocked / defect PHDFAN defect Connection 24 V DRIVER PBA -> PHDFAN Fuse F1 DRIVERS PBA defect Connection PHDFAN -> DRIVERS PBA
Yes
Obstruction / leakage cooling channels printhead PHDPUMP defect Air passage heat exchanger blocked / polluted
104
TSM Oc 9800
Diagnostics
SDS
1 PrintHeaD
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
04 Printhead 201
Test nr.
Component
Signal
Description
Parameter test 04-1-01 ~Light intensity PHD~
Light intensity printhead Light output of the printhead (range 0 - 255, default 128)
Input tests 04-2-01
04G1
PrintHeaD SUP- Printhead supply error ply ERror ON = print head supply unit switched off
04M2
PrintHeaD FAN Printhead fan ON = printhead fan switched on Hardware diagnoses: CONDRIOUTDIAG PrintHeaD SUP- Printhead supply ply Disconnect 0401X1 ON = printhead supply switched on and fan turning On time 15 sec. Hardware diagnoses: PHDSUPER
04-4-02
Functions 04 (printhead), 09 (original handling), 10 (scanner) and 11 (image processing) in warm condition
Functions 04 (printhead), 09 (original handling), 10 (scanner) and 11 (image processing) in cold condition
04-6-04
Printhead / PBA PrintHeaD Leds can be switched on and off data receiver The Leds are switched off after 20 sec.
202
TSM Oc 9800
SDS
Test nr. Info tests 04-9-01
Component
Signal
Description
04R1
~PHD TEMPerature SEnsor (adc)~
Actual A/D value of the printhead temperature sensor (range 0 ... 1023)
System tests 50 ~Testprint mode~
Copy with test pattern of black strokes on the leading edge

51 ~Testprint adjust PHD~
Copy with test patterns of black / grey / white strokes in transversal direction Limit the number of copies to prevent pollution of the engine, select test 50
ed.5
04 Printhead 203
204
TSM Oc 9800
SDS
Adjustments
1 ~Testprint adjust PHD~ (every service visit)
Aim:
Make sure that the printhead exposes the drum with the correct amount of light in order to have an optimal copy quality.
Check: Note: Clean diaphragm and SLA (selfocusing lens array) with special lens
cleaning tool, code no. 1989.414. Check if the printhead is locked in the correct position. Mount all printer covers.
1 2 3 4
Select SDS test 43 and enter the value 930. Push the start button. Select roll width A0 (36), unfolded and make 5 sheets. Carry out SDS test 51 ~Testprint adjust PHD~. (feed the sheet landscape).
5 Push the start button.
(After 1 min. the sheet is fed in and a testprint is made.)

6 Specification: the background on the copy must be as follows:
s s s s s
area G no background area H no background area I no background area J just visible background area K background
ed.5
04 Printhead 301
Correction: No background on the testprint in area J 1 Select the SDS test 04-1-01. 2 Change the setting to a value e.g. 10 below the actual value. 3 Repeat the procedure from point 4. Background on the testprint in area I 1 Select the SDS test 04-1-01. 2 Change the setting to a value e.g. 10 above the actual value. 3 Repeat the procedure from point 4.
Note:
The most reliable testmoment is immediately after a long time running. Two test strokes must be without background: G and H. At that moment the light sensivity of the drum is most critical. In case of doubts, execute the PHD adjustment at that moment.
302
TSM Oc 9800
Adjustments
2 ~Testprint adjust PHD~ (new drum or after cleaning the drum).

Aim:
Make sure that the printhead exposes the drum with the correct amount of light in order to have an optimal copy quality.
Check: Note: Clean diaphragm and SLA (selfoc lens array) with special lens cleaning tool, code no. 1989.414. Check if the printhead is locked in the correct position. Mount all printer covers. 1 2 3 4
Select SDS test 43 and enter value 930 mm. Push the start button. Select roll width A0 (34/36), unfolded and make 5 sheets. Carry out SDS test 51 ~Testprint adjust PHD~. (Feed the sheet landscape)
5 Push the start button.
(After 1 min. the sheet is fed in and a testprint is made.)

6 Specification: the background on the copy must be as follows:
s s s s s
area G no background area H no background area I no background area J no background area K just visible background
ed.5
04 Printhead 303
Correction: No background on the testprint in area K 1 Select the SDS test 04-1-01. 2 Change the setting to a value e.g. 10 below the actual value. 3 Repeat the procedure from point 4.
Background on the testprint in area J 1 Select the SDS test 04-1-01. 2 Change the setting to a value e.g. 10 above the actual value. 3 Repeat the procedure from point 4.
304
TSM Oc 9800
Adjustments
3 Check Printhead
Aim:
Check 1: to check if all LEDs are switched on. Check 2: to check if all LEDs are switched off when button S1 on the DATA RECEIVER PBA is pressed.
Check: 1
Test to check if all LEDs are switched on.

1 2 3 4
Switch off the machine. Remove the front cover. Disconnect from the printhead connector 0401X1. Disconnect from the developing unit connector 05X1 and the air supply tube..
0401X1 05X1
5 6 7 8 9 10
Open the developing unit. Open the drawer of the cold process to the first stop. Switch on the machine and switch off the environment light if possible. Activate SDS test 04-4-02. Place a sheet of paper in front of the printhead. Check if the LEDs are switched on.
ed.5
04 Printhead 305
Check: 2
Test to check if all LEDs are switched off. Close the developing unit. Remount connector 05X1 and the air supply tube. Close the drawer of the cold process and lock the printhead. Close the opening between the printhead and the developing unit (with e.g. a roll core) to prevent that the drum is exposed by environment light. 15 Activate SDS test 50. 16 Select the A0 (36) roll width. 17 Push the button S1 on the DATA RECEIVER PBA twice while the copy receiving material is leaving the machine.
11 12 13 14 Note: Do not touch this button earlier to prevent toner pollution. 18 Black bands on the print should appear.
306
TSM Oc 9800
Adjustments
Dis-/assemblies
1 Cold process drawer
Caution: Close the upper and lower paper roll drawers and the paper sheet-feeding section if opened. 1 2 3 4
Switch off the engine. Open the top front cover. Remove the front cover. Disconnect all the connectors between the drawer of the cold process and the engine.
0401X1
22X4
22X5
5 6 7 8
Unlock and open the drawer of the cold process unit as far as possible. Loosen at the left side the drawer locking screws (2 screws). Remove at the right side the drawer locking nuts (2 nuts). Lift the drawer of the cold process from the rail and place the drawer on a flat surface.
ed.5
04 Printhead 401
2 Replacing the printhead

General Due to recent new developments the printhead of the Oc 9800/9700 has been improved to end in a longer lifetime of the printhead and in fewer service visits with regard to the printhead and the data receiver PBA. The new printhead has been approved as follows:
s s s s
- a new data receiver PBA - application of overshoot diodes - new LED drivers - some mechanical improvements.
The existing field population can not be modified. You can not put a new printhead in a machine with an old printhead, serial number < 2291 for Oc 9800 and < 527 for Oc 9700. The new data receiver PBA (5584019) can be combined with the old (code 5600367) and the new printhead (code 5600414). The old data receiver PBA (code 5583392) is only applicable with the old printhead (code 5600367). The combination of the new data receiver PBA with the old printhead is not recommended. Only in an emergency you may do this. During the next service visit you have to exchange the data receiver PBA. Recognition of an old or a new printhead can be done by looking in the split, about 1 cm wide, left from the data receiver PBA and just below the aluminium profile of the printhead, holding the big capacitors. When you see only, at the bottom of the split, the heads of M4 bolts then it is an old printhead. When you also see in between these heads of the bolts black capacitors then it is a new printhead.
Note: Handle the printhead with care. Never position the printhead on its diaphragm, this will lead to damage and to bad copy quality (out of focus).
Caution: Close the upper and lower paper roll drawer and the paper sheet-feeding section if opened.
402
TSM Oc 9800
Dis-/assemblies
Note: Auxiliary tools stored on the bottom of the cooling unit are:
- 1 funnel - 2 caps - 1 U-shaped pipe - 3 clips Use liquid of furnished bottle to refill the system.
1 2 3 4 5 6 7
Switch off the engine. Open the top front cover. Remove the front cover. Disconnect at the left side connector 22X4. Disconnect at the right side the connectors 22X5 and 0401X1. Open the drawer of the cold process as far as possible. Disconnect the connectors of the print head 0401X2, 2x power cables (1x 10mm, 1x 13mm) and ground cable.
power ground 0401X2 0401X1
22X5
8 9 10 11
Remove the cover of the cooling unit. Find the two caps (inside the cooling unit). Open the drawer of the cold process completely. Put a towel underneath the tube pillar
ed.5
04 Printhead 403
22X4
lower tube
cover
upper tube max.
min.
12 Remove the upper tube from the printhead. Note: The printhead must stay in its mounting position. 13 Close the upper tube pillar with a cap. 14 Mount the upper tube in the clip. 15 Remove the lower tube from the printhead. Note: The printhead must stay in its mounting position. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Close the lower tube pillar with a cap. Mount the lower tube in the clip. Mount the U-shaped pipe in the tubes. Remove carefully the printhead from drawer of the cold process and put the unit on a table. Do not place on the diaphragm side. Check if there is still liquid in the new printhead. If yes: remove the caps and add the liquid into the bottle (put down the caps on the cooling unit bottom). If not: remove the caps and put down the caps on the cooling unit bottom). Mount the new printhead in the drawer of the cold process. Mount the tubes to the printhead. Move the drawer of the cold process into the drum cleaning position. Connect all connectors between engine and the drawer of the cold process. Connect all connections to the printhead. Switch on the engine. Wait until the liquid level in the reservoir is stationary. If the level is below the low indication, add liquid from the furnished bottle. Place the funnel in a empty bottle. Remove the caps of the replaced print head.
404
TSM Oc 9800
Dis-/assemblies
33 34 35 36 37 38 39 40
Empty the replaced printhead. Mount back the caps to the replaced printhead. Close the bottle. Put the funnel and the caps in the cooling unit. Mount the cooling unit cover. Close the drawer of the cold process unit. Mount the top front cover. Carry out adjustment 1 see ~Testprint adjust PHD~ (every service visit) on page 301.
ed.5
04 Printhead 405
3 Disassembly cooling unit

Caution: Close the upper and lower paper roll drawer and the paper sheet feeding section if opened.
Use liquid of furnished bottle to refill the system.

1 2 3 4 5 6 7 8 9 10
Switch off the engine. Open the front top cover. Remove the front cover. Disconnect all the connectors between the drawer of the cold process and the engine. Open the drawer of the cold process as far as possible. Disconnect on the left side the connector 04X1 from the cooling unit. Remove the cover from the unit. Remove the U-shaped pipe, 3 clips, 2 caps) from the unit bottom. Put a towel underneath the tube pillar. Remove the upper tube from the print head.
Note: Take care, the print head must stay its mounting position.
11 Mount cap in the upper tube pillar. 12 Mount the upper tube in the clip. 13 Remove the lower tube from the printhead. Note: Take care, the print head must stay its mounting position. 14 15 16 17 18 19 20
Mount the cap in the lower tube pillar. Mount the lower tube in the clip. Mount the U-shaped pipe in the tubes. Remove the cooling unit (3 screws) and place on a table. Install new cooling unit see Installation cooling unit on page 407. Empty the replaced cooling unit see Removal old cooling liquid on page 408. Prepare the replaced cooling unit for transport see Preparation cooling unit for transport on page 408.
406
TSM Oc 9800
Dis-/assemblies
4 Installation cooling unit

Caution: Close the upper and lower paper roll drawer and the paper sheet feeding section if opened. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Mount the new cooling unit to the drawer. Put a towel underneath the tube pillar. Remove the lower cap from the print head and mount the lower tube. Remove the upper cap from the print head and mount the upper tube. Remove the cap from the heat exchanger. Mount the return tube to the heat exchanger. Connect the connector 04X1 of the cooling unit. Remove the return tube from the reservoir. Put the funnel in the reservoir. Add liquid to the maximum. Put the return tube into the reservoir. Close the drawer. Connect all connectors. Switch on the engine. Check if liquid returns into the reservoir. Switch off the engine after the liquid level is stationary. Add liquid if neccesairy. Put all tools back into the cooling unit. Mount the cover of the cooling unit. Close the drawer of the cold process. Lock the print head unit. Mount the front cover.
ed.5
04 Printhead 407
5 Removal old cooling liquid

Caution: Close the upper and lower paper roll drawer and the paper sheet feeding section if opened. 1 2 3 4
The cooling unit is already removed from the engine. Put the funnel in the bottle (used to fill the new unit). Remove the tubes one by one from the clips and hold them above the bottle. Empty the cooling unit completely.
6 Preparation cooling unit for transport

1 2 3 4 5 6 7
Put all loose parts into the cooling unit. Mount the cover on the reservoir. Put the return tube into the reservoir. Mount the tubes into the clips. Mount the U-shaped pipe into the tubes. Mount the cover on the cooling unit. Pack the cooling unit for transport.
7 Refilling liquid
Caution: Close the upper and lower paper roll drawer and the paper sheet feeding section if opened
Use de-mineralized water to refill the cooling unit if the level becomes too low.
1 2 3 4 5 6 7 8
Switch off the engine. Open the front top cover. Remove front cover. Open the drawer of the cold process to drum cleaning position. Remove the cover from the cooling unit. Remove the return tube from reservoir lid. Put the funnel in the reservoir. Add de-mineralized water to the indication max.
TSM Oc 9800 Dis-/assemblies
408
9 10 11 12 13 14 15 16
Put the return tube in the reservoir. Switch on the engine. If the level is correct switch off the engine. If the level is too low repeat the sequence. Put funnel back in the unit. Mount the unit cover. Close the drawer of the cold process. Mount the front cover.
8 Liquid pump
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Carry out the points 1 up to 16 from Disassembly cooling unit on page 406. Carry out Removal old cooling liquid on page 408. Disconnect the pump connector. Replace the pump. Connect the lower pipe, (pump inlet) with the reservoir. Connect the upper pipe, (pump outlet) through the lower unit hole with the printhead. Remove the return tube from the reservoir. Put the funnel in the reservoir. Add liquid to the maximum. Put the return tube into the reservoir. Switch on the engine. Check if liquid returns into the reservoir. Switch off the engine after the liquid level is stationary. Add liquid if necessary. Put all tools back into the cooling unit. Mount the cover of the cooling unit. Close the drawer of the cold process. Lock the printhead unit. Mount the front cover.
ed.5
04 Printhead 409
410
TSM Oc 9800
Dis-/assemblies
1 General
The printhead uses the light from LEDs to discharge the drum. The Oc 9800 is "a white writing" printer. This means light from the LEDs is used to discharge the photoconductor (drum) where white is needed on the copy. After exposure a latent (non visible) image is present on the drum. A second function of the print head is framing. Framing (discharging of the drum by switching on the LEDs) in the width direction as well as in the length direction is done by the printhead. This is done to reduce pollution in the printer. The exposure function in the Oc 9800 can be divided in the following sections:
s s s
printhead cooling section interface and supply
ed.5
04 Printhead 501
2 Printhead
The printhead consists of:
Drum
SLA
temp. sensor heatsink
Cooling channels Diaphragm glass plate LED and LED drivers
Heatsink
The heatsink is the carrier from the LEDs and LED drivers. It is also used for cooling purpose. A cooling liquid circulates through the heatsink to keep the temperature in a stable range over the total width of the printhead. On top of the heatsink is a substrate layer (40% Chromium and 60% Fe) on which the LED chips are glued with a heat conductive paste.
LEDs and LED drivers
In total 14.592 LEDs (mounted on 114 LED chips, each chip has 128 LEDs integrated circuits) are mounted on the heatsink. One LED chip on the left and right-hand side (8.2 mm) is always switched on (used for framing in the length direction). 112 Chips are used to create the latent image (14.336 LEDs = 910.4 mm). This image creating part of the LED bar is divided into 4 banks of 228 mm. Each bank is connected to two serial data lines. One line is connected to the even LEDs and the other is used for the odd LEDs. The image creating LEDs are also used for the regular framing of 3 mm for each format (except 36)
502
TSM Oc 9800
Above the LEDs a glass plate is mounted to create a dust free area and to prevent oxidation of the LED surface.
SLA
A Self focusing Lens Array (SLA) of glass fibres is mounted in front of the LEDs. Via the lens array and the diaphragm 5% of the light is projected on the drum surface, 95% is not used.
Diaphragm
To create an uniform exposure (no scattered light) of the drum, a diaphragm is mounted in front of the SLA. The diaphragm also prevents pollution of the SLA. It is necessary to clean the SLA and diaphragm at regular intervals with a special cleaning brush (code number 1989.414).
3 Framing
The second function of the printhead is framing in order to prevent pollution in the system. The printhead takes care of width direction and length direction framing.
ed.5
04 Printhead 503
Width direction framing is done in between 2 copies. All LEDs of the printhead switch on and the total width of the drum is discharged. Length direction framing The LEDs remaining part beside the latent image on the drum is discharged by switching on the LEDs on the outside of the printhead.
4 Cooling
The printhead is mounted in the cold process unit at short distance from the drum. The straightness of the lens is determined by the straightness of the heatsink. The temperature of the heatsink is max. 50 C (122 F). Water cooling is used to cool the heatsink of the print head and takes care of a low temperature of the LED s. A low LED temperature results in a higher light output. The water cooling keeps also the temperature even over the total width of the printhead and so an even light output of the printhead is guaranteed. The cooling unit consists of:
Printhead
pump
reservoir
PHDTEMPSE
tubes
heat exchanger PHD fan
504
TSM Oc 9800
The fan cools the heat exchanger. The warm cooling liquid from the printhead is transported to the heat exchanger, passes the reservoir and is transported to the heatsink via the pump.
Cooling liquid
The system is filled with 1 litre liquid. The cooling liquid used is 3 parts demineralized water and 1 part propylene glycol (to prevent corrosion and algae-forming). In water the concentration of salts is reduced via an electrical process and is not the same liquid as used in the pre-heating unit.
Temperature sensor
A temperature sensor (PHDTEMPSE) is mounted on the heatsink. The function of this sensor is to regulate the duty cycle of the LEDs to guarantee a constant light-output when the temperature of the heatsink changes. If the temperature rises the light output will decrease and the temperature becomes lower. The heatsink temperature depends on the environment temperature, the number of LEDs switched on and the adjusted duty cycle.
ed.5
04 Printhead 505
506
TSM Oc 9800
Printhead (PHD)
PHD
PHDTEMPSE
04PBA1 PHD data receiver
22X5
PHDFAN PHD cooling unit 04G1 PHD power supply
ed.5
04 Printhead 601
602
TSM Oc 9800
1
22G1 CONSUPLV
2
22PBA5 DRIVERS
X8 5 6 7 8 9 10 1 2 3 4 F4 4A X5 7 F1 4A 30 PHDFAN-B X11 29 +24V
3
22X5 34
5
04X1 5
M
11 6
PHDFAN
04M2
CTFDOORSW
+24V 1 O6S1 2
PTRFRAMESW
1 15S1 2
22PBA1 CPU I/O

X13 1 2 3 5 X6 27 28 X11 18 +5V GND +24V GND CONDRIINDIAG CONDRIOUTDIAG PHDFAN X10 1 2 3 5 X6 27 28 X7 18
8 X12 12
+24V-SW
CONEMS2-B
15
+24V-SW
CONEMS2
22K2-2A
C
22PBA4 SSR
6 5 4 L2 N2 22X010 3 1 4 X6 9 N2S L2S X9 1 2 X8 6 3 L2 N2 6 2 8 4
22Z2
L2S
22X4 1
M
1
PHDPUMP
04M1
12
N2S
3 2
3 2 22X005 04X5
22X006-4
22PBA5 DRIVERS
04PBA1 PHD DATA RECEIVER

+5V +5V GND GND 22X5 25 24 23 22 X2 1 2 3 4 S1 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 SD_NEG8 SD_POS8 SD_NEG7 SD_POS7 SD_NEG6 SD_POS6 SD_NEG5 SD_POS5 SD_NEG4 SD_POS4 SD_NEG3 SD_POS3 SD_NEG2 SD_POS2 SD_NEG1 SD_POS1 GND GND CLOCK_NEG CLOCK_POS GND GND LOAD_NEG LOAD_POS GND GND STB_NEG STB_POS
11PBA2
X3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
X9 1 2 3 4
22G1 CONSUPLV
+ PHD 400VDC PHD PHD+12VDC PHDON-OFF
G3 G4
+4V GND4V
X2 X3
22PBA1 CPU I/O

X11 5 13 4 PHDSUPER GND PHDSUP 22X5 18 6 17 G2 1 2 3
04X6
04X8 (MOD.9801-21)
TEST BW CAP_0401X1
+5VAN
PHDTEMPSE -T -T
04R1 X4 16 17 +5VAN PHDTEMPSE PHDTEMPSE
X3 1 2 X2 5 6
20 21
ed.5
TSM Oc 9800
04 Printhead 701
BW PROCESSING
G4 1 2 3 4
22X4 4 5 6 7
04G1 PHD SUPPLY

G1 1 2 3 4
04E1 PHD PRINTHEAD
X4
TEST SWITCH
Oc
Oc 9800
05 DEVELOPMENT
Contents
Diagnostics
1 Faults
101
SDS
1 DEVeloping
201
Adjustments
1 ~DEV unit adjustment~
301
Dis-/assemblies
1 Developing unit 401 2 Removal/installation the developing unit 3 Toner sensor (DEVTONSE) 403
402
1 General 501
601
Diagrams
1 Development
701
ed.5
05 Development
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. DEVeloping 05000 - 05999 code display 05501 MRE: ~Speed DEVMO out of range~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
Open the developing unit. Turn the magnet roller manually
Blocked: Remarks:
Sent back via Your cordination Check if one of the error codes described below has occurred via you data dump and/or test 35, error counters > 0 Ask/Check room temperature, this has to be < 32 oC, (90 o F) . Check how the toner is stored. The toner has to be stored cool.(< 35 o C/ 95 o F) Implement Modification 27 Drum fan rotation sensor.( Only in combination with firmware release or higher). In case the developer unit is jammed and has to be replaced, please send it back to Venlo by using the Original Package and according the local procedure.Fill in the unit reporting card and in addition add the next information to be send with the unit: Has one of the error codes as described above caused the jammed developer unit?. If yes which one. What was the highest room temperature? What was the storage temperature of the toner? nation with firmware rel
Logistics:
22-4-02 Possible cause CONMOSUP CONMOSUP switching (listen)
Remark
ON
No
DRIVERS PBA paper feeding motors defect (CONMOSUP) also not functioning
ed.5
05 Development 101
05-6-05 CONDRI DEVMOPWM OUTDIAG (100%)
DEVMO Possible cause turning DRIVERS PBA defect DEVMO blocked / defect Connection DRIVERS PBA -> DEVMO
Remark
OFF ON
ON (discon- Yes nect 2205X5) No
OFF (disconnect 2205X5)
DRIVERS PBA defect Connection DRIVERS PBA -> CPU_IO PBA CPU_IO PBA defect
05-2-02 DEVMOSE
Possible cause
Remark
Continuously OFF/ON when moving pulse disc
DEMOSE defect Pulse disc defect Connection DEVMOSE -> CPU_IO PBA CPU_IO PBA defect
05-2-01 DEVTONSE
Developing unit full Possible cause and / or refill toner icon continuously on DEVTONSE defect Connection DEVTONSE -> CPU_IO PBA CPU_IO PBA defect
Remark
Continuously Yes OFF
102
TSM Oc 9800
Diagnostics
SDS
1 DEVeloping
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
05 Development 201
Component
Signal
Description
05B2 05B1
DEVeloper TONer SEnsor DEVeloper MOtor SEnsor
Developing toner sensor OFF = toner available Developing motor sensor ON = sensor blocked by pulse disk


05-6-05
05M1
DEVeloper MOtor PWM
~DEVeloper MOtor (DEVMO)~
Activate the developing motor at normal speed or at 100% PWM signal
System tests 43 ~Cut sheet length~

52 ~Black mode~
Black copy with framing

Copy with black image of 30 cm length and thin black line in the centre of the white area
202
TSM Oc 9800
SDS
Adjustments
Aim:
To make sure that the developing unit is in line with the the printhead. Carry out this adjustment after: - printer installation - printhead replacement - developing unit replacement
Check:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Switch off the engine Open the top cover. Remove the top front cover. Disconnect the connector 05X1 on the right side. Remove the air supply tube of the ASV probe at the left side. Release the developing unit and pull it out. Clean the edges, 30 mm (1), of the toner brush on the developing roller with the vacuum cleaner: Turn the developing roller manually. Put the developing unit back into the engine. Make sure that you install the developing unit correctly against the drum cams and lock the unit. Connect the connector 05X1 and put the air supply tube back into position. Close the front cover. Close the top cover. Switch on the engine. Select SDS test 43 and enter a length of 930 mm. Push the start button. Select the roll width A0 (34/36), unfolded, 3 copies and push the start button. Carry out SDS test 55 ~DEV unit adjustment~ (first 300 mm = black copy, then 300 mm black line in the centre). Feed the sheet (90 degrees turned = width of 930 mm) in the paper sheet feeding.
ed.5
05 Development 301
Copy
x y
18 Measure on the copy the distance x and y. 19 Specification: The average difference (x-y) between left and right hand must
be less than 2 mm.
Correction: 1 2 3 4 5 6 7 8 9 10 11 12
Do dis-/assemblyDeveloping unit on page 401. Measure the distance of the front position block on the left side. Loosen at the left and right the unit position blocks (2 x Allen screws each). Adjust the left front block to (x-y)/2 mm to the left or right and tighten. Adjust the left rear block to the same position and tighten. Move the rail at the right-hand side to the outside. Move the developing unit into the engine. Tighten the right rear position block. Slide out the developing unit. Tighten the right front position block. Move the developing unit into the engine. Carry out SDS tests 43 and 55 and check the difference again.
Note: The sliding blocks of the developing unit must slightly touch the drum.
302
TSM Oc 9800
Adjustments
Dis-/assemblies
1 Developing unit
Caution: Close the upper and lower paper roll drawers and the paper-sheet feeding section if opened. 1 Open the top cover. 2 Remove the top front cover. 05X1
3 Disconnect the connector 05X1 at the right side.
ed.5
05 Development 401
air supply tube
4 Pull out the air supply tube at the left. 5 Release the developing unit. 6 Pull the developing unit completely outwards.
2 Removal/installation the developing unit

Caution: Close the upper and lower paper roll drawer and the paper sheet-feeding section if opened.
Warning:
2 persons are needed to remove the developing unit out of the machine.
Removal: 1 Carry out dis-/assemblyDeveloping unit on page 401. 2 Lift and remove the developing unit with 2 persons. Installation: 3 Mount the new developing unit. 4 Connect the connectors and the air supply tube. 5 Fill the developing unit with 1 bottle of toner. 6 Carry out the adjustment 1~DEV unit adjustment~ on page 301. 7 Add a second bottle of toner to the developing unit.
402
TSM Oc 9800
Dis-/assemblies
3 Toner sensor (DEVTONSE)

Caution: Close the upper and lower paper roll drawer and the paper-sheet feeding section if opened. 1 2 3 4 5
Carry out dis-/assemblyDeveloping unit on page 401). Remove the top cover of the developing unit. Remove the toner at the sensor position Disconnect connector from the sensor. Remove the toner sensor DEVTONSE (2 screws).
ed.5
05 Development 403
404
TSM Oc 9800
Dis-/assemblies
1 General
The function of the developing unit is to develop the latent image on the drum. The developing system uses one-component toner.
The developing unit comprises:
doctor blade
refill opening
scraper mechanism developing roller
toner supply reservoir toner supply mechanism magnet DEVTONSE
drum
8 magnet poles
ed.5
05 Development 501
Toner supply reservoir
The toner reservoir can contain 2 kg of toner. Each toner bottle contains 1 kg of toner and is sealed. When the toner bottle is placed in the refill opening of the developing unit, two knives cut 90% of the seal and the toner drops into the developing unit. Add always only 1 bottle of toner at a time.
scraper mechanism developing roller
toner sensor
toner supply mechanism
Toner supply mechanism
The toner supply mechanism mixes the toner and equalizes the toner level in the reservoir and transports the toner from the reservoir to the developing roller. The mechanism consists of four racks which are driven by the developing motor. If too much toner is used (e.g. a lot of black copies are made) the toner will not be even over the total width and the result might be an uneven copy.
Scraper mechanism
With small size copies (e.g. A4 or A size copies), a lot of toner is build up in front of the doctor blade. A scraper mechanism mounted just in front of the doctor blade reduces the build up of toner. This mechanism keeps the toner meniscus at a constant thickness.
502
TSM Oc 9800
Developing roller
Inside the developing roller 8 fixed magnet poles are positioned to transport the toner into the direction of the doctor blade and drum.
doctor blade magnet poles
DEVTONSE
The developing roller is a non-magnetic roller which is driven by the developing motor (DEVMO). The diameter of the developing roller 62.5 mm. The developing roller turns in the opposite direction to the drum. At the nearest distance between the drum and developing roller the toner is transferred to the charged drum. The latent image is developed and becomes visible. The developing roller also removes residual toner (after transfer) from the drum. The residual toner is transported into the toner reservoir. So the developing roller is at the same time a cleaning roller.
Doctor blade
The doctor blade transfers a fixed and even amount of toner on the developing roller towards the drum. The distance between the doctor blade and the developing roller is fixed at 1.0 mm.
Note: During the lifetime of the machine toner will gather on top of the doctor
blade. This toner may drop between the doctor blade and the developing cover causing toner pollution in the machine. Preventive Maintence is needed.
ed.5
05 Development 503
Toner sensor
The toner sensor (DEVTONSE) is mounted at the bottom of the reservoir. Toner empty detection is done with this sensor. The sensor is functioning on the principle of a electrical field measurement. The toner supply mechanism has four racks. Between two of these racks a magnet is mounted. This magnet cleans every turn (12 sec.) the toner sensor. The distance between the magnet and sensor is 1.5 mm. If enough toner is in the developing unit the magnet cleans the sensor for a very short period because the next rack will add toner on the sensor. If the amount of toner becomes less, the sensor generates a signal, but the second rack moves enough toner on the sensor. If the amount becomes too low, the signal of the toner sensor stays active too long and the add toner indication is displayed.
Drive
The developing roller is driven by the developing motor DEVMO. The speed of the roller is 60 m/min. (197 ft/min.). The toner supply mechanism and the scraper mechanism are also driven by the developing roller. The toner supply mechanism turns with a speed of 8 m/min. (26 ft/min.) and the scraper mechanism at a speed of 5 m/min. (16.5 ft/min).
504
TSM Oc 9800
Developing unit (DEV)
DRUASVCOMPSE PBA
DEVTONSE
DEVMOSE DEVMO
ed.5
05 Development 601
602
TSM Oc 9800
1
22G1 CONSUPLV
G2 1 2 3 4 5 6 G3 1 2 3 4 +24V GND +24V GND +24V GND +5V GND +5V GND X8 5 6 7 8 9 10 1 2 3 4
2
22PBA5 DRIVERS
X5 9 RL 10
3
DEVMO+
4
05X1 5
5
05X3 2
M
DEVMO4 1
DEVMO
05M1
22PBA1 CPU I/O
F4 4A X10 1 2 3 5 X6 27 28 X7 10 1 X11 9
X13 1 2 3 5 X6 27 28 X11 10 1 X4 6
+5V GND +24V GND CONDRIINDIAG CONDRIOUTDIAG
F3 4A
+24V
10
DEVTONSE
05B2
CONMOSUP DEVMOPWM
10
GND
12
DEVTONSE
11
21 22 23
+5V DEVMOSE GND
1 2 3 05X001 9
1 2 3
DEVMOSE
05B1
22X003-1
05X002 DEVROLLER
05X003 RESTASVREF
H
ed.5 TSM Oc 9800 05 Development 701
Oc
Oc 9800
06 COMPACT TRANSFUSE TRANSFUSE
Contents
Diagnostics
1 Faults
101
SDS
1 Compact Transfer transFuse 201
Adjustments
1 ~Pressure roller torque~ 301 2 ~1 : 1 Image length cor. engine~ 301 3 Working pressure pneumatic system 304 4 Fixation on heavy tracing paper 305
Dis-/assemblies
1 CTF fuser roller cleaner 401 2 CTF fuser roller 402 3 CTF pressure roller hole cleaner 403 4 CTF pressure roller build up cleaner 404 5 Cleaner rollers 405 6 CTF pressure roller 406 7 CTFFHE1 (lower) 407 8 CTFFHE2 (upper) 408 9 Pressure roller cleaner heater 408 10 CTFFTEMPSE (Non Contact Temperature Sensor) 11 Rollerassys output guideplate 409
409
1 CTF general 501 2 Transfer steps 502 3 Temperature 505 4 Fuser roller temperature regulation (CTFFTEMPSE) 507 5 CTF roller positions 509 6 Cleaning rollers 515 7 Toner dosing 516 8 Paper sensing 517
ed.5
06 Compact transfer transfuse
1 Component location
601
Diagrams
1 Compact transfer transfuse CTF1 (from engine 484) 701 2 Compact transfer transfuse CTF1 (up to engine 483) 702 3 Compact transfer transfuse CTF2 703 4 Compact transfer transfuse pneumatics 704 5 Modification 25 705
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Compact Transfer transFuse 06000 - 06999 code display 06001 FE:~Main supply not switched off~
Possible cause Remark
06101 PE: ~Temp. fuse rol. too high: CTFFTEMPSE~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
06-4-03 CTFFHE
CTFFHE radiates Yes
Possible cause
Remark
OFF ON
SSR PBA defect CTFHETRIAC defect
Attention for switching on too long: CTFFHETEMPERSW
ed.5
06 Compact transfer transfuse 101
06102 PE: ~CTFFTEMPSE out of order~ 06502 MRE: ~CTFFTEMPSE out of order~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
06-4-01 CTFTUBSO
CONCTFTUBSO DRIswitching OUTDI (listen) AG ON No
Possible cause
Remark
OFF
Connection CTFTUBSO -> DRIVERS PBA DRIVERS PBA defect
ON
OFF
No
Connection CTFTUBSO -> DRIVERS PBA Connection 24 V DRIVERS PBA -> CTFTUBSO CTFFTEMPSE defect
06-9-04 CTFNCTS Cali- Possible cause bration factor
Remark
> 40
Glass tube CTFFTEMPSE polluted CTFFTEMPSE defect
06-4-02 CTFREFHE
CONDRI- Possible cause OUTDIAG ON Connection CTFREFHE -> DRIVERS PBA DRIVERS PBA defect Connection CTFREFHE -> DRIVERS PBA Connection 24 V DRIVERS PBA -> CTFREFHE CTFFTEMPSE defect
Remark
OFF
ON
OFF
102
TSM Oc 9800
Diagnostics
CTFPYRSE is a DC voltage between 0.2 and 1.5 V plus a certain AC voltage, during this test, of 0.2 V minimum. The frequency of CTFPYRSE must be 1 Hz. The signal can be measured between 2201X3 pin 6 and TP2 of the CPU_IO PBA. Most Volt meters have also a digital bar presentation of the measured value which indicates the 1 Hz. Put your meter in most accurate range as possible.
06-6-06 CTFPYRSE check Digital bar on Voltmeter (DC) commutes between two values Possible cause Remark
ON
No
Connection CTFPYRSE -> CPU_IO PBA CTFFTEMPSE defect
06-9-01 CTFREF-TE MPSE
Rptc = 360 510 Ohm Yes Yes
Possible cause
Remark
ADC value >1016 ADC value < 48
CTFREFTEMPSE open CPU_IO PBA defect CTFREFTEMPSE short circuit Connection CTFREFTEMPSE -> CPU_IO PBA CPU_IO PBA defect disconnect 2201X3
Possible cause
CPU_IO PBA defect
06103 PE: ~Temp. pressure rol. clean. too high~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
06-4-04 CTFPCLEHE Possible 06-9-02 CTFCLEHE- cause TEMPSE Remark
OFF
ADC value rising
SSR PBA defect
Attention: dont switch on too long or CTFPCLEHETEMPERSW switches off
ed.5
06104 PE: ~CTFPCLEHETEMPSE short / open circuit~ 06505 MRE: ~CTFPCLEHETEMPSE short / open circuit~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
06-9-03 Rntc = CTFPCLEHE- 0.6 - 700 kOhm TEMPSE Possible cause Remark
ADC value > 980
Yes
CTFPCLEHETEMPSE short circuit CPU_IO PBA defect disconnect 2201X3
ADC value < 16
Yes
CTFPTEMPSE open Connection CTFPTEMPSE -> CPU_IO PBA + 5VAN signal of 2201X3, X4, X5 (short circuit to earth) CPU_IO PBA defect
06105 PE: ~Fuser roller cleaner full~ Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
06-8-03 Possible cause Number black images fuser roller Remark
900 black images
End of life time fuser roller cleaner Counter has not been resetted after last replacement
104
TSM Oc 9800
Diagnostics
06106 PE: ~Pressure roller cleaner full~

06-8-04 Number black images pressure roller Possible cause Remark
400 black images
End of life time pressure roller cleaner Counter has not been resetted after last replacement
06501 MRE: ~Speed CTFPMO out of range~

06-4-08 CTFPMO CTFPMOPWM turning Possible cause Remark
OFF ON
Yes Yes No
CTFPINV defect CPU_IO PBA defect Connection L2 -> DRUFANINV Connection CPU_IO PBA -> DRUFANINV CTFPMO defect Bearing pressure roller blocked CTFPINV defect Hinges CTFPMO blocked CTFPMO defect / blocked
06-2-01 CTFPMOSE
Possible cause
Remark
Pulse disc loose of CTFPMO or MADMO Continuously OFF/ON when turning pulse disc CTFPMOSE defect Pulse disc defect Connection CTFPMOSE -> CPU_IO PBA CPU_IO PBA defect
Blockade motor shaft and check that the pulse disc cant rotate
ed.5
06-4-06 CTFFSVA
CONDRIOUTDIAG ON
2nd step in Yes
Possible cause
Remark
OFF
DRIVERS PBA defect Connection CTFFSVA -> DRIVERS PBA
06502 MRE: ~CTFFTEMPSE out of order~ on page 102 Always: Check the toner in the developer unit and if necessary clean the developer unit with a vacuum cleaner and replace the toner. Toner gets sticky by to high temperature
06503 MRE ~Temp. fuse rol. too low: CTFFTEMPSE~ 06504 MRE ~Warm. up fuse rol. more than 30 min.~
06-4-03 06-9-01 Possible cause CTFFHE CTFFTEMPSE Remark
rising WARM SDS
ON
No
Connection SSR PBA -> CTFFHETRIAC Connection CTFFHETRIAC -> CTFFHE CTFFHETRIAC defect SSR PBA defect Broken heaters / CTFFTEMPERSW defect Circuit breaker off Rctffhe1 = 5 Ohm Rctffhe2 = 10 Ohm
Yes
Short circuit among 2 heater strips
06505 MRE: ~CTFPCLEHETEMPSE short / open circuit~ on page 104 06506 MRE: ~Temp. pressure rol. cleaner too low~ 06507 MRE: ~Warmi.up pres. rol. cleaner > 10 min.~
106
TSM Oc 9800
Diagnostics
06-4-04 06-9-02 CTFPCLEHE CTFPCLE-
Possible cause
Remark
HETMPSE rising
ON
No
Connection SSR PBA -> CTFPCLEHE SSR PBA defect CTFPCLEHE / CTFPCLEHETEMPERSW defect Circuit breaker off Rctfpclehe = 44 Ohm
06508 MRE: ~Power-up: run CTFPMO not allowed~

06-4-06 CTFSFVA
CONDRIOUTDIAG ON
Possible cause 2nd transfer step continuously on
Remark
OFF
Yes
DRIVERS PBA defect Connection CTFSVA -> DRIVERS PBA CTFSFVA defect
OFF
Yes
CTFSFVA defect CTFSFCYLL/R mechanically defect
06701 ORE: ~Paper too late at CTFOUTSE~
ed.5
Possible cause
Remark
Copy output plate / CTFOUTSE polluted New pressure roller cleaner is not cleaning correctly -> pressure roller polluted
06-2-02 CTFOUTSE Possible cause
Machine must be in stand-by for at least 30 min.

Remark
Continuously OFF
CTFOUTSE defect Connection CTFOUTSE -> CPU_IO PBA CPU_IO PBA defect
06-4-06 CTFSFVA
CONTransfuse Possible cause DRIstep in OUTDI AG OFF No Connection CTFSFVA -> DRIVERS PBA Connection 24 V DRIVERS PBA -> CTFSFVA DRIVERS PBA defect ON No CTFSFVA defect Pneumatic connection CTFSFVA Pneumatic connection CTFSFCYLL/R CTFSFCYLL/R defect CTFCOMP defect
Remark
ON
to be continued
108
TSM Oc 9800
Diagnostics
continued
06-4-07 CONDRI- Transfer CTFSPVA OUTDIAG pressure Possible cause Remark
step in ON OFF No Connection CTFSPVA -> DRIVERS PBA Connection 24 V DRIVERS PBA -> CTFSPVA DRIVERS PBA defect ON CTFSPVA defect Pneumatic connection CTFSPVA Pneumatic connection CTFSFCYLL/R
06-4-08 CTFPMOPWM
Possible cause Pressure roller running
Remark
ON
No
Cardan clutch CTFPMO loose

Remark
23-4-01 Input roller pre- Possible cause MADMO heating turning
ON
No
One way bearing input roller preheating defect Pulleys MADMO lose / belt defect Pulley clutch MADMO fuser roller lose
Yes
Cardan clutch MADMO fuser roller lose

Remark
Possible cause
Hinge cardan clutch CTFPMO blocking
to be continued
ed.5
continued When using the paper roll drawers:

12-4-02 CONDRIPRDSTRACL OUTDIAG
Drive verti- Possible cause cal transport No Connection DRIVERS PBA -> PRDSTRACL Connection PRDSTRACL -> DRIVERS PBA DRIVERS PBA defect
Remark
ON
OFF
ON
PRDSTRACL defect
Possible cause
Remark
Mechanical defect U/L knife Paper sealed on the roll core
When using the paper sheet feeder:

13-4-01 PSFCL
CONDRIOUTDIAG OFF
Rollers PSF turning No
Possible cause
Remark
ON
Connection DRIVERS PBA -> PSFCL Connection PSFCL -> DRIVERS PBA DRIVERS PBA defect
ON
PSFCL defect
to be continued
110
TSM Oc 9800
Diagnostics
continued
13-4-02 PSFSO
CONDRI- Possible cause OUTDIAG OFF Connection DRIVERS PBA -> PSFSO Connection PSFSO -> DRIVERS PBA DRIVERS PBA defect ON PSFSO defect
Remark
ON
Possible cause
Remark
Skewed feeding of sheets One way bearing PSF defect

06702 ORE: ~CTFOUTSE too late free~

CTF output guiding plate exit pinch polluted
Preventive maintenance
06-2-02 CTFOUTSE
Possible cause
Remark
Continuously ON
CTFOUTSE defect Actuator defect Connection CTFOUTSE -> CPU_IO PBA CPU_IO PBA defect
06703 ORE: ~Paper jam at exit pinch: CTFTRANSE~
ed.5
Possible use
Remark
Exit plate CTFOUTSE polluted Slipping wheel CTFTRANSE

06-2-04 CTFTRANSE Possible cause Remark
Continuously ON or OFF when moving pulse disc
Connection CTFTRANSE -> CPU_IO PBA CTFTRANSE defect Wheel / pulse disc CTFTRANSE defect Bearing copy output pinch blocked Toothed belt copy output pinch defect Toothed belt adjusting gauge lose / blocked CPU_IO PBA defect
15-2-01 PTRBULSE
Possible cause
Remark
Continuously OFF
PTRBULSE defect Actuator defect Connection PTRBULSE -> DISTRIBUTION SENSOR PBA Connection DISTRIBUTION SENSOR PBA -> IO_INTERFACE1 PBA Connection7 IO_INTERFACE1 PBA -> CPU_IO PBA DISTRIBUTION SENSOR PBA defect IO_INTERFACE1 PBA defect CPU_IO PBA defect
06901 SWAR: ~Pap. speed out of range: CTFTRANSE~
112
TSM Oc 9800
Diagnostics
Possible cause
Remark
Wheel / pulse disc CTFTRANSE lose
06902 SWAR: ~Fuse roller cleaner almost full~

Fuser roller cleaner > 720 black images
06903 SWAR: ~Press. roller cleaner almost full~

Pressure roller cleaner > 300 black images

ed.5
114
TSM Oc 9800
Diagnostics
SDS
1 Compact Transfer transFuse
3
Test nr.
Component
Signal
Description
see SDS
31
~Log / res err & ser cnt~
see SDS
32 ~Last error logging (OWAR/SWAR/ORE/MRE/PE/FE)~
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr.
Component
Signal
Description
Parameter test 06-1-01 ~CTFREFTEMPSE resistance low (Ohm)~
(range 350 - 390, default 370) value mentioned on sticker

06-1-02 ~CTFREFTEMPSE resistance high (Ohm)~
(range 480 - 520, default 500) value mentioned on sticker

06-1-03 ~1 to 1 image length cor. printer (mm/10)~
(range 6800 - 7400, default 7000)

06-1-04 ~Paper Quality Factor~
0 = good quality paper (red label) 1 = normal paper (default) 2 = paper with a lot of paperdust
Input tests 06-2-01
06B1
CTF Pressure -roller MOtor SEnsor CTF OUTput SEnsor CTF DOOR SWitch
CTF pressure roller motor sensor ON = sensor blocked by pulsdisk CTF output sensor ON = paper detected CTF door switch ON = door open
06-2-02 06-2-03 06-2-04 06-2-05
06B2 06S1 06B3 06S2
CTF TRANport CTF transport sensor SEnsor ON = sensor blocked by pulsdisk CTF OUTput HOod SWitch CTF output hood switch ON = heater unit open
202
TSM Oc 9800
SDS
Test nr.
Component
Signal
Description
06Y4
CTF TUBe SOlenoid
CTF tube solenoid ON = solenoid activated Hardware diagnoses: CONDRIOUTDIAG
06-4-02
CTF REFerence CTF reference heater HEater ON = reference heater switched on value mentioned on sticker: Hardware diagnoses: CONDRIOUTDIAG 06E1 / 06E2A/B CTF Fuser-roller CTF fuser roller heater HEater ON = fuser roller heater switched on max. time 30 sec. CTF Pres. roller CTF pressure roller cleaner heater CLEaner HEater ON = pressure roller heater switched on max. time 30 sec. 06Y2 CTF Set-up Transfer VAlve CTF set up transfer valve ON = transfer pinch closed Hardware diagnoses: CONDRIOUTDIAG max. time 30 sec.
06-4-03
06-4-04
06-4-05
06-4-06
06Y1
CTF Set-up Fuse CTF set up fuse valve VAlve ON = fuse pinch closed Hardware diagnoses: CONDRIOUTDIAG CTF Set-up Pressure VAlve CTF set-up pressure valve selection high / low pinch pressure roller ON = high pressure CTF pressure roller motor pwm ON = motor turn at maximum speed
06-4-07
06-4-08
06M2
CTF Pressureroller MOtor PWM
ed.5
Test nr.
Component
Signal
Description
Functions 06 (CTF), 12 (paper roll drawers), 13 (paper sheet feeder), 14 (pre-heater), 23 (main drive) in warm condition
Functions 06 (CTF), 12 (paper roll drawers), 13 (paper sheet feeder), 14 (pre-heater), 23 (main drive) in cold condition
06-6-05 ~CTFFTEMPSE replaced~
NCTS is replaced
06-6-06 ~Check CTFPYRSE~
CTFREFHE during test ON CTFTUBSO frequency 1 Hz

06-6-07 Check pneumatic valves
All pneumatic CTF positions can be checked. Use the start button or remote control button to switch to the next position: transfuse closed high pressure transfer closed transfuse opened (toner dosing position) transfuse closed transfer opened low pressure transfuse opened
Adjustment tests 06-7-01 ~Pressure roller torque adjustment~
Test takes about 5 minutes after the machine is warm Automatic adjustment for the Pressure roller. Setting is automatically stored in memory
204
TSM Oc 9800
SDS
Test nr.
Component
Signal
Description
Consumable tests 06-8-01 ~Fuse roller (lm)~
usage counter of the CTF fuse roller (range 0 - 9999999 m)

06-8-02 ~Pressure roller (lm)~
usage counter of the CTF pressure roller (range 0 - 9999999 m)

06-8-03 ~Fuse roller cleaner (bl.im.)~
usage counter of (black) toner images dosed to the CTF fuse roller cleaner SWAR at 720 black images PE at 900 black images
06-8-04
~Pressure roll. hole cl. (bl.im.)~
usage counter of (black) toner images dosed to the CTF pressure roller gap cleaner SWAR at 300 black images PE at 400 black images
06-8-05 ~Pressure roll. build-up cl. (lm)~
usage counter of the CTF pressure roller build cleaner (range 0 - 9999999 m)
Info tests 06-9-01 ~CTF REFerence TEMP. SEnsor (adc)~
(value A/D range 0 - 1023)

06-9-02
CTFFTEMPSE ~CTF Fuse TEMP> SEnsor ~ Calculated CTF fuse roller temperature from CTFREFTEMPSE and CTFPYRSE (range 0 - 2000 C/10) value in stand-by approx. 1024 CTFPCLEHETEMPSE CTF NCTS
~CTFP CLeaner Heater TEMPSE (adc)~
06-9-03
(value A/D range 0 - 1023)

~CTF NCTS calibration factor~
06-9-04
Last calculated CTF NCTS calibration factor (range 2 - 40)
ed.5
Test nr. 06-9-05
Component
Signal
Description ~CTFPRMO speed (mm/min.)~
CTFPRMO
Last determined speed from PRMO mm/min. (range 9600-10150)

System tests 52 ~Black mode~

53 ~1 : 1 mode~
Copy with gray pattern and white stroke 1 cm width and 70 cm length in the centre
206
TSM Oc 9800
SDS
Adjustments
1 ~Pressure roller torque~
This test must be carried out if:
s
after a new fuser roller and/or a new fuser pressure roller is / are mounted and after the rollers have been removed and remounted. separation problems at fuser roller or pressure roller occur.
Aim:
Correct speed of the pressure roller regarding to the speed of the fuser roller.
Check: 1 Make several copies on polyester film. 2 Check if sheet separation problems at the fuser roller or pressure roller occur.
Correction:
Carry out SDS test 06-7-01.
2 ~1 : 1 Image length cor. engine~

Carry out this test when you have replaced CTFTRANSE. Adjustment 23 Main drive belt on page 975 must be correct. Adjustment ~Pressure roller torque~ on page 301 must be correct.
Note: In key operator mode Calibration in machine / zoom window must be
1.000.
Aim:
Ensure that the image on the copy of the engine is 1 : 1. (This is done by calibrating CTFTRANSE and adjusting the Printhead frequency)
ed.5
feed direction
700 +/- 0.5 Check: 1 2 3 4 5
Carry out SDS test 53. Select A0 (34/36) roll width 75 gr/m2 paper. Make 5 copies. Measure on copy 3, 4 and 5 the length of the white stroke on the copy. The average length of the white stroke must be 700 +/- 0.5 mm.
302
TSM Oc 9800
Adjustments
Correction: 1 Carry out SDS test 06-1-03. 2 Change the SDS value to average measured value x10 (e.g. 705.5 mm, enter 3 4 5 6
7055). Carry out SDS test 53. Select A0 (841 mm) roll width 75 gr/m2. Make 3 copies. Measure the length of the white stroke on the last copy.
ed.5
3 Working pressure pneumatic system

Aim:
Correct working pressure for the CTF and PREHEATER function.

Check: 1 Remove the left side cover. 2 Check if the total pneumatic system is connected. 3 Check if the pressure of the reservoir (readable on small indicator) is above 7
bar.
4 Check if the compressor motor is switched off and pressure is on the system. 5 Specification: The air pressure should be 5.4 bar.
Correction: 1 Pull the reduction valve upwards and adjust the working pressure to 5.4 bar (ar-
row on marked line on the pressure indication).
reduction valve
working pressure indication
304
TSM Oc 9800
Adjustments
4 Fixation on heavy tracing paper

This adjustment / setting can only be done if the new brake (PRTEBR, part no. 7015.738 and the new ~Drivers PBA~ 22 PBA5 part no. 5584.001) is mounted.)
Aim:
Increase the fixation of toner, only if the fixation of the image is not sufficient on heavy tracing paper.
Check:
Check the fixation according the description see Toner adhesion on page 1112 of chapter FAULTS.
Correction:
Set the jumper X13 on 22PBA5 from NOM to MAX.

MAX: stronger brake force, necessary if fixation is not sufficient, only for heavy tracing paper. The jumper X13 is located in the middle of the PBA
Warning:
Check the position of the jumper X13. Must be positioned on NOM. Otherwise the timing belt of the drive of the pre-heater will wear out too fast. The jumper on position MAX, only if the customer is complaining about the fixation of toner on heavy tracing paper!!
ed.5
306
TSM Oc 9800
Adjustments
Dis-/assemblies
Return the fuser roller, the pressure roller and the cleaner rollers according to the local agreements.
1 CTF fuser roller cleaner

1 Open the rear top cover. 2 Open the PTR unit and the CTF unit.
locking plate
3 Remove on the left and right side the locking plate from the CTF fuser roller 4 5 6 7
cleaner. Move the CTF fuser roller cleaner towards you. Move the CTF fuser roller cleaner to the left. Remove the CTF fuser roller cleaner. Carry out dis-assembly see Cleaner rollers on page 405.
Installation of a new roller:
1 2 3 4
Clean the new roller with Oc K cleaner. Mount the new roller. Carry out the SDS test 06-8-03 (~Fuse roller cleaner (bl. im.)~). Enter the value 0.
ed.5
Note: Fill in the reporting card and return the roller according to the local
agreements.
2 CTF fuser roller

1 Carry out dis-/assembly CTF fuser roller cleaner on page 401.
Allen screw
2 Loosen the Allen screw from the coupling of the CTF fuser roller so far that
you can move the coupling from the shaft on the right side.
3 Remove the CTF fuser roller. Installation of a new roller: 4 5 6 7
Mount the new roller. Carry out SDS test 06-7-01 (~Pressure roller torque adjustment~). Carry out SDS test 06-8-01 (~Fuse roller (lm)~). Enter the value 0.
agreements.
402
TSM Oc 9800
Dis-/assemblies
3 CTF pressure roller hole cleaner

1 Open the PTR unit. 2 Disconnect (as viewed from the rear) at the right the connector 06X3 and at the
left the connector 06X4 from the pressure roller heater unit.
pressure roller heater unit
3 4 5 6 7 8
Push the connectors through the frame. Remove the CTF pressure roller heater unit. Remove the securing brackets from the CTF pressure roller hole cleaner. Remove the CTF pressure roller hole cleaner. Carry out dis-/assembly see Cleaner rollers on page 405. Also replace the pressure roller build up cleaner see CTF pressure roller build up cleaner on page 404.
Installation of a new roller:.
1 2 3 4
Clean the new roller with Oc K cleaner. Mount the new roller. Carry out SDS test 06-8-04 (~Pressure roll. hole cl. (lm.)~). Enter the value 0.
agreements.
ed.5
4 CTF pressure roller build up cleaner

1 Carry out dis-/assembly CTF fuser roller on page 402. 2 Release and open the preheating unit.
pressure roller with guide plate
3 Open the CTF heater unit. 4 Loosen the Allen screw from the pressure roller coupling and move the cou-
pling from the shaft.

5 Remove at the left (as viewed from the rear) the earth strap from the guide
plate.
6 Push the 2nd step cylinder shaft upwards and move the CTF pressure roller
with guide plate towards you.

7 Remove the CTF pressure roller build up cleaner. 8 Also replace the pressure roller hole cleaner see CTF pressure roller hole
cleaner on page 403.

Installation of a new roller: 1 2 3 4
Clean the new roller with Oc K cleaner. Mount the new roller. Carry out SDS test 06-8-05 (~Pressure roll. build up cl. (bl.im.)~). Enter the value 0.
agreements.
404
TSM Oc 9800
Dis-/assemblies
5 Cleaner rollers
plastic ring
cleaning roller plastic ring
clip clip metal bush metal bush
shaft
1 2 3 4 5
Remove the cleaning roller. Remove at both sides the clip. Remove the metal bushes. Remove the cleaning roller from the shaft. Remove with the shaft the plastic ring from the inside of the cleaning roller.
Note: Mount the plastic bushes with the curve to the cleaning roller centre.
Never use force when mounting the plastic rings.

6 Mount on one side the plastic ring, the metal bush and the clip. 7 Mount the cleaning roller over the shaft. 8 Mount at the other side the plastic ring, the metal bush and the clip.
Note: When a cleaner must be replaced, you always have to use the new cir-
clips and the new toroide rings, which are packed together with the new cleaner bush. After assembling of the cleaner you must convinced yourself, before mounting the new cleaner assembling into the engine of the Oc 9800, that the security clips (ring, ext.) are not worn out and have been well mounted in the grooves of the shaft ends. Bad mounted cleaner rollers can cause damaging off the cleaner roller ends and illegal toner overflow.
ed.5
6 CTF pressure roller

1 Carry out dis-/assembly CTF fuser roller cleaner on page 401. 2 Carry out dis-/assembly CTF fuser roller on page 402. 3 Loosen the Allen screw (2 mm) of the coupling from the CTF pressure roller
shaft.
4 Move the coupling to the right side. 5 Remove at the left (as viewed from the rear) the earth strap from the guide
plate.
6 Push the 2nd step cylinder (large one) shaft and lift the CTF pressure roller
with guide plate towards you.

7 Loosen at the right (as viewed from the rear) the screw from the CTF pressure
roller locking plate.

8 Push the locking plate downwards. 9 Move the CTF pressure roller to the left. Note: Do not drop the roller bearings. 10 Move the pressure roller at the right side towards you. 11 Remove the CTF pressure roller. Installation of a new roller: Note: Be sure that you have 2 new bearings with the roller. 1 2 3 4 5
Mount the new bearings on the new roller. Mount the new roller. Carry out SDS test 06-7-01 (~Pressure roller torque adjustment~ 5 minutes). Carry out SDS test 06-8-02 (~Pressure roller (lm)~). Enter the value 0.
agreements.
406
TSM Oc 9800
Dis-/assemblies
7 CTFFHE1 (lower)
1 2 3 4
Do dis-/assembly CTF fuser roller cleaner on page 401. Do dis-/assembly CTF fuser roller on page 402. Carry out 01 Drum dis-/assembly The drum cleaning position on page 401. Cover the drum with a sheet of paper.
HE1 lower heater
5 Disconnect at the left and right side the connectors from the heater. 6 Remove (as viewed from the rear) at the right side 2 screws from the heater
unit.
7 Lift (as viewed from the rear) the heater unit at the right side and remove the
unit through the frame.
ed.5
8 CTFFHE2 (upper)
1 2 3 4 5 6 7 8 9 10 11
Open the rear top cover. Cut the cable ties. Disconnect the connectors 06X2 and 06X1. Remove the 2 fixing screws from the heater unit. Remove the heater unit. Remove the heater unit black cover. Remove the two large head screws from the fuser heater. Remove at the right two screws from the heater element. Release the cable bundle with connector 06X1. Release the ground wire. Move the heater element to the left and lift it out.
9 Pressure roller cleaner heater

1 Open the rear top cover. 2 Open the PTR unit.
3 Disconnect on the frame outside on the right (as viewed from the rear) the con-
nector 06X3 and on the left the connector 06X4.

4 Lift and remove the pressure roller cleaner heater.
408
TSM Oc 9800
Dis-/assemblies
10 CTFFTEMPSE (Non Contact Temperature Sensor)

1 2 3 4
Carry out 01 Drum dis-/assembly The drum cleaning position on page 401. Carry out CTF fuser roller cleaner on page 401. Cut the cable ties from the wiring bundle. Remove the CTFFTEMPSE. Check after mounting a new CTFFTEMPSE if the housing is locked, to avoid damage of the drum. Installation
1 2 3 4 5 6
Write in the logbook the high and low resistance marked on the new NCTS. Carry out SDS test 06-1-01. Enter the low resistance value. Carry out SDS test 06-1-02. Enter the high resistance value. Carry out SDS test 06-6-05 (NCTS replaced).
11 Rollerassys output guideplate

When the roller assys have been worn-out (see codenumber 1989.746 Z-600), you can replace the little red rollers instead the whole guide plate.
Note: The screws, which are used for mounting the guide plate assy and the
roller assys have been treated with screw lock. Use a good screw driver for losing those screws. The roller assys are fitted with counter sunk screws with a Pozidriv cross access. Make use of a Pozidriv screw driver, when using a Phillips screw driver the cross access in the screw will break.
ed.5
410
TSM Oc 9800
Dis-/assemblies
1 CTF general
The function of the CTF unit is:
s s
transfer the toner image from the drum onto the fuser roller (1st transfer step) transfer and fuse the toner image from the fuser roller onto the copy material (2nd transfer step)
The CTF unit consists of:

CTFFuser HEater2 CTFFHE2 fuser roller cleaner
CTFFTEMP SE
pressure roller gap cleaner
pressure roller
CTFPressure roller CLEaner HEater pressure roller build cleaner
fuser roller
CTFFuser HEater1 CTFFHE1
ed.5
2 Transfer steps
First transfer step
fuser roller pressure roller 1st transfer
drum
The first transfer step is the transfer of the toner image from the drum onto the fuser roller. The fuser roller is pressed against the drum with 2 small pneumatic cylinders. This is the so called first pinch. Pressure and 2 different materials (a hard drum a soft roller) are needed to transfer toner particles from the drum to the soft fuser roller. The fuser roller is an aluminium roller with a silicon rubber layer. Drive The drum and the fuser roller are driven by the same motor MADMO. The speed of the fuser roller is 10 m/min. The speed of the drum is always 3% faster. The higher speed of the drum is needed to transfer the carbon particles of the toner from the drum to the fuser roller. After the 1st transfer the toner image on the fuser roller is now turning into the direction of the pressure roller.
502
TSM Oc 9800
Second transfer step
2nd transfer
pressure roller pre-heater fuser roller
drum
The second transfer step needs heat and pressure to get a correct transfer and fusing of the toner particles onto the copy material. The copy material is fed in between the hard pressure roller and the soft fuser roller. The pressure roller and the fuser roller are pressed together with the 2 large pneumatic cylinders. This is called the second pinch. The preheated copy material is fed from the preheater unit into the second pinch. The toner is fused on the copy material. Drive The fuser roller is driven by the main drive motor (MADMO). The pressure roller is driven by the CTF pressure roller motor (CTFPMO). Separation of the copy material from the fuser roller is easier if there is a speed difference between the pressure and fuser roller and therefore the speed of the pressure roller is about 4% less than the fuser roller speed. The speed difference is automatically adjusted when running SDS test 06-7-01 Pressure roller torque adjustment.
Note:
After changing the fuser roller or pressure roller or if separation problems occur at the CTF it is necessary to carry out SDS test 06-7-01 and adjustment~1 : 1 Image length cor. engine~ on page 301 .
The copy material with the fused image is fed over a guide plate to the paper
ed.5
transport section.
504
TSM Oc 9800
3 Temperature
Fuser temperature
Two heaters CTFFHE1 and CTFFHE2 are used to heat the fuser roller to the correct fuse temperature. The elements are positioned outside the roller. Only the surface of the fuser roller is heated. The resistance value of CTFFHE1 element is 6-7 Ohm and from CTFFHE2, which are 2 elements, the resistance value is approx.12-14 Ohm.
CTFFHETEMPERSW
CTFFHE2 CTFTEMP SE
CTFFHE1
CTFPCLEHETEMPERSW
CTFPCLEHE1 and 2
CTFFTEMPSE (CTF fuser temperature sensor) measures the temperature of the fuser roller. This information is used to control the fuser roller heater elements. The temperature of the fuser roller is:
s s
Stand-by: 102 C During RUN: 100 C
ed.5
CTFFTEMPSE also generates a error code if:

s s s
the fuser roller temperature in run is higher than 105 C the fuser roller temperature in stand-by is higher than 110 C. the warming up time is longer than 30 minutes.
CTFFHETEMPERSW (overheat temperature switch) switches the elements off if the temperature of the elements becomes too high.
Pressure roller cleaners temperature
Two heater elements are used to heat the pressure roller cleaners. The total resistance value of the 2 elements is 44 Ohm. CTFPCLEHETEMPSE controls the temperature of the heating elements. During warming up the temperature of the heating elements is 175 C and after warming up the temperature is kept at 125 C. CTFPCLEHETEMPSE also generates a error code if
s s
the pressure roller cleaning temperature is higher than 183 C. the pressure roller cleaning temperature has not reached the set point within 10 minutes.
CTFPCLEHETEMPERSW (overheat temperature switch) switches the elements off if the elements are not any more controlled by CTFPCLEHETEMPSE.
506
TSM Oc 9800
4 Fuser roller temperature regulation (CTFFTEMPSE)

This sensor measures the temperature from the fuser roller surface without making contact with the roller. Principle: Measure the IR (Infra Red) radiation (optical) from an object. This information is obtained with the aid of a pyro-electrical detector. The pyro-electrical detector is only sensitive for changes in received IR radiation. For this reason the measurement is done between a reference object and the real object (fuser roller). Execution:
fuser roller
tube
PTC and heater 06PBA1
CTFTUBSO
reference object
The pyro-electrical detector and a part of the electronics are put behind a tube which has a window to avoid toner pollution of the tube and incorrect measurements.
ed.5
The block diagram of the sensor is as follows:
CPU and I/O CTF REFHE 0 24V dri ver CTFREF HEB
sensor unit
reference heater
24
A1 GNDAN
CTFREFTEMPSE
reference PTC
+10VAN A1 GNDAN 0
CTFPYRSE CTF TUBSO 24 V 24V dri ver CTFTUB SOB
pyro electrical detector
solenoid
The tube is moved by a solenoid (CTFTUBSO) and its gravitation, between the reference object and the fuser roller. The reference object is a ceramic material. On one side of this object a power resistor, the reference heater (CTFREFHE), is mounted and at the other side a PTC resistance is mounted. The software controls the reference temperature in such a way that the pyro-electrical detector (CTFPYRSE) sees a determined value. CTFPYRSE generates an AC voltage if there is a radiation difference between the object and fuser roller. The resistance value of the PTC resistor is an indication of its temperature. With this temperature and the amplitude of the AC signal from the pyro-electrical detector the object temperature is calculated.
508
TSM Oc 9800
5 CTF roller positions

The CTF rollers can have four different positions:
s s s s
Wait (machine switched off) Stand-by /warming-up Run / Toner dosing pressure roller cleaner Toner dosing fuser roller cleaner
transfer open open open closed closed closed open open open pinch (CTFSTVA) Transfuse open closed closed closed open closed closed closed open pinch (CTFSFVA) high high high high high low low Pressure low low
(CTFSPVA) 2 = Stand-by (warming up) 4 = Run / toner dosing Pressure roller cleaner 5 = Toner dosing Fuser Roller Cleaner 6 = Run / toner dosing Pressure roller cleaner 8 = Stand-by / warming up Step 1, 3, 7 and 9 are not used steps during normal operation.
Transfer (1st): The transfer pinch is opened and closed by 2 small pneumatic cylinders CTFSTCYL. The cylinders are operated with valve CTFSTVA. Transfuse (2nd): The transfuse pinch is opened and closed with 2 large pneumatic cylinders CTFSFCYL. The cylinders are operated with valve CTFSFVA. Pressure:
ed.5
The supplied pressure changes between low (3 bar) and high (5.6 bar) with valve CTFSPVA.
510
TSM Oc 9800
Wait position (machine switched off):
In Wait position is no contact between the drum and the fuser roller and between the fuser roller and the pressure roller. Also all cleaning rollers are free from the fuser roller and pressure roller.
CTFSFCYL
CTFSTCYL
ed.5
Stand-by
In this position all rollers, except the fuser roller and drum (first pinch), are in contact with each other at low pressure.
CTFSFCYL
CTFSTCYL
512
TSM Oc 9800
Run
All pinches are closed at full pressure.
full pressure
full pressure
Toner dosing pressure roller cleaners
The engine takes the Run position, so all pinches are closed at full pressure. A black image is transported to the pressure roller and both cleaners. This is the same position as the RUN position, but without paper.
ed.5
Toner dosing fuser roller cleaner
The engine goes to the Run position, only the second transfer step is opened. The toner dosage pawls are moved above the large cylinders and push down the cylinder cores, the transfuse step between fuser and pressure roller is opened. Now a black toner image is transported to the fuser roller cleaner.
toner dosage pawl CTFSFCYL
transfuse step
drum
fuse roller CTFSTCYL
514
TSM Oc 9800
6 Cleaning rollers
The CTF unit contains three cleaner rollers: CTF fuser roller cleaner CTF pressure roller gap cleaner CTF pressure roller build cleaner
Fuser roller cleaner
The function of this roller is cleaning of the fuser roller from residual toner and paper dust. Residual toner on the silicone fuser roller sticks to the cleaner roller, because the adhesion force between toner particles and the cleaner roller is larger than the adhesion force between toner particles and silicon fuser roller. The mixture of toner and paper dust may not be build-up on the cleaner roller but pressed into the cleaner via the gaps. Removal of paper dust is only achieved when the layer on the cleaning roller stays sticky. This is achieved by periodical dosing toner (black images) on the cleaning rollers.
Pressure roller gap cleaner
This roller is the same type of roller as the fuser roller cleaner. The function is to remove toner from the pressure roller.
Pressure roller build cleaner
This cleaner roller has a smooth surface. The function of this cleaner is to remove the residual toner from the pressure roller, this means the toner which is not removed by the gap cleaner. The pressure roller gap cleaner and the pressure roller build cleaner are also used to push the pressure roller against the fuser roller.
New CTF cleaner rollers
When new rollers are replaced the corresponding SDS consumable test must be reset. Before the first run, after warming up, the fuser cleaning roller is supplied with 2 black images. After half an hour, when the engine is in the stand-by position the toner dosing is done for the pressure cleaning roller, (at that time this roller is at its working temperature (> 85 C). Bad mounted cleaner rollers cab cause damaging of the cleaner roller ends and illegal toner overflow.
Note: see Cleaner rollers on page 405
ed.5
7 Toner dosing
Toner dosing fuser cleaner roller
Paper contains paper dust which can pollute the fuser and pressure roller. Copy quality will decrease immediately. In normal operation (default setting SDS test 06-1-04 = 1) of the engine, when different paper sizes are used during copying, the fuser roller will get once in 200 length meters a toner dosage. Toner dosage means that the drum is charged but the printhead is not switched on, so no exposure takes place and the drum becomes a black image. The black image is transferred onto the fuser roller. The second transfer step in opened. The black image is taken off the fuser roller when passing the fuser cleaner roller. The cleaning function of the fuser cleaning roller is improved again. Toner dosing to the fuser roller is also done if more than 100 length meters from the same size are made at ones. After 720 black images a SWAR (service warning) is generated. After 900 black images the roller is full and a PE (permanent error) occurs.
Toner dosing pressure cleaner roller
For the same reason as the fuser roller the pressure roller also needs cleaning. The toner dosing for the pressure roller is once in 400 length meters. If more than 200 length meters are made from the same size dosing takes place. After 300 black images a SWAR (service warning) is generated. After 400 black images the roller is full and a PE (permanent error) occurs.
Paper quality
When paper is used which causes much more dust, the frequency of toner dosing can be increased in SDS with parameter test 06-1-04 (Paper Quality factor) = 2. The fuser roller cleaner becomes toner dosing ones on 100 length meters and the pressure roller ones on 200 length meters. If more than 50 and 100 length meters from one size are made toner dosing takes place. When paper is used which causes less dust (e.g. Red label), the frequency of toner dosing can be decreased in SDS with parameter test 06-1-04 (Paper Quality factor) = 0. The fuser roller cleaner becomes toner dosing ones on 300 length meters and the pressure roller ones on 500 length meters. If more than 150 and 300 length meters from one size are made toner dosing takes place.
Note: change the Paper quality factor only after contacting your local co-
ordinator.
516
TSM Oc 9800
8 Paper sensing
Jam sensing is done with two sensors. - CTFOUTSE (output sensor) - CTFTRANSE (transport sensor).
CTFOUTSE
This sensor, mounted just behind the pressure roller, detects the leading and trailing edge of the copy leaving the CTF. If the copy e.g. sticks to the fuser roller the sensor does not detect the leading edge of the copy in time and the transport of the copy material and CTF is stopped immediately to avoid that the copy reaches the fuser cleaning roller. Also an error is indicated in the display.
CTFTRANSE
The transport sensor has two functions:

1 paper jam detection 2 measures the material speed to get 1:1 printhead frequency speed
Paper jam detection CTFTRANSE detects the transport of the copy to the paper transport unit. A puls-disc with a one way bearing is driven by the exit roller. If the copy stops in the exit, due to a paper jam, the puls-disc is also stopped. The engine will stop immediately to avoid that the copy reaches the fuser cleaning roller. Paper speed The most important speed is the speed in the second pinch, because this speed determines if the copy is 1 : 1. CTFTRANSE measures the actual copy speed. SDS test 53 is used to check the 1:1 mode of the copy. The speed of the copy is measured by the pulse disc. If the actual speed does not correspond with the stored one, the printhead frequency is adjusted for the next copy in order to get a correct 1 : 1 copy. Normally all copies of the same roll have the same correct length. Only when an other roll width or different material is loaded on a roll spindle it is possible that the first copy is incorrect, but the second one is corrected by the printhead frequency.
ed.5
518
TSM Oc 9800
CTF
CTFPMO
MADMO CONSTEPUPTRAFO
CTFSFVA CTFSTVA CTFSPVA
CTFINV PBA for CTFPMO CTFCOMP CTFHETTRIAC
ed.5
CTFDOORSW
CTFOUTHOSW
CTFFTEMPSE 06PBA1 NCTEMP SENS. + CTFREFHE + CTFTUBSO + CTFREFTEMPSE
CTFFHE2
CTFFHETEMPERSW
CTFFHE1
CTFPCLEHE 1 + 2 CTFPCLEHETEMPERSW
602
TSM Oc 9800
CONEMS3 CONEMS2 CONEMS1
CONCONEMS
22PBA4 SSR
22PBA3 CURSENS
CTFOUTSE CTFTRANSE
ed.5
604
TSM Oc 9800
1
22G1 CONSUPLV
3
X8 5 6 7 8 9 10 1 2 3 4
4
22PBA5 DRIVERS
F1 4A
22PBA1 CPU I/O
F4 4A X10 1 2 3 5 X6 27 28 1 2 3 4 5
X13 1 2 3 5 X6 27 28 1 2 3 4 5
+5V GND +24V GND CONDRIINDIAG CONDRIOUTDIAG CTFTUBSO CTFREFHE CTFSFVA CTFSTVA CTFSPVA
CTFFTEMPSE 06PBA1 NC TEMP.SENS

X3 1 3 6 +10VAN GNDAN CTFPYRSE 06X12 1 3 6 X1 1 2 3 06X12 7 8 +24V CTFREFHE-B X11 1 2
5 4
GNDAN CTFREFTEMPSE
CTFREFHE
5 4
-T
CTFREFTEMPSE
+T
9 +24V X12 10
CTFTUBSO
06Y4
D
06S2 22 21 30 CTFOUTHOSW GND CTFDOORSW 4 1 11 12 1 3
10
CTFTUBSO-B
17
CTFOUTHOSW
+24V
X5 7
CTFDOORSW
06S1
X12 19
CTFSFVA-B
06X7 1
CTFSFVA
06Y1
PTRFRAMESW
1 15S1 2 +24V-SW 8 21 CTFSTVA-B 2
29
GND
3 2
CTFSTVA
06Y2
X5 10 12 11
+5V GND CTFPMOSE
22X11 6 8 7
1 3 2
CTFPMOSE
06B1
5 18 X11 20 12
CTFSPVA-B +24V-SW CONEMS2-B
3 4
CTFSPVA
06Y3
06U1 CTFPINV
13 CTFPMOPWM U2 2 F1 5A U6 2 U2 1 U4 2 1 3 4 U6 4 GND 06X5 2 3 1 4 6 5
23U1 MADINV
U6 5 4 -UzK
22X006-1
E T1 T2 T3 +UzK
CTFPMO
M
3
15
+24V-SW
CONEMS2
22K2-2A
06M2 23 20 +24V GND
5 300VDC
+UzK
22PBA4 SSR
X1 30 28
22Z2
4 5 N2 L2 22X010 1 F2 3A 4 1 X7 5 L2-S N2-S X9 3 2 X8 3 6 N2 L2 2 6 4 8
22T1 CONSTEPUPTRAFO
1 208V 2 220V 3 230/240V 4 230V 5 N2-S L2-S L2-SSU
X7 2 1 3
N2-S
06X8 3
AUTO / OFF
M
1
CTFCOMP
06M1
L2-SSU
1 2
22X008
CTF 1 (from engine 484) ed.5 TSM Oc 9800 06 Compact transfer transfuse 701
1
22G1 CONSUPLV
3
X8 5 6 7 8 9 10 1 2 3 4
4
22PBA5 DRIVERS
F1 4A
22PBA1 CPU I/O
F4 4A X10 1 2 3 5 X6 27 28 1 2 3 4 5
X13 1 2 3 5 X6 27 28 1 2 3 4 5
+5V GND +24V GND CONDRIINDIAG CONDRIOUTDIAG CTFTUBSO CTFREFHE CTFSFVA CTFSTVA CTFSPVA
CTFFTEMPSE 06PBA1 NC TEMP.SENS

X3 1 3 6 +10VAN GNDAN CTFPYRSE 06X12 1 3 6 X1 1 2 3 06X12 7 8 +24V CTFREFHE-B X11 1 2
5 4
GNDAN CTFREFTEMPSE
CTFREFHE
5 4
-T
CTFREFTEMPSE
+T
9 +24V X12 10
CTFTUBSO
06Y4
D
06S2 22 21 30 CTFOUTHOSW GND CTFDOORSW 4 1 11 12 1 3
10
CTFTUBSO-B
17
CTFOUTHOSW
+24V
X5 7
CTFDOORSW
06S1
X12 19
CTFSFVA-B
06X7 1
CTFSFVA
06Y1
PTRFRAMESW
1 15S1 2 +24V-SW 8 21 CTFSTVA-B 2
29
GND
3 2
CTFSTVA
06Y2
X5 10 12 11
+5V GND CTFPMOSE
22X11 6 8 7
1 3 2
CTFPMOSE
06B1
5 18 X11 20 12
CTFSPVA-B +24V-SW CONEMS2-B
3 4
CTFSPVA
06Y3
06U1 CTFPINV
13 CTFPMOPWM GND RUNFWD U1 3 4 5 U2 2 U1 2 U2 9 7 6 8 4 F1 5A 5 GND 06X5 2 1 3 4 6
23U1 MADINV
U2 5 4 -UzK
22X006-1
E T2 T1 T3 +UzK
CTFPMO
M
3
15
+24V-SW
CONEMS2
22K2-2A
06M2 23 20 +24V GND
5 300VDC
+UzK
22PBA4 SSR
X1 30 28
22Z2
4 5 N2 L2 22X010 1 F2 3A 4 1 X7 5 L2-S N2-S X9 3 2 X8 3 6 N2 L2 2 6 4 8
22T1 CONSTEPUPTRAFO
1 208V 2 220V 3 230/240V 4 230V 5 N2-S L2-S L2-SSU
X7 2 1 3
N2-S
06X8 3
AUTO / OFF
M
1
CTFCOMP
06M1
L2-SSU
1 2
22X008
ed.5
TSM Oc 9800
CTF 1 (up to engine 483) 06 Compact transfer transfuse 702
1
22G1 CONSUPLV
3
X8 5 6 7 8 9 10 1 2 3 4
4
22PBA5 DRIVERS
F1 4A
22PBA1 CPU I/O
F4 4A X10 1 2 3 5
X13 1 2 3 5
+5V GND +24V GND
X3 30
CTFDOORSW 4 1
+24V
X5 7
CTFDOORSW
06S1
PTRFRAMESW
1 15S1 2 +24V-SW 8 X12 11 CONEMS1-B
29
GND
C
X3 23 25 24 26 28 27 +5V GND CTFOUTSE +5V GND CTFTRANSE 06X2 1 2 3 4 5 6 1 3 2 1 3 2
3 2
CTFOUTSE
06B2
16
+24V-SW
CONEMS1
22K1-2A
CTFTRANSE
06B3
12
CONEMS2-B
15 +5VAN CTFPCLEHETEMPSE 06X4 1

-T
+24V-SW
CONEMS2
22K2-2A
15 12
CTFPCLHETEMPSE
06R1
23 20
+24V GND
22PBA4 SSR
X9 8 7 9 6 4 X3 10 2 GND +5V CONSSRINDIAG CTFFHE CTFPCLEHE X1 8 7 9 6 4 X1 30 28 X10 3 1 5 4 N1-SM CTFHEG CTFHEC-2 CTFHEC-2 06X1 1
6
CTFFHETTRIAC
06V1
22PBA3 CURSENS
E
22Z1
CONEARTHCUR +5VAN
X1 1 3
N1-SM L1-SM L1-S N1-S
4 6 5
N1 L1
2 6
4 8
N1-S L1-S
X13 1 2 X14 1 2 X11 1 4
CTFFHE2
06E2A
22X007-1
06X001
6
CTFFHETEMPERSW
06S04
3 06X9 1 2
6
CTFFHE2
06E2B
CTFFHE1
06E1
L1-SM
22Z2
5 4 6 N2 L2
22X010
X9 2 3 1
X8 3 6
N2 L2
2 6
4 8
4 1 X6 6
L2-S N2-S
L2-S
06X3 1
CTFPCLEHETEMPERSW
06S03
88
G
3 CTFPCLEHEC
88
CTFPCLEHE1
06E3
CTFPCLEHE2
06E4
22X007-2
06X002
H
CTF 2 ed.5 TSM Oc 9800 06 Compact transfer transfuse 703
6
CTFSTCYL-R first transfer step
A
0.3
)(
CTFSFCYL-R fuser step
B
CTFSFCYL-L fuser step
PREHEATING
)(
0.3
CTFSTCYL-L first transfer step
RED 2 BLUE 4
D
RED 2 BLUE 4
CTFSFVA fuser
LEVEL
CTFSTVA transfer
E
3 BAR 0.4 BAR 3 BAR 5.6 BAR
CTFSPVA high / low pressure
5.6 BAR
MOD. 29 TIMER ON/OFF
H
PNEUMATICS ed.5 TSM Oc 9800 06 Compact transfer transfuse 704
1
22PBA1 CPU I/O
X5 10 12 11
+5V GND CTFPMOSE
22X11 6 8 7
1 3 2
CTFPMOSE
06B1
22PBA5 DRIVERS
X11 20
06U1 CTFPINV
13 CTFPMOPWM U1 3 4 5 U2 2 U1 2 U2 9 7 6 8 4 F1 5A 5 GND 06X5 2 3 1 4 6
23U1 MADINV
22X006-1
E T1 T2 T3
CTFPMO
M
3
06M2
U6 5 4
-UzK 300VDC +UzK
To 23 Main drive 703 22PBA1 CPU I/O

X5 10 12 11 +5V GND CTFPMOSE 22X11 6 8 7
(Up to engine 483)
1 3 2
CTFPMOSE
06B1
22PBA5 DRIVERS
X11 20
06U1 CTFPINV
13 CTFPMOPWM U2 2 F1 5A U6 2 U2 1 U4 2 1 3 4 U6 4 GND 06X5 2 3 1 4 6 5
23U1 MADINV
U6 5 -UzK
22X006-1
E T1 T2 T3
CTFPMO
M
3
06M2
5 300VDC
+UzK
To 23 Main drive 703 (From engine 484)
H
Modification 25 ed.5 TSM Oc 9800 06 Compact transfer transfuse 705
Oc
Oc 9800
07 DISCHARGING
Contents
Diagnostics
1 Faults
101
SDS
1 DisCHarge
201
Adjustments
1 Discharge unit
301
Dis/-assemblies
1 Discharging unit 401 2 Pin array 401 3 Fans 402 4 Discharging LEDs 402
1 General 501
1 Component locations 601 2 Corona supply 602 3 Discharge fans and Leds 602
Diagrams
1 Discharging 701
ed.5
07 Discharging
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. DisCHarging 07000 - 07999 code display 07501 MRE: ~Failure DCHSTASUP: (DCHSTASUPER)~
Possible cause Remarks
Bad / no DRU sliding contact
Check / clean sliding contact
07-6-05 DCHS- 24 V DCHST- TASU- present PER on ASUP
Possible cause
Remarks
0701G1 DCHSTASUP defect (continuously on) Connection DCHSTASUPER -> CPU_IO PBA
OFF
OFF
Yes
disconnect 2201X4
CPU I/O PBA defect (DCHSTASUPER)
ed.5
07 Discharging 101
07-6-05 DCHS- 24 V DCHST- TASU- present PER on ASUP
Possible cause
Remarks
0701G1 Connection 24 V DRIVERS PBA -> DCHSTASUP F3 on DRIVERS PBA defect Other 24 V users on 2205X11 Yes Connection DCHSTASUP -> pin array Connection backing DisCHarging -> DCHSTASUP Connection CPU_IO PBA -> DCHSTASUP Connection DCHSTASUPER -> CPU_IO PBA DCHSTASUP defect (continuously off) Pin array disconnected / broken Positioning DCH to drum incorrect Polluted / humid isolation blocks
ON
ON
No
102
TSM Oc 9800
Diagnostics
07901 SWAR: ~Failure DCHFAN (1-2): (DCHFANER)~

07-4-01 DCHFAN
DCHFA NER OFF
Fans turning (listen) No
Possible cause 24 V present on all fans
Remarks
OFF
Yes
Connection DCHFANER -> CPU_IO PBA CPU_IO PBA PBA defect
OFF (disconnect 2201X11
Yes No No
DRIVERS PBA defect Connection 24 V DRIVERS PBA -> DCHFAN 1 or 2 Fuse F3 DRIVERS PBA defect
ON
ON
Connection 24 V other users on DRIVERS PBA on 2205X11 DRIVERS PBA defect Yes Yes DCHFAN 1 or 2 defect
ed.5
07 Discharging 103
104
TSM Oc 9800
Diagnostics
SDS
1 DisCHarge
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
07 Discharging 201
Component
Signal
Description
07M1/07M2 07G1
DisCHarge FAN Discharge fan error ERror ON = fans not turning DisCHarge Discharge static supply error STAtic SUPply ON = discharge supply switched off ERror
07M1 / 07M2 / 07E2
DisCHarging Discharge fans and led FAN / DisON = 2 fans and discharge leds switched on. CHarging LEDs ON = printhead fan switched on Hardware diagnoses: DCHFANER
Functions 01 (drum), 02 (corona), 05 (developer) and 07 (discharge) in warm condition

Functions 01 (drum), 02 (corona), 05 (developer) and 07 (discharge) in cold condition

07-6-05
07G1
~DisCHarging StAtic SUPply~
During the test the drum is turning and the discharge leds are on activate the test: ~ DCHSTASUP: OFF~ ~ DCHSTASUPER: ON/OFF~ push the <start> button ~ DCHSTASUP: ON~ ~ DCHSTASUPER: ON/OFF~
Consumable tests 07-8-01 ~Discharging pin array (lm)~
(range 0 ... 9999999 m, norm 200000 m)
202
TSM Oc 9800
SDS
Adjustments
1 Discharge unit
Carry out this adjustment when you have replaced the discharge unit.
Aim:
Correct sidewards position of the discharge unit.

Check: 1 Measure the distance between the discharge unit and the left and right hand
side lower drum support.

2 The distance may be 1 mm max. at both sides. 3 Specification: No space between the E-ring and the bush -A-.
discharge unit
lower drum support
bush B max. 1 mm E-ring
bush A
spacers
Correction: 1 Adjust with bush -B-. 2 Exchange with spacers from the other side of the unit.
ed.5
07 Discharging 301
302
TSM Oc 9800
Adjustments
Dis/-assemblies
1 Discharging unit
sheet feeding section if opened

1 2 3 4
Carry out function 04 dis-/assembly Cold process drawer on page 401). Remove the discharge unit and place it slightly to the rear of the machine. Disconnect the connectors 07X1, 0701G1 and the HV connector. Pull the discharge unit out of the machine.
2 Pin array
1 Carry out dis-/assembly Discharging unit on page 401. 2 Remove at both sides the clear plastic covers of the pin arrays mounting blocks. 3 Remove the two Allen screws from the pin arrays mounting block at the non 4 5 6 7 8 9 10 11 12
wiring side. Move mounting block of the pin array 10 mm inwards. Remove the old pin array. Mount the new pin array at the wiring side. Mount the other side at the mounting block. Move the mounting block to the outside. Mount the screws in the mounting block of the pin arrays. Mount the clear plastic covers. Carry out SDS test 07-8-01. Enter the value 0.
Note: Dispose of the old corona pin array in accordance with your local reg-
ulations to the local Oc organisation.
ed.5
07 Discharging 401
3 Fans
1 2 3 4 5
Carry out dis-/assembly Discharging unit on page 401. Remove the L-shaped cover above the LED bar (4 screws). Remove the U-shaped cover of the unit (10 screws). Disconnect the connectors. Remove the fans.
Note: Mount the longest shoulder screws through the two cover plates.
4 Discharging LEDs
1 2 3 4 5
Carry out dis-/assembly Discharging unit on page 401. Remove the screws from each PBA. Disconnect the connectors. Remove the PBAs. After mounting the new PBAs, cut the wires from the most right-hand connector.
402
TSM Oc 9800
Dis/-assemblies
1 General
The discharge unit discharges the drum and neutralizes the remaining toner on the drum. The discharge unit consists of:
:
drum
DCH pin array
DCH LEDs carbon filter fans (2 x)
Pin array
The discharge pin array is identical to the charge corona pin array.
Leds
3 x 32 LEDs discharge the residual charge on drum and toner.
ed.5
07 Discharging 501
Air circulation
The air around the pin arrays is circulated by 2 fans at the bottom of the discharge unit. The air (including ozone) is blown through the active carbon filter. This filter removes the ozone. After the ozone filter the air is sucked over the pin array. The lifetime of the carbon filter is machine lifetime.
drum pin array
active carbon filter
fan (2x)
502
TSM Oc 9800
07E2/3/4 DCHLED 1, 2, 3
DCHFAN 1/2
07G1 DCH STASUP
ed.5
07 Discharging 601
2 Corona supply
The corona supply voltage for the discharge corona pin array is negative 3 kV DC on which is superimpost an AC voltage of 3 kV 16 kHz. The total corona current (It) is devided into the photoconductor current (Ip) and the backplane current (Ib). It = Ip + Ib = ...... + ......... A. Control signal DCHSTSSUP (discharge start supply) from the CPU-IO (22PBA1) switches on the high voltage supply PBA. DCHSTASUPER is the error detection signal.
3 Discharge fans and Leds

Signal DCHFAN switches on the two fans in the discharge unit. DCHFANER is the error detection signal.
Three discharge Led PBAs mounted on the unit are also switched on with the signal DCHFAN.
602
TSM Oc 9800
1
22G1 CONSUPLV
2
22PBA5 DRIVERS
X8 5 6 7 8 9 10 1 2 3 4 F4 4A X10 1 2 3 5 X7 20 2 X6 27 27 28 F3 4A 24 25 X11 23
3
DCHFAN1-B 22X5 32
4
07X1 3
5
07X4 1
M
DCHFAN1-DCHFAN2-B 9 33 4 5 2 07X5 1
DCHFAN1
07M1
M
26 DCHFAN2-10 6 2
DCHFAN2
07M2
07E2 DCHLED1
8 6 +24V GND 19 8 1 2 E1 2 1 E2 2 1
07E3 DCHLED2
E1 2 1 E2 2 1
07E4 DCHLED3
E1 2 1
22PBA1 CPU I/O
X13 1 2 3 5 X11 20 2 X6 27
+5V GND +24V GND DCHFAN DCHFANER
07G1 DCHSTASUP
+24V GND 12 5 G1 1 4 G3 HV G2 1 07X2 07E1 07X3
CONDRIINDIAG
2 3
X4 10 11
DCHSTASUP DCHSTASUPER
15 16
2 3
H
ed.5 TSM Oc 9800 07 Discharging 701
Oc
Oc 9800
09 ORIGINAL HANDLING
Contents
Diagnostics
1 Faults
101
SDS
1 ORiGinal handling
201
Adjustments
1 ~Original length correction~ 301 2 ~1 : 1 Image length correction scanner~ 302 3 ~Scanning leading edge correction~ 303 4 ~Scanning trailing edge correction~ 304 5 ORGPPSO (ORiGinal Paper Present SOlenoid) 305 6 Front / rear original delivery 306 7 ORGISE and ORGSYNSE (ORiGinal Input SEnsor and ORiGinal SYNchronisation SEnsor) 306 8 ORGPJSE (ORiGinal Paper Jam SEnsor) 307
Dis-/assemblies
1 ORGMO (ORiGinal MOtor) 401 2 Gauge roller 402 3 ORGISE / ORGPRESE (ORiGinal Input SEnsor, ORiGinal paper PREesent SEnsor) 402 4 ORGPJSE (Paper Jam SEnsor) 402
1 General 501 2 Original input section 502 3 Original trough-feed section 502 4 Original motor (ORGMO) 503 5 Original width detection 504
601
ed.5
09 Original handling
Diagrams
1 Original handling 701
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. ORiGinal handling 09000 - 09999 code display 09701 ORE: ~Original too late at ORGSYNSE~
Toothed belt ORGMO loose / defect

09-2-09 ORGSYNSE
Possible cause
Remark
Continuously Connection CONSOLE CPU PBA -> OFF KEYPAD3 PBA Connection ORGSYNSE -> KEYPAD3 PBA ORGSYNSE defect Actuator defect CONSOLE CPU PBA defect KEYPAD3 PBA defect
ed.5
09-4-01 ORGPPSO
CONMIX OUTDIAG OFF
Original Possible cause stop open No Connection CONSOLE CPU PBA -> KEYPAD3 PBA Connection KEYPAD3 PBA -> MIXED SUPPLY Connection MIXED SUPPLY -> ORGPPSO MIXED SUPPLY defect KEYPAD3 PBA defect
Remark
ON
ON
ORGPPSO blocked / defect Original stop blocked Adjust stop
09-2-13 ORGISE
Possible cause
Remark
Continuously Connection CONSOLE_CPU PBA -> ON KEYPAD3 PBA Connection ORGISE -> KEYPAD3 PBA ORGISE defect Actuator defect CONSOLE_CPU PBA defect KEYPAD3 PBA defect
Possible cause
Remark
Toothed belt ORGMO Loose / defect
102
TSM Oc 9800
Diagnostics
09702 ORE: ~ORGSYNSE too late free~

~
09-2-09 ORGSYNSE
Possible cause
Remark
Continuously ON
Connection CONSOLE_CPU PBA -> KEYPAD3 PBA Connection ORGSYNSE -> KEYPAD3 PBA ORGSYNSE defect Actuator defect CONSOLE_CPU PBA defect KEYPAD3 PBA defect
09703 ORE: ~Original too late at ORGPJSE~

E
Possible cause
Remark
Glass plate not properly mounted (not straight)
Position correctly
09-2-10 ORGPJSE
Possible cause
Remark
Continuously OFF
Connection CONSOLE_CPU PBA -> KEYPAD3 PBA Connection ORGPJSE -> KEYPAD3 PBA ORGPJSE defect Actuator defect CONSOLE_CPU PBA defect KEYPAD3 PBA defect
ed.5
09704 ORE: ~ORGPJSE too late free~
Possible cause
Remark
Glass plate not properly mounted (not straight)

09-2-10 ORGPJSE Possible cause
Position correctly
Remark
Continuously ON
Connection CONSOLE_CPU PBA -> KEYPAD3 PBA Connection ORGPJSE -> KEYPAD3 PBA ORGPJSE defect Actuator defect CONSOLE_CPU PBA defect KEYPAD3 PBA defect
104
TSM Oc 9800
Diagnostics
09705 ORE: ~Speed ORGMO out of range~
09-2-12 Possible cause ORGMOSE
Remark
ContinuORGMOSE defect ously OFF / Pulse disc defect ON when turning Connection CONSOLE_CPU PBA -> KEYPAD3 PBA pulsdisc Connection ORGMOSE -> KEYPAD3 PBA KEYPAD3 PBA defect CONSOLE_CPU PBA defect
09-4-02 CONMIX ORGMO Possible cause ORGMOPWM OUTDIAG running
Remark
(100%)
OFF
ON (disconnect 1001G3) OFF
Yes
MIXED SUPPLY defect
ON
No
Connection CONSOLE_CPU PBA -> KEYPAD3 PBA Connection KEYPAD3 PBA ->MIXED SUPPLY Connection MIXED SUPPLY -> 09X2 -> ORGMO ORGMO blocked / defect MIXED SUPPLY defect
ed.5
106
TSM Oc 9800
Diagnostics
SDS
1 ORiGinal handling
see SDS
31
see SDS
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr.
Component
Signal
Description
Parameter test 09-1-01 ~Original length correction (mm/10)~
Adjusting the original length measurement (range -250 - +250, default 0, mm/10) Check the length of the last original with test 09-9-01
09-1-02 ~1 : 1 image length cor. scanner (mm/10)~
Adjusting the scan speed correction offset (range -500 - + 500, default 0, mm/10)
09-1-03 ~Scanning leading edge corr. (mm/10)~
Adjusting the offset of the distance between scan-head and synchronisation sensor for the leading edge margin (range 0 - 200, default 0, mm/10)
09-1-04 ~Scanning trailing edge corr. (mm/10)~
Adjusting the offset of the distance between scan-head and synchronisation sensor for the trailing edge margin (range 0 - 400, default 0, mm/10)
Input tests 09-2-01 09-2-02 09-2-03 09-2-04 09-2-05 09-2-06 09-2-07
09B2 09B3 09B4 09B5 09B6 09B10 09B11
ORiGinal Original present sensor PREsent SEnsor ON = original detected ORiGinal WIDth Original width sensor 1 SEnsor1 ON = original detected ORiGinal WIDth Original width sensor 2 SEnsor2 ON = original detected ORiGinal WIDth Original width sensor 3 SEnsor3 ON = original detected ORiGinal WIDth Original width sensor 4 SEnsor4 ON = original detected ORiGinal WIDth Original width sensor 5 SEnsor5 ON = original detected ORiGinal WIDth Original width sensor 6 SEnsor6 ON = original detected
202
TSM Oc 9800
SDS
Test nr. 09-2-08 09-2-09 09-2-10 09-2-11 09-2-12 09-2-13
Component
Signal
Description
09B12 09B7 09B8 09S1 09B1 09B9
ORiGinal WIDth Original width sensor 7 SEnsor7 ON = original detected ORiGinal SYN- Original synchronisation sensor chro SEnsor ON = original detected ORiGinal Paper Original paper jam sensor Jam SEnsor ON = original detected ORiGinal Original safety switch SAFety SWitch ON = scanner closed ORiGinal MOtor Original motor sensor SEnsor ON = sensor blocked by pulse disc ORiGinal Input Original input sensor SEnsor ON = original detected
09Y1
ORiGinal Paper Original paper present solenoid Present SOleON = original pinch closed, original stop noid opened Hardware diagnoses: CONMIXOUTDIAG ORiGinal MOtor Original motor PWM PWM ON = motor is activated at maximum PWM. Hardware diagnoses: CONMIXOUTDIAG
09-4-02
09M1
ed.5
Test nr. Info tests 09-9-01
Component
Signal
Description
~Measured original length (mm/10)~
Length last measure original (range 0 ... 60000 mm/10)

System tests 56 ~Adjust scanner mode~
Copy of the (service test) original with background and 4 cm white stroke at the leading and trailing edge
204
TSM Oc 9800
SDS
Adjustments
1 ~Original length correction~
Note: The original may not be curled, otherwise an incorrect length measure-
ment will be the result.

Aim:
Make sure that the length measurement from the service test original with the scanner is within +/- 1 mm.
Check:
1 2 3 4 5
Measure the length of the service test original along the input arrow. Feed the test original in input arrow direction and make a copy. Carry out SDS test 09-9-01 and read out the measured original length. Repeat 2 times step 2 up to 4. Calculate the average of the read out values and compare them with the actual length of the service test original. 6 Specification: The differencebetween the actual length and the average measured length must be less than +/- 1.0 mm.
Correction:
Average length too long:

1 Carry out SDS test 09-1-01. 2 Decrease the indicated value with 10 x the calculated average difference.
Average length too short:

1 Carry out SDS test 09-1-01. 2 Increase the indicated value with 10 x the calculated average difference.
ed.5
2 ~1 : 1 Image length correction scanner~

Note: The following printer adjustments must be within the specifications.
Function 06 ~1 : 1 Image length cor. engine~ on page 301
Aim:
Make sure the image on the copy is 1: 1 with the image on the original.
Check: 1 Carry out SDS test 42. 2 Select A1 (22/24) roll width. 3 Feed the original in portrait direction
and make a copy.

4 Feed the original 4 times again and
push the start button.

5 Match the original with the copies 3,
4 and 5 along the line Xe of the original and Xh of the copy. 6 Measure the difference in length on all 3 copies in mm. 7 Calculate the average difference. 8 Specification: The max. average difference must be between -/+ 1 mm.
Correction: Image length on copy too long: 1 Carry out SDS test 09-1-02. 2 Decrease the indicated value with 10
x the calculated average difference.

Image length on copy too short: 1 Carry out SDS test 09-1-02. 2 Increase the indicated value with 10 x the calculated average difference.
Make once again a copy and measure if the difference in length is within 1.0 mm.
302
TSM Oc 9800
Adjustments
3 ~Scanning leading edge correction~

Adjustment ~1 : 1 Image length correction scanner~ on page 302 must be correct.
Aim:
Make sure that the scanner starts scanning the leading edge of the original on the correct moment.
Check: 1 Carry out SDS test 56. 2 Select roll width A0 (36). 3 Feed the test original in input arrow 4 5 6
image scanning starts too early
direction. Make 3 times 1 copy. Match the original with the copies. Calculate the average difference between the original leading edge and the grey leading edge on the copies Specification: The average difference between the original leading edge and the grey leading edge on the copies must be within +/- 1.0 mm.
Correction:
Copy max. 1 mm
start scanning leading edge original
image scanning starts too late
Copy max. 1 mm leading edge original start scanning
When the average of the grey leading edge on the copies is too long: 1 Carry out SDS test 09-1-03. 2 Increase the indicated value with 10 x the average difference. When the average of the grey leading edge on the copies is too short: 1 Carry out SDS test 09-1-03. 2 Decrease the indicated value with 10x the average difference.
ed.5
4 ~Scanning trailing edge correction~

Adjustment ~1 : 1 Image length correction scanner~ on page 302 and ~Scanning leading edge correction~ on page 303 must be correct.
Aim:
Make sure that the scanner stops scanning of the trailing edge on the correct moment.
Check: 1 Carry out SDS test 56. 2 Select roll width A0 (36). 3 Feed the test original in input arrow 4 5 6
direction. Make 3 times 1 copy. Match the original with the copies. Calculate the average difference between the original trailing edge and the grey trailing edge on the copies. Specification: The average difference between the original trailing edge and the grey trailing edge on the copies must be within +/- 1.0 mm.
Correction:
image scanning stops too late
trailing edge original stop scanning
max. 1 mm Copy
When the average of the grey trailing edge on the copies is too long:
1 Carry out SDS test 09-1-04. 2 Decrease the indicated value with 10x
the average difference. When the average of the grey trailing edge on the copies is too short:
1 Carry out SDS test 09-1-04. 2 Increase the indicated value with 10 x
trailing edge original

image scanning stops too early
max. 1 mm Copy
the average difference.
304
TSM Oc 9800
Adjustments
5 ORGPPSO (ORiGinal Paper Present SOlenoid)

Aim:
Correct lifting of the original stop to pass the original and a correct pressure of the soft rollers on the original.
Check: 1 Remove the scanner upper left side cover. 2 Specification 1: The distance between the solenoid housing and the disc must
be 8 +/- 0.2 mm.

3 Push the core into the solenoid until the soft rollers touch the original feed roll-
er.
4 Specification 2: The distance between the disc and the solenoid housing must
be 2.5 +/- 0.5 mm.

Correction: 1 1 Adjust with the solenoid mounting screws the distance to 8 +/-0.2 mm.
Correction: 2 1 Adjust the distance to 2.5 +/- 0.5 mm with the bracket mounting screws.
solenoid mounting screws
ORGPPSO
bracket mounting screws
8 +/- 0.2 mm
2.5 +/- 0.5 mm

soft rollers
core disc
original feed roller
ed.5
6 Front / rear original delivery

Aim:
Make sure that the originals are delivered.

Check: 1 Push the delivery flap to rear delivery. 2 Specification: The flap must be just
adjusting strip
free from the delivery rollers.

Correction:
Adjust with the adjusting strip.
delivery roller
7 ORGISE and ORGSYNSE (ORiGinal Input SEnsor and ORiGinal SYNchronisation SEnsor)
Aim:
Make sure that the originals are detected.

Check: 1 Open the scanner. 2 Specification: The top of the sensor
ORGISE ORGSYNSE
6 +/- 0.5
levers must be 6 +/- 0.5 mm above the bottom plate.

Correction: 1 Remove Gauge roller on page 402. 2 Adjust with the sensor mounting
sensor bracket
bracket.
306
TSM Oc 9800
Adjustments
8 ORGPJSE (ORiGinal Paper Jam SEnsor)

Aim:
Make sure that the originals are detected.

Check: 1 Open the scanner. 2 Specification: The top of the sensor
ORGPJSE
7 -0.5 /+0
lever must be 7 -0.5 / +0 mm above the bottom plate.

Correction: 1 Remove Gauge roller on page 402. 2 Adjust with the sensor mounting
sensor brakket
bracket.
ed.5
308
TSM Oc 9800
Adjustments
Dis-/assemblies
1 ORGMO (ORiGinal MOtor)
1 Remove the bottom left cover from the scanner stand (1 screw). 2 Remove the top left cover from the scanner stand (1 screw).
belt tensioner connector 09X2
drive belt Confidential 1999 Oc-Technologies B.V.
motor frame plate
3 4 5 6 7 8 9 10
Loosen the gear belt tensioner (2 screws). Remove the drive belt. Disconnect connector 09X2. Loosen 4 screws from the motor frame plate. Remove the drive belt. Push the motor frame plate to the front of the scanner. Remove the motor frame plate with the motor. Tension the drive belt after assembling.
ed.5
2 Gauge roller
1 Remove at the left and right side the covers from the scanner stand. 2 Remove the gauge roller tension springs at the left and right. Note: Do not drop the rod inside the springs. 3 4 5 6 7 8
Remove the gauge roller drive belt at the right. Remove the drive pulley at the right. Remove the roller bearings at the left and right. Open the scanner. Remove the gauge roller. If the gauge roller is replaced carry out the SDS test 10-7-01TL intensity adjust on page 277.
3 ORGISE / ORGPRESE (ORiGinal Input SEnsor, ORiGinal paper PREesent SEnsor)

1 Carry out dis-/assembly Gauge roller on page 402. 2 Remove the sensor mounting bracket (2 screws). 3 After assembly carry out adjustment ORGISE and ORGSYNSE (ORiGinal
Input SEnsor and ORiGinal SYNchronisation SEnsor) on page 306
4 ORGPJSE (Paper Jam SEnsor)

1 Carry out dis-/assembly Gauge roller on page 402. 2 Remove the sensor mounting bracket (2 screws). 3 After assembly carry out adjustment ORGPJSE (ORiGinal Paper Jam SEn-
sor) on page 307
402
TSM Oc 9800
Dis-/assemblies
1 General
The original handling transports the original through the scanner. The function consists of: - an original input section - an original trough-feed section - an original output section
ORGWIDSE 1...4 / 1...7 ORGPRESE
originals stop (ORGPPSO)
exposure lamp
original feed
gauge roller
ORGSAFSW
ORGISE
ORGSYNSE
ORGPJSE
ed.5
2 Original input section

Sequence: The original is fed in with the image face up against the original side guide at the left ( Oc 9810 scanners with modification no. 3 have a sliding side guide and 3 extra width sensors no.5 - 7). First the width sensors ORGWIDSE are activated and then the original present sensor (ORGPRESE). The original motor (ORGMO) starts and the input roller feeds the original towards the original stop. Just before the original stop, the original input sensor (ORGISE) detects the original. ORGMO stops and the original is correctly positioned against the original stop.
3 Original trough-feed section

Sequence: Press the <START> button. The original stop is lifted (ORGPPSO) and the soft feed rollers are pushed on top of the original. The original motor (ORGMO) starts and the original is fed in. The original synchronisation sensor (ORGSYNSE) detects the original. This sensor is used for the synchronisation of the scanning start moment at the leading edge and the scanning stop moment at the trailing edge. The original is fed over the white gauge roller to the scanning position. The original activates ORGPJSE original paper jam sensor. ORGPJSE detects a jam if the original reaches the sensor too late. The original is fed out of the scanner via the output roller and ejected over the guide plate to the front of the scanner or onto a table behind the scanner. Rear delivery must be selected for thick originals.
Automatic feed
When using automatic feed the minimum distance between two originals must be at least 80 mm (3.1). The moment the original leaves ORGSYNSE, ORGPPSO is de-energised and the next original is stopped by the original stop. As soon as the trailing edge has left the ORGPJSE, ORGPPSO is energised again and the original is fed.
502
TSM Oc 9800
Filing strips
Originals with filing strips must be fed in as follows: - Filing strip at the left-hand side Feed the filing strip over the original side guide. The filing strip is thus outside the scanning area and causes no problems with the sensors in the original handling - Filing strip at the leading edge. There is no detection of the filing strip when the original is fed with the strip at the leading edge. The result is that the filing strip is always visible on the copy except when the operator selects a shorter leading edge. - Filing strip at the trailing edge. The operator has to select a shorter trailing edge.
4 Original motor (ORGMO)

For 1:1 image, the speed of the original motor (ORGMO) is 100%(10 m/min.). Magnification in length direction is done by reducing the speed between 100 and 25%. The magnification in the width direction is done by the scanner processing PBA (10PBA1). The speed of the original motor for reduction is always 100%. In length and width direction the B/W processing PBA (11PBA2) takes care of the reduction.
ed.5
5 Original width detection

Without modification 3
Width detection of the original is necessary to select the correct roll width in the printer when copying in the automatic feed mode. The selected roll width also depends on he chosen magnification ratio. The original present sensor and the 4 width sensors are positioned so that the they can detect the various width formats. .
ORGPRESE ORGWIDSE 1 / 2 / 3 / 4 original side guide
The selection has to be made in SDS e.g. DIN or (8.5 or 9) range. The table below shows the activated sensors and the corresponding size.
Size ORG PRESE ORGWIDSE 1 ORGWID- ORGWID- ORGWIDSE 2 SE 3 SE 4
DIN A4 A (8.5 or 9) DIN A3 B (11 or 12) DIN A2 C (17 or 18) A1 D (22 or 24) DIN A0 E (34 ) 914mm or 36
1 1 1 1 1 1
0 1 * * * *
0 0 1 * * *
0 0 0 1 * *
0 0 0 0 1 1
* = dont care 0 = not activated 1 = activated
504
TSM Oc 9800
With modification 3 (3 extra sensors)
Width detection of the original is necessary to select the correct roll width in the printer when copying in the automatic feed mode. The selected roll width also depends on he chosen magnification ratio. The original present sensor and the 7 width sensors are positioned so that the they can detect the various width formats.
.
104
ORGWIDSE 1 / 2 / 3 / 5/ 4/ 6/ 7 ORGSYNSE
original side guide
48
ORGISE
104 242 319 470 572 624 777 880
ORGPRESE
A4 210
A3 297
A2 420
B2 500
A1 594
B1 707
A0 841
36 914
The selection has to be made in SDS 90: ori. width det.: 5 or 8 sensors. The table below shows the activated sensors and the corresponding size.
Size PRESE WIDSE 1 WIDSE 2 WIDSE 3 WIDSE 5 WIDSE 4 WIDSE 6 WIDSE 7
DIN A4 A 8.5 - 9 DIN A3 B 11 - 12 DIN A2 C 17 - 18 B2 D 22 DIN A1 D 24 B1 DIN A0 E 34 914mm - 36
1 1 1 1 1 1 1 1
0 1 * * * * * *
0 0 1 * * * * *
0 0 0 1 * * * *
0 0 0 0 1 * * *
0 0 0 0 0 1 * *
0 0 0 0 0 0 1 *
0 0 0 0 0 0 0 1
* = dont care
0 = not activated
1 = activated
ed.5
506
TSM Oc 9800
ORGPPSO ORGSAFSW
ORGMO and ORMOSE
ed.5
ORGPJSE
ORGWIDSE 1,2,3,5,4,6,7
EXP. LAMP
ORGSYNSE ORGISE ORGPRESE
ORGSAFSW
ORGPRESE
ORGWIDSE ORGISE
ORGSYNSE
ORGPJSE
Right side view
602
TSM Oc 9800
10G1 Mixed supply
22PBA8
Keypad3
22PBA2
Console CPU
ed.5
604
TSM Oc 9800
1
22G1 CONSUPLV
G5 1 2 3 ENGINE 22X1 SCA+400VDC L SCA-400VDC M SCACONTROL K N 22X004 10X1 L M K N
2
10G1 MIXED SUPPLY
G1 2 3 4 1 10X13 G4 4 3 2
3
ORGPPSO-
ORGPPSO
ORGPPSO+ ORGMO09X2 2 09X1 2 09Y1
M
G2 1 2 3 4 7 8 9 10 15 16 17 18 11 12 1 F 3A 2 4 ORGSAFSW 1
ORGMO
09M1
22PBA2 CONSOLE_CPU
TP1 X1 1 2 3 4 5 6 7 8 9 10 11 X3 1 2 3 X7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 +5V +5V +5V +5V GND GND GND GND +12V +12V +12V +12V GND GND
22PBA8 KEYPAD3
X3 2 X3 5 4 3 +5V ORGMOSE GND 3 4 5 1 2 3
ORGMOSE
09B1
TP0
ORGSAFSW
09S1 F 1 3A G3 3 4 5 6 ORGMOPWM ORGPPSO CONMIXINDIAG CONMIXOUTDIAG X2 3 4 5 6 X1 1 2 3 4 5 6 8 9 20 12 13 14 15 16 17 18 19 24 25 26 27 28 30 ORGMO+ GND 1 26 25 24 1 3 +5V ORGPRESE GND 1 2 3
B
TP2 TP3 TP4 TP5
ORGPRESE
09B2
23 22 21
+5V ORGWIDSE1 GND
1 2 3
ORGWIDSE1
09B3
+12V +5V GND GND NRD3 NRD4 NWR3 NWR4 BNRESET KP3D0 KP3D1 KP3D2 KP3D3 KP3D4 KP3D5 KP3D6 KP3D7 KP3A1 KP3A2 KP3A3 KP3A4 INT3 +5V
20 19 18
+5V ORGWIDSE2 GND
1 2 3
ORGWIDSE2
09B4
17 16 15
+5V ORGWIDSE3 GND
1 2 3
ORGWIDSE3
09B5
14 13 12
+5V ORGWIDSE ORGWIDSE4 GND 09X3 6 5 4
1 2 3
ORGWIDSE4
09B6
11 10 9
+5V ORGSYNSE GND
1 3 2
ORGSYNSE
09B7
8 7 6
+5V ORGPJSE GND
3 2 1
1 3 2
ORGPJSE
09B8
29 28 27
+5V ORGISE GND
9 8 7
1 3 2
ORGISE
09B9
E
32 31 30 +5V ORGWIDESE5 GND 09X4 2 1 X2 8 ORGWIDESE6 1 3 2 1 3 2
MOD. 9810-03
ORGWIDESE5
09B10
ORGWIDESE6
09B11
F
9 ORGWIDESE7
1 3 2
ORGWIDESE7
09B12
H
ed.5 TSM Oc 9800 09 Original handling 701
Oc
Oc 9800
10 SCANNER
Contents
SDS
1 SCAnner 201
Adjustments
1 TL intensity adjust 301 2 Scanner exposure lamp 302
Dis-/assemblies
1 Scanner side covers 401 2 Operating panel 401 3 Exposure lamp 402 4 Glass plate scan window 403 5 Scan head (CCD unit) 404
1 General 501 2 The light path 501 3 The one line CCD 502 4 Block diagram data path 503 5 Mixed power supply 506
601
Diagrams
1 Scanner
701
ed.5
10 Scanner
TSM Oc 9800
Contents
SDS
1 SCAnner
see SDS
31
see SDS
see SDS
see SDS
see SDS
see SDS
ed.5
10 Scanner 201
Test nr.
Component
Signal
Description
10E1
SCAnner LAmp Scan lamp puls width modulation PWM ON = 100% PWM drive
Adjustment tests 10-7-01
10E1
~TL intensity adjust~
Start the test after the engine is in stand-by. (warmed up) The test takes about 6 min.
System tests
202
TSM Oc 9800
SDS
Adjustments
1 TL intensity adjust
Carry out this test after replacement or reinstallation of: - scanner exposure lamp or - CCD unit or - gauge roller or - glass plate or if uneven background (strokes of 60 mm (CCD chip) or 300 mm (CCD PBA) appears. The light intensity is adjusted to the optimum setting regarding quality of all parts in the optical system as e.g. lamp and CCDs.
Check:
No check.
Correction: 1 Carry out SDS test 41, WARM SDS. 2 Carry out SDS test 10-7-01.
Note: If Test failedis indicated:check and correct the light path and carry
out the tests again.
ed.5
10 Scanner 301
2 Scanner exposure lamp

Aim:
screws lamp holder bracket
Make sure that the exposure lamp does not touch the scanhead.
Check: 1 Remove the scanner side cover on the
stopper
left and the right. 2 Specification: the distance between the lamp and the stopper must be 1 +/0.5 mm on both sides.
Correction: 1 Loosen 2 screws. 2 Adjust the position of the lamp holder
bracket.
3 Tighten the screws.
1 +/- 0.5 exposure lamp
302
TSM Oc 9800
Adjustments
Dis-/assemblies
1 Scanner side covers
1 2 3 4
Open the scanner. Remove the outside screw at the left and right underneath the scanner. Close the scanner. Remove the scanner side covers to the rear.
Note: All covers are connected with a ground wire.
screw
2 Operating panel
1 Release and remove the two front covers besides the operating panel. 2 Remove two screws left and right from the operating panel. 3 Turn (swing) the operating panel towards you until it locks.
ed.5
10 Scanner 401
3 Exposure lamp
1 Carry out dis-/assembly Scanner side covers on page 401. 2 Open the scanner. 3 Turn the exposure lamp 90 (out of locking position).
bracket
4 5 6 7 8 9 10 11 12
Remove he bracket and the cover of the lamp fitting. Remove at the left or right side the lamp fitting. Remove lamp to the left / right. Slide the new lamp carefully to the opposite side. Mount the lamp in the fitting. Mount on the other side the lamp in the fitting and turn the lamp 90 . Check adjustment Scanner exposure lamp on page 302. Assemble all covers. Carry out the SDS test 10-7-01TL intensity adjust on page 301.
402
TSM Oc 9800
Dis-/assemblies
4 Glass plate scan window

Carry out dis-/assembly Scanner side covers on page 401. Open the scanner. Remove the black plastic bearing holders from the upper output roller. Push the output roller to the rear. Remove on the left and right side the upper screw from the glass plate holder. Loosen on the left and right side the other screw from the glass plate holder. Push the glass plate to the rear and rotate the glass plate holder to the rear. Remove the glass plate. When mounting the glass plate holder, push the glass plate holder on the rear upwards, then to the front, now tighten the screws. Check if the glass plate is in line with the glass plate holder, so that the diaphragm of the glass plate is parallel with the gauge roller. 10 Carry out the SDS test 10-7-01TL intensity adjust on page 301.
1 2 3 4 5 6 7 8 9
Cleaning: Clean the glass plate with a towel soaked with water. Clean the gauge roller with cleaner A code no. 1068116.
ed.5
10 Scanner 403
5 Scan head (CCD unit)

From machine number 980100487 some items are dedicated to the EMC version of the scan head.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Open the scanner. Remove the screws from the scanner side covers (1 screw each side). Close the scanner. Remove the scanner side covers and disconnect the ground wires. Remove the lower rear cover of the scanner (1 screw at each side and 2 screws at the rear side). Lower the sensor plate by loosening 2 bolts and 1 taptite at both sides. Turn the exposure lamp 90 (out of locking position). Remove at both sides the lamp holder brackets (2 screws on each side). Remove the exposure lamp. Remove the two front covers besides the operating panel. Remove the 4 operating panel mounting screws. Swing the operating panel to the front. Disconnect 10 connectors and 1 earth wire from the operating panel. Remove the operating panel and place it on a flat surface with the display downwards. Open and remove the scanner centre top cover. Remove at the right the centre top cover bracket (including the distance bolts). Remove at the right the operating panel brackets (upper and lower). EMC version: loosen the bundles from the rear plate assy (3 cable ties). EMC version: remove the plate assy (4 x M4 taptite) to the rear. Remove the EMC protection covers from CCD PBA connectors. Disconnect the connectors from the CCD PBAs and move them to the rear. Remove at the right side the T-form scan head mounting bracket with bush (3 screws). Remove at the left side the 2 scan head mounting screws. Lift out the scan head, first at the right side. Mount the (new) scan head very carefully in the scanner frame. EMC version: while replacing the scan head, keep it left before lowering. EMC version: check if all lips of the sensor plate are in the correct position. EMC version: replace the plate assy, lift the front side. EMC version: check if all lips of the EMC scan head are in the correct position. EMC version: tighten the CCD bundles again to the plate assy with 3 cable ties. EMC version: check if at the right side (inside the top frame) the 3 plastic insulated bundles are fixed together with a cable tie to prevent damage by the fan blades.
404
TSM Oc 9800
Dis-/assemblies
32 Mount at the left side the 2 scan head mounting screws (do not tighten them). 33 Mount at the right side the T-form bracket and the 3 screws (do not tighten
them).
34 Push the scan head softly at the left and right side (at the same time) to the rear
and slightly downwards until it touches the bearing needle of the gauge roller.
35 Tighten the 2 screws at the left side first. 36 Push scan head at the right side softly to the rear and slightly downwards until
it touches the bearing needle.

37 Now tighten the 3 screws at the right side. Be sure that the scan head is mount38 39 40 41 42 43
ed without torsion. Check if the bracket of the scan head touches the gauge roller. Mount the lamp bracket at the right side. Mount the exposure lamp. Mount the left side lamp bracket. Remount the sensor plate in the upper position. Remount the operating panel and connect all connectors and the earth wire.
Note: while replacing the supply connectors and the EMC covers on the CCD PBA, support the PBA at the metal strip on the solder side. While replacing the EMC covers be aware of damaging electronic components.
44 45 46 47 48
Check adjustment Scanner exposure lamp on page 302. Remount all covers. Switch on the machine and carry out SDS test 41 (warm SDS). Carry out the SDS test 10-7-01, TL intensity adjust on page 301. Check the alignment of the CCD chips by making 3 copies of the service test original in landscape direction: 1. exposure setting 0 2. exposure setting -7 and automatic exposure off 3. exposure setting -7, automatic exposure off and stretch X-direction 100% and Y-direction 400% Especially pay attention to the diagonal lines on the copies. If there are interrupts in these or other lines, repeat the complete procedure.
ed.5
10 Scanner 405
406
TSM Oc 9800
Dis-/assemblies
1 General
The aim of the scanner function is to convert the information of the original into a digital form. The 3 different functions of the scanner are:
s s s
the original transport (see function 09 original handling) the light path the one line CCD.
2 The light path

The light path exposes the original and transfers the light to the CCD units. The light path consists of:
CCD2
partial mirror
exposure lamp
CCD 1 and 3
SLA
mirror (2x)
original direction
glass plate with diaphragm
gauge roller
ed.5
10 Scanner 501
Exposure lamp
The exposure lamp is a fluorescent lamp of 50 W. Light from the exposure lamp is projected by two mirrors on top of the original. The original is transported over the turning gauge roller and is exposed. The amount of reflected light depends on the kind of information on the original. White areas on the original will reflect light and dark areas will reflect no light. Grey areas will reflect less light than white areas. The reflected light is transported via the diaphragm, through the Self focusing Lens Array (SLA) to the partial mirror. The partial mirror is a special glass plate which reflects 50% of the light and transmits 50% of the light. The reflected light is used for CCD units 1 and 3 and the transmitted light is used for CCD unit 2.
Note: The SDS test TL intensity adjust (10-7-01) should be carried out after replacement of the exposure lamp, CCD unit, gauge roller or glass plate. The light output of the exposure lamp is adjusted to the optimum setting.
3 The one line CCD

The Charged Coupled Device (CCD) converts the detected light amount into an analogue voltage. The height of the analogue voltage is related to the light amount. The scanner of the Oc 9800 has 3 CCD PBAs. These PBAs are positioned in such a way that they cover a 1 pixel scanline at once. CCD PBA1 and 3 (positioned at the left and right-hand side) are positioned vertically and use the reflected light of the partial mirror and CCD PBA 2 (positioned in the middle of the scanner) uses the transmitted light of the partial mirror. Each CCD PBA contains 5 IC blocks. The IC blocks are 0.25 mm shifted and are positioned as follows: .....
CCD1 CCD2
.....
.....
.....
.....
0.25 mm
CCD3
Each block contains 960 pixels. In total 14.400 pixel will scan the total width of the original (914 mm E-size). The scanning resolution is 400 dots/inch (dpi) in both directions. One scanline has a width of approx. 0.064 mm
502
TSM Oc 9800
4 Block diagram data path

The data path block diagram describes the various data steps on the CCD PBA and SCANNER PROCESSING PBA.
CCD
The scanline consists of 3 identical CCD PBAs with in total 14.400 pixels.
Offset compensation
Every CCD PBA is equipped with some extra CCD pixels outside the scan range. These pixels are covered (dark pixel), and do not receive any light. Every pixel generates in the dark a DC voltage, which is not needed. The offset compensation compensates all pixels for this DC level.
Note: . The offset compensation is carried out when the machine is switched
on.
ed.5
10 Scanner 503
Adj. Amplifier
The adjustable amplifier amplifies the analog voltage to the optimum input range for the ADC. In this way the total range of the ADC is used. The adjustable amplifier is needed to compensate system tolerances of the 5 IC on each CCD PBA. The setting of the adjustable amplifier is based on the CCD information from the gauge roller. This is done during scanner calibration.
Note: The amplifier is adjusted after switching on the machine: Scanner is
being calibrated.
ADC
The ADC (Analog Digital Converter) converts the analog voltage into an 8 bit digital signal.
Multiplexing
To reduce the amount of electrical connections to the SCANNER PROCESSING PBA and to gain higher performance the data of the 3 ADC is multiplexed.
Interface
The interface function takes care of the transmission from and to the SCANNER PROCESSING PBA.
Staggering (on Scanner Processing PBA)
The staggering function is needed because the IC blocks on the CCD PBA are 0.25 mm shifted. It is necessary to compensate the scanned fractional lines to complete lines. The staggering compensation is not fixed because the original speed can vary between 25 and 100%. One scanline is approx. 0.064 mm and so a correction of 4 pixel lines takes place at an original speed of 100% (1: 1 magnification). A maximum of 16 pixel lines are corrected at an original speed of 25% (400% magnification).
504
TSM Oc 9800
Unevenness compensation (on Scanner processing PBA)
The unevenness compensation compensates for Differences in light output of the exposure lamp over the total width, tolerances in the reflected light of the gauge roller, s tolerances in the SLA (Self focusing Lens Array) and s variation in pixel sensitivity of the CCDs. The unevenness compensation is automatically carried out before the entrance of every original. The unevenness compensation acts as follows:
s s
The exposure lamp is switched on, the original motor is active and the gauge roller is turning. The light of the exposure lamp is reflected by the white gauge roller and is detected by each pixel of the CCD PBAs. The measured digital value for each pixel should have a value of225. If the value is lower e.g. 200, a compensation of +25 for this pixel is needed. If the value is higher e.g. 230, a compensation of -5 for this pixel is needed.
Note: The unevenness compensation (for each pixel) is automatically done at
the entrance of each original into the scanner. The compensation value (e.g. +25 (or -5)) is added to the actual pixel value (e.g. 150) during the scan of the original. The result is a new value of 175 (or 145)).The compensation value stays the same until a new original is entered. Now the digital information is available for further image processing functions on the SCANNER PROCESSING, SET/DOC MEMORY and B/W PBA. This is explained in the function 11 Image Processing.
ed.5
10 Scanner 505
5 Mixed power supply

The supply for the scanner is the MIXED POWER supply. The input voltage is approx. 400 V from the engine.
Warning: Switch off the mains supply before disconnecting the scanner supply
cable. Wait 2 minutes before disconnecting the scanner supply cable. The outputs of the MIXED POWER supply are:
s
s s
outputs: low voltage outputs +5V, +12V, +18V, +24V for the CCD PBAs and control panel. Lamp: power supply for the 50 W exposure lamp. Drivers: power supply for the original motor (ORGMO) and solenoid.
Exposure lamp
The exposure lamp is 50 W fluorescent lamp. The light output of the lamp can be regulated between 10 and 100% with the SCALAPWM signal.
506
TSM Oc 9800
SCALA
10PBA1 Scanner Proccessing PBA
ed.5
10 Scanner 601
10G1 Mixed Supply
602
TSM Oc 9800
22PBA8 Keypad 3
22PBA 2 CONSOLE CPU
2 1
10 PBA 5 CCD 3 10 PBA 4 CCD 2 10 PBA 3 CCD 1
ed.5
10 Scanner 603
604
TSM Oc 9800
1
ENGINE
2
22X1 k m e 10X1 k m e
5
X4 2 3 1
6
10PBA1 SCANNER PROC
11PBA1
X3 2 3 4
DLINK1 NDLINK1 GND
22G1 CONSUPLV
G5 1 2 3 SCA 400VDC SCA SCACONTROL L M K N 22X004 L M K N BOTTOM FRAME 10X13 TOP FRAME
10G1 MIXED SUPPLY

G1 2 3 4 1 G7 1 3 +5V GND X2 1 2
10PBA3 CCD1
G6 1 4 7 10 13 +5V GND +12V -12V +18V X2 4 5 2 3 1 X1 1 ..... 17 20 ..... 36 X6 1
TOP COVER LEFT 10X3 10X5 TOP COVER RIGHT 10X16 10X4 FRAME BRACKET 10X15 10X6 10X14 CONSOLE FRAME RIGHT COVER 10X8 10X7_1 10X9 FEED PLATE LEFT DOOR 10X10 10X11 10X7_2 LEFT COVER 10X7_3 10X12 REAR DOOR
..... CAPCCD1
34
10PBA4 CCD2
2 5 8 11 14 +5V GND +12V -12V +18V X2 4 5 2 3 1 X1 1 ..... 17 20 ..... 36 X7 1
..... CAPCCD2
BOTTOM FRAME
34
C
22PBA1 CPU I/O
X14 10 9 8 7 6 4 3 2 1 GND CONCTS CONNCTS CONNRXD CONRXD CONRTS CONNRTS CONNTXD CONTXD H T S V U W X Y Z H T S V U W X Y Z
10PBA5 CCD3
3 6 9 12 15 +5V GND +12V -12V +18V X2 4 5 2 3 1 X1 1 ..... 17 20 ..... 36 10E1 2 4 X8 1
..... CAPCCD3
34
G5 1 2
SCALA1 SCALA3 SCALA4 SCALA2
LAMP-FLU
1 3
D
22PBA2 CONSOLE_CPU
X10 5 6 8 7 1 2 4 3 11
3 4 G4 5
FROM SCANNER 487 +24V 10M1 1
SCAFAN1
M
10M1
10M2 1
SCAFAN2
M
10M2
GND
22PBA8 KEYPAD3
+5V +5V +5V +5V GND GND GND GND +12V +12V +12V +12V GND GND +12V +5V GND GND NRD3 NRD4 NWR3 NWR4 BNRESET KP3D0 KP3D1 KP3D2 KP3D3 KP3D4 KP3D5 KP3D6 KP3D7 KP3A1 KP3A2 KP3A3 KP3A4 INT3 +5V G2 1 2 3 4 7 8 9 10 15 16 17 18 11 12 F ORGSAFSW 3A X3 2 X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 X4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 GND SCASYNC_1 GND SCARECON_1 GND SCADA0-1 GND SCADA1-1 GND SCADA2-1 GND SCADA3-1 GND SCADA4-1 GND SCADA5-1 GND SCADA6-1 GND SCADA7-1 GND SCASYNC_1 GND SCARECON_1 GND SCADA0-2 GND SCADA1-2 GND SCADA2-2 GND SCADA3-2 GND SCADA4-2 GND SCADA5-2 GND SCADA6-2 GND SCADA7-2 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 X3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
E
TP1
TP0
TP2 TP3 TP4
X1 1 2 3 4 5 6 7 8 9 10 11 X3 1 2 3 X7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24
ORGSAFSW
F 3A G3 2 5 6 4 09S1 X2 2 5 6 X1 1 2 3 4 5 6 8 9 20 12 13 14 15 16 17 18 19 24 25 26 27 28 30 3 GND 1
SCALAPWM CONMIXINDIAG CONMIXOUTDIAG
TP5
ed.5
TSM Oc 9800
10 Scanner 701
Oc
Oc 9800
11 IMAGE PROCESSING
Contents
Diagnostics
1 Faults
101
SDS
1 IMage Processing
201
Dis-/assemblies
1 SIMM PBA on SET MEMORY PBA 401 2 Upgrade DOC MEMORY -> SET MEMORY 402
1 General 501 2 Scanner Processing PBA (10 PBA1) 3 DOC / SET memory 506 4 B/W Processing PBA 508
502
601
Diagrams
1 Image processing
701
ed.5
11 Image processing
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Image Processing 11000 - 11999 code display 11501 MRE: ~Failure BW_PROC -> PHD connect~
.
Possible cause
Remark
Failure data connection B/W PBA -> PHD DATA_RECEIVER PBA

If 11501 occurs together with 11904 / 11906 / 11907 / 11908 after IMP selftest 11-6-05 and NOT after power_up, than:
Connection 5 V supply connection DOC / SET_MEM PBA -> B/W PROCESSING PBA B/W PROCESSING PBA defect
If 11501 occurs together with 11904 / 11906 / 11907 / 11908 after power-up AND after IMP selftest 11-6-05, than:
Connection CPU_IO PBA -> DOC / SET_MEM PBA Connection DOC / SET_MEM PBA -> B/W PROCESSING PBA
If 11501 occurs together with 11904 / 11906 / 11907 / 11908 ONLY after IMP selftest 11-6-05 and NOT after power-up, than
Connection CPU_IO PBA -> B/W PROCESSING PBA
ed.5
11 Image processing 101
11901 SWAR: ~Failure PBA SCANNER_PROC~
If switching machine off and on again does not solve the problem, than SCANNER_PROCESSING PBA is defect
11902 SWAR: ~Controller -> engine taxi failure~
Detection not implemented yet
11903 SWAR: ~Failure scanner -> engine taxi link~
11904 SWAR: ~Failure PBA DOC_MEM / SET_MEM~

DOC_MEM / SET_MEM PBA defect
If 11904 occurs together with 11501 / 11906 / 11907 / 11908 after IMP selftest 11-6-05 (NOT after power-up) OR together with 11906 / 11907 / 11908 after power-up, than
Connection 5 V supply DOC / SET_MEM PBA -> B/W_PROCESSING PBA B/W_PROCESSING PBA defect
If 11904 occurs together with 11906 / 11907 after power-up OR IMP selftest 11-6-05 than
Configuration DOC / SET_MEM PBA not correct DOC / SET_MEM PBA defect
Check with test 90
102
TSM Oc 9800
Diagnostics
If 11904 occurs together with 11501 / 11906 / 11907 / 11908 after power-up AND after IMP selftest 11-6-05, than
Connection CPU_IO PBA -> DOC / SET_MEM PBA Connection DOC / SET_MEM PBA -> B/W PROCESSING PBA
Connection CPU_IO PBA -> B/W PROCESSING PBA
11905 SWAR: ~Set memory TAXI error~
11906 SWAR: ~SIMM failure~
Possible cause
Remark
Bad contact SIMM module on DOC / SET_MEM PBA Connection CPU_IO PBA -> DOC / SET_MEM PBA If 11906 after power-up ONLY
If 11906 occurs together with 11501 / 11904 / 11907 / 11908 after IMP selftest 11-6-05 OR together with 11904 / 11907 / 11908 after power-up, than
Connection 5 V supply DOC / SET_MEM PBA -> B/W_PROCESSING PBA
ed.5
Possible cause
Remark
B/W_PROCESSING PBA defect
If 11906 occurs together with 11904 / 11907 after power-up OR IMP selftest 11-6-05, than
Check with test 90
Connection CPU_IO PBA -> DOC / SET_MEM PBA Connection DOC / SET_MEM PBA -> B/W_PROCESSING PBA
Connection DOC / SET_MEM PBA -> B/W_PROCESSING PBA
11907 SWAR: ~MEM -> B/W PROC connection failure~
104
TSM Oc 9800
Diagnostics
Possible cause
Remark
Connection DOC / SET_MEM PBA -> B/W_PROCESSING PBA
If ONLY 11907 after power-up and NOT after IMP selftest 11-6-05
If 11907 occurs together with 11501 / 11904 / 11906 / 11908 after IMP selftest 11-6-05 (and NOT after power-up) OR together with 11904 / 11906 / 11908 after power-up, than
If 11907 occurs together with 11904 / 11906 after power-up OR after IMP selftest 11-6-05, than
Possible cause
Remark
Check with test 90
Connection CPU_IO PBA -> DOC / SET_MEM PBA Connection DOC / SET_MEM PBA -> B/W_PROCESSING PBA
Connection CPU_IO PBA -> B/W_PROCESSING PBA
11908 SWAR: ~Failure Black / White PBA warning~
ed.5
Possible cause
Remark
B/W_PROCESSING PBA defect
If 11908 occurs together with 11501 / 11904 / 11906 / 11907 after IMP selftest 11-6-05 (and NOT after power-up) OR together with 11904 / 11906 / 11907 after power-up, than
Connection CPU_IO PBA -> DOC / SET_MEM PBA DOC / SET_MEM PBA -> B/W_PROCESSING PBA
Connection CPU_IO PBA -> B/W_PROCESSING PBA
106
TSM Oc 9800
Diagnostics
11909 SWAR: ~CPU -> BW_PROC connection failure~
Possible cause
Remark
Connection CPU_IO PBA -> B/W_PROCESSING PBA B/W_PROCESSING PBA defect If ONLY 11909 after power-up and NOT after IMP selftest 11-6-05
11910 SWAR: ~CPU I/O-> DOC / SET MEM connection fail~
Possible cause
Remark
Connection CPU_IO PBA -> DOC / SET_MEM PBA
If ONLY 11910 after power-up and NOT after IMP selftest 11-6-05
11911 SWAR: ~CPU -> SCAN PROC connection fail.~

Connection KEYPAD_3 PBA -> SCA_PROCESSING PBA
11912 SWAR: ~ SCAN PROC CPU connection fail~
Possible cause
Remark
Connection SCA_PROCESSING PBA -> KEYPAD_3 PBA
ed.5
108
TSM Oc 9800
Diagnostics
SDS
1 IMage Processing
see SDS
31
see SDS
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr.
Component
Signal
Description
11-6-05 ~Self test image processing~
Test to check the functioning of the ~Scanner Processing PBA, SET/DOC Memory PBA and Black/White PBA.
System tests
202
TSM Oc 9800
SDS
Dis-/assemblies
1 SIMM PBA on SET MEMORY PBA
To change or add RAM SIMM modules proceed as follows:
1 2 3 4 5 6
Remove the right hand side covers. Disconnect the cable to the controller (to Host and to Printer) (if available). Remove the controller (if available). Remove the cover of the SET MEMORY PBA. Uncouple and remove the faulty SIMM PBA. Place the SIMM PNRAM module.
Note: Start with the first SIMM module always in slot D1.
7 8 9 10
Close the cover. Connect the controller (if needed). Check and adjust the configuration with SDS 90 ~Configuration~. Carry out SDS test 11-6-05 (~Self test image processing~) to check the functioning of the new SIMM. Test if printer produces copies with wallpaper.
Set the configuration to the lowest possible memory (36 MB). Place 2 SIMMs in the first 2 slots of the Setmem PBA. Switch auto exposure on the operator panel off. Set the manual exposure to -7. Make a set of 2 times 3 copies with the Oc test original (portrait). Check the copies for wallpaper. If wallpaper appears then one or both SIMMs are corrupt and have to be replaced. 8 If not then the SIMMs are correct. 9 Repeat the test if necessary for each SIMM module.
1 2 3 4 5 6 7 Note: If the test does not solve the problem fill in the questionnaire and send it
with wallpaper samples via your local coordinator to SPS-ES Venlo.
ed.5
2 Upgrade DOC MEMORY -> SET MEMORY

1 2 3 4 5 6 7 8
Remove the right hand side covers. Disconnect the cable to the controller (to Host and to Printer) (if available). Remove the controller (if available). Remove the cover of the DOC MEMORY PBA. Remove the DOC MEMORY PBA. Mount the SET MEMORY PBA. Check the configuration of the new SET MEMORY. Place (if needed) the SIMM PBAs.
Note: Start with the first SIMM module always in slot D1.
9 Close the cover. 10 Adjust the configuration with SDS test 90 ~Configuration~. 11 Carry out SDS test 11-6-05 (~Self test image processing~) to check the func-
tioning of the new memory.
402
TSM Oc 9800
Dis-/assemblies
Questionnaire
NR Question Answer
1 2 3 4 5
What kind of machine and which configuration? What is the version of the engine / scanner software? What kind of controller and which version?
9700 / 9800 Configuration: Version: EPC / FBBS / DRI Version:
What is the version of the PAS / Repro Desk soft- Version: ware? What kind of SIMMs are used in the controller (brand name / size)? Bank 1: Bank 2: Bank 3: Bank 4: Bank 5: Bank 6: Bank 7: Bank 8:
What kind of SIMMs are used in the engine (brand Bank 1: name / size)? Bank 2: Bank 3: Bank 4: Bank 5: Bank 6: Bank 7: Bank 8: Is the wallpaper reproduceble? Yes / No (if yes, describe how it can be reproduced as additional information) Every hour / day / week / month / year ...... wallpapers Whole copy/print / The middle of copy / print / The end or start of the copy / print
8 9
How often is wallpaper produced? Which part of the copy / print is wallpaper?
10 11 12 13 14
Which percentage of the copy / print is wallpaper? About ...... percent Is it a blank wallpaper? Was it during a copy-job or print-job? Yes / No Copy-job / Print-job
Was this the only copy / print with wallpaper in the Yes / No job? Was it sort by set or sort by page? Sort by set / Sort by page
ed.5
15 16 17 18 19 20 21 22 23
What kind of job was it?
Matrix job / Normal job / Bypass job / Interrupt job
Was the copy / print with wallpaper the first / last First / Last / In-between or an in-between copy / print of the job? Were there more copies / prints with wallpaper of There were ..... wallpapers of ..... the same original/file? originals / files If there were more copies / prints with wallpaper Yes, No........................ of the same originals / files, are they all the same? Was there a switch from a copy-job to a print-job Yes / No Print-job to copy-job / or vice-versa? Copy-job to print-job Was there a set-memory-full warning short before Yes / No or after the wallpaper appeared? What percentage of the set-memory was full? About ..... percent
Was there a controller reset or a TAXI board reset? No / Controller reset / TAXI board reset Was there an error or warning message (accessible No / Yes with SDS)? The message was:
404
TSM Oc 9800
Dis-/assemblies
1 General
The aim of the image processing function is to create: s a good copy quality s a retention function s an editing function. s a zoom function The image processing function takes care of a good copy quality for most types of originals. Nearly independent to the quality of the original e.g. opaque or diazo, the output quality should be at a high level.
The image processing functions take place on the following PBAs:
On the next pages the image processing functions of the Scanner Processing PBA, DOC/SET memory and B/W (Black and White) Processing PBA are described.
ed.5
2 Scanner Processing PBA (10 PBA1)

The digital information (14400 pixels /line from the CCDs) with 256 grey values from the scanner is the input for the image processing function. The following functions are available on the Scanner Processing PBA:
s s s s s
Scanner buffer Enlargement (width direction) ABC (automatic background compensation) Filtering Error diffusion
Block diagram
CCD information from scanner process ing PBA
Scanner buffer / invert blue print
Enlargement
ABC Automatic Background Compensation
8b/ pixel Filtering Error diffusion
1b/ pixel
to DOC / SET memory
Scanner buffer
The scanner buffer is used to temporarily store the incoming information. If the original is a blue print (selected in key operator mode) the information is inverted.
Enlargement
At this position in the image processing enlargement in the width direction is carried out. Enlargement in the length direction is already achieved by a lower speed of the original.
502
TSM Oc 9800
ABC (Automatic Background Compensation)
The ABC makes sure that background on the copy is eliminated without loss of information. Every 4th scan line of the scanner the ABC is evaluating the information. Each pixel has a grey value (between 0 and 225). The ABC counts the number of pixels with the same grey value in the scan line. The grey value with the highest number of pixels is the background level. Grey values below the background level are deleted and only the darker information is printed. Every next 4th scan line of the original is checked by the ABC and if necessary the background level is adjusted again.
Note: If the background on the original is fluctuating too much, e.g. a map with a lot of green areas, light blocks might appear over the total width of the copy. Solution: switch off the ABC to receive a copy with even background. Filtering
Filters are used to emphasize specific information. The image quality is improved. Weak lines or areas (low contrast) (see line A and area C) are emphasized in normal mode. The result for area C is a visible darker border around the surface. Normal information (B) is kept at the same level and is not involved.The output after filtering is 8bit/pixel.
input
optical density A B C 1 scanline output
background level
optical density background level
1 scanline
ed.5
Error diffusion
The error diffusion function converts the 8bit / pixel information (256 grey values) into a 1 bit / pixel information (black or white). It transforms the grey values between the min. and max. value into a black or a white pixel Normal mode
Pixel White
+7
-7
Black min. value e.g 80 max. value e.g.190 grey value 255
If the grey value is below the minimum value, it is converted into a black pixel on the copy. If the grey value is above the maximum value, it is converted into a white pixel on the copy. If the grey value is between the minimum and maximum value, the error diffusion has to decide if the pixel becomes white or black. In this case also the information (grey value) of the pixel in the previous line and the pixel beside the pixel are used for the judgement whether the pixel becomes white or black. The judgement results also the prevention of Moir effects.
Lighter / Darker button (+7 / -7): The lighter /darker button function is also incorporated in the error diffusion function. The lighter/darker button changes the position (value) of the maximum value. More or less grey values are changed into white pixels.
504
TSM Oc 9800
Dark mode
Pixel White
+7
-7
Black min. value e.g 80 max. value e.g 160 grey value
255
If the operator selects the dark mode the max. value is reduced from 190 to e.g. 160. The influence on the copy is that weak information or background is changed into white pixels and a smaller range (between min. and max. value) of grey scales on the copy. Photo mode
Pixel White
+7
-7
Black min. value e.g 50 max. 255 value e.g. 190 grey value
If the operator selects Photo mode the minimum value is changed from 80 to e.g. 50. The influence on the copy is a smaller dark pixel range and a larger range for grey values on the copy.
ed.5
3 DOC / SET memory

The function of the DOC/SET memory is to eliminate the need to repeat feeding of originals in the scanner. The digital information of the scanned original is used to make several prints of one original (DOC memory), or even to create sets of copies (SET memory).
DOC memory
Doc(ument) memory can store one scanned original of maximum A0 or E size, for multiple copying. Single copying of a longer original is also possible. The DOC memory is 36 Mbyte SIMM (2 x 18Mbyte) and is not adjustable. The size of an A0(E) size is approx. 32 (36) Mb). The data stored in the DOC memory is never compressed.
SET memory
SET memory can store a set of scanned originals for multiple copying. The number of originals that fits into the SET memory depends on:
s s s s
the size of the original the amount of information on the original the compression factor the size of the SET memory itself
Originals with smaller or larger black/white areas are compressed. The compression factor is not fixed and depends on the information on the original. With a compression factor of e.g. 10, an A0(E) size is reduced to 3.2 (3.6) Mbyte. The SET memory is available as a 36 Mbyte, 72 Mbyte, 108 Mbyte or 144 Mbyte configuration. The SIMMs are mounted on the SET memory PBA.
506
TSM Oc 9800
Capacity Set memory
Memory
Capacity
36 Mbyte Set Memory 72 Mbyte Set Memory 108 Mbyte Set memory 144 Mbyte Set memory
5-15 A0 / E or 25 mixed sizes (A4..A0,7%density) 15-30 A0 / E or 50 mixed sizes(A4..A0,7% density) 30-45 A0 / E or 75 mixed sizes(A4..A0,7%density) 45-60A0/E or 100 mixed sizes(A4..A0,7%density)
ed.5
4 B/W Processing PBA

The following editing functions take place on the B/W (Black and White) PBA: s Reduction s Stamp s Error diffusion s Buffer s Editing function s B/W post processing
1 bit / pixel Reduction from SET / DOC MEMORY PBA
8 bit / pixel
1bit / pixel Stamp Error diffusion
Buffer
Editing functions
B/W post processing to printhead PBA
horizontal position PHD
508
TSM Oc 9800
Reduction
The reduction of the black and white image information in length and width direction is the first action on the B/W PBA. A pixel area of e.g. 4 x 4 pixels and a reduction factor of 25% is reduced to 1 pixel. The new pixel will have a grey value between 0 and 255 (= 8 bit / pixel).
25% reduction 4 x4 pixels black or white
grey value 0...255
Stamp
After reduction the stamp is added to the digital image. The stamp is available in several grey values as well as in black.
Error diffusion
The same error diffusion function (without the lighter/darker function) as on the Scanner Processing PBA is used (seeScanner Processing PBA (10 PBA1) on page 502) to decide whether the grey value of a pixel has to be converted into a black or white pixel. The output is a 1bit/pixel information
Buffer
The buffer on the B/W processing PBA takes care of speed fluctuations on the PBA. The incoming and outgoing speed is not influenced.
Editing function
The various editing functions like erase and image shift in the key operator mode, are carried out in this block. The horizontal positioning of the information (needed because the rolls of copy material are not in the centre of the spool (only A0/E size are in the centre position) is done in this part of the image processing.
ed.5
B/W post processing
The B/W post processing knows a certain amount of regular patterns and adjusts irregular patterns to these regular patterns.
s s
A pixel line with a missing pixel changes into a complete pixel line (A). A line under 45 degrees with a missing pixel is converted in a complete line (B). A single pixel changes into 2 pixels (C) (to make it visible).
input A output
Note:
The image processing function can be tested by using SDS test 11-6-05 Self test image processing. This test checks: - the communication between the image processing PBAs and the CPU I/O PBA - the communication between SET / DOC memory PBA and the B / W processing PBA. - the data transfer between these PBAs. There is no check on the data transfer from the Scanner Processing PBA and SET/DOC memory PBA.
510
TSM Oc 9800
10PBA1 SCANNER PROC.
ed.5
11PBA2 B/W PROC PBA
11PBA1 DOC Memory or 11PBA1 SET Memory
602
TSM Oc 9800
1
FROM ENGINE 484
2
11PBA5 RFI
X1 1 2 X2 1 2 X5 4 3
3
11PBA1 DOCUM. MEMORY OR 11PBA1 SET MEMORY (OPTIONAL B860)
X5 1 2 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 +5V GND GND MEM_PAGE GND MEM_LINE GND MEM_VALID GND RED_NEXT_PIX GND SPA_NEXT_LINE GND RED_CLK40A GND RED_CLK20A GND RED_CLK40B GND RED_CLK20B GND MEM_DATAE0 MEM_DATAE1 MEM_DATAE2 GND MEM_DATAE3 MEM_DATAO0 GND MEM_DATAO1 MEM_DATAO2 MEM_DATAO3 GND IMPRECON GND MEM_RING_SYNC GND MEM_RING_D0 MEM_RING_D1 MEM_RING_D2 MEM_RING_D3 GND MEM_RING_D4 MEM_RING_D5 MEM_RING_D6 MEM_RING_D7 GND X4 1 2
4
11PBA2 BW PROCESSING
X3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 SD_NEG8 SD_POS8 SD_NEG7 SD_POS7 SD_NEG6 SD_POS6 SD_NEG5 SD_POS5 SD_NEG4 SD_POS4 SD_NEG3 SD_POS3 SD_NEG2 SD_POS2 SD_NEG1 SD_POS1 GND GND CLOCK_NEG CLOCK_POS GND GND LOAD_NEG LOAD_POS GND GND STB_NEG STB_POS
5
X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
6
04PBA1 PHD DATA RECEIVER
22G1 CONSUPLV
G3 5 6
+5V GND
RFI POWER 2x connector for printer only 22X1 k m e X3 2 3 4
10PBA1 SCANNER PROC

X4 2 3 1 DLINK1 NDLINK1 GND 10X1 k m e
11D1
EXT. MEMORY-1
11D2
EXT. MEMORY-2
OPTIONAL B860 20D1 CONTROLLER

D3 1 2 4 5 8 6 GND DLINK2 NDLINK2 GND +5V RESET CAPDL X4 1 2 3 4 5 6
11D3
EXT. MEMORY-3
11D4
EXT. MEMORY-4
11D5
D4 1 2 4 5 8 6
GND DLINK_OUT NDLINK_OUT GND +5V RESET CAPUL
X14 1 2 3 4 5 6
EXT. MEMORY-5
11D6
EXT. MEMORY-6
11D7
EXT. MEMORY-7
11D8
EXT. MEMORY-8
D
FROM ENGINE 484
22PBA1 CPU I/O

X15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GND IMPSYNCO IMPRECONO IMPDA0O IMPDA1O GND IMPDA2O IMPDA3O GND IMPDA4O IMPDA5O GND IMPDA6O IMPDA7O GND
11PBA4 RFI
X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
TEST BW CAP_0401X1
11PBA3 RFI
X16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GND IMPSYNCI IMPRECONI IMPDA0I IMPDA1I GND IMPDA2I IMPDA3I GND IMPDA4I IMPDA5I GND IMPDA6I IMPDA7I GND X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
H
ed.5 TSM Oc 9800 11 Image processing 701
RFI SIGNAL 15x
RFI SIGNAL 15x
Oc
Oc 9800
12 PAPER ROLL DRAWERS
Contents
Diagnostics
1 Faults
101
SDS
1 Paper Roll Drawers
201
Adjustments
1 Straightness cutting of the paper 301 2 Straightness leading edge margin 304 3 ~Offset cutting length PRDU~ 307 4 ~Offset cutting length PRDL~ 308 5 ~PRD leading edge correction~ 309 6 Size label 310
Dis-/assemblies
1 Paper roll drawers 401 2 Vertical transport paper roll drawers 402 3 Feed rollers roll 1 / 3 402 4 Feed rollers roll 2 / 4 403 5 Roll feed motor 403 6 Knife unit 404 7 PRD(U/L)KNIMO (Paper Roll Drawer Upper/Lower KNIfe MOtor) 404 8 PRD(U/L)FEDOPSE (Paper Roll Drawer Upper/Lower FEed OPosite SEnsor) 405 9 PRDUWIDSE (Paper Roll Drawer Upper WIDth SEnsors) 405 10 PRD(U/L)LEADSE (Paper Roll Drawer Upper/Lower LEADing edge SEnsor) 405 11 PRD(U/L)LENSE (Paper Roll Drawer Upper/Lower LENgth SEnsor 406 12 PRD(U/L)PRESE 1 / 3 (Paper Roll Drawer Upper/Lower PREsent SEnsor) 406 13 PRD(U/L)PRESE 2 / 4 (Paper Roll Drawer Upper/Lower PREsent SEnsor) 406
ed.5
12 Paper roll drawers
1 General 501 2 Roll feed system 502 3 Knife 504 4 Length measurement 504 5 Roll width detection 505 6 Chip tray 506 7 Paper through feed 507 8 Roll selection 507 9 End of roll 507 10 Securities 508
1 Component location 601 2 Roll feed 604 3 Feed motor control 605
Diagrams
1 Paper roll drawer lower 701 2 Paper roll drawer upper 702
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Paper Roll Drawers 12000 - 12999 code display 12101, 12102, 12103, 12104 PE: ~Paper feeding: PRD(U/L)PRESEn not act.~ 12501, 12502, 12503, 12504 MRE: ~Paper feeding: PRD(U/L)PRESEn not act~
12-2-07 / 12-2-08 Possible cause 12-2-28 / 12-2-29 PRD(U/L)RUNSEn Remark
Continuously ON
PRD(U/L)RUNSEn defect Connection PRD(U/L)RUNSEn -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect (disconnect 2201X7 or 2201X10)
12-2-05 / 12-2-06 Possible cause 12-2-26 / 12-2-27 PRD(U/L)PRESEn
Remark
Continuously OFF
PRD(U/L)PRESEn defect Actuator defect Connection PRD(U/L)PRESEn -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA
ed.5
12 Paper roll drawers 101
12105, 12107 PE: ~Too long/late at PRD(U/L)KNIPOSSE~ 12505, 12507 MRE: ~Too long/late at PRD(U/L)KNIPOSSE~
12-2-01 Possible cause 12-2-22 PRD(U/L)KNIPOSSE Remark
Continuously ON / OFF when turning pulse disc
PRD(U/L)KNIPOSSE defect Pulse disc defect Connection PRD(U/L)KNIPOSSEn -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect
12-2-02 12-2-23 PRD(U/L)KNIMOSE
Possible cause
Remark
Continuously ON when turning pulse disc
PRD(U/L)KNIMOSE defect Pulse disc defect Connection PRD(U/L)KNIMOSEn -> PRD(U/L)DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect (disconnect 2201X7 or 2201X10)
102
TSM Oc 9800
Diagnostics
12-6-09 12-6-10 PRD(U/L)KNI MOnPWM
CONDRI- Knife OUTDIAG turning (100% PWM) OFF (disconnect 2205X1) No
Possible cause
Remark
ON (100% PWM)
DRIVERS PBA defect PRD(U/L)KNIMO defect / mech. blocked F2 DRIVERS PBA defect
ON (disconnect 2205X1)
Connection DRIVERS PBA -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> PRD(U/L)KNIMO
12106, 12108 PE: ~Wrong knife position after cut~ 12506, 12508 MRE: ~Wrong knife position after cut~
12-2-01 Possible cause 12-2-22 PRD(U/L)KNI POSSE
Remark
Continuously ON when turning pulse disc
PRD(U/L)KNIPOSSE defect Pulse disc defect Connection PRD(U/L)KNIPOSSEn -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect (disconnect 2201X7 or 2201X10)
ed.5
12-2-02 12-2-23 PRD(U/L) KNIMOSE
Possible cause
Remark
Continuously OFF when turning pulse disc
PRD(U/L)KNIMOSE defect Pulse disc defect Connection PRD(U/L)KNIMOSEn -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect
12-6-09 CONDRI Knife OUTDIAG turning 12-6-10 (100% PWM) PRD(U/L) KNIMOPWM
Possible cause
Remark
OFF
Yes
DRIVERS PBA defect Mechanical defect knife stop
ON ON (100% PWM)
104
TSM Oc 9800
Diagnostics
12109, 12110 PE: ~Direction failure: PRD(U/L)FEDMODIRDE~ 12509, 12510 MRE: ~Direction failure: PRD(U/L)FEDMODIRDE~
~
12-6-05 12-6-06 PRD(U/L) FEDMOn
PRD(U/L)FED PRD(U/L)FEDMO turning in the MODIRDE right
Possible cause
Remark
direction BACKWARD FORWARD No DRIVERS PBA
Forward normal speed Backward normal speed Backward normal speed
FORWARD
Yes
Connection PRDU/LFEDMODIRDE -> CPU_IO PBA CPU_IO PBA defect
FORWARD disconnect 2201X6
12111, 12112, 12113, 12114 PE: ~Speed PRD(U/L)FEDMOn too high~ 12515, 12516, 12517, 12518 MRE: ~Speed PRD(U/L)FEDMOn too high~
12-6-05 CONDRI PRD(U/L) Possible cause 12-6-06 OUTDIAG FEDMOn turning PRD(U/L)FEDMOn (100%
Remark
PWM) ON
OFF
Yes
DRIVERS PBA defect
12501, 12502, 12503, 12504 MRE: ~Paper feeding: PRD(U/L)PRESEn not act~ on page 101 12505, 12507 MRE: ~Too long/late at PRD(U/L)KNIPOSSE~ on page 102 12506, 12508 MRE: ~Wrong knife position after cut~ on page 103 12509, 12510 MRE: ~Direction failure: PRD(U/L)FEDMODIRDE~ on page 105
ed.5
12511,12513 MRE: ~Time out length measure PRD(U/L)LENSE~
Possible cause
Remark
Wheel PRD(U/L)LENSE polluted / slipping Pulse disc defect PRD(U/L)LENSE defect Connection PRD(U/L)LENSE -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect
12512, 12514 MRE: ~Too few pulses PRD(U/L)LENSE~
12-2-04 12-2-25 PRD(U/L)LENSE
Possible cause
Remark
Continuously ON Wheel PRD(U/L)LENSE blocked when turning pulse Pulse disc defect disc Receiving material fixed on paper roll core PRD(U/L)LENSE defect CPU_IO PBA defect (disconnect 2201X7 or 2201X10) Continuously OFF Wheel PRD(U/L)LENSE blocked when turning pulse Pulse disc defect disc Receiving material fixed on paper roll core PRD(U/L)LENSE defect Connection PRD(U/L)LENSE -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect
106
TSM Oc 9800
Diagnostics
12701, 12702, 12703, 12704 ORE: ~Sheet too late at PRD(U/L)LEADSE~
12-2-03 12-2-24 PRD(U/L)LEADSE
Possible cause
Remark
Continuously OFF
PRD(U/L)LEADSE defect Actuator defect Connection PRD(U/L)LEADSE -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> CPU_IO PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect
12-6-05 12-6-06 PRD(U/L)F EDMOn
CON- PRD(U/L) Possible cause DRIFEDMOn OUTDI turning AG (100%) ON No PRD(U/L)FEMOn mechanical blocked Friction clutch paper roll core defect PRD(U/L)FEDMOn defect OFF DRIVERS PBA defect
Remark
ON (100% PWM)
Possible cause
Remark
Humid receiving material Paper fixed on the paper roll core One way bearing vertical transport defect Knife not cutting correctly Wheel PRD(U/L)LENSE blocked
to be continued
ed.5
continued
12-4-02 PRDSTRACL CONDRI OUTDIAG
Vertical trans- Possible cause port functioning when loading paper SERVICE COPY MODE No DRIVERS PBA defect PRDSTRACL defect Connection DRIVERS PBA Toothed belt PRDS defect Toothed belt MADMO loose / defect
Remark
ON
OFF ON
12705, 12706, 12707, 12708 ORE: ~PRD(U/L)LEADSE too late free~
12-2-03 Possible cause 12-2-24 PRD(U/L)LEADSE
Remark
Continuously ON
PRD(U/L)LEADSE defect Actuator defect CPU_IO PBA defect (disconnect 2201X7 or 2201X10)
23-4-01 MADMO
Input roller PREHE turning No
Possible cause
Remark
ON
Pulley / one way bearing input roller defect
Possible cause
Remark
Paper fixed on the paper roll core Knife not cutting correctly
108
TSM Oc 9800
Diagnostics
12709, 12710, 12711, 12712 ORE: ~Speed PRD(U/L)FEDMOn too low~
12-6-07 12-6-08 PRD(U/L)FED MOSE
Possible cause
Remark
Continuously OFF when moving pulse disc
PRD(U/L)FEDMOSEn defect Pulse disc defect Connection PRD(U/L)FEDMOnSE -> PRD(U/L) DISTRIBUTION PBA Connection PRD(U/L) DISTRIBUTION PBA -> DRIVERS PBA Connection DRIVERS PBA -> CPU_IO PBA
12-6-05 CONPRD(U/L) Possible cause 12-6-06 DRIOUT- FEDMOn turning PRD(U/L)FEDMOn DIAG
Remar k
ON (100% PWM)
ON
No
PRD(U/L)FEDMOn blocked (customer) Friction clutch paper roll core defect PRD(U/L)FEDMO defect
OFF
DRIVERS PBA defect
ed.5
12713 ORE: ~Sheet too late at PRDSSYNSE~

~
12-2-34 Possible cause PRDSSYNSE
Remark
Continuously OFF
Connection PRDSSYNSE -> CPU_IO PBA PRDSSYNSE defect Actuator defect CPU_IO PBA defect
12-4-01 PRDUSAMP SO
Possible cause CONDRIOUTDIAG
Remark
OFF
ON
Connection DRIVERS PBA -> PRDUSAMPSO DRIVERS PBA defect
ON
PRDUSAMPSO blocked / defect
Possible cause
Remark
Knife not cutting correctly
12-4-02 PRDS TRACL
CONDRIOUTDI AG OFF ON
Vertical trans- Possible cause port functioning when loading paper SERVICE COPY MODE No DRIVERS PBA defect PRDSTRACL defect Connection DRIVERS PBA Toothed belt PRDS defect Toothed belt MADMO lose / defect
Remark
ON
110
TSM Oc 9800
Diagnostics
12714 ORE: ~PRDSSYNSE too late free~

~
Remark
Continuously ON
PRDSSYNSE defect Actuator defect CPU_IO PBA defect (disconnect 2201X8)
12-4-02 CONDRI- Vertical PRDSTRACL OUTDIAG transport
Possible cause
Remark
functioning when loading paper SERVICE COPY MODE DRIVERS PBA defect PRDSTRACL defect Connection DRIVERS PBA -> PRDSTRACL Toothed belt vertical transport defect Toothed belt MADMO lose / defect Yes One way bearing input roller PREHE defect Pulley input roller PREHE lose
ON
OFF ON
No
ed.5
12715 ORE: ~Chip at PRDSSYNSE after error~ 12716 ORE: ~PRDSSYNSE active during chipping~
Remark
Continuously ON
12-4-01 CONDRI- Possible cause PRDUSAMPSO OUTDIAG
Remark
OFF
ON
Connection DRIVERS PBA -> PRDUSAMPSO DRIVERS PBA defect
ON
PRDUSAMPSO blocked / defect
12717 ORE: ~PRDUWIDSE 1-9 act. before start chipping~
12-2-13 up to 12-2-22 Possible cause PRDUWIDSE 1-9
Remark
Continuously ON
PRDUWIDSEn defect Actuator defect CPU_IO PBA defect (disconnect 2201X7)
112
TSM Oc 9800
Diagnostics
12718, 12719 ORE: ~Chip: PRD(UL)LEADSE too late at / free~
12-2-03 Possible cause PRD(U/L) LEADSE
Remark
Continuously ON
PRD(UL)LEADSE defect Actuator defect CPU_IO PBA defect (disconnect 2201X7)
Continuously OFF
PRD(UL)LEADSE defect Actuator defect Connection PRD(UL)LEADSE -> PRD(U/L) DISTRIBUTION PBA Connection PRD(UL) DISTR. PBA -> CPU_IO PBA Connection PRD(UL) DISTR. PBA -> DRIVERS PBA
CPU_IO PBA defect
Possible cause
Remark
Humid or bad receiving material Environment temperature too low overnight Toothed belt PRDS defect Min. 17 C (62.6 F)
ed.5
114
TSM Oc 9800
Diagnostics
SDS
1 Paper Roll Drawers
Test nr Component Signal Description
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr
Component
Signal
Description
Parameter test 12-1-01 ~Offset cutting length PRDU mm/10~
Adjustment of the cutting moment from the upper paper roll drawer (range -200 - +200, default 0, mm/10)
12-1-02 ~Offset cutting length PRDL mm/10~
Adjustment of the cutting moment from the upper paper roll drawer (range -200 - +200, default 0, mm/10)
12-1-03 ~PRD leading edge correction mm/10~
Adjustment of leading edge margin (range 0 -200, default 0, mm/10)

12-1-04 ~PRD Knife speed~
Adjustment of speed of the knife (range 10.000 - 14.000, default 10.780)

Input tests 12-2-01 12-2-02 12-2-03 12-2-04 12-2-05 12-2-06 12-2-07 12-2-08 12-2-09
12B17 12B1 12B2 12B7 12B3 12B4 12B5 12B6 12S1
PRDU KNIfe Paper roll drawer upper knife position sensor POSition SEnsor ON = knife not in home position PRDU KNIfe MOtor SEnsor PRDU LEADing SEnsor Paper roll drawer upper knife motor sensor ON = sensor blocked by pulse disc Paper roll drawer upper leading edge sensor ON = paper present
PRDU LENgth Paper roll drawer upper length sensor SEnsor ON = sensor blocked by pulse disc PRDU PREsent Paper roll drawer upper present sensor 1 SEnsor 1 ON = no paper present roll 1 PRDU PREsent Paper roll drawer upper present sensor 2 SEnsor 2 ON = no paper present roll 2 PRDU RUN SEnsor 1 PRDU RUN SEnsor 2 PRDU OPen SWitch Paper roll drawer upper run sensor 1 ON = roll 1 not empty Paper roll drawer upper run sensor 2 ON = roll 2 not empty Paper roll drawer upper open switch ON = upper drawer open
202
TSM Oc 9800
SDS
Test nr 12-2-10 12-2-11 12-2-12 12-2-13 12-2-14 12-2-15 12-2-16 12-2-17 12-2-18 12-2-19 12-2-20 12-2-21 12-2-22 12-2-23 12-2-24 12-2-25 12-2-26
Component
Signal
Description
12B31 12PBA2 12PBA2 12B8 12B9 12B10 12B11 12B12 12B13 12B14 12B15 12B16 12B25 12B18 12B19 12B24 12B20
PRDU FEeD Paper roll drawer upper feed opposite sensor OPposite SEnsor ON = unit positioned PRDU FEeD SWitch 1 PRDU FEeD SWitch 2 PRDU WIDth SEnsor 1 PRDU WIDth SEnsor 2 PRDU WIDth SEnsor 3 PRDU WIDth SEnsor 4 PRDU WIDth SEnsor 5 PRDU WIDth SEnsor 6 PRDU WIDth SEnsor 7 PRDU WIDth SEnsor 8 PRDU WIDth SEnsor 9 Paper roll drawer upper feed switch 1 ON = switch of roll 1 activated Paper roll drawer upper feed switch 2 ON = switch of roll 2 activated Paper roll drawer upper width sensor 1 ON = paper present Paper roll drawer upper width sensor 2 ON = paper present Paper roll drawer upper width sensor 3 ON = paper present Paper roll drawer upper width sensor 4 ON = paper present Paper roll drawer upper width sensor 5 ON = paper present Paper roll drawer upper width sensor 6 ON = paper present Paper roll drawer upper width sensor 7 ON = paper present Paper roll drawer upper width sensor 8 ON = paper present Paper roll drawer upper width sensor 9 ON = paper present
PRDL KNIfe Paper roll drawer lower knife position sensor POSition SEnsor ON = knife not in home position PRDL KNIfeM- Paper roll drawer lower knife motor sensor Otor SEnsor ON = sensor blocked by pulse disc PRDL LEADing SEnsor PRDL LENgth SEnsor Paper roll drawer lower leading edge sensor ON = paper present Paper roll drawer lower length sensor ON = sensor blocked by pulse disc
PRDL PREsent Paper roll drawer lower present sensor 3 SEnsor 3 ON = no paper present roll 3
ed.5
Test nr 12-2-27 12-2-28 12-2-29 12-2-30 12-2-31 12-2-32 12-2-33 12-2-34
Component
Signal
Description
12B21 12B22 12B23 12S2 12B32 12PBA3 12PBA3 12B26
PRDL PREsent Paper roll drawer lower present sensor 4 SEnsor 4 ON = no paper present roll 4 PRDL RUN SEnsor 3 PRDL RUN SEnsor 4 PRDL OPen SWitch Paper roll drawer lower run sensor 3 ON = roll 3 not empty Paper roll drawer lower run sensor 4 ON = roll 4 not empty Paper roll drawer lower open switch ON = lower drawer open
PRDL FEeD Paper roll drawer lower feed opposite sensor OPposite SEnsor ON = unit positioned PRDL FEeD SWitch 3 PRDL FEeD SWitch 4 Paper roll drawer lower feed switch 3 ON = switch of roll 3 activated Paper roll drawer lower feed switch 4 ON = switch of roll 4 activated
PRDS SYNchro- Paper roll drawer support synchronisation nisation SEnsor sensor ON = paper present
12Y1
PRDU SAMPle Paper roll drawer upper sample solenoid SOlenoid ON = solenoid activated, paper fed in chip tray Hardware diagnoses: CONDRIOUTDIAG PRDS TRAnsport CLutch Paper roll drawer support transport clutch ON = clutch activated Hardware diagnoses: CONDRIOUTDIAG
12-4-02
12Y2
204
TSM Oc 9800
SDS
Test nr
Component
Signal
Description
12-6-05 12-6-06
12M2/3 12M5/6 12B27/28
PRDU FEeding Paper roll drawer upper feed motor roll 1/2 MOtor 1/2 PRDL FEeding Paper roll drawer lower feed motor roll 3/4 MOtor 3/4 PRDU FEeding Paper roll drawer upper feed motor sensor MOtor 1/2 SEn- roll 1/2 sor PRDL FEeding Paper roll drawer lower feed motor sensor MOtor 3/4 SEn- roll 3/4 sor PRDU KNIfe MOtor PRDL KNIfe MOtor Paper roll drawer upper knife motor PWM Paper roll drawer lower knife motor PWM
12-6-07
12-6-08
12B29/30
12-6-09 12-6-10
12M1 12M4

50 52 ~Testprint mode~ ~Black mode~

53 ~1 to 1 mode~
ed.5
206
TSM Oc 9800
SDS
Adjustments
1 Straightness cutting of the paper
Note: This adjustment is possible from machine number 306 and must be done when a knife has been replaced. Aim:
To be sure that the paper is cut straight.

Check: 1 Make 5 copies A0 (36) from an original (min. length 600 mm). 2 Mark the leading edge on copy 4 and 5. 3 Place copy 4 and 5 on each other as shown in figure 1A, 1B and 1C.
output direction
output direction
1A
1B
face up face down
1C
4 Position them as shown in next figure. 5 Measure the distance X1 or X2, depends on the situation. 6 Specification: 0.5 x X1 or 0.5 x X2 must be 1mm or less.
ed.5
these sides straight
X1
match this corner X2
Note:
After modification 39 this adjustment can also be done with SDS test 12-1-04 (Changing the speed of the knife motor).
Correction:
If 0.5 x X1 is more than 1 mm:

1 2 3 4 5 6
Loosen the bolt -A- at the non drive side Move the knife 0.5 x X1 in arrow 1 direction. Position the pin -B- at the drive side as shown. Tighten the bolt -A-. Repeat the check points 1 up to 6. Continue with point 7. If 0.5 x X2 is more than 1 mm:
1 2 3 4 5 6
Loosen the bolt -A- at the non drive side. Move the knife 0.5 x X2 in arrow 2 direction. Position the pin -B- at the drive side as shown. Tighten the bolt -A-. Repeat the check points 1 up to 6. Continue with point 7.
302
TSM Oc 9800
Adjustments
0 +0.3 / -0
pin B
drive side
7 Adjust the fixing bolts of the knife motor to obtain a distance of 0.1 +0.1 / -0
mm.
0.1 +0.1 / -0
fixing bolts
ed.5
2 Straightness leading edge margin

Note: This adjustment is possible from machine number 306.
Adjustment 1 see Straightness cutting of the paper on page 301 must be correct.
Aim:
To be sure that the left and right leading edge margin is within 1 mm.
Check: 1 2 3 4 5 6
Carry out SDS test 53. Select A0 (34/36) roll width 75 gr/m2 paper. Make 5 copies from both paper roll drawers. Measure on both 5th copy the distance K1 and K2. Calculate the average value of K1 and K2. Specification: the average value from K1 and K2 must be 1 mm or less.
K1
K2
Correction:
If the average of K1 and K2 is more than 1 mm and the average of K1 is more than K2.
1 Loosen the adjusting bold. 2 Loosen the taptites.
304
TSM Oc 9800
Adjustments
3 4 5 6
Move the adjustment plate in arrow 1 direction. Tighten the bold and the taptites. Repeat the check points 1 up to 6. Continue with point 7. If the average of K1 and K2 is more than 1 mm and the average of K2 is more than K1
1 2 3 4 5 6
Loosen the adjusting bold. Loosen the taptites. Move the adjustment plate in arrow 2 direction. Tighten the bold and the taptites. Repeat the check points 1 up to 6. Continue with point 7.
adjustment plate
adjusting bolt
taptites
ed.5
7 Adjust plate -A- with the bolts -B- in such a way that the distance between roll-
er and rear side frame plate is 73.5 + / - 0.2mm.
bolts B
plate A
73.5 +0.2/-0.2 mm
306
TSM Oc 9800
Adjustments
3 ~Offset cutting length PRDU~

Function 23 adjustment 1 Main drive belt on page 975 must be correct. Adjustment 1Straightness cutting of the paper on page 301 must be correct.
Aim:
Make sure that the knife cuts the desired copy length.
Check: 1 2 3 4 5 6 7
Load roll 1 or 2 (the upper drawer) with an A2 (17/18) roll. Carry out SDS test 43. Enter the value 600. Select roll width A2 (17/18). Make 3 copies. Measure the length of the copies and calculate the average length. Specification: the average length must be 600 + / - 0.5 mm.
Correction:
If the average is less than 599.5 mm:

1 Carry out SDS test 12 - 1 - 01. 2 Increase the indicated value with 10 x the average deviation.
If the average is more than 600.5 mm:

1 Carry out SDS test 12 - 1 - 01. 2 Decrease the indicated value with 10 x the average deviation.
ed.5
4 ~Offset cutting length PRDL~

Function 23 adjustment 1 Main drive belt on page 975 must be correct. Adjustment 1 Straightness cutting of the paper on page 301 must be correct.
Aim:
Make sure that the knife cuts the desired copy length.
Check: 1 2 3 4 5 6 7
Load roll 3 or 4 (the lower drawer) with an A2 (17/18) roll. Carry out SDS test 43. Enter the value 600. Select roll width A2 (17/18). Make 3 copies. Measure the length of the copies and calculate the average length. Specification: the average length must be 600 + / - 0.5 mm.
Correction:
If the average is less than 599.5 mm:

If the average is more than 600.5 mm:

308
TSM Oc 9800
Adjustments
5 ~PRD leading edge correction~

Function 23 adjustment 1 Main drive belt on page 975 must be correct. Adjustment 1 Straightness cutting of the paper on page 301 must be correct.
Aim:
Make sure that the head margin on the copies is within the specifications.
Check: 1 2 3 4 5 6 7
Carry out SDS test 53. Select A0 (34/36) roll width and make 3 copies. Select A1 (22/24) roll width and make 3 copies. Select A2 (17/18) roll width and make 3 copies. Select A3 (11/12) roll width and make 3 copies. Measure on all copies the framing margin in the centre of the leading edge. Specification: the average framing margin of the 12 copies must be within 3 +/- 0.5 mm, one single framing margin may be 2 mm.
3 +/- 0.5 mm
Correction:
If the average width is less than 2.5 mm.

If the average width is more than 3.5 mm.

ed.5
6 Size label
This adjustment concerns all four size labels.
Aim:
Make sure that the paper rolls are correct positioned in width direction.
Check: 1 Carry out SDS test 53 ~Testprint mode~ and make 3 copies from all 4 paper
rolls.
2 Measure on the 3th copy from each roll the framing width K1 and K2. 3 Specification: the difference must be less than 1 mm.
K1
K2
A0
36
X Correction: 1 Move the size label half of the differ-
ence to the left or right side and tighten the screw. 2 When using the inch sizes turn the size label up side down and adjust the label as described above.
detail X
310
TSM Oc 9800
Adjustments
Dis-/assemblies
1 Paper roll drawers
When you remove the lower paper roll drawer put some paper between the lower and upper drawer to prevent damage of the upper drawer.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Open the upper paper roll drawer. Remove from the inside 1 screw of the right side cover. Open the sheet feeder approx. 20 cm. Remove the right side cover from the paper roll drawers. Close the sheet feeder. Open the paper drawer completely. Remove the paper spindles. Disconnect on the rear right side on the swing arm the connectors 1201X1 and 1201X2. Release on the rear right side the ground wire. Remove the mounting screw from the hinge lock. Remove the black cover at the front right side from the drawer. Loosen at the left and right side the locking bolts (M6), which secure the drawer to the rail. Remove the carrier bar from inside the upper or lower drawer front. Put the carrier bar in the square holes above the roll feed 1 or 3. Turn the bar until it locates in the groove (no locking mechanism). Remove the drawer from the rail (2 persons).
Note: The weight is approx. 85 kg (187 lbs).
When removing the upper drawer, be careful with the guide plates underneath the drawer. Put the drawer on a table or a platform.
Note: When assembling the carrier discs must fall into the holes of the drawer
rail. After assembly be sure of correct mounting the connectors 1201X1 and 1201X2 to the distribution PBA.
ed.5
2 Vertical transport paper roll drawers

1 Remove paper spindle 1 or 3. 2 Remove at the right side the right rear cover (1 screw inside and 1 screw out-
side of the frame).

3 Upper drawer only: disconnect on the right side the PRD(U/L)SAMPSO con-
nector.
4 Remove at the right side the ground wire. 5 Open the vertical transport unit (upper drawer with the chip tray). 6 Remove at the left and right side the upper bearing part from the transport
roller of the vertical transport.

7 Remove the vertical transport (upper drawer with the chip tray).
3 Feed rollers roll 1 / 3

1 2 3 4 5 6 7 8 9
Remove the paper spindle. Upper drawer only: remove chip tray. Remove the opposite feed unit (2 green grips). Remove the cover above the feed rollers 1 or 3. Remove on the right side the rear side cover (1 screw inside and 1 screw outside of the frame). Loosen on the right side the belt tensioner. Remove on the left and right side the upper bearing part. Remove on the right side the chip tray locking bracket. Remove the feed rollers.
402
TSM Oc 9800
Dis-/assemblies
4 Feed rollers roll 2 / 4

1 2 3 4 5 6 7 8
Remove the paper spindle. Remove upper feed plate (green grip). Remove on the right side the side front cover (2 screws inside frame). Remove on the right side the small frame plate above the feed rollers. Remove the plate above the feed rollers. Release on the right side the belt tensioner. Remove on the left and right side the upper bearing lock. Remove the feed rollers.
5 Roll feed motor

When you remove the lower paper roll drawer put some paper between the lower and upper drawer to prevent damage of the upper drawer.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Open the paper drawer completely. Remove the carrier bar from inside drawer front. Put the carrier bar in the rectangle holes above the roll feed 1 or 3. Turn the bar until it locates in the groove. Lift the drawer at the right side a few cm. Push the right side rail to the inside. Put the two carrier discs over the rail. Remove at the right side the rear cover (1 screw inside and 1 screw outside of the frame). Remove at the right side the front cover (2 screws inside). Release the drive belt on the right side. Remove for motor roll 2 and 4 the gear from the lower feed roller. Remove the bottom plate. Disconnect the connector from the motor and motor sensor. Remove the motor (4 screws).
ed.5
6 Knife unit
1 Do dis-/assembly Vertical transport paper roll drawers on page 402. 2 Release on the left side the spring of the knife position arrester. 3 Remove underneath the drawer on the left and right hand side the knife unit 4 5 6 7
mounting screws. Remove the paper guide plate over length measurement sensor. Push the knife unit to the rear. Remove the knife unit straight up. Carry out adjustment 1Straightness cutting of the paper on page 301
Note: The weight is approx.11.5 kg (25.3 lbs).
7 PRD(U/L)KNIMO (Paper Roll Drawer Upper/Lower KNIfe MOtor)

1 2 3 4 5 6 7 8 9 10 11 12
Open the paper roll drawer completely. Remove the carrier bar in the front, inside one of the drawers. Put the carrier bar in the square holes above the roll feed 1 or 3. Turn the bar until the groove is located in the side frame (no locking position). Lift the drawer at the left hand side a few cm. Push the rail to the inside. Put the two carrier discs over the rail. Remove on the left side the knife drive gear. Remove the bottom plate. Disconnect the motor and the motor sensor connector. Remove the four motor mounting screws. Remove the motor.
Note: Make sure that the 1 mm spacer is nearest positioned to the knife to get
correct alignment of motor and knife drive gear.
404
TSM Oc 9800
Dis-/assemblies
8 PRD(U/L)FEDOPSE (Paper Roll Drawer Upper/Lower FEed OPosite SEnsor)

1 2 3 4 5
Remove paper spindle 1 or 3. Upper drawer only; remove the chip tray. Remove the opposite unit. Remove the cover above the feed rollers. Remove the sensor.
9 PRDUWIDSE (Paper Roll Drawer Upper WIDth SEnsors)

1 2 3 4 5 6
Pull out the sheet feeder approx. 20 cm. Remove the right side cover over the paper roll drawers (1 screw inside). Put the sheet feeder back into the machine. Open the paper drawer completely. Remove the bar with the width sensors from the upper drawer rear side . Remove the width sensor.
10 PRD(U/L)LEADSE (Paper Roll Drawer Upper/Lower LEADing edge SEnsor)

1 2 3 4 5
Pull out the sheet feeder approx. 20 cm. Remove the right side cover over the paper roll drawers. Put the sheet feeder back into the machine. Open the paper drawer completely. Remove the leading edge sensor from the drawer rear side.
ed.5
11 PRD(U/L)LENSE (Paper Roll Drawer Upper/Lower LENgth SEnsor

1 2 3 4 5
Open the paper roll drawer completely. Do dis-/assembly Vertical transport paper roll drawers on page 402. Remove the paper guide plate. Remove bracket with the sensor. Remove the sensor.
12 PRD(U/L)PRESE 1 / 3 (Paper Roll Drawer Upper/Lower PREsent SEnsor)

1 2 3 4 5 6
Remove the paper spindle. Remove upper feed plate (green grip). Remove on the right side the side front cover (2 screws inside frame). Remove on the right side the small frame plate above the feed rollers. Remove the plate above the feed rollers. Remove the present sensor.
13 PRD(U/L)PRESE 2 / 4 (Paper Roll Drawer Upper/Lower PREsent SEnsor)

1 Open the paper drawer. 2 Remove the present sensor from underneath.
406
TSM Oc 9800
Dis-/assemblies
1 General
The function of the two paper roll drawers is to feed copy material automatically from one of the rolls and to cut the material to the correct length. Both drawers comprise:
s s s s s
s s
two paper rolls PRDU/LPRESE present sensor cutter PRDU/LLENSE puls-disc for length measurement PRDU/LLEADSE leading edge sensor opposite unit The upper drawer also comprises: PRDUWIDSE width detection sensors (9x) chip tray
chip tray roll 1 roll 2
PRDUWIDSE
PRDU LEAD SE PRDLLEAD SE opposite unit roll 3 roll 4
PRDLLENSE
cutter
PRDLPRESE
ed.5
The following functions are used in the paper path from paper roll drawers to preheating unit:
s s s s s s s s s
roll feed system knife length measurement roll width detection chip tray paper through feed roll selection end of roll securities
2 Roll feed system

Each of the drawers comprises two roll spindles and a knife; each spindle comprises a roll feed motor and sensors. The roll spindles can be loaded with material from 279 mm (11) up to 914 mm (36). Only 841 (A0 size) and 36 (E size) are centred in the drawers. The other sizes are not exactly centred. The first reason for this is to avoid jams (dog ears at the paper edges) in the paper path during paper transport through the printer; second reason is that the width detection can be done with a minimum numbers of sensors. The material must be positioned on the spindle just between the size indicators. Place the spindle with roll in the drawer and feed the material between the feed rollers. Push the corresponding feed switch (green button on the right side). The feed rollers, driven by the paper feed motor, transport the material at 5 m/min. until the material activates the present sensor. The feed motor starts again when the drawer is closed. The rollers transport the material via the knife unit to the second pinch rollers (90 curve). The vertical transport is driven by MADMO (main drive motor) via clutch PRDSTRACL. The transport rollers drive the copy material upwards where the leading edge sensor detects the material. The knife motor is energised and the knife cuts one or four chips (SDS setting) from the material. The paper chip passes the width detection sensors to detect the roll width. The paper chip is transported into the chip tray.
502
TSM Oc 9800
Chips are cut to prevent pollution in the system and to ensure that the edge of the paper is straight. After the material is cut, the feed motor reverses its direction and retracts the material to ensure that the common paper path in the drawers is free. The rolls are retracted approx. 30 mm from the knife.
A sliding clutch is mounted on each the spindle drive gear to keep tension on the paper. Roll 1 / 3 are fed and cut first if two rolls are loaded in both drawer. To ensure that long sheets are fed straight through the engine, the speed increases 2% in each next pinch in the paper path.
PRDULEADSE Confidential 1999 Oc-Technologies B.V. PRDUWIDSE PRDUSAMPSO chip tray roll 1 / 3 roll 2 / 4
2nd pinch rollers rotating knife
PRDUPRESE PRDUFEDMO 1/2 PRDURUNSE
ed.5
3 Knife
The cutting system is driven by a motor. A rotating knife cuts the material during transport. The PRDUKNIMOPWM (puls width modulation) signal controls the speed of the PRDUKNIMO. PRDU/LKNIPOSSE (knife position sensor) detects after cutting whether the knife is returned in the home position. The knife unit is mounted 11.7 mm slant in the drawer. This is necessary for a correct rectangle cut while cutting is done during paper transport. The minimum cut length is 170 mm. The min. copy length is 205 mm. The max. copy length limited by the first fold is 6000 mm (236). The max. copy length limited by the second fold is 2500 mm (98.5) The max. copy length unfolded cut length is endless.
4 Length measurement
The PRDU/LLENSE (length sensor) measures the length to be cut with a pulse disc. The copy material drives a wheel with the pulse disc. The feed rollers transport the paper through the knife unit to the second pinch rollers which are driven by the main motor. When PRDU/LLEADSE (leading edge sensor) detects the leading edge of the copy material, a counter starts counting the pulses generated by the pulse disc sensor. Because of the mechanical position of PRDU/LLENSE, PRDU/LLEADSE and the knife corresponds the length to measure with the length to cut minus the distance from leading edge sensor to pulse disc and the distance from pulse disc to knife. These are fixed distances and known in the engine software.
504
TSM Oc 9800
5 Roll width detection

Nine sensors detect the material width. The sensors are mounted in the upper drawer vertical transport. Detection is done for Europe A- and B-sizes or USA 8.5, 9 and 30 range sizes. During installation the selection is done via the SDS. Every time when a roll is loaded and a chip is cut, the sensors detect the width, so the engine knows the width and the position (roll 1, 2, 3 or 4) of that specific roll.
European sizes
.
Roll width (mm)
Europe size
Sensors 4 9 3 2 1 5 6 7 8
A3 A2 A1 A0 36
297 420 594 841 914
A3 / A4 A2 / A3 A1 / A2 A0 / A1 1 1 1 * * * *
1 1 * * *
1 * * * * 1 * * * 1 * * * * 1 1
B2 B1
500 707
B2 / B3 B1 / B2 1
1 *
* *
* *
1 * * 1
1 = activated * = dont care
ed.5
American sizes
Roll width (mm)
USA size ANSI
Sensors 4 9 3 2 1 5 6 7 8
11" 17" 22" 34"
279 432 559 864
A/B B/C C/D D/E 1 1 * 1 * *
1 * * * 1 * * 1 * * 1
width
(mm)
size ARCH
12" 18" 24" 36" 30"
305 457 610 914
A/B B/C C/D D/E 30" x 42" & 21" x 30" 1 1 * 1 * *
1 * * *
1 * * * 1 * * 1 * * 1
762
1 = activated * = dont care
6 Chip tray
The chip (the cut material) passes the chip flap operated by PRDUSAMPSO (sample solenoid) and is dropped in the chip tray in the upper drawer. The length of the chip is approx. 170 mm. To prevent glue from tapes coming into the process path at least one chip is cut. In SDS the number of chips to cut can be set to 1 or 4.
506
TSM Oc 9800
7 Paper through feed

The PRDSTRACL (transport clutch) activates the vertical transport in the paper roll drawers and the through feed of the paper to the preheater. The PRDSSYNSE (support synchronisation sensor) determines the start print moment, the paper does not stop at the PRDSSYNSE. The software controls the clutch.
8 Roll selection
The roll selection can be done automatically or manually.
s
automatically: the roll depends of the original width and the reduce/enlarge setting on the operating panel. The roll width is presented to the engine as digital information. manually: roll width has to be selected on the operator panel.
The key operator has the possibility to set the engine to roll switch function. This means that at the end of the roll, the engine automatically switches to next roll if more same size rolls are loaded.
9 End of roll
At the end of the roll the spindle stops turning and a spring is released. The retraction mechanism retracts the spindle and deactivates the PRDU/LRUNSE (run sensor) and the end of roll signal is generated. The operator panel indicates reload roll x. When a roll is empty it is possible to continue with another roll. Important lengths regarding to the end of roll situation are: - the min. through feed length is 205 mm - the min. chip length is 170 mm - the max. chip length is 175 mm
ed.5
Five situations, depend on the length from the last sheet, are possible: 1 - the already fed length is more than 205 mm. The sheet is cut and ejected on the unfolded delivery tray. 2 - the already fed length is between 175 and 205 mm The sheet is cut after 205 mm is passed and ejected on the unfolded delivery tray. 3 - the already fed length is between 170 and 175 mm. The sheet is cut and ejected in the chip tray. 4 - the already fed length is less than 170 mm and has passed the 90 curve. The sheet is cut after 170 mm is passed and ejected in the chip tray. 5 - the already fed length is less than 170 mm. The sheet is retracted until the common paper path is free. In all situations the end of the roll must be removed from the feed rollers.
10 Securities
PRDUFEDOPSE (opposite sensor checks if roll feed system 1 or 3 is correctly positioned. PRDU/LOPSW (open switch) generates the signal paper roll drawer open.
508
TSM Oc 9800
Paper Roll Drawer Upper (front view)
PRDSSYNSE PRDSTRACL
PRDUSAMPSO PRDUWIDSE1/9 4 9 3 2 1 5 6 7 8
PRDULEADSE
PRDSSYNSE (synchronisation sensor) and PRDSTRACL (transport clutch) are mounted just above the paper roll drawers.
ed.5
Paper Roll Drawer Upper (top view)
PRDUKNIMO PRDULENSE PRDUKNIMOSE PRDUFEDOPSE
12PBA1 PRDUKNIPOSSE PRDUFEDMO1 PRDUFEDMOSE1 PRDUFEDMOSE2 PRDUPRESE1 PRDUFEDMO2 PRDURUNSE1
PRDUOPSW PRDUPRESE2
PRDUFEDSW1 PRDUFEDSW2 PRDURUNSE2
602
TSM Oc 9800
Paper Roll Drawer Lower (front view))
PRDLLEADSE
PRDLLEADSE
Paper Roll Drawer Lower (top view)

12PBA4 PRDLLENSE PRDLKNIMOSE PRDLKNIPOSSE PRDLFEDMO3 PRDLFEDMOSE3 PRDLFEDOPSE PRDLFEDMOSE4 PRDLPRESE3 PRDLFEDMO4 PRDLRUNSE3
PRDLKNIMO
PRDLOPSW PRDLPRESE4
PRDLFEDSW3 PRDLFEDSW4 PRDLRUNSE4
ed.5
2 Roll feed
Each paper drawer contains two paper roll systems. The following description describes the feed and the copying cycle from roll 1. The function is the same for all four roll systems, only the component name and roll number changes. After roll spindle 1 with material has been placed in the holder of the paper roll drawer, the material must be fed between the feed rollers (first pinch rollers) until a small bulge is formed. Push the PRDUFEDSW1 (green feed button) to start the PRDUFEDMO1 (roll feed motor). The paper is transported until PRDUPRESE1 (present sensor) detects the paper. PRDUFEDMO1 stops. PRDUFEDMO1 starts again when the paper drawer is closed. The leading edge of the material passes the knife unit and the PRDULENSE (length measure sensor) towards the PRDULEADSE (leading sensor). The MADMO (main motor) drives the paper transport the moment the leading edge passes the second pinch rollers. The PRDUFEDMO1 stops 10 sec. after PRDUFEDSW is pushed when no paper is fed . When PRDULEADSE detects the paper PRDUKNIMO (knife motor) switches on and the knife cuts the material. PRDUFEDMO1 stops, reverses its direction and retracts the material until the common paper path is free. The PRDUSAMPSO (sample solenoid) energizes and the cut sheet (chip) is ejected into the chip tray. The length of the chip is 170 mm. In SDS it is possible to adjust the number of chips (1 or 4) to be cut. The PRDUWIDSE 1 to 9 (roll width sensors) measure the chip width for the roll width detection. Detection of the width is necessary to tell the engine which roll is in which position.
604
TSM Oc 9800
3 Feed motor control

The PRDUFEDMOPWM signal controls the speed of the PRDUFEDMO. When a new roll is fed the PRDUFEDMO turns at a speed of 5 m/min. (16.4 ft/min.). The PRDUFEDMO changes direction after the paper is cut and retracts the paper until the common paper path is free. The rolls 3 will be retracted approx 30 mm.
22PBA1 CPU I/O

PRDLFEDMODIRDE
22PBA5 DRIVERS
PRDLFEDMO4-A1 +24V
M
PRDLFEDMO4
PRDLFEDMO4-A2 +5V GND 1 3 2

PRDLFEDMO4SE
CONMOSUP
PRDLFEDMO4SE GND
PRDLFEDMOPWM PRDLFEDMODIR
PRDLFEDMO3-A1
M
PRDLFEDMO3
PRDLFEDMO3-A2 +5V GND +24V PRDLFEDMO3SE 1 3 2

PRDLFEDMO3SE
PRDLFEDMOSE
PRDLFEDMOSEL GND
ed.5
606
TSM Oc 9800
1
22G1 CONSUPLV
G3 1 2 3 4 G2 1 2 3 4 5 6 +5V GND +5V GND +24V GND +24V GND +24V GND
2
X8 1 2 3 4 5 6 7 8 9 10 F4 4A X10 1 2 3 5 X6 27 28 12X2 1 +24V X12 2 F2 4A
3
22PBA5 DRIVERS
X3 2 3 +5V GND
4
12PBA4 DISTRIBUTION
X1 2 3 X4 22 19 21 X6 14 13 15 8 7 9 X3 5
5
PRDLFEDSW4 GND PRDLFEDSW3 X1 3 2 1
6
12PBA3 PRDLFEDSW
+5V GND PRDLFEDOPSE +5V GND PRDLKNIPOSSE PRDLKNIMO-A1
1 3 2 1 3 2 1
PRDLFEDOPSE
12B32
PRDLKNIPOSSE
12B25
22PBA1 CPU I/O
X13 1 2 3 5 X6 27 28
10
PRDLKNIMO-A1
M
9 RL F1 4A 6 PRDLFEDMO4-A1 6 PRDLKNIMO-A2 10 6 X6 12 11 10 X3 3 PRDLKNIMO-A2 +5V GND PRDLKNIMOSE PRDLFEDMO4-A1 2 1 3 2 1
PRDLKNIMO
12M4
PRDLKNIMOSE
12B18
PRDSTRACL
12Y2
M
8 PRDLFEDMO4-A2 8 4 X4 2 1 3 6 5 4 8 7 9 X3 1 PRDLFEDMO4-A2 +5V GND PRDLFEDMO4SE +5V GND PRDLPRESE4 +5V GND PRDLRUNSE4 PRDLFEDMO3-A1 2 1 3 2 1 2 3 1 3 2 1
PRDLFEDMO4
12M6
2 X11 10 X8 4 CONMOSUP
PRDSTRACL-B
1 X7 10 PRDLFEDMO4SE
PRDLFEDMO4SE
12B30
12
12
GND 4 2
+24V-LS
X5 4
PRDLPRESE4
12B21
PRDLOPSW
12S2 5 PFDLOPSW 3 1 +24V 3 5 X6 9 14 22 19 17 30 24 PRDSTRACL PRDLKNIMOPWM PRDLFEDMODIR PRDLFEDMOPWM PRDLFEDMODIRDE PRDLFEDMOSE PRDLFEDMOSEL X6 9 14 22 19 17 30 24
PRDLRUNSE4
12B23
PRDLFEDMO3-A1
PRDLFEDMO3
12M5
PRDLFEDMO3-A2
11 RL +24V
PRDLFEDMO3SE
11
X10 10 9 11 2 1 6 8 5 7 3 4
PRDLFEDSW4 PRDLFEDSW3 PRDLFEDOPSE PRDLKNIPOSSE PRDLKNIMOSE PRDLPRESE4 PRDLRUNSE4 PRDLPRESE3 PRDLRUNSE3 PRDLLEADSE PRDLLENSE
X2 4 3 22 11 12 7 9 6 8 5 10
2 X4 14 13 11 X6 2 1 3 X4 18 17 20 16 15 12 X6 6 5 4
PRDLFEDMO3-A2 +5V GND PRDLFEDMO3SE +5V GND PRDLPRESE3 +5V GND PRDLRUNSE3 +5V GND PRDLLEADSE +5V GND PRDLLENSE
2 1 3 2 1 2 3 1 3 2 1 3 2 1 3 2
PRDLFEDMO3SE
12B29
PRDLPRESE3
12B20
PRDLRUNSE3
12B22
PRDLLEADSE
12B19
PRDLLENSE
12B24
22X002-2
12X001
X8 1 3 2
+5V GND PRDSSYNSE
22X12 5 6 7
1 2 3
PRDSSYNSE
12B26
H
PAPER ROLL DRAWER LOWER
ed.5
TSM Oc 9800
1
22G1 CONSUPLV
2
X8 1 2 3 4 5 6 7 8 9 10 F4 4A X10 1 2 3 5 X6 27 28 F2 4A
3
22PBA5 DRIVERS
X1 2 3 +5V GND
4
12PBA1 DISTRIBUTION
X1 2 3 X4 22 19 21 X6 14 13 15 X3 7
5
PRDUFEDSW2 GND PRDUFEDSW1 X1 3 2 1
6
12PBA2 PRDUFEDSW
+5V GND PRDUFEDOPSE PRDUSAMPSO-B
1 3 2 1
PRDUFEDOPSE
12B31
PRDUSAMPSO-B
PRDUSAMPSO
1 +24V-US 1 8 X6 8 7 9 X3 5 +24V- US +5V GND PRDUKNIPOSSE PRDUKNIMO-A1 12Y1 2 1 3 2 1
22PBA1 CPU I/O
X13 1 2 3 5 X6 27 28
PRDUKNIPOSSE
12B17
RL 10 PRDUKNIMO-A1 9
M
9 PRDUKNIMO-A2 10 6 X6 12 11 10 X3 3 PRDUKNIMO-A2 +5V GND PRDUKNIMOSE-1 PRDUFEDMO2-A1 2 1 3 2 1
PRDUKNIMO
12M1
PRDUKNIMOSE
12B1
PRDUFEDMO2-A1
C
8 X11 10 CONMOSUP X7 10 12 X8 6 GND 4 2 +24V-US X5 2
M
PRDUFEDMO2-A2 8 4 X4 2 1 3 6 5 4 8 7 9 X3 1 PRDUFEDMO2-A2 +5V GND PRDUFEDMO2SE +5V GND PRDUPRESE2 +5V GND PRDURUNSE2 PRDUFEDMO1-A1 2 1 3 2 1 2 3 1 3 2 1
PRDUFEDMO2
12M3
PRDUFEDMO2SE
12B30
PRDUFEDMOSE2
12
PRDUPRESE2
12B21
PRDUOPSW
12S1
PRDURUNSE2
12B6
PRDUOPSW
3 1
+24V
PRDUFEDMO1-A1
M
X6 25 13 21 20 11 29 23 PRDUSAMPSO PRDUKNIMOPWM PRDUFEDMODIR PRDUFEDMOPWM PRDUFEDMODIRDE PRDUFEDMOSE PRDUFEDMOSEL X6 25 13 21 20 11 29 23 7 PRDUFEDMO1-A2 7 2 X4 14 13 11 X6 2 1 3 X4 18 17 20 16 15 12 X6 6 5 4 X5 2 1 3 6 5 4 8 7 9 12 11 10 14 13 15 18 17 16 PRDUFEDMO1-A2 +5V GND PRDUFEDMO1SE +5V GND PRDUPRESE1 +5V GND PRDURUNSE1 +5V GND PRDULEADSE +5V GND PRDULENSE +5V GND PRDUWIDSE1 +5V GND PRDUWIDSE2 +5V GND PRDUWIDSE3 +5V GND PRDUWIDSE4 +5V GND PRDUWIDSE5 +5V GND PRDUWIDSE6 2 1 3 2 1 2 3 1 3 2 1 3 2 1 3 2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
PRDUFEDMO1
12M2
PRDUFEDMO1SE
12B27
11 RL +24V
PRDUFEDMOSE1
11
PRDUPRESE1
12B3
X7 19 18 20 2 1 6 8 5 7 3 4 9 10 11 12 13 14 15 16 17
PRDUFEDSW2 PRDUFEDSW1 PRDUFEDOPSE PRDUKNIPOSSE PRDUKNIMOSE PRDUPRESE2 PRDURUNSE2 PRDUPRESE1 PRDURUNSE1 PRDULEADSE PRDULENSE PRDUWIDSE1 PRDUWIDSE2 PRDUWIDSE3 PRDUWIDSE4 PRDUWIDSE5 PRDUWIDSE6 PRDUWIDSE7 PRDUWIDSE8 PRDUWIDSE9
X2 4 3 22 11 12 7 9 6 8 5 10 13 14 15 16 17 18 19 20 21
PRDURUNSE1
12B5
PRDULEADSE
12B2
PRDULENSE
12B7
PRDUWIDSE1
12B8
PRDUWIDSE2
12B9
PRDUWIDSE3
12B10
PRDUWIDSE7
12B14
1 2 3 1 2 3 1 2 3
+5V GND PRDUWIDSE7 +5V GND PRDUWIDSE8 +5V GND PRDUWIDSE9
X5 20 19 21 24 23 22 26 25 16
PRDUWIDSE4
12B11
PRDUWIDSE8
12B15
PRDUWIDSE5
12B12
PRDUWIDSE9
12B16
PRDUWIDSE6
12B13
H
ed.5
22X002-1
12X002
PAPER ROLL DRAWER UPPER
TSM Oc 9800
Oc
Oc 9800
13 PAPER SHEET FEEDING
Contents
Diagnostics
1 Faults
101
SDS
1 ~Paper Sheet Feeder 201
Adjustments
1 ~PSF leading edge correction~
301
Dis-/assemblies
1 Paper sheet feed 401
1 General 501
601
Diagrams
1 Paper sheet feeding 701
ed.5
13 Paper sheet feeding
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Paper Sheet Feeding 13000 - 13999 code display 13701 ORE: ~Sheet too late at PSFSYNSE~
13-2-02 PSFSYNSE Possible cause Remark
Continuously Connection PSFSYNSE -> CPU_IO PBA OFF Actuator defect PSFSYNSE defect CPU_IO PBA defect
13-2-01 PSFPRESE
Possible cause
Remark
Continuously PSFPRESE defect ON Actuator defect CPU_IO PBA defect (disconnect 2201X8) Continuously PSFPRESE defect OFF Actuator defect Connection PSFPRESE -> 13X1 -> CPU_IO PBA CPU_IO PBA defect
to be continued
ed.5
continued
13-4-02 PSFSO
CONDRI OUTDIAG ON ON (disconnect 2201X8)
Possible cause
Remark
OFF
Connection DRIVERS PBA -> PSFSO DRIVERS PBA defect DRIVERS PBA defect Connection DRIVERS PBA -> 13X1 -> PSFSO PSFSO defect
ON
OFF ON
13-4-01 PSFCL
CONDRIOUTDIAG OFF ON
Possible cause
Remark
ON
DRIVERS PBA defect Connection DRIVERS PBA -> 13X1 -> PSFCL PSFCL defect Sheet not inserted correctly Toothed belt lose / defect One way bearing defect Toothed belt MADMO lose / defect
102
TSM Oc 9800
Diagnostics
SDS
1 ~Paper Sheet Feeder
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr.
Component
Signal
Description
Parameter test 13-1-01 ~PSF leading edge correction mm/10~
Adjustment of leading edge margin (range 0 - 200, default 0, mm/10)

Input tests 13-2-01 13-2-02 13-2-03
13B1 13B2
PSF PREsent SEnsor
Paper sheet feeder present sensor ON = paper present
PSF SYNchroni- Paper sheet feeder synchronisation sensor sation SEnsor On = paper present PSF OPen SWitch Paper sheet feeder open switch ON = sheet feeder closed
13Y1
PSF CLutch
Paper sheet feeder clutch ON = clutch activated, sheet feeder driven Hardware diagnoses: CONDRIOUTDIAG Paper sheet feeder solenoid ON = solenoid activated, paper feed from sheet feeder Hardware diagnoses: CONDRIOUTDIAG
13-4-02
13Y2
PSF SOlenoid
202
TSM Oc 9800
SDS
Test nr.
Component
Signal
Description

53 ~1 to 1 mode~
ed.5
204
TSM Oc 9800
SDS
Adjustments
1 ~PSF leading edge correction~
Aim:
Make sure that the leading edge framing on the copies is within the specifications.
Check: 1 2 3 4 5 6 7
Carry out SDS test 43. Enter the value 1189. Select roll width A0 (34/36) and make 3 copies. Carry out SDS test 53. Select manual sheet feeding. Feed the sheets via the sheet feeding. Measure on all copies the framing margin in the centre of the leading edge on all copies. 8 Specification: the average framing margin of the 3 copies must not exceed 3 +/- 0.5 mm, single deviation from the framing margin may be 2 mm.
3 +/- 0.5 mm
ed.5
Correction:
If the average width is less than 2.5 mm.

If the average width is more than 3.5 mm.

302
TSM Oc 9800
Adjustments
Dis-/assemblies
1 Paper sheet feed
1 Open the paper sheet feeder completely. 2 Push the left and right slides of the drawer inwards to access the locking
screws.
3 Remove the locking screw from the centre at the unit on the left and the right. 4 Lift the front from the sheet feeder and remove the sheet feeder from the rail
and place it on a flat surface.
ed.5
402
TSM Oc 9800
Dis-/assemblies
1 General
The function of paper sheet feeder is to feed sheets manually. When using the sheet feeder the operator has to select manual feed on the operating panel. Feed a sheet so that the paper forms a small bulge to ensure that the leading edge of the paper is aligned against the feed rollers. PSFPRESE (paper sheet feeder present sensor) is activated. PSFSO (paper sheet feeder solenoid) activates, the feed rollers turn slightly by an eccentric connection and the paper is fed for approx. 6 mm. When PSFCL (paper sheet feeder clutch) is energised, the sheet is transported and activates PSFSYNSE (synchronisation sensor) which determines the start print moment. The unit is driven by MADMO (main motor). The sheet must be fed correctly according to the size indicators on the feed table and the image to be printed must correspond with the sheet width.
Note: There is no sheet width detection in the paper sheet feeding, therefore if the image is wider than the fed sheet width, the system will be polluted.
ed.5
502
TSM Oc 9800
PSFOPSW
PSFSYNSE
PSFPRESE PSFCL PSFSO
ed.5
602
TSM Oc 9800
1
22G1 CONSUPLV
2
22PBA5 DRIVERS
X8 5 6 7 8 9 10 1 2 3 4 F4 4A F1 4A 3 8 PSFCL-B +24V X12 4 +24V
3
13X1 2
PSFCL
13Y1 1 4
PSFSO
9 PSFSO-B 13Y2 3
22PBA1 CPU I/O

X13 1 2 3 5 X6 27 28 X11 21 22 +5V GND +24V GND CONDRIINDIAG CONDRIOUTDIAG PSFCL PSFSO PSFOPSW GND +5V GND PSFPRESE +5V GND PSFSYNSE X10 1 2 3 5 X6 27 28 X7 21 22 12 13 5 6 7 8 9 10 1 2 3 1 2 3
X4 9 8 X8 8 10 9 11 13 12
PSFPRESE
13B1
PSFSYNSE
13B2
11 22X003-2 13X001
H
ed.5 TSM Oc 9800 13 Paper sheet feeding 701
Oc
Oc 9800
14 PREHEATING
Contents
Diagnostics
1 Faults
101
SDS
1 PREheater 201
Adjustments
1 Drive belt preheater 301 2 Brake force of the pre-heater brake (PRETBR) 302
Dis-/assemblies
1 Preheating unit 401 2 Paper guide cloth 404 3 Silicon rollers 405
1 General 501 2 Preheating 502 3 Copy transport 504
1 Brake PRETBR 601 2 Component location 601
Diagrams
1 Preheating 701 2 Pneumatics 702
ed.5
14 Preheating
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. PREheating 14000 - 14999 code display 14101 PE: ~Temp PREHEating too high: PRETEMPSE~
~
14-4-01 PREHE
14-9-01 PRETEMPSE
Possible cause
Remarks
(NTC) Off
Rising
SSR PBA defect
Attention for switching on too long PREHETEMPERSW
PREHETRIAC
14102 PE: ~PRETEMPSE short / open circuit~ 14501 MRE: ~PRETEMPSE short / open circuit~
14-9-01 PRETEMPSE
Rntc = 3 - 350 Possible cause kOhm No Yes PRETEMPSE defect (short circuit) CPU_IO PBA defect (disconnect 2201X5) PRETEMPSE defect (open) Connection PRETEMPSE -> CPU_IO PBA Yes Connection + 5VAN signal of 2201X3, X4, X5 (short circuit to earth) CPU_IO PBA defect
Remarks
ADC value > 672
ADC value < 16
No
ed.5
14 Preheating 101
14502 MRE: ~Temp PREHEating too low: PRETEMPSE~ 14503 MRE: ~Warming up PREHEating > 30 min.~
14-4-01 PREHE 14-9-01 Possible cause Remarks
PRETEMPSE (NTC) rising No Connection SSR PBA -> PREHETRIAC Connection PREHETRIAC -> PREHE PREHETRIAC defect SSR PBA defect PREHE1, 2 and 3 defect PREHE / PREHETEMPERSW defect / defect Circuit breaker off Mains voltage off (L3) Yes Leakage preheater PREHE1, 2 and 3 defect R PREHE = 17 Ohm R PREHE = 17 Ohm
ON during at least 30 sec.
102
TSM Oc 9800
Diagnostics
SDS
1 PREheater
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
14 Preheating 201
Test nr.
Component
Signal
Description
Output tests 14-4-01 14-4-02
14E1/2/3 14Y1
PREheater HEater
Preheater heater 1/2/3 ON = heater switched on
PREheater Preheater transport brake Transport BRake ON = brake active Data 0 hardware diagnoses: CONDRIOUTDIAG
Consumable tests 14-8-01 ~Paper guide cloth (lm)~
Length counter (range 0 - 99999999 m, norm 200000 m)

Info tests~ 14R1 14-9-01
PREheater TEMP SEnsor
~PREheating TEMPerature SEnsor (adc)~
Actual A/D value of the preheater temperature sensor (range 0 ... 1023) value in stand-by approx. 505
202
TSM Oc 9800
SDS
Adjustments
1 Drive belt preheater
Aim:
Make sure that the preheater drive belt is tensioned correctly.

Check:
The adjusting bracket must just touch the pulley strip.

Note: Only the screws of the adjusting bracket are outside the frame. Correction:
1 2 3 4 5
Loosen at the left side the screws of the adjusting bracket. Move the adjusting bracket upwards until it just touches the pulley strip. Tighten the screws. Switch on the machine for 1 minute. Check the adjustment again.
drive belt
spring
screws pulley strip
adjusting bracket
ed.5
14 Preheating 301
2 Brake force of the pre-heater brake (PRETBR)

Modification bulletin 28 on the modification record is marked.
Aim:
Improve the toner fixation on heavy tracing paper.

Check:
Make a copy from the test original on tracing paper. The image on the copy may not be erasable.
Correction:
Set the jumper, located in the middle of the drivers PBA (22PBA5) at the right side in the position ~MAX~.
Modification 28 is not marked on the modification record.

1 Release the Allen screw from the fuser roller roller coupling. 2 Release the Allen screw from the pressure roller coupling. Note: Do not drop the Allen screws. 3 Release the tensioner of the main drive belt. 4 Disconnect the connectors 06X5, 22X11, 23X1 and the ground wire from the
motor plate.
5 Remove the motor plate (3 nuts). 6 Replace the existing magnetic brake for a new one (code 7015.738). (Do not
forget to remove the gear protection).

Note: during assembling check the correct position of the drive shaft bearing
above PRETBR.
7 Replace at the right side the drivers PBA (22PBA5) for a new one (code
5584.001).
8 Set the jumper, located in the middle of the drivers PBA (22PBA5) in the po-
sition ~MAX~.
302
TSM Oc 9800
Adjustments
Dis-/assemblies
1 Preheating unit
Warning: Two technicians are needed to dis-/assemble the preheater unit.
The weight is approx. 25 kg.

1 Carry out function 06 dis-/assembly CTF fuser roller cleaner on page 401). 2 Carry out function 06 dis-/assembly CTF fuser roller on page 402). 3 Release the Allen screw from the pressure roller coupling. Note: Do not drop the Allen screw.
4 Release the tensioner of the main drive belt. 5 Disconnect the connectors 06X5, 22X11, 23X1 and the ground wire from the
motor plate.
6 Remove the motor plate (3 nuts). Note: during assembling check the correct position of the drive shaft bearing
above PRETBR.
7 Close the CTF heater unit. 8 Disconnect (as viewed from the rear) on the left the connector 06X4 and on the
right the connector 06X3 from the pressure roller heater.

9 Remove the pressure roller heater unit.
ed.5
14 Preheating 401
10 Remove the securing brackets from the pressure roller gap cleaner.
securing brackets
11 12 13 14
15 16 17 18 19 20 21
Remove the pressure roller gap cleaner. Release and open the preheating unit. Open the CTF heater unit. Push the 2nd step cylinder shaft upwards, push the guide plate with pressure roller upwards from underneath and then lift the pressure roller with guide plate towards you. Lift out the pressure roller build cleaner. Close the pressure roller with guide plate. Close the CTF heater unit. Push the 2nd step cylinder shaft upwards and push the small yokes (supports from the pressure roller hole cleaner) to the inside. Remove the screws and loosen on the left and right the 2nd step shaft from the 2nd step cylinder. Remove the 2nd step cylinders from the 2nd step shaft. Remove at the right and left side the brackets from the 2nd step shaft.
402
TSM Oc 9800
Dis-/assemblies
Note: Do not drop the brackets.

bracket
screw
22 Remove the 2nd step shaft with the small yokes. 23 Remove the cable ties from the preheater cable bundles (mark the position of
the bundles).
24 Disconnect on the left (as viewed from the rear) the connector 14X2 and on the
right the connector 14X1 and push them to the frame inside.
25 Remove on the left (as viewed from the rear outside the frame) the cable ties 26 27 28 29
from the preheater liquid hose (mark the position of the hose). Close the air supply main tap on the compressor. Remove the brass caps from the 2nd step cylinders. Disconnect the preheater liquid hose and close both sides with the brass caps. Push the liquid hose to the frame inside.
Note: Do carefully the next points, the unit can drop when not done correctly.
30 Close and lock the preheating unit. 31 Loosen the screws of the spring loaded security brackets. 32 Hold with two persons the preheating unit and unlock the unit with the green
handle.
33 Keep holding the unit and push down both security brackets, attention: the unit
is free and the weight is 25 kg.

34 Carefully unlock and remove the preheating unit.
Note: Connect the liquid hose and open the air supply tap after mounting the
preheating unit.
ed.5
14 Preheating 403
Note: If any liquid is lost from the preheating unit during dis-/assembly, refill
liquid into the reservoir. When mounting the build-up cleaner release the locking handle of the preheating unit.
Note: When the pre-heating unit is already disassembled continue with dis-/as-
sembly 2 except point 1 and 4.
2 Paper guide cloth

1 Carry out function 06 CTF dis-/assembly CTFFHE1 (lower) on page 407. 2 Release (as viewed from the rear) on the right frame outside the shaft fixing
nut.
3 Remove (as viewed from the rear) on the left side the shaft fixing plate (2
screws).
4 Release the preheating unit. 5 Move the shaft to the left and position them in the locking position. 6 Remove at the left (as viewed from the rear) the E-ring from the lower shaft of
the guide cloth assembly at the frame outside.

7 Carefully lift out the paper guide cloth. 8 After a new guide cloth is mounted carry out the SDS the test 14-8-01. 9 Enter the value 0.
Note: When mounting the guide cloth check if the cloth passes in between the
fixed roller and the movable shaft. The shoulder on the shaft must fit into the frame.
404
TSM Oc 9800
Dis-/assemblies
3 Silicon rollers
1 2 3 4
Carry out dis-/assembly Preheating unit on page 401. Remove the preheating drive belt. Remove one of the gears of the drive belt. Remove the roller mounting plate.
ed.5
14 Preheating 405
406
TSM Oc 9800
Dis-/assemblies
1 General
The preheater unit has the following functions:
1 preheating of the copy material before it enters the CTF (Compact Transfer
transFuse) section to ensure optimum toner fixation.

2 optimal copy transport of the copy into the CTF section.
CTF unit
preheater unit
preheater roller
guide cloth
ed.5
14 Preheating 501
2 Preheating
PRETEMPSE Preheater roller / brake (PRETBR)
Preheating section
Preheater elements PREHE1, 2, 3
Preheater guide cloth
PREHETEMPERSW
The preheating section filled with the heating liquid enables a uniform and good heat transfer over the total width of the copy material. The copy material is pre-heated during the transport of the copy material over the warm aluminium frame. A preheater guide cloth keeps the copy material in good contact with the preheating section. The liquid in the preheater section consists of water and MPG (Mono Propylene Glucol)). The MPG is added to the water to prevent freezing . The preheater section itself is completely filled with 5 litres liquid. It is connected via a hose with an expansion reservoir which contains 2 litres. The reservoir is positioned at the left-hand side of the machine. At the outside of the reservoir a level indication is available to check the liquid level. If the liquid level becomes too low the refill opening on top of the reservoir can be used. The liquid in the preheater section is warmed up with 3 heating elements (PREHE1,2 and 3). The liquid in the preheater section will expand and shrink owing to higher and lower temperatures. The liquid in the preheater section is warmed up till 100 C. To prevent boiling of the liquid, an over pressure of 0.4 bar is supplied to the expansion reservoir. The over-pressure is tapped from the pneumatic system. First the working pressure is reduced to 3 bar and next this pressure is reduced to o.4 bar. Both valve are factory adjusted. The last valve incorporates also a safety blow off
502
TSM Oc 9800
valve to protect the system for a too high over pressure. When the machine is switched off the over-pressure is released. The temperature of the preheating section is controlled by the PRETEMPSE sensor (NTC) (at the top of the section). If the temperature of the preheater becomes too high the resetable safety switch PREHETEMPERSW will switch of the heating elements.
preheater unit
liquid reservoir
level indication 3 bar reduction valve
0.4 bar reduction valve and safety blow off valve
ed.5
14 Preheating 503
3 Copy transport
The copy material is transported by the preheater roller which is driven by MADMO, the main drive motor. The copy is then transported into the second transfer pinch of the CTF. The speed in the CTF second transfer pinch is higher than the speed in the preheating section. The paper tends to pull at the preheater roller, but this is prevented by a one-way bearing mounted on the roller. For paper width sizes of more than 594 mm (A1, A0, D and E sizes) the preheater transport brake (PRETBR), mounted on the preheater roller, is energized. It pulls at the copy material and keeps it flat before it moves into the second transfer pinch. This is done to prevent creases and the skeleton effect on the copy material.
504
TSM Oc 9800
1 Brake PRETBR
Two types of brakes excist. An older type of 0,25A and a newer type of 0,5A. The newer type of brake part no. 7015.738 works only with a newer type of ~Driver PBA~ part no. 5584.001. On this PBA is a jumper X13 to set the brake force to NOM or MAX. NOM: is the normal brake force. MAX: stronger brake force, necessary if the fixation is not sufficient on heavy tracing paper, see Fixation on heavy tracing paper on page 305. The material will be better pre-heated. If not necessary, set the jumper X13 on NOM, otherwise the timing belt of the pre-heater drive will wear out too fast.
PRETEMPSE
PREHE 1, 2, 3
PREHETEMPERSW
ed.5
14 Preheating 601
PRETBR
3 bar reduction valve liquid reservoir compressor
0.4 bar reduction valve
PREHETRIAC
602
TSM Oc 9800
1
22G1 CONSUPLV
3
X8 5 6 7 8 9 10 1 2 3 4
4
22PBA5 DRIVERS
F1 4A
22PBA1 CPU I/O
F4 4A X10 1 2 3 5 X6 27 28 6 X5 7
X13 1 2 3 5 X6 27 28 6
+5V GND +24V GND CONDRIINDIAG CONDRIOUTDIAG PRETBR-D0
X5 5
22X11 1
14X3 1
PRETBR
14Y1
+24V
CTFDOORSW
1 06S1 2
PTRFRAMESW
1 15S1 X12 14 2 +24V-SW 8
CONEMS3-B
CONEMS3
22K3-2A
+24V-SW
13
+24V GND X5 4 5 X9 9 1 +5VAN PRETEMPSE 14X2 1 2
23 20
-T
-T
PRETEMPSE
14R1
22PBA4 SSR
X1 30 28 9 1 X12 5 6 4 3 N3-S PREHEG PREHEC-2 PREHEC-2 14X1 1
52
PREHETRIAC
14V1
CONSSRINDIAG PREHE
PREHE1
14E1
22Z3
52
PREHE2
14E2
4 6 5
N3 L3
2 6
4 8
N3-S L3-S
X11 6 3
52
PREHE3
14E3
22X010 1 L3-S 3
PRETEMPERSW
14S1
22X007-3
14X001
H
ed.5 TSM Oc 9800 14 Preheating 701
6
CTFSTCYL-R first transfer step
A
0.3
)(
CTFSFCYL-R fuser step
B
CTFSFCYL-L fuser step
PREHEATING
)(
0.3
CTFSTCYL-L first transfer step
RED 2 BLUE 4
D
RED 2 BLUE 4
CTFSFVA fuser
LEVEL
CTFSTVA transfer
E
3 BAR 0.4 BAR 3 BAR 5.6 BAR
CTFSPVA high / low pressure
5.6 BAR
MOD. 29 TIMER ON/OFF
H
PNEUMATICS ed.5 TSM Oc 9800 14 Preheating 702
Oc
Oc 9800
15 PAPER TRANSPORT
Contents
Diagnostics
1 Faults
101
SDS
1 PaperTRransport 201
Dis-/assemblies
1 PTR unit (without folder) 401 2 PTR unit (with folder) 402 3 PTRBULSE (Paper TRansport BULge SEnsor) 403 4 PTRUFOSE (Paper TRansport UnFold Output SEnsor) 403 5 PTRTRAISEn (Paper TRansport TRAIling edge SEnsors) 403
1 General 501
601
Diagrams
1 Paper transport without folder 701 2 Paper transport with folder 702
ed.5
15 Paper transport
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Paper TranspoRt 15000 - 15999 code display 15101 PE: ~PTRTRAISE1/2/3 error~ See error code 15701 and 15703
15701 ORE: ~Paper too late at PTRTRAISE1~

15-2-03 Possible cause PTRTRAISE1
Remark
Continuously OFF
Connection PTRTRAISE1 -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRTRAISE1 defect CPU_IO PBA defect
ed.5
15 Paper transport 101
15702 ORE: ~PTRTRAISE1 too late free~

15-2-03 Possible cause PTRTRAISE1 Remark
Continuously ON
15703 ORE: ~Paper too late at PTRTRAISE3~

~
15-2-05 PTRTRAISE3
Possible cause
Remark
Continuously OFF
15-4-01 PTRUFOSO
CONFOL1 OUTDIAG ON OFF
Possible cause
Remark
OFF
POWER IO PBA defect PTRUFOSO defect / blocked
102
TSM Oc 9800
Diagnostics
15704 ORE: ~PTRTRAISE3 too late free~

~
Remark
Continuously ON
Connection PTRTRAISE3 -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO INTERFACE PBA Connection IO INTERFACE PBA -> CPU_IO PBA Actuator defect PTRTRAISE3 defect CPU_IO PBA defect
15705 ORE: ~Speed PTRMO/FOL1INMO out of range~

~
18-6-05 CONFOL1 PTRMO turning FOL1INMO OUTDIAG (100% PWM) (PTRMO)
Possible cause
Remark
OFF ON (100% PWM)
Yes No
POWER IO PBA defect PTRMO defect / blocked Connection POWER_IO PBA -> PTRMO
Yes
PTRMOSE / pulse disc defect Connection PTRMOSE -> IO_INTERFACE PBA IO_INTERFACE PBA defect (LM629) (check by switching with FOL2 IO_INTERFACE PBA if present)
No
POWER_IO PBA defect
ed.5
15706 ORE: ~Paper too late at PTRUFOSE~

15-2-02 PTRUFOSE Possible cause Remark
Continuously Connection PTRUFOSE -> SENSOR DISTRIBUOFF TION PBA Connection SENSOR DISTRIBUTION PBA -> IO INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRUFOSE defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect (check by switching with FOL2 IO_INTERFACE PBA if present) CPU_IO PBA defect
15-4-01 CONFOL1 PTRUFOSO OUTDIAG
Possible cause
Remark
ON
OFF ON
POWER_IO PBA defect Connection POWER_IO PBA -> 18X4 -> PTRUFOSO PTRUFOSO defect
104
TSM Oc 9800
Diagnostics
15707 ORE: ~PTRUFOSE too late free~

15-2-02 PTRUFOSE Possible cause Remark
Continuously Connection PTRUFOSE -> SENSOR DISTRIBUON TION PBA Connection SENSOR DISTRIBUTION PBA -> IO INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRUFOSE defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect (check by switching with FOL2 IO_INTERFACE PBA if present)
CPU_IO PBA defect
15901 SWAR: ~Start run: PTRBULSE not free~

15-2-01 PTRBULSE Possible cause Remark
Continuously Connection PTRBULSE -> SENSOR DISTRIBUON TION PBA Connection SENSOR DISTRIBUTION PBA -> IO INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRBULSE defect SENSOR DISTR. PBA defect IO_INTERFACE PBA defect (check by switching with FOL2 IO_INTERFACE PBA if present) CPU_IO PBA defect
ed.5
106
TSM Oc 9800
Diagnostics
SDS
1 PaperTRransport
Analysis info tests 30 Reset PE & handicaps~
see SDS
31 Log / res err & ser cnt~
see SDS
32
Last error logging (OWAR/SWAR/ORE/MRE/PE/FE)~
34 Error top 10 (OWAR/SWAR/ORE/MRE/PE/FE)~
35 Error counters > 0~
see SDS
36 Consumable counters~
see SDS
37 Parameters settings~
see SDS
38 Serv. / Mark. counters~
see SDS
ed.5
Test nr.
Component
Signal
Description
Parameter test 15-1-01
15B1
PTR TRAiling SEnsor
Dist. PTRTRAISE1 - FOL1STARTSE mm/100~
Distance between trailing sensor 1 and startsensor (range 42000 - 50000, default 44610, mm/100)
15-1-02
15B2
PTR TRAiling SEnsor
15-1-03
15B3
PTR TRAiling SEnsor
Input tests 15-2-01 15-2-02 15-2-03 15-2-04 15-2-05 15-2-06
15B4 15B5 15B1 15B2 15B3 15S1
PTR BULge SEnsor PTR UnFolded Output SEnsor PTR TRAIling SEnsor 1 PTR TRAIling SEnsor 2 PTR TRAIling SEnsor 3 PTR FRAME SWitch
Paper transport bulge sensor ON = bulge detected Paper transport unfolded output sensor ON = paper detected Paper transport trailing sensor 1 ON = paper present Paper transport trailing sensor 2 ON = paper present Paper transport trailing sensor 3 ON = paper present Paper transport frame switch ON = door open
202
TSM Oc 9800
SDS
Test nr.
Component
Signal
Description
15Y1
PTR UnFOld SOlenoid
Paper transport unfolded solenoid ON = solenoid activated, unfolded output Hardware diagnoses: CONFOL1OUTDIAG
Special tests 15-6-01 Make function warm~
Functions 15 (paper transport) and 18 (folder) in warm condition

15-6-02 Make function cold~
Functions 15 (paper transport) and 18 (folder) in cold condition

18-6-05 System tests 57
PTRMOtor
Paper TRansport MOtor
Adjust ptr/fold1~
A1 (22/24~) in roll 1 position 20 sheets are folded This test determines the parameters for tests 15-1-01/02/03
ed.5
204
TSM Oc 9800
SDS
Dis-/assemblies
1 PTR unit (without folder)
Warning: Carry out this dis-/assembly with two technicians.
The weight is 35 kg.

1 2 3 4 5 6
7 8 9 10
Remove the copy receiving tray. Open the PTR unit. Measure and note the length from the joint ball connections. Release at the rear left and right the joint ball connections from the side covers. Remove (as viewed from the rear) the left and right side covers. Disconnect on the left-hand side from the wiring bundle between the PTR and the engine the connectors 1801X2, 1801X4 and 22X13. Close the PTR unit. Remove the PTR rear cover. Remove on both sides the PTR unit locking plates. Open the PTR unit halfway and lift out the PTR unit.
side cover
rear cover joint ball
Note: When mounting the PTR unit to the printer check the springs on the left and right for correct position.
ed.5
2 PTR unit (with folder)

Warning: Do this dis-/assembly with two technicians.
The weight is 35 kg.

1 Remove the copy receiving tray. 2 Loosen from inside the folder on the left and right two screws from the left and
right side folder top cover.

3 Remove the left and right side folder top covers with side covers. 4 Open the PTR unit. 5 Release on the rear left and right side the joint ball connections from the side
covers.
6 Remove the left and right side covers. 7 Disconnect on the left hand side from the wiring bundle between the PTR and 8 9 10 11 12 13
the engine the connectors 1801X4 and 22X13. Disconnect on the left the connectors 18X4 and 2201X5. Remove on the right the PTR drive belt between folder and PTR. Close the PTR unit. Remove the PTR rear cover. Remove on both sides the PTR unit locking plates. Open the PTR unit halfway and lift out the unit, first to the engine front side and then upwards.
Note: When mounting the PTR unit to the printer check the springs on the left and right for correct position.
Mounting the rear cover.

1 Close the PTR unit and lock the delivery unit. 2 Mount the rear cover.
402
TSM Oc 9800
Dis-/assemblies
3 PTRBULSE (Paper TRansport BULge SEnsor)

1 2 3 4
Open the PTR unit. Remove at the left and right the hinge plate. Remove the PTR unit cover (left and right 1screw). Remove PTRBULSE.
4 PTRUFOSE (Paper TRansport UnFold Output SEnsor)

1 2 3 4
Open the PTR unit. Remove on the left and right side the hinge plate. Remove the PTR unit cover (left and right one screw). Remove PTRUFOSE.
5 PTRTRAISEn (Paper TRansport TRAIling edge SEnsors)

1 Open the PTR unit. 2 Remove the rear cover. 3 Remove the sensors.
Note: After replacement of one of the sensors carry out SDS test 57 ~Adjust ptr
/ fold1~
ed.5
404
TSM Oc 9800
Dis-/assemblies
1 General
The function of paper transport is to transport the copy to the folder or to eject the copy unfolded onto the receiving tray.
PTRBULSE CTF
bulge fingers Confidential 1999 Oc-Technologies B.V.
PTRUFOSE
unfolded receiving tray PTRTRAISE 1..3
folder
Copies which leave the CTF unit are fed into the paper transport. To prevent copies from being torn out of the CTF unit, the speed of the PTR is less than the speed of the CTF and a bulge is formed between CTF and PTR. As soon as the bulge becomes too large PTRBULSE (bulge sensor) is operated by the copy. The speed of the output motor increases and the bulge becomes less. If unfolded copy delivery is selected PTRUFOSO (unfolded output solenoid) is activated and the copies are ejected onto the receiving tray. PTRUFOSE (unfolded output sensor) detects whether the copies have been correctly delivered onto the receiving tray. PTRTRAISE 1 to 3 have the function to detect the trailing edge of the copy when it is folded, see function 18 - FOLDER.
ed.5
502
TSM Oc 9800
PTRBULSE CTF
bulge fingers
PTRUFOSE Confidential 1999 Oc-Technologies B.V.
unfolded receiving tray PTRTRAISE 1..3
folder
ed.5
PTRFRAMESW PTRUFOSO 15PBA2 POWER I/O (without folder)
15 PBA1 SENSOR DISTRIBUTION
PTRBULSE
PTRMO (without folder)
602
TSM Oc 9800
1
22G1 CONSUPLV
2
X8 5 6 7 8 9 10 1 2 3 4 F4 4A
3
22PBA5 DRIVERS
X8 12 11 +24V-SW GND 22X13 1 2 3 15X001
4
15PBA2 POWER I/O
X6 7 X1 2 X3 1 PTRMO+
M
2 X4 7 6 5 X8 5 6 PTRMO2
PTRMO
15M1
F1 4A
22X003-4
+5V PTRMOSE-1 GND
1 2 3
PTRMOSE
15B6
PTRUFOSO +24V
PTRUFOSO
15Y1
(or fixed position) 22PBA1 CPU I/O

X13 1 2 3 5 +5V GND +24V GND X10 1 2 3 5
X8 19
CTFDOORSW
PTRFRAMESW 4 1 2 06S1 1 +24V
X5 7
C
20
PTRFRAMESW
15S1 GND 3 2 +24V-SW 8
18PBA1 I/O INTERFACE

X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 +5V +5V GND BD0 BD1 BD2 BD3 GND BD4 BD5 BD6 BD7 GND BA1 BA2 BA3 BA4 GND NASIC1_RD NASIC1_WR GND NINT5 NINT4 BNRESET BNOE GND X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 X2 24 23 7 1 21 +5V GND PTRMOPWM PTRMOSE PTRUFOSO (from SW2.0) X7 1 2 17 20 4
15PBA1 SENSOR DISTRIBUTION

X4 16 15 6 13 12 8 7 +5V GND PTRTRAISE3-B PTRBULSE PTRUFOSE PTRTRAISE1-B PTRTRAISE2-B X2 8 7 4 2 3 6 5 X3 13 15 14 10 11 12 7 8 9 1 3 2 4 5 6 +5V GND PTRTRAISE1 +5V GND PTRTRAISE2 +5V GND PTRTRAISE3 +5V GND PTRBULSE +5V GND PTRUFOSE 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
PTRTRAISE1
15B1
PTRTRAISE2
15B2
PTRTRAISE3
15B3
PTRBULSE
15B4
PTRUFOSE
15B5
H
WITHOUT FOLDER
ed.5
TSM Oc 9800
1
22PBA1 CPU I/O
X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 +5V +5V GND BD0 BD1 BD2 BD3 GND BD4 BD5 BD6 BD7 GND BA1 BA2 BA3 BA4 GND NASIC1_RD NASIC1_WR GND NINT5 NINT4 BNRESET BNOE GND X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 X2 24 23 21 11 13 14 1 2 3
2
+5V GND PTRUFOSO-1 PTRDOORSW-B FOL1OUTDIAG FOL1INPDIAG ENC1 ENC2 ENC3
4
X7 1 2 8 14 12 11 20 19 18
5
18PBA3 POWER I/O
X8 5 6 X6 5 6 7 8 PTRUFOSO +24V 18X4 5 6 7 PTRDOORSW 9
PTRUFOSO
15Y1
GND
8 10
15PBA1 SENSOR DISTRIBUTION

X4 16 15 6 13 12 8 7 +5V GND PTRTRAISE3-B PTRBULSE PTRUFOSE PTRTRAISE1-B PTRTRAISE2-B X2 8 7 4 2 3 6 5 X3 13 15 14 10 11 12 7 8 9 1 3 2 4 5 6 +5V GND PTRTRAISE1 +5V GND PTRTRAISE2 +5V GND PTRTRAISE3 +5V GND PTRBULSE +5V GND PTRUFOSE 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
PTRTRAISE1
15B1
PTRTRAISE2
15B2
PTRTRAISE3
15B3
PTRBULSE
15B4
PTRUFOSE
15B5
X8 19 20
PTRFRAMESW GND
22PBA5 DRIVERS
PTRFRAMESW
+24V-SW 3 2 15S1 4 1
X13 1 2 3 5
+5V GND +24V GND
X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10
X5 8
CTFDOORSW
7 +24V 1 O6S1 2
22G1 CONSUPLV
F1 4A
X8 12 11 X12 12
+24V-SW GND
22X13 1 2
CONEMS2-B
15
+24V-SW
CONEMS2
22K2-2A
22PBA4 SSR 22Z2

6 5 4 L2 22X010 N2 X9 1 2 3 X8 6 3 L2 N2 6 2 8 4
18G1 FOLSUPLV
G1 3 1 2 G5 G4 3 1 G2 1 3 F1
N2-S L2-S
X2 5 6
1 4
N2-S L2-S
18X16 GND +5V GND +24V
18X002-1
22X012-1
2201X5 2 1 X1 2 1
5A
H
WITH FOLDER
ed.5
TSM Oc 9800
Oc
Oc 9800
18 FOLDER
Contents
Diagnostics
1 Faults
101
SDS
1 FOLder 201
Adjustments
1 ~Adjust ptr / fold1~ 301 2 Second folding unit 302 3 FOL1 guide plate 303 4 Distance from the copy guide to the frame in the intermediate transport (without Reinforcement Unit) 304 5 Flat guide plate of the 2nd folding unit 306 6 Height of the belt unit and zero-line 307 7 FOL Output PUnch Eject SOlenoid (FOLOPUESE) 309 8 Paper guide flap belt unit 310 9 The adjusting procedure for the Reinforcement Unit 312 10 Position of the copy guide in the intermediate transport (with Reinforcement Unit) (basic setting) 316 11 Hinges (basic setting) 317 12 Position of the Reinforcement Unit in the frame (basic setting) 318 13 Locking plate 319 14 Stopper angle 320 15 Stopper position (basic setting) 321 16 Third copy guide (inside the second folding unit) 322 17 Vertical position of the small copy guide (basic setting) 323 18 Horizontal position of the small copy guide (basic setting) 324 19 Position of the retraction solenoid of the small copy guide (basic setting) 325 20 Position of the copy guide in the intermediate transport (with Reinforcement
ed. 5
18 Folder
Unit) (fine-tuning) 326 21 Stopper position (fine-tuning) 329 22 Position of the Reinforcement Unit in the frame (fine-tuning) 331 23 Position of the retraction solenoid of the small copy guide (fine-tuning) 333 24 Retracted position of the small copy guide (fine-tuning) 334 25 Horizontal position of the small copy guide (fine-tuning) 335 26 Vertical position of the small copy guide (fine-tuning) 336 27 Long copy guide to small copy guide 338 28 Position of the upper knife 339 29 Long copy anti wrinkle procedure (first fold). 340 30 Polyester strips on the front and the rear guide plate of the first fold 342 31 Polyester strip on the bottom guide plate of the second fold 343 32 FOL1OUTDEFSO (Solenoid of the delivery flap of the first fold) (Only for modification 07 of 700/705/715). 344 33 Adjusting plate 2nd folding rollers 346
Dis-/assemblies
1 ~FOL1DEFCL~ (clutch of 1st fold) 401 2 ~FOL2DEFCL~ (clutch of 2nd fold) 402 3 ~FOL1FOLMO~ and ~FOL2FOLMO~ 403
1 General folding 501 2 Folding programmes 503 3 Folding package definition and distances 504 4 Folding length for DIN size folding in the 1st fold 505 5 Folding length for DIN size folding in the 2nd fold 506 6 DIN folding 507 7 Ericsson folding 507 8 1st fold 508 9 Inner transport 508 10 2nd fold 509 11 First fold delivery 510 12 Drive belt PTR - folder 513 13 The Reinforcement Unit (RU) 514
601
TSM Oc 9800
Contents
Diagrams
1 Folder first fold 701 2 Folder second fold up to nr. 3000 702 3 Folder second fold from nr. 3000 703 4 Folder otionals 704 5 Folder Reinforcement 705 6 FolderReinforcement 706
ed. 5
18 Folder
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. FOLder 18000 - 18999 code display 18101 PE: ~FOL1FOLMO controller failure~
18-6-06 ~FOL1FOLM O~
CONFOL1 ~FOL1FOL OUTDIAG MO~ turning (100%) ON (disconnect 1803X5) Yes No
Possible cause
Remark
OFF
~POWER_IO PBA~ defect ~FOL1FOLMO~ defect / blocked Connection ~POWER_IO PBA~ -> ~FOL1FOLMO~
ON (100% PWM)
Yes
~FOL1FOLMOSE~ / pulse disc defect Connection ~FOL1FOLMOSE~ -> ~IO_INTERFACE PBA~ ~FOL1_IO_INTERF ACE PBA~ defect (Check by switching with ~FOL2_IO_INTERF ACE PBA~ if present)
No
~POWER_IO PBA~ defect
ed. 5
18 Folder 101
18102 PE: ~FOL2INMO controller failure~ 18505 MRE: ~FOL2INMO controller failure~
18-6-08 ~FOL2IN MO~
CONFOL2 ~FOL2IN OUTDIAG MO~ turning (100% PWM) ON (disconnect 1810X3) Yes No
Possible cause
Remark
OFF ON (100% PWM)
~POWER_IO PBA~ defect ~FOL2INMO~ defect / blocked Connection ~FOL2_POWER_IO PBA~ -> ~FOL2INMO~
Yes
~FOL2INMOSE~ / pulse disc defect Connection ~FOL2INMOSE~ -> ~IO_INTERFACE PBA~ ~FOL2_IO INTERFACE PBA~ defect (LM629) (Check by switching with ~FOL1_IO_INTERFACE PBA~)
No
102
TSM Oc 9800
Diagnostics
18103 PE: ~FOL2FOLMO controller failure~ 18506 MRE: ~FOL2FOLMO controller failure~
~
18-6-09 ~FOL2FOL MO~
CONFOL2 ~FOL2FOL OUTDIAG MO~ turning (100% PWM) ON (disconnect 1810X5) Yes No
Possible cause
Remark
OFF ON (100% PWM)
Yes
~FOL2FOLMOSE~ / pulse disc defect Connection ~FOL2FOLMOSE~ -> ~IO_INTERFACE PBA~ ~FOL2_IO_INTERFA CE PBA~ defect (LM629) (Check by switching with ~FOL1_IO_INTERFA CE PBA~)
No
18104 PE: ~FOL2_IO_INTERFACE PBA defect~ 18508 MRE: ~FOL2_IO_INTERFACE PBA defect~
~FOL2_IO_INTERFACE PBA~ defect
Check by changing with ~FOL1_IO_INTERFACE PBA~
Check electrical connection between ~FOL2 I/O interface PBA~ and ~CPU I/O PBA~
ed. 5
18 Folder 103
18105 PE: ~FOLOPUMO error~ 18509 MRE: ~FOLOPUMO error~.

18-4-07 ~FOLOPUMO~ ~FOLOPUMO~ turning Possible cause
OFF
Yes
~I/O BOARD PBA~ defect Electrical connection between ~I/O PBA~ and ~FOLOPUMO~ Electrical connection between ~Relay PBA~ and ~FOLOPUMO~
ON
NO
~FOLOPUMOHOMESE~ defect ~FOLOPUMO~ defect ~Relay PBA~ defect ~I/O PBA~ defect Electrical connection between ~I/O PBA~ and ~FOLOPUMO~ Electrical connection between ~Relay PBA~ and ~FOLOPUMO~
18-2-20 ~FOLOPUMOHOMESE~
Possible cause
Continuously ON
~FOLOPUMOHOMESE~ defect / polluted ~I/O PBA~ defect
Continuously OFF
Connection between ~FOLOPUMOHOMESE~ and ~I/O PBA~ ~FOLOPUMOHOMESE~ defect ~I/O PBA~ defect
104
TSM Oc 9800
Diagnostics
18-2-21 ~FOLOPUMOHOENDSE~
Possible cause
Continuously ON
~FOLOPUMOENDSE~ defect / polluted ~I/O PBA~ defect
Continuously OFF
Connection between ~FOLOPUMOENDSE~ and ~I/O PBA~ ~FOLOPUMOENDSE~ defect ~I/O PBA~ defect
18106 PE: ~FOLOADJMO error ~ 18510 MRE: ~FOLOADJMO error~

18-4-06 ~FOLOADJMO~
~FOLOADJ MO turning~
Possible cause
OFF
Yes
~I/O PBA~ defect ~Relay PBA~ defect Electrical connection between ~I/O PBA~ and ~FOLOADJMO~ Electrical connection between ~Relay PBA~ and ~FOLOADJMO~
ON
NO
~FOLOADJMOHOMESE~ defect ~FOLOADJMO~ defect ~Relay PBA~ defect Electrical connection between ~I/O PBA~ and ~FOLOADJMO~ Electrical connection between ~Relay PBA~ and ~FOLOADJMO~
18-2-17 ~FOLOADJMOHOMESE~
Possible cause
Continuously ON
~FOLOADJMOHOMESE~ defect / polluted ~I/O PBA~ defect
ed. 5
18 Folder 105
18-2-17 ~FOLOADJMOHOMESE~
Possible cause
Continuously OFF
Connection between ~FOLOADJMOHOMESE~ and ~I/O PBA~ ~FOLOADJMOHOMESE~ defect ~I/O PBA~ defect
18-2-18 ~FOLOADJMOENDSE~
Possible cause
Continuously ON
~FOLOADJMOENDSE~ defect / polluted ~I/O PBA~ defect
Continuously OFF
Connection between ~FOLOADJMOENDSE~ and ~I/O PBA~ ~FOLOADJMOENDSE~ defect ~I/O PBA~ defect
18107 PE: ~FOL2RUMOHOMESE not active~ 18511 MRE: ~ FOL2RUMOHOMESE not active ~
Possible cause
The stamp is mechanically blocked ~FOL2RUSTAMPSO~ or the clutch is not correctly adjusted ~FOL2RUHOMESE~ is defective The drive chain is broken The drive motor is not connected or defective ~18PBA17~ is defective
106
TSM Oc 9800
Diagnostics
18501, 18502 MRE: ~Wrong position FOL(1/2)DEFCL~

18-2-03 Possible cause 18-2-07 ~FOL(1/2)DE POSE~ Remark
Continuously ON / OFF
Connection ~FOL(1/2)DEPOSE~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL(1/2)DEPOSE~ defect ~SENSOR DISTRIBUTION PBA~ defect
~IO_INTERFACE PBA~ defect (Check by switching with ~FOL2_IO_INTERFACE PBA~ if present) ~CPU_IO PBA~ defect
ed. 5
18 Folder 107
18503 MRE: ~FOL1INMO controller failure~

18-6-05 ~FOL1I N MO~
CONFOL1 OUTDIAG (100% PWM) ON (disconnect 1803X3)
~FOL1IN MO~ turning Yes No
Possible cause
Remark
OFF ON (100% PWM)
~POWER_IO PBA~ defect ~FOL1INMO~ defect / blocked Connection ~FOL1_POWER_IO PBA~ -> ~FOL1INMO~
Yes
~FOL1INMOSE~ / pulse disc defect Connection ~FOL1INMOSE~ -> ~IO_INTERFACE PBA~ ~FOL1 IO INTERFACE PBA~ defect (LM629) (Check by switching with ~FOL2_IO_INTERFACE PBA~ if present)
No
~POWER IO PBA~ defect
108
TSM Oc 9800
Diagnostics
18504 MRE: ~FOL1FOLMO controller failure~

Possible cause
Remark
OFF ON (100% PWM)
Yes
~FOL1FOLMOSE~ / pulse disc defect Connection ~FOL1FOLMOSE~ -> ~IO_INTERFACE PBA~ ~FOL1_IO_INTER FACE PBA~ defect (LM629) (Check by switching with ~FOL2_IO_INTER FACE PBA~ if present)
No
18505 MRE: ~FOL2INMO controller failure~ on page 102 18506 MRE: ~FOL2FOLMO controller failure~ on page 103
18507 MRE: ~FOL1 IO INTERFACE PBA defect~

~FOL1_IO_INTERFACE PBA~ defect
Check by switching with ~FOL2_IO_INTERFACE PBA~ if present
ed. 5
18 Folder 109
18508 MRE: ~FOL2_IO_INTERFACE PBA defect~ on page 103 18509 MRE: ~FOLOPUMO error~. on page 104 18510 MRE: ~FOLOADJMO error~ on page 105 18511 MRE: ~ FOL2RUMOHOMESE not active ~ on page 106 18701 ORE: ~Paper too late at FOL1STARTSE~
18-2-01 ~FOL1START SE~ Possible cause Remark
Continuously OFF
Connection ~FOL1STARTSE~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL1STARTSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Check by switching with ~FOL2_IO_INTERFACE PBA~ if present) ~CPU_IO PBA~ defect
110
TSM Oc 9800
Diagnostics
18702 ORE: ~FOL1STARTSE too late free~

Continuously ON Connection ~FOL1STARTSE~ -> ~SENSOR DISTR. PBA~ Connection ~SENSOR DISTRIBUTION PBA~ ->~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL1STARTSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Check by switching with ~FOL2_IO_INTERFACE PBA~ if present) ~CPU_IO PBA~ defect
18703 ORE: ~Distance FOL1 copies too small~

Software failure folding program
ed. 5
18 Folder 111
18704 ORE: ~Speed FOL1FOLMO out of range~

Possible cause
Remark
OFF ON (100% PWM)
Yes
~FOL1FOLMOSE~ / pulse disc defect Connection ~FOL1FOLMOSE~ -> ~IO_INTERFACE PBA~ ~FOL1_IO_INTER FACE PBA~ defect (LM629) (Check by switching with ~FOL2_IO_INTER FACE PBA~ if present)
No
Possible cause
Remark
If activating 18-6-05 (FOL1FOLMO) is not possible
112
TSM Oc 9800
Diagnostics
18705 ORE: ~Paper too late at FOL2TRAISE1~

18-2-05 ~FOL2TRAISE1~ Possible cause Remark
Continuously OFF
Connection ~FOL2TRAISE1~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2TRAISE1~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Check by switching with ~FOL1_IO_INTERFACE PBA~)
~CPU_IO PBA~ defect
18-4-03 ~FOL2FLAT SO~
CONFOL2 OUTDIAG OFF ON
Possible cause
Remark
ON
~POWER_IO PBA~ defect Connection ~POWER_IO PBA~ (18PBA10) -> ~FOL2FLATSO~ ~PTRUFOSO~ defect
Possible cause
Remark
Eccentric mechanism lifting roller stuck Check last error logging 18901->18905 Too much curl in receiving material Height second folding not adjusted correctly
ed. 5
18 Folder 113
18706 ORE: ~Paper too late at FOL2TRAISE2~

Continuously OFF
Connection ~FOL2TRAISE2~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2TRAISE2~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Check by switching with ~FOL1_IO_INTERFACE PBA~) ~CPU_IO PBA~ defect
18-4-03 ~FOL2FLAT SO~
CONFOL2 OUTDIAG OFF ON
Possible cause
Remark
ON
~POWER_IO PBA~ defect Connection ~POWER_IO PBA~ (18PBA10) -> ~FOL2FLATSO~ ~PTRUFOSO~ defect
Possible cause
Remark
Eccentric mechanism lifting roller stuck Check last error logging 18901->18905
114
TSM Oc 9800
Diagnostics
18707 ORE: ~FOL2TRAISE2 too late free~

Continuously ON
Connection ~FOL2TRAISE2~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2TRAISE2~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Check by switching with ~FOL1_IO_INTERFACE PBA~)
~CPU_IO PBA~ defect
ed. 5
18 Folder 115
18708 ORE: ~Paper too late at FOL2STARTSE~

Continuously OFF
Connection ~FOL2STARTSE~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~ SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2STARTSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Possible check: interchange with ~FOL1_IO_INTERFACE PBA~) ~CPU_IO PBA~ defect
18-2-06 Possible cause ~FOL2TRAISE2
Remark
~ Continuously OFF Connection ~FOL2TRAISE2~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2TRAISE2~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Possible check: interchange with ~FOL1_IO_INTERFACE PBA~) ~CPU_IO PBA~ defect
116
TSM Oc 9800
Diagnostics
18709 ORE: ~FOL2STARTSE too late free~

Continuously ON Connection ~FOL2STARTSE~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA ->~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2STARTSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Possible check: interchange with ~FOL1_IO_INTERFACE PBA~) ~CPU_IO PBA~ defect
18-2-06 Possible cause ~FOL2TRAISE2
Remark
~ Continuously OFF Connection ~FOL2TRAISE2~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2TRAISE2~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect (Possible check: interchange with ~FOL1_IO_INTERFACE PBA~) ~CPU_IO PBA~ defect
ed. 5
18 Folder 117
18710 ORE: ~Distance FOL2 copies too small~

Software failure folding program
18711 ORE: ~Speed FOL2INMO out of range~

18-6-08 ~FOL2IN MO~
CONFOL2 ~FOL2IN OUTDIAG MO~ turn(100% ing PWM) ON (disconnect 1810X3) Yes No
Possible cause
Remark
OFF ON (100% PWM)
~POWER_IO PBA~ defect ~FOL2INMO~ defect / blocked Connection ~FOL2 POWER_IO PBA~ -> ~FOL2FOLMO~
Yes
~FOL2INMOSE~ / pulse disc defect Connection ~FOL2INMOSE~ -> ~IO_INTERFACE PBA~ ~FOL2_IO_INTERFACE PBA~ defect (LM629) Loose static eliminator blocking transport
No
118
TSM Oc 9800
Diagnostics
18712 ORE: ~Speed FOL2FOLMO out of range~

18-6-09 ~FOL2FOL MO~ CONFOL2 ~FOL2FOL Possible cause OUTDIAG MO~ turnRemark
(100% PWM) ON (disconnect 1810X5)
ing
OFF ON (100% PWM)
Yes No
Yes
~FOL2FOLMOSE~ / pulse disc defect Connection ~FOL2FOLMOSE~ -> ~IO_INTERFACE PBA~ ~FOL2_IO_INTERFACE PBA~ defect (LM629)
No
18713 ORE: ~Paper too late at FOL2OUTSE~

18-2-10 Possible cause ~FOL2OUTSE~ Remark
Continuously OFF
Connection ~FOL2OUTSE~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2OUTSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect ~CPU_IO PBA~ defect
ed. 5
18 Folder 119
18714 ORE: ~FOL2OUTSE too late free~

18-2-10 Possible cause ~FOL2OUTSE~ Remark
Continuously ON
Connection ~FOL2OUTSE~ -> ~SENSOR DISTRIBUTION PBA~ Connection ~SENSOR DISTRIBUTION PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL2OUTSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect ~CPU_IO PBA~ defect
18715 ORE: ~Paper too late at FOLOPUSTARTSE~

18-2-19 ~FOLOPUSTARTSE~ Possible cause Remark
Continuously ON
Connection ~FOLOPUSTARTSE~ -> ~I/O_BOARD PBA~ Actuator defect ~FOLOPUSTARTSE~ defect
18716 ORE: ~FOLOPUSTARTSE too late free~

18-2-19 ~FOLOPUSTARTSE~ Possible cause Remark
Continuously ON
Connection ~FOLOPUSTARTSE~ ->~I/O_BOARD PBA~ Actuator defect ~FOLOPUSTARTSE~ defect
120
TSM Oc 9800
Diagnostics
18717 ORE: ~Paper too late at FOLOBELT1SE~

18-2-23 ~FOLOBELT1SE~ Possible cause Remark
Continuously ON
Connection ~FOLOBELT1SE~ -> ~I/O_BOARD PBA~ Actuator defect ~FOLOBELT1SE~ defect
18718 ORE: ~FOLOBELT1SE too late free~

Continuously ON
Connection ~FOLOBELT1SE~ ->~I/O_BOARD PBA~ Actuator defect ~FOLOBELT1SE~ defect
18719 ORE: ~Paper too late at FOLOBELT2SE~

Continuously ON
Connection ~FOLOBELT2SE~ -> ~I/O_BOARD PBA~ Actuator defect ~FOLOBELT2SE~ defect
ed. 5
18 Folder 121
18720 ORE: ~FOLOBELT2SE too late free~

Continuously ON
Connection ~FOLOBELT2SE~ ->~I/O_BOARD PBA~ Actuator defect ~FOLOBELT2SE~ defect
18721 ORE: ~FOL2TRAISE1 too late free~

Possible cause
Paper jam on intermediate transport Drive belt of intermediate transport loose or broken FOL2TRAISE1 defect (e.g. actuator) Connection FOL2TRAISE1 -> sensor distr. PBA Connection sensor distr. PBA -> I/O interface PBA Sensor distr. PBA defect I/O interface PBA defect CPU-I/O PBA defect
122
TSM Oc 9800
Diagnostics
18722 ORE: ~FOLOFFOUTSE too late free~

Possible cause
Paper jam at output sensor Output sensor defect Actuator defect Connection FOL2TRAISE1 -> sensor distr. PBA Connection sensor distr. PBA -> I/O interface PBA Sensor distr. PBA defect I/O interface PBA defect CPU-I/O PBA defect
18723 ORE: ~Paper too late at FOLOFFOUTSE~

Possible cause
Paper jam on intermediate transport Drive belt of intermediate transport loose or broken
18724 ORE: ~Paper too late at FOL2RUSTARTSE~

Possible cause
Copy blocked on intermediate transport, by: s ~FOL2TRAISE1~ not activated s the drive belt is not running correctly s the copy is slipping on the transport (too little grip) s ~FOL2RUSTARTSE~ is defective s ~FOL2RUDOORSW~ is defective s ~18PBA17~ is defective
ed. 5
18 Folder 123
18725 ORE: ~FOL2RUJAMSW not active~

Possible cause
The tape is blocked in the tape path The microswitch ~FOL2RUJAMSW~ is defective
18726 ORE: ~FOL2RUSTARTSE too late free~

Possible cause
The copy is not transported after reinforcement, due to: s the stopper is not released or sticking s the copy is sticking to the stamp s the copy is jammed in the intermediate transport s the intermediate transport does not function s ~FOL2RUSTARTSE~ is defective s ~18PBA17~ is defective
18727 ORE: ~FOL2RUSTARTSE free too soon~

Possible cause
~FOL2RUSTARTSE~ is defective The solenoid ~FOL2RUSTOPSO~ is not activated ~18PBA17~ is defective
124
TSM Oc 9800
Diagnostics
18901 SWAR: ~FOL1 lift up position too late~

18-2-12 ~FOL1LIUP SE~ Possible cause Remark
Continuously OFF
Connection ~FOL1LIUPSE~ -> ~STEPPER_MOTOR CONTROLLER PBA~ Connection ~STEPPER_MOTOR CONTROLLER PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL1LIUPSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect
~CPU_IO PBA~ defect
18-6-11 ~FOL1LI MO~
~FOL1LI MO~ turning No
Possible cause
Remark
ON
Eccentric roller lifting mechanism stuck Connection ~STEPPER_MOTOR CONTROLLER PBA~ -> ~FOL1LIMO~ ~STEPPER_MOTOR CONTROLLER PBA~ defect
Yes
Toothed belt / pulley ~FOL1LIMO~ loose ~FOL1_IO_INTERFACE PBA~ defect
ed. 5
18 Folder 125
18902 SWAR: ~FOL1 lift low position too late~

18-2-11 ~FOL1LI DOWNSE~ Possible cause Remark
Continuously Connection ~FOL1LIDOWNSE~ -> ON ~STEPPER_MOTOR CONTROLLER PBA~ Connection ~STEPPER_MOTOR CONTROLLER PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL1LIDOWNSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect ~CPU_IO PBA~ defect
18-6-11 ~FOL1LI ~FOL1LIMO~ MO~ turn-
Possible cause
Remark
ing No
ON
Connection ~STEPPER_MOTOR CONTROLLER PBA~ -> ~FOL1LIMO~ ~STEPPER_MOTOR CONTROLLER PBA~ defect
Yes
Toothed belt / pulley ~FOL1LIMO~ loose FOL1_IO_INTERFACE PBA defect
126
TSM Oc 9800
Diagnostics
18903 SWAR: ~FOL1 lift low position too soon~

18-6-11 ~FOL1LI MO~
~FOL1LI MO~ turning No
Possible cause
Remark
ON
Yes
Toothed belt / pulley ~FOL1LIMO~ loosen ~FOL1_IO_INTERFACE PBA~ defect
18904 SWAR: ~FOL1 lift roller error~

18-2-11 ~FOL1LI DOWNSE~ Possible cause Remark
Continuously Connection ~FOL1LIDOWNSE~ -> ON ~STEPPER_MOTOR CONTROLLER PBA~ Connection ~STEPPER MOTOR CONTROLLER PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL1LIDOWNSE~ defect ~SENSOR DISTRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect ~CPU_IO PBA~ defect
to be continued
ed. 5
18 Folder 127
continued
18-2-12 ~FOL1LI UPSE~ Possible cause Remark
Continuously Connection ~FOL1LIUPSE ~-> OFF ~STEPPER_MOTOR CONTROLLER PBA~ Connection ~STEPPER_MOTOR CONTROLLER PBA~ -> ~IO_INTERFACE PBA~ Connection ~IO_INTERFACE PBA~ -> ~CPU_IO PBA~ Actuator defect ~FOL1LIUPSE~ defect ~SENSOR DITRIBUTION PBA~ defect ~IO_INTERFACE PBA~ defect ~CPU_IO PBA~ defect
18-6-11 Possible cause ~FOL1LI ~FOL1LIMO~ MO~ turning
Remark
ON
No
Yes
Toothed belt / pulley ~FOL1LIMO~ loose ~FOL1_IO_INTERFACE PBA~ defect
18905 SWAR: ~STEPping MOTor CONTRol PBA defect~

18-6-11 ~FOL1LI ~FOL1LI MO~ MO~ turning Possible cause Remark
ON
No
Connection ~STEPPER_MOTOR CONTROLLER PBA~ -> ~FOL1INMO~ ~STEPPER_MOTOR CONTROLLER PBA~ defect
Yes
Toothed belt / pulley ~FOL1LIMO~ loose ~FOL_IO_INTERFACE PBA~ defect
128
TSM Oc 9800
Diagnostics
SDS
1 FOLder
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed. 5
18 Folder 201
Test nr.
Component
Signal
Description
Parameter test 18-1-01 ~Diameter roller FOL1INMO mm/100~
FOL1INMO diameter of the 1st fold input roller (range 2700 - 3300, default 3006) value mentioned on roller and installation card
18-1-02 ~Dist. FOL1STARTSE - FOL1 roll. mm/100~
FOLD1START distance (range 8000 - 11000, default 9510) value mentioned on installation card
18-1-03 ~Diameter roller FOL2INMO mm/100~
FOL2INMO diameter of the 2nd fold input roller (range 3700 - 4300, default 4050) value mentioned on roller and installation card
18-1-04 ~Dist. FOL2STARTSE - FOL2 roll. mm/100~
FOLD2START distance (range 10000-14000, default 12300) value mentioned on installation card
18-1-05 ~Overlap correction FOL1 mm ~
(Overlap 1st fold (range 0-5, default 0)

18-1-06 ~Max. nr. of copies on FOLO belts~
nr. of copies after FOLOBELTxENDSE is active (range 0 - 100, default 5)

18-1-07 ~FOL wrinkle speed factor (in %)~
(range 100 - 130)

18-1-08 ~FOL wrinkle fold distance~
(range 0 - 80)
202
TSM Oc 9800
SDS
Test nr. Input tests 18-2-01 18-2-02 18-2-03
Component
Signal
Description
~FOL1 START Fol1 start sensor SEnsor~ ON = paper present ~FOL1 DOOR SWitch~ Fol1 door switch ON = door open
~FOL1 DEflec- Fol1 deflector position sensor tor POsition ON/OFF related to the position of the 1st SEnsor~ folding flap ~FOL2 START Fol2 start sensor SEnsor~ ON = paper present ~FOL2 TRAIling SEnsor 1~ ~FOL2 TRAIling SEnsor 2~ Fol2 trailing sensor 1 ON = paper present Fol2 trailing sensor 2 ON = paper present
18-2-04 18-2-05
18-2-06 18-2-07
~FOL2 DEFlec- Fol1 deflector position sensor tor POsition ON/OFF related to the position of the 2nd SEnsor~ folding flap ~FOL2 TRAY SWitch~ ~FOL2 DOOR SWitch~ Fol2 tray switch ON = tray open Fol2 door switch ON = door open
18-2-08 18-2-09 18-2-10 18-2-11
~FOL2 OUTput Fol2 output sensor 1 SEnsor 1~ ON = paper present ~FOL1 LIft Fol1 lift down sensor DOWN SEnsor~ ON = lift of the folding rollers in lower position ~FOL1 LIft UP Fol1 lift up sensor SEnsor~ ON = lift of the folding rollers in the upper position ~CON FOL1 INput DIAGnose~ CON Fol1 input diagnose ON = diagnose signal correct
18-2-12
18-2-13
18-2-14
~CON FOL1 CON Fol1 output diagnose OUTput DIAG- OFF = diagnose signal correct nose~
ed. 5
18 Folder 203
Test nr. 18-2-15
Component
Signal
Description
~CON FOL2 INput DIAGnose~
CON Fol2 input diagnose ON = diagnose signal correct
18-2-16
~CON FOL2 CON Fol2 output diagnoses OUTput DIAG- OFF = diagnose signal correct nose~ ~FOL Output Folder output adjust motor sensor ADJust MOT. ON = motor not in home position HOME SEnsor~ ~FOL Output ADJust MOtor END SEnsor~ ~FOL OutputPUnch START SEnsor~ Folder output adjust motor end sensor ON = motor not in end position Folder output punch start sensor ON = paper present, punch can start
18-2-17
18-2-18
18-2-19
18-2-20
~FOL Output Folder output punch motor home sensor PUnch MOtor ON = motor in home position HOME SEnsor~ ~FOL Output PUnch MOtor END SEnsor~ ~FOL Output PUnch DOOR SWitch~ Folder output punch motor end sensor ON = motor in end position Folder output punch door switch ON = door closed
18-2-21
18-2-22
18-2-23 18-2-24
~FOL Output Folder output belt 1 sensor BELT1 SEnsor~ ON = paper present ~FOL Output BELT1 END SEnsor~ ~FOL Output BELT1 DOOR SWitch~ Folder output belt 1 end sensor ON = paper present Folder output belt 1 door switch ON = door belt 1 closed
18-2-25
18-2-26 18-2-27
~FOL Output Folder output belt 2 sensor BELT2 SEnsor~ ON = paper present ~FOL Output BELT2 END SEnsor~ Folder output belt 2 end sensor ON = paper present
204
TSM Oc 9800
SDS
Test nr. 18-2-28
Component
Signal
Description
~FOL Output BELT2 DOOR SWitch~
Folder output belt 2 door switch ON = door belt 2 closed
18-2-29 18-2-30 18-2-31
~First Fold Out- First fold output sensor put SEnsor~ ON = paper present ~FOL2 RU DOOR SWitch~ ~FOL2 RU INTermediate transport DOOR SWitch~ ~FOL2 RU COVER SWitch~ Front door switch of the reinforcement unit OFF = door closed Door switch of the intermediate transport OFF = door closed
18-2-32
Top cover switch of the reinforcement unit OFF = door closed
18-2-33
~FOL2 RU Start sensor of the reinforcement unit (sepaSTART SEnsor~ rate receiver and transmitter) ON = paper present ~FOL2 RU Sensor for checking the position of the reinstamp HOME forcement stamp position SEnsor~ ON = stamp in home position ~FOL2 RU EMPTY SWitch~ Sensor for detecting the presence/absence of reinforcement tape ON = tape present
18-2-34
18-2-35
18-2-36 18-2-37
~FOL2 RU tape Tape jam detection switch JAM SWitch~ ON = tape jam ~FOL2 RU Fol2 reinforcement unit output diagnose OUTput DIAGnose~ ~FOL2 RU INput DIAGnose~ Fol2 reinforcement unit input diagnose
18-2-38
ed. 5
18 Folder 205
Test nr.
Component
Signal
Description
~FOL1 DEFlec- Fol1 deflector clutch tor CLutch ~ Clutch of the 1st folding flap ON = clutch activated Hardware diagnoses: CONFOL1OUTDIAG ~FOL1 OUTput Fol1 output deflector solenoid DEFlector SOle- ON = solenoid activated, output 1st fold noid~ Hardware diagnoses: CONFOL1OUTDIAG ~FOL2 FLAT SOlenoid~ Fol2 flat solenoid ON = solenoid activated, plate in top position Hardware diagnoses: FOL2OUTDIAG
18-4-02
18-4-03
18-4-04
~FOL2 DEFlec- Fol2 deflector clutch tor CLutch~ Clutch of the 2nd folding flap ON = clutch activated Hardware diagnoses: FOL2OUTDIAG ~FOL2 OUTput Fol2 OUTput tray SOlenoid tray SOlenoid~ ON = solenoid activated, output to sorter Hardware diagnoses: FOL2OUTDIAG ~FOL Output FOL Output ADJust MOtor ADJust MOtor~ ON = motor turns, pushes the sheet in between the punch unit ~FOL Output FOL Output PUnch MOtor PUnch MOtor~ ON = motor turns, ready to punch (eccentric) ~FOL Output PUnch Eject SOlenoid~ ~FOL Output Paper TRansport MOtor~ ~FOL Output BELT VAlve~ FOL Output PUnch Eject SOlenoid (stopper with plastic wheel) FOL Output Paper TRansport MOtor ON = motor turns (total transport) FOL Output BELT VAlve OFF = sheet to belt 1 ON = sheet to belt 2
18-4-05
18-4-06
18-4-07
18-4-08
18-4-09
18-4-10
206
TSM Oc 9800
SDS
Test nr. 18-4-11 18-4-12 18-4-13 18-4-14
Component
Signal
Description
~FOL Output FOLOutput BELT 1 MOtor BELT1 MOtor~ ON = motor turns ~FOL Output FOLOutput BELT 2 MOtor BELT2 MOtor~ ON = motor turns ~First FOLOut- ~First fold delivery motor~ put MOtor~ ~FOL2 RU STOP SOlenoid~ ~FOL2 RU GUIDe SOlenoid~ ~FOL2 RU MOtor~ Reinforcement Unit stopper solenoid ON = stopper up Reinforcement Unit GUIDe SOlenoid ON = guide retracted Reinforcement Unit drive MOtor ON = motor turns
18-4-15
18-4-16
Functions 15 (paper transport) and 18 (folder) in warm condition

Functions 15 (paper transport) and 18 (folder) in cold condition

18-6-05 18-6-06 18-6-07
~FOL1 INput MOtor~ ~FOL1 FOL MOtor~
~Fol1 INput MOtor~ ~Fol1 FOL MOtor~ ~Simulate Fold 1~
simulation of the 1st folding

18-6-08 18-6-09 18-6-10
~FOL2 INput MOtor~ ~FOL2 FOL MOtor~
~Fol2 INput MOtor~ ~Fol2 FOL MOtor~ ~Simulate Fold 2~
simulation of the 2nd folding
ed. 5
18 Folder 207
Test nr. 18-6-11
Component
Signal
Description ~FOL1 lift motor ~
~FOL1 LIft MOtor~
Folding rollers initiated, rollers in upper or lower position

~Simulate first fold delivery~
18-6-12
FOL2INMO and FOLOFFOUTMO are continuously running

18-6-13 ~Simulate RU stopper~
The intermediate transport starts running; with every next push on the start button the stopper goes up or down
18-6-14 ~Simulate RU stamp~
Put a sheet that is folded once on the intermediate transport. Push the start-button: the stopper goes up and the intermediate transport starts running. The sheet is stopped by the stopper and is reinforced. The stopper goes down, and 1/2 a second later the intermediate transport is stopped. Remove the sheet. This test can be interrupted during tape transport or stamping.
18-6-15
~FOL2RU STAMPSO~
~FOL2 RU STAMP SOlenoid~
The solenoid is activated/deactivated. If after this test the drive motor is activated, the stamp will be activated once
~FOL2 RU STAMP SOlenoid turn~
18-6-16
18-6-17
~FOL2RUSTA MPSO + FOL2RUGUID SO + FOL2RUMO~ ~FOL2RU STAMP 1/2TURN~
The stamp is activated once with every push on the Start-button and the motor is activated
~FOL2 RU STAMP 1/2 TURN~
The stamp is closed with a push on the Start-button and opened with the next push (refer to the functional description????)
18-6-18
~FOL2RUTAPE ~FOL2 RU TAPE transport SOlenoid~ SO~ The solenoid is activated/deactivated. If after this test the drive motor is activated, one length of tape will be transported
208
TSM Oc 9800
SDS
Test nr. 18-6-19
Component
Signal
Description
~FOL2RUTAPE ~FOL2 RU TAPE transport turn~ SO + The tape transport is activated once with FOL2RUMO~ every push on the Start-button and the motor is activated
Info tests 18-9-01 ~Measured copy length engine (mm)~
,Length of copy made by engine (range 0 - 70000)

18-9-02 ~Measured copy length folder (mm)~
Length of copy measured by folder (range 0 - 70000)

System tests 57 ~Adjust ptr/fold1~
A1 (22/24) in roll 1 position 20 sheets are folded This test determines the parameters for tests 15-1-01/02/03
ed. 5
18 Folder 209
210
TSM Oc 9800
SDS
Adjustments
1 ~Adjust ptr / fold1~
This test must be done when a folder is installed or after replacement of PTRTRAISE1/2/3 and/or FOL1STARTSE.
Aim:
Measurement of the distance between PTRTRAISE1/2/3 - FOL1STARTSE and storing in memory.

Check: 1 Carry out test 90 and configure the folder. 2 Carry out installation test 73 ~Install folder~ (18-1-01 / 02 / 03 / 04 (see chapter
SDS).
3 Feed roll width A1 (22/24) in roll 1 position. 4 Carry out SDS test 57.
(20 copies from roll 1 are made and folded).

Correction: 5 The new values are automatically stored in the memory.
Note: Check the folding quality.
Write down the settings from PTRTRAISE1/2/3 - FOL1STARTSE (15-1-01 / 02 / 03 (parameter tests) in the logbook and/or factory preset card.
ed. 5
18 Folder 301
2 Second folding unit

Aim:
To feed the copy from the 1st fold to the 2nd folding unit without being jammed.
Check: 1 Close all covers of the folding units. 2 Specification: the distance between the cover of the 1st fold and the cover of
the intermediate transport unit must be parallel and 12 2 mm.

Correction: 1 Mount spacer plates between the wheels and the bottom of the frame to place
the unit parallel (you can find the plates at the inside of the 2nd folding unit against the side frame plate).
302
TSM Oc 9800
Adjustments
3 FOL1 guide plate

Aim:
To ensure that the folded copies are straight and correctly fed onto the intermediate transport.
Check: 1 Make 5 A0 folded copies. 2 The flap may not touch the folding roller and the copies must be fed straight. Correction: 1 Remove the left and right side covers from the 1st fold. 2 Adjust the bracket bar at the left with 1 nut and at the right with 2 screws in
such a way that the distance between the roller and the flap is 1 + 0.5 / - 0 mm.
ed. 5
18 Folder 303
4 Distance from the copy guide to the frame in the intermediate transport (without Reinforcement Unit)
Aim:
To feed the copy straight and correctly into the 2nd folding section
Check: 1 Measure skewness -X- of the folded copy.
Specification: X < 2 mm
X <2mm X
Correction: If the situation is like A: 1 Measure the distance -C- between the rollers and the guide -E- at the left and
the right.
2 Loosen bolts -D- (3x). 3 At the left correct distance -C- to 2.0 + 0 / - 0.5 mm. 4 Push guide -E- a little towards the rollers at the right hand side.
304
TSM Oc 9800
Adjustments
C = 2 +0/-5mm
5 6 7 8
Tighten the bolts handtight. Make a folded copy and measure skewness -X-. If necessary repeat steps 1 upto 6. Continue with step 16.
If the situation is like B: 9 Measure the distance -C- between the rollers and the guide -E- at the left and
the right.
10 Loosen bolts -D- (3x). 11 At the right correct distance -C- to 2.0 + 0 / - 0.5 mm. 12 Push guide -E- a little towards the rollers at the left hand side.
13 Tighten the bolts handtight. 14 Make a folded copy and measure skewness -X-. 15 If necessary repeat steps 9 upto 14. 16 Make sure the distance from the guide to the rollers is at least 0.5 mm. 17 Tighten bolts -D- (3x). 18 Check the specifications again.
ed. 5
18 Folder 305
5 Flat guide plate of the 2nd folding unit

Aim:
To feed the copy flat into the 2nd folding unit in such a way that no creases in the package occur in the 2nd fold.
Check: 1 Make 2 A0 folded copies. 2 Specification: no creases in the folded copies in the 2nd fold. Correction: 1 2 3 4 5 6
Open the paper delivery tray and the rear door of the 2nd folding unit. Remove the front cover of the 2nd folding unit. Switch the machine to SDS. Activate SDS test 18-4-03. Loosen the fixing screws of the solenoid (FOL2FLATSO). Adjust the distance between the flat guide plate and the bottom guide plate to 10 0.5 mm. 7 Tighten the fixing screws of the solenoid. 8 Switch to service copy mode and check again for creases.
flat guide plate
bottom guide plate solenoid
306
TSM Oc 9800
Adjustments
6 Height of the belt unit and zero-line

Aim:
To obtain a correct feeding from the folded packages into the belt unit.
Check: 1 Make some folded copies and check if they are correctly fed into the belt unit. 2 Specification 1: The height between the input guide plate of the belt unit must
be 1mm below the output guide plate from the second folding unit.
3 Specification 2: The zero-line of the second folding unit and the zero-line of
the belt unit must be shifted 10 mm.

Correction: 1
Height:
output guide plate Confidential 1999 Oc-Technologies B.V. input guide plate
1 mm
1 Adjust the distance of 1 mm with the levelling feet of the belt unit.
ed. 5
18 Folder 307
Correction: 2
Zero-line:
1 Feed a A4 through the second folding unit and stop it at the moment it is fed
into the belt unit. This is the zero line of the second folding unit.
belt unit 2nd fold
10 mm zero line 2nd fold zero line belt unit
2 Adjust the distance of 10 mm by moving the belt unit sidewards. 3 Lock the belt unit to the second folding unit with the 2 bolts.
308
TSM Oc 9800
Adjustments
7 FOL Output PUnch Eject SOlenoid (FOLOPUESE)

Aim:
To be sure that the copy is stopped for punching and transported correctly to the belt unit.
Check: 1 Remove the belt unit rear cover. 2 Open the belt unit front cover. 3 Specification 1: When the solenoid is not activated the copy stop must be in
horizontal position.
4 Carry out SDS test 18-4-08. 5 Specification 2: When the solenoid is energized the copy must be transported
to the belt unit by the plastic wheel and the drive roller.
Correction: 1 Adjust the horizontal position with the eccentric. 2 Adjust the transport with the position of the solenoid.
eccentric copy stop FOLOPUESE
plastic wheel
drive roller
ed. 5
18 Folder 309
8 Paper guide flap belt unit

Aim:
To be sure that the copy is fed straight through the guide flap onto the 1st or 2nd belt.
Check: 1 Select copy delivery 1st belt and make 5 A0 folded copies. 2 Select copy delivery 2nd belt and make 5 A0 folded copies. 3 Specifications:
when the solenoid is not activated the distance between the guide plate -A- and the guide flap must be 2.5 0.5 mm. when the solenoid is energized the distance between the guide plate -C- and the guide flap must be 3.5 0.5 mm.
Correction: 1 2 3 4 5
Open the lower belt unit side door. Remove the upper front and rear cover from the belt unit. Open the guide plate -B-. Loosen the screws from stopper -A- and -B- at the front and rear side. Adjust with stopper -A- the distance between the guide plate -A- and the guide flap to 2.5 0.5 mm. 6 Activate SDS test 18-4-10.
to 1st belt
guide plate B guide plate A stopper B
2.5 +0.5/-0.5 mm
guide flap stopper A
copy entrance
310
TSM Oc 9800
Adjustments
7 Adjust with stopper -B- the distance between the guide plate -C- and the guide
flap to 3.5 0.5 mm.
8 Make 5 folded copies and check the specifications again.

guide plate C to 2nd belt
stopper B
3.5 +0.5/-0.5 mm
guide flap
copy entrance
ed. 5
18 Folder 311
9 The adjusting procedure for the Reinforcement Unit

Like any other Oc machine, you only check / adjust a component in case of a problem. The reinforcement unit is no exception to that rule. The criteria are: is the position of the reinforcement strip according to the specifications as stated in adjustments 21 Stopper position (fine-tuning) on page 329 and 22 Position of the Reinforcement Unit in the frame (fine-tuning) on page 331. If these criteria are met you are ready, or you have a problem elsewhere. The adjustments of the reinforcement unit can be divided into two groups: the basic settings and the fine-tuning. When the machine concerned was already equipped with a reinforcement unit, you only have to check, and if necessary carry out, the adjustments of the last group (fine-tuning, adjustments 20 upto 27). In case you have installed or replaced the reinforcement unit you better start with the first group (basic settings, adjustments 10 upto 19). The adjustments of the reinforcement unit influence each other. Therefore it is necessary to maintain a certain order of adjustments. It also means that, in case you have performed one of the adjustments of the following list, you also have to carry out all of the next adjustments in this list. Basic adjustments, which you normally only have to carry out after installation / replacement of the Reinforcement Unit, are: s 10 Position of the copy guide in the intermediate transport (with Reinforcement Unit) (basic setting) on page 316 s 11 Hinges (basic setting) on page 317 s 12 Position of the Reinforcement Unit in the frame (basic setting) on page 318 s 13 Locking plate on page 319 s 14 Stopper angle on page 320 s 15 Stopper position (basic setting) on page 321 s 16 Third copy guide (inside the second folding unit) on page 322 s 17 Vertical position of the small copy guide (basic setting) on page 323 s 18 Horizontal position of the small copy guide (basic setting) on page 324 s 19 Position of the retraction solenoid of the small copy guide (basic setting) on page 325. After this series of basic adjustments you have to check, and if necessary carry out adjustment 2 Second folding unit on page 302.
312
TSM Oc 9800
Adjustments
Note: In case you have to carry out one of the following adjustments 20, 21, or 22, first retract and fix the small copy guide of the reinforcement unit, e.g. with a rubber band, in order to prevent it from interfering with the adjustment you are carrying out.
If the reinforcement strip is not properly glued on the copy, you have to carry out one or more of the following adjustments: s 20 Position of the copy guide in the intermediate transport (with Reinforcement Unit) (fine-tuning) on page 326 s 21 Stopper position (fine-tuning) on page 329 s 22 Position of the Reinforcement Unit in the frame (fine-tuning) on page 331 s 23 Position of the retraction solenoid of the small copy guide (fine-tuning) on page 333 s 24 Retracted position of the small copy guide (fine-tuning) on page 334 s 25 Horizontal position of the small copy guide (fine-tuning) on page 335 s 26 Vertical position of the small copy guide (fine-tuning) on page 336 s 27 Long copy guide to small copy guide on page 338. Adjustment 28, Position of the upper knife on page 339, can be carried out independently from any other adjustment.
ed. 5
18 Folder 313
Flowchart:
Only after installation:
Start
Reinforcement unit present?
Yes Yes No Folding package skewed Position of binding strip OK?
Yes
No
adjustment 4 on page 304
END
adjustment 12 on page 318 and adjustment 13 on page 319
adjustment 17 on page 323, adjustment 18 on page 324, and adjustment 19 on page 325 Continued on page
315
314
TSM Oc 9800
Adjustments
From page
314
Retract the small guide
adjustment 23 adjustment 24 adjustment 25 adjustment 26 adjustment 27
on page 333, on page 334, on page 335, on page 336, and on page 338
Start here for fine tuning:
Position of strip according to specifications?
No
Yes END
ed. 5
18 Folder 315
10 Position of the copy guide in the intermediate transport (with Reinforcement Unit) (basic setting)
Note: This and other adjustments influence each other! Refer to Adjustment 9
for the correct order of the adjustments.

Aim:
To prevent copies from running under the guide, and to guide the copies straight into the reinforcement unit and the second folding unit.
Check: 1 Measure distance -A-. It should be 1.5 0.5 mm over the entire length of guide
-B-.
A = 1.5 0.5mm
Correction: 1 2 3 4
Loosen bolts -C- (2x) and -D- (3x). Push guide -B- against the rollers. Measure distance -E- at the left and the right. Adjust distance -E- to a value of 1.5 0.5 mm less than the value you measured in step 3. 5 Tighten bolts -C- (2x). Now the distance towards the rollers is fixed. 6 Slide guide -B- as far as possible to the left (this enables you to carry out the other adjustments; in the end of the adjusting procedure you will have to slide guide -B- to the right, according to Adjustment 27, Long copy guide to small copy guide on page 338). 7 Tighten bolts -D- (3x).
316
TSM Oc 9800
Adjustments
11 Hinges (basic setting)


Aim:
To create a correct starting point for the next adjustments.

Correction:
D = 34 1mm
B = 18 1mm
1 Adjust the female hinge -A- on the reinforcement unit in such a way that dis-
tance -B- is 18 1 mm.

2 Adjust the male hinge -C- on the frame of the second folding unit in such a way
that distance -D- is 34 1 mm.

3 Move plate -E- against hinge -C- and tighten the bolts.
ed. 5
18 Folder 317
12 Position of the Reinforcement Unit in the frame (basic setting)


Aim:

Check: 1 Open the reinforcement unit and check if the appropriate washer is placed on
the lower hinge.

2 Put a steel ruler on surface -A- and check if surfaces -A- and -B- are parallel
within 0.5 mm.

B A
D E G C F
Correction: 1 2 3 4 5 6 7 8 9 10
Open the reinforcement unit. Remove the cover. Loosen bolts -C- (2x). Lift bracket -D- and close the unit. Loosen bolts -E- (3x). Level the unit with eccentric screw -F- (surfaces -A- and -B- parallel within 0.5 mm). Tighten bolts -E-. Make sure bracket -D- rests on roll -G-. Tighten bolts -C-. Mount the cover.
318
TSM Oc 9800
Adjustments
13 Locking plate

Aim:
To make sure the Reinforcement Unit locks properly.

Check:
If distance -A- is between 0 and 1 mm.

Correction:
B C
E Confidential 1999 Oc-Technologies B.V.
A = 0-1mm
1 2 3 4 5 6
Loosen bolts -B- (2x). Move plate -C- towards you. Loosen bolts -D- (2x). Move plate -E- in such a way that distance -A- is between 0 and 1 mm. Tighten bolts -D- (2x). Pull the unit towards you, move plate -C- against the frame plate -F-, and tighten bolts -B- (2x).
ed. 5
18 Folder 319
14 Stopper angle

Aim:
To prevent copies from slipping downward along the stopper / slipping over the stopper.
Check:
The angle between the upper surface of the rollers and the stopper must be just a little more than 90 degrees. This can be checked by manually pushing down the stopper, while a piece of paper is touching the stopper. The paper may not be pulled down by the stopper.
Note: The drawing below right is a view from the rear side of the unit.
B A 91 +1
Correction: 1 Loosen bolts -A- (2x). 2 Turn eccentric bolts -B- in such a way that bolts -A- (2x) are in the middle of
the slots in the stopper.

3 Tighten bolts -A- (2x). 4 Loosen bolts -C- (2x). 5 Move the solenoid -D- upwards to increase the angle or downwards to decrease
the angle.
6 Tighten bolts -C- (2x).
320
TSM Oc 9800
Adjustments
15 Stopper position (basic setting)


Aim:

Check: 1 Measure distance -A-, it should be 1 0.5 mm. 2 Measure distance -B-, it should be A + 1 0.5 mm Note: Distance -B- should always be bigger than distance -A-.
D Confidential 1999 Oc-Technologies B.V. C
A = 1 0.5mm
B = A + 1 0.5mm
Correction: 1 2 3 4
Loosen bolts -C- (2x). Turn eccentric bolt -D- to change distance -A- to 1 0.5 mm. Turn eccentric bolt -E- to change distance -B- to A + 1 0.5 mm. Tighten bolts -C- (2x).
ed. 5
18 Folder 321
16 Third copy guide (inside the second folding unit)


Aim:
To prevent the guide from touching the rollers.

Check: 1 Distance -A- between guide -B- and rollers -C- should be 1.5 0.5 mm.
A = 1.5 0.5mm
Correction: 1 Loosen bolts -D- (2x). 2 Move guide -B- to the correct distance. 3 Tighten bolts -D- (2x).
322
TSM Oc 9800
Adjustments
17 Vertical position of the small copy guide (basic setting)


Aim:

Check:
Measure distance -A- at the left and the right. It should be 13 1 mm.
A = 13 1mm
B Confidential 1999 Oc-Technologies B.V. C
Correction: 1 Loosen screw -B-. 2 Move block -C- up or down until A = 13 1 mm. 3 Tighten screw -B-.
ed. 5
18 Folder 323
18 Horizontal position of the small copy guide (basic setting)


Aim:

Check:
Bolts -A- should be in the middle of the slots.

B
Correction: 1 Loosen bolts -A- (2x). 2 Move plate -B- left or right until bolts -A- are in the middle of the slots. 3 Tighten bolts -A- (2x).
324
TSM Oc 9800
Adjustments
19 Position of the retraction solenoid of the small copy guide (basic setting)

Aim:

Check:
Bolts -A- should be in the middle of the slots.
B A
Correction: 1 Loosen bolts -A- (2x). 2 Move solenoid -B- up or down until bolts -A- are in the middle of the slots. 3 Tighten bolts -A- (2x).
ed. 5
18 Folder 325
20 Position of the copy guide in the intermediate transport (with Reinforcement Unit) (fine-tuning)

Aim:
To guide the copies straight into the reinforcement unit and the second folding unit.
Check: 1 Measure skewness -X- of the folded copy.
Specification: X < 2 mm
X <2mm X <2mm
Correction: If the situation is like A: 1 Measure distance -C- between the rollers and the guide -F- at the left and the
right.
2 Loosen bolts -D- (2x) and -E- (3x). 3 At the left correct distance -C- to 2.0 + 0 / - 0.5 mm. 4 Push guide -F- a little towards the rollers at the right hand side.
326
TSM Oc 9800
Adjustments
D F
5 6 7 8
Tighten all the bolts handtight. Make a folded copy and measure skewness -X-. If necessary repeat steps 1 upto 6. Continue with step 16.
If the situation is like B: 9 Measure distance -C- between the rollers and the guide -F- at the left and the
right.
10 Loosen bolts -D- (2x) and -E- (3x). 11 At the right correct distance -C- to 2.0 + 0 / - 0.5 mm. 12 Push guide -F- a little towards the rollers at the left hand side.
13 Tighten all the bolts handtight. 14 Make a folded copy and measure skewness -X-. 15 If necessary repeat steps 9 upto 14. 16 Make sure the distance from the guide to the rollers is at least 0.5 mm. 17 Tighten bolts -D- (2x). Now the distance towards the rollers is fixed. 18 Slide guide -F- as far as possible to the left (this enables you to carry out the
other adjustments. At the end of the adjusting procedure you have to slide
ed. 5
18 Folder 327
guide -F- as far as possible to the right. Make sure it does not interfere with the small copy guide of the Reinforcement Unit). 19 Tighten bolts -E- (3x).
328
TSM Oc 9800
Adjustments
21 Stopper position (fine-tuning)


Aim:
To make sure the reinforcement strip is glued correctly on the copy in length direction.
Check: 1 Make 5 copies, A1, folded
and reinforced.
2 Check dimension -A-. It
should be 108.5 1 mm.
A = 108.5 1mm
Correction:
C B
F = D + 1 0.5mm
1 2 3 4
If -A- is more than 108.5 + 1 mm: Loosen bolts -B- (2x). Turn eccentric bolt -C- to decrease distance -D-. Turn eccentric bolt -E- to decrease distance -F- to D + 1 0.5 mm. Tighten bolts -B- (2x).
ed. 5
18 Folder 329
1 2 3 4
If -A- is less than 108.5 1 mm: Loosen bolts -B- (2x). Turn eccentric bolt -C- to decrease distance -D-. Turn eccentric bolt -E- to decrease distance -F- to D + 1 0.5 mm. Tighten bolts -B- (2x).
Note: Distance -F- should always be more than distance -D-.
Note: Make sure the stopper does not touch the roller.
330
TSM Oc 9800
Adjustments
22 Position of the Reinforcement Unit in the frame (fine-tuning)


Aim:
To make sure the reinforcement strip is glued correctly on the copy in width direction.
Check: 1 Make 5 copies, A1, folded and
reinforced.
2 Check dimension -A-. It should
be 12 1 mm and parallel within 0.5 mm.

Correction:
B C
A = 12 1mm
If -A- is larger than 12 + 1 mm: 1 Loosen bolts -B- (2x). 2 Move plate -C- as many millimetres to the inside as -A- differs from 12 mm 3 4 5 6
(create a gap -D- between plate -C- and hinge -E- accordingly). Tighten bolts -B-. Loosen bolts -F- (2x). Move hinge -E- against plate -C-. Tighten bolts -F- (2x).
ed. 5
18 Folder 331
If -A- is smaller than 12 - 1 mm: 7 Loosen bolts -F- (2x). 8 Move hinge -E- as many millimetres to the outside as -A- differs from 12 mm 9 10 11 12
(create a gap -D- between hinge -E- and plate -C- accordingly). Tighten bolts -F-. Loosen bolts -B- (2x). Move plate -C- against hinge -E-. Tighten bolts -B- (2x).
If the strip is not glued parallel to the edge of the copy:
K H G
13 Loosen bolts -G- (2x) and bolts -H- (2x). 14 Pull the unit towards you (without releasing the latch) and turn bolts -I- (2x)
both the same number of turns, until the unit -J- is parallel to the frame of the intermediate transport -K-. 15 Tighten bolts -H- (2x). 16 Move plate -L- against the frame -K- of the intermediate transport. 17 Tighten bolts -G- (2x).
332
TSM Oc 9800
Adjustments
23 Position of the retraction solenoid of the small copy guide (fine-tuning)


Aim:
To put the small copy guide in the right home position (horizontally).
Check: 1 Make sure solenoid -A- is not activated. 2 Measure distance -B-. It should be between 0.1 and 0.5 mm.
B = 0.1 - 0.5mm
Remove the door of the reinforcement unit. Loosen bolts -C- (2x). Move solenoid -A- in such a way that distance -B- is between 0.1 and 0.5 mm. Tighten bolts -C- (2x). Mount the door.
ed. 5
18 Folder 333
24 Retracted position of the small copy guide (fine-tuning)


Aim:
To prevent the small copy guide from being hit by the lower stamp, if the retraction solenoid does not function.
Check: 1 2 3 4
Unlock the single-revolution clutch in order to release the stamp drive. Manually move up stamp -A- until bracket -B- is released. Measure distance -C-. It should be 4.6 2 mm. Manually move up stamp -A- to its top position and push it downwards again until the solenoid locks it in its home position.
C = 4.6 2mm
A B D
Correction: 1 2 3 4 5 6
Unlock the single-revolution clutch in order to release the stamp drive. Manually move up stamp -A- until bracket -B- is released. Loosen bolt -D-. Move bracket -B- up or down until distance -C- is 4.6 2 mm. Tighten bolt -D-. Manually move up stamp -A- to its top position and push it downwards again until the solenoid locks it in its home position.
334
TSM Oc 9800
Adjustments
25 Horizontal position of the small copy guide (fine-tuning)


Aim:
To align the small copy guide of the reinforcement unit with the copy guide of the intermediate transport, in order to prevent copy transport jams and for skew reinforcement strips.
Check:
Put a steel ruler -A- against the long copy guide at position -B-. The distance between the steel ruler and the short copy guide should be 0.5 + 0.5/- 0 mm at both ends -C- and -D- of the short copy guide.
B D
A C
F E
Correction: 1 Open the unit. 2 Loosen bolts -E- and -F-. 3 In case of a difference at position -C-: move the plate -G- on the side of bolt
-E- with the difference you measured in the check above. In case of a difference at position -D-: move the plate -G- on the side of bolt -F- with the difference you measured in the check above. 4 Tighten bolts -E- and -F-.
ed. 5
18 Folder 335
26 Vertical position of the small copy guide (fine-tuning)


Aim:
To align the small copy guide of the reinforcement unit with the copy guide of the intermediate transport, and with the second folding unit, in order to prevent for jams in the copy transport.
Check:
Put a steel ruler -A- on the small copy guide. The distance between the steel ruler and the short copy guide should be 0.5 + 0.5/- 0 mm at position -B-, and 2 0.5 mm at position -C-.
Note: The picture below is a view from the rear.
A D
B= 0.5 -0/+0.5mm
C = 2 0.5mm
Correction: In case of a difference at position -B-: 1 Loosen screw -D-. 2 Move the plate -E- on the side of screw -D- with the difference you measured
in the check above.

3 Tighten screw -D-.
336
TSM Oc 9800
Adjustments
In case of a difference at position -C-: 4 Loosen screw -F-. 5 Move the plate -E- on the side of screw -F- with the difference you measured
in the check above.

6 Tighten screw -F-.
ed. 5
18 Folder 337
27 Long copy guide to small copy guide


Aim:
To make sure the small guide of the reinforcement unit does not touch the long copy guide of the intermediate transport.
Check:
Distance -A- should be 2 1 mm
A=2 1mm B C
Correction: 1 Loosen bolts -B- (3x). 2 Move guide -C- to the left or the right to create a distance -A- of 2 1 mm. 3 Tighten bolts -E- (3x).
338
TSM Oc 9800
Adjustments
28 Position of the upper knife

Aim:
To make sure the knife cleanly cuts the reinforcement tape.

Check: 1 Release the single revolution clutch. 2 Move up the bottom stamp until the top of the moving knife -X- reaches the
top of the fixed knife -Y-.

3 Check if the distance between the knives at the top of the knives -A- is 0.1 mm. 4 At the same position of the knives, distance -B- must be 0.5 mm.
A = 0.1mm
Y Y Confidential 1999 Oc-Technologies B.V. C
B= 0.5mm
Correction: 1 Loosen bolts -C- (2x). 2 Move the fixed knife -Y- in such a position that the conditions as given above,
are fulfilled.
3 Tighten bolts -C- (2x).
ed. 5
18 Folder 339
29 Long copy anti wrinkle procedure (first fold).

Aim: Prevent wrinkles in long copies in the first fold.
The adjustment procedure is added to avoid wrinkles by varying the speed of the first folding rollers. The following two SDS test are needed to do the adjustment: 18-1-07: FOL1 wrinkle speed factor (Default: 100) 18-1-08: FOL1 wrinkle fold distance. In the default mode the folding process is not changed. Adjusting the parameters in the above SDS tests does not influence the folding of standard A3-A0 (B-E) sizes. The table below shows the combinations of SDS tests 18-1-07 and 18-1-08. The shaded fields indicate the combinations of the values of 18-1-07 and 08.
Speed (18-1-07) Distance (18-1-08)
100
105
110
115
120
125
130
0 10 20 30 40 50 60
Check: 1 Make a 6m long folded copy on a A0 (36) format. 2 Activate SDS test 18-9-02 and read out the value. The value should indicate a
figure larger than 6000 (between 6000 and 6025 and never lower than 6000).
3 Check the quality of the folded package: the folded package should have no
wrinkles.
Correction: 1 2 3 4
Activate SDS test 18-1-07 and fill in the value 100. Activate SDS test 18-1-08 and fill in the value: 0. Make a 6m long folded copy on a A0 (36) format. Activate SDS test 18-9-02 and read out the value. The value should indicate a figure larger than 6000 (between 6000 and 6025 and never lower than 6000).
340
TSM Oc 9800
Adjustments
5 Check the quality of the folded package: the folded package should have no
wrinkles.
6 If the package shown wrinkles adjust SDS test 18-1-07 and 08 to the next field
to the right and down (e.g. values 105/10, 110/20 etc). and continue with point 3. 7 If the package shows no wrinkles activate SDS 57.
ed. 5
18 Folder 341
30 Polyester strips on the front and the rear guide plate of the first fold
Aim:
To prevent for dog ears at the leading edge of folded copies. Also wrinkles near the leading edge are prevented for.
Check: 1 Make 5 folded copies A3 from an A1 roll. 2 Check for dog ears / wrinkles at the leading edge. Correction:
10MM Rear plate
10MM Front plate
1 Remove transport covering. 2 Remove left and right side panels. 3 Disconnect plug X1 from the sensor PBA and lead the cable through the hole
in the frame.
4 Unscrew both hinge pins on the left and right. 5 Remove the front and rear plate together. 6 Fit the polyester strips to the front and rear plates according to the drawing
above after cleaning the glue surfaces.

Caution: Beware the sharp edges of the plates! 7 Fit the front and rear plates in the reverse order.
342
TSM Oc 9800
Adjustments
31 Polyester strip on the bottom guide plate of the second fold

Aim:
To prevent copies from skewing in the second fold.

Check: 1 Make 5 folded copies A3 from an A1 roll. 2 Check for dog ears / wrinkles at the leading edge. Correction: 1 Open the front door and remove the back cover. 2 At the front, remove the circlip, the nylon washer and the bearing bush of the
shaft of the 2nd folding flap. At the rear, remove the E-ring, and the circlip. Loosen the allen screw in lever assy. Remove the lever assy. Remove the circlip and the nylon washer from the shaft of the 2nd folding flap. Remove the bearing of the shaft of the 2nd folding flap. Open the delivery section of the 2nd folding device and open the pressure roller section. 9 Now the complete 2nd folding flap can be removed. See drawing.
3 4 5 6 7 8
10 Exchange the lower profile of the folding flap by the new profile, provided with
the polyester strip.

11 Mount all the parts in reverse order.
ed. 5
18 Folder 343
32 FOL1OUTDEFSO (Solenoid of the delivery flap of the first fold) (Only for modification 07 of 700/705/715).
Aim:
Basic adjustment of the the new FOL1OUTDEFSO solenoid.

Check:
Correction: 1 Lever 1 must be aligned to lever 2.
The set screw must be tightened after alignment.
Frame
Lever 2
Lever 1
set screw Lever 2 Lever 1
2 Lever 2 and 3 must have the position as shown in the figure below.
344
TSM Oc 9800
Adjustments
3 Adjust by moving the bracket to the lowest position after lossening bolts 2 and
3.
bolts2 Lever 3
180
bolts 3
Lever 2 Confidential 1999 Oc-Technologies B.V.
Lever 1
4 Move the bracket upwards untill lever 2 and 3 are in one line.
Make sure that lever 1 does not move upwards.

5 Thighten the bolts 2 and 3. 6 The gap as shown in the figure must be between 2.3 and 2.7 mm.
This can be adjusted: - loossen the bolts 4 - move the solenoid Lever 2 and 3 must be in horizontal position.
Lever 2 Lever 3
ed. 5
18 Folder 345
33 Adjusting plate 2nd folding rollers

Aim:
To prevent skewing of A3 packages in the 2nd folding section, causing wrinkles

Check: 1 Make 5 folded copies A3 from an A3 or A2 roll. 2 Check for wrinkles. Correction: 1 Remove the rear cover of the second folding unit. 2 Mount plate -A-, code nr. 1999.099, as shown below.
Make sure plate -A- does just not touch shaft -B-.
A
3 4 5 6 7 8 9 10
Make 5 folded copies A3 from an A3 or A2 roll. Check for wrinkles. Loosen bolt -C-. Move plate -A- to the left in such a way roller -D- does just not touch roller -E-. Tighten bolt -C-. Make 5 folded copies A3 from an A3 or A2 roll. Check for wrinkles. If there still are wrinkles, increase the distance between the rollers -D- and -Egradually, until the wrinkles have disappeared or the folding accuracy runs out of the specification.
346
TSM Oc 9800
Adjustments
Dis-/assemblies
1 ~FOL1DEFCL~ (clutch of 1st fold)
Assemble the clutch as follows:
F C M A B E
A B
H 1 2 3 4 5
Push the clutch -A- in direction -B- to the end position. Turn the Allen screw -M- of clutch -A- into clutch -A- until it touches shaft -F-. Unscrew -M- 1/4 turn and lock it with LOCTITE222. Push weight -C- over clutch -A-. Secure weight -C- with two Allen screws -D-. . 6 Turn weight -C- in the direction -Euntil the clutch is in the locking position. G G 7 Turn shaft -F- in the same direction -E- until crank -G- is in the vertical position. 905 8 Secure weight -C- to the shaft with 2 Allen screws -H-.
9 Adjust the actuator -L- to 90 degrees
+/- 5 degrees as shown in figure

L
ed. 5
18 Folder 401
2 ~FOL2DEFCL~ (clutch of 2nd fold)

Assemble the clutch as follows
A B E
A B
H 1 2 3 4 5 6 7
Push the clutch -A- in direction -B- to the end position. Turn the Allen screw -M- of clutch -A- into clutch -A- until it touches shaft -F-. Unscrew -M- 1/4 turn and lock it with LOCTITE222. Push weight -C- over clutch -A-. Secure weight -C- with two Allen screws -D-. Turn weight -C- in the direction -E- until the clutch is in the locking position. Turn shaft -F- in the same direction -E- until crank -G- is in the horizontal position. 8 Secure weight -C- to the shaft with 2 Allen screws -H-. 9 Adjust the actuator -L- to 90 degrees +/- 5 degrees as shown in figure.
402
TSM Oc 9800
Dis-/assemblies
3 ~FOL1FOLMO~ and ~FOL2FOLMO~

1 Connect the wires of the motor as follows:
s s
wire number 1807001 to number 1 on the motor. wire number 1807002 to number 2 on the motor. The numbers are not shown on the motor.
ed. 5
18 Folder 403
404
TSM Oc 9800
Dis-/assemblies
1 General folding
The folder uses a folding flap and 4 folding rollers for the first as well as the second folding. The copy is transported by the feed rollers, guided by the folding flap to be fed in between 2 folding rollers. First the folding flap is positioned to the right and the folding rollers turn in direction 1. After a calculated length of transported paper, depending of the selected programme, the folding flap is moved into the left position and the turning direction of the folding rollers is reversed into direction 2. A bulge is created and the copy is fed between the folding rollers to fold the bulge.
folding flap feed rollers
folding rollers
ed. 5
18 Folder 501
After a certain time, the folding flap is moved into the right position and also the turning direction of the rollers is reversed. A bulge is created and fed between folding rollers. Again the bulge is folded. The distance between two folds is variable.
bulge
This folding principle is used in the 1st fold, as well as in the 2nd fold.
502
TSM Oc 9800
2 Folding programmes
The basic folding programmes are:
DIN
s s s
190 x 297 mm 210 x 297 mm including 20 mm binding edge (left hand side). 210 x 297 mm
Ericsson
s s s
190 x 297 mm 210 x 297 mm including 20 mm binding edge (right hand side). 210 x 297 mm
USA
s s
s s
8.5 x 11" 9 x 12" 8.5 x 11" with binding edge 9 x 12" with binding edge
AFNOR like
In key operatory mode it is possible to set the folding programme to different values for the 1st and 2nd fold as well as the binding edge. These folding settings are:
1st fold 186 - 230 mm (7.3 - 9") in steps of 1 mm (0.1) 273 - 310 mm default 210 mm (8.5 or 9")
2nd fold
(10.9" - 12.2")
in steps of 1 mm (0.1)
default 297 mm (11 or 12")
Binding edge
0 or 15 - 30 mm (0 or 0.6 - 1.2")
default 20 mm (0.8")
in steps of 1 mm (0.1) Attention: When switching off and on the machine the settings return to the standard program.
ed. 5
18 Folder 503
3 Folding package definition and distances

The size of the folding package in the 1st and 2nd fold are defined as follows:
1st fold:
e.g. A0 size copy Width = 210 mm Binding = 0 mm * = 5 mm overlap (value set in SDS) L.E. = Leading edge T.E. = Trailing edge
Attention: With fixed overlap, all inside folds are left and right 5 mm shorter. Without overlap, all inside folds are in line.
2nd fold:
e.g. A0 size copy Length = 297 mm * = 3 mm overlap (fixed)
504
TSM Oc 9800
4 Folding length for DIN size folding in the 1st fold

190 mm * = 5 mm A0 7 = 190 mm 6 = 139 mm 5 = 134 mm 4 = 180 mm 3 = 180 mm 2 = 180 mm 1 = 185 mm 5 = 190 mm 4 = 145.5 mm 3 = 140.5 mm 2 = 180 mm 1 = 185 mm 5 = 190 mm 4 = 112 mm 3 = 107 mm 2 = 90 mm 1 = 95 mm 3 = 190 mm 2 = 115 mm 1 = 115 mm 210 with 20 mm binding edge * = 5 mm 7 = 190 mm 6 = 129 mm 5 = 124 mm 4 = 180 mm 3 = 180 mm 2 = 180 mm 1 = 205 mm 5 = 190 mm 4 = 135.5 mm 3 = 130.5 mm 2 = 180 mm 1 = 205 mm 5 = 190 mm 4 = 102 mm 3 = 97 mm 2 = 90 mm 1 = 115 mm 3 = 190 mm 2 = 105 mm 1 = 125 mm 210 mm * = 5 mm 7 = 210 mm 6 = 189 mm 5 = 184 mm 4 = 100 mm 3 = 100 mm 2 = 200 mm 1 = 205 mm 5 = 210 mm 4 = 115.5 mm 3 = 110.5 mm 2 = 200 mm 1 = 205 mm 3 = 210 mm 2 = 192 mm 1 = 192 mm
A1
A2
A3
3 = 210 mm 2 = 105 mm 1 = 105 mm
ed. 5
18 Folder 505
5 Folding length for DIN size folding in the 2nd fold

297 mm * = 3 mm A0 1 = 300 mm 2 = 297 mm 3 = 244 mm 1 = 300 mm 2 = 294 mm 1 = 297 mm 2 = 120 mm -
A1
A2
A3
506
TSM Oc 9800
6 DIN folding
A0 size
7 Ericsson folding
Ericsson A0 size
ed. 5
18 Folder 507
8 1st fold
The copy is transported from the PTR (paper transport unit) into the 1st folding section. The leading edge of the copy activates the 1st fold start sensor (FOL1STARTSE) and the 1st fold folding motor (FOL1FOLMO) is energized to feed the copy into the 1st folding section. The speed of FOL1FOLMO depends on the speed of FOL1INMO (folding input motor). The folding flap is operated by the 1st fold deflector clutch (FOL1DEFCL). This clutch has two fixed positions. Before the last fold is made in the 1st folding section, the 1st fold output deflection solenoid (FOL1OUTDEFSO) is energized to feed the folded package onto the inner transport.
9 Inner transport
The copy is dropped onto the inner transport. The FOL2TRAISE1 (trailing edge sensor) is activated. The inner transport rollers and the transport in the 2nd fold section are driven by the 2nd fold input motor (FOL2INMO). On the inner transport, the copies are aligned against a guide plate and transported straight into the 2nd folding section. The copy is fed underneath the guide plate of the 2nd fold flat solenoid (FOL2FLATSO) which is in a raised position. On the inner transport, the 2nd fold start sensor (FOL2STARTSE) is activated. The 2nd fold input motor (FOL2INMO) is energized and the guide plate is moved downwards. The maximum width of the inner transport is 230 mm (9).
508
TSM Oc 9800
10 2nd fold
The principle of the 2nd fold is the same as the 1st fold only that it is just turned 90 degrees. Folding starts when the 2nd fold start sensor (FOL2STARTSE) is activated. The folding rollers are driven by 2nd fold motor (FOL2FOLMO) with a variable speed 22 to 24 m/min. After the copy is folded, it is fed out upwards into the copy receiving tray or to the punch and belt unit. The capacity of the receiving tray for 80 gr. paper is:
s s s s
A0 size 22 packages A1 size 45 packages A2 size 40 packages A3 size 350 packages A4 size > 400 packages
Rest length
Rest lengths shorter than 120 mm can not be folded. When the length sensor detects a rest length shorter than 120 mm, the folding programme will be adapted to make a complete folded package. This package however is not a DIN standard package.
ed. 5
18 Folder 509
11 First fold delivery

The First Fold Delivery (FFD) is an extension to the second folding section. With this device it is possible to deliver prints and copies after they have been folded in the first folding section only. Copies / prints are delivered into a copy container, to the opposite side as the second folding section. Copies / prints between 2.5 and 6 m long are automatically delivered into this FFD container. With a setting on the operator panel it is also possible to deliver copies < 2.5 m into the FFD container. The capacity of the container is 6 to 10 copies (75 g/m2) of 6 m long, folded on 210 mm width and with binding edge of 20 mm. Copies / prints are delivered face-up. In case that a copy / print has to be delivered to the FFD, the rotation direction of the intermediate transport is reversed as soon as the copy/print is delivered onto the rollers of the intermediate transport. When the FOLOFFOUTSE sensor (First Fold Output Sensor) is reached, motor FOLOFFOUTMO starts running, drives a pair of transport rollers. By these transport rollers the copy / print is delivered into the FFD container. As soon as the trailing edge of the copy/print has reached the FOLOFFOUTSE sensor the motor is stopped after approx. 1 second.
Note: The engine software must have at least level R3.1 and the P.A.S. software
must have at least level R3.0

Conditions:
s
It is not possible to modify a second folding section to provide it with an FFD. For this reason the complete second folding section has to be exchanged. The first folding section from serial number 070500100 can be modified with mod. kit 5799.648 to enable combining with a second folding section with FFD. First folding sections with serial numbers > 070503001 can be combined with second folding sections with FFD (also with serial number > 071003001).
510
TSM Oc 9800
ed. 5
FOLOFFOUTSE FOLOFFOUTMO
18 Folder 511
Accessories
Behind the folding unit, a delivery belt unit can be installed. On this unit, 1 or 2 delivery belts can be mounted. The belt are driven by FOLOBELTxMO (folding belt motor) and transports the folded copy some centimetres. When FOLOBELTxENDSE (folding belt end sensor) is activated, the belt accepts still a number of copies. This number is adjustable with SDS test 18-1-06. The next copies will be delivered on the other belt. When both belts are full the printing job is interrupted and starts again when one of the belts is empty.
belt 2
FOLOBELTx ENDSE belt 1
punch unit
512
TSM Oc 9800
Punch unit
After the copy is folded, 4 holes can be punched in the filling edge of the package. It is possible to remove the two outer pins, to punch only two holes. The package is transported till a stopper plate (adjustable by the operator). Two knocker fingers, driven by FOLOADJMO positions the filing edge straight into the punch pinch. The punch motor FOLOPUMO drives with an eccentric the punch pins and a pressure plate to hold the package in position. Several sensors detect the position of the knocker fingers, punch pins and folded package.
12 Drive belt PTR - folder
drive belt
ed. 5
18 Folder 513
13 The Reinforcement Unit (RU)

General
The reinforcement unit is an optional to the second folding section of the Oc 9800/9700. It adds a pre-punched, self-adhesive, filing strip to the folded copy. Advantages of this type of filing strip are: s it is much stronger than holes punched directly into the copy; s the copy can be unfolded without being taken out of the binder mechanism. The name of the Reinforcement Unit is abbreviated in the SDS and electrical diagrams as RU.
The reinforcement unit consists of the following parts:

5 7 4 3
6 8 9
11 2 1
10 1 2 3 4 5 6
the roll holder the guide roller the pin roller the transfer section the knife section the stamp section
514
TSM Oc 9800
7 8 9 10 11
the reinforcement head the protective sheet rollers and the slide FOL2GUIDSO the drive section the frame
The roll holder
The roll holder holds a roll of reinforcement tape. The tape is tensioned by a brake at the rear side of the roll holder, to prevent it from unrolling.
The guide roller
The side plates of the roll holder and a non-driven guide roller guide the tape towards the pin roller.
The pin roller
The pin roller provides the stamp with the correct length of reinforcement tape (111.125 mm), by turning half a revolution per copy. In order to prevent slip of the tape the pin roller is equipped with 10 pins, which correspond with holes in the tape. The rotation of the pin roller is determined by a half-a-revolution clutch.
The transfer section
The transfer section has three goals: s it separates the protective sheet from the adhesive tape; s it guides the separated protective sheet away from the knife; s it guides the tape through the knife towards the stamp unit.
The knife section
The knife section consists of an upper and a lower knife. The upper knife is spring-loaded and mounted on the front frameplate. The lower knife is mounted on the lower stamp. In the home position the upper knife is leaning against the lower knife outside the tape path. The tape is guided on the left and right hand side, outside the area where the glue is sitting, by a guide plate that is mounted on the upper knife. For cleaning the knives, SDS-test 18-6-17 is created. When you select this test and start it with the <PRINT> button, the clutch and the motor are activated for a short time. The knives are now accessible for cleaning. When you push the <PRINT> button again, the clutch and the motor are activated for a short time again.
Note: At the end of this procedure, the stamp will not be in its home position.
This will be corrected automatically once the machine is put in copy mode.
ed. 5
18 Folder 515
The stamp section
The stamp section consists of a lower stamp and an upper stamp. The reinforcement strip is put onto the lower stamp and held by two spring-loaded guide rails. Vertical movement of the strip is blocked by the guide rail, closest to the frameplate. The two stamps are driven by the same mechanism and therefore move at the same time: when the upper stamp moves down, the lower stamp moves up, and vice versa. In order to get an even pressure of the stamp, i.e. to compensate for mechanical tolerances, the pressure plate of the upper stamp is mounted on a foamy rubber layer. For smooth guidance of the copy, this pressure plate is teflon coated. A sticker on the frame of the intermediate transport indicates how the reinforcement tape has to be inserted between the stamps.
The reinforcement head
The reinforcement head holds the upper stamp and is mounted between the frameplates of the unit.
The protective sheet rollers and the slide
The protective sheet is put between two rollers. These rollers turn when the drive motor is running, they gently pull the protective sheet off the tape, stiffen the sheet, and feed it onto the slide, away from the knife. Stiffening the sheet is achieved by the shape of the rollers (cam and groove). There is a container for collecting the protective sheet. In order to feed the leading edge of the protective sheet of a new roll, the slide can be lifted on the right hand side to open the pinch between the rollers.
FOL2GUIDSO
A small copy guide guides the copy through the Reinforcement Unit, between the stamps. A solenoid, called FOL2GUIDSO, pulls away the small copy guide in order to prevent it from colliding with the moving stamp. In case of a malfunction of the solenoid, a mechanical safety takes over its function.
516
TSM Oc 9800
The drive section
-Revolution Clutch
Distribution PBA Chain Tensioner Single-Revolution Clutch FOL2RUSTAMPSO

Chain
DC-Motor
The entire reinforcement unit is driven by one DC-motor (FOL2RUMO) and a chain. The pin roller is driven via a half-a-revolution clutch (FOL2RUTAPESO). The stamp is driven via a single-revolution clutch (FOL2RUSTAMPSO). The protective sheet rollers are driven directly by the chain. The chain can be tensioned with an adjustable sprocket.
The frame
The frame consists of two plates and 5 spacers.
ed. 5
18 Folder 517
Detection circuit 3
1 2
1 2 3 4
FOL2RUHOMESE FOL2RUEMPTYSE FOL2RUJAMSW FOL2RUSTARTSE (transmitter and receiver)

Sensor FOL2RUHOMESE
When the reinforcement unit is inoperative, the lower stamp should be in the bottom position and the upper stamp in the top position. This corresponds with a certain position of a slot in the excentric disk that drives the stamp. Sensor FOL2RUHOMESE checks the position of the slot. If this position is not correct error message 18511 is displayed.
Sensor FOL2RUEMPTYSE
Sensor FOL2RUEMPTYSE is an L-shaped sensor, located in the path of the reinforcement tape. A transmitter sends infrared light in the direction of a receiver. If the light path is not blocked by the tape, the control knows that the roll of tape is finished. A message in the operator panel tells the operator to reload reinforcement tape.
518
TSM Oc 9800
Sensor FOL2RUJAMSW
Sensor FOL2RUJAMSW, a micro-switch, is placed in front of the knife unit. It detects the position of the guide plate. When a tape jam occurs the guide plate will move upwards and the switch will be activated. This will result in error message 18725.
Sensor FOL2RUSTARTSE
Sensor FOL2RUSTARTSE consists of a separate transmitter, located in the intermediate transport of the 2nd fold, and a receiver, located in the top stamp section. It detects the presence of the copy in the reinforcement unit.
Operation
The functioning of the reinforcement unit is controlled from the software of the engine. The initial position of the reinforcement unit is: s the lower stamp in the bottom position s the upper stamp in the top position s the pin roller in a locked position s the leading edge of the reinforcement tape in the knife section The working sequence of the reinforcement unit is as follows:
1 FOL2RUSTARTSE detects the copy; 2 the drive motor FOL2RUMO is switched on: the chain and the protective sheet
rollers start running;

3 the half-a-revolution clutch FOL2RUTAPESO is activated: the pin roller turns
4 5
7 8 9
180 degrees and one length (111.125 mm) of reinforcement tape is supplied onto the lower stamp; FOL2GUIDSO moves the small guide out of the working area of the stamp; at the moment the lower stamp hits the pressure plate of the upper stamp, the guide rails move out of the working area and the reinforcement tape is glued onto the copy; the single-revolution clutch FOL2RUSTAMPSO is activated: the eccentric disks make one full turn, moving the lower stamp upwards and the upper stamp downwards; while the lower stamp moves upwards, the knife cuts the tape; the eccentric disks finish the turn, the stamps return to the home position, and the guide rails drop back into place; the drive motor FOL2RUMO stops.
ed. 5
18 Folder 519
520
TSM Oc 9800
1st fold.
FOL1 STARTSE FOL1DOORSW FOL1LIFDOWNSE 18PBA7 SENSOR DISTR. FOLD FOL1OUT DEFSO FOL1LIFUPSE
FOL1LIFMO
1st fold
FOL1DEPOSE 18K1-2A Relay FOL1DEFCL
18PBA15 Step motor control FOL1FOLMO 18PBA3 Power I/O FOL1FOLMOSE 18G1 FOLSUPLV FOL1IN MOSE FOL1INMO
ed. 5
18 Folder 601
2nd fold
FOL2OUTSE FOL2TRAISE1 FOL2DE POSE
FOLOFFOUTSE FOL2 STARTSE
FOL2DOORSW FOL2TRAISE2 FOLOFFOUTMO
FOL2OUTSO
FOL2TRAYSW
18K2-2A
18PBA14 SENSOR DISTR. FOLD
FOL2FLATSO
18PBA17 PBA REINFORCEMENT
RELAY PBA 18PBA16
18PBA10 POWER I/O
602
TSM Oc 9800
2nd fold
FOL2INMOSE
FOL2INMO
FOL2DEFCL
FOL2DEFPOSE
FOL2FOLMO Confidential 1999 Oc-Technologies B.V. FOL2FOLMOSE
ed. 5
18 Folder 603
Lower belt unit
FOLOBELT1ENDSE
FOLOBELT1SE FOLOBELTVA
FOLOBELT1 DOORSW
FOLOPU DOORSW
POWER SUPPLY
604
TSM Oc 9800
Lower belt unit
FOLOPUEJSO
RELAY BOARD FOLOBELT1MO I/O BOARD
ed. 5
18 Folder 605
Upper belt unit
Upper belt unit
FOLOBELT2SE
FOLOBELT2 DOORSW
FOLOBELT2MO
FOLOBELT2ENDSE
606
TSM Oc 9800
Punch unit
FOLOPUMOENDSE
FOLOPUSTARTSE
FOLOPUMOHOMESE
FOLOPUMO FOLOPTRMO FOLOADJMOHOMESE FOLOADJMO FOLOADJMOENDSE
ed. 5
18 Folder 607
First Fold delivery
FOLOFFOUTSE
FOLOFFOUTMO
608
TSM Oc 9800
1
22PBA1 CPU I/O
X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 +5V +5V GND BD0 BD1 BD2 BD3 GND BD4 BD5 BD6 BD7 GND BA1 BA2 BA3 BA4 GND NASIC1_RD NASIC1_WR GND NINT5 NINT4 BNRESET BNOE GND X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 X3 FOL1LIDOWNSE-B 4 FOL1LIUPSE-B 5 X2 FOL1LISTART 4 FOL1LIRESET 5 FOL1LISTA0 15 FOL1LISTA1 16
2
2202X3 1 2 6 3 +5V GND FOL1STARTSE FOL1DEPOSE
4
X2 8 7 6 1 X1 1 2 3 X3 13 14 15
5
18PBA7 SENSOR DISTRIBUTION FOLD
+5V GND FOL1STARTSE +5V FOL1DEPOSE GND 1 2 3 1 2 3
6
FOL1STARTSE
18B1
FOL1DEPOSE
18B4
18PBA3 POWER I/O

2202X2 24 23 22 21 20 19 17 18 9 7 10 11 12 13 14 1 2 3 +5V GND RESERVEOUT PTRUFOSO PTRFEDCL PTRCORCL FOL1DEFCL FOL1OUTDEFSO FOL1FOLMOPWM FOL1INMOPWM FOL1MOCW PTRDOORSW FOL1DOORSW FOL1OUTDIAG FOL1INDIAG FOL1INMOSE FOL1FOLMOSE-1 FOL1FOLMOSE-2 X7 1 2 3 4 5 6 8 7 16 17 15 14 13 12 11 20 19 18 X2 1 2 3 4 FOL1DEFCL +24V FOL1OUTDEFSO +24V
FOL1DEFCL
18Y1
FOL1OUTDEFSO
18Y2
X5 2
FOL1FOLMO
18X3 2
FOL1FOLMO
M
18M2
18PBA15 STEP MOTOR CONTROL

X1 3 4 8 5 7 6 X2 1 2 3 4 5 6 X3 6 3 1 4 2 5 +5V FOL1LIDOWNSE GND +5V FOL1LIUPSE GND 18X22 1 2 3 4 5 6 18X20 1 2 3 4 1 2 3 1 2 3
+24V
1 18X21 4 3
FOL1LIDOWNSE
18B14 X4 1 2 3 4 GND FOL1FOLMOSEB FOL1FOLMOSEA +5V 1 2 3 4
FOL1FOLMOSE 18PBA5
FOL1LIUPSE
18B13
M
4
FOL1LIMO
18M5
GND +24V
FOL1INMOSE 22PBA5 DRIVERS

5 6 7 +5V FOL1INMOSE GND 1 2 3 18B5
X13 1 2 3 5
+5V GND +24V GND
X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10
X5 7
CTFDOORSW
+24V 1 O6S1 2
PTRFRAMESW
8 +24V-SW 2 15S1 1
X3 2
FOL1INMO
18X3 2
FOL1INMO
M
18M1
22G1 CONSUPLV
F1 4A
X8 12 11 X12 12
+24V-SW GND
22X13 1 2
+24V
1 18X21 6 5
CONEMS2-B
15
+24V-SW
CONEMS2
22K2-2A X6 5 6 PTRDOORSW 18X4 9
22PBA4 SSR 22Z2

6 5 4 L2 22X010 N2 X9 1 2 3 X8 6 3 L2 N2 6 2 8 4
7 8 1 2
GND FOL1DOORSW
18G1 FOLSUPLV
G
F1 5A
G1 3 1 2 G5 G4 3 1 G2 2 4 3 1
N2-S L2-S
X2 5 6
1 4
N2-S L2-S X1 2 1
3 4
FOL1DOORSW
GND 18S1 4 1 3 2 10
FRAME EARTH CONNECTION 18X16 GND +5V +24V GND +24V GND 18X002-1 22X012-1 2201X5 2 1 18X11
FOL1SAFRL1
18X21 2 18K1-2A
ed.5
TSM Oc 9800
FIRST FOLD 18 Folder 701
1
22PBA1 CPU I/O
X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 +5V +5V GND BD0 BD1 BD2 BD3 GND BD4 BD5 BD6 BD7 GND BA1 BA2 BA3 BA4 GND NASIC2_RD NASIC2_WR GND NINT5 NINT4 BNRESET BNOE GND X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
2
2209X3 1 2 8 3 7 6 5 2209X5 1 2 3 4 5 6 7 8 9 10 11 12 19 2209X2 24 23 17 18 19 9 7 10 12 11 13 14 1 2 3 +5V GND 5V FOL2DEFCL-1 FOL2OUTSO-1 FOL2FLATSO-1 FOL2FOLMOPWM FOL2INMOPWM FOL2MOCW FOL2DOORSW-B FOL2TRAYSW-B FOL2OUTDIAG FOL2INDIAG FOL2INMOSE FOL2FOLMOSE-1 FOL2FOLMOSE-2 +5V GND FOL2STARTSE-B FOL2DEPOSE-B FOL2OUTSE-B FOL2TRAISE2-B FOL2TRAISE1-B 18X5 8 7 1 6 2 3 4 18X19 1 2 3 4 5 6 7 8 9 10 11 12 13 18X1 1 2 5 4 3 11 12 10 8 9 7 6 15 14 13
3
X2 8 7 4 6 2 5 1
4
X3 7 8 9 13 14 15 1 2 3 10 11 12 X1 1 2 3 +5V GND FOL2STARTSE +5V GND FOL2DEPOSE +5V GND FOL2OUTSE +5V GND FOL2TRAISE2 +5V GND FOL2TRAISE1 18X10 1 2 3
5
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
6
FOL2STARTSE
18B9
FOL2DEPOSE
18B11
FOL2OUTSE
18B7
(to OPTIONALS 704)
FOL2TRAISE2
18B10
FOL2TRAISE1
18B6
18PBA10 POWER I/O

X7 1 2 8 7 6 16 17 15 13 14 12 11 20 19 18 X2 1 2 3 4 X8 1 2 FOL2DEFCL +24V FOL2OUTSO +24V FOL2FLATSO +24V
FOL2DEFCL
18Y3
FOL2OUTSO
18Y4
FOL2FLATSO
18Y5
X5 2
FOL2FOLMO
1810X5 2
18X6 2
FOL2FOLMO
18M4 8 6
D
1 +24V
22PBA5 DRIVERS
X13 1 2 3 5 +5V GND +24V GND X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10 X5 7 +24V
CTFDOORSW
1 O6S1 2
X4 1 2 3 4
+5V FOL2FOLMOSEB FOL2FOLMOSEA GND
1 2 3 4
FOL2FOLMOSE 18PBA12
PTRFRAMESW
8 +24V-SW 2 15S1 1
22G1 CONSUPLV
F1 4A
X8 12 11 X12 12
+24V-SW GND
22X13 1 2
5 6 7
+5V FOL2INMOSE GND
1 2 3
FOL2INMOSE
18B12
CONEMS2-B
X3 2
FOL2INMO
1810X3 2
18X7 2
15
+24V-SW
CONEMS2
22K2-2A 1 +24V 1
FOL2INMO
18M3
22PBA4 SSR 22Z2

6 5 4 L2 22X010 N2 X9 1 2 3 X6 1 2 1810X6 1 4 1 1810X6 2 X8 6 3 4 2 L2 N2 6 2 8 4 1
18G1 FOLSUPLV
G1 3 1 2 N2-S L2-S X2 5 6 1 4 N2-S L2-S
FOL2DOORSW
FOL2DOORSW
3 18X16 GND +5V 18X15 18X8 4 3 1 G5 18X002-1 22X012-1 4 5 6 1810X1 2 1 X1 2 1 GND FOL2TRAYSW 4 5
18S4 3 2 18X18 1 3
G4 3 1 F1 5A G3 3 1
2201X5 2 1 18X14
3 6 4 1
GND +24V
FOL2TRAYSW
7 GND
18S3 3 2
FOL2SAFRL1
18K2-2A 7 8
H
ed.5 TSM Oc 9800
SECOND FOLD up to nr. 3000 18 Folder 702
(to OPTIONALS 704)
1
22PBA1 CPU I/O
2
2209X3 1 2 8 3 7 6 5 4 +5V GND FOL2STARTSE-B FOL2DEPOSE-B FOL2OUTSE-B FOL2TRAISE2-B FOL2TRAISE1-B FOLOFFOUTSE 18X5 8 7 1 6 2 3 4 5
3
X2 8 7 4 6 2 5 1 3
4
X3 7 8 9 13 14 15 1 2 3 10 11 12 4 5 6 X1 1 2 3 +5V GND FOL2STARTSE +5V FOL2DEPOSE GND +5V GND FOL2OUTSE 18X9 1 2 3 18X12 +5V 1 GND 2 FOLOFFOUTSE 3 +5V GND FOL2TRAISE2 +5V GND FOL2TRAISE1 18X10 1 2 3
5
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
6
FOL2STARTSE
18B9
FOL2DEPOSE
18B11
FOL2OUTSE
18B7
(to OPTIONALS 704)
2209X4 16 15 13 12 11 10 9 8 7 2209X2 4 5
+5V GND FOLOINPDIAG FOLOOUTDIAG FOLOBELTDOORSW FOLODOORSW FOLOINSE FOLOOUTSE FOLOBELTENDSE
18X34 1 2 3 4 5 6 7 8 9
FOL2TRAISE2
18B10
FOLOFFOUTSE
18B15
FOL2TRAISE1
18B6
FOLOPTRMO FOLOBELCL
10 11 18X7 6 1 5 3 2 4 18X23 1 7 8 6 4 5 3 2 11 10 9 X7 1 2 4 4 7 6 8 16 17 15 13 14 12 11 20 19 18
18PBA10 POWER I/O

24 23 21 20 18 19 17 9 7 10 12 11 13 14 1 2 3 +5V GND FOLOFFOUTMO FOL2INMOCW FOL2OUTSO-1 FOL2FLATSO-1 FOL2DEFCL-1 FOL2FOLMOPWM FOL2INMOPWM FOL2MOCW FOL2DOORSW-B FOL2TRAYSW-B FOL2OUTDIAG FOL2INPDIAG FOL2INMOSE-1 FOL2FOLMOSE-1 FOL2FOLMOSE-2 X2 1 2 3 4 X8 1 2 6 FOL2DEFCL +24V FOL2OUTSO +24V FOL2FLATSO +24V +24V 18X30 2
FOL2DEFCL
18Y3
FOL2OUTSO
18Y4
FOL2FLATSO
18Y5
M
5 FOLOFFOUTMO 1
FOLOFFOUTMO
18M6
D
X13 1 2 3 5 +5V GND +24V GND X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10
22PBA5 DRIVERS
X5 7 +24V
CTFDOORSW
1 O6S1 2
X5 2
FOL2FOLMO
1810X5 2
18X6 2
M
1 1
FOL2FOLMO
18M4 8 6
PTRFRAMESW
8 +24V-SW 2 15S1 1 1 X4 1 2 3 4 +24V +5V FOL2FOLMOSEB FOL2FOLMOSEA GND
22G1 CONSUPLV
F1 4A
X8 12 11 X12 12
+24V-SW GND
22X13 1 2
1 2 3 4
FOL2FOLMOSE 18PBA12
CONEMS2-B
15
+24V-SW
CONEMS2
22K2-2A
5 6 7 X6 1
+5V FOL2INMOSE GND FOL2DOORSW
1 2 3
FOL2INMOSE
18B12
22PBA4 SSR 22Z2

6 5 L2 22X010 N2 X9 1 2 3 X8 6 3 L2 N2 6 2 8 4
4 1
FOL2DOORSW
GND FOL2TRAYSW
18S2 3 2 18X18 1 3 4 1 18X18 1 2
F
G1 3 1 2 G5 G4 3 1
18G1 FOLSUPLV
N2-S L2-S X2 5 6 1 4 N2-S L2-S 5
FOL2TRAYSW
18X16 GND +5V 18X002-1 22X012-1 8 GND
18S3 3 2 18X27 1 2
FOL2SAFRL1
18K2-2A 2201X5 2 1
F1 5A
18PBA16 RELAY
X6 7 X1 2 X8 4 3 X3 1 2 +24V GND +24V FOL2INMOCW +24V FOL2INMO X2 1 2 7 3 6 5 X1 2 1 8 FOL2INMO 18X7 1 X2 9 +24V 2 4
(to OPTIONALS 704) FOL2INMO

M
18M3
18X15
G3 3 1
GND +24V
18X8 4 3 1
18X14
ed.5
TSM Oc 9800
SECOND FOLD from nr. 3001 18 Folder 703
1
22PBA1 CPU I/O
2
2209X5 1 2 3 4 5 6 7 8 9 10 11 12 19 18X19 1 2 3 4 5 6 7 8 9 10 11 12 13
3
I/O BOARD
1813X1 J1 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 J7 1 J8 11 J7 10 J9 2 J8 2 13 J9 1 J8 1 12 J9 3 J7 13 J9 4 J7 6 J8 6 J9 5
4
+5V GND FOLOPUSTARTSE +5V FOLOPUMOENDSE GND +5V FOLOPUMOHOMESE GND +5V FOLOADJMOENDSE GND +5V FOLOADJMOTHOMESE GND
5
1 2 3 1 2 3 1 3 2 1 2 3 1 2 3
6
FOLOPUSTARTSE
(PUNCH UNIT)
FOLOPUMOENDSE
(PUNCH UNIT)
FOLOPUMOHOMESE
(PUNCH UNIT)
FOLOADJMOENDSE
(PUNCH UNIT)
FOLOADJMOHOMESE
(PUNCH UNIT)
FOLOPUNEJSO (PUNCH UNIT)

J3 2 1 2 +24V
RELAY BOARD
J12 7
FOLOPUMO
J3 4 1
(PUNCH UNIT)
GND
J13 3
C
1
FOLOADJMO
1
(PUNCH UNIT)
GND
BELT2DOORSW
2 3 1 4
J23 4 7
BELT1DOORSW
2 3 1 4
D
6 5
PUDOORSW +24V J5 6 2 1 J9 GND 6 3 4 J6 FOLOPUDOORSW 3 J9 GND 7 J6 FOLOBELT1DOORSW 4 J9 GND 8 J6 FOLOBELT2DOORSW 5 J5 7
SECOND BELT UNIT

FOLOBELT2MO
J3 6 J24 4 2
J24 5
GND
J13 5
J7 4 J8 19 3
+5V GND FOLOBELT2ENDSE
J25 1 2 3
J24 1 2 3 J23 1 2 3
FOLOBELT2ENDSE
1 3 2
J7 3 J8 8 5
+5V GND FOLOBELT2SE
FOLOBELT2SE
1 2 3
22PBA5 DRIVERS
X13 1 2 3 5
+5V GND +24V GND
X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10
FOLOBELT1MO
J3 5 2
GND
J13 4
22G1 CONSUPLV
FOLOPTRMO
J4 1 1
+24V
J12 9
J7 5 J8 10 4 X1 21 CONCONEMSSUP
+5V GND FOLOBELT1ENDSE
J26 1 2 3
FOLOBELT1ENDSE
1 3 2
17
CONKEYSW
CONCONEMS
22K4-2A
J7 2 J8 7 J7 9
+5V GND FOLOBELT1SE
FOLOBELT1SE
1 2 3
22PBA4 SSR 22Z2

6 5 4 L2 22X010 N2 X9 1 2 3 X5 1 2 L2 N2
FOLOBELTVA
6 2 8 4 J3 3 1 2 +24V J12 8
POWER SUPPLY
G1 3 1 2 G5 J15 1 J16 1 3 J14 4 2
N2-MNO L2-MNO
22X9 3 1 2
X3 6 3
X4 3 2
N2-MNO L2-MNO
FRAME EARTH CONNECTION 18X? ? 22X? 18X? J5 3 J2 1 2
J5 8 9 J4 3 2 J5 5 4
2 1 +24V GND 18X18 1 3 R2 4 J13 7 J11 1 3 J13 1 3
+24V +5V GND GND +24V
from SECOND FOLD 702 / 703
24V J12
ed.5
TSM Oc 9800
OPTIONALS 18 Folder 704
1
PBA, CPU 22PBA01
X2
+5V +5V GND DATA DATA DATA DATA GND DATA DATA DATA DATA
2
PBA, I/O interface 22PBA 02/09
X1 X3 18X5
+5V GND 5V FOL2DEPOSE FOLOFFOUTSE FOL2TRAISE1 FOL2TRAISE2 FOL2OUTSE1 FOL2STARTSE
4
PBA, SENSOR DIST. FOLD 18PBA14
X2 X1
5
18B6 FOL2TRAISE1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2 3 4 5 6 7 8
X2
8 7 6 5 4 3 2 1
+5V GND 5V FOL2DEPOSE FOLOFFOUTSE FOL2TRAISE1 FOL2TRAISE2 FOL2OUTSE1 FOL2STARTSE
1 2 3 4 5 6 7 8
X3
1 2 3
+5V GND 5V FOL2TRAISE1
1 2 3
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
18B7 FOL2OUTSE1
1 2 3
+5V GND 5V FOL2OUTSE1
1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 17
FOL2INMOSE1 FOL2FOLMOSE1 FOL2FOLMOSE2
18X23
12 11 10 9
GND ADRES ADRES ADRES ADRES GND CONTROL CONTROL GND CONTROL NINT CONTROL CONTROL GND
(To PBA power I/O Folder 2 18PBA10 X7 (702))
X3
18x12
18B15 FOLOFFOUTSE
+5V GND 5V FOLOFFOUTSE
4 5 6
+5V GND 5V FOLOFFOUTSE
1 2 3
FOL2INMOPWM FOL2FOLMOPWM FOL2MOCW FOL2TRAYSW
8 7 6 5 4 3 2 1
FOL2DOORSW FOL2OUTDIAG FOL2INPDIAG FOL2DEFCL
18B9 FOL2STARTSE
X3 18x10
7 8 9
+5V GND 5V FOL2STARTSE
+5V GND 5V FOL2STARTSE
1 2 3
24 25 26
FOL2OUTSO FOL2FLATSO FOL2INMOCW FOLOFFOUTMO
6 5 4 3 2 1
18X19
(To PBA power I/O Folder 2 18PBA10 X7 (702))
18x1
18B10 FOL2TRAISE2
X3 18x9
+5V GND 5V FOL2TRAISE2 +5V GND 5V FOL2TRAISE2
10 11 12
1 2 3
22 23 24
X5
GND 5V +5 V
E
18B11 FOL2DEPOSE
+5V FOL2DEPOSE GND 5V
X3
13 14 15
1 2 3
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
F
(To REINFORCE 706)
11 12 13 14 15 16 17 18 19 20
H
REINFORCEMENT
6
18 Folder 705
ed.5
TSM Oc 9800
1
18X19 .18X24
3
PBA, REINFORCEMENT 18 PBA 17
X1 X6
FOLODATA0 FOLODATA1 FOLODATA2 FOLODATA3 FOLODATA4 FOLODATA5
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 11 12
X5
+24 V FOL2RUSTOPSO +24 V
18X29
1 2 1
A
(FROM REINFORCE 705)
2 3 4 5 6 7 8 9
18Y6 FOL2RUSTOPSO
18X28
A
M
18M7-1 FOL2RUMO 18Y7 FOL2RUSTAMPSO 18Y8 FOL2RUTAPESO 18Y8 FOL2RUGUIDSO
18S7
FOL2RUMO +24 V FOL2RUSTAMPSO +24 V FOL2RUTAPESO +24 V FOL2RUGUIDSO
2 4 5 7 8 3 6
18S11
FOLODATA6 FOLODATA7 FOLOCTRL0
8 9 10
FOLOCTRL1 FOLOCTRL2
.18X25
11
FOLOCTRL3 FOL2RUINPDIAG
10 11 12 14 13 15
1 2 3 4 5 6
OPTIONAL PUNCH UNIT & DELIVERY BELTS
22X9 1813X1
12 13 14 15 16
FOL2RUINTDOORSW
18S10
1 3
X7
+ 24V
GND 5V +5 V
FOL2RUCOVERSW
FOL2RUDOORSW PBA,RELAY 18 PBA 16

X3
1 2
+24 V GND 24V
1 2
X2 X4
FOLODATA0 FOLODATA1 FOLODATA2 FOLODATA3 FOLODATA4 FOLODATA5
L2
22X9-1 22X9-2 22X9-3
(FROM 18 FOLDER 704)
1 2 3
J11
1 2 3 4 5 6 7 8 9
X3
1 6 7 8 9 10 11 12 13 14 15 16
FOL2RUSTARTSE
18X26
FOL2RUJAMSW GND 5V FOL2RUDOORSW1 GND 5V FOL2RUDOORSW2 GND 5V FOL2RUCOVERSW GND 5V
18S12
EARTH N2
6 7
FOL2RUJAMSW
18S7
4 5 6 7 8 9 10
18X21-3 18X21-2 18X21-1
FOL2RUDOORSW1
18S10
FOLODATA6 FOLODATA7 FOLOSEL4
FOL2RUDOORSW2
18S11
FOL2RUCOVERSW
FOLOSEL1 FOLOSEL2 FOLOSEL3
1 2 3 4 5 6 7
X4
11 12 13 14 15 16
X1
GND 5V
PBA, IR-TX/RX
17 18 19 20
+5 V GND 5V +5 V
3 1
18PBA20
GND 5V
18X26
X1
FOL2RUSTARTSE GND 5V +5 V
11 12 10
+ 5V
2 3 1
PBA, IR-TX/RX
5 4 3 2
F
18X26 X2
GND 5V FOL2RUEMPTYSE FOL2RUHOMESE
18PBA19
X3
2 3 4
1 2 3 4 5 6 7 8
1 2 3
+5V
18B17 FOL2RUHOMESE
4 5 6 10 11 12
+5V GND 5V FOL2RUHOMESE
1 3 2
18B18 FOL2RUEMPTYSE
G
18X28-9
18X28-9
18X17
7
GND 5V
1 2 3
8 9 13 14 15
FOL2RUEMPTYSE
18X22
H
REINFORCEMENT 6 18 Folder 706
PBA, SENSOR (DISTRIBUTION FOLD) 18 PBA 21
ed.5
TSM Oc 9800
Oc
Oc 9800
19 FINISHING
Contents
Diagnostics
1 Faults
101
SDS
Adjustments
1 The paper input guide 301 2 The delivery input solenoid (DELINSO) 303 3 The delivery output solenoid bin (2-5) (DELOUTSOBIN) 305 4 The delivery output solenoid bin 6 (DELOUTSOBIN6) 306 5 The belt tension of the TRI drive belt 307 6 The belts tension 308 7 The HCS with regard to Oc 9700 / 9800 309 8 The delivery transport intermediate open switch (DELTRIOPSW) 311
Dis-/assemblies
1 The transport intermediate (TRI) 401 2 The belts of the TRI 404 3 The set separation motors (DELSEPMO) 406 4 The main drive motor (DELPTRMO) 406 5 The delivery bins 407 6 The uppper door 408 7 DELBULSE 409 8 DELINSE 409 9 DELTRIOPSW 409 10 DELTRIOUTSE 410 11 DELSYNSE 411 12 DELOUTSE1 412 13 DELOUTSE2-6 412 14 DELBINOPSE 413 15 DELBINEMSE PBA 413 16 DELSEPINISE 413 17 DELVERTINSE 414 18 DELINSO 414 19 DELOUTSOBIN 414
ed.5
19 Finishing
1 General. 501
1 Component names 601 2 Component location 605
Diagrams
1 High capacity stacker 1 2 High capacity stacker 2
701 702
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date.
High Capacity Stacker 19000 - 19999 code display. 19001 FE: ~HCS softw. watchdog occurred twice~
Second performance overload
Switch the HCS OFF and ON
19101, 19102, 19103, 19104, 19105, 19106 PE: ~DEL BIN (1-6) INItialisation failed~ 19504, 19505, 19506, 19507, 19508, 19509 MRE: ~DEL BIN (1-6) INItialisation failed~ 19735, 19736, 19737, 19738, 19739, 19740 ORE: ~BIN(1-6)SEP too soon in home position~
19-2-12 / -15 / -19 / -23 / -27 / -31 DELSEP(1-6)INISE Possible cause Remarks
DELSEP(1-6)INISE defect Connections DELSEP(1-6)INISE -> PBA DISTRIBUTION(1-6) Connections HCS CPU I/O -> PBA DISTRIBUTION(1-6) Connections HCS CPU I/O -> DELSEPMO(1-6) Drive spindles mechanical jammed
ed.5
19 Finishing 101
19-6-03 5 V regulated test
Possible cause
Remarks
Failed
LV Power Supply defective + 24 V not present Connection LV Power Supply -> HCS CPU I/O HCS CPU I/O defective
19-6-04 Separation test
Possible cause
Remarks
disconnect 1901X11 on HCS CPU I/O Failed
HCS CPU I/O defective
All doors must be closed and the TRI in position
19-6-06 HCS bin shift test
Possible cause
Remarks
Failed
DELSEPMO(1-6) Wiring
19501 MRE: ~Communication failure DEL -> CPU engine~

HCS CPU I/O engine defective HCS CPU I/O defective RS232 defective 5 V defective
Check LV Power Supply / wiring
102
TSM Oc 9800
Diagnostics
Execute communication test (at HCS CPU)
Possible cause
Remarks
C flashes on HCS CPU I/O when test is running Communication test FAILED HCS CPU I/O defective 5 indicated on Wiring HCS CPU I/O -> CPU I/O HCS CPU I/O engine Communication test OKAY snake running on HCS CPU I/O
- switch off the HCS - disconnect connector 1901X9 from HCS CPU I/O - connect test connector E to 1901X9 - switch SDS switch (on HCS CPU I/O to SDS Switch on the HCS
Note: Switch the SDS switch back to ~RUN~ position.
Execute communication test (at engine PBA I/O interface)
Possible cause
Remarks
- switch off the HCS and engine - disconnect connector X6 from PBA I/O interface - connect test connector E to X6 - switch on the engine Communication test FAILED PBA I/O interface board defective Wiring HCS CPU I/O -> engine PBA I/O interface Communication test OKAY
ed.5
19 Finishing 103
19503 MRE: ~Speed DELPTRMO too high~

Timing belt
19-6-05 Motor running Possible cause DELPTRMO
Remarks
No
HCS CPU I/O defective Connection HCS CPU I/O -> DELPTRMO
19504, 19505, 19506, 19507, 19508, 19509 MRE: ~DEL BIN (1-6) INItialisation failed~ see page 101
104
TSM Oc 9800
Diagnostics
19701 ORE: ~Paper too late at DELINSE~

19-2-06 DELINSE Possible cause Remarks
Continuously OFF
DELINSE defective Connection HCS CPU I/O -> DELSINSE
19-4-01 DELINSO
Possible cause
Remarks
Continuously OFF
DELINSO defective Connection HCS CPU I/O -> DELINSO Input flap blocked
Possible cause
Remarks
Failed
ed.5
19 Finishing 105
19702 ORE: ~DELINSE too late free~

Paper clipping to sensor Timing belt not correctly tensioned
19-2-06 DELINSE
Possible cause
Remarks
Continuously ON
DELINSE defective Connection HCS CPU I/O -> DELINSE
19-4-01 DELINSO
Possible cause
Remarks
Continuously OFF
DELINSO defective Connection HCS CPU I/O -> DELINSO Input flap blocked
19-2-05 DELBULSE
Possible cause
Remarks
Continuously OFF
DELBULSE defective Connection DELBULSE -> PBA DISTRIBUTION7 Connection HCS CPU I/O -> PBA DISTRIBUTION7
Possible cause
Remarks
Failed
106
TSM Oc 9800
Diagnostics
19703 ORE: ~Paper too late at DELVERTINSE~

Timing belt not correctly tensioned
19-4-011 DELOUTSOBIN6
Possible cause
Remarks
Continuously ON
DELOUTSOBIN6 blocked Connection DELOUTSOBIN6 -> HCS CPU I/O
19-2-07 DELSYNSE
Possible cause
Remarks
DELSYNSE defective Connection HCS CPU I/O -> DELSYNSE
19-2-09 DELVERTINSE
Possible cause
Remarks
Continuously OFF
DELVERTINSE defective Connection HCS CPU I/O -> DELVERTINSE
Possible cause
Remarks
Failed
ed.5
19 Finishing 107
19704 ORE: ~DELVERTINSE too late free~

Timing belt not correctly tensioned
19-2-09 DELVERTINSE
Possible cause
Remarks
Continuously ON
DELVERTINSE defective Connection HCS CPU I/O -> DELVERTINSE
Possible cause
Remarks
Failed
LV Power Supply defective + 24 V not present Connection LV Power Supply -> CPU I/O HCS CPU I/O defective
19705, 19707, 19709, 19711, 19713, 19715 ORE: ~Paper too late at DELOUTSE (1-6)~
Timing belt not correctly tensioned Paper path blocked
19-2-13 / -17 / -21 / -25 / -29 Possible cause /-33 DELOUTSE(1-6)
Remarks
Continuously OFF
DELOUTSE(1-6) defective Connection DELOUTSE1 -> HCS CPU I/O Connection DELOUTSE(2-5) -> PBA DISTRIBUTION(1-5) Connection PBA DISTRIBUTION(1-5) -> HCS CPU I/O
108
TSM Oc 9800
Diagnostics
19-4-03 / -05 / -07 / -09 / -11 DELOUTSOBIN(2-6)
Possible cause
Remarks
Continuously ON
DELOUTSOBIN(2-6) defective / blocked Connection DELOUTSOBIN(2-6) -> HCS CPU I/O
Possible cause
Remarks
Failed
19706, 19708, 19710, 19712, 19714, 19716 ORE: ~DELOUTSE (1-6) too late free~
Timing belt not correctly tensioned Paper path blocked
19-2-13 / -17 / -21 / -25 / -29 /-33 DELOUTSE(1-6)
Possible cause
Remarks
Continuously ON
DELOUTSE(1-6) defective Connection DELOUTSE1 -> HCS CPU I/O Connection DELOUTSE(2-6) -> PBA DISTRIBUTION(1-5) Connection PBA DISTRIBUTION(1-5) -> HCS CPU I/O
19-4-03 / -05 / -07 / -09 / -11 DELOUTSOBIN(2-6)
Possible cause
Remarks
Continuously ON
DELOUTSOBIN(2-6) defective / blocked
ed.5
19 Finishing 109
19-4-03 / -05 / -07 / -09 / -11 DELOUTSOBIN(2-6)
Possible cause
Remarks
Connection DELOUTSOBIN(2-6) -> HCS CPU I/O
Possible cause
Remarks
Failed
19717 ORE: ~Speed DELPTRMO too low~

Timing belt not correctly tensioned Loose puls disc / soiled
19-2-10 DELPTRMOSE
Possible cause
Remarks
Contiuously ON / OFF
DELPTRMOSE defec5tive Connections DELPTRMOSE ->HCS CPU I/O Sensor soiled
Possible cause
Remarks
Failed
LV Power Supply defective + 24 V not present Connections LV Power Supply -> HCS CPU I/O HCS CPU I/O defective
110
TSM Oc 9800
Diagnostics
19-6-05 DELPTRMO
Motor running Possible cause No HCS CPU I/O defective Connections HCS CPU I/O -> DELPTRMO
Remarks
ON
19718, 19720, 19723, 19725, 19727, 19729 ORE: ~BIN(1-6)SEP not / too late in home pos.~ 19719, 19721, 19724, 19726, 19728, 19730 ORE: ~BIN(1-6)SEP not / too late out off home pos.~
Possible cause
Remarks
Drive spindles mechanicaly blocked
19-2-12 / -15 / -19 / -23 / -27 / Possible cause -31 DELSEP(1-6)INISE
Remarks
DELSEP(1-6)INISE defective Connection DELSEP(1-6)INISE -> PBA DISTRIBUTION(1-6) Connection PBA DISTRIBUTION(1-6) -> HCS CPU I/O Connections HCS CPU I/O -> DELSEPMO1-6 ->
Possible cause
Remarks
Failed
ed.5
19 Finishing 111
19-6-04 Separation test
Possible cause
Remarks
disconnect 1901X11 on HCS CPU I/O Failed
HCS CPU I/O defective
19-6-06 HCS bin shift test
Possible cause
Remarks
Failed
DELSEPMO(1-6)
19731 ORE: ~Paper too late at DELTRIOUTSE~

Paper transport belts blocked Timing belt TRI not correctly tensioned Timing belt PTR not correctly tensioned Puls disc loose / soiled
19-2-05 DELBULSE
Possible cause
Remarks
Continuously ON
DELBULSE defective / soiled Connection HCS CPU I/O -> DELBULSE
19-2-08 DELTRIOUTSE
Possible cause
Remarks
Continuously OFF
DELTRIOUTSE defective Connection HCS CPU I/O -> DELTRIOUTSE
112
TSM Oc 9800
Diagnostics
19=2-10 DELPTRMOSE
Possible cause
Remarks
DELPTRMOSE defective / soiled Loose connection
Possible cause
Remarks
Failed
19-6-05 Motor running Possible cause DELPTRMO
Remarks
No
HCS CPU I/O defective Connection HCS CPU I/O -> DELPTRMO
19732 ORE: ~DELTRIOUTSE too late free~

Timing belt TRI not correctly tensioned
19-2-08 DELTRIOUTSE
Possible cause
Remarks
Continuously ON
DELTRIOUTSE blocked / defective Connection HCS CPU I/O -> DELTRIOUTSE
ed.5
19 Finishing 113
Possible cause
Remarks
Failed
19733 ORE:~Paper too late at DELSYNSE~

Paper transport belts mechanically blocked Timing belt TRI not correctly tensioned Timing belt PTR not correctly tensioned Puls disc loose / soiled
19-2-05 DELBULSE
Possible cause
Remarks
Continuously ON
DELBULSE defective / soiled Connection HCS CPU I/O -> DELBULSE
19-2-07 DELSYNSE
Possible cause
Remarks
Continuously OFF
DELSYNSE defective Connection HCS CPU I/O -> DELSYNSE
During start no problem
114
TSM Oc 9800
Diagnostics
Possible cause
Remarks
Failed
19734 ORE: ~DELSYNSE too late free~

Timing belt TRI not correctly tensioned

19-2-07 DELSYNSE
Possible cause
Remarks
Continuously ON
DELSYNSE blocked / defective Connection HCS CPU I/O -> DELSYNSE
Possible cause
Remarks
Failed
ed.5
19 Finishing 115
19735, 19736, 19737, 19738, 19739, 19740 ORE: ~BIN(1-6)SEP too soon in home position~see page 101 19901 SWAR: ~HCS softw. watchdog occurred once~
116
TSM Oc 9800
Diagnostics
SDS
Test number Parameter test 19-1-01 Component Signal Description
~Maximum number of copies~ ~in HCS bins~ (range 10 - 200, default 200)
Input tests 19-2-01

19S2 19S3 19S4
~DELivery Upper DOOR~ Delivery upper door switch ~SWitch~ OFF = door closed ~DELivery Lower DOOR~ Delivery lower door switch ~SWitch~ OFF = door closed ~DEL TRI OPen SWitch~ Delivery transport intermediate open switch OFF = operating position Delivery transport intermediate position switch OFF = operating position
19-2-02 19-2-03
19-2-04
19S1
~DEL TRI POSition SWitch~
19-2-05 19-2-06 19-2-07 19-2-08
19B2 19B1 19B3 19B4
~DELivery BULge SEnsor~ Delivery bulge sensor ON = bulge present ~DELivery INput SEnsor~ Delivery input sensor ON = paper present ~DELivery SYNchronization SEnsor~ ~DEL TRI OUTput SEnsor~ ~DELivery VERTical~ ~INput SEnsor~ ~DELivery PTR MOtor SEnsor~ Delivery synchronization sensor ON = paper present Delivery transport intermediate output sensor ON = paper present Delivery vertical input sensor ON = paper present Delivery paper transport motor sensor Pulses
19-2-09 19-2-10
19B25 19B24
ed.5
19 Finishing 201
Test number 19-2-11 19-2-12
Component Signal
Description
19PBA10 19B18
~DELivery BIN 1 EMpty~ Delivery bin 1 empty sensor ~SEnsor~ ON = bin empty ~DELivery SEParation 1~ ~INIt SEnsor~ ~DELivery OUTput ~ ~SEnsor 1~ Delivery separation 1 initialisation sensor ON = home position Delivery output sensor 1 ON = paper present
19-2-13 19-2-14 19-2-15
19B5 19PBA11 19B19
~DELivery BIN 2 EMpty~ Delivery bin 2 empty sensor ~SEnsor ~ ON = bin empty ~DELivery SEParation 2~ ~INIt SEnsor~ ~DELivery BIN 2 OPen~ ~SEnsor~ ~DELivery OUTput~ ~SEnsor 2~ Delivery separation 2 initialisation sensor ON = home position Delivery bin 2 open sensor ON = bin open Delivery output sensor 2 OFF = paper present
19-2-16 19-2-17 19-2-18 19-2-19
19B12 19B6 19PBA12 19B20
~DELivery BIN 3 EMpty~ Delivery bin 3 empty sensor ~SEnsor~ ON = bin empty ~DELivery SEParation 3~ ~INIt SEnsor~ ~DELivery BIN 3 OPen~ ~SEnsor~ ~DELivery OUTput~ ~SEnsor 3~ Delivery separation 3 initialisation sensor ON = home position Delivery bin 3 open sensor ON = bin open Delivery output sensor 3 ON = paper present
19-2-20 19-2-21 19-2-22 19-2-23
19B13~ 19B7 19PBA13 19B21
~DELivery BIN 4 EMpty~ Delivery bin 4 empty sensor ~SEnsor~ ON = bin empty ~DELivery SEParation 4~ ~INIt SEnsor~ ~DELivery BIN 4 OPen~ ~SEnsor~ ~DElivery OUTput~ ~SEnsor 4~ Delivery Separation 4 initialisation sensor ON = home position Delivery bin 4 open sensor ON = bin open Delivery output sensor 4 ON = paper present
19-2-24 19-2-25
19B14 19B8
202
TSM Oc 9800
SDS
Test number 19-2-26 19-2-27
Component Signal
Description
19PBA14 19B22
~DElivery BIN 5 EMpty~ ~SEnsor~ ~DELivery SEParation 5~ ~INIt SEnsor~ ~DELivery BIN 5 OPen~ ~SEnsor~ ~DElivery OUTput~ ~SEnsor 5~
Delivery bin 5 empty sensor ON = bin empty Delivery separation 5 initialisation sensor ON = home position Delivery bin 5 open sensor ON = bin open Delivery output sensor 5 ON = paper present
19-2-28 19-2-29 19-2-30 19-2-31

19B15 19B9 19PBA15 19B23
~DELivery BIN 6 EMpty~ Delivery bin 6 empty sensor ~SEnsor~ ON = bin empty ~DELivery SEParation 6~ ~INIt SEnsor~ ~DELivery BIN 6 OPen~ ~SEnsor~ ~DELivery OUTput~ ~SEnsor 6~ Delivery separation 6 initialisation sensor ON = home position Delivery bin 6 open sensor ON = bin open Delivery output sensor 6 ON = paper present
19-2-32 19-2-33
19B16 19B10
Output tests 19-4-01 19-4-02 19-4-03 19-4-04 19-4-05 19-4-06 19-4-07
19Y1 19V1 19Y7 19V2 19Y6 19V3 19Y5
~DELivery INput SOlenoid~ ~DELivery BIN LED 1~ ~DELivery OUTput~ ~SOlenoid BIN 2 ~ ~DELivery BIN LED 2~ ~DELivery OUTput~ ~SOlenoid BIN 3~ ~DELivery BIN LED 3~ ~DELivery OUTput~ ~SOlenoid BIN 4~
Delivery input solenoid ON = sheets to TRI Delivery bin led 1 ON = LED on Delivery output solenoid bin 2 ON = sheets to bin 2 Delivery bin led 2 ON = LED on Delivery output solenoid bin 3 ON = sheets to bin 3 Delivery bin led 3 ON = LED on Delivery output solenoid bin 4 ON = sheets to bin 4
ed.5
19 Finishing 203
Test number 19-4-08 19-4-09 19-4-10 19-4-11 19-4-12 19-4-13
Component Signal
Description
19V4 19Y4 19V5 19Y3 19V6
~DELivery BIN LED 4~ ~DELivery OUTput~ ~SOlenoid BIN 5~ ~DELivery BIN LED 5~ ~DELivery OUTput~ ~SOlenoid BIN 6 ~ ~DELivery BIN LED 6~ ~DEL buzzer~
Delivery bin led 4 ON = LED on Delivery output solenoid bin 5 ON = sheets to bin 5 Delivery bin led 5 ON = LED on Delivery output solenoid bin 6 ON = sheets to bin 6 Delivery bin led 6 ON = LED on Delivery buzzer on CPU I/O PBA
Special tests 19-6-01 19-6-02 19-6-03 ~Make function warm~ ~Make function cold~ ~5 V regulated test~
Output diagnosis test on board transformation 24 V - 5 V inverter All doors must be closed and the TRI must be in position during the test
19-6-04 ~Separation test~
Output diagnosis test set separation Disconnect 1901X11 on 19PBA1 CPU I/O All doors must be closed and the TRI must be in position during the test
204
TSM Oc 9800
SDS
Test number 19-6-05
Component Signal
Description ~DELivery PTR MOtor~ ~(DELPTRMO)~
DELivery Paper TRansport MOtor Activates the main motor at normal speed or at 100% PWM signal(for a short moment) All doors must be closed and the TRI must be in position during the test
19-6-06 ~HCS bin shift test~
after bin selection the bin will shift when pushing the start button All doors must be closed and the TRI must be in position during the test
Info tests 19-9-01 ~HCS release~
Release number of HCS software used (0-99)

19-9-02 ~HCS version~

19-9-03 ~HCS patch~
ed.5
19 Finishing 205
206
TSM Oc 9800
SDS
Adjustments
1 The paper input guide
Aim:
The copies must be tranported without jamming in the transport intermediate (TRI).
Check: 1 Measure the distance between the upper paper guide and the notches on the
lower paper guide at the left, in the centre and at the right side.
2 Specification: the distance must be 2 mm.
upper paper guide
2 mm
2 mm
lower paper guide
ed.5
19 Finishing 301
adjusting screws
2 mm
Correction: 1 Remove the side covers from the TRI (3 screws). 2 Adjust the distance to 2 mm with the 3 adjusting screws at the left and right
side.
3 Remount the covers.
302
TSM Oc 9800
Adjustments
2 The delivery input solenoid (DELINSO)

Aim:
The copies must be fed into the TRI without jamming.

Check: 1 2 3 4
Carry out SDS test 19-4-01. remove the left side cover from the TRI. Measure the distance between the flap and the top of the left frame of the TRI. Specifications: s the distance must be 91 -0/+3 mm (3.58) when the solenoid is activated. s the core of the solenoid must freely move into the coil.
nut A nut B
91 -0/+3 mm
flap Confidential 1999 Oc-Technologies B.V.
lever
shaft
5 mm
screws
Remove the 4 lower screws from the bottom cover of the TRI. Loosen (remove) the 4 upper screws from the bottom cover of the TRI. Remove the bottom cover of the TRI. Place the TRI is in operating position. Turn the nut A until the spring is unloaded, the flap must be in the lower position.
ed.5
19 Finishing 303
Turn the nut A until the flap is in the upper position. Load the spring 5 mm more and secure with the nut B. Activate SDS test 19-4-01. Adjust the distance to 91 -0/+3 mm with the 2 screws of the solenoid. Activate the solenoid several times by means of output test 19-4-01, and check the distance one more time. 11 Position the lever on the shaft in the middle of the core. 12 Remount the covers.
6 7 8 9 10
304
TSM Oc 9800
Adjustments
3 The delivery output solenoid bin (2-5) (DELOUTSOBIN)

Aim:
The copies must be fed into the delivery bins without jamming.
Check: 1 Carry out SDS tests 19-4-03/05/07/09. 2 Specifications:
s
the deflector should lay parallel with respect to the paper guide plate when the solenoid is deactivated. the core of the solenoid must freely move into the coil.
mounting screws lever Confidential 1999 Oc-Technologies B.V. shaft
deflector
paper guide
Correction: 1 Remove the upper / lower side cover at the right side. 2 Open the upper door. 3 Adjust the position of the deflector parallel with respect to the paper guide
plate with the solenoid mounting screws.

4 Position the lever on the shaft in the middle of the core. 5 Remount the covers.
ed.5
19 Finishing 305
4 The delivery output solenoid bin 6 (DELOUTSOBIN6)

Aim:
The copies must be fed into bin number 6, or upwards to the other bins without jamming.
Check: 1 Carry out the SDS test 19-4-11. 2 Specifications:
s
the deflector flap may not touch the lower guide plate when the solenoid is deactivated. the core of the solenoid must freely move into the coil.
deflector flap > 0 mm shaft lever
lower guide plate bracket fixing screws
Correction: 1 Remove the lower side cover at the right side. 2 Loosen the solenoid bracket fixing screws. 3 Move the bracket slowly upwards until the deflector nose touches the lower 4 5 6 7
guide plate. Then move the solenoid bracket 1 mm downwards and fix the screws. Carry out SDS test 19-4-11 several times to check for correct functioning. Position the lever on the shaft in the middle of the core. Remount the cover.
306
TSM Oc 9800
Adjustments
5 The belt tension of the TRI drive belt

Aim:
A correct tension of the TRI drive belt.

Check:
No check available.
fixing screws
Remove the left side cover from the TRI. Loosen the 2 fixing screws so the spring tensions the belt. Tighten the screws. Carry out SDS test 19-6-05 for one minute. Repeat the adjustment once. Remount the cover.
ed.5
19 Finishing 307
6 The belts tension

The adjustment is only given for one belt tension, all other have the same principle.
Aim:
A correct tension of the drive belts.

Check:
No check available.
Remove the upper / lower side cover at the right side. Loosen the fixing screws A and B so the spring tensions the belt. First tighten the screw A in the slotted hole and then the screw B. Carry out SDS test 19-6-05 for one minute. Repeat the adjustment once. Remount cover.
308
TSM Oc 9800
Adjustments
7 The HCS with regard to Oc 9700 / 9800

Aim:
To ensure the copies are fed into without jamming into the HCS.
Check: 1 Measure the distance between the HCS and the Oc 9700 / 9800 at a height of
approximately 130 mm (5.12) at the left and right side.

2 Measure the height from the HCS with respect to the floor. 3 Specifications:
s
the distance between the HCS and the Oc 9700 / 9800 must be 815 +/- 3 mm (32 +/- 0.11) at the left and right side. the height of the HCS must be 100 mm (4) from the floor and parallel with the Oc 9700 / 9800. the HCS must be aligned with the Oc 9700 / 9800 and the DELTRIPOSSW must be activated.
HCS Oc 9700 / 9800
815 +/- 3 mm
100 mm
130 mm
ed.5
19 Finishing 309
Correction: 1 Adjust the distance to 815 +/- 3 mm (32) between HCS and Oc 9700 / 9800
by positioning the HCS behind the Oc 9700 / 9800.

2 Position the aluminium blocks underneath the adjustable feet. 3 Adjust the height to 100 mm (4) with the levelling bolts and the aluminium
blocks underneath the HCS frame.

4 Open the TRI and check if the DELTRIPOSSW is operated by the safety pawl
from the Oc 9700 / 9800 interface.

5 Push the input flap in activated position and check the dimensions given in the
figure.
6 Make sure that the engine cover and HCS are parallel within 2 mm (0.08"). 7 Check the distance of 815 +/- 3 mm (32) one more time.
safety pawl
Transport intermediate (TRI)
TRI
4.9 -2 / +1 mm interface Oc 9700 / 9800
3.6 -0/+3 mm
310
TSM Oc 9800
Adjustments
8 The delivery transport intermediate open switch (DELTRIOPSW)

Aim:
The switch must operate when the TRI is operating position.

Check: 1 Open the TRI and check if an error code is displayed. 2 Remove the side cover from the TRI at the right side. 3 Specification:
Remove side cover from TRI at the right side. When the TRI is in operating position, it must be possible to push the plunger 1 mm more.
Oc 9800 / 9700 interface
switch lever
detail
fixing screws
Correction: 1 Adjust the switch bracket with the fixing screws so that it is possible to push
the plunger 1 +/- 0.1 mm more.

2 Remount the cover.
ed.5
19 Finishing 311
312
TSM Oc 9800
Adjustments
Dis-/assemblies
1 The transport intermediate (TRI)
1 Remove the screws from the side covers of the TRI from the bottom (3 screws
each). Remove the side covers from the TRI. Loosen the drive belt tensioner at the left side. Remove the drive belt from the tensioner. Disconnect connector 19X20 at the right side. Cut the 2 cable ties to loosen the bundle from the TRI. Remove the bundle with female connector 19X20 from the TRI. Close the TRI. Remove the 4 lower screws from the bottom cover of the TRI. Remove (loosen) the 4 upper screws from the bottom cover of the TRI. Remove the bottom cover. Remove the lower side covers at the left and right side (2 screws). Open the TRI and the upper door. Remove the 3 screws of the lower corner covers at the left and right side. Close the upper door. Remove the lower corner covers. Loosen the 4 screws (inside the holes) from the cover of the upper guide (see next page). 18 Remove the cover from the upper guide. 19 Loosen the 2 limitation screws to open the upper guide. 20 Remove the 2 fixing screws from the upper guide.
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Note: The TRI moves upwards when the upper guide is removed. 21 Remove the upper guide.
ed.5
19 Finishing 401
4 screws
upper guide
lower corner cover
cover upper guide
lower side cover screws side cover
left side cover
Warning: Carry out in order the points 22 up to and including 25, to prevent
that the TRI jumps out of correct position.

22 Remove the upper security clips from the gas dampers of the TRI by pushing
them upwards.
Note: The TRI may drop when removing the gas dampers. 23 Remove the gas dampers from the TRI. 24 Open the TRI to the operating position. 25 Remove the locking plates which are mounted over the bearings from the TRI
at the left and right side.

26 Lift the TRI from the bearings and place the TRI on a flat table.
Short remark when mounting the TRI: Position the TRI on the bearings. Mount the locking plates. Close the TRI and hold the TRI in position. Use the special tool, which is delivered with the HCS to mount the gas dampers. 31 Remount the security clips over the gas dampers. 32 The length of the free cable bundle must be 510 +/- 2 mm (20).
27 28 29 30
402
TSM Oc 9800
Dis-/assemblies
33 Remount all other parts.
19X20
cable bundle TRI
ed.5
19 Finishing 403
2 The belts of the TRI

1 Carry out disassembly see The transport intermediate (TRI) on page 401. 2 Disconnect connector 1909X1 from the distribution PBA at the right side. 3 Cut the 2 cable ties between DELTRIOUTSE and the distribution PBA
19PBA9 from the bracket.

4 Remove the guide plate with the sensor DELTRIOUTSE (2x2 screws). 5 Remove the lever plate from DELTRIPOSSW (screw + nut) at the right side. 6 Remove the cover behind the input guide plate (6 screws).
4 screws
2 screws input guide plate
input guide flap
7 Disconnect connector 19X13 at the left side. 8 Remove the connector 19X13 from the bracket at the left side. 9 Disconnect the wires from DELTRIOPSW (black wires on outside when con10 11 12 13 14 15
necting again). Remove the switch activator (4 screws). Push the cable bundle to the inside of the TRI frame. Remove 2x3 screws from the paper input guide cover at the left and right side. Lift up the paper input guide cover at the front left side. Loosen from the solenoid lever the screw from the shaft of the input guide flap. Remove the circlips from the shaft of the input guide flap at the left inside and outside.
404
TSM Oc 9800
Dis-/assemblies
16 Remove the circlip from the bush of the shaft of the input guide flap at the right 17 18 19 20 21
side. Remove the bush from the shaft at the right side. Remove the shaft with the input guide flap. Remove the upper bearing parts from the drive roller at the left and right side. Lift the drive roller upwards and remove the roller. Replace the belts.
Note: During assembly check the correct position of the actuator from DEL-
TRIOPSW. After assembly carry out adjustment see The paper input guide on page 301.
ed.5
19 Finishing 405
3 The set separation motors (DELSEPMO)

1 Remove the upper and the lower covers at the right side. 2 Remove the long cover at the right side (9 screws). 3 Only for replacement of DELSEPMO 4 and 5:
disconnect all connectors from the CPU I/O PBA (use your wrist strap) remove the 2 fixing screws from the bracket on which the PBA is mounted against the frame s remove the bracket with the PBA 4 Loosen the tension spring of the motor. 5 Remove the motor (3 screws).
s s
Mounting the motor

s s s s
mount the screws hand tight mount the drive belt, the belt may not touch the frame mount the spring, so the spring tensions the belt tighten the screws of the motor
4 The main drive motor (DELPTRMO)

1 2 3 4 5 6
Remove the lower side cover at the left side. Remove the cover underneath the lower door. Remove the cover from the motor (3 screws). Disconnect the connectors 19X4 (motor) and 19B24 (motor sensor). Release the belt tension (2 screws). Replace the motor (4 screws). After assembly carry out adjustment see The belts tension on page 308.
406
TSM Oc 9800
Dis-/assemblies
5 The delivery bins

When (all) delivery bins must be removed, the easiest way is to start with bin number 6 (the lower bin).
1 Loosen the right side screw from the bracket with the DELBINEMSE PBA
(viewed from the rear).

2 Loosen the left side screw from the bracket with the DELBINEMSE PBA
(viewed from the rear).

3 Turn the bracket downwards. 4 Open the delivery bin (above the loosened bracket) aligned with the left side of
the HCS.
5 Remove the bracket which operates the sensor DELBINOPSE (1 screw). 6 Remove the catch from the delivery bin position magnet (2 screws). 7 Slide out the delivery bin.
bracket DELBINEMSE PBA catch bracket DELBINOPSE
ed.5
19 Finishing 407
6 The uppper door

1 Remove the screws from the cover of the upper door (3 screws).
Note: The door will close rapidly when the cover is removed. 2 Lift the cover from the upper door. 3 Twist the security clips from the gas dampers of the upper door out and pull the 4 5 6 7 8 9 10 11 12
clips up at the frame side (bottom). Remove the gas dampers from the frame. Open the upper door. Remove the screws from the hinges at the door side. Close the upper door. Disconnect the earth wire at the left side. Remove the screws from the locking plates from the upper door (2 x 2 screws). Shift the locking plates to the inside. Open the upper door. Lift out the upper door. During assembly:
s s s
first mount the gas dampers and the security clips push the upper door into the correct position mount and tighten the screws of the locking plates
408
TSM Oc 9800
Dis-/assemblies
7 DELBULSE
1 2 3 4 5 6 7 8 9
Loosen the 4 screws (inside the holes) from the cover of the upper guide. Remove the cover. Loosen the limitation screws of the upper guide. Lift the upper guide for easier removal of the cover behind the input guide plate. Remove the cover behind the input guide plate (6 screws). Remove the 2 upper screws from the bracket with the sensor. Disconnect the connector. Remove the shaft from the bracket. Replace the sensor.
8 DELINSE
Loosen the 4 screws (inside the holes) from the cover of the upper guide. Remove the cover. Loosen the limitation screws of the upper guide. Lift the upper guide for easier removal of the cover behind the input guide plate. 5 Remove the cover behind the input guide plate (6 screws). 6 Disconnect the connector. 7 Replace the sensor.
1 2 3 4
9 DELTRIOPSW
After replacement, carry out adjustment see The delivery transport intermediate open switch (DELTRIOPSW) on page 311.
ed.5
19 Finishing 409
10 DELTRIOUTSE
1 2 3 4
Remove the 4 lower screws from the bottom cover of the TRI. Remove (loosen) the 4 upper screws from the bottom cover of the TRI. Remove the bottom cover. Replace the sensor.
410
TSM Oc 9800
Dis-/assemblies
11 DELSYNSE
1 Carry out disassembly see The uppper door on page 408. 2 Loosen 4 screws (inside the holes) from the cover of the upper guide of the 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
TRI. Remove the cover from the upper guide. Remove the lower side covers at the left and right side. Remove the long cover at the right side (9 screws). Disconnect all connectors from the CPU I/O PBA at the right side (use your wrist strap). Remove the 2 fixing screws from the bracket on which the PBA is mounted against the frame. Remove the bracket with the PBA (push upwards and out). Disconnect the connectors from the power supply PBA at the left side. Remove the wiring from the clips. Remove the bracket with the power supply PBA (3 screws). Move the circlip from the support shaft of the upper door at the left frame inside inwards. Remove the bracket from the shaft center. Shift the support shaft to the left and move the right end of the support shaft to the rear. Remove DELSEPMO5 see page 406 Disconnect the connector of the sensor. Remove the screws from the strip with the wiring of the sensor from the frame (2x2 screws). Push the strip upwards. Replace the sensor.
ed.5
19 Finishing 411
12 DELOUTSE1
Remove the upper cover at the left side. Remove the upper and lower side cover at the right side. Remove the long cover at the right side (9 screws). Remove the triangle top cover (4 screws). Remove the top covers at the left and right side (1 inside from underneath). Open the upper door. Loosen 3 screws from the cover at the inside, underneath the top cover. Remove the inside cover. Remove at the left side the upper corner cover (4 screws). Remove at the left side the U shaped frame at the top (5 screws). Remove the curved cover which is mounted underneath the top frame (2x2 screws). 12 Disconnect the connector from DELOUTSE1. 13 Remove the upper paper guide plate with the sensor (4 screws). 14 Replace the sensor.
1 2 3 4 5 6 7 8 9 10 11
13 DELOUTSE2-6
1 Carry out disassembly see The delivery bins on page 407, the delivery bin 2 3 4 5 6 7 8 9 10 11
which is above the sensor to replace. Remove the upper and lower side covers at the right side. Remove the long cover at the right side (9 screws). Remove the upper and lower side covers at the left side. Remove the long left side cover (9 screws). Disconnect the connectors from the LEDs. Remove the cover from the delivery bin output (4 screws). Remove the screws from the guide plate with the sensor (2x2 screws). Disconnect the connector. Remove the guide plate with the sensor. Replace the sensor. During assembly push the guide plate down onto the spacers.
412
TSM Oc 9800
Dis-/assemblies
14 DELBINOPSE
1 Carry out disassembly see The delivery bins on page 407, the corresponding
delivery bin. Remove the upper and lower side covers at the left and right side. Remove the long cover at the right side (9 screws). Remove the cover from the delivery bin output. Remove the screw from the bracket with the sensor at the right side (viewed from the rear). 6 Replace the sensor.
2 3 4 5
15 DELBINEMSE PBA
1 Remove the cover from the sensor PBA (2 screws). 2 Disconnect the connector. 3 Replace the PBA (3 screws).
16 DELSEPINISE
1 Carry out disassembly see The delivery bins on page 407, the corresponding 2 3 4 5 6 7 8 9 10 11
delivery bin. Remove the upper and lower cover at the right side. Remove the long cover at the right side (9 screws). Remove the cover from the delivery bin output (4 screws). Remove the screws from the strip with the magnets. Shift the strip inwards. Remove the 2 screws from the strip with the sensor. Cut the cable tie at the frame outside. Turn the strip. Remove the sensor (do not damage the sensor lever). Disconnect the sensor.
ed.5
19 Finishing 413
17 DELVERTINSE
1 Carry out disassembly see The delivery bins on page 407, the delivery bin 2 3 4 5
number 5. Remove the upper and lower side cover at right side. Remove the long cover at the right side (8 screws). Remove the cover from the delivery bin output. Replace the sensor.
18 DELINSO
1 2 3 4
Remove the side cover of the TRI at the right side (3 screws). Remove the 4 lower screws from the bottom cover of the TRI. Loosen (remove) the 4 upper screws from the bottom cover of the TRI. Remove the bottom cover. After replacement, carry out adjustment see The delivery input solenoid (DELINSO) on page 303.
19 DELOUTSOBIN
1 2 3 4 5 6
Remove the upper and lower side cover at the right side. Remove the long cover at the right side (8 screws). Disconnect the connector from the solenoid. Loosen the solenoid lever from the shaft. Remove the solenoid mounting screws. Remove the solenoid lever together with the solenoid. After replacement, carry out adjustment see The delivery output solenoid bin (2-5) (DELOUTSOBIN) on page 305.
414
TSM Oc 9800
Dis-/assemblies
1 General.
The high capacity stacker (HCS) is a stacker for unfolded copy delivery upto A0 / E size (36 x 44) copies. The HCS consists of:
s s s
a transport intermediate (TRI) a vertical transport 6 bins
bin 1
vertical transport
TRI
PTR
bin 6
LEDs
The copies from the Oc 9800 are transported from the PTR (paper transport) via an interface unit into the TRI (transport intermediate). The interface unit is mounted in the output of the PTR and guides the copies into the TRI. Once, the copies arrive in the vertical transport they are delivered into one of the bins.
ed.5
19 Finishing 501
The HCS features 4 basic delivery methods:

s s s
Per set: the copies of each set are delivered into another bin Per job: the copies of each job are delivered into another bin Copy stack: the copies of the sets and the jobs are delivered into the same bin until the bin is full, then delivery switches to the next bin Addressable bin: the copies of the sets and the jobs are delivered into a operator definable bin
Set as well as job separation will be affected by shifting the bins 10 cm (4) sideways in between the sets. A stepping motor, one for each bin, (DELSEPMO1-6) shifts the bin between the sets or jobs. Copies longer than 1220 mm (48) will always be delivered into bin number 1. These copies require attention from the operator to prevent jams. LEDs are mounted besides the bins on the vertical transport, to indicate the status of the bins or action to take by the operator:
s s s
continuously on = bin in use flashing slowly = bin full flashing fast and buzzer = close bin immediately, delivery in process
502
TSM Oc 9800
Transport intermediate
DELBULSE DELINSE DELTRIOPSW DELTRIPOSSW
copy
DELINSO
DELTRIOUTSE
The delivery paper transport motor (DELPTRMO) drives the transport belts in the TRI. The delivery input solenoid (DELINSO) guides the copies into the TRI. The delivery input sensor (DELINSE) detects if the copies are fed into the TRI and detects the leading and trailing edges for timing actions. The output sensor (DELTRIOUTSE) detects if the copies leave the TRI a certain time after DELINSE has detect the entering of the copies. The bulge sensor (DELBULSE) controls the speed from DELPTRMO.
ed.5
19 Finishing 503
Vertical transport
The transport rollers are also driven by DELPTRMO. A sensor (DELVERTINSE) checks if the copies arrive in the vertical transport. The synchronisation sensor (DELSYNSE) starts the timing if the leading and
504
TSM Oc 9800
trailing edges of the copies are in time at the bin output sensors (DELOUTSE1-6). When the copy arrives in the TRI the copy will be delivered into a bin via a reflector which is operated by the delivery output solenoid (DELOUTSOBIN2-6). Bins All the bins, except bin number 1, are extensible 30 cm (12) for convenient copy removal. Each bin contains 4 sensors. The delivery bin empty sensor (DELBIN1-6EMSE) detects whether the bin is empty. The delivery separation initialisation sensor (DELSEP1-6INISE) detects the correct position of the bins and moves the bins to their initial position when the machine is switched on. The delivery bin open sensor (DELBIN1-6OPSE) detects whether a bin is opened for removal of copies. The delivery output sensor (DELOUTSE1-6) detects if the leading and trailing edges of the copies have left the vertical transport and are delivered into the bin. The delivery output solenoid (DELOUTSOBIN2-6) guides the copies into the selected bin. Bin number 1 has a fixed guide plate.
ed.5
19 Finishing 505
506
TSM Oc 9800
1 Component names
19-High Capacity Stacker Component Description Translation
DELOUTSE1 DELOUTSE2 DELOUTSE3

~DELivery OUTput~ ~SEnsor 1~ ~DELivery OUTput~ ~SEnsor 2~ ~DELivery OUTput~ ~SEnsor 3~ ~DELivery OUTput~ ~SEnsor 4~ ~DELivery OUTput~ ~SEnsor 5~ ~DELivery OUTput~ ~SEnsor 6~
Delivery output sensor 1 Delivery output sensor 2 Delivery output sensor 3 Delivery output sensor 4 Delivery output sensor 5 Delivery output sensor 6
DELOUTSE4 DELOUTSE5 DELOUTSE6 DELSEP1INISE DELSEP2INISE DELSEP3INISE DELSEP4INISE DELSEP5INISE DELSEP6INISE DELBIN1EMSE DELBIN2EMSE DELBIN3EMSE
~DELivery SEParation 1 Delivery separation 1 iniINItialisation SEnsor~ tialisation sensor ~DELivery SEParation 2 Delivery separation 2 iniINItialisation SEnsor~ tialisation sensor ~DELivery SEParation 3 Delivery separation 3 iniINItialisation SEnsor~ tialisation sensor ~DELivery SEParation 4 Delivery separation 4 iniINItialisation SEnsor~ tialisation sensor ~DELivery SEParation 5 Delivery separation 5 iniINItialisation SEnsor~ tialisation sensor ~DELivery SEParation 6 Delivery separation 6 iniINItialisation SEnsor~ tialisation sensor ~DELivery BIN 1~ ~EMpty SEnsor~ ~DELivery BIN 2 ~ ~EMpty SEnsor~ ~DELivery BIN 3 ~EMpty SEnsor~ Delivery bin 1 empty sensor Delivery bin 2 empty sensor Delivery bin 3 empty sensor
ed.5
19 Finishing 601
Component
Description
Translation
DELBIN4EMSE DELBIN5EMSE DELBIN6EMSE DELBIN2OPSE DELBIN3OPSE DELBIN4OPSE DELBIN5OPSE DELBIN6OPSE DELBINTXEMSE DELTRIOPSW
~DELivery BIN 4~ ~EMpty SEnsor~ ~DELivery BIN 5~ ~EMpty SEnsor~ ~DELivery BIN 6~ ~EMpty SEnsor~ ~DELivery BIN 2 ~ ~OPen SEnsor~ ~DELivery BIN 3 ~ ~OPen SEnsor~ ~DELivery BIN 4 ~ ~OPen SEnsor~ ~DELivery BIN 5 ~ ~OPen SEnsor~ ~DELivery BIN 6 ~ ~OPen SEnsor~ ~DELivery BIN TX~ ~EMpty SEnsor PBA~ ~DELivery TRansport~ ~Intermediate Open~ ~SWitch~ ~DELivery SYNchronization SEnsor~ ~DELivery TRansport~ ~Intermediate OUTput~ SEnsor~ ~DELivery INput SEnsor~
Delivery bin 4 empty sensor Delivery bin 5 empty sensor Delivery bin 6 empty sensor DELivery BIN 2 OPen SEnsor DELivery BIN 3 OPen SEnsor DELivery BIN 4 OPen SEnsor DELivery BIN 5 OPen SEnsor DELivery BIN 6 OPen SEnsor DELivery BIN TX EMpty SEnsor PBA DELivery TRansport Intermediate Open SWitch DELivery SYNchronization SEnsor DELivery TRansport Intermediate OUTput SEnsor DELivery INput SEnsor
DELSYNSE DELTRIOUTSE
DELINSE DELBULSE DELPTRMOSE
~DELivery BULge SEn- DELivery BULge SEnsor sor~ ~DELivery Paper TRans- DELivery Paper TRansport MOtor SEnsor~ port MOtor SEnsor ~DELivery TRansport~ DELivery TRansport ~Intermediate POSition~ Intermediate POSition ~SWitch~ SWitch ~DELivery Lower~ ~DOOR SWitch~ ~DELivery Upper~ ~DOOR SWitch~ DELivery Lower DOOR SWitch DELivery Upper DOOR SWitch
DELTRIPOSSW
DELLDOORSW DELUDOORSW
602
TSM Oc 9800
Component
Description
Translation
DELOUTSOBIN2 DELOUTSOBIN3 DELOUTSOBIN4 DELOUTSOBIN5 DELOUTSOBIN6 DELSEPMO1 DELSEPMO2

~DELivery OUTput~ ~SOlenoid BIN 2 ~ ~DELivery OUTput~ ~SOlenoid BIN3 ~ ~DELivery OUTput~ ~SOlenoid BIN 4 ~ ~DELivery OUTput~ ~SOlenoid BIN5~ ~DELivery OUTput~ ~SOlenoid BIN 6 ~ ~DELivery SEParation~ ~MOtor 1~ ~DELivery SEParation~ ~MOtor 2~ ~DELivery SEParation~ ~MOtor 3~ ~DELivery SEParation~ ~MOtor 4~ ~DELivery SEParation~ ~MOtor 5~ ~DELivery SEParation~ ~MOtor 6~
DELivery OUTput SOlenoid BIN 2 DELivery OUTput SOlenoid BIN3 DELivery OUTput SOlenoid BIN 4 DELivery OUTput SOlenoid BIN5 DELivery OUTput SOlenoid BIN 6 DELivery SEParation MOtor 1 DELivery SEParation MOtor 2 DELivery SEParation MOtor 3 DELivery SEParation MOtor 4 DELivery SEParation MOtor 5 DELivery SEParation MOtor 6
DELSEPMO3 DELSEPMO4 DELSEPMO5 DELSEPMO6 DELBINLED1 DELBINLED2 DELBINLED3 DELBINLED4 DELBINLED5 DELBINLED6 DELPTRMO DELINSO CONEMS2
~DELivery BIN LED 1~ DELivery BIN LED 1 ~DELivery BIN LED 2~ DELivery BIN LED 2 ~DELivery BIN LED 3~ DELivery BIN LED 3 ~DELivery BIN LED 4~ DELivery BIN LED 4 ~DELivery BIN LED 5~ DELivery BIN LED 5 ~DELivery BIN LED 6~ DELivery BIN LED 6 ~DELivery Paper TRans- DELivery Paper TRansport MOtor~ port MOtor ~DELivery INput SOlenoid~ ~CONtrol Electro Magnetic Switch 2~ DELivery INput SOlenoid CONtrol Electro Magnetic Switch 2
ed.5
19 Finishing 603
604
TSM Oc 9800
Transport intermediate (TRI)
DELBULSE 19B2 DELTRIOPSW 19S4 DELTRIPOSSW 19S1
DELINSE 19B1
Oc 9800 / 9700 19PBA09 DELINSO 19Y1
DELTRIOUTSE 19B4
ed.5
19 Finishing 605
Sensors / PBA (left hand side)
19PBA16
trafo
DELSUPLV 19G01
606
TSM Oc 9800
Sensors / PBA (right hand side)
19PBA03 19PBA04 DELBIN2OPSE 19B12
DELOUTSE1 19B5
DELOUTSE2 19B6
19PBA05 DELBIN3OPSE 19B13 Confidential 1999 Oc-Technologies B.V. DELOUTSE3 19B7
19PBA06 DELBIN4OPSE 19B14
DELOUTSE4 19B8
DELVERTINSE 19B25 DELBIN5OPSE 19B15 19PBA08
DELOUTSE5 19B9 19PBA07 DELOUTSE6 10B10
DELBIN6OPSE 19B16
DELTRIOUTSE 19B4
DELSYNSE 19B3
ed.5
19 Finishing 607
Motors / solenoids / PBA (right hand side)
DELOUTSOBIN2 19Y7
DELSEPMO1 19M2
DELOUTSOBIN3 19Y6
DELSEPMO2 19M3
DELOUTSOBIN4 19Y5
DELSEPMO3 19M4 CPU-I/O PBA 19PBA01 DELSEPMO4 19M5
DELOUTSOBIN5 19Y4
DELSEPMO5 19M6
DELOUTSOBIN6 19Y3
DELSEPMO6 19M7 DELPTRMO 19M1 DELPTRMOSE
608
TSM Oc 9800
1
22PBA1 CPU I/O
2
X6 3 2 5 4 1 DELTXD DELRXD DELRTS DELCTS GND 19X5 2 3 4 5 7
4
19PBA1 CPU I/O
X9 2 3 4 5 1 X12 1 +24VSAF
5
19X4 2
M
2 X4 10 11 12 DELPTRMO +5V DELPTRMOSE GND 1 1 2 3
DELPTRMO
19M1
DELPTRMOSE
19B24
CAP19X5
X8 6 1 2 3 4 1 2 3 1 3 2 +5VR DELBIN1EMSE GND X4 1 2 3 3 2 1 12 9 11 10 19X20 +5V 3 GND 4 DELINSE 5 DELBULSE 6 DELTRIOUTSE 8 X13 1 2 3 4 6 8 7 5 4 4 5 6 8 15 DELTRIPOSSW DELLDOORSW GND DELUDOORSW X6 1 2 X13 7 10 11 8 9 X14 1 2 3 4 5 6 7 8 9 10 11 12
+24V DELINSO +24VSAF
19X23 1 2
19X20 1 2
19X13 1 2 19X15 1 2 19X16 1 2 19X17 1 2 19X18 1 2 19X19 1 2 19X21 1 2 3 4 5 6 7 8 9 10 11 12 19X7 1 2 3 4 19X8 1 2 3 4 19X9 1 2 3 4 19X10 1 2 3 4 19X11 1 2 3 4 19X12 1 2 3 4
DELINSO
19Y1
DELBIN1EMSE 19PBA10 DELSYNSE

19B3
DELBIN6OUTSO
19Y3
+5VR GND DELSYNSE +5VR GND DELOUTSE1
DELBIN6OUTSO +24VSAF DELBIN5OUTSO +24VSAF DELBIN4OUTSO +24VSAF DELBIN3OUTSO +24VSAF DELBIN2OUTSO
4 5 6 7 8 9
DELBIN5OUTSO
19Y4
DELOUTSE1
19B5
DELBIN4OUTSO
19Y5
19PBA9 DISTRIBUTION7 DELTRIOUTSE
19B4
1 2 3 1 2 3 1 3 2
+5V GND DELTRIOUTSE +5V GND DELINSE +5V GND DELBULSE GND GND
X1 1 2 3 X3 1 2 3
DELINSE
19B1
X2 8 7 2 3 1
DELBIN3OUTSO
19Y6
DELBIN2OUTSO
19Y7
DELBULSE
19B2
+5V DELBINLED1 +5V DELBINLED2 +5V DELBINLED3 +5V DELBINLED4 +5V DELBINLED5 +5V DELBINLED6
DELBINLED1
19V1
DELBINLED2
19V2
D
DELTRIOPSW
3 2 19S4 4 1
DELBINLED3
19V3
DELTRIPOSSW
4 2 19S1 3 1
19X20 11 10 9 12 7
DELLDOORSW DELUDOORSW
3 2 19S3 4 1 3 2 19S2 4 1 GND +24V +24VB
DELBINLED4
19V4
FRAME EARTH CONNECTION 19X22
TRANSPORT-INTERMEDIATE EARTH CONNECTION 19X14 X13 DELTRIOPSW 5
DELBINLED5
19V5
22PBA5 DRIVERS
X13 1 2 3 5
+5V GND +24V GND
X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10
X5 7
+24V
CTFDOORSW
1 O6S1 2
DELBINLED6
19V6
TP1 +5V TP2 +5VR
PTRFRAMESW
8 +24V-SW 2 15S1 1
22G1 CONSUPLV
X11 1 2 TP3 +24VSAF 3 14 TP4 GND
M
4
DELSEPMO1
19M2
F1 4A X12 12 CONEMS2-B
SDS
5 4 7 16
M
4
DELSEPMO2
19M3
CONEMS2
15 +24V-SW 22K2-2A LED 9 6 11 18
M
4
DELSEPMO3
19M4
22PBA4 SSR 22Z2

6 5 4 L2 22X010 N2 X9 1 2 3 X8 6 3 L2 6 N2 2 8 4 5V
19G1 DELSUPLV
G1 2 N2-S
19S7 19T1
208V 220V
13 8 15 20
M
4
DELSEPMO4
19M5
19Z1
2 LOAD LINE
19S6
1
19X1 X2 5 1
1 4
N2-S L2-S 17 10 19 22
G
F1 5A 1 3 G2 1 2 3 4 L2-S 230/240V
M
4
DELSEPMO5
19M6
19S5
2 1 2 3 6 X1 1 2 3 4
+5V GND +24V GND
19X3 FRAME EARTH CONNECTION19X2
21 12 23 24
M
4
DELSEPMO6
19M7
TO HIGH CAPACITY STACKER 2 ON PAGE 702 ed.5 TSM Oc 9800
HIGH CAPACITY STACKER1 19 OPTIONALS 701
3
19PBA1 CPU I/O
X2 1 2 3 4 5
4
+5V GND DELOUTSE3 DELBIN2INISE DELBIN3EMSE X2 8 7 2 4 5 X3 1 2 3 7 8 9 10 11 12
5
19PBA3 DISTRIBUTION1
+5V GND DELOUTSE2 +5V GND DELSEP1INISE +5V GND DELBIN2EMSE 1 2 3 1 3 2 1 3 2 4
FROM HIGH CAPACITY STACKER ON PAGE 701
DELOUTSE2
19B6
DELSEP1INISE
19B18
DELBIN2EMSE 19PBA11
6 7 8 9 10 11
+5V GND DELOUTSE3 DELBIN2OPSE DELSEP2INISE DELBIN3EMSE
X2 8 7 2 3 4 5
X3 1 2 3 4 5 6 7 8 9 10 11 12
+5V GND DELOUTSE3 +5V GND DELBIN2OPSE +5V GND DELSEP2INISE +5V GND DELBIN3EMSE
1 2 3 1 3 2 1 3 2 1 3 2 4
DELOUTSE3
19B7
DELBIN2OPSE
19B12
DELSEP2INISE
19B19
DELBIN3EMSE 19PBA12
C
12 13 14 15 16 17 +5V GND DELOUTSE4 DELBIN3OPSE DELSEP3INISE DELBIN4EMSE
X2 8 7 2 3 4 5 X3 1 2 3 4 5 6 7 8 9 +5V GND DELOUTSE4 +5V GND DELBIN3OPSE +5V GND DELSEP3INISE +5V GND DELBIN4EMSE 1 2 3 1 3 2 1 3 2 1 3 2 4
DELOUTSE4
19B8
DELBIN3OPSE
19B13
DELSEP3INISE
19B20
10 11 12
DELBIN3EMSE 19PBA13
18 19 20 21 22 23 +5V GND DELOUTSE5 DELBIN4OPSE DELSEP4INISE DELBIN5EMSE X2 8 7 2 3 4 5 X3 1 2 3 4 5 6 7 8 9 10 11 12 +5V GND DELOUTSE5 +5V GND DELBIN4OPSE +5V GND DELSEP4INISE +5V GND DELBIN5EMSE 1 2 3 1 3 2 1 3 2 1 3 2 4
DELOUTSE5
19B9
DELBIN4OPSE
19B14
DELSEP4INISE
19B21
DELBIN5EMSE 19PBA14
24 25 26 27 28 29 +5V GND DELOUTSE6 DELBIN5OPSE DELSEP5INISE DELBIN6EMSE X2 8 7 2 3 4 5 X3 1 2 3 4 5 6 7 8 9 10 11 12 +5V GND DELOUTSE6 +5V GND DELBIN5OPSE +5V GND DELSEP5INISE +5V GND DELBIN6EMSE 1 2 3 1 3 2 1 3 2 1 3 2 4
DELOUTSE6
19B10
DELBIN5OPSE
19B15
DELSEP5INISE
19B22
DELBIN6EMSE 19PBA15
X3 1 2 4 5 +5V GND DELBIN6OPSE DELSEP6INISE X2 8 7 3 4 X3 4 5 6 7 8 9 10 11 +5V GND DELBIN6OPSE +5V GND DELSEP6INISE +5V GND 1 3 2 1 3 2 1 3 2 4
DELBIN6OPSE
19B16
DELSEP6INISE
19B23
H
ed.5 TSM Oc 9800
DELBINTXEMSE 19PBA16
HIGH CAPACITY STACKER 2 19 OPTIONALS 702
Oc
Oc 9800
20 INTERFACE
Contents
Diagnostics
1 Faults 101 2 LED indication table 115 3 Oc Repro / Scan Station errors (messages)
117
SDS
1 The Oc 9800 Controller SDS 201 2 The functional tests of the controller. 204 3 Block diagram controller 207 4 Functional test description 208
Dis-/assemblies
1 Firmware upgrade (Bootprom and ROM module PBA) 2 Memory module (SIMM) 403 3 FBBS motherboard PBA 407 4 Allocation PBAs in Oc Local Bus extensions 408 5 Interface extension PBA (e.g. SCSI) 409 6 TAXI printer/scanner and RADICAL PBA 410 7 Controller Power supply 410 8 General information SCSI PBAs 412
401
1 General 501 2 Controller characteristics 503 3 Process 505 4 Printing 506 5 Print size of originals 508 6 Scan to File 510 7 Scan size of originals 511 8 PAS (Printroom Application Software) 9 SCAN STATION 513 10 SCSI PBAs 514 11 PC characteristics 516
512
ed.5
20 Interface
1 Component location 601 2 FBBS PBA 602 3 ROM module PBA 603 4 SCSI PBA 603 5 Connectors 604
Diagrams
1 FBBS
701
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Interface 20000 - 20999 code display 20801 OWAR: ~Controller selftest error~
20802 OWAR: ~Harddisk error~ Not used in FBBS controller 20803 OWAR: ~Radical pba error~
Radical PBA loose. (not properly mounted in the controller)
* Check position on the motherboard. * Execute the controller functional test RDBT to verify whether the board is okay
ed.5
20 Interface 101
20804 OWAR: ~SCSI pba error~ LED indication table on page 115 (or +100 pages of the ST software) can give you additional information regarding the next possible causes. .
SCSI PBA loose (not properly mounted in the controller). Faulty SCSI PBA in the controller. SCSI bus not properly terminated.
Check positioning Execute the controller functional test SCBT to verify whether the board is okay. In Controller: SW1 on the SCSI OLB board (outside the controller) should be in the ON position. In Host: Verify the end of the SCSI bus, it should terminate the bus properly. * If the Adaptec 1542CF board is used, SW1 of the board should also be in the ON position. All 3 LEDs are ON. * If the Adaptec 1542 CP is used: termination has to be enabled with the SCSISelect utility. * If the Adaptec 2940 is used: jumper J3 not properly set. Switch 1: in the ON position. Switch 2: jumper between 2 and 3 (makes operation of switch 1 possible), default setting 2-3. Switch 3: jumper between 2 and 3 (depends on components on the SCSI board). Switch 4: termpower is active if the jumper is between 1 and 2. Termpower can only be activated by software if the jumper is between 2 and 3, default setting 2-3. Switch 5: jumper between 1 and 2 (depends on components on the SCSI board).
Wrong configuration setting of the switches on the SCSI PBA.
20805 OWAR: ~Ethernet pba error

102
TSM Oc 9800
Diagnostics
20806 OWAR: ~Taxi interface Scanner pba ~

20807 OWAR: ~Vector firmware checksum error~

20808 OWAR: ~Vector extention checksum error~

ed.5
20 Interface 103
20809 OWAR: ~DRAM simm pbas error~
Possible cause
Remark
The installed frame buffer All LEDs on the controller are OFF. DRAM SIMM modules dont match with the configuration settings in SDS test 90. One of the SIMMs defect or makes bad contact. Not all LEDs are OFF (LED indication table on page 115 or +100 pages in the ST software). Use the controller functional tests TSIM 0-6 to identify the faulty SIMM. If it is properly installed, clean its connector or replace it.
Possible cause
Execute special test 22-6-09 Test service bus
Test FAILED with connector G - Electrical connections: of test bundle 7991.293 on 10X2 * CPU_CONSOLE-PBA -> 10X2 CPU_CONSOLE-PBA defect Test CORRECT with connector G - Electrical connections: * 10X2 -> Laptop of test bundle 7991.293 on 10X2 - Laptop defect
Note: Also test plug 7991.290 can be used.
20810 OWAR: ~TAXI interface printer pba~
Possible cause
Remark
Taxi printer pba or adapter pba not properly set.
* Check position. * Execute the controller functional test TPBT to verify whether the board is okay.
104
TSM Oc 9800
Diagnostics
20811 OWAR: ~Communication error contr(oller) -> engine~ This is the only error generated by the engine: if the engine has lost the communication with the controller or if the engine cannot get in contact with the controller (during power on for example), then this error is generated.
Service switch on the controller in the ON position. Connection: bad contact firmware ROM module (FBBS SW SRC or Boot PROM) on FBBS motherboard (FBBS PBA). Connection: communication cable between controller and CPU_IO PBA.
All LEDs are continuously OFF or ON. See LED indication table on page 115 or the +100 pages of the ST software.
Connection: mains to controller supply. Connection: cable between controller and set-memory at set-memory side not properly mounted (or too tight). Connection: one of the SIMMs makes bad contact. Controller supply defect. BOOTPROM SW SCR and / or ROM module (FBBS SW SRC) defect. FBBS motherboard (FBBS PBA) defect. Faulty frame buffer SIMMs. See LED indication table on page 115. Micron SIMMs with the identification MT8D432M-7 and a batch reference starting with 95, cause the error 20811 when printing large (vector) files. See LED indication table on page 115 or +100 pages of the ST software.
CPU_IO code is C. (after 30 sec.) Possible cause
- Switch off the machine. -No Put connector C of test bundle 7991.293 in PBA-CPU_IO, X17. Switch on the machine in normal mode.
- CPU_IO-PBA defect
ed.5
20 Interface 105
TCSP test via Laptop Possible cause okay
- Switch off the machine. - No Put connector D of test bundle 7991.293 on 20D1. Switch on the machine in normal mode with the controller service switch on.
Possible cause (FBBS board defect) Remark
- Electrical connection *20D1 -> P5 - FBBS board defect (see next table for details)
- Service switch on the controller in the - See also the LED identification table ON position - Electrical connections - bad contact firmware ROM module (FBBS SW SRC) -> FBBS mother board (FBBS PBA) - mains to controller supply - one of the SIMMs makes bad contact - Controller supply defect - BOOTPROM SW SRC and/or ROM module (FBBS SW SRC) defect - Faulty frame buffer SIMMs - Micron SIMMs with the identification MT8D432M-7 and a batch reference starting with 95, cause the error 20811 when printing large (vector) files
Possible cause
- Electrical connections: 20D1 -> CPU_IO-PBA
106
TSM Oc 9800
Diagnostics
20812 OWAR: ~Communication error engine -> contr(oller)~
Possible cause
Remark
Electrical connections
Communication cable between controller and CPU_IO PBA. No display message if the controller is removed from the configuration and the system is rebooted. No display message if the controller is removed from the configuration and the system is rebooted. Remove the controller from the configuration and reboot the system. Read out the display message / error help.
CPU_IO PBA defect.
Non controller error.
Copy counter code is Possible cause 9999 (after 10 sec.) - CONSOLE_CPU-PBA - Switch off the machine. - No defect Put connector A of test bundle 7991.293 in PBA-CONSOLE_ CPU, X10. Switch on the machine in normal mode. CPU_IO code is C. (after 30 sec.) - No
Possible cause
- Switch off the machine. Put connector B of test bundle 7991.293 in PBA-CPU_IO, X14. Switch on the machine in normal mode.
Possible cause
- CPU_IO-PBA defect
Remark
- Electrical connections: - CPU_CONSOLE-PBA -> scanner cable -> CPU_IO-PBA - For a few ms. - +5V CONSUPLV short circuit to earth - For a few ms, LCD will be temp. dark - +5V CONMIXSUPLV short circuit to earth
ed.5
20 Interface 107
20813 OWAR: ~Not enough memory to complete opp(eration)~
Possible cause
The vector drawings contains too many polygons; part of the drawing is printed The display list of the vector drawing doesnt fit in the DLL memory; part of the drawing is printed There is too less memory available for the sorted vector list (only for vector drawings); the drawing is not printed If banding has to be done (the rasterized plot doesnt fit in the controller memory), then some vectors may cross bands. If there are too many of these vectors, then this error is generated and the drawing is only partially printed The raster drawing is too large; e.g. a tiff file with the header at the end should be read completely before rasterisation can take place. Then it should fit into the DLL memory. The drawing is not printed.
Remark
If the DLL memory can be increased, then this may solve the problem. Otherwise this file cannot be printed completely. All data of this file that cannot be handled will be thrown away. If Oc ReproStation is used, the next RCF-file will be processed by the controller as the start of a new file. If it is not used and no RCF is used before the next file, then the controller has to detect the end of the file that cannot be printed. This may be difficult and takes some time. There is no need to reboot the system. The error can be reset.
20814 OWAR: ~Set is splitted~

Possible cause
The set is splitted, because the complete set doesnt fit in the set memory, or the set contains a long plot (i.e. a non standard size plot) which doesnt fit in the frame buffer. The set is splitted in 2 or more sub sets, depending on the number of originals in the set and/or the number of long plots in the set.
Remark
Increase set memory and / or frame buffer, depending on which one is too small.
108
TSM Oc 9800
Diagnostics
20815 OWAR: ~Not enough set memory~

Possible cause
The plot doesnt fit into the set memory, even if this was empty when the system started storing the plot in it. Hence, the plot cannot be processed. .
Remark
If the size of the set memory is not yet the maximum, then the plot may fit in, if the set memory is increased (whether it fits or not depends on the plot size)
20820 OWAR: ~RS-232 host / contr. (to controller) framing error~
Possible cause
Connection: connected host -> controller (RS232) Settings of this link at both sides. The number of stop bits and data bits should be the same at both the Oc 9800 and the host
20821 OWAR: ~RS-232 host / contr. (to controller) parity error~
Possible cause
Connection: connected host -> controller (RS232) Settings of this link at both sides. The parity settings should be the same at both the Oc 9800 and the host
ed.5
20 Interface 109
20822 OWAR: ~RS-232 host / contr. (to controller) overrun error~

~
Possible cause
Connection: connected host -> controller (RS232) Settings of this link at both sides. The baudrate settings should be the same at both the Oc 9800 and the host
20830 OWAR: ~SCSI: cmd (command) group error~
Possible cause
Remark
Connection: connected host -> controller (SCSI) Settings of this link.
The SCSI cable should not be removed when machine and host are switched on. Switch OFF both!
110
TSM Oc 9800
Diagnostics
20831 OWAR: ~SCSI: chip error~
Possible cause
Remark
SCSI link bad or defect.
Check the cable (try another one) and check its connection at both ends. The SCSI cable should not be removed when machine and host are switched on. Switch OFF both!. Verify that each device on the SCSI bus has a different SCSI ID.
SCSI settings wrong (SCSI ID setting).
Controller SCSI PBA not prop- Check that the board is properly mounted on erly mounted. the FBBS motherboard. Run the functional test SCBT to check that the SCSI board in the controller is okay. SCSI bus termination fault. Controller: Check that SW1 of the SCSI PBA board (at the outside of the controller) is in the ON position. Host: If the Adaptec AHA 1542CF board is used, check that SW1 of this board is in the ON position. If the Adaptec AHA 1542CP board is used check if the SCSI termination is enabled. If the Adaptec AHA 2940 board is used check if the jumper J3 is properly placed.
Wrong SCSI ID of the Adaptec This board should have the SCSI ID 7 board. (default) Problem in the PC. Try another PC. If the Adaptec AHA SCSI board is used in the host PC, try the diagnostics of this board. First the Oc 9800 should be powered on, and if it is idle (ready for copy), then the host should be powered on. During the power up sequence of the host, the Oc 9800 should be recognised as the Tandberg TDC 3600 tape device.
Incorrect boot sequence.
ed.5
20 Interface 111
20832 OWAR: ~SCSI: parity error~

~
Possible cause
Remark
Connection: Connected host -> controller (SCSI) Settings of this link.
The SCSI cable should not be removed when machine and host are switched on. Switch OFF both!
20860 OWAR: ~Interpr. (eter) error: command not supported~

~
Possible cause
Remark
The plot file contains a command which is not supported by the controller. Check the plot file.
20861 OWAR: ~Interpr. (eter) error: syntax error~
Possible cause
Remark
A syntax error is detected in the data of the plot file (e.g. the data should be Tiff, but some data is not according the Tiff specifications). Check the plot file
20862 OWAR: ~Language not recognized~
Possible cause
Remark
The Automatic Language Sensing (ALS) function of the controller was not able to detect the type of the plot file. The file is thrown away. No output is generated. Verify that the file contains data of one of the supported languages. Try to re-print the file and use an RCF header to specify the type of the language.
112
TSM Oc 9800
Diagnostics
20863 OWAR: ~Plot is clipped~

~
Possible cause
Remark
The plot doesnt fit entirely on the selected paper size. A part of it is not printed (clipped). Check the settings used for the plot (may be you should use a larger paper size) and the plot file.
20864 OWAR: ~Language feature not supported~

Plot contains a language feature what is not supported.
E.g. LZW compression, colour in raster files.
20870 OWAR: ~host prot(ocol), job description error~

r
Possible cause
Remark
The RCF header contains a not yet implemented or non existing command/ APPLDATA.
Verify that the contents of the RCF header is according the RCF reference Manual.
20871 OWAR: ~RCF: not supported applic(ation) data~

~
Possible cause
Remark
The RCF header contains a not supVerify that the contents of the RCF ported APPLDATA (probably an old one header is according the RCF referof Version 1). The whole line in the ence Manual. header on which the error is found is ignored.
20872 OWAR: ~RCF: not supported parameter~

The RCF header contains a not supVerify that the contents of the RCF ported APPLDATA parameter (probably header is according the RCF referan old one of Version 1). Only the wrong ence Manual. parameter(s) are ignored.
ed.5
20 Interface 113
20901 SWAR: ~Illegal ram configuration contr(oller).~

~
Switch machine Possible cause OFF/ON: all LEDs on controller OFF after selftest? No See LED identification able.on page 115 or the +100 pages of the ST software.
Remark
Frame Buffer slot or SIMM If the configuration check in SDS is defect or bad contact. test 90 equals the installed DRAM SIMMs in the controller, then run the controller tests TMEM (lasts 30 minutes!) or TSIM 0-6 (before OS-launch) (lasts 4 minutes per SIMM), to identify the faulty SIMM. If the tests fails check if the clean its connector or replace it SIMMs is properly and run the test again. installed.
114
TSM Oc 9800
Diagnostics
2 LED indication table

The 3 LEDs on the controller box give an indication about the behaviour of the controller. After switching on the machine, the 3 LEDs are switched on for a few seconds, then they are switched on and off one by one. This means that the first pass of the tests are oke. Then the LEDs stay on for a longer time, can be up to 4 minutes depending the amount of memory installed.
LED 1 LED 2 LED 3 Defect module Directly after switching on
OFF
OFF
OFF
2nd CPU does not boot (e.g. bootprom incorrectly inserted, service switch on). The controller stays in hardware reset. Also the error code 20811 will be displayed. OFF
OFF OFF ON ON OFF OFF ON BLINK OFF BLINK BLINK OFF OFF BLINK BLINK OFF BLINK BLINK ON
OFF OFF OFF OFF ON ON ON ON OFF OFF OFF BLINK BLINK BLINK BLINK ON ON ON OFF
After the selftest is finished:
All modules okay ON OFF ON OFF ON OFF ON BLINK OFF BLINK OFF BLINK OFF BLINK BLINK OFF BLINK BLINK OLB board in extension slot A defect. OLB board in extension slot B defect. OLB board in extension slot C defect. OLB board in extension slot D defect. OLB board in extension slot E defect. OLB board in extension slot F defect. SEE Note Mother board error Mem. Frame Buffer 1_ SIMM 1 error, 20901 Mem. Frame Buffer 1_ SIMM 2 error, 20901 Mem. Frame Buffer 1_ SIMM 3 error, 20901 Mem, Frame Buffer 2_ SIMM 1 error, 20901 Mem. Frame Buffer 2_ SIMM 2 error, 20901 Mem. Frame Buffer 2_ SIMM 3 error, 20901 Memory configuration error Primary DRAM (DLL) SIMM 1 error, 20809 Secondary DRAM (RSR) SIMM 1 error, 20809 Cabled Hard Disk error Standard controller Firmware error
ed.5
20 Interface 115
Note: With the FBBS release < 3.3 this indicates a SCSI problem. It occurs if
the PC is connected via SCSI and the system is booted while the PC is off.
116
TSM Oc 9800
Diagnostics
3 Oc Repro / Scan Station errors (messages)

Most of the Oc Repro and Scan Station errors (messages) are self explaining. The following errors need an explanation:
s s s s s
Oc 9800 not responding Job Ticket is still arriving, not complete yet. Plot image is divided on 2 copies Processing Scan Job message doesnt disappear Unnamed file was not found
Oc 9800 not responding - This implies that Machine Monitor has lost the connection with the Oc 9800. - Only one application can be active: Repro Station or Scan Station! If trying both at the same time, then the message trying to connectis displayed. - Centronics connection is heavily in use Check as follows:
Check if the status of the Oc 9800 is ~Ready to copy~ state Check the SCSI connection Activate Scan for SCSI devices in Repro Station Configured - SCSI menu.
The system should not be in warming up state. Both connectors correctly connected? The found IDs must match with the configured IDs. (Default is: 0 - 4)
Run the SCSI interrogator (This Adaptec A tape device should be recogtool is installed during the installation of the nised at the SCSI ID of the Oc ADAPTEC SCSI PBA). 9800. Power down the PC by switching it off. (Do not carry out a soft reset Ctrl-Alt-Del) Switch it on again. During the boot procedure it should recognise the Oc 9800 as a Tandberg tape device of the type TDC 3600. If all the checks for SCSI still do not result in printing with SCSI, try to print with Centronics. Other application is active. Centronics in use. Close this application. Stop printing via centronics or wait till printing is ready.
ed.5
20 Interface 117
Possible cause
Remark
Disabled in operator panel Scan -to-file disabled in the configuration
Enable. Enable in SDS 90
Job ticket is still arriving, not complete yet (in the Repro Station queue) If this happens with a job submitted by Job Director, it is an indication that the job ticket is not yet present in Repro Station queue. Job Director first writes an empty job ticket in this queue, then the data files and finally the complete job ticket, as an indication that all data is stored in the Repro Station queue.
The message appears with a large job, when the files have to be transferred via the network to the Repro Station queue The message appears if the network is very slow.
Plot image is divided on 2 (or more) copies This error can occur with or without Repro Station.
Calcomp file with wrong checksum setting HPGL file: too short plot time out setting Slow PC Once a problem reported with a PC active in slow mode (about 10 MHz). The output was totally corrupted. Try the same job using only using the PC and no network
Conflict with network card in PC
Pen 0 set to end of file although SP0 appears HP-GL and HP-GL/2 in the middle of the job
118
TSM Oc 9800
Diagnostics
Processing Scan Job doesnt disappear This error occurs only when using Scan to File.
Internal cable not connected on the Taxi Scanner PBA
Unnamed file was not found
Possible cause
Remark
A checkplot is generated in the Repro Station queue and the job show up time is smaller than the time needed to generate the plot.
Increase the job show up time to a value larger than the max. generation time.
ed.5
20 Interface 119
120
TSM Oc 9800
Diagnostics
SDS
1 The Oc 9800 Controller SDS
see SDS
31
see SDS
see SDS
see SDS
see SDS
see SDS
ed.5
20 Interface 201
Test nr.
Component
Signal
Description
Parameter test Input tests Output tests Special tests Info tests Note: The INFO test gives only valid informa-
tion if the controller is part of the system (machine in ~warm~ condition). Activate SDS test 41/42 before you start with the info tests~
20-9-01 20-9-02 20-9-03 20-9-04 20-9-05
~SCSI present (0 = No, 1 = Yes)~ ~radical board present (0 = No, 1 = Yes)~ ~taxi printer present (0 = No, 1 = Yes)~ ~taxi scanner present (0 = No, 1 = Yes)~ ~ethernet present (0 = No, 1 = Yes)~
not available with FBBS

20-9-06 20-9-07 ~harddisk present (0 = No, 1 = Yes)~ ~primary (vector) cpu RAM (Mbyte) (DLL)~
How much DLL RAM is configured (16/32 Mb)

20-9-08 ~secondary (raster) cpu RAM (Mbyte) (RSR)~
How much CPU RAM is available (4 Mb)

20-9-09 ~frame buffer / memory size (Mbyte)~
How much total memory RAM is available (48 - 192 Mb)

20-9-10 ~Controller release~
Release number of the controller software (0-99)
202
TSM Oc 9800
SDS
Test nr. 20-9-11
Component
Signal
Description ~Controller version~
Version number of the controller software (0 - 99)

20-9-12 ~Controller patch~
Patch number of the controller software (0-99)

20-9-13 ~poker lib. release~
Release number of the poker library software used in the controller (0-99)
20-9-14 ~poker lib. version~
Version number of the poker library software used in the controller (0-99)
20-9-15
~poker lib. patch~
Patch number of the poker library software used in the controller (0-99)
System tests
ed.5
20 Interface 203
2 The functional tests of the controller.

The functional test software is the software running on the FBBS board after the board is powered-up with the service switch active. The functional test is to check the FBBS assembly and all the PBAs added onto this PBA as:
s s s
DRAM SIMMs modules ROM modules All OLB PBAs used in this controller.
Special Tools for functional test: Bundle codenumber: 7991.293 Setup for the functional test:
1 Switch off the machine 2 Connect the laptop to the serial port of the controller with the standard serial
3 4 5
6 7 8 9
mini DIN 8 male to SUBD 25 female (code number 4914.052) and a serial adapter SUBD 9 female to 25 male (code number 7991.486). Activate a terminal emulation program on the PC (e.g WINDOWS Terminal). Select Settings and Communications. Adjust the settings to: s Baud rate 9600, data bits 8, stop bit 1, no Parity, Flow control Xon/Xoff and e.g. Com1. Switch the service switch on the controller to the ON position Switch ON the machine. Now you will get some initialisation messages on the screen of your PC and finally you get the prompt ~functest>~. In release R1.2 the information on the screen looks like: (in newer releases??) Functional tests: initializing RPC package ... initializing RAM package (primary part) ... local memory range: 0x27000000 - 0x28000000 shared memory ranges: frame buffer 1: 0x83000000 - 0x86000000 frame buffer 2: 0x0 - 0x0 frame buffer 1 configuration: 1 frame buffer 2 configuration: 0 initializing RAM package (secondary part) ... packing memory ... Functest>
204
TSM Oc 9800
SDS
If you do not get this message or only a part of it and you have executed all steps as listed the FBBS mother board has a failure and must be replaced.
10 Use the ~HELP~ command to get an overview of all the available Functional
tests. Not all of them are useful in the field, as some are used for repair and manufacturing purposes. The following tests are useful:
Functional test Description With- With out O/S O/S Part 1 Part 2
SLPT (1/2) GCPT CONF

Select the primary or secondary part (section) Get the current part that is used for tests Display the controller hardware configuration Start the operating system of the controller List of all the available commands Test all memory (30 minutes!) Test a SIMM module (4 minutes / SIMM) Test the ROM modules Test the SPINACH internals
x x x x x x x x x
x x x x x x x x
x x x x x x x x x x x x x OLB
x x x x x x x x x x x x OLB
STOS HELP TMEM TSIM (0...6) TROM (1/2) SPIN ECCX ECHO TCRG ENIT TCIN TCSP SCBT
Echo Centronics input in hexadecimal form Echo user input in hexadecimal form Test the configuration register of the selected part Enable and test interrupts x x x
Test the internals of the Companion x Chip Test the Companion Chip link to the printer SCSI Board Test x -
ed.5
20 Interface 205
Functional test
Description
With- With out O/S O/S
Part 1
Part 2
ETBT RDBT TPBT TSBT QUIT
EThernet Board Test (for future release) RaDical Board Test TAXI Printer Board Test TAXI Scanner Board Test exit the functional test mode (not yet available)
x x x
x -
OLB OLB OLB OLB
OLB OLB OLB OLB
Without O/S: the test can be used without the Operating System e.g. before the Operating System is started. With O/S : the test can only be used after the Operating System is started. Part 1: primary section of the controller. Part 2 : secondary section of the controller. x = yes = no OLB = Oc Local Bus slot name has to be indicated (A....F) depending where the PBA is mounted. The controller consists of two parts: the primary part (part 1) and the secondary part (part 2). Access to the secondary part is through the primary part and thus some checks on the primary part should be performed before checking the secondary part. Part-specific tests are automatically launched on the concerned part, i.e. you don't have to select that part before running the test. Tests which can be performed on both parts are launched on the selected part. Some tests can be run without the Operating System (OS) of the controller, e.g. memory tests. Other tests need resources which are only available with the operating system running. Whether the Operating System is needed or not is stated in the test description. When the Functional Test mode is entered, the operating system is not yet launched. Now only a subset of the tests can be run. To run the other tests, the user has to issue the command STOS (STart Operating System) to launch the operating system. A test that needs the operating system which is not running, is rejected.
206
TSM Oc 9800
SDS
3 Block diagram controller
The upper part of the block diagram is primary part of the controller (part 1). The lower part (without the FRAME BUFFER) is the secondary part (part 2). The FRAME buffer is used by the primary as well as the secondary part of the controller.
ed.5
20 Interface 207
4 Functional test description

General tests
General Commands
SLPT
SeLect ParT Syntax : SLPT [1|2]
SLPT selects the part on which part specific commands will take effect. SLPT 1 selects the Primary part; SLPT 2 selects the Secondary part. This test is available both before and after OS launch. GCPT tells the user to which part his part specific commands are currently directed. The part selected by default at start-up is the Primary part. This test is available both before and after OS launch. CONF displays the controller's hardware configuration as recognized by the controller software itself: -the commercial release number, -the current RAM configuration (local RAM of both parts and Frame Buffer), -the type of the boards found in the OLB slots. The complete configuration is given, whatever the selected part. Therefore this is an ideal test to start the functional tests with. This test is available both before and after OS launch.
GCPT
Get Currently selected ParT for processing Syntax : GCPT
CONF
display controller's hardware CONFiguration Syntax : CONF
STOS
STart Operating System Syntax : STOS
STOS launches the operating system on both parts, enabling new commands. The availability of each command before and after that launch is given in each command description.
Attention:
Do not hit the keyboard before the prompt shows up!
208
TSM Oc 9800
SDS
General Commands
HELP
display the list of available commands
HELP displays the COMPLETE list of commands that can be used in the functional test mode. Note that some commands are not useful in the field. At a given time, a given command may not be available for one of the following reasons: - it needs the OS and the OS hasn't been started, - it cannot be run under the OS and the OS has been started, This test is available both before and after OS launch.
Memory tests
Memory tests check DRAM data and address paths for each of the DRAM ranges present on the board:
s s s
local DRAM (on the primary and secondary part), "SPINACH" DRAM, frame buffer DRAM (access through the primary and secondary parts).
These tests can be launched on all the DRAM visible from the selected part, or a given SIMM slot. Each test consists of two passes: a write pass and a read pass. Address paths are checked by first writing to each address throughout the DRAM a value equal to that address. A second pass then reads back the written data and checks for identity between each address and the value read at that address. Data paths are checked with the same procedure but using respectively 0x00, 0x55, 0xAA and 0xFF as data for each pair of passes.
ed.5
20 Interface 209
Possible memory tests:

Memory tests
TMEM
Test all MEMory Syntax : TMEM Note: This test takes 30 minutes (alternative: use TSIM test)
TMEM tests all DRAM ranges known to or detected by the software with a read and write operation. On an error the test is ended and the address at which the error occurred is displayed to the user, with the value that produced the error. This test is NOT available if the DRAM configuration recognition phase during booting fails to recognize a commercial configuration. This test is only available before OS launch.
TSIM
Test a SIMM module Syntax: TSIM 0-6 This test lasts 4 minutes / SIMM
TSIM does the same job as TMEM, but now on a memory range corresponding to a specified SIMM module. This range is determined by the software itself using the data gathered during the DRAM configuration recognition phase. The test is performed using the address ranges that are actually used to address this SIMM module in normal mode. This test is still available if the DRAM configuration recognition phase fails to recognize a valid configuration, i.e. if the 3 LEDs on the controller indicate that there is a memory problem. In that case use this test. If it fails, check if the SIMM is properly installed, clean it's connector, or replace it and run this test again. TSIM 0 tests the local DRAM (part specific), TSIM 1 to TSIM 6 test the corresponding frame buffer SIMMs (both parts). This test is only available before OS launch.
210
TSM Oc 9800
SDS
Memory tests
TROM
Test ROM modules Syntax : TROM 1-2
TROM detects the ROM configuration, and calculates and displays the ROM contents' external checksums (one per chip). It also recalculates and crosschecks the ROM's embedded checksum (last 16 bit word of the PROM set). The parameter indicates the module to test: module 1 or module 2 on the primary part, module 1 on secondary part (if present). This test is available both before and after OS launch.
Spinach tests
These tests are useful if you suspect that the centronics and/or serial interface of the controller are not working correctly. Further, the tests SPIN and ECCX can be used if you suspect the FBBS PBA.
Spinach tests
SPIN
test SPinach INternal registers Syntax : SPIN
SPIN accesses the spinach's internal registers in two passes: (1) a write pass then (2) a read pass (similar to the memory tests). The purpose of this test is to detect the accessibility of the spinach chip. If this test fails, you have to replace the FBBS mother board. This test is only available before OS launch.
ed.5
20 Interface 211
Spinach tests
ECCX
ECho characters received via the Centronics(X) port Syntax : ECCX
ECCX reads characters on the Centronics port and displays them in hexadecimal format on your PC until a pre-defined number of characters (2048) or a time-out is reached. To get data on your screen you have to sent data via Centronics to the controller, i.e. connect another PC to the Centronics port (or also your PC) and print a file via Centronics. If this test fails, then: - check if your cable to the Centronics port is properly connected at both ends. - if your cable is okay (try another one) - replace the FBBS mother board (if the other actions fail) This test is only available after OS launch.
ECHO
ECHO characters received via the serial (RS232) port Syntax : ECHO
ECHO tests the RS232 link, which is the one to which your PC is connected during the functional tests. The testing of this link is an "ECHO" mode, where the controller prints back via the serial the line, the hexadecimal value of the characters received from the your PC. I.e. you have to type some text on your keyboard which is then returned and displayed in hexadecimal format on the screen. The test is exited by the character sequence "qq". Once you have successfully started the functional tests, this test cannot fail, because you are using the same serial interface for the functional tests. This test is available both before and after OS launch.
212
TSM Oc 9800
SDS
Configuration register test
Configuration register test
TCRG
Test the Configura- TCRG tests the configuration register tion ReGister of the currently selected part (each Syntax : TCRG part contains a configuration register). On part 1, this test also enables visual checking of the backpanel LEDS, which are shortly switched on and off in sequence (LED 1 then LED 2 then LED 3). The test of such a register consists in testing its read/write sections. The purpose of the test is to check the register's accessibility. If this test fails, then you have to replace the FBBS mother board. This test is only available before OS launch.
ed.5
20 Interface 213
Interrupt tests
For each interrupt, the test consists of:

s s
connecting a test routine to that interrupt through its interrupt vector, triggering the interrupt by the appropriate means.
The triggering of the interrupt launches the corresponding interrupt routine which sends a specific message back to the user. The interrupt sources are different for each CPU. Primary part interrupt allocation:
Int. level Source Tested
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Abort Spinach UART DPRAM Mother board DMA channel 0 Mother board DMA channel 1 Spinach Centronics OLB Slot 1 OLB Slot 2 OLB Slot 3 Operating System tick Spinach internal DMA (CX) Spinach external DMA (SCSI) SPY tic Spinach SCSI No interrupt pending
No Yes Yes
implicitly tested with OLB board tests implicitly tested with OLB board tests
Implicit (see ECCX command) see OLB board tests see OLB board tests see OLB board tests Yes implicit (see ECCX command) No (not used) No (not used) No (not used) -
214
TSM Oc 9800
SDS
Note: In the first part both Centronics direct interrupt and Centronics DMA interrupt are tested.
ed.5
20 Interface 215
Secondary part interrupt allocation:
Int. level
Source
Tested
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Abort Printer receiver ready Printer transmitter Debug receiver ready Debug transmitter ready Mother board DMA channel 0 Mother board DMA channel 1 DPRAM Operating System tick OLB Slot 1 OLB Slot 2 OLB Slot 3 SPY tic No interrupt pending
No (not used) No No No (not used) No (not used)
implicitly tested with OLB board tests implicitly tested with OLB board tests
Yes Yes see OLB board tests see OLB board tests see OLB board tests No (not used) -
Note: In the secondary part, the interrupt controller is part of the companion
chip.
216
TSM Oc 9800
SDS
Possible tests:
Interrupt test
ENIT
ENable and test InTerrupts Syntax : ENIT
ENIT installs interrupt routines, enables the interrupts and triggers them. All interrupts are disabled at the end of the test. For each tested interrupt, two checks are performed: - check that the CPU receives an
interrupt,
- check that it receives the
expected one.
If this test fails, then the FBBS mother board needs to be replaced. This test is only available before OS launch.
ed.5
20 Interface 217
Companion chip tests
The companion chip manages:

s s
the interrupts of the secondary part, the control link (engine link) to the printer.
Hence, this test is useful if you suspect the connection between controller and engine. If this link is not working properly, then you probably also have got the error 20811 on the scanner operator panel. For the interrupts, see the section about testing the interrupts. The control link cannot be tested without a physical connection to the printer or at least a loop back connector (not available at the moment). Available tests:
Companion chip tests
TCIN
Test Companion chip TCIN accesses the companion INternal registers chip's internal registers in two Syntax : TCIN passes: a write pass then a read pass. This test is only available before OS launch. If this test fails, then you have to replace the FBBS mother board.
TCSP
Test Companion chip TCSP tests transmission and link to printer reception on the TAXI printer Syntax : TCSP serial port. This test needs a loop back connector (this connector and a code number are not yet available). TCSP sends a test string of test characters on the link (TXD) and checks that each character is correctly received (RXD). This test is available only before OS launch. If this test fails, then you have to replace the FBBS mother board.
218
TSM Oc 9800
SDS
OLB board tests
Use these tests if one of the OLB boards are not working correctly or if during power-up the LEDs of the controller indicate that a certain OLB board is defect. If such a test fails, then: check if the board is properly mounted. try another slot on the OLB bus (see Allocation PBAs in Oc Local Bus extensions on page 408) for which board can be used in which slot. s try a new board (also in an other slots) s replace the FBBS mother board, if all the other actions fail For all these tests you have to specify the slot used by the OLB board. If you don't know it, then you can run the CONF test or you can check the print settings output.
s s
OLB board tests
SCBT
SCsi Board Test Syntax: SCBT A-F
SCBT launches the test of the SCSI board. It uses the test functions part of the SCSI driver, and thus can only be launched after the Operating System has been launched. You have to specify the slot used by the SCSI board. Note: this test can be executed only once, since you started the functional tests. If you try it a second time you will get the error message 'Sorry, I cannot test the same board twice'. If you want to execute this test again, you need to restart the functional test, by switching the power of the Oc 9800 off and on.
ETBT
EThernet Board Test Syntax : ETBT A-F TAXI Scanner Board Test Syntax : TSBT A-F
I/O card not available in our controller
TSBT
TSBT launches the test of the TAXI Scanner board. It uses the test functions part of the TAXI Scanner driver, and thus can only be launched before the Operating System has been launched. You have to specify the slot used by the board.
ed.5
20 Interface 219
OLB board tests
RDBT
RADICAL board test RDBT launches the test of the RADICAL Syntax: RDBT A-F board. It uses specific tests, not part of the RADICAL driver, and thus can only be launched before the Operating System has been launched. You have to specify the slot used by the board. TAXI Printer Board Test Syntax : TPBT A-F TPBT launches the test of the TAXI Printer board. It uses specific tests, not part of the TAXI Printer driver, and thus can only be launched before the Operating System has been launched. You have to specify the slot used by the board. A possible error message of this test is 'unexpected trap cut [2]; stopped'. If you get this message, then you have to replace the FBBS mother board.
TPBT
220
TSM Oc 9800
SDS
Dis-/assemblies
Note:
s
Before dis/-connecting the interface cable(s) make sure that the host is powered down and the Oc 9800 is switched off. Connections in the controller are very critical. Bad connections may lead to various controller failures. Please use a wrist wrap and take care when reinstalling controller items. It is strongly advised to place the controller on a flat table for maximum visibility in order to reinstall properly and prevent bad connections.
1 Firmware upgrade (Bootprom and ROM module PBA)

To upgrade the firmware of the FBBS controller, proceeds as follows:
1 Execute the ~print settings~ to print all user parameters. 2 Refer to the modification bulletin which describes the new firmware release, in
3 4 5 6 7 8
10 11 12
order to check the compatibility of this release with the machine technical level. Switch off the machine. Remove the right hand side engine covers. Remove the controller and place it on a table. Open the controller drawer. Remove the ROM module PBA (2 Allen screws and plates) from the primary ROM slot no.1, see Electrical description FBBS PBA on page 602 Place the new ROM module PBA. Make sure that the arrow indication is in line with the arrow indication on the FBBS PBA. If the boot EPROM has to be replaced, remove the OLB (Oc Local Bus) PBA in slot A and change the Eprom (Eprom 1 in U53) and reinstall the OLB PBA again in slot A. Support the FBBS motherboard to prevent for being bended. Close the controller and install it in the engine. Remount the engine covers. Switch on the machine.
Note: Check the 3 LEDs near the service switch and the operating panel for
failure information.
ed.5
20 Interface 401
13 Execute the ~print settings~ to check the user parameters.
402
TSM Oc 9800
Dis-/assemblies
2 Memory module (SIMM)

1 Switch off the machine. 2 Remove the right side engine covers. 3 Remove the controller to a table for maximum visibility during the SIMM
(ex)change or adding.
Secundary ROM primary OLB secundary OLB Secundary CPU spinach ASIC slot slot FB2 slot (Frame buffer) centronics A D 2 1 0 serial secundary local DRAM (RSR / Raster) printer command slot E Primary ROM module 1 2
companon chip
slot B
slot C Power Primary CPU
slot F
SERVICE primary local DRAM (DLL/Vector))
2 1 0 FB1 slot (Frame buffer)
4 Open the controller and carry out the necessary changes according the table on
next page.
Note: Use a wrist wrap to avoid damaging electronics.
Take care during dis/-assembling of the SIMM(s) for not damaging the SIMM sockets on the FBBS board. After assembly every SIMM must be checked visual for correct positioning. May be you have to remove the OLB boards for better accessibility of the SIMM slots.
ed.5
20 Interface 403
5 Reinstall the controller into the machine.
404
TSM Oc 9800
Dis-/assemblies
6 Switch on the machine and check/adjust in SDS 90 (configuration) the new
controller configuration (if you have to change the configuration, dont forget to switch the machine off and on).
Note: Watch the 3 LEDs on the controller and the operating panel if there is
no failure with the SIMM module. If needed execute functional tests TMEM or TSIM in the controller SDS.
7 Execute the ~print settings~ to check if the new memory configuration is listed
on the output.
8 Mount the controller and the engine covers.
Note: Explanation of abbreviations:
Dll: Display list SRS: Raster FB1: Frame Buffer part 1 FB2: Frame Buffer part 2 (not used for scan to file)
Supported controller Memory configurations
Configuration DLL Memory RSR Memory FB1 Memory 1 2 3 4 5 6 7 8 1 x 16MB 1 x 16MB 1 x 16MB 1 x 16MB 1 x 32MB 1 x 32MB 1 x 32MB 1 x 32MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 3 x 16MB 3 x 32MB 3 x 16MB 3 x 32MB 3 x 16MB 3 x 32MB 3 x 16MB 3 x 32MB
FB2 Memory N.A. N.A. 3 x 16MB 3 x 32MB N.A. N.A. 3 x 16MB 3 x 32MB
ed.5
20 Interface 405
406
TSM Oc 9800
Dis-/assemblies
3 FBBS motherboard PBA

1 2 3 4 5 6
Execute the ~print settings~ to print all user parameters. Remove the right side engine covers. Remove the controller and place it on a flat table. Open the controller. Remove the connectors. Remove the ROM module PBA, the SIMMs and all the extension PBAs.
Note: Remount the SIMMs in the same slots on the new PBA (different type of SIMMs are used . 4, 16, and 32 MB is possible.)
7 Remove the FBBS motherboard PBA from the drawer. 8 Remove the boot Eprom from the old PBA (Eprom 1 in U53) and mount it on
the new PBA.

9 Mount the new motherboard PBA in the controller. 10 Mount the ROM module PBA the extension PBAs and the connectors on the
new PBA.
11 Mount the controller and connect the cables. 12 Switch on the machine. Note: Check the 3 LEDs near the service switch and the operating panel for
13 Execute the ~print settings~ to check that no parameters are changed.
If parameters are changed adjust them in SDS or system administrator mode.

Note: With the functional tests CONF, TMEM, etc. it is also possible to check
the functioning of the new PBA.

14 Check the function of the controller with the Plot Director (only centronics).
SCSI can be tested with Job Director and Repro Station.

15 Mount the controller and engine covers. 16 Connect the customer environment and check the functioning of the controller.
ed.5
20 Interface 407
4 Allocation PBAs in Oc Local Bus extensions

The FBBS PBA has 6 extension slots. The slots are listed from A up to F: The standard slot selection is:
s s s s s s
Slot A: Radical PBA Slot B: SCSI PBA Slot C: (empty) Slot D: TAXI scanner (Scan Station function) Slot E: (empty) Slot F: TAXI printer. (Repro Station function)
The mentioned list of slots is the default and advised use. Only for problem solving purpose some of the PBA can be tested by the controller SDS in the following slots:
s s s s
SCSI PBA can be used in slot A, B and C, RADICAL PBA can be used in slot A,B, and C, TAXI printer PBA has to be used in slot F, TAXI scanner has to be used in slot D.
408
TSM Oc 9800
Dis-/assemblies
5 Interface extension PBA (e.g. SCSI)
1 2 3 4
Execute the ~print settings~ to print all user parameters. Remove the right side engine covers. Open the controller. Remove and (or) mount the (new) interface extension PBA according the list: Allocation PBAs in Oc Local Bus extensions on page 408.
Note:
When installing the OLB SCSI PBA, check the jumper setting of the SCSI PBA: SW1 (external) ON (SCSI termination) SW2 2-3 SW3 2-3 (factory setting, do not change) SW4 2-3 SW5 1-2 (factory setting, do not change)
5 Close the controller. 6 Switch on the machine. Note: Check the 3 LEDs near the service switch and the operating panel for
7 Execute the ~print settings~ and check if the new interface extension PBA is
listed on the configuration.

8 If SCSI: connect the SCSI interface cable to the PBA. 9 Test the new interface PBA (eventually with customer).
Note: With the functional tests of the controller SDS it is also possible to check the functioning of the new PBA.
ed.5
20 Interface 409
6 TAXI printer/scanner and RADICAL PBA

Execute the ~print settings~ to print all user parameters. Remove the right side engine covers. Open the controller. Only TAXI PBA: remove the connector of the TAXI PBA. Replace or mount the new PBA according: Allocation PBAs in Oc Local Bus extensions on page 408 Only TAXI PBA: is connected to the motherboard with an adapter board. 6 Only TAXI PBA: connect the connector of the TAXI PBA. 7 Switch on the machine.
1 2 3 4 5 Note: Check the 3 LEDs near the service switch and the operating panel for
8 Execute the ~print setting~ and check if the (new) PBA is listed in the config-
uration.
Note: With the functional tests RDBT (for Radical PBA), TPBT (for TAXI
printer PBA) or TSBT (for TAXI scanner PBA) it is also possible to check the functioning of the new PBA.
9 Test the new PBA (eventually with customer).
- Print raster files to check the RADICAL and TAXI printer PBA. - Scan to File to check TAXI scanner pba.
7 Controller Power supply

1 2 3 4
Execute the ~print settings~ to print all user parameters. Remove the right side covers. Open the controller. Check if the new power supply is identical or different from the one in the controller.
Warning: There are 2 types of power supplies with different electrical connec-
tions. Look at the electrical diagram for correct wire connection.

5 Remove the power supply and disconnect all connections from the old power
supply and install them correctly on the new one.

6 Switch on the machine.
410
TSM Oc 9800
Dis-/assemblies
Note: Check the 3 LEDs near the service switch and the operating panel for
7 Test the controller function (e.g. with the Plot Director).
ed.5
20 Interface 411
8 General information SCSI PBAs

Termination
The SCSI bus need to be terminated at both ends. This means that we have to check which devices are connected to this bus. If only the Oc 9800 is attached to the Adaptec PBA, then the SCSI bus contains just 2 devices: the Adaptec PBA (host adapter) and the Oc 9800. SCSI termination has to be enabled at these 2 devices. If another SCSI device, e.g. a CD-ROM or hard disk, is also connected to the Adaptec PBA its a different situation. Now you have both internal and external devices connected to the Adaptec PBA. Termination has to be enabled at the last external device, the Oc 9800, and the last internal device. On all the other devices including the Adaptec PBA termination should be disabled. If termination is not done properly serious errors could occur. (e.g. contents of the hard disk can be destroyed).
Connecting devices to the SCSI bus
If a device has to be connected to the SCSI bus, all devices on the bus should be switched off.
Multiple SCSI boards
If the PC contains more SCSI boards, be sure that the correct board is selected by Machine Monitor!
Note: Before dis-/connecting the SCSI cable switch off all devices. If not a de-
vice connected to the bus can be damaged.

Software versions
For the best performance, use always the newest drivers. This may be not the software delivered with the SCSI package. Check for new drivers on the Adaptec website: www.adaptec.com.
On next pages the dis-/assemblies of several SCSI boards are described.
412
TSM Oc 9800
Dis-/assemblies
ADAPTEC 1542CF SCSI PBA (for PC)
The Adaptec SCSI PBA is mounted in the customers PC and can be used for Repro Station and Scan Station. The installation of the Adaptec 1542CF SCSI PBA and the software delivered with the PBA is almost completely documented in the manuals delivered with the PBA:
1 Installation of the PBA in the customers PC has to be done as described in the
Adaptec Users guide AHA-1540C Series High Performance Bus Master ISA-to SCSI Host Adapters.
Note:
The 1542CF SCSI PBA must be placed in a ISA slot. Do not change any dip switch setting on the PBA yet.
2 After installing the PBA, boot the PC and press <Ctrl> <A> as soon as a mesConfidential 1999 Oc-Technologies B.V.
sage is displayed that tells you that you have to do that to start the SCSI Select utility. The use of this utility is also described in the Adaptec Users guide AHA-1540C Series High Performance Bus Master ISA-to SCSI Host Adapters. 3 Use this SCSI Select utility to run the diagnostics of the PBA to check that it can properly communicate with the memory of the PC. Do not change any settings of the PBA, unless you need to( because e.g. the interrupt or the address used by the Adaptec PBA are already in use by another PBA).
Note: Never change the SCSI ID setting of the Adaptec PBA: leave it at 7 ! 4 Power down the PC and set the dip switches 1,5,6,7, and 8 in the ON (= down)
position to enable: s hardware SCSI termination s disable the floppy part of the PBA s disable the BIOS of the PBA Leave the other switches in the OFF (= up) position.
5 Finally install the software delivered with the PBA as described in the Adaptec
Users Guide Adaptec EZ-SCSI for windows (chapter 2). This is the ASPI software needed for Repro Station and Scan Station to print with the SCSI interface.
Warning: When connecting or disconnecting the SCSI cable between the PC
and the controller, both devices must be switched off.
ed.5
20 Interface 413
ADAPTEC 1542CP SCSI PBA (for PC)
Note: Use this board only in a 16-bits system.
Use the AHA 2940AU in a 32-bits system. This SCSI PBA has a plug and play PBA, which means an easy installation on systems that support plug and play (via BIOS or Windows 95/NT). If you have to install the PBA on a system that does not support this mode (e.g. Windows 3.1 / 3.11), some additional actions are necessary.
Installation SCSI in a PC that does not support Plug and Play
The following steps are needed:

1 Disable Plug and Play mode by changing switch1 on the Adaptec PBA in the
down position.
2 Disable the floppy by changing switch 5 in the down position. 3 If the Adaptec PBA should have another address than the default one, then
4 5 6
7 8
change dipswitch 2,3,4 according the documentation (see the Adaptec documentation for possible addresses settings). Install the PBA in a free ISA-slot of the customers PC. Reboot the PC and press <Ctr><A> if you get the Adaptec boot message (which also refers to these two keys) to start the SCSI Select utility. Select addresses and channels that are free in the PC with this utility (some information about addresses and channels in use can be determined using e.g. the MSD command (MicroSoft Diagnostics). Enable the SCSI Termination (in the Configuration menu). Power down the PC and change switch 6,7, and 8 in the down position, to disable BIOS of the card (Do this afterwards, because BIOS is needed to run SCSI Select utility!). Finally power on the PC again and install the ASPI driver required by Repro Station by installing the EZ-SCSI software delivered on the floppy disks with the Adaptec PBA (This software will automatically detect the AHA 1542 CP PBA and the ASPI driver and aspi4dos.sys will be installed on the PC and the config.sys file will be updated to load this driver at the boot time). More detailed information about using the SCSI Select and installing the PBA in the PC can be found in the Adaptec documentation included the box containing the SCSI PBA.
414
TSM Oc 9800
Dis-/assemblies
Note: The Adaptec SCSI software can be delivered partly on a cd-rom and
floppies. Then proceed as described in:Installation of only a part of the software (no cd-rom drive present). on page 418
Installing SCSI in a PC supporting Plug and Play
The new modern software on PCs and I/O cards support plug and play. This means that an easily install in one of the free ISA slots in this PC is possible and we do not have to worry about IRQ, DMA and address conflicts. However some sometimes the installation of the SCSI PBA is not done properly. In case the Plug and Play mode is not functioning, disable the Plug and Play mode of the SCSI PBA and select manually the correct addresses / channels and follow the installation of Installation SCSI in a PC that does not support Plug and Play on page 414. In the Plug and Play system you may disable the floppy by changing dipswitch 5 to the down position on the Adaptec PBA.
PC with on board SCSI PBA
Some PCs with an SCSI on the motherboard are installed. Sometimes a conflict between the Adaptec SCSI manager and the standard installed SCSI manager occurs. In other words: dont use the internal SSI board to connect the Oc 9800. The work around procedure is to disable the installed SCSI manager (remove it from the config.sys). The consequence is that all devices, except the hard-disk which is used for booting are no longer accessible. If needed connect the other devices e.g. CD ROM to the Adaptec PBA. For detailed information see the Adaptec documentation.
ed.5
20 Interface 415
416
TSM Oc 9800
Dis-/assemblies
Adaptec PCI SCSI PBA (for PC) AHA 2940 or AHA 2940AU
These PBAs have to be installed on a PCI bus. There are no dip switches on these PBAs and with the SCSI Select utility several software settings can be made. The AHA 2940 has a jumper to set the termination. The AHA 2940AU has no jumper, also the PBA is smaller. Installation of the PCI SCSI PBA:
1 AHA 2940:
2 3 4
5 6
If only the Oc 9800 is connected to this board (as recommended) put a jumper shunt (code no. 1300407) on J3 to terminate this board (error 20804). AHA 2940AU: There is no jumper! Install the PBA in a free PCI slot of the customer PC. Power on the PC and press <Ctrl><A> if you get the Adaptec boot message to start the SCSI Select utility. AHA 2940: Set SCSI termination to enable in the Configure / View host Adapter settings window if only the Oc 9800 is connected. If more devices are connected, follow the guidelines in the Adaptec documentation. AHA 2940AU: Keep the setting on default (Automatic). The host adapter will automatically detect if the software termination must be enabled or disabled. Select Advanced configuration options and set the Host Adapter BIOSto disabled. Save the changes and leave the SCSI Select utility. Install the ASPI driver required by Machine Monitor by installing the EZ-SCSI software delivered with the Adaptec PBA (This software will automatically detect the AHA 2940/AU PBA and the ASPI driver and aspi8dos.sys will be installed on the PC and the config.sys file will be updated to load this driver at the boot time). More detailed information can be found in the Adaptec documentation included the box containing the SCSI PBA.
Note: For the best performance, use always the newest drivers. Check for new
drivers from the Adaptec websit e: www.adaptec.com
ed.5
20 Interface 417
Note: From EZ-SCSI 4.0 onwards, the software is delivered on a cd-rom and
two floppies. Only floppy Adaptec EZ-SCSI for Windowsand the cd-rom is needed. If no cd-rom drive is present, then use a set of floppies from an earlier delivered board, or install only a part of the software.
Installation of only a part of the software (no cd-rom drive present).
Installation of only the contents of the floppy implies that not all the software is installed. Continue as follow: Leave Windows Insert the floppy Adaptec EZ-SCSI for Windows in the floppy drive. Activate the dos-installation with DOSINST <return> Use the default setup and follow the instructions on the screen, and the drivers will be installed. If the Adaptec board is not found during the default setup, then custom setup can be used. Now the Adaptec PCI SCSI host adapter must be selected. Then follow the instructions on the screen and the drivers will be installed. The file WINASPI.DLL is missing now. This file is present on the first floppy of REPRO and SCAN STATION software. Copy this file to the WINDOWS/SYSTEM directory
Note: Missing are all the Adaptec utilities (like SCSI interrogator), but these
are not needed to run Repro or Scan Station.
Warning: Some PCs require a patch of the BIOS, e.g. Compaq. Please consult your local system consultant.
Warning: Before connecting or disconnecting the SCSI cable between the de-
vices: SWITCH OFF ALL DEVICES!! If not, a device connected to the bus can be damaged.
418
TSM Oc 9800
Dis-/assemblies
1 General
The controller functions of the FBBS controller are:
s
s s
Processes: conversion and transformation of plot data to Oc 9800 specific raster formats and performs scaling, rotation etc. Connectivity: connects the Oc 9800 to the customer environment Remote Control Format (RCF): accepts and interprets RCF-data to control printing (and later scanning) and finishing aspects.
Graphic languages
The following graphic languages are supported (can be set to automatic language sensing ALS, except ASCII): :
Vector
HPGL HPGL/2 CALCOMP 906/907

Raster
supported plotter emulation: reference is HP7586B plotter supported plotter emulation: HP650C and HP750C.
TIFF
CALS
supported subset: full TIFF 5.0 extended with 6.0 monochrome tiled files. additional CCITT Bi-level encoding: CCITT group 3 (T.4) 1 and 2 Dimensional encoding CCITT group 4 (T.6) encoding only CALS type 1 is supported
HP-RTL
ASCII
HP-GL fonts, 3 sizes
ed.5
20 Interface 501
FBBS Abbreviations:
FBBS: Frisco Basic B Specific (controller of the Family RISc COntrollers (FRISCO) specific for the Oc 9800). shared DRAM for data exchange between the 2 parts of the controller and the engine. Frame buffer consists of 2 parts FB1 and FB2 specific ASIC chip for controlling Centronics (CX) and serial links (and for future purpose a SCSI link to a hard disk). Oc Local Bus. Controller bus for the connection of extension boards, like RADICAL, SCSI, TAXI, Ethernet and VPI. SPINACH is part of the mother board. Operating System. VxWorks for this controller. that part of the controller mother board containing: CPU1 local ROM and local DRAM ZPRAM (not used) SPINACH centronics (CX) link SCSI link to a hard disk (not used) Serial (RS) links 3 OLB slots access to the Frame buffer that part of he FBBS board containing: CPU2 local ROM (boot ROM) and local DRAM Companion chip (includes also the printer link) 3 OLB slots access to the Frame buffer. Zero Power RAM (battery powered, not used). Raster Acceleration Board A OLB PBA for processing raster data, e.g. for rotation of raster files and for compression and decompression of raster data OLB board for communication with the printer. One TAXI board is used for printing (to transfer data from the controller to the engine) and a second one is used for Scan to File (to transfer data from the scanner to the controller).
Frame buffer:
SPINACH:
OLB:
OS:
Primary part:
Secondary part:
ZPRAM:
RADICAL:
TAXI:
502
TSM Oc 9800
2 Controller characteristics
Dual CPU 40 MHz SPARC (RISC family) 2 ROM modules standard & optional (for future purpose) 1 boot ROM, on secondary part 6 Oc Local Bus Extension slots A-F Slot A: Radical PBA Slot B: SCSI PBA Slot C: future Slot D: TAXI scanner (Scan Station function) Slot E: future Slot F: TAXI printer DLL memory (16/32 Mb) 1 DRAM module FRAME buffer (48 - 192 MB) 6 DRAM modules Scan to file uses only Frame Buffer 1
Software features:
s s s s s s s s
- Plot processing for various languages through many interfaces. - ALS automatic language sensing - Plot transformation (scaling, rotation ...) - Remote control through host - Configuration through engine Local User Interface - Error recovery feature - Scan to file function - Diagnostic tests for production and service
Connections internal:
- power supply - serial for engine commands - taxi printer - taxi scan to file
Connections external:
- RS232 serial - centronics - SCSI
ed.5
20 Interface 503
Supported controller Memory configurations from Release 2.0
Configuration DLL Memory RSR Memory FB1 Memory 1 2 3 4 5 6 7 8 1 x 16MB 1 x 16MB 1 x 16MB 1 x 16MB 1 x 32MB 1 x 32MB 1 x 32MB 1 x 32MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 1 x 4MB 3 x 16MB 3 x 32MB 3 x 16MB 3 x 32MB 3 x 16MB 3 x 32MB 3 x 16MB 3 x 32MB
FB2 Memory N.A. N.A. 3 x 16MB 3 x 32MB N.A. N.A. 3 x 16MB 3 x 32MB
Explanation of abbreviations: Dll : Display List SRS : Raster FB1 : Frame Buffer part 1 FB2 : Frame Buffer part 2
Note: FB2 is not used for Scan to File!
504
TSM Oc 9800
3 Process
Block diagram
The upper part of the block diagram is the primary part and the lower part is the secondary part. The primary part takes care of:
s s
handling the data received from the host converting the received data into specific Oc 9800 raster format and store it in the common FRAME buffer.
The primary part contains also the SCSI and RADICAL PBA. The secondary part takes care of:
s
transferring the specific Oc 9800 raster format from the FRAME buffer to the engine. transferring the data transfer from the engine to the controller for scan-to-file.
ed.5
20 Interface 505
4 Printing
The printing can be divided into two different types of data:
1 Printing vector data 2 Printing raster data Block diagram for printing vector data
If data is received and the Automatic Language Sensing (ALS) is enabled (e.g. data format AUTOMATIC is specified with Repro Station), the ALS tries to determine which data format it is. If the format is recognized the interpreter for the data format is started. The interpreter creates an intermediate format which is stored in the DLL memory (Display List memory). The intermediate format is sorted to get a sorted vector list. The sorted vector list format is converted into the Oc 9800 specific raster (bitmap) format which is stored in the Frame Buffer. Finally this bitmap is sent via the TAXI interface to the SET memory PBA of the engine. The data is compressed and stored in the SET memory. If the Automatic Language Sensing (ALS) function is disabled, then the data format has to be specified (e.g. HP-GL in Repro Station). The interpreter starts directly.
506
TSM Oc 9800
The intermediate format of the data has to fit completely in the DLL memory. If the file doesnt fit the warning 20813 is generated. (For further information see Fault description). The size of the Frame buffer is between 48 and 192 Mb. If the file does not fit in the Frame buffer Banding is used: That part of the file that fits into the Frame buffer is sent to the SET memory. The display shows the message DOWNLOADING PRINTFILES. The Frame buffer is cleared and the next part of the file is stored in the Frame buffer and sent over. The process continues till the complete file is sent. This happens e.g. with long plots.
Block diagram for printing raster data
Host
Controller
Automatic Language Sensing DLL used for storage Frame Buffer
Engine
Set Memory
Rendering Interpreter
TAXI
Radical
= Raster data = Bitmap = Process = Memory = Buffer
The process for raster formats is nearly the same as for vector data. The raster DATA is interpreted and temporarily stored in the DLL memory. Next it is decompressed by the Radical PBA (if the file was compressed) and rendered (conversion into the specific Oc 9800 bitmap format) and stored into the Frame buffer. The raster data does not have to fit in the DLL memory.
ed.5
20 Interface 507
For detailed information about the instructions for the controller to use features of the Oc 9800 engine (like folding, stamping, punching, roll selection, reduction and shifting) and the controller functions (like rotation, enlargement, handling data formats) see the User Manual and Programmers Manual. Not all processing is done in the controller. Some actions like reduction, most of the shift function, some edge corrections are done in the engine (image processing) This is the same process as with copying.
5 Print size of originals

For printing the size of the Frame Buffer has impact to the size of the file that can be rotated. For configurations, see Controller characteristics on page 503
Maximum print size with rotation
Configuration 1 and 5 2 and 6 3 and 7 4 and 8
Maximum file size 23.5Mb 47Mb 47Mb 94Mb
Max. W x L or equivalent 594 x 841mm 24 x 34 841 x 3800mm 34 x 149.5 841 x 3800mm 34 x 149.5 841 x 7600mm 34 x 299
Due to the fact that during rotating a part of the FB is used for handling the plot, the Max. Wx L column is not linear increasing compared with the several FB memory size combinations
Maximum print size for long plots
Maximum W x L or equivalent 841 x 1850mm - 34 x 73 841 x 3800mm - 34 x 149.5 841 x 3800mm - 34 x 149.5 841 x 7600mm - 34 x 299
Attention: Maximum length is 15000mm (590.5), Maximum width is 914mm (36).
508
TSM Oc 9800
6 Scan to File
The controller also can transport data from the SET memory PBA to the host computer. After scanning a analogue original, the data can be stored on the host computer harddisk as a TIFF or CALS raster file with a resolution of 200 or 400 dpi.
Block diagram for scanning raster data
Controller Scan Station

uncompress
Engine Scanner
Without copy CCD
TAXI scanner resolution conversion
Frame Buffer
Set Memory
= Bitmap = Buffer = Raster data
With copy
= Process
= Memory
The CCDs of the scanner scans an original with 400dpi. The data is transferred to the SET memory PBA. From here the data is transferred to: - the TAXI scanner PBA in the controller - the TAXI scanner PBA in the controller and to the image processPBA in the engine, to make at the same moment a copy On the TAXI scanner PBA the data is converted in the resolution and the type of language chosen by the operator. The result is stored in the Frame Buffer, only in part 1. When the file has to be compressed, the data is transferred to the Radical PBA for compression and back to the Frame Buffer. From the Frame Buffer the compressed or uncompressed data is (added with a header) transferred directly to the SCSI PBA and then to the host computer (or network) to be stored on the harddisk. For additional info, see the Scan Station user manual and on-line help.
ed.5
20 Interface 509
7 Scan size of originals

For Scan to File the maximum size of originals that can be uploaded with respect to the Frame Buffer memory configuration are given in the next table.
Original size
Max. W x L or equivalent (200dpi) 841 x 6300mm 34 x 248 841 x 14000mm 34 x 551 841 x 6300mm 34 x 248 841 x 14000mm 34 x 551
Max. W x L or equivalent (400dpi) 841 x 1500mm 34 x 59 841 x 3250mm 34 x 128 841 x 1500mm 34 x 59 841 x 3250mm 34 x 128
Note:
FB2 is not used for Scan to File For configuration, see Controller characteristics on page 503
Note:
510
TSM Oc 9800
8 PAS (Printroom Application Software)

This printroom application consists of Job Director, Job Director Configurer, Repro Station and Machine Monitor. The applications run only under Windows 3.1/3.11, Windows 95 and Windows NT3.51/4.0. The system consists of:
Jo b D ire cto r Jo b D ire cto r C o nfig ure r R e pro S tatio n M a chin e M on ito r 5 0 p ins m ini ce n tron ics co n n ector D o ng le S C S I-2 ca b le A d ap te c S C S I 5 0 p ins co n n ector A m p li o r M ini A S P I drive rs ( C D -R O M o r F lo pp y)
( C D -R O M o r F lo pp ies)
S C S I bo a rd O c lo ca l b u s
F B B S co ntro lle r
The PAS applications are distributed on CD-Rom. It is possible to create floppies from the CD-Rom, for customers who do not have a CD-Rom drive in the PC. For detailed information about both applications, see the User manuals. The installation of these is also described in these manuals. The Oc Repro Station software is protected by a dongle on the centronics port. If the customer is also using applications who are using also Dongles, then they are built on each other. Even more is possible (e.g. AutoCad). The order of the dongles can be important. See the corresponding manuals. Examples: -Autocad dongle must be in LPT1 and in 1st position. -~Oc View Station~ dongle must be in 1st position, LPT not important. - Repro Station dongle can be placed anywhere.
ed.5
20 Interface 511
9 SCAN STATION
The scan printroom application software consists of Scan Station, Machine Monitor and the Oc View Station (the old Spicer Imagination viewer can be upgraded).In the package you find also the needed hardware: Taxi Scanner PBA and the Upload cable. The applications run under Windows 3.1/3.11, Windows 95 and Windows NT3.51/4.0 The system consists of:
S ca n S tatio n M a chin e M on itor O c V iew S ta tio n
5 0 p ins m ini ce n tron ics co n n ector
S C S I b oa rd O c lo ca l b u s
D o ng le S C S I-2 ca b le
TA X I sca nn e r O c lo ca l b u s
A S P I drivers (C D -R o m o r flo pp ies)
A d ap te c 5 0 p ins co n n ector A M P L I o r M in i
F B B S co n tro lle r U p lo a d ca ble E n gin e S e t M e m o ry P B A
Scan Station and the Oc View Station are distributed on CD-Rom. It is possible to create floppies from the CD-Rom, for customers who do not have a CD-Rom drive in the PC. For detailed information about both the applications, see the User manuals. The installation of these applications are also described in these manuals. The Oc View Station software is protected by a dongle on the centronics port. If the customer is also using Repro Station, then there are built 2 dongles on each other. Even more is possible. The order of the dongles for the Repro Station and Viewer Station is not important. For other applications, see the corresponding manuals. The cable connection (SCSI) is between Machine Monitor and the controller. Machine Monitor can handle back-channel communication, but the FBBS controller can not generate back-channel information.
512
TSM Oc 9800
10 SCSI PBAs
The Oc 9800 Repro Station and Scan Station application requires a SCSI PBA in the PC to communicate via Machine Monitor with the controller. The following SCSI solutions are possible:
s s s s s
Adaptec 1542 CF PBA (connector: Amphenol M) Adaptec 1542 CP PBA (connector: Mini SCSI M) PCs with an on-board SCSI PBA (connector: Mini SCSI M) Adaptec AHA 2940 PBA (connector: Mini SCSI M) Adaptec 2940 AU PBA (connector: Mini SCSI M)
SCSI cable
A SCSI cable is needed to connect the SCSI board in the PC with the SCSI connector of the controller. The controller has a Mini SCSI M connector, the connector on the SCSI board in the PC depends of the board type. It can be a MINI SCSI M connector or an Amphenol M connector.
Adaptec 1542 CF PBA
The first deliveries of SCSI PBAs was the Adaptec CF PBA. For communication between the PC and the Oc 9800 a Mini SCSI M / Amphenol M cable is needed. This SCSI PBA uses the ISA bus of the PC and is not recommended for a 32-bits Operating System.
Adaptec 1542 CP PBA
This is the latest release of the SCSI PBA. For communication between the PC and Oc 9800 a Mini SCS MI/ Mini SCSI M cable is needed. Other differences with the 1542 CF PBA are:
s s
switch 1 on the PBA is used for enabling /disabling the plug and play mode. defaults for the SCSI Device Configuration and Advanced Configuration Options are different SCSI termination can only be controlled by the SCSI Select utility
This SCSI PBA uses the ISA bus of the PC and is not recommended for a 32-bits Operating System.
ed.5
20 Interface 513
PC with on-board SCSI PBA
Some PCs are equipped with an on-board SCSI PBA. Sometimes this board is not ASPI compatible (specific dedicated drivers are used).
Adaptec AHA 2940 SCSI
The Adaptec AHA 2940 SCSI PBA uses the PCI bus. Aspi drivers to install the SCSI board can (will) be delivered on CD-ROM. The production of this board is stopped by the producer. For communication between the PC and Oc 9800 a Mini SCSI M/ Mini SCSI M cable is needed. This PCI board is recommended for a 32-bits Operating System.
Adaptec 2940AU SCSI
This is the successor of the AHA 2940 SCSI pba and has no jumper. The Adaptec 2940AU SCSI PBA uses the PCI bus. Aspi drivers to install the SCSI board can (will) be delivered on CD-ROM. For communication between the PC and Oc 9800 a Mini SCSI M/ Mini SCSI M cable is needed. This PCI board is recommended for a 32-bits Operating System.
514
TSM Oc 9800
11 PC characteristics
To run the Oc PAS applications:
s s s s s s
Job Director Job Director Configurer Repro Station Scan Station Oc View Station (upgraded Spicer Imagination) Machine Monitor
on a standard PC, the following characteristics are recommended:

s
s s
s s s
Pentium 100 MHz Intel processor, running Windows 95 or Windows NT 3.51/4.0 for the 32-bit applications or Windows 3.1/3.11 for the 16-bit applications For View Station onWindows NT3.51: Service Pack 5 is required. 32 Mb internal memory free on internal harddisk 3,5 Mb for Repro Station 6 Mb for Scan Station 10 Mb for View Station sufficient disk space to save the files a TCP/IP network, if remote connections are needed a free PCI slot for the Adaptec SCSI PBA (for Machine Monitor) a free centronics port. The Oc View Station and the Repro Station are supplied with a dongle. The View Station dongle must be in the 1st position, LPT is not important. The Repro Station dongle can be placed in any order.
Note: 1
If the applications are divided over more PCs, then the characteristics can be lower.
Note: 2
If applications are running on the same PC, then the Windows version must be be the same.
ed.5
20 Interface 515
516
TSM Oc 9800
Controller
Command 20D1
Upload 20D4
1 2 3
Download 20D3
LED
Service Switch
220V 20D1
ed.5
20 Interface 601
2 FBBS PBA
Secundary ROM primary OLB secundary OLB Secundary CPU spinach ASIC slot slot FB2 slot (Frame buffer) centronics A D 2 1 0 serial secundary local DRAM (RSR / Raster) printer command slot E Primary ROM module 1 2
companon chip slot B
slot C Power Primary CPU
slot F
SERVICE primary local DRAM (DLL/Vector))
2 1 0 FB1 slot (Frame buffer)

Connectors
External
s s
serial centronics
Internal
s s s s s
Power -> power supply PBA printer -> serial communication between controller and CPU PBA TAXI printer - > set memory TAXI scanner <- from set memory Service -> to service switch and 3 LEDs
602
TSM Oc 9800
3 ROM module PBA
U7 U1 P1
U8 Sw2 SW 1 U6
4 SCSI PBA
PBA layout
Jumper settings: SW1(external) SW2 SW3 SW4 SW5 ON (SCSI termination) 2-3 2-3 (factory setting, do not change) 2-3 1-2 (factory setting, do not change)
ed.5
20 Interface 603
5 Connectors
Centronics port
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
Plotter Pin No
Signal direction
Name of signal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19-35 36
Plotter to host Plotter to host Plotter to host Plotter to host Plotter to host Host to plotter Host to plotter Host to plotter Hoost to plotter Host to plotter Host to plotter Host to plotter Host to plotter Host to plotter Host to plotter Host to plotter Host to plotter Host to plotter ------Plotter to host
BSY SELECT ACKN FAULTN PAPEROUT Data 1 Data 2 Data 3 Data 4 Data 5 Data 6 Data 7 Data 8 IINITN STROBEN SELECTINN AUTOFDN Host Logic High GND Peripheral Logic High
Busy Select Acknowledge Fault Paper error Data 1 (LSB) Data 2 Data 3 Data 4 Data 5 Data 6 Data 7 Data 8 (MSB) Initialize Strobe Select in
Ground
604
TSM Oc 9800
Serial port
Plotter Pin Signal no
Name of the signal
1 2 3 4 5 6 7 8
Host to plotter Plotter to host Host to plotter -------Plotter to host Host to plotter -------Plotter to host
DTR CTS TX TGND RX RTS RGND DSR
Data terminal ready Clear to send Transmit data Protective ground Received plot data Ready to send Host ground (RS423 on;y) Data set ready
ed.5
20 Interface 605
606
TSM Oc 9800
1
22PBA1 CPU I/O
X17 1 2 3 4 7 8 +5V GND (RXD) (CTS) (TXD) (RTS)
3
20FBBS
20D1 10 1 2 4 5 8 P5 PRINTER
SERIAL
CENTRONICS
11PBA1 SET MEMORY (OPTIONAL B860)

X15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GND IMPSYNCO IMPRECONO IMPDA0O IMPDA1O GND IMPDA2O IMPDA3O GND IMPDA4O IMPDA5O GND IMPDA6O IMPDA7O GND X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
11D1
EXT. MEMORY-1
11D2
EXT. MEMORY-2
11D3
EXT. MEMORY-3
11D4
EXT. MEMORY-4
X4 1 2 3 4 5 6
GND DLINK2 NDLINK2 GND +5V RESET CAPDL
20D3 1 2 4 5 8 6
X1
P20 SLOT F
P21
SCSI
SLOT A
TAXI DOWNLOAD
SCSI
11D5
EXT. MEMORY-5 X14 1 2 3 4 5 6 20D4 1 2 4 5 8 6 P2 P18 SLOT D
11D6
EXT. MEMORY-6
11D7
EXT. MEMORY-7
GND DLINK_OUT NDLINK_OUT GND +5V RESET CAPUL
UPLOAD
11D8
EXT. MEMORY-8
22PBA5 DRIVERS
X13 1 2 3 5
+5V GND +24V GND
X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10 P4 1 4 2 5 SERVICE 3 8
22G1 CONSUPLV
X1 21
LED1 LED2 LED3 OFF/ON
CONCONEMSSUP
17
CONKEYSW
CONCONEMS
22K4-2A
22PBA4 SSR 22Z2

6 5 4 L2 22X010 N2 X9 1 2 3 X5 1 2 L2 N2 6 2 8 4
6 7
1 3
2 4
20POWER SUPPLY
N L GND 20 1 2 3 4 5 6 7 8 +5V +5V GND GND -12V GND +12V 20D2 N2-MNO 3 L2-MNO 1 2 22X012-3 P25 1 3 2 4 9 6 7 FANS X3 2 5 X4 3 2 N2-MNO L2-MNO
P17 1
+12V
M
2 3 GND GND
FAN
NFS200-7608
M
4 P24 1 +12V
FAN
+12V
OR
M
FANS 2 3 GND GND
FAN
1 2 3 4 5 6 7 8
RBQ151
+5V +5V GND GND GND -12V +12V
M
4 +12V
FAN
FBBS
ed.5
TSM Oc 9800
20 Interface 701
Oc
Oc 9800
20 INTERFACE EPC/DRI
Contents
Diagnostics
1 Faults 101 2 Oc Repro / Scan Station errors (messages)
113
SDS
1 The Oc 9800 Controller SDS 1201 2 The functional tests of the controller. 1204 3 Functional test description 1207
Dis-/assemblies
1 Embedded Power Controller 1401 2 EPC software 1402 3 EPC Upgrade Backup Software 1403 4 EPC Demo plot (Test print) 1404 5 Radical PBA 1405 6 Priscat PBA 1406 7 Centronics I/O PBA 1407 8 Hard disk 1407 9 Power supply unit 1408 10 Motherboard 1409 11 Memory module (SIMM) 1410 12 General information SCSI PBAs 1411
ed.5
20 Interface EPC/DRI
1 General 1501 2 Features 1501 3 System overview 1502 4 Embedded Power Controller characteristics 1505 5 Process 1507 6 Printing 1508 7 Print size of originals for rotated image 1511 8 Print size of originals for long plots 1512 9 Scan to File 1513 10 Scan size of originals 1514 11 PAS (Printroom Application Software) 1515 12 SCAN STATION 1516 13 SCSI PBAs 1517 14 PC characteristics 1519
1 Component location 1601 2 Embedded Power Controller (EPC) Extensions 3 Controller PBA overview 1604 4 Motherboard 1605 5 Radical PBA 1606 6 Priscat PBA 1607 7 Centronics PBA 1608
1602
Diagrams
1 EPC 1701 2 DRI 1702
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Interface 20000 - 20999 code display
POWER UP TEST ERRORS: 20801 - 20810 20801 MRE: ~FBBS selftest error~ Not used in Embedded Power Controller
20802 MRE: ~Harddisk error~ Problem: if the controller was booted: no test plot, Ethernet may not work (swapping)
Harddisk crashed
Reboot and examine the boot messages, displayed in the Terminal window, SDS: see
Terminal window on page 1205

Reboot will generate error 20811
20803 MRE: ~Radical pba error~

Radical PBA loose. (not properly mounted in the controller), or defect.
ed.5
20 Interface EPC/DRI 101
20804 MRE: ~SCSI pba error~ (Controller)

.
Possible cause
Remark
Faulty SCSI in the controller. SCSI bus not properly terminated.
Change motherboard. In Controller: In LUI of the scanner: set terminator to ON. In Host: Verify the end of the SCSI bus, it should terminate the bus properly. * If the Adaptec 1542 CP/2940/2940AU is used: termination has to be enabled with the SCSISelect utility. * If the Adaptec 2940 is used: jumper J3 not (properly) set.
After booting, the SCSI ID is changed.
Reboot both: the host PC and the controller (engine).
20805 MRE: ~Ethernet error~

Parameters not okay .
Ask customer for the right parameters and fill in as System Administrator.
20806 MRE: ~Taxi interface Scanner pba (PRISCAT)~

PRISCAT or ~riser~ pba not properly mounted or faulty.
* Check position. * Execute the controller functional tests TSBT, LSBT, LTBT to verify whether the board is okay.
20807 MRE: ~Vector firmware checksum error~ Not used in Embedded Power Controller. 20808 MRE: ~Vector extension checksum error~ Not used in Embedded Power Controller.
102
TSM Oc 9800
Diagnostics
20809 MRE: ~DRAM simm pbas error~
Possible cause
Remark
The installed memory DRAM * Total memory > SDS setting SIMM modules dont match with * Maximum memory < 64MB the configuration settings in SDS test 90. One of the SIMMs defect or makes bad contact. * Reboot and examen the bank messages, displayed in the Terminal window, SDS: see

* If it is properly installed, clean its connector or replace it.
20810 MRE: ~TAXI interface printer pba~ (PRISCAT)~
Possible cause
Remark
PRISCAT or ~riser~ pba not properly mounted or faulty.
* Check position. * Execute the controller functional tests LSBT, LTBT to verify whether the board is okay.
ed.5
ENGINE - CONTROLLER COMMUNICATION ERROR: 20811-20812 20811 MRE: ~Communication error contr(oller) -> engine~ This is the only error generated by the engine: if the engine has lost the communication with the controller or if the engine cannot get in contact with the controller (during power on for example), then this error is generated.
General: Reboot and examine the messages, displayed in the Terminal window, SDS: see Terminal window on page 1205. Controller out of use * Check power switch. * Listen if the fan is turning. * No messages in the terminal window. * Listen if the fan is turning. * No messages in the terminal window. * Listen if the fan is turning. * No messages in the terminal window. Reload software on harddisk. * Only the first messages are correct. No new messages when trying to load the software. * Check with test LTBT * Check cables
Connection: mains to controller supply. Controller power supply defect.
Software corrupt.
Connection: communication cable between controller and CPU_IO PBA. Connection: cable between controller and set-memory at set-memory side not properly mounted (or too tight). Connection: one of the SIMMs makes bad contact. Motherboard defect. Wrong position PCI I/O cards.
Check memory information (bank 0-7) displayed in the terminal window. No message in the terminal window Position in chapter Electrical description: see Controller
PBA overview on page 1604

RADICAL pba defect Test RDBT
104
TSM Oc 9800
Diagnostics
Possible cause
Remark
PRISCAT pba defect Harddisk defect
Test TSBT, LSBT, LTBT Check harddisk results in the terminal window: * Attaching to IDE disk device doesnt work * Could not initialize IDE driver * Error loading file: error no. = 0x3d0002 * Cant load bootfile Harddisk was not stopped properly. Wait 5 seconds before switching the system ON again. 16 MB SIMMsin the memory have to be used in slot 1 and 2.
System switched OFF and ON too quickly.
16 MB SIMMs in slot 3 and 4 32 MB SIMMs in slot 1 and 2 Scan to file will result in error 20811 (some scans oke, then receiving error20811)
20812 MRE: ~Communication error engine -> contr(oller)~
Possible cause
Remark
Internal and external communication cables between PRISCAT and CPU_IO PBA. No display message if the controller is removed from the configuration and the system is rebooted. No display message if the controller is removed from the configuration and the system is rebooted. Test LSBT. Remove the controller from the configuration and reboot the system. Read out the display message / error help.
CPU_IO PBA defect.
PRISCAT PBA defect Non controller error.
ed.5
MISCELLANEOUS ERRORS: 20813 - 20815 20813 OWAR: ~Not enough memory to complete opp(eration)~
Possible cause
The vector drawings contains too many polygons; part of the drawing is printed The display list of the vector drawing doesnt fit in the DLL memory; part of the drawing is printed There is too less memory available for the sorted vector list (only for vector drawings); the drawing is not printed If banding has to be done (the rasterized plot doesnt fit in the controller memory), then some vectors may cross bands. If there are too many of these vectors, then this error is generated and the drawing is only partially printed The raster drawing is too large; e.g. a tiff file with the header at the end should be read completely before rasterisation can take place. Then it should fit into the DLL memory. The drawing is not printed. With a free text/ image stamp the plot must fit in the DLL. If not than e.g. rendering is not done and error 20813 occurs.
Remark
106
TSM Oc 9800
Diagnostics
Possible cause
Remark

Possible cause
The plot doesnt fit into the set memory. Hence, the plot cannot be processed. .
Remark
ed.5
RS323 ERRORS: 20820 - 20822 20820 OWAR: ~RS-232 host / contr. (to controller) framing error~ Not used in Embedded Power Controller. 20821 OWAR: ~RS-232 host / contr. (to controller) parity error~ Not used in Embedded Power Controller. 20822 OWAR: ~RS-232 host / contr. (to controller) overrun error~ Not used in Embedded Power Controller.
SCSI ERRORS: 20830 - 20832 20830 OWAR: ~SCSI: cmd (command) group error~ Not used in Embedded Power Controller.
20831 OWAR: ~SCSI: chip error~ Not used in Embedded Power Controller.
20832 OWAR: ~SCSI: parity error~ Not used in Embedded Power Controller.
108
TSM Oc 9800
Diagnostics
GRAPHIC LANGUAGE ERRORS: 20860 - 20864 20860 OWAR: ~Interpr. (eter) error: command not supp(orted)~


ed.5


110
TSM Oc 9800
Diagnostics
HOST PROTOCOL ERRORS: 20870 - 20872 20870 OWAR: ~Host prot(ocol), job description error~
Syntax error. Verify that the contents of the RCF header is according the RCF reference Manual
Possible cause
Remark

ed.5
20901 SWAR: ~Illegal ram configuration contr(oller)~
Possible cause
Remark
Check the configuration in SDS test 90, if the memory matches the installed DRAM SIMMs in the controller. Memory slot or SIMM is defect or bad contact. Reboot and examine the bank messages, displayed in the Terminal window, SDS: see Clean its connector or replace it and run the test again.
112
TSM Oc 9800
Diagnostics

Most of the Oc Repro, Scan Station and Machine Monitor errors (messages) are self explaining. The following errors need an explanation:
s s s s s s
Oc scanner / printer not responding Job Ticket is still arriving, not complete yet. Plot image is divided on 2 copies Processing Scan Job message doesnt disappear Unnamed file was not found Error incorrect RCF only with EPC; special character in printer stamps, backchannel stopped.
Oc scanner / printer not responding - This implies that Machine Monitor has lost the connection with the Oc 9800. - Only one application can be active: Repro Station or Scan Station! If trying both at the same time, then the message trying to connectis displayed. - Centronics connection is heavily in use Check as follows:
Check if the status of the Oc 9800 is ~ Ready to copy~ Check the SCSI connection Activate Scan for SCSI devices in Repro Station Configure - SCSI menu.
Run the SCSI interrogator (This Adaptec The tape device TDC 3600 tool is installed during the installation of the should be recognised at the SCSI ADAPTEC SCSI PBA). ID of the Oc 9800. Power down the PC by switching it off. (Do not carry out a soft reset Ctrl-Alt-Del) Switch it on again. During the boot procedure it should recognise the Oc 9800 as a Tandberg tape device of the type TDC 3600. If all the checks for SCSI still do not result in printing with SCSI, try to print with Centronics. Other application is active. Close this application.
ed.5
Possible cause
Remark
Centronics in use. Disabled in operator panel Scan -to-file disabled in the configuration
Stop printing via centronics or wait till printing is ready. Enable. Enable in SDS 90
Calcomp file with wrong checksum setting HPGL file: too short plot time out setting Slow PC Once a problem reported with a PC active in slow mode (about 10 MHz). The output was totally corrupted. Try the same job using only the PC and no network HP-GL and HP-GL/2
Conflict with network card in PC Pen 0 set to end of file although SP0 appears in the middle of the job
114
TSM Oc 9800
Diagnostics
~Processing Scan Job~ doesnt disappear This error occurs only when using Scan to File.
Internal cable not connected on X2 of the Taxi Scanner part of the PRISCAT pba
Possible cause
Remark
ed.5
116
TSM Oc 9800
Diagnostics
SDS
see SDS
31
see SDS
32 ~Last error logging~ ~OWAR/SWAR/ORE/MRE/PE/FE)~
34 ~Error top 10~ ~OWAR/SWAR/ORE/MRE/PE/FE)~
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr.
Component
Signal
Description
Parameter test Input tests Output tests Special tests
Info tests
Note: The INFO test gives only valid informa-
20-9-01
~SCSI present (0 = No, 1 = Yes)~
integrated in motherboard
20-9-02 20-9-03 ~radical board present (0 = No, 1 = Yes)~ ~taxi printer present (0 = No, 1 = Yes)~
integrated in Priscat PBA

20-9-04 ~taxi scanner present (0 = No, 1 = Yes)~

20-9-05 ~ethernet present (0 = No, 1 = Yes)~

How much CPU RAM is available Not relevant for EPC

1202
TSM Oc 9800
SDS
Test nr. 20-9-10
Component
Signal
Description ~Controller release~

20-9-11 ~Controller version~


20-9-14
~poker lib. version~
20-9-15 ~poker lib. patch~
System tests
ed.5
2 The functional tests of the controller.

The functional test software is the software running on the Embedded Power Controller, when the controller is powered-up with the CTRL+T pressed in a terminal software application. The functional test is to check and set the controller assembly and all the PBAs
s s s s
DRAM SIMMs modules Priscat and Radical PBAs used in this controller. Time / date setting (not relevant for the controller functions) software change
Tools for functional tests:

Serial cable Centronics cable Loop connector Link cable code number: 1302522 code number: 1302520 code number: 7991.293 code number: 7991.520
Setup for the functional test:

1 Switch off the machine. 2 Connect the laptop to the serial port COM1 of the controller with the serial ca-
ble (code number 1302522).

3 Activate a terminal emulation program on the PC (e.g WINDOWS Terminal). 4 Select Settings and Communications. 5 Change the settings to: Com1, Baud rate 9600, data bits 8, stop bit 1, no Parity,
Flow control to none. Select Settings, Terminal Preferences, Translations. Change the language setting to: None Switch ON the machine. Now you will get some initialisation messages on the screen of your PC (see next page) 10 Press during the message:~ Now Press CTRL+T to launch functional test~ the ~CTRL+T~ on the laptop. (See arrow on next page). Attention: you have only 5 seconds to activate the functional tests!!
6 7 8 9
Note: The screen information of the functional test can be saved in a file for
e.g. for analysing. (Terminal: transfers, receiving text files, file name) Read the file with a text application.
1204
TSM Oc 9800
SDS
Terminal window
Text on screen during booting-up (this is an example of a configuration).

Embedded Power Controller starting up... VxWorks version : 5.3.1 PROM version : 1.0 DRAM Test.... Bank 0: 128 Mbyte 0x00000000 - 0x07FFFFFF...OK Bank 1: ...empty Bank 2: ...empty Bank 3: ...empty Bank 4: ...empty Bank 5: ...empty Bank 6: ...empty Bank 7: ...empty Entering sysIbcGetPciToIrqRouting Exiting sysIbcGetPciToIrqRouting Entering sysIbcGetPciToIrqRouting Exiting sysIbcGetPciToIrqRouting VxWorks System Boot Copyright 1984-1996 Wind River Systems, Inc. CPU: Motorola ULTRA - PowerPC 604 Version: 5.3.1 BSP version: 1.1/4 Creation date: Aug 14 1997, 20:03:09 Press any key to stop auto-boot... 0 auto-booting... boot device : ide=0,4,5 processor number : 0 host name : eridan file name : /ide0/EPC1.2 inet on ethernet (e) : 134.188.138.40 host inet (h) : 134.188.136.50 gateway inet (g) : 134.188.138.4 user (u) : reader ftp password (pw) : fbbstarget flags (f) : 0x5aa50000 target name (tn) : friscognac other (o) : dc Attaching to IDE disk device... done. Loading /ide0/EPC1.2...1710852 + 141768 + 1508 + 170532 + 1108 + 832 + 384304 Starting at 0x180000... Attaching to IDE disk device... IDE disk is initialized as /ide0/ Press CTRL+T to launch SPS functional test... 3 OCE100 driver installed RADICAL driver installed PRISCAT driver installed Functional tests: Functest>
ed.5
Note: The bank information corresponds not with the slots on the mother-
board. . <CTRL+O> = to boot on the older software version, if exist. <CTRL+P> = only for production use. <CTRL+A> = when for any reason a test stays in a loop. <CTRL + E> = formats the harddisk. After reboot message to download new software.
tests. Not all of them are useful in the field, as some are used for repair and manufacturing purposes. Help list with a general description:
Functional test Description
~HELP~ CONF ~TIME~ UPGD UPBK DLDP ECCX TPBT TSBT LTBT LSBT RDBT ~QUIT~
List of all the available commands Current controller configuration Setup time and date Upgrade software on the harddisk Back to the previous software version, if existing Download demo plot to the harddisk Testing of the centronics output Test of TAXI Print logic (Priscat) Test of TAXI Scan logic (Priscat) Link test of TAXI transfer, print and scan lines. Test of serial command link PRISCAT Test of Radical board Reboot the controller (turn off/on the machine)
1206
TSM Oc 9800
SDS

HELP
Displays the list of all available commands
~Functest> HELP~ __________________~ LIST OF COMMANDS~ ____________________ ~HELP~ ~Show help information~
~CONF~
Show help information
~Display the current controller Display the current controller conconfiguration~ figuration
~TIME~
~Setup time and date.

Used as a date/time reference in Scan-to-file~
Setup time and date.

Used as a date/time reference in Scan-to-file
UPGD UPBK DLDP

ECCX
~Upgrade application~
Upgrade application
~Back to previous version (if Back to previous version (if existexisting)~ ing) ~Download demo plot file~ ~Echo characters sent to Centronics output~ ~Test of TAXI Print Logic~ ~Test of TAXI Scan Logic~ ~Test of TAXI transfer~ ~Test of TAXI Serial port~ ~Test of RADICAL Interface~ ~Quit (Turn off/on machine)~ Download demo plot file Echo characters sent to Centronics output Test of TAXI Print Logic Test of TAXI Scan Logic Test of TAXI transfer Test of TAXI Serial port Test of RADICAL Interface Quit (Turn off/on machine)
TPBT TSBT LTBT LSBT RDBT ~QUIT~
~Cmd Ok.~ ~Functest>~
ed.5
CONF
~Display the current controller configuration~ Next information is from the ITC training machine: Functest> CONF Commercial release number: 1.2 Internal release number: 1.1.13 Scanning PCI slots... Slot 1: RADICAL board detected. Slot 2: PRISCAT board detected. Slot 3: Empty. Searching centro... board detected. Memory configuration... Slot 1: 064 Mb Slot 2: 064 Mb Slot 3: 000 Mb Slot 4: 000 Mb -------Total RAM size: 128 Mb Disk model... IBM-DJAA-31700 Cmd Ok.
1208
TSM Oc 9800
SDS
~TIME~
Date and time is given. If you have change it or not: confirm with <ENTER> Settings have no function in the system ~Functest> TIME~ ~THU DEC 19 15:51:07 1996~ ~day .......... [thursday] :~ ~month ..... [december] :~ ~date ..........[19] :~ ~hour ........ [15] :~ ~minutes .. [51] :~ ~seconds ...[7] :~ ~year ........ [1996] :~ ~Cmd Ok.~ ~Functest>~
UPGD
~UPGraDe software~ With this command, a newer software version is downloaded on the harddisk inside the controller. The existing version on the harddisk is renamed as being the older software. An already existing older version is so overwritten. A centronics cable (code no. 1302520) between the laptop and the centronics I/O of the controller is also needed to download the controller software. The upgrade software is about 2 MB. To use this software: reboot the system. For the exact action of installing:see Dis-/assemblies EPC software on page 1402
UPBK
~UPgradeBacKup software~ With this command, the existing older boot software version (if exists on the harddisk) is renamed to be the newest boot software version. This means that the previous software does not exist anymore on the harddisk! To use this software: reboot the system. For the exact action of installing:see Dis-/assemblies EPC Upgrade Backup Software on page 1403.
ed.5
DLDP
~DownLoad DemoPlot~ With this command, a demo plot (test print on the operator panel) is downloaded from the laptop to the harddisk. The download needs the centronics cable (code no. 1302520) between the laptop and the controller. For the exact action of installing:see Dis-/assemblies EPC Demo plot (Test print) on page 1404
ECCX
~ECho Characters centroniX~ With this command, the centronics connection is tested. Connect a centronics cable between the centronics port of the motherboard and the centronics port of the Centronics I/O board. Activate the test. 0and 1data is sent over the serial cable to the screen of the laptop. If the test failed: (check) - centronics connection, cable - Centronics I/O board - riser board - motherboard
TPBT
~Taxi Printer Board Test~ Test not available.
TSBT
~Taxi Scanner Board Test~ With this command, the TAXI scanner part of the PRISCAT I/O board is tested. Specific data is written and read. The sent and failed received patterns are displayed. If the test failed: (check) - PRISCAT pba - riser board - motherboard
1210
TSM Oc 9800
SDS
LTBT
~Link Transfer Board Test~ With this command, the data transfer between TAXI PRINT and TAXI SCAN on the PRISCAT pba is tested. Loosen the connectors ~Upload~ and ~Download~ at the outside of the controller, see Component location on page 1601 Connect the test cable (code no. 7991.520) between the ~Upload~ and ~Download~connectors at the outside of the controller. Activate the test. The sent and failed received patterns are displayed. If the test failed: (check) - the test cable - riser board - PRISCAT - motherboard
ed.5
LSBT
~Link of Serial command Board Test~ With this command, the serial command line of the controller is tested. Disconnect the ~Serial command~ connector on the outside of the controller, see Component location on page 1601). Place the special loop connector (code no. 7991.293). Reboot the system. Activate the test. A set of characters is sent and displayed: ~The quick brown fox jumped over the lazy dog~. If the test failed: - check the internal cables between serial command connector and the connector X3 on the PRISCAT pba - riser board - PRISCAT - motherboard
RDBT
~RaDical Board Test~ With this command, the RADICAL board is tested. Activate the test. Specific data is written and read. Corrupted data is always displayed. If the test failed: (check) - riser board - RADICAL pba - motherboard
~QUIt~
With this command, the functional tests are switched off. To start the controller operating system: reboot the system.
1212
TSM Oc 9800
SDS
Dis-/assemblies
Note:
s
Before dis/-connecting the controller cable(s) make sure that the host is powered down and the Oc 9700/9800 is switched off. Connections in the controller are very critical. Bad connections may lead to various controller failures. Please use a wrist strap , antistatic mat and take care when reinstalling controller items. It is strongly advised to place the controller on a flat table for maximum visibility in order to reinstall properly and prevent bad connections. Check after dis-/assemblies the EPC controller with your laptop. If correct, connect host environment and check again.
1 Embedded Power Controller

1 Execute the ~print settings~ to print all user parameters. 2 Switch off the host and the Oc 9700/9800. 3 Disconnect at the front side of the engine the connectors from the controller 4 5 6 7 8 9 10 11 12 13
and the scanner. Remove the front cover from the engine. Remove the right top cover from the engine. Remove the right side covers from the engine. Remove at the right side the front upper and lower cover from the engine. Disconnect the data connectors from the controller see Component location on page 1601. Disconnect the power supply connector (2001D2) from the controller. Remove at the front side of the engine the 2 lower mounting screws from the controller. Loosen at the front side of the engine the 2 upper mounting screws from the controller. Remove the controller and place the controller on a flat table. Remove (if needed) the cover from the controller (24 screws).
ed.5
2 EPC software
Needed:
s s s
Serial cable, code no. 1302.522 Centronics cable, code no. 1302.520 Controller software
1 Connect between the laptop and the controller: the serial cable on COM1 and
the centronics cable on the Centronics I/O pba.

2 Activate the functional tests, see The functional tests of the controller. on
page 1204
3 Activate the functional test: UPGD. 4 5 6 7
Message: ......~Transfer controller software through the centronics port:~ Open the Windows DOS screen. Position the DOS and the Terminal windows so that you can see both. Click in the Windows DOS screen to make it active. Copy the controller software from the correct drive and path: copy /b <file name> lpt1 Follow the instructions on the screen: (~install new software / save old~) Wait till the file is downloaded. Close the Windows DOS screen. Reboot the system. Check the software release in the functional test: ~CONF~. Check the functioning of the controller with the ~Plot Director~.
8 9 10 11 12 13
1402
TSM Oc 9800
Dis-/assemblies
3 EPC Upgrade Backup Software

Needed:
s
Serial cable, code no. 1302.522
Connect between the laptop and the controller: the serial cable on COM1. Activate the functional tests, see Functional test description on page 1207 Activate the functional test: UPBK. Follow the instructions on the screen: (~Retrieving previous application version will erase current version SURE?(Y/N):~ 5 Reboot the system. 6 Check the software release in the functional test: ~CONF~. 7 Check the functioning of the controller with the ~Plot Director~.
1 2 3 4
ed.5
4 EPC Demo plot (Test print)

Needed:
s s s
Serial cable, code no. 1302.522 Centronics cable, code no. 1302.520 Demo plot software

2 Activate the functional tests, see The functional tests of the controller. on
page 1204
3 Activate the functional test: DLDP. 4 5 6 7
Message: ......~Transfer Demo Plot software through the centronics port:~ Open the Windows DOS screen. Position the DOS and the Terminal windows so that you can see both. Click in the Windows DOS screen to make it active. Copy the controller software from the correct drive and path: copy /b <file name> lpt1
8 Follow the instructions on the screen: 9 10 11 12
(~Loading file...Press ESC to abort the transfer. Wait till the file is downloaded. Close the Windows DOS screen. Reboot the system. Check the demo plot by activating it from the operator panel.
1404
TSM Oc 9800
Dis-/assemblies
5 Radical PBA
1 Remove the controller, see page 1401. 2 Remove the screw (5.5 mm) opposite of the connector of the Radical PBA. 3 Replace or mount the (new) PBA.
If mounting a new pba: check the jumper (SW) settings, see chapter Electrical Description Radical PBA on page 1606
Note: The Radical PBA must be mounted in the PCI slot 1. 4 Remount the controller. 5 Connect all connectors to the controller. 6 Execute the functional test ~CONF~ and check if the (new) PBA is listed in the
configuration.
Note: With the functional controller test RDBT it is possible to check the functioning of the PBA. 7 Make a scan to file, Tiff with compression to test the new PBA, (the PBA is
only used for scan to file).
ed.5
6 Priscat PBA
1 Remove the controller, see page 1401. 2 Remove the Radical PBA, see page 1405 (for easier accessibility of the Priscat
PBA).
3 Disconnect the 3 connectors from the Priscat PBA. 4 Remove the screw (5.5 mm) opposite of the connector of the Priscat PBA. 5 Remove at the right outside of the controller the screw from the second mount-
ing bracket of the Priscat PBA.

6 Remove the PBA. 7 Mount the bracket to the new PBA. 8 Replace or mount the (new) PBA.
Note: The Priscat PBA must be mounted in the PCI slot 2. 9 10 11 12 13
Remount the Radical PBA. Connect the 3 connectors to the Priscat PBA. Remount the controller. Connect all connectors to the controller. Execute the functional test ~CONF~ and check if the (new) PBA is listed in the configuration.
Note: With the functional controller tests LSBT and TSBT it is possible to check the functioning of the PBA.
14 Test the new PBA.
- Print files to check the print part. - Scan to file to check the scan part.
1406
TSM Oc 9800
Dis-/assemblies
7 Centronics I/O PBA

1 Remove the controller, see page 1401.
For next points see Controller PBA overview on page 1604.

2 Remove the Radical PBA, see page 1405 and the Priscat PBA, see page 1406
(for easier accessibility of the Centronics PBA).

3 Remove the screw (5.5 mm) opposite of the connector of the Centronics PBA. 4 Remove the PBA. 5 Replace or mount the (new) PBA.
6 7 8 9
10
If mounting a new pba: check the jumper and dipswitch (J / SW) settings, see chapter Electrical Description Centronics PBA on page 1608 Remount all components in the controller. Remount the controller. Connect all connectors to the controller. Execute the functional test ~CONF~ and check if the (new) PBA is listed in the configuration. (EPC name: OCE 100 ISA board) Test the new PBA with your ~Plot Director~, or with the function test: ECCX.
8 Hard disk
1 2 3 4 5 6 7
Remove the controller, see page 1401. Disconnect the supply connector (P5) from the hard disk. Disconnect the IDE connector from the hard disk. Remove at the left outside the Allen screw from the holder of the hard disk. Remove at the front side 2 screws from the holder with the hard disk. Remove the holder with the hard disk. Replace the hard disk (6 screws).
Note: The hard disk must be configured as ~Master~, jumper on position 1.
8 9 10 11
Remount the holder with the hard disk. Connect all the connectors. Remount the controller. Download the software and the Demo Plot, see Functional Description tests UPGD and DLDP.
ed.5
9 Power supply unit

1 2 3 4 5 6 7 8 9 10 11 12
Remove the controller, see page 1401. Remove the hard disk unit, see page 1407. Disconnect the connectors of the supply unit from the motherboard (P1-P2). Disconnect at the outside the connector from the 220 V power supply unit. Remove at the right outside 4 screws from the power supply unit. Remove at the top outside 2 screws from the support bracket of the power supply unit. Remove the 2 screws from the bracket of the ON/OFF switch from the controller. Mount the support bracket to the new power supply unit. Replace or mount the (new) power supply unit. Connect all the connectors. Remount the controller. Test the controller function (e.g. with the ~Plot Director~).
1408
TSM Oc 9800
Dis-/assemblies
10 Motherboard
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23
Remove the controller, see page 1401. Remove the Radical PBA, see page 1405. Remove the Priscat PBA, see page 1406. Remove the Centronics PBA, see page 1407. Remove the hard disk see Hard disk on page 1407. Remove the power supply unit see Power supply unit on page 1408 except the ON/OFF switch. Remove at the right outside the screw from the bracket which holds the Riser PBA in position. Loosen at the left inside the screw from the bracket which holds the Riser PBA in position. Remove the bracket. Remove the Riser PBA. Disconnect the connector (J5) of the fan from the motherboard (Position of the connectors on the PBA see page 1605. Disconnect the IDE connector (J4) from the motherboard. Disconnect the SCSI2 connector (J6) from the motherboard. Remove the BOOT flash, the SIMM(s) and the cache board from the motherboard and mount these on the new motherboard. Remove at the outside the 2 nuts from the connectors COM1 and Ethernet AUI. Remove the motherboard (8 Allen screws). Remount all disassembled parts and PBAs according: see Controller PBA overview on page 1604. Remount the controller. Connect all connectors to the controller. Reboot the system and ~print settings~. Use the laptop to sent a plot (~Plot Director~). Switch of the machine and connect the host environment. Test the function of the controller.
ed.5
11 Memory module (SIMM)

1 Remove the controller, see page 1401. 2 Remove the hard disk see Hard disk on page 1407. 3 Remove the power supply, see page 1408 (for easier accessibility of the mem-
ory modules) except the ON/OFF switch.

4 Remove / mount the (new) SIMM(s).
Warning: Slot 1 and 2, and (if needed) also 3 and 4 must be filled with the same
size of Mb. Do not mixed up e.g. 16Mb with 32Mb!!

Note: Take care during dis-/assembling of the SIMM(s) or expanders for not
damaging and polluting the sockets on the motherboard. After assembly every SIMM or expander must be checked visual for correct positioning.
5 Remount the controller. 6 Connect all connectors to the controller. 7 Switch on the engine and check/adjust in SDS 90 (configuration) the new con-
troller configuration (if you want to change the configuration do not forget to switch the engine OFF and ON). 8 Execute the ~print settings~ and check if the new memory configuration is listed in the settings.
Configuration
Slot 1 and 2
Slot 3 and 4
64 Mbyte 96 MByte 128 Mbyte 160 MByte 192 MByte 256 Mbyte
2 x 16 MB 2 x 32 MB 2 x 16 MB 2 x 32 MB 2 x 64MB 2 x 16 MB 2 x 32 MB 2 x 64 MB
2 x 16 MB 2 x 32 MB 2 x 32 MB 2 x 64 MB 2 x 64 MB 2 x 64 MB
1410
TSM Oc 9800
Dis-/assemblies

Termination

Software versions
For the best performance, use always the newest drivers. This may be not the software delivered with the SCSI package. Check for new drivers on the Adaptec website: www.adaptec.com.
ed.5
Note:
2 After installing the PBA, boot the PC and press <Ctrl> <A> as soon as a mes-
1412
TSM Oc 9800
Dis-/assemblies
This SCSI PBA has a plug and play PBA, which means an easy installation on systems that support plug and play (via BIOS or Windows 95/NT). If you have to install the PBA on a system that does not support this mode (e.g. Windows 3.1 / 3.11), some additional actions are necessary.

down position.
4 5 6
7 8
ed.5
1414
TSM Oc 9800
Dis-/assemblies
ed.5
1 AHA 2940:
2 3 4
5 6
drivers at www.adaptec.com
1416
TSM Oc 9800
Dis-/assemblies
ed.5
1418
TSM Oc 9800
Dis-/assemblies
1 General
The controller functions of the Embedded Power Controller (EPC) are:
s
s s
Processes: conversion and transformation of plot data to Oc 9700/9800 specific raster formats and performs scaling, rotation etc. Connectivity: connects the Oc 9700/9800 to the customer environment Remote Control Format (RCF): accepts and interprets RCF-data to control printing, scanning and finishing aspects.
2 Features
s s s s
Standard computer mother board. Standard for more PPC copiers (e.g. Oc 9800/ 9700) To improve a high plotting speed of the system, 8 A0 copies a minute. Backchannel communication with the host computer: Configuration, status information, accounting. Ethernet connection: Ethernet connection: TCP/IP build-in interface is provided (only with LPD protocol), other protocols: use a Microplex box. Physical interface provided: AUI / 10BaseT. Overlays & templates: The possibility to merge 2 digital files together and print the result. Hooks for language filters via PAS: The controller cant process all kind of formats. The PAS application hooks 3rd parties filters to add language filters, e.g. Postscript level 2 and PS fonts, DWG (Autodesk) PAS: Printroom applications for printing and scan-to-file. Regular updates to recognise new functions and new hardware.
ed.5
3 System overview
1502
TSM Oc 9800
Graphic languages
The following graphic languages are supported by the ~Embedded Power Controller~ (can be set to automatic language sensing ALS, except ASCII): :
Vector

Raster
supported plotter emulation: reference is HP7586B plotter supported plotter emulation: HP650C and HP750C
TIFF
CALS
HP-RTL
ASCII
Other languages must be hooked to the PAS application, options are e.g.: PostScript level 2, DWG. See Repro Station for which language a converter is installed.
ed.5
Embedded Power Controller abbreviations:
Name
Explanation
Power Controller: PCI ISA SCSI
Motorola CPU-board with MPC 604 processor. Peripheral Component Interface bus. 32 bit wide data path bus. Industry Standard Architecture 16 bit wide data path bus. Small Computer Standard Interface Intelligent I/O, each connected device has a unique ID. DRAM which contains the bitmap of the image to be printed. Fast temporary RAM memory for last items read from the main memory. Real Time Operating System VxWorks for this controller. Attachment Unit Interface connector type between I/O card in a PC and the Ethernet network. Connector type between I/O in a PC and the Ethernet network, implemented on twisted pair cabling. Transmission Control Protocol / Internet Protocol Line Printer Daemon (Unix) printer software for Ethernet NonVolatile RAM (battery powered). Raster Acceleration board I/O board for compression of raster data, only for Scan to File. PRInter SCAnner Taxiboard I/O board for communication with the printer. * One side of the board is used for printing (to transfer data from the controller to the engine). * The other side is used for Scan to File (to transfer data from the scanner to the controller). * Serial link connection for command line.
Frame buffer
Cache
RTOS
AUI
10BASE-T
TCP/IP
LPD socket NVRAM

RADICAL
PRISCAT
1504
TSM Oc 9800
4 Embedded Power Controller characteristics

Mother board
Motorola ULTRA board with 133 MHz PowerPC 604 processor 1 boot EPROM memory 3 PCI slots 3 ISA slots SCSI
Ethernet DLL memory 11 / 27 MB (16 / 32 in SDS) FRAME buffer 41 - 228 MB Total memory 64 - 256 MB Harddisk IDE Centronics ISA PRISCAT PCI RADICAL PCI
on riser board on riser board Intergrated on motherboard, main purpose: printing and scan to file, also used for backchannel communication with Machine Monitor integrated on motherboard is part of the total memory is part of the total memory 4 SIMM slots.
dedicated I/O card

Printer TAXI I/O card Scanner TAXI I/O card. Serial link commandline Hardware compression I/O card, only for Scan to File.
Harddisk
s s s s s s
IDE disk controller 1.7 or 4.3 Gbyte DMA access controller software (easy upgrade) test print for swapping data, if needed (Ethernet)
Software features:
s s s s
- Plot processing for various languages through many interfaces. - ALS automatic language sensing - Plot transformation (scaling, rotation ...) - Remote control through host
ed.5
s s s s
- Configuration through engine Local User Interface - Error recovery feature - Scan to file function - Diagnostic tests for production and service
Connections external: see Embedded Power Controller (EPC) Extensions
on page 1602 - RS232 serial (COM1, only for service) - 2 centronics (1x integrated centronics only for service, 1x I/O pba) - SCSI - Ethernet (AUI or 10BAseT)
Configuration

Configuration DLL Memory 1 2 3 4 5 6 7 8 9 10 11 12 11MB 27MB 11MB 27MB 11MB 27MB 11MB 27MB 11MB 27MB 11 MB 27 MB
Frame buffer OS Total mem.
41MB not supported 70MB 56MB 102MB 88MB 134MB 120MB 166MB 152MB 228MB 213MB
12MB
64MB
15MB 13MB 15MB 13MB 15MB 13MB 15MB 13MB 17MB 16MB
96MB 96MB 128MB 128MB 160MB 160MB 192MB 192MB 256MB 256MB
DLL : Display List (size adjusted in SDS test 90) Frame buffer : bitmap buffer OS: Operating System Total memory = DLL + frame buffer + OS
1506
TSM Oc 9800
5 Process
Block diagram EPC
cache
4 SIMM slots Host bus
not used
HOST/PCI bridge PCI bus
Ethernet
SCSI2
graphics
HOST / LEGAGY bridge PCI / ISA
floppy General I /O keyboard centronics com 1 com 2 mouse
slot 1 Radical
slot 2 Priscat
slot 3
PCI slots ISA slots slot 1 Centronics slot 2 slot 3
local bus buffer
NVRAM
sound ISA bus
ide
The system is divided in three bus parts: the host bus part, the PCI bus part and the ISA bus part. The bus connections are made by bridge-chips.
s
The host bus: - very high speed local CPU bus, 128 bits wide, dedicated to the architecture of the CPU. The PCI bus: - high speed I/O bus, 32 bits wide. The ISA bus: - slow speed I/O bus, 16 bits wide.
ed.5
6 Printing
1 Printing vector data 2 Printing raster data
Block diagram for printing vector data
If data is received and the Automatic Language Sensing (ALS) is enabled (e.g. data format AUTOMATIC is specified with Repro Station), the ALS tries to determine which data format it is. If the format is recognized the interpreter for the data format is started. The interpreter creates an intermediate format which is stored in the DLL memory (Display List memory). The intermediate format is sorted to get a sorted vector list. The sorted vector list format is converted into the Oc 9800 specific raster (bitmap) format which is stored in the Frame Buffer. Finally this bitmap is sent via the PRINTER TAXI part of the PRISCAT interface to the SET memory PBA of the engine. The data is compressed stored in the SET memory.
1508
TSM Oc 9800
If the Automatic Language Sensing (ALS) function is disabled, then the data format has to be specified (e.g. HP-GL in Repro Station). The interpreter starts directly. The intermediate format of the data has to fit completely in the DLL memory. If the file doesnt fit the warning 20813 is generated. (For further information see Fault description). The size of the Frame buffer is between 41 and 228 Mb. If the file does not fit in the Frame buffer Banding is used: That part of the file that fits into the Frame buffer is sent to the SET memory. The display shows the message DOWNLOADING PRINTFILES. The Frame buffer is cleared and the next part of the file is stored in the Frame buffer and sent over. The process continues till the complete file is sent. This happens e.g. with long plots.
The process for raster formats is nearly the same as for vector data. The raster DATA is interpreted and temporarily stored in the DLL memory. Next the file is rendered (conversion into the specific Oc 9700 bitmap format)
ed.5
and stored into the Frame buffer. The raster data does not have to fit in the DLL memory, except if the header is on the end of the file. For detailed information about the instructions for the controller to use features of the Oc 9800 engine (like folding, stamping, punching, roll selection, reduction and shifting) and the controller functions (like rotation, enlargement, handling data formats) see the User Manual, the RCF manual and the Job Ticket manual.
Note: Not all processing is done in the controller. Some actions like reduction,
most of the shift function, some edge corrections are done in the engine (image processing).
1510
TSM Oc 9800
7 Print size of originals for rotated image

For printing the size of the Frame Buffer has impact to the size of the file that can be rotated. Vector: are always rotated in the DLL buffer. Raster: are rotated in the Frame buffer. The rotation algorithm requires a second buffer to store the rotated bitmap. Thus, a bitmap can be rotated if it fits into half of the frame buffer.
For configurations, see Embedded Power Controller characteristics on page 1505

Maximum print size with rotation for raster files
ConfiDLL guration 1
FB
Maximum file size 20.5 MB
Maximum W x L or equivalent 914 x 750 (36 x 29.5)
11MB 41MB
2 3 4 5 6 7 8 9 10 11 12
27MB not available. 11MB 70MB 27MB 56MB 11MB 102MB 27MB 88MB 11MB 134MB 27MB 120MB 11MB 166MB 27MB 152MB 11MB 228MB 27MB 213MB 35 MB 28 MB 51 MB 44 MB 67 MB 60 MB 83 MB 76 MB 114MB 106,5MB 914 x 1250 (36 x 49) 914 x 1000 (36 x 39.4) 914 x 1850 (36 x 72.8) 914 x 1600 (36 x 63) 914 x 2450 (36 x 96.5) 914 x 2200 (36 x 86.6) 914 x3050 (36 x 120) 914 x 2800 (36 x 110) 914 x 4200 (36 x 165) 914 x 3900 (36x153.5)
ed.5
8 Print size of originals for long plots

The long plot functionality depends of the ~Set Memory~ size in the engine. A file can only be printed, if it fits entirely into the ~Set Memory~. Otherwise a message is displayed on the scanner LUI and the file is not printed. If the file fits entirely into the ~Frame buffer~ of the controller, it can be reprinted if an error occurs. If the file does not fit entirely into the ~Frame buffer~ of the controller, it sends the file by chuncks to the engine. The file is printed, but if an error occurs now, it can not be reprinted! Maximum print length is 15 meters (590.5) For configurations, see Embedded Power Controller characteristics on page 1505
Configuration 1 2 3 4 5 6 7 8 9 10 11 12
DLL 11MB 27MB 11MB 27MB 11MB 27MB 11MB 27MB 11MB 27MB 11MB 27MB
FB 41MB 70MB 56MB 102MB 88MB 134MB 120MB 166MB 152MB 228MB 213MB
Maximum W x L or equivalent 914 x 1500 (36 x 59) 914 x 2550 (36 x 88.6) 914 x 2050 (36 x 80.7) 914 x 3750 (36 x 147.6) 914 x 3200 (36 x 126) 914 x 4900 (36 x 193) 914 x 4400 (36 x 173.2) 914 x 6100 (36 x 240.2) 914 x 5600 (36 x 220.5) 914 x 8400 (36 x 330.7) 914 x 7850 (36 x 309)
not available.
Attention: Maximum length is 15 meters (590.5) Maximum width is 914 mm (36)
1512
TSM Oc 9800
9 Scan to File
The controller also can transport data from the SET memory PBA to the host computer. After scanning an analogue original, the data can be stored on the host computer harddisk as a TIFF or CALS raster file with a resolution of 200 or 400 dpi.
The CCDs of the scanner scans an original with 400dpi. The data is transferred to the SET memory PBA. From here the data is transferred to: - the scanner part of the Priscat PBA in the controller, or to - the scanner part of the Priscat PBA in the controller and to the Black & White processing PBA in the engine, to make at the same moment a copy. The compression (if chosen by the operator) is done by the Radical pba. The language conversion (CALS, TIFF tiled, stripped) is done in the DLL buffer by the controller software.
ed.5

The digital image of an original is stored, on the fly, into the controllers Frame Buffer without any compression. Thus an original can be scanned if its digital image fits entirely into the Frame Buffer. For configuration, see Embedded Power Controller characteristics on page 1505
Original size
ConfiDLL guration 1 2 3 4 5 6 7 8 9 10 11 12
FB
Maximum W x L or equivalent (200 dpi)
Maximum W x L or equivalent (400 dpi)
11MB 41MB
914 x 5200 (36x204.7) 914 x 1300 (36 x 51.2)
27MB not available. 11MB 70MB 27MB 56MB 11MB 102MB 27MB 88MB 11MB 134MB 27MB 120MB 11MB 166MB 27MB 152MB 11MB 228MB 27MB 213MB 914 x 9000 (36 x 354) 914 x 2250 (36 x 88.6) 914 x 7200 (36 x283.5 ) 914 x 13200 (36x519.7) 914 x 1800 (36 x 70.9 ) 914 x 3300 (36 x 129.9)
914 x 11400 (36 x449) 914 x 2850 (36 x 112.2) 914x17200 (36x677.2) 914 x 4300 (36 x 169.3) 914x15400 (36x606.3) 914 x 3850 (36 x 151.6) 914x21400 (36x842.5) 914 x 5350 (36 x 210.6) 914x19600 (36x771.7) 914 x 4900 (36 x 192.9) 914x29200 (36 x1150) 914 x 7300 (36 x 287.4) 914x27600 (36 x1087) 914 x 6900 (36 x 271.7)
1514
TSM Oc 9800

This printroom application software consists of Job Director, Job Director Configurer, Repro Station and Machine Monitor. The applications run only under Windows 3.1/3.11, Windows 95 and Windows NT3.51/4.0. The system consists of:
Job D ire cto r Job D ire cto r C o nfig ure r R e p ro S ta tio n M a chin e M on ito r
S C S I M in i con n ector E m be dd e d P o w er C o n tro lle r
RS D o n gle
S C S I-2 cab le A d ap te c S C S I A d ap te c S C S I 5 0 p ins con n ector A m pli o r M in i
A S P I drive rs ( C D -R O M o r F lo pp y)
The PAS applications are distributed on CD-Rom. It is possible to create floppies from the CD-Rom, for customers who do not have a CD-Rom drive in the PC. For detailed information about the applications, see the User Manuals. The installation of these applications is also described in these manuals. The Repro Station software is protected by a Dongle on the centronics port. When the customer is using applications who are using also Dongles, they are build on eachother. The cable connection (SCSI) is between Machine Monitor and the controller. Machine Monitor can handle back-channel communication with the EPC controller.
ed.5
12 SCAN STATION
The scan printroom application software consists of Scan Station, Machine Monitor and the Oc View Station (the old Spicer Imagination viewer can be upgraded).In the package you find also the needed hardware: the RADICAL PBA and the Upload cable. The applications run only under Windows 3.1/3.11, Windows 95 and Windows NT3.51/4.0. The system consists of:
S ca n S tation M a chin e M on itor O c V iew S ta tio n R A D IC A L
S C S I M in i co n n ector V ie w S ta tio n D o n gle E m b e d de d P o w e r C o n troller U p loa d ca ble S C S I-2 ca b le A d ap te c 5 0 p ins co n n ector A M P L I o r M in i to E n g in e S et M e m ory P B A
Scan Station and View Station are distributed on CD-Rom. It is possible to create floppies from the CD-Rom, for customers who do not have a CD-Rom drive in the PC. For detailed information about both applications, see the User manuals. The installation of these is also described in these manuals. The Oc View Station software is protected by a dongle on the centronics port. If the customer is also using Repro Station, then there are built 2 dongles on each other. Even more is possible. The order of the dongles can be important. See the corresponding manuals. Examples: -Autocad dongle must be in LPT1 and in 1st position. -~Oc View Station~ dongle must be in 1st position, LPT not important. - Repro Station dongle can be placed anywhere.
1516
TSM Oc 9800
13 SCSI PBAs
The Oc 9700/9800 Repro Station and Scan Station application requires a SCSI PBA in the PC to run. The following SCSI solutions are possible:
s s s s s
SCSI cable
Adaptec 1542 CF PBA
This was the first delivery of SCSI PBAs. For communication between the PC and the Oc 9800 a Mini SCSI M / Amphenol M cable is needed. This SCSI PBA uses the ISA bus of the PC and is not recommended for a 32-bits Operating System.
Adaptec 1542 CP PBA
This is the update of the first SCSI PBAs. For communication between the PC and Oc 9800 a Mini SCSI M/ Mini SCSI M cable is needed. Other differences with the 1542 CF PBA are:
s s
ed.5
Adaptec 2940AU SCSI
1518
TSM Oc 9800
s s s s s s

s
s s
s s s
Pentium 100 MHz Intel processor, running Windows 95 or Windows NT 3.51/4.0 for the 32-bit applications or Windows 3.1/3.11 for the 16-bit applications For View Station on Windows NT3.51: Service Pack 5 is required. 32 Mb internal memory free on internal harddisk 3,5 Mb for Repro Station 6 Mb for Scan Station 10 Mb for View Station sufficient disk space to save the files a TCP/IP network, if remote connections are needed a free PCI slot for the Adaptec SCSI PBA (for Machine Monitor) a free centronics port. Oc View and Repro Station are supplied with a dongle. The View Station dongle must be in the 1st position, LPT is not important. The Repro dongle can be placed anywhere.
Note: 1
Note: 2
ed.5
1520
TSM Oc 9800
Embedded Power Controller
220 V supply
Serial commands
Confidential 1998 Oc Technologies B.V.
ON / OFF switch Download
Upload
ed.5
2 Embedded Power Controller (EPC) Extensions
top side
only service
Ethernet AUI
COM 1
SCSI 2
Centronics only service (ECCX)

Ethernet 10BaseT
Centronics PBA
left side
not used at all
Connectors: External
s s s s
serial centronics ethernet (AUI or 10BaseT) SCSI
1602
TSM Oc 9800
Internal
s s s s s s s s s s
Power -> power supply PBA ON / OFF switch -> power supply PBA Priscat taxi printer (X1) - > to set memory Priscat taxi scanner (X2) <- from set memory Priscat (X3) -> serial communication between controller and CPU I/O PBA SCSI -> motherboard hard disk -> motherboard power supply -> hard disk power supply -> motherboard motherboard -> fan
PCI slots on riser board, mandatory:

s s
slot 1 = Radical board slot 2 = Priscat board slot 3 = not used
ISA slots on riser board, mandatory:

s s s
slot 1 = Centronics PBA slot 2 = not used slot 3 = not used
ed.5
3 Controller PBA overview

Riser board 1 PCI slots 2 Radical PBA
3 3 ISA slots 2 1 X1
Priscat PBA X2 X3
Centronics PBA
CPU Motherboard
Connectors on Priscat X1 Taxi printer connector X2 Taxi scanner connector X3 Serial commands connector
1604
TSM Oc 9800
4 Motherboard
Centronics only service 10BaseT AUI
COM1 SCSI2
Riser board P2 Supply connectors
Cache board 512 kB

Confidential 1998 Oc Technologies B.V. J5 fan 1 pin 1 and 2 connected SCSI2 connector
P1
IDE connector CPU
J6 J4
U16 slot 4 U11 slot 3 U7 slot 2 U3
SIMMS
slot 1
Boot ROM
not for service
Configuration
Slot 1 and 2
Slot 3 and 4
64 Mbyte 96 MByte 128 Mbyte 128 Mbyte 160 MByte 192 MByte 256 Mbyte
2 x 16 MB 2 x 32 MB 2 x 16 MB 2 x 32 MB 2 x 64MB 2 x 16 MB 2 x 32 MB 2 x 64 MB
2 x 16 MB 2 x 32 MB 2 x 32 MB 2 x 64 MB 2 x 64 MB 2 x 64 MB
ed.5
5 Radical PBA
SW1 1 1 SW2
1 SW3
Jumper settings SW1

SW2 SW3 1-2 1-2 1-2
Code number: 7009010
Newer Radical board
Code number: 7033694 is fully compatible with the previous one. Differences are: - jumpers are replaced by fixed resistors - Switches SW1, SW2 and SW3 are cancelled - Board layout has been changed.
1606
TSM Oc 9800
6 Priscat PBA
Codenumber: 2998.662
Jumper settings: SW1 1-2 SW2 2-3
Jumper settings: SW1 1 - 2 for future development 2 - 3 for use with the EPC controller Connectors on both PBAs: X1 Taxi printer connection X2 Taxi scanner connection X3 Serial command connection X4 Production only
Both PBAs are interchangable.

ed.5 20 Interface EPC/DRI 1607
7 Centronics PBA
J1 OUT
10 J2
J3
J4
J6
J7 CN1
SW1 1
ON 8 OFF 1
SW2 6 J5
DQ1
DK1
IRQ7
1 SW1 ON
8 SW2 ON OFF
OFF
This board is seen as LPT3 device which means the I/O address is equal to 0x0278. Jumpers:
J1 J2 J3 J4 J5 J6 J7 both in IN position (the board is used in input mode) position 1(the board uses fastbyte protocol transfer 200 s set-up time) NO (DMA selection channel 1) NO (DMA selection channel 1) IRQ7 DQ1 (DMA selection channel 1) DK1 (DMA selection channel 1)
Dip switches:
SW1 SW2 see figure (hexa 02) see figure (hexa 78)
1608
TSM Oc 9800
1
22PBA1 CPU I/O
X17 1 2 3 4 7 8 +5V GND (RXD) (CTS) (TXD) (RTS)
4
20PBA1 EPC 1/2
D1 10 1 2 4 5 8
11PBA1 SET MEMORY 11PBA4 RFI

X15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GND IMPSYNCO IMPRECONO IMPDA0O IMPDA1O GND IMPDA2O IMPDA3O GND IMPDA4O IMPDA5O GND IMPDA6O IMPDA7O GND X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
11D1
EXT. MEMORY-1
11D2
EXT. MEMORY-2 X4 1 2 3 4 5 6 GND DLINK2 NDLINK2 GND +5V RESET CAPDL D3 1 2 3 4 5 6
RFI SIGNAL 15x
11D3
EXT. MEMORY-3
11D4
EXT. MEMORY-4
11D5
EXT. MEMORY-5 X14 1 2 3 4 5 6 GND DLINK_OUT NDLINK_OUT GND +5V RESET CAPUL D4 1 2 3 4 5 6
11D6
EXT. MEMORY-6
11D7
EXT. MEMORY-7
11D8
EXT. MEMORY-8
22PBA5 DRIVERS
X13 1 2 3 5
+5V GND +24V GND
X10 1 2 3 5 F4 4A X8 1 2 3 4 5 6 7 8 9 10
22G1 CONSUPLV
X1 21
CONCONEMSSUP
17
CONKEYSW
CONCONEMS
22K4-2A
22PBA4 SSR 22Z2

6 5 4 L2 22X010 N2 X9 1 2 3 X5 1 2 L2 N2 6 2 8 4
X4 3 2 X3 2 5
N2-MNO L2-MNO L2-MNO N2-MNO D2 1 3 2 22X012-3
H
EPC 1/2
ed.5
TSM Oc 9800
20 Interface 1701
1
22G1 CONSUPLV 11PBA5 RFI
X1 1 2 X2 1 2 G3 5 6
2
X5 4 3
3
11PBA1 SET MEMORY
+5V GND
RFI POWER 2x connector for printer only 22X1 k m e X3 2 3 4
11D1
EXT. MEMORY-1
10PBA4 IPU-IO
X6 10 9 11 DLINK1 NDLINK1 GND
11D2
EXT. MEMORY-2
TO BW PROCESSING + PHD DATA RECEIVER
22PBA1 CPU I/O

X15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GND IMPSYNCO IMPRECONO IMPDA0O IMPDA1O GND IMPDA2O IMPDA3O GND IMPDA4O IMPDA5O GND IMPDA6O IMPDA7O GND
11PBA4 RFI
X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
RFI SIGNAL 15x
EXTERNAL PC 21PBA1 DRI

X4 1 2 3 X14 2 3 X3 20 1 2 3 4 X2 7 5 4 3 2
20D2
D1 7 5 4 3 2
GND DLINK2 NDLINK2 DLINK_OUT NDLINK_OUT
DIRECT RASTER INTERFACE
GND CTS RTS RXD TXD
20PBA1
X4 14 1 2 3 4 D2 14 1 2 3 4
X17 1 2 3 4 7 8
+5V GND RXD CTS TXD RTS
X1 6 5 3 4 1 2
GND SERIN_P SERIN_N SEROUT_P SEROUT_N
H
Direct Raster Interface (DRI) ed.5 TSM Oc 9800 20 Interface 1702
(PCI-TAXI BOARD)
Oc
Oc 9800
20 INTERFACE EPC 2
Contents
Diagnostics
1 Faults 2101 2 Oc Repro / Scan Station errors (messages)
2113
SDS
1 The Oc 9800 Controller SDS 2201 2 The functional tests of the EPC2 controller. 3 Functional test description 2210
2204
Dis-/assemblies
1 Embedded Power Controller 2401 2 EPC 2 software 2402 3 EPC 2 Upgrade Backup Software 2403 4 EPC2 Demo plot (Test print) 2404 5 ~Radical PBA~ 2405 6 ~Priscat PBA~ 2406 7 Hard disk 2406 8 EPC2 Hard disk jumper settings 2408 9 Power supply unit 2408 10 Motherboard 2409 11 Memory module (DIMM) 2411 12 General information SCSI PBAs 2412
ed.5
20 Interface EPC 2
1 General 2501 2 Features 2501 3 System overview 2502 4 EPC2 controller characteristics 2505 5 Process 2507 6 Printing 2509 7 Print size of originals for rotated image 2512 8 Print size of originals for long plots 2513 9 Scan to File 2514 10 Scan size of originals 2515 11 PAS (Printroom Application Software) 2516 12 SCAN STATION 2517 13 SCSI PBAs 2518 14 PC characteristics 2520
1 Component location 2601 2 Embedded Power Controller 2 (EPC 2) Extensions 3 Controller PBA overview 2603 4 Motherboard 2605 5 Radical PBA 2606 6 Priscat PBA 2607
2602
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. Interface 20000 - 20999 code display
POWER UP TEST ERRORS: 20801 - 20810 20801 MRE: Not used in EPC2 controller
20802 MRE: ~Harddisk error~ Problem: if the controller was booted: no test plot, Ethernet may not work (swapping)
Harddisk crashed
Reboot and examine the boot messages, displayed in the Terminal window, SDS: see

Reboot will generate error 20811
20803 MRE: ~Radical pba error~

Radical PBA loose. (not properly mounted in the controller), or defect.
ed.5
20 Interface EPC 2 2101
20804 MRE: ~SCSI pba error~ (Controller)

.
Possible cause
Remark
Faulty SCSI in the controller. SCSI bus not properly terminated.
Change motherboard. In Controller: In LUI of the scanner: set terminator to ON. In Host: Verify the end of the SCSI bus, it should terminate the bus properly. * If the Adaptec 1542 CP/2940/2940AU is used: termination has to be enabled with the SCSISelect utility. * If the Adaptec 2940 is used: jumper J3 not (properly) set.
After booting, the SCSI ID is changed.
Reboot both: the host PC and the controller (engine).
20805 MRE: ~Ethernet error~

Parameters not okay .
Ask customer for the right parameters and fill in as System Administrator.
20806 MRE: ~Taxi interface Scanner pba (PRISCAT)~

PRISCAT pba not properly mounted or faulty.
* Check position. * Execute the controller functional tests TSBT, LSBT, LTBT to verify whether the board is okay.
20807 MRE: Not used in EPC2 controller. 20808 MRE: Not used in EPC2 controller.
2102
TSM Oc 9800
Diagnostics
20809 MRE: ~DRAM Dimm pbas error~
Possible cause
Remark
The installed memory DIMM modules dont match with the configuration settings in SDS test 90. One of the DIMMs defect or makes bad contact.
* Total memory > SDS setting * Maximum memory < 64MB
* Reboot and examen the bank messages, displayed in the Terminal window, SDS: see

* If it is properly installed, clean its connector or replace it.
20810 MRE: ~TAXI interface printer pba~ (PRISCAT)~
Possible cause
Remark
PRISCAT pba not properly mounted or faulty.
* Check position. * Execute the controller functional tests LSBT, LTBT to verify whether the board is okay.
ed.5
ENGINE - CONTROLLER COMMUNICATION ERROR: 20811-20812 20811 MRE: ~Communication error contr(oller) -> engine~ This is the only error generated by the engine: if the engine has lost the communication with the controller or if the engine cannot get in contact with the controller (during power on for example), then this error is generated.
General: Reboot and examine the messages, displayed in the Terminal window, SDS: see Terminal window on page 2205. Controller out of use * Check power switch. * Listen if the fan is turning. * No messages in the terminal window. * Listen if the fan is turning. * No messages in the terminal window. * Listen if the fan is turning. * No messages in the terminal window. Reload software on harddisk. * Only the first messages are correct. No new messages when trying to load the software. * Check with test LTBT * Check cables
Connection: mains to controller supply. Controller power supply defect.
Software corrupt.
Connection: communication cable between controller and CPU_IO PBA. Connection: cable between controller and set-memory at set-memory side not properly mounted (or too tight). Connection: one of the DIMMss makes bad contact. Motherboard defect. Wrong position PCI I/O cards.
Check memory information (bank 0-3) displayed in the terminal window. No message in the terminal window Position in chapter Electrical description: see Controller
PBA overview on page 2603

RADICAL pba defect Test RDBT
2104
TSM Oc 9800
Diagnostics
Possible cause
Remark
PRISCAT pba defect Harddisk defect
Test TSBT, LSBT, LTBT Check harddisk results in the terminal window: * Attaching to IDE disk device doesnt work * Could not initialize IDE driver * Error loading file: error no. = 0x3d0002 * Cant load bootfile Harddisk was not stopped properly. Wait 5 seconds before switching the system ON again.
System switched OFF and ON too quickly.
20812 MRE: ~Communication error engine -> contr(oller)~
Possible cause
Remark
Internal and external communication cables between PRISCAT and CPU_IO PBA. No display message if the controller is removed from the configuration and the system is rebooted. No display message if the controller is removed from the configuration and the system is rebooted. Test LSBT. Remove the controller from the configuration and reboot the system. Read out the display message / error help.
CPU_IO PBA defect.
PRISCAT PBA defect Non controller error.
ed.5
MISCELLANEOUS ERRORS: 20813 - 20815 20813 OWAR: ~Not enough memory to complete op(eration)~
Possible cause
The vector drawings contains too many polygons; part of the drawing is printed The display list of the vector drawing doesnt fit in the DLL memory; part of the drawing is printed There is too less memory available for the sorted vector list (only for vector drawings); the drawing is not printed If banding has to be done (the rasterized plot doesnt fit in the controller memory), then some vectors may cross bands. If there are too many of these vectors, then this error is generated and the drawing is only partially printed The raster drawing is too large; e.g. a tiff file with the header at the end should be read completely before rasterisation can take place. Then it should fit into the DLL memory. The drawing is not printed. With a free text/ image stamp the plot must fit in the DLL. If not than e.g. rendering is not done and error 20813 occurs.
Remark
2106
TSM Oc 9800
Diagnostics
Possible cause
Remark

Possible cause
The plot doesnt fit into the set memory. Hence, the plot cannot be processed. .
Remark
ed.5
RS323 ERRORS: 20820 - 20822 20820 OWAR: Not used in EPC2 Controller. 20821 OWAR: Not used in EPC2 Controller 20822 OWAR: Not used in EPC2 Controller. SCSI ERRORS: 20830 - 20832 20830 OWAR: Not used in EPC2 Controller. 20831 OWAR: Not used in EPC2 Controller. 20832 OWAR: Not used in EPC2 Controller.
2108
TSM Oc 9800
Diagnostics
GRAPHIC LANGUAGE ERRORS: 20860 - 20864 20860 OWAR: ~Interpr. (eter) error: command not supp(orted)~


ed.5


2110
TSM Oc 9800
Diagnostics
HOST PROTOCOL ERRORS: 20870 - 20872 20870 OWAR: ~Host prot(ocol), job description error~
Syntax error. Verify that the contents of the RCF header is according the RCF reference Manual
Possible cause
Remark

ed.5
20901 SWAR: ~Illegal ram configuration contr(oller)~
Possible cause
Remark
Check the configuration in SDS test 90, if the memory matches the installed DIMMs in the controller. Memory slot or DIMM is defect or bad contact. Reboot and examine the bank messages, displayed in the Terminal window, SDS: see Clean its connector or replace it and run the test again.
2112
TSM Oc 9800
Diagnostics

Most of the Oc Repro, Scan Station and Machine Monitor errors (messages) are self explaining. The following errors need an explanation:
s s s s s s
Oc scanner / printer not responding Job Ticket is still arriving, not complete yet. Plot image is divided on 2 copies Processing Scan Job message doesnt disappear Unnamed file was not found Error incorrect RCF only with EPC; special character in printer stamps, backchannel stopped.
Oc scanner / printer not responding - This implies that Machine Monitor has lost the connection with the Oc 9800. - Only one application can be active: Repro Station or Scan Station! If trying both at the same time, then the message trying to connectis displayed. - Centronics connection is heavily in use Check as follows:
Check if the status of the Oc 9800 is ~ Ready to copy~ Check the SCSI connection Activate Scan for SCSI devices in Repro Station Configure - SCSI menu.
Run the SCSI interrogator (This Adaptec The tape device TDC 3600 tool is installed during the installation of the should be recognised at the SCSI ADAPTEC SCSI PBA). ID of the Oc 9800. Power down the PC by switching it off. (Do not carry out a soft reset Ctrl-Alt-Del) Switch it on again. During the boot procedure it should recognise the Oc 9800 as a Tandberg tape device of the type TDC 3600. If all the checks for SCSI still do not result in printing with SCSI, try to print with Centronics. Other application is active. Close this application.
ed.5
Possible cause
Remark
Centronics in use. Disabled in operator panel Scan -to-file disabled in the configuration
Stop printing via centronics or wait till printing is ready. Enable. Enable in SDS 90
Calcomp file with wrong checksum setting HPGL file: too short plot time out setting Slow PC Once a problem reported with a PC active in slow mode (about 10 MHz). The output was totally corrupted. Try the same job using only the PC and no network HP-GL and HP-GL/2
Conflict with network card in PC Pen 0 set to end of file although SP0 appears in the middle of the job
2114
TSM Oc 9800
Diagnostics
~Processing Scan Job~ doesnt disappear This error occurs only when using Scan to File.
Internal cable not connected on X2 of the Taxi Scanner part of the PRISCAT pba
Possible cause
Remark
ed.5
2116
TSM Oc 9800
Diagnostics
SDS
see SDS
31
see SDS
32 ~Last error logging~ ~OWAR/SWAR/ORE/MRE/PE/FE)~
34 ~Error top 10~ ~OWAR/SWAR/ORE/MRE/PE/FE)~
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr.
Component
Signal
Description
Parameter test Input tests Output tests Special tests
Info tests
Note: The INFO test gives only valid informa-
20-9-01
~SCSI present (0 = No, 1 = Yes)~
20-9-02 20-9-03 ~radical board present (0 = No, 1 = Yes)~ ~taxi printer present (0 = No, 1 = Yes)~

20-9-04 ~taxi scanner present (0 = No, 1 = Yes)~

20-9-05 ~ethernet present (0 = No, 1 = Yes)~

How much CPU RAM is available Not relevant for EPC

2202
TSM Oc 9800
SDS
Test nr. 20-9-10
Component
Signal
Description ~Controller release~

20-9-11 ~Controller version~


20-9-14
~poker lib. version~
20-9-15 ~poker lib. patch~
System tests
ed.5
2 The functional tests of the EPC2 controller.

The functional test software is the software running on the EPC2 controller, when the controller is powered-up with the CTRL+T pressed in a terminal software application. The functional test is to check and set the controller assembly and all the PBAs
s s s s
DIMMs modules Priscat and Radical PBAs used in this controller. Time / date setting (not relevant for the controller functions) software change
Tools for functional tests:

Serial cable Centronics cable Loop connector Link cable code number: 1302522 code number: 1302520 code number: 7991.293 code number: 7991.520
Setup for the functional test:

1 Switch off the machine. 2 Connect the laptop to the serial port COM1 of the controller with the serial ca-
ble (code number 1302522).

3 Activate a terminal emulation program on the PC (e.g WINDOWS Terminal). 4 Select Settings and Communications. 5 Change the settings to: Com1, Baud rate 9600, data bits 8, stop bit 1, no Parity,
Flow control to none. Select Settings, Terminal Preferences, Translations. Change the language setting to: None Switch ON the machine. Now you will get some initialisation messages on the screen of your PC (see next page) 10 Press during the message:~ Now Press CTRL+T to launch functional test~ the ~CTRL+T~ on the laptop. (See arrow on next page). Attention: you have only 5 seconds to activate the functional tests!!
6 7 8 9
Note: The screen information of the functional test can be saved in a file for
e.g. for analysing. (Terminal: transfers, receiving text files, file name) Read the file with a text application.
2204
TSM Oc 9800
SDS
Terminal window
Text on screen during booting-up (this is an example of a configuration).

Embedded Power Controller 2 starting up... VxWorks version : 5.3.1 PROM version : 0.6 DRAM Test.... Bank 0 .... empty Bank 1 .... empty Bank 2 .... empty Bank 3 64 Mbyte ... OK VxWorks System Boot Copyright 1984-1996 Wind River Systems, Inc. CPU: Motorola MTX - MPC 604r Version: 5.3.1 BSP version: 1.1/1 Creation date: Oct 27 1998, 14:38:29 auto-booting...
boot device : ata=0,0 processor number : 0 file name : /ide0/MTX inet on ethernet (e) : 134.188.138.48:ffffff00 host inet (h) : 134.188.136.50 gateway inet (g) : 134.188.138.4 user (u) : reader ftp password (pw) : fbbstarget flags (f) : 0x5aa50000 target name (tn) : friscoureur other (o) : dc Attaching to ATA disk device... done. Press CTRL-O to boot on application old version. Loading /ide0/MTX...2513768 Starting at 0x16610c... Press CTRL+T to launch SPS functional test... Starting EPC2 Application (PRL)ENABLE COMM. RECEIVED cpt_init = 1 (PRT) Controller SEND ENABLE COM (PRL)ENABLE COMM. RECEIVED cpt_init = 2 Attaching network interface dc0... done. Attaching network interface lo0... done. Creating DL partition:11816960 bytes initialy added. Frame Size = 43 DL size = 16 Mbytes OS remain 1 Mbytes Real Frame Size = 45524936 bytes Real DL size = 11816960 bytes Controller is Ready ...
ed.5
Text on screen with CTRL-T (this is an example of a configuration)

Embedded Power Controller 2 starting up... VxWorks version : 5.3.1 PROM version : 0.6 DRAM Test.... Bank 0 .... empty Bank 1 .... empty Bank 2 .... empty Bank 3 64 Mbyte ... OK VxWorks System Boot Copyright 1984-1996 Wind River Systems, Inc. CPU: Motorola MTX - MPC 604r Version: 5.3.1 BSP version: 1.1/1 Creation date: Oct 27 1998, 14:38:29 auto-booting... boot device : ata=0,0 processor number : 0 file name : /ide0/MTX inet on ethernet (e) : 134.188.138.48:ffffff00 host inet (h) : 134.188.136.50 gateway inet (g) : 134.188.138.4 user (u) : reader ftp password (pw) : fbbstarget flags (f) : 0x5aa50000 target name (tn) : friscoureur other (o) : dc Attaching to ATA disk device... done. Press CTRL-O to boot on application old version. Loading /ide0/MTX...2515312 Starting at 0x1663f8... Press CTRL+T to launch SPS functional test... Functest>
2206
TSM Oc 9800
SDS
Text on the screen with CTRL-E (this is an example of a configuration)

Embedded Power Controller 2 starting up... VxWorks version : 5.3.1 PROM version : 0.6 DRAM Test.... Bank 0 .... empty Bank 1 .... empty Bank 2 .... empty Bank 3 64 Mbyte ... OK VxWorks System Boot Copyright 1984-1996 Wind River Systems, Inc. CPU: Motorola MTX - MPC 604r Version: 5.3.1 BSP version: 1.1/1 Creation date: Oct 27 1998, 14:38:29 auto-booting... boot device : ata=0,0 processor number : 0 file name : /ide0/MTX inet on ethernet (e) : 134.188.138.48:ffffff00 host inet (h) : 134.188.136.50 gateway inet (g) : 134.188.138.4 user (u) : reader ftp password (pw) : fbbstarget flags (f) : 0x5aa50000 target name (tn) : friscoureur other (o) : dc (^E) Attaching to ATA disk device... You pressed CTRL-E key. Do you confirm erase of disk ? (Y confirm/ N cancel):Y MON NOV 16 15:31:54 1998 day ........ [monday] : month ...... [november] : date ....... [16] : hour ....... [15] : minutes .... [31] : seconds .... [54] : year ....... [1998] : Disk is being initialized Making Volume named /ide0/ Transfer controller software through the centronics port: Loading file... Press ESC to abort the transfer. Transfer progress: 100% Transfer successful. Checksum:0x094137C8 Writing file to disk...done. Operation complete. Transfer success. Turn machine OFF then ON to take into account the modifications.
ed.5
Text on the screen with CTRL-O (this is an example of a configuration)

Embedded Power Controller 2 starting up... VxWorks version : 5.3.1 PROM version : 0.6 DRAM Test.... Bank 0 .... empty Bank 1 .... empty Bank 2 .... empty Bank 3 64 Mbyte ... OK VxWorks System Boot Copyright 1984-1996 Wind River Systems, Inc. CPU: Motorola MTX - MPC 604r Version: 5.3.1 BSP version: 1.1/1 Creation date: Oct 27 1998, 14:38:29 auto-booting... boot device : ata=0,0 processor number : 0 file name : /ide0/MTX inet on ethernet (e) : 134.188.138.48:ffffff00 host inet (h) : 134.188.136.50 gateway inet (g) : 134.188.138.4 user (u) : reader ftp password (pw) : fbbstarget flags (f) : 0x5aa50000 target name (tn) : friscoureur other (o) : dc ttaching to ATA disk device... done. Press CTRL-O to boot on application old version. You pressed CTRL-O key. Do you confirm boot on previous application version ? (Y confirm/ N cancel):Y Loading /ide0/EPC.old...1632108 + 136880 + 452 + 174656 + 904 + 828 + 374533 Starting at 0x180000... Press CTRL+T to launch SPS functional test... Starting EPC2 Application (PRL)ENABLE COMM. RECEIVED cpt_init = 1 (PRT) Controller SEND ENABLE COM (PRL)ENABLE COMM. RECEIVED cpt_init = 2 Attaching network interface dc0... done. Attaching network interface lo0... done. Creating DL partition:11816960 bytes initialy added. Frame Size = 43 DL size = 16 Mbytes OS remain 1 Mbytes Real Frame Size = 45524936 bytes Real DL size = 11816960 bytes Controller is Ready ...
2208
TSM Oc 9800
SDS
Note: The bank information corresponds not with the slots on the mother-
board. . <CTRL+O> = to boot on the older software version, if exist. <CTRL+P> = only for production use. <CTRL+A> = when for any reason a test stays in a loop. <CTRL +E> = formats the harddisk. After reboot message to download new software.
tests. Not all of them are useful in the field, as some are used for repair and manufacturing purposes. Help list with a general description:
Functional test
Description
~HELP~ CONF ~TIME~ UPGD UPBK DLDP ECCX TPBT TSBT LTBT LSBT RDBT ~QUIT~
List of all the available commands Configuration Setup time and date Upgrade software on the harddisk Back to the previous software, if existing Demo plot is downloaded on the harddisk Testing of the centronics output Test of TAXI Print logic (Priscat) Test of TAXI Scan logic (Priscat) Link test of TAXI transfer, print and scan lines. Test of serial command link PRISCAT Test of Radical board Reboot the controller
ed.5

HELP
Displays the list of all available commands ~Functest> HELP~ __________________~ LIST OF COMMANDS~ ____________________ ~HELP~
~CONF~
~Show help information~
Show help information
~Display the current controller Display the current controller conconfiguration~ figuration
~TIME~ UPGD UPBK DLDP

ECCX
~Setup time and date~

No function in the system.
Setup time and date Upgrade application
~Upgrade application~
~Back to previous version (if Back to previous version (if existexisting)~ ing) ~Download demo plot file~ ~Echo characters sent to Centronics output~ ~Test of TAXI Print Logic~ ~Test of TAXI Scan Logic~ ~Test of TAXI transfer~ ~Test of TAXI Serial port~ ~Test of RADICAL Interface~ ~Quit (Turn off/on machine)~ Download demo plot file Echo characters sent to Centronics output Test of PRISCAT Print Logic Test of PRISCAT Scan Logic Test of PRISCAT transfer Test of PRISCAT Serial port Test of RADICAL Interface Quit (Turn off/on machine)
TPBT TSBT LTBT LSBT RDBT ~QUIT~
~Cmd Ok.~ ~Functest>~
2210
TSM Oc 9800
SDS
~CONF~
~Display the current controller configuration~ Example: Commercial release number: 1.2.5 Internal release number: 1.2.5 Scanning PCI slots... Slot 1: PRISCAT board detected. Slot 2: RADICAL board detected. Slot 3: Empty. Memory -configuration... Slot 1: 032 Mb Slot 2: 032 Mb Slot 3: 032 Mb Slot 4: 032 Mb
Total RAM size: 128 Mb Disk Model ... IBM-DHEA-34331 Cmd Ok.
~TIME~
Date and time is given. If you have change it or not: confirm with <ENTER> Settings have no function in the system Example: ~Functest> TIME~ ~WED OCT 21 14:09:20 1998~ ~day .......... [wednesday] :~ ~month ..... [october] :~ ~date ..........[21] :~ ~hour ........ [14] :~ ~minutes .. [9] :~ ~seconds ...[20] :~ ~year ........ [1998] :~ ~Cmd Ok.~
ed.5
UPGD
~UPGraDe software~ With this command, a newer software version is downloaded on the harddisk inside the controller. The existing version on the harddisk is renamed as being the older software. An already existing older version is so overwritten. A centronics cable (code no. 1302520) between the laptop and the centronics I/O of the controller is also needed to download the controller software. The upgrade software is about 2 MB. To use this software: reboot the system. For the exact action of installing:see Dis-/assemblies EPC 2 software on page 2402 Example: ~Controller software release 1.2.4~ ~Transfer controller software through the centronics port:~ ~Loading file...~ ~Press ESC to abort the transfer.~ ~Transfer progress: 100%~ ~Transfer successful. Checksum:0x0942454A~ ~Do you want to replace version 1.2.4 by version 1.2.5 ?~ ~Press Y to confirm, N to cancel: Y~ ~Writing file to disk...done.~ ~Operation complete.~ ~Turn machine OFF then ON to take into account the modifications.~
UPBK
~UPgradeBacKup software~ With this command, the existing older boot software version (if exists on the harddisk) is renamed to be the newest boot software version. This means that the previous software does not exist anymore on the harddisk! To use this software: reboot the system. For the exact action of installing:see Dis-/assemblies EPC 2 Upgrade Backup Software on page 2403. Example: (Test runs successfully) ~Retreiving the old software version will overwrite the current one.~ ~Please confirm (Y/N):Y~ ~Operation completed.~
2212
TSM Oc 9800
SDS
~Turn machine OFF then ON to take into account the modifications.~
Example; Test failure. ~Functest> UPBK~ ~Retreiving the old software version will overwrite the current one.~ ~Please confirm (Y/N):Y~ ~No previous version found on disk.~ ~Operation canceled.~ ~Cmd Ok.~
DLDP
~DownLoad DemoPlot~ With this command, a demo plot (test print on the operator panel) is downloaded from the laptop to the harddisk. The download needs the centronics cable (code no. 1302520) between the laptop and the controller. For the exact action of installing:see Dis-/assemblies EPC2 Demo plot (Test print) on page 2404 Example: ~Transfer Demo plot file through the centronics port:~ ~Loading file...~ ~Press ESC to abort the transfer.~ ~Transfer progress: 100%~ ~Transfer successful. Checksum:0x00AB8244~ ~Writing file to disk...done.~ ~Operation complete.~ ~Cmd Ok.~
ECCX
~ECho Characters centroniX~ With this command, the centronics connection is tested. Connect a centronics cable between the 2 centronics ports of the motherboard . Activate the test. If the test fails check the following items. - centronics connection, cable - riser board - motherboard
ed.5
Example: display message if test is running O.K.: ~Test of data transfer in process...~ ~10240 data transfer in 2 seconds. Data rate 5 kBytes/s~ ~Test completed successfully...~ ~Cd Ok.~ Example: display message if test failed: ~Functest> ECCX~ ~Test of data transfer in process......failed~ ~Test aborted~ ~Cmd Ok.~
TPBT
~Taxi Printer Board Test~ Test not available.
TSBT
~Taxi Scanner Board Test~ With this command, the TAXI scanner part of the PRISCAT I/O board is tested. Specific data is written and read. The sent and failed received patterns are displayed. If the test failed check the following items. - PRISCAT pba - motherboard Example: display message if test is O.K.: ~Testing all TXM_print_out_counter_register possible values from 0 to 255...Ok~ ~Testing all TXM print_in_counter_register possible values from 0 to 1023...Ok~ ~Testing TXM_mask_IT_register all values from 0 to 0x3F...Ok~ ~Testing TXM_control_register all values from 0 to 255...Ok~ ~Data path test of TAXI SCANNER board in process...~ ~Test completed successfully.~ ~Cmd Ok.~
2214
TSM Oc 9800
SDS
LTBT
~Link Transfer Board Test~ With this command, the data transfer between TAXI PRINT and TAXI SCAN on the PRISCAT pba is tested. Loosen the connectors ~Upload~ and ~Download~ at the outside of the controller, see Component location on page 2601 Connect the test cable (code no. 7991.520) between the ~Upload~ and ~Download~connectors at the outside of the controller. Activate the test. The sent and failed received patterns are displayed. If the test failed: (check) - the test cable - PRISCAT - motherboard Example: display message if test is O.K.:
~Test of data transfer between TAXI PRINT and TAXI SCAN~ ~Verify transfer...OK~ ~Cmd Ok.~ Example: display message if test failed: ~Functest> LTBT~ ~Test of data transfer between TAXI PRINT and TAXI SCAN~ ~interrupt: TxmISRfromPci:~ ~txsTransferError 00005008nd TAXI ~ ~logTask: 1 log messages lost.~ ~Verify transfer...failed~ ~Cmd Ok.~
ed.5
LSBT
~Link of Serial command Board Test~ With this command, the serial command line of the controller is tested. Disconnect the ~Serial command~ connector on the outside of the controller, see Component location on page 2601). Place the special loop connector (code no. 7991.293). Reboot the system. Activate the test. A set of characters is sent and displayed: ~The quick brown fox jumped over the lazy dog~. If the test failed: - check the internal cables between serial command connector and the connector X3 on the PRISCAT pba - PRISCAT - motherboard Example: display message if test is O.K.: ~Sent: The quick brown fox jumped over the lazy dog...OK~ Cmd Ok.~
Example: display message if test failed: ~Sent: The quick brown fox jumped over the lazy dog~ ~Test failed.~ ~Cmd Ok.~
2216
TSM Oc 9800
SDS
RDBT
~RaDical Board Test~ With this command, the RADICAL board is tested. Activate the test. Specific data is written and read. Corrupted data is always displayed. If the test failed: (check) - RADICAL pba - motherboard Example: display message if test is O.K.: ~RADICAL board test in process...~ ~Test of internal registers...Ok~ ~Test of data transfer...~ ~Data transfer in process...~ ~Test completed successfully... 13107200 data(32bits) transfered.~
~Cmd Ok.~
~QUIt~
With this command, the functional tests are switched off. To start the controller operating system: reboot the system.
ed.5
2218
TSM Oc 9800
SDS
Dis-/assemblies
Note:
s
Before dis/-connecting the controller cable(s) make sure that the host is powered down and the Oc 9700/9800 is switched off. Connections in the controller are very critical. Bad connections may lead to various controller failures. Please use a wrist strap , antistatic mat and take care when reinstalling controller items. It is strongly advised to place the controller on a flat table for maximum visibility in order to reinstall properly and prevent bad connections. Check after dis-/assemblies the EPC controller with your laptop. If correct, connect host environment and check again.
1 Embedded Power Controller

1 Execute the ~print settings~ to print all user parameters. 2 Switch off the host and the Oc 9700/9800. 3 Disconnect at the front side of the engine the connectors from the controller 4 5 6 7 8 9 10 11 12 13
and the scanner. Remove the front cover from the engine. Remove the right top cover from the engine. Remove the right side covers from the engine. Remove at the right side the front upper and lower cover from the engine. Disconnect the data connectors from the controller see Component location on page 2601. Disconnect the power supply connector (2001D2) from the controller. Remove at the front side of the engine the 2 lower mounting screws from the controller. Loosen at the front side of the engine the 2 upper mounting screws from the controller. Remove the controller and place the controller on a flat table. Remove (if needed) the cover from the controller (24 screws).
ed.5
2 EPC 2 software
Needed:
s s s
Serial cable, code no. 1302.522 Centronics cable, code no. 1302.520 Controller software

2 Activate the functional tests, see The functional tests of the EPC2 controller.
on page 2204
3 Activate the functional test: UPGD. 4 5 6 7
Message: ......~Transfer controller software through the centronics port:~ Open the Windows DOS screen. Position the DOS and the Terminal windows so that you can see both. Click in the Windows DOS screen to make it active. Copy the controller software from the correct drive and path: copy /b <file name> lpt1 Follow the instructions on the screen: (~install new software / save old~) Wait till the file is downloaded. Close the Windows DOS screen. Reboot the system. Check the software release in the functional test: ~CONF~. Check the functioning of the controller with the ~Plot Director~.
8 9 10 11 12 13
2402
TSM Oc 9800
Dis-/assemblies
3 EPC 2 Upgrade Backup Software

Needed:
s
Serial cable, code no. 1302.522
1 Connect between the laptop and the controller: the serial cable on COM1. 2 Activate the functional tests, see Help list with a general description: on page
2209
3 Activate the functional test: UPBK. 4 Follow the instructions on the screen:
(~Retrieving the old software version will overwrite the current one Please confirm?(Y/N):~) 5 Reboot the system. 6 Check the software release in the functional test: ~CONF~. 7 Check the functioning of the controller with the ~Plot Director~.
ed.5
4 EPC2 Demo plot (Test print)

Needed:
s s s
Serial cable, code no. 1302.522 Centronics cable, code no. 1302.520 Demo plot software

2 Activate the functional tests, see The functional tests of the EPC2 controller.
on page 2204
3 Activate the functional test: DLDP. 4 5 6 7
Message: ......~Transfer Demo Plot file through the centronics port:~ Open the Windows DOS screen. Position the DOS and the Terminal windows so that you can see both. Click in the Windows DOS screen to make it active. Copy the controller software from the correct drive and path: copy /b <file name> lpt1
8 Follow the instructions on the screen: 9 10 11 12
(~Loading file...Press ESC to abort the transfer. Wait till the file is downloaded. Close the Windows DOS screen. Reboot the system. Check the demo plot by activating it from the operator panel.
2404
TSM Oc 9800
Dis-/assemblies
5 ~Radical PBA~
1 Remove the controller, see page 2401. 2 Remove the screw (5.5 mm) opposite of the connector of the Radical PBA. 3 Replace or mount the (new) PBA.
Note: The Radical PBA must be mounted in the PCI slot J2. 4 Remount the controller. 5 Connect all connectors to the controller. 6 Execute the functional test ~CONF~ and check if the (new) PBA is listed in the
configuration.
Note: With the functional controller test RDBT it is possible to check the functioning of the PBA. 7 Make a scan to file, Tiff with compression to test the new PBA, (the PBA is
only used for scan to file).
ed.5
6 ~Priscat PBA~
Remove the controller, see page 2401. Disconnect the 3 connectors from the Priscat PBA. Remove the screw (5.5 mm) opposite of the connector of the Priscat PBA. Remove at the right outside of the controller the screw from the second mounting bracket of the Priscat PBA. 5 Remove the PBA. 6 Mount the bracket to the new PBA. 7 Replace or mount the (new) PBA. If mounting a new pba: check the jumper (SW) settings, see chapter Electrical Description Radical PBA on page 2606
1 2 3 4 Note: The Priscat PBA must be mounted in the PCI slot J1. 8 9 10 11
Connect the 3 connectors to the Priscat PBA. Remount the controller. Connect all connectors to the controller. Execute the functional test ~CONF~ and check if the (new) PBA is listed in the configuration.
Note: With the functional controller tests LSBT and TSBT it is possible to check the functioning of the PBA. 12 Test the new PBA. - Print files to check the print part. - Scan to file to check the scan part.
7 Hard disk
1 2 3 4 5 6 7
Remove the controller, see page 2401. Disconnect the supply connector (P5) from the hard disk. Disconnect the IDE connector from the hard disk. Remove at the left outside the Allen screw from the holder of the hard disk. Remove at the top side the 2 screws from the holder with the hard disk. Remove the holder with the hard disk. Replace the hard disk (6 screws).
Note: The hard disk must be configured as ~Master~, jumper on position J1
and J4 . see EPC2 Hard disk jumper settings on page 2408

8 Remount the holder with the hard disk. 9 Connect all the connectors. 10 Remount the controller.
2406
TSM Oc 9800
Dis-/assemblies
11 Download the software and the Demo Plot, see Functional Description tests
UPGD and DLDP.
ed.5
8 EPC2 Hard disk jumper settings

The hard disk should have the following jumper settings:
JP1 JP2 JP3 JP4
1 2
3 4
5 6
7 8
JP1: installed JP2: not installed JP3: not installed JP4: installed
Note: The jumper must be installed in order to configure the drive as device 0 (Master).
9 Power supply unit

1 Remove the controller, see page 2401. 2 Disconnect the P1 connector of the supply unit from the J35 connector of the
motherboard.
3 Disconnect at the outside the connector from the 220 V power supply unit. 4 Remove at the right outside 4 screws from the power supply unit. 5 Remove at the top outside 2 screws from the support bracket of the power sup6 7 8 9 10
ply unit. Mount the support bracket to the new power supply unit. Replace or mount the (new) power supply unit. Connect all the connectors. Remount the controller. Test the controller function (e.g. with the ~Plot Director~).
2408
TSM Oc 9800
Dis-/assemblies
10 Motherboard
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18
Remove the controller, see page 2401. Remove the Radical PBA, see page 2405. Remove the Priscat PBA, see page 2406. Remove the hard disk see Hard disk on page 2406. Remove the power supply unit see Power supply unit on page 2408 Disconnect the IDE connector (J24) from the motherboard. Disconnect the SCSI2 connector (J38) from the motherboard. Remove the 2x BOOT flash and the DIMM(s) from the motherboard and mount these on the new motherboard. Remove at the outside the 2 nuts from the connectors COM2 and Ethernet AUI. Remove the motherboard (10 Allen screws). Check the jumper settings: J37 1-2 (Flash bank A enabled) and J27 1-2 (Power on). The other jumpers are for factory use only and must be off (no jumper installed) Remount all disassembled parts and PBAs according: see Controller PBA overview on page 2603. Remount the controller. Connect all connectors to the controller. Reboot the system and ~print settings~. Use the laptop to sent a plot (~Plot Director~). Switch of the machine and connect the host environment. Test the function of the controller.
ed.5
Boot DIMMs
2410
TSM Oc 9800
Dis-/assemblies
11 Memory module (DIMM)

1 Remove the controller, see page 2401. 2 Remove the power supply, see page 2408 (for easier accessibility of the mem-
ory modules).
3 Remove / mount the (new) DIMM(s).
Warning: Slot 1 and 2, and (if needed) also 3 and 4 must be filled with the same
size of Mb. Do not mixed up e.g. 32Mb with 64Mb!!

Note: Take care during dis-/assembling of the DIMM(s) or expanders for not
damaging and polluting the sockets on the motherboard. After assembly every DIMM or expander must be checked visual for correct positioning.
4 Remount the controller. 5 Connect all connectors to the controller. 6 Switch on the engine and check/adjust in SDS 90 (configuration) the new con-
troller configuration (if you want to change the configuration do not forget to switch the engine OFF and ON). 7 Execute the ~print settings~ and check if the new memory configuration is listed in the settings.
Configuration Slot 1 and 2 XU6 and 5 Slot 3 and 4 XU4 and 3
64 Mbyte 128 Mbyte 192 MByte 256 Mbyte
2 x 32 Mb 2 x 32 Mb 2 x 64Mb 2 x 64 Mb 2 x 32 Mb 2 x 64 Mb 2 x 128 Mb
empty 2 x 32 Mb empty 2 x 32 Mb 2 x 64 Mb 2 x 64 Mb empty
ed.5

Termination

Software versions
For the best performance, use always the newest drivers. This may be not the software delivered with the SCSI package. Check for new drivers on the Adaptec webside: www.adaptec.com.
2412
TSM Oc 9800
Dis-/assemblies
Note:
2 After installing the PBA, boot the PC and press <Ctrl> <A> as soon as a mesConfidential 1999 Oc-Technologies B.V.
ed.5
This SCSI PBA has a plug and play PBA, which means an easy installation on systems that support plug and play (via BIOS or Windows 95/NT). If you have to install the PBA on a system that does not support this mode (e.g. Windows 3.1 / 3.11), some additional actions are necessary.

down position.
4 5 6
7 8
2414
TSM Oc 9800
Dis-/assemblies
ed.5
s
2416
TSM Oc 9800
Dis-/assemblies
1 AHA 2940:
2 3 4
5 6
drivers at www.adaptec.com
ed.5
2418
TSM Oc 9800
Dis-/assemblies
1 General
The controller functions of the EPC2 controller are:
s
s s
Processes: conversion and transformation of plot data to Oc 9700/9800 specific raster formats and performs scaling, rotation etc. Connectivity: connects the Oc 9700/9800 to the customer environment Remote Control Format (RCF): accepts and interprets RCF-data to control printing, scanning and finishing aspects.
2 Features
s s s s
Standard computer mother board. Standard for more PPC copiers (e.g. Oc 9800/ 9700) To improve a high plotting speed of the system. Backchannel communication with the host computer: Configuration, status information, accounting. Ethernet connection: Ethernet connection: TCP/IP build-in interface is provided (only with LPD protocol), other protocols: use a Microplex box. Physical interface provided: AUI / 10BaseT / 100BaseT. Overlays & templates: The possibility to merge 2 digital files together and print the result. Hooks for language filters via PAS: The controller cant process all kind of formats. The PAS application hooks 3rd parties filters to add language filters, e.g. Postscript level 2 and PS fonts, DWG (Autodesk) PAS: Printroom applications for printing and scan-to-file. Regular updates to recognise new functions and new hardware. The Oc 9700 ~SET Memory PBA~ cant process sets and matrix, this is done by PAS.
ed.5
3 System overview
2502
TSM Oc 9800
Graphic languages
The following graphic languages are supported by the ~Embedded Power Controller~ (can be set to automatic language sensing ALS, except ASCII): :
Vector

Raster
supported plotter emulation: reference is HP7586B plotter supported plotter emulation: reference are Design Jet Hp 650/750 plotters
TIFF
CALS
HP-RTL
ASCII
Other languages must be hooked to the PAS application, options are e.g.: PostScript level 2, DWG. See Repro Station for which language a converter is installed.
ed.5
Embedded Power Controller abbreviations: Name Explanation
Power Controller: PCI ISA SCSI
Motorola CPU-board with MPC 604r 300Mhz processor. Peripheral Component Interface bus. 32 bit wide data path bus. Industry Standard Architecture 16 bit wide data path bus. Small Computer Standard Interface Intelligent I/O, each connected device has a unique ID. DRAM which contains the bitmap of the image to be printed. Fast temporary RAM memory for last items read from the main memory. Real Time Operating System VxWorks for this controller. Attachment Unit Interface connector type between I/O card in a PC and the Ethernet network. Connector type between I/O in a PC and the Ethernet network, implemented on twisted pair cabling. Transmission Control Protocol / Internet Protocol Line Printer Daemon (Unix) printer software for Ethernet NonVolatile RAM (battery powered). Raster Acceleration board I/O board for compression of raster data, only for Scan to File. PRInter SCAnner Taxiboard I/O board for communication with the printer. * One side of the board is used for printing (to transfer data from the controller to the engine). * The other side is used for Scan to File (to transfer data from the scanner to the controller). * Serial link connection for command line.
Frame buffer
Cache
RTOS
AUI
10Base-T / 100Base-T
TCP/IP
LPD socket NVRAM

RADICAL
PRISCAT
2504
TSM Oc 9800
4 EPC2 controller characteristics

Mother board
Motorola MTX board with 300 MHz Power PC 604r processor 1 boot EPROM memory 3 PCI slots SCSI
Ethernet DLL memory 11 / 27 MB (16 / 32 in SDS) FRAME buffer 41 - 216 MB Total memory 64 - 256 MB Harddisk ATA PRISCAT PCI RADICAL PCI
Intergrated on motherboard, main purpose: printing and scan to file, also used for backchannel communication with Machine Monitor integrated on motherboard is part of the total memory is part of the total memory 4 DIMM slots. Printer TAXI I/O card Scanner TAXI I/O card. Serial link commandline Hardware compression I/O card, only for Scan to File.
Harddisk
s s s s s s
ATA disk controller 4.3 Gbyte DMA access controller software (easy upgrade) test print for swapping data, if needed (Ethernet)
Software features:
s s s s s s s s
- Plot processing for various languages through many interfaces. - ALS automatic language sensing - Plot transformation (scaling, rotation ...) - Remote control through host - Configuration through engine Local User Interface - Error recovery feature - Scan to file function - Diagnostic tests for production and service
ed.5
Connections external: see Embedded Power Controller 2 (EPC 2) Exten-
sions on page 2602 - RS232 serial (COM2, only for service) - 2 centronics (1x integrated centronics only for service, 1x integrated centronics for data centronics port) - SCSI - Ethernet (AUI or 10BaseT/ 100BaseT)
Configuration

Configuration DLL Memory 1 2 3 4 5 6 7 11 11 27 11 27 11 27
Frame buffer OS Total mem.
41 102 88 166 152 230 216
12 15 13 15 13 15 13
64 Mb 128 Mb 128 Mb 192 Mb 192 Mb 256 Mb 256 Mb
DLL : Display List (size adjusted in SDS test 90) Frame buffer : bitmap buffer OS: Operating System Total memory = DLL + frame buffer + OS
2506
TSM Oc 9800
5 Process
Block diagram EPC 2
ed.5
The system is divided in three bus parts: the host bus part, the PCI bus part and the ISA bus part. The bus connections are made by bridge-chips.
s
The host bus: - very high speed local CPU bus, 128 bits wide, dedicated to the architecture of the CPU. The PCI bus: - high speed I/O bus, 32 bits wide. The ISA bus: - slow speed I/O bus, 16 bits wide.
2508
TSM Oc 9800
6 Printing
1 Printing vector data 2 Printing raster data
Block diagram for printing vector data
If data is received and the Automatic Language Sensing (ALS) is enabled (e.g. data format AUTOMATIC is specified with Repro Station), the ALS tries to determine which data format it is. If the format is recognized the interpreter for the data format is started. The interpreter creates an intermediate format which is stored in the DLL memory (Display List memory). The intermediate format is sorted to get a sorted vector list. The sorted vector list format is converted into the Oc 9800 specific raster (bitmap) format which is stored in the Frame Buffer. Finally this bitmap is sent via the PRINTER TAXI part of the PRISCAT interface to the SET memory PBA of the engine. The data is compressed stored in the SET memory.
ed.5
If the Automatic Language Sensing (ALS) function is disabled, then the data format has to be specified (e.g. HP-GL in Repro Station). The interpreter starts directly. The intermediate format of the data has to fit completely in the DLL memory. If the file doesnt fit the warning 20813 is generated. (For further information see Fault description). The size of the Frame buffer is between 41 and 228 Mb. If the file does not fit in the Frame buffer Banding is used: That part of the file that fits into the Frame buffer is sent to the SET memory. The display shows the message DOWNLOADING PRINTFILES. The Frame buffer is cleared and the next part of the file is stored in the Frame buffer and sent over. The process continues till the complete file is sent. This happens e.g. with long plots.
2510
TSM Oc 9800
The process for raster formats is nearly the same as for vector data. The raster DATA is interpreted and temporarily stored in the DLL memory. Next the file is rendered (conversion into the specific Oc 9800 bitmap format) and stored into the Frame buffer. The raster data does not have to fit in the DLL memory, except if the header is on the end of the file. For detailed information about the instructions for the controller to use features of the Oc 9800 engine (like folding, stamping, punching, roll selection, reduction and shifting) and the controller functions (like rotation, enlargement, handling data formats) see the User Manual and Programmers Manual.
Note: Not all processing is done in the controller. Some actions like reduction,
most of the shift function, some edge corrections are done in the engine (image processing).
ed.5
7 Print size of originals for rotated image

For printing the size of the Frame Buffer has impact to the size of the file that can be rotated. Vector: are always rotated in the DLL buffer. Raster: are rotated in the Frame buffer. The rotation algorithm requires a second buffer to store the rotated bitmap. Thus, a bitmap can be rotated if it fits into half of the frame buffer. For configurations, see EPC2 controller characteristics on page 2505
Maximum print size with rotation for raster files
ConfiDLL guration 1 2 3 4 5 6 7
FB
Maximum file size 20.5 MB 51 MB 44 MB 83 MB 76 MB 114MB 106,5MB
Maximum W x L or equivalent 914 x 750 (36 x 29.5) 914 x 1850 (36 x 72.8) 914 x 1600 (36 x 63) 914 x3050 (36 x 120) 914 x 2800 (36 x 110) 914 x 4200 (36 x 165) 914 x 3900 (36x153.5)
Total mem.
11MB 41MB 11MB 102MB 27MB 88MB 11MB 166MB 27MB 152MB 11MB 228MB 27MB 213MB
64 Mb 128 Mb 128 Mb 192 Mb 192 Mb 256 Mb 256 Mb
2512
TSM Oc 9800
8 Print size of originals for long plots

The long plot functionality depends of the ~Set Memory~ size in the engine. A file can only be printed, if it fits entirely into the ~Set Memory~. Otherwise a message is displayed on the scanner LUI and the file is not printed. If the file fits entirely into the ~Frame buffer~ of the controller, it can be reprinted if an error occurs. If the file does not fit entirely into the ~Frame buffer~ of the controller, it sends the file by chuncks to the engine. The file is printed, but if an error occurs now, it can not be reprinted! Maximum print length is 15 meters (590.5) For configurations, see EPC2 controller characteristics on page 2505
Configuration 1 2 3 4 5 6 7
DLL 11MB 11MB 27MB 11MB 27MB 11MB 27MB
FB 41MB 102MB 88MB 166MB 152MB 228MB 213MB
Maximum W x L or equivalent 914 x 1500 (36 x 59) 914 x 3750 (36 x 147.6) 914 x 3200 (36 x 126) 914 x 6100 (36 x 240.2) 914 x 5600 (36 x 220.5) 914 x 8400 (36 x 330.7) 914 x 7850 (36 x 309)
Total mem.
64 Mb 128 Mb 128 Mb 192 Mb 192 Mb 256 Mb 256 Mb
Attention: Maximum length is 15 meters (590.5) Maximum width is 914 mm (36)
ed.5
9 Scan to File
The controller also can transport data from the SET memory PBA to the host computer. After scanning an analogue original, the data can be stored on the host computer harddisk as a TIFF or CALS raster file with a resolution of 200 or 400 dpi.
The CCDs of the scanner scans an original with 400dpi. The data is transferred to the SET memory PBA. From here the data is transferred to: - the scanner PRISCAT PBA in the controller, or to - the scanner PRISCAT PBA in the controller and to the Black / White processing PBA in the engine, to make at the same moment a copy. The compression (if chosen by the operator) is done by the Radical pba. The language conversion (CALS, TIFF tiled, stripped) is done in the DLL buffer by the controller software.
2514
TSM Oc 9800

The digital image of an original is stored, on the fly, into the controllers Frame Buffer without any compression. Thus an original can be scanned if its digital image fits entirely into the Frame Buffer. For configuration, see EPC2 controller characteristics on page 2505
Original size
Configuration 1 2
DLL
Maximum W x L or equivalent (200 dpi) 914 x 5200 (36x204.7) 914 x 13200 (36x519.7) 914 x 11400 (36 x449) 914x21400 (36x842.5) 914x19600 (36x771.7) 914x29200 (36 x1150) 914x27600 (36 x1087)
Maximum W x L or equivalent (400 dpi) 914 x 1300 (36 x 51.2) 914 x 3300 (36 x 129.9) 914 x 2850 (36 x 112.2) 914 x 5350 (36 x 210.6) 914 x 4900 (36 x 192.9) 914 x 7300 (36 x 287.4) 914 x 6900 (36 x 271.7)
Total mem.
16 Mb 16Mb 32Mb 16Mb 32Mb 16 Mb 32 Mb
64 Mb 128 Mb 128 Mb 192 Mb 192 Mb 256 Mb 256 Mb
3 4 5 6 7
ed.5

The printroom application software consists of Job Director, Job Director Configurer, Repro Station and Machine Monitor. The applications run only under Windows 3.1/3.11, Windows 95 and Windows NT3.51/4.0. The system consists of:
Job D ire cto r Job D ire cto r C o nfig ure r R e p ro S ta tio n M a chin e M on ito r
S C S I M in i con n ector E m be dd e d P o w er C o n tro lle r
RS D o n gle
S C S I-2 cab le A d ap te c S C S I A d ap te c S C S I 5 0 p ins con n ector A m pli o r M in i
A S P I drive rs ( C D -R O M o r F lo pp y)
The PAS applications are distributed on CD-Rom. It is possible to create floppies from the CD-Rom, for customers who do not have a CD-Rom drive in the PC. For detailed information about the applications, see the User Manuals. The installation of these applications is also described in these manuals. The Repro Station software is protected by a Dongle on the centronics port. When the customer is using applications who are using also Dongles, they are build on eachother. The cable connection (SCSI) is between Machine Monitor and the controller. Machine Monitor can handle back-channel communication with the EPC controller.
2516
TSM Oc 9800
12 SCAN STATION
The scan printroom application software consists of Scan Station, Machine Monitor and the Oc View Station (the old Spicer Imagination viewer can be upgraded).In the package you find also the needed hardware: the RADICAL PBA and the Upload cable. The applications run only under Windows 3.1/3.11, Windows 95 and Windows NT3.51/4.0. The system consists of:
S ca n S tation M a chin e M on itor O c V iew S ta tio n R A D IC A L
S C S I M in i co n n ector
V ie w S ta tio n D o n gle
E m b e d de d P o w e r C o n troller U p loa d ca ble S C S I-2 ca b le to E n g in e S et M e m ory P B A
A d ap te c 5 0 p ins co n n ector A M P L I o r M in i
Scan Station and the View Station are distributed on CD-Rom. It is possible to create floppies from the CD-Rom, for customers who do not have a CD-Rom drive in the PC. For detailed information about both applications, see the User manuals. The installation of these is also described in these manuals. The Oc View Station software is protected by a dongle on the centronics port. If the customer is also using Repro Station, then there are built 2 dongles on each other. Even more is possible. The order of the dongles can be important. See the corresponding manuals. Examples: -Autocad dongle must be in LPT1 and in 1st position. -~Oc View Station~ dongle must be in 1st position, LPT not important. - Repro Station dongle can be placed anywhere.
ed.5
13 SCSI PBAs
The Oc 9700/9800 Repro Station and Scan Station application requires a SCSI PBA in the PC to run. The following SCSI solutions are possible:
s s s s s
SCSI cable
Adaptec 1542 CF PBA
This was the first delivery of SCSI PBAs. For communication between the PC and the Oc 9800 a Mini SCSI M / Amphenol M cable is needed. This SCSI PBA uses the ISA bus of the PC and is not recommended for a 32-bits Operating System.
Adaptec 1542 CP PBA
This is the update of the first SCSI PBAs. For communication between the PC and Oc 9800 a Mini SCSI M/ Mini SCSI M cable is needed. Other differences with the 1542 CF PBA are:
s s
2518
TSM Oc 9800
Adaptec 2940AU SCSI

ed.5
s s s s s s

s
s s
s s s
Pentium 100 MHz Intel processor, running Windows 95 or Windows NT 3.51/4.0 for the 32-bit applications or Windows 3.1/3.11 for the 16-bit applications For View Station on Windows NT3.51: Service Pack 5 is required. 32 Mb internal memory free on internal harddisk 3,5 Mb for Repro Station 6 Mb for Scan Station 10 Mb for View Station sufficient disk space to save the files a TCP/IP network, if remote connections are needed a free PCI slot for the Adaptec SCSI PBA (for Machine Monitor) a free centronics port. Oc View Station and Repro Station are supplied with a dongle. The Viewer Station dongle must be in the 1st position, LPT is not important. The Repro Station dongle can be placed anywhere.
Note: 1
Note: 2
2520
TSM Oc 9800
Embedded Power Controller
220 V supply
Serial commands
Download
Upload
ed.5
2 Embedded Power Controller 2 (EPC 2) Extensions
only for service
CENTRONICS
Connectors: External
s s s s
serial centronics ethernet (AUI or 10BaseT/100BaseT) SCSI
Internal
s s s s
s s s s s
Power -> power supply PBA Priscat taxi printer (X1) - > to set memory Priscat taxi scanner (X2) <- from set memory Priscat (X3) -> serial communication between controller and CPU I/O PBA (engine) SCSI -> motherboard hard disk -> motherboard power supply -> hard disk power supply -> motherboard PSU -> fan
2602
TSM Oc 9800
3 Controller PBA overview

RADICAL PRISCAT
Connectors on Priscat X1 Taxi printer connector X2 Taxi scanner connector X3 Serial commands connector
ed.5
MTX Connector/Jumper Descriptions Reference Designator Function Comment
J1 J2 J3 J5 Upper J5 Lower J6 J7 Upper J7 Lower J8 Upper J8 Lower J23 J27 J35 J37 J38 XU1 XU2 XU3 XU4 XU5 XU6
32-bit PCI slot 1 32-bit PCI slot 2 32-bit PCI slot 3 Ethernet AUI Test centronics port (ECCX functional test) Ethernet 10/100 Base-T COM2 COM1 Keyboard Mouse Data Centronics I/F ATX Power Control Power Flash Bank Select SCSI Flash Bank Flash Bank DIMM Bank B DIMM Bank B DIMM Bank A DIMM Bank A
Priscat PBA location Radical PBA location Not used
For functional test activation Not used Not used Not used Short to turn ATX power supply on From PSU 1-2 position (Flash Bank A selected) Upper Byte Lower Byte Upper 72-Bits Lower 72-Bits Upper 72-Bits Lower 72-Bits
2604
TSM Oc 9800
4 Motherboard
Slot 4 Slot 3 Slot 2 Slot 1
Configuration
Slot 1 and 2 XU6 and 5
Slot 3 and 4 XU4 and 3
64 Mbyte 128 Mbyte 192 MByte 256 Mbyte
2 x 32 Mb 2 x 32 Mb 2 x 64Mb 2 x 64 Mb 2 x 32 Mb 2 x 64 Mb 2 x 128 Mb
empty 2 x 32 Mb empty 2 x 32 Mb 2 x 64 Mb 2 x 64 Mb empty
ed.5
5 Radical PBA
SW1 1 1 SW2
1 SW3
Jumper settings SW1 SW2 SW3 1-2 1-2 1-2
Code number: 7009010
Newer Radical board
Code number: 7033694 is fully compatible with the previous one. Differences are: - jumpers are replaced by fixed resistors - Switches SW1, SW2 and SW3 are cancelled - Board layout has been changed.
2606
TSM Oc 9800
6 Priscat PBA
Jumper settings: SW1 1-2 SW2 2-3
Jumper settings: SW1 1 - 2 for future development 2 - 3 for use with the EPC controller Connectors on both PBAs: X1 Taxi printer connection X2 Taxi scanner connection X3 Serial command connection X4 Production only
Both PBAs are interchangable.

ed.5 20 Interface EPC 2 2607
2608
TSM Oc 9800
Oc
Oc 9800
22 CONTROL
Contents
Diagnostics
1 Faults
101
SDS
1 CONtroller 201
Adjustments
1 Calibration mains voltage measurement. 301
Dis-/assemblies
1 CPU I/O PBA 401 2 SSR PBA 401 3 Console CPU PBA 402 4 22G1 CONSUPLV (LV supply) 403 5 DC power supply (Folder and Belt unit) 404 6 Software upgrading procedure 405
1 Oc 9800 abbreviations 501 2 The hardware diagnostic system 504
1 Component location 601 2 Location modification stickers 604 3 Component names 607 4 Indentification bundle names 621
Diagrams
1 Control 1 701 2 Control 2 with scanner 702 3 Control 3 stand alone printer 703
ed.5
22 Control
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. CONtrol 22000 -22999 code display 22001 + CPU_IO code 3 FE: ~Checksum fail EPROM SCA: 22PBA02~
~
Possible cause
Remark
CPU CONSOLE PBA defect Defective scanner EPROMS

22002 + CPU_IO code 3 on FE: ~CPU 22PBA02 Fatal Error (SCAnner)~

CPU CONSOLE PBA defect
22003 + CPU_IO no code FE: ~Communication fail detection CPU_CONSOLE PBA~

)
Possible cause
Remark
Connection CONSUPLV (5 V) -> CPU_IO PBA F4 DRIVERS-PBA defect CONSUPLV defect CPU_IO PBA defect
22003 + CPU_IO code. (point) FE: ~CPU_IO PBA defect -> Communication failure detection CPU CONSOLE PBA~
~
Possible cause
Remark
CPU_IO PBA defect
ed.5
22 Control 101
22003 + CPU_IO code 1 FE: ~Checksum failure EPROMs CPU_IO PBA -> Communication failure CPU CONSOLE PBA~
~
Possible cause
Remark
EPROMS CPU_IO PBA defect CPU_IO PBA defect
22003 + CPU_IO code 2 FE: ~CPU_IO PBA defect -> communication error CPU CONSOLE PBA~
~
Possible cause
Remark
CPU_IO PBA defect Uncontrolled static discharge which interferes with the CPU
22003 + CPU_IO code 3 FE: ~Communication failure CPU CONSOLE PBA -> CPU_IO PBA~
~
Possible cause
Remark
Bad / dirty sliding contact compensation voltage drum Connection CPU_CONSOLE PBA -> scanner cable -> CPU_IO PBA Defective scanner cable CPU_IO PBA defect CPU_CONSOLE PBA defect Uncontrolled static discharge which interferes with the CPU
22003 + CPU_IO code 4 FE: ~Watchdog detection CPU_IO PBA -> communication failure CPU CONSOLE PBA~
~
Possible cause
Remark
CPU_IO PBA defect Uncontrolled static discharge which interferes with the CPU
102
TSM Oc 9800
Diagnostics
22003 + CPU_I/O code 9 FE: ~Software error on CPU I/O-PBA -> communication failure CPU CONSOLE I/O-PBA~
~
Possible cause
Remark
Defective printer software
The current job is finished and code 9 is displayed on the CPU_IO PBA. The cause of the error is a software bug and the problem must be reported to the R&D department via the following procedure: Execute SDS test 91 (serial number) with value 101010101 and read out the values of R&D info test 22-9-81 -> 91. After this, enter the original serial number again. Notify your Technical Coordinator Department about the problem together with the read values.
22004 + CPU_IO code 3 FE: ~Watchdog SCAnner failure 22PBA02~

~
Possible cause
Remark
CPU_CONSOLE PBA defect Defective scanner R1.2 only. The problem is known if the machine is configsoftware ured in Spanish and can also occur with other languages. Replace the software with the latest version available.
22009 + CPU_IO code 3 FE: ~Software error 22PBA02 (console)~

~
Possible cause
Remark
Defective scanner The current job is finished and code 3 is displayed on the software CPU_IO PBA. The course of the error is a software bug and the problem must be reported to the R&D department via the next procedure: Execute SDS test 91 (serial number) with value 101010101 and read out the values of R&D info test 22-9-81 -> 91. After this, enter the original serial number again. Notify your Technical Coordinator Department about the problem together with the read values.
ed.5
22 Control 103
22101 PE: ~Copy counter not connected~

)
22-2-01 CONCNTPR
Possible cause
Remark
Continuously ON Copy counter defect or not connected CONSUPLV defect
22-4-01 CONCNT
CONDRI OUTDIAG ON
Possible cause
Remark
OFF
Connection DRIVERS PBA -> CONCNT DRIVERS PBA defect DRIVERS PBA defect Connection F1 DRIVERS PBA defect Connection DRIVERS PBA -> CONCNT CONCNT defect
Loose 2205X7
ON
OFF ON
22102 PE: ~Checksum BBR failure 22PBA02 SCA~

~
22-6-07 Initialise BBR CPU_CONSOLE PBA
Possible cause
Remark
Again 22102 after switching off / on
Voltage battery CPU_CONSOLE Charging time: max. PBA < 3 V if the downtime is 20 hrs. more than 30 days CPU_CONSOLE PBA defect
104
TSM Oc 9800
Diagnostics
22103 PE: ~Checksum BBR failure 22PBA01 printer~

~
22-6-06 Initialise BBR CPU_IO PBA
Possible cause
Remark
Again 22103 after switching off / on
Voltage battery CPU_IO PBA < 3 Loading time: max. V if the downtime is more than 20 hrs. 30 days CPU_IO PBA defect
22104 PE: ~PRDUKNIMO controller failure~ 22105 PE: ~PRDLKNIMO controller failure~
~
Possible cause
Remark
CPU_IO PBA defect

22106 PE: ~CONCONEMS supvol out of range~

~
22-9-01 CONCONEMSSUPVOL
Possible cause
Remark
ADC value > 560 (30 V DC) ADC value < 56 (3 V DC)
Mains voltage too high SSR PBA defect Mains voltage too low SSR PBA defect
Check mains voltage Check mains voltage
ed.5
22 Control 105
22107 PE: ~Earth current out of range~

22-9-03 CONCONEARTHCUR Possible cause Remark
ADC value > 716
Connection CTFFHE CFTFHE defect / polluted CURSENS PBA defect CPU_IO PBA defect
ADC value < 100
Connection CURSENS PBA -> CPU_IO PBA CURSENS PBA defect
22501 MRE: ~ADC failure CPU_I/O PBA 22PBA 01~

~
Switch machine OFF Possible cause / ON 24V on 2201X13? Yes No CPU_IO PBA defect Connection 24V CONSUPLV -> DRIVERS PBA Connection 24V DRIVERS -> CPU_IO PBA CONSUPLV defect
Remark
106
TSM Oc 9800
Diagnostics
22502 MRE: ~CONCONEMS supvol out of range~

)
22-9-01 CONCONEMSSUPVOL
Possible cause
Remark
ADC value > 560 (30 V DC)
Mains voltage too high SSR PBA defect CPU_IO PBA defect disconnect 2201X3
Check mains voltage
ADC value < 56 (3 V DC)
Mains voltage too low SSR PBA defect SSR PBA defect CPU_IO PBA defect Connection SSR PBA -> CPU_IO PBA
Check mains voltage
22503 MRE: ~Mains voltage out of range~

)
22-9-02 Possible cause CONMAINSVOL
Remark
Voltage > 265 V L1
Mains voltage too high SSR PBA not adjusted after replacement CPU_IO PBA not adjusted after replacement SSR PBA defect
Check mains L1 22 adju 1 22 adju 1
Voltage < 150 V L1
Mains voltage too low SSR PBA not adjusted after replacement CPU_IO PBA not adjusted after replacement SSR PBA defect
Check mains L1 22 adju 1 22 adju 1
ed.5
22 Control 107
22504 MRE: ~Fail watchdogtest printer 22PBA01~

)
Possible cause
Remark
CPU_IO PBA defect Try to switch machine off / on and SDS on / off again
22505 MRE: ~Fail watchdogtest SCanner 22PBA02~

)
Possible cause
Remark
CPU CONSOLE PBA defect
Try to switch machine off / on and SDS on / off again
22506 MRE: ~PRDUKNIMO controller failure~

~
Possible cause
Remark
CPU_IO PBA defect
22507 MRE: ~PRDLKNIMO controller failure~

CPU_IO PBA defect
22508 MRE: ~MADMO controller failure~

~
Possible cause
Remark
CPU_IO PBA defect
22509 MRE: ~CTFPMO controller failure~

CPU_IO PBA defect
108
TSM Oc 9800
Diagnostics
22510 MRE: ~Earth current out of range ~

)
22-9-03 CONEARTHCUR
Possible cause
Remark
ADC value > 716 Connection CTFFHE CTFFHE defect CURSENS PBA defect CPU_IO PBA defect disconnect 2201X3 ADC value < 100 Connection CURSENS PBA -> CPU_IO PBA CURSENS PBA defect
22511 MRE: ~Keypad_3 PBA defect~
22901 SWAR: ~BBR inform. failure 22PBA02 (SCA)~

22-6-07 Initialise BBR CPU_CONSOLE PBA Possible cause Remark
Again 22901 after switching OFF / ON
Voltage battery CPU_CONSOLE PBA < Loading time: 3 V if the downtime is more than 30 days max. 20 hrs. CPU_CONSOLE PBA defect
22902 SWAR: ~BBR info. failure 22PBA01 printer~

22-6-06 Initialise BBR CPU_IO PBA Possible cause Remark
Again 22902 after switching OFF / ON
Voltage battery CPU_IO PBA < 3 V if the Loading time: downtime is more than 30 days max. 20 hrs. CPU_IO PBA defect
ed.5
22 Control 109
22903 SWAR: ~Fail Real Time Clock with timer: ON~

CPU_IO PBA defect (RTC)
22904 SWAR: ~Service bus transmission failure~

22-6-09 Test service bus Possible cause Remark
Test not OK with testconnector 7991.290 on 10X2
Connection CPU CONSOLE . PBA -> 10X2 CPU_ CONSOLE PBA defect
Test failed with testconnector 7991.290 on RS 232 connector cable Test OK with testconnector 7991.290 on RS 232 connector cable
Connection 10X2 -> laptop
Laptop failure
110
TSM Oc 9800
Diagnostics
Faults if NO SDS is available * 1 Machine is totally dead * 2 Machine is totally dead after CONEMS activated * 3 No LCD (display) indication
* 1 Machine is totally dead Switch CONKEYSW on CONCONEMS switches (listen) Possible cause
YES
Continue with description: Main voltage between L2,N2 > 198 V AC on CONSUPLV G1-1,3
CONKEYSW switched ON Main voltage between L2 and N2 > 198 V AC on Terminal block Possible cause
NO
Ask assistance of local electrician
CONKEYSW switched ON Main voltage between L2 and N2 > 198 V AC on SSR PBA, connector X9 - 1 and 3 Possible cause
NO
22 Q 3 defect / OFF 22Z2 defect / OFF Electrical connection between terminal block and SSR PBA
ed.5
22 Control 111
CONKEYSW switched ON Voltage on SSR PBA between TP2 and 3 > 20 V DC Possible cause
NO YES
SSR PBA defect CONKEYSW defect CONCONEMS defect Electrical connection between SSR PBA and CONKEYSW Electrical connection between SSR PBA and CONCONEMS
CONKEYSW switched ON Main voltage between L2 and N2 > 198 V AC on CONSUPLV G1-1 and 3 Possible cause
NO
Electrical connection between SSR PBA and CONSUPLV SSR PBA defect
YES
If machine is a stand alone printer continue with: Disconnect MIXED SUPPLY G2, G3 (Stand-alone model only)
112
TSM Oc 9800
Diagnostics
CONKEYSW switched ON Disconnect CONSUPLV G2, G3 and G4 Voltage between frame Possible cause (GND) and MIXED SUPPLY G1-2 > 300 V AC G1-3 < - 80 V AC G1-4 < - 60 V AC
NO
CONSUPLV defect Electrical connection CONSUPLV and MIXED SUPPLY
CONKEYSW switched ON Disconnect MIXED SUPPLY G2 and G3 (stand alone only)

Voltage between frame Possible cause (GND) and CONSOLE CPU PBA TP1 > 4.7 V DC TP2 > 10 V DC TP3 > 10 V DC TP4 > 10 V DC
NO (for scanner)
MIXED SUPPLY defect Electrical connection between MIXED SUPPLY and CONSOLE CPU PBA
NO (for stand alone printer)
CONLVSUP defect Electrical connection between CONLVSUP and CONSOLE CPU PBA CONSOLE CPU PBA defect Console Firmware defect
YES
ed.5
22 Control 113
* 2 Machine is totally dead after CONEMS activated Possible cause Remark
Electrical connection between SSR PBA and CTFPCLEHE(1/2) short circuit to drum (left side edge)
*3 No LCD (display) indication Note: The other functions of the operating panel (push buttons/ 7 segment displays) are functioning.
Possible cause
Remark
Electrical connection between SUPPLY TL INVERTER PBA and LCD
TL Lamp is off
Electrical connection between CONSU- TL Lamp is off PLV and SUPPLY TL INVERTER PBA Electrical connection CONSOLE CPU PBA and LCD CONSOLE CPU PBA defect LCD defect SUPPLY TL INVERTER PBA defect TL Lamp is off TL Lamp is off TL Lamp is off TL Lamp is off
114
TSM Oc 9800
Diagnostics
SDS
1 CONtroller
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
22 Control 201
Test nr. Input tests 22-2-01 22-2-02 22-2-03
Component
Signal
Description
CONtrol CouN- Control counter present Ter PResent ON = counter not present CONtrol KEY SWitch CONtrol REMote COpy SWitch Control key switch scanner in timer position ON = switch in timer position Control remote copy switch pressed ON = switch pressed
22-2-04
CONtrol DRIv- Control detection diagnose signal active ers INput DIAG- ON = diagnose correct nose CONtrol DRIv- Control detection diagnose signal active ers OUTput OFF = diagnose correct DIAGnose CONtrol MIXed Control detection diagnose signal active supply INput OFF = diagnose correct DIAGnose CONtrol MIXed Control detection diagnose signal active supply OUTput OFF = diagnose correct DIAGnose CONtrol Solid Control detection diagnose signal active State Relays OFF = diagnose correct INput DIAGnose
22-2-05
22-2-06
22-2-07
22-2-08
22Y1
CONtrol CouN- Control counter Ter mechanical total counter ON = counter activated Hardware diagnoses: CONCNTPR CONtrol MOtor Control motor supply SUPply motor supply relays (22Y..) activated ON = relays activated CONtrol REMote COpy LED Control remote copy key led drive of the remote copy key led ON = led on
22-4-02
22-4-03
202
TSM Oc 9800
SDS
Test nr.
Component
Signal
Description
Special tests 22-6-01 ~button test operating panel~
Each push button on the operating panel has his own number indication in the display: Function key 1 (left) = 0 Function key 2/3/4/5 = 1/2/3/4 Function key 6 (right) = 5 Down key = 6 Up key = 7 Section key 4 (right) = 8 Section key 3/2 = 9/10 Section key 1 (left) = 11 Key operator key = 12 Start key = 13 Numeric key 0/1/2/3/4/5/6/7/8/9 = 14/15/16/17/18/19/29/21/22/23 Correction key = 24 and end of test Stop key = 26 Roll 1 selection key = 27 Roll 2 selection key = 28 Roll 3 selection key = 29 Roll 4 selection key = 30 Sheet feed key = 31 Auto-roll key = 32 Zoom step down = 33 Zoom step up = 34 Zoom 100% = 35 Auto zoom = 36 Zoom scroll up = 37 Zoom scroll down = 38 Stamp key = 39 Fold key = 40 Set input key = 41 Exposure light = 42 Exposure dark = 43
22-6-02 ~leds test operating panel~
Leds are switched on/off in sequence with frequency of 1 Hz and numbers from 0..9 are indicated in the displays. The test lasts 15 seconds.
22-6-03 ~display test operating panel~
The LCD display is switched between maximum and half light intensity (frequency 1 Hz)
ed.5
22 Control 203
Test nr. 22-6-04
Component
Signal
Description ~CONtrol EMS~
CTF and PTR must be closed The CONEMS can be activated with the start button. The test is switched off with the correction button. The CONEMS is switched off for approx. 10 sec. and is switched on again. COLD SDS is activated.
22-6-05 ~enable / disable buzzer~
Test to activate (enable) or deactivate (disable) the buzzer. If the buzzer is enabled the buzzer will beep for a short moment.
22-6-06 ~initialize BBR engine~
BBR (Battery Back-up Ram) data reset to default if key 9 is pressed

22-6-07 ~initialize BBR console~
BBR data reset to default if key 9 is pressed
204
TSM Oc 9800
SDS
Test nr. 22-6-08 Must be done when software is corrupt or new software is installed
Component
Signal
Description ~input diagnoses~ This test checks the input diagnosis signals of the SSR PBA, MIXED Supply PBA, DRIVERS PBA and FOLd 1 PBA (and FOLd 2 PBA if a folder is in the configuration)
Automatically done when switching to SDS, (results are shown in the second screen)
The following input diagnose lines are tested: ~conssrindiag~ from: DRUm ASV COMPensation PWM CTF Fuser roller HEater CTF Pres. roller CLEaner HEater PREheater Heater ~conmixindiag~ from: ORiGinal Paper Present SOlenoid ORiGinal MOtor PWM ~condriindiag~ from: DRUm COLD PROCess FAN CORona FAN PrintHeaD FAN DEVeloper MOtor CTF TUBe SOlenoid CTF REFerence HEater CTF Set-up Transfer VAlve CTF Set-up Fuse VAlve CTF Set-up Pressure VAlve DisCHarging FAN/DisCHarging LEDs PRDU SAMPle SOlenoid PRDS TRAnsport CLutch PRDU and L FED MOtor PRDU and L FED MOtor DIRection PRDU and L FED MOtor SELection PRDU and L KNife MOtor PSF CLutch PSF SOlenoid PREheater Transport BRake Data 0 CONtrol MOtor SUPply CONtrol EMS ~confol1indiag~ from: PTR UnFOld SOlenoid If folder is configured: ~confol1indiag~ from: FOL1DEFlector CLutch FOL1 OUTput DEFlector SOlenoid ~confol2indiag~ from: FOL2 FLAT SOlenoid FOL2 DEFlector CLutch FOL2 OUTput tray SOlenoid FOLOFFOUTMO FOL2RUSTOPSO FOL2RUGUIDSO FOL2RUMO
ed.5
22 Control 205
Test nr. 22-6-09
Component
Signal
Description ~Service bus test~
Use test connector (7991.290)

Info tests 22--9-01
CONtrol power CONtrol EMS SUPply VOLtage
~CON CON EMS SUPply VOLtage (adc)~
Actual A/D value of the supply voltage measured on the safety relays (range 0 ... 1023)
22-9-02
CONtrol power ~CONtrol MAINS VOLtage (V/10)~ MAIN Supply Measured supply voltage VOLtage (range 1800 - 2550 V/10) CONtrol EARTH CURrent
~CON EARTH CURrent (adc)~
22-9-03
Earth current reading (range 0 - 1023)
System tests
206
TSM Oc 9800
SDS
Adjustments
1 Calibration mains voltage measurement.
Carry out this adjustment only after replacement of the CPU_I/O PBA or SSR PBA.
Aim:
Correct temperature range of the fuser heaters and a stable CTF temperature regulation.
Correction: 1 Switch off the engine. 2 Remove the left hand side cover.
Caution: parts of the SSR PBA are still connected to the mains supply.
SSR PBA
R92 TP 5 6
3 4 5 6 7 8 9
Adjust the voltmeter to AC and a range of 300 Volt minimum. Connect the voltmeter between TP5 and 6 on the SSR PBA. Switch on the engine. Measure the supply voltage. Select SDS test 22-9-02 (supply voltage x 10). Wait till the reading on the operating panel is stable. Adjust with R92 on the SSR PBA the reading on the operating panel to the value on the voltmeter (+/- 1V).
ed.5
22 Control 301
302
TSM Oc 9800
Adjustments
Dis-/assemblies
1 CPU I/O PBA
1 Before removing the CPU I/O PBA read out the consumable counters, param-
eter settings, configuration and hardware counters or make a data dump with the ST program. 2 Install the new PBA. 3 Carry out the SDS tests:
SDS test Name
22-6-06
Init BBR engine
4 Fill in or dump the consumable counters, parameter settings, configuration,

hardware counter and customer settings.

5 Carry out the following adjustments:
s s s
Calibration mains voltage measurement. on page 301 Working pressure pneumatic system on page 304 function 06 - CTF ~1 : 1 Image length cor. engine~ on page 301 function 06 - CTF
Note: the machine should be switched on for 5 hours to charge the battery.
2 SSR PBA
Installation: Carry out adjustment Calibration mains voltage measurement. on page 301
ed.5
22 Control 401
3 Console CPU PBA

1 Before removing the CONSOLE CPU PBA read out the consumable counters,
parameter settings, configuration, hardware counter and customer settings or make a data dump with the ST program.
Note: The ST programm does not dump the customer settings. Read them out
manually.
2 Install the new PBA. 3 Carry out the SDS tests: SDS test Name
22-6-07
Init BBR console
4 Fill in or dump the consumable counters, parameter settings, configuration,
hardware counter and customer settings.

5 Carry out adjustment TL intensity adjust on page 301function 10 Scanner
(if a Scanner is available).
402
TSM Oc 9800
Dis-/assemblies
4 22G1 CONSUPLV (LV supply)

Note: When replacing the LV supply unit due to a breakdown pay attention to
the following: Verify if an error elsewhere in the machine (e.g. the LV Printhead power supply) did not cause the break down of the LV supply. Solve the other problem first. Load the CONSUPLV step by step.
Note: Do not open the power supply. This may lead to damage by metal chips from the cover.
Note: Never replace the fuse inside the LV power supply as this may lead to
more damage in the machine. After installation of the new unit connect the connectors as follows: Switch off the machine. Connect 22G1G1 22PBA4 SSR PBA (220V). Switch on the machine and check functioning. Switch off the machine. Connect 22G2 22PBA5 Drivers PBA (5V). Switch on the machine and check functioning. Switch off the machine. Connect 22G1G3 22PBA5 Drivers PBA (+24V). Switch on the machine and check functioning. Switch off the machine. Connect 22G1G5 10G1 Mixed supply (SCA + / - 400V DC). Switch on the machine: at this moment it is possible to analyse with SDS test 32, errors possibly related to the problem. 13 Connect 22G1G4 04 Printhead (PHD + / - 400V, PHD + 12 V DC). 14 Switch on the machine and check functioning.
1 2 3 4 5 6 7 8 9 10 11 12
ed.5
22 Control 403
5 DC power supply (Folder and Belt unit)

1 Check if the selector switch on the DC power supply is at the required 230 V
position.
404
TSM Oc 9800
Dis-/assemblies
6 Software upgrading procedure

General
s
Always wear a wrist strap during an upgrade in order to prevent damage on PBA's. Take care when replacing the EPROMs in the sockets. Note the orientation of the EPROM, to be recognised at the top of the EPROM and on the socket on the PBA. Before upgrading the engine, printer/scanner console software, all the consumable counters, parameter settings, service info, customer settings and connectivity settings should be saved. This can be done by making manual notes of the settings or by making a data dump via the Service Terminal and the print settings via scanner/printer console.
Upgrading the 9701/9801 Engine software
1 2 3 4
Upgrading the engine software implies that the CPU firmpack in the engine has to be replaced: Switch off the machine. Open the right-hand side covers of the engine. Remove the controller, if present. Replace the two CPU Engine EPROMs on the Engine CPU IO PBA with the two new CPU Engine EPROMs (see parts and tools for the correct codenumber): EPROM 1 in D18 and EPROM 2 in D19. Re-assemble in reverse order.
Upgrading the 9710/9810 Scanner Console software
1 2 3
Upgrading the console control software implies that the CPU firmpack on the console PBA has to be replaced: Switch off the machine. Open the operating panel of the console. Replace the four CPU console EPROMs on the Console CPU PBA with the four new CPU Console EPROMs (see parts and tools for the correct codenumbers): EPROM 1 in D8, EPROM 2 in D7, EPROM 3 in D10, and EPROM 4 in D9. Re-assemble in reverse order.
ed.5
22 Control 405
Upgrading the 9708/9808 Printer Console software
1 2 3
Upgrading the stand-alone printer console control software implies that the CPU firmpack on the console PBA has to be replaced: Switch off the machine. Open the operating panel of the console. Replace the four CPU Console EPROMs on the Console CPU PBA with the four new CPU Console EPROMs (see parts and tools for the correct codenumbers): EPROM 1 in D8, EPROM 2 in D7, EPROM 3 in D10, and EPROM 4 in D9. Re-assemble in reverse order.
Re-installing the machine parameters/customer settings/print settings
It is strongly recommended to re-install the machine parameter settings and the print settings using the latest Service Terminal Software (from R5.31 Rev.F). If not available all the settings should be re-installed manually.
Using the Service Terminal Software to upload the machine parameter settings/print settings
The following actions are required: s Switch on the system in SDS mode. s Ignore the BBR warnings. s Execute test 22-6-06 ~Init BBR engine~. s Execute test 22-6-07 ~Init BBR console~. s Switch the machine to cold SDS using SDS test 40. s Upload the machine parameter settings, print settings, controller settings by using Service Terminal. s Check and if necessary adjust the new machine configuration. s Execute test 42 and wait until the machine is warm. s Execute adjustment test 10-7-01, ~TL intensity adjustment~. This adjustment is not necessary in case of a Stand Alone Printer. s Execute adjustment test 06-7-01, ~Pressure Roller Torque adjustment~. s Execute the ~1:1 Image length correction printer~ adjustment (adjustment 1 chapter 06, CTF). s Execute the ~1:1 Image length correction scanner~ adjustment (adjustment 2 chapter 09, Original handling). This adjustment is not necessary in case of a Stand Alone Printer. s Check the copy / print quality. s Mark the appropriate modification number in SDS test 95. s Mark the appropriate modification number on the yellow stickers in the machine parts concerned. s Mark the appropriate modification number in the logbook.
406
TSM Oc 9800
Dis-/assemblies
s s s s
Switch off SDS. Switch the machine off and on. Restore the correct time and date in the Key Operator mode. Restore the stamps.
Re-installing machine parameter settings/print settings manually
The following actions are required: s Switch on the system in SDS mode. s Ignore the possible BBR warnings. s Activate SDS test 70, ~Install machine~ and execute all the tests completely. s Activate SDS test 71, ~Install engine~ and only: Refill the parameter settings (xx-1-xx tests) according to the saved information, except: test 06-1-03,~1:1 image length correction printer~. s Execute adjustment test 06-7-01, ~Pressure roller torque adjustment~. s Activate SDS test 72, ~Install scanner~ in case the scanner is a part of the configuration and only: Execute adjustment test 10-7-01, ~TL intensity adjustment~. Refill the parameter settings (xx-1-xx tests) according to the saved information, except: test 09-1-02, ~1:1 image length correction scanner~. s Refill the following parameter settings according to the saved information: 15-1-01, ~Distance PTRTRAISE 1~, 15-1-02, ~Distance PTRTRAISE 2~, 15-1-03, ~Distance PTRTRAISE 3~. s Activate SDS test 73, ~Install folder~ in case the folder is a part of the configuration and: Refill all the parameter settings (xx-1-xx tests) according to the saved information. s Activate SDS test 74, ~Customer installation~, and execute all the tests completely. s Execute the following consumable counter tests and complete the settings according to the saved information: Execute test 01-8-01, ~Drum (lm)~, Execute test 02-8-01, ~Corona pin array (lm)~, Execute test 06-8-01, ~Fuse roller (lm)~, Execute test 06-8-02, ~Pressure roller (lm)~, Execute test 06-8-03, ~Fuse roller cleaner (bl.im.)~, Execute test 06-8-04, ~Pressure roller hole cleaner (bl.im.)~, Execute test 06-8-05, ~Pressure roller build up cleaner (lm)~, Execute test 07-8-01, ~Discharging pin array (lm)~, Execute test 14-8-01, ~Paper guide cloth (lm)~, s Re-install the print settings as they are mentioned on the copy of the Print Settings. s Execute the ~1:1 Image length correction printer~ adjustment (adjustment 1 chapter 06, CTF).
ed.5
22 Control 407
s s s
s s s s s
Execute the ~1:1 Image length correction scanner~ adjustment (adjustment 2 chapter 09, Original handling). Check the copy / print quality. Mark the appropriate modification number in SDS test 95. Mark the appropriate modification number on the yellow stickers in the machine parts concerned. Mark the appropriate modification number in the logbook. Switch off SDS. Switch the machine off and on again. Restore the correct time and date in the Key Operator mode. Restore the not saved customer settings as listed in enclosure 1.
408
TSM Oc 9800
Dis-/assemblies
1 Oc 9800 abbreviations
The Oc 9800 uses specific abbreviations for components used in the machine. These names are used in various functions e.g. SDS, electrical diagrams, functional descriptions and fault descriptions The abbreviation is made from the english names of the CAS function, followed by the component name and eventually followed by a signal name. An example is: PTRMODIR PTR = Paper TRansport (CAS function) MO = MOtor (Component name) DIR = DIRection (Signal)
The following CAS functions are used:

Number CAS Function Abbreviation
01 02 04 05 06
DRUm CORona PrintHeaD DEVeloping Compact Transfer transFuse - Set-up - Fuser roller - Pressure roller
DRU COR PHD DEV CTF CTFS CTFF CTFP DCH ORG SCA IMP PRD PRDU PRDL PRDS PSF
07 09 10 11 12
DisCHarging ORiGinal SCAnner IMage Processing Paper Roll Drawers - Upper - Lower - Support
13
Paper Sheet Feeding
ed.5
22 Control 501
Number
CAS Function
Abbreviation
14 15 18
PREheater - Transport Paper TRansport - Unfolded output FOLder - 1st fold - 2nd fold - Punch consolidate - Output
PRE PRET PTR PTRU FOL FOL1 FOL2 FOLP FOLO INT CON MAD CUS
20 22 23 25
INTerface Control - engine/ scanner MAin Drive Customer
The following component names are used:
Component name
Abbreviation
AIR BALlast BRake CAPacitor CouNTer CLutch COMPRessor CYLinder DEtection FAN HEater INVerter KEY
AIR BAL BR CAP CNT CL COMPR CYL DE FAN HE INV KEY
502
TSM Oc 9800
Component name
Abbreviation
LED LAmp MOtor PUMP SEnsor SOlenoid STAtic SUPply SWitch VAlve
LED LA MO PUMP SE SO STA SUP SW VA
The following signal names are used:
Signal name
Abbreviation
Amplified Analog voltage Buffered Filtered DIRection ENable CouNTer CUrrent ERror Pulse Width Modulation TEMPerature
A VAN B F DIR EN CNT CU ER PWM TEMP
ed.5
22 Control 503
2 The hardware diagnostic system

The Oc 9800 is equipped with hardware diagnose lines and tests. Their function is to determine where the error occurred in the electrical circuit with the help of the hardware on the PBA. The following PBAs are equipped with hardware diagnoses:
s s s s s
SSR PBA, DRIVERS PBA, MIXED supply PBA, 18PBA10 Power I/O (PTR and FOLD1) 18PBA3 Power I/O (FOLD 2)
The drawing below is the situation for the PHDFAN.
< <
The PHDFAN signal (5V) from the CPU I/O PBA is sent to the DRIVERS PBA. This signal is used to de-/activate the PHDFAN driver circuit which will switch on/off the PHDFAN-B signal (24 V signal line). For the hardware diagnosis two feedback lines are available from the DRIVERS PBA to the CPU I/O PBA. The feedback lines are CONDRIINDAG and CONDRIOUTDIAG.
504
TSM Oc 9800
INDIAG lines
The CONDRIINDAG line is the feedback line used for the input signal. The incoming signal (PHDFAN) on the DRIVER PBA is checked. Via an OR-circuit the CPU I/O is informed about the several incoming signals on the DRIVERS PBA, including the PHDFAN signal. The INDIAG line is tested when the technician
s
enters the 2nd SDS screen
Note: Look carefully at the display indication.

s
activating SDS test 22-6-08.
If a feedback signal is OK the display will indicate: input diagnoses correct If the feedback signal fails the display will indicate: input diagnoses incorrect on e.g. PrintHeaD FAN.
OUTDIAG lines
The OUTDIAG line is a feedback line used to check if the OUTPUT signal on the PBA is activated (24 V signal switched on / off).
Note: The OUTDIAG line gives no feedback on the behaviour of the signal be-
tween the PBA (e.g. DRIVERS PBA) and the component, or the component itself. The OUTDIAG line is tested during the OUTPUT test. e.g. The OUTDIAG test for the PHDFAN is as follows: Activate SDS test 04-4-01 (PHDFAN) The SDS screen indicates:
value: outdiag:
OFF OFF
CONtrol DRIvers OUTput DIAGnose
Activate the <START> button:
ed.5
22 Control 505
The SDS screen indicates:
value: outdiag:
ON ON
Possibility 1: The PHD fan is turning:

s
no error occurred
or
Possibility 2:The PHD fan is not turning:

s s
connection problem (wire, connector) between the PBA and the component the PHDFAN is defect.
or
The SDS screen can also indicate:
value: outdiag:
ON OFF
The buzzer gives an intermittent signal. Possibility 3: The PHDFAN is not turning:
s
error on DRIVERS PBA.
506
TSM Oc 9800
22T1 CONSTEPUP TRAFO
06U1 Rear 23U1 Front
see next page
ed.5
22 Control 601
CONCONEMS CONEMS1,2,3
LINE filters 22Z1 ..Z3
Circuit breakers 22Q1-22Q6
3 2 1
22Q6 22Q5 22Q4 22Q3 22Q2 22Q1
22PBA4 SSR
22PBA3 Cursens
PE Terminal block
602
TSM Oc 9800
18 PBA1 I/O 1 st fold + PTR 18PBA2 I/O 2 nd fold 11PBA2 BW Proc.
Controller
11PBA1 DOC MEM 11PBA1 SET MEM
22G1 CONSUPLY 22PBA1 CPU i/O 22PBA5 Drivers
ed.5
22 Control 603
2 Location modification stickers

Engine:
Modification sticker Engine
Modification sticker Controller
604
TSM Oc 9800
Scanner:
Modification sticker scanner
First fold:
Modification sticker 1st fold
ed.5
22 Control 605
Second fold:
Modification sticker 2nd fold
Printer only version:
Modification sticker behind operating panel on engine.
606
TSM Oc 9800
3 Component names
01-Drum DRU Name Component
DRUASVCOMPSE
DRUm Apparent Surface Voltage COMPensation SEnsor DRUm Apparent Surface Voltage COMPensation PUMP DRUm COLDPROces FAN 1-2 DRUm FAN DRUm FAN CAPacitor DRUm FAN INVerter DRUm FAN SWitch DRUm FAN TEMPerature SEnsor
DRUASVCOMPPUMP
DRUCOLDPROCFAN 1-2 DRUFAN DRUFANCAP

DRUFANINV DRUFANSW DRUFANTEMPSE
02-Corona COR Name Component
COR CORFAN(1-3) CORPIN CORSUP
CORona (unit) CORona FAN (1-3) CORona PIN array CORona SUPply
ed.5
22 Control 607
04-Printhead PHD Name Component
PBA, (PHD) DATA RECEIVER PHD PHDFAN PHDPUMP PHDSUP PHDTEMPSE
PBA, (PrintHeaD) DATA RECEIVER PrintHeaD (unit) PrintHeaD FAN PrintHeaD PUMP PrintHeaD SUPply PrintHeaD TEMPerature SEnsor
05- Developing DEV Name Component
DEV DEVMO DEVMOSE DEVTONSE
DEVeloping (unit) DEVeloping MOtor DEVeloping MOtor SEnsor DEVeloping TONer SEnsor
608
TSM Oc 9800
06 Compact transfer transfuse CTF
Fuser-roller CTFF Set-up CTFS Pressure-roller CTFP

Name Component
CTFCOMP CTFDOORSW CTFFHE
Compact Transfer transFuse COMPressor Compact Transfer transFuse DOOR SWitch Compact Transfer transFuse Fuser-roller HEater
CTFFHETEMPERSW Compact Transfer transFuse Fuser-roller HEater TEMPerature ERror SWitch CTFFTEMPSE Compact Transfer transFuse Fuser-roller TEMPerature SEnsor Compact Transfer transFuse OUTput SEnsor Compact Transfer transFuse OUTput HOod SWitch Compact Transfer transFuse Pressure-roller CLEaner HEater
CTFOUTSE CTFOUTHOSW CTFPCLEHE
CTFPCLEHETEMPSE Compact Transfer transFuse Pressure-roller CLEaner HEater TEMPerature SEnsor CTFPCLEHETEMPERSW Compact Transfer transFuse Pressure-roller CLEaner HEater TEMPerature ERror SWitch Compact Transfer transFuse Pressure-roller INVerter Compact Transfer transFuse Pressure-roller MOtor Compact Transfer transFuse Pressure-roller MOtor SEnsor
CTFPINV CTFPMO CTFPMOSE
ed.5
22 Control 609
Name
Component
CTFREFSE CTFSFVA CTFSFCYL CTFSPVA CTFSTCYL CTFSTVA CTFTRANSE
Compact Transfer transFuse REFerence SEnsor Compact Transfer transFuse Set-up Fuse VAlve Compact Transfer transFuse Set-up Fuse Cylinder Compact Transfer transFuse Set-up Pressure VAlve Compact Transfer transFuse Set-up Transfer CYLinder Compact Transfer transFuse Set-up Transfer VAlve Compact Transfer transFuse TRANsport SEnsor
07- Discharging DCH Name Component
PBA, DCHLED (1-3) DCHFAN(1-2) DCHSTAPIN DCHSTASUP
PBA, DisCHarging LED (1-3) DisCHarging FAN (1-2) DisCHarging STAtic PIN array DisCHarging STAtic SUPply
610
TSM Oc 9800
09-Original Handling ORG Name Component
ORGISE ORGMO ORGMOSE ORGPJSE ORGPPSO ORGPRESE ORGSAFSW

ORiGinal Input SEnsor ORiGinal handling MOtor ORiGinal handling MOtor SEnsor ORiGinal Paper Jam SEnsor ORiGinal handling Paper Present SOlenoid ORiGinal PREsent SEnsor ORiGinal SAFety SWitch ORiGinal SYNchronisation SEnsor ORiGinal WIDth SEnsor (1-4)
ORGSYNSE ORGWIDSE(1-4)
ed.5
22 Control 611
10-Scanner SCA Name Component
PBA, SCANNER PROCESSING PBA, SCASUPDI PBA, SCACCD1 PBA, SCACCD2 PBA, SCACCD3 PBA, SCAADC1 PBA, SCAADC2 PBA, SCAADC3 SCALA SCAMIX
PBA, SCAnner Processing PBA, SCAnner SUPply DIstribution PBA, SCAnner Charge Coupled Device 1 PBA, SCAnner Charge Coupled Device 2 PBA, SCAnner Charge Coupled Device 3 PBA, SCAnner Analog Digital Conversion 1 PBA, SCAnner Analog Digital Conversion 2 PBA, SCAnner Analog Digital Conversion 3 SCAnner LAmp SCAnner MIXed
11- Image processing IMP Name Component
PBA, BLACK-WHITE PROCESSING PBA, DOCUMENT MEMORY PBA, SET MEMORY (OPTIONAL)
PBA, BLACK-WHITE PROCESSING PBA, DOCUMENT MEMORY PBA, SET MEMORY (optional)
EXTENDED MEMORY EXTENDED MEMORY
(OPTIONAL I.C.W. PBA,SET MEMORY) 11D1, 11D2, 11D3, 11D4, 11D5, 11D6, 11D7, 11D8
612
TSM Oc 9800
12- Paper roll drawers PRD
Upper PRDU Lower PRDL Support PRDS

Name Component
PRDUFEDMO(1-2)
Paper Roll Drawers Upper FEeDer MOtor (1-2) Paper Roll Drawers Upper FEeDer MOtor SEnsor (1-2) Paper Roll Drawer Upper FEeD OPposite SEnsor Paper Roll Drawer Upper FEeD SWitch (1-2) Paper Roll Drawers Upper KNIfe MOtor Paper Roll Drawers Upper KNIfe MOtor SEnsor Paper Roll Drawers Upper KNIfe POSition SEnsor Paper Roll Drawers Upper LEADing SEnsor Paper Roll Drawers Upper LENgth SEnsor Paper Roll Drawer Upper OPen SWitch Paper Roll Drawers Upper PREsent SEnsor (1-2) Paper Roll Drawers Upper RUN SEnsor (1-2) Paper Roll Drawers Upper SAMPle SOlenoid Paper Roll Drawers Upper WIDe SEnsor (1-9)
PRDUFEDMOSE(1-2)
PRDUFEDOPSE PRDUFEDSW (1-2)

PRDUKNIMO PRDUKNIMOSE
PRDUKNIPOSSE
PRDULEADSE PRDULENSE PRDUOPSW PRDUPRESE(1-2)
PRDURUNSE(1-2) PRDUSAMPSO PRDUWIDSE(1-9)
ed.5
22 Control 613
Name
Component
PRDLFEDMO(3-4)
Paper Roll Drawers Lower FEeDer MOtor (3-4) Paper Roll Drawers Lower FEeDer MOtor SEnsor (3-4) Paper Roll Drawer Lower FEeD OPposite SEnsor Paper Roll Drawer Lower FEeD SWitch (3-4) Paper Roll Drawers Lower KNIfe MOtor Paper Roll Drawers Lower KNIfe MOtor SEnsor Paper Roll Drawers Lower KNIfe POSition SENsor Paper Roll Drawers Lower LEADing SEnsor Paper Roll Drawers Lower LENgth SEnsor Paper Roll Drawer Lower OPen SWitch Paper Roll Drawers Lower PREsent SEnsor (3-4) Paper Roll Drawers Lower RUN SEnsor (3-4) Paper Roll Drawer Support SYNchronisation SEnsor Paper Roll Drawers Support TRAnsport CLutch
PRDLFEDMOSE(3-4)
PRDLFEDOPSE PRDLFEDSW (3-4) PRDLKNIMO PRDLKNIMOSE
PRDLKNIPOSSE
PRDLLEADSE PRDLLENSE PRDLOPSW PRDLPRESE(3-4)
PRDLRUNSE(3-4) PRDSSYNSE
PRDSTRACL
614
TSM Oc 9800
13-Paper sheet feeder PSF Name Component
PSFCL PSFOPSW PSFPRESE PSFSO PSFSYNSE
Paper Sheet Feeder CLutch Paper Sheet Feeder OPen SWitch Paper Sheet Feeder PREsent SEnsor Paper Sheet Feeder SOlenoid Paper Sheet Feeder SYNchronisation SEnsor
4-Preheater PRE
Name
Component
PREHE PRETBR PRETEMPSE PRETEMPERSW
PREheater HEater PREheater Transport BRake PREheater TEMPerature SEnsor PREheater TEMPerature ERror SWitch
ed.5
22 Control 615
15-Paper transport PTR Name Component
PTRBULSE PTRFRAMESW PTRMO PTRMOSE PTRTRAISE1 PTRTRAISE2 PTRTRAISE3 PTRUFOSE PTRUFOSO
Paper TRansport BULge SEnsor Paper TRansport FRAME SWitch Paper TRansport MOtor Paper TRansport MOtor SEnsor Paper TRansport TRAIling SEnsor 1 Paper TRansport TRAIling SEnsor 2 Paper TRansport TRAIling SEnsor 3 Paper TRansport UnFold Output SEnsor Paper TRansport UnFold Output SOlenoid
616
TSM Oc 9800
18-Folder FOL Name Component
PBA, FOL1 IO-INTERFACE
PBA, FOL1 IO-INTERFACE
PBA, FOL1 POWER-I/O PBA, FOLDer 1 POWER-I/O FOL1DEFCL FOL1DEPOSE FOL1DOORSW FOL1FOLMO FOL1FOLMOSE FOL1FOLSE1 FOL1FOLSE2 FOL1INMO FOL1INMOSE FOL1LIMO FOL1LIDOWNSE FOL1LIUPSE FOL1STARTSE FOL1OUTDEFSO PBA, FOL2 IO-INTERFACE FOLder 1 DEFlector CLutch FOLder 1 DEflector POsition SEnsor FOLder 1 DOOR SWitch FOLder 1 FOLder MOtor FOLder 1 FOLding MOtor SEnsor FOLder 1 FOLding SEnsor 1 FOLder 1 FOLding SEnsor 2 FOLder 1 INput MOtor FOLder 1 Input MOtor SEnsor FOLder 1 LIft MOtor FOLder 1 LIft DOWN SEnsor FOLder 1LIft UP SEnsor FOLder 1START SEnsor FOLder 1 OUTput DEFlector SOlenoid PBA, FOL2 IO-INTERFACE
PBA, FOL2 POWER-I/O PBA, FOLder 2 POWER-I/O FOL2DEFCL FOL2DEPOSE FOL2DOORSW FOLder 2 DEFlector CLutch FOLder 2 DEflector POsition SEnsor FOLder 2 DOORSWitch
ed.5
22 Control 617
Name
Component
FOL2FLATSO FOL2FOLMO FOL2FOLMOSE FOL2INMO FOL2INMOSE FOL2OUTSE FOL2OUTSO FOL2STARTSE FOL2TRAISE1 FOL2TRAISE2 FOL2TRAYSW FOLSUPLV
Optionals belt 1 unit
FOLder 2 FLAT SOlenoid FOLder 2 FOLder MOtor FOLder 2 FOLder MOtor SEnsor FOLder 2 INput MOtor FOLder 2 INput MOtor SEnsor FOLder 2 OUTput SEnsor FOLder 2 OUTput SOlenoid FOLder 2 START SEnsor FOLder 2 TRAIling SEnsor 1 FOLder 2 TRAIling SEnsor 2 FOLder 2 TRAY SWitch FOLder SUPply Low Voltage
BELT1DOORSW FOLOBELT1SE FOLOBELT1ENDSE FOLOBELT1MO FOLOBELTVA FOLOPTRMO I/O BOARD RELAY BOARD
punch unit
BELT1 DOOR SWitch FOLder Output BELT1 SEnsor FOLder Output BELT 1 END SEnsor FOLder Output BELT 1 FOLder Output BELT VAlve FOLder Output Paper Transport MOtor
618
TSM Oc 9800
Name
Component
FOLOADJMO FOLOPUSTARTSE FOLOPUMOENDSE FOLOPUMOHOMESE SIDE JOG END SIDEJOGHOME PUDOORSW FOLOPUNEJSO FOLOPUMO
belt2 unit
FOLder Output ADJust MOtor FOLder Output PUnch START SEnsor FOLder Output PUnch MOtor END SEnsor FOLder Output PUnch MOtor HOME Sensor
PUnch DOOR SWitch FOLder Output PUnch EJect SOlenoid FOLder Output PUnch MOtor
FOLOBELT2SE FOLOBELT2ENDSE BELT2DOORSW FOLOBELT2MO
FOLder Output BELT 2 SEnsor FOLder Output BELT 2 END SEnsor BELT 2 DOOR SWitch FOLder Output BELT 2 MOtor
ed.5
22 Control 619
22-Control CON Name Component
CIRCUIT BREAKER CONCNT CONCONEMS CONDRIINDIAG CONDRIOUTDIAG CONEMS1 CONEMS2 CONEMS3 CONFIG BAR CONREMCON CONKEYSW CONSDSSW CONSTEPUPTRAFO CONSUPLV FUSE(1-2) LCD PBA, BACKLIGHT PBA, CPU-IO PBA, CONSOLE-CPU PBA, CURSENS PBA, DRIVERS PBA, KEYPAD1
CIRCUIT BREAKER CONtrol CouNTer CONtrol power CONtrol Electro Magnetic Switch CONtrol DRIvers INput DIAGnosis CONtrol DRIvers OUTput DIAGnosis CONtrol Electro Magnetic Switch 1 (L1) CONtrol Electro Magnetic Switch 2 (L2) CONtrol Electro Magnetic Switch 3 (L3) CONFIG BAR CON REMote CONnection CONtrol KEYSWitch CONtrol Service Diagnostic System SWitch CONtrol STEPUP TRAnsFOrmer CONtrol SUPply Low Voltage FUSE(1-2) LCD PBA, BACKLIGHT PBA, Central Processor Unit-Inputs Outputs PBA, CONSOLE-Central Processor Unit PBA, CURrent SENSor PBA, DRIVERS PBA, KEYPAD1
620
TSM Oc 9800
Name
Component
PBA, KEYPAD2 PBA, KEYPAD3 PBA, KEYPAD4 PBA, SSR RFI FILTER(1-3) SERVICE CONNECTOR
23-Main drive MAD Name
PBA, KEYPAD2 PBA, KEYPAD3 PBA, KEYPAD4 PBA, Solid State Relays RFI FILTER(1-3) SERVICE CONNECTOR
Component
MADMO MADMOSE
MAin Drive MOtor MAin DRive MOtor SEnsor MAin Drive MOtor INVerter
MADMOINV
4 Indentification bundle names

Numbers are printed on the wires in a bundle, e.g. 120106. 12 = number of CAS-group 01 = bundle number 06 = wire number Search for 12W01 in the spare parts list to find the accompanying code number.
ed.5
22 Control 621
622
TSM Oc 9800
1
PE PE PE
2
EARTH 22X010 CIRCUIT BREAKERS
3
X9 2 LINE FILTERS 3 1 5 6 4 L1 6 N1 2 8 4
4
22PBA4 SSR
TP2 TP1 X1 20 19 18 17 21
5
WITH SCANNER CONCONEMS-B GND CONKEYSW CONKEYSW CONCONEMSSUP 22X8 22X1 3 E 2 1 C A 10X1 E C A
6
CONKEYSW
22S1
3 6 1 4 2 5
A
N3 L1 N1 L2 N2 N3 L1 N1 L2 N2 L3 N3 L1 N1
LINE LOAD
1 1
22Q2
2
X11 4 1
L1-S N1-S
CONCONSUP
22Q1
22Z1
CONCONEMS
22K4-2A
22Q3
L2 N2 L3 1 1 2 3 1
22Z2
LINE LOAD 5 6 4 L2 N2 X9 1 3
F1 0.031A
22Q4
2
B
L3
22Q5
1 1 2 3 1
22Z3
LINE LOAD 5 6 4 6 2 8 4 X11 L3-S 3 N3-S 6
22Q6
2
X5 1 2 X4 3 2 X3 1 4 3 6 5 2 X12 1 5 X6 6 3 9 12 7 10 X2 6 5 12 11 15 14 X7 4 5
L2 N2 N2-MNO L2-MNO L2-MNO N2-MNO L2-MNO N2-MNO L2-MNO N2-MNO L3-S N3-S L2-S
6 2
8 4
22G1 CONSUPLV
G1 1 3 2 18-FOLDER 20-CONTROLLER 22X002-4
22X014 PE 22X016 MAIN-FRAME
22X015 MAIN FRAME 00X00 FRAME-DOORS 8 4 6 2 X8 6 3 1 4
N2 L2 L2-S N2-S
14-PREHEATING
C
22PBA5 DRIVERS
X12 12 15 14 13 11 16 X5 8 CONEMS2-B +24V-SW CONEMS3-B +24V-SW CONEMS1-B +24V-SW
06-CTF L2-S N2-S L2-S N2-S L2-S N2-S L2-S N2-S L2-S N2-S L2-SSU N2-S 04-PRINTHEAD 23-MAIN DRIVE
CONEMS2
22K2-2A
PHD 400VDC PHD PHD+12V PHDON-OFF
G4 1 2 3 4
CONEMS3
22K3-2A
18-FOLDER/19-SRU 01-DRUM 01-DRUM
CONEMS1
22K1-2A
06-CTF
PTRFRAMESW
+24V-SW 2 15S1 1
22T1 CONSTEPUPTRAFO
1 208V 2 220V 3 230/240V 4 230V 5 N2-S L2-S L2-SSU
F2 3A
X7 2 1 3 X1 28 30
10G1 MIXED SUPPLY

SEE 22-CONTROL 702 MAINS VOLTAGE METER G1 2 3 4 X3 8 16 X9 7 8 13 11 9 1 2 3 SCA+400VDC SCA-400VDC SCACONTROL G5 1 2 3
CTFDOORSW
7 X12 23 20 X12 6 +24V +24V GND 1 O6S1 2
22PBA1 CPU I/O

X1 14 16 7 8 13 11 9 TP6 X10 3 2 CONMAINSVOL CONCONEMSSUPVOL +5V GND CONKEYSW CONCONEMS CONSSRINDIAG
22PBA3 CURSENS
+24V 22X10 1
CONCNT
22Y1
CONCNT-B
2 X1 1 3
X14 2 1 X13 N1-SM 1 L1-SM 2 N1-S L1-S
TP5
06-CTF CONEARTHCUR +5VAN X3 10 2 X8 14 16 17 11 X11 6 7 X6 27 28 10 X13 1 2 3 5
S1
BATTERY A1
F
X7 6 7 X6 27 28 10 X10 1 2 3 5 X8 1 2 3 4 5 6 7 8 9 10 CONCNT CONCNTPR CONDRIINDIAG CONDRIOUTDIAG CONEMS +5V GND +24V GND +5V GND +5V GND +24V GND +24V GND +24V GND
22X2 +5V 2 GND 3 REMOTE SWITCH CONREMCOSW 1 CONREMCOLED 4
11PBA1
X5 4 3 +5V GND G3 5 6
F4 4A
F1 4A
H
ed.5
1 2 3 4 G2 1 2 3 4 5 6
TSM Oc 9800
CONTROL 1 22 Control 701
2
G2 5 13
3
10G1 MIXED SUPPLY
+5V GND
4
G1 1 2 G2 1 3
6
22LCD1 LCD DISPLAY
22G2 SUPPLY TL-INVERTER
A
ENGINE
22G1 CONSUPLV
G5 1 2 3 22X1 SCA L SCA 400VDC M SCACONTROL K N 22X004 Fuse 10X1 L M K N G1 2 3 4 1 Fuse 3A G2 1 2 3 4 7 8 9 10 15 16 17 18 11 12 G3 6 5 +5V +5V +5V +5V GND GND GND GND +12V +12V +12V +12V GND GND CONMIXOUTDIAG CONMIXINDIAG
22PBA2 CONSOLE_CPU
X1 1 2 3 4 5 6 7 8 9 10 11 X3 1 2 3 TP1 X4 1 2 3 4 5 6 7 8 9 10 11 12 13 15 +5V GND CL2 ENLCD FLM CL1 GND M LCD0 LCD1 LCD2 LCD3 -24V GND LCD1 1 2 3 4 5 6 7 8 9 10 11 12 13 15
TP0
3A
TP2 TP3 TP4 TP5
S1
1 2 3 BATTERY A1
22PBA6 KEYPAD1
X5 2 5 6 7 8 9 10 11 12 13 14 15 16 17 +25V KP1S1 KP1S2 KP1S3 KP1S4 KP1S5 KP1S6 KP1S7 KP1S8 KP1S9 KP1S10 KP1S11 KP1S12 KP1S13 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14
22PBA8 KEYPAD3
X2 5 6 X1 1 2 3 4 5 6 8 9 20 12 13 14 15 16 17 18 19 24 25 26 27 28 30
+12V +5V GND GND NRD3 NRD4 NWR3 NWR4 BNRESET KP3D0 KP3D1 KP3D2 KP3D3 KP3D4 KP3D5 KP3D6 KP3D7 KP3A1 KP3A2 KP3A3 KP3A4 INT3 +5V
X7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24
22PBA7 KEYPAD2
X6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 +12V +5V GND NRD1 NRD2 NWR1 NWR2 NRESET KP2D0 KP2D1 KP2D2 KP2D3 KP2D4 KP2D5 KP2D6 KP2D7 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E
22PBA1 CPU I/O
X14 10 9 8 7 6 4 3 2 1 GND CONCTS CONNCTS CONNRXD CONRXD CONRTS CONNRTS CONNTXD CONTXD H T S V U W X Y Z H T S V U W X Y Z X10 11 3 4 2 1 7 8 6 5
22PBA9 KEYPAD4
X9 1 2 3 4 5 6 7 8 9 13 14 15 16 17 18 19 20 +12V +5V GND GND KP4S1 KP4S2 KP4S3 KP4S4 KP4S5 KP4D0 KP4D1 KP4D2 KP4D3 KP4V1 KP4V1 KP4V1 KP4V1 X1 1 2 3 4 5 6 7 8 9 13 14 15 16 17 18 19 20
G
22PBA9 KEYPAD4
22PBA6 KEYPAD1
22PBA2 CONSOLE_CPU
22PBA8 KEYPAD3 CONSDSSW
X5 19 20 1 X11 1 2 3 4 5
22S2 CONSDSSW +5V +5V 1
CONSDSSW
3
22LCD1 LCD DISPLAY

22G2
H
ed.5
22PBA7 KEYPAD2
TXD RTS RXD CTS GND
10X2 2 4 3 5 7
RS232
TSM Oc 9800
CONTROL 2 WITH SCANNER 22 Control 702
1
ENGINE
3
22PBA8 RFI COMBI
X3 X4 2 1 3 2 1 5 6 9 10 11 +5V +5V GND GND +12V +12V +12V 3 4 +5V GND
4
G1 1 2 G2 1 3
6
22LCD1 LCD DISPLAY
22G2 SUPPLY TL-INVERTER
22G1 CONSUPLV
G6 2 1 3
+5V GND +12V
22PBA2 CONSOLE_CPU
X1 2 1 5 6 9 10 11 8 7 X3 3 2 1 X10 11 3 4 2 1 7 8 6 5 TP1 TP0 TP2 X4 1 2 3 4 5 6 7 8 9 10 11 12 13 15 +5V GND CL2 ENLCD FLM CL1 GND M LCD0 LCD1 LCD2 LCD3 -24V GND LCD1 1 2 3 4 5 6 7 8 9 10 11 12 13 15
OPERATING PANEL 22X011
GND GND
B
22X004-3 22X009 CONSOLE X2 9 3 4 2 1 7 8 6 5 X1 9 3 4 2 1 7 8 6 5 12 +12V
22PBA1 CPU I/O

X14 10 9 8 7 6 4 3 2 1 GND CONCTS CONNCTS CONNRXD CONRXD CONRTS CONNRTS CONNTXD CONTXD GND CONCTS CONNCTS CONNRXD CONRXD CONRTS CONNRTS CONNTXD CONTXD
22PBA6 KEYPAD1
X5 2 5 6 7 8 9 10 11 12 13 14 15 16 17 +25V KP1S1 KP1S2 KP1S3 KP1S4 KP1S5 KP1S6 KP1S7 KP1S8 KP1S9 KP1S10 KP1S11 KP1S12 KP1S13 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14
S1
1 2 3 BATTERY A1
22PBA7 KEYPAD2
X6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 +12V +5V GND NRD1 NRD2 NWR1 NWR2 NRESET KP2D0 KP2D1 KP2D2 KP2D3 KP2D4 KP2D5 KP2D6 KP2D7 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CONSDSSW
3
22S2 1 CONSDSSW +5V +5V
X2 15 16 17
X1 15 16 17
CONSDSSW +5V +5V
X5 19 20 1 X11 1 2 3 4 5
RS232
22X6 2 4 3 5 7
TXD RTS RXD CTS GND
10 11 12 13 14
10 11 12 13 14
TXD RTS RXD CTS GND
CONKEYSW See 22 Control 701
22PBA6 KEYPAD1
22PBA2 CONSOLE_CPU
22LCD1 LCD DISPLAY

22G2
H
ed.5
22PBA7 KEYPAD2 CONSDSSW
TSM Oc 9800
CONTROL 3 STAND ALONE PRINTER 22 Control 703
Oc
Oc 9800
23 MAIN DRIVE
Contents
Diagnostics
1 Faults
101
SDS
1 MAin Drive
201
Adjustments
1 Main drive belt 301 2 Motor plate drive belt 302 3 Drive belt preheater 303 4 Drive belt paper transport 304
601
Diagrams
1 Main drive (from engine 484) 701 2 Main drive (up to engine 483) 702 3 Modification 25 703
ed.5
23 Main drive
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. MAin Drive 23000 - 23999 code display 23501 MRE: Speed MADMO out of range~
23-2-01 MADMOSE Possible cause Remark
Pulse disc loose of MADMO or CTFPMO

Blockade motor shaft and check that the pulse disc cant rotate.
Continuously ON
Pulse disc defect MADMOSE defect CPU_IO PBA defect disconnect 2201X5
Continuously OFF
Connection MADMOSE-> CPU_IO PBA Pulse disc defect MADMOSE defect CPU_IO PBA defect
to be continued
ed.5
23 Main drive 101
continued
23-4-01 MADMO MADMO turning Possible cause Remark
OFF ON
Yes No
MADMOINV defect CPU_IO PBA defect MADMO defect MADMOINV defect Connection L2-> MADMOINV Connection CPU_IO PBA -> MADINV Connection Drivers PBA -> MADINV MADMO mechanically blocked PRETBR mechanically blocked Bearings preheating rollers blocked Bearings input roller preheating blocked Hinges / clutches MADMO blocked Bearings pulleys MADMO blocked Bearings fuser roller blocked Bearings drum blocked
22-6-04 CONEMS Possible cause (or test 40) switching CONEMS (listening!)
Remark
ON
Yes No
Connection mains L2 -> CONEMS2 F1 DRIVERS PBA defect 24V users on 2205X11 24V users on 2205X12 24V users on 2205X1 (PRDL) 24V users on 2205X3 (PRDU) 24V users on 2205X5 (PRD(U/L)OPSW DRIVERS PBA defect
102
TSM Oc 9800
Diagnostics
SDS
1 MAin Drive
see SDS
see SDS
32
see SDS
see SDS
see SDS
see SDS
ed.5
23 Main drive 201
Test nr. Input tests 23-2-01
Component
Signal
Description
23B1
MAin Drive MOtor SEnsor
Main drive motor sensor ON = sensor blocked by pulsdisc
23M1
MAin Drive MOtor PWM
Main drive motor PWM ON = motor activated at 100% PWM
Functions 06 (CTF), 12 (paper roll drawer), 13 (paper sheet feeder), 14 (pre-heater) and 23 (main drive) in warm condition
Functions 06 (CTF), 12 (paper roll drawer), 13 (paper sheet feeder), 14 (pre-heater) and 23 (main drive) in cold condition
System tests
202
TSM Oc 9800
SDS
Adjustments
1 Main drive belt
Aim:
Make sure that the drum drive belt is tensioned correctly, to prevent that: - The shaft end of the paper transport roller (z-1230 index 1) will break off. - Head margins of the copies/prints are out of specs.
Check:
Bracket -E- must just touch the shoulder -D-.

Correction: 1 Loosen the bolt -A- and loosen the bolt -B- just enough to move the tensioner.
Note: Axial play for bolt B is not allowed. 2 Move the bracket -C- in arrow direction until the shoulder -D- just touches the
bracket -E-.
3 Tighten first the bolt -B- than bolt -A-. 4 Carry out SDS test 23-4-01 for 1 minute or turn a few times the main drive belt
with the crank from the heater unit.

5 Repeat point 1 up to 3.
A E
D B
ed.5
23 Main drive 301
2 Motor plate drive belt

Aim:
Make sure that the motor plate drive belt is tensioned correctly.
Check:
Bracket -D- must touch bracket -E-.

Loosen the bolts -A-, -B- and -C-. Move the bracket -D- until it touches the bracket -E-. Tighten first the bolts -A- than the bolts -B- and -C-. Switch on the engine. Carry out SDS test 23-4-01 for 1 minute. Repeat point 1 up to 3.
E A B
302
TSM Oc 9800
Adjustments
3 Drive belt preheater

Aim:
Make sure that the preheater drive belt is tensioned correctly.

Check:
The adjusting bracket must just touch the pulley strip.

Note: Only the screws of the adjusting bracket are outside the frame. Correction: 1 2 3 4 5
Loosen at the left side the screws of the adjusting bracket. Move the adjusting bracket upwards until it just touches the pulley strip. Tighten the screws. Switch on the machine for 1 minute. Check the adjustment again.
drive belt
spring
screws pulley strip
adjusting bracket
ed.5
23 Main drive 303
4 Drive belt paper transport

Aim:
To ensure that the drive belt paper transport is tensioned correctly to avoid speed differences during transport.
Check:
Corner -B from bracket -A- must touch bracket -C-.

Loosen the bolts -D- and -E-. Move the bracket -A- until the corner -B- touches the bracket -C-. Tighten first the bolt -D- than bolt -E-. Switch on the machine and make some copies. Check the adjustment again.
drive belt
bracket A corner B bracket C
screw D
screw E
304
TSM Oc 9800
Adjustments
MADMO
MADINV
ed.5
23 Main drive 601
602
TSM Oc 9800
1
22G1 CONSUPLV
2
22PBA5 DRIVERS
X8 5 6 7 8 9 10 1 2 3 4 F4 4A F1 4A 8 +24V-SW X5 7 +24V
4
CTFDOORSW
1 O6S1 2 1
5
PTRFRAMESW
2 15S1
22PBA1 CPU I/O

X13 1 2 3 5 X6 27 +5V GND +24V GND X10 1 2 3 5 X6 27 X12 12 CONEMS2-B 22K2-2A 15 CONDRIINDIAG +24V-SW
CONEMS2
GND
X11 21
23U1 MADINV
U6 5 F1 5A 4 GND U2 1 -UzK +UzK 300VDC
to 06U1 CTFPINV on page 06-701
2 22X006-2 N2-S L2-S 23X1 5 1 U4 1 4 3 2 6 T1 T3 T2 E 1 4 3 2 1 3 2
22PBA4 SSR
X6 10 7 X8 1 4 N2-S L2-S 4 8 2 6
X5 9
3 MADMOPWM 2
MADMO
M
3
23M1
6 8 7
+5V GND MADMOSE
22X11 3 5 4
MADMOSE
23B1
22X006-3
23X001
22Z2
6 5 4 L2 N2 22X010 3 3 X9 1 2 6 L2 N2
H
(from engine 484) ed.5 TSM Oc 9800 23 Main drive 701
1
22G1 CONSUPLV
2
22PBA5 DRIVERS
X8 5 6 7 8 9 10 1 2 3 4 F4 4A F1 4A 8 +24V-SW X5 7 +24V
4
CTFDOORSW
1 O6S1 2 1
5
PTRFRAMESW
2 15S1
22PBA1 CPU I/O

X13 1 2 3 5 X6 27 +5V GND +24V GND X10 1 2 3 5 X6 27 X12 12 CONEMS2-B 22K2-2A 15 CONDRIINDIAG +24V-SW
CONEMS2
GND
X11 21
23U1 MADINV
U2 5 4 U1 2 4 5 3 23X1 5 6 T3 T2 T1 E 4 3 1 2 1 3 2 3 -UzK 300VDC +UzK
GND GND RUNFWD X5 9
2 22X006-2 N2-S L2-S
22PBA4 SSR
X6 10 7 X8 1 4 N2-S L2-S 4 8 2 6
MADMOPWM
1 8 7 6 9 6 8 7 +5V GND MADMOSE 22X11 3 5 4
MADMO
M
3
23M1
MADMOSE
23B1
22X006-3
23X001
22Z2
6 5 4 L2 N2 22X010 3 3 X9 1 2 6 L2 N2
H
ed.5 TSM Oc 9800 (up to engine 483) 23 Main drive 702
2
23U1 MADINV
U2 5 -UzK
A
U1 2 GND RUNFWD X5 9 MADMOPWM 4 5 3
300VDC 4 +UzK
2 22X006-2 3 N2-S L2-S
22PBA4 SSR
X6 10 7 X8 1 4 N2-S L2-S 4 8 2 6
From 06 Compact transfer transfuse 705

23X1 5 6 T3 T2 T1 E 4 3 1 2 1 3 2
B
+5V GND MADMOSE 22X11 3 5 4
8 7 6 9 6 8 7
MADMO
M
3
23M1
MADMOSE
23B1
22X006-3
23X001
22Z2
6 5 4
L2 N2 22X010
X9 1 2 3
6 3
L2 N2
(Up to engine 484)
23U1 MADINV
U6 5 F1 5A -UzK +UzK 300VDC
E
U2 1
2 22X006-2 N2-S L2-S
22PBA4 SSR
X6 10 7 X8 1 4 N2-S L2-S 4 8 2 6
X5 9
3 MADMOPWM 2 1 U4 1 4 3 2 6 T1 T3 T2 E 1 4 3 2 1 3 2
From 06 Compact transfer transfuse 705

23X1 5
MADMO
M
3
F
6 8 7 +5V GND MADMOSE 22X11 3 5 4
23M1
MADMOSE
23B1
22X006-3
23X001
22Z2
6 5 4
L2 N2 22X010
X9 1 2 3
6 3
L2 N2
H
Modification 25 ed.5 TSM Oc 9800 (From engine 484) 23 Main drive 703
Oc
Oc 9800
25 CUSTOMER/ENVIROMENT
Contents
Diagnostics
1 Faults
101
SDS
1 CUStomer / environment
201
1 Machine configurations 501 2 Model series and configuration types of the Oc 9800
502
ed.5
25 Customer / environment
TSM Oc 9800
Contents
Diagnostics
1 Faults
Use the ST program for the latest up-date. CUStomer / environment 25000 - 25999 code display 25701 ORE: ~Upper / lower paper roll open~
12-2-09 PRDUOPSW Possible cause 12-2-30 PRDLOPSW Remark
Continuously ON
Connection PRD(U/L)OPSW -> CPU_IO PBA PRD(U/L)OPSW defect Receiving material stuck on roll core
Instruct customer
25702 ORE: ~Covers CTF open: (CTFDOORSW)~

06-2-03 CTFDOORSW Possible cause Remark
Continuously ON
.
Connection CTFDOORSW -> CPU_IO PBA CTFDOORSW defect
06-2-05 Possible cause CTFOUTHOSW
Remark
Continuously ON
Connection CTFOUTHOSW -> CPU_IO PBA CTFOUTHOSW defect
ed.5
25 Customer / environment 101
25703 ORE: ~PTRDOOR open: PTRFRAMESW~

)
15-2-06 PTRFRAMESW
Possible cause
Remark
Continuously ON Connection PTRFRAMESW -> CPU_IO PBA PTRFRAMESW defect
25704 ORE: ~FOL1DOORS open: FOL1DOORSW~

)
18-2-02 Possible cause FOL1DOORSW
Remark
Continuously ON
Connection FOL1DOORSW -> POWER_IO PBA Connection POWER_IO PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA FOL1DOORSW defect
25705 ORE: ~Folding: door FOL2 open~

18-2-08 Possible cause FOL2TRAYSW Remark
Continuously ON
Connection FOL2TRAYSW -> POWER_IO PBA Connection POWER_IO PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA FOL2TRAYSW defect
102
TSM Oc 9800
Diagnostics
18-2-09 FOL2DOORSW
Possible cause
Remark
Continuously ON Connection FOL2DOORSW -> POWER_IO PBA Connection POWER_IO PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA FOL2DOORSW
25706 ORE: ~folder output delivery doors open~

~
18-2-22 FOLOPUDOORSW
Possible cause
Remark
Continuously Connection FOLOPUDOORSW -> POWER_IO ON PBA Connection POWER_IO PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA FOLOPUDOORSW defect
18-2-25 Possible cause FOLOBELT1 DOORSW
Remark
Continuously Connection FOLOBELT1DOORSW -> POWER_IO ON PBA Connection POWER_IO PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA FOLOBELT1DOORSW defect
ed.5
18-2-28 Possible cause FOLOBELT2 DOORSW
Remark
Continuously Connection FOLOBELT2DOORSW -> POWER_IO ON PBA Connection POWER_IO PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA FOLOBELT2DOORSW defect
25707 ORE: ~SCA open (ORGSAFSW) while scanning~

~
09-2-08 Possible cause ORGSAFSW
Remark
Continuously Connection ORGSAFSW -> KEYPAD3 PBA ON Scanner not closed correctly Instruct customer ORGSAFSW defect
104
TSM Oc 9800
Diagnostics
25708, 25709, 25710, 25711 ORE: ~Wrong format roll 1-4: PRDUWIDSE 1-9~
)
12-2-13 up to 12-2 21 PRDUWIDSE 1-9
Possible cause
Remark
Continuously ON PRDUWIDSEn defect Actuator defect CPU_IO PBA defect (disconnect 2201X7) Continuously OFF PRDUWIDSEn defect Actuator defect Connection PRDUWIDSEn -> PRDU DISTRIBUTION PBA Connection PRDU DISTRIBUTION PBA -> CPU_IO PBA
Connection PRDU DISTRIBUTION PBA -> DRIVERS PBA CPU_IO PBA defect
ed.5
25712 ORE: ~Warm up: p. path CTF /PRDS / PSF not free~
06-2-02 CTFOUTSE Possible cause Remark
Continuously ON
12-2-34 PRDSSYNSE
Possible cause
Remark
Continuously ON
13-2-02 PSFSYNSE Possible cause
Remark
Continuously ON
Connection PSFSYNSE -> 13X1 -> CPU_IO PBA Actuator defect PSFSYNSE defect CPU_IO PBA defect (disconnect 2201X8)
106
TSM Oc 9800
Diagnostics
25713 ORE: ~PRDUFEDOP unit not present~

~
12-2-10 Possible cause PRDUFEDOPSE
Remark
Continuously OFF
Feed opposite unit badly positioned Connection PRDUFEDOPSEn -> PRDU DISTRIBUTION PBA Connection PRDU DISTRIBUTION PBA -> CPU_IO PBA Connection PRDU DISTRIBUTION PBA -> DRIVERS PBA Actuator defect PRDUFEDOPSEn defect CPU_IO PBA defect
25714 ORE: ~PRDLFEDOP unit not present~

~
12-2-31 Possible cause PRDLFEDOPSE
Remark
Continuously OFF
Feed opposite unit badly positioned Connection PRDLFEDOPSEn -> PRDU DISTRIBUTION PBA Connection PRDL DISTRIBUTION PBA -> CPU_IO PBA Connection PRDL DISTRIBUTION PBA -> DRIVERS PBA Actuator defect PRDLFEDOPSEn defect CPU_IO PBA defect
ed.5
25715 ORE: ~Start run: paper path PRD not free~

~
12-2-03 / 12-2 24 PRD(U/L)LEADSE
Possible cause
Remark
Continuously ON
PRD(U/L)LEADSE defect Actuator defect CPU_IO PBA defect (disconnect 2201X7 or 2201X10)
25716 ORE: ~Start run: paper path PSF not free~

~
13-2-02 PSFSYNSE
Possible cause
Remark
Continuously ON
Connection PSFSYNSE -> 13X1 -> CPU_IO PBA Actuator defect PSFSYNSE defect CPU_IO PBA defect (disconnect 2201X8)
25717 ORE: ~Paper path PRDS / CTF not free~

)
06-2-02 CTFOUTSE
Possible cause
Remark
Continuously ON
12-2-34 PRDSSYNSE
Possible cause
Remark
Continuously ON
108
TSM Oc 9800
Diagnostics
25718 ORE: ~Start run: paper path PTR not free~

~
15-2-01 PTRBULSE
Possible cause
Remark
Continuously ON
Connection PTRBULSE -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRBULSE defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect CPU_IO PBA defect
15-2-02 PTRUFOSE
Possible cause
Remark
Continuously Connection PTRUFOSE -> SENSOR DISTRIBUON TION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRUFOSE defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect CPU_IO PBA defect
ed.5
Remark
Continuously ON
Connection PTRTRAISE2 -> SENSOR DISTRIBUTON PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRTRAISE2 defect CPU_IO PBA defect
Remark
Continuously ON
Connection PTRTRAISE1 -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRTRAISE1 defect CPU_IO PBA defect
15-2-05 PTRTRAISE3
Possible cause
Remark
Continuously ON
110
TSM Oc 9800
Diagnostics
25719 ORE: ~Start run: FOL pap. path not free~

,
15-2-01 PTRBULSE
Possible cause
Remark
Continuously ON
Connection PTRBULSE -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect PTRBULSE defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect CPU_IO PBA defect
Remark
Continuously ON
to be continued
ed.5
continued
18-2-01 FOL1STARTSE Possible cause Remark
Continuously ON
Connection FOL1STARTSE -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect FOL1STARTSE defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect CPU_IO PBA defect
18-2-10 Possible cause FOL2OUTSE1
Remark
Continuously ON
Connection FOL2OUTSE1 -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect FOL2OUTSE1 defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect CPU_IO PBA defect
to be continued
112
TSM Oc 9800
Diagnostics
continued
18-2-06 Possible cause FOL2TRAISE2 Remark
Continuously ON
Connection FOL2TRAISE2 -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect FOL2TRAISE2 defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect CPU_IO PBA defect
18-2-04 FOL2STARTSE
Possible cause
Remark
Continuously ON
Connection FOL2STARTSE -> SENSOR DISTRIBUTION PBA Connection SENSOR DISTRIBUTION PBA -> IO_INTERFACE PBA Connection IO_INTERFACE PBA -> CPU_IO PBA Actuator defect FOL2STARTSE defect SENSOR DISTRIBUTION PBA defect IO_INTERFACE PBA defect CPU_IO PBA defect
ed.5
25720 ORE: ~Start run: original path not free~ 25721 ORE: ~Start calibrate: org path not free~
09-2-06 ORGSYNSE Possible cause Remark
Continuously Connection CONSOLE_CPU PBA -> KEYPAD3 ON PBA Connection ORGSYNSE -> 09X3 -> KEYPAD3 PBA ORGSYNSE defect Actuator defect KEYPAD3 PBA defect CONSOLE_CPU PBA defect
09-2-07 ORGPJSE
Possible cause
Remark
Continuously Connection CONSOLE_CPU PBA -> KEYPAD3 ON PBA Connection ORGPJSE -> 09X3 -> KEYPAD3 PBA ORGPJSE defect Actuator defect KEYPAD3 PBA defect CONSOLE_CPU PBA defect
09-4-01 CONMIX- Original Possible cause ORGPPSO OUTDIAG stop open
Remark
ON
OFF
No
Connection CONSOLE CPU PBA -> KEYPAD3 PBA Connection KEYPAD3 PBA -> MIXED SUPPLY Connection MIXED SUPPLY -> ORGPPSO MIXED SUPPLY defect KEYPAD3 PBA defect
ON
ON
No
ORGPPSO blocked / defect
114
TSM Oc 9800
Diagnostics
25722 ORE: ~Power down in run: remove paper~

~
Possible cause
Remark
Machine switched off during RUN or Error situation
Instruct the customer that he must not switch off the machine during a run. After an ORE all paper must be removed as indicated in the operating panel before switching off the machine.
Key switch defect Connection SSR PBA -> CONCONEMS Connection CONCONEMS -> SSR PBA Connection SSR PBA -> key switch Connection key switch -> SSR PBA Connection F1 L2 -> SSR PBA defect
SSR PBA defect
Switch machine OFF / ON 24 V on 2201X13
Possible cause
Remark
No
Connection 24 V CONSUPLV -> DRIVERS PBA Connection 24 V DIVERS PBA -> CPU_IO PBA CONSUPLV defect
ed.5
25723, 25724, 25725, 25726, 25727 ORE: ~DEL BIN (2-6) open during delivery~
BIN not closed
19-2-16 / -20 / -24 / -28 / -32 DELBIN(2-6)OPSE
Possible cause
Remark
Continuously OFF
Actuator closed bin does not activate the sensor Connection HCS CPU I/O -> PBA DISTRIBUTION PBA(2-6) Connection PBA DISTRIBUTION PBA(2-6) -> DELBIN(2-6)OPSE DELBIN(2-6)OPSE defective
Possible cause
Remark
Failed
LV power supply defective + 24 V not present Connections LV Power supply -> HCS CPU I/O HCS CPU I/O defective
25728 ORE: ~DEL paper path not free at start~

Paper path not free
Check
19-2-06 DELINSE
Possible cause
Remark
Continuously ON
Sensor defective / blocked Connection DELSINSE -> PBA DISTRIBUTION7 Connection HCS CPU I/O -> PBA DISTRIBUTION7
Only during start
116
TSM Oc 9800
Diagnostics
19-2-07 DELSYNSE
Possible cause
Remark
Continuously ON
Sensor defective / blocked Connection DELSYNSE -> HCS CPU I/O
Only during start
19-2-08 DELTRIOUTSE
Possible cause
Remark
Continuously ON
Sensor defective / blocked Only durConnection DELTRIOUTSE -> PBA ing start DISTRIBUTION7 Connection HCS CPU I/O -> PBA DISTRIBUTION7
19-2-09 DELVERTINSE
Possible cause
Remark
Continuously ON
Sensor defective / blocked Connection DELVERTINSE -> PBA DISTRIBUTION5 Connection HCS CPU I/O -> PBA DISTRIBUTION5
19-2-13 / -17 / -19 / -21 / -25 / -29 / -33 DELOUTSE(1-6)
Possible cause
Remark
Continuously ON
Sensor defective / blocked Connection DELOUTSE1 -> HCS CPU I/O Connection DELOUTSE(2-6) -> PBA DISTRIBUTION(1-5) Connection HCS CPU I/O -> PBA DISTRIBUTION(1-5)
Only during start
ed.5
25729 ORE: ~DELivery door(s) open~

Doors HCS not closed TRI not correctly positioned to the Oc 9800
19-2-01 DELUDOORSW
Possible cause
Remark
Continuously ON
Switch defective / blocked Connection DELUDOORSW -> HCS CPU I/O
Only during start
19-2-02 DELLDOORSW
Possible cause
Remark
Continuously ON
Sensor defective / blocked Connection DELLDOORSW -> HCS CPU I/O
Only during start
19-2-03 DELTRIOPSW
Possible cause
Remark
Continuously ON
Switch defective / blocked Only during Connection DELTRIOPSW -> HCS start CPU I/O
19-2-04 DELTRIPOSSW
Possible cause
Remark
Continuously ON
Switch defective / blocked Connection DELTRIPOSSW -> HCS CPU I/O
Only during start
25734 ORE:~Bypass feed open~

118
TSM Oc 9800
Diagnostics
25735 ORE: ~RU_DOORS_OPEN~

18-2-30 FOL2RUDOORSW 18-2-31 FOL2RUINTDOORSW 18-2-32 FOL2RUCOVERSW Possible cause Remark
Continuously ON
Connection FOL2RUDOORSW1/2/3 > Power_I/O PBA Connection POWER_I/O PBA > CPU_I/O PBA FOL2RUDOORSW1/2/3 defect
ed.5
120
TSM Oc 9800
Diagnostics
1 Machine configurations
The Oc 9800 has a lot of configurations. All configurations consist of machine types. The machine types are classified into 4 categories:
s
Basic unit (M): A basic unit is an uniquely identifiable unit which controls the configuration. The basic unit has a serial number. The serial number of this unit will be the serial number of the configuration type. The basic unit has a modification record. Peripheral (P): This machine type is unique as well and has a serial number. When a peripheral is added to the configuration it effects the configuration type. The peripheral has a modification record. Accessory (A): The accessory is not a unique machine type and has no serial number. When adding an accessory (A) to the configuration it affects the configuration type. Accessory (L): The accessory is not a unique machine type and has no serial number. When adding an accessory (L) to the configuration it does not affect the configuration type.
The machine types with the classification (M) and (P) have serial numbers. The serial number of the total configuration consists of:
s s
the configuration type number (e.g. 9836) the serial number of the basic unit
e.g. 9836 xx101 The modification bulletins will mention the machine type for which the modification is applicable (not the configuration type). When a modification is executed the modification number concerned at the modification record in the machine type must be marked.
ed.5
2 Model series and configuration types of the Oc 9800

The following 3 model series of the Oc 9800 are available:
s s s
model series 9835, the copier model series 9855, the printer model series 9875, the hybrid.
The following configurations types with machine types are available: x = part of the configuration type o = optional (does not influence the configuration type)
Model series 9835 (copier)
Configuration types Machine types
9836
9837
9840
9841
Engine (M) Doc. Memory (A) Set. Memory (A) Memory modules (L) Stamp unit (L) Unfolded output (L) Scanner (P) INTERFACING Controller (P) Long plot option (L) SCSI interface (L) VPI (L)
9801 9802 9803 9804 9805 9807 9810
x x
x x
x o o o x o o x o o x
x o o o x
9812 9813 9814 9815
Ethernet interface (L) 9816 Postscript (L) 9817
Configuration types
9836
9837
9840
9841
to be continued on next page
502
TSM Oc 9800
Configuration types
9836
9837
9840
9841
FINISHING 1st fold (P) 2nd fold (P) 2nd Fold with RU 705 710 712 x x x o o o o x x x o o o o
Transport unit and 1st 850 belt (L) 2nd belt (L) Punch unit EUR (L) Punch unit USA (L) 851 730 720
SOFTWARE APPLICATIONS Scan to file (L) Repro station (L)

9820 9821
9836 9837 9840 9841
Configuration types
ed.5
Model series 9855: Printer
9856
9857
9860
9861
Engine Doc Memory Set Memory Memory modules Stamp unit Unfolded output Scanner INTERFACING Controller Long plot option SCSI interface VPI interface Ethernet Postscript FINISHING 1st fold 2nd fold 2nd Fold with RU Transport unit and 1st belt 2nd belt Punch unit EUR Punch unit USA
9801 9802 9803 9804 9805 9807 9810
x o o o
x o o o
x o o o
x o o o
9812 9813 9814 9815 9816 9817
x o o o o
x o o o o
x o o o o x
x o o o o x
705 710 712 850 851 730 720
x x x o o o o
x x x o o o o
SOFTWARE APPLICATIONS Scan to file Repro station

Configuration types
9820 9821 o
9856
o
9857
o
9860
o
9861
504
TSM Oc 9800
Model series 9875: Hybrid
9876
9877
9880
9881
Engine Doc Memory Set Memory Memory modules Stamp unit Unfolded output Scanner INTERFACING Controller
9801 9802 9803 9804 9805 9807 9810
x o o o x
x o o o x
x o o o x
x o o o x
9812 9813 9814 9815 9816 9817
x o o o o
x o o o o
x o o o o x
x o o o o x
Long plot option SCSI interface VPI interface Ethernet Postscript FINISHING 1st fold 2nd fold 2nd Fold with RU Transport unit and 1st belt 2nd belt Punch unit EUR Punch unit USA
705 710 712 850 851 720 730
x x x o o o o
x x x o o o o
SOFTWARE APPLICATIONS Scan to file Repro station

Configuration types
9820 9821
o o
9876
o o
9877
o o
9880
o o
9881
ed.5
Capacity Set memory
Name
Capacity of originals
Set memory PBA and 36 Mb Set memory PBA and 72 Mb Set memory PBA and 108 Mb Set memory PBA and 144 Mb
5 - 15 A0 / E or 25 mixed (7% density)
15 - 30 A0 / E or 50 mixed (7% density) 30 - 45 A0 / E or 75 mixed (7% density)
45 - 60 A0 / E or 100 mixed (7% density)
506
TSM Oc 9800
SDS
1 CUStomer / environment
see SDS
31
see SDS
see SDS
see SDS
see SDS
see SDS
ed.5
Test nr.
Component
Signal
Description
Parameter test 25-1-01 ~DIN stamp X position 1 mm~
(range 0 - 1219, default 150)

25-1-02 ~DIN stamp Y position 1 mm~

25-1-03 ~DIN stamp X position 2 mm~


25-1-05 ~DIN stamp X position 3 mm~


25-1-07 ~Ericsson stamp X position 1 mm~

25-1-08 ~Ericsson stamp Y position 1 mm~




202
TSM Oc 9800
SDS
Special test 25-6-01 ~Fill default stamp strings
Stamps 3-10 are filled language depended with the default settings: stamp 3 CONFIDENTIAL stamp 4 FOR INFORMATION ONLY stamp 5 NEW RELEASE stamp 6 MODIFIED stamp 7 NOT RELEASED stamp 8 INVALID stamp 9 ORDERED stamp 10 PROTOTYPE
ed.5
204
TSM Oc 9800
SDS
Oc
Oc 9800
PREVENTIVE MAINTENANCE
Contents
Preventive Maintenance
1 General 101 2 Program A 101 3 Program B (additional program after cleaning the DRUM) 104 4 Program C: Additional program after changing the DRUM). (Only if the drum is at the end of the lifetime) 104 5 Consumables 105 6 Preventive maintenance Reinforcement unit 106
ed.5
TSM Oc 9800
Contents
1 General
Preventive Maintenance is needed to guarantee a correct performance of the machine and to prevent additional visits and costs. The Oc 9800 Preventive Maintenance program can be divided into 4 programs:
s s s
Program A: carried out every visit Program B: additional actions after cleaning the drum Program C: additional actions after replacement of the drum. (only if the drum is at the end of the lifetime) Reinforcement unit
2 Program A
Datadump
Make a datadump with the ST program and store it on the logfloppy and/or the harddisk of your laptop.
Consumable life time check:
In the first entry screen of the SDS can be checked which consumables must be replaced due to the active warning indication (SDS test 36). This warning becomes actives if the minimum lifetime (norm value) is reached. Take action to deactivate the warning.
Note: Do not forget to reset the counters after replacement of e.g. the cleaning
rollers.
Scanner: 1 Clean the exposure glass plate with non-woven Masslin towel and Oc O
cleaner or a glass cleaner (local purchase).

2 Clean the gauge roller with Oc A-cleaner.
ed.5
Preventive maintenance 101
CTF output: 1 Check the CTF output guide plate (near CTFOUTSE) for toner.
Clean if necessary with cleaner T (code number: 1990072 EUR)

Developing unit:
toner
doctor blade
toner
1 2 3 4 5
Remove the top cover of the developing unit. Remove the toner from the top of the doctor blade. Mount the top cover. Remove dust from the outside of the developing unit. Check the toner brush and remove irregularities.
Compressor unit (CTF): 1 Check if the air pressure is at 5.4 Bar in stand-by mode when the compressor
is switched off.
2 Check the oil level of the compressor and add if needed. 3 Check the reservoir under the compressor and empty it if needed. 4 Check if the hose between the drain and the valves is clean.
If not, replace the filter and the 0-rings inside the drain.
Preheater: 1 Check the liquid level of the preheater and add if needed. Main drive 1 Check adjustment 1 function 23 Main drive belt on page 301. 2 Check adjustment drive belt paper transport.
102
TSM Oc 9800
Printhead: 1 Clean the printhead diaphragm with a Masslin towel and clean the self focus-
ing lens array with the lens brush.

2 Check the level of the cooling liquid of the printhead and add new one if need-
ed.
3 Carry out adjustment 1 function 04 ~Testprint adjust PHD~ (every service vis-
it) on page 301.

Drum: 1 Carry out adjustment 2 function 01 ~DRU ASV test~ on page 302
- If background appears clean the drum.

2 Grease the drum shaft end dis-/assemblies 01- Drum see Grease procedure of
the drum shaft end on page 414.
Black copy 1 Carry out SDS test 52 ~Black mode~ on an A0 / E size. 2 Check for skeleton images.
- If skeleton images appear see function ~FAULTS~

Copy quality 1 Check the copy quality. 2 Read out the top 10 error counter with SDS test 34 and 35 (if necessary take
action).
3 Fill in the logbook. 4 Reset all counters with SDS test 31, the counters are reset and logged when
SDS is switched off.
ed.5
3 Program B (additional program after cleaning the DRUM)

Paper roll drawers: 1 Grease the disk of the rotating knives of the upper and lower paper roll drawer
with Molycote-GN Plus.

2 Clean the paper input roller and opposite roller with Oc O cleaner. 3 Remove paper strips out of the knife section. Preheater 1 Check the paper guide cloth and the lower and upper guide strip, change them
if needed.
Scanner 1 Carry out the SDS test 10-7-01 (~TL intensity adjust~).
4 Program C: Additional program after changing the DRUM). (Only if the drum is at the end of the lifetime)
Preheater 1 Change the paper guide cloth and the lower and upper guide strips. Corona 1 Change the corona pin arrays (2) Discharge corona: 1 Change the discharge corona pin array.
104
TSM Oc 9800
5 Consumables
Consumable
Code number
Reason of replacement
Drum
1989.423
After cleaning of the drum again background appears with SDS test 54 Replace when replacing the drum or min. target of 200.000 lm Replace when replacing the drum or min. target of 200.000 lm Replace when replacing the drum or min. target of 200.000 lm SDS indication: SWAR at 720 black images PE at 900 black images SDS indication: SWAR at 300 black images PE at 400 black images Replace at the same time as pressure roller cleaning roller min. target 100.000 lm min. target 105.000 lm
Pin array charge corona
1989.410 (1 set of 3 pin arrays) 1989.410
Pin array discharge corona Paper guide cloth and guide strips Fuser roller cleaner
1990.142
1988.334
Pressure roller cleaner roller
1988.335
Build up cleaner
1988.336
Pressure roller Fuser roller
7040.881 1989.678
ed.5
6 Preventive maintenance Reinforcement unit

(Also refer to: Operator guide Oc 9800, chapter reinforcement).
General
In the reinforcement unit strips are cut from a roll of material. The knife is passing through glue on the tape, covered with a protective sheet. At every cutting movement small particles of this glue can stick to the knives. When the knives are not clean enough, tape jams can occur. A felt strip is mounted next to the knife to prevent that too much glue will stick to the knife.
Operator maintenance
We recommend the operator to clean the knife parts at every change of tape rolls. The knife parts must be cleaned with Oc cleaner K. The felt strip next to the knife must at the same time be greased with silicon oil. Take care that the felt is not saturated with silicon oil. To facilitate access to the knife parts in the operator mode a special program has been developed. This can be activated as follows:
1 - Select ~Finishing~ 2 - Select ~Fold delivery~ 3 - Select ~Clean reinforcement knife~
The stamp of the reinforcement unit is now going into a position that the knife is easily accessible. As soon as the reinforcement unit is put into working position, the stamp returns to the home position. Of course this feature can also be used by the Service Technician for cleaning the knives.
Code numbers:
Oc cleaner K,
bottle 250 ml, EUR: USA: bottle 60 ml,
1929 022 1929 023 (different label) 7991 167
Silicon oil,
106
TSM Oc 9800
Maintenance by the service technician
The service technician must check the status of the knives at every service visit. If necessary he must clean the knife thoroughly with cleaner K and put a drop of silicon oil on the felt next to the knife. In SDS a special test is made: Special 18-6-17 FOL2RUSTAMPTURN. With this test the stamp can make half a turn and in this it is placed into a good position to clean the knife. The stamp can be put back into its original position by doing this special test again. Other parts of the unit do not require preventive maintenance.
ed.5
108
TSM Oc 9800
Oc
Oc 9800
MISCELLANEOUS
Contents
Copier specifications
1 Copier specifications 101 2 Folder specifications 105 3 Belt unit 106 4 High Capacity Stacker 107 5 Reinforcement Unit specifications
108
ed.5
Miscellaneous
TSM Oc 9800
Contents
1 Copier specifications
Specifications
Model Scanning process Copying process
Speed Reproduction scale
Digital retention Originals
Original feed
Scanner and separate print engine CCD scanning with Oc resolution 400 dpi image processing Organic drum LED Print head Monocomponent toner Compact Transfer transFuse (CTF) 10 m/min. 32.8 lf/min. 25-400% Autozoom 9 Fixed zoom steps Manual selection: - 1% steps - fine adjustment 0.1% 1-999 Size: Min. width: 210 mm (8.5) Min. length: 210 mm (8.5) Max. width: 1036 mm (40 3/4) Max. length: guaranteed: 6m (20 lf) Max. image width: 914 mm (36) Type: Plain Paper Transparent paper Vellum Polyester film Thickness: max. 2.5 mm (1/10) Curl: Min. diameter 50 mm (2) Soft feed Automatic original alignment
ed.5
Miscellaneous 101
Specifications
Copies
Size Min. Max.
LxW 210 x 297 mm 8.5 x 11 6000 x 914 mm 20 ft x 36 max. guaranteed 60-110 g/m2 16-30 lbs 60 - 110 g/m2 16-30 lbs 3.5 - 4.5 mil. 16 - 20 lbs synchro standard cut Maximum diameter roll 184 mm (7,2)
Copies
Type: Plain paper Transparent paper Polyester Vellum 4 rolls
Media feed
manual feed Unfolded: max. 100 A0/E Copy Delivery Tray (CDT) Folded: receiving tray delivery belts Exposure control Automatic Background Compensation (ABC) Manual fine tuning Special exposure modes Photo mode Dark originals Blueprints Multi copy 1 -999 Single document process- Multiple copying of single ing (DOC memory) originals up to A0 (E) size Set processing (SET mem- Multiple copying of sets of ory) (optional) originals with digital sorting of copies 36Mb Max. size set Average size set: 5 - 15 A0/E approx. 25 mixed originals 72Mb 15-30 A0/E approx. 50 mixed originals 108 Mb 30-45 A0/E approx. 75 mixed originals 144 Mb 45-60 A0/E approx. 100 mixed originals Special functions Pre-programming Auto zoom / auto roll Auto roll switch Copying to standard sizes Programmable default settings Copy delivery
102
TSM Oc 9800
Specifications
Job memory Matrix copying Leading / trailing edge compensation Editing functions Mirror Image shift Auto alignment Stretch Image erase Stamping (optional) 50 messages programmable 3 positions 2 fonts 4 grey scales Toner consumption 0.7 g/m2 Dimensions (W x D x H) Scanner
+/- 100 mm
inside / outside 40 characters
Engine Folder (1st and 2nd) Belt unit Required floor space Weight packed 16 m2 / --- square feet Scanner Engine 1st Fold 2nd Fold Belt unit Scanner Engine 1st Fold 2nd Fold Belt unit
1320 x 650 x 1230 mm 52 x 26 x 49 1720 x 1100 x 1370 mm 68 x 44 x 54 1968 x 607 x 899 mm 77.5 x 24 x 35.5 730 x 500 x 1150 mm 29 x 20 x 45.5 175 kg / 387 lbs 765 kg / 1690 lbs 70 kg / 155 lbs 110 kg / 243 lbs 98 kg / 217 lbs 145 kg / 320 lbs 735 kg / 1623 lbs 60 kg / 133 lbs 100 kg / 220 lbs 90 kg / 200 lbs
Weight unpacked
ed.5
Miscellaneous 103
Specifications
Mains supply
50 Hz
60 Hz
230 V, 3 phase, 14,11, 11 A. 400 V, 3 phase and neutral, 9, 4, 9 A. 415 V, 3 phase and neutral, 9, 4, 9 A. 240 V 1 phase, 22 A. 240 V 3 phase, 14, 11, 11 A. 208 V 3 phase, 14, 11, 11 A. 220 V, 3 phase, 14, 11, 11 A. 380 V, 3 phase and neutral, 9, 4, 9 A 415 V, 3 phase and neutral, 9, 4, 9.
Power consumption Warming up time
Warming up 5 kW Stand-by 1.0 kW Run 3.5 kW 20 min.
104
TSM Oc 9800
2 Folder specifications
Specifications
1st Fold input
min. max.
1st and 2nd Fold input
min. max.
Material
plain paper vellum
297 x 420 mm 11.5 x 16.5 914.4 x 6000 mm 36x 236 297 x 420 mm 11.5 x 16.5 914.4 x 2500 mm 36x 98.5 60 - 110 g/m2 16 - 30 lbs 16 - 24 lbs 190 x 297 mm 210 x 297 mm 210 x 297 mm including filing edge 20 mm, left side 190 x 210 mm 210 x 297 mm 210 x 297 mm including filing edge 20 mm, right side 8.5 x 11 9 x 12 8.5 x 11 with filing edge 9 x 12 with filing edge 210 x 297 mm default 210 mm
Folding methods
standard DIN
Ericsson
USA
1st Fold 2nd Fold
Belt unit
Punch
Afnor like 186 - 230 mm (7.3 - 9) steps of 1 mm (0.1) 273 - 310 mm default 297 mm (10.9 - 12.2) steps of 1 mm (0.1) 15 - 30 mm (0.6 - 1.2) default 20 mm steps of 1 mm (0.1) capacity per belt and paper A0 / E : approx. 100 75 g/m2 A1 / D : approx. 100 A2 / C : approx. 150 A3 / B : approx. 400 A4 / A : approx. > 400 Oc 730 (EUR) 2 or 4 holes Oc 720 (USA) 3 holes
ed.5
Miscellaneous 105
3 Belt unit
Specifications
Dimensions (W x D x H) 1Belt unit (Oc 850) 2 Belt units (Oc 851) Weight Weight Belt capacity Belt unit Oc 850 Belt unit Oc 851 75 g/m2
Punch
Maximum copy length Oc 730 (EUR) Oc 720 (USA)
Number of folds in package Required floor space 1.4 m2 (15 square feet) Power supply From the engine Power consumption Additional 0.1 kW
730 x 500 x 1150 mm 29 x 20 x 45.5 730 x 500 x 1470 mm 29 x 20 x 58 80 kg / 176 lbs 110 kg / 243 lbs A0 / E : about 100 A1 / D : about100 A2 / C : about 150 A3 / B : about. 400 A4 / A : > 400 1220 mm (48) 2 or 4 holes 3 holes Maximum 2
106
TSM Oc 9800
4 High Capacity Stacker
Specifications
Machine type: Dimensions: Weight: Speed: Capacity: Materials:
High Capacity Stacker Unfolded copies only WxDxH
Number of output bins: Features: Copy size Noise level: Power supply: Power consumption Connection: Safety approval: Radio interference: Required floor space: Floor strength Power consumption: Room conditions:
Including packing Excluding packing 7 m/min. 200 copies per bin Plain paper Vellum Transparent Polyester 6 Set / job separation on all All bins, except bin 1, are output bins extensible for convenient copy removal. Minimum 210 x 297 mm (8.5 x 11) Maximum 1220 x 914mm (48 x 36) Stand by <30 dB(A) During operation 66 dB (A) 115 V, 230 V single fase 50 / 60 Hz. From the engine Stand by 30 W Run 100 W Serial (RS 232) TV-GS TV-FS 7 m2 (75.4 square feet) 100 kg/m2 (220 pound/m2 Stand by 30 W During operation 100 W Temperature: 17 -34 oC (63-93 oF) R.H. 10 - 90 %
2280 x 1426 x 1370 mm 89.7 x 56.2 x 54 425 kg (937 pounds) 390 kg (860 pounds) adjusted by engine 75 g/m2 60 - 110g/m2 16 - 20 lbs 60 - 110 g/m2 not recommended
ed.5
Miscellaneous 107
5 Reinforcement Unit specifications

Specifications
Dimensions (l x w x h) Weight Power source Power consumption Tape cutting length Tape glueing position in longitudinal direction Tape glueing position in transversal direction
Parallellism of tape and frame Repeated tape accuracy in 0.5 mm both directions Tape pressing force to when peeling of the tape, even pressure over the plain paper of 75 gr/sqm the paper will tear entire reinforcement strip, no loose ends of the strip allowed Adhesive strength of the stronger than paper over the entire length of the tape to plain paper of 75 strip, both for tearing and gr/sqm peeling Reinforcement tape dimensions according to no lose/half-lose punching transport holes till the end particles allowed Protective sheet no weak points allowed sheet may not break due to pulling force Protective sheet pulling sufficient to remove the the sheet may not run force protective sheet under the knife and it may not breake Duration of one cycle of 1.17 secs nominal the reinforcement stamp 1.5 secs maximum Duration of tape transport 0.73 secs nominal by the pin wheel 1.2 secs maximum Tape jam Maximum 2 x per roll of with recommended tape reinforcement tape and proper cleaning intervals
575 x 23 x 450 mm 12.5 kg without tape 24 Volt supplied by folder 31 Watts maximum, in normal mode 111.125 0.5 mm 37.5 1 mm from a hole in the tape to the M6 holes in the rear frameplate 80 1 mm from a hole in the tape to the outside of the rear frameplate within 0.5 mm
108
TSM Oc 9800
ed.5
Miscellaneous 1041
1042
TSM Oc 9800
Oc
Oc 9800
INSTALLATION
Contents
Engine
1 Without High Capacity Stacker 101 2 Unpacking of the engine 103 3 Removing the transport securities: 106 4 Minimizing the size of the engine (76 cm) 109 5 Levelling and height adjustment of the engine. 109 6 Mains connection. 110
Scanner
7 Unpacking the scanner 112 8 Removing the transport securities 113

Engine
9 Filling of the Printhead with cooling liquid 115 10 Installation unfolded copy delivery 116 11 Preparation of the engine for folder installation 118 12 Connections belt unit and reinforcement unit (RU) 119
Folder
13 Installation Oc 705 behind the Oc 9800
120
Folder optionals
14 Installation folder optionals 123 15 Upper belt unit (Oc 851). 125 16 Installation punch unit (Oc 720/730)
128
Installation High Capacity Stacker (HCS) Oc 880
17 Special tool 129 18 Unpacking and assembling 129 19 Preparation of the Oc 9700 / 9800 135 20 Final 136
ed.5
Installation
Packing the HCS
Final
21 Final preparations 140 22 Installation adjustments 140
Controller
23 FBBS Controller 141 24 EPC 1 / EPC 2 Controller 142 25 DRI (Direct Raster Interface). 143 26 Testing the controller 143
TSM Oc 9800
Contents
Engine
1 Without High Capacity Stacker
ed.5
Installation 101
With High Capacity Stacker
102
TSM Oc 9800
Engine
2 Unpacking of the engine

Dimensions
Engine on pallet
Engine
Additional tools
s s s
WxDxH Kg 1860 x 1250 x 1600 mm 74 x 50 x 63765 1720 x 1100 x 1370 mm 68 x 44 x 54735
Lbs 1690 1623
pallet truck (1500 mm (59) long). spirit-level. open-end spanners 17 mm and 30 mm.
Remove: 1 2 3 4 5 6 7 8
The packing straps (if present). The cardboard box upwards (if present). The plastic bag. The copy receiving tray from the engine. The box with the start kit from the pallet. The 4 wooden blocks from the pallet. The long wooden bars at the front and rear side (4 bolts 17 mm). The 2 steel bars (4 bolts 17 mm). The start kit contains: 2 bottles with toner 1 bottle with printhead liquid 2 white gloves 1 user manual 1 logbook + holder 1 martor snitty 1 keyring
ed.5
Installation 103
Lifting the engine from the pallet:
1 Always place the pallet truck under the machine from the copy delivery side.
Be sure that the arms dont touch the covers of the paper roll drawers.
2 Place the 4 wooden blocks, dimension of 17 cm upwards, on the pallet truck
place it under the engine.

Note: Make sure that the blocks are placed at the edges of the bottom plate of
the engine.
3 Unscrew the 4 bolts in the bottom of the engine, with which the engine is fixed
to the pallet (4 bolts 17 mm).

4 Lift the engine. 5 Check if the four levelling feet of the engine have been screwed completely up-
wards (80 mm (3.1) remaining).

6 Remove the side blocks of the pallet. 7 Place the long wooden bars under the levelling feet of the engine. Note: Make sure that the wooden blocks between the shelves are situated under the feet.
long wooden bar
104
TSM Oc 9800
Engine
8 Place the engine on the long wooden bars. 9 Place the 4 wooden blocks, dimension of 80 cm upwards, on the pallet truck. 10 Lift the engine. Note: Make sure that the blocks are placed at the edges of the bottom plate of
the engine.
11 Place the long wooden bars between the levelling feet of the engine. Warning: Not outside the levelling feet (bending of the bottom plate of the en-
gine).
12 13 14 15 16
Adjust the levelling feet at a height of 100 mm (3.9). Move the engine down on the long wooden bars. Remove the 4 blocks from the pallet truck. Lift the engine again and remove the long bars. Place the engine on its levelling feet.
ed.5
Installation 105
3 Removing the transport securities:

Paper sheet feeding 1 Remove all transport tapes and foam strips. 2 Remove the front cover and all side covers at the left and right side of the en-
gine.
3 Remove the 2 security bolts from the sheet feeding (M 4x30 mm).
The bolts are marked and can be found in the main frame at the left and right hand side near the drawer. 4 Remove the foam strips from the sheet feeding.
Paper roll drawers 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Remove the left and right side top covers from the engine. Remove the left and right side upper and lower covers from the engine. Open the sheet feeding as far as possible by releasing the end stops. Remove the side covers of the paper roll drawers, the screws are inside the frame. Remove the 4 red brackets from the main frame and the upper and lower paper roll drawer. Loosen inside the upper paper roll drawer the screws from the 2 metal blocks from the transport security rod inside the drawer. Remove on the left the screw from the transport security rod. Remove the transport security bar to the left. Remove on the left the transport security from the compressor unit. Remove on the left the transport security from the preheating reservoir. Remove the waste reservoir underneath the compressor. Loosen the two screws from the left lower cover. Remove the left lower cover. Loosen the screw from the right lower cover. Remove the right lower cover. Disconnect the connector 06X8 from the compressor unit. Unplug the air supply hose from the compressor unit. Loosen the three mounting screws from the compressor unit. Lift out the compressor unit. Open the upper drawer. Remove the 2 metal blocks. Loosen inside the lower paper roll drawer the screws from the 2 metal blocks from the transport security rod inside the drawer. Remove on the left the screw from the transport security rod. Remove the transport security rod to the left. Open the lower drawer. Remove the 2 metal blocks.
106
TSM Oc 9800
Engine
27 Remove from the drawers:
28 29 30 31
the 2 red brackets from the feed-opposite unit the cable ties from the paper roll holders and the cutting mechanism s all foam blocks and transport tapes. Open the chip tray and remove the foam strips from the cutting mechanism. Place the lifting bar in the square holes in front of the upper paper roll drawer. Close the paper roll drawers. Close the sheet feeding.
s s
Developing unit / Printhead security bolt
DRUASV probe
printhead locking handle
1 Remove the 2 transport security bolts above the developing unit. 2 Remove the tape of the locking mechanism of the developing unit and hook the
springs in the working position. Disconnect on the right the connector 05X1 from the developing unit. Remove the air supply tube on the left side. Open the developing unit completely to the service position. Remove the calibration plate of the DRUASV-probe. Hold the bar with the DRUASV-probe and remove the cable ties . Position the DRUASV-probe in working position and mount the calibration plate. 9 Close and lock the developing unit. 10 Connect the air supply tube and the connector 05X1. 11 Remove the cable ties in the middle and from the locking handles of the printhead and lock the printhead.
3 4 5 6 7 8
ed.5
Installation 107
CTF / PREHEATER 1 Open the CTF top cover and remove the foam blocks. 2 Open the PTR-unit.
transport security bolt
lower position
3 Remove on the right side (as viewed from the rear) the transport security bolt
of the locking handle of the pre-heating section and mount the bolt in the lower position. 4 Open the CTF heater unit.
.
red strip
locking plate
brass stop
108
TSM Oc 9800
Engine
Remove the red locking plates at the left and the right side. Remove the cable ties from the shaft ends of the fuser roller cleaner. Close the CTF heater unit. Remove the 2 red strips of cylinder assy (eliminate the pressure by pushing the shaft to the upper position). 9 Mount the brass screws, which were holding the red strips, back in the cylinder assy.
5 6 7 8 Note: Be careful when tightening these brass stops. 10 Check 22PBA5. On the new pba part. no. 5584.001 the jumper X13 must be
on position NOM, not on MAX.

11 Close the PTR and the CTF top cover.
4 Minimizing the size of the engine (76 cm)

1 Carry out dis-/assembly 1 function 12 Paper roll drawers on page 401 (upper 2 3 4 5 6 7 8 9
and lower). Remove the rails (2 screws each). Carry out dis-/assembly 1 function 13 Paper sheet feed on page 401. Remove the rail (3 nuts each). Carry out dis-assembly 1 function 15 PTR unit (without folder) on page 401 or dis-/assembly 2 PTR unit (with folder) on page 402. Remove the side covers. Remove the supports of the side covers. Remove the paper transport supports. Remove a part of the pre-heater locking mechanism.
5 Levelling and height adjustment of the engine.

1 Check if the height of the levelling feet is 100 mm. 2 Put a spirit-level on the rectangle bar of the developing unit and level the en-
gine with the levelling feet.

3 Put the spirit-level perpendicular (in the rear front direction) on the left and
right side frame top of the engine and level the engine.
ed.5
Installation 109
6 Mains connection.
The mains voltage of the Oc 9800 can be configured by placing strips in the terminal block. The following configurations are possible:
s s s
star configuration (3-phase) delta configuration (3-phase) 1-phase configuration
1 Guide the mains supply cable through the bottom plate and the strain relieve. 2 Tighten the strain relieve. 3 Connect the mains supply cable and mount the connection strip(s) in the ter-
minal block corresponding to the desired mains voltage configuration.

STAR
DELTA
1-PHASE
For USA only (centre tap)
The spare terminal, marked For USA only, is used to connect the centre tab wire in case of 120/240V 1-phase connection.
Note: In a star-configuration make sure that the NEUTRAL and PHASE wires
are properly connected. Serious damage to the machine can occur if NEUTRAL and PHASE are interchanged or if the NEUTRAL is not connected. For the 1-phase configuration the neutral and phase wires are interchangeable. Be sure to connect the wires thorough to prevent any fire risk.
110
TSM Oc 9800
Engine
4 Check if the transformer 22T1, on the left, is connected according to mains
supply voltage.
5 6 7 8
Mount the compressor unit. Connect the air hose and connector 06X8. Mount the waste reservoir. Mount all covers, except the front cover.
ed.5
Installation 111
Scanner
7 Unpacking the scanner
Dimensions
kg Scanner on pallet W x D x H = 1540 x 760 x 1520 mm61 x 30 x 60 185 W x D x H = 1320 x 650 x 1230 mm52 x 26 x 49 140 Scanner
Remove: 1 2 3 4 5
Lbs 410 310
The packing straps (if present). The cardboard box upwards (if present). The plastic cover. The lamp with box from the rear side of the scanner and put it on a save place. The left and right side covers from the scanner stand (4 covers).
Lifting the scanner from the pallet:
U-shape bracket
1 Remove on one side the 2 screws (17 mm), with which the U-shape bracket is
mounted on the pallet.

2 Loosen on the same side 1 screw (17 mm), with which the U-shape bracket is
mounted to the scanner.

3 Loosen at the same side the nut (17 mm) from the scanner leg, with which the
U-shape bracket is mounted to the scanner.

4 Remove the U-shape bracket.
112
TSM Oc 9800
Scanner
5 Loosen on the opposite side the screw and the nut with which the U-shape
bracket is mounted to the scanner.

6 Turn the scanner wheels on this side as much as possible in running direction
(> 90 o). 7 Place the scanner, with two persons, on its wheels onto the floor. 8 Move the scanner over the wooden guides and place it on the floor.
8 Removing the transport securities

1 Remove transport cable ties on the left and right side.
cable ties
Open the upper part of the scanner. Remove the three foam strips on top of the gauge roller. Remove the fixing bolts from the side covers of the upper part of the scanner. Close the upper part and remove the side covers (disconnect the ground wires). Open the upper part again. Remove on one side the cover from the exposure lamp holder. Remove the lamp fitting. Place the exposure lamp in the scanner and mount the lamp fitting. Turn the lamp 90 o. Mount the cover over the exposure lamp holder. Check adjustment 2 function 10 SCAnner Scanner exposure lamp on page 302. 13 Mount the scanner covers. 14 Panel overlays (language dependent). - Clean left and right frame of the panel, with Oc cleaner K - Glue the 2 panel overlays on the frame
2 3 4 5 6 7 8 9 10 11 12
ed.5
Installation 113
15 Connect the cable between the scanner and the engine, fasten the strain relief
clamp.
114
TSM Oc 9800
Scanner
Engine
9 Filling of the Printhead with cooling liquid
The liquid is delivered together with 2 bottles of toner in the start kit.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Open the drawer of the cold process to service position. Remove the cover from the cooling unit. Pull out the return tube from the reservoir. Place the funnel into the reservoir. Add liquid to approx. 2 cm under the maximum indication on the reservoir. Loosen the upper tube from the printhead. Fill the last 2 cm from the reservoir via the tube. Fit the upper tube back to the printhead. Place the return tube into the reservoir. Close the drawer of the cold process. Switch on the machine. Switch off the machine after the liquid is stabilised. Remove the return tube. Place the funnel into the reservoir. Add liquid to the maximum. Place the return tube into the reservoir. Switch on the machine. Repeat the procedure if the level is still too low. Put the funnel into the reservoir. Mount the cover of the cooling unit. Close the drawer of the cold process unit. Lock the printhead. Mount the front cover.
ed.5
Installation 115
10 Installation unfolded copy delivery

Table
The first series of machines were delivered with a simple table.

1 Lift it at the front and hook it in the frame of the engine (below the paper trans-
port unit).
2 Level the rack in 2 directions by means of the levelling feet.
CDT (Copy Delivery Table) Oc 965
Newer machines are delivered with a new delivery table on wheels. Older machines can be equipped with this table.
1 Unpack the cardboard box. 2 Mount the table conform the mounting instructions, which are supplied inside
the box.
3 Mount the intermediate guides, these are delivered separately with the CDT.
- Mount one intermediate guide at the rear side of the CDT. - Mount the other intermediate guide inside the PTR of the engine. (Remove temporary at one side a pin with M10 nut (Z1510 index 275)) 4 Check the height between the CDT and the PTR and adjust the table height if necessary.
116
TSM Oc 9800
Engine
ODT (Original Delivery Table) Oc 965
Older machines can be equipped with this table. This table is placed behind the scanner. For mounting instructions, see also the CDT. The intermediate guide is different and of course, mounted against the original output of the scanner.
LPE (Long Plot Escape) Oc 881 (not available any more)
1 2 3 4 5
Unpack the cardboard box. Remove the lower cover plate of the engine. Mount the two position snappers. Check / adjust the position of the snappers with the LPE. Remount the cover plate and place the LPE.
Snapper
ed.5
Installation 117
11 Preparation of the engine for folder installation

1 2 3 4 5 6 7 8 9 10 11 12 13
Open the PTR unit. Remove the black cover of the PTR unit. Disconnect the connectors from PTRMO and PTRMOSE. Remove the drive belt. Remove PTRMO. Remove the toothed gear. Mount the new belt. Remove the cable bundle and PBA 15. Remove the connector 22X13 and on 18PBA 02 the connector 18X2. Install 18PBA09 on the right side besides 18PBA02. Connect the flat cable connector X1. Cut the cable tie from the PTRUFOSO. Close the PTR unit.
118
TSM Oc 9800
Engine
12 Connections belt unit and reinforcement unit (RU)
I/O int.
X5
X1
Belt unit
I/O int.
X5
18X24 18X25
X1
Belt unit
I/O int.
X5
18X24 18X25 X1 RU
18X24 18X25 I/O int. X5 X1 RU X2/X3 X1 Belt unit
The configurations which are possible with the RU and/or the belt unit are shown in the figure above. A = old situation, one cable bundle from the I/O INT. to the belt unit B = new situation, the bundle is provided with the connectors 18X24 and 18X25 C = with RU only D = with RU and belt unit, the belt unit is connected to X2 and X3 on the RU. The lay-out from X2 and X3 is the same as from 18X24 and 18X25.
ed.5
Installation 119
Folder
Dimensions
kg 1st fold on pallet L x W x H = 1300 x 650 x 650 mm 52 x 26 x 26 70 2nd fold on pallet L x W x H = 1030 x 660 x 2050 mm41 x 26 x 81 110 without RU 2nd fold on pallet L x W x H = 2340 x 770 x 1075 mm92 x 31 x 43 140 with RU
Lbs 155 243 310
13 Installation Oc 705 behind the Oc 9800

First folding unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Remove the box of the first folding unit from the pallet (if present). Remove the plastic bag. Remove the four bolts with nuts, which fix the folding unit to the pallet. Remove all transport tapes and foam strips. Remove all side covers (for the left and right upper cover screws inside the folding unit). Remove the 2 upper screws from the cover plate underneath the first folding unit. Remove the cover. Take the 2 red lifting handles. Open all hinged covers from the first folding unit. Fit the red lifting handles on the right and left frame plate in the appropriate key holes. Lift the unit with two persons and place it in the grooves of the bar on the rear of the Oc 9800. Connect the right side the power supply connector 1801G1 and the earth wire. Check if the input voltage switch on the DC power supply is set to the 230 V position. Mount the cover plate with the 2 lifting handles in front of the power supply. Open the paper transport unit. Connect on the left side the connector 18X4. Connect the new delivered bundle on the left side to the connectors 2201X5 and 18X4 in the first fold. Connect the wires to PTRUFOSO, the earth wire and connector 22X13 in the 8engine. Fasten the cable bundle with a cable tie to the main bundle. Cut the cable tie from the PTRUFOSO core.
120
TSM Oc 9800
Folder
21 Guide at the left side of the machine all cable bundles through the slot in the
Oc 9800.
Note: Pay attention to connect the following connectors correctly to the PBA
to avoid damages of the connectors.

22 Connect the connectors to the PBA's as follows:
To 18PBA09 (left hand PBA), the connectors 2209X2 - 2209X3 and 2209X5 To 18PBA02 (right hand PBA), the connectors 2202X2 and 2202X3. 23 Mount on the right side the timing belt between the PTR-unit and the folder. 24 Mount on the right side the PTR drive belt. 25 Mount the lower right side cover to the first folding unit.
s s
Second folding unit with reinforcement unit Oc 712 1 2 3 4 5
Remove the cardboard box (if present). Remove the dust cover. Remove the cartons with the covers and the FFD (first fold delivery) tray. Loosen the bolts, which fix the unit to the pallet (13 mm). Push the unit with the aid of a dock board from the pallet.
Note: Do not lift the unit at the intermediate transport
6 Remove all transport tapes, the cable ties from the first fold delivery rollers and
the reinforcement unit.

7 Mount the bracket, which is inside the waste tray of the reinforcement unit, to
the right support of the cover over the intermediate transport.

8 Continue with item 7 of second folding unit without reinforcement unit Second folding unit without reinforcement unit 1 2 3 4 5 6 7 8 9 10 11 12 13
Remove the cardboard box (if present). Remove the cartons with the covers and the FFD (first fold delivery) tray. Remove the four bolts (17 mm), which fix the unit to pallet. Turn the unit on its wheels. Remove the wooden bar from the frame of the 2nd folding unit (4 bolts 10 mm). Remove all transport tapes and the cable ties from the first fold delivery rollers. Remove the foam strips from between the folding rollers and 2 cable ties. Remove the nut and ring from the position pin from the first folding unit. Place the 2nd folding unit behind the 1st folding unit. Check if the position pin of the 2nd folding unit fits with the first folding unit. Mount on the left side the ring and nut which fix the 2nd with the first folding unit. Connect on the left side the connectors 18X1, 18X5, 18X8 and 18X19. Mount the long rear cover.
ed.5
Installation 121
Note: In case the bundle of connector 18X19 is too short: remove the counter
connector from the frame and connect the connectors underneath the frame.
14 Level the second fold, by putting adjustment plates if necessary between the
15 16 17 18
19 20 21 22 23 24 25 26
bottom of the frame and the wheels (these plates are packed inside to the side frame of the 2nd fold) Adjust the height position of the second fold with respect to the first fold 12 mm and parallel. Lock the 2nd folding unit with the nut and ring at the left side. Remove the transport security bolt from the reinforcement unit (behind the door of the unit). Adjust the height position of the lower PTR-handle of the Oc 9800. The safety switch FOL1DOORSW may not be operated by the top cover of the folding unit when the lower PTR-handle is not in the locked position. Mount the rear lower cover. Mount all covers on the folder. Mount the FFD tray. Switch on the engine. Activate SDS. Carry out test 90. Configure the folder. Switch off SDS and switch off and on the engine.
122
TSM Oc 9800
Folder
Folder optionals
Dimensions
Frame and lower belt unit on L x W x H = pallet (Oc 850) 1020 x 700 x 1350 mm Upper belt unit in box (Oc 851) Punch unit in box LxWxH= 1020 x 530 x420 mm LxWxH= 450 x 200 x 160 mm
40.2 x 27.6 x 53.2 40.2 x 20.9 x 16.5 17.7 x 7.9 x 6.3
Oc 720 (USA) / Oc 730 (EUR)
14 Installation folder optionals

Frame and lower belt unit 1 Remove the carton box. 2 Remove the packing materials. 3 Remove the cover, the belt unit and the receiving rack (positioned against the 4 5 6 7 8
frame unit). Remove the transport bolt (key 10 mm) in the bottom plate. Open the side door. Remove the transport bolt (key 10 mm) in the bottom plate. Remove the frame belt unit from the pallet. Remove all covers of the frame belt unit.
ed.5
Installation 123
upper cover belt unit rear covers
front cover output cover
front door
9 Remove the front door and check if the power selection switch is set to 220 V
(behind holes in frame underneath type label at the bottom).

10 If a punch unit is required see Installation punch unit (Oc 720/730) on page
128.
11 Unpack the lower belt section. 12 Remove the black locking bold (M4x7 mm). Note: For next point, 1 person holds the unit while another connects the sensor
and the earth wire.

13 Hold the belt unit against the lower frame unit. 14 Connect the connector to the sensor and connect the earth wire (wire below the
lower shaft). Push earth wire from the output cover to the side against the frame. Position the belt section (lift it at the front and hook it in the frame) Lock the belt unit with the bolt (M4 x 7) from front side belt unit. Mount the tooth drive belt: s remove the E clip of the upper gear s remove the gear s mount the timing belt together with the gear s mount the E clip 19 Connect the earth wire with the output cover (do not mount the cover if the 2nd belt has to be installed. 20 Mount the receiving rack (4 washers and 2 screws), the smallest washers against the frame.
15 16 17 18
124
TSM Oc 9800
Folder optionals
receiving rack M3 screw
frame
nylon ring
metal rings
15 Upper belt unit (Oc 851).

1 2 3 4
Open the box and unpack the unit. Take the upper output unit and place it on the top of the frame belt unit. Remove the cover. Mount the 4 bolts (one star ring for grounding).
Note: Check if the unit is in line with the lower frame.
5 6 7 8 9
Mount the tooth drive belt between the upper and lower unit. Remove the jumper connector and leave the jumper in side the unit. Connect the connector of the motor from the upper unit. Unpack the upper belt section. Remove the black locking bold (M4x7) from front side belt unit.
Note: For next point, 1 person holds the unit while another connects the sensor
and the earth wire.

10 Connect the connector to the sensor and connect the earth wire (below the low11 12 13 14 15
er shaft). Push earth wire from the output cover to the side against the frame. Position the belt section (lift it at the front and hook it in the frame) Lock the belt unit with the M4 x 7 bolt at the front side. Connect the earth wire and mount the output cover with a little cover. Mount the output cover from the lower belt unit if not yet mounted.
ed.5
Installation 125
16 Mount the drive belt:
remove the E clip of the upper gear remove the gear s mount the timing belt together with the gear s mount the E clip 17 Mount the receiving rack (2 screws/ ring), the smallest washers against the frame.
s s
receiving rack M3 screw
frame
nylon ring
metal rings
Preparation 2nd folding unit 1 Remove the "old" side rear cover of the 2nd folding unit. 2 Remove front door 2nd folding unit and the rear covers of the 2nd folding unit. 3 Feed the two bundles (one with connector 1813X1 and one with a jumper)
through the middle hole of the new cover.

4 Mount the new rear cover. Connection between 2nd fold and the frame unit (Oc 850) 1 2 3 4 5 6 7 8 9
Place the frame belt unit near the 2nd folding unit. Guide the two cable bundles, through the holes, to rear of the unit. Remove the bolts from the supports. Place the unit against the second folding unit. Carry out function 18 adjustment Height of the belt unit and zero-line on page 307. Guide the long bundle (via the cable guides) with 1813X1 to the I/OPBA and the other bundle with 18X18 to the RELAY PBA in the Oc 850. Position the jumper connector at one of the cable guides. Connect connector 1813X1 on the PBA. Open the side door of the belt unit.
126
TSM Oc 9800
Folder optionals
10 Remove the small lower cover of the first folding unit. 11 Position the 220 V supply cable bundle under the frame unit and 2nd folding
12 13 14 15 16 17 18 19
unit through the hole of the cover of the first folding unit and secure the strain relief. Connect the supply cable with connector 22X9. Mount all covers of the belt units. Switch on the engine. Activate SDS. Carry out test 90. Configure the belt unit. Select the SDS test 18-1-06 and set the belt capacity. Switch off SDS and switch OFF and ON the engine.
ed.5
Installation 127
16 Installation punch unit (Oc 720/730)

1 Unpack the punch unit. 2 Open the side door of the frame belt unit. 3 Remove the side copy guide bracket from the frame unit, together with the 2
space bushes.
4 Remove the support with plastic bearing from the copy guide bracket. 5 Remove 2 position pins (7 mm) and 2 screws from the punch unit. 6 Mount the punch unit, use the position pins of 7 mm. Note: Do not damage the 2 optical switches during installation. Guide the left
spring on the right side from the sensor.

7 8 9 10 11 12 13 14 15
Secure the unit with 2 screws M6. Fix the 2 tension springs onto the brass brackets. Mount the bracket with plastic bearings onto the punch unit. Place the punch unit waste tray. Switch on the engine. Activate SDS. Carry out test 90. Configure the punch unit. Switch off the SDS and switch OFF and ON the engine.
Note: It is necessary to remove the 2 outside punches from the 4 hole punch
unit. to have a 2 hole punch unit.
128
TSM Oc 9800
Folder optionals

17 Special tool
Magnetic nut driver 7 mm.
18 Unpacking and assembling

1 2 3 4 5 6
Remove the staples from the cardboard box. Remove the cardboard box. Remove the plastic bag. Remove the shipping straps from the small box and the 2 ramps. Remove the small box and the 2 ramps from the pallet. Remove the large shipping straps which hold the delivery bins, the rectangular box and 2 long wooden beams.
Note: When removing the box and the beams the upright stored delivery bins
become unstable and might drop!

7 Remove the 2 long wooden beams and the rectangle box from the upper wood-
en plate.
8 Remove the upper wooden plate. 9 Remove the square box from the bottom of the pallet. 10 Remove the 6 delivery bins from the pallet.
ed.5
Installation 129
small box
shipping brackets
bin support
frame
2 ramps
bin 6x
11 Loosen the 4 shipping brackets of the delivery bin support from the frame. 12 Remove the delivery bin support from the wooden plate (do not damage the
sensor cover from the lower bin).

13 Remove the 4 shipping brackets from the delivery bin support. 14 Remove the lower wooden plate. 15 Remove the 4 eyes with space bushes from the bottom and the top of the frame 16 17 18 19 20 21
(13 mm). Remove the 4 shipping brackets of the castors from the wheels. Turn the wheels to the same running direction. Mount the 2 long wooden beams on the pallet at the left and right side. Place the 2 ramps against the pallet. Carefully roll off the HCS frame from the pallet. Open the boxes.
130
TSM Oc 9800
The small box contains:

s s
the 2 inner corner covers of the frame fixing material
The rectangle box contains:

s s s s s s s s
the 2 lower beams of the delivery bin support the long side cover of the delivery bin support the Oc 9700 / 9800 interface 7 wheel running supports of the delivery bins 6 round aluminium blocks 2 bin output covers (bin 3 and 6) the bottom cover fixing materials / parts
The square box contains:

s s s s s s s s s
the DELBINTXEMSE PBA 6 rectangular catches the brackets from DELBIN(2-6)OPSE 2 cable bundles the upper beams of the delivery bin support the triangle top cover 18 PBA1 I/O INTERFACE PBA tool for mounting gas dampers fixing materials / parts
ed.5
Installation 131
22 Mount the 7 wheel running supports of the delivery bin to the frame in the same
position as from the other delivery bins.
bin wheel running support
23 Mount the straight connecting beam with 2 bolts (M8x16) hand tight on top of
the delivery bin support.
straight beam
diagonal beam
bin support
132
TSM Oc 9800
24 Mount the 2 short connecting beams with 4 bolts (M8x16) hand tight to the
bottom of the frame.

25 Turn the adjustable feet from the bin support and the HCS frame to a height of
40 mm (1.6").
26 Place the delivery bin support with the adjustable feet on the round aluminium
blocks.
27 Mount the straight connecting beam hand tight to the frame with 2 bolts
(M8x16).
28 Mount the lower part of the delivery bin support hand tight to the short con-
necting beams with 4 bolts (M8x16) each.

Note: Before mounting the diagonal connecting beam, take care of the bundle of the DELBINTXEMSE PBA, feed the bundle through the hole in the frame of the diagonal beam 29 Mount the diagonal connecting beam hand tight between the top of the frame
and the delivery bin support with 4 bolts (M8x16).

30 Tighten all bolts from the beams to the delivery bin support and the frame. 31 Connect the cable bundle with the DELBINTXEMSE PBA. 32 Mount the bracket with the DELBINTXEMSE PBA in the diagonal. Be sure 33 34 35 36 37 38
the earth connection is made properly. Mount the triangular top cover (4 screws). Remove at the right side the upper and lower side covers from the HCS frame. Remove the long side cover at the right side (9 screws). Mount the bin output covers to bin 3 and 6 (different covers). Remount the long cover. Assemble the delivery bins in the following sequence starting with the upper delivery bin:
s
s s s s s
Loosen the screw from the bracket of the sensor at the left side DELBIN(1-6)EMSE Loosen the screw at the right side Swing the bracket of the sensor downwards Position the delivery bin in such a way to remount the bracket of the sensor Open the bin approximately 100 mm (4) Mount at the left side from the sensor bracket the rectangular catch into the delivery bin from below (2 screws)
Note: The catch from the upper delivery bin should fit into the carrier plate for the set separator; the other 5 catches should be attracted by the magnets for set separators.
ed.5
Installation 133
Mount the actuating plate for DELBIN(2-6)OPSE with 1 screw at the right side from the bracket with DELBIN(2-6)EMSE sensor Mount all the delivery bins according preceding description
bracket DELBIN(1-6)EMSE
rectangular catch
bracket DELBIN(2-6)OPSE
39 Place the bottom cover between the delivery bin support and the frame. 40 Remove the tapes from the TRI and from the sensor fingers of the TRI. 41 Remove the 2 shipping plates which hold the TRI and the upper door (4 screws 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
each). Remove the foam blocks. Open the TRI. Open the upper door from the frame. Mount the 2 upper inner corner covers (4 screws). Close the upper door and the TRI. Remove the tape from the lower door. Open the lower door and remove the tape from the input guide flap. Close the lower door. Mount the long side cover to the delivery bin support. Before positioning the HCS behind the Oc 9700 / 9800, prepare this machine according see Preparation of the Oc 9700 / 9800 on page 135. Remove the aluminium blocks underneath the delivery bin support. Roll the HCS behind the Oc 9700 / 9800. Carry out function 19 adjustment The HCS with regard to Oc 9700 / 9800 on page 309. Place the aluminium blocks underneath the delivery bin support levelling feet. Adjust the height of the feet. Connect the power supply cable and the data cable from the Oc 9700 / 9800 with the HCS. Continue with FINAL see Final on page 136.
134
TSM Oc 9800
19 Preparation of the Oc 9700 / 9800

Oc 9700: All engines are prepared. Oc 9800: Machine numbers 980100118, 522, 605, 680, 686, 689, 690 and from number 980100692 are already prepared.
1 2 3 4 5 6 7 8 9 10
Remove the top cover from the Oc 9700 / 9800 at the right side. Remove the side upper and lower cover at the right side. Remove the cover underneath the PTR. Remove the rear upper and lower cover at the left side. Mount the new 18PBA1 I/O-INTERFACE PBA and connect with the CPU-I/O PBA. Connect all the connectors. Mount the supply bundle to connector 22X9. Connect the connector 2202X6 from the databundle to the new 18PBA1 I/O-INTERFACE on connector X6. Mount 2 strain reliefs. Mount all covers of the Oc 9700 / 9800. Installation interface unit Oc 9700: Remove the output guide plate from the PTR. Oc 9700 / 9800:
11 12 13 14 15
Loosen the 2 knurled screws and slide the brackets inwards. Open the cover from the PTR. Lift and swing the unit into the output section of the Oc 9800. Slide the brackets outwards and tighten the knurled screws. Continue with the assembling.
Note: Remove the interface from the PTR (paper transport) of the Oc
9800/978 when you must carry out the SDS system tests with a sheet width of 930 mm. These tests are the following:
s s s
test 51 ~Testprint adjust PHD~ test 54 ~DRU ASV test~ test 55 ~DEV unit adjustment~
ed.5
Installation 135
20 Final
Switch on the HCS. Switch the Oc 9700 / 9800 in SDS mode. Execute SDS test 90 "Configuration" and configure the HCS. Execute all the input tests (19-2-xx), the output tests (19-4-xx) and the special tests (19-6-xx) to check the HCS. 5 Return to user mode and switch the Oc 9700 / 9800 off and on again.
1 2 3 4
136
TSM Oc 9800
Packing the HCS

1 2 3 4 5 6 7
Open the TRI. Open the upper door of the frame. Disassemble the inner upper corner covers at the right and left side. Close the upper door. Close the TRI. Place T form foam blocks between the frame and the upper door. Secure the TRI with 2 transport security plates (each 4 screws). Carry out the points 8 up to 13 for all delivery bins, start with the lower delivery bin.
bracket DELBIN(1-6)EMSE Confidential 1999 Oc-Technologies B.V. bracket magnet catch bracket DELBIN(2-6)OPSE
bin wheel running support
8 9 10 11 12 13 14 15 16 17 18 19
Remove the bracket from the magnet catches (2 screws). Remove the bracket from DELBIN(2-6)OPSE. Remove the screw at the right side from the bracket of DELBIN(1-6)EMSE. Loosen the screw at the left side and turn the bracket with the delivery bin empty PBA 900 downwards. Slide out the delivery bin carefully. Remount the bracket of DELBIN(1-6)EMSE. Remove the bin wheel running supports from bin 2 up to 6 at the right side. Remove the bin wheel running supports from bin 5 and 6 at the left side Remove the triangle top cover (3 screws). Remove the bottom cover. Remove the rear cover of the delivery bin support. Remove the bracket with the DELBINTXEMSE PBA above the delivery bin number 1.
ed.5
Installation 137
20 Disconnect the connector. 21 First remove the 2 short support beams between the bin support and the frame. 22 Remove the upper diagonal beam from the frame, attention for the connector
from the DELBINTXEMSE PBA.

23 Remove the other upper delivery bin support beam, do not drop the delivery 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
bin support. Turn the levelling feed from the frame upwards. Remove the aluminium blocks. Remove the levelling feed from the frame. Mount the 2 long wooden beams on the pallet. Place the 2 ramps to the pallet side. Roll the frame on the pallet. Mount the security brackets between the wheel and the wheel housing from the frame. Fix the security brackets with the pallet (2 bolts and 2 nuts). Place the wooden transport plate on the bottom of the frame. Mount the 4 transport security brackets to the delivery bin support. Place the delivery bin support on the wooden plate and fix the delivery bin support with the 4 shipping brackets to the frame. Remove the levelling feed from the bin support. Mount the transport security brackets with eyes and space bushes (2 in the upper part of frame and 2 in the bottom). Place the delivery bins on the wooden plate. Place the wooden plate on top of the delivery bins. Pack all disassembled parts in the boxes. The small box contains:
s s
2 inner upper corner cover fixing materials / parts
The rectangle box contains:

s s s s s s s
the bottom cover the rear delivery bin support cover the Oc 9700 / 9800 interface the 2 lower delivery bin support beams 6 round aluminium blocks 6 levelling feed fixing materials / parts
138
TSM Oc 9800
Packing the HCS
The square box contains:

s s s s s s s s s
the triangle top cover the upper delivery bin support beams 6 magnet catches 7 delivery bin wheel running supports the DELBINTXEMSE PBA the brackets from DELBIN(2-6)OPSE 18 PBA1 INTERFACE I/O PBA 2 cable bundles fixing materials / parts
40 Place the rectangle box on the wooden plate. 41 Place the 2 long wooden beams besides the box. 42 Mount the chipping straps cross over through the eyes of the transport security 43 44 45 46 47 48 49 50 51
brackets and tighten the straps. Open the lower door of the frame and stick tape to the guide flap. Close the lower door and tape the door. Tape the bulge 2 fingers on top of the TRI. Tape the small box with the 2 ramps together. Tape the small box with ramps to the delivery bin support. Place the square box on the pallet. Mount the plastic bag across the unit. Place the carton box. Attach the carton box to the pallet.
ed.5
Installation 139
Final
21 Final preparations
1 Shake one bottle of toner and add it into the developing unit. 2 Load the paper roll drawers with paper. 3 Mount the side covers of the paper roll drawers (open the upper drawer to fix
the screws from inside).

4 Mount all covers to the engine.
22 Installation adjustments
1 Switch on the engine. 2 Activate SDS.
If the first entry screen shows the BBR checksum / information error codes:
s s s s
22901 SWAR 22902 SWAR 22102 PE 22103 PE
Execute the installation tests 70 / 71 / 72 / 73 / 74 completely (see SDS ~INSTALLATION~ tests (70 - 79) on page 1192.
3 4 5 6 7 8 9 10 11
Carry out SDS test 90 (configuration) and do the required settings. Carry out 05 DEV ~DEV unit adjustment~ on page 301. Carry out SDS test 41 WARM SDS. Carry out SDS test 10-7-01, 10 SCA TL intensity adjust on page 301. (not needed for the Printer Only version) Activate SDS test 09-1-01/09-1-02/09-1-03/09-1-04 and fill in the values as write on the scanner installation card Carry out SDS test 73 (Install folder) Carry out test 74 (Customer). Make copies from the service test original and check the copy quality see Service test original on page 115. Make a data dump with the ST program on the machine logfloppy. If there is no logfloppy with the machine create the floppy now.
140
TSM Oc 9800
Final
Controller
23 FBBS Controller
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Switch off the engine and disconnect the mains supply. Remove the right top cover and the two side covers. Remove the right rear covers from the engine. Disconnect the scanner data cable from the engine. Remove the cover from the SET memory and the B/W PBAs (20 screws). Connect the connector 1101X4 to the small PBA on the SET memory PBA (data cable). Connect the other connector to the CPU_IO PBA on the left upper side (control cable). Mount the cover with the 20 screws. Mount two screws in the upper holes of the controller box. Hang the controller to the frame. Mount the controller with four screws. Connect the supply connector to the controller. Connect the data cable to the controller (lower connector). Connect the control cable to the controller (upper connector). Connect the scanner data cable. Put the switch on the controller in the OFF position. Mount all covers. Switch on the engine. Activate SDS and select test 90. Configure the controller. Switch off the SDS. Switch off and on again the engine.
ed.5
Installation 141
24 EPC 1 / EPC 2 Controller

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Switch off the engine and disconnect the mains supply. Remove the right top cover and the two side covers. Remove the right rear covers from the engine. Disconnect the scanner data cable from the engine. Remove the cover from the SET memory and the B/W PBAs (20 screws). Connect the connector 1101X4 to the small PBA on the SET memory PBA (data cable). Connect the other connector to the CPU_IO PBA on the left upper side (control cable). Mount the cover with the 20 screws. Mount two screws in the upper holes of the controller box. Hang the controller to the frame. Mount the controller with four screws. Connect the supply connector to the controller. Connect the upload/download cable to the controller. Connect the control cable to the controller (upper connector). Connect the scanner data cable. Mount all covers. Switch on the engine. Activate SDS and select test 90. Configure the controller (Controller type Power = EPC). Switch off the SDS. Switch off and on again the engine. Print out the print settings (3 pages). Check the settings.
142
TSM Oc 9800
Controller
25 DRI (Direct Raster Interface).

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Remove the right side cover of the engine. Remove the connectors of the controller Remove the controller. Remove the connector of the Set Memory PBA. Connect the connectors 1101X4 and X14 of the DRI unit to the Set Memory PBA. Mount the cover of the Set Memory PBA. Connect 2201X17 of the DRI unit to the CPU I/O PBA. Mount the DRI unit. Switch on the machine. Switch to SDS. Change the configuration, SDS test 90: controller type to ~DRI~ and plot to yes and upload to yes (if scan to file is needed). Switch off the machine. Connect the host PC environment to the DRI unit. Switch on the machine and check the DRI function.
26 Testing the controller

1 Enter system administrator mode.
2 3 4 5 6
Set available ALS formats Set default language settings s Set default connection settings s Print default controller settings (select machine / print settings and push the start button). Check the settings. Connect the laptop via the centronics connector with the controller. Check the controller functioning with the Oc 9800 Service Plot Tool. Connect the controller to customer environment. Check the controller functioning with customer plots.
s s
ed.5
Installation 143
144
TSM Oc 9800
Controller
Oc
Oc 9800
FAULTS
Contents
Faults
1 Faults overview 101 2 General information 104 3 Service test original 115 4 Copy quality 127 5 SDS not available 155 6 Faults without error messages 159 7 Failing consumables 161
Electrical faults
1 FAULT procedures 201

ed.5
Faults
TSM Oc 9800
Contents
Faults
1 Faults overview
Copy quality
Copy quality general / No image on copy on page 127 s Blank copy Copy quality general / Uneven image on page 127 Skeleton image middle s Skeleton image on sides of copy s Skeleton image on leading edge s Catskin s Uneven background s Moire effect
s
Copy quality general / Weak image on page 131 Weak image s Weak image not being copied correctly
s
Copy quality general / ghost image on page 133 Ghost image caused in 1st transfer s Ghost image caused in 2nd transfer s Digital ghost image
s
Copy quality general / Image erasable on page 134 Image erasable
Copy quality general / Black copy on page 135 Black copy unframed s Black copy framed
s
Copy quality general / Unsharp image on page 136 Unsharp image
ed.5
Faults 101
Spots,stains,stripes,scratches / Spots/stains on page 137 s Missing image, white stains/spots s Black stains/spots s Soiled backside s Black spots / stains / background is digital s Analogue background Spots,stains,stripes,scratches / Stripes, scratches on page 141 Missing image, stripes / scratches in feed direction s Missing image, stripes / scratches perpendicular to feed direction s Black stripes / scratches perpendicular to feed direction s Black stripes / scratches in feed direction s Wall paper s Black stripes first few copies, perpendicular to feed direction
s
Position,deforming,magnification / Image position on page 145 Image position in feed direction s Image distorted in width direction
s
Position,deforming,magnification / Framing on page 147 Incorrect framing Position,deforming,magnification / Image deformed on page 148 Copy image is deformed
Position,deforming,magnification / Magnification ratio on page 149 Magnification ratio incorrect in feed direction s Magnification ratio perpendicular to the feed direction incorrect
s
Receiving materials damaged, soiled in engine / Folds, wrinkles on page 150 Folds / wrinkles on leading edge s Wrinkles all over the copy s Moisture on copies
s
Receiving materials damaged, soiled / In 1st fold on page 151 Wrinkles s Dog ears s Damaged leading edge s Unsharp folds s Wrong fold length
s
102
TSM Oc 9800
Faults
Receiving materials damaged, soiled / In 2nd fold on page 153 s Dog ears leading edge s Damaged leading edge Receiving materials damaged, soiled / in belt, punch unit on page 154 Dog ears s Punch holes wrong positioned
s
SDS not available

Machine is totally dead on page 155 s CONCONEMS ON s CONCONEMS OFF Machine is totally dead after CONEMS activated on page 158
Only LCD (display) dead on page 158
Faults without error messages

Machine not getting warm on page 159 Fol1indiag error on page 159 Controller LED Identification Table on page 163 Damaged ends of the clean rollers on page 159 Illegal toner over flow on page 159
Failing consumables
ed.5
Faults 103
2 General information
Introduction
This section on copy quality contains a range of examples of copy quality phenomena which you can use as a tool for remedying copy quality problems with the Oc 9800. The information is arranged in such a way that you can quickly determine which copy quality problem you are confronted with and how you may be able to remedy it. Every copy quality problem comprises a description, a list of possible causes and the corresponding check procedures/remarks. Remarks and suggestions for improvement of this section can be notified to SPS-ES (Service Product Support-Engineering Systems) via your Technical Coordinator. This chapter Copy Quality contains the following sections to provide support:
s s
starting conditions tools
Starting conditions 1 Remedy any SDS or operator fault message. 2 Switch the system off and on again to have a defined starting situation. 3 Use only authorized media (Oc 75 g/m2 plain paper) as receiving material un-
less otherwise indicated.

4 Use the Oc 9800 Test Chart, SDS tests (51 up to 54) and test files to evoke the
copy quality problem.
104
TSM Oc 9800
Faults
Tools Excluding the scanner, controller and/or printer.
If the copy quality problem causes extra image as spots, stains, stripes and background, the structure of this fault as to be seen on the copy (e.g. background) tells you about the source of the problem. Digital structure The structure of the added image is digital. This means that the image consists of defined pixels. If the structure of the fault is of a digital kind the problem is probably caused in the scanner, image processing function of the printer only version or controller. Analogue structure The structure of the added image is analogue. There is no structure of defined pixels. If the added information is of an analog kind the problem is caused in the printer process section. Also the following test prints/copies might help you to find out in which section the problem is caused:
Test Checks
SDS-50 Oc 9800 Test chart SDS-51 (Testprint PHD) SDS-52 (Black mode) SDS-43 (Cut sheet length) Service plot tool
Optical symptom
Printer Error 01503 Scanner-Printer Printer Printer Printer Controller / printer
If a given copy quality phenomenon is caused in the optical section of the scanner (gauge-roller, glass plate) you can simply check this by making a reduced or enlarged copy. The copy quality phenomenon will also be reduced or enlarged.
Gauge roller
If a given copy quality problem repeats every 10.5 cm (4.1), the problem is on the gauge roller.
OPC drum
If a given copy quality problem repeats every 62 cm (24.4), the problem is related to the OPC-drum.
ed.5
Faults 105
CTF fuser roller
If a given copy quality problem repeats every 33 cm (13), the problem is related to the CTF roller.
CTF pressure roller
If a given copy quality problem repeats every 7 cm (2.75), the problem is related to the CTF pressure roller.
Developing unit
If a given copy quality problem repeats every 3 cm (1.2), the problem is related to the developing roller.
Printhead
Lighter / darker strokes of 228 mm (89.8) in the feed direction (PHD section). Lighter / darker strokes of 8.2 mm (3.3) in the feed direction (PHD chip).
CCD unit
Lighter / darker strokes of 300 mm in the feed direction (CCD PBA). Lighter / darker strokes of 60 mm in the feed direction (CCD chip)
106
TSM Oc 9800
Faults
Skeleton image
As a consequence of the Oc 9800 printing process it is possible that skeleton images occur. The skeleton image can be described as strokes with less or no image density. Also the copy material might be deformed slightly (wrinkles) on those strokes. The skeleton image is worst on a black copy. In principle skeleton images are caused by velocity differences in the width direction of the copy material. Those velocity differences can be caused by e.g. an uneven pinch. There are three types of skeleton images:
1 Skeleton in the middle of the copy 2 Skeleton on the sides of the copy 3 Skeleton on the leading edge 1
ed.5
Faults 107
1 Skeleton in the middle of the copy
Description: In the middle of the copy strokes (arch form) with a lower image density can be seen. Also the copy material might be deformed. This phenomenon is on the copy an up building phenomenon which means that on the first part of the copy the image is correct and gets worse towards the end of the copy.
Cause: The skeleton image in the middle of the copy is caused by a concave CTF-pinch. This concave CTF-pinch can be caused by uneven pressure roller cleaners or a worn out pressure/fuser roller. Solution:
s
s s
Check visually if the pinches are made correctly (cylinders). Correct if necessary. Check and if necessary replace the pressure roller cleaners. If the upper two solutions are not the solution the pressure roller should be replaced. It is possible that after replacing the CTF pressure roller, instead of the "skeleton in the middle" phenomenon the "skeleton on the sides" phenomenon appears. In this case also the fuser roller needs to be replaced.
108
TSM Oc 9800
Faults
2 Skeleton on the sides of the copy
Description: On the sides of the copy strokes with less image density can be seen. Also the copy material might be deformed. This phenomenon is on the copy an up building phenomenon which means that on the first part of the copy the image is correct and gets worse towards the end of the copy. Cause: The skeleton image on the sides of the copy is caused by a convex CTF-pinch. This convex CTF-pinch can be caused by uneven pressure roller cleaners or a convex CTF fuser roller. Solution:
s s
Check and if necessary replace the pressure roller cleaners. If this gives no solution replace the CTF fuser roller. It is possible that after replacing the CTF fuser roller, instead of the "skeleton on the sides" phenomenon the "skeleton in the middle" phenomenon appears. In this case also the pressure roller needs to be replaced.
ed.5
Faults 109
3 Skeleton on the leading edge
Description: At the leading edge of the copy, strokes with a lower image density can be seen. The copy material might also be deformed in width direction. Cause: The skeleton image at the beginning of the copy is caused by an incorrect entering of the copy material in the CTF-pinch.
s
Solution: Check the copy material transport in the preheater.
110
TSM Oc 9800
Faults
Wax /talc pollution General:
Due to the structure of the copy materials and the Oc 9800 copying process, the OPC drum and/or CTF rollers may be polluted with wax and/or talc, coming from the copy materials. Talc and wax pollution both may lead to analogue background on the copies, each with its own specific structure.
Talc pollution Recognizing talc pollution
If the drum is polluted with talc, background on the copies will be the result. The background can be recognized by its specific scaly and wavy structure. It can be seen mainly in strokes, related to the edges (in the feed direction) of the copy material. In worse cases also thick lines in the width direction on the copy will be surrounded with this scaly and wavy background.
<------Paper feed direction.

Cleaning a drum polluted with talc
Talc pollution on the drum can be cleaned according to the normal Drum Cleaning Procedure, see chapter DRUM Drum cleaning procedures on page 406.
ed.5
Faults 111
Preventing talc pollution
Normally, if Oc labelled copy materials are used, talc pollution should not lead to background within 50.000lm. If however, talc pollution leading to background occurs frequently sooner than 50.000lm, SPS-ES in Venlo should be informed via your local Support Department. Inform SPS-ES via the normal Problem Report procedure. Include detailed information about:
s s s
s s s
Drum lifetime Copy material batch numbers used by customer How soon background on copy caused by talc appears after cleaning the drum Machine serial number Examples Any other relevant information
If the customer does not use Oc labelled copy materials and the background appears frequently within 50.000lm, SPS-ES in Venlo should be informed via your local Support Department. Oc labelled copy materials should be advised to the customer in order to reduce the service costs (drum-cleaning).
112
TSM Oc 9800
Faults
Wax pollution
Recognizing wax pollution
If the drum is polluted with wax, toner will be developed on the drum via mechanical forces resulting in background on the copy. ASV compensation (DRU-ASV test) has only a little influence on the amount of background. Background caused by wax pollution can be recognized by its specific spotted and cloudy structure. Background caused by wax usually starts in the middle of the drum since this part "sees" most paper.
<------Paper feed direction.

Solving problems cause by wax
If wax pollution occurs, the CTF fuse roller will be polluted with wax till he roller is saturated. As a consequence this polluted CTF fuser roller will pollute the drum. From System Upgrade R 2.0, a wax cleaning procedure exist in SDS. This OPC wax cleaning procedure heats the drum up to 50C (122F) and the melted wax will be transported to the CTF fuser roller. For that reason the CTF fuser roller should be replaced before the cleaning procedure is activated, see chapter 01-Drum OPC wax cleaning procedure on page 410
Note: To raise the temperature of the drum to 50C (122F), the cooling fan is
switch of and the temperature sensor is set to the higher temperature.
ed.5
Faults 113
Preventing wax pollution
Normally if Oc labelled copy materials are used, wax pollution should not occur. If however, wax pollution leading to background occurs, SPS-ES in Venlo should be informed via your local Support Department.Inform SPS-ES via the normal Problem Report procedure. Include detailed information about:
s s s s s s
Drum lifetime CTF fuser roller lifetime Copy material batch numbers used by customer Machine serial number Examples Any other relevant information
If the customer does not use Oc labelled copy materials and background caused by wax occurs, SPS-ES in Venlo should be informed via your local Support Department. Oc labelled copy materials should be advised to the customer in order to reduce the service costs.
Summary
Background caused by talc pollution:

s
Clean drum
Background caused by wax pollution:

s s s
Replace CTF fuser roller Execute the SDS test wax cleaning procedure. Report to SPS Venlo via local Service and TUS organisation.
114
TSM Oc 9800
Faults
3 Service test original

Machine condition When checking the copy quality specifications make sure that:
s s
the machine is adjusted as described in the TSM the machine should be warmed up for at least 30 minutes (in stand-by or in run mode) after the scanner display indicates ready to copy. after replacing a new roll of copy material the first 5 copies / prints can not be used to determine copy quality.
Specifications, measuring methods and adjustments. Maximum Optical Density (Dmax) Printer
Test: Check: Norm:
Adjustment:
Copier
SDS system test 50- "testprint mode" Compare the optical density of the black stroke on 5 different points on the leading edge of the testprint, with the Agfa greyscale The average Dmax should be at least equal to 0.9 on the Agfa greyscale. Unevenness of Dmax should not exceed 2 steps (0.2) on the Agfa greyscale Not applicable Make 5 copies of the Oc 9800 service test original : - run length = 5 - exposure = 0 - ABC = on Compare on the 5 th copy the optical density of stroke Ib on points XIIa, XIIe and XIIi. The average Dmax should be at least equal to 0.9 on the Agfa greyscale. Evenness of Dmax should not exceed 2 steps (0.2) on the Agfa greyscale
Test:
Check: Norm:
Adjustment:
Not applicable
ed.5
Faults 115
Evenness in grey Copier
Test:
Check:
Norm: Adjustment:
Make 7 copies of Oc 9800 Test Chart at different exposure settings: - exposure setting - = -7, -6, -5, -4, -3, -2, -1, - run length = 1 - ABC = off. The copy on which the average optical density is approx. 0.3 (Agfa grey scale) is the reference copy Measure on the reference copy the optical density of beam Ia on 5 different spots in width direction. The evenness of the grey information should be within 0.3 on the Agfa greyscale. Not applicable.
Reproduction of weak lines Copier
Test:
Check: Norm: Adjustment:
Make 10 copies of the Oc 9800 Test Chart at different exposure settings: exposure setting = -4 up to +5 run length = 1 ABC = on Determine at how many exposure settings line Va is printed without interrupts and also having no background. At least 1 exposure setting should be possible. Not applicable.
116
TSM Oc 9800
Faults
Readability Copier
Test:
Check:
Make 5 copies of the Oc 9800 Test Chart: exposure = 0 run length = 5 ABC = on. The 5 th copy is the reference copy. Determine which isomires (IVa up to IVh) are still readable. Readable is when the direction of at least 7 from the 8 isomires can be recognized.
Norm: Adjustment
Synchronisation Copier / printer
Isomire 140 should be readable. Not applicable.
Test:
Check:
Norm: Adjustment:
Make 5 copies of the Oc 9800 Test Chart : Exposure = 0 Run length = 5 ABC = on. The 5 th copy is the reference copy. Examine the 2.0 lp/mm stroke on the left side of the copy (IIIa and IIIf). The lines should be visible separately. Not applicable
ed.5
Faults 117
Toner adhesion Printer
Test: Check: Norm: Adjustment: Note:

Copier
SDS test 52, "Black mode. Make a fold after 25 cm (10) of the leading edge on the copy. Measure the width of the interruptions in the fold. The width of the interruptions should not exceed 0.25 mm. Not applicable If the toner adhesion is good on Oc plain paper it is also OK for Oc transparent and Oc polyester film Make 5 copies of the Oc 9800 Test Chart : Exposure = 0 Run length = 5 ABC = on. The 5 th copy is the reference copy. Make a fold on position XIIe of the black stroke and measure the width of the white area in the fold. The width of the interruptions should not exceed 0.25 mm.
Test
Check: Norm:
118
TSM Oc 9800
Faults
1 : 1 accuracy Printer (feed direction
Test: Check: Norm: Adjustment: Test:
SDS test 53, "1:1 mode" Measure the length of the white beam and adjust the length accordingly. Accuracy < 0.1%. 06 CTF adjustment 1.
Copier (feed direction)
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Place the test original on the copy and measure the difference between the length of line Xa-Xd on the copy and original. The 1:1 accuracy of all 5 copies < 2.5 mm. 09 ORIGINAL adjustment 2. Modification 9810 -01
Copier (width direction)
Test:
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Place the test original on the copy and measure the difference between the length of line Xe-Xh on the copy and original. The 1:1 accuracy of all 5 copies < 3.5 mm. Not applicable.
ed.5
Faults 119
Copy length Printer
Test: Check: Norm: Adjustment:

Copier
SDS test 43, "Cut sheet length" Sheet length 600 mm. Measure the length of the cut sheet and adjust accordingly. 600 2 mm. 12 PRD adjustment 1/2. Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Measure the length difference from the 5 copies , compared with the original length. The copy length accuracy < 4 mm. 09 ORIGINALS adjustment 1.
Copier (in run of 25 copies)
Test:
Check: Norm: Adjustment: Test:
Make 25 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 25 ABC = off. Measure the maximum length difference from the 25 copies. The maximum difference must be < 3 mm. Not applicable
120
TSM Oc 9800
Faults
Image position on leading edge Copier
Test:
Check:
Norm: Adjustment:
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Measure on the copies on the left hand side the distance Ca from the -10 line to the edge of the material. Measure on the copies on the right hand side the distance Cb from the -10 line to the edge of the material. Measure also the distances Oa and Ob on the left and right hand side of the original. Calculate the difference a = Oa-Ca and b = Ob-Cb. Image position on leading edge (a+b)/2 < 3 mm 09 ORIGINALS adjustment 3
ed.5
Faults 121
Left/right differences in image position on leading edge Copier
Test:
Check:
Norm: Adjustment:
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Measure on the copies on the left hand side the distance Ca from the -10 line to the edge of the material. Measure on the copies on the right hand side the distance Cb from the -10 line to the edge of the material. Measure also the distances Oa and Ob on the left and right hand side of the original. Calculate the difference a = Oa-Ca and b = Ob-Cb. Left/right difference image position on leading edge (a-b) < 2 mm Not applicable
122
TSM Oc 9800
Faults
Image position on side edges Copier
Test:
Check:
Norm: Adjustment:
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Measure on the copies at the left side at the leading edge the distance Cc from the -10 line to the edge of the material. Measure also on the original at the left side at the leading edge the distance Oc from the -10 line to the edge of the material. Calculate the difference c = Oc-Cc. The image position on the edge c < 4 mm. All copies should meet this norm. Not applicable.
ed.5
Faults 123
Image position on side edge, difference on leading and trailing edge. Copier
Test:
Check:
Norm: Adjustment:
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Measure on the copies at the left side at the leading edge the distance Cc from the -10 line to the edge of the material. Measure on the copies on the left hand side at the trailing edge the distance Cd from the -10 line to the edge of the material. Measure also the distances Oc and Od on the left d side leading and trailing edge of the original. Calculate the difference c = Oc-Cc and d = Od-Cd. The image position on the side edge (c-d) < 2 mm. All copies should meet this norm. Not applicable.
124
TSM Oc 9800
Faults
Framing at the leading edge. Copier
Test:
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Measure on the copies the framing at the leading edge on the left (K1) and on the right (K2) side. The framing at the leading edge be: K1, K2 > 0.5 mm. All copies should meet this norm. Not applicable.
ed.5
Faults 125
Framing at the side edges. Copier
Test:
Check:
Norm:
Adjustment:
Make 5 copies of the Oc 9800 Test Chart : Exposure = -7 Run length = 1 ABC = off. Measure on the copies the framing at the left leading and trailing edge (K5 and K6). Measure on the copies the framing at the left leading and trailing edge (K7 and K8). The framing at the side edges left: K5, K6 > 0.5 mm, right: K7, K8 > 0.5 mm All copies should meet this norm. Not applicable.
126
TSM Oc 9800
Faults
4 Copy quality
Copy quality general / No image on copy
Blank copy Possible cause Checking procedure / Remark
Drum exposed by false light Position developing unit not correct
Front cover not positioned Check locking position
Developing roller not run- SDS: 05-6-05 ning Compressor defect Working pressure should be 5.4 bar
First transfer (drum-CTF) SDS: 06-6-07 step not correct

Second transfer SDS: 06-6-07 (CTF-Paper) step not correct Incorrect ABC Incorrect configuration Defective SIMMs PBA SET-MEMORY Defective PBA_SET-MEMORY Defective PBA_B/W-PROCESSING Defective PBA_SCAN-PROCESSING Defective CONTROLLER Electrical connections IMP section Printhead defect Scanlamp defect Image processing not correctly initialised, switch machine off and on SDS: 90 SDS: 11-6-05, check positioning SDS: 11-6-05 SDS: 11-6-05
SDS: 11-6-05
Controller SDS tests and try copying Check Carry out adjustment 04 Printhead see Check
Printhead on page 305

SDS: 10-4-01
Copy quality general / Uneven image
ed.5
Faults 127
Skeleton image in middle of copy Description: Image density is too low partly in the middle of the copy and / or material has wrinkles Possible cause Checking procedure / Remark
Concave fuse pinch
SDS: 06-8-04 Check pressure roller gap cleaner on its evenness SDS: 06-8-05 Check pressure roller build up cleaner on its evenness Check evenness of the pressure roller SDS: 06-1-04 Paper quality factor not correct
Skeleton Image on sides of copy Description: Image density is too low partly on the sides of the copy and / or material has wrinkles Possible cause Checking procedure / Remark
Convex fuse pinch Concave fuse pinch
SDS: 06-8-01 Check fuser roller on its evenness SDS: 06-8-04 Check pressure roller gap cleaner on its evenness SDS: 06-8-05 Check pressure roller build up cleaner on its evenness
Skeleton image on leading edge Description: Image density is too low partly on the top of the copy and / or material has wrinkles. Possible cause Checking procedure / Remark
Entrance to fuse pinch not correct
SDS: 14-8-01 Worn out paper guide cloth Check preheating unit on its position SDS: 14-4-02 PRETBR
128
TSM Oc 9800
Faults
Catskin Description: Image density differences all over the copy (catskin structure). Possible cause Checking procedure / Remark
Copy material is Check paperfeed over preheater unit not heated evenly SDS: 14-8-01 Worn out paper guide cloth of preheater No solution possible
Uneven background Description: Image density background is uneven Possible cause Checking procedure / Remark
Incorrect use of ABC
Switch off ABC
Badly adjusted CCD chip Uneven stroke of 6 cm (2.4) in the feed direction SDS: 10-7-01 function 10 Scanner (see TL intensity adjust on page 301) In photo mode or on grey copy no total cure. Badly adjusted CCD PBA Uneven stroke of 30 cm (11.8) in the feed direction SDS: 10-7-01function 10 Scanner (see TL intensity adjust on page 301) In photo mode or on grey copy no total cure. Coloured originals Uneven stroke of 30 cm in feed direction due to different lightpath to the CCD PBAs. No solution possible. Clean / replace scan-roller Correct SDS: 10-4-01 Scanner lamp
Scan-roller soiled / damaged Copy glass not mounted correctly Defective SLA
Corona pin array polluted Uneven lines of approx. 3 mm (0.1) in the feed direction. Clean or replace the corona pin array DRUM with talc polluted Clean DRUM according the procedure DRUM with wax polluted Clean DRUM according the OPC wax cleaning procedure. Diaphragm PHD polluted Clean
ed.5
Faults 129
Moire effect Description: Fine patterns on original are printed with uneven structure. Possible cause Checking procedure / Remark
Photo mode not used
Check with photo mode
130
TSM Oc 9800
Faults
Copy quality general / Weak image

Weak image Description: Image density is too low, weak lines are not printed correctly Possible cause Checking procedure / Remark
Developing unit out of toner Fuser roller temperature too low
SDS: 05-2-01 DEVTONSE Frequency of development roller (3 cm (1.2)) visible on copy SDS: 06-1-01 CTFREFTEMPSE low, check resistance value on sticker of CTFTEMPSE SDS: 06-1-02 CTFREFTEMPSE high, check resistance value on sticker of CTFTEMPSE
Fuser roller worn out
SDS: 06-8-01 Image density is lower in the middle of copy
Paper dust on fuser roller Check the functioning of the fuser roller cleaner Fuser pressure too low
SDS: 06-6-07 Check pneumatics Check the air pressure SDS: 06-6-07 Check pneumatics Check the air pressure Check printhead position Clean printhead diaphragm / lens
First transfer step not correct Printhead out of focus Printhead diaphragm / lens soiled
B/W_PROCESSING-PB SDS: 11-6-05 A defect Electrical connections B/W_PROC-PBA Check
ed.5
Faults 131
Weak information not being copied correctly Description: It is not possible to copy weak information without getting background Possible cause Checking procedure / Remark
Exposure adjustment printhead not correct Dirty OPC, uneven OPC charge Printhead out of focus Printhead diaphragm / lens soiled
SDS test 51, see function 04 see ~Testprint adjust
PHD~ (every service visit) on page 301

SDS test 54, See function 01 ~DRU ASV test~
on page 302
Clean the drum according procedure Check printhead position Clean printhead diaphragm / lens
Image Processing not cor- Switch machine off and on rectly initialised (ABC = Automatic Background Compensation)
132
TSM Oc 9800
Faults
Copy quality general / ghost image

Ghost images due to incorrect 1st transfer Description: Image repeats every 62 cm (24.4)(Drum) in feed direction Possible cause Checking procedure / Remark
Soiled discharge pin array SDS: 07-8-01, clean or replace pin array Soiled discharge LEDs Discharge current too low Defective discharge LED After drum cleaning Clean discharge LEDs Residual image is weak SDS: 07-4-01 Residual image is strong
SDS 43: Make 25 A0 (36) by 930mm (36.6) blank copies to solve the problem
Ghost images due to incorrect 2nd transfer Description: Image repeats every 31.5 cm (12.4)(fuser roller) in feed direction Possible cause Checking procedure / Remark
Fuser roller temperature too low
SDS: 06-1-01 CTFREFTEMPSE low, check resistor value on sticker CTFTEMPSE SDS: 06-1-02 CTFREFTEMPSE high, check resistor value on sticker CTFTEMPSE
Fuser roller worn out
SDS: 06-8-01 Image density is lower in the middle of copy
Paper dust on fuser roller Check the functioning of the fuser roller cleaner Fuser pressure too low SDS: 06-6-07 Check pneumatics Check air pressure
ed.5
Faults 133
Digital ghost image Description: Image repeats every 22.7 cm (8.9 ) (perpendicular on feed direction. Possible cause Checking procedure / Remark
Bad connection B/W PBA -> PHD Defective B/W PBA Defective PHD
Check bundles / connectors SDS: 11-6-05, Self test image processing Check / replace
Copy quality general / Image erasable

Image is erasable Description: Image is not fixed on receiving material and can be erased easily Possible cause Checking procedure / Remark
Level preheating liquid too low Preheater element defect Fuser roller temperature too low
Check level and refill if necessary SDS: 14-4-01 PREHE SDS: 14-9-01 PREHETEMPSE SDS: 06-1-01 CTFREFTEMPSE low, check resistor value on sticker SDS: 06-1-02 CTFREFTEMPSE high, check resistor value on sticker
Fuser pressure too low
SDS: 06-6-07 Check pneumatics Check air pressure (5.4 bar)
Incorrect receiving material
Receiving material out of specifications If receiving material is transparent material: (14-PREHEATING see Brake force of the pre-heater brake (PRETBR) on page 302).
134
TSM Oc 9800
Faults
Copy quality general / Black copy

Black copy, unframed Description: Copy / print is black, including the framing sides in length direction Possible cause Checking procedure / Remark
Incorrect configuration Bad sliding contact drum Connection between B/W PBA and Printhead Defective printhead Data receiver PBA defect B/W PBA defect
SDS: 90 Check carbon brushes Check bundle / connectors Carry out adjustment 04 Printhead see Check

Carry out adjustment 04 Printhead see Check

SDS: 11-6-05 Self test image processing
Black copy, framed Description: Copy / print is black, excluding the framing sides Possible cause Checking procedure / Remark
Scanlamp defect Connections CCD unit SIMMs defect / bad contact
SDS: 10-4-01 SCALA Check connections SDS: 11-6-05 Self test image processing
ed.5
Faults 135
Copy quality general / Unsharp image

Unsharp image Description: Image on copy is unsharp Possible cause Checking procedure / Remark
Printhead position Self focusing lens array (SLA) printer soiled Printhead damaged (diaphragm)
Check printhead locking position Clean SLA Check / replace
136
TSM Oc 9800
Faults
Spots,stains,stripes,scratches / Spots/stains
Missing image, white stains / spots Description: On black parts to be seen as white stains / spots Possible cause Checking procedure / Remark
Scratch on OPC drum
SDS test 52, black mode Fault repeats every 62 cm (24.4) Clean or replace the drum SDS test 52, black mode Fault repeats every 62 cm(24.4) Clean the drum SDS: 01-9-01 check DRUM temperature
Toner or glue on OPC drum
Scratch on fuser roller
SDS test 52, black mode Fault repeats every 33 cm(13) Clean or replace the fuser roller SDS test 52, black mode Fault repeats every 7 cm (2.75). May also result in deformed images Clean / replace pressure roller
Scratch on CTF pressure roller
ed.5
Faults 137
Black stains / spots Description: Copy / print is polluted with black stains / spots Possible cause Checking procedure / Remark
Toner fused on OPC drum SDS test 51, see function 04 see ~Testprint adjust

Fault repeats every 62 cm (24.4) Too high drum temperature. SDS: 06-1-01 CTFREFTEMPSE low, check resistor value on sticker SDS: 06-1-02 CTFREFTEMPSE high, check resistor value on sticker DRUMFAN not turning, check fan, inverter PBA Too high Drum temperature Clean the drum according the procedure Glue sticked on the drum SDS test 51, see function 04 see ~Testprint adjust PHD~ (every service visit) on page 301 Fault repeats every 62 cm(24.4) Clean the drum according the procedure Toner dosing procedure not correctly functioning SDS: 06-6-07 Check pneumatics and toner dosing mechanism
Soiled backside Description: Backside of copy / print is soiled with spots / stains Possible cause Checking procedure / Remark
Scratches on CTF pressure roller
SDS test 51, see function 04 see ~Testprint adjust PHD~ (every service visit) on page 301 Fault repeats every 7 cm (2.75) Occurs mostly after toner dosage. Clean or replace the pressure roller.
Too low temperature pressure roller-cleaner
SDS: 06-9-03 CTFPCLEHETEMPSE SDS: 06-4-04 CTFPCLEHE Check heater
Pressure roller build up cleaner
SDS: 06-4-05 Check evenness of the pressure roller build up cleaner
Toner dosing procedure SDS: 06-6-07 Check pneumatics and toner dosing not correctly functioning mechanism Dirt in paperpath Check/clean
138
TSM Oc 9800
Faults
Black stains / spots / background is digital Description: Copy is polluted with digital black stains / spots / background. Pixels are recognizable spots Possible cause Checking procedure / Remark
Scan-roller soiled
Make copy of blank A0 transparent original. Spots repeats every 10.5 cm (4.1) Clean the gauge roller Make copy of blank A0 transparent original. Always stripes. Clean the original glass Instruct key operator / customer Instruct key operator / customer
Original glass soiled
Folds in original ABC (Automatic Background Compensation) not correct applied ABC (Automatic Background Compensation) start effect
Only on first 15 mm (0.6) of the copy
ed.5
Faults 139
Analogue background Description: Random toner soil, no pixel structure present Possible cause Checking procedure / Remark
Toner fused on OPC drum SDS test 51, see function 04 see ~Testprint adjust

Fault repeats every 62 cm (24.4) SDS: 06-1-01 CTFREFTEMPSE low, check resistor value on sticker SDS: 06-1-02 CTFREFTEMPSE high, check resistor value on sticker DRUMFAN not turning, check fan, inverter PBA Too high Drum temperature Clean the drum according the procedure Glue on OPC drum SDS test 51, see function 04 see ~Testprint adjust

Fault repeats every 62 cm (24.4) Clean the drum according the procedure Moisture on OPC drum SDS test 51, see function 04 see ~Testprint adjust PHD~ (every service visit) on page 301 Inspect the drum, Spots/stains repeat every 62 cm (24.4) Disappears during copying Drum not cleaned correctly V-rest out of specifications (not compensated) Clean the drum according the procedure SDS: 01-4-03 DRUASVCOMPPWM SDS: 01-9-02 DRUASVCOMPSE Random stripes/strokes, often dependent of format Exposure adjustment printhead not correct Talc pollution Wax pollution SDS test 51, see function 04 see ~Testprint adjust

Background with stripe structure Clean the drum according the procedure Wax cleaning procedure chapter 01-Drum OPC
wax cleaning procedure on page 410
140
TSM Oc 9800
Faults
Spots,stains,stripes,scratches / Stripes, scratches

Missing image, stripes/scratches in feed direction Description: Image loss , on black parts to be seen as strokes in feed direction, with less image Possible cause Checking procedure / Remark
Drum exposed to false light Scratch on OPC drum
Close all covers SDS test 52, black mode Fault repeats every 62 cm (24.4) Clean or replace the drum SDS test 52, black mode Fault repeats every 62 cm (24.4) Clean or replace the drum SDS test 52, black mode Fault repeats every 33 cm (13) Clean or replace the fuser roller SDS test 52, black mode Fault repeats every 7 cm (2.25) May also result in deformed images
Toner or glue on OPC drum Scratch on fuser roller
Scratch on CTF pressure roller
Soiled development unit SDS test 52, black mode Inspect and clean the developing roller / unit Soil on / under original glass Polluted printhead Make a copy of black original, Inspect and clean the original glass Clean the diaphragm
ed.5
Faults 141
Missing image, stripes perpendicular to feed direction Description: Image loss, on black parts to be seen as white strokes or strokes with less image perpendicular to feed direction. Possible cause Checking procedure / Remark
Development unit out of toner Compressor defect First transfer (drum CTF) step not correct Second transfer (CTF paper) step not correct Defective SIMMs
SDS: 05-2-01 DEVTONSE Working pressure should be 5.4 bar SDS: 06-6-07 SDS: 06-6-07 SDS: 11-6-05 Self test image processing
Black stripes Description: Black stripes / strokes perpendicular to feed direction Possible cause Checking procedure / remark
Bad slide contact OPC drum Defective PHD data receiver Defective SIMMs
Check carbon brushes SDS test 51, see function 04 see ~Testprint adjust

SDS: 11-6-05 Self test image processing
142
TSM Oc 9800
Faults
Black stripes in feed direction Possible cause Checking procedure / Remark
Defective printhead Defective PHD data receiver PBA Soiled self focusing lens array printhead Soiled PHD diaphragm Discharge LEDs polluted Soiled exposure glass scanner Soiled gauge roller scanner


Clean SLA (could be caused by a polluted development unit) Clean diaphragm Clean discharge LEDs Clean exposure glass Clean gauge roller Check connections
Connections in CCD unit
Bad cut paper rolls causes Clean Fuser roller and Drum paper dust on CTF fuser roller and Drum
ed.5
Faults 143
Wallpaper Description: Random digital stripes all over the copy/print Possible cause Checking procedure / Remark
Incorrect configuration Defective SIMM
SDS test 90 Configuration SDS 11-6-05 Self test image process Check connections (11-Image processing dis-/assemblies see SIMM PBA on SET MEMORY PBA on page 401). SDS: 11-6-05 SDS: 11-6-05 SDS: 11-6-05
Defective SetMem PBA Defective PBA B/W-PROCESSING Defective PBA SCAN-PROCESSING
Defective CONTROLLER Controller SDS tests and try Electrical connections IMP section Check
Black stripes first few copies, perpendicular to feed direction
Black stripes on first few copies perpendicular to feed direction. (62cm) Incorrect pressure between CTF fuser and pressure roller Fuse pressure incorrect SDS: 06-7-01 and 53
SDS: 06-6-07 Check air pressure
CTF fuser roller polluted by paper. Pollution transported via slip after run to the Drum
Replace fuser roller Report via PR (copy material used)
144
TSM Oc 9800
Faults
Position,deforming,magnification / Image position

Image position in feed direction Description: Image is not correctly positioned in feed direction Possible cause Checking procedure / Remark
Leading edge not correct Check adjustment function 09 ~Scanning leading
edge correction~ on page 303

Trailing edge not correct Check adjustment function 09 ~Scanning trailing

Pulsdics MADMO/CTFPMO slipping Tension main drive belt MADMO not correct Pulsdisc slipping MADMO/CTFPRMO Broken transmission joint
Check adjustment function 23 Main drive belt on
page 301
Check Check joints
Copy material not correct SDS test 43 Cut sheet length cutted Framing not correct Check adjustment function 12 PRD ~PRD leading

Check adjustment function 13 PSF adjustment 1 Original length measure- Check adjustment function 09 ~Original length correction~ on page 301 ment not correct Cutting not correct Check adjustment function 12 PRD ~Offset cutting
length PRDU~ on page 307

Distortion in paper trans- Check paper transport port SDS: 14-4-02 PRETBR Plate drive assy PRDS defect Workaround: Tighten pin to plate. Report via PR Check guide cloth (position holes)
PREheater guide cloth wrongly mounted
ed.5
Faults 145
Image position in width direction Description: Image is not correctly positioned in the width direction Possible cause Checking procedure / Remark
Image edit function active Developing unit not correctly positioned Paper spool not correctly positioned
De-select edit function Check adjustment function 05 DEVELOPMENT
~DEV unit adjustment~ on page 301

Check adjustment function 12 PRD Size label on
page 310
146
TSM Oc 9800
Faults
Position,deforming,magnification / Framing
Incorrect framing Description: Image has no framed edges Possible cause Checking procedure / remark
Framing in the feed direc- Check adjustment function 12 PRD ~PRD leading edge correction~ on page 309 tion is not correct Check adjustment function 13 PSF ~PSF leading

Framing in the width direction not correct Developing unit not correctly positioned Check adjustment function 05 DEVELOPMENT
~DEV unit adjustment~ on page 301

Paper spool not correctly positioned Check adjustment function 12 PRD Size label on
page 310
ed.5
Faults 147
Position,deforming,magnification / Image deformed

Image is deformed Description: Image is deformed, wavy lines. Possible cause Checking procedure / Remark
Original is shifted during scanning Concave fuser pinch
Check original path SDS: 06-8-04 check pressure roller hole cleaner on its evenness SDS: 06-8-05 check pressure roller build cleaner on its evenness
Convex fuser pinch
SDS: 06-8-01 Check fuser roller on its evenness Check pressure roller on its evenness
Entrance to fuser pinch not correct
Check position of preheating unit SDS: 14-4-02 PRETBR
148
TSM Oc 9800
Faults
Position,deforming,magnification / Magnification ratio

Magnification ratio in feed direction not correct Possible cause Checking procedure / Remark
Incorrect zoom calibration setting Printer not correct adjusted
Check in key-operator mode Check adjustment function 06 CTF ~1 : 1 Image
length cor. engine~ on page 301

Check CTFTRANSE
Pulse disk defect / loose on Main drive motor Scanner not correct adjusted
SDS: 23-2-01MADMOSE
Check adjustment function 09 ORIGINALS ~1 : 1
Image length correction scanner~ on page 302
Original is shifted during Check original path scanning Concave fuse pinch SDS: 06-8-04 Check pressure roller hole cleaner on its evenness SDS: 06-8-05 Check pressure roller build cleaner on its evenness Convex fuser pinch SDS: 06-8-01 Check fuser roller on its evenness Check pressure roller on its evenness Incorrect printer velocity Check pulse disk MADMO / CTFPMO slipping SDS: 06-7-01 Pressure roller torque adjustment
Magnification ratio perpendicular to the feed direction incorrect Possible cause Checking / Remark
Incorrect zoom calibration Check in key-operator mode setting
ed.5
Faults 149
Receiving materials damaged, soiled in engine / Folds, wrinkles

Folds / wrinkles on leading edge Description: Copying materials are being deformed during copying process on leading edge Possible cause Checking procedure / Remark
Entrance to fuser pinch not correct Entrance preheater not correct PREheater guide cloth wrongly mounted Entrance fuser-pinch not correct
SDS: 14-8-01 Check preheating unit SDS: 14-4-02 PRETBR Inspect paper path Check guide cloth (position holes) Inspect paper path
Entrance folder not correct Inspect paper path Glue on preheater caused by fluor paper
.
Clean preheater and report via PR
Wrinkles all over the copy Description: Copy material is deformed all over the copy Possible cause Checking procedure / Remark
Humid copy material

.
Check humidity
Wrinkles all over the copy in transparent copy material in machine numbers 980100098-980100407 Description: Copy material is deformed all over the copy Possible cause Checking procedure / Remark
Too high force of particular rollers in the PTR unit
Execute modification 17
Moisture on copies Description: Copy material has moisture spots on leading edge Possible cause Checking procedure / Remark
Condensation at CTF output
Disappears after a few copies
150
TSM Oc 9800
Faults
Receiving materials damaged, soiled / In 1st fold

Wrinkles Description: Wrinkles in 1st fold package Possible cause Checking procedure / Remark
Wrong paper quality (waved paper) Environmental aspects Lift mechanism
Use only Oc paper Check environmental conditions (humidity, temperature) Check functioning FOL1LIMO SDS 18-6-11
Paper is not entering Check the position of the guide plate in front of the smoothly between the pinch. 1st folding roller and the pressure roller For long copies/prints (7 Execute adjustment 29 long copy antiwrinkle proceA0/E-sizes length) dure see Long copy anti wrinkle procedure (first fold). on page 340 .
Dog ears Description: Dog ears at the edges of the 1st fold package Possible cause Checking procedure / Remark
Use only Oc paper Check environmental conditions (humidity, temperature) Check functioning FOL1LIMO SDS 18-6-11
Paper is not entering Check the position of the guide plate in front of the smoothly between the pinch. 1st folding roller and the pressure roller
ed.5
Faults 151
Damaged leading edge Description: Damaged leading edge Possible cause Checking procedure / Remark
Use only Oc paper Check environmental conditions (humidity, temperature) Check functioning FOL1LIMO 18-6-11
Paper is not entering Check the position of the guide plate in front of the smoothly between the pinch 1st folding roller and the pressure roller
Unsharp folds Description: No sharp edges in the folding package Possible cause Checking procedure / Remark
Lift mechanism remains Check lift mechanism FOL1LIMO SDS 18-6-11 open
Wrong fold length Description: Folding length not according to specification Possible cause Checking procedure / Remark
Wrong default setting
Check settings / instruct key operator
Wrong pressure between Check pressure / check position of spring / change folding roller and pres- spring sure roller
152
TSM Oc 9800
Faults
Receiving materials damaged, soiled / In 2nd fold

Dog ears leading edge Description: Dog ears at the leading edge corner of the second fold package (especially A3 size copies) Possible cause Checking procedure / Remark
Package is not entering smoothly between the folding roller and the pressure roller.
Add a melinex strip on the lower profile of the 2nd folding flap. Melinex strip should stick out 12mm of the folding flap. Increase distance between pressure / folding roller at problem side.
Damaged leading edge Description: Damaged leading edge of the folded package (especially A3) copies) Possible cause
Checking procedure / Remark
Package is not entering smoothly between the folding roller and the pressure roller.
Add a melinex strip on the lower profile of the 2nd folding flap. Melinex strip should stick out 12mm of the folding flap. Increase distance between pressure/folding roller at problem side.
ed.5
Faults 153
Receiving materials damaged, soiled / in belt, punch unit

Dog ears Description: Dog ears on the copy after entering the belt unit Possible cause Checking procedure / Remark
Height position of the Belt unit in respect with the folder not correct.
see Height of the belt unit and zero-line on page 307 function 18-Folding
Punch holes wrong positioned Description: Punched holes not at the correct position. Possible cause Checking procedure / Remark
Side adjustment mechanism not correct positioned
Check position / adjust / instruct key operator. Check the FOLOADJMU function (18-4-06)
Obstruction in copy path Check for piece of paper or object. in punch unit
154
TSM Oc 9800
Faults
5 SDS not available

Machine is totally dead
Switch CONKEYSW on CONCONEMS switches (listen) Possible cause
YES NO
Continue with description: CONCOMEMS ON Continue with next descriptions: CONCONEMS OFF
Note: For all next tests the switch CONKEYSW must remain ON! CONCONEMS OFF
Main voltage between L2 and N2 > 198 V AC on Terminal block
Possible cause
NO
CONCONEMS OFF Main voltage between L2 and N2 > 198 V AC on SSR PBA, connector X9 - 1 and 3
Ask assistance of local electrician
Possible cause
NO
22 Q 3 defect / OFF 22Z2 defect / OFF Electrical connection between terminal block and SSR PBA
ed.5
Faults 155
CONCONEMS OFF Voltage on SSR PBA between TP2 and 3 > 20 V DC Possible cause
NO YES
SSR PBA defect CONKEYSW defect CONCONEMS defect Electrical connection between SSR PBA and CONKEYSW Electrical connection between SSR PBA and CONCONEMS
CONCONEMS ON Main voltage between L2 and N2 > 198 V AC on CONSUPLV G1-1 and 3 Possible cause
NO
Electrical connection between SSR PBA and CONSUPLV SSR PBA defect
YES
If machine is a stand alone printer continue with: CONCONEMS ON Disconnect MIXED SUPPLY G2, G3.
CONCONEMS ON Disconnect CONSUPLV G2, G3 and G4 Voltage between frame Possible cause (GND) and MIXED SUPPLY G1-2 > 300 V AC G1-3 < - 80 V AC G1-4 < - 60 V AC
NO
CONSUPLV defect Electrical connection CONSUPLV and MIXED SUPPLY
156
TSM Oc 9800
Faults
CONCONEMS ON Disconnect MIXED SUPPLY G2 and G3 Voltage between frame Possible cause (GND) and CONSOLE CPU PBA TP1 > 4.7 V DC TP2 > 10 V DC TP3 > 10 V DC TP4 > 10 V DC
NO (for scanner)
MIXED SUPPLY defect Electrical connection between MIXED SUPPLY and CONSOLE CPU PBA
NO (for stand alone printer)

CONLVSUP defect Electrical connection between CONLVSUP and CONSOLE CPU PBA CONSOLE CPU PBA defect Console Firmware defect
YES
ed.5
Faults 157
Machine is totally dead after CONEMS activated

Electrical connection between SSR PBA and CTFPCLEHE(1/2) short circuit to drum (left side edge)
Only LCD (display) dead

Note: The other functions of the operating panel (push buttons/ 7 segment displays) are functioning. Possible cause Remark
Electrical connection between SUPPLY TL INVERTER PBA and LCD
TL Lamp is off
Electrical connection between CONSU- TL Lamp is off PLV and SUPPLY TL INVERTER PBA Electrical connection CONSOLE CPU PBA and LCD CONSOLE CPU PBA defect LCD defect SUPPLY TL INVERTER PBA defect TL Lamp is on TL Lamp is on TL Lamp is on TL Lamp is off
158
TSM Oc 9800
Faults
6 Faults without error messages

Machine not getting warm
Not known
Report via PR. Workaround: Increase shut-off time to 12hours, if possible.
Fol1indiag error
Software bug
Ignore
Damaged ends of the clean rollers

Bad mounted clean rollers
see Cleaner rollers on page 405
Illegal toner over flow

Illegal toner flow will result in:
1 overflow cleaner(s), or 2 melted toner on the heater, with or without smell/smoke development.
In case of overflow of the cleaners check the setting of the paper quality, quality of the pneumatic system or the heaters. Correct if necessary. The following items have to be checked to prevent an illegal toner flow:
1 Faulty PHD light intensity adjustment.
Phenomena: slightly background on copies/prints and toner transport without copy media to consumables. Too less light generated by the PHD. Due to this mis-adjustment there will be a continuous toner flow through the engine outside the chosen format < A0/36. This can be checked by the appearance of speckles and lines on a cut sheet length print (use max. width = 36/914mm).
ed.5
Faults 159
It is advisable to execute the SDS-test 51 Test print adjust PHD" (with 930mm wide sheets!!) three times for an objective result. In case of a failing PHD return the PHD including the 3 test sheets
2 Due to uneven pollution of the drum, locally the drum surface voltage will
exceed the minimum of the working area of the drum characteristic (-10V to +10V). Phenomenon: slightly background on copies/prints. At the position of the ASV-probe the drum will be compensated until Vrest=0. This problem manifests itself in toner contamination just around the position of printed information, at the end of a long run (blossoming/shadow). Proving this is possible by generating approx. 20 sheets (length f.e. 1300mm) of SDS-test 43 "Cut sheet length". Executing the improved drum cleaning procedure (explained in Information Bulletin 9700/9800-1047) mostly cures this problem.
3 Drum pollution caused by a malfunctioning or a polluted DCH-unit.
Phenomenon: toner transport without copy media to consumables. This will lead to a heavy toner flow to the cleaners during the warm-up and pressure torque adjustment procedure. However during run the PHD will discharge the drum sufficiently. After printing solid images there are still slightly visible images on the next prints. Check the DCH-unit regarding pollution and clean if necessary, or check lifetime of arrays and replace if necessary.
4 Toner dashing in the developing unit.
Phenomenon: toner transport without copy media to consumables. As a result of contamination on top of the doctorblade and sudden vibrations in/at the machine the toner will fall onto the drum. In case of a closed transfer pinch the toner will be cleaned by the fuser roller cleaner. However when the pinch is opened the toner will fall immediately in the CTF lower heater, and might cause dangerous situations: keep machine as clean as possible. From release 3.4 (Eng/Sca) the software is provided with a controlled start up speed of the development unit to prevent toner dashing as much as possible.
5 Framing faults
Framing faults also will lead to an extravagant toner flow outside the paper formats. It might be caused by faulty paper roll position, not correctly executed manual feed (no width detection present) or a lack of control of the PHD (defective frame function). It is important to use 930mm wide sheets during SDS-test 51.
6 Cleaners
Not correctly mounted cleaners may also cause shifting of the cleaners result-
160
TSM Oc 9800
Faults
ing in not cleaned areas of the pressure or fuser roller. New cleaners have to be mounted with new toroid rings and new circlips
7 Failing consumables
Failing consumable Cause (targeted lifetime) Copy quality Action(s)
Drum
Fuser roller (>100.000 lm)
Pressure roller (>75.000 lm)
Fuser roller cleaner (720/900 black images)
1.scratches-----> white lines/spots ---------------------> replace drum 2.(other) pollutions (talc)-----> spots, background, ---------------------> new clean procedure 3.wax-----------> see IB 9700/9800-1012-> new wax clean procedure 1.damages-----> white spots/areas ---------------------> replace fuser roller 2.swelling in the middle ---------> skeleton at the sides --------------> also check (lifetime) press roll cleaners wear-out format wise ------------> skeleton in the middle ------------> use test 52; check also (lifetime) press roll cleaners cleaner full / illegal toner flow------------> run over, bumping ---------------------> check causes, replace cleaner exceeded lifetime (black images, error 06902) ---------> ---------------------> preventive replacement of the cleaner total stop (error 06105) ---------> ---------------------> replace cleaner
ed.5
Faults 161
Failing consumable Cause (targeted lifetime)
Copy quality
Action(s)
Pressure roller cleaner cleaner full / ille(320/400 black gal toner images) flow----------> run over, bumping ---------------------> check causes, replace cleaner toner contamination in the middle----------> skeleton at the sides --------------> replace cleaner exceeded lifetime (black images, error 06903) ---------> ---------------------> preventive replacement of the cleaner total stop (error 06106) ---------> ---------------------> replace cleaner Pressure roller build-up toner contaminacleaner tion in the mid(< lifetime pressure dle ---------> skeleton at the sides roller cleaner) ---------------> replace cleaner; also press. roll hole cleaner cleaner full / illegal toner flow------------> bumping after a cold start up------> replace cleaner; also press. roll hole cleaner
162
TSM Oc 9800
Faults
Controller LED Identification Table

The 3 LEDs on the controller box give an indication about the behaviour of the controller. After switching on the machine, the 3 LEDs are switched on for a few seconds, then they are switched on and off one by one. This means that the first pass of the tests are ok. Then the LEDs stay on for a longer time, can be up to 4 minutes depending the amount of memory installed.
LED 1 LED 2 LED 3 Defect module Directly after switching on
OFF
OFF
OFF
2nd CPU does not boot (e.g. bootprom incorrectly inserted, service switch on). The controller stays in hardware reset. Also the error code 20811 will be displayed. OFF ON
OFF OFF ON ON OFF OFF ON BLINK OFF BLINK BLINK OFF OFF BLINK BLINK OFF BLINK BLINK ON
OFF OFF OFF OFF ON ON ON ON OFF OFF OFF BLINK BLINK BLINK BLINK ON ON ON OFF
After the selftest is finished:
All modules okay OLB board in extension slot A defect. OLB board in extension slot B defect. OLB board in extension slot C defect. OLB board in extension slot D defect. OLB board in extension slot E defect. OLB board in extension slot F defect. SEE Note Mother board error Mem. Frame Buffer 1_ SIMM 1 error, 20901 Mem. Frame Buffer 1_ SIMM 2 error, 20901 Mem. Frame Buffer 1_ SIMM 3 error, 20901 Mem, Frame Buffer 2_ SIMM 1 error, 20901 Mem. Frame Buffer 2_ SIMM 2 error, 20901 Mem. Frame Buffer 2_ SIMM 3 error, 20901 Memory configuration error Primary DRAM (DLL) SIMM 1 error, 20809 Secondary DRAM (RSR) SIMM 1 error, 20809 Cabled Hard Disk error Standard controller Firmware error
OFF ON OFF ON OFF ON BLINK OFF BLINK OFF BLINK OFF BLINK BLINK OFF BLINK BLINK
ed.5
Faults 163
Note: With the FBBS release < 3.3 this indicates a SCSI problem. It occurs if
the PC is connected via SCSI and the system is booted while the PC is off.
164
TSM Oc 9800
Faults
Electrical faults
1 FAULT procedures
The errors (display message) in the Oc 9800 can be divided into the following categories, with priorities from important to less important:
xx000 - xx099 xx100 - xx199 xx500 - xx599 xx700 - xx799

FE PE MRE ORE OWAR SWAR
xx800 - xx899 xx900 - xx999
~Fatal Error~ ~Permanent Error~ ~Machine Recoverable Error~ ~Operator Recoverable Error~ ~Operator WARning~ ~Service WARning~
The presentation of the error message uses always five digits (e.g. 04501):
s
s s
the first two digits represent the function (CAS function) in which function the error occurred (e.g. 04 Printhead) the third digit represents the number of that error category (e.g. 5) the last two digits represent the sequence number within the error category (e.g. 01)
FE (~Fatal Error~)
A fatal error is an error in the control function. The correct functioning of the control function is not guaranteed. The functioning of the machine will be switched off and if possible, an error code will be displayed on the screen. The error must be reset by switching OFF and ON. In case that the error is no more present, the machine will start up.
ed.5
Faults 201
PE (~Permanent Error~) / Handicap
A permanent error is an error which results in a service call. The error remains after switching OFF and ON. In some cases it is still possible to use the machine, but with reduced functionality until service has solved the error. Actions taken by the engine and the operator:
s
running copies are finished if possible and delivered into the unfolded copy tray if it is not possible for the engine, the machine stops, a message is displayed and the operator is asked to take action.
Handicap Some permanent errors are used as a handicap. A Handicap is a limited use of a part of the machine. An example is e.g. the handicap of the lower roll compartment. No roll width indication in the display for the rolls 3 and 4. The key operator is able to copy from roll 1 and 2 and the manual feed selection. Handicaps can occur in the following sections:
s s
Paper roll drawer upper / lower Upper / lower belt
Actions taken by the service technician:

s s
s s
activate the SDS: only test 30 is available. activate test 30 (Reset PE & handicaps) and push the <start> button: the PE is reset. push the <start> button once again to reset the handicap. Read out the error counters to gain information of the occurred error.
202
TSM Oc 9800
Electrical faults
MRE (~Machine Recoverable Error~)
Machine recoverable errors are errors in the system. The operator can try to restart by pushing the <START> button. When an MRE is repeatedly detected it can change to a PE.
ORE (~Operator Recoverable Error~)
Operator recoverable errors, such as paper jams or cover errors, can be solved by the operator. The machine stops copying and if possible the copies will be delivered. A message (text and machine image) is displayed and indicates what covers have to be opened to correct the error. After the error is corrected the operator can continue with job recovery or a new job. A scanner error has no influence on the copying cycle.
OWAR (~Operator WARning~)
These errors indicates a problem in a certain part of the machine. The key operator must take proper action to get rid of the problem?.
SWAR (~Service WARning~)
A service warning is a message which is only displayed in SDS. If it occurs in the normal mode it is stored in the memory and the operator will be unaware of this error. When entering in SDS, the display shows the warning in the first entry screen and reminds the service engineer of a possible preventive maintenance problem. Take a preventive action e.g. change a cleaning roller to reset the warning.
ed.5
Faults 203
204
TSM Oc 9800
Electrical faults
Oc
Oc 9800
SDS/LAPTOP
Contents
SDS
1 General 101 2 SDS structure 103 3 States of the SDS 104 4 From Stand-by into SDS 106 5 From SDS into Stand-by 106 6 Operating the SDS 107 7 SDS screens 109 8 ~Functions~ tests (01-29) 111 9 ~ANALYSE INFO~ tests (30 - 39) 116 10 ~SYSTEM~ tests (40 - 69) 123 11 ~INSTALLATION~ tests (70 - 79) 126 12 ~SERVICE info~ tests (90 - 99) 131
Laptop
1 Oc 9800 laptop applications 201 2 Service Terminal software 202 3 Working with ST during a normal machine visit. 203 4 The analyse part of ST. 208 5 Copy quality problems. 213 6 Store and restore machine parameters. 214 7 Store, restore and editing stamps via ST 216 8 No SDS or Datadump available 218 9 Short overview of the Information and Modification Bulletins. 219 10 ST general info / hotnews page. 220
Service Plot Tool
ed.5
SDS / LAPTOP
TSM Oc 9800
Contents
SDS
1 General
The purpose of the Service Diagnostic System (SDS) is to support the service engineer in identifying the cause of errors and to provide information of the errors themselves. It is also an important tool for adjustments and installation of the Oc 9800 machine configuration. The objectives are: - lower MTTR/short diagnose time - less or no repeat calls - no early replacements of consumables - no incorrect replacements of parts. - right PM activities to avoid CM calls The SDS tests are classified into a number of categories:
Test type Test number
~Diagnosis~
~Function tests~ ~Analysis tests~ ~System tests~
01 - 25 30 - 39 40 - 69 70 - 79 80 - 89 (laptop only) 90 - 99
~Installation~ ~Registration~
~Installation tests~ ~Marketing information tests~ ~Service information tests~
The main characteristics of the SDS are: - ~Function tests~. In this part are located the input tests, output tests, special tests, settings and error counting per Cas-group. - ~Analysis test~. This part gives information about the number of errors since the last visit, presented in various ways.
ed.5
SDS / LAPTOP 101
- ~System tests~. In this test a number of specific test can be executed to check complete systems in the machine. - ~Registration~. In this part service and marketing information is stored, the number of copies, number of originals, number of folded copies, number of plot, etc., etc. are counted. With the Service Terminal software application, used on a laptop, it is possible to make a datadump of all the machine data. Problems can be analyst without using the machine SDS. By modem or E-mail you can have, in an easy way, the latest fault diagnostics and copy quality phenomens helpfiles. The ST application is described on see Oc 9800 laptop applications on page 201
102
TSM Oc 9800
SDS
2 SDS structure
SDS
DIAGNOSIS
Installation
Registration
Function test 01 - 25 Confidential 1999 Oc-Technologies B.V.
Analysis test 30 - 39
System test 40 -69
Installation 70 -79
Marketing info 80-89
Service info 90 - 99
01 DRU 02 COR 04 PHD 05 DEV 06 CTF 07 DCH 09 ORG 10 SCA 11 IMP 12 PRD 13 PSF 14 PRE 15 PTR 18 FOL 19 Delivery 20 INT 22 CON 23 MAD 24 ACC 25 CUS
81 Marketing counters 40 To cold SDS 41 To warm SDS 42 Service copy mode 43 Cut sheet length 50 Testprint mode 51 Testprint adjust PHD 52 Black mode 53 1:1 mode 54 DRU ASV test 55 DEV unit adjustment 56 Adjust scanner mode 57 Adjust ptr/fold1
70 Install machine 71 Install engine 72 Install scanner 73 Install folder 74 Customer install. 75 Reset consu.
0 Counters 1 Parameters 2 Input 4 Output 6 Special 7 Adjust 8 Consumables 9 Info
30 Reset PE & handicaps 31 Log/res err&ser cnt 32 Last error logging 34 Error top ten 35 Error counters > 0 36 Consumable counters 37 Parameters settings 38 Serv. / mark. counters 39 Error history (only laptop)
90 Configuration 91 Serial number 93 Paper series 94 Passwords 95 Modification records 96 Language 97 Preset copy counters 98 Hour counter
ed.5
SDS / LAPTOP 103
3 States of the SDS

In SDS 3 states are defined. The function of these states is that the service technician, depending on the machine state, is limited in the possibilities of using the SDS, to avoid unsafe situations. The states of the SDS are:
s s s
~Zero SDS~ ~Cold SDS~ ~Warm SDS~
~Zero SDS~
The machine gets this state, when the machine is switched to service mode and when a fault of the type PE (~Permanent Error~), MRE (~Machine Recoverable Error~) or ORE (~Operator Recoverable Error~) occurs in SDS, during a test. In this state, only a limited part of the total SDS is available, namely that part that is absolutely necessary to get a view on the occurred errors. The 220 V supply voltage for all functions except control is switched off (CONEMS1, 2 and 3 switch OFF).
104
TSM Oc 9800
SDS
The following tests are possible in ~Zero SDS~:

s s
s s
Test type 30 - 39: Analysis info (among reset active error) Test type 70 - 79: Installation (among initialize BBR (~Battery Back-up Ram~) Test type 80 - 89: only in the ST programm (marketing info) Test type 90 - 99: Service info
and when no error is active also:

s
Test type 40 - 69: System tests (among test 42 service copy mode)
~Cold SDS~
When e.g. special test 40 is activated, the function becomes the state cold, that means all the actuators are switched off. This test can not be interrupted. After the test the machine is in cold SDS.
If an error occurs during the test, the normal SDS error handling starts, that means the machine switches to zero SDS. CONEMS switches ON if the CTF and PTR doors are closed. In cold SDS inputs can be read and outputs can be made active. Some functions can be made Warm or Cold via a special test. With special test 41 it is possible to start to ~Warm SDS~.
~Warm SDS~
When e.g special test 41 is activated, the function becomes on stand-by. If an ORE, MRE or PE error occurs during the test, the normal SDS error handling starts that means the machine switches to ~zero SDS~. After the test the machine is in stand-by if all other functions are warm too. All functions are warm. When the machine has reached the state warm, the CTF still has to warm up before copying can be started.
ed.5
SDS / LAPTOP 105
4 From Stand-by into SDS

SDS becomes active when the service switch on the scanner (behind the small cover at the right side besides the operating panel) is switched to the service position. An spanner icon, shown in the display, indicates that the machine is in SDS.
5 From SDS into Stand-by

The SDS is deactivated by switching the service switch to the normal position. The SDS watchdog test is done (code 22004 is displayed). Switch the machine OFF and ON again.
106
TSM Oc 9800
SDS
6 Operating the SDS

To operate the SDS the following buttons are used:
Button: <START>
used for:
s s s s
going to next screen start selected test confirm input values ending tests immediately ending tests going back to previous screen buttons for input number scrolling backwards scrolling backwards scrolling forwards scrolling forwards scrolling forwards input value positive input value positive input value negative input value negative
<CORRECTION>
s s
<0> .. <9>
<SCROLL UP> <COPY LIGHTER>

<SCROLL DOWN>
s s
s s s
<COPY DARKER>
<ZOOM STEP UP> <SCROLL UP> <ZOOM STEP DOWN> <SCROLL DOWN>
s s s s
The service engineer can use a remote switch to activate output and special tests, this switch uses the function of the <START> button.
ed.5
SDS / LAPTOP 107
Scrolling
Scrolling means going along the different possibilities with the scroll buttons. In the display there will be a > in front of the selected possibility. By pushing <SCROLL UP> or <COPY LIGHTER> you go backwards to the previous possibility, by pushing <SCROLL DOWN> or <COPY DARKER> you go forwards to the next possibility. Holding down one of the buttons continuously has the same effect as pressing the button repeatedly.
108
TSM Oc 9800
SDS
7 SDS screens
Push the <START> button to select the next screen and the <CORRECTION> button to select the previous screen. The SDS is developed in such away, that 2 entry screens show up, before the first test/analyse screen These 2 entry screens contains important information of the status of the machine and are the trigger to further investigation.
~FIRST ENTRY screen~
This screen appears when the SDS is switched on:
MACHINE
: zero
FIRST ENTRY
for second entry screen
Consumables: Drum (l.m.) Fuse roller (l.m.) Pressure roller (l.m.) Fuse roller cleaner(bl.im.) Press. roll. hole cl.(bl.im.)
: 5040 : 104271 : 2830 : 285 : 142
Warnings: 01901 DRUm temp. too low: DRUFANTEMPSE
Date counter reset: 21 feb 96 Copies since counter reset: 504 Software vers: Cons. 1.2, Eng. 1.2
ed.5
SDS / LAPTOP 109
The screen gives a overview of the following items: - actual life time of the consumables in linear meters or black images. - warnings - System date, date and copy length meters since previous counter reset - software versions and if applicable the Permanent errors and/or Handicaps (CON = Console (scanner) and ENG = engine) With this screen you can see in one view if and which consumables have to be replaced, possible warnings, permanent errors and the various software versions. Objective of this screen is to give all the information which is necessary to start trouble shooting and which Preventive Maintenance actions has to be done.
~SECOND ENTRY~ screen
This screen shows the results of the automatic self test (test 22-6-08 INPUT DIAGNOSTICS) which is automatically carried out by entering the SDS. The results of this test are indicated in the second entry screen.
for testmode screen
MACHINE
: zero
SECOND ENTRY
C
Automatic self test: 22-6-08 input Diagnoses
for first entry screen
input diagnoses correct
Objective of this screen is to give all information if the I/O input commandlines are working correctly or not. If not, a message appears with the component name.
110
TSM Oc 9800
SDS
8 ~Functions~ tests (01-29)

~TESTMODE ~screen
Depending on the SDS state (~ZERO~, ~COLD~, ~WARM~) the possible test modes are displayed.
MACHINE
: cold
TESTMODE
Enter testnumber or press
C
TESTMODE FUNCTION TESTTYPE TESTNUMBER : 30-39 analyse info : : : ..
for second entry screen process functions original functions paper functions general functions analyse info system tests installation service info
01-08 09-11 12-21 22-29 30-39 40-69 70-79 90-99
In ~zero~ SDS, only the test numbers 30-99 are visible. In ~cold and warm~ SDS, all the numbers 01-99 are visible. If a PE error exists, only test numbers 30-39 are visible.
ed.5
SDS / LAPTOP 111
~FUNCTION ~screen
Appears if in the TESTMODE screen a number between 01 and 25 is entered. A list of functions is displayed. Select the function to test (e.g. 04 Printhead).
MACHINE : cold FUNCTION : cold Testmode Function Testtype Test number
FUNCTION
C
01 02 04 05 06 07
Enter function or press for testmode screen Drum Corona Printhead Developing CTF Discharging
: 01-08 Process functions : .. : . : ..
... scroll for more ...
~TESTTYPE~ screen
The screen displays the various test types of the function which was selected (e.g. 04 ~Printhead~). These 9 testtypes are the same for all 25 functions. Selection of the test type is possible. (e.g. Parameters)
Enter testtype or press
MACHINE : cold FUNCTION : cold Testmode Function Testtype Test number
Testtype
C
0 1 2 4 6 7 8 9
for testmode screen Counters Parameters Inputs Outputs Special Adjustments Consumables Info
: 01-08 Process functions : 04 Printhead : . : ..
112
TSM Oc 9800
SDS
~TESTNUMBER ~screen
The screen displays the previous selected ~TESTMODE~, ~FUNCTION~, ~TESTTYPE~ and list of ~TESTNUMBERS~. Select a test number, the lower screen part displays the actual value.
MACHINE : cold Function : cold Testmode Function Testtype Test number value: min. value max. value new value : : : :
Test number Test active
Enter new value, zoom for + or -, to save & stop, to stop.
01-08 Process functions 04 Printhead 1 Parameters 01 Light-intensity PHD
: : : :
50 0 255 ...
To activate a function test, in total five numbers have to be entered (e.g. 04-1-01), all others (e.g. system tests) have two numbers.
TEST NUMBERS (functions 01 - 29) 0 ~Counter tests~:
The counter tests show a list with occurred errors. The counter tests are immediately active after the selection of the test by pressing <START>. When scrolling through the list, the error type and the error number are presented immediately.
1 ~Parameter tests~:
These tests can be read out and values can be changed.

s s s
Select the test number, the value is indicated. The selected parameter test can be activated by pressing <START>. The actual value and the min. and max. value are displayed.
ed.5
SDS / LAPTOP 113
A new value can be entered with the numeric buttons (for a positive value push the <ZOOM STEP UP> or <SCROLL UP> button, for a negative value push the <ZOOM STEP DOWN> or <SCROLL DOWN> button. Leave the test with the <CORRECTION> button (no change). Confirmation is done when the <START> button is pushed.
2 ~Input tests~:
These tests can be used to check the correct functioning of sensors. Select the test number. Push the <START> button to activate the test. s The value is displayed: OFF = not active, ON = active. A buzzer gives a signal when the input is active. Dont forget to activate or deactivate the sensor for correct checking.
s s s
The test is ended by pushing the <CORRECTION> button.
4 ~Output tests~:
Motors, solenoids and other outputs can be tested. The output tests can also be activated with the remote control switch.
s s s
s s
Select the test number. Press <START> to activate the test. The SDS state changes from Warm to Cold, the display shows the momentary OFF/ON condition. Start and stop the test with the <START> button or the remote switch. Components with hardware diagnosis indicate if the CON...OUTDIAG is functioning. The test is ended by pushing the <CORRECTION> button.
6 ~Special tests~:
One or more units can be prepared or checked.

s s
s s
Select the test number, some tests need more selections. Start the test with the <START> button or the remote switch, TEST RUNNING is displayed, after the test TEST DONE is displayed. Stop the test with the <CORRECTION> button. Some test numbers have more subdivisions, like: motor left- or right-hand turn, controlled or uncontrolled speed.
114
TSM Oc 9800
SDS
7 ~Adjustment test~
With these tests adjustments are automatically done by the machine.

s s
Select the test number. Start the test with the <START> button or the remote switch, TEST RUNNING is displayed, after the test TEST DONE is displayed. Stop the test with the <CORRECTION> button.
8 ~Consumable tests~:
These tests show a list from the used consumables with their quantities.
s s s s s s
Select the test number. The value is indicated. Push the <START> button to activate the test. MIN. VALUE, MAX. VALUE and NEW VALUE are indicated. Change if necessary the value and confirm with the <START> button. Stop the test with the <CORRECTION> button.
9 ~Information tests~:
The tests give information about machine parameter settings, every 550 msec. the information is checked again. These tests are active immediately after selection. They show the last measured value which is stored in the BBR and the MIN and MAX. VALUE, changing is not possible. Stop the test with the <CORRECTION> button.
ed.5
SDS / LAPTOP 115
9 ~ANALYSE INFO~ tests (30 - 39)
The analysis information screen appears when in the test mode screen a number between 30 and 39 is selected.
MACHINE
: cold
Testnumber
C
Testmode Function Testtype Test number : 30-39 Analysis info : : : -30 31 32 34 35 36 37 38
for testmode screen Reset PE & handicaps Log/Res. err & ser. cnt Last error loggin Error top 10 Error counters > 0 Consumable counters Parameter settings Usage counters serv. /mark
... scroll for more ..
Select a test number or scroll to the test number. Activate the test with the <START> button, go back to the previous screen with the <CORRECTION> button.
116
TSM Oc 9800
SDS
The following ANALYSIS information tests are available:
Analyse Name info tests 30 ~Reset PE & handicaps~
Active PE errors & handicaps are reset. Activate SDS test 30: Press the start button to reset the PE error. Visible is now the handicap screen. Press the start button once again to reset the handicap.
31
~Log / res err & ser cnt~ Error and service counters are reset
and logged in error history when SDS is switched off

32
~Last error logging~
The last 15 machine errors (FE, PE, MRE, ORE, OWAR, SWAR) are displayed: Errors are sorted in date and time. 32.1 last errors (all) in normal user mode 32.2 last system errors (MRE, PE, FE) in normal user mode 32.3 last errors (all) in service mode 32.4 last system errors (MRE, PE, FE) in service mode These counters are not reset with test 31 The last 10 errors or warnings are displayed Errors are sorted to absolute or relative numbers. 34.1 absolute top ten (all) 34.2 absolute system top ten (MRE, PE, FE) 34.3 relative error top ten (all) 34.4 relative system error top ten (MRE, PE, FE) These counters are reset with test 31 All error counters with a value > 0 are displayed. Errors are sorted in order of the CAS functions. Test type 0 in SDS functions 01-25. These counters are reset with test 31
34
~Error top 10~
35
~Error counters > 0~
ed.5
SDS / LAPTOP 117
Analyse Name info tests 36 ~Consumable counters~
Name, actual value and (if necessary) the norm value are displayed. Test type 8 in SDS functions 01-25. These counters are not reset with test 31 Name, min., max., and actual value are displayed Test type 1 in SDS functions 01-25. material is displayed nr of jobs nr of plot jobs nr of upload jobs nr of copy mem overflows when copying nr of orgs nr of prints/copies nr of bypass_copies plots nr of folded_copies plots nr of punched_copies plots total nr of inits (from cold to warm) total nr of powerup total meters plain paper meters transparent meters film meters
37
~Parameter settings~
38
~Serv. / Mark. counters~ Information about jobs and used
39
~Error history~
Only available with the ST program on the laptop
118
TSM Oc 9800
SDS
Explanation of the named groupes in several screens
Presented screen example is: test 32.3 Last error logging in service mode.
MACHINE
: zero
Testnumber Test active
to leave test
1/3
Testmode Function Testtype Test number
: : : :
30-39 Analyse info --32 Last error logging
32.3 last error in service mode

H 0 0 0 0 0 0 0 0 0 1 Error 23501 18904 12718 25722 15701 12512 12515 12705 12512 15705 Name Speed MADMO out of range FOL1 lift roller error Chip.: PRDULEADSE too late at / free Powerdown in run Upper/lower paper roll draw open Too few pulses PRDULENSE Speed PRDUFEDMO1 too high PRDULEADSE1 too late free Too few pulses PRDULENSE Speed PTRMO/FOL1INMO out of range Cnt 1 1 1 0 0 2 1 1 1 3 CopyCnt 14505 14505 14424 14424 14424 14424 14424 14424 14424 14410 Date 26mar96 26mar96 23mar96 23mar96 23mar96 23mar96 23mar96 23mar96 23mar96 15mar96 hh:mm:ss 09:10:45 12:00:16 16:00:23 15:55:06 15:52:55 15:50:36 15:50:34 15:50:29 15:50:20 11:22:33
... scroll for more ...
History When a 0 is displayed, the error has been occurred since the last visit. When a 1 is displayed, the error has been occurred before the last visit. When a service visit is closed by resetting the error counters to 0, all history values are added by 1 (visible after re-entering SDS). The error code is displayed. Gives the description of the error. Number of errors since last visit. Value of the copy counter on the moment the error occurs.
Error Name Cnt CopyCnt Date
Date when the error occurs.
hh: Time when the error occurs mm:ss On next page is another screen example presented.
ed.5
SDS / LAPTOP 119
Presented screen example is: test 34 Error topp 10.
MACHINE
: zero
Test number Test active
to leave test
1/2
: : : :
30-39 Analyse info --34 Error top 10
34.1 absolute error top ten

N 1 2 3 Error 22004 09703 18703 Description Watchdog: Scanner failure 22PBA02 Original too late at ORGPJSE Distance FOL1 copies too small Cnt 32 5 3 Usage 583 583 800 Relative 1 : 18 1 : 116 1 : 266
N Error Name Cnt Usage
Position in the top 10 list. The error code is displayed. Gives the description of the error. The number of errors since last visit. Number for copies, originals, folded copies, prints or plots: CAS-group 1-8 linear meter 9 - 11 number of originals 12 - 15 number of copies 18 number of folded copies 20 22 - 25 Result of the usage divided by absolute
Relative
120
TSM Oc 9800
SDS
Solving handicaps.
The ~First Entry~ screen tells you also if there is a handicap. The cause of the handicap can be found in the same way as described in the previous chapters. Search in e.g. the Last system error during normal user mode for the errors which could lead for the handicap.
~Checking warnings.~
The ~First Entry ~screen tells you also if there are warnings present. The cause of the warnings can be found in the same way as described in the previous chapters. Search in e.g. the Last system error during normal user mode for the warning-errors which could lead to a new service-call in the near future.
ed.5
SDS / LAPTOP 121
Preventive maintenance.
The ~First Entry~ screen displays the consumable counters actual values. To check if a consumable is almost at the end of his lifetime the next procedure can be executed;
1 Select Analysis Info. 2 Select test 36 ~Consumable Counters~.
The next screen, ~Consumable counters~, appears. In this screen you can see if any consumable part has almost reached end of lifetime. The best thing to do is to change the consumable part during this visit, if available, or order it to do it during the next machine-visit Before end of lifetime there will be also a service warning and when end of lifetime of the cleaners is reached, there will be a total machine stop! .
MACHINE
: cold
Testnumber Test active
to leave test
1/2
: 30-39 Analyse info : : : 36 Consumable counters
tstnr. 01801 02801 06801 06802 06803 06804
Counter name Drum Corona pin array Fuse roller Pressure roller Fuse roller cleann. Press. roll. hole cl.
(lm) (lm) (lm) (lm) (bl. im.) (bl. im.)
value 5040 5040 104271 2830 285 142
norm value -200000 --720 300
... Scroll for more...
122
TSM Oc 9800
SDS
10 ~SYSTEM~ tests (40 - 69)
The system test screen appears when in the testmode screen a number between 40 and 69 is selected.
s s
Select a test number or scroll to the test number. Activate the test with the <START> button, go back to the testmode screen with the <CORRECTION> button.
MACHINE
: cold
Testnumber
C
Testmode Function Testtype Test number : 40 - 69 System tests : : : .. 40 41 42 43 50 51 52 53 54 55 56
for testmode screen To cold SDS To warm SDS Service copy mode Cut sheet length Testprint mode Testprint adjust PHD Black mode 1 to 1 mode DRU ASV test DEV unit adjustment Adjust scanner mode
... Scroll for more...
ed.5
SDS / LAPTOP 123
The following ~SYSTEM~ information tests are available

Note: the fully explanation of how to use the test copies with a special pattern,
are described in according functions.:

SYSTEM tests 40 41 Name ~To cold SDS~ ~To warm SDS~
Machine switches to cold SDS Machine switches to warm SDS, this is possible from all SDS states. From zero SDS to warm SDS are 3 phases to go, ZERO, COLD/WARMING UP, WARM. Stop the test with <CORRECTION>. After activating this test, the machine is ready for use as in operator mode. An icon in copy counter shows a picklock (warning machine still in SDS). Setting of necessary cut sheet length. Cut sheets are used for adjustments checking. Used in several functions. Copy with test patterns of black strokes (see test 51). Copy with test patterns of black / white and grey strokes. (see ~Testprint adjust PHD~ (every service visit) on page 301 and see
42
~Service copy mode~
43
~Cut sheet length~
50
~Testprint mode~
51
~Testprint adjust PHD~
~Testprint adjust PHD~ (new drum or after cleaning the drum). on page 303, function 04-PHD).
To prevent for pollution, select test 50 if more testcopies are needed.
52 ~Black mode~
Solid black test pattern with 15 cm white leading edge and framing. Used in several functions.
124
TSM Oc 9800
SDS
SYSTEM tests 53
Name ~1 to 1 mode~
Copy with gray pattern and a white stroke in the centre. (see ~1 : 1 Image length cor. engine~ on page 301, function 06-CTF). Preventive check of drum future deterioration (see ~DRU ASV test~ on page 302, function 01-DRU). Copy with black image of 30 cm length and thin black line in the centre of the white area. (see ~DEV unit adjustment~ on page 301, function 04-DEV). Copy of the (service test) original with background and 3 cm white stroke at the leading and trailing edge. (See ~Original length correction~ on page 301,
54
~DRU ASV test~
55
~DEV unit adjustment~
56
~Adjust scanner mode~
~1 : 1 Image length correction scanner~ on page 302, ~Scanning leading edge correction~ on page 303, and ~Scanning trailing edge correction~ on page 304.).
57 ~Adjust ptr / fold 1~
Automatic distance adjustment between PTR and folder. 20 sheets are folded with A1 (22/24) in roll 1 position (see ~Adjust ptr / fold1~ on page 301, function 18-FOLDER).
ed.5
SDS / LAPTOP 125
11 ~INSTALLATION~ tests (70 - 79)

The installation screen appears when in the testmode screen a number between 70 and 79 is selected.
s s
s s
Select a test number or scroll to the test number. Activate the test with the <START> button, go back to the testmode screen with the <CORRECTION> button. Select setting with the <SCROLL UP> and <SCROLL DOWN> buttons. Adjust / confirm setting with the <START> button.
MACHINE
: cold
Testnumber
C
Testmode Function Testtype Test number : 70-74 Installation : : : .. 70 71 72 73 74
for testmode screen Install machine Install engine Install scanner Install folder Customer install
... Scroll for more ...
126
TSM Oc 9800
SDS
The following INSTALLATION tests are available:

Installation tests 70 Name ~Install machine~ Test number
22-6-06 22-6-07 90
~Init BBR ENGINE~ (Battery Backup Ram) ~Init BBR CONSOLE~ ~Configuration~
see Configuration on page 130

After changing: switch the machine OFF and ON again 91 ~Serial number~ (see ~SERVICE info~ tests (90 - 99) on page 131) ~Modification records~ (see ~SERVICE info~ tests (90 - 99) on page 131) ~Preset copy counters~
95
97
see ~SERVICE info~ tests (90 - 99) on page 131)

98 ~Hour counter~
see ~SERVICE info~ tests (90 - 99) on page 131)

71 ~Install engine~
06-1-01
~CTFREFTEMPSE resistance low (Ohm) ~ Enter resistance value from sticker ~CTFREFTEMPSE resistance high (Ohm)~ Enter resistance value from sticker ~Pressure roller torque~ approx. 5 min. when the machine is in stand-by (see ~Pressure roller torque~ on page 301, function 06-CTF) ~Cut sheet length~ ~Offset cutting length PRDU~ (see ~Offset cutting length PRDU~ on page 307, function 12-PRD) ~Cut sheet length~ ~Offset cutting length PRDL~ (see ~Offset cutting length PRDL~ on page 308, function 12-PRD)
06-1-02
06-7-01
43 + 12-1-01
43 + 12-1-02
ed.5
SDS / LAPTOP 127
Installation tests
Name
Test number
51 + 04-1-01
~Testprint adjust PHD~ ~Light intensity PHD~ (see ~Testprint adjust PHD~ (every service visit) on page 301, function 04-PHD) ~DEV unit adjustment~ (see ~DEV unit adjustment~ on page 301, function 05-DEV) ~1 : 1 Image length corr. engine~ (see ~1 : 1 Image length cor. engine~ on page 301, function 06-CTF) ~1 to 1 mode~ ~PRD leading edge correction~ (see ~PRD leading edge correction~ on page 309, function 12-PRD) ~1 to 1 mode~ ~PSF leading edge correction~ (see ~PSF leading edge correction~ on page 301, function 13-PSF) ~TL intensity adjust~, 6 min. (see TL intensity adjust on page 301, function 10-SCANNER) ~Adjust scanner mode~ ~Original length correction~ (see ~Original length correction~ on page 301, function 09-ORIG.) ~Adjust scanner mode~ ~1 : 1 Image length correction scanner~. (see ~1 : 1 Image length correction scanner~ on page 302, function 09-ORIG.) ~Adjust scanner mode~ ~Scanning leading edge corr.~ (see ~Scanning leading edge correction~ on page 303, function 09-ORIG.) ~Adjust scanner mode~ ~Scanning trailing edge corr.~ (see ~Scanning trailing edge correction~ on page 304, function 09-ORIG.) ~Diameter roller FOL1INMO~ (value on roller/installation sheet) ~Dist. FOL1STARTSE - FOL1 roll.~ (value in logbook/installation sheet)
55
53 + 06-1-03 53 12-1-03
53 + 13-1-01
72
~Install scanner~
10-7-01
56 09-1-01
56 09-1-02
56 09-1-03
56 09-1-04
73
~Install folder~
18-1-01 18-1-02
128
TSM Oc 9800
SDS
Installation tests
Name
Test number
18-1-03 18-1-04 57
~Diameter roller FOL2INMO~~ (value on roller/installation sheet) ~Dist. FOL2STARTSE - FOL2 roll.~ (value in logbook/installation sheet) ~Adjust ptr / fold1~ Automatic distance adjustment between PTR and folder. 20 sheets are folded with A1 (22/24) in roll 1 position (see ~Adjust ptr / fold1~ on page 301, function 18-FOLDER) ~Paper series~ (see ~Paper series~ on page 130) ~Passwords~ (see ~SERVICE info~ tests (90 - 99) on page 131) ~Language~ (see ~SERVICE info~ tests (90 - 99) on page 131) ~Fill default stamp strings 3 - 10~ (see SDS on page 201, function 25-CUSTOMER / ENV.) ~Overlap correction FOL1 mm~ ~Max. nr. of copies on FOLO belts~ ~Max. nr. of copies in HCS bins~ ~Stamp positions for folding methodes DIN and Ericson~ ~Service copy mode~ (see ~SYSTEM~ tests (40 - 69) on page 123) Reset all the consumable counters
74
~Customer install.~
93
94
96
25-6-01
18-1-05 18-1-06 19-1-01 25-1-01 till 25-1-12 42
75
~Consumables counters~
Switch the scanner and engine OFF and ON again after you have finished the INSTALLATION tests.
ed.5
SDS / LAPTOP 129
Configuration
Table 1 ~Configuration~ (test 90)

Memory doc memory Mem. size 36 MB Clock 12 h clock Value input inches Copy counting meters method Original width 8 sensors detection Nr. of paper 4 rolls rolls Stamp selectied No Stamp Folder No Folder Deposit belts no belts Punch unit No Reinforce unit No Longcopy No escape unit High Capacity No Stacker Copy No Plot No Upload No Controller type EPC (embedded) Primary (Vec- No plot tor) cpu RAM Frame buffer No plot memory size B1 paper size B1 = 700 mm Drum fan rota- No tion sensor
~Paper series~
set memory 72 24 h clock metric square meters 5 sensors
108
144
feet
square feet
Stamp 1 and 2 Fold 1 belt Yes Yes Yes Yes
1 fold output 2 belts
Yes Yes Yes FBBS (embedded) DRI (external) 16 Mb 32 Mb 48 up/to 192 Mb in steps of 16 Mb B1 = 707 mm Yes
Table 2 ~Paper series~ (test 93)

Paper size Number of chips roll 1 Number of chips roll 2 Number of chips roll 3 Number of chips roll 4 DIN, DIN and CARTO, only 8.5 inch serie, mixed 8.5 and 9 inch serie 1 chip / 4 chips 1 chip / 4 chips 1 chip / 4 chips 1 chip / 4 chips
130
TSM Oc 9800
SDS
12 ~SERVICE info~ tests (90 - 99)

The service info screen appears when in the testmode screen a number between 90 and 99 is selected.
s s
s s
Select a test number or scroll to the test number. Activate the test with the <START> button, go back to the testmode screen with the <CORRECTION> button. Select setting with the <SCROLL UP> and <SCROLL DOWN> buttons. Adjust setting with the <START> button.
MACHINE
: cold
Testnumber
C
Testmode Function Testtype Test number : 90-99 Service info : : : .. 90 91 93 94 95 96 97 98
for testmode screen Configuration Serial number Paper sizes Passwords Modification records Language Preset copy counter Hour counter
ed.5
SDS / LAPTOP 131
The following ~SERVICE ~info tests are available:

SERVICE Name info tests 90 ~Configuration~
Machine configuration setting (see Configuration on page 130). After changing the configuration switch the machine OFF and ON again Machine serial number Paper size configuration setting (see ~Paper series~ on page 130) Key operator and system administrator password setting. Default is 98000 Modification records for Scanner Engine 1st Fold 2nd Fold Controller Removing a wrong number: enter the wrong number, make it negative (-) by pushing the scroll down button and confirm with the ~Start~ button. Language setting: Dutch / UK English German / French US English / Spanish Danish / Italian Swedish / Norwegian Finnish/Portuguese Copy counter setting: selection: meters / m2 / feet / feet2 Hours that machine has been switched on
91 93 94
~Serial number~ ~Paper series~ ~Passwords~
95
~Modification records~
96
~Language~
97
~Preset copy counters~ ~Hour counter~
98
132
TSM Oc 9800
SDS
Laptop
1 Oc 9800 laptop applications
The Oc 9800 has an extended SDS. The optionals like Folder, Belt unit and Controller are completely integrated in the Service Diagnose System. The SDS in combination with the laptop applications helps the technician to bring the Oc 9800 within specifications by giving him the right information. Objectives of the SDS and Laptop applications are:
s
fast and right diagnose of the problem - lower MTTR / short diagnose time - less or no repeat calls - no early replacements of consumables - no incorrect replacements of parts Right PM activities to avoid CM calls
For the Oc 9800 the following applications are available:

1 Service Terminal software (ST). 2 Service plot tool (SPT).
ed.5
SDS / LAPTOP 201
2 Service Terminal software

With the ST software, it is possible to make a datadump from the Oc 9800 configuration. These informations can be examined by a same kind of SDS as used with the operator panel display. The ST SDS is extended with:
s
the 39 analyse test, to compare the performance of the CAS-groups up to 5 or 8 service visits backwards. the 71 memory management, to read and write machine parameters and stamps between the Oc 9800 and the laptop. the 100+ Laptop specific info test, includes: copy quality analyse, informations about service bulletins, how to work when the machine is dead and general ST info. all error codes and copy quality problems have there own Diagnostics, which are faster updated via e.g. E-mail as in the TSM.
Note: In these chapters only the differences to the machine SDS are explained. Newest version of help and 100+ files for ST.
To have the best performance, you need to have the newest version of the ST software and the latest updates of the faults diagnostics help file, c9800_en.hlp and the 110+ files, sta_9800.hlp and sta_9800.def. You should have got them from your local organisation. If not ask for them. You need them to work correctly with the ST application.
The main reasons why you should use ST are:
s
Fast and correct diagnose of the problem. This is achieved because the ST 9800 fault-help and copy-quality files are constantly updated by SPS-Venlo and after this they are available for you. In practice this means that every new information coming from the field regarding these files are immediately edited to the files. The fault chapters of your TSM are updated in a much lower frequency, so they are less accurate. Distance help. If you have a problem at the machine that you can't solve without local help (or SPS-Venlo help). The logfloppy (data) of the machine could give the local organisation (or SPS-Venlo) a lot of information about the problem. If available, you can send the logfloppy (data) to him by modem at the customer-site to get almost accurate help. Machine down time. With ST you can do a lot of things, normally executed under the machine-SDS, at your laptop. This means that the machine can
202
TSM Oc 9800
Laptop
meanwhile stay warming-up or warm. Again this will lead to shorter maintenance times. Preventive maintenance. With ST you can execute preventive maintenance because you can see the evaluation of faults per Cas-group per length meters/originals etc. during the previous machine-visits. Machine data. After a firmware-update (console or engine) or a PBA exchange (CPU_IO or CONSOLE_CPU) you don't have to execute the time-consuming filling of all the installation parameters and the customer stamps settings. With ST you can do it in a few seconds via a machine-parameter upload and download. Stamps. In cases that you have to program the stamps for the customer it can be done via ST which give you normal keyboard editing facilities. Again this is much quicker than directly editing on the machine-console.
What do you need to get ST working.

This part describes what hard and firmware you require to get ST working. Hardware. Laptop, supplied via your local organisation. 0-modem bundle (Interface <--> laptop) Part NO. 7991.408 Firmware. You must have DOS (version 3.0 or higher) installed on your laptop. The latest, most up to date, version of ST installed on your laptop.
Remarks. ST is correct running under DOS. It needs at least 570KB free memory to work. It is also possible to run it under Windows in a DOS-window. But if you run into trouble, go back to a clean DOS-environment. Check if you have enough memory available for running ST at your laptop by the DOS command: mem. Check if the largest executable program size is at least 570K. If not, execute a memory organiser like e.g. Memmaker or get support from your local organisation.
3 Working with ST during a normal machine visit.
ed.5
SDS / LAPTOP 203
The ST is almost the same as the machine SDS, only ST is extended with much more possibilities. Next chapters gives you only an overview of the differences between ST and the normal machine SDS.
Making a datadump from the machine to the laptop.
The first item to do during a normal machine visit is to make a datadump from the machine to the laptop via the next procedure!
1 Switch the machine in SDS-mode. Note: If your visit is not for solving an error of the machine, the datadump can
also be made in normal user mode. This means that the customer still can use the machine.
2 Connect the datadump cable to the machine. The connector is situated near the
keyswitch under the original table or at the right side of the console if the machine is a printer only configuration. 3 Connect the datadump cable to your laptop. 4 Switch on your laptop.
Note: The serial connection is RS232 based. This means that you must have no
power on at least one side of the cable during connecting the cable to the laptop or the machine. The above procedure takes care of that. Insert the machine-logfloppy in drive A of the laptop. If you don't have a machine-logfloppy execute: Making a machine logfloppy at the end of this chapter, otherwise skip this chapter.
5 Type at your DOS-prompt: st <Enter>
204
TSM Oc 9800
Laptop
A screen similar as the next box, Main Menu, should appear.
Oc ST 5.3 Report Logbook Analysis M&s Config eXit
Main Menu
13/02/96 16:22
F1=Help
1 Choose via the arrow keys the option: Reports <Enter> Note: This is the method to select an option in ST. 2 Select Create. 3 Select Datadump. A screen similar as the next box, Create Service rapport
should appear.
Oc ST 5.3 Create Service Report 13/02/96 16:22
Datadump from File: not available Machine
Import Datadump Job -travel -visit -tasks -hours -parts -save eXit
F1=Help
4 Select machine. The datadump from the machine to the laptop is made.
ed.5
SDS / LAPTOP 205
5 Select Job. A screen similar as the next box, Create Service Report, should ap-
pear.
Oc ST 5.3 08:48 + Jobnumber Modelseries Config.type Serial number Customer Cascode 01 Cascode 02 Cascode 03 SDS message Create Service Report Job : Billable : : 9877 : 0987700115 : : : : : + : + Import Datadump Job travel visit tasks hours parts save eXit + + F1=Help F8=Invoice + + 16/01/96 +
Fill in the Job screen. Config type and Serial number are filled in automatically.
Warning: Check that the configuration-type and serial number are valid num-
bers, e.g. 9877 and 0987700115, see chapter 25 of the TSM. The configuration-type is generated by SDS test 90, the serial number is generated by SDS test 91.If the serial number is not correct, it will lead to ST execution problems!
Note: Depending of the OPCO policy all the screens must be weather or not
filled in. ST gives an error message if you want to skip mandatory input. <F1> gives you help information about every input.
6 Select Save. You can get some warning-messages. Make sure that all warnings
are not relevant for your situation.

7 Select Both. The data is stored on the logfloppy and on your data disk (= lap-
top-harddisk). This means that you always have a backup of the datadump.
8 Select eXit (2x) 9 Keep the logfloppy with the machine
206
TSM Oc 9800
Laptop
Making a machine logfloppy.
The machine-logfloppy contains all the history of the machine. It should always be kept with the machine. If you want to make a copy of it use one of the next procedures:
1 Copy of the machine logfloppy.
Type the next command at the DOS-prompt:

s
diskcopy a: a: <Enter>, and follow the instructions on the screen.
2 If no machine logfloppy is available:
ST will create automatic one during saving of the datadump.

s
Insert an empty 1.44 Mb formatted floppy in the laptop. The diskette will be labeled ##LOGFLOPPY during saving.
ed.5
SDS / LAPTOP 207
4 The analyse part of ST.

At this moment you should see the Main Menu of ST. This is the starting point for going to the analysis part of ST.
1 Select Analysis. 2 Select Service Report. 3 Select Logfloppy. The next screen similar as the next box, Analyse Menu,
should become visible.
Oc ST 5.3 Machine Service report Case-study eXit
Analysis menu
14/02/96 16:22
Stored On ? Data disk Logfloppy Service report backup diskette
F1=Help
4 The next screen shows all the service visits. Select the upper job, this is the last
stored datadump.
5 Select e.g. the last 8 visits.
For preventive maintenance it is neccessory to compare more visits to see if the trend of the presented figures indicates if the performance of any function of the machine increases or decreases. A change in the trend is the trigger to analyse that group more in detail.
Note: If there are less then 8 visits with different date on the logfloppy, the
number of available datadumps are read into ST.
208
TSM Oc 9800
Laptop
The next screen similar as the next box, First-Entry, should become visible.
OTS4904 ANALYSIS 5.3 16/01/96 10:50 +--------------------------------------------------------------------------+ | 9877.00115 FIRST ENTRY |ENTER for second entry screen | | |ESCAPE to exit | +------------------------------------+-------------------------------------| | Consumables |Warnings | | OPC drum : 5040 l.metres |01901 DRUm temp. too low: DRUFANTEMPS| | Charging unit : 64604 |04901 PHDTEMPSE short/open circuit | | DCH pinarray : 64604 l.metres |11906 SIMM failure | | Fuse roller : 104271 l.metres | | | Pressure roller : 2830 l.metres | | | Clnr fuse roller : 285 black img| | | Clnr press.roller: 67 black img| | | Build up cleaner : 20294 l.metres | | | Paper guid. cloth: 64604 l.metres | | | | | | | | +------------------------------------+-------------------------------------| | System date: 18/01/96 |Firmware release: CON:1.3.0 ENG:1.2.0| | Date counter reset: 16/01/96 |CTRL:170.170.170 PKRL:170.170.170 ...| | |Permanent error code: 06102 | | No. of copies: |Handicap: Lower drawer | +--------------------------------------------------------------------------+ F1=Help
This screen is similar as the screen that you see if you use SDS on the machine. The differences are: SDS: Permanent error is presented in the lower left side of the screen, handicap is not presented. ST: Permanent error and handicap is presented in the lower right side of the screen.
ed.5
SDS / LAPTOP 209
The next screen is similar as the next box, Second-Entry, should become visible.
OTS4904 ANALYSIS 5.3 9801.00105 SECOND ENTRY 13/02/96 16:22 ENTER for testmode screen ESCAPE for first entry screen No. of copies: -Error description Abs
Systematic Call Approch
Date 29/01/96
Proess Abs Usage 0 56
Rel --
Originals Abs Usage 1 31
Rel 1:....31
Paper Abs Usage 1 88
Rel 1:....88
F1=Help
This second entry screen is similar as with the normal SDS. Extra information is that you can see between how many visits an analyse can be made.
The next screens show you how to work with ST.
s s
Select the new test 39, select 1 of the 4 CAS-groups to analyse, <Enter>,
OTS4904 ANALYSIS 5.3 16/01/96 14:51 +--------------------------------------------------------------------------+ | 9877.00115 TESTNUMBER | ENTER for function info Group| | | ESCAPE to stop test 1-4| +------------------------------------+-------------------------------------| | TESTMODE : 3039 Analysis info | Usage: | | FUNCTION : -| No. of metres of copies and plots | | TESTTYPE : -| | | TESTNUMBER: 39 Error history | | +--------------------------------------------------------------------------| | Process Originals Paper | |_ | |Date Abs Usage Rel Abs Usage Rel Abs Usage Rel | |16/01/96 110 1100 1:....10 0 2 -0 11 -| |20/12/95 3 247 1:....82 5 16 1:.....3 11 574 1:....52| |20/10/95 91 49458 1:...543 203 11582 1:....57 380 41552 1:...109| |07/09/95 74 14564 1:...196 83 3168 1:....38 126 12284 1:....97| | | +--------------------------------------------------------------------------+ F1=Help
210
TSM Oc 9800
Laptop
select from that group 1 of the sub sections for more specific information, <Enter>.
select then 1 of the error codes for final analyse, <Enter>.
ed.5
SDS / LAPTOP 211
By pressing <F2> the Diagnosticsof this error code is presented on the screen. This could be more than 1 pages, press PgDn. This is the same Diagnosticsas in the TSM manual, only the digital updating via e.g. modem is much more faster than on paper!
The presented help screen(s) give you all the information about the test(s) you can execute in order to find the problem. These tests must be executed by the machine SDS. Note: The tables display only the fault situations of the test like Diagnostics in the TSM. The same possibilities with the Diagnostic screen is also possible in all the 30-39 groups, where error codes are presented, e.g. test 32.4 ..
OTS4904 ANALYSIS 5.3 16/01/96 11:10 +--------------------------------------------------------------------------+ |9877.00115 TESTNUMBER | Page| | | ESCAPE to stop test 1-2 | +--------------------------------------------------------------------------| | TESTMODE : 30-39 Analysis info | | FUNCTION : | +-------------------Help On CTFTEMPSE out of order-------------------------+ | 06102 PE; CTFFTEMPSE out of order. | | | |--------------------------------------------------------------------------| | 06401 | CONDRI | CTFTUBSO | Possible cause Remark | | CTFTUBSO| OUTDIAG| switching | | | | | (listen!) | | +--------------------------------------------------------------------------+ | OFF | ON | No | -Electrical connections: | | | | | * CTFTUBSO > DRIVERSPBA | | | | | -DRIVERSPBA defect | |---------|----------------------------------------------------------------| | ON | OFF | No | -Electrical connections: | | | | | * CTFTUBSO > DRIVERSPBA | | | | | * 24V DRIVERSPBA > CTFTUBSO | | | | | -CTFFTEMPSE defect | +------------------------------------------------------------------Page 1-4+
-After solving the problem7x <Esc> brings you back to the First Entry screen.
Solving customer complaints
Another advantage of ST is the possibility to react accurate to customer complaints, for instance many paperjams in the upper tray. With means of tests 32 up to 35 you can determine the cause of the problem and take action similar as described in the precious chapters. In this way you dont have to make a lot of copies to see the fault yourself.
212
TSM Oc 9800
Laptop
5 Copy quality problems.

This chapter describes step by step how to solve copy quality problems via ST, starting from the First Entry screen.
s
For example: totally black copy with framing.
1 2 3 4 5 6 7
<Enter> (2x). Select test 100+ laptop specific info. Select Copy quality. Select Copy quality general. Select Black copy. Select Black Copy framed. <F1>.
Note: Diagnostics of the 100+ laptop specific info tests is visible by activating <F1> Diagnostics of error codes is visible by activating <F2>
The next screen, Help on black copy framed, appears.
All the possible causes for this problem are listed over 1 or more pages. <Esc> (6x) takes you back to the First Entry screen.
ed.5
SDS / LAPTOP 213
6 Store and restore machine parameters.

Since ST version 5.3 is bi-directional, it is possible to store (dump) machine parameters to the laptop, but also to restore the parameters to the machine. This chapter gives you a step by step guidance how to use restore with the ST: during a firmware upgrade (console and/or engine) or a PBA Console-CPU and/or CPU-IO exchange.
Store:
Make a datadump from the machine to the laptop, (see page 204), and execute the service action of the firmware upgrade.
Warning: not included are:
- operator settings e.g.: memory, paper rolls.
Restoring data, i.e. making a datadump from the laptop, to the machine. 1 2 3 4 5
Select test 70 - 79 Installation in the ST application. Select test 71 Memory Management. Select test 71.1 Complete Memory. Select Write (to machine/disk). Select Write to machine.
Note: : At this point the machine must be put in cold-SDS in order to execute
the datadump from the laptop to the machine.
214
TSM Oc 9800
Laptop
OTS4904 ANALYSIS 5.3 9801.00105 INSTALLATION INFO ENTER for testnumber ESCAPE for testtype
13/02/96 16:22
: : : :
70-79 Installation 71.1 Complete memory 3 Write <to machine/disk> 02 Write to logfloppy
01 Write to machine 02 Write to logfloppy 03 Write to tempory memory
F1=Help
6 Pressing <Esc> (6x) takes SDS back to the First Entry screen. 7 Execute with the machine SDS, tests:
- 06-7-01: pressure roller torque adjustment - 10-7-01: TL intensity adjustment - 53: 1:1 image length correction printer.
Note: 1 For all tests, the machine must be in warm condition.
Note: 2 Test 10-7-01 is not available when the configuration is a Stand Alone
(= no scanner).
8 Restore (by service or key-operator) the operator settings.
ed.5
SDS / LAPTOP 215
7 Store, restore and editing stamps via ST

Since ST version 5.3 is bi-directional, it is possible to store (dump) stamps to the laptop, edit the stamps and restore the stamps to the machine. This chapter gives you a step by step guidance how to do with the ST.
1 2 3 4 5 6 7 8 9 10
Make a datadump from the machine to the laptop. Select test 70 - 79 Installation. Select test 71 Memory Management. Select test 71.4 Stamps. Select Read (from machine/disk). Select Read from logfloppy. <Enter>. <Esc>. Select Modify/View. The next screen, Stamps modify/view, should appear.
OTS4904 ANALYSIS 5.3 16/01/96 13:37 +--------------------------------------------------------------------------+ | 9877.00115 INSTALLATION INFO | ENTER to accept changes Page| | | ESCAPE to cancel changes 1-5| +--------------------------------------------------------------------------| | TESTMODE : 7079 Installation | | FUNCTION : 71.4 Stamps | | TESTTYPE : 2 Modify/view | | TESTNUMBER: -| +--------------------------------------------------------------------------| | No Stamp text +-----------+ | | 1 Example | | | | 2 Preliminairy | | | | 3 Confidential | | | | 4 Oce' Nederland | f | | | 5 | | | | 6 | | | | 7 | P | | | 8 | | | | 9 | | | | 10 | | | | +-----------+ | +--------------------------------------------------------------------------+ F1=Help F5=Special character PgDn=Next page
In this screen you can create and / or change the stamps. Every stamp is saved in ST after pressing <Enter>.
11 Press <Enter>.
216
TSM Oc 9800
Laptop
Writing the edited stamps from the laptop to the machine. 1 Select Write (to machine/Disk). 2 Select Write to machine. Note: At this point the machine must be in cold-SDS in order to execute the datadump from the laptop to the machine.
OTS4904 ANALYSIS 5.3 9801.00105 INSTALLATION INFO ENTER for testnumber ESCAPE for testtype
13/02/96 16:24
: : : :
70-79 Installation 71.4 Stamps 3 Write <to machine/disk> 02 Write to machine
01 Write to machine 02 Write to logfloppy 03 Write to tempory memory
F1=Help
3 Pressing <Esc> (6x) takes ST back to the First Entry screen.
ed.5
SDS / LAPTOP 217
8 No SDS or Datadump available
s s s s
Select test 100+ laptop specific info Select test SDS not available Select the test you want to do. Select Diagnosticsby pressing F1=Help
This screen is a fault help on e.g. totally machine-dead situation. The help screen(s) give you a step by step guidance to get SDS / machine working again.
218
TSM Oc 9800
Laptop
9 Short overview of the Information and Modification Bulletins.
s s s
Select test 100+ laptop specific info Select test bulletins Select the wanted type of bulletins For Information bulletins, press F1 to see a short overview list For Modification bulletins: Select the wanted part of the machine configuration and press F1 to see a short overview list.
OTS4904 ANALYSIS 5.3 1 Modification bulletins 16/01/96 11:10 +--------------------------------------------------------------------------+ |9801.00115 | | | | ESCAPE for previous menu | +--------------------------------------------------------------------------| | 1 Modification bulletins | 1.1 Engine | | | 1.2 Scanner | +--------------------------------------| 1.3 stAnd alone + | | 1.4 Controller | | | 1.5 First fold | |--------------------------Help On 1.4 Controller--------------------------| | | | Controller - Modification bulletins short-list. | | | +--------------------------------------------------------------------------+ | Mod. |Regular | Subject | Bulletin | | Number |from | | | | |Machine | | | |---------|----------------------------------------------------------------| | -01 |-200 | -SCSI PBA | -Apr-96 | | -02 |-390 | -Firmware R1.2 | -1/15/95 | | -11 |-183 | -Firmware R1.1 | -1/3/95 | | -22 || -Firmware R2.0 | -Apr-96 | +------------------------------------------------------------------Page 1-1+
ed.5
SDS / LAPTOP 219
10 ST general info / hotnews page.
s s s
Select test 100+ laptop specific info. Select test ST General info / hotnews. Press F1 to see relevant information.
OTS4904 ANALYSIS 5.3 Laptop specific info 16/01/96 11:40 +--------------------------------------------------------------------------+ |9801.00115 | ENTER for next menu | | | ESCAPE for for testmode | +--------------------------------------------------------------------------| | | Copy quality | | | SDS not available | +--------------------------------------| Bulletins + | | sts General info / hotnews | | | eXit | |-----------------------Help On sts General info / hotnews-----------------| |sts General info / hotnews. | | | +--------------------------------------------------------------------------+ | Item | |--------------------------------------------------------------------------| |- Please report remarks/update suggestions on STS to your local TECO or | | Laptop Manager to improve STS! | +------------------------------------------------------------------Page 1-1+
220
TSM Oc 9800
Laptop
Service Plot Tool

Note: For a complete description of the Service Plot Tool, see Information Bulletin 1004!
The Service Plot Tool is a laptop application what must be used in combination with the controller in the Oc 9800. It is a relative simple menu structured software program to create a RCF header on top of the digital drawing. This header contains all the possibilities for the plot languages and for the Oc 9800 configuration. You can set e.g. the plot origin, automatic language sensing, pen settings, the number of copies, folding yes or no.
The SPT is provide with a set of sample plot files, which can be plotted via the standard centronics or serial connection between laptop and controller . Plotting these well known sample plots proves that the Oc 9800 configuration is performing well, before the controller is connected to the customer environment. It is also possible to check (view) the RCF header structure and compare this with the header created by the customer, to analyse settings made by the customer.
Oc 9800 Service Plot Test Release 1.0 June 23, 1995 Number of copies ......: Media & Roll selection : Pen Widths & Patterns .: Scale, Rotate, Shift ..: Edge correction,Framing: Finishing Attributes ..: Special Features ......: File Format ...........: Plotter Type ..........: Origin ................: Pen Zero Termination ..: 1 Press Press Press Press Press Press
code number 7991.487
ENTER ENTER ENTER ENTER ENTER ENTER
for for for for for for
sub sub sub sub sub sub
menu menu menu menu menu menu
HPGL 7585B Center Enabled
Selected HPGL File : Configured destination : Cursor = Select F1 = Print
>C:\SPT9800\HPGL1-A3.PLT LPT1 F3 = Quit F4 = Configure
F2 = View RCF
ed.5
SDS / LAPTOP 221
222
TSM Oc 9800
Service Plot Tool

TSM 9800

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TSM 9800

Uploaded by

Copyright:

Available Formats

Oc

Technical Service Manual

Oc Codenumber: 0910330 Edition: 5

390 PBA(s) 397 Settings/Parameters

ed.4, Februrary 1997, Code no. 0109.280

Confidential 1997 Oc-Nederland B.V., Venlo

ES DIGITAL PPC-2 (Oc 9700/9800 series)

ed.4, Februrary 1997, Code no. 0109.280

Confidential 1997 Oc-Nederland B.V., Venlo

ES DIGITAL PPC-2 (Oc 9700/9800 series)

25.Customer/Environment/ Supplies/Installation/ Customer 951 No fault on arrival

ed.4, Februrary 1997, Code no. 0109.280

Confidential 1997 Oc-Nederland B.V., Venlo

Confidential 1999 Oc-Technologies B.V.

Confidential 1999 Oc-Technologies B.V.

1999 Oc-Technologies B.V.

At whom is the TSM Oc 9800 targeted?

For the attention of:

ply with local regulations.

Confidential 1999 Oc-Technologies B.V.

7 CURRENT STATUS SHEET

ADJU DISA FUNC ELEC E.D.

ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5

ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5

ed.5 ed.5 ed.5 ed.5 ed.5 ed.5

ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5

05 06 07 09 10 11 12 13 14 15 18 19 20 (1-999) 20 (1001-1999) 20 (2001-2999) 22 23 25

Preventive maint. Miscellaneous Parts list 9800 Parts list 976

ed.5 ed.5 ed.2 ed.1

8 MODIFICATION / INFORMATION BULLETIN SURVEY

ITC DOCUMENTATION CHANGE REQUEST FORM

DOCUMENT TO BE CHANGED Manual : Edition :

Please attach extra pages if necessary

1 Component locations 601 2 ASV measurement 603 3 Compensation voltage 604

Confidential 1999 Oc-Technologies B.V.

01501 MRE: ~DRUFANTEMPSE open / short-circuit~

01-9-01 DRUFANTEMPSE (NTC)

R NTC = 100 Ohm 300 kOhm Yes

ADC value > 808

DRUFANTEMPSE defect (short-circuit) CPU_IO PBA defect disconnect 2201X4

ADC value < 144

01505 MRE: ~Too high positive ASV in stand-by~

Recently cleaned OPC drum Newly installed OPC drum

01506 MRE: "Too high negative ASV in stand-by"

Confidential 1999 Oc-Technologies B.V.

01507 MRE: "Too high positive ASV val. in run"

See error code 01505 Capacitor charge unit + charge unit

Special test 01-6-03 See error code 01505

01508 MRE: "Too high negative ASV val. in run"

01509 MRE: "ASV init. pulse not detected"

01901 SWAR: ~Drum temp.(erature) too low: DRUFANTEMPSE~

DRUFANINV defect Environment temperature too low

Analysis info tests 30 ~Reset PE & handicaps~

~Last error logging (OWAR/SWAR/ORE/MRE/PE/FE)~

Test nr. Input tests 01-2-01 01-2-02

DRUm FAN SWitch DRUM FAN ROTation SEnsor

Output tests 01-4-01 01-4-02

Drum fan PWM ON = drumfan switched on

Special tests 01-6-01 ~Make function warm~

Functions 01 (drum), 02 (corona), 05 (developing) and 07 (discharging) are in warm condition

Functions 01 (drum), 02 (corona), 05 (developing) and 07 (discharging) are in cold condition

Test nr. 01-6-04

Description ~View last ASV probe/volt. values~