Oce 9800

Oc
Technical Service Manual

Oc 9800
Oc Codenumber: 0910330
GB
Edition: 5
ES DIGITAL PPC-2 (Oc 9700/9800 series)
CAS-C
(Oc 705/710 + 850) (Oc 880) (Oc 965)
1.Photoconductor/Drum 5.Developing 238 Mechanical connections
239 Electrical connections
001 Drum assy 161 Doctor blade
240 Others
002 Carbon brush 162 Spacing disk
003 ASV compensation sensor 163 Magnet roller
7.Cleaning/Discharging
004 Fan(s)
005 Drum fan invertor 165 Gear(s) 241 Pin array
006 NTC 166 Toner 242 Fan(s)
167 Scraper mechanism 243 High voltage supply
029 Adjustments 168 Toner supply funnel 244 LED(s)
030 PBA(s) 246 Ozone filter
031 Motor(s) 189 Sensor(s)
190 PBA(s) 247 Discharging unit assy
037 Settings/Parameters 191 Motor(s)
038 Mechanical connections 270 PBA(s)
039 Electrical connections 197 Settings/Parameters
040 Others 198 Mechanical connections 277 Settings/Parameters
199 Electrical connections 278 Mechanical connections
2.Charging 200 Others 279 Electrical connections
280 Others
041 Corona (pin array)
6.Compact Transfer Transfuse
042 Fan(s)
9.Original Handling
201 Fuse roller
046 Ozone filter 202 Pressure roller 321 Glass plate
203 Cleaner(s) 322 Gauge/feed roller
070 PBA(s) 323 Scanner lamp
075 Power Supply 205 Compressor 324 White original plate
077 Settings/Parameters 206 Compressor control unit
078 Mechanical connections 207 Cylinder(s) 348 Switch(es)
079 Electrical connections 208 Valve(s) 349 Sensor(s)
080 Others 209 Hose(s) 350 PBA(s)
351 Motors
4.Exposure 210 Heater(s)
211 Bearing(s) 353 Solenoid(s)
121 Printhead
212 Output guide
357 Settings/Parameters
136 Fan(s)
217 Fuse roller Temperature 358 Mechanical connections
137 Hose(s)
sensor 359 Electrical connections
138 Cooling unit/liquid
218 Thermal switch(es) 360 Others
139 NTC
219 Clutch(es)/Brake(s)
220 Solenoid(s) 10.Image-scanning
150 PBA(s)
155 Power supply 361 Scanning unit/Camera
227 Invertor pressure roller
362 Scanner-engine cable
motor
157 Settings/parameters 363 Mirror
228 Switch(es)
158 Mechanical connections 364 Fan(s)
229 Sensor(s)
230 PBA(s)
160 Others 390 PBA(s)
231 Motor(s)
SYMPTOMS ACTIONS
1 General copy quality 1 Replace (life time)
2 Image position/ deformation/ size 2 Replace (defective)
3 Spots/ stripes/ pullution 3 Install (missing part)
4 Fusing/ finishing (delivery) 4 Adjust,correct
5 Jammed or damaged original or copy 5 Repair/fix
6 - 6 Clean/ dismount/ lubricate
7 Total stop 7 Replenish/ drain
8 Control 8 Instruct/ install
9 Noise/ odour/ damage/ others 9 -
ed.4, Februrary 1997, Code no. 0109.280 Confidential 1997 Oc-Nederland B.V., Venlo
ES DIGITAL PPC-2 (Oc 9700/9800 series)
CAS-C
398 Mechanical connections 538 Switch(es) 730 Static eliminator(s)
399 Electrical connections 539 Sensor(s) 731 Mechanical switch(es)
400 Others 540 PBA(s) 732 Damper(s)
11.Image processing 557 Settings/Parameters 742 Fan(s)

558 Mechanical connections
430 PBA(s)
559 Electrical 745 Fuse(s)
560 Others 747 LED(s)
437 Settings
748 Switch(es)
15.Paper Transport 749 Sensor(s)
440 Others 564 Paper guide plates
750 PBA(s)
565 Rollers
751 Motor(s)
12.Paper Roll Drawers
568 Switch(es)
441 Paper spool(s) 753 Solenoid(s)
569 Sensor(s)
442 Feeding roller(s) 754 Power supply
570 PBA(s)
443 Belt(s)
571 Motor(s)
444 Cutter 757 Settings/Parameters
573 Solenoid(s)
446 Gear(s) 759 Electrical connections
447 Tensioner(s) 760 Others
448 Drawer rails
20.Interfacing
468 Switch(es)
600 Others Oc Host Interface HW/cables
469 Sensor(s)
470 PBA(s) 771 Data cable
18.Folding/Folding Output
471 Motor(s) 772 Protocol convertor
472 Clutch(es)/Brake(s) 681 Clutch(es)/Brake(s) 773 Interface failure
473 Solenoid(s) 685 Gear(s) 774 Interface setting
686 Paper guide plate(s) 775 SCSI termination
477 Settings/Parameters 687 Folding roller(s)
478 Mechanical connections 688 Timing belt(s)/pulley(s) Data emulation
479 Electrical connections 689 Feed rollers
776 Incorrect data
480 Others 690 Folding flap
777 Unsupported command/file
format
13.Paper Sheet Feeding 700 Motor(s)
778 Incorrect or no output
701 Solenoid(s)
481 Sheet feeding roller(s)
702 Sensor(s)
482 Belt(s) Controller
703 Static eliminators
483 Gear(s)
704 PBA(s) 781 Memory
705 Power supply 782 Disk
509 Sensor(s)
783 Fan(s)
510 PBA(s)
710 Punch unit 784 PBA(s)
511 Motor(s)
711 Renforcement unit 785 Software/firmware
712 Receiving belt(s) 786 Power supply unit
513 Solenoid(s)
713 Safety switch(es)
790 Switch(es)
717 Settings/Parameters 791 Controller settings
719 Electrical connections 798 Mechanical connections
520 Others
720 Others 799 Electrical connections
800 Others
14.Preheating
19.Delivery
521 Paper guide cloth 21.Host Software
721 Paper guide plate(s)
522 Paper driving rollers
722 Timing belt(s)/pulley(s) Oc Application SW
523 Heater(s)
723 Gear(s)
524 Liquid (-container) 821 Oc JobDirector failure
724 Feed roller
525 Thermal switch(es) 822 Oc JobDirector setting
725 Bearing(s)
526 Clutch(es)/Brake(s) 823 Oc PlotDirector failure
726 Transport belts
527 Solenoid(s) 824 Oc PlotDirector setting
528 Belt
ES DIGITAL PPC-2 (Oc 9700/9800 series) CAS-C
825 Oc Reprostation failure 952 Incorrect operation
953 Original
826 Oc Reprostation setting 954 Exaggerated demands
827 Oc ScanStation failure
828 Oc ScanStation setting 960 Others Customers
829 ScanStation Viewer failure
830 ScanStation Viewer setting Environment
961 Humidity/Temperature
Oc Drivers & Convertors/SW
962 Main power supply
831 Oc Drivers SW failure 963 Host connection
832 Oc Drivers SW setup
833 Oc Convertor SW failure 970 Others Environment
834 Oc Convertor SW setup
Supplies
Customer SW/application
971 Paper
836 SW/application failure 972 Specialities
837 SW/application setup 973 Toner
974 (Cooling) Liquid
22.Control
980 Others Supplies
841 Memory
842 Relay(s)
Installation (problems)/
843 Line filter(s)
Integration/Instruction
844 Stepdown transformer
845 Fuse(s) Use all other codes and:
846 Copy counter
981 Integration
847 Fan(s)
982 Training/Instruction
848 Switch(es)
849 Sensor(s)
991 Packing
992 Covers
855 PBA(s)/EPROM(s)
993 Transport securities
856 Power supplies
995 Oc Application SW
877 Settings/parameters
996 Oc Drivers/Convertors/
SW
880 Others
997 Customer SW/application
998 Others Installation/
23.Main Drive
Integration/Instruction
881 Timing belt(s)
882 Gear(s) 999 Complete system okay
883 Tensioner(s)
884 Bearing(s)
909 Invertor main drive motor

910 PBA(s)
911 Motor(s)
913 Adjustments
920 Others
25.Customer/Environment/
Supplies/Installation/ Cus-
tomer
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 equip-
ment 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 clear-
ly 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 in-
complete 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 in-
form 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:
Oc-Technologies B.V.
For the attention of: 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 descrip-
tions 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.

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 in-
jury.
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:
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 Techni-
cal Service Manual.
ed.5 Preface 105

6 EDITION REVIEW
EDITION DATE CHAPTER SECTION
ed.1 May 1995 All All
ed.2 April 1996 All All
ed.3 July 1996 Faults All
01-Drum All (except Diagrams)
09-Originals All (except Diagrams)
20-Interface All (except Diagrams)
ed.4 April 1997 Installation All
Faults SDS
19-Finishing All
20-Interface All (from on page 1001)
1-7 Diagrams
11-23 Diagrams
ed.5 Februari 1999 all all
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

7 CURRENT STATUS SHEET
CHAPTER TOC SECTION
Preface ed.5 ed.5
TOC INS
Installation ed.5 ed.5
TOC CQ E.F. TOC SDS LAP
Faults ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
Functions TOC DIAG SDS ADJU DISA FUNC ELEC E.D.
01 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
02 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5

10 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
11 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
14 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
15 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
20 (1-999) ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
20 (1001-1999) ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
20 (2001-2999) ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
23 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5
25 ed.5 ed.5 ed.5 ed.5
TOC COP CON
ed.5 Preface 107

CHAPTER TOC SECTION
Preventive maint. ed.5 ed.5 ed.5
Miscellaneous ed.5 ed.5
Parts list 9800 ed.2
Parts list 976 ed.1
8 MODIFICATION / INFORMATION BULLETIN SURVEY

See MERLIN Database
9 SAFETY DATA
For information about safety data, see the User Manual Oc 9800.

o ITC DOCUMENTATION CHANGE REQUEST FORM o
Requested by : Country :
Department :
Approved by : Tel :
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 SIGNED : DATE :
Technicians send this request form to : Technical Coordination Department
Technical Coordination please send this Oc-Technologies B.V.

request form to : Attn. of: Manager International Training Centre - Service
P.O. Box 101
5900 MA VENLO
The Netherlands
Oc
Oc 9800
01 DRUM
Contents
Diagnostics
1 Faults 101
SDS
1 Drum 201
Adjustments
1 The ASV probe for the drum 301
2 ~DRU ASV test~ 302
3 Drum security 303
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

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 Possible cause Remark
DRUFANROTSE
ON
OFF
01501 MRE: ~DRUFANTEMPSE open / short-circuit~

~
01-9-01 R NTC = Possible cause Remark

DRUFAN- 100 Ohm -
TEMPSE 300 kOhm
(NTC)
ADC value Yes DRUFANTEMPSE defect
> 808 (short-circuit)
CPU_IO PBA defect
disconnect 2201X4
ADC value Yes DRUMFANTEMPSE
< 144 defect (open circuit)
Electrical connection
DRUFANTEMPSE ->
CPU_ IO PBA
Electrical connection:
* DRUMFANTEMPSE
--> CPU_IO-PBA.
* +5VAN signal of
2201X3, X4 X5 short cir-
cuit to earth
CPU_ IO PBA defect
ed.5 01 Drum 101

01502 MRE: ~Drum temp.(erature). too high: DRUFANTEMPSE~
01-4-01 DRUFAN Possible cause Remark

DRUFANPWM turning
ON No DRUFAN defect
Connection L2 -> DRUFANINV
(green led off)
Connection DRUFANPWM
->DRUFANINV
DRUFANINV defect
CPU_IO PBA defect
Yes Environment temperature too Max. 32 C
high
Air inlet blocked
Cover panel air outlet wrongly
mounted
01504 MRE: ~DRUMFAN not connected: DRUFANSW~


DRUMFANSW
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 posi-
tion 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 con-
tact 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
ed.5 01 Drum 103

01508 MRE: "Too high negative ASV val. in run"
Possible cause
Incorrect system configuration (DOCMEM instead of SETMEM v.v.)
Too low PHD light intensity setting
Dirty PHD diaphragm
Defective PHD
Actions
Correct system configuration
If the PHD is involved, it can be checked, when there is enough light in the envi-
ronment, 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

01901 SWAR: ~Drum temp.(erature) too low: DRUFANTEMPSE~
~
01-4-01 Drumfan Possible cause Remarks

DRUFANPWM turning
OFF Yes DRUFANINV defect
No Environment temperature too Min. 17 C
low
06-4-05 CONDRI- 1st trans- Possible cause Remarks

(06-6-07) OUTDIAG fer step
CTFSTVA 1st activated
transfer step
ON OFF No DRIVERS PBA defect
ON No CTFSTVA defect Listen
Pneumatic connection ->
CTFSFVA
Pneumatic connection
-> CTFSTVA
-> CTFSTCYLL/R
Connection CTFSTVA ->
DRIVERS PBA
CTFSTCYLL/R defect
CTFCOMP defect
ed.5 01 Drum 105

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) serv-
ice mode
34 ~Error top 10
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

Input tests
01-2-01 01M1 DRUm FAN Drum fan switch

SWitch ON = connection X01 correct.
01-2-02 DRUM FAN Drum fan rotation sensor

ROTation SEn- ON/OFF when drum rotating
sor
Output tests
01-4-01 01M1 DRUm FAN- Drum fan PWM

PWM ON = drumfan switched on
01-4-02 01M2/01M3 DRUm COLD- Drum cold process fans 1 and 2 activated
PROCess FAN ON = fans activated
Hardware diagnosis:
CONDRIOUTDIAG
01-4-03 DRUm ASV Drum ASV compensation voltage

COMPensation ON = 100% PWM (> 35 V DC)
PWM
Special tests
01-6-01 ~Make function warm~

Functions 01 (drum), 02 (corona), 05 (devel-
oping) and 07 (discharging) are in warm con-
dition
01-6-02 ~Make function cold~

oping) and 07 (discharging) are in cold con-
dition
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

01-6-04 ~View last ASV probe/volt. values~

The average and lowest/highest values of the
ASV-compensation as well as the ASV-
probe values over the last minuteduring copy-
ing.
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 ~DRUm FAN TEMPerature SEnsor (adc)~

Actual A/D value 0-1023
01-9-02 01B3 ~DRUm ASV COMP. Sensor (V/10)~

Actual output value of ASV sensor
(range -100 ... + 100 V / 10)
01-9-03 ~Drum 45V Comp. last value (V/10)~

(range 0 - 400)
System tests
43 ~Cut sheet length~

Setting of necessary sheet length for adjust-
ments 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 Switch off the machine.
5 Open the top front cover.
6 Remove the front cover.
7 Remove the air tube at the left side.
8 Disconnect the connector 05X1 from the developing unit.
9 Pull out the developing unit as far as possible.
10 Remove the DRUASVCOMPSE adjusting plate.
11 Move the bar with the ASV probe on the left and right side to its top position.
12 Clean the probe.
13 Mount the adjusting plate over the ASV probe and check if the plate is con-
nected to the ground wire.
14 The adjusting plate must touch the plastic block and the rubber stopper must
touch the probe.
15 Push the developing unit into the machine, do not lock the unit.
16 Mount the air tube in the machine and plug in the connector 05X1.
17 Switch on the machine.
18 Carry out SDS test 40, cold SDS.
19 Carry out SDS test 01-9-02.
20 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:

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 Carry out SDS test 43.
2 Enter the value 930.
3 Push the start button.
4 Select: roll width A0 (34/36), unfolded and 2 copies.
6 Carry out SDS test 54 with 2 copies selected.
7 Feed one sheet in landscape direction into the sheet feeder.
8 Feed the other sheet in landscape direction into the sheet feeder.
9 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 Remove the left and right side top covers.
2 Remove the left and right side top covers.
3 Carry out SDS test 40, COLD SDS.
4 Carry out test 06-6-07.
5 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

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 B A C
D D
E E
F F

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 ten-
sioner
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.

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
Aim:
To make sure that the copy quality is increased.
Tools for drum cleaning:
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 ar-
eas. 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 (re-
peating 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

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 pollu-
tion 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.
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

5 cm and moisten the towel with Oc cleaner K.
When pressing in the towel no cleaner liquid should drip off.
9 Press the wet cleaning towel against the rotating OPC Drum at the polluted
place during 3 drum revolutions.
10 Repeat this once again with a new wet cleaning towel.
11 Press a new dry cleaning towel against the OPC Drum at the polluted place dur-
ing 3 drum revolutions.
12 Close the machine.
13 Judge the result of the cleaning procedure by executing:
adjustment ~DRU ASV test~ on page 302.
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.

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
P. The drum should get back its original colour and a smooth surface without
flames.
8 Clean the drum again with Oc cleaner K using new towels and gloves.
Repeat this twice again with new towels.
9 Dry the drum with new cleaning towels and gloves.

10 Remount the drum in the machine and fan (right side) and air inlet (left side).
11 Carry out adjustment 23 Main driveMain drive belt on page 975
12 Remount the developing unit.
13 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).
14 Close the drawer of the cold process, do not mount the front cover.
15 Carry out SDS test 43 and enter a value of 930.
17 Select an A0(36) roll and make 10 copies.
18 Place the developing unit in the locking position and hook the tension springs
back again.
19 Mount the front cover.
20 Check adjustment 23 Main driveMain drive belt on page 975 again.
21 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.
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
and closing the unit with the locking handles before and not behind the locking
bolts. (The toner should not touch the drum.).
4 Switch the machine on in SDS mode.
5 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~.
6 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.
8 Reposition the developer unit.

3 Drum replacement
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 Fit the lifting brackets to the drum shaft and lock them.
3 Turn the lifting handle to move the drum out of the drum box.
4 Remove the tape from the drum protection sheet.
5 Remove the drum protection sheet from the drum.
6 Remove the two foam blocks, preventing turning of the drum during transport.
7 Turn the drum to the working position.
8 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
brush or cloth. Do not allow MOLYCOTE-GN Plus to get into your eyes.
13 Remount all parts.
14 Tighten the belt tensioner manually.
15 Push the developing unit into the machine.
16 Connect the air tube and connect the connector 05X1.

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
away from the drum and lock it in the transport position with 2 bolts (no toner
is developed to the drum).
20 Carry out the adjustment Main drive belt on page 975 function 23 Main drive.
21 Carry out SDS test 42 (Service copy mode, machine is warming up).
22 Carry out SDS test 43 and enter a value of 930.
24 Select an A0 (36) roll and make 10 copies.
25 Remove the 2 bolts and place the developing unit in the locking position and
hook the tension springs back again.
26 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.

4 Removal of the drum pulley
Note: (Drum pulley removal toolkit 7991.581).
1 Remove the inlet pipe of the drum at main drive side.

2 Remove the carbon and the brass plate from the drum pulley.
3 Insert the disassembling tool (7991.528) in the shaft hole.
4 Mount the metal plate (7093.204) with tapties (2111.275) on pulley.
5 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.
The procedure is as follows:

1 Remove the pulley from the drum shaft-end.
2 Remove all grease of the shaft end and from the inside of the pulley bush.
3 Grease the drum shaft-end with Molycote-GN Plus.
4 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 res-
idues of the cleaner P. Make some copies to judge the cleaning results.
Tools for drum cleaning:
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)

Drum Cleaning Instruction
1 Open the top cover.

3 Open the drawer of the cold process unit, until it clicks in the first position.
4 Remove the air supply tube of the DRU-ASV probe.
5 Slide out the developing unit completely.
6 Cover the cold process unit with a sheet of paper.
7 Activate SDS-test 23-4-01.
Note: Use the remote control switch in order to stop the main drive immediate-
ly 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 Repeat this once again with a new wet cleaning towel.

10 Press a new dry cleaning towel against the drum during 3 revolutions.
11 Place the developing unit in the machine.
12 Connect the air supply tube and connector 05X1.
13 Close the drawer of the cold process unit, lock it and unlock the PHD.
14 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:
drum number
machine type and serial number
country
the date of installation of the consumable
3 Store the new card in the engine

4 After replacement:
5 Take out the Drum reporting card of the removed drum.
6 Fill in at the reporting card:
the date of removal of the consumable
consumable counter in lm
"Reason of removal" indicated with numbers
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.

1 Copy process
There are 5 steps involved in the copy process around the drum:
developing
drum developing unit
roller
fuser roller
exposure
charging
discharging
1 Charging
2 Exposure
3 Developing
4 Transfer
5 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 alu-
minium cylinder coated with two layers of photoconductive material. The first
layer is the generation layer and the second is the transfer layer. The photocon-
ductor 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 Sur-
face Voltage of the drum after development.
3 Charging
The charge corona unit has 2 pin ar-

rays. The pin arrays (supplied with a pin array
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 su-
perimposed. drum
After charging, the drum has an Ap-

parent Surface Voltage (ASV) of -130
V.
502 TSM Oc 9800 Functional description

4 Exposure
Exposure: drum
The digital information of an original cooling
is transferred via the image process-
ing 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 orig-
inal are discharged on the drum by the
LEDs of the printhead.
Black parts (image areas) of the orig- SLA LEDs
inal are not discharged on the drum.
After the exposure function a latent
(not visible) image remains on the
drum surface.
Framing:
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 doctor
develop-
component toner. Magnetic forces
ing roller
transport the toner to the developing
roller. The doctor blade transfers a
fixed amount of toner on the develop-
ing roller. The toner on the developing
roller develops the latent image on the
drum. The developing unit also re-
moves residual toner (from the previ-
ous copy) from the drum. The
developing unit therefore also acts as
a cleaning unit.
drum
6 Compact Transfer transFuse

The transfer of the toner from the
fuser roller
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.
2nd step 1st

step

7 Discharging
The discharge unit contains a pin ar- pin array Drum
ray and a LED bar.
The charged toner and the residual
LEDs
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 super-
imposed.
The discharge LEDs are mounted on
3 PBAs (3 x 32 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 en-
sure 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 cool-
ing 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 be-
comes 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 run-
ning 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.

ASV probe
The ASV probe, mounted on the developing unit, measures the Apparent Sur-
face 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 mid-
dle of the drum.
When 914 mm (36) paper is used the measurement and compensation is car-
ried out in the distance between two copies (10 cm).
ASV probe
36
36
A0 100
mm
DRUM
ASV Probe cleaning

The electrode of the probe is sensitive to pollution. An air pump (DRUASV-
COMPPUMP) 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

1 Component locations
Drum DRUFANTEMPSE DRUFANMO
Sliding
contact
DRUFANROTSE
DRUCOLDPROCFAN1+2
DRUASVPROBE DRUASVCOMPSE
DRUASVCOMPPUMP
ed.5 01 Drum 601

DRUFANMO
DRUFANROTSE
01X1 and 01B2

01X2
DRUFANINV
602 TSM Oc 9800 Electrical description

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:
Housing
Tuning fork
Piezo element
Electrode
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 dis-
charging 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 con-
tinues 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 volt-
age 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 back-
ground a positive compensation voltage is supplied to the drum via a carbon
brush.
The height of the compensation voltage is regulated with the DRUASVCOMP-

PWM signal.
On the SSR-PBA, this signal is converted in a DC voltage DRUASVCOMP be-
tween 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)
Compensation
DRUASV voltage on
COMPSE DRUASV sliding contact
COMP (e.g.+10V)
PWM
DRUASV
COMPSE
PBA CPU
I/O DRUASV
22Z2 COMP
L2
N2 SSR
PBA 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.

1 2 3 4 5 6
22G1 CONSUPLV 22PBA5 DRIVERS DRUCOLDPROCFAN1
G2 X8 F1 X11 22X12 01X6
+24V +24V
1 5 31 1 1
GND 4A
2 6 M
A 3
+24V
7 01M2
GND DRUCOLDPROCFAN1-B
4 8 32 2 2
+24V
5 9 01X7
GND +24V
6 10 33 3 1
G3
M
+5V 01M3
1 1 DRUCOLDPROCFAN2-B
GND 34 4 2
2 2
+5V
3 3 DRUCOLDPROCFAN2
GND
4 4
CTFDOORSW PTRFRAMESW
X5
F4 +24V
7 1 2 1 2
4A
O6S1 15S1
B 22PBA1 CPU I/O 8
+24V-SW
X13 X10
+5V
1 1 X12
CONEMS2-B
2 2 12
+24V
3 3 22K2-2A
GND
5 5
+24V-SW
X6 X6 15
CONDRIINDIAG CONEMS2
27 27
CONDRIOUTDIAG
28 28
X11 X7
DRUCOLDPROCFAN
12 12 22PBA4 SSR DRUM
X9 X11 F3
DRUFANPWM GND X1 X1 01X5
2 12 4A +24V DRUASVCOMP
23 28 23 1 01X
C X5 01B2
+24V
7 20
GND
30
+5V 1
1 1
DRUFANROTSE 2 +5V ....+35V
2 2 TP4
GND 3
3
01B1 DRUASVCOMPSE
3
05X1 B1
DRUFANROTSE 6 1
DRUASVCOMPSE
19 7 2
GNDAN
20 8 3
DRUASVPROBE
D COMPSUP
01X2
+5VAN
1 1
+45V
-T
-T
DRUFANTEMPSE TP3
01R1
DRUFANTEMPSE
2 2
X9
CONSSRINDIAG
9 9 X15 01X1
+5V GND
7 7 2 9
GND
8 8
DRUASVCOMPPWM DRUFANSW
12 12
DRUFANSW DRUFANSW
10 10 1 8
E
CONCONSUP
22Z2 DRUASVCOMPPUMP
0.031A
F1 X2 05X2
X9 L2S
L2 12 1
6 1
M 01M4
5 2 1
N2 22X010 N2S
4 3 11 2
X8
N2
4 2 3
L2
8 6 6 01X1
L2-S L2-S
4 15 5
N2-S
F 1
01U1 DRUFANINV
U6 U6
N2-S L2-S
14 3 1 6
U4
T3
4 4
T2 M
3 3
T1 3 01M1
1 1
2 E
2 2
22X003-2
DRUFANMO
F1 5A
G U2
GND
1
DRUFANPWM
2
05X1 05X001
9
H 22X003-1 05X002 DEVROLLER 05X003 RESTASVREF
FROM ENGINE 484

ed.5 TSM Oc 9800 01 Drum 701
1 2 3 4 5 6
22G1 CONSUPLV 22PBA5 DRIVERS
G2 X8 F1 X11 22X12 01X6
+24V +24V
1 5 31 1 1
GND 4A
2 6 M DRUCOLDPROCFAN1
A 3
+24V
7 01M2
GND DRUCOLDPROCFAN1-B
4 8 32 2 2
+24V
5 9 01X7
GND +24V
6 10 33 3 1
M DRUCOLDPROCFAN2
G3
+5V 01M3
1 1 DRUCOLDPROCFAN2-B
GND 34 4 2
2 2
+5V
3 3
GND
4 4
X5
F4 +24V
7 1 2 1 2
4A
O6S1 15S1
B 22PBA1 CPU I/O 8
+24V-SW
X13 X10
+5V
1 1 X12
GND CONEMS2-B
2 2 12
+24V
3 3 22K2-2A
GND
5 5
+24V-SW
X6 X6 15
CONDRIINDIAG CONEMS2
27 27
CONDRIOUTDIAG
28 28
X11 X7
DRUCOLDPROCFAN
12 12 22PBA4 SSR
X9 X11 F3
DRUFANPWM GND X1 X1 01X5
2 12 4A +24V DRUASVCOMP DRUM
23 28 23 1
C +24V
7 20
GND
30 01X
+5V ....+35V
TP4
01B1 DRUASVCOMPSE
05X1 B1
6 1
X4
DRUASVCOMPSE
19 7 2
GNDAN
20 8 3
DRUASVPROBE
D COMPSUP
01X2
+5VAN
1 1
+45V
-T
-T
DRUFANTEMPSE TP3
01R1
DRUFANTEMPSE
2 2
X9
CONSSRINDIAG
9 9 X15 01X1
+5V GND
7 7 2 9
GND
8 8
DRUASVCOMPPWM DRUFANSW
12 12
DRUFANSW DRUFANSW
10 10 1 8
E
CONCONSUP
22Z2
0.031A
F1 X2 05X2
X9 L2S
L2 12 1
6 1
M DRUASVCOMPPUMP
5 2
22X010
1 01M4
N2 N2S
4 3 11 2
X8
N2
4 2 3
L2
8 6 6 01X1
L2-S L2-S
4 15 5
N2-S
F 1
01U1 DRUFANINV
U2 U2
N2-S L2-S
14 3 1 6
T3 DRUFANMO
8 4
T2 M
7 3
T1 3
6 1 01M1
E
2 9 2
22X003-2
F1 5A
U1
GND
4
RUNFWD
G 5
GND
2
DRUFANPWM
3
05X1 05X001
9
H 22X003-1 05X002 DEVROLLER 05X003 RESTASVREF
UP TO ENGINE 483
ed.5 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
2 High voltage supply unit 602
3 Corona fans 602
Diagrams
1 Corona 701
ed.5 02 Corona
Diagnostics
1 Faults
CORona 02000 - 02999 code display
02501 MRE: ~CORona SUPply failure: (CORSUPER)~
02-6-05 CORSU 24 V Possible cause Remark

CORSUP PER present on
02G1
OFF OFF Yes CORSUP defect (continu-
ously ON)
Connection CORSUPER ->

CPU_IO PBA
OFF dis- Yes CPU_ IO PBA defect (COR-
connect SUPER)
2201X4
ON ON No 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 (continu-
ously off)
Pin array disconnected / bro-
ken
Polluted or humid isolation
blocks
ed.5 02 Corona 101

02901 SWAR: ~Failure CORFAN (1-3): CORFANER~
02-4-01 COR- FANs 24 V Possible cause Remark

CORFAN FANER turning present on
(listen) all fans
OFF OFF No No Connection
CORFANER ->
CPU_IO PBA
CPU_IO PBA defect
OFF dis- Yes Yes DRIVERS PBA
connect defect
2201X11
ON ON No No Fuse F3 DRIVERS
PBA defect
24 V DRIVERS
PBA -> CORFAN 1,
2 or 3
Other 24 V users on
2205X11
DRIVERS PBA
defect
Yes Yes CORFAN 1, 2 or 3
defect

SDS
1 CORona
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS
ed.5 02 Corona 201

Input tests
02-2-01 02G1 CORona SUP- Corona supply error

ply ERror ON = corona supply switched off
02-2-02 02M1 / 2 / 3 CORona FAN Corona fans error

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
Special tests

dition

dition
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 Switch off the engine.

4 Disconnect on the right side the connectors 22X5 and 0401X1 from the print-
head.
5 Disconnect on the left hand side the connector 22X4 from the printhead.
6 Unlock on the left and right side the drawer of the cold process unit.
7 Open the drawer of the cold process unit as far as possible.

8 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 Carry out dis-/assembly Corona unit on page 401.

2 Place the corona unit on a flat surface.
3 Remove the clear plastic covers on both sides.
4 Release the tensioner of the corona pin array on the side without connector.
5 Remove the corona pin arrays.
Note: Do not touch the corona pin array with your fingers.
Never clean the corona pin arrays.
Installation
1 Mount the corona pin array on the side with connector.

2 Guide it between the flat side of the supporting blocks.
3 Install the other side and tension the spring.
4 Remount the 2 plastic covers.
Note: Dispose of the old corona pin array according to your local regulations
to the local Oc organization.

3 Corona fans
Caution: Close the upper and lower paper roll drawers and the paper-sheet
1 Carry out dis-/assembly Corona unit on page 401.

2 Remove on one side the metal side cover plate (4 screws).
3 Remove the earth connection (1 screw).
4 Remove the metal side cover plate.
5 Remove 2 screws from the fan(s).
6 Mount the side cover plate.
7 Turn the unit.
8 Remove the other side cover plate.
9 Remove two screws from the fan(s).
10 Remove the fan(s).
11 Mount the fan(s) with two screws.
12 Remount the side cover plate.

13 Turn the unit.
14 Remove the other side cover plate.
15 Mount on the other side the fan(s).
16 Remount the side cover plate.
ed.5 02 Corona 403

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 be-
tween 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 sup-

plied 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.

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 superim-
posed.
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.

1 2 3 4 5 6
G2 X8 X11 22X5 02X1 02X3
+24V CORFAN1-B
1 5 15 28 1 1
GND
2 6 M CORFAN1
A 3
+24V
7 02M1
GND CORFAN1--
4 8 16 2 2 2
+24V
5 9 02X4
GND F3 CORFAN2-B
6 10 17 30 3 1
4A M CORFAN2
G3
+5V 02M2
1 1 CORFAN2--
GND 18 3 4 2
2 2
+5V 02X5
3 3 CORFAN3-B
GND 19 31 5 1
4 4
M CORFAN3
02M3
F4 CORFAN3--
22 4 6 2
4A
22PBA1 CPU I/O
B X13
+5V
X10
1 1
GND
2 2
+24V
3 3 02G1 CORSUP 02X9
GND
5 5
G1 G3
+24V CORPIN
X11 X7 13 29 1 HV
CORFAN GND 02E1
17 17 14 1 4
CORFANER G2 02X2
11 11 02X7
1
02X8
X6 X6
CONDRIINDIAG
27 27
2
02X6
02X10
3
X4
C 14
CORSUP
13 2
CORSUPER
15 14 3
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). 303
3 Check Printhead 305
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
Diagrams
1 Printhead 701
ed.5 04 Printhead
Diagnostics
1 Faults
PrintHeaD 04000 - 04999 code display
04101 PE: ~PHD temp. too high: PHDTEMPSE~

.
04-4-01 CONDRI PHDFAN Possible cause Remarks

PHDFAN OUTDIAG turning
ON OFF No PHDFAN blocked /

defect
ON No PHDFAN defect
Connection 24 V
DRIVER PBA ->
PHDFAN
Fuse F1 DRIVERS
PBA defect
Connection PHDFAN
-> DRIVERS PBA
Yes Obstruction / leakage
cooling channels print-
head
PHDPUMP defect
Air passage heat
exchanger blocked /
polluted
ed.5 04 Printhead 101

04501 MRE: ~PrintHeaD supply fail: (PHDSUPER)~
04-4-02 PHDSUPER Possible cause Remarks

PHDSUP
OFF OFF PHDSUP defect
Connection PHDSUPER ->
CPU_IO PBA
OFF disconnect CPU_IO PBA defect (PHDSU-
2201X11 PER)
ON ON PHDSUP defect
Connection CONSUPPLV
(400 V DC) -> PHDSUP
PHDSUP
Connection PHDSUPER ->
CPU_IO PBA

04901 SWAR: ~PHDTEMPSE open / short circuit~
04-9-01 R NTC = 0.1 - 300 Possible cause Remarks

PHDTEMPSE kOhm
ADC value > Yes PHDTEMPSE defect (short
808 circuit)
CPU_IO PBA defect (dis-
connect 2201X4)
DATA_RECEIVER PBA
defect (disconnect 0401X3)
ADC value < Yes PHDTEMPSE defect (open
160 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

04902 SWAR: ~PHD temp. too high: PHDTEMPSE~
04-4-01 CONDRI- PHD- Possible cause Remark

PHDFAN OUTDIAG FAN turn-
ing
ON OFF No PHDFAN blocked / defect
ON No PHDFAN defect
Connection 24 V
DRIVER PBA -> PHDFAN
Fuse F1 DRIVERS PBA
defect
Connection PHDFAN ->
DRIVERS PBA
Yes Obstruction / leakage cool-
ing channels printhead
PHDPUMP defect
Air passage heat exchanger
blocked / polluted

SDS
1 PrintHeaD
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

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
Output tests
04-4-01 04M2 PrintHeaD FAN Printhead fan

ON = printhead fan switched on
Hardware diagnoses:
CONDRIOUTDIAG
04-4-02 PrintHeaD SUP- Printhead supply

ply Disconnect 0401X1
ON = printhead supply switched on and fan
turning
On time 15 sec.
Hardware diagnoses:
PHDSUPER
Special tests

Functions 04 (printhead), 09 (original han-
dling), 10 (scanner) and 11 (image process-
ing) in warm condition

ing) 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

Info tests
04-9-01 04R1 ~PHD TEMPerature SEnsor (adc)~

Actual A/D value of the printhead tempera-
ture 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 pollu-
tion of the engine, select test 50

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 Select SDS test 43 and enter the value 930.

3 Select roll width A0 (36), unfolded and make 5 sheets.
4 Carry out SDS test 51 ~Testprint adjust PHD~.
(feed the sheet landscape).

(After 1 min. the sheet is fed in and a testprint is made.)
6 Specification: the background on the copy must be as follows:

area G no background
area H no background
area I no background
area J just visible background
area K background

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

2 Change the setting to a value e.g. 10 above the actual value.
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.

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 Select SDS test 43 and enter value 930 mm.

3 Select roll width A0 (34/36), unfolded and make 5 sheets.
4 Carry out SDS test 51 ~Testprint adjust PHD~.
(Feed the sheet landscape)

(After 1 min. the sheet is fed in and a testprint is made.)
6 Specification: the background on the copy must be as follows:

area G no background
area H no background
area I no background
area J no background
area K just visible background

Correction:
No background on the testprint in area K
2 Change the setting to a value e.g. 10 below the actual value.
Background on the testprint in area J

2 Change the setting to a value e.g. 10 above the actual value.

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.

3 Disconnect from the printhead connector 0401X1.
4 Disconnect from the developing unit connector 05X1 and the air supply tube..
0401X1 05X1
5 Open the developing unit.

6 Open the drawer of the cold process to the first stop.
7 Switch on the machine and switch off the environment light if possible.
8 Activate SDS test 04-4-02.
9 Place a sheet of paper in front of the printhead.
10 Check if the LEDs are switched on.

Check: 2
Test to check if all LEDs are switched off.
11 Close the developing unit.

12 Remount connector 05X1 and the air supply tube.
13 Close the drawer of the cold process and lock the printhead.
14 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 receiv-
ing material is leaving the machine.
Note: Do not touch this button earlier to prevent toner pollution.
18 Black bands on the print should appear.

Dis-/assemblies
1 Cold process drawer
Caution: Close the upper and lower paper roll drawers and the paper
sheet-feeding section if opened.

4 Disconnect all the connectors between the drawer of the cold process and the
engine.
0401X1
22X5
22X4
5 Unlock and open the drawer of the cold process unit as far as possible.
6 Loosen at the left side the drawer locking screws (2 screws).
7 Remove at the right side the drawer locking nuts (2 nuts).
8 Lift the drawer of the cold process from the rail and place the drawer on a flat
surface.

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:
- 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 print-
head 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 dia-
phragm, 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

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.

4 Disconnect at the left side connector 22X4.
5 Disconnect at the right side the connectors 22X5 and 0401X1.
6 Open the drawer of the cold process as far as possible.
7 Disconnect the connectors of the print head 0401X2, 2x power cables (1x
10mm, 1x 13mm) and ground cable.
power ground 0401X2 0401X1
22X5
8 Remove the cover of the cooling unit.

9 Find the two caps (inside the cooling unit).
10 Open the drawer of the cold process completely.
11 Put a towel underneath the tube pillar

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 Close the lower tube pillar with a cap.

17 Mount the lower tube in the clip.
18 Mount the U-shaped pipe in the tubes.
19 Remove carefully the printhead from drawer of the cold process and put the
unit on a table. Do not place on the diaphragm side.
20 Check if there is still liquid in the new printhead.
21 If yes: remove the caps and add the liquid into the bottle (put down the caps on
the cooling unit bottom).
22 If not: remove the caps and put down the caps on the cooling unit bottom).
23 Mount the new printhead in the drawer of the cold process.
24 Mount the tubes to the printhead.
25 Move the drawer of the cold process into the drum cleaning position.
26 Connect all connectors between engine and the drawer of the cold process.
27 Connect all connections to the printhead.
28 Switch on the engine.
29 Wait until the liquid level in the reservoir is stationary.
30 If the level is below the low indication, add liquid from the furnished bottle.
31 Place the funnel in a empty bottle.
32 Remove the caps of the replaced print head.

33 Empty the replaced printhead.
34 Mount back the caps to the replaced printhead.
35 Close the bottle.
36 Put the funnel and the caps in the cooling unit.
37 Mount the cooling unit cover.
38 Close the drawer of the cold process unit.
39 Mount the top front cover.
40 Carry out adjustment 1 see ~Testprint adjust PHD~ (every service visit) on
page 301.

3 Disassembly cooling unit
Caution: Close the upper and lower paper roll drawer and the paper sheet
Use liquid of furnished bottle to refill the system.

2 Open the front top cover.
4 Disconnect all the connectors between the drawer of the cold process and the
engine.
5 Open the drawer of the cold process as far as possible.
6 Disconnect on the left side the connector 04X1 from the cooling unit.
7 Remove the cover from the unit.
8 Remove the U-shaped pipe, 3 clips, 2 caps) from the unit bottom.
9 Put a towel underneath the tube pillar.
10 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 Mount the cap in the lower tube pillar.

15 Mount the lower tube in the clip.
16 Mount the U-shaped pipe in the tubes.
17 Remove the cooling unit (3 screws) and place on a table.
18 Install new cooling unit see Installation cooling unit on page 407.
19 Empty the replaced cooling unit see Removal old cooling liquid on page 408.
20 Prepare the replaced cooling unit for transport see Preparation cooling unit for
transport on page 408.

4 Installation cooling unit
1 Mount the new cooling unit to the drawer.

2 Put a towel underneath the tube pillar.
3 Remove the lower cap from the print head and mount the lower tube.
4 Remove the upper cap from the print head and mount the upper tube.
5 Remove the cap from the heat exchanger.
6 Mount the return tube to the heat exchanger.
7 Connect the connector 04X1 of the cooling unit.
8 Remove the return tube from the reservoir.
9 Put the funnel in the reservoir.
10 Add liquid to the maximum.
11 Put the return tube into the reservoir.
12 Close the drawer.

13 Connect all connectors.
15 Check if liquid returns into the reservoir.
16 Switch off the engine after the liquid level is stationary.
17 Add liquid if neccesairy.
18 Put all tools back into the cooling unit.
19 Mount the cover of the cooling unit.
20 Close the drawer of the cold process.
21 Lock the print head unit.

5 Removal old cooling liquid
1 The cooling unit is already removed from the engine.

2 Put the funnel in the bottle (used to fill the new unit).
3 Remove the tubes one by one from the clips and hold them above the bottle.
4 Empty the cooling unit completely.
6 Preparation cooling unit for transport

1 Put all loose parts into the cooling unit.
2 Mount the cover on the reservoir.
4 Mount the tubes into the clips.
5 Mount the U-shaped pipe into the tubes.
6 Mount the cover on the cooling unit.
7 Pack the cooling unit for transport.
7 Refilling liquid
feeding section if opened
Use de-mineralized water to refill the cooling unit if the level becomes too low.

2 Open the front top cover.
3 Remove front cover.
4 Open the drawer of the cold process to drum cleaning position.
5 Remove the cover from the cooling unit.
6 Remove the return tube from reservoir lid.
8 Add de-mineralized water to the indication max.

9 Put the return tube in the reservoir.
11 If the level is correct switch off the engine.
12 If the level is too low repeat the sequence.
13 Put funnel back in the unit.
14 Mount the unit cover.
8 Liquid pump
1 Carry out the points 1 up to 16 from Disassembly cooling unit on page 406.
2 Carry out Removal old cooling liquid on page 408.
3 Disconnect the pump connector.
4 Replace the pump.

5 Connect the lower pipe, (pump inlet) with the reservoir.
6 Connect the upper pipe, (pump outlet) through the lower unit hole with the
printhead.
7 Remove the return tube from the reservoir.
12 Check if liquid returns into the reservoir.
13 Switch off the engine after the liquid level is stationary.
14 Add liquid if necessary.
15 Put all tools back into the cooling unit.
18 Lock the printhead unit.

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 di-
rection 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:
printhead
cooling section
interface and supply

2 Printhead
The printhead consists of:
Drum SLA temp. sensor

heatsink
Cooling
chan-
nels
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)

Above the LEDs a glass plate is mounted to create a dust free area and to pre-
vent 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 spe-
cial 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.

Width direction framing is done in between 2 copies.
All LEDs of the printhead switch on and the total width of the drum is dis-
charged.
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

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 guar-
antee a constant light-output when the temperature of the heatsink changes.
If the temperature rises the light output will decrease and the temperature be-
comes lower.
The heatsink temperature depends on the environment temperature, the

number of LEDs switched on and the adjusted duty cycle.

Printhead (PHD)
PHD PHDTEMPSE 04PBA1

PHD data receiver
22X5
PHDFAN
PHD cooling unit 04G1

PHD power supply

1 2 3 4 5 6
G2 X8 F1 X11 22X5 04X1
+24V +24V
1 5 29 34 5
GND 4A
2 6 M PHDFAN
A 3
+24V
7 04M2
GND PHDFAN-B
4 8 30 11 6
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
X5
F4 +24V
7 1 2 1 2
4A
O6S1 15S1
B 22PBA1 CPU I/O 8
+24V-SW
X13 X10
+5V
1 1 X12
GND CONEMS2-B
2 2 12
+24V
3 3
GND
5 5 CONEMS2
+24V-SW
X6 X6 15
CONDRIINDIAG 22K2-2A
27 27
CONDRIOUTDIAG
28 28
X11 X7
PHDFAN
18 18
22PBA4 SSR
22Z2
X9 X8
L2 L2
6 1 6 6 8
N2
5 2 3 2 4
N2 22X010
4 3
N2S
1
L2S
4
X6 22X4
D 9
L2S
1 1
M PHDPUMP
1 04M1
N2S
12 3 3
2 2
22X006-4 22X005 04X5
22PBA5 DRIVERS 04PBA1 PHD DATA RECEIVER 11PBA2

X1 X3
X9 22X5 X2 SD_NEG8
+5V 1 1
1 25 1 SD_POS8
+5V 2 2
E 2
GND
24 2
3
SD_NEG7
3
3 23 3 SD_POS7
GND 4 4
4 22 4 SD_NEG6
5 5
SD_POS6
S1 6 6
SD_NEG5
7 7
SD_POS5
8 8
SD_NEG4
9 9
SWITCH
TEST
SD_POS4
10 10
SD_NEG3
11 11
SD_POS3
12 12
SD_NEG2
04G1 04E1 PHD 13 13
SD_POS2
22G1 CONSUPLV 14 14
PHD SUPPLY PRINTHEAD SD_NEG1
G4 22X4 G1 X4 15 15
BW PROCESSING
PHD + SD_POS1
1 4 1 16 16
F 2
PHD 400VDC -
5 2 17
GND
17
PHD+12VDC GND
3 6 3 18 18
PHDON-OFF CLOCK_NEG
4 7 4 19 19
G3 X2 CLOCK_POS
+4V 20 20
GND
21 21
GND
G4 X3 22 22
22PBA1 CPU I/O GND4V LOAD_NEG
23 23
LOAD_POS
X11 22X5 G2 24 24
PHDSUPER GND
5 18 1 04X6 25 25
GND GND
13 6 2 26 26
PHDSUP STB_NEG
4 17 3 27 27
STB_POS
28 28
29 29
04X8
30 30
G (MOD.9801-21)
31 31
32 32
TEST
33 33
BW
34 34
X3
+5VAN
1 CAP_0401X1
PHDTEMPSE -T
-T
04R1 PHDTEMPSE
2
X4 X2
+5VAN
H 16
PHDTEMPSE
20 5
17 21 6
ed.5 TSM Oc 9800 04 Printhead 701

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 402
3 Toner sensor (DEVTONSE) 403
1 General 501
Diagrams
1 Development 701
ed.5 05 Development
Diagnostics
1 Faults
DEVeloping 05000 - 05999 code display
05501 MRE: ~Speed DEVMO out of range~

Open the developing unit. Turn the magnet roller manually
Blocked: Sent back via Your cordination
Remarks: 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).
Logistics: 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
22-4-02 CONMOSUP Possible cause Remark

CONMOSUP switching (listen)
ON No DRIVERS PBA paper feeding motors
defect (CONMOSUP) also not functioning
ed.5 05 Development 101

05-6-05 CONDRI DEVMO Possible cause Remark
DEVMOPWM OUTDIAG turning
(100%)
OFF ON (discon- Yes DRIVERS PBA defect
nect 2205X5)
ON No DEVMO blocked /
defect
Connection DRIVERS
PBA -> DEVMO
OFF (discon- DRIVERS PBA defect
nect 2205X5)
Connection DRIVERS
PBA -> CPU_IO PBA
CPU_IO PBA defect
05-2-02 DEVMOSE Possible cause Remark

Continuously OFF/ON DEMOSE defect
when moving pulse
disc Pulse disc defect
Connection DEVMOSE -> CPU_IO PBA
CPU_IO PBA defect
05-2-01 Developing unit full Possible cause Remark

DEVTONSE and / or refill toner
icon continuously on
Continuously Yes DEVTONSE defect
OFF
Connection DEVTONSE
-> CPU_IO PBA
CPU_IO PBA defect

SDS
1 DEVeloping
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Input tests
05-2-01 05B2 DEVeloper Developing toner sensor

TONer SEnsor OFF = toner available
05-2-02 05B1 DEVeloper Developing motor sensor

MOtor SEnsor ON = sensor blocked by pulse disk
Special tests

dition

dition
05-6-05 05M1 DEVeloper ~DEVeloper MOtor (DEVMO)~

MOtor PWM Activate the developing motor at normal
speed or at 100% PWM signal
System tests

ments checking
52 ~Black mode~
Black copy with framing
55 ~DEV unit adjustment~

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 Switch off the engine

3 Remove the top front cover.
4 Disconnect the connector 05X1 on the right side.
5 Remove the air supply tube of the ASV probe at the left side.
6 Release the developing unit and pull it out.
7 Clean the edges, 30 mm (1), of the toner brush on the developing roller with
the vacuum cleaner: Turn the developing roller manually.
8 Put the developing unit back into the engine.
9 Make sure that you install the developing unit correctly against the drum cams
and lock the unit.
10 Connect the connector 05X1 and put the air supply tube back into position.
11 Close the front cover.
12 Close the top cover.
14 Select SDS test 43 and enter a length of 930 mm.
16 Select the roll width A0 (34/36), unfolded, 3 copies and push the start button.
17 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 feed-
ing.

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 Do dis-/assemblyDeveloping unit on page 401.
2 Measure the distance of the front position block on the left side.
3 Loosen at the left and right the unit position blocks (2 x Allen screws each).
4 Adjust the left front block to (x-y)/2 mm to the left or right and tighten.
5 Adjust the left rear block to the same position and tighten.
6 Move the rail at the right-hand side to the outside.
7 Move the developing unit into the engine.
8 Tighten the right rear position block.
9 Slide out the developing unit.
10 Tighten the right front position block.
11 Move the developing unit into the engine.
12 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.

Dis-/assemblies
1 Developing unit
Caution: Close the upper and lower paper roll drawers and the paper-sheet

2 Remove the top front cover.
05X1
3 Disconnect the connector 05X1 at the right side.

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
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.

3 Toner sensor (DEVTONSE)
Caution: Close the upper and lower paper roll drawer and the paper-sheet
1 Carry out dis-/assemblyDeveloping unit on page 401).

2 Remove the top cover of the developing unit.
3 Remove the toner at the sensor position
4 Disconnect connector from the sensor.
5 Remove the toner sensor DEVTONSE (2 screws).

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
develop-
ing roller
toner
supply
reservoir
toner
supply
mech-
anism
8 mag-
net
drum magnet DEVTONSE
poles

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
mecha-
nism
develop-
ing roller
toner toner supply

sensor 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 roll-
er. 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.

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 develop-

ing motor (DEVMO). The diameter of the developing roller 62.5 mm. The de-
veloping 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 devel-
oping 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 devel-
oping 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.

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 sec-
ond 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).

Developing unit (DEV)
DRUASV-
COMPSE DEVTONSE
PBA DEVMOSE
DEVMO

1 2 3 4 5 6
G2 X8 X5 05X1 05X3
+24V DEVMO+
1 5 9 5 2
GND
2 6 RL M DEVMO
A 3
+24V
7 05M1
GND DEVMO-
4 8 10 4 1
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F4
22PBA1 CPU I/O
4A
X13 X10
+5V
1 1
B 2
GND
2
+24V
3 3
GND
5 5
X6 X6
CONDRIINDIAG
27 27 F3 X11
CONDRIOUTDIAG +24V
28 28 9 10 1 DEVTONSE
4A
05B2
X11 X7
CONMOSUP GND
10 10 10 12 2
DEVMOPWM
1 1
X4
DEVTONSE
6 11 3
C
+5V
21 1 1 DEVMOSE
DEVMOSE
22 2 2 05B1
GND
23 3 3
05X001
9
22X003-1 05X002 DEVROLLER 05X003 RESTASVREF
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) 409
11 Rollerassys output guideplate 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

Diagnostics
1 Faults
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~

06-4-03 CTFFHE Possible Remark

CTFFHE radiates cause
OFF Yes SSR PBA Attention for switching on too long:
defect CTFFHETEMPERSW
ON CTFHETRIAC
defect
ed.5 06 Compact transfer transfuse 101

06102 PE: ~CTFFTEMPSE out of order~
06502 MRE: ~CTFFTEMPSE out of order~
06-4-01 CON- CTFTUBSO Possible cause Remark

CTFTUBSO DRI- switching
OUTDI (listen)
AG
OFF ON No 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 Remark

bration factor
> 40 Glass tube CTFFTEMPSE pol-
luted
CTFFTEMPSE defect
06-4-02 CONDRI- Possible cause Remark

CTFREFHE OUTDIAG
OFF ON Connection CTFREFHE ->
DRIVERS PBA
DRIVERS PBA defect
ON OFF Connection CTFREFHE ->
DRIVERS PBA
Connection 24 V DRIVERS
PBA -> CTFREFHE
CTFFTEMPSE defect

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 val-
ue which indicates the 1 Hz. Put your meter in most accurate range as possible.
06-6-06 Digital bar on Volt- Possible cause Remark

CTFPYRSE meter (DC) com-
check mutes between two
values
ON No Connection CTFPYRSE
-> CPU_IO PBA
CTFFTEMPSE defect
06-9-01 Rptc = 360 - Possible cause Remark

CTFREF-TE 510 Ohm

MPSE
ADC value Yes CTFREFTEMPSE open
>1016
CPU_IO PBA defect
ADC value < Yes CTFREFTEMPSE short circuit
48
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~

06-4-04 06-9-02 Possible Remark

CTFPCLEHE CTFCLEHE- cause
TEMPSE
OFF ADC value SSR PBA Attention: dont switch on too long
rising defect or CTFPCLEHETEMPERSW
switches off

06104 PE: ~CTFPCLEHETEMPSE short / open circuit~
06505 MRE: ~CTFPCLEHETEMPSE short / open circuit~
06-9-03 Rntc = Possible cause Remark

CTFPCLEHE- 0.6 - 700
TEMPSE kOhm
ADC value > Yes CTFPCLEHETEMPSE short
980 circuit
CPU_IO PBA defect discon-
nect 2201X3
ADC value < Yes CTFPTEMPSE open
16
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~


Number black
images fuser roller
900 black images End of life time fuser roller
cleaner
Counter has not been resetted
after last replacement

06106 PE: ~Pressure roller cleaner full~

Number black
images pressure
roller
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 Possible cause Remark

CTFPMOPWM turning
OFF Yes CTFPINV defect
ON Yes CPU_IO PBA defect
No Connection
L2 -> DRUFANINV
DRUFANINV
CTFPMO defect
Bearing pressure roller
blocked
CTFPINV defect
Hinges CTFPMO blocked
CTFPMO defect / blocked

CTFPMOSE
Pulse disc loose of CTF- Blockade motor shaft
PMO or MADMO and check that the
pulse disc cant rotate
Continuously OFF/ON CTFPMOSE defect
when turning pulse disc
Pulse disc defect
Connection CTFPMOSE ->
CPU_IO PBA
CPU_IO PBA defect

06-4-06 CONDRI- 2nd Possible cause Remark
CTFFSVA OUTDIAG step in
OFF ON Yes DRIVERS PBA defect

Connection CTFFSVA ->
DRIVERS PBA
06502 MRE: ~CTFFTEMPSE out of order~ on page 102

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 Remark

CTFFHE CTFFTEMPSE
rising WARM
SDS
ON No Connection SSR PBA ->
CTFFHETRIAC
Connection CTFFHETRIAC
-> CTFFHE
CTFFHETRIAC defect
SSR PBA defect
Broken heaters / Rctffhe1 = 5 Ohm
CTFFTEMPERSW defect Rctffhe2 = 10
Ohm
Circuit breaker off
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.~

06-4-04 06-9-02 Possible cause Remark
CTFPCLEHE CTFPCLE-
HETMPSE
rising
ON No Connection SSR PBA ->
CTFPCLEHE
SSR PBA defect
CTFPCLEHE / CTFPCLE- Rctfpclehe = 44
HETEMPERSW defect Ohm
Circuit breaker off
06508 MRE: ~Power-up: run CTFPMO not allowed~
06-4-06 CONDRI- 2nd trans- Possible cause Remark

CTFSFVA OUTDIAG fer step con-
tinuously on
OFF ON 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~

E

Copy output plate / CTFOUTSE polluted
New pressure roller cleaner is not cleaning Machine must be in stand-by for
correctly -> pressure roller polluted at least 30 min.

CTFOUTSE
Continuously CTFOUTSE defect
OFF
Connection CTFOUTSE -> CPU_IO PBA
CPU_IO PBA defect
06-4-06 CON- Transfuse Possible cause Remark

CTFSFVA DRI- step in
OUTDI
AG
ON OFF No Connection CTFSFVA ->
DRIVERS PBA
Connection 24 V DRIVERS
PBA -> CTFSFVA
DRIVERS PBA defect
ON No CTFSFVA defect
CTFSFVA
CTFSFCYLL/R
CTFSFCYLL/R defect
CTFCOMP defect
to be continued

continued
06-4-07 CONDRI- Transfer Possible cause Remark

CTFSPVA OUTDIAG pressure
step in
ON OFF No Connection CTFSPVA ->
DRIVERS PBA
Connection 24 V DRIV-
ERS PBA -> CTFSPVA
DRIVERS PBA defect
ON CTFSPVA defect
CTFSPVA
CTFSFCYLL/R
06-4-08 Pressure Possible cause Remark

CTFP- roller running
MOPWM
ON No Cardan clutch CTFPMO loose
23-4-01 Input roller pre- Possible cause Remark

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

Hinge cardan clutch CTFPMO blocking
to be continued

continued
When using the paper roll drawers:
12-4-02 CONDRI- Drive verti- Possible cause Remark

PRDSTRACL OUTDIAG cal trans-
port
DRIVERS PBA ->
PRDSTRACL
Connection
PRDSTRACL ->
DRIVERS PBA
DRIVERS PBA
defect
ON PRDSTRACL
defect

Mechanical defect U/L knife
Paper sealed on the roll core
When using the paper sheet feeder:
13-4-01 CONDRI- Rollers Possible cause Remark

PSFCL OUTDIAG PSF turn-
ing
ON OFF No Connection DRIVERS PBA
-> PSFCL
Connection PSFCL ->
DRIVERS PBA
DRIVERS PBA defect
ON PSFCL defect
to be continued

continued

PSFSO OUTDIAG
ON OFF Connection DRIVERS PBA -> PSFSO
Connection PSFSO -> DRIVERS PBA
DRIVERS PBA defect
ON PSFSO defect

Skewed feeding of sheets
One way bearing PSF defect
06702 ORE: ~CTFOUTSE too late free~

CTF output guiding plate exit pinch pol- Preventive maintenance
luted
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~

Possible use Remark
Exit plate CTFOUTSE polluted
Slipping wheel CTFTRANSE

CTFTRANSE
Continuously Connection CTFTRANSE -> CPU_IO PBA
ON or OFF
when moving CTFTRANSE defect
pulse disc
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

PTRBULSE
Continuously PTRBULSE defect
OFF
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~

Wheel / pulse disc CTFTRANSE lose
06902 SWAR: ~Fuse roller cleaner almost full~

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

Pressure roller cleaner > 300 black images Preventive maintenance

SDS
1 Compact Transfer transFuse

3
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Parameter test
06-1-01 ~CTFREFTEMPSE resistance low

(Ohm)~
value mentioned on sticker
06-1-02 ~CTFREFTEMPSE resistance high

(Ohm)~
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 CTF pressure roller motor sensor

-roller MOtor ON = sensor blocked by pulsdisk
SEnsor
06-2-02 06B2 CTF OUTput CTF output sensor

SEnsor ON = paper detected
06-2-03 06S1 CTF DOOR CTF door switch

SWitch ON = door open
06-2-04 06B3 CTF TRANport CTF transport sensor

SEnsor ON = sensor blocked by pulsdisk
06-2-05 06S2 CTF OUTput CTF output hood switch

HOod SWitch ON = heater unit open
202 TSM Oc 9800 SDS

Output tests
06-4-01 06Y4 CTF TUBe CTF tube solenoid

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
06-4-03 06E1 / 06E2A/B CTF Fuser-roller CTF fuser roller heater

HEater ON = fuser roller heater switched on
max. time 30 sec.
06-4-04 CTF Pres. roller CTF pressure roller cleaner heater

CLEaner HEater ON = pressure roller heater switched on

max. time 30 sec.
06-4-05 06Y2 CTF Set-up CTF set up transfer valve

Transfer VAlve ON = transfer pinch closed
Hardware diagnoses:
CONDRIOUTDIAG
max. time 30 sec.
06-4-06 06Y1 CTF Set-up Fuse CTF set up fuse valve

VAlve ON = fuse pinch closed
Hardware diagnoses:
CONDRIOUTDIAG
06-4-07 CTF Set-up CTF set-up pressure valve

Pressure VAlve selection high / low pinch pressure roller
ON = high pressure
06-4-08 06M2 CTF Pressure- CTF pressure roller motor pwm

roller MOtor ON = motor turn at maximum speed
PWM

Special tests

Functions 06 (CTF), 12 (paper roll drawers),
13 (paper sheet feeder), 14 (pre-heater), 23
(main drive) in warm condition

(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

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
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
06-9-03 CTFPCLEHE- ~CTFP CLeaner Heater TEMPSE (adc)~

TEMPSE (value A/D range 0 - 1023)
06-9-04 CTF NCTS ~CTF NCTS calibration factor~

Last calculated CTF NCTS calibration factor
(range 2 - 40)

06-9-05 CTFPRMO ~CTFPRMO speed (mm/min.)~

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:
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 fre-
quency)

feed
direction
700 +/- 0.5

Check:
2 Select A0 (34/36) roll width 75 gr/m2 paper.
3 Make 5 copies.
4 Measure on copy 3, 4 and 5 the length of the white stroke on the copy.
5 The average length of the white stroke must be 700 +/- 0.5 mm.

Correction:
2 Change the SDS value to average measured value x10 (e.g. 705.5 mm, enter
7055).
4 Select A0 (841 mm) roll width 75 gr/m2.
5 Make 3 copies.
6 Measure the length of the white stroke on the last copy.

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

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 mount-
ed.)
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 fix-
ation of toner on heavy tracing paper!!

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
cleaner.
4 Move the CTF fuser roller cleaner towards you.
5 Move the CTF fuser roller cleaner to the left.
6 Remove the CTF fuser roller cleaner.
7 Carry out dis-assembly see Cleaner rollers on page 405.
Installation of a new roller:

1 Clean the new roller with Oc K cleaner.
2 Mount the new roller.
3 Carry out the SDS test 06-8-03 (~Fuse roller cleaner (bl. im.)~).

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.

5 Carry out SDS test 06-7-01 (~Pressure roller torque adjustment~).
6 Carry out SDS test 06-8-01 (~Fuse roller (lm)~).
agreements.

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 Push the connectors through the frame.

4 Remove the CTF pressure roller heater unit.
5 Remove the securing brackets from the CTF pressure roller hole cleaner.
6 Remove the CTF pressure roller hole cleaner.
7 Carry out dis-/assembly see Cleaner rollers on page 405.
8 Also replace the pressure roller build up cleaner see CTF pressure roller build
up cleaner on page 404.
Installation of a new roller:.

3 Carry out SDS test 06-8-04 (~Pressure roll. hole cl. (lm.)~).
agreements.

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.

3 Carry out SDS test 06-8-05 (~Pressure roll. build up cl. (bl.im.)~).
agreements.

5 Cleaner rollers
plastic ring cleaning roller
plastic ring
clip
clip
metal metal
bush bush
shaft
1 Remove the cleaning roller.

2 Remove at both sides the clip.
3 Remove the metal bushes.
4 Remove the cleaning roller from the shaft.
5 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 clean-
er 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.

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.
Note: Be sure that you have 2 new bearings with the roller.
1 Mount the new bearings on the new roller.

3 Carry out SDS test 06-7-01 (~Pressure roller torque adjustment~ 5 minutes).
4 Carry out SDS test 06-8-02 (~Pressure roller (lm)~).
agreements.

7 CTFFHE1 (lower)
1 Do dis-/assembly CTF fuser roller cleaner on page 401.
2 Do dis-/assembly CTF fuser roller on page 402.
3 Carry out 01 Drum dis-/assembly The drum cleaning position on page 401.
4 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.

8 CTFFHE2 (upper)
2 Cut the cable ties.
3 Disconnect the connectors 06X2 and 06X1.
4 Remove the 2 fixing screws from the heater unit.
5 Remove the heater unit.
6 Remove the heater unit black cover.
7 Remove the two large head screws from the fuser heater.
8 Remove at the right two screws from the heater element.
9 Release the cable bundle with connector 06X1.
10 Release the ground wire.
11 Move the heater element to the left and lift it out.
9 Pressure roller cleaner heater

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.

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

1 CTF general
The function of the CTF unit is:
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 fuser roller

HEater2 cleaner
CTFFHE2
CTFFTEMP
SE
pressure
roller gap pressure
cleaner roller
CTFPres-
fuser roller
sure roller
CLEaner
HEater
pressure
CTFFuser
roller
HEater1
build
CTFFHE1
cleaner

2 Transfer steps
First transfer step
fuser roller
1st transfer
pressure
roller
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.

Second transfer step
2nd trans-
fer
pressure
roller
drum
fuser
pre-heater roller
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 ma-
terial 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 differ-
ence 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 oc-
cur 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

transport section.

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.
CTFFHE2
CTFFHETEM-
PERSW CTFTEMP
SE
CTFFHE1
CTFPCLEHE-
TEMPERSW
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 ele-
ments.
The temperature of the fuser roller is:
Stand-by: 102 C
During RUN: 100 C

CTFFTEMPSE also generates a error code if:
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 re-
sistance 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
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 ele-

ments off if the elements are not any more controlled by CTFPCLEHE-
TEMPSE.

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 radia-
tion.
For this reason the measurement is done between a reference object and the
real object (fuser roller).
Execution:
tube PTC and heater

fuser roller 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 meas-
urements.

The block diagram of the sensor is as follows:
CPU and I/O sensor unit
CTF CTFREF
REFHE HEB
refer-
24V
ence
0 dri
heater
ver
24
CTFREFTEMPSE refer-
A1 ence
GNDAN PTC
pyro
+10VAN
CTFPYRSE electri-
A1 cal
GNDAN detector
CTF CTFTUB
TUBSO SOB
0 24V
24 V dri solenoid
ver
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 py-
ro-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-elec-
trical detector the object temperature is calculated.

5 CTF roller positions
The CTF rollers can have four different positions:
Wait (machine switched off)

Stand-by /warming-up
Run / Toner dosing pressure roller cleaner
Toner dosing fuser roller cleaner
1 2 3 4 5 6 7 8 9
transfer open open open closed closed closed open open open
pinch
(CTF-
STVA)
Transfuse open closed closed closed open closed closed closed open
pinch
(CTFS-
FVA)
Pressure low low high high high high high low low
(CTF-
SPVA)
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:

The supplied pressure changes between low (3 bar) and high (5.6 bar) with
valve CTFSPVA.

Wait position (machine switched off):
In Wait position is no contact between the drum and the fuser roller and be-
tween the fuser roller and the pressure roller. Also all cleaning rollers are free
from the fuser roller and pressure roller.
CTFSFCYL
CTFSTCYL

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

Run
All pinches are closed at full pressure.
full pressure
full pres-
sure
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.

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

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 re-
move 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 sup-
plied 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

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 dos-
ing 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 Qual-
ity 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.

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.

1 Component location
CTF
CTFPMO
MADMO
CON-
STEPUP-
TRAFO
CTFINV
CTFSFVA
PBA
CTFSTVA for
CTF-
CTFSPVA PMO
CTF-
COMP
CTF-
HET-
TRIAC

CTFDOORSW CTFOUTHOSW CTFFTEMPSE
06PBA1 NCTEMP
SENS. +
CTFREFHE +
CTFTUBSO +
CTFREFTEMPSE
CTFFHE2 CTFFHETEMPERSW CTFFHE1
CTFPCLEHE 1 + 2
CTFPCLEHETEMPERSW

CONEMS3 CONCONEMS
CONEMS2
CONEMS1
22PBA4 SSR 22PBA3

CURSENS
CTFOUTSE
CTFTRANSE

1 2 3 4 5 6
G2 X8 F1
+24V
1 5
GND 4A
2 6
A 3
+24V
7
GND
4 8
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F4
22PBA1 CPU I/O 4A
X13 X10
+5V
1 1
GND
B 2
+24V
2
3 3
GND
5 5
X6 X6
CONDRIINDIAG
27 27
CONDRIOUTDIAG
28 28
CTFTUBSO
1 1
CTFREFHE
2 2
CTFSFVA
3 3
CTFSTVA
4 4
CTFSPVA
5 5
CTFFTEMPSE
06PBA1 NC TEMP.SENS
C X3 06X12 X1
+10VAN
1 1 1
GNDAN
3 3 2
CTFPYRSE
6 6 3
06X12 X11
+24V
7 1
CTFREFHE CTFREFHE-B
GNDAN 8 2
5 5
CTFREFTEMPSE
4 4 CTFREFTEMPSE
+T
-T
X12
+24V
9 10
CTFTUBSO
06Y4
CTFTUBSO-B
D 10 17
06S2
CTFOUTHOSW
CTFOUTHOSW
22 11 1 3
GND
21 12
X5
CTFDOORSW +24V
30 7
4
1
CTFDOORSW X12 06X7

CTFSFVA-B CTFSFVA
06S1 19 1
06Y1
PTRFRAMESW
3
2
GND +24V-SW
29 1 2 8
E 15S1 21
CTFSTVA-B
2
CTFSTVA
06Y2
X5 22X11
+5V
10 6 1 CTFPMOSE CTFSPVA-B CTFSPVA
GND 5 3
12 8 3 06B1 06Y3
CTFPMOSE
11 7 2
+24V-SW
06U1 CTFPINV 18 4
U2 U2 X11
CTFPMOPWM GND
13 2 1 20 CONEMS2-B
12
F1 5A
U4 06X5
E
U6 2 2 CTFPMO +24V-SW CONEMS2
T1 M 15
2 1 3 22K2-2A
T2 3
3 1 06M2
F 23U1 MADINV
22X006-1
4
T3
4 +24V
23
U6 U6 GND
-UzK +UzK 20
5 5 4 6
300VDC
+UzK
4 5
22PBA4 SSR
X1
30
28
22Z2
X9 X8
N2 N2
4 3 3 2 4
L2
5 2 6 6 8
G 6
L2 22X010
1
F2 3A L2-S
4
N2-S
22T1 CONSTEPUPTRAFO 1
X7
N2-S
1 2
208V X7 06X8
2 N2-S
220V L2-S 5 3
3 1 AUTO / OFF CTFCOMP
230/240V M
4 1 06M1
230V L2-SSU L2-SSU
5 3 4 1
H 2
22X008
CTF 1 (from engine 484)
ed.5 TSM Oc 9800 06 Compact transfer transfuse 701
1 2 3 4 5 6
G2 X8 F1
+24V
1 5
GND 4A
2 6
A 3
+24V
7
GND
4 8
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F4
22PBA1 CPU I/O 4A
X13 X10
+5V
1 1
GND
B 2
+24V
2
3 3
GND
5 5
X6 X6
CONDRIINDIAG
27 27
CONDRIOUTDIAG
28 28
CTFTUBSO
1 1
CTFREFHE
2 2
CTFSFVA
3 3
CTFSTVA
4 4
CTFSPVA
5 5
CTFFTEMPSE
06PBA1 NC TEMP.SENS
C X3 06X12 X1
+10VAN
1 1 1
GNDAN
3 3 2
CTFPYRSE
6 6 3
06X12 X11
+24V
7 1
CTFREFHE CTFREFHE-B
GNDAN 8 2
5 5
CTFREFTEMPSE
4 4 CTFREFTEMPSE
+T
-T
X12
+24V
9 10
CTFTUBSO
06Y4
CTFTUBSO-B
D 10 17
06S2
CTFOUTHOSW
CTFOUTHOSW
22 11 1 3
GND
21 12
X5
CTFDOORSW +24V
30 7
4
1
CTFDOORSW X12 06X7

CTFSFVA-B CTFSFVA
06S1 19 1
06Y1
PTRFRAMESW
3
2
GND +24V-SW
29 1 2 8
E 15S1 21
CTFSTVA-B
2
CTFSTVA
06Y2
X5 22X11
+5V
10 6 1 CTFPMOSE CTFSPVA-B CTFSPVA
GND 5 3
12 8 3 06B1 06Y3
CTFPMOSE
11 7 2
+24V-SW
06U1 CTFPINV 18 4
U1 U1 X11
CTFPMOPWM GND
13 3 2 20 CONEMS2-B
GND 12
4
RUNFWD
5 U2 06X5
E
U2 9 2 CTFPMO +24V-SW CONEMS2
T2 M 15
2 7 1 22K2-2A
T1 3
6 3 06M2
F 23U1 MADINV
22X006-1
8
T3
4 +24V
+UzK 23
U2 4 6 GND
-UzK 20
5 5
300VDC F1 5A
+UzK
4 5
22PBA4 SSR
X1
30
28
22Z2
X9 X8
N2 N2
4 3 3 2 4
L2
5 2 6 6 8
G 6
L2 22X010
1
F2 3A L2-S
4
N2-S
22T1 CONSTEPUPTRAFO 1
X7
N2-S
1 2
208V X7 06X8
2 N2-S
220V L2-S 5 3
3 1 AUTO / OFF CTFCOMP
230/240V M
4 1 06M1
230V L2-SSU L2-SSU
5 3 4 1
H 2
22X008
CTF 1 (up to engine 483)

1 2 3 4 5 6
G2 X8 F1
+24V
1 5
GND 4A
2 6
A 3
+24V
7
GND
4 8
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F4
22PBA1 CPU I/O 4A
X13 X10
+5V
1 1
GND
B 2
+24V
2
3 3
GND
5 5
X3 X5
CTFDOORSW +24V
30 7
4
1
CTFDOORSW
06S1
PTRFRAMESW
3
2
GND +24V-SW
29 1 2 8
15S1 X12
C 11
CONEMS1-B
X3 06X2
+5V +24V-SW CONEMS1
23 1 1 CTFOUTSE 16
GND 22K1-2A
25 2 3 06B2
CTFOUTSE
24 3 2
+5V CONEMS2-B
26 4 1 CTFTRANSE 12
GND
28 5 3 06B3
CTFTRANSE
27 6 2
+24V-SW CONEMS2
15
22K2-2A
06X4
+5VAN +24V
15 1 23
D -T
CTFPCLHETEMPSE
20
GND
06R1
CTFPCLEHETEMPSE
12 2
22PBA4 SSR
X9 X1
GND
8 8 X1
+5V
7 7 30
CONSSRINDIAG
9 9 28
CTFFHE
6 6
CTFPCLEHE X10
4 4
3
N1-SM CTFFHETTRIAC
06V1
22PBA3 CURSENS CTFHEG
1
X3 X1 X13 CTFHEC-2
CONEARTHCUR N1-SM 5
E 10
+5VAN
1
L1-SM
1
06X1 6
2 3 2 CTFHEC-2 CTFFHE2
4 1
X14 06E2A
L1-S
1
N1-S
22Z1 2 22X007-1 06X001 CTFFHETEMPERSW
2
X11 06S04
N1 N1-S
4 2 4 1
L1 L1-S 6
6 6 8 4 CTFFHE2
3
5 06E2B
06X9 6
CTFFHE1
1
L1-SM 06E1
2 2
22Z2
22X010
F X9
5 2 X8
N2 N2
4 3 3 2 4
L2 L2
6 1 6 6 8
L2-S
4
N2-S
1
X6 06X3
L2-S CTFPCLEHETEMPERSW
6 1
06S03
88
CTFPCLEHE1
G 06E3
88
CTFPCLEHEC CTFPCLEHE2
3 3
06E4
22X007-2 06X002
2
H
CTF 2
1 2 3 4 5 6
CTFSTCYL-R
first transfer step
A
0.3
)(
CTFSFCYL-R
fuser step
CTFSFCYL-L
fuser step
PREHEATING
)(
0.3
C CTFSTCYL-L
first transfer step
RED 2
BLUE 4
D CTFSFVA
fuser
RED 2
BLUE 4
CTFSTVA
LEVEL transfer
E CTFSPVA
high / low pressure
3 BAR
0.4 BAR 3 BAR
5.6 BAR
5.6 BAR
G
MOD. 29
TIMER
ON/OFF
H
PNEUMATICS
1 2 3 4 5 6
22PBA1 CPU I/O
A X5
+5V
22X11
10 6 1 CTFPMOSE
GND
12 8 3 06B1
CTFPMOSE
11 7 2 22PBA5 DRIVERS
06U1 CTFPINV
U1 U1 X11
CTFPMOPWM GND
13 3 2 20
4
5 U2 06X5
E
U2 9 2 CTFPMO
T1 M
2 7 3
T2 3
6 1 06M2
23U1 MADINV 22X006-1 T3
8 4
U6 4
-UzK
B 5 5
F1 5A
6
300VDC
+UzK
4 5
To 23 Main drive 703 (Up to engine 483)
22PBA1 CPU I/O
X5 22X11
+5V
10 6 1 CTFPMOSE
GND
C 12
CTFPMOSE
8 3 06B1
11 7 2 22PBA5 DRIVERS
06U1 CTFPINV
U2 U2 X11
CTFPMOPWM GND
13 2 1 20
F1 5A
U4 06X5
E
U6 2 2 CTFPMO
T1 M
2 1 3
T2 3
3 1 06M2
23U1 MADINV 22X006-1 T3
4 4
U6 U6
-UzK
5 5 4 6
300VDC
D 4
+UzK
5
To 23 Main drive 703

(From engine 484)
H
Modification 25

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
2 Corona supply 602
3 Discharge fans and Leds 602
Diagrams
1 Discharging 701
ed.5 07 Discharging
Diagnostics
1 Faults
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 Possible cause Remarks

DCHST- TASU- present
ASUP PER on
0701G1
OFF OFF Yes DCHSTASUP defect (continuously
on)
Connection DCHSTASUPER ->
CPU_IO PBA
discon- CPU I/O PBA defect
nect (DCHSTASUPER)
2201X4
ed.5 07 Discharging 101

07-6-05 DCHS- 24 V Possible cause Remarks
DCHST- TASU- present
ASUP PER on
0701G1
ON ON No 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 -> DCH-
STASUP
Connection DCHSTASUPER ->
CPU_IO PBA
DCHSTASUP defect (continuously
off)
Pin array disconnected / broken
Positioning DCH to drum incorrect
Polluted / humid isolation blocks

07901 SWAR: ~Failure DCHFAN (1-2): (DCHFANER)~
07-4-01 DCHFA Fans 24 V Possible cause Remarks

DCHFAN NER turning present on
(listen) all fans
OFF OFF No Yes Connection
DCHFANER ->
CPU_IO PBA
OFF (dis- CPU_IO PBA PBA
connect defect
2201X11
Yes DRIVERS PBA
defect
ON ON No No Connection 24 V
DRIVERS PBA ->
DCHFAN 1 or 2
Fuse F3 DRIVERS
PBA defect
Connection 24 V
other users on
DRIVERS PBA on
2205X11
DRIVERS PBA
defect
Yes Yes DCHFAN 1 or 2
defect

SDS
1 DisCHarge
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Input tests
07-2-01 07M1/07M2 DisCHarge FAN Discharge fan error

ERror ON = fans not turning
07-2-02 07G1 DisCHarge Discharge static supply error

STAtic SUPply ON = discharge supply switched off
ERror
Output tests
07-4-01 07M1 / 07M2 / DisCHarging Discharge fans and led

07E2 FAN / Dis- ON = 2 fans and discharge leds switched on.
CHarging LEDs ON = printhead fan switched on
Hardware diagnoses:
DCHFANER
Special tests

oper) and 07 (discharge) in warm condition

oper) 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.

Dis/-assemblies
1 Discharging unit
sheet feeding section if opened
1 Carry out function 04 dis-/assembly Cold process drawer on page 401).

2 Remove the discharge unit and place it slightly to the rear of the machine.
3 Disconnect the connectors 07X1, 0701G1 and the HV connector.
4 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
wiring side.
4 Move mounting block of the pin array 10 mm inwards.
5 Remove the old pin array.
6 Mount the new pin array at the wiring side.
7 Mount the other side at the mounting block.
8 Move the mounting block to the outside.
9 Mount the screws in the mounting block of the pin arrays.
10 Mount the clear plastic covers.
Note: Dispose of the old corona pin array in accordance with your local reg-
ulations to the local Oc organisation.

3 Fans
2 Remove the L-shaped cover above the LED bar (4 screws).
3 Remove the U-shaped cover of the unit (10 screws).
4 Disconnect the connectors.
5 Remove the fans.
Note: Mount the longest shoulder screws through the two cover plates.
4 Discharging LEDs
2 Remove the screws from each PBA.
3 Disconnect the connectors.
4 Remove the PBAs.
5 After mounting the new PBAs, cut the wires from the most right-hand connec-
tor.
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
DCH
pin array
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.

Air circulation
The air around the pin arrays is circulated by 2 fans at the bottom of the dis-
charge 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 car-
bon filter
fan (2x)

07E2/3/4
DCHLED
1, 2, 3
DCHFAN
1/2
07G1
DCH
STASUP

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.

1 2 3 4 5 6
G2 X8 F3 X11 22X5 07X1 07X4
+24V DCHFAN1-B
1 5 23 32 3 1
GND 4A
2 6 M DCHFAN1
A 3
+24V
7 07M1
GND DCHFAN1--
4 8 24 9 4 2
+24V
5 9 07X5
GND DCHFAN2-B
6 10 25 33 5 1
M DCHFAN2
G3
+5V 07M2
1 1 DCHFAN2--
GND 26 10 6 2
2 2
+5V
3 3
GND
4 4 07E2 DCHLED1 07E3 DCHLED2 07E4 DCHLED3
E1 E2 E1 E2 E1
+24V
F4 8 19 1 2 2 2 2 2
GND
4A 6 8 2 1 1 1 1 1
22PBA1 CPU I/O
B X13
+5V
X10
1 1
GND
2 2
+24V
3 3 07G1 DCHSTASUP
GND
5 5
G1 G3
+24V 07E1
X11 X7 27 12 1 HV
DCHFAN GND
20 20 28 5 4
DCHFANER G2 07X3
2 2 07X2
1
X6 X6
CONDRIINDIAG
27 27
2
3
X4
C 10
DCHSTASUP
15 2
DCHSTASUPER
11 16 3
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 SYNchro-
nisation 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
ed.5 09 Original handling

Diagrams
1 Original handling 701

Diagnostics
1 Faults
ORiGinal handling 09000 - 09999 code display
09701 ORE: ~Original too late at ORGSYNSE~

Toothed belt ORGMO loose / defect

ORGSYNSE
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 Original handling 101

09-4-01 CONMIX Original Possible cause Remark
ORGPPSO OUTDIAG stop open
CONSOLE CPU PBA ->
KEYPAD3 PBA
Connection KEYPAD3
PBA -> MIXED SUPPLY
Connection MIXED
SUPPLY -> ORGPPSO
MIXED SUPPLY defect
KEYPAD3 PBA defect
ON ORGPPSO blocked /
defect
Original stop blocked Adjust
stop

ORGISE
Continuously Connection CONSOLE_CPU PBA ->
ON KEYPAD3 PBA
Connection ORGISE -> KEYPAD3 PBA
ORGISE defect
Actuator defect
CONSOLE_CPU PBA defect
KEYPAD3 PBA defect

Toothed belt ORGMO Loose / defect

09702 ORE: ~ORGSYNSE too late free~
~

ORGSYNSE
ON KEYPAD3 PBA
Connection ORGSYNSE -> KEYPAD3 PBA
ORGSYNSE defect
Actuator defect
KEYPAD3 PBA defect
09703 ORE: ~Original too late at ORGPJSE~

E

Glass plate not properly mounted (not straight) Position correctly

ORGPJSE
OFF KEYPAD3 PBA
Connection ORGPJSE -> KEYPAD3 PBA
ORGPJSE defect
Actuator defect
KEYPAD3 PBA defect

09704 ORE: ~ORGPJSE too late free~

Glass plate not properly mounted (not straight) Position correctly

ORGPJSE
Continu- Connection CONSOLE_CPU PBA -> KEYPAD3 PBA
ously ON
Connection ORGPJSE -> KEYPAD3 PBA
ORGPJSE defect
Actuator defect
KEYPAD3 PBA defect

09705 ORE: ~Speed ORGMO out of range~

ORGMOSE
Continu- ORGMOSE defect
ously OFF /
ON when Pulse disc defect
turning
pulsdisc Connection CONSOLE_CPU PBA -> KEYPAD3 PBA
Connection ORGMOSE -> KEYPAD3 PBA
KEYPAD3 PBA defect
09-4-02 CONMIX ORGMO Possible cause Remark

ORGMOPWM OUTDIAG running

(100%)
OFF ON (dis- Yes MIXED SUPPLY defect
connect
1001G3)
CONSOLE_CPU PBA ->
KEYPAD3 PBA
Connection KEYPAD3
PBA ->MIXED SUPPLY
Connection MIXED SUP-
PLY -> 09X2 -> ORGMO
ORGMO blocked / defect
MIXED SUPPLY defect

SDS
1 ORiGinal handling
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

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
Input tests
09-2-01 09B2 ORiGinal Original present sensor

PREsent SEnsor ON = original detected
09-2-02 09B3 ORiGinal WIDth Original width sensor 1

SEnsor1 ON = original detected





202 TSM Oc 9800 SDS


09-2-09 09B7 ORiGinal SYN- Original synchronisation sensor

chro SEnsor ON = original detected
09-2-10 09B8 ORiGinal Paper Original paper jam sensor

Jam SEnsor ON = original detected
09-2-11 09S1 ORiGinal Original safety switch

SAFety SWitch ON = scanner closed
09-2-12 09B1 ORiGinal MOtor Original motor sensor

SEnsor ON = sensor blocked by pulse disc
09-2-13 09B9 ORiGinal Input Original input sensor

SEnsor ON = original detected
Output tests
09-4-01 09Y1 ORiGinal Paper Original paper present solenoid

Present SOle- ON = original pinch closed, original stop
noid opened
Hardware diagnoses:
CONMIXOUTDIAG
09-4-02 09M1 ORiGinal MOtor Original motor PWM

PWM ON = motor is activated at maximum PWM.
Hardware diagnoses:
CONMIXOUTDIAG
Special tests



Info tests
09-9-01 ~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 back-
ground 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 Measure the length of the service test original along the input arrow.
2 Feed the test original in input arrow direction and make a copy.
3 Carry out SDS test 09-9-01 and read out the measured original length.
4 Repeat 2 times step 2 up to 4.
5 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 meas-
ured length must be less than +/- 1.0 mm.
Correction:
Average length too long:

2 Decrease the indicated value with 10 x the calculated average difference.
Average length too short:

2 Increase the indicated value with 10 x the calculated average difference.

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:
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 origi-
nal 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 dif-
ference must be between -/+ 1 mm.
Correction:
Image length on copy too long:
2 Decrease the indicated value with 10
x the calculated average difference.
Image length on copy too short:

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.

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. image scanning starts too early
2 Select roll width A0 (36). start
3 Feed the test original in input arrow scanning
direction. Copy
4 Make 3 times 1 copy. max. 1 mm leading
5 Match the original with the copies. edge
6 Calculate the average difference be- original
tween the original leading edge and

the grey leading edge on the copies
7 Specification: The average difference
image scanning
between the original leading edge and starts too late
the grey leading edge on the copies Copy
must be within +/- 1.0 mm.
max. 1 mm leading
edge
Correction: original
When the average of the grey leading
edge on the copies is too long: start
scanning
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:
2 Decrease the indicated value with 10x

4 ~Scanning trailing edge correction~
Adjustment ~1 : 1 Image length correction scanner~ on page 302 and ~Scan-
ning 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:

2 Select roll width A0 (36).
3 Feed the test original in input arrow
image scanning
direction. stops too late
4 Make 3 times 1 copy.
5 Match the original with the copies.
6 Calculate the average difference be-
tween the original trailing edge and trailing
the grey trailing edge on the copies. edge
7 Specification: The average difference original
between the original trailing edge and max. 1 mm
the grey trailing edge on the copies Copy
must be within +/- 1.0 mm.
stop
Correction: scanning
When the average of the grey trailing
edge on the copies is too long:

2 Decrease the indicated value with 10x trailing
the average difference. edge
original max. 1 mm
When the average of the grey trailing image scanning
edge on the copies is too short:

stops too early Copy

2 Increase the indicated value with 10 x

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 bracket
ORGPPSO
screws mounting
screws
2.5 +/- 0.5 mm

8 +/- 0.2 mm
soft rollers
core
disc
original feed roller

6 Front / rear original delivery
Aim:
Make sure that the originals are deliv-
adjusting
ered. strip
Check:
1 Push the delivery flap to rear delivery.
2 Specification: The flap must be just
free from the delivery rollers.
Correction: delivery
Adjust with the adjusting strip. roller
7 ORGISE and ORGSYNSE (ORiGinal Input SEnsor and ORiG-

inal SYNchronisation SEnsor)
Aim:
Make sure that the originals are de- ORGISE
tected. ORG-
SYNSE 6 +/- 0.5
Check:
1 Open the scanner.
2 Specification: The top of the sensor
levers must be 6 +/- 0.5 mm above the
bottom plate.
Correction:
1 Remove Gauge roller on page 402. sensor bracket
2 Adjust with the sensor mounting
bracket.

8 ORGPJSE (ORiGinal Paper Jam SEnsor)
Aim:
Make sure that the originals are de-
ORGPJSE
tected. 7 -0.5 /+0
Check:
1 Open the scanner.
2 Specification: The top of the sensor
lever must be 7 -0.5 / +0 mm above
the bottom plate.
Correction:
sensor
1 Remove Gauge roller on page 402. brakket
2 Adjust with the sensor mounting
bracket.

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 ten- connector 09X2

sioner
drive belt
motor frame plate
3 Loosen the gear belt tensioner (2 screws).

4 Remove the drive belt.
5 Disconnect connector 09X2.
6 Loosen 4 screws from the motor frame plate.
8 Push the motor frame plate to the front of the scanner.
9 Remove the motor frame plate with the motor.
10 Tension the drive belt after assembling.

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 Remove the gauge roller drive belt at the right.

4 Remove the drive pulley at the right.
5 Remove the roller bearings at the left and right.
6 Open the scanner.
7 Remove the gauge roller.
8 If the gauge roller is replaced carry out the SDS test 10-7-01TL intensity ad-
just on page 277.
3 ORGISE / ORGPRESE (ORiGinal Input SEnsor, ORiGinal pa-

per 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

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
originals stop
ORGWIDSE 1...4 / 1...7 (ORGPPSO) exposure lamp
ORGPRESE
original
feed gauge roller
ORGSAFSW ORGPJSE
ORGISE ORGSYNSE

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 to-
wards 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, ORG-
PPSO 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.

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.

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 ORGWID- ORGWID- ORGWID- ORGWID-

PRESE SE 1 SE 2 SE 3 SE 4
DIN A4 1 0 0 0 0
A (8.5 or 9)
DIN A3 1 1 0 0 0
B (11 or 12)
DIN A2 1 * 1 0 0
C (17 or 18)
A1 1 * * 1 0
D (22 or 24)
DIN A0 1 * * * 1
E (34 )
914mm or 36 1 * * * 1
* = dont care
0 = not activated
1 = activated

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
original
side 48 ORGSYNSE
guide
ORGISE
104
242 319 470 572 624 777 880

A4 A3 A2 B2 A1 B1 A0 36
ORGPRESE 210 297 420 500 594 707 841 914
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 PRE- WID- WID- WID- WID- WID- WID- WID-

SE SE 1 SE 2 SE 3 SE 5 SE 4 SE 6 SE 7
DIN A4 1 0 0 0 0 0 0 0
A 8.5 - 9
DIN A3 1 1 0 0 0 0 0 0
B 11 - 12
DIN A2 1 * 1 0 0 0 0 0
C 17 - 18
B2 1 * * 1 0 0 0 0
D 22
DIN A1 1 * * * 1 0 0 0
D 24
B1 1 * * * * 1 0 0
DIN A0 1 * * * * * 1 0
E 34
914mm - 36 1 * * * * * * 1
* = dont care 0 = not activated 1 = activated

ORGPPSO
ORGSAFSW
ORGMO and
ORMOSE

ORGPJSE ORGWIDSE 1,2,3,5,4,6,7
EXP. LAMP
ORGSYNSE
ORGISE
ORGPRESE
ORGSAFSW
ORGPRESE
ORGWIDSE ORGPJSE
ORGSYNSE
ORGISE
Right side view

10G1
Mixed supply
22PBA8 22PBA2
Keypad3 Console CPU

1 2 3 4 5 6
22G1 CONSUPLV ENGINE 10G1 MIXED SUPPLY
G5 22X1 10X1 G1 G4
SCA+400VDC ORGPPSO-
1 L L 2 4
SCA-400VDC ORGPPSO
2 M M 3 09Y1
SCACONTROL ORGPPSO+
A 3 K K 4 3
09X2 09X1
N N 1 ORGMO-
22X004 2 2 2
10X13 M ORGMO
09M1
22PBA2 CONSOLE_CPU
1 1
X1 G2 F
+5V 22PBA8 KEYPAD3
1 1
TP1 +5V 3A X3 X3
2 2 ORGSAFSW +5V
+5V 2 5 3 1 ORGMOSE
3 3 ORGMOSE
+5V 4 4 2 09B1
2
4
4 4 GND
GND 3 5 3
5 7
TP0 GND ORGSAFSW
6 8
GND 09S1
7 9 +5V
GND 26 1 ORGPRESE
B
1
3
8 10 F ORGPRESE
+12V ORGMO+ GND 25 2 09B2
TP2 9 15 1 1 GND
+12V 3A 24 3
10 16
+12V
11 17
TP3 G3 X2
ORGMOPWM +5V
TP4 X3 3 3 23 1 ORGWIDSE1
+12V ORGPPSO ORGWIDSE1
1 18 4 4 22 2 09B3
GND CONMIXINDIAG GND
TP5 2 11 5 5 21 3
GND CONMIXOUTDIAG
3 12 6 6
+5V
20 1 ORGWIDSE2
X7 X1 ORGWIDSE2
+12V 19 2 09B4
1 1 GND
+5V 18 3
2 2
GND
3 3
GND
C 4
NRD3
4
17
+5V
1 ORGWIDSE3
5 5 ORGWIDSE3
NRD4 16 2 09B5
6 6 GND
NWR3 15 3
7 8
NWR4
8 9
BNRESET
9 20 +5V
KP3D0 14 1 ORGWIDSE4
10 12 ORGWIDSE
ORGWIDSE4
KP3D1 13 2 09B6
11 13 GND
KP3D2 12 3
12 14
KP3D3
13 15
KP3D4 09X3
14 16 +5V
KP3D5 11 6 1 ORGSYNSE
15 17 ORGSYNSE
KP3D6 10 5 3 09B7
16 18 GND
KP3D7 9 4 2
17 19
KP3A1
D 18
KP3A2
24
19 25 +5V
KP3A3 8 3 1 ORGPJSE
20 26 ORGPJSE
KP3A4 7 2 3 09B8
21 27 GND
INT3 6 1 2
22 28
+5V
24 30
+5V
29 9 1 ORGISE
ORGISE
28 8 3 09B9
GND
27 7 2
E MOD. 9810-03
+5V
32 1 ORGWIDESE5
ORGWIDESE5
31 3 09B10
GND
30 2
09X4
2
1
X2 1 ORGWIDESE6
ORGWIDESE6
8 3 09B11
2
F 1 ORGWIDESE7
ORGWIDESE7
9 3 09B12
2
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
Diagrams
1 Scanner 701
ed.5 10 Scanner
SDS
1 SCAnner
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS
ed.5 10 Scanner 201

Output tests
10-4-01 10E1 SCAnner LAmp Scan lamp puls width modulation

PWM ON = 100% PWM drive
Special tests


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.
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
Make sure that the exposure lamp
lamp holder
does not touch the scanhead. bracket
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

Dis-/assemblies
1 Scanner side covers

1 Open the scanner.
2 Remove the outside screw at the left and right underneath the scanner.
3 Close the scanner.
4 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 Remove he bracket and the cover of the lamp fitting.

5 Remove at the left or right side the lamp fitting.
6 Remove lamp to the left / right.
7 Slide the new lamp carefully to the opposite side.
8 Mount the lamp in the fitting.
9 Mount on the other side the lamp in the fitting and turn the lamp 90 .
10 Check adjustment Scanner exposure lamp on page 302.
11 Assemble all covers.
12 Carry out the SDS test 10-7-01TL intensity adjust on page 301.

4 Glass plate scan window
1 Carry out dis-/assembly Scanner side covers on page 401.
2 Open the scanner.
3 Remove the black plastic bearing holders from the upper output roller.
4 Push the output roller to the rear.
5 Remove on the left and right side the upper screw from the glass plate holder.
6 Loosen on the left and right side the other screw from the glass plate holder.
7 Push the glass plate to the rear and rotate the glass plate holder to the rear.
8 Remove the glass plate.
9 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 dia-
phragm of the glass plate is parallel with the gauge roller.
10 Carry out the SDS test 10-7-01TL intensity adjust on page 301.
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 ver-
sion of the scan head.
1 Open the scanner.

2 Remove the screws from the scanner side covers (1 screw each side).
3 Close the scanner.
4 Remove the scanner side covers and disconnect the ground wires.
5 Remove the lower rear cover of the scanner (1 screw at each side and 2 screws
at the rear side).
6 Lower the sensor plate by loosening 2 bolts and 1 taptite at both sides.
7 Turn the exposure lamp 90 (out of locking position).
8 Remove at both sides the lamp holder brackets (2 screws on each side).
9 Remove the exposure lamp.
10 Remove the two front covers besides the operating panel.
11 Remove the 4 operating panel mounting screws.
12 Swing the operating panel to the front.
13 Disconnect 10 connectors and 1 earth wire from the operating panel.
14 Remove the operating panel and place it on a flat surface with the display
downwards.
15 Open and remove the scanner centre top cover.
16 Remove at the right the centre top cover bracket (including the distance bolts).
17 Remove at the right the operating panel brackets (upper and lower).
18 EMC version: loosen the bundles from the rear plate assy (3 cable ties).
19 EMC version: remove the plate assy (4 x M4 taptite) to the rear.
20 Remove the EMC protection covers from CCD PBA connectors.
21 Disconnect the connectors from the CCD PBAs and move them to the rear.
22 Remove at the right side the T-form scan head mounting bracket with bush (3
screws).
23 Remove at the left side the 2 scan head mounting screws.
24 Lift out the scan head, first at the right side.
25 Mount the (new) scan head very carefully in the scanner frame.
26 EMC version: while replacing the scan head, keep it left before lowering.
27 EMC version: check if all lips of the sensor plate are in the correct position.
28 EMC version: replace the plate assy, lift the front side.
29 EMC version: check if all lips of the EMC scan head are in the correct posi-
tion.
30 EMC version: tighten the CCD bundles again to the plate assy with 3 cable
ties.
31 EMC version: check if at the right side (inside the top frame) the 3 plastic in-
sulated bundles are fixed together with a cable tie to prevent damage by the fan
blades.

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 mount-
ed without torsion.
38 Check if the bracket of the scan head touches the gauge roller.
39 Mount the lamp bracket at the right side.
40 Mount the exposure lamp.
41 Mount the left side lamp bracket.
42 Remount the sensor plate in the upper position.
43 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 compo-
nents.
44 Check adjustment Scanner exposure lamp on page 302.

45 Remount all covers.
46 Switch on the machine and carry out SDS test 41 (warm SDS).
47 Carry out the SDS test 10-7-01, TL intensity adjust on page 301.
48 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

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:
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)
glass plate with

diaphragm
original
direction
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 re-
flected 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 posi-
tioned 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 par-
tial mirror.
Each CCD PBA contains 5 IC blocks. The IC blocks are 0.25 mm shifted and
are positioned as follows:
..... ..... ..... 0.25

..... ..... mm
CCD1 CCD2 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

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 adjust-
able 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 infor-
mation 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 PROCESS-
ING PBA and to gain higher performance the data of the 3 ADC is multi-
plexed.
Interface
The interface function takes care of the transmission from and to the SCAN-
NER 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 pix-
el lines are corrected at an original speed of 25% (400% magnification).

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,
tolerances in the SLA (Self focusing Lens Array) and
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:
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:
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.

SCALA
10PBA1
Scanner
Proccessing
PBA
ed.5 10 Scanner 601

10G1
Mixed Supply

22PBA8 22PBA 2
Keypad 3 CONSOLE CPU
1
10 PBA 5 CCD 3
10 PBA 4 CCD 2
10 PBA 3 CCD 1
ed.5 10 Scanner 603

1 2 3 4 5 6
ENGINE
10PBA1 SCANNER PROC
11PBA1
X3 22X1 10X1 X4
DLINK1
2 k k 2
NDLINK1
A 3
GND
m m 3
4 e e 1
10G1 MIXED SUPPLY

22G1 CONSUPLV
G7 X2
G5 G1 +5V
SCA 1 1
1 L L 2 GND
SCA 400VDC 3 2
2 M M 3
SCACONTROL
3 K K 4
10PBA3 CCD1
BOTTOM FRAME G6 X2 X1 X6
N N 1 +5V
22X004 1 4 1 1
TOP COVER LEFT GND
10X13 4 5 .....
10X3 +12V
7 2 17
10X5 -12V
10 3 .....
TOP FRAME
TOP COVER RIGHT +18V
B 10X4 10X16
13 1 20
.....
CAPCCD1
FRAME BRACKET 36 34
10X15
10X14 10X6 10PBA4 CCD2
CONSOLE FRAME X2 X1 X7
+5V
2 4 1 1
GND
RIGHT COVER 5 5 .....
10X8 +12V
8 2 17
10X7_1 10X9 -12V
11 3 .....
+18V
FEED PLATE 14 1 20
BOTTOM FRAME
.....
LEFT DOOR CAPCCD2
10X10 36 34
10X7_2 10X11
C LEFT COVER
10PBA5 CCD3
X2 X1 X8
+5V
10X7_3 10X12 3 4 1 1
22PBA1 CPU I/O GND
6 5 .....
X14 REAR DOOR +12V
GND 9 2 17
10 H H -12V
CONCTS 12 3 .....
9 T T +18V
CONNCTS 15 1 20
8 S S
CONNRXD .....
7 V V CAPCCD3
CONRXD 36 34
6 U U
CONRTS
4 W W
CONNRTS
3 X X G5 LAMP-FLU 10E1
CONNTXD SCALA1
2 Y Y 1 1 2
CONTXD
1 Z Z
SCALA3
2 3 4
D SCALA4
3
SCALA2
22PBA2 CONSOLE_CPU 4
X10 FROM SCANNER 487
5
G4 10M1 10M2
6 +24V SCAFAN1 SCAFAN2
5 1 1
8
M 10M1 M 10M2
7
1 GND
6 2 2
2
4
3 22PBA8 KEYPAD3
11 X5 X1
GND
1 1
E X1
+5V
G2 F X3 2
SCASYNC_1
2
1 1 ORGSAFSW GND
TP1 +5V 3A 2 3 3
2 2 SCARECON_1
+5V 4 4
3 3 GND
+5V 5 5
4 4 SCADA0-1
GND 6 6
5 7 GND
TP0 GND 7 7
6 8 SCADA1-1
GND ORGSAFSW 8 8
7 9 GND
GND GND 9 9
8 10 F 4 3 1 SCADA2-1
+12V 10 10
TP2 9 15 09S1 GND
+12V 3A 11 11
10 16 SCADA3-1
+12V 12 12
11 17 GND
TP3 G3 X2 13 13
SCALAPWM SCADA4-1
TP4 X3 2 2 14 14
+12V CONMIXINDIAG GND
1 18 5 5 15 15
F TP5 2
GND
11 6
CONMIXOUTDIAG
6 16
SCADA5-1
16
GND GND
3 12 17 17
SCADA6-1
18 18
X7 X1 GND
+12V 19 19
1 1 SCADA7-1
+5V 20 20
2 2
GND
3 3 X4 X3
GND GND
4 4 1 1
NRD3 SCASYNC_1
5 5 2 2
NRD4 GND
6 6 3 3
NWR3 SCARECON_1
7 8 4 4
NWR4 GND
8 9 5 5
BNRESET SCADA0-2
9 20 6 6
KP3D0 GND
10 12 7 7
KP3D1 SCADA1-2
G 11
KP3D2
13 8
GND
8
12 14 9 9
KP3D3 SCADA2-2
13 15 10 10
KP3D4 GND
14 16 11 11
KP3D5 SCADA3-2
15 17 12 12
KP3D6 GND
16 18 13 13
KP3D7 SCADA4-2
17 19 14 14
KP3A1 GND
18 24 15 15
KP3A2 SCADA5-2
19 25 16 16
KP3A3 GND
20 26 17 17
KP3A4 SCADA6-2
21 27 18 18
H 22
INT3
28 19
GND
19
+5V SCADA7-2
24 30 20 20
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) 502
3 DOC / SET memory 506
4 B/W Processing PBA 508
Diagrams
1 Image processing 701
ed.5 11 Image processing

Diagnostics
1 Faults
Image Processing 11000 - 11999 code display
11501 MRE: ~Failure BW_PROC -> PHD connect~

.

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
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 Check with test 90
DOC / SET_MEM PBA defect

AND after IMP selftest 11-6-05, than

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~

Bad contact SIMM module on DOC / SET_MEM
PBA
Connection CPU_IO PBA -> DOC / SET_MEM If 11906 after power-up
PBA ONLY
11-6-05 OR together with 11904 / 11907 / 11908 after power-up, than

B/W_PROCESSING PBA

If 11906 occurs together with 11904 / 11907 after power-up OR IMP selftest
11-6-05, than


PBA
Connection DOC / SET_MEM PBA ->
B/W_PROCESSING PBA

B/W_PROCESSING PBA
11907 SWAR: ~MEM -> B/W PROC connection failure~

Connection DOC / SET_MEM PBA -> If ONLY 11907 after
B/W_PROCESSING PBA power-up and NOT after
IMP selftest 11-6-05
11-6-05 (and NOT after power-up) OR together with 11904 / 11906 / 11908
after power-up, than

B/W_PROCESSING PBA
If 11907 occurs together with 11904 / 11906 after power-up OR after IMP
selftest 11-6-05, than


PBA
B/W_PROCESSING PBA

Connection CPU_IO PBA -> B/W_PROCESSING
PBA
11908 SWAR: ~Failure Black / White PBA warning~


11-6-05 (and NOT after power-up) OR together with 11904 / 11906 / 11907
after power-up, than

B/W_PROCESSING PBA

PBA
DOC / SET_MEM PBA -> B/W_PROCESSING
PBA

PBA

11909 SWAR: ~CPU -> BW_PROC connection failure~

PBA
B/W_PROCESSING PBA defect If ONLY 11909 after
power-up and NOT after
11910 SWAR: ~CPU I/O-> DOC / SET MEM connection fail~

Connection CPU_IO PBA -> DOC / SET_MEM If ONLY 11910 after
PBA power-up and NOT after
11911 SWAR: ~CPU -> SCAN PROC connection fail.~

Connection KEYPAD_3 PBA ->
SCA_PROCESSING PBA
11912 SWAR: ~ SCAN PROC CPU connection fail~

Connection SCA_PROCESSING PBA ->
KEYPAD_3 PBA

SDS
1 IMage Processing
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Special tests


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 Remove the right hand side covers.

2 Disconnect the cable to the controller (to Host and to Printer) (if available).
3 Remove the controller (if available).
4 Remove the cover of the SET MEMORY PBA.
5 Uncouple and remove the faulty SIMM PBA.
6 Place the SIMM PNRAM module.
Note: Start with the first SIMM module always in slot D1.
7 Close the cover.

8 Connect the controller (if needed).
9 Check and adjust the configuration with SDS 90 ~Configuration~.
10 Carry out SDS test 11-6-05 (~Self test image processing~) to check the func-
tioning of the new SIMM.
Test if printer produces copies with wallpaper.
1 Set the configuration to the lowest possible memory (36 MB).

2 Place 2 SIMMs in the first 2 slots of the Setmem PBA.
3 Switch auto exposure on the operator panel off.
4 Set the manual exposure to -7.
5 Make a set of 2 times 3 copies with the Oc test original (portrait).
6 Check the copies for wallpaper.
7 If wallpaper appears then one or both SIMMs are corrupt and have to be re-
placed.
8 If not then the SIMMs are correct.
9 Repeat the test if necessary for each SIMM module.
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.

2 Upgrade DOC MEMORY -> SET MEMORY
1 Remove the right hand side covers.
2 Disconnect the cable to the controller (to Host and to Printer) (if available).
3 Remove the controller (if available).
4 Remove the cover of the DOC MEMORY PBA.
5 Remove the DOC MEMORY PBA.
6 Mount the SET MEMORY PBA.
7 Check the configuration of the new SET MEMORY.
8 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.

Questionnaire
NR Question Answer
1 What kind of machine and which configuration? 9700 / 9800 Configuration:
2 What is the version of the engine / scanner soft- Version:

ware?
3 What kind of controller and which version? EPC / FBBS / DRI Version:
4 What is the version of the PAS / Repro Desk soft- Version:

ware?
5 What kind of SIMMs are used in the controller Bank 1:

(brand name / size)? Bank 2:
Bank 3:
Bank 4:
Bank 5:
Bank 6:
Bank 7:
Bank 8:
6 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:
7 Is the wallpaper reproduceble? Yes / No (if yes, describe how it can

be reproduced as additional infor-
mation)
8 How often is wallpaper produced? Every hour / day / week / month /

year ...... wallpapers
9 Which part of the copy / print is wallpaper? Whole copy/print /

The middle of copy / print /
The end or start of the copy / print
10 Which percentage of the copy / print is wallpaper? About ...... percent
11 Is it a blank wallpaper? Yes / No
12 Was it during a copy-job or print-job? Copy-job / Print-job
13 Was this the only copy / print with wallpaper in the Yes / No
job?
14 Was it sort by set or sort by page? Sort by set / Sort by page

15 What kind of job was it? Matrix job / Normal job / Bypass
job / Interrupt job
16 Was the copy / print with wallpaper the first / last First / Last / In-between
or an in-between copy / print of the job?
17 Were there more copies / prints with wallpaper of There were ..... wallpapers of .....
the same original/file? originals / files
18 If there were more copies / prints with wallpaper Yes, No........................

of the same originals / files, are they all the same?
19 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
20 Was there a set-memory-full warning short before Yes / No

or after the wallpaper appeared?
21 What percentage of the set-memory was full? About ..... percent
22 Was there a controller reset or a TAXI board reset? No / Controller reset / TAXI board
reset
23 Was there an error or warning message (accessible No / Yes

with SDS)? The message was:

1 General
The aim of the image processing function is to create:
a good copy quality
a retention function
an editing function.
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 di-
azo, 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 de-
scribed.

2 Scanner Processing PBA (10 PBA1)
The digital information (14400 pixels /line from the CCDs) with 256 grey val-
ues from the scanner is the input for the image processing function.
The following functions are available on the Scanner Processing PBA:
Scanner buffer
Enlargement (width direction)
ABC (automatic background compensation)
Filtering
Error diffusion
Block diagram
CCD
infor-
mation Scanner ABC
Enlargement
from buffer / Automatic Back-
scan- invert blue ground Compen-
ner print sation
process
ing PBA
8b/ 1b/
pixel pixel
Filtering Error
diffusion
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 in-
verted.
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.

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 back-
ground 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 im-
proved. Weak lines or areas (low contrast) (see line A and area C) are empha-
sized 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 in-
volved.The output after filtering is 8bit/pixel.
input
optical
density
A B C
background level
1 scanline
output
optical
density
background level
1 scanline

Error diffusion
The error diffusion function converts the 8bit / pixel information (256 grey val-
ues) into a 1 bit / pixel information (black or white). It transforms the grey val-
ues between the min. and max. value into a black or a white pixel
Normal mode
Pixel +7 0 -7
White
Black
min. max. 255
value value
e.g 80 e.g.190
grey value
If the grey value is below the minimum value, it is converted into a black pix-
el on the copy.
If the grey value is above the maximum value, it is converted into a white pix-
el on the copy.
If the grey value is between the minimum and maximum value, the error dif-
fusion 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 maxi-
mum value. More or less grey values are changed into white pixels.

Dark mode
+7 -7
Pixel
White
Black
min. max. 255
value value
e.g 80 e.g 160
grey value
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 +7 -7
White
Black
min. max. 255
value value
e.g 50 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.

3 DOC / SET memory
The function of the DOC/SET memory is to eliminate the need to repeat feed-
ing 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:
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 com-
pression 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.

Capacity Set memory
Memory Capacity
36 Mbyte 5-15 A0 / E
Set Memory or 25 mixed sizes (A4..A0,7%density)
72 Mbyte 15-30 A0 / E
Set Memory or 50 mixed sizes(A4..A0,7% density)
108 Mbyte 30-45 A0 / E

Set memory or 75 mixed sizes(A4..A0,7%density)
144 Mbyte 45-60A0/E

Set memory or 100 mixed sizes(A4..A0,7%density)

4 B/W Processing PBA
The following editing functions take place on the B/W (Black and White)
PBA:
Reduction
Stamp
Error diffusion
Buffer
Editing function
B/W post processing
1 bit / pixel 8 bit / pixel 1bit / pixel
Reduction Stamp Error

diffusion
from
SET / DOC
MEMORY
PBA
Buffer Editing B/W post

functions processing
to
printhead
PBA
horizontal position
PHD

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 grey value
white 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 po-
sition) is done in this part of the image processing.

B/W post processing
The B/W post processing knows a certain amount of regular patterns and ad-
justs irregular patterns to these regular patterns.
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 output
A
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 process-
ing 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.

10PBA1
SCANNER
PROC.

11PBA2
B/W PROC PBA
11PBA1 DOC Memory

or
11PBA1 SET Memory

1 2 3 4 5 6
FROM ENGINE 484
11PBA1 DOCUM. MEMORY OR
22G1 CONSUPLV 11PBA5 RFI 11PBA1 SET MEMORY (OPTIONAL B860) 11PBA2 BW PROCESSING 04PBA1 PHD DATA RECEIVER
G3 X1 X2 X5 X5 X4 X3 X1
+5V +5V SD_NEG8
5 1 1 4 1 1 1 1
GND GND SD_POS8
A 6 2 2 3 2 2 2
SD_NEG7
2
3 3
RFI POWER 2x X1 X1 SD_POS7
GND 4 4
1 1 SD_NEG6
MEM_PAGE 5 5
2 2 SD_POS6
connector GND 6 6
3 3 SD_NEG5
for printer only MEM_LINE 7 7
10PBA1 SCANNER PROC 4 4 SD_POS5
GND 8 8
X4 10X1 22X1 X3 5 5 SD_NEG4
DLINK1 11D1 MEM_VALID 9 9
2 k k 2 6 6 SD_POS4
NDLINK1 EXT. MEMORY-1 GND 10 10
3 m m 3 7 7 SD_NEG3
GND RED_NEXT_PIX 11 11
1 e e 4 8 8 SD_POS3
GND 12 12
9 9 SD_NEG2
SPA_NEXT_LINE 13 13
11D2 10 10 SD_POS2
GND 14 14
EXT. MEMORY-2 11 11 SD_NEG1
RED_CLK40A 15 15
12 12 SD_POS1
B OPTIONAL B860
13
GND
13
16
GND
16
RED_CLK20A 17 17
20D1 CONTROLLER 14 14 GND
11D3 GND 18 18
D3 X4 15 15 CLOCK_NEG
GND EXT. MEMORY-3 RED_CLK40B 19 19
1 1 16 16 CLOCK_POS
DLINK2 GND 20 20
2 2 17 17 GND
NDLINK2 RED_CLK20B 21 21
4 3 18 18 GND
GND GND 22 22
5 4 11D4 19 19 LOAD_NEG
+5V MEM_DATAE0 23 23
8 5 EXT. MEMORY-4 20 20 LOAD_POS
RESET MEM_DATAE1 24 24
6 6 21 21 GND
MEM_DATAE2 25 25
22 22 GND
CAPDL GND 26 26
23 23 STB_NEG
11D5 MEM_DATAE3 27 27
24 24 STB_POS
EXT. MEMORY-5 MEM_DATAO0 28 28
D4 X14 25 25
GND GND 29 29
1 1 26 26
C 2
DLINK_OUT
2 27
MEM_DATAO1
27
30 30
NDLINK_OUT MEM_DATAO2 31 31
4 3 11D6 28 28
GND MEM_DATAO3 32 32
5 4 EXT. MEMORY-6 29 29 TEST
+5V GND 33 33
8 5 30 30 BW
RESET IMPRECON 34 34
6 6 31 31
GND
32 32
CAPUL 11D7 MEM_RING_SYNC CAP_0401X1
33 33
EXT. MEMORY-7 GND
34 34
MEM_RING_D0
35 35
MEM_RING_D1
36 36
MEM_RING_D2
11D8 37 37
MEM_RING_D3
EXT. MEMORY-8 38 38
GND
39 39
MEM_RING_D4
40 40
D 41
MEM_RING_D5
41
FROM ENGINE 484 MEM_RING_D6
42 42
MEM_RING_D7
22PBA1 CPU I/O 11PBA4 RFI 43 43
GND
X15 X1 X2 X2 44 44
GND
1 1 1 1
IMPSYNCO
2 2 2 2
IMPRECONO
3 3 3 3
IMPDA0O
4 4 4 4
IMPDA1O
5 5 5 5
RFI SIGNAL 15x
GND
6 6 6 6
IMPDA2O
7 7 7 7
IMPDA3O
8 8 8 8
GND
9 9 9 9
IMPDA4O
E 10
IMPDA5O
10 10 10
11 11 11 11
GND
12 12 12 12
IMPDA6O
13 13 13 13
IMPDA7O
14 14 14 14
GND
15 15 15 15
11PBA3 RFI
X16 X1 X2 X2
GND
1 1 1 1
IMPSYNCI
2 2 2 2
IMPRECONI
3 3 3 3
IMPDA0I
4 4 4 4
F 5
IMPDA1I
5 5 5
RFI SIGNAL 15x
GND
6 6 6 6
IMPDA2I
7 7 7 7
IMPDA3I
8 8 8 8
GND
9 9 9 9
IMPDA4I
10 10 10 10
IMPDA5I
11 11 11 11
GND
12 12 12 12
IMPDA6I
13 13 13 13
IMPDA7I
14 14 14 14
GND
15 15 15 15
ed.5 TSM Oc 9800 11 Image processing 701

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 SEn-
sor) 405
9 PRDUWIDSE (Paper Roll Drawer Upper WIDth SEnsors) 405
10 PRD(U/L)LEADSE (Paper Roll Drawer Upper/Lower LEADing edge SEn-
sor) 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
2 Roll feed 604
3 Feed motor control 605
Diagrams
1 Paper roll drawer lower 701
2 Paper roll drawer upper 702

Diagnostics
1 Faults
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 Remark

12-2-28 / 12-2-29
PRD(U/L)RUNSEn
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
-> DRIVERS PBA
CPU_IO PBA defect (disconnect 2201X7 or
2201X10)
12-2-05 / 12-2-06 Possible cause Remark

12-2-26 / 12-2-27
PRD(U/L)PRESEn
Continuously OFF PRD(U/L)PRESEn defect
Actuator defect
Connection PRD(U/L)PRESEn ->
-> CPU_IO 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~

12-2-22
PRD(U/L)KNIPOSSE
Continuously ON / PRD(U/L)KNIPOSSE defect
OFF when turning
pulse disc Pulse disc defect
Connection PRD(U/L)KNIPOSSEn ->
Connection PRD(U/L) DISTRIBU-
TION PBA -> CPU_IO PBA
Connection PRD(U/L) DISTRIBU-
TION PBA -> DRIVERS PBA
CPU_IO PBA defect

12-2-23
PRD(U/L)KNIMOSE
Continuously ON PRD(U/L)KNIMOSE defect
when turning pulse
Connection PRD(U/L)KNIMOSEn ->
PRD(U/L)DISTRIBUTION PBA
Connection PRD(U/L) DISTRIBUTION
PBA -> CPU_IO PBA
PBA -> DRIVERS PBA
CPU_IO PBA defect
(disconnect 2201X7 or 2201X10)

12-6-09 CONDRI- Knife Possible cause Remark
12-6-10 OUTDIAG turning
PRD(U/L)KNI (100%
MOnPWM
PWM)
ON OFF (dis- No DRIVERS PBA defect

(100% PWM) connect
2205X1) PRD(U/L)KNIMO defect /
mech. blocked
F2 DRIVERS PBA defect
ON (dis- Connection DRIVERS PBA
connect -> PRD(U/L) DISTRIBU-
2205X1) TION PBA
Connection PRD(U/L) DIS-
TRIBUTION PBA ->
PRD(U/L)KNIMO
12106, 12108 PE: ~Wrong knife position after cut~

12506, 12508 MRE: ~Wrong knife position after cut~


12-2-22
PRD(U/L)KNI
POSSE
Continuously PRD(U/L)KNIPOSSE defect
ON when
turning pulse Pulse disc defect
disc
Connection PRD(U/L)KNIPOSSEn -> PRD(U/L)
DISTRIBUTION PBA
Connection PRD(U/L) DISTRIBUTION PBA ->
CPU_IO PBA
DRIVERS PBA
CPU_IO PBA defect

12-2-23
PRD(U/L)
KNIMOSE
Continu- PRD(U/L)KNIMOSE defect
ously OFF
when turn- Pulse disc defect
ing pulse
disc Connection PRD(U/L)KNIMOSEn ->
CPU_IO PBA
DRIVERS PBA
CPU_IO PBA defect
12-6-09 CONDRI Knife Possible cause Remark

12-6-10 OUTDIAG turning
PRD(U/L) (100% PWM)
KNIMOPWM
OFF ON (discon- Yes DRIVERS PBA defect
nect 2205X1)
ON ON Mechanical defect knife
(100% PWM) stop

12109, 12110 PE: ~Direction failure: PRD(U/L)FEDMODIRDE~
12509, 12510 MRE: ~Direction failure: PRD(U/L)FEDMODIRDE~
~
12-6-05 PRD(U/L)FED PRD(U/L)FEDMO Possible cause Remark

12-6-06 MODIRDE turning in the
PRD(U/L) right
FEDMOn direction
Forward BACK- No DRIVERS PBA
normal WARD
speed
Backward FORWARD
normal
speed
Backward FORWARD Yes Connection
normal PRDU/LFED-
speed MODIRDE ->
CPU_IO PBA
FORWARD CPU_IO PBA
disconnect defect
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 Remark

12-6-06 OUTDIAG FEDMOn
PRD(U/L)FEDMOn (100% turning
PWM)
OFF ON 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

12511,12513 MRE: ~Time out length measure PRD(U/L)LENSE~

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~

12-2-25
PRD(U/L)LENSE
Continuously ON Wheel PRD(U/L)LENSE blocked
when turning pulse
Receiving material fixed on paper roll core
CPU_IO PBA defect
Continuously OFF Wheel PRD(U/L)LENSE blocked
when turning pulse
Receiving material fixed on paper roll core
Connection PRD(U/L)LENSE ->
-> CPU_IO PBA
-> DRIVERS PBA
CPU_IO PBA defect

12701, 12702, 12703, 12704 ORE: ~Sheet too late at PRD(U/L)LEADSE~


12-2-24
PRD(U/L)LEADSE
Continuously OFF PRD(U/L)LEADSE defect
Actuator defect
Connection PRD(U/L)LEADSE ->
PBA -> CPU_IO PBA
PBA -> DRIVERS PBA
CPU_IO PBA defect
12-6-05 CON- PRD(U/L) Possible cause Remark

12-6-06 DRI- FEDMOn
PRD(U/L)F OUTDI turning
EDMOn
AG
(100%)
ON ON No PRD(U/L)FEMOn mechanical
(100% blocked
PWM)
Friction clutch paper roll core
defect
PRD(U/L)FEDMOn defect
OFF DRIVERS PBA defect

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

continued
12-4-02 CONDRI Vertical trans- Possible cause Remark

PRD- OUT- port function-
STRACL DIAG ing when
loading paper
SERVICE
COPY MODE
ON PRDSTRACL defect
Connection DRIVERS PBA
Toothed belt PRDS defect
Toothed belt MADMO
loose / defect
12705, 12706, 12707, 12708 ORE: ~PRD(U/L)LEADSE too late free~

12-2-24
PRD(U/L)LEADSE
Continuously ON PRD(U/L)LEADSE defect
Actuator defect
CPU_IO PBA defect
23-4-01 Input roller Possible cause Remark

MADMO PREHE turning
ON No Pulley / one way bearing input
roller defect

Paper fixed on the paper roll core

12709, 12710, 12711, 12712 ORE: ~Speed PRD(U/L)FEDMOn too low~


12-6-08
PRD(U/L)FED
MOSE
Continuously PRD(U/L)FEDMOSEn defect
OFF when mov-
ing pulse disc Pulse disc defect
Connection PRD(U/L)FEDMOnSE ->
-> DRIVERS PBA
Connection DRIVERS PBA -> CPU_IO PBA
12-6-05 CON- PRD(U/L) Possible cause Remar

12-6-06 DRIOUT- FEDMOn k
PRD(U/L)FEDMOn DIAG turning
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

12713 ORE: ~Sheet too late at PRDSSYNSE~
~

PRDSSYNSE
Continuously Connection PRDSSYNSE -> CPU_IO PBA
OFF
PRDSSYNSE defect
Actuator defect
CPU_IO PBA defect
12-4-01 CON- Possible cause Remark

PRDUSAMP DRIOUT-
SO DIAG
OFF ON Connection DRIVERS PBA ->
PRDUSAMPSO
DRIVERS PBA defect
ON PRDUSAMPSO blocked / defect

12-4-02 CON- Vertical trans- Possible cause Remark

PRDS DRI- port function-
TRACL OUTDI ing when
loading paper
AG SERVICE
COPY MODE
ON PRDSTRACL defect
Connection DRIVERS PBA
Toothed belt MADMO lose
/ defect

12714 ORE: ~PRDSSYNSE too late free~
~

PRDSSYNSE
Continuously PRDSSYNSE defect
ON
Actuator defect
CPU_IO PBA defect (disconnect 2201X8)
12-4-02 CONDRI- Vertical Possible cause Remark

PRDSTRACL OUTDIAG transport
functioning
when load-
ing paper
SERVICE
COPY
MODE
ON 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

12715 ORE: ~Chip at PRDSSYNSE after error~
12716 ORE: ~PRDSSYNSE active during chipping~

PRDSSYNSE
Continuously PRDSSYNSE defect
ON
Actuator defect

PRDUSAMPSO OUTDIAG
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 Remark

PRDUWIDSE 1-9
Continuously ON PRDUWIDSEn defect
Actuator defect

12718, 12719 ORE: ~Chip: PRD(UL)LEADSE too late at / free~


PRD(U/L)
LEADSE
Continu- PRD(UL)LEADSE defect
ously ON
Actuator defect
Continu- PRD(UL)LEADSE defect
ously
OFF Actuator defect
Connection PRD(UL)LEADSE -> PRD(U/L) DISTRI-
BUTION PBA
Connection PRD(UL) DISTR. PBA -> CPU_IO PBA
Connection PRD(UL) DISTR. PBA -> DRIVERS PBA
CPU_IO PBA defect

Humid or bad receiving material
Environment temperature too low overnight Min. 17 C (62.6 F)

SDS
1 Paper Roll Drawers

Test nr Component Signal Description
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

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 12B17 PRDU KNIfe Paper roll drawer upper knife position sensor
POSition SEnsor ON = knife not in home position
12-2-02 12B1 PRDU KNIfe Paper roll drawer upper knife motor sensor
MOtor SEnsor ON = sensor blocked by pulse disc
12-2-03 12B2 PRDU LEAD- Paper roll drawer upper leading edge sensor
ing SEnsor ON = paper present
12-2-04 12B7 PRDU LENgth Paper roll drawer upper length sensor
12-2-05 12B3 PRDU PREsent Paper roll drawer upper present sensor 1
SEnsor 1 ON = no paper present roll 1
12-2-06 12B4 PRDU PREsent Paper roll drawer upper present sensor 2
12-2-07 12B5 PRDU RUN Paper roll drawer upper run sensor 1
SEnsor 1 ON = roll 1 not empty
12-2-08 12B6 PRDU RUN Paper roll drawer upper run sensor 2
12-2-09 12S1 PRDU OPen Paper roll drawer upper open switch
SWitch ON = upper drawer open
202 TSM Oc 9800 SDS

12-2-10 12B31 PRDU FEeD Paper roll drawer upper feed opposite sensor
OPposite SEnsor ON = unit positioned
12-2-11 12PBA2 PRDU FEeD Paper roll drawer upper feed switch 1
SWitch 1 ON = switch of roll 1 activated
12-2-12 12PBA2 PRDU FEeD Paper roll drawer upper feed switch 2
12-2-13 12B8 PRDU WIDth Paper roll drawer upper width sensor 1
SEnsor 1 ON = paper present
12-2-22 12B25 PRDL KNIfe Paper roll drawer lower knife position sensor
POSition SEnsor ON = knife not in home position
12-2-23 12B18 PRDL KNIfeM- Paper roll drawer lower knife motor sensor
Otor SEnsor ON = sensor blocked by pulse disc
12-2-24 12B19 PRDL LEAD- Paper roll drawer lower leading edge sensor
ing SEnsor ON = paper present
12-2-25 12B24 PRDL LENgth Paper roll drawer lower length sensor
12-2-26 12B20 PRDL PREsent Paper roll drawer lower present sensor 3

12-2-27 12B21 PRDL PREsent Paper roll drawer lower present sensor 4
12-2-28 12B22 PRDL RUN Paper roll drawer lower run sensor 3
12-2-29 12B23 PRDL RUN Paper roll drawer lower run sensor 4
12-2-30 12S2 PRDL OPen Paper roll drawer lower open switch
SWitch ON = lower drawer open
12-2-31 12B32 PRDL FEeD Paper roll drawer lower feed opposite sensor
OPposite SEnsor ON = unit positioned
12-2-32 12PBA3 PRDL FEeD Paper roll drawer lower feed switch 3
12-2-33 12PBA3 PRDL FEeD Paper roll drawer lower feed switch 4
12-2-34 12B26 PRDS SYNchro- Paper roll drawer support synchronisation

nisation SEnsor sensor
ON = paper present
Output tests
12-4-01 12Y1 PRDU SAMPle Paper roll drawer upper sample solenoid
SOlenoid ON = solenoid activated, paper fed in chip
tray
Hardware diagnoses:
CONDRIOUTDIAG
12-4-02 12Y2 PRDS TRAns- Paper roll drawer support transport clutch
port CLutch ON = clutch activated
Hardware diagnoses:
CONDRIOUTDIAG
204 TSM Oc 9800 SDS

Special tests


12-6-05 12M2/3 PRDU FEeding Paper roll drawer upper feed motor roll 1/2
MOtor 1/2
12-6-06 12M5/6 PRDL FEeding Paper roll drawer lower feed motor roll 3/4
MOtor 3/4
12-6-07 12B27/28 PRDU FEeding Paper roll drawer upper feed motor sensor
MOtor 1/2 SEn- roll 1/2
sor
12-6-08 12B29/30 PRDL FEeding Paper roll drawer lower feed motor sensor
MOtor 3/4 SEn- roll 3/4
sor
12-6-09 12M1 PRDU KNIfe - Paper roll drawer upper knife motor PWM
MOtor
12-6-10 12M4 PRDL KNIfe - Paper roll drawer lower knife motor PWM
MOtor
System tests

ments checking
50 ~Testprint mode~
52 ~Black mode~
53 ~1 to 1 mode~

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.

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 Loosen the bolt -A- at the non drive side

2 Move the knife 0.5 x X1 in arrow 1 direction.
3 Position the pin -B- at the drive side as shown.
4 Tighten the bolt -A-.
5 Repeat the check points 1 up to 6.
6 Continue with point 7.
If 0.5 x X2 is more than 1 mm:
1 Loosen the bolt -A- at the non drive side.

2 Move the knife 0.5 x X2 in arrow 2 direction.
3 Position the pin -B- at the drive side as shown.
4 Tighten the bolt -A-.

0 +0.3 / -0
1 2
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

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 cor-
rect.
Aim:
To be sure that the left and right leading edge margin is within 1 mm.
Check:
2 Select A0 (34/36) roll width 75 gr/m2 paper.
3 Make 5 copies from both paper roll drawers.
4 Measure on both 5th copy the distance K1 and K2.
5 Calculate the average value of K1 and K2.
6 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.

3 Move the adjustment plate in arrow 1 direction.
4 Tighten the bold and the taptites.
If the average of K1 and K2 is more than 1 mm and the average of K2 is more

than K1
1 Loosen the adjusting bold.

2 Loosen the taptites.
3 Move the adjustment plate in arrow 2 direction.
4 Tighten the bold and the taptites.
adjustment adjusting bolt

plate
1 2
taptites

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

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 Load roll 1 or 2 (the upper drawer) with an A2 (17/18) roll.
4 Select roll width A2 (17/18).
5 Make 3 copies.
6 Measure the length of the copies and calculate the average length.
7 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:

2 Decrease the indicated value with 10 x the average deviation.

4 ~Offset cutting length PRDL~
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 Load roll 3 or 4 (the lower drawer) with an A2 (17/18) roll.
4 Select roll width A2 (17/18).
5 Make 3 copies.
6 Measure the length of the copies and calculate the average length.
7 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:


5 ~PRD leading edge correction~
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:
2 Select A0 (34/36) roll width and make 3 copies.
6 Measure on all copies the framing margin in the centre of the leading edge.
7 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.


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
Correction:
1 Move the size label half of the differ-
ence to the left or right side and tight-
en the screw.
2 When using the inch sizes turn the
size label up side down and adjust the
label as described above.
detail X

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 Open the upper paper roll drawer.

2 Remove from the inside 1 screw of the right side cover.
3 Open the sheet feeder approx. 20 cm.
4 Remove the right side cover from the paper roll drawers.
5 Close the sheet feeder.
6 Open the paper drawer completely.
7 Remove the paper spindles.
8 Disconnect on the rear right side on the swing arm the connectors 1201X1 and
1201X2.
9 Release on the rear right side the ground wire.
10 Remove the mounting screw from the hinge lock.
11 Remove the black cover at the front right side from the drawer.
12 Loosen at the left and right side the locking bolts (M6), which secure the draw-
er to the rail.
13 Remove the carrier bar from inside the upper or lower drawer front.
14 Put the carrier bar in the square holes above the roll feed 1 or 3.
15 Turn the bar until it locates in the groove (no locking mechanism).
16 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.

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

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

2 Remove the carrier bar from inside drawer front.
3 Put the carrier bar in the rectangle holes above the roll feed 1 or 3.
4 Turn the bar until it locates in the groove.
5 Lift the drawer at the right side a few cm.
6 Push the right side rail to the inside.
7 Put the two carrier discs over the rail.
8 Remove at the right side the rear cover (1 screw inside and 1 screw outside of
the frame).
9 Remove at the right side the front cover (2 screws inside).
10 Release the drive belt on the right side.
11 Remove for motor roll 2 and 4 the gear from the lower feed roller.
12 Remove the bottom plate.
13 Disconnect the connector from the motor and motor sensor.
14 Remove the motor (4 screws).

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
mounting screws.
4 Remove the paper guide plate over length measurement sensor.
5 Push the knife unit to the rear.
6 Remove the knife unit straight up.
7 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 Open the paper roll drawer completely.
2 Remove the carrier bar in the front, inside one of the drawers.
3 Put the carrier bar in the square holes above the roll feed 1 or 3.
4 Turn the bar until the groove is located in the side frame (no locking position).
5 Lift the drawer at the left hand side a few cm.
6 Push the rail to the inside.
7 Put the two carrier discs over the rail.
8 Remove on the left side the knife drive gear.
9 Remove the bottom plate.
10 Disconnect the motor and the motor sensor connector.
11 Remove the four motor mounting screws.
12 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.

8 PRD(U/L)FEDOPSE (Paper Roll Drawer Upper/Lower FEed
OPosite SEnsor)
1 Remove paper spindle 1 or 3.
2 Upper drawer only; remove the chip tray.
3 Remove the opposite unit.
4 Remove the cover above the feed rollers.
5 Remove the sensor.
9 PRDUWIDSE (Paper Roll Drawer Upper WIDth SEnsors)

1 Pull out the sheet feeder approx. 20 cm.
2 Remove the right side cover over the paper roll drawers (1 screw inside).
3 Put the sheet feeder back into the machine.

5 Remove the bar with the width sensors from the upper drawer rear side .
6 Remove the width sensor.
10 PRD(U/L)LEADSE (Paper Roll Drawer Upper/Lower LEAD-

ing edge SEnsor)
1 Pull out the sheet feeder approx. 20 cm.
2 Remove the right side cover over the paper roll drawers.
3 Put the sheet feeder back into the machine.
5 Remove the leading edge sensor from the drawer rear side.

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

PREsent SEnsor)
2 Remove upper feed plate (green grip).
3 Remove on the right side the side front cover (2 screws inside frame).
4 Remove on the right side the small frame plate above the feed rollers.
5 Remove the plate above the feed rollers.
6 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.

1 General
The function of the two paper roll drawers is to feed copy material automati-
cally from one of the rolls and to cut the material to the correct length.
Both drawers comprise:
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
PRDU-
WIDSE
PRDU
LEAD
SE
opposite unit roll 3 roll 4

PRDL-
LEAD
SE
PRDL- cutter PRDLPRESE

LENSE

The following functions are used in the paper path from paper roll drawers to
preheating unit:
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 com-
prises 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.

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 in-
creases 2% in each next pinch in the paper path.
PRDULEADSE
roll 1 / 3 roll 2 / 4
PRDUWIDSE
PRDUSAMPSO
chip tray
2nd pinch PRDUPRESE

rollers
PRDURUNSE
PRDUFEDMO 1/2
rotating knife

3 Knife
The cutting system is driven by a motor. A rotating knife cuts the material dur-
ing transport. The PRDUKNIMOPWM (puls width modulation) signal con-
trols 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.

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 siz-
es. 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 Europe Sensors

width (mm) size 4 9 3 2 1 5 6 7 8

A3 297 A3 / A4 1 1
A2 420 A2 / A3 1 * 1
A1 594 A1 / A2 1 * * * * 1
A0 841 A0 / A1 1 * * * * * * 1
36 914 1 * * * * * * * 1
B2 500 B2 / B3 1 * * 1
B1 707 B1 / B2 1 * * * * * 1
1 = activated
* = dont care

American sizes
Roll USA Sensors

width (mm) size ANSI 4 9 3 2 1 5 6 7 8
11" 279 A/B 1
17" 432 B/C 1 * 1
22" 559 C/D 1 * * * 1
34" 864 D/E 1 * * * * * * 1
width (mm) size ARCH

12" 305 A/B 1 1
18" 457 B/C 1 * * 1
24" 610 C/D 1 * * * * 1
36" 914 D/E 1 * * * * * * * 1
30" 762 30" x 42" & 1 * * * * * 1

21" x 30"
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.

7 Paper through feed
The PRDSTRACL (transport clutch) activates the vertical transport in the pa-
per 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.
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 re-
traction 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

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.

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.

Paper Roll Drawer Upper (top view)
PRDUKNIMO 12PBA1
PRDULENSE PRDUKNIPOSSE
PRDUKNIMOSE PRDUFEDMO1
PRDUFEDMOSE1
PRDUFEDOPSE
PRDUFEDMOSE2
PRDUPRESE1
PRDUFEDMO2
PRDURUNSE1
PRDUOPSW
PRDUPRESE2
PRDUFEDSW1
PRDUFEDSW2
PRDURUNSE2

Paper Roll Drawer Lower (front view))
PRDLLEADSE
PRDLLEADSE
Paper Roll Drawer Lower (top view)

12PBA4
PRDLKNIMO
PRDLLENSE PRDLKNIPOSSE
PRDLKNIMOSE PRDLFEDMO3
PRDLFEDMOSE3
PRDLFEDOPSE
PRDLFEDMOSE4
PRDLPRESE3
PRDLFEDMO4
PRDLRUNSE3
PRDLOPSW
PRDLPRESE4
PRDLFEDSW3
PRDLFEDSW4
PRDLRUNSE4

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) de-
tects 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 PRDU-
LENSE (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 pa-

per is fed .
When PRDULEADSE detects the paper PRDUKNIMO (knife motor) switch-

es 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 po-
sition.

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 pa-
per until the common paper path is free.
The rolls 3 will be retracted approx 30 mm.
22PBA1 CPU I/O 22PBA5 DRIVERS
PRDLFEDMODIRDE PRDLFEDMO4-A1
M PRDLFEDMO4
+24V PRDLFEDMO4-A2
+5V 1 PRDLFEDMO4SE
GND 3
CONMOSUP 2
PRDLFEDMO4SE
GND
PRDLFEDMOPWM PRDLFEDMO3-A1
M PRDLFEDMO3
PRDLFEDMODIR PRDLFEDMO3-A2
+5V 1 PRDLFEDMO3SE
PRDLFEDMOSE GND 3
2
PRDLFEDMO3SE
+24V
PRDLFEDMOSEL
GND

1 2 3 4 5 6
22G1 CONSUPLV 22PBA5 DRIVERS 12PBA4 DISTRIBUTION 12PBA3 PRDLFEDSW
G3 X8 F2 X3 X1 X4 X1
+5V +5V PRDLFEDSW4
1 1 2 2 22 3
GND GND GND
2 2 4A 3 3 19 2
A 3
+5V
3 21
PRDLFEDSW3
1
GND
4 4
G2 X6
+24V +5V
1 5 14 1 PRDLFEDOPSE
GND GND
2 6 13 3 12B32
+24V PRDLFEDOPSE
3 7 15 2
GND
4 8
+24V +5V
5 9 8 1 PRDLKNIPOSSE
GND GND
6 10 7 3 12B25
PRDLKNIPOSSE
9 2
F4
22PBA1 CPU I/O X3
4A PRDLKNIMO-A1 PRDLKNIMO-A1
10 9 5 1
X13 X10
+5V M PRDLKNIMO
1 1
B 2
GND
2 PRDLKNIMO-A2 PRDLKNIMO-A2
12M4
+24V 9 10 6 2
3 3
GND RL X6
5 5 +5V
12 1 PRDLKNIMOSE
X6 X6 GND
CONDRIINDIAG F1 11 3 12B18
27 27 PRDLKNIMOSE
CONDRIOUTDIAG 4A 10 2
28 28
X3
PRDLFEDMO4-A1 PRDLFEDMO4-A1
12X2 X12 6 6 3 1
+24V
PRDSTRACL 1 2 M PRDLFEDMO4
12M6
12Y2 PRDLFEDMO4-A2 PRDLFEDMO4-A2
8 8 4 2
PRDSTRACL-B
2 1 X4
+5V
2 1 PRDLFEDMO4SE
X11 X7 GND
CONMOSUP 1 3 12B30
10 10 PRDLFEDMO4SE PRDLFEDMO4SE
C 12 12 3 2
X8 X5 +5V
GND +24V-LS 6 1 PRDLPRESE4
4 4 GND
5 2 12B21
PRDLPRESE4
4
2
4 3
PRDLOPSW +5V
PRDLRUNSE4
8 1
12S2 GND
7 3 12B23
PRDLRUNSE4
3
1
9 2
PFDLOPSW +24V
5 3 X3
PRDLFEDMO3-A1 PRDLFEDMO3-A1
5 5 1 1
M PRDLFEDMO3
X6 X6 12M5
PRDSTRACL PRDLFEDMO3-A2 PRDLFEDMO3-A2
9 9 7 7 2 2
PRDLKNIMOPWM
D 14
PRDLFEDMODIR
14 X4
+5V
22 22 14 1 PRDLFEDMO3SE
PRDLFEDMOPWM GND
19 19 13 3 12B29
PRDLFEDMODIRDE PRDLFEDMO3SE PRDLFEDMO3SE
17 17 11 11 11 2
PRDLFEDMOSE
30 30 X6
PRDLFEDMOSEL +24V +5V
24 24 RL 2 1 PRDLPRESE3
GND
1 2 12B20
PRDLPRESE3
3 3
X4
+5V
X10 X2 18 1 PRDLRUNSE3
PRDLFEDSW4 GND
10 4 17 3 12B22
PRDLFEDSW3 PRDLRUNSE3
9 3 20 2
PRDLFEDOPSE
11 22
PRDLKNIPOSSE +5V
2 11 16 1 PRDLLEADSE
E 1
PRDLKNIMOSE
12 15
GND
3 12B19
PRDLPRESE4 PRDLLEADSE
6 7 12 2
PRDLRUNSE4
8 9 X6
PRDLPRESE3 +5V
5 6 6 1 PRDLLENSE
PRDLRUNSE3 GND
7 8 5 3 12B24
PRDLLEADSE PRDLLENSE
3 5 4 2
PRDLLENSE
4 10
22X002-2 12X001
X8 22X12
+5V
1 5 1 PRDSSYNSE
GND
3 6 2 12B26
PRDSSYNSE
2 7 3
H
PAPER ROLL DRAWER LOWER
ed.5 TSM Oc 9800 12 Paper roll drawers 701
1 2 3 4 5 6
22G1 CONSUPLV 22PBA5 DRIVERS 12PBA1 DISTRIBUTION 12PBA2 PRDUFEDSW
G3 X8 F2 X1 X1 X4 X1
+5V +5V PRDUFEDSW2
1 1 2 2 22 3
GND GND GND
2 2 4A 3 3 19 2
A 3
+5V
3 21
PRDUFEDSW1
1
GND
4 4
G2 X6
+24V +5V
1 5 14 1 PRDUFEDOPSE
GND GND
2 6 13 3 12B31
+24V PRDUFEDOPSE
3 7 15 2
GND
4 8 X3
+24V PRDUSAMPSO-B PRDUSAMPSO-B
5 9 4 4 7 1
GND
6 10 PRDUSAMPSO
12Y1
F4 +24V-US +24V- US
22PBA1 CPU I/O 1 1 8 2
4A
X6
X13 X10 +5V
+5V 8 1 PRDUKNIPOSSE
1 1 GND
B 2
GND
2
7
PRDUKNIPOSSE
3 12B17
+24V 9 2
3 3 RL
GND X3
5 5 PRDUKNIMO-A1 PRDUKNIMO-A1
10 9 5 1
X6 X6 M PRDUKNIMO
CONDRIINDIAG
27 27 12M1
CONDRIOUTDIAG PRDUKNIMO-A2 PRDUKNIMO-A2
28 28 9 10 6 2
X6
+5V
12 1 PRDUKNIMOSE
GND
11 3 12B1
PRDUKNIMOSE-1
10 2
X3
PRDUFEDMO2-A1 PRDUFEDMO2-A1
6 6 3 1
M PRDUFEDMO2
C PRDUFEDMO2-A2 PRDUFEDMO2-A2
12M3
8 8 4 2
X4
X11 X7 +5V
CONMOSUP 2 1 PRDUFEDMO2SE
10 10 GND
1 3 12B30
PRDUFEDMOSE2 PRDUFEDMO2SE
12 12 3 2
+5V
X8 X5 6 1 PRDUPRESE2
GND +24V-US GND
6 2 5 2 12B21
PRDUPRESE2
4 3
4
2
+5V
PRDUOPSW 8 1 PRDURUNSE2
GND
12S1 7 3 12B6
PRDURUNSE2
9 2
3
1
D 7
PRDUOPSW +24V
1 PRDUFEDMO1-A1
X3
PRDUFEDMO1-A1
5 5 1 1
M PRDUFEDMO1
12M2
X6 X6 PRDUFEDMO1-A2 PRDUFEDMO1-A2
PRDUSAMPSO 7 7 2 2
25 25
PRDUKNIMOPWM X4
13 13 +5V
PRDUFEDMODIR 14 1 PRDUFEDMO1SE
21 21 GND
PRDUFEDMOPWM 13 3 12B27
20 20 PRDUFEDMOSE1 PRDUFEDMO1SE
PRDUFEDMODIRDE 11 11 11 2
11 11
PRDUFEDMOSE X6
29 29 +5V
PRDUFEDMOSEL +24V 2 1 PRDUPRESE1
23 23 RL GND
1 2 12B3
PRDUPRESE1
3 3
X4
E X7
PRDUFEDSW2
X2
18
+5V
1 PRDURUNSE1
19 4 GND
PRDUFEDSW1 17 3 12B5
18 3 PRDURUNSE1
PRDUFEDOPSE 20 2
20 22
PRDUKNIPOSSE
2 11 +5V
PRDUKNIMOSE 16 1 PRDULEADSE
1 12 GND
PRDUPRESE2 15 3 12B2
6 7 PRDULEADSE
PRDURUNSE2 12 2
8 9
PRDUPRESE1 X6
5 6 +5V
PRDURUNSE1 6 1 PRDULENSE
7 8 GND
PRDULEADSE 5 3 12B7
3 5 PRDULENSE
PRDULENSE 4 2
4 10
PRDUWIDSE1
9 13 X5
PRDUWIDSE2 +5V
10 14 2 1 PRDUWIDSE1
PRDUWIDSE3 GND
F 11
PRDUWIDSE4
15 1
PRDUWIDSE1
2 12B8
12 16 3 3
PRDUWIDSE5
13 17
PRDUWIDSE6 +5V
14 18 6 1 PRDUWIDSE2
PRDUWIDSE7 GND
15 19 5 2 12B9
PRDUWIDSE8 PRDUWIDSE2
16 20 4 3
PRDUWIDSE9
17 21
+5V
8 1 PRDUWIDSE3
GND
7 2 12B10
PRDUWIDSE3
9 3
X5
+5V
PRDUWIDSE7 1 20 +5V
PRDUWIDSE4
GND 12 1
12B14 2 19 GND
PRDUWIDSE7 11 2 12B11
3 21 PRDUWIDSE4
10 3
G PRDUWIDSE8 1
+5V
24 +5V
GND 14 1 PRDUWIDSE5
12B15 2 23 GND
3 22 PRDUWIDSE5
15 3
+5V
PRDUWIDSE9 1 26 +5V
PRDUWIDSE6
GND 18 1
12B16 2 25 GND
3 16 PRDUWIDSE6
16 3
H
22X002-1 12X002
PAPER ROLL DRAWER UPPER

ed.5 TSM Oc 9800 12 Paper roll drawers 702
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
Diagrams
1 Paper sheet feeding 701
ed.5 13 Paper sheet feeding

Diagnostics
1 Faults
Paper Sheet Feeding 13000 - 13999 code display
13701 ORE: ~Sheet too late at PSFSYNSE~

PSFSYNSE
Continuously Connection PSFSYNSE -> CPU_IO PBA
OFF
Actuator defect
PSFSYNSE defect
CPU_IO PBA defect

PSFPRESE
Continuously PSFPRESE defect
ON
Actuator defect
Continuously PSFPRESE defect
OFF
Actuator defect
Connection PSFPRESE -> 13X1 -> CPU_IO PBA
CPU_IO PBA defect
to be continued
ed.5 13 Paper sheet feeding 101

continued
13-4-02 CONDRI Possible cause Remark

PSFSO OUTDIAG
OFF ON Connection DRIVERS PBA -> PSFSO
ON (discon- DRIVERS PBA defect
nect 2201X8)
ON OFF DRIVERS PBA defect
ON Connection DRIVERS PBA -> 13X1 ->
PSFSO
PSFSO defect

PSFCL OUTDIAG
ON Connection DRIVERS PBA -> 13X1 ->
PSFCL
PSFCL defect
Sheet not inserted correctly
Toothed belt lose / defect
One way bearing defect
Toothed belt MADMO lose / defect

SDS
1 ~Paper Sheet Feeder

Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Parameter test
13-1-01 ~PSF leading edge correction mm/10~

Adjustment of leading edge margin
Input tests
13-2-01 13B1 PSF PREsent Paper sheet feeder present sensor

SEnsor ON = paper present
13-2-02 13B2 PSF SYNchroni- Paper sheet feeder synchronisation sensor

sation SEnsor On = paper present
13-2-03 PSF OPen Paper sheet feeder open switch

SWitch ON = sheet feeder closed
Output tests
13-4-01 13Y1 PSF CLutch Paper sheet feeder clutch

ON = clutch activated, sheet feeder driven
Hardware diagnoses:
CONDRIOUTDIAG
13-4-02 13Y2 PSF SOlenoid Paper sheet feeder solenoid

ON = solenoid activated, paper feed from
sheet feeder
Hardware diagnoses:
CONDRIOUTDIAG
Special tests


202 TSM Oc 9800 SDS

System tests

Setting of necessary sheet length for
adjustments checking
53 ~1 to 1 mode~

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 specifica-
tions.
Check:
3 Select roll width A0 (34/36) and make 3 copies.
5 Select manual sheet feeding.
6 Feed the sheets via the sheet feeding.
7 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

Correction:
If the average width is less than 2.5 mm.

If the average width is more than 3.5 mm.


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.

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 op-
erating 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.

PSFOPSW
PSFSYNSE
PSFPRESE
PSFCL PSFSO

1 2 3 4 5 6
G2 X8 F1 X12 13X1
+24V +24V
1 5 4 2
GND 4A
2 6 PSFCL
A 3
+24V
7 13Y1
GND PSFCL-B
4 8 3 1
+24V
5 9
GND +24V
6 10 8 4
PSFSO
G3
+5V 13Y2
1 1 PSFSO-B
GND 9 3
2 2
+5V
3 3
GND
4 4
F4
4A
B 22PBA1 CPU I/O

X13 X10
+5V
1 1
GND
2 2
+24V
3 3
GND
5 5
X6 X6
CONDRIINDIAG
27 27
CONDRIOUTDIAG
28 28
X11 X7
PSFCL
21 21
PSFSO
22 22
X4
C 9
PSFOPSW
12
GND
8 13
X8
+5V
8 5 1 PSFPRESE
GND
10 6 2 13B1
PSFPRESE
9 7 3
+5V
11 8 1 PSFSYNSE
GND
13 9 2 13B2
PSFSYNSE
12 10 3
11
D 22X003-2 13X001
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
Diagrams
1 Preheating 701
2 Pneumatics 702
ed.5 14 Preheating
Diagnostics
1 Faults
PREheating 14000 - 14999 code display
14101 PE: ~Temp PREHEating too high: PRETEMPSE~

~
14-4-01 14-9-01 Possible cause Remarks

PREHE PRETEMPSE
(NTC)
Off Rising SSR PBA defect Attention for switching on
too long PREHETEM-
PERSW
PREHETRIAC
14102 PE: ~PRETEMPSE short / open circuit~

14501 MRE: ~PRETEMPSE short / open circuit~
14-9-01 Rntc = 3 - 350 Possible cause Remarks

PRETEMPSE kOhm
ADC value > 672 No PRETEMPSE defect
(short circuit)
Yes CPU_IO PBA defect
(disconnect 2201X5)
ADC value < 16 No PRETEMPSE defect (open)
Connection PRETEMPSE ->
CPU_IO PBA
Yes Connection + 5VAN signal of
2201X3, X4, X5 (short circuit
to earth)
CPU_IO PBA defect
ed.5 14 Preheating 101

14502 MRE: ~Temp PREHEating too low: PRETEMPSE~
14503 MRE: ~Warming up PREHEating > 30 min.~
14-4-01 14-9-01 Possible cause Remarks

PREHE PRETEMPSE
(NTC) rising
ON dur- No Connection SSR PBA ->
ing at PREHETRIAC
least 30
sec. Connection PREHETRIAC ->
PREHE
PREHETRIAC defect
SSR PBA defect
PREHE1, 2 and 3 defect R PREHE = 17
Ohm
PREHE / PREHETEMPERSW
defect / defect
Circuit breaker off
Mains voltage off (L3)
Yes Leakage preheater
PREHE1, 2 and 3 defect R PREHE = 17
Ohm

SDS
1 PREheater
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Output tests
14-4-01 14E1/2/3 PREheater Preheater heater 1/2/3

HEater ON = heater switched on
14-4-02 14Y1 PREheater Preheater transport brake

Transport BRake ON = brake active
Data 0 hardware diagnoses:
CONDRIOUTDIAG
Special tests


Consumable tests
14-8-01 ~Paper guide cloth (lm)~

Length counter
(range 0 - 99999999 m, norm 200000 m)
Info tests~
14-9-01 14R1 PREheater ~PREheating TEMPerature SEnsor
TEMP SEnsor (adc)~
Actual A/D value of the preheater tempera-
ture 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 Loosen at the left side the screws of the adjusting bracket.
2 Move the adjusting bracket upwards until it just touches the pulley strip.
4 Switch on the machine for 1 minute.
5 Check the adjustment again.
drive belt
spring
screws
pulley strip
adjusting
bracket

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~.

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.

10 Remove the securing brackets from the pressure roller gap cleaner.
securing
brackets
11 Remove the pressure roller gap cleaner.

12 Release and open the preheating unit.
14 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.
15 Lift out the pressure roller build cleaner.
16 Close the pressure roller with guide plate.
18 Push the 2nd step cylinder shaft upwards and push the small yokes (supports
from the pressure roller hole cleaner) to the inside.
19 Remove the screws and loosen on the left and right the 2nd step shaft from the
2nd step cylinder.
20 Remove the 2nd step cylinders from the 2nd step shaft.
21 Remove at the right and left side the brackets from the 2nd step shaft.

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
from the preheater liquid hose (mark the position of the hose).
26 Close the air supply main tap on the compressor.
27 Remove the brass caps from the 2nd step cylinders.
28 Disconnect the preheater liquid hose and close both sides with the brass caps.
29 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.

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 preheat-
ing 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.
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.

3 Silicon rollers
1 Carry out dis-/assembly Preheating unit on page 401.
2 Remove the preheating drive belt.
3 Remove one of the gears of the drive belt.
4 Remove the roller mounting plate.

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

2 Preheating
PRETEMPSE
Preheater roller /
brake (PRETBR)
Preheating
section
Preheater
elements
PREHE1, 2, 3
Preheater guide
cloth
PREHETEM-
PERSW
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 alumini-
um 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 Propyl-
ene Glucol)). The MPG is added to the water to prevent freezing .
The preheater section itself is completely filled with 5 litres liquid. It is con-
nected via a hose with an expansion reservoir which contains 2 litres. The res-
ervoir 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

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 be-
comes too high the resetable safety switch PREHETEMPERSW will switch of
the heating elements.
preheater unit
liquid reservoir
level indication
3 bar reduction
0.4 bar reduc- valve
tion valve and
safety blow off
valve

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 pre-
heater transport brake (PRETBR), mounted on the preheater roller, is ener-
gized. 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.

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
PREHETEM-
PERSW

PRETBR
3 bar
reduc-
tion
valve
com-
pressor
liquid
reservoir
0.4 bar
reduc-
tion
PREHE-
valve
TRIAC

1 2 3 4 5 6
G2 X8 F1
+24V
1 5
GND 4A
2 6
A 3
+24V
7
GND
4 8
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F4
22PBA1 CPU I/O 4A
X13 X10
+5V
1 1
GND
B 2
+24V
2
3 3
GND
5 5 X5 22X11 14X3
X6 X6 5 1 1
CONDRIINDIAG PRETBR
27 27
CONDRIOUTDIAG 14Y1
28 28
PRETBR-D0
6 6 6 2 2
X5
+24V
7
C CTFDOORSW PTRFRAMESW
+24V-SW
1 2 1 2 8
06S1 15S1
X12
CONEMS3-B
14
CONEMS3 +24V-SW
13
22K3-2A
+24V
23
GND
20
D X5 14X2
+5VAN
4 1
-T PRETEMPSE
-T
14R1
22PBA4 SSR
PRETEMPSE X1 X12
5 2
30 5
N3-S PREHETRIAC
14V1
28 PREHEG
6
X9 PREHEC-2
CONSSRINDIAG 4
9 9
PREHE 14X1 52
1 1 PREHEC-2 PREHE1
3 1
14E1
52
22Z3 PREHE2
X11 14E2
N3 N3-S
E 4
L3
2 4
L3-S
6
52
6 6 8 3 PREHE3
5 14E3
22X010 PRETEMPERSW
L3-S 14S1
1 3
22X007-3 14X001
2
ed.5 TSM Oc 9800 14 Preheating 701

1 2 3 4 5 6
CTFSTCYL-R
first transfer step
A
0.3
)(
CTFSFCYL-R
fuser step
CTFSFCYL-L
fuser step
PREHEATING
)(
0.3
C CTFSTCYL-L
first transfer step
RED 2
BLUE 4
D CTFSFVA
fuser
RED 2
BLUE 4
CTFSTVA
LEVEL transfer
E CTFSPVA
high / low pressure
3 BAR
0.4 BAR 3 BAR
5.6 BAR
5.6 BAR
G
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
Diagrams
1 Paper transport without folder 701
2 Paper transport with folder 702
ed.5 15 Paper transport

Diagnostics
1 Faults
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~

PTRTRAISE1
Continuously Connection PTRTRAISE1 -> SENSOR DISTRIBU-
OFF TION 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~

PTRTRAISE1
ON TION PBA
IO INTERFACE PBA
Actuator defect
PTRTRAISE1 defect
CPU_IO PBA defect
15703 ORE: ~Paper too late at PTRTRAISE3~

~

PTRTRAISE3
OFF TION PBA
IO INTERFACE PBA
Actuator defect
PTRTRAISE3 defect
CPU_IO PBA defect
15-4-01 CONFOL1 Possible cause Remark

PTRUFOSO OUTDIAG
OFF ON POWER IO PBA defect
OFF PTRUFOSO defect / blocked

15704 ORE: ~PTRTRAISE3 too late free~
~

PTRTRAISE3
ON TION 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 Possible cause Remark

FOL1INMO OUTDIAG turning
(PTRMO) (100% PWM)
OFF ON (discon- Yes POWER IO PBA defect

nect 1502X3)
ON No PTRMO defect / blocked
(100%
PWM) 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)
OFF (discon- No POWER_IO PBA defect
nect 1502X3)

15706 ORE: ~Paper too late at PTRUFOSE~

PTRUFOSE
Continuously Connection PTRUFOSE -> SENSOR DISTRIBU-
OFF TION 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

PTRUFOSO OUTDIAG
ON OFF POWER_IO PBA defect
ON Connection POWER_IO PBA ->
18X4 -> PTRUFOSO
PTRUFOSO defect

15707 ORE: ~PTRUFOSE too late free~

PTRUFOSE
ON TION PBA
IO INTERFACE PBA
PBA
Actuator defect
PTRUFOSE defect
CPU_IO PBA defect
15901 SWAR: ~Start run: PTRBULSE not free~

PTRBULSE
Continuously Connection PTRBULSE -> SENSOR DISTRIBU-
ON TION PBA
IO INTERFACE PBA
PBA
Actuator defect
PTRBULSE defect
SENSOR DISTR. PBA defect
CPU_IO PBA defect

SDS
1 PaperTRransport
Analysis info tests
30 Reset PE & handicaps~

see SDS
31 Log / res err & ser cnt~

see SDS
32 Last error logging

last 15 errors
mode
ice mode
34 Error top 10
35 Error
counters > 0~
see SDS
36 Consumable counters~
see SDS
37 Parameters settings~
see SDS
38 Serv. / Mark. counters~

see SDS

Parameter test
15-1-01 15B1 PTR TRAiling Dist. PTRTRAISE1 - FOL1STARTSE

SEnsor mm/100~
Distance between trailing sensor 1 and start-
sensor
(range 42000 - 50000, default 44610,
mm/100)

SEnsor mm/100~
sensor
(range 40000 - 44000, default 41050,
mm/100)

SEnsor mm/100~
sensor
(range 29000 - 32500, default 30520,
mm/100)
Input tests
15-2-01 15B4 PTR BULge Paper transport bulge sensor

SEnsor ON = bulge detected
15-2-02 15B5 PTR UnFolded Paper transport unfolded output sensor

Output SEnsor ON = paper detected
15-2-03 15B1 PTR TRAIling Paper transport trailing sensor 1



15-2-06 15S1 PTR FRAME Paper transport frame switch

SWitch ON = door open
202 TSM Oc 9800 SDS

Output tests
15-4-01 15Y1 PTR UnFOld Paper transport unfolded solenoid

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~

(folder) in cold condition
18-6-05 PTRMOtor Paper TRansport MOtor
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

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 Remove the copy receiving tray.

3 Measure and note the length from the joint ball connections.
4 Release at the rear left and right the joint ball connections from the side covers.
5 Remove (as viewed from the rear) the left and right side covers.
6 Disconnect on the left-hand side from the wiring bundle between the PTR and
the engine the connectors 1801X2, 1801X4 and 22X13.
7 Close the PTR unit.

8 Remove the PTR rear cover.
9 Remove on both sides the PTR unit locking plates.
10 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.

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.
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
the engine the connectors 1801X4 and 22X13.
8 Disconnect on the left the connectors 18X4 and 2201X5.
9 Remove on the right the PTR drive belt between folder and PTR.
11 Remove the PTR rear cover.
12 Remove on both sides the PTR unit locking plates.
13 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.

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

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

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~

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
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.

PTRBULSE
CTF
bulge fingers
PTRUFOSE
unfolded
receiving
tray
PTRTRAISE
1..3
folder

PTRFRAMESW
PTRUFOSO 15PBA2 POWER I/O
(without folder)
15 PBA1
SENSOR
DISTRI-
BUTION
PTRBULSE
PTRMO (without
folder)

1 2 3 4 5 6
22G1 CONSUPLV 22PBA5 DRIVERS 15PBA2 POWER I/O
G2 X8 X8 22X13 X6 X3
+24V +24V-SW PTRMO+
1 5 12 1 7 1 1
GND
2 6 X1 M PTRMO
A 3
+24V
7 11
GND
2 2 15M1
GND PTRMO-
4 8 3 2 2
+24V
5 9 22X003-4 15X001
GND F1
6 10 X4
+5V
4A 7 1 PTRMOSE
G3 PTRMOSE-1
+5V 6 2 15B6
1 1 GND
GND 5 3
2 2
+5V
3 3
GND X8
4 4 PTRUFOSO
5 PTRUFOSO
F4 +24V 15Y1
6
4A
(or fixed position)
B 22PBA1 CPU I/O
X13 X10
+5V
1 1
GND
2 2
+24V
3 3
GND
5 5
CTFDOORSW
X8 X5
PTRFRAMESW +24V
19 2 1 7
06S1
4
1
PTRFRAMESW
C 15S1
3
2
GND +24V-SW
20 8
18PBA1 I/O INTERFACE

X1 X1 X2 X7
+5V +5V
1 1 24 1
+5V GND
2 2 23 2
GND PTRMOPWM
3 3 7 17
BD0 PTRMOSE
4 4 1 20
BD1 PTRUFOSO (from SW2.0)
D 5
BD2
5 21 4
6 6
BD3
7 7
GND
8 8
BD4
9 9
BD5 15PBA1 SENSOR DISTRIBUTION
10 10
BD6
11 11 X4 X2 X3
BD7 +5V +5V
12 12 16 8 13 1 PTRTRAISE1
GND GND GND
13 13 15 7 15 2 15B1
BA1 PTRTRAISE3-B PTRTRAISE1
14 14 6 4 14 3
BA2 PTRBULSE
15 15 13 2
BA3 PTRUFOSE +5V
16 16 12 3 10 1 PTRTRAISE2
BA4 PTRTRAISE1-B GND
17 17 8 6 11 2 15B2
GND PTRTRAISE2-B PTRTRAISE2
18 18 7 5 12 3
E 19
NASIC1_RD
19
NASIC1_WR +5V
20 20 7 1 PTRTRAISE3
GND GND
21 21 8 2 15B3
NINT5 PTRTRAISE3
22 22 9 3
NINT4
23 23
BNRESET +5V
24 24 1 1 PTRBULSE
BNOE GND
25 25 3 2 15B4
GND PTRBULSE
26 26 2 3
+5V
4 1 PTRUFOSE
GND
5 2 15B5
PTRUFOSE
6 3
H
WITHOUT FOLDER
ed.5 TSM Oc 9800 15 Paper transport 701
1 2 3 4 5 6
22PBA1 CPU I/O 18PBA1 I/O INTERFACE 18PBA3 POWER I/O
X1 X1 X2 X7
+5V +5V
1 1 24 1 X8 18X4
+5V GND PTRUFOSO
2 2 23 2 5 5 PTRUFOSO
GND PTRUFOSO-1
A 3
BD0
3 21
PTRDOORSW-B
8
+24V 15Y1
4 4 11 14 6 6
BD1 FOL1OUTDIAG
5 5 13 12
BD2 FOL1INPDIAG 7
6 6 14 11 X6
BD3 ENC1 PTRDOORSW
7 7 1 20 5 9
GND ENC2
8 8 2 19 6
BD4 ENC3
9 9 3 18
BD5
10 10 7
BD6 GND
11 11 8 8
BD7
12 12 15PBA1 SENSOR DISTRIBUTION
GND
13 13 10
BA1 X4 X2 X3
14 14 +5V +5V
BA2 16 8 13 1 PTRTRAISE1
15 15 GND GND
BA3 15 7 15 2 15B1
16 16 PTRTRAISE3-B PTRTRAISE1
BA4 6 4 14 3
B 17
GND
17
13
PTRBULSE
2
18 18 PTRUFOSE +5V
NASIC1_RD 12 3 10 1 PTRTRAISE2
19 19 PTRTRAISE1-B GND
NASIC1_WR 8 6 11 2 15B2
20 20 PTRTRAISE2-B PTRTRAISE2
GND 7 5 12 3
21 21
NINT5
22 22 +5V
NINT4 7 1 PTRTRAISE3
23 23 GND
BNRESET 8 2 15B3
24 24 PTRTRAISE3
BNOE 9 3
25 25
GND
26 26 +5V
1 1 PTRBULSE
GND
3 2 15B4
PTRBULSE
2 3
+5V
4 1 PTRUFOSE
C 5
GND
2 15B5
PTRUFOSE
6 3
X8
PTRFRAMESW
19
GND
20
22PBA5 DRIVERS PTRFRAMESW

X13 X10 X5 3 4
+5V +24V-SW
1 1 8 2 1
GND
2 2 15S1
D 3
+24V
3
GND
5 5 CTFDOORSW
F4 +24V
7 1 2
22G1 CONSUPLV 4A
G3 X8 O6S1
+5V
1 1
GND
2 2
+5V
3 3 X8 22X13
GND F1 +24V-SW
4 4 12 1
GND
G2 4A 11 2
+24V
1 5
GND
2 6 X12
+24V CONEMS2-B
3 7 12
GND
E 4
+24V
8
5 9 CONEMS2
GND +24V-SW
6 10 15
22K2-2A
22PBA4 SSR
22Z2
X9 X8
L2 L2
6 1 6 6 8
22X010 N2
5 2 3 2 4
N2
4 3
18G1 FOLSUPLV
G1 X2
N2-S N2-S
3 5 1
L2-S L2-S
F 1 6 4
2
G5 18X002-1 22X012-1
18X16
G4 2201X5
GND
3 2
+5V
1 1
G2 X1
GND
1 2
+24V
3 1
F1
G 5A
H
WITH FOLDER
ed.5 TSM Oc 9800 15 Paper transport 702
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 (with-
out 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

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
Diagnostics
1 Faults
FOLder 18000 - 18999 code display
18101 PE: ~FOL1FOLMO controller failure~
18-6-06 CONFOL1 ~FOL1FOL Possible cause Remark

~FOL1FOLM OUTDIAG MO~ turning
O~ (100%)
OFF ON (dis- Yes ~POWER_IO PBA~

connect defect
1803X5)
ON No ~FOL1FOLMO~
(100% PWM) defect / blocked
Connection
~POWER_IO PBA~
-> ~FOL1FOLMO~
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)
OFF (dis- No ~POWER_IO PBA~
connect defect
1803X5)
ed. 5 18 Folder 101

18102 PE: ~FOL2INMO controller failure~
18505 MRE: ~FOL2INMO controller failure~
18-6-08 CONFOL2 ~FOL2IN Possible cause Remark

~FOL2IN OUTDIAG MO~ turn-
MO~ (100% ing
PWM)
OFF ON (dis- Yes ~POWER_IO PBA~ defect
connect
ON 1810X3) No ~FOL2INMO~ defect /
(100% blocked
PWM)
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~)
OFF (dis- No ~POWER_IO PBA~ defect
connect
1810X3)

18103 PE: ~FOL2FOLMO controller failure~
18506 MRE: ~FOL2FOLMO controller failure~
~

~FOL2FOL OUTDIAG MO~ turning
MO~ (100%
PWM)
connect defect
1810X5)
ON No ~FOL2FOLMO~ defect
(100% PWM) / blocked
Connection
~POWER_IO PBA~ ->
~FOL2FOLMO~
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~)
connect defect
1810X5)
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~ Possible cause

~FOLOPUMO~ turning
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
PBA~ and ~FOLOPUMO~
PBA~ and ~FOLOPUMO~
18-2-20 Possible cause

~FOLOPUMO-
HOMESE~
Continuously ON ~FOLOPUMOHOMESE~ defect /
polluted
~I/O PBA~ defect
Continuously OFF Connection between ~FOLOPUMO-
HOMESE~ and ~I/O PBA~
~FOLOPUMOHOMESE~ defect
~I/O PBA~ defect

~FOLOPUMO-
HOENDSE~
Continuously ON ~FOLOPUMOENDSE~ defect / pol-
luted
~I/O PBA~ defect
Continuously OFF Connection between ~FOLOPU-
MOENDSE~ and ~I/O PBA~
~FOLOPUMOENDSE~ defect
~I/O PBA~ defect
18106 PE: ~FOLOADJMO error ~

18510 MRE: ~FOLOADJMO error~
18-4-06 ~FOLOADJ MO Possible cause

~FOLOADJMO~ turning~
OFF Yes ~I/O PBA~ defect
~Relay PBA~ defect
PBA~ and ~FOLOADJMO~
ON NO ~FOLOADJMOHOMESE~ defect
~FOLOADJMO~ defect
~Relay PBA~ defect

~FOLOADJMO-
HOMESE~
Continuously ON ~FOLOADJMOHOMESE~ defect /
polluted
~I/O PBA~ defect
ed. 5 18 Folder 105

~FOLOADJMO-
HOMESE~
Continuously OFF Connection between ~FOLOADJ-
MOHOMESE~ and ~I/O PBA~
~FOLOADJMOHOMESE~ defect
~I/O PBA~ defect

~FOLOADJ-
MOENDSE~
Continuously ON ~FOLOADJMOENDSE~ defect /
polluted
~I/O PBA~ defect
Continuously OFF Connection between ~FOLOADJ-
MOENDSE~ 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

18501, 18502 MRE: ~Wrong position FOL(1/2)DEFCL~

18-2-07
~FOL(1/2)DE
POSE~
Continuously Connection ~FOL(1/2)DEPOSE~ ->
ON / OFF ~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~

~FOL1I OUTDIAG MO~ turn-
N MO~ (100% PWM) ing
OFF ON (discon- Yes ~POWER_IO PBA~ defect

nect 1803X3)
ON No ~FOL1INMO~ defect /
(100% blocked
PWM)
Connection
~FOL1_POWER_IO PBA~
-> ~FOL1INMO~
disc defect
Connection
~FOL1INMOSE~ ->
~IO_INTERFACE PBA~
~FOL1 IO INTERFACE
PBA~ defect (LM629)
~FOL2_IO_INTERFACE
PBA~ if present)
OFF (discon- No ~POWER IO PBA~ defect
nect 1803X3)

18504 MRE: ~FOL1FOLMO controller failure~

MO~ (100%
PWM)
connect defect
1803X5)
ON No ~FOL1FOLMO~
Connection
~POWER_IO PBA~
-> ~FOL1FOLMO~
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)
connect defect
1803X5)
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~ Check by switching with
defect ~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~

~FOL1START
SE~
Continuously Connection ~FOL1STARTSE~ ->
OFF ~SENSOR DISTRIBUTION PBA~
Connection ~SENSOR DISTRIBUTION PBA~
-> ~IO_INTERFACE PBA~
Connection ~IO_INTERFACE PBA~ ->
~CPU_IO PBA~
Actuator defect
~FOL1STARTSE~ defect
~FOL2_IO_INTERFACE PBA~ if present)
~CPU_IO PBA~ defect

18702 ORE: ~FOL1STARTSE too late free~

~FOL1START
SE~
Continuously ON Connection ~FOL1STARTSE~ ->
~SENSOR DISTR. PBA~
->~IO_INTERFACE PBA~
~CPU_IO PBA~
Actuator defect
~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~

MO~ (100%
PWM)
connect defect
1803X5)
ON No ~FOL1FOLMO~
Connection
~POWER_IO PBA~
-> ~FOL1FOLMO~
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)
connect defect
1803X5)

~POWER_IO PBA~ defect If activating 18-6-05 (FOL1FOLMO) is not
possible

18705 ORE: ~Paper too late at FOL2TRAISE1~

~FOL2TRAISE1~
Continuously OFF Connection ~FOL2TRAISE1~ ->
~SENSOR DISTRIBUTION PBA~
~CPU_IO PBA~
Actuator defect
~FOL2TRAISE1~ defect
~FOL1_IO_INTERFACE PBA~)
~CPU_IO PBA~ defect

~FOL2FLAT OUTDIAG
SO~
ON OFF ~POWER_IO PBA~ defect
ON Connection ~POWER_IO PBA~
(18PBA10) -> ~FOL2FLATSO~
~PTRUFOSO~ defect

Eccentric mechanism lifting roller stuck Check last error logging
18901->18905
Too much curl in receiving material
Height second folding not adjusted cor-
rectly
ed. 5 18 Folder 113

18706 ORE: ~Paper too late at FOL2TRAISE2~

~FOL2TRAISE2~
Continuously OFF Connection ~FOL2TRAISE2~ ->
~CPU_IO PBA~
Actuator defect
~CPU_IO PBA~ defect

~FOL2FLAT OUTDIAG
SO~
ON OFF ~POWER_IO PBA~ defect
ON Connection ~POWER_IO PBA~
(18PBA10) -> ~FOL2FLATSO~
~PTRUFOSO~ defect

Eccentric mechanism lifting roller stuck Check last error logging
18901->18905

18707 ORE: ~FOL2TRAISE2 too late free~

~FOL2TRAISE2~
Continuously ON Connection ~FOL2TRAISE2~ ->
Connection ~SENSOR DISTRIBUTION
PBA~ -> ~IO_INTERFACE PBA~
~CPU_IO PBA~
Actuator defect
~CPU_IO PBA~ defect
ed. 5 18 Folder 115

18708 ORE: ~Paper too late at FOL2STARTSE~

~FOL2START
SE~
Continuously Connection ~FOL2STARTSE~ ->
Connection ~ SENSOR DISTRIBUTION
~CPU_IO PBA~
Actuator defect
(Possible check: interchange with
~CPU_IO PBA~ defect

~FOL2TRAISE2
~
Continuously Connection ~FOL2TRAISE2~ ->
~CPU_IO PBA~
Actuator defect
~CPU_IO PBA~ defect

18709 ORE: ~FOL2STARTSE too late free~

~FOL2START
SE~
Continuously ON Connection ~FOL2STARTSE~ ->
Connection ~SENSOR DISTRIBUTION PBA
->~IO_INTERFACE PBA~
~CPU_IO PBA~
Actuator defect
~CPU_IO PBA~ defect

~FOL2TRAISE2
~
Continuously Connection ~FOL2TRAISE2~ ->
~CPU_IO PBA~
Actuator defect
~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~

~FOL2IN OUTDIAG MO~ turn-
MO~ (100% ing
PWM)
OFF ON (dis- Yes ~POWER_IO PBA~ defect
connect
ON 1810X3) No ~FOL2INMO~ defect /
(100% blocked
PWM)
Connection ~FOL2
POWER_IO PBA~ ->
~FOL2FOLMO~
disc defect
Connection
~FOL2INMOSE~ ->
~IO_INTERFACE PBA~
~FOL2_IO_INTERFACE
PBA~ defect (LM629)
Loose static eliminator
blocking transport
OFF (dis- No ~POWER_IO PBA~ defect
connect
1810X3)

18712 ORE: ~Speed FOL2FOLMO out of range~

~FOL2FOL OUTDIAG MO~ turn-
MO~ (100% ing
PWM)
connect defect
1810X5)
ON No ~FOL2FOLMO~ defect /
(100% blocked
PWM)
Connection
~POWER_IO PBA~ ->
~FOL2FOLMO~
Yes ~FOL2FOLMOSE~ /
pulse disc defect
Connection
~FOL2FOLMOSE~ ->
~IO_INTERFACE PBA~
~FOL2_IO_INTERFACE
PBA~ defect (LM629)
connect defect
1810X5)
18713 ORE: ~Paper too late at FOL2OUTSE~

~FOL2OUTSE~
Continuously Connection ~FOL2OUTSE~ ->
~IO_INTERFACE PBA~
~CPU_IO PBA~
Actuator defect
~FOL2OUTSE~ defect
~CPU_IO PBA~ defect
ed. 5 18 Folder 119

18714 ORE: ~FOL2OUTSE too late free~

~FOL2OUTSE~
Continuously Connection ~FOL2OUTSE~ ->
ON ~SENSOR DISTRIBUTION PBA~
~IO_INTERFACE PBA~
~CPU_IO PBA~
Actuator defect
~FOL2OUTSE~ defect
~CPU_IO PBA~ defect
18715 ORE: ~Paper too late at FOLOPUSTARTSE~

~FOLOPUS-
TARTSE~
Continuously ON Connection ~FOLOPUSTARTSE~ ->
~I/O_BOARD PBA~
Actuator defect
~FOLOPUSTARTSE~ defect
18716 ORE: ~FOLOPUSTARTSE too late free~

~FOLOPUSTARTSE~
Continuously ON Connection ~FOLOPUSTARTSE~
->~I/O_BOARD PBA~
Actuator defect
~FOLOPUSTARTSE~ defect

18717 ORE: ~Paper too late at FOLOBELT1SE~

~FOLOBELT1SE~
Continuously ON Connection ~FOLOBELT1SE~ ->
~I/O_BOARD PBA~
Actuator defect
~FOLOBELT1SE~ defect
18718 ORE: ~FOLOBELT1SE too late free~

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

~FOLOBELT2SE~
Continuously ON Connection ~FOLOBELT2SE~ ->
~I/O_BOARD PBA~
Actuator defect
ed. 5 18 Folder 121

18720 ORE: ~FOLOBELT2SE too late free~

~FOLOBELT2SE~
Continuously ON Connection ~FOLOBELT2SE~
->~I/O_BOARD PBA~
Actuator 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

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:
~FOL2TRAISE1~ not activated
the drive belt is not running correctly
the copy is slipping on the transport (too little grip)
~FOL2RUSTARTSE~ is defective
~FOL2RUDOORSW~ 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:
the stopper is not released or sticking
the copy is sticking to the stamp
the copy is jammed in the intermediate transport
the intermediate transport does not function
18727 ORE: ~FOL2RUSTARTSE free too soon~
Possible cause
The solenoid ~FOL2RUSTOPSO~ is not activated

18901 SWAR: ~FOL1 lift up position too late~

~FOL1LIUP
SE~
Continuously Connection ~FOL1LIUPSE~ ->
OFF ~STEPPER_MOTOR CONTROLLER PBA~
Connection ~STEPPER_MOTOR CONTROL-
LER PBA~ -> ~IO_INTERFACE PBA~
PBA~
Actuator defect
~FOL1LIUPSE~ defect
~CPU_IO PBA~ defect
18-6-11 ~FOL1LI Possible cause Remark

~FOL1LI MO~ turning
MO~
ON No 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~

~FOL1LI
DOWNSE~
Continuously Connection ~FOL1LIDOWNSE~ ->
ON ~STEPPER_MOTOR CONTROLLER PBA~
Connection ~STEPPER_MOTOR CONTROLLER
PBA~
Actuator defect
~FOL1LIDOWNSE~ defect
~CPU_IO PBA~ defect

~FOL1LIMO~ MO~ turn-
ing
ON No Connection ~STEPPER_MOTOR
CONTROLLER PBA~ ->
~FOL1LIMO~
~STEPPER_MOTOR CONTROL-
LER PBA~ defect
loose
FOL1_IO_INTERFACE PBA defect

18903 SWAR: ~FOL1 lift low position too soon~

~FOL1LI MO~ turn-
MO~ ing
CONTROLLER PBA~ ->
~FOL1LIMO~
LER PBA~ defect
loosen
~FOL1_IO_INTERFACE PBA~
defect
18904 SWAR: ~FOL1 lift roller error~


~FOL1LI
DOWNSE~
Continuously Connection ~FOL1LIDOWNSE~ ->
ON ~STEPPER_MOTOR CONTROLLER PBA~
Connection ~STEPPER MOTOR CONTROLLER
PBA~
Actuator defect
~FOL1LIDOWNSE~ defect
~CPU_IO PBA~ defect
to be continued
ed. 5 18 Folder 127

continued

~FOL1LI
UPSE~
Continuously Connection ~FOL1LIUPSE ~->
OFF ~STEPPER_MOTOR CONTROLLER PBA~
Connection ~STEPPER_MOTOR CONTROLLER
PBA~
Actuator defect
~FOL1LIUPSE~ defect
~SENSOR DITRIBUTION PBA~ defect
~CPU_IO PBA~ defect

~FOL1LIMO~ MO~ turning
CONTROLLER PBA~ ->
~FOL1LIMO~
LER PBA~ defect
loose
~FOL1_IO_INTERFACE PBA~
defect
18905 SWAR: ~STEPping MOTor CONTRol PBA defect~

~FOL1LI MO~ MO~ turning
CONTROLLER PBA~ ->
~FOL1INMO~
LER PBA~ defect
loose
~FOL_IO_INTERFACE PBA~ defect

SDS
1 FOLder
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS
ed. 5 18 Folder 201

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
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

Input tests
18-2-01 ~FOL1 START Fol1 start sensor

SEnsor~ ON = paper present
18-2-02 ~FOL1 DOOR Fol1 door switch

SWitch~ ON = door open
18-2-03 ~FOL1 DEflec- Fol1 deflector position sensor

tor POsition ON/OFF related to the position of the 1st
SEnsor~ folding flap
18-2-04 ~FOL2 START Fol2 start sensor

SEnsor~ ON = paper present
18-2-05 ~FOL2 TRAIl- Fol2 trailing sensor 1

ing SEnsor 1~ ON = paper present
18-2-06 ~FOL2 TRAIl- Fol2 trailing sensor 2

ing SEnsor 2~ ON = paper present
18-2-07 ~FOL2 DEFlec- Fol1 deflector position sensor

tor POsition ON/OFF related to the position of the 2nd
SEnsor~ folding flap
18-2-08 ~FOL2 TRAY Fol2 tray switch

SWitch~ ON = tray open
18-2-09 ~FOL2 DOOR Fol2 door switch

SWitch~ ON = door open
18-2-10 ~FOL2 OUTput Fol2 output sensor 1

SEnsor 1~ ON = paper present
18-2-11 ~FOL1 LIft Fol1 lift down sensor

DOWN SEnsor~ ON = lift of the folding rollers in lower posi-
tion
18-2-12 ~FOL1 LIft UP Fol1 lift up sensor

SEnsor~ ON = lift of the folding rollers in the upper
position
18-2-13 ~CON FOL1 CON Fol1 input diagnose

INput DIAG- ON = diagnose signal correct
nose~
18-2-14 ~CON FOL1 CON Fol1 output diagnose

OUTput DIAG- OFF = diagnose signal correct
nose~
ed. 5 18 Folder 203

18-2-15 ~CON FOL2 CON Fol2 input diagnose

INput DIAG- ON = diagnose signal correct
nose~
18-2-16 ~CON FOL2 CON Fol2 output diagnoses

OUTput DIAG- OFF = diagnose signal correct
nose~
18-2-17 ~FOL Output Folder output adjust motor sensor

ADJust MOT. ON = motor not in home position
HOME SEnsor~
18-2-18 ~FOL Output Folder output adjust motor end sensor

ADJust MOtor ON = motor not in end position
END SEnsor~
18-2-19 ~FOL Output- Folder output punch start sensor

PUnch START ON = paper present, punch can start
SEnsor~
18-2-20 ~FOL Output Folder output punch motor home sensor

PUnch MOtor ON = motor in home position
HOME SEnsor~
18-2-21 ~FOL Output Folder output punch motor end sensor

PUnch MOtor ON = motor in end position
END SEnsor~
18-2-22 ~FOL Output Folder output punch door switch

PUnch DOOR ON = door closed
SWitch~
18-2-23 ~FOL Output Folder output belt 1 sensor

BELT1 SEnsor~ ON = paper present
18-2-24 ~FOL Output Folder output belt 1 end sensor

BELT1 END ON = paper present
SEnsor~
18-2-25 ~FOL Output Folder output belt 1 door switch

BELT1 DOOR ON = door belt 1 closed
SWitch~
18-2-26 ~FOL Output Folder output belt 2 sensor

BELT2 SEnsor~ ON = paper present
18-2-27 ~FOL Output Folder output belt 2 end sensor

BELT2 END ON = paper present
SEnsor~
204 TSM Oc 9800 SDS

18-2-28 ~FOL Output Folder output belt 2 door switch

BELT2 DOOR ON = door belt 2 closed
SWitch~
18-2-29 ~First Fold Out- First fold output sensor

put SEnsor~ ON = paper present
18-2-30 ~FOL2 RU Front door switch of the reinforcement unit

DOOR SWitch~ OFF = door closed
18-2-31 ~FOL2 RU Door switch of the intermediate transport
INTermediate OFF = door closed
transport DOOR
SWitch~
18-2-32 ~FOL2 RU Top cover switch of the reinforcement unit

COVER OFF = door closed
SWitch~
18-2-33 ~FOL2 RU Start sensor of the reinforcement unit (sepa-

START SEnsor~ rate receiver and transmitter)

ON = paper present
18-2-34 ~FOL2 RU Sensor for checking the position of the rein-

stamp HOME forcement stamp
position SEnsor~ ON = stamp in home position
18-2-35 ~FOL2 RU Sensor for detecting the presence/absence of

EMPTY reinforcement tape
SWitch~ ON = tape present
18-2-36 ~FOL2 RU tape Tape jam detection switch

JAM SWitch~ ON = tape jam
18-2-37 ~FOL2 RU Fol2 reinforcement unit output diagnose

OUTput DIAG-
nose~
18-2-38 ~FOL2 RU Fol2 reinforcement unit input diagnose

INput DIAG-
nose~
ed. 5 18 Folder 205

Output tests
18-4-01 ~FOL1 DEFlec- Fol1 deflector clutch

tor CLutch ~ Clutch of the 1st folding flap
ON = clutch activated
Hardware diagnoses:
CONFOL1OUTDIAG
18-4-02 ~FOL1 OUTput Fol1 output deflector solenoid

DEFlector SOle- ON = solenoid activated, output 1st fold
noid~ Hardware diagnoses:
CONFOL1OUTDIAG
18-4-03 ~FOL2 FLAT Fol2 flat solenoid

SOlenoid~ ON = solenoid activated, plate in top position
Hardware diagnoses:
FOL2OUTDIAG
18-4-04 ~FOL2 DEFlec- Fol2 deflector clutch

tor CLutch~ Clutch of the 2nd folding flap
ON = clutch activated
Hardware diagnoses:
FOL2OUTDIAG
18-4-05 ~FOL2 OUTput Fol2 OUTput tray SOlenoid

tray SOlenoid~ ON = solenoid activated, output to sorter
Hardware diagnoses:
FOL2OUTDIAG
18-4-06 ~FOL Output FOL Output ADJust MOtor

ADJust MOtor~ ON = motor turns, pushes the sheet in
between the punch unit
18-4-07 ~FOL Output FOL Output PUnch MOtor

PUnch MOtor~ ON = motor turns, ready to punch
(eccentric)
18-4-08 ~FOL Output FOL Output PUnch Eject SOlenoid

PUnch Eject (stopper with plastic wheel)
SOlenoid~
18-4-09 ~FOL Output FOL Output Paper TRansport MOtor

Paper TRans- ON = motor turns
port MOtor~ (total transport)
18-4-10 ~FOL Output FOL Output BELT VAlve

BELT VAlve~ OFF = sheet to belt 1
ON = sheet to belt 2
206 TSM Oc 9800 SDS

18-4-11 ~FOL Output FOLOutput BELT 1 MOtor

BELT1 MOtor~ ON = motor turns
18-4-12 ~FOL Output FOLOutput BELT 2 MOtor

BELT2 MOtor~ ON = motor turns
18-4-13 ~First FOLOut- ~First fold delivery motor~

put MOtor~
18-4-14 ~FOL2 RU Reinforcement Unit stopper solenoid

STOP SOle- ON = stopper up
noid~
18-4-15 ~FOL2 RU Reinforcement Unit GUIDe SOlenoid

GUIDe SOle- ON = guide retracted
noid~
18-4-16 ~FOL2 RU Reinforcement Unit drive MOtor

MOtor~ ON = motor turns
Special tests

(folder) in warm condition

(folder) in cold condition
18-6-05 ~FOL1 INput ~Fol1 INput MOtor~

MOtor~
18-6-06 ~FOL1 FOL ~Fol1 FOL MOtor~

MOtor~
18-6-07 ~Simulate Fold 1~

simulation of the 1st folding
18-6-08 ~FOL2 INput ~Fol2 INput MOtor~

MOtor~
18-6-09 ~FOL2 FOL ~Fol2 FOL MOtor~

MOtor~
18-6-10 ~Simulate Fold 2~

simulation of the 2nd folding
ed. 5 18 Folder 207

18-6-11 ~FOL1 LIft ~FOL1 lift motor ~

MOtor~ Folding rollers initiated, rollers in upper or
lower position
18-6-12 ~Simulate first fold delivery~

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 interme-
diate transport. Push the start-button: the
stopper goes up and the intermediate trans-
port starts running. The sheet is stopped by
the stopper and is reinforced. The stopper
goes down, and 1/2 a second later the inter-
mediate transport is stopped. Remove the
sheet. This test can be interrupted during tape
transport or stamping.
18-6-15 ~FOL2RU ~FOL2 RU STAMP SOlenoid~

STAMPSO~ The solenoid is activated/deactivated. If after
this test the drive motor is activated, the
stamp will be activated once
18-6-16 ~FOL2RUSTA ~FOL2 RU STAMP SOlenoid turn~

MPSO + The stamp is activated once with every push
FOL2RUGUID on the Start-button and the motor is activated
SO +
FOL2RUMO~
18-6-17 ~FOL2RU ~FOL2 RU STAMP 1/2 TURN~
STAMP The stamp is closed with a push on the
1/2TURN~ 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

18-6-19 ~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.

(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).

3 FOL1 guide plate
Aim:
To ensure that the folded copies are straight and correctly fed onto the interme-
diate 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
A B
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.

C = 2 +0/-5mm
D E
5 Tighten the bolts handtight.

6 Make a folded copy and measure skewness -X-.
7 If necessary repeat steps 1 upto 6.
8 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.
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.

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 Open the paper delivery tray and the rear door of the 2nd folding unit.
2 Remove the front cover of the 2nd folding unit.
3 Switch the machine to SDS.
5 Loosen the fixing screws of the solenoid (FOL2FLATSO).
6 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

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

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.

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.
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
FOLOP-
copy stop UESE
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 Open the lower belt unit side door.
2 Remove the upper front and rear cover from the belt unit.
3 Open the guide plate -B-.
4 Loosen the screws from stopper -A- and -B- at the front and rear side.
5 Adjust with stopper -A- the distance between the guide plate -A- and the guide
flap to 2.5 0.5 mm.
to 1st belt
guide plate B
guide plate A
stopper
B
2.5 +0.5/-0.5 mm
guide flap
stopper A
copy entrance

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.
to 2nd belt
guide plate C
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 spec-
ifications 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 installa-
tion / replacement of the Reinforcement Unit, are:
10 Position of the copy guide in the intermediate transport (with Reinforce-
ment Unit) (basic setting) on page 316

11 Hinges (basic setting) on page 317
12 Position of the Reinforcement Unit in the frame (basic setting) on page
318
13 Locking plate on page 319
14 Stopper angle on page 320
15 Stopper position (basic setting) on page 321
16 Third copy guide (inside the second folding unit) on page 322
17 Vertical position of the small copy guide (basic setting) on page 323
18 Horizontal position of the small copy guide (basic setting) on page 324
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.

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:
20 Position of the copy guide in the intermediate transport (with Reinforce-
ment Unit) (fine-tuning) on page 326

21 Stopper position (fine-tuning) on page 329
22 Position of the Reinforcement Unit in the frame (fine-tuning) on page
331
23 Position of the retraction solenoid of the small copy guide (fine-tuning)
on page 333
24 Retracted position of the small copy guide (fine-tuning) on page 334
25 Horizontal position of the small copy guide (fine-tuning) on page 335
26 Vertical position of the small copy guide (fine-tuning) on page 336

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 Position of bind-
skewed ing strip OK?
Yes No
adjustment 4 on page 304 adjustment 10 on page

316
adjustment 2 on page 302 adjustment 11 on page

317
END adjustment 12 on page 318

and
adjustment 13 on page 319

and
adjustment 17 on page 323,

and
Continued on page 315

From page 314
Retract the small guide

adjustment 21 on page 329 and


adjustment 26 on page 336, and
adjustment 21 on page 329 and

Start here for fine adjustment 22 on page 331
tuning:
Position of No
strip according to
specifications?
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
B C D
Correction:
1 Loosen bolts -C- (2x) and -D- (3x).
2 Push guide -B- against the rollers.
3 Measure distance -E- at the left and the right.
4 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).

11 Hinges (basic setting)
Aim:
To create a correct starting point for the next adjustments.
Correction:
D = 34 1mm
A B = 18 1mm C E
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 F
Correction:
1 Open the reinforcement unit.
2 Remove the cover.
3 Loosen bolts -C- (2x).
4 Lift bracket -D- and close the unit.
5 Loosen bolts -E- (3x).
6 Level the unit with eccentric screw -F- (surfaces -A- and -B- parallel within 0.5
mm).
7 Tighten bolts -E-.
8 Make sure bracket -D- rests on roll -G-.
9 Tighten bolts -C-.
10 Mount the cover.

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 D
A = 0-1mm
1 Loosen bolts -B- (2x).

2 Move plate -C- towards you.
4 Move plate -E- in such a way that distance -A- is between 0 and 1 mm.
6 Pull the unit towards you, move plate -C- against the frame plate -F-, and tight-
en bolts -B- (2x).
F B
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
C D
B A
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).
5 Move the solenoid -D- upwards to increase the angle or downwards to decrease
the angle.
6 Tighten bolts -C- (2x).

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 C
A = 1 0.5mm
B = A + 1 0.5mm
E C
Correction:
2 Turn eccentric bolt -D- to change distance -A- to 1 0.5 mm.
3 Turn eccentric bolt -E- to change distance -B- to A + 1 0.5 mm.
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:
2 Move guide -B- to the correct distance.

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
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.
Correction:
2 Move plate -B- left or right until bolts -A- are in the middle of the slots.

19 Position of the retraction solenoid of the small copy guide (ba-
sic setting)
Aim:
Check:
Bolts -A- should be in the middle of the slots.
B
A
Correction:
2 Move solenoid -B- up or down until bolts -A- are in the middle of the slots.
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
A B
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.

C
D E
F
5 Tighten all the bolts handtight.

8 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.

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).

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
E B
If -A- is more than 108.5 + 1 mm:

2 Turn eccentric bolt -C- to decrease distance -D-.
3 Turn eccentric bolt -E- to decrease distance -F- to D + 1 0.5 mm.
4 Tighten bolts -B- (2x).
ed. 5 18 Folder 329

If -A- is less than 108.5 1 mm:
2 Turn eccentric bolt -C- to decrease distance -D-.
3 Turn eccentric bolt -E- to decrease distance -F- to D + 1 0.5 mm.
Note: Distance -F- should always be more than distance -D-.
Note: Make sure the stopper does not touch the roller.

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 A = 12 1mm
0.5 mm.
Correction:
B D
If -A- is larger than 12 + 1 mm:

2 Move plate -C- as many millimetres to the inside as -A- differs from 12 mm
(create a gap -D- between plate -C- and hinge -E- accordingly).
3 Tighten bolts -B-.
4 Loosen bolts -F- (2x).
5 Move hinge -E- against plate -C-.
6 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
(create a gap -D- between hinge -E- and plate -C- accordingly).
9 Tighten bolts -F-.
11 Move plate -C- against hinge -E-.
If the strip is not glued parallel to the edge of the copy:
K H G
J I L
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).

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
Correction:
1 Remove the door of the reinforcement unit.
3 Move solenoid -A- in such a way that distance -B- is between 0.1 and 0.5 mm.
5 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 re-
traction solenoid does not function.
Check:
1 Unlock the single-revolution clutch in order to release the stamp drive.
2 Manually move up stamp -A- until bracket -B- is released.
3 Measure distance -C-. It should be 4.6 2 mm.
4 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 Unlock the single-revolution clutch in order to release the stamp drive.
2 Manually move up stamp -A- until bracket -B- is released.
3 Loosen bolt -D-.
4 Move bracket -B- up or down until distance -C- is 4.6 2 mm.
5 Tighten bolt -D-.
6 Manually move up stamp -A- to its top position and push it downwards again
until the solenoid locks it in its home position.

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.
A
B
D 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 E F
B C
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-.

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:
2 Move guide -C- to the left or the right to create a distance -A- of 2 1 mm.
3 Tighten bolts -E- (3x).

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 C
B= 0.5mm
Correction:
2 Move the fixed knife -Y- in such a position that the conditions as given above,
are fulfilled.
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 100 105 110 115 120 125 130

(18-1-07)
Distance
(18-1-08)
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 Activate SDS test 18-1-07 and fill in the value 100.

2 Activate SDS test 18-1-08 and fill in the value: 0.
3 Make a 6m long folded copy on a A0 (36) format.
4 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).

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 10MM
Rear plate 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.

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.
3 At the rear, remove the E-ring, and the circlip.
4 Loosen the allen screw in lever assy.
5 Remove the lever assy.
6 Remove the circlip and the nylon washer from the shaft of the 2nd folding flap.
7 Remove the bearing of the shaft of the 2nd folding flap.

8 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.
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.

3 Adjust by moving the bracket to the lowest position after lossening bolts 2 and
3.
bolts2 Lever 3
180
bolts 3
Lever 2 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 4
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 wrin-
kles
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-.
B C

5 Loosen bolt -C-.
6 Move plate -A- to the left in such a way roller -D- does just not touch roller -E-.
7 Tighten bolt -C-.
10 If there still are wrinkles, increase the distance between the rollers -D- and -E-
gradually, until the wrinkles have disappeared or the folding accuracy runs out
of the specification.

Dis-/assemblies
1 ~FOL1DEFCL~ (clutch of 1st fold)

Assemble the clutch as follows:
F C M A
B
E
F C M A
B
E
H D
1 Push the clutch -A- in direction -B- to the end position.

2 Turn the Allen screw -M- of clutch -A- into clutch -A- until it touches shaft -F-.
3 Unscrew -M- 1/4 turn and lock it with LOCTITE222.
4 Push weight -C- over clutch -A-.
5 Secure weight -C- with two Allen screws -D-.
6 Turn weight -C- in the direction -E- .
until the clutch is in the locking posi-
tion. G
7 Turn shaft -F- in the same direction G
-E- until crank -G- is in the vertical
position.
8 Secure weight -C- to the shaft with 2 905
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
F C M A
B
E
F C M A
B
E
H D
1 Push the clutch -A- in direction -B- to the end position.

2 Turn the Allen screw -M- of clutch -A- into clutch -A- until it touches shaft -F-.
3 Unscrew -M- 1/4 turn and lock it with LOCTITE222.
4 Push weight -C- over clutch -A-.
5 Secure weight -C- with two Allen screws -D-.
6 Turn weight -C- in the direction -E- until the clutch is in the locking position.
7 Turn shaft -F- in the same direction -E- until crank -G- is in the horizontal po-
sition.
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 G

3 ~FOL1FOLMO~ and ~FOL2FOLMO~
1 Connect the wires of the motor as follows:
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

1 General folding
The folder uses a folding flap and 4 feed rollers

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 folding
flap folding roll-
be fed in between 2 folding rollers. ers
First the folding flap is positioned to
the right and the folding rollers turn in
direction 1.
After a calculated length of transport-

ed paper, depending of the selected
programme, the folding flap is moved 1
into the left position and the turning
direction of the folding rollers is re-
versed into direction 2.
A bulge is created and the copy is fed
between the folding rollers to fold the
bulge.
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 bulge
folding rollers.
Again the bulge is folded.
The distance between two folds is

variable.
This folding principle is used in the 1st fold, as well as in the 2nd fold.

2 Folding programmes
The basic folding programmes are:
DIN
190 x 297 mm
210 x 297 mm including 20 mm binding edge (left hand side).
210 x 297 mm
Ericsson
190 x 297 mm
210 x 297 mm including 20 mm binding edge (right hand side).
210 x 297 mm
USA
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 default 210 mm

(7.3 - 9") (8.5 or 9")
in steps of 1 mm (0.1)
2nd fold 273 - 310 mm default 297 mm

(10.9" - 12.2") (11 or 12")
Binding edge 0 or 15 - 30 mm default 20 mm (0.8")

(0 or 0.6 - 1.2")
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)

4 Folding length for DIN size folding in the 1st fold
190 mm 210 with 20 mm 210 mm

binding edge
* = 5 mm * = 5 mm * = 5 mm
A0 7 = 190 mm 7 = 190 mm 7 = 210 mm

6 = 139 mm 6 = 129 mm 6 = 189 mm
5 = 134 mm 5 = 124 mm 5 = 184 mm
4 = 180 mm 4 = 180 mm 4 = 100 mm
3 = 180 mm 3 = 180 mm 3 = 100 mm
2 = 180 mm 2 = 180 mm 2 = 200 mm
1 = 185 mm 1 = 205 mm 1 = 205 mm
A1 5 = 190 mm 5 = 190 mm 5 = 210 mm

4 = 145.5 mm 4 = 135.5 mm 4 = 115.5 mm
3 = 140.5 mm 3 = 130.5 mm 3 = 110.5 mm
2 = 180 mm 2 = 180 mm 2 = 200 mm
1 = 185 mm 1 = 205 mm 1 = 205 mm
A2 5 = 190 mm 5 = 190 mm 3 = 210 mm

4 = 112 mm 4 = 102 mm 2 = 192 mm
3 = 107 mm 3 = 97 mm 1 = 192 mm
2 = 90 mm 2 = 90 mm
1 = 95 mm 1 = 115 mm
A3 3 = 190 mm 3 = 190 mm 3 = 210 mm

2 = 115 mm 2 = 105 mm 2 = 105 mm
1 = 115 mm 1 = 125 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
A1 1 = 300 mm
2 = 294 mm
A2 1 = 297 mm
2 = 120 mm
A3 -

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 in-
put 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 de-
flection 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 trans-
ported 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).

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 vari-
able 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:
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 deliv-
ered 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, mo-
tor 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:
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 ex-
changed.
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).

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 ac-
cepts 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

Punch unit
After the copy is folded, 4 holes can be punched in the filling edge of the pack-
age. 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 fold-
ed 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:

it is much stronger than holes punched directly into the copy;
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 4 3
7
11
10
1 the roll holder

2 the guide roller
3 the pin roller
4 the transfer section
5 the knife section
6 the stamp section

7 the reinforcement head
8 the protective sheet rollers and the slide
9 FOL2GUIDSO
10 the drive section
11 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:
it separates the protective sheet from the adhesive tape;
it guides the separated protective sheet away from the knife;
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 mount-
ed 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 acti-
vated 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 rein-
forcement 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 frame-
plate.
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 rein-
forcement 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.

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
1 FOL2RUHOMESE
2 FOL2RUEMPTYSE
3 FOL2RUJAMSW
4 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 cor-
rect 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 re-
ceiver. 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 re-
load reinforcement tape.

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 er-
ror message 18725.
Sensor FOL2RUSTARTSE
Sensor FOL2RUSTARTSE consists of a separate transmitter, located in the in-
termediate 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:

the lower stamp in the bottom position
the upper stamp in the top position

the pin roller in a locked position
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
180 degrees and one length (111.125 mm) of reinforcement tape is supplied
onto the lower stamp;
4 FOL2GUIDSO moves the small guide out of the working area of the stamp;
5 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;
6 the single-revolution clutch FOL2RUSTAMPSO is activated: the eccentric
disks make one full turn, moving the lower stamp upwards and the upper stamp
downwards;
7 while the lower stamp moves upwards, the knife cuts the tape;
8 the eccentric disks finish the turn, the stamps return to the home position, and
the guide rails drop back into place;
9 the drive motor FOL2RUMO stops.
ed. 5 18 Folder 519

1st fold.
FOL1DOORSW
FOL1
STARTSE
FOL1LIFDOWNSE
FOL1LIFUPSE
18PBA7
SENSOR
DISTR.
FOLD
FOL1OUT
DEFSO FOL1LIFMO
1st fold
FOL1DEPOSE 18K1-2A
Relay FOL1DEFCL
18PBA15
Step motor
control
FOL1FOLMO FOL1IN
18PBA3 18G1 MOSE
Power I/O FOLSUPLV
FOL1FOLMOSE 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
18PBA10
POWER I/O
RELAY PBA
18PBA17 PBA REIN- 18PBA16
FORCEMENT

2nd fold
FOL2INMOSE
FOL2INMO
FOL2DEFCL
FOL2DEFPOSE
FOL2FOLMO
FOL2FOLMOSE
ed. 5 18 Folder 603

Lower belt unit
FOLOBELT1ENDSE FOLOBELT1SE
FOLO-
BELTVA
FOLOBELT1
DOORSW
FOLOPU POWER
DOORSW SUPPLY

Lower belt unit
FOLOPUEJSO
RELAY BOARD
FOLOBELT1MO
I/O BOARD
ed. 5 18 Folder 605

Upper belt unit
FOLOBELT2SE FOLOBELT2
Upper belt unit
DOORSW
FOLOBELT2MO
FOLOBELT2ENDSE

Punch unit
FOLOPUSTARTSE
FOLOPU-
MOENDSE
FOLOPUMO-
HOMESE
FOLOPUMO
FOLOPTRMO
FOLOADJMOHOMESE
FOLOADJMO FOLOADJMOENDSE
ed. 5 18 Folder 607

First Fold delivery
FOLOFFOUTSE FOLOFFOUTMO

1 2 3 4 5 6
22PBA1 CPU I/O 18PBA1 I/O INTERFACE 18PBA7 SENSOR DISTRIBUTION FOLD
X1 X1 X1
+5V 2202X3 X2 +5V
1 1 +5V 1 1 FOL1STARTSE
+5V 1 8 GND
2 2 GND 2 2 18B1
GND 2 7 FOL1STARTSE
A 3
BD0
3
6
FOL1STARTSE
6
3 3
4 4 FOL1DEPOSE X3
BD1 3 1 +5V
5 5 13 1 FOL1DEPOSE
BD2 FOL1DEPOSE
6 6 14 2 18B4
BD3 GND
7 7 15 3
GND
8 8
BD4
9 9
BD5
10 10 18PBA3 POWER I/O
BD6
11 11
BD7
12 12 2202X2 X7 X2
GND +5V FOL1DEFCL
13 13 24 1 1 FOL1DEFCL
BA1 GND
14 14 23 2 18Y1
BA2 RESERVEOUT +24V
15 15 22 3 2
BA3 PTRUFOSO
16 16 21 4 FOL1OUTDEFSO
BA4 PTRFEDCL 3 FOL1OUTDEFSO
B 17
GND
17 20
PTRCORCL
5
18Y2
18 18 19 6 +24V
NASIC1_RD FOL1DEFCL 4
19 19 17 8
NASIC1_WR FOL1OUTDEFSO
20 20 18 7
GND FOL1FOLMOPWM
21 21 9 16
NINT5 FOL1INMOPWM
22 22 7 17
NINT4 FOL1MOCW
23 23 10 15
BNRESET PTRDOORSW
24 24 11 14
BNOE FOL1DOORSW
25 25 12 13
GND FOL1OUTDIAG
26 26 13 12
FOL1INDIAG
X3 14 11
FOL1LIDOWNSE-B FOL1INMOSE
4 1 20
FOL1LIUPSE-B FOL1FOLMOSE-1 X5 18X3
5 2 19 FOL1FOLMO FOL1FOLMO
FOL1FOLMOSE-2 2 2
X2 3 18
FOL1LISTART M 18M2
C FOL1LIRESET
4
5
FOL1LISTA0 1
15
FOL1LISTA1 18X21
16
4 8 6
+24V
1 3
18PBA15 STEP MOTOR CONTROL
X1 X2 18X22
+5V FOL1LIDOWNSE FOL1FOLMOSE
3 1 1 1
FOL1LIDOWNSE X4
4 2 2 2 18B14 GND
GND 1 1
8 3 3 3 FOL1FOLMOSEB
2 2
5 FOL1FOLMOSEA 18PBA5
+5V 3 3
7 4 4 1 FOL1LIUPSE +5V
FOL1LIUPSE 4 4
6 5 5 2 18B13
GND
6 6 3
D X3 18X20
6 1
3 2 M FOL1LIMO
1 3 4 18M5
4 4
GND
2
+24V
5
FOL1INMOSE
+5V
5 1
FOL1INMOSE
6 2 18B5
22PBA5 DRIVERS CTFDOORSW GND
7 3
X13 X10 X5
+5V +24V
E 1
GND
1 7 1 2
2 2 O6S1
+24V X3 18X3
3 3 FOL1INMO FOL1INMO
GND 2 2
5 5 PTRFRAMESW
M 18M1
F4 +24V-SW
8 2 1
22G1 CONSUPLV 4A
15S1 1
G3 X8
+5V 18X21
1 1
GND 6 4 2
2 2 +24V
+5V X8 22X13 1 5
3 3 +24V-SW
GND F1 12 1
4 4 GND
4A 11 2
G2
+24V
1 5
GND
2 6 X12
+24V CONEMS2-B
F 3
GND
7 12
4 8
+24V
5 9 CONEMS2
GND +24V-SW
6 10 15
22K2-2A
X6 18X4
22PBA4 SSR PTRDOORSW
5 9
22Z2
X9 X8 6
L2 L2
6 1 6 6 8
22X010 N2
5 2 3 2 4 7
GND
N2 8 8
4 3
FOL1DOORSW
1
18G1 FOLSUPLV
2
G1 X2
N2-S N2-S
G 3
L2-S
5 1
L2-S 3 FOL1DOORSW
1 6 4
18S1
GND
X1 4 4 3
2
F1 FRAME EARTH CONNECTION 2 1 2 10
G5 18X002-1 22X012-1
5A 18X16 18X11
G4 2201X5 1
GND
3 2 7
+5V
1 1 FOL1SAFRL1
G2 18X21 18K1-2A
+24V
2 2
GND
H 4
+24V
3
GND
1 1
FIRST FOLD
ed.5 TSM Oc 9800 18 Folder 701
1 2 3 4 5 6
X2 X1 X3 18X10
+5V 2209X3 18X5 X2 +5V
1 1 +5V 7 1 1 FOL2STARTSE
+5V 1 8 8 GND
2 2 GND 8 2 2 18B9
GND 2 7 7 FOL2STARTSE
A 3
BD0
3
8
FOL2STARTSE-B
1 4
9 3 3
4 4 FOL2DEPOSE-B
BD1 3 6 6 +5V
5 5 FOL2OUTSE-B 13 1 FOL2DEPOSE
BD2 7 2 2 GND
6 6 FOL2TRAISE2-B 14 2 18B11
BD3 6 3 5 FOL2DEPOSE
7 7 FOL2TRAISE1-B 15 3
GND 5 4 1
8 8
BD4 +5V
9 9 2209X5 18X19 1 1 FOL2OUTSE
BD5 GND
10 10 1 1 2 2 18B7
BD6 FOL2OUTSE
(to OPTIONALS 704)

11 11 2 2 3 3
BD7
12 12 3 3
GND +5V
13 13 4 4 10 1 FOL2TRAISE2
BA1 GND
14 14 5 5 11 2 18B10
BA2 FOL2TRAISE2
15 15 6 6 12 3
BA3
16 16 7 7 X1
BA4 +5V
B 17
GND
17 8 8 1
GND
1 FOL2TRAISE1
18 18 9 9 2 2 18B6
NASIC2_RD FOL2TRAISE1
19 19 10 10 3 3
NASIC2_WR
20 20 11 11
GND
21 21 12 12
NINT5
22 22 19 13
NINT4
23 23 18PBA10 POWER I/O
BNRESET
24 24 2209X2 18X1 X7 X2
BNOE +5V FOL2DEFCL
25 25 24 1 1 1 FOL2DEFCL
GND GND 5V
26 26 23 2 2 18Y3
FOL2DEFCL-1 +24V
17 5 8 2
FOL2OUTSO-1
18 4 7 FOL2OUTSO
FOL2FLATSO-1 3 FOL2OUTSO
19 3 6
FOL2FOLMOPWM 18Y4
9 11 16 +24V
FOL2INMOPWM 4
C 7
FOL2MOCW
12 17
10 10 15 X8
FOL2DOORSW-B FOL2FLATSO
12 8 13 1 FOL2FLATSO
FOL2TRAYSW-B
11 9 14 18Y5
FOL2OUTDIAG +24V
13 7 12 2
FOL2INDIAG
14 6 11
FOL2INMOSE
1 15 20
FOL2FOLMOSE-1
2 14 19
FOL2FOLMOSE-2
3 13 18
X5 1810X5 18X6
FOL2FOLMO
2 2 2
M FOL2FOLMO
18M4
1 1
D
8 6
+24V
1
X4
+5V
22PBA5 DRIVERS 1
FOL2FOLMOSEB
1 FOL2FOLMOSE
CTFDOORSW 2 2
18PBA12
X13 X10 X5 FOL2FOLMOSEA
+5V +24V 3 3
1 1 7 1 2 GND
GND 4 4
2 2 O6S1
+24V
3 3
GND
5 5 PTRFRAMESW
F4 +24V-SW
8 2 1
E 22G1 CONSUPLV 4A
15S1
G3 X8
+5V
1 1
GND
2 2
+5V +5V
3 3 X8 22X13 5 1 FOL2INMOSE
GND F1 +24V-SW FOL2INMOSE
4 4 12 1 6 2 18B12
4A GND GND
G2 11 2 7 3
+24V
1 5
GND
2 6 X12
+24V CONEMS2-B
3 7 12 X3 1810X3 18X7
GND FOL2INMO
4 8 2 2 2
+24V FOL2INMO
5 9 CONEMS2 M
GND +24V-SW
6 10 15 18M3
22K2-2A 1 1
F 22PBA4 SSR
22Z2 4 2
X9 X8 +24V
L2 L2 1
6 1 6 6 8
22X010 N2
5 2 3 2 4
N2
4 3
18G1 FOLSUPLV
X6 1810X6 1810X6
G1 X2 FOL2DOORSW
N2-S N2-S 1 1 2
3 5 1
L2-S L2-S
4
1
1 6 4
(to OPTIONALS 704)
2
FOL2DOORSW 18S4
2
3
G5 18X002-1 22X012-1
G
3
2
18X16 18X18
GND
G4 2201X5 4 4 3 1
GND
3 2
+5V FOL2TRAYSW
1 1 5 5 6 3
4
1
F1 18X15 18X14
5A 18X8 6
G3 4 1810X1 X1 FOL2TRAYSW 18S3
GND
3 3 2 2 7
FOL2SAFRL1
3
2
+24V 18K2-2A
1 1 1 1 GND
8 8 7
H
SECOND FOLD up to nr. 3000

1 2 3 4 5 6
X2 X1 X3 18X10
+5V 2209X3 18X5 X2 +5V
1 1 +5V 7 1 1 FOL2STARTSE
+5V 1 8 8 GND
2 2 GND 8 2 2 18B9
GND 2 7 7 FOL2STARTSE
A 3
BD0
3
8
FOL2STARTSE-B
1 4
9 3 3
4 4 FOL2DEPOSE-B
BD1 3 6 6 +5V
5 5 FOL2OUTSE-B 13 1 FOL2DEPOSE
BD2 7 2 2 FOL2DEPOSE
6 6 FOL2TRAISE2-B 14 2 18B11
BD3 6 3 5 GND
7 7 FOL2TRAISE1-B 15 3
GND 5 4 1
8 8 FOLOFFOUTSE
BD4 4 5 3 +5V
9 9 1 1 FOL2OUTSE
BD5 GND
10 10 2 2 18B7
BD6 FOL2OUTSE
11 11 3 3
BD7 2209X4 18X34
12 12 +5V 18X9
GND 16 1 +5V
13 13 GND 10 1 1 FOL2TRAISE2
(to OPTIONALS 704)

BA1 15 2 GND
14 14 FOLOINPDIAG 11 2 2 18B10
BA2 13 3 FOL2TRAISE2
15 15 FOLOOUTDIAG 12 3 3
BA3 12 4
16 16 FOLOBELTDOORSW 18X12
BA4 11 5 +5V
B 17
GND
17
10
FOLODOORSW
6
4
GND
1 1 FOLOFFOUTSE
18 18 FOLOINSE 5 2 2 18B15
NASIC2_RD 9 7 FOLOFFOUTSE
19 19 FOLOOUTSE 6 3 3
NASIC2_WR 8 8
20 20 FOLOBELTENDSE X1
GND 7 9 +5V
21 21 1 1 FOL2TRAISE1
NINT5 GND
22 22 2 2 18B6
NINT4 2209X2 FOL2TRAISE1
23 23 FOLOPTRMO 3 3
BNRESET 4 10
24 24 FOLOBELCL
BNOE 5 11
25 25
GND 18PBA10 POWER I/O
26 26
18X7 X7 X2
+5V FOL2DEFCL
24 6 1 1 FOL2DEFCL
GND
23 1 2 18Y3
FOLOFFOUTMO +24V
21 5 4 2
FOL2INMOCW
20 3 4 FOL2OUTSO
C 18
FOL2OUTSO-1
2 7
3 FOL2OUTSO
FOL2FLATSO-1 18Y4
19 4 6 +24V
4
18X23
FOL2DEFCL-1
17 1 8 X8
FOL2FOLMOPWM FOL2FLATSO
9 7 16 1 FOL2FLATSO
FOL2INMOPWM
7 8 17 18Y5
FOL2MOCW +24V
10 6 15 2
FOL2DOORSW-B
12 4 13 18X30
FOL2TRAYSW-B +24V
11 5 14 6 2
FOL2OUTDIAG
13 3 12 M FOLOFFOUTMO
FOL2INPDIAG
14 2 11
FOL2INMOSE-1 FOLOFFOUTMO 18M6
1 11 20 5 1
FOL2FOLMOSE-1
2 10 19
FOL2FOLMOSE-2
3 9 18
D
22PBA5 DRIVERS CTFDOORSW X5 1810X5 18X6
FOL2FOLMO
X13 X10 X5 2 2 2
+5V +24V
1 1 7 1 2 M FOL2FOLMO
GND
2 2 O6S1
+24V 18M4
3 3 1 1
GND
5 5 PTRFRAMESW
F4 +24V-SW 8 6
8 2 1 +24V
22G1 CONSUPLV 4A 1
G3 X8 15S1
+5V X4
1 1 +5V
2
GND
2
1
FOL2FOLMOSEB
1 FOL2FOLMOSE
+5V 2 2
3 3 X8 22X13 FOL2FOLMOSEA 18PBA12
GND +24V-SW 3 3
E 4 4 F1 12
GND
1
4
GND
4
G2 4A 11 2
+24V
1 5
GND
2 6 X12
+24V CONEMS2-B +5V
3 7 12 5 1 FOL2INMOSE
GND FOL2INMOSE
4 8 6 2 18B12
+24V GND
5 9 CONEMS2 7 3
GND +24V-SW
6 10 15
22K2-2A X6
FOL2DOORSW
1
22PBA4 SSR
22Z2
4
1
(to OPTIONALS 704)
X9 X8
L2 L2
6 1 6 6 8 FOL2DOORSW 18S2
22X010 N2
5 2 3 2 4
N2
F
3
2
4 3 18X18 18X18
GND
4 1 1
18G1 FOLSUPLV
FOL2TRAYSW
G1 X2 5 3 2
N2-S N2-S
3 5 1
4
1
L2-S L2-S
1 6 4
FOL2TRAYSW 18S3
2
FOL2SAFRL1
3
2
G5 18X002-1 22X012-1 18X27 18K2-2A

18X16 GND
8 1
G4 2201X5
GND
3 2
+5V 2
1 1
F1 18PBA16 RELAY
G 5A X6 X2 X2
+24V +24V
7 1 9 2 4
X1
GND
2 2
X8 18X7
+24V FOL2INMO
4 7 1
FOL2INMOCW
3 3 M
X3 18M3
+24V FOL2INMO
1 6 8 2
18X15 18X14 FOL2INMO
18X8 2 5
H G3
GND
4 X1
3 3 2
+24V
1 1 1
SECOND FOLD from nr. 3001
1 2 3 4 5 6
22PBA1 CPU I/O 18PBA2 I/O INTERFACE I/O BOARD
X2 X1 2209X5 18X19 1813X1 J1 +5V
+5V J7 1 1 FOLOPUSTARTSE
1 1 1 1 1 1 GND
+5V J8 11 2 (PUNCH UNIT)
2 2 2 2 2 2 FOLOPUSTARTSE
GND J7 10 3
A 3
BD0
3 3 3 3 3
4 4 4 4 4 4 +5V
BD1 J9 2 1 FOLOPUMOENDSE
5 5 5 5 5 5 FOLOPUMOENDSE
BD2 J8 2 2 (PUNCH UNIT)
6 6 6 6 6 6 GND
BD3 13 3
7 7 7 7 7 7
GND
8 8 8 8 8 8 +5V
BD4 J9 1 1 FOLOPUMOHOMESE
9 9 9 9 9 9 FOLOPUMOHOMESE
BD5 J8 1 3 (PUNCH UNIT)
10 10 10 10 10 10 GND
BD6 12 2
11 11 11 11 11 11
BD7
12 12 12 12 12 12 +5V
GND J9 3 1 FOLOADJMOENDSE
13 13 19 13 13 13 FOLOADJMOENDSE
BA1 J7 13 2 (PUNCH UNIT)
14 14 GND
BA2 J9 4 3
15 15
BA3
16 16 +5V
BA4 J7 6 1 FOLOADJMOHOMESE
B 17
GND
17
J8 6
FOLOADJMOTHOMESE
2 (PUNCH UNIT)
18 18 GND
NASIC1_RD J9 5 3
19 19
NASIC1_WR
20 20
GND
21 21 FOLOPUNEJSO (PUNCH UNIT) RELAY BOARD
NINT5
22 22 J3 J12
NINT4 +24V
23 23 2 1 2 7
BNRESET
24 24
BNOE
25 25
GND
26 26 FOLOPUMO (PUNCH UNIT)
J3 J13
M GND
4 1 2 3
C FOLOADJMO (PUNCH UNIT)
M GND
1 1 2 2
BELT2DOORSW BELT1DOORSW PUDOORSW +24V J5
J23 6
2 1 4 2 1 2 1 J9
GND
3 4 7 3 4 3 4 6
J6
FOLOPUDOORSW SECOND BELT UNIT
3
J9 FOLOBELT2MO
GND J3 J24 J24 J13
7 M GND
6 4 2 1 5 5
J6
FOLOBELT1DOORSW
4
J9 FOLOBELT2ENDSE
GND J25 J24
D 8
J7 4
+5V
1 1 1
J6 GND
FOLOBELT2DOORSW J8 19 2 2 3
6 5 FOLOBELT2ENDSE
3 3 3 2
J5
5 7
J23 FOLOBELT2SE
+5V
J7 3 1 1
GND
J8 8 2 2
FOLOBELT2SE
5 3 3
22PBA5 DRIVERS
X13 X10 FOLOBELT1MO
+5V
E 1
GND
1 J3
M GND
J13
2 2 5 2 1 4
+24V
3 3
GND
5 5
F4 FOLOPTRMO
22G1 CONSUPLV 4A J4 J12
M +24V
G3 X8 1 1 2 9
+5V
1 1
GND
2 2
+5V FOLOBELT1ENDSE
3 3 J26
GND +5V
4 4 J7 5 1 1
GND
G2 J8 10 2 3
+24V FOLOBELT1ENDSE
1 5 4 3 2
GND
2 6 X1
+24V CONCONEMSSUP
F 3
GND
7 21 FOLOBELT1SE
4 8 +5V
+24V J7 2 1
5 9 CONCONEMS GND
GND CONKEYSW J8 7 2
6 10 17 FOLOBELT1SE
22K4-2A J7 9 3
22PBA4 SSR
22Z2
X9 X5 FOLOBELTVA
L2 L2
6 1 1 6 8 J3 J12
22X010 N2 +24V
5 2 2 2 4 3 1 2 8
N2
4 3
POWER SUPPLY
G1 22X9 X3 X4
N2-MNO N2-MNO J5
G 3
L2-MNO
3 6 3
L2-MNO 8 2
1 1 3 2
9 1
J4 R2
2 2 +24V
FRAME EARTH CONNECTION 3 4
G5 ? 22X? J13
18X? 18X? GND
J15 J5 2 7
+24V
1 3 18X18 J11
J16 J2 J5 1 1
1
+5V
1 5
from SECOND FOLD 702 / 703 3 3
GND
3 2 4 J13
H J14
GND
1 24V
4 3
+24V J12
2
OPTIONALS
1 2 3 4 5 6
PBA, CPU PBA, I/O interface PBA, SENSOR DIST. FOLD
22PBA01 22PBA 02/09 18PBA14 18B6
FOL2TRAISE1
X2 X1 X3 18X5 X2 X1
+5V +5V +5V +5V
1 1 1 8 1 1 1
A 2
+5V
2 2
GND 5V
7
GND 5V
2 2
GND 5V
2 A
GND FOL2DEPOSE FOL2DEPOSE FOL2TRAISE1
3 3 3 6 3 3 3
DATA FOLOFFOUTSE FOLOFFOUTSE
4 4 4 5 4
DATA FOL2TRAISE1 FOL2TRAISE1
5 5 5 4 5
DATA FOL2TRAISE2 FOL2TRAISE2
6 6 6 3 6 18B7
DATA FOL2OUTSE1 FOL2OUTSE1 FOL2OUTSE1
7 7 7 2 7 X3
FOL2STARTSE FOL2STARTSE +5V
GND
8 8 8 1 8 1 1
DATA GND 5V
9 9 2 2
B DATA
FOL2OUTSE1 B
10 10 X2 3 3
DATA FOL2INMOSE1
11 11 1 18X23
DATA FOL2FOLMOSE1
12 2 12
12
GND FOL2FOLMOSE2
13 3 11 18B15
13
ADRES 4 FOLOFFOUTSE
(To PBA power I/O Folder 2

14 14 10 X3 18x12
ADRES +5V +5V
15 15 5 9 4 1
ADRES FOL2INMOPWM GND 5V GND 5V
16 16 6 8 5 2
18PBA10 X7 (702)) FOLOFFOUTSE FOLOFFOUTSE
C 17
ADRES
17
7
FOL2FOLMOPWM
7 6 3 C
GND FOL2MOCW
18 8 6
18
CONTROL FOL2TRAYSW
19 9 5
19
CONTROL FOL2DOORSW
20 20 10 4 18B9
GND FOL2OUTDIAG FOL2STARTSE
21 21 11 3 X3 18x10
FOL2INPDIAG +5V +5V
CONTROL 12
22 22 2 7 1
NINT FOL2DEFCL GND 5V GND 5V
23 13 1 8 2
23 FOL2STARTSE FOL2STARTSE
CONTROL 14 9 3
D 24
CONTROL
24 D
25 25 15
GND 16
26 26
17 18x1 18B10
(To PBA power I/O Folder 2
FOL2OUTSO FOL2TRAISE2
18 6 X3 18x9
FOL2FLATSO +5V +5V
19 5 10 1
GND 5V GND 5V
18PBA10 X7 (702))
FOL2INMOCW
20 4 11 2
FOLOFFOUTMO FOL2TRAISE2 FOL2TRAISE2
21 3 12 3
E 22 E
GND 5V
23 2
+5 V
24 1 18B11
FOL2DEPOSE
X3
X5 18X19 +5V
13 1
1 1 FOL2DEPOSE
14 2
2 2 GND 5V
15 3
3 3
F 4 4
F
(To REINFORCE 706)
5 5
6 6
7 7
8 8
9 9
10 10
G 11 11 G
12 12
13 13
14 14
15 15
16
17
18
H H
19
20
REINFORCEMENT
1 2 3 4 5 6
1 2 3 4 5 6
PBA, REINFORCEMENT
18 PBA 17
18X19 .18X24 X1 X6
FOLODATA0 +24 V 18X29
1 1 1 1 1 18Y6
FOLODATA1 FOL2RUSTOPSO FOL2RUSTOPSO
2 2 2 2 2
A 3 3
FOLODATA2
3 3
+24 V 18X28
1
A
18M7-1
4 4
FOLODATA3
4 M
(FROM REINFORCE 705)
FOLODATA4 FOL2RUMO
FOL2RUMO
5 5 5 4 2
FOLODATA5 +24 V
6 6 6 5 4 18Y7
FOLODATA6
7 7 6
FOL2RUSTAMPSO
5 FOL2RUSTAMPSO
7
FOLODATA7 +24 V
8 8 8 7 7 18Y8
FOLOCTRL0 FOL2RUTAPESO
9 9 9 8 8 FOL2RUTAPESO
FOLOCTRL1 +24 V
B 10 11 3 18Y8 B
FOLOCTRL2 FOL2RUGUIDSO FOL2RUGUIDSO
.18X25 11 12 6
FOLOCTRL3
10 1 12 X5 18S11 FOL2RUINTDOORSW 18S7
FOL2RUINPDIAG + 24V
11 2 13 1 18S10
GND 5V FOL2RUCOVERSW FOL2RUDOORSW
12 3 14 3
+5 V
PBA,RELAY
14 4 15 18 PBA 16
X7 X3
13 5 16 +24 V
1 1
15 6 GND 24V
C OPTIONAL 2 2 C
PUNCH UNIT &
DELIVERY BELTS
22X9 1813X1 X2 X4
L2 22X9-1 FOLODATA0 FOL2RUSTARTSE
1 1 1 18X26 18S12
(FROM 18 FOLDER 704)
EARTH 22X9-2 FOLODATA1 FOL2RUJAMSW

2 2 6 6
N2 22X9-3 FOLODATA2 GND 5V FOL2RUJAMSW
3 3 7 7 18S7
FOLODATA3 FOL2RUDOORSW1
J11 4 4 8
18X21-3 FOLODATA4 GND 5V FOL2RUDOORSW1
D 5 5 9 18S10 D
18X21-2 FOLODATA5 FOL2RUDOORSW2
6 6 10
18X21-1 FOLODATA6 GND 5V FOL2RUDOORSW2
7 7 11 18S11
FOLODATA7 FOL2RUCOVERSW
8 8 12
FOLOSEL4 GND 5V FOL2RUCOVERSW
9 9 13
X3 14
FOLOSEL1
10 1 15
FOLOSEL2
11 2 16 X1
PBA, IR-TX/RX
E FOLOSEL3
3
GND 5V
3 18PBA20 E
12 17
+5 V
13 4 18 1
GND 5V GND 5V
14 5 19
+5 V
15 6 20
16 7 18X26 X1
FOL2RUSTARTSE
X4 11 2
+ 5V
GND 5V PBA, IR-TX/RX
5 12 3
GND 5V
4 +5 V
18PBA19
F FOL2RUEMPTYSE
10 1 F
3
FOL2RUHOMESE
2
18X26 X2 X3
2 1 1
3 2 2 18B17
FOL2RUHOMESE
4 3 3
+5V
4 4 1
GND 5V
G 5 5 5 3 G
FOL2RUHOMESE
6 6 2
18X28-9 7 10
8 11 18B18
FOL2RUEMPTYSE
12
+5V
18X17 7 1
18X28-9
GND 5V
8 2
FOL2RUEMPTYSE
9 3
H 18X22 13
H
PBA, SENSOR
(DISTRIBUTION FOLD) 14
18 PBA 21 15
REINFORCEMENT
1 2 3 4 5 6
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
Diagrams
1 High capacity stacker 1 701
2 High capacity stacker 2 702

Diagnostics
1 Faults
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 / Possible cause Remarks

-27 / -31
DELSEP(1-6)INISE
Continuously ON / OFF 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 Possible cause Remarks
5 V regulated test
Failed LV Power Supply defective
+ 24 V not present
Connection LV Power Supply -> HCS
CPU I/O
HCS CPU I/O defective

Separation test
disconnect 1901X11 on
HCS CPU I/O
Failed HCS CPU I/O defective All doors
must be
closed and
the TRI in
position

HCS bin shift test
Failed DELSEPMO(1-6) All doors
Wiring must be
closed and
the TRI in
position
19501 MRE: ~Communication failure DEL -> CPU engine~

HCS CPU I/O engine defective
RS232 defective
5 V defective Check LV
Power Sup-
ply / wiring

Execute communication Possible cause Remarks
test (at HCS CPU)
- 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 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
Note: Switch the SDS switch back to ~RUN~ position.
Execute communication Possible cause Remarks

test (at engine PBA I/O
interface)
- 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

19503 MRE: ~Speed DELPTRMO too high~
Timing belt
19-6-05 Motor running Possible cause Remarks

DELPTRMO
No HCS CPU I/O defective All doors must
Connection HCS CPU I/O -> be closed and
DELPTRMO the TRI in
position
19504, 19505, 19506, 19507, 19508, 19509 MRE:

~DEL BIN (1-6) INItialisation failed~ see page 101

19701 ORE: ~Paper too late at DELINSE~

DELINSE
Continuously OFF DELINSE defective
Connection HCS CPU I/O ->
DELSINSE

DELINSO
Continuously OFF DELINSO defective
DELINSO
Input flap blocked

5 V regulated test
+ 24 V not present
Connection LV Power Supply ->
HCS CPU I/O

19702 ORE: ~DELINSE too late free~
Paper clipping to sensor
Timing belt not correctly tensioned

DELINSE
Continuously ON DELINSE defective
DELINSE

DELINSO
Continuously OFF DELINSO defective
DELINSO
Input flap blocked

DELBULSE
Continuously OFF DELBULSE defective
Connection DELBULSE -> PBA
DISTRIBUTION7
Connection HCS CPU I/O -> PBA
DISTRIBUTION7

5 V regulated test
+ 24 V not present
HCS CPU I/O

19703 ORE: ~Paper too late at DELVERTINSE~

DELOUTSOBIN6
Continuously ON DELOUTSOBIN6 blocked
Connection DELOUTSOBIN6 -> HCS
CPU I/O

DELSYNSE
Continuously ON / OFF DELSYNSE defective
Connection HCS CPU I/O -> DEL-
SYNSE

DELVERTINSE
Continuously OFF DELVERTINSE defective
Connection HCS CPU I/O -> DELV-
ERTINSE

5 V regulated test
+ 24 V not present
HCS CPU I/O

19704 ORE: ~DELVERTINSE too late free~


DELVERTINSE
Continuously ON DELVERTINSE defective
Connection HCS CPU I/O -> DELV-
ERTINSE

5 V regulated test
+ 24 V not present
Connection LV Power Supply -> CPU
I/O
19705, 19707, 19709, 19711, 19713, 19715 ORE:

~Paper too late at DELOUTSE (1-6)~
Paper path blocked
19-2-13 / -17 / -21 / -25 / -29 Possible cause Remarks

/-33
DELOUTSE(1-6)
Continuously OFF DELOUTSE(1-6) defective
Connection DELOUTSE1 -> HCS
CPU I/O
Connection DELOUTSE(2-5) -> PBA
DISTRIBUTION(1-5)
Connection PBA DISTRIBU-
TION(1-5) -> HCS CPU I/O

-11
DELOUTSOBIN(2-6)
Continuously ON DELOUTSOBIN(2-6) defective /
blocked
Connection DELOUTSOBIN(2-6)
-> HCS CPU I/O

5 V regulated test
+ 24 V not present
Connection LV Power Supply -> HCS
CPU I/O
19706, 19708, 19710, 19712, 19714, 19716 ORE:

~DELOUTSE (1-6) too late free~
Paper path blocked

-29 /-33
DELOUTSE(1-6)
Continuously ON DELOUTSE(1-6) defective
Connection DELOUTSE1 -> HCS
CPU I/O
Connection DELOUTSE(2-6) -> PBA
DISTRIBUTION(1-5)

-11
DELOUTSOBIN(2-6)
Continuously ON DELOUTSOBIN(2-6) defective /
blocked

-11
DELOUTSOBIN(2-6)
Connection DELOUTSOBIN(2-6) ->
HCS CPU I/O

5 V regulated test
+ 24 V not present
HCS CPU I/O
19717 ORE: ~Speed DELPTRMO too low~

Loose puls disc / soiled

DELPTRMOSE
Contiuously ON / OFF DELPTRMOSE defec5tive
Connections DELPTRMOSE ->HCS
CPU I/O
Sensor soiled

5 V regulated test
+ 24 V not present
Connections LV Power Supply ->
HCS CPU I/O

DELPTRMO
ON No HCS CPU I/O defective All doors
Connections HCS CPU I/O -> must be
DELPTRMO closed and the
TRI in posi-
tion
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.~
Drive spindles mechanicaly
blocked
19-2-12 / -15 / -19 / -23 / -27 / Possible cause Remarks

-31
DELSEP(1-6)INISE
Continuously ON / OFF DELSEP(1-6)INISE defective
Connection DELSEP(1-6)INISE ->
Connections HCS CPU I/O ->
DELSEPMO1-6 ->

5 V regulated test
+ 24 V not present
HCS CPU I/O

Separation test
disconnect 1901X11 on
HCS CPU I/O
Failed HCS CPU I/O defective All doors
must be
closed and
the TRI in
position

HCS bin shift test
Failed DELSEPMO(1-6) All doors
must be
closed and
the TRI in
position
19731 ORE: ~Paper too late at DELTRIOUTSE~

Paper transport belts blocked
Timing belt TRI not correctly tensioned
Timing belt PTR not correctly ten-
sioned
Puls disc loose / soiled

DELBULSE
Continuously ON DELBULSE defective / soiled
BULSE

DELTRIOUTSE
Continuously OFF DELTRIOUTSE defective
Connection HCS CPU I/O -> DELTRI-
OUTSE

19=2-10 Possible cause Remarks
DELPTRMOSE
Continuously ON / OFF DELPTRMOSE defective / soiled
Loose connection

5 V regulated test
+ 24 V not present
HCS CPU I/O

DELPTRMO
No HCS CPU I/O defective All doors must
Connection HCS CPU I/O -> be closed and
DELPTRMO the TRI in posi-
tion
19732 ORE: ~DELTRIOUTSE too late free~

Timing belt TRI not correctly ten-
sioned

DELTRIOUTSE
Continuously ON DELTRIOUTSE blocked / defective
TRIOUTSE

5 V regulated test
+ 24 V not present
HCS CPU I/O
19733 ORE:~Paper too late at DELSYNSE~

Paper transport belts mechanically
blocked
sioned
Timing belt PTR not correctly ten-
sioned
Puls disc loose / soiled

DELBULSE
Continuously ON DELBULSE defective / soiled
BULSE

DELSYNSE
Continuously OFF DELSYNSE defective During start
Connection HCS CPU I/O -> DEL- no problem
SYNSE

5 V regulated test
+ 24 V not present
HCS CPU I/O
19734 ORE: ~DELSYNSE too late free~

sioned

DELSYNSE
Continuously ON DELSYNSE blocked / defective
SYNSE

5 V regulated test
+ 24 V not present
HCS CPU I/O

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~

SDS
Test number Component Signal Description
Parameter test
19-1-01 ~Maximum number of copies~

~in HCS bins~
Input tests
19-2-01 19S2 ~DELivery Upper DOOR~ Delivery upper door switch

~SWitch~ OFF = door closed
19-2-02 19S3 ~DELivery Lower DOOR~ Delivery lower door switch

~SWitch~ OFF = door closed
19-2-03 19S4 ~DEL TRI OPen SWitch~ Delivery transport intermediate

open switch
OFF = operating position
19-2-04 19S1 ~DEL TRI POSition Delivery transport intermediate

SWitch~ position switch
OFF = operating position
19-2-05 19B2 ~DELivery BULge SEnsor~ Delivery bulge sensor

ON = bulge present
19-2-06 19B1 ~DELivery INput SEnsor~ Delivery input sensor

ON = paper present
19-2-07 19B3 ~DELivery SYNchroniza- Delivery synchronization sensor

tion SEnsor~ ON = paper present
19-2-08 19B4 ~DEL TRI OUTput SEn- Delivery transport intermediate

sor~ output sensor
ON = paper present
19-2-09 19B25 ~DELivery VERTical~ Delivery vertical input sensor

~INput SEnsor~ ON = paper present
19-2-10 19B24 ~DELivery PTR MOtor Delivery paper transport motor

SEnsor~ sensor
Pulses

19-2-11 19PBA10 ~DELivery BIN 1 EMpty~ Delivery bin 1 empty sensor

~SEnsor~ ON = bin empty
19-2-12 19B18 ~DELivery SEParation 1~ Delivery separation 1 initialisa-

~INIt SEnsor~ tion sensor
ON = home position
19-2-13 19B5 ~DELivery OUTput ~ Delivery output sensor 1

~SEnsor 1~ ON = paper present

~SEnsor ~ ON = bin empty

ON = home position
19-2-16 19B12 ~DELivery BIN 2 OPen~ Delivery bin 2 open sensor

~SEnsor~ ON = bin open
19-2-17 19B6 ~DELivery OUTput~ Delivery output sensor 2

~SEnsor 2~ OFF = paper present


ON = home position
19-2-20 19B13~ ~DELivery BIN 3 OPen~ Delivery bin 3 open sensor



19-2-23 19B21 ~DELivery SEParation 4~ Delivery Separation 4 initialisa-

ON = home position

19-2-25 19B8 ~DElivery OUTput~ Delivery output sensor 4

202 TSM Oc 9800 SDS

19-2-26 19PBA14 ~DElivery BIN 5 EMpty~ Delivery bin 5 empty sensor


ON = home position

19-2-29 19B9 ~DElivery OUTput~ Delivery output sensor 5



ON = home position


Output tests
19-4-01 19Y1 ~DELivery INput SOle- Delivery input solenoid

noid~ ON = sheets to TRI
19-4-02 19V1 ~DELivery BIN LED 1~ Delivery bin led 1

ON = LED on
19-4-03 19Y7 ~DELivery OUTput~ Delivery output solenoid bin 2

~SOlenoid BIN 2 ~ ON = sheets to bin 2

ON = LED on

~SOlenoid BIN 3~ ON = sheets to bin 3

ON = LED on



ON = LED on


ON = LED on

~SOlenoid BIN 6 ~ ON = sheets to bin 6

ON = LED on
19-4-13 ~DEL buzzer~ Delivery buzzer on CPU I/O

PBA
Special tests
19-6-03 ~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 separa-
tion
Disconnect 1901X11 on
19PBA1 CPU I/O
the test
204 TSM Oc 9800 SDS

19-6-05 ~DELivery PTR MOtor~

~(DELPTRMO)~
DELivery Paper TRansport
MOtor
Activates the main motor at nor-
mal speed or at 100% PWM sig-
nal(for a short moment)
the test
19-6-06 ~HCS bin shift test~

after bin selection the bin will
shift when pushing the start but-
ton
the test
Info tests
19-9-01 ~HCS release~

Release number of HCS soft-
ware used (0-99)
19-9-02 ~HCS version~

Release number of HCS
software used (0-99)
19-9-03 ~HCS patch~
Release number of HCS
software used (0-99)

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

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.

2 The delivery input solenoid (DELINSO)
Aim:
The copies must be fed into the TRI without jamming.
Check:
2 remove the left side cover from the TRI.
3 Measure the distance between the flap and the top of the left frame of the TRI.
4 Specifications:
the distance must be 91 -0/+3 mm (3.58) when the solenoid is activated.
the core of the solenoid must freely move into the coil.
nut A nut B
91 -0/+3 mm
flap
lever
shaft
5 mm
screws
Correction:
1 Remove the 4 lower screws from the bottom cover of the TRI.
2 Loosen (remove) the 4 upper screws from the bottom cover of the TRI.
3 Remove the bottom cover of the TRI.
4 Place the TRI is in operating position.
5 Turn the nut A until the spring is unloaded, the flap must be in the lower posi-
tion.

6 Turn the nut A until the flap is in the upper position.
7 Load the spring 5 mm more and secure with the nut B.
9 Adjust the distance to 91 -0/+3 mm with the 2 screws of the solenoid.
10 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.

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:
the deflector should lay parallel with respect to the paper guide plate when
the solenoid is deactivated.
mounting
screws
lever
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 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:
the deflector flap may not touch the lower guide plate when the solenoid is
deactivated.
shaft
deflector flap
> 0 mm 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
guide plate.
4 Then move the solenoid bracket 1 mm downwards and fix the screws.
5 Carry out SDS test 19-4-11 several times to check for correct functioning.
7 Remount the cover.

5 The belt tension of the TRI drive belt
Aim:
A correct tension of the TRI drive belt.
Check:
No check available.
fixing screws
Correction:
1 Remove the left side cover from the TRI.
2 Loosen the 2 fixing screws so the spring tensions the belt.
4 Carry out SDS test 19-6-05 for one minute.
5 Repeat the adjustment once.

6 The belts tension
The adjustment is only given for one belt tension, all other have the same prin-
ciple.
Aim:
A correct tension of the drive belts.
Check:
No check available.
Correction:
1 Remove the upper / lower side cover at the right side.
2 Loosen the fixing screws A and B so the spring tensions the belt.
3 First tighten the screw A in the slotted hole and then the screw B.
4 Carry out SDS test 19-6-05 for one minute.
5 Repeat the adjustment once.
6 Remount cover.

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:
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

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

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.

Dis-/assemblies
1 The transport intermediate (TRI)

1 Remove the screws from the side covers of the TRI from the bottom (3 screws
each).
2 Remove the side covers from the TRI.
3 Loosen the drive belt tensioner at the left side.
4 Remove the drive belt from the tensioner.
5 Disconnect connector 19X20 at the right side.
6 Cut the 2 cable ties to loosen the bundle from the TRI.
7 Remove the bundle with female connector 19X20 from the TRI.
8 Close the TRI.
10 Remove (loosen) the 4 upper screws from the bottom cover of the TRI.
11 Remove the bottom cover.
12 Remove the lower side covers at the left and right side (2 screws).
13 Open the TRI and the upper door.
14 Remove the 3 screws of the lower corner covers at the left and right side.
15 Close the upper door.
16 Remove the lower corner covers.
17 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.
Note: The TRI moves upwards when the upper guide is removed.
21 Remove the upper guide.

upper guide
4 screws
lower corner cover
cover upper
guide
lower side
cover left side cover
screws 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:
27 Position the TRI on the bearings.

28 Mount the locking plates.
29 Close the TRI and hold the TRI in position.
30 Use the special tool, which is delivered with the HCS to mount the gas damp-
ers.
31 Remount the security clips over the gas dampers.
32 The length of the free cable bundle must be 510 +/- 2 mm (20).

33 Remount all other parts.
19X20
cable bundle
TRI

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 con-
necting again).
10 Remove the switch activator (4 screws).
11 Push the cable bundle to the inside of the TRI frame.
12 Remove 2x3 screws from the paper input guide cover at the left and right side.
13 Lift up the paper input guide cover at the front left side.
14 Loosen from the solenoid lever the screw from the shaft of the input guide flap.
15 Remove the circlips from the shaft of the input guide flap at the left inside and
outside.

16 Remove the circlip from the bush of the shaft of the input guide flap at the right
side.
17 Remove the bush from the shaft at the right side.
18 Remove the shaft with the input guide flap.
19 Remove the upper bearing parts from the drive roller at the left and right side.
20 Lift the drive roller upwards and remove the roller.
21 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.

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

remove the bracket with the PBA
4 Loosen the tension spring of the motor.

5 Remove the motor (3 screws).
Mounting the motor
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 Remove the lower side cover at the left side.
2 Remove the cover underneath the lower door.
3 Remove the cover from the motor (3 screws).
4 Disconnect the connectors 19X4 (motor) and 19B24 (motor sensor).
5 Release the belt tension (2 screws).
6 Replace the motor (4 screws).
After assembly carry out adjustment see The belts tension on page 308.

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

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
clips up at the frame side (bottom).
4 Remove the gas dampers from the frame.
6 Remove the screws from the hinges at the door side.
8 Disconnect the earth wire at the left side.
9 Remove the screws from the locking plates from the upper door (2 x 2 screws).
10 Shift the locking plates to the inside.
12 Lift out the upper door.
During assembly:
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

7 DELBULSE
1 Loosen the 4 screws (inside the holes) from the cover of the upper guide.
2 Remove the cover.
3 Loosen the limitation screws of the upper guide.
4 Lift the upper guide for easier removal of the cover behind the input guide
plate.
6 Remove the 2 upper screws from the bracket with the sensor.
7 Disconnect the connector.
8 Remove the shaft from the bracket.
9 Replace the sensor.
8 DELINSE
1 Loosen the 4 screws (inside the holes) from the cover of the upper guide.
2 Remove the cover.
3 Loosen the limitation screws of the upper guide.
4 Lift the upper guide for easier removal of the cover behind the input guide
plate.
9 DELTRIOPSW
After replacement, carry out adjustment see The delivery transport intermedi-
ate open switch (DELTRIOPSW) on page 311.

10 DELTRIOUTSE
2 Remove (loosen) the 4 upper screws from the bottom cover of the TRI.

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
TRI.
3 Remove the cover from the upper guide.
4 Remove the lower side covers at the left and right side.
6 Disconnect all connectors from the CPU I/O PBA at the right side (use your
wrist strap).
7 Remove the 2 fixing screws from the bracket on which the PBA is mounted
against the frame.
8 Remove the bracket with the PBA (push upwards and out).
9 Disconnect the connectors from the power supply PBA at the left side.
10 Remove the wiring from the clips.
11 Remove the bracket with the power supply PBA (3 screws).
12 Move the circlip from the support shaft of the upper door at the left frame in-
side inwards.
13 Remove the bracket from the shaft center.
14 Shift the support shaft to the left and move the right end of the support shaft to
the rear.
15 Remove DELSEPMO5 see page 406
16 Disconnect the connector of the sensor.
17 Remove the screws from the strip with the wiring of the sensor from the frame
(2x2 screws).
18 Push the strip upwards.

12 DELOUTSE1
1 Remove the upper cover at the left side.
2 Remove the upper and lower side cover at the right side.
4 Remove the triangle top cover (4 screws).
5 Remove the top covers at the left and right side (1 inside from underneath).
7 Loosen 3 screws from the cover at the inside, underneath the top cover.
8 Remove the inside cover.
9 Remove at the left side the upper corner cover (4 screws).
10 Remove at the left side the U shaped frame at the top (5 screws).
11 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).
13 DELOUTSE2-6
1 Carry out disassembly see The delivery bins on page 407, the delivery bin
which is above the sensor to replace.
2 Remove the upper and lower side covers at the right side.
4 Remove the upper and lower side covers at the left side.
5 Remove the long left side cover (9 screws).
6 Disconnect the connectors from the LEDs.
7 Remove the cover from the delivery bin output (4 screws).
8 Remove the screws from the guide plate with the sensor (2x2 screws).
10 Remove the guide plate with the sensor.
During assembly push the guide plate down onto the spacers.

14 DELBINOPSE
1 Carry out disassembly see The delivery bins on page 407, the corresponding
delivery bin.
2 Remove the upper and lower side covers at the left and right side.
4 Remove the cover from the delivery bin output.
5 Remove the screw from the bracket with the sensor at the right side (viewed
from the rear).
15 DELBINEMSE PBA
1 Remove the cover from the sensor PBA (2 screws).
3 Replace the PBA (3 screws).
16 DELSEPINISE
1 Carry out disassembly see The delivery bins on page 407, the corresponding
delivery bin.
2 Remove the upper and lower cover at the right side.
4 Remove the cover from the delivery bin output (4 screws).
5 Remove the screws from the strip with the magnets.
6 Shift the strip inwards.
7 Remove the 2 screws from the strip with the sensor.
8 Cut the cable tie at the frame outside.
9 Turn the strip.
10 Remove the sensor (do not damage the sensor lever).
11 Disconnect the sensor.

17 DELVERTINSE
1 Carry out disassembly see The delivery bins on page 407, the delivery bin
number 5.
2 Remove the upper and lower side cover at right side.
4 Remove the cover from the delivery bin output.
18 DELINSO
1 Remove the side cover of the TRI at the right side (3 screws).
3 Loosen (remove) the 4 upper screws from the bottom cover of the TRI.
After replacement, carry out adjustment see The delivery input solenoid (DE-
LINSO) on page 303.
19 DELOUTSOBIN
1 Remove the upper and lower side cover at the right side.
3 Disconnect the connector from the solenoid.
4 Loosen the solenoid lever from the shaft.
5 Remove the solenoid mounting screws.
6 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.

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:
a transport intermediate (TRI)

a vertical transport
6 bins
vertical transport PTR

bin 1 TRI
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.

The HCS features 4 basic delivery methods:
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 oper-
ator 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 sta-
tus of the bins or action to take by the operator:
continuously on = bin in use

flashing slowly = bin full
flashing fast and buzzer = close bin immediately, delivery in process

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 cer-
tain time after DELINSE has detect the entering of the copies.
The bulge sensor (DELBULSE) controls the speed from DELPTRMO.

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

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.

1 Component names
19-High Capacity Stacker
Component Description Translation

DELOUTSE1 ~DELivery OUTput~ Delivery output sensor 1
~SEnsor 1~
~SEnsor 2~
~SEnsor 3~
~SEnsor 4~
~SEnsor 5~
~SEnsor 6~
DELSEP1INISE ~DELivery SEParation 1 Delivery separation 1 ini-
INItialisation SEnsor~ tialisation sensor
DELBIN1EMSE ~DELivery BIN 1~ Delivery bin 1 empty
~EMpty SEnsor~ sensor
DELBIN2EMSE ~DELivery BIN 2 ~ Delivery bin 2 empty
DELBIN3EMSE ~DELivery BIN 3 Delivery bin 3 empty

DELBIN2OPSE ~DELivery BIN 2 ~ DELivery BIN 2
~OPen SEnsor~ OPen SEnsor
DELBINTXEMSE ~DELivery BIN TX~ DELivery BIN TX
~EMpty SEnsor PBA~ EMpty SEnsor PBA
DELTRIOPSW ~DELivery TRansport~ DELivery TRansport
~Intermediate Open~ Intermediate Open
~SWitch~ SWitch
DELSYNSE ~DELivery SYNchroni- DELivery SYNchroniza-
zation SEnsor~ tion SEnsor
DELTRIOUTSE ~DELivery TRansport~ DELivery TRansport
~Intermediate OUTput~ Intermediate OUTput
SEnsor~ SEnsor
DELINSE ~DELivery INput SEn- DELivery INput SEnsor
sor~
DELBULSE ~DELivery BULge SEn- DELivery BULge SEnsor
sor~
DELPTRMOSE ~DELivery Paper TRans- DELivery Paper TRans-
port MOtor SEnsor~ port MOtor SEnsor
DELTRIPOSSW ~DELivery TRansport~ DELivery TRansport

~Intermediate POSition~ Intermediate POSition
~SWitch~ SWitch
DELLDOORSW ~DELivery Lower~ DELivery Lower DOOR
~DOOR SWitch~ SWitch
DELUDOORSW ~DELivery Upper~ DELivery Upper DOOR
~DOOR SWitch~ SWitch

DELOUTSOBIN2 ~DELivery OUTput~ DELivery OUTput SOle-
~SOlenoid BIN 2 ~ noid BIN 2
~SOlenoid BIN3 ~ noid BIN3
~SOlenoid BIN5~ noid BIN5
DELSEPMO1 ~DELivery SEParation~ DELivery SEParation
~MOtor 1~ MOtor 1
~MOtor 2~ MOtor 2
~MOtor 3~ MOtor 3
~MOtor 4~ MOtor 4
~MOtor 5~ MOtor 5
~MOtor 6~ MOtor 6
DELBINLED1 ~DELivery BIN LED 1~ DELivery BIN LED 1
DELPTRMO ~DELivery Paper TRans- DELivery Paper TRans-
port MOtor~ port MOtor
DELINSO ~DELivery INput SOle- DELivery INput SOle-
noid~ noid
CONEMS2 ~CONtrol Electro Mag- CONtrol Electro Mag-
netic Switch 2~ netic Switch 2

Transport intermediate (TRI)
DELBULSE
19B2 DELINSE
DELTRIOPSW 19B1
19S4
DELTRIPOSSW
19S1
Oc 9800
/ 9700
19PBA09
DELINSO
19Y1
DELTRIOUTSE
19B4

Sensors / PBA (left hand side)
19PBA16
trafo
DELSUPLV
19G01

Sensors / PBA (right hand side)
DELOUTSE1
19PBA03 19B5
19PBA04
DELOUTSE2
DELBIN2OPSE 19B6
19B12
19PBA05
DELOUTSE3
DELBIN3OPSE 19B7
19B13
19PBA06
DELOUTSE4
DELBIN4OPSE 19B8
19B14
DELVERTINSE
19B25 DELOUTSE5
19B9
19PBA07
DELBIN5OPSE
19B15 DELOUTSE6
10B10
19PBA08
DELTRIOUTSE
DELBIN6OPSE 19B4
19B16
DELSYNSE
19B3

Motors / solenoids / PBA (right hand side)
DELOUTSOBIN2
19Y7
DELSEPMO1 DELOUTSOBIN3
19M2 19Y6
DELSEPMO2 DELOUTSOBIN4
19M3 19Y5
DELSEPMO3
DELOUTSOBIN5
19M4
19Y4
CPU-I/O PBA
19PBA01
DELSEPMO4
19M5
DELOUTSOBIN6
DELSEPMO5 19Y3
19M6
DELSEPMO6
19M7
DELPTRMO
19M1
DELPTRMOSE

1 2 3 4 5 6
22PBA1 CPU I/O 18PBA1 I/O INTERFACE 19PBA1 CPU I/O
X1 X1 X12 19X4
+5V X6 19X5 X9 +24VSAF
1 1 DELTXD 1 2
+5V 3 2 2 DELPTRMO
2 2 DELRXD M
GND 2 3 3
A 3
BD0
3
5
DELRTS
4 4 DELPTRMO
19M1
4 4 DELCTS 2 1
BD1 4 5 5
5 5 GND X4
BD2 1 7 1 +5V
6 6 10 1 DELPTRMOSE
BD3 DELPTRMOSE
7 7 11 2 19B24
GND GND
8 8 CAP19X5 12 3
BD4
9 9
BD5
10 10
BD6
11 11 X8 19X23 19X20 19X13
BD7 +24V
12 12 6 1 1 1 DELINSO
GND
13 13 X4 19Y1
BA1 +5VR DELINSO
14 14 1 1 3 2 2 2
BA2 DELBIN1EMSE
15 15 DELBIN1EMSE 2 2
BA3 GND 19X15
16 16 3 3 +24VSAF
BA4 19PBA10 2 1 DELBIN6OUTSO
B 17
GND
17 4
19Y3
18 18 DELBIN6OUTSO
NASIC1_RD +5VR 1 2
19 19 DELSYNSE 1 4
NASIC1_WR GND
20 20 19B3 2 5 19X16
GND DELSYNSE +24VSAF
21 21 3 6 12 1 DELBIN5OUTSO
NINT5
22 22 19Y4
NINT4 +5VR DELBIN5OUTSO
23 23 DELOUTSE1 1 7 9 2
BNRESET GND
24 24 19B5 3 8
BNOE DELOUTSE1 19X17
25 25 2 9 +24VSAF
GND 11 1 DELBIN4OUTSO
26 26
DELBIN4OUTSO 19Y5
19PBA9 DISTRIBUTION7 10 2
X1
+5V X2 19X20 X13 19X18
DELTRIOUTSE 1 1 +5V +24VSAF
DELBIN3OUTSO
GND 8 3 1 8 1
2 2 GND
C 19B4
3
DELTRIOUTSE
3
7 4
DELINSE
2
DELBIN3OUTSO 19Y6
2 5 3 7 2
X3 DELBULSE
+5V 3 6 4
DELINSE 1 1 DELTRIOUTSE 19X19
GND 1 8 6 +24VSAF
19B1 2 2 5 1 DELBIN2OUTSO
DELINSE
3 3 19Y7
DELBIN2OUTSO
4 2
+5V
DELBULSE 1 4
GND
19B2 3 5
DELBULSE X6 19X21
2 6
1
+5V
1
DELBINLED1
DELBINLED1 19V1
GND 2 2
8
GND
15
DELTRIPOSSW
X13
3
+5V
3
DELBINLED2
7 DELBINLED2 19V2
DELLDOORSW 4 4
D GND
10
11
DELUDOORSW
8 5
+5V
5
DELBINLED3
DELBINLED3 19V3
DELTRIOPSW DELTRIPOSSW DELLDOORSW DELUDOORSW 6 6
19X20
GND
3 4 4 3 11 3 4 3 4 9
2 1 2 1 10 2 1 2 1 X14 7
+5V
7
DELBINLED4
+24V DELBINLED4 19V4
19S4 19S1 19S3 19S2 1 8 8
+24VB
9 2
FRAME EARTH CONNECTION 12 TRANSPORT-INTERMEDIATE EARTH CONNECTION
9
+5V
9
DELBINLED5
19X22 19X14 X13 DELBINLED5 19V5
DELTRIOPSW 10 10
7 5
22PBA5 DRIVERS
X13 X10 X5 CTFDOORSW 11
+5V
11
DELBINLED6
+5V +24V TP1 +5V DELBINLED6 19V6
E 1
GND
1 7 1 2 12 12
2 2 O6S1
+24V
3 3 TP2 +5VR
GND X11 19X7
5 5 PTRFRAMESW
1 1
F4 +24V-SW
22G1 CONSUPLV 8 2 1 TP3 2 2 M DELSEPMO1
4A
15S1 +24VSAF 3 3 4 19M2
G3 X8
+5V 14 4
1 1
GND
2 2 TP4 GND
+5V 19X8
3 3
GND F1 5 1
4 4
4A 4 2 M DELSEPMO2
G2
+24V SDS 7 3 4 19M3
1 5 X12
GND CONEMS2-B 16 4
2 6 12
+24V
F 3
GND
7 CONEMS2 19X9
4 8 22K2-2A
+24V +24V-SW 9 1
5 9 15
GND 6 2 M DELSEPMO3
6 10 LED
11 3 4 19M4
22PBA4 SSR
18 4
22Z2
X9 X8
L2 L2 5V
6 1 6 6 8 19X10
22X010 N2
5 2 3 2 4 13 1
N2 8 2 M DELSEPMO4
4 3
15 3 4 19M5
20 4
19G1 DELSUPLV 19S7
19Z1 19S6
G1 19T1 19X1 X2
N2-S N2-S 19X11
2 2 1 1 5 1
17 1
G
LOAD
10 2 M DELSEPMO5
LINE
208V L2-S
4 19 3 4 19M6
220V
19S5 22 4
F1 L2-S 230/240V
1 2 1 2 6
5A 19X12
3 3
G2 19X3 FRAME EARTH CONNECTION19X2 X1
21 1
+5V 12 2 M DELSEPMO6
1 1
GND 23 3 4 19M7
2 2
+24V 24 4
3 3
GND
4 4
H
TO HIGH CAPACITY STACKER 2 ON PAGE 702 HIGH CAPACITY STACKER1
ed.5 TSM Oc 9800 19 OPTIONALS 701
1 2 3 4 5 6
19PBA1 CPU I/O 19PBA3 DISTRIBUTION1
FROM HIGH CAPACITY STACKER ON PAGE 701
X2 X2 X3
+5V +5V
1 8 1 1 DELOUTSE2
GND GND
2 7 2 2 19B6
A 3
DELOUTSE3
2 3
DELOUTSE2
3
DELBIN2INISE
4 4
DELBIN3EMSE +5V
5 5 7 1 DELSEP1INISE
GND
8 3 19B18
DELSEP1INISE
9 2
+5V
10 1
GND DELBIN2EMSE
11 3
DELBIN2EMSE
12 2 19PBA11
4
19PBA4 DISTRIBUTION2
X2 X3
+5V +5V
6 8 1 1 DELOUTSE3
GND GND
7 7 2 2 19B7
B 8
DELOUTSE3
2 3
DELOUTSE3
3
DELBIN2OPSE
9 3
DELSEP2INISE +5V
10 4 4 1 DELBIN2OPSE
DELBIN3EMSE GND
11 5 5 3 19B12
DELBIN2OPSE
6 2
+5V
7 1 DELSEP2INISE
GND
8 3 19B19
DELSEP2INISE
9 2
+5V
10 1
GND DELBIN3EMSE
11 3
DELBIN3EMSE
12 2 19PBA12
4
C 19PBA5 DISTRIBUTION3
X2 X3
+5V +5V
12 8 1 1 DELOUTSE4
GND GND
13 7 2 2 19B8
DELOUTSE4 DELOUTSE4
14 2 3 3
DELBIN3OPSE
15 3
DELSEP3INISE +5V
DELBIN4EMSE GND
17 5 5 3 19B13
DELBIN3OPSE
6 2
+5V
7 1 DELSEP3INISE
GND
8 3 19B20
DELSEP3INISE
9 2
D 10
+5V
1
GND DELBIN3EMSE
11 3
DELBIN4EMSE
12 2 19PBA13
4
X2 X3
+5V +5V
18 8 1 1 DELOUTSE5
GND GND
19 7 2 2 19B9
DELOUTSE5 DELOUTSE5
20 2 3 3
DELBIN4OPSE
21 3
DELSEP4INISE +5V
DELBIN5EMSE GND
23 5 5 3 19B14
DELBIN4OPSE
6 2
E +5V
7 1 DELSEP4INISE
GND
8 3 19B21
DELSEP4INISE
9 2
+5V
10 1
GND DELBIN5EMSE
11 3
DELBIN5EMSE
12 2 19PBA14
4
X2 X3
+5V +5V
24 8 1 1 DELOUTSE6
GND GND
25 7 2 2 19B10
DELOUTSE6 DELOUTSE6
26 2 3 3
DELBIN5OPSE
F 27
DELSEP5INISE
3
+5V
DELBIN6EMSE GND
29 5 5 3 19B15
DELBIN5OPSE
6 2
+5V
7 1 DELSEP5INISE
GND
8 3 19B22
DELSEP5INISE
9 2
+5V
10 1
GND DELBIN6EMSE
11 3
DELBIN6EMSE
12 2 19PBA15
4
G X3
+5V
X2 X3
+5V
1 8 4 1 DELBIN6OPSE
GND GND
2 7 5 3 19B16
DELBIN6OPSE DELBIN6OPSE
4 3 6 2
DELSEP6INISE
5 4
+5V
7 1 DELSEP6INISE
GND
8 3 19B23
DELSEP6INISE
9 2
+5V
10 1
GND DELBINTXEMSE
11 3
H 2 19PBA16
4
HIGH CAPACITY STACKER 2
ed.5 TSM Oc 9800 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) 401
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
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) 512
9 SCAN STATION 513
10 SCSI PBAs 514
11 PC characteristics 516
ed.5 20 Interface
2 FBBS PBA 602
3 ROM module PBA 603
4 SCSI PBA 603
5 Connectors 604
Diagrams
1 FBBS 701

Diagnostics
1 Faults
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 prop- * Check position on the motherboard.
erly mounted in the controller) * 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 Check positioning
mounted in the controller).
Faulty SCSI PBA in the control- Execute the controller functional test SCBT
ler. to verify whether the board is okay.
SCSI bus not properly termi- In Controller:
nated. 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 ter-
minate the bus properly.
* If the Adaptec 1542CF board is used, SW1
of the board should also be in the ON posi-
tion. All 3 LEDs are ON.
* If the Adaptec 1542 CP is used: termina-
tion has to be enabled with the SCSISelect
utility.
* If the Adaptec 2940 is used: jumper J3 not
properly set.
Wrong configuration setting of Switch 1: in the ON position.
the switches on the SCSI PBA. Switch 2: jumper between 2 and 3 (makes
operation of switch 1 possible), default set-
ting 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).
20805 OWAR: ~Ethernet pba error

20806 OWAR: ~Taxi interface Scanner pba ~
20807 OWAR: ~Vector firmware checksum error~

20808 OWAR: ~Vector extention checksum error~

20809 OWAR: ~DRAM simm pbas error~

The installed frame buffer All LEDs on the controller are OFF.
DRAM SIMM modules dont
match with the configuration set-
tings in SDS test 90.
One of the SIMMs defect or Not all LEDs are OFF (LED indication
makes bad contact. 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.
Execute special test Possible cause

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~

Taxi printer pba or adapter pba * Check position.
not properly set. * Execute the controller functional test TPBT
to verify whether the board is okay.

20811 OWAR: ~Communication error contr(oller) -> engine~
This is the only error generated by the engine: if the engine has lost the com-
munication 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 All LEDs are continuously OFF
position. or ON. See LED indication
table on page 115 or the +100
Connection: pages of the ST software.
bad contact firmware ROM module (FBBS
SW SRC or Boot PROM) on FBBS mother-
board (FBBS PBA).
Connection:
communication cable between controller and
CPU_IO PBA.
Connection:
mains to controller supply.
Connection:
cable between controller and set-memory at
set-memory side not properly mounted (or too
tight).
Connection: See LED indication table on
one of the SIMMs makes bad contact. page 115 or +100 pages of the
ST software.
Controller supply defect.
BOOTPROM SW SCR and / or ROM module
(FBBS SW SRC) defect.
FBBS motherboard (FBBS PBA) defect. See LED indication table on
page 115.
Faulty frame buffer SIMMs. Micron SIMMs with the identifi-
cation MT8D432M-7 and a
batch reference starting with 95,
cause the error 20811 when
printing large (vector) files.
CPU_IO code is C. (after 30 sec.) Possible cause

- Switch off the machine. -No - CPU_IO-PBA
Put connector C of test bun- defect
dle 7991.293 in
PBA-CPU_IO, X17.
Switch on the machine in
normal mode.

TCSP test via Laptop Possible cause
okay
- Switch off the machine. - No - Electrical connection
Put connector D of test bun- *20D1 -> P5
dle 7991.293 on 20D1. - FBBS board defect (see
Switch on the machine in next table for details)
normal mode with the con-
troller service switch on.
Possible cause (FBBS board defect) Remark

- 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

20812 OWAR: ~Communication error engine -> contr(oller)~


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.
CPU_IO PBA defect. No display message if the controller is
removed from the configuration and the sys-
tem is rebooted.
Non controller error. Remove the controller from the configura-
tion and reboot the system.
Read out the display message / error help.
Copy counter code is Possible cause

9999 (after 10 sec.)
- Switch off the machine. - No - CONSOLE_CPU-PBA
Put connector A of test bundle defect
7991.293 in PBA-CONSOLE_
CPU, X10. Switch on the
machine in normal mode.
CPU_IO code is C. Possible cause

(after 30 sec.)
- Switch off the machine. - No - CPU_IO-PBA defect
Put connector B of test bundle
7991.293 in PBA-CPU_IO,
X14.
Switch on the machine in
normal mode.

- 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

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 mem-
ory), 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. Other-
wise this file cannot be printed completely.
All data of this file that cannot be handled will be thrown away. If Oc Repro-
Station 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.

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:
Settings of this link at both sides. The parity settings should be the same at both
the Oc 9800 and the host

20822 OWAR: ~RS-232 host / contr. (to controller) overrun error~
~
Possible cause
Connection:
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~

Connection: The SCSI cable should not be
connected host -> controller (SCSI) removed when machine and host are
switched on. Switch OFF both!
Settings of this link.

20831 OWAR: ~SCSI: chip error~


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!.
SCSI settings wrong (SCSI ID Verify that each device on the SCSI bus has a
setting). different SCSI ID.
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 posi-
tion.
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.
Incorrect boot sequence. 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.

20832 OWAR: ~SCSI: parity error~
~

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

~

The plot file contains a command which is not supported by the
controller. Check the plot file.
20861 OWAR: ~Interpr. (eter) error: syntax error~

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 specifica-
tions). Check the plot file
20862 OWAR: ~Language not recognized~

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.

20863 OWAR: ~Plot is clipped~
~

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


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

~

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

ported APPLDATA parameter (probably header is according the RCF refer-
an old one of Version 1). Only the wrong ence Manual.
parameter(s) are ignored.

20901 SWAR: ~Illegal ram configuration contr(oller).~
~
Switch machine Possible cause Remark

OFF/ON: all
LEDs on con-
troller OFF
after selftest?
No See LED identification
able.on page 115 or the
+100 pages of the ST soft-
ware.
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.

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 min-
utes depending the amount of memory installed.
LED 1 LED 2 LED 3 Defect module

OFF OFF OFF Directly after switching on
2nd CPU does not boot (e.g. bootprom incor-
rectly inserted, service switch on).
The controller stays in hardware reset.
Also the error code 20811 will be displayed.
OFF OFF OFF After the selftest is finished:
All modules okay
ON OFF OFF OLB board in extension slot A defect.

OFF ON OFF OLB board in extension slot B defect.
ON ON OFF OLB board in extension slot C defect.
OFF OFF ON OLB board in extension slot D defect.
ON OFF ON OLB board in extension slot E defect.
OFF ON ON OLB board in extension slot F defect.
SEE Note
ON BLINK ON Mother board error
BLINK OFF OFF Mem. Frame Buffer 1_ SIMM 1 error, 20901
OFF BLINK OFF Mem. Frame Buffer 1_ SIMM 2 error, 20901
BLINK BLINK OFF Mem. Frame Buffer 1_ SIMM 3 error, 20901
OFF OFF BLINK Mem, Frame Buffer 2_ SIMM 1 error, 20901
BLINK OFF BLINK Mem. Frame Buffer 2_ SIMM 2 error, 20901
OFF BLINK BLINK Mem. Frame Buffer 2_ SIMM 3 error, 20901
BLINK BLINK BLINK Memory configuration error
BLINK OFF ON Primary DRAM (DLL) SIMM 1 error, 20809
OFF BLINK ON Secondary DRAM (RSR) SIMM 1 error, 20809
BLINK BLINK ON Cabled Hard Disk error
BLINK ON OFF Standard controller Firmware error

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.

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:
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 The system should not be in
~Ready to copy~ state warming up state.
Check the SCSI connection Both connectors correctly con-
nected?
Activate Scan for SCSI devices in Repro The found IDs must match with
Station Configured - SCSI menu. the configured IDs.
(Default is: 0 - 4)
Run the SCSI interrogator (This Adaptec A tape device should be recog-
tool 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 recog-
nise 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 Cen-
tronics.
Other application is active. Close this application.
Centronics in use. Stop printing via centronics or
wait till printing is ready.

Disabled in operator panel Enable.
Scan -to-file disabled in the configuration 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 net-
work 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.
Conflict with network card in PC Try the same job using only
using the PC and no network
Pen 0 set to end of file although SP0 appears HP-GL and HP-GL/2
in the middle of the job

Processing Scan Job doesnt disappear
This error occurs only when using Scan to File.

Internal cable not connected on
the Taxi Scanner PBA

A checkplot is generated in the Increase the job show up time to a value
Repro Station queue and the job larger than the max. generation time.
show up time is smaller than the

time needed to generate the plot.

SDS
1 The Oc 9800 Controller SDS
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

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 (ma-
chine in ~warm~ condition).
Activate SDS test 41/42 before you start with the
info tests~
20-9-01 ~SCSI present (0 = No, 1 = Yes)~
20-9-02 ~radical board present (0 = No, 1 = Yes)~
20-9-03 ~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)~

not available with FBBS
20-9-06 ~harddisk present (0 = No, 1 = Yes)~
20-9-07 ~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

20-9-11 ~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
20-9-15 ~poker lib. patch~

Patch number of the poker library software

System tests

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:
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
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).
3 Activate a terminal emulation program on the PC (e.g WINDOWS Terminal).
4 Select Settings and Communications.
5 Adjust the settings to:
Baud rate 9600, data bits 8, stop bit 1, no Parity, Flow control Xon/Xoff and
e.g. Com1.
6 Switch the service switch on the controller to the ON position
7 Switch ON the machine.
8 Now you will get some initialisation messages on the screen of your PC and
finally you get the prompt ~functest>~.
9 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:
Func- Description With- With Part Part

tional out O/S 1 2
test O/S
SLPT Select the primary or secondary x x x x
(1/2) part (section)
GCPT Get the current part that is used for x x x x
tests
CONF Display the controller hardware x x x x
configuration
STOS Start the operating system of the x - x x

controller
HELP List of all the available commands x x x x
TMEM Test all memory (30 minutes!) x - x x

TSIM Test a SIMM module x - x x
(0...6) (4 minutes / SIMM)
TROM Test the ROM modules x x x x
(1/2)
SPIN Test the SPINACH internals x - x -
ECCX Echo Centronics input in hexadeci- - x x -
mal form
ECHO Echo user input in hexadecimal x x x -
form
TCRG Test the configuration register of x - x x
the selected part
ENIT Enable and test interrupts x - x x
TCIN Test the internals of the Companion x - - x
Chip
TCSP Test the Companion Chip link to x - - x
the printer
SCBT SCSI Board Test - x OLB OLB

Func- Description With- With Part Part
tional out O/S 1 2
test O/S
ETBT EThernet Board Test (for future - x OLB OLB
release)
RDBT RaDical Board Test x - OLB OLB
TPBT TAXI Printer Board Test x - OLB OLB
TSBT TAXI Scanner Board Test x - OLB OLB

QUIT exit the functional test mode (not
yet available)
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 sec-
ondary 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 per-
formed 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 op-
erating system running. Whether the Operating System is needed or not is stat-
ed 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.

4 Functional test description
General tests
General
Commands
SLPT SeLect ParT SLPT selects the part on which part
Syntax : SLPT [1|2] 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 Get Currently selected GCPT tells the user to which part his
ParT for processing part specific commands are currently
Syntax : GCPT directed.
The part selected by default at
start-up is the Primary part.
after OS launch.
CONF display controller's hard- CONF displays the controller's hard-

ware CONFiguration ware configuration as recognized by
Syntax : CONF 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 func-
tional tests with.

after OS launch.
STOS STart Operating System STOS launches the operating system
Syntax : STOS on both parts, enabling new com-
mands.
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 availa- HELP displays the COMPLETE list
ble commands 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,
after OS launch.
Memory tests
Memory tests check DRAM data and address paths for each of the DRAM
ranges present on the board:
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 ad-
dress.
Data paths are checked with the same procedure but using respectively 0x00,
0x55, 0xAA and 0xFF as data for each pair of passes.

Possible memory tests:
Memory tests
TMEM Test all MEMory TMEM tests all DRAM ranges
Syntax : TMEM known to or detected by the software
with a read and write operation. On
Note: This test takes an error the test is ended and the
30 minutes address at which the error occurred is
(alternative: displayed to the user, with the value
use TSIM test) that produced the error.
This test is NOT available if the

DRAM configuration recognition
phase during booting fails to recog-
nize a commercial configuration.
This test is only available before OS

launch.
TSIM Test a SIMM module TSIM does the same job as TMEM,
Syntax: TSIM 0-6 but now on a memory range corre-
This test lasts 4 min- sponding to a specified SIMM mod-
utes / SIMM ule. This range is determined by the
software itself using the data gathered
during the DRAM configuration rec-
ognition phase. The test is performed
using the address ranges that are actu-
ally used to address this SIMM mod-
ule in normal mode.
This test is still available if the

DRAM configuration recognition
phase fails to recognize a valid con-
figuration, 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 connec-
tor, 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).

launch.
210 TSM Oc 9800 SDS

Memory tests
TROM Test ROM modules TROM detects the ROM configura-
Syntax : TROM 1-2 tion, 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).

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 INter- SPIN accesses the spinach's internal

nal registers registers in two passes: (1) a write
Syntax : SPIN 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.

launch.

Spinach tests
ECCX ECho characters ECCX reads characters on the Centro-

received via the Cen- nics port and displays them in hexa-
tronics(X) port decimal format on your PC until a
Syntax : ECCX 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 Centro-
nics 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 ECHO tests the RS232 link, which is

received via the the one to which your PC is connected
serial (RS232) port during the functional tests. The testing
Syntax : ECHO 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 hexa-
decimal 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.

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 regis-
ter). 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 reg-
ister's accessibility.
If this test fails, then you have to

replace the FBBS mother board.

launch.

Interrupt tests
For each interrupt, the test consists of:
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 Abort No
14 Spinach UART Yes
13 DPRAM Yes
12 Mother board DMA channel implicitly tested with OLB
0 board tests
1 board tests
10 Spinach Centronics Implicit (see ECCX com-
mand)
9 OLB Slot 1 see OLB board tests
6 Operating System tick Yes
5 Spinach internal DMA (CX) implicit (see ECCX com-
mand)
4 Spinach external DMA No (not used)
(SCSI)
3 SPY tic No (not used)
2 Spinach SCSI No (not used)
1 - -
0 No interrupt pending -
214 TSM Oc 9800 SDS

Note: In the first part both Centronics direct interrupt and Centronics DMA in-
terrupt are tested.

Secondary part interrupt allocation:
Int. level Source Tested

15 Abort No (not used)
14 Printer receiver ready No
13 Printer transmitter No
12 Debug receiver ready No (not used)
11 Debug transmitter ready No (not used)
0 board tests
1 board tests
8 DPRAM Yes
7 Operating System tick Yes
3 SPY tic No (not used)
2 - -
1 - -
0 No interrupt pending -
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 ENIT installs interrupt routines, ena-

InTerrupts bles the interrupts and triggers them.
Syntax : ENIT 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.

launch.

Companion chip tests
The companion chip manages:
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.

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 cor-
rectly received (RXD).
This test is available only before

OS launch.

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 de-
fect. 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 ex-
tensions on page 408) for which board can be used in which slot.
try a new board (also in an other slots)
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 set-
tings output.
OLB board
tests
SCBT SCsi Board Test SCBT launches the test of the SCSI
Syntax: SCBT A-F 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 I/O card not available in our controller
Syntax : ETBT A-F
TSBT TAXI Scanner Board TSBT launches the test of the TAXI
Test Scanner board. It uses the test functions
Syntax : TSBT A-F part of the TAXI Scanner driver, and thus
can only be launched before the Operat-
ing System has been launched. You have
to specify the slot used by the board.

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.
TPBT TAXI Printer Board TPBT launches the test of the TAXI
Test Printer board. It uses specific tests, not
Syntax : TPBT A-F part of the TAXI Printer driver, and thus
can only be launched before the Operat-
ing 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.
220 TSM Oc 9800 SDS

Dis-/assemblies
Note:
Before dis/-connecting the interface cable(s) make sure that the host is pow-
ered 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 rein-
stalling controller items.
It is strongly advised to place the controller on a flat table for maximum vis-
ibility 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
order to check the compatibility of this release with the machine technical lev-
el.
4 Remove the right hand side engine covers.
5 Remove the controller and place it on a table.
6 Open the controller drawer.
7 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
8 Place the new ROM module PBA.
Make sure that the arrow indication is in line with the arrow indication on the
FBBS PBA.
9 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.
10 Close the controller and install it in the engine.
11 Remount the engine covers.
Note: Check the 3 LEDs near the service switch and the operating panel for
failure information.

13 Execute the ~print settings~ to check the user parameters.

2 Memory module (SIMM)
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

serial Secundary CPU
spinach ASIC
slot slot FB2 slot (Frame buffer)
centronics A D 2 1 0
secundary local
DRAM (RSR /
Raster)
companon chip printer
command
slot slot
E Primary ROM
B module
1 2
slot slot
C F
Power
Primary CPU
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.

5 Reinstall the controller into the machine.

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 FB2 Memory
1 1 x 16MB 1 x 4MB 3 x 16MB N.A.
2 1 x 16MB 1 x 4MB 3 x 32MB N.A.
3 1 x 16MB 1 x 4MB 3 x 16MB 3 x 16MB
4 1 x 16MB 1 x 4MB 3 x 32MB 3 x 32MB
5 1 x 32MB 1 x 4MB 3 x 16MB N.A.
6 1 x 32MB 1 x 4MB 3 x 32MB N.A.
7 1 x 32MB 1 x 4MB 3 x 16MB 3 x 16MB
8 1 x 32MB 1 x 4MB 3 x 32MB 3 x 32MB

3 FBBS motherboard PBA
3 Remove the controller and place it on a flat table.
4 Open the controller.
5 Remove the connectors.
6 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.
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.

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:
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 con-
troller SDS in the following slots:
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.

5 Interface extension PBA (e.g. SCSI)

4 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
5 Close the controller.

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.

6 TAXI printer/scanner and RADICAL PBA
4 Only TAXI PBA: remove the connector of the TAXI PBA.
5 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.
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

2 Remove the right side covers.
4 Check if the new power supply is identical or different from the one in the con-
troller.
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.

7 Test the controller function (e.g. with the Plot Director).


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 con-
tains 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.

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 mes-
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 Adapt-
ers.
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:
hardware SCSI termination
disable the floppy part of the PBA
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.

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
change dipswitch 2,3,4 according the documentation (see the Adaptec docu-
mentation for possible addresses settings).
4 Install the PBA in a free ISA-slot of the customers PC.
5 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.
6 Select addresses and channels that are free in the PC with this utility (some in-
formation about addresses and channels in use can be determined using e.g. the
MSD command (MicroSoft Diagnostics).
7 Enable the SCSI Termination (in the Configuration menu).
8 Power down the PC and change switch 6,7, and 8 in the down position, to dis-
able BIOS of the card (Do this afterwards, because BIOS is needed to run SCSI
Select utility!).
9 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 con-
taining the SCSI PBA.

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 soft-
ware (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 prop-
erly. 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 / chan-
nels and follow the installation of Installation SCSI in a PC that does not sup-
port 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 in-
stalled 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.

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 sev-
eral 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:
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!
2 Install the PBA in a free PCI slot of the customer PC.
3 Power on the PC and press <Ctrl><A> if you get the Adaptec boot message to
start the SCSI Select utility.
4 AHA 2940:
Set SCSI termination to enable in the Configure / View host Adapter set-
tings window if only the Oc 9800 is connected. If more devices are connect-
ed, 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.
5 Select Advanced configuration options and set the Host Adapter BIOSto
disabled.
6 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 de-
tect the AHA 2940/AU PBA and the ASPI driver and aspi8dos.sys will be in-
stalled 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 includ-
ed 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

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 cus-
tom 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.

1 General
The controller functions of the FBBS controller are:
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 lan-
guage sensing ALS, except ASCII): :
Vector
HPGL supported plotter emulation: reference is HP7586B
plotter
HPGL/2 supported plotter emulation: HP650C and HP750C.
CALCOMP 906/907
Raster
TIFF 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
CALS only CALS type 1 is supported
HP-RTL
ASCII HP-GL fonts, 3 sizes

FBBS Abbrevia-
tions:
FBBS: Frisco Basic B Specific (controller of the Family
RISc COntrollers (FRISCO) specific for the Oc
9800).
Frame buffer: shared DRAM for data exchange between the 2 parts
of the controller and the engine.
Frame buffer consists of 2 parts FB1 and FB2
SPINACH: specific ASIC chip for controlling Centronics (CX)
and serial links (and for future purpose a SCSI link to
a hard disk).
OLB: 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.
OS: Operating System. VxWorks for this controller.
Primary part: 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
Secondary part: 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.
ZPRAM: Zero Power RAM (battery powered, not used).
RADICAL: Raster Acceleration Board
A OLB PBA for processing raster data, e.g. for rota-
tion of raster files and for compression and decom-
pression of raster data
TAXI: 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).

2 Controller characteristics
Dual CPU 40 MHz SPARC (RISC family)

2 ROM modules standard & optional (for future pur-
pose)
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:
- 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

Supported controller Memory configurations from Release 2.0
Configuration DLL Memory RSR Memory FB1 Memory FB2 Memory
1 1 x 16MB 1 x 4MB 3 x 16MB N.A.
2 1 x 16MB 1 x 4MB 3 x 32MB N.A.
3 1 x 16MB 1 x 4MB 3 x 16MB 3 x 16MB
4 1 x 16MB 1 x 4MB 3 x 32MB 3 x 32MB
5 1 x 32MB 1 x 4MB 3 x 16MB N.A.
6 1 x 32MB 1 x 4MB 3 x 32MB N.A.
7 1 x 32MB 1 x 4MB 3 x 16MB 3 x 16MB
8 1 x 32MB 1 x 4MB 3 x 32MB 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!

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:
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:
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.

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.

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 Engine

DLL
used for Frame Set

Automatic storage Buffer Memory
Language
Sensing
Ren-
dering TAXI
Interpreter
Radical
= Raster data = Buffer
= Bitmap
= Memory
= Process
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.

For detailed information about the instructions for the controller to use features
of the Oc 9800 engine (like folding, stamping, punching, roll selection, reduc-
tion and shifting) and the controller functions (like rotation, enlargement, han-
dling 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 Maximum file size Max. W x L
or equivalent
1 and 5 23.5Mb 594 x 841mm
24 x 34
2 and 6 47Mb 841 x 3800mm
34 x 149.5
3 and 7 47Mb 841 x 3800mm
34 x 149.5
4 and 8 94Mb 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

Configuration Maximum W x L or equivalent
1 and 5 841 x 1850mm - 34 x 73
2 and 6 841 x 3800mm - 34 x 149.5
3 and 7 841 x 3800mm - 34 x 149.5
4 and 8 841 x 7600mm - 34 x 299
Attention:
Maximum length is 15000mm (590.5),
Maximum width is 914mm (36).

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 Engine Scanner

Without CCD
Scan copy
Station TAXI scanner
resolution
uncompress conversion
Frame Set
Buffer Memory
= Bitmap
= Buffer With copy
= Raster data
= 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 process-
PBA 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.

7 Scan size of originals
For Scan to File the maximum size of originals that can be uploaded with re-
spect to the Frame Buffer memory configuration are given in the next table.
Original size
Configuration Max. W x L or Max. W x L or
equivalent (200dpi) equivalent (400dpi)
1 and 5 841 x 6300mm 841 x 1500mm
34 x 248 34 x 59
2 and 6 841 x 14000mm 841 x 3250mm
34 x 551 34 x 128
3 and 7 841 x 6300mm 841 x 1500mm
34 x 248 34 x 59
4 and 8 841 x 14000mm 841 x 3250mm
34 x 551 34 x 128
Note:
FB2 is not used for Scan to File
For configuration, see Controller characteristics on page 503
Note:

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
( C D -R O M M a chin e M on ito r
5 0 p ins m ini
o r F lo pp ies)
ce n tron ics S C S I bo a rd
co n n ector O c lo ca l b u s
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 F B B S co ntro lle r
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)
The PAS applications are distributed on CD-Rom. It is possible to create flop-

pies 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.

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
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 S C S I b oa rd
ce n tron ics O c lo ca l b u s
co n n ector
TA X I sca nn e r
D o ng le O c lo ca l b u s
S C S I-2
ca b le
A d ap te c F B B S co n tro lle r
A S P I drivers 5 0 p ins
(C D -R o m U p lo a d ca ble
co n n ector
o r flo pp ies) A M P L I o r M in i
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 possi-
ble 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 Sta-
tion and Viewer Station is not important. For other applications, see the corre-
sponding manuals.
The cable connection (SCSI) is between Machine Monitor and the controller.
Machine Monitor can handle back-channel communication, but the FBBS con-
troller can not generate back-channel information.

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:
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 con-
nector 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 communica-
tion 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:
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.

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.
M cable is needed.

11 PC characteristics
To run the Oc PAS applications:
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:
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 sup-
plied 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.

Controller
Command
20D1
Upload
20D4
1
2
Download 3
20D3
LED
Service 220V
Switch 20D1

2 FBBS PBA
Secundary ROM primary OLB secundary OLB
serial Secundary CPU
spinach ASIC
slot slot FB2 slot (Frame buffer)
centronics A D 2 1 0
secundary local
DRAM (RSR /
Raster)
companon chip printer
command
slot slot
E Primary ROM
B module
1 2
slot slot
C F
Power
Primary CPU
SERVICE
primary local
DRAM (DLL/Vector))
2 1 0
FB1 slot (Frame buffer)
Connectors
External
serial
centronics
Internal
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

3 ROM module PBA
U7 U8
Sw2
U1 U6
P1 SW 1
4 SCSI PBA
PBA layout
Jumper settings:
SW1(external) ON (SCSI termination)

SW2 2-3
SW4 2-3

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 Signal direction Name of signal

Pin No
1 Plotter to host BSY Busy
2 Plotter to host SELECT Select
3 Plotter to host ACKN Acknowledge
4 Plotter to host FAULTN Fault
5 Plotter to host PAPEROUT Paper error
6 Host to plotter Data 1 Data 1 (LSB)
7 Host to plotter Data 2 Data 2
9 Hoost to plotter Data 4 Data 4
13 Host to plotter Data 8 Data 8 (MSB)
14 Host to plotter IINITN Initialize
15 Host to plotter STROBEN Strobe
16 Host to plotter SELECTINN Select in
17 Host to plotter AUTOFDN
18 Host to plotter Host Logic High
19-35 ------- GND Ground
36 Plotter to host Peripheral Logic
High

Serial port
Plotter Pin Signal Name of the signal

no
1 Host to plotter DTR Data terminal ready
2 Plotter to host CTS Clear to send
3 Host to plotter TX Transmit data
4 -------- TGND Protective ground
5 Plotter to host RX Received plot data
6 Host to plotter RTS Ready to send
7 -------- RGND Host ground (RS423 on;y)
8 Plotter to host DSR Data set ready

1 2 3 4 5 6
22PBA1 CPU I/O 20FBBS
X17 20D1 P5
+5V
1 10
PRINTER
GND
2 1 SERIAL
(RXD)
A 3
(CTS)
2
4 4
(TXD)
7 5
(RTS)
8 8
CENTRONICS
11PBA1 SET MEMORY (OPTIONAL B860)
X15 X2 11D1
GND
1 1 EXT. MEMORY-1
IMPSYNCO
2 2
IMPRECONO
3 3
IMPDA0O 11D2
4 4
IMPDA1O EXT. MEMORY-2
5 5
GND
6 6
B 7
IMPDA2O
7
IMPDA3O 11D3 X4 20D3 X1 P20 P21
8 8 GND
GND EXT. MEMORY-3 1 1 SCSI
9 9 DLINK2
IMPDA4O 2 2 TAXI
10 10 NDLINK2
SLOT A
SLOT F
IMPDA5O
11D4 3 4
DOWNLOAD SCSI A
11 11 GND
GND 4 5
12 12 EXT. MEMORY-4 +5V
IMPDA6O 5 8
13 13 RESET
IMPDA7O 6 6
14 14
GND 11D5
15 15
EXT. MEMORY-5 CAPDL
X14 20D4 P2 P18

11D6 GND
1 1
EXT. MEMORY-6 DLINK_OUT
2 2
SLOT D
NDLINK_OUT
C 3
GND
4
UPLOAD
11D7 4 5
+5V
EXT. MEMORY-7 5 8
RESET
6 6
11D8
CAPUL
EXT. MEMORY-8
22PBA5 DRIVERS
X13 X10
D 1
+5V
1
GND
2 2
+24V
3 3
GND
5 5
F4
22G1 CONSUPLV 4A
G3 X8
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
G2
+24V
1 5 P4
GND LED1
E 2
+24V
6 X1
CONCONEMSSUP
1
3 7 21 4
GND
4 8
5
+24V
9 2
LED2
GND CONKEYSW CONCONEMS
6 10 17 5
22K4-2A
SERVICE
22PBA4 SSR 3
LED3
22Z2 8
X9 X5
L2 L2
6 1 1 6 8
22X010 N2 OFF/ON
5 2 2 2 4
6 1 2
N2
4 3 3 4
7
20POWER SUPPLY
F N2-MNO
20D2 X3 X4
N2-MNO
N 3 2 3
L2-MNO L2-MNO
L 1 5 2 P17
+12V
1
GND 2 M FAN
20 22X012-3 GND
2
FANS
P25
+5V
1 1 GND
+5V 3
NFS200-7608
2 3
GND M FAN
3 2
GND
4 4 +12V
4
5
-12V
6 9
GND
7 6 P24
G 8
+12V
7 1
+12V
M FAN
OR
GND
2
FANS
+5V
1 GND
+5V 3
2
GND M FAN
3
GND
4 +12V
RBQ151
GND 4
5
-12V
6
H 7
+12V
8
FBBS
ed.5 TSM Oc 9800 20 Interface 701
Oc
Oc 9800
20 INTERFACE EPC/DRI
Contents
Diagnostics
1 Faults 101
SDS
2 The functional tests of the controller. 1204
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
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
12 SCAN STATION 1516
13 SCSI PBAs 1517
2 Embedded Power Controller (EPC) Extensions 1602
3 Controller PBA overview 1604
4 Motherboard 1605
5 Radical PBA 1606
6 Priscat PBA 1607
7 Centronics PBA 1608
Diagrams
1 EPC 1701
2 DRI 1702

Diagnostics
1 Faults
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, dis-
played in the Terminal window, SDS: see
Terminal window on page 1205
Reboot will generate error 20811
20803 MRE: ~Radical pba error~

erly mounted in the controller), * Execute the controller functional test
or defect. RDBT to verify whether the board is okay
ed.5 20 Interface EPC/DRI 101

20804 MRE: ~SCSI pba error~ (Controller)
.

Faulty SCSI in the controller. Change motherboard.
nated. In LUI of the scanner: set terminator to ON.
In Host:
* If the Adaptec 1542 CP/2940/2940AU is
used: termination has to be enabled with the
SCSISelect utility.
(properly) set.
After booting, the SCSI ID is Reboot both: the host PC and the controller
changed. (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 * Check position.
properly mounted or faulty. * 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~


20809 MRE: ~DRAM simm pbas error~


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 * Reboot and examen the bank messages,
makes bad contact. displayed in the Terminal window, SDS: see
* If it is properly installed, clean its connec-
tor or replace it.
20810 MRE: ~TAXI interface printer pba~ (PRISCAT)~


PRISCAT or ~riser~ pba not * Check position.
properly mounted or faulty. * Execute the controller functional tests

LSBT, LTBT to verify whether the board is
okay.

ENGINE - CONTROLLER COMMUNICATION ERROR: 20811-20812
20811 MRE: ~Communication error contr(oller) -> engine~


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.
Connection: * Listen if the fan is turning.
mains to controller supply. * No messages in the terminal
window.
Controller power supply defect. * Listen if the fan is turning.
window.
Software corrupt. Reload software on harddisk.
* Only the first messages are
correct. No new messages
when trying to load the soft-
ware.
Connection: * Check with test LTBT
communication cable between controller and * Check cables
CPU_IO PBA.
Connection:
tight).
Connection: Check memory information
one of the SIMMs makes bad contact. (bank 0-7) displayed in the ter-
minal window.
Motherboard defect. No message in the terminal
window
Wrong position PCI I/O cards. Position in chapter Electrical
description: see Controller
PBA overview on page 1604
RADICAL pba defect Test RDBT

PRISCAT pba defect Test TSBT, LSBT, LTBT
Harddisk defect 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
System switched OFF and ON too quickly. Harddisk was not stopped
properly.
Wait 5 seconds before switch-
ing the system ON again.
16 MB SIMMs in slot 3 and 4 16 MB SIMMsin the memory
32 MB SIMMs in slot 1 and 2 have to be used 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)~


Electrical connections Internal and external communication cables
between PRISCAT and CPU_IO PBA.
No display message if the controller is
tem is rebooted.
tem is rebooted.
PRISCAT PBA defect Test LSBT.

MISCELLANEOUS ERRORS: 20813 - 20815
20813 OWAR: ~Not enough memory to complete opp(eration)~
Possible cause
drawing is printed
With a free text/ image stamp the plot must fit in the DLL. If not than e.g. ren-
dering is not done and error 20813 occurs.
Remark
can be reset.

Possible cause
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.
Possible cause
The plot doesnt fit into the set memory. Hence, the plot cannot be processed. .
Remark

RS323 ERRORS: 20820 - 20822
20820 OWAR: ~RS-232 host / contr. (to controller) framing error~

20821 OWAR: ~RS-232 host / contr. (to controller) parity error~

20822 OWAR: ~RS-232 host / contr. (to controller) overrun error~

SCSI ERRORS: 20830 - 20832
20830 OWAR: ~SCSI: cmd (command) group error~

20831 OWAR: ~SCSI: chip error~

20832 OWAR: ~SCSI: parity error~


GRAPHIC LANGUAGE ERRORS: 20860 - 20864
20860 OWAR: ~Interpr. (eter) error: command not supp(orted)~





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.


HOST PROTOCOL ERRORS: 20870 - 20872
20870 OWAR: ~Host prot(ocol), job description error~

The RCF header contains a not yet Syntax error.
implemented or non existing command/ Verify that the contents of the RCF
APPLDATA. header is according the RCF refer-
ence Manual

ignored.


20901 SWAR: ~Illegal ram configuration contr(oller)~

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 con- Clean its connector or replace it
tact. and run the test again.
Reboot and examine the bank messages, dis-


Most of the Oc Repro, Scan Station and Machine Monitor errors (messages)
are self explaining. The following errors need an explanation:
Oc scanner / printer not responding

Error incorrect RCF only with EPC; special character in printer stamps,
backchannel stopped.

Check as follows:

Check if the status of the Oc 9800 is ~ The system should not be in
Ready to copy~ warming up state.
nected?
Station Configure - SCSI menu. the configured IDs.
(Default is: 0 - 4)
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.
Switch it on again.
tronics.


slow.


corrupted.
Conflict with network card in PC Try the same job using only the
PC and no network
Pen 0 set to end of file although SP0 HP-GL and HP-GL/2
appears in the middle of the job

~Processing Scan Job~ doesnt disappear

X2 of the Taxi Scanner part of the
PRISCAT pba


SDS
Analysis info tests

see SDS

see SDS
32 ~Last error logging~

~OWAR/SWAR/ORE/MRE/PE/FE)~
last 15 errors
mode
ice mode
34 ~Error top 10~


see SDS
see SDS
see SDS

see SDS

Parameter test
Input tests
Output tests
Special tests
Info tests
info tests~

integrated in motherboard

integrated in Priscat PBA



(DLL)~
(16/32 Mb)

(RSR)~
Not relevant for EPC

(64 - 256 Mb)
1202 TSM Oc 9800 SDS


(0-99)

(0 - 99)

(0-99)



System tests

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
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 code number: 1302522

Centronics cable code number: 1302520
Loop connector code number: 7991.293
Link cable code number: 7991.520

2 Connect the laptop to the serial port COM1 of the controller with the serial ca-
ble (code number 1302522).
5 Change the settings to: Com1, Baud rate 9600, data bits 8, stop bit 1, no Parity,
Flow control to none.
6 Select Settings, Terminal Preferences, Translations.
7 Change the language setting to: None
9 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!!
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.

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>

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.
Help list with a general description:

Func- Description
tional
test
~HELP~ List of all the available commands
CONF Current controller configuration
~TIME~ Setup time and date
UPGD Upgrade software on the harddisk
UPBK Back to the previous software version, if existing
DLDP Download demo plot to the harddisk
ECCX Testing of the centronics output
TPBT Test of TAXI Print logic (Priscat)
TSBT Test of TAXI Scan logic (Priscat)
LTBT Link test of TAXI transfer, print and scan lines.
LSBT Test of serial command link PRISCAT
RDBT Test of Radical board
~QUIT~ Reboot the controller (turn off/on the machine)

HELP
Displays the list of all available commands
~Functest> HELP~
__________________~ LIST OF COMMANDS~ ____________________
~HELP~ ~Show help information~ Show help information
~CONF~ ~Display the current controller Display the current controller con-
configuration~ figuration
~TIME~ ~Setup time and date. Setup time and date.
Used as a date/time reference Used as a date/time reference in
in Scan-to-file~ Scan-to-file
UPGD ~Upgrade application~ Upgrade application
UPBK ~Back to previous version (if Back to previous version (if exist-
existing)~ ing)
DLDP ~Download demo plot file~ Download demo plot file
ECCX ~Echo characters sent to Echo characters sent to Centron-
Centronics output~ ics output
TPBT ~Test of TAXI Print Logic~ Test of TAXI Print Logic
TSBT ~Test of TAXI Scan Logic~ Test of TAXI Scan Logic
LTBT ~Test of TAXI transfer~ Test of TAXI transfer
LSBT ~Test of TAXI Serial port~ Test of TAXI Serial port
RDBT ~Test of RADICAL Inter- Test of RADICAL Interface
face~
~QUIT~ ~Quit (Turn off/on Quit (Turn off/on machine)
machine)~
~Cmd Ok.~
~Functest>~

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.

~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!
For the exact action of installing:see Dis-/assemblies EPC Upgrade Backup
Software on page 1403.

DLDP
~DownLoad DemoPlot~
With this command, a demo plot (test print on the operator panel) is download-
ed from the laptop to the harddisk.
The download needs the centronics cable (code no. 1302520) between the lap-
top 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.
- PRISCAT pba
- riser board
- motherboard

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 con-
troller, see Component location on page 1601
Connect the test cable (code no. 7991.520) between the ~Upload~ and ~Down-
load~connectors at the outside of the controller.
Activate the test.
- the test cable
- riser board
- PRISCAT
- motherboard

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 connec-
tor X3 on the PRISCAT pba
- riser board
- PRISCAT
- motherboard
RDBT
~RaDical Board Test~
With this command, the RADICAL board is tested.
Activate the test.
Corrupted data is always displayed.
- riser board
- RADICAL pba
- motherboard
~QUIt~
With this command, the functional tests are switched off.
To start the controller operating system: reboot the system.

Dis-/assemblies
Note:
Before dis/-connecting the controller cable(s) make sure that the host is pow-
ered down and the Oc 9700/9800 is switched off.
various controller failures. Please use a wrist strap , antistatic mat and take
care when reinstalling controller items.
Check after dis-/assemblies the EPC controller with your laptop.
If correct, connect host environment and check again.
1 Embedded Power Controller

2 Switch off the host and the Oc 9700/9800.
3 Disconnect at the front side of the engine the connectors from the controller
and the scanner.
4 Remove the front cover from the engine.
5 Remove the right top cover from the engine.
6 Remove the right side covers from the engine.
7 Remove at the right side the front upper and lower cover from the engine.
8 Disconnect the data connectors from the controller see Component location
on page 1601.
9 Disconnect the power supply connector (2001D2) from the controller.
10 Remove at the front side of the engine the 2 lower mounting screws from the
controller.
11 Loosen at the front side of the engine the 2 upper mounting screws from the
controller.
12 Remove the controller and place the controller on a flat table.
13 Remove (if needed) the cover from the controller (24 screws).

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

3 EPC Upgrade Backup Software
Needed:
1 Connect between the laptop and the controller: the serial cable on COM1.
2 Activate the functional tests, see Functional test description on page 1207
3 Activate the functional test: UPBK.
4 Follow the instructions on the screen:
(~Retrieving previous application version will erase current version
SURE?(Y/N):~

4 EPC Demo plot (Test print)
Needed:

Demo plot software
2 Activate the functional tests, see The functional tests of the controller. on
page 1204
3 Activate the functional test: DLDP.
Message: ......~Transfer Demo Plot software through the centronics port:~

(~Loading file...Press ESC to abort the transfer.
12 Check the demo plot by activating it from the operator panel.

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 func-
tioning 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).

6 Priscat PBA
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.
Note: The Priscat PBA must be mounted in the PCI slot 2.
9 Remount the Radical PBA.

10 Connect the 3 connectors to the Priscat PBA.
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.

7 Centronics I/O PBA
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.
If mounting a new pba: check the jumper and dipswitch (J / SW) settings, see
chapter Electrical Description Centronics PBA on page 1608
6 Remount all components in the controller.
configuration. (EPC name: OCE 100 ISA board)
10 Test the new PBA with your ~Plot Director~, or with the function test:
ECCX.
8 Hard disk
2 Disconnect the supply connector (P5) from the hard disk.
3 Disconnect the IDE connector from the hard disk.
4 Remove at the left outside the Allen screw from the holder of the hard disk.
5 Remove at the front side 2 screws from the holder with the hard disk.
6 Remove the holder with the hard disk.
7 Replace the hard disk (6 screws).
Note: The hard disk must be configured as ~Master~, jumper on position 1.
8 Remount the holder with the hard disk.

9 Connect all the connectors.
11 Download the software and the Demo Plot, see Functional Description tests
UPGD and DLDP.

9 Power supply unit
2 Remove the hard disk unit, see page 1407.
3 Disconnect the connectors of the supply unit from the motherboard (P1-P2).
4 Disconnect at the outside the connector from the 220 V power supply unit.
5 Remove at the right outside 4 screws from the power supply unit.
6 Remove at the top outside 2 screws from the support bracket of the power sup-
ply unit.
7 Remove the 2 screws from the bracket of the ON/OFF switch from the control-
ler.
8 Mount the support bracket to the new power supply unit.
9 Replace or mount the (new) power supply unit.
12 Test the controller function (e.g. with the ~Plot Director~).

10 Motherboard
2 Remove the Radical PBA, see page 1405.
3 Remove the Priscat PBA, see page 1406.
4 Remove the Centronics PBA, see page 1407.
5 Remove the hard disk see Hard disk on page 1407.
6 Remove the power supply unit see Power supply unit on page 1408 except
the ON/OFF switch.
7 Remove at the right outside the screw from the bracket which holds the Riser
PBA in position.
8 Loosen at the left inside the screw from the bracket which holds the Riser PBA
in position.
9 Remove the bracket.
10 Remove the Riser PBA.
11 Disconnect the connector (J5) of the fan from the motherboard (Position of the
connectors on the PBA see page 1605.
12 Disconnect the IDE connector (J4) from the motherboard.

13 Disconnect the SCSI2 connector (J6) from the motherboard.
14 Remove the BOOT flash, the SIMM(s) and the cache board from the mother-
board and mount these on the new motherboard.
15 Remove at the outside the 2 nuts from the connectors COM1 and Ethernet AUI.
16 Remove the motherboard (8 Allen screws).
17 Remount all disassembled parts and PBAs according: see Controller PBA
overview on page 1604.
20 Reboot the system and ~print settings~.
21 Use the laptop to sent a plot (~Plot Director~).
22 Switch of the machine and connect the host environment.
23 Test the function of the controller.

11 Memory module (SIMM)
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.

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 list-
ed in the settings.
Configuration Slot 1 and 2 Slot 3 and 4

64 Mbyte 2 x 16 MB 2 x 16 MB
2 x 32 MB
96 MByte 2 x 16 MB 2 x 32 MB
128 Mbyte 2 x 32 MB 2 x 32 MB
2 x 64MB
160 MByte 2 x 16 MB 2 x 64 MB
192 MByte 2 x 32 MB 2 x 64 MB
256 Mbyte 2 x 64 MB 2 x 64 MB

Termination

be switched off.

by Machine Monitor!
Software versions
Check for new drivers on the Adaptec website: www.adaptec.com.

the PBA:

Note:
ers.
PBA).
position to enable:



down position.

Select utility!).



2940AU

1 AHA 2940:
AHA 2940AU:
There is no jumper!
4 AHA 2940:
AHA 2940AU:
disabled.
the boot time).
drivers at www.adaptec.com

needed.

- Leave Windows
be damaged.

1 General
The controller functions of the Embedded Power Controller (EPC) are:
Processes: conversion and transformation of plot data to Oc 9700/9800 spe-

cific raster formats and performs scaling, rotation etc.
Connectivity: connects the Oc 9700/9800 to the customer environment
printing, scanning and finishing aspects.
2 Features
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:
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.

3 System overview

Graphic languages
The following graphic languages are supported by the ~Embedded Power Con-
troller~ (can be set to automatic language sensing ALS, except ASCII): :
Vector
plotter
HPGL/2 supported plotter emulation: HP650C and HP750C
CALCOMP 906/907
Raster
HP-RTL
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.

Embedded Power Controller abbreviations:
Name Explanation
Power Controller: Motorola CPU-board with MPC 604 processor.
PCI Peripheral Component Interface bus.
32 bit wide data path bus.
ISA Industry Standard Architecture
SCSI Small Computer Standard Interface
Intelligent I/O, each connected device has a unique
ID.
Frame buffer DRAM which contains the bitmap of the image to be
printed.
Cache Fast temporary RAM memory for last items read
from the main memory.
RTOS Real Time Operating System
VxWorks for this controller.
AUI Attachment Unit Interface
connector type between I/O card in a PC and the
Ethernet network.
10BASE-T Connector type between I/O in a PC and the Ethernet
network, implemented on twisted pair cabling.
TCP/IP Transmission Control Protocol / Internet Protocol
LPD socket Line Printer Daemon (Unix)
printer software for Ethernet
NVRAM NonVolatile RAM (battery powered).
RADICAL Raster Acceleration board
I/O board for compression of raster data, only for
Scan to File.
PRISCAT PRInter SCAnner Taxiboard
I/O board for communication with the printer.
* One side of the board is used for printing (to trans-
fer 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.

4 Embedded Power Controller characteristics
Mother board
Motorola ULTRA board with
133 MHz PowerPC 604 processor
1 boot EPROM memory
3 PCI slots on riser board
3 ISA slots on riser board
SCSI Intergrated on mother-
board, main purpose: print-
ing and scan to file, also
used for backchannel com-
munication with Machine
Monitor
Ethernet integrated on motherboard
DLL memory 11 / 27 MB (16 / 32 in SDS) is part of the total memory

FRAME buffer 41 - 228 MB is part of the total memory
Total memory 64 - 256 MB 4 SIMM slots.

Harddisk IDE
Centronics ISA dedicated I/O card
PRISCAT PCI Printer TAXI I/O card
Scanner TAXI I/O card.
Serial link commandline
RADICAL PCI Hardware compression I/O
card, only for Scan to File.
Harddisk
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:

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 Frame buffer OS Total mem.

1 11MB 41MB 12MB 64MB
2 27MB not supported
3 11MB 70MB 15MB 96MB
4 27MB 56MB 13MB 96MB
5 11MB 102MB 15MB 128MB
6 27MB 88MB 13MB 128MB
7 11MB 134MB 15MB 160MB
8 27MB 120MB 13MB 160MB
9 11MB 166MB 15MB 192MB
10 27MB 152MB 13MB 192MB
11 11 MB 228MB 17MB 256MB
12 27 MB 213MB 16MB 256MB
DLL : Display List (size adjusted in SDS test 90)

Frame buffer : bitmap buffer
OS: Operating System
Total memory = DLL + frame buffer + OS

5 Process
Block diagram EPC
cache
4 SIMM slots
Host bus
HOST/PCI Ethernet SCSI2 graphics

not
bridge
used
PCI bus
HOST / floppy
LEGAGY slot 1 slot 2 slot 3
bridge keyboard Radical Priscat

PCI / ISA General
centronics PCI slots
I /O com 1 ISA slots
local bus
buffer com 2 slot 1 slot 2 slot 3
Centronics
mouse
NVRAM sound ide

ISA bus
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.
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.

6 Printing

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.

directly.

plots.
Next the file is rendered (conversion into the specific Oc 9700 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.
dling 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).

7 Print size of originals for rotated image
can be rotated. Vector: are always rotated in the DLL buffer.
Raster: are rotated in the Frame buffer. The rotation algorithm requires a sec-
ond 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

Confi- DLL FB Maximum file size Maximum W x L
guration or equivalent
1 11MB 41MB 20.5 MB 914 x 750 (36 x 29.5)
2 27MB not available.

3 11MB 70MB 35 MB 914 x 1250 (36 x 49)
4 27MB 56MB 28 MB 914 x 1000 (36 x 39.4)
5 11MB 102MB 51 MB 914 x 1850 (36 x 72.8)
6 27MB 88MB 44 MB 914 x 1600 (36 x 63)
7 11MB 134MB 67 MB 914 x 2450 (36 x 96.5)
8 27MB 120MB 60 MB 914 x 2200 (36 x 86.6)
9 11MB 166MB 83 MB 914 x3050 (36 x 120)
10 27MB 152MB 76 MB 914 x 2800 (36 x 110)
11 11MB 228MB 114MB 914 x 4200 (36 x 165)
12 27MB 213MB 106,5MB 914 x 3900 (36x153.5)
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

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 re-
printed 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

Confi- DLL FB Maximum W x L or equivalent
guration
1 11MB 41MB 914 x 1500 (36 x 59)
3 11MB 70MB 914 x 2550 (36 x 88.6)
4 27MB 56MB 914 x 2050 (36 x 80.7)
5 11MB 102MB 914 x 3750 (36 x 147.6)
6 27MB 88MB 914 x 3200 (36 x 126)
7 11MB 134MB 914 x 4900 (36 x 193)
8 27MB 120MB 914 x 4400 (36 x 173.2)
9 11MB 166MB 914 x 6100 (36 x 240.2)
10 27MB 152MB 914 x 5600 (36 x 220.5)
11 11MB 228MB 914 x 8400 (36 x 330.7)
12 27MB 213MB 914 x 7850 (36 x 309)
Attention:
Maximum length is 15 meters (590.5)
Maximum width is 914 mm (36)

9 Scan to File
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 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.

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
Confi- DLL FB Maximum W x L or Maximum W x L
guration equivalent (200 dpi) or equivalent (400 dpi)
1 11MB 41MB 914 x 5200 (36x204.7) 914 x 1300 (36 x 51.2)
3 11MB 70MB 914 x 9000 (36 x 354) 914 x 2250 (36 x 88.6)
4 27MB 56MB 914 x 7200 914 x 1800
(36 x283.5 ) (36 x 70.9 )
5 11MB 102MB 914 x 13200 914 x 3300
(36x519.7) (36 x 129.9)
6 27MB 88MB 914 x 11400 (36 x449) 914 x 2850 (36 x 112.2)
7 11MB 134MB 914x17200 (36x677.2) 914 x 4300 (36 x 169.3)
8 27MB 120MB 914x15400 (36x606.3) 914 x 3850 (36 x 151.6)
9 11MB 166MB 914x21400 (36x842.5) 914 x 5350 (36 x 210.6)
10 27MB 152MB 914x19600 (36x771.7) 914 x 4900 (36 x 192.9)
11 11MB 228MB 914x29200 (36 x1150) 914 x 7300 (36 x 287.4)
12 27MB 213MB 914x27600 (36 x1087) 914 x 6900 (36 x 271.7)

This printroom application software consists of Job Director, Job Director
Configurer, Repro Station and Machine Monitor.
NT3.51/4.0.
Job D ire cto r

Job D ire cto r C o nfig ure r
R e p ro S ta tio n
o r F lo pp ies) S C S I M in i
con n ector
RS E m be dd e d
D o n gle P o w er
C o n tro lle r
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
A S P I drive rs 5 0 p ins
( C D -R O M con n ector
o r F lo pp y) A m pli o r M in i

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.
Machine Monitor can handle back-channel communication with the EPC con-
troller.

12 SCAN STATION
upgraded).In the package you find also the needed hardware: the RADICAL
NT3.51/4.0.
S ca n S tation
M a chin e M on itor R A D IC A L
O c V iew S ta tio n
S C S I M in i
co n n ector
V ie w
S ta tio n E m b e d de d
D o n gle 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
(C D -R o m co n n ector
Scan Station and View Station are distributed on CD-Rom. It is possible to cre-
ate 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.

each other. Even more is possible. The order of the dongles can be important.
See the corresponding manuals.
Examples:

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:

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 Operat-
ing 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


M cable is needed.
Adaptec 2940AU SCSI

M cable is needed.

Job Director
Repro Station
Scan Station
Machine Monitor

For View Station on Windows NT3.51: Service Pack 5 is required.
a free centronics port. Oc View and Repro Station are supplied with a don-
gle. The View Station dongle must be in the 1st position, LPT is not impor-
tant. The Repro dongle can be placed anywhere.
Note: 1
lower.
Note: 2
be the same.

Embedded Power
Controller
220 V supply
Serial commands
Confidential 1998 Oc Technologies B.V.
ON / OFF
switch
Download
Upload

2 Embedded Power Controller (EPC) Extensions
top side
COM 1
only service SCSI 2
Ethernet AUI
Centronics
only service
(ECCX)
Ethernet
10BaseT
Centronics
PBA
left side
not used at all
Connectors:
External
serial
centronics
ethernet (AUI or 10BaseT)
SCSI

Internal

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:
slot 1 = Radical board

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

slot 2 = not used
slot 3 = not used

3 Controller PBA overview
Riser board
1
PCI
slots 2 Radical PBA
3 Priscat PBA
X1 X2 X3
3
ISA
slots 2
Centronics PBA
CPU
Motherboard
Connectors on Priscat
X1 Taxi printer connector
X2 Taxi scanner connector
X3 Serial commands connector

4 Motherboard
Centronics
only service
10BaseT AUI COM1 SCSI2
Riser
board
P2 Supply
connectors
P1
Cache
board
512 kB
J5 SCSI2 connector
fan 1 J6
pin 1 and 2 connected J4

IDE connector
CPU U16 slot 4

U11 slot 3
SIMMS
U7 slot 2
U3 slot 1
Boot ROM not for service

64 Mbyte 2 x 16 MB 2 x 16 MB
2 x 32 MB
96 MByte 2 x 16 MB 2 x 32 MB
128 Mbyte 2 x 32 MB 2 x 32 MB
128 Mbyte 2 x 64MB
160 MByte 2 x 16 MB 2 x 64 MB
192 MByte 2 x 32 MB 2 x 64 MB
256 Mbyte 2 x 64 MB 2 x 64 MB

5 Radical PBA
SW1
1
1 1
SW2 SW3
Jumper settings Code number:

7009010
SW1 1-2
SW2 1-2
SW3 1-2
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.

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.

7 Centronics PBA
J1
OUT
10 0
J3 J4 J6 J7
J2
CN1
ON
SW1 SW2 DQ1 DK1
1 8 OFF 1 6
J5
IRQ7
1 8 1 6
ON ON
SW1 SW2
OFF OFF
This board is seen as LPT3 device which means the I/O address is equal to
0x0278.
Jumpers:
J1 both in IN position (the board is used in input mode)
J2 position 1(the board uses fastbyte protocol transfer 200 s set-up time)
J3 NO (DMA selection channel 1)
J4 NO (DMA selection channel 1)
J5 IRQ7
J6 DQ1 (DMA selection channel 1)
J7 DK1 (DMA selection channel 1)
Dip switches:
SW1 see figure (hexa 02)
SW2 see figure (hexa 78)

1 2 3 4 5 6
22PBA1 CPU I/O 20PBA1 EPC 1/2
X17 D1
+5V
1 10
GND
2 1
(RXD)
A 3
(CTS)
2
4 4
(TXD)
7 5
(RTS)
8 8
11PBA1 SET MEMORY

11PBA4 RFI
X15 X1 X2 X2 11D1
GND
1 1 1 1 EXT. MEMORY-1
IMPSYNCO
2 2 2 2
IMPRECONO
3 3 3 3
IMPDA0O 11D2
4 4 4 4
IMPDA1O EXT. MEMORY-2
5 5 5 5
RFI SIGNAL 15x
GND X4 D3
6 6 6 6 GND
B 7
IMPDA2O
7 7 7
1
DLINK2
1
IMPDA3O 11D3 2 2
8 8 8 8 NDLINK2
GND EXT. MEMORY-3 3 3
9 9 9 9 GND
IMPDA4O 4 4
10 10 10 10 +5V
IMPDA5O 5 5
11 11 11 11 11D4 RESET
GND 6 6
12 12 12 12 EXT. MEMORY-4
IMPDA6O
13 13 13 13
IMPDA7O CAPDL
14 14 14 14
GND 11D5
15 15 15 15
EXT. MEMORY-5
X14 D4
GND
1 1
DLINK_OUT
11D6 2 2
NDLINK_OUT
EXT. MEMORY-6 3 3
GND
4 4
C 5
+5V
5
11D7 RESET
6 6
EXT. MEMORY-7
CAPUL
11D8
EXT. MEMORY-8
22PBA5 DRIVERS
X13 X10
D 1
+5V
1
GND
2 2
+24V
3 3
GND
5 5
F4
22G1 CONSUPLV 4A
G3 X8
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
G2
+24V
1 5
GND
E 2
+24V
6 X1
CONCONEMSSUP
3 7 21
GND
4 8
+24V
5 9 CONCONEMS
GND CONKEYSW
6 10 17
22K4-2A
22PBA4 SSR
22Z2
X9 X5
L2 L2
6 1 1 6 8
22X010 N2
5 2 2 2 4
N2
4 3
F X4
N2-MNO
3
L2-MNO
2
X3 D2
L2-MNO
2 1
N2-MNO
5 3
2
22X012-3
H
EPC 1/2

1 2 3 4 5 6
22G1 CONSUPLV 11PBA5 RFI 11PBA1 SET MEMORY

G3 X1 X2 X5
+5V
5 1 1 4
GND
A 6 2 2 3
RFI POWER 2x
connector
11D1
for printer only
10PBA4 IPU-IO EXT. MEMORY-1
X6 22X1 X3
DLINK1
10 k 2
NDLINK1
9 m 3
GND 11D2 TO BW PROCESSING +
11 e 4
EXT. MEMORY-2
PHD DATA RECEIVER
22PBA1 CPU I/O 11PBA4 RFI

B X15 X1 X2 X2
GND
1 1 1 1
IMPSYNCO
2 2 2 2
IMPRECONO
3 3 3 3
IMPDA0O
4 4 4 4
IMPDA1O
5 5 5 5
RFI SIGNAL 15x
GND
6 6 6 6
IMPDA2O EXTERNAL PC
7 7 7 7
IMPDA3O
8 8 8 8
GND 21PBA1 DRI 20D2
9 9 9 9
IMPDA4O
10 10 10 10
IMPDA5O
11 11 11 11
GND X4 X3 X2 D1
12 12 12 12 GND GND
IMPDA6O 1 20 7 7
13 13 13 13 DLINK2 CTS
C 14
IMPDA7O
14 14 14
2
NDLINK2
1 5
RTS
5
GND 3 2 4 4
15 15 15 15 RXD
X14 3 3
DIRECT RASTER INTERFACE

DLINK_OUT TXD
2 3 2 2
NDLINK_OUT
3 4
20PBA1
(PCI-TAXI BOARD)
X4 D2
GND
14 14
SERIN_P
1 1
SERIN_N
X17 X1 2 2
+5V SEROUT_P
D 1
GND
6 3
SEROUT_N
3
2 5 4 4
RXD
3 3
CTS
4 4
TXD
7 1
RTS
8 2
H
Direct Raster Interface (DRI)
Oc
Oc 9800
20 INTERFACE EPC 2
Contents
Diagnostics
1 Faults 2101
SDS
2 The functional tests of the EPC2 controller. 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
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
12 SCAN STATION 2517
13 SCSI PBAs 2518
2 Embedded Power Controller 2 (EPC 2) Extensions 2602
3 Controller PBA overview 2603
4 Motherboard 2605
5 Radical PBA 2606
6 Priscat PBA 2607

Diagnostics
1 Faults
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, dis-
Reboot will generate error 20811
20803 MRE: ~Radical pba error~

erly mounted in the controller), * Execute the controller functional test
or defect. RDBT to verify whether the board is okay
ed.5 20 Interface EPC 2 2101

20804 MRE: ~SCSI pba error~ (Controller)
.

Faulty SCSI in the controller. Change motherboard.
nated. In LUI of the scanner: set terminator to ON.
In Host:
* If the Adaptec 1542 CP/2940/2940AU is
used: termination has to be enabled with the
SCSISelect utility.
(properly) set.
After booting, the SCSI ID is Reboot both: the host PC and the controller
changed. (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 * Check position.
mounted or faulty. * 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.

20809 MRE: ~DRAM Dimm pbas error~


The installed memory DIMM * Total memory > SDS setting
modules dont match with the * Maximum memory < 64MB
configuration settings in SDS
test 90.
One of the DIMMs defect or * Reboot and examen the bank messages,
makes bad contact. displayed in the Terminal window, SDS: see
* If it is properly installed, clean its connec-
tor or replace it.
20810 MRE: ~TAXI interface printer pba~ (PRISCAT)~


PRISCAT pba not properly * Check position.
mounted or faulty. * Execute the controller functional tests

LSBT, LTBT to verify whether the board is
okay.

ENGINE - CONTROLLER COMMUNICATION ERROR: 20811-20812
20811 MRE: ~Communication error contr(oller) -> engine~


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.
window.
Connection: * Listen if the fan is turning.
mains to controller supply. * No messages in the terminal
window.
Controller power supply defect. * Listen if the fan is turning.
window.
Software corrupt. Reload software on harddisk.
* Only the first messages are
correct. No new messages
when trying to load the soft-
ware.
Connection: * Check with test LTBT

communication cable between controller and * Check cables
CPU_IO PBA.
Connection:
tight).
Connection: Check memory information
one of the DIMMss makes bad contact. (bank 0-3) displayed in the ter-
minal window.
Motherboard defect. No message in the terminal
window
Wrong position PCI I/O cards. Position in chapter Electrical
description: see Controller
PBA overview on page 2603
RADICAL pba defect Test RDBT

PRISCAT pba defect Test TSBT, LSBT, LTBT
Harddisk defect 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
System switched OFF and ON too quickly. Harddisk was not stopped
properly.
Wait 5 seconds before switch-
ing the system ON again.
20812 MRE: ~Communication error engine -> contr(oller)~


Electrical connections Internal and external communication cables
between PRISCAT and CPU_IO PBA.
No display message if the controller is
tem is rebooted.
tem is rebooted.
PRISCAT PBA defect Test LSBT.

MISCELLANEOUS ERRORS: 20813 - 20815
20813 OWAR: ~Not enough memory to complete op(eration)~
Possible cause
drawing is printed
With a free text/ image stamp the plot must fit in the DLL. If not than e.g. ren-
dering is not done and error 20813 occurs.
Remark
can be reset.

Possible cause
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.
Possible cause
The plot doesnt fit into the set memory. Hence, the plot cannot be processed. .
Remark

RS323 ERRORS: 20820 - 20822
20820 OWAR: Not used in EPC2 Controller.

20821 OWAR: Not used in EPC2 Controller
SCSI ERRORS: 20830 - 20832


GRAPHIC LANGUAGE ERRORS: 20860 - 20864
20860 OWAR: ~Interpr. (eter) error: command not supp(orted)~





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.


HOST PROTOCOL ERRORS: 20870 - 20872
20870 OWAR: ~Host prot(ocol), job description error~

The RCF header contains a not yet Syntax error.
implemented or non existing command/ Verify that the contents of the RCF
APPLDATA. header is according the RCF refer-
ence Manual

ignored.


20901 SWAR: ~Illegal ram configuration contr(oller)~

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 con- Clean its connector or replace it
tact. and run the test again.
Reboot and examine the bank messages, dis-


Most of the Oc Repro, Scan Station and Machine Monitor errors (messages)
are self explaining. The following errors need an explanation:

Error incorrect RCF only with EPC; special character in printer stamps,
backchannel stopped.

Check as follows:

Check if the status of the Oc 9800 is ~ The system should not be in
Ready to copy~ warming up state.
nected?
Station Configure - SCSI menu. the configured IDs.
(Default is: 0 - 4)
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.
Switch it on again.
tronics.


slow.


corrupted.
Conflict with network card in PC Try the same job using only the
PC and no network
Pen 0 set to end of file although SP0 HP-GL and HP-GL/2
appears in the middle of the job

~Processing Scan Job~ doesnt disappear

X2 of the Taxi Scanner part of the
PRISCAT pba


SDS
Analysis info tests

see SDS

see SDS
32 ~Last error logging~

last 15 errors
mode
ice mode
34 ~Error top 10~


see SDS
see SDS
see SDS

see SDS

Parameter test
Input tests
Output tests
Special tests
Info tests
info tests~





(DLL)~
(16/32 Mb)

(RSR)~
Not relevant for EPC

(64 - 256 Mb)


(0-99)

(0 - 99)

(0-99)



System tests

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
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 code number: 1302522

Centronics cable code number: 1302520
Loop connector code number: 7991.293
Link cable code number: 7991.520

2 Connect the laptop to the serial port COM1 of the controller with the serial ca-
ble (code number 1302522).
5 Change the settings to: Com1, Baud rate 9600, data bits 8, stop bit 1, no Parity,
Flow control to none.
6 Select Settings, Terminal Preferences, Translations.
7 Change the language setting to: None
9 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!!
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.

Terminal window
Text on screen during booting-up (this is an example of a configuration).
Embedded Power Controller 2 starting up...

PROM version : 0.6
DRAM Test....
Bank 0 .... empty
Bank 1 .... empty
Bank 2 .... empty
Bank 3 64 Mbyte ... OK
VxWorks System Boot

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

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
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...
Starting EPC2 Application
(PRL)ENABLE COMM. RECEIVED cpt_init = 1
(PRT) Controller SEND ENABLE COM
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 ...

Text on screen with CTRL-T (this is an example of a configuration)

PROM version : 0.6
DRAM Test....
Bank 0 .... empty
Bank 1 .... empty
Bank 2 .... empty
VxWorks System Boot

Version: 5.3.1
BSP version: 1.1/1
auto-booting...

host inet (h) : 134.188.136.50
gateway inet (g) : 134.188.138.4
user (u) : reader
other (o) : dc
Attaching to ATA disk device... done.

Loading /ide0/MTX...2515312
Starting at 0x1663f8...
Functest>

Text on the screen with CTRL-E (this is an example of a configuration)

PROM version : 0.6
DRAM Test....
Bank 0 .... empty
Bank 1 .... empty
Bank 2 .... empty
VxWorks System Boot

Version: 5.3.1
BSP version: 1.1/1
auto-booting...


host inet (h) : 134.188.136.50
gateway inet (g) : 134.188.138.4
user (u) : reader
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.

Text on the screen with CTRL-O (this is an example of a configuration)

PROM version : 0.6
DRAM Test....
Bank 0 .... empty
Bank 1 .... empty
Bank 2 .... empty
VxWorks System Boot

Version: 5.3.1
BSP version: 1.1/1
auto-booting...

host inet (h) : 134.188.136.50
gateway inet (g) : 134.188.138.4
user (u) : reader
other (o) : dc
ttaching to ATA disk device... done.
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...
Starting EPC2 Application
(PRT) Controller SEND ENABLE COM
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 ...

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.
Help list with a general description:

Func- Description
tional
test
~HELP~ List of all the available commands
CONF Configuration
~TIME~ Setup time and date
UPGD Upgrade software on the harddisk
UPBK Back to the previous software, if existing
DLDP Demo plot is downloaded on the harddisk
ECCX Testing of the centronics output
TPBT Test of TAXI Print logic (Priscat)
TSBT Test of TAXI Scan logic (Priscat)
LTBT Link test of TAXI transfer, print and scan lines.
LSBT Test of serial command link PRISCAT
RDBT Test of Radical board
~QUIT~ Reboot the controller

HELP
Displays the list of all available commands
~Functest> HELP~
__________________~ LIST OF COMMANDS~ ____________________
~HELP~ ~Show help information~ Show help information
~CONF~ ~Display the current controller Display the current controller con-
configuration~ figuration
~TIME~ ~Setup time and date~ Setup time and date
No function in the system.
UPGD ~Upgrade application~ Upgrade application
UPBK ~Back to previous version (if Back to previous version (if exist-
existing)~ ing)
DLDP ~Download demo plot file~ Download demo plot file
ECCX ~Echo characters sent to Echo characters sent to Centron-
Centronics output~ ics output
TPBT ~Test of TAXI Print Logic~ Test of PRISCAT Print Logic
TSBT ~Test of TAXI Scan Logic~ Test of PRISCAT Scan Logic
LTBT ~Test of TAXI transfer~ Test of PRISCAT transfer
LSBT ~Test of TAXI Serial port~ Test of PRISCAT Serial port
RDBT ~Test of RADICAL Inter- Test of RADICAL Interface
face~
~QUIT~ ~Quit (Turn off/on Quit (Turn off/on machine)
machine)~
~Cmd Ok.~
~Functest>~

~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.~

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.
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!
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.~

~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 download-
ed from the laptop to the harddisk.
The download needs the centronics cable (code no. 1302520) between the lap-
top 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

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.
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.~

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 con-
troller, see Component location on page 2601
Connect the test cable (code no. 7991.520) between the ~Upload~ and ~Down-
load~connectors at the outside of the controller.
Activate the test.
- the test cable
- PRISCAT
- motherboard
~Test of data transfer between TAXI PRINT and TAXI SCAN~

~Verify transfer...OK~
~Cmd Ok.~
~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.~

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 connec-
tor X3 on the PRISCAT pba
- PRISCAT
- motherboard
~Sent: The quick brown fox jumped over the lazy dog...OK~
Cmd Ok.~
~Sent: The quick brown fox jumped over the lazy dog~
~Test failed.~
~Cmd Ok.~

RDBT
~RaDical Board Test~
With this command, the RADICAL board is tested.
Activate the test.
Corrupted data is always displayed.
- RADICAL pba
- motherboard
~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.

Dis-/assemblies
Note:
Before dis/-connecting the controller cable(s) make sure that the host is pow-
ered down and the Oc 9700/9800 is switched off.
various controller failures. Please use a wrist strap , antistatic mat and take
care when reinstalling controller items.
Check after dis-/assemblies the EPC controller with your laptop.
If correct, connect host environment and check again.
1 Embedded Power Controller

2 Switch off the host and the Oc 9700/9800.
3 Disconnect at the front side of the engine the connectors from the controller
and the scanner.
4 Remove the front cover from the engine.
5 Remove the right top cover from the engine.
6 Remove the right side covers from the engine.
7 Remove at the right side the front upper and lower cover from the engine.
8 Disconnect the data connectors from the controller see Component location
on page 2601.
9 Disconnect the power supply connector (2001D2) from the controller.
10 Remove at the front side of the engine the 2 lower mounting screws from the
controller.
11 Loosen at the front side of the engine the 2 upper mounting screws from the
controller.
12 Remove the controller and place the controller on a flat table.
13 Remove (if needed) the cover from the controller (24 screws).

2 EPC 2 software
Needed:

Controller software
2 Activate the functional tests, see The functional tests of the EPC2 controller.
on page 2204
3 Activate the functional test: UPGD.
Message: ......~Transfer controller software through the centronics port:~
8 Follow the instructions on the screen: (~install new software / save old~)

3 EPC 2 Upgrade Backup Software
Needed:
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.
(~Retrieving the old software version will overwrite the current one
Please confirm?(Y/N):~)

4 EPC2 Demo plot (Test print)
Needed:

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.
Message: ......~Transfer Demo Plot file through the centronics port:~

(~Loading file...Press ESC to abort the transfer.
12 Check the demo plot by activating it from the operator panel.

5 ~Radical PBA~
2 Remove the screw (5.5 mm) opposite of the connector of the Radical PBA.
Note: The Radical PBA must be mounted in the PCI slot J2.

configuration.
Note: With the functional controller test RDBT it is possible to check the func-
tioning 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).

6 ~Priscat PBA~
2 Disconnect the 3 connectors from the Priscat PBA.
3 Remove the screw (5.5 mm) opposite of the connector of the Priscat PBA.
4 Remove at the right outside of the controller the screw from the second mount-
ing bracket of the Priscat PBA.
5 Remove the PBA.
6 Mount the bracket to the new PBA.
Note: The Priscat PBA must be mounted in the PCI slot J1.
8 Connect the 3 connectors to the Priscat PBA.

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
2 Disconnect the supply connector (P5) from the hard disk.
3 Disconnect the IDE connector from the hard disk.
4 Remove at the left outside the Allen screw from the holder of the hard disk.
5 Remove at the top side the 2 screws from the holder with the hard disk.
6 Remove the holder with the hard disk.
7 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.

11 Download the software and the Demo Plot, see Functional Description tests
UPGD and DLDP.

8 EPC2 Hard disk jumper settings
The hard disk should have the following jumper settings:
JP1 JP2 JP3 JP4

1 3 5 7
2 4 6 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

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 sup-
ply unit.
6 Mount the support bracket to the new power supply unit.
7 Replace or mount the (new) power supply unit.
10 Test the controller function (e.g. with the ~Plot Director~).

10 Motherboard
2 Remove the Radical PBA, see page 2405.
3 Remove the Priscat PBA, see page 2406.
5 Remove the power supply unit see Power supply unit on page 2408
6 Disconnect the IDE connector (J24) from the motherboard.
7 Disconnect the SCSI2 connector (J38) from the motherboard.
8 Remove the 2x BOOT flash and the DIMM(s) from the motherboard and
mount these on the new motherboard.
9 Remove at the outside the 2 nuts from the connectors COM2 and Ethernet AUI.
10 Remove the motherboard (10 Allen screws).
11 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 in-
stalled)
12 Remount all disassembled parts and PBAs according: see Controller PBA
overview on page 2603.

15 Reboot the system and ~print settings~.
16 Use the laptop to sent a plot (~Plot Director~).
17 Switch of the machine and connect the host environment.
18 Test the function of the controller.

Boot
DIMMs

11 Memory module (DIMM)
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.

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 list-
ed in the settings.

XU6 and 5 XU4 and 3
64 Mbyte 2 x 32 Mb empty
128 Mbyte 2 x 32 Mb 2 x 32 Mb
2 x 64Mb empty
192 MByte 2 x 64 Mb 2 x 32 Mb
2 x 32 Mb 2 x 64 Mb
256 Mbyte 2 x 64 Mb 2 x 64 Mb
2 x 128 Mb empty

Termination

be switched off.

by Machine Monitor!
Software versions
Check for new drivers on the Adaptec webside: www.adaptec.com.

the PBA:

Note:
ers.
PBA).
position to enable:



down position.
Select utility!).



2940AU

1 AHA 2940:
AHA 2940AU:
There is no jumper!
4 AHA 2940:
AHA 2940AU:
disabled.
the boot time).
drivers at www.adaptec.com

needed.

- Leave Windows
be damaged.

1 General
The controller functions of the EPC2 controller are:
Processes: conversion and transformation of plot data to Oc 9700/9800 spe-

cific raster formats and performs scaling, rotation etc.
Connectivity: connects the Oc 9700/9800 to the customer environment
printing, scanning and finishing aspects.
2 Features
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.
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.

3 System overview

Graphic languages
The following graphic languages are supported by the ~Embedded Power Con-
troller~ (can be set to automatic language sensing ALS, except ASCII): :
Vector
plotter
HPGL/2 supported plotter emulation: reference are Design
Jet Hp 650/750 plotters
CALCOMP 906/907
Raster
HP-RTL
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.

Embedded Power Controller abbreviations:
Name Explanation
Power Controller: Motorola CPU-board with MPC 604r 300Mhz proc-
essor.
PCI Peripheral Component Interface bus.
ISA Industry Standard Architecture
SCSI Small Computer Standard Interface
Intelligent I/O, each connected device has a unique
ID.
Frame buffer DRAM which contains the bitmap of the image to be
printed.
Cache Fast temporary RAM memory for last items read
from the main memory.
RTOS Real Time Operating System
VxWorks for this controller.
AUI Attachment Unit Interface
connector type between I/O card in a PC and the
Ethernet network.
10Base-T / Connector type between I/O in a PC and the Ethernet
100Base-T network, implemented on twisted pair cabling.
TCP/IP Transmission Control Protocol / Internet Protocol
LPD socket Line Printer Daemon (Unix)
printer software for Ethernet
NVRAM NonVolatile RAM (battery powered).
RADICAL Raster Acceleration board
I/O board for compression of raster data, only for
Scan to File.
PRISCAT PRInter SCAnner Taxiboard
I/O board for communication with the printer.
* One side of the board is used for printing (to trans-
fer 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.

4 EPC2 controller characteristics
Mother board
Motorola MTX board with
300 MHz Power PC 604r processor
1 boot EPROM memory
3 PCI slots
SCSI Intergrated on mother-
board, main purpose: print-
ing and scan to file, also
used for backchannel com-
munication with Machine
Monitor
Ethernet integrated on motherboard
DLL memory 11 / 27 MB (16 / 32 in SDS) is part of the total memory

FRAME buffer 41 - 216 MB is part of the total memory
Total memory 64 - 256 MB 4 DIMM slots.
Harddisk ATA
PRISCAT PCI Printer TAXI I/O card
Scanner TAXI I/O card.
Serial link commandline
RADICAL PCI Hardware compression I/O
card, only for Scan to File.
Harddisk
ATA disk controller
4.3 Gbyte
DMA access
controller software (easy upgrade)
test print
for swapping data, if needed (Ethernet)
Software features:

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 Frame buffer OS Total mem.

1 11 41 12 64 Mb
2 11 102 15 128 Mb
3 27 88 13 128 Mb
4 11 166 15 192 Mb
5 27 152 13 192 Mb
6 11 230 15 256 Mb
7 27 216 13 256 Mb
DLL : Display List (size adjusted in SDS test 90)

Frame buffer : bitmap buffer
OS: Operating System
Total memory = DLL + frame buffer + OS

5 Process
Block diagram EPC 2

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.
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.

6 Printing


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.

directly.

plots.

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.
dling 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).

7 Print size of originals for rotated image
can be rotated. Vector: are always rotated in the DLL buffer.
Raster: are rotated in the Frame buffer. The rotation algorithm requires a sec-
ond 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

Confi- DLL FB Maximum Maximum W x L Total mem.
guration file size or equivalent
1 11MB 41MB 20.5 MB 914 x 750 64 Mb
(36 x 29.5)
2 11MB 102MB 51 MB 914 x 1850 128 Mb
(36 x 72.8)
3 27MB 88MB 44 MB 914 x 1600 128 Mb
(36 x 63)
4 11MB 166MB 83 MB 914 x3050 192 Mb
(36 x 120)
5 27MB 152MB 76 MB 914 x 2800 192 Mb
(36 x 110)
6 11MB 228MB 114MB 914 x 4200 256 Mb
(36 x 165)
7 27MB 213MB 106,5MB 914 x 3900 256 Mb
(36x153.5)
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

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 re-
printed 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

Confi- DLL FB Maximum W x L Total mem.
guration or equivalent
1 11MB 41MB 914 x 1500 64 Mb
(36 x 59)
2 11MB 102MB 914 x 3750 128 Mb
(36 x 147.6)
3 27MB 88MB 914 x 3200 128 Mb
(36 x 126)
4 11MB 166MB 914 x 6100 192 Mb
(36 x 240.2)
5 27MB 152MB 914 x 5600 192 Mb
(36 x 220.5)
6 11MB 228MB 914 x 8400 256 Mb
(36 x 330.7)
7 27MB 213MB 914 x 7850 256 Mb
(36 x 309)
Attention:
Maximum length is 15 meters (590.5)
Maximum width is 914 mm (36)

9 Scan to File
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 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.

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
Confi- DLL Maximum W x L Maximum W x L Total mem.
guration or equivalent (200 or equivalent (400
dpi) dpi)
1 16 Mb 914 x 5200 914 x 1300 64 Mb
(36x204.7) (36 x 51.2)
2 16Mb 914 x 13200 914 x 3300 128 Mb
(36x519.7) (36 x 129.9)
3 32Mb 914 x 11400 914 x 2850 128 Mb

(36 x449) (36 x 112.2)
4 16Mb 914x21400 914 x 5350 192 Mb
(36x842.5) (36 x 210.6)
5 32Mb 914x19600 914 x 4900 192 Mb
(36x771.7) (36 x 192.9)
6 16 Mb 914x29200 914 x 7300 256 Mb
(36 x1150) (36 x 287.4)
7 32 Mb 914x27600 914 x 6900 256 Mb
(36 x1087) (36 x 271.7)

The printroom application software consists of Job Director, Job Director Con-
figurer, Repro Station and Machine Monitor.
NT3.51/4.0.
Job D ire cto r

Job D ire cto r C o nfig ure r
R e p ro S ta tio n
o r F lo pp ies) S C S I M in i
con n ector
RS E m be dd e d
D o n gle P o w er
C o n tro lle r
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
A S P I drive rs 5 0 p ins
( C D -R O M con n ector
o r F lo pp y) A m pli o r M in i

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.
Machine Monitor can handle back-channel communication with the EPC con-
troller.

12 SCAN STATION
upgraded).In the package you find also the needed hardware: the RADICAL
NT3.51/4.0.
S ca n S tation
M a chin e M on itor R A D IC A L
O c V iew S ta tio n
S C S I M in i
co n n ector
V ie w
S ta tio n
E m b e d de d
D o n gle 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
(C D -R o m co n n ector
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.
each other. Even more is possible. The order of the dongles can be important.
See the corresponding manuals.
Examples:

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:

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 Operat-
ing 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


M cable is needed.
Adaptec 2940AU SCSI

M cable is needed.

Job Director
Repro Station
Scan Station
Machine Monitor

For View Station on Windows NT3.51: Service Pack 5 is required.
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
lower.
Note: 2
be the same.

Embedded Power
Controller
220 V supply
Serial commands
Download
Upload

2 Embedded Power Controller 2 (EPC 2) Extensions
only for
service
CENTRONICS
Connectors:
External
serial
centronics
ethernet (AUI or 10BaseT/100BaseT)
SCSI
Internal

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

3 Controller PBA overview
RADICAL PRISCAT
Connectors on Priscat
X1 Taxi printer connector
X2 Taxi scanner connector
X3 Serial commands connector

MTX Connector/Jumper Descriptions
Reference Function Comment

Designator
J1 32-bit PCI slot 1 Priscat PBA location
J2 32-bit PCI slot 2 Radical PBA location
J3 32-bit PCI slot 3 Not used
J5 Upper Ethernet AUI
J5 Lower Test centronics port
(ECCX functional test)
J6 Ethernet 10/100 Base-T
J7 Upper COM2 For functional test activation
J7 Lower COM1 Not used
J8 Upper Keyboard Not used
J8 Lower Mouse Not used
J23 Data Centronics I/F
J27 ATX Power Control Short to turn ATX power supply on
J35 Power From PSU
J37 Flash Bank Select 1-2 position (Flash Bank A selected)
J38 SCSI
XU1 Flash Bank Upper Byte
XU2 Flash Bank Lower Byte
XU3 DIMM Bank B Upper 72-Bits
XU4 DIMM Bank B Lower 72-Bits
XU5 DIMM Bank A Upper 72-Bits
XU6 DIMM Bank A Lower 72-Bits

4 Motherboard
Slot 4
Slot 3
Slot 2
Slot 1

XU6 and 5 XU4 and 3
64 Mbyte 2 x 32 Mb empty
128 Mbyte 2 x 32 Mb 2 x 32 Mb
2 x 64Mb empty
192 MByte 2 x 64 Mb 2 x 32 Mb
2 x 32 Mb 2 x 64 Mb
256 Mbyte 2 x 64 Mb 2 x 64 Mb
2 x 128 Mb empty

5 Radical PBA
SW1
1
1 1
SW2 SW3
Jumper settings Code number:

7009010
SW1 1-2
SW2 1-2
SW3 1-2
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.

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.

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
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
Diagnostics
1 Faults
CONtrol 22000 -22999 code display
22001 + CPU_IO code 3 FE: ~Checksum fail EPROM SCA: 22PBA02~

~

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~
)

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~
~

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~
~

EPROMS CPU_IO PBA defect
CPU_IO PBA defect
22003 + CPU_IO code 2 FE: ~CPU_IO PBA defect -> communication error
CPU CONSOLE PBA~
~

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~
~

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
22003 + CPU_IO code 4 FE: ~Watchdog detection CPU_IO PBA ->

communication failure CPU CONSOLE PBA~
~

CPU_IO PBA defect

22003 + CPU_I/O code 9 FE: ~Software error on CPU I/O-PBA ->
communication failure CPU CONSOLE I/O-PBA~
~

Defective printer The current job is finished and code 9 is displayed on the
software 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~

~

CPU_CONSOLE
PBA defect
Defective scanner R1.2 only. The problem is known if the machine is config-
software 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)~

~

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 proce-
dure:
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~
)

CONCNTPR
Continuously ON Copy counter defect or not connected
CONSUPLV defect
22-4-01 CONDRI Possible cause Remark

CONCNT OUTDIAG
OFF ON Connection DRIVERS PBA -> Loose
CONCNT 2205X7
DRIVERS PBA defect
Connection F1 DRIVERS PBA defect
ON Connection DRIVERS PBA ->
CONCNT
CONCNT defect
22102 PE: ~Checksum BBR failure 22PBA02 SCA~

~

Initialise BBR
CPU_CONSOLE
PBA
Again 22102 after Voltage battery CPU_CONSOLE Charging time: max.
switching off / on PBA < 3 V if the downtime is 20 hrs.
more than 30 days

22103 PE: ~Checksum BBR failure 22PBA01 printer~
~

Initialise BBR
CPU_IO PBA
Again 22103 after Voltage battery CPU_IO PBA < 3 Loading time: max.
switching off / on 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~
~

CPU_IO PBA defect
22106 PE: ~CONCONEMS supvol out of range~

~

CONCONEMSSUPVOL
ADC value > 560 Mains voltage too high Check mains voltage
(30 V DC) SSR PBA defect
ADC value < 56 Mains voltage too low Check mains voltage
ed.5 22 Control 105

22107 PE: ~Earth current out of range~

CONCONEARTHCUR
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 Remark

/ ON
24V on 2201X13?
Yes CPU_IO PBA defect
No Connection 24V CONSUPLV ->
DRIVERS PBA
Connection 24V DRIVERS -> CPU_IO
PBA
CONSUPLV defect

22502 MRE: ~CONCONEMS supvol out of range~
)

CONCONEMSSUPVOL
ADC value > 560 Mains voltage too high Check mains voltage
(30 V DC)
SSR PBA defect
CPU_IO PBA defect discon-
nect 2201X3
ADC value < 56 Mains voltage too low Check mains voltage
SSR PBA defect
CPU_IO PBA defect
Connection SSR PBA ->
CPU_IO PBA
22503 MRE: ~Mains voltage out of range~

)

CONMAINSVOL
Voltage > 265 V Mains voltage too high Check
L1 mains L1
SSR PBA not adjusted after replacement 22 adju 1
CPU_IO PBA not adjusted after replacement 22 adju 1
SSR PBA defect
Voltage < 150 V Mains voltage too low Check
L1 mains L1
SSR PBA not adjusted after replacement 22 adju 1
CPU_IO PBA not adjusted after replacement 22 adju 1
SSR PBA defect
ed.5 22 Control 107

22504 MRE: ~Fail watchdogtest printer 22PBA01~
)

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

)

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

~

CPU_IO PBA defect
22507 MRE: ~PRDLKNIMO controller failure~

CPU_IO PBA defect
22508 MRE: ~MADMO controller failure~

~

CPU_IO PBA defect
22509 MRE: ~CTFPMO controller failure~

CPU_IO PBA defect

22510 MRE: ~Earth current out of range ~
)

CONEARTH-
CUR
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)~

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

Initialise BBR
CPU_IO PBA
Again 22902 after Voltage battery CPU_IO PBA < 3 V if the Loading time:
switching OFF / downtime is more than 30 days max. 20 hrs.
ON
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~

Test service bus
Test not OK with testcon- Connection CPU CONSOLE .
nector 7991.290 on 10X2 PBA -> 10X2
CPU_ CONSOLE PBA
defect
Test failed with testconnec- Connection 10X2 -> laptop
tor 7991.290 on RS 232
connector cable
Test OK with testconnector Laptop failure
7991.290 on RS 232 con-
nector cable

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 CON- CONCONEMS Possible cause

KEYSW switches
on (listen)
YES Continue with description:
Main voltage between L2,N2 > 198 V AC
on CONSUPLV G1-1,3
CONKEYSW switched ON
Main voltage between Possible cause

L2 and N2 > 198 V AC
on Terminal block
NO Ask assistance of local electrician

on SSR PBA, connec-
tor X9 - 1 and 3
NO 22 Q 3 defect / OFF
22Z2 defect / OFF
Electrical connection between terminal block and
SSR PBA
ed.5 22 Control 111

Voltage on SSR PBA Possible cause

between TP2 and 3
> 20 V DC
NO SSR PBA defect
YES CONKEYSW defect
CONCONEMS defect
Electrical connection between SSR PBA and CON-
KEYSW
Electrical connection between SSR PBA and CON-
CONEMS

on CONSUPLV G1-1
and 3
NO Electrical connection between SSR PBA and CON-
SUPLV
SSR PBA defect
YES If machine is a stand alone printer continue with:
Disconnect MIXED SUPPLY G2, G3 (Stand-alone
model only)

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
Disconnect MIXED SUPPLY G2 and G3 (stand alone only)

(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 CONLVSUP defect
printer)
Electrical connection between CONLVSUP and
CONSOLE CPU PBA
YES CONSOLE CPU PBA defect
Console Firmware defect
ed.5 22 Control 113

* 2 Machine is totally dead after CONEMS activated

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 dis-
plays) are functioning.

Electrical connection between SUPPLY TL Lamp is off
TL INVERTER PBA and LCD
Electrical connection between CONSU- TL Lamp is off
PLV and SUPPLY TL INVERTER PBA
Electrical connection CONSOLE CPU TL Lamp is off
PBA and LCD
CONSOLE CPU PBA defect TL Lamp is off
LCD defect TL Lamp is off
SUPPLY TL INVERTER PBA defect TL Lamp is off

SDS
1 CONtroller
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS
ed.5 22 Control 201

Input tests
22-2-01 CONtrol CouN- Control counter present

Ter PResent ON = counter not present
22-2-02 CONtrol KEY Control key switch scanner in timer position

SWitch ON = switch in timer position
22-2-03 CONtrol Control remote copy switch pressed

REMote COpy ON = switch pressed
SWitch
22-2-04 CONtrol DRIv- Control detection diagnose signal active

ers INput DIAG- ON = diagnose correct
nose
22-2-05 CONtrol DRIv- Control detection diagnose signal active

ers OUTput OFF = diagnose correct
DIAGnose
22-2-06 CONtrol MIXed Control detection diagnose signal active

supply INput OFF = diagnose correct
DIAGnose
22-2-07 CONtrol MIXed Control detection diagnose signal active

supply OUTput OFF = diagnose correct
DIAGnose
22-2-08 CONtrol Solid Control detection diagnose signal active

State Relays OFF = diagnose correct
INput DIAGnose
Output tests
22-4-01 22Y1 CONtrol CouN- Control counter

Ter mechanical total counter
ON = counter activated
Hardware diagnoses:
CONCNTPR
22-4-02 CONtrol MOtor Control motor supply

SUPply motor supply relays (22Y..) activated
ON = relays activated
22-4-03 CONtrol Control remote copy key led

REMote COpy drive of the remote copy key led
LED ON = led on
202 TSM Oc 9800 SDS

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
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 maxi-
mum and half light intensity
(frequency 1 Hz)
ed.5 22 Control 203

22-6-04 ~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 (disa-
ble) 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

22-6-08 Automatically ~input diagnoses~

Must be done when This test checks the input diagnosis
done when switching to signals of the SSR PBA, MIXED Supply
SDS, (results are
software is shown in the sec- PBA, DRIVERS PBA and FOLd 1 PBA
corrupt or ond screen) (and FOLd 2 PBA if a folder is in the
new configuration)
software is The following input diagnose lines are tested:
installed ~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:
FOL1DEFlector CLutch
FOL1 OUTput DEFlector SOlenoid
FOL2 FLAT SOlenoid
FOL2 DEFlector CLutch
FOL2 OUTput tray SOlenoid
FOLOFFOUTMO
FOL2RUSTOPSO
FOL2RUGUIDSO
FOL2RUMO
ed.5 22 Control 205

22-6-09 ~Service bus test~

Use test connector (7991.290)
Info tests
22--9-01 CONtrol power ~CON CON EMS SUPply VOLtage (adc)~

CONtrol EMS Actual A/D value of the supply voltage meas-
SUPply VOLt- ured on the safety relays
age (range 0 ... 1023)
22-9-02 CONtrol power ~CONtrol MAINS VOLtage (V/10)~

MAIN Supply Measured supply voltage
VOLtage (range 1800 - 2550 V/10)
22-9-03 CONtrol ~CON EARTH CURrent (adc)~

EARTH CUR- Earth current reading
rent (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:
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 Adjust the voltmeter to AC and a range of 300 Volt minimum.
4 Connect the voltmeter between TP5 and 6 on the SSR PBA.
6 Measure the supply voltage.
7 Select SDS test 22-9-02 (supply voltage x 10).
8 Wait till the reading on the operating panel is stable.
9 Adjust with R92 on the SSR PBA the reading on the operating panel to the val-
ue on the voltmeter (+/- 1V).
ed.5 22 Control 301

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:
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).

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 Print-
head 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:

2 Connect 22G1G1 22PBA4 SSR PBA (220V).

3 Switch on the machine and check functioning.
5 Connect 22G2 22PBA5 Drivers PBA (5V).
8 Connect 22G1G3 22PBA5 Drivers PBA (+24V).
11 Connect 22G1G5 10G1 Mixed supply (SCA + / - 400V DC).
12 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).
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.

6 Software upgrading procedure
General
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 con-
sumable 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

Upgrading the engine software implies that the CPU firmpack in the engine has
to be replaced:

2 Open the right-hand side covers of the engine.
3 Remove the controller, if present.
4 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 codenum-
ber):
EPROM 1 in D18 and
EPROM 2 in D19.
5 Re-assemble in reverse order.
Upgrading the 9710/9810 Scanner Console software

Upgrading the console control software implies that the CPU firmpack on the
console PBA has to be replaced:
2 Open the operating panel of the console.
3 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 codenum-
bers):
EPROM 1 in D8,
EPROM 2 in D7,
EPROM 3 in D10, and
EPROM 4 in D9.
ed.5 22 Control 405

Upgrading the 9708/9808 Printer Console software
Upgrading the stand-alone printer console control software implies that the
CPU firmpack on the console PBA has to be replaced:
2 Open the operating panel of the console.
3 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 codenum-
bers):
EPROM 1 in D8,
EPROM 2 in D7,
EPROM 3 in D10, and
EPROM 4 in D9.
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:
Switch on the system in SDS mode.
Ignore the BBR warnings.
Execute test 22-6-06 ~Init BBR engine~.
Execute test 22-6-07 ~Init BBR console~.
Switch the machine to cold SDS using SDS test 40.
Upload the machine parameter settings, print settings, controller settings by
using Service Terminal.

Check and if necessary adjust the new machine configuration.
Execute test 42 and wait until the machine is warm.
Execute adjustment test 10-7-01, ~TL intensity adjustment~. This adjust-
ment is not necessary in case of a Stand Alone Printer.

Execute adjustment test 06-7-01, ~Pressure Roller Torque adjustment~.
Execute the ~1:1 Image length correction printer~ adjustment (adjustment 1
chapter 06, CTF).

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.
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 ma-
chine parts concerned.

Mark the appropriate modification number in the logbook.

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:
Switch on the system in SDS mode.
Ignore the possible BBR warnings.
Activate SDS test 70, ~Install machine~ and execute all the tests completely.
Activate SDS test 71, ~Install engine~ and only:
Refill the parameter settings (xx-1-xx tests) according to the saved informa-
tion, except: test 06-1-03,~1:1 image length correction printer~.
Execute adjustment test 06-7-01, ~Pressure roller torque adjustment~.
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 informa-
tion, except: test 09-1-02, ~1:1 image length correction scanner~.

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~.
Activate SDS test 73, ~Install folder~ in case the folder is a part of the con-
figuration and:
Refill all the parameter settings (xx-1-xx tests) according to the saved infor-
mation.
Activate SDS test 74, ~Customer installation~, and execute all the tests com-
pletely.
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)~,
Re-install the print settings as they are mentioned on the copy of the Print
Settings.
Execute the ~1:1 Image length correction printer~ adjustment (adjustment 1
chapter 06, CTF).
ed.5 22 Control 407

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 ma-
chine 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.

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, func-
tional descriptions and fault descriptions
The abbreviation is made from the english names of the CAS function, fol-
lowed 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 DRUm DRU
02 CORona COR
04 PrintHeaD PHD
05 DEVeloping DEV
06 Compact Transfer CTF
transFuse
- Set-up CTFS
- Fuser roller CTFF
- Pressure roller CTFP
07 DisCHarging DCH
09 ORiGinal ORG
10 SCAnner SCA
11 IMage Processing IMP
12 Paper Roll Drawers PRD
- Upper PRDU
- Lower PRDL
- Support PRDS
13 Paper Sheet Feeding PSF
ed.5 22 Control 501

Number CAS Function Abbreviation
14 PREheater PRE
- Transport PRET
15 Paper TRansport PTR
- Unfolded output PTRU
18 FOLder FOL
- 1st fold FOL1
- 2nd fold FOL2
- Punch consolidate FOLP
- Output FOLO
20 INTerface INT
22 Control - engine/ CON
scanner
23 MAin Drive MAD
25 Customer CUS
The following component names are used:
Component name Abbreviation

AIR AIR
BALlast BAL
BRake BR
CAPacitor CAP
CouNTer CNT
CLutch CL
COMPRessor COMPR
CYLinder CYL
DEtection DE
FAN FAN
HEater HE
INVerter INV
KEY KEY

Component name Abbreviation
LED LED
LAmp LA
MOtor MO
PUMP PUMP
SEnsor SE
SOlenoid SO
STAtic STA
SUPply SUP
SWitch SW
VAlve VA
The following signal names are used:
Signal name Abbreviation

Amplified A
Analog voltage VAN
Buffered B
Filtered F
DIRection DIR
ENable EN
CouNTer CNT
CUrrent CU
ERror ER
Pulse Width Modulation PWM
TEMPerature TEMP
ed.5 22 Control 503

2 The hardware diagnostic system
The Oc 9800 is equipped with hardware diagnose lines and tests. Their func-
tion 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:
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 DRIV-
ERS PBA to the CPU I/O PBA. The feedback lines are CONDRIINDAG and
CONDRIOUTDIAG.

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-cir-
cuit the CPU I/O is informed about the several incoming signals on the DRIV-
ERS PBA, including the PHDFAN signal.
The INDIAG line is tested when the technician
enters the 2nd SDS screen
Note: Look carefully at the display indication.
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 it-
self.
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: OFF
outdiag: OFF CONtrol DRIvers OUTput DIAGnose
Activate the <START> button:
ed.5 22 Control 505

The SDS screen indicates:
value: ON
outdiag: ON CONtrol DRIvers OUTput DIAGnose
Possibility 1: The PHD fan is turning:
no error occurred
or
Possibility 2:The PHD fan is not turning:
connection problem (wire, connector) between the PBA and the component
the PHDFAN is defect.
or
The SDS screen can also indicate:
value: ON
outdiag: OFF CONtrol DRIvers OUTput DIAGnose
The buzzer gives an intermittent signal.
Possibility 3: The PHDFAN is not turning:
error on DRIVERS PBA.

22T1
CONSTEPUP
TRAFO
06U1 Rear
23U1 Front
see next page
ed.5 22 Control 601

CONCONEMS LINE
filters Circuit breakers
CONEMS1,2,3 22Z1 ..Z3 22Q1-22Q6
3 22Q6
22Q5
2 22Q4
22Q3
1
22Q2
22Q1
22PBA4 22PBA3 PE
SSR Cursens Terminal block

18 PBA1 I/O
1 st fold + PTR
18PBA2 I/O
2 nd fold
11PBA2
BW Proc.
Controller
11PBA1 22G1
DOC MEM CONSUPLY
11PBA1
SET MEM
22PBA1 22PBA5
CPU i/O Drivers
ed.5 22 Control 603

2 Location modification stickers
Engine:
Modification
sticker
Engine
Modification
sticker
Controller

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.

3 Component names
01-Drum DRU
Name Component
DRUASVCOMPSE DRUm Apparent Sur-
face Voltage COMPensa-
tion SEnsor
DRUASVCOMPPUMP DRUm Apparent Sur-
face Voltage COMPensa-
tion PUMP
DRUCOLDPROCFAN DRUm COLDPROces
1-2 FAN 1-2
DRUFAN DRUm FAN
DRUFANCAP DRUm FAN CAPacitor
DRUFANINV DRUm FAN INVerter
DRUFANSW DRUm FAN SWitch

DRUFANTEMPSE DRUm FAN TEMPera-
ture SEnsor
02-Corona COR
Name Component
COR CORona (unit)
CORFAN(1-3) CORona FAN (1-3)
CORPIN CORona PIN array
CORSUP CORona SUPply
ed.5 22 Control 607

04-Printhead PHD
Name Component
PBA, (PHD) DATA PBA, (PrintHeaD) DATA
RECEIVER RECEIVER
PHD PrintHeaD (unit)
PHDFAN PrintHeaD FAN
PHDPUMP PrintHeaD PUMP
PHDSUP PrintHeaD SUPply
PHDTEMPSE PrintHeaD TEMPerature
SEnsor
05- Developing DEV
Name Component
DEV DEVeloping (unit)
DEVMO DEVeloping MOtor
DEVMOSE DEVeloping MOtor SEn-
sor
DEVTONSE DEVeloping TONer SEn-
sor

06 Compact transfer transfuse CTF
Fuser-roller CTFF
Set-up CTFS
Pressure-roller CTFP
Name Component
CTFCOMP Compact Transfer transFuse
COMPressor
CTFDOORSW Compact Transfer transFuse
DOOR SWitch
CTFFHE Compact Transfer transFuse
Fuser-roller HEater
CTFFHETEMPERSW Compact Transfer transFuse
Fuser-roller HEater
TEMPerature ERror
SWitch
CTFFTEMPSE Compact Transfer transFuse

Fuser-roller TEMPerature
SEnsor
CTFOUTSE Compact Transfer transFuse
OUTput SEnsor
CTFOUTHOSW Compact Transfer transFuse
OUTput HOod SWitch
CTFPCLEHE Compact Transfer transFuse
Pressure-roller CLEaner
HEater
CTFPCLEHETEMPSE Compact Transfer transFuse
Pressure-roller CLEaner
HEater TEMPerature SEn-
sor
CTFPCLEHETEM- Compact Transfer transFuse
PERSW Pressure-roller CLEaner
HEater TEMPerature ERror
SWitch
CTFPINV Compact Transfer transFuse
Pressure-roller INVerter
CTFPMO Compact Transfer transFuse
Pressure-roller MOtor
CTFPMOSE Compact Transfer transFuse
Pressure-roller MOtor SEn-
sor
ed.5 22 Control 609

Name Component
CTFREFSE Compact Transfer transFuse
REFerence SEnsor
CTFSFVA Compact Transfer transFuse
Set-up Fuse VAlve
CTFSFCYL Compact Transfer transFuse
Set-up Fuse Cylinder
CTFSPVA Compact Transfer transFuse
Set-up Pressure VAlve
CTFSTCYL Compact Transfer transFuse
Set-up Transfer CYLinder
CTFSTVA Compact Transfer transFuse
Set-up Transfer VAlve
CTFTRANSE Compact Transfer transFuse
TRANsport SEnsor
07- Discharging DCH
Name Component
PBA, DCHLED (1-3) PBA, DisCHarging LED
(1-3)
DCHFAN(1-2) DisCHarging FAN (1-2)
DCHSTAPIN DisCHarging STAtic PIN
array
DCHSTASUP DisCHarging STAtic
SUPply

09-Original Handling ORG
Name Component
ORGISE ORiGinal Input SEnsor
ORGMO ORiGinal handling
MOtor
ORGMOSE ORiGinal handling
MOtor SEnsor
ORGPJSE ORiGinal Paper Jam
SEnsor
ORGPPSO ORiGinal handling Paper
Present SOlenoid
ORGPRESE ORiGinal PREsent SEn-
sor
ORGSAFSW ORiGinal SAFety
SWitch
ORGSYNSE ORiGinal SYNchronisa-

tion SEnsor
ORGWIDSE(1-4) ORiGinal WIDth SEnsor
(1-4)
ed.5 22 Control 611

10-Scanner SCA
Name Component
PBA, SCANNER PBA, SCAnner Process-
PROCESSING ing
PBA, SCASUPDI PBA, SCAnner SUPply
DIstribution
PBA, SCACCD1 PBA, SCAnner Charge
Coupled Device 1
Coupled Device 2
Coupled Device 3
PBA, SCAADC1 PBA, SCAnner Analog
Digital Conversion 1
SCALA SCAnner LAmp
SCAMIX SCAnner MIXed
11- Image processing IMP
Name Component
PBA, BLACK-WHITE PBA, BLACK-WHITE
PROCESSING PROCESSING
PBA, DOCUMENT PBA, DOCUMENT
MEMORY MEMORY
PBA, SET MEMORY PBA, SET MEMORY
(OPTIONAL) (optional)
EXTENDED MEMORY EXTENDED MEMORY
(OPTIONAL I.C.W. PBA,SET MEMORY)
11D1, 11D2, 11D3, 11D4, 11D5, 11D6, 11D7, 11D8

12- Paper roll drawers PRD
Upper PRDU
Lower PRDL
Support PRDS
Name Component
PRDUFEDMO(1-2) Paper Roll Drawers
Upper FEeDer MOtor
(1-2)
PRDUFEDMOSE(1-2) Paper Roll Drawers
Upper FEeDer MOtor
SEnsor (1-2)
PRDUFEDOPSE Paper Roll Drawer Upper
FEeD OPposite SEnsor
PRDUFEDSW (1-2) Paper Roll Drawer Upper
FEeD SWitch (1-2)
PRDUKNIMO Paper Roll Drawers

Upper KNIfe MOtor
PRDUKNIMOSE Paper Roll Drawers
Upper KNIfe MOtor
SEnsor
PRDUKNIPOSSE Paper Roll Drawers
Upper KNIfe POSition
SEnsor
PRDULEADSE Paper Roll Drawers
Upper LEADing SEnsor
PRDULENSE Paper Roll Drawers
Upper LENgth SEnsor
PRDUOPSW Paper Roll Drawer Upper
OPen SWitch
PRDUPRESE(1-2) Paper Roll Drawers
Upper PREsent SEnsor
(1-2)
PRDURUNSE(1-2) Paper Roll Drawers
Upper RUN SEnsor (1-2)
PRDUSAMPSO Paper Roll Drawers
Upper SAMPle SOlenoid
PRDUWIDSE(1-9) Paper Roll Drawers
Upper WIDe SEnsor
(1-9)
ed.5 22 Control 613

Name Component
PRDLFEDMO(3-4) Paper Roll Drawers
Lower FEeDer MOtor
(3-4)
PRDLFEDMOSE(3-4) Paper Roll Drawers
Lower FEeDer MOtor
SEnsor (3-4)
PRDLFEDOPSE Paper Roll Drawer Lower
FEeD OPposite SEnsor
PRDLFEDSW (3-4) Paper Roll Drawer Lower
FEeD SWitch (3-4)
PRDLKNIMO Paper Roll Drawers
Lower KNIfe MOtor
PRDLKNIMOSE Paper Roll Drawers
Lower KNIfe MOtor
SEnsor
PRDLKNIPOSSE Paper Roll Drawers
Lower KNIfe POSition
SENsor
PRDLLEADSE Paper Roll Drawers
Lower LEADing SEnsor
PRDLLENSE Paper Roll Drawers
Lower LENgth SEnsor
PRDLOPSW Paper Roll Drawer Lower
OPen SWitch
PRDLPRESE(3-4) Paper Roll Drawers
Lower PREsent SEnsor
(3-4)
PRDLRUNSE(3-4) Paper Roll Drawers
Lower RUN SEnsor (3-4)
PRDSSYNSE Paper Roll Drawer Sup-
port SYNchronisation
SEnsor
PRDSTRACL Paper Roll Drawers Sup-
port TRAnsport CLutch

13-Paper sheet feeder PSF
Name Component
PSFCL Paper Sheet Feeder
CLutch
PSFOPSW Paper Sheet Feeder OPen
SWitch
PSFPRESE Paper Sheet Feeder
PREsent SEnsor
PSFSO Paper Sheet Feeder SOle-
noid
PSFSYNSE Paper Sheet Feeder SYN-
chronisation SEnsor
4-Preheater PRE
Name Component
PREHE PREheater HEater
PRETBR PREheater Transport
BRake
PRETEMPSE PREheater TEMPerature
SEnsor
PRETEMPERSW PREheater TEMPerature
ERror SWitch
ed.5 22 Control 615

15-Paper transport PTR
Name Component
PTRBULSE Paper TRansport BULge
SEnsor
PTRFRAMESW Paper TRansport
FRAME SWitch
PTRMO Paper TRansport MOtor
PTRMOSE Paper TRansport MOtor
SEnsor
PTRTRAISE1 Paper TRansport TRAIl-
ing SEnsor 1
ing SEnsor 2
ing SEnsor 3
PTRUFOSE Paper TRansport UnFold
Output SEnsor
PTRUFOSO Paper TRansport UnFold
Output SOlenoid

18-Folder FOL
Name Component
PBA, FOL1 IO-INTER- PBA, FOL1 IO-INTER-
FACE FACE
PBA, FOL1 POWER-I/O PBA, FOLDer 1
POWER-I/O
FOL1DEFCL FOLder 1 DEFlector
CLutch
FOL1DEPOSE FOLder 1 DEflector
POsition SEnsor
FOL1DOORSW FOLder 1 DOOR SWitch
FOL1FOLMO FOLder 1 FOLder MOtor
FOL1FOLMOSE FOLder 1 FOLding
MOtor SEnsor
FOL1FOLSE1 FOLder 1 FOLding SEn-
sor 1
FOL1FOLSE2 FOLder 1 FOLding SEn-
sor 2
FOL1INMO FOLder 1 INput MOtor
FOL1INMOSE FOLder 1 Input MOtor
SEnsor
FOL1LIMO FOLder 1 LIft MOtor
FOL1LIDOWNSE FOLder 1 LIft DOWN
SEnsor
FOL1LIUPSE FOLder 1LIft UP SEnsor
FOL1STARTSE FOLder 1START SEnsor
FOL1OUTDEFSO FOLder 1 OUTput
DEFlector SOlenoid
PBA, FOL2 IO-INTER- PBA, FOL2 IO-INTER-
FACE FACE
PBA, FOL2 POWER-I/O PBA, FOLder 2
POWER-I/O
FOL2DEFCL FOLder 2 DEFlector
CLutch
FOL2DEPOSE FOLder 2 DEflector
POsition SEnsor
FOL2DOORSW FOLder 2 DOORSWitch
ed.5 22 Control 617

Name Component
FOL2FLATSO FOLder 2 FLAT SOle-
noid
FOL2FOLMO FOLder 2 FOLder MOtor
FOL2FOLMOSE FOLder 2 FOLder MOtor
SEnsor
FOL2INMO FOLder 2 INput MOtor
FOL2INMOSE FOLder 2 INput MOtor
SEnsor
FOL2OUTSE FOLder 2 OUTput SEn-
sor
FOL2OUTSO FOLder 2 OUTput SOle-
noid
FOL2STARTSE FOLder 2 START SEnsor
FOL2TRAISE1 FOLder 2 TRAIling SEn-
sor 1
FOL2TRAISE2 FOLder 2 TRAIling SEn-
sor 2
FOL2TRAYSW FOLder 2 TRAY SWitch
FOLSUPLV FOLder SUPply Low
Voltage
Optionals
belt 1 unit
BELT1DOORSW BELT1 DOOR SWitch
FOLOBELT1SE FOLder Output BELT1
SEnsor
FOLOBELT1ENDSE FOLder Output BELT 1
END SEnsor
FOLOBELT1MO FOLder Output BELT 1
FOLOBELTVA FOLder Output BELT
VAlve
FOLOPTRMO FOLder Output Paper
Transport MOtor
I/O BOARD
RELAY BOARD
punch unit

Name Component
FOLOADJMO FOLder Output ADJust
MOtor
FOLOPUSTARTSE FOLder Output PUnch
START SEnsor
FOLOPUMOENDSE FOLder Output PUnch
MOtor END SEnsor
FOLOPUMOHOMESE FOLder Output PUnch
MOtor HOME Sensor
SIDE JOG END
SIDEJOGHOME
PUDOORSW PUnch DOOR SWitch
FOLOPUNEJSO FOLder Output PUnch
EJect SOlenoid
FOLOPUMO FOLder Output PUnch
MOtor
belt2 unit
FOLOBELT2SE FOLder Output BELT 2
SEnsor
FOLOBELT2ENDSE FOLder Output BELT 2
END SEnsor
BELT2DOORSW BELT 2 DOOR SWitch
FOLOBELT2MO FOLder Output BELT 2
MOtor
ed.5 22 Control 619

22-Control CON
Name Component
CIRCUIT BREAKER CIRCUIT BREAKER
CONCNT CONtrol CouNTer
CONCONEMS CONtrol power CONtrol
Electro Magnetic Switch
CONDRIINDIAG CONtrol DRIvers INput
DIAGnosis
CONDRIOUTDIAG CONtrol DRIvers OUT-
put DIAGnosis
CONEMS1 CONtrol Electro Mag-
netic Switch 1 (L1)
netic Switch 2 (L2)
netic Switch 3 (L3)
CONFIG BAR CONFIG BAR
CONREMCON CON REMote CONnec-
tion
CONKEYSW CONtrol KEYSWitch
CONSDSSW CONtrol Service Diag-
nostic System SWitch
CONSTEPUPTRAFO CONtrol STEPUP
TRAnsFOrmer
CONSUPLV CONtrol SUPply Low
Voltage
FUSE(1-2) FUSE(1-2)
LCD LCD
PBA, BACKLIGHT PBA, BACKLIGHT
PBA, CPU-IO PBA, Central Processor
Unit-Inputs Outputs
PBA, CONSOLE-CPU PBA, CONSOLE-Cen-
tral Processor Unit
PBA, CURSENS PBA, CURrent SENSor
PBA, DRIVERS PBA, DRIVERS
PBA, KEYPAD1 PBA, KEYPAD1

Name Component
PBA, SSR PBA, Solid State Relays
RFI FILTER(1-3) RFI FILTER(1-3)
SERVICE CONNEC- SERVICE CONNEC-
TOR TOR
23-Main drive MAD
Name Component
MADMO MAin Drive MOtor
MADMOSE MAin DRive MOtor
SEnsor
MADMOINV MAin Drive MOtor

INVerter
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

1 2 3 4 5 6
EARTH 22PBA4 SSR WITH SCANNER CONKEYSW
22S1
PE PE PE 22X010 X9 TP2 X1 22X8 22X1 10X1
CONCONEMS-B
2 TP1 20 3 E E 3
A CIRCUIT BREAKERS LINE FILTERS
GND
6
22Q1 22Z1 19 2 C C 1
CONKEYSW
CONCONSUP
18 1 A A 4
N3 N3 N3 1 2 3 5
LOAD
X11 2
LINE
22Q2 L1 L1-S
6 6 8 4 CONKEYSW 5
N1 N1-S 17
L1 L1 L1 1 2 1 4 2 4 1
CONCONEMSSUP CONCONEMS
21
N1 N1 N1 22K4-2A
F1 0.031A
22Q3 22Z2
L2 L2 L2 1 2 3 5
LOAD
X9 X5
LINE
22Q4 L2 L2
6 1 1 6 8
N2 N2
N2 N2 N2 1 2 1 4 3 2 2 4
X4
B 3
N2-MNO
L3 L3 L3 L2-MNO
2 22G1 CONSUPLV
22Q5 22Z3
X3 G1
L2-MNO
1 2 3 5 1 1
LOAD
X11 N2-MNO
LINE
22Q6 L3-S 4 3
6 6 8 3
N3-S 2
1 2 1 4 2 4 6 L2-MNO
3
N2-MNO 18-FOLDER 22X002-4
6
L2-MNO
22X014 PE 22X015 MAIN FRAME 5
N2-MNO 20-CONTROLLER
2
X12
22X016 MAIN-FRAME 00X00 FRAME-DOORS X8 L3-S
N2 1
8 6 6 N3-S 14-PREHEATING
L2 5
4 2 3
X6
C L2-S
1 6
L2-S
N2-S 06-CTF G4
4 3 PHD
L2-S 1
22PBA5 DRIVERS 9 PHD 400VDC
N2-S 04-PRINTHEAD 2
X12 CONEMS2 12 PHD+12V
CONEMS2-B L2-S 3
12 7 PHDON-OFF
22K2-2A N2-S 23-MAIN DRIVE 4
10
+24V-SW
15 X2
L2-S
6
CONEMS3 N2-S 18-FOLDER/19-SRU
CONEMS3-B 5
14 L2-S
22K3-2A 12
N2-S 01-DRUM
+24V-SW 11
13 L2-S
15
N2-S 01-DRUM
CONEMS1 14
CONEMS1-B
11 X7
D 22K1-2A 4
L2-SSU
+24V-SW N2-S 06-CTF
16 5
PTRFRAMESW 22T1 CONSTEPUPTRAFO 10G1 MIXED SUPPLY
X5
+24V-SW X7
8 2 1 N2-S G1 G5
1 2 SCA+400VDC
F2 3A
15S1 SEE 2 1
208V SCA-400VDC
2 22-CONTROL 702 3 2
220V L2-S SCACONTROL
3 1 4 3
230/240V
4
CTFDOORSW 22PBA1 CPU I/O
MAINS VOLTAGE METER
230V L2-SSU
+24V 5 3 X1 X3
7 1 2 CONMAINSVOL
14 8
O6S1 CONCONEMSSUPVOL
X12 X1 16 16
+24V
23 28 X9
GND +5V
E 20 30 7
GND
7
8 8
22PBA3 CURSENS CONKEYSW
X14 13 13
X12 22X10 N1-S CONCONEMS
+24V 2 11 11
6 1 L1-S CONSSRINDIAG
CONCNT 1 9 9
X13 TP5 TP6 X10
22Y1 N1-SM
1 3 1
CONCNT-B L1-SM 06-CTF
7 2 2 2 2 S1
X1 X3 3
CONEARTHCUR
1 10
+5VAN BATTERY
3 2
A1
22X2 X8
+5V
2 14
GND
3 16
F REMOTE SWITCH
1
CONREMCOSW
17
CONREMCOLED
4 11
X7 X11
CONCNT
6 6
CONCNTPR
7 7
X6 X6
CONDRIINDIAG
27 27
CONDRIOUTDIAG
28 28
CONEMS
10 10
X10 X13 11PBA1
+5V
1 1 X5 G3
GND +5V
2 2 4 5
+24V GND
3 3 3 6
GND
5 5
G F4
4A X8
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F1 G2
+24V
5 1
4A GND
6 2
+24V
7 3
GND
8 4
+24V
H 9
GND
5
10 6
CONTROL 1
ed.5 TSM Oc 9800 22 Control 701
1 2 3 4 5 6
10G1 MIXED SUPPLY 22G2 SUPPLY TL-INVERTER 22LCD1 LCD DISPLAY
G2 G1 G2
+5V
5 1 1
GND
13 2 3
A
ENGINE
22G1 CONSUPLV 22PBA2 CONSOLE_CPU
G5 22X1 10X1 G1 Fuse G2 X1 X4 LCD1
SCA +5V +5V
1 L L 2 1 1 1 1
SCA 400VDC 3A +5V GND
2 M M 3 2 2 TP1 2 2
SCACONTROL +5V CL2
3 K K 4 3 3 3 3
+5V ENLCD
4 4 4 4
GND FLM
N N 1 7 5 5 5
22X004 GND CL1
8 6 TP0 6 6
GND GND
9 7 7 7
GND M
Fuse 10 8 8 8
+12V LCD0
15 9 9 9
B 3A 16
+12V
10 TP2 10
LCD1
10
+12V LCD2
17 11 TP3 11 11
LCD3
12 12
X3 -24V
+12V TP4 13 13
18 1 GND
GND 15 15
11 2
GND TP5
12 3
G3
CONMIXOUTDIAG
6
CONMIXINDIAG 22PBA6 KEYPAD1
5 1
X5 X1
S1 2 +25V
2 1
3 KP1S1
5 2
KP1S2
22PBA8 KEYPAD3 BATTERY 6 3
KP1S3
X2 A1 7 4
C 5 8
KP1S4
5
KP1S5
6 9 6
KP1S6
X1 X7 10 7
+12V KP1S7
1 1 11 8
+5V KP1S8
2 2 12 9
GND KP1S9
3 3 13 10
GND KP1S10
4 4 14 11
NRD3 KP1S11
5 5 15 12
NRD4 KP1S12
6 6 16 13
NWR3 KP1S13
8 7 17 14
NWR4
9 8
BNRESET
20 9
KP3D0
12 10
KP3D1
13 11 22PBA7 KEYPAD2
D 14
KP3D2
12 X6 X1
KP3D3 +12V
15 13 1 1
KP3D4 +5V
16 14 2 2
KP3D5 GND
17 15 3 3
KP3D6 NRD1
18 16 4 4
KP3D7 NRD2
19 17 5 5
KP3A1 NWR1
24 18 6 6
KP3A2 NWR2
25 19 7 7
KP3A3 NRESET
26 20 8 8
KP3A4 KP2D0
27 21 9 9
INT3 KP2D1
28 22 10 10
+5V KP2D2
30 24 11 11
KP2D3
12 12
KP2D4
E 13
KP2D5
13
14 14
22PBA1 CPU I/O KP2D6
15 15
X14 X10 KP2D7
GND 16 16
10 H H 11
CONCTS
9 T T 3
CONNCTS
8 S S 4
CONNRXD
7 V V 2 22PBA9 KEYPAD4
CONRXD
6 U U 1 X9 X1
CONRTS +12V
4 W W 7 1 1
CONNRTS +5V
3 X X 8 2 2
CONNTXD GND
2 Y Y 6 3 3
CONTXD GND
1 Z Z 5 4 4
KP4S1
5 5
KP4S2
6 6
F 7
KP4S3
7
KP4S4
8 8
KP4S5
9 9
KP4D0
13 13
KP4D1
14 14
KP4D2
15 15
KP4D3
16 16
KP4V1
17 17
KP4V1
18 18
KP4V1
19 19
KP4V1
20 20
G X5
22S2 CONSDSSW
22PBA6 KEYPAD1 CONSDSSW
19 1 3
22PBA9 22PBA8 KEYPAD3 +5V
22PBA2 CONSOLE_CPU 20
KEYPAD4 +5V
1
CONSDSSW
22LCD1 LCD DISPLAY

X11 10X2
TXD RS232
22G2 1 2
RTS
2 4
RXD
3 3
CTS
4 5
H 22PBA7 KEYPAD2 5
GND
7
CONTROL 2 WITH SCANNER

1 2 3 4 5 6
ENGINE 22PBA8 RFI COMBI 22G2 SUPPLY TL-INVERTER 22LCD1 LCD DISPLAY
X3 G1 G2
22G1 CONSUPLV +5V
3 1 1
GND
G6 X4 4 2 3
+5V
A 2 2
GND
1 1
+12V 22PBA2 CONSOLE_CPU
3 3
X1
+5V
2 2 TP1 X4 LCD1
+5V +5V
1 1 1 1
GND GND
5 5 TP0 2 2
GND CL2
6 6 3 3
+12V ENLCD
9 9 TP2 4 4
+12V FLM
10 10 5 5
+12V CL1
11 11 6 6
OPERATING PANEL GND GND
8 7 7
22X011 GND M
7 8 8
LCD0
9 9
B X3
10
LCD1
10
22X004-3 22X009 3 LCD2
11 11
2 LCD3
CONSOLE +12V 12 12
12 1 -24V
13 13
22PBA1 CPU I/O GND
15 15
X14 X2 X1 X10
GND GND
10 9 9 11
CONCTS CONCTS
9 3 3 3
CONNCTS CONNCTS
8 4 4 4
CONNRXD CONNRXD 22PBA6 KEYPAD1
7 2 2 2
CONRXD CONRXD X5 X1
6 1 1 1 +25V
CONRTS CONRTS 2 1
4 7 7 7 KP1S1
CONNRTS CONNRTS 5 2
3 8 8 8 KP1S2
CONNTXD CONNTXD 6 3
2 6 6 6 KP1S3
CONTXD CONTXD 7 4
C 1 5 5 5
8
KP1S4
5
KP1S5
9 6
KP1S6
10 7
KP1S7
11 8
KP1S8
12 9
KP1S9
13 10
KP1S10
14 11
KP1S11
15 12
KP1S12
1 16 13
KP1S13
S1 2 17 14
3
BATTERY
A1
22PBA7 KEYPAD2
D X6 X1
+12V
1 1
+5V
2 2
GND
3 3
NRD1
4 4
NRD2
CONSDSSW 22S2 5 5
X2 X1 X5 NWR1
CONSDSSW CONSDSSW 6 6
3 1 15 15 19 NWR2
+5V +5V 7 7
16 16 20 NRESET
+5V +5V 8 8
17 17 1 KP2D0
9 9
KP2D1
10 10
KP2D2
22X6 X11 11 11
RS232 TXD TXD KP2D3
2 10 10 1 12 12
RTS RTS KP2D4
E 4
RXD
11 11
RXD
2 13
KP2D5
13
3 12 12 3 14 14
CTS CTS KP2D6
5 13 13 4 15 15
GND GND KP2D7
7 14 14 5 16 16
CONKEYSW See 22 Control 701
G 22PBA6 KEYPAD1
22PBA2 CONSOLE_CPU
22LCD1 LCD DISPLAY
22G2
H 22PBA7 KEYPAD2
CONSDSSW CONTROL 3 STAND ALONE PRINTER

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
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

Diagnostics
1 Faults
MAin Drive 23000 - 23999 code display
23501 MRE: Speed MADMO out of range~

MADMOSE
Pulse disc loose of MADMO or CTFPMO Blockade motor
shaft and check
that the pulse
disc cant rotate.

Continuously Pulse disc defect
ON
MADMOSE defect
CPU_IO PBA defect disconnect 2201X5
Continuously Connection MADMOSE-> CPU_IO PBA
OFF
Pulse disc defect
MADMOSE defect
CPU_IO PBA defect
to be continued
ed.5 23 Main drive 101

continued
23-4-01 MADMO Possible cause Remark

MADMO turning
OFF Yes MADMOINV defect
CPU_IO PBA defect
ON No 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 Remark

(or test 40) switching
CONEMS (listening!)
ON Yes Connection mains L2 -> CONEMS2
No 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

SDS
1 MAin Drive
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Input tests
23-2-01 23B1 MAin Drive Main drive motor sensor

MOtor SEnsor ON = sensor blocked by pulsdisc
Output tests
23-4-01 23M1 MAin Drive Main drive motor PWM

MOtor PWM ON = motor activated at 100% PWM
Special tests

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

2 Motor plate drive belt
Aim:
Make sure that the motor plate drive belt is tensioned correctly.
Check:
Bracket -D- must touch bracket -E-.
Correction:
1 Loosen the bolts -A-, -B- and -C-.
2 Move the bracket -D- until it touches the bracket -E-.
3 Tighten first the bolts -A- than the bolts -B- and -C-.
5 Carry out SDS test 23-4-01 for 1 minute.
6 Repeat point 1 up to 3.
A
B

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 Loosen at the left side the screws of the adjusting bracket.
2 Move the adjusting bracket upwards until it just touches the pulley strip.
4 Switch on the machine for 1 minute.
drive belt
spring
screws
pulley strip
adjusting
bracket

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-.
Correction:
1 Loosen the bolts -D- and -E-.
2 Move the bracket -A- until the corner -B- touches the bracket -C-.
3 Tighten first the bolt -D- than bolt -E-.
4 Switch on the machine and make some copies.
drive belt
bracket A
corner B bracket C
screw screw E
D

MADMO
MADINV

1 2 3 4 5 6
G2 X8 F1 X5
+24V +24V
1 5 7 1 2 1 2
GND 4A
2 6 O6S1 15S1
A 3
+24V
7
GND +24V-SW
4 8 8
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F4
4A
B 22PBA1 CPU I/O

X13 X10
+5V
1 1 X12
GND CONEMS2-B
2 2 12
+24V
3 3 22K2-2A
GND
5 5
+24V-SW
15
X6 X6 CONEMS2
CONDRIINDIAG
27 27
X11
GND
21
C
23U1 MADINV
U6
-UzK
5
F1 5A 300VDC to 06U1 CTFPINV on page 06-701
+UzK
4
U2
GND
1 2
22PBA4 SSR
22X006-2
X6 X8
N2-S N2-S
3 10 1 4 2
X5 L2-S L2-S
D 9
MADMOPWM
2
7 4 8 6
23X1
5
1
6
U4
T1
1 1 MADMO
T3
4 4 M
T2 3
3 3 23M1
E
2 2
22X11
+5V
6 3 1 MADMOSE
GND
8 5 3 23B1
MADMOSE
7 4 2
E
22X006-3 23X001
22Z2
X9
L2 L2
6 1 6
5 2
N2 22X010 N2
4 3 3
H
(from engine 484)
ed.5 TSM Oc 9800 23 Main drive 701
1 2 3 4 5 6
G2 X8 F1 X5
+24V +24V
1 5 7 1 2 1 2
GND 4A
2 6 O6S1 15S1
A 3
+24V
7
GND +24V-SW
4 8 8
+24V
5 9
GND
6 10
G3
+5V
1 1
GND
2 2
+5V
3 3
GND
4 4
F4
4A
B 22PBA1 CPU I/O

X13 X10
+5V
1 1 X12
GND CONEMS2-B
2 2 12
+24V
3 3 22K2-2A
GND
5 5
+24V-SW
15
X6 X6 CONEMS2
CONDRIINDIAG
27 27
X11
GND
21
C
23U1 MADINV
U2
-UzK
5
300VDC to 06U1 CTFPINV on page 06-702
+UzK
4
U1
GND
2 2
22PBA4 SSR
GND 22X006-2
4
X6 X8
RUNFWD N2-S N2-S
5 3 10 1 4 2
X5 L2-S L2-S
D 9
MADMOPWM
3
7 4 8 6
23X1
5
1 6
T3
8 4 MADMO
T2
7 3 M
T1 3
6 1 23M1
E
9 2
22X11
+5V
6 3 1 MADMOSE
GND
8 5 3 23B1
MADMOSE
7 4 2
E
22X006-3 23X001
22Z2
X9
L2 L2
6 1 6
5 2
N2 22X010 N2
4 3 3
(up to engine 483)

1 2 3 4 5 6
23U1 MADINV
U2
-UzK
5
300VDC to 06U1 CTFPINV on page 06-702
A 4
+UzK
U1
2 2
22PBA4 SSR
GND 22X006-2
4
X6 X8
RUNFWD N2-S N2-S
5 3 10 1 4 2
X5 L2-S L2-S
MADMOPWM 7 4 8 6
9 3 From 06 Compact transfer transfuse 705
23X1
5
1 6
T3
8 4 MADMO
B 7
T2
3 M
T1 3
6 1 23M1
E
9 2
22X11
+5V
6 3 1 MADMOSE
GND
8 5 3 23B1
MADMOSE
7 4 2
22X006-3 23X001
22Z2
X9
L2 L2
C 6 1 6
5 2
N2 22X010 N2
4 3 3
(Up to engine 484)

D
23U1 MADINV
U6
-UzK
5
F1 5A 300VDC
+UzK
E 4
U2
1 2
22PBA4 SSR
22X006-2
X6 X8
N2-S N2-S
3 10 1 4 2
X5 L2-S L2-S
MADMOPWM From 06 Compact transfer transfuse 705 7 4 8 6
9 2
23X1
5
1
6
U4
T1
1 1 MADMO
T3
4 4 M
F 3
T2
3
3
23M1
E
2 2
22X11
+5V
6 3 1 MADMOSE
GND
8 5 3 23B1
MADMOSE
7 4 2
22X006-3 23X001
22Z2
X9
L2 L2
6 1 6
G 5
22X010
2
N2 N2
4 3 3
H
Modification 25 (From engine 484)
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

Diagnostics
1 Faults
CUStomer / environment 25000 - 25999 code display
25701 ORE: ~Upper / lower paper roll open~
12-2-09 PRDUOPSW Possible cause Remark

12-2-30 PRDLOPSW
Continuously ON Connection PRD(U/L)OPSW ->
CPU_IO PBA Instruct customer
PRD(U/L)OPSW defect
Receiving material stuck on roll core
25702 ORE: ~Covers CTF open: (CTFDOORSW)~

CTFDOORSW
Continuously Connection CTFDOORSW -> CPU_IO PBA
ON
CTFDOORSW defect

CTFOUTHOSW
Continuously Connection CTFOUTHOSW -> CPU_IO PBA
ON
CTFOUTHOSW defect
ed.5 25 Customer / environment 101

25703 ORE: ~PTRDOOR open: PTRFRAMESW~
)

PTRFRAMESW
Continuously ON Connection PTRFRAMESW -> CPU_IO PBA
PTRFRAMESW defect
25704 ORE: ~FOL1DOORS open: FOL1DOORSW~

)

FOL1DOORSW
Continuously Connection FOL1DOORSW -> POWER_IO PBA
ON
Connection POWER_IO PBA -> IO_INTERFACE
PBA
PBA
FOL1DOORSW defect
25705 ORE: ~Folding: door FOL2 open~

FOL2TRAYSW
Continuously Connection FOL2TRAYSW -> POWER_IO PBA
ON
PBA
PBA
FOL2TRAYSW defect

FOL2DOORSW
Continuously ON Connection FOL2DOORSW -> POWER_IO
PBA
Connection POWER_IO PBA ->
IO_INTERFACE PBA
PBA
FOL2DOORSW
25706 ORE: ~folder output delivery doors open~

~

FOLOPU-
DOORSW
Continuously Connection FOLOPUDOORSW -> POWER_IO

ON PBA
PBA
FOLOPUDOORSW defect

FOLOBELT1
DOORSW
Continuously Connection FOLOBELT1DOORSW -> POWER_IO
ON PBA
PBA
FOLOBELT1DOORSW defect

FOLOBELT2
DOORSW
Continuously Connection FOLOBELT2DOORSW -> POWER_IO
ON PBA
PBA
FOLOBELT2DOORSW defect
25707 ORE: ~SCA open (ORGSAFSW) while scanning~

~

ORGSAFSW
Continuously Connection ORGSAFSW -> KEYPAD3 PBA
ON
Scanner not closed correctly Instruct customer
ORGSAFSW defect

25708, 25709, 25710, 25711 ORE: ~Wrong format roll 1-4: PRDUWIDSE 1-9~
)
12-2-13 up to Possible cause Remark

12-2 21
PRDUWIDSE
1-9
Continuously ON PRDUWIDSEn defect
Actuator defect
Continuously PRDUWIDSEn defect
OFF
Actuator defect
Connection PRDUWIDSEn -> PRDU DISTRI-
BUTION PBA
Connection PRDU DISTRIBUTION PBA ->
CPU_IO PBA
DRIVERS PBA
CPU_IO PBA defect

25712 ORE: ~Warm up: p. path CTF /PRDS / PSF not free~

Actuator defect
CPU_IO PBA defect
12-2-34 PRDSSYNSE Possible cause Remark

Continuously ON PRDSSYNSE defect
Actuator defect
13-2-02 PSFSYNSE Possible cause Remark

Continuously ON Connection PSFSYNSE -> 13X1 ->
CPU_IO PBA
Actuator defect
PSFSYNSE defect

25713 ORE: ~PRDUFEDOP unit not present~
~

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

~

PRDLFEDOPSE
Continuously Feed opposite unit badly positioned
OFF
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

25715 ORE: ~Start run: paper path PRD not free~
~
12-2-03 / 12-2 24 Possible cause Remark

PRD(U/L)LEADSE
Continuously ON PRD(U/L)LEADSE defect
Actuator defect
CPU_IO PBA defect
25716 ORE: ~Start run: paper path PSF not free~

~

PSFSYNSE
Continuously Connection PSFSYNSE -> 13X1 -> CPU_IO PBA
ON
Actuator defect
PSFSYNSE defect
25717 ORE: ~Paper path PRDS / CTF not free~

)

Actuator defect
CPU_IO PBA defect

PRDSSYNSE
Continuously ON PRDSSYNSE defect
Actuator defect

25718 ORE: ~Start run: paper path PTR not free~
~

PTRBULSE
ON TION PBA
IO_INTERFACE PBA
Actuator defect
PTRBULSE defect
IO_INTERFACE PBA defect
CPU_IO PBA defect

PTRUFOSE
ON TION PBA
IO_INTERFACE PBA
Actuator defect
PTRUFOSE defect
CPU_IO PBA defect

PTRTRAISE2
ON TON PBA
IO_INTERFACE PBA
Actuator defect
PTRTRAISE2 defect
CPU_IO PBA defect

PTRTRAISE1
ON TION PBA
IO_INTERFACE PBA
Actuator defect
PTRTRAISE1 defect
CPU_IO PBA defect

PTRTRAISE3
ON TION PBA
IO_INTERFACE PBA
Actuator defect
PTRTRAISE3 defect
CPU_IO PBA defect

25719 ORE: ~Start run: FOL pap. path not free~
,

PTRBULSE
ON TION PBA
IO_INTERFACE PBA
PBA
Actuator defect
PTRBULSE defect
CPU_IO PBA defect

PTRTRAISE1
ON TION PBA
IO_INTERFACE PBA
Actuator defect
PTRTRAISE1 defect
CPU_IO PBA defect
to be continued

continued

FOL1STARTSE
Continuously ON Connection FOL1STARTSE ->
SENSOR DISTRIBUTION PBA
IO_INTERFACE PBA
Connection IO_INTERFACE PBA ->
CPU_IO PBA
Actuator defect
FOL1STARTSE defect
CPU_IO PBA defect

FOL2OUTSE1
Continuously Connection FOL2OUTSE1 ->
ON SENSOR DISTRIBUTION PBA
IO_INTERFACE PBA
Actuator defect
FOL2OUTSE1 defect
CPU_IO PBA defect
to be continued

continued

FOL2TRAISE2
Continuously Connection FOL2TRAISE2 ->
ON SENSOR DISTRIBUTION PBA
IO_INTERFACE PBA
PBA
Actuator defect
FOL2TRAISE2 defect
CPU_IO PBA defect

FOL2STARTSE
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
CPU_IO PBA defect

25720 ORE: ~Start run: original path not free~
25721 ORE: ~Start calibrate: org path not free~

ORGSYNSE
Continuously Connection CONSOLE_CPU PBA -> KEYPAD3
ON PBA
Connection ORGSYNSE -> 09X3 -> KEYPAD3 PBA
ORGSYNSE defect
Actuator defect
KEYPAD3 PBA defect

ORGPJSE
Continuously Connection CONSOLE_CPU PBA -> KEYPAD3
ON PBA
Connection ORGPJSE -> 09X3 -> KEYPAD3 PBA
ORGPJSE defect
Actuator defect
KEYPAD3 PBA defect
09-4-01 CONMIX- Original Possible cause Remark

ORGPPSO OUTDIAG stop open
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

25722 ORE: ~Power down in run: remove paper~
~

Machine switched off during RUN or Error Instruct the customer that he
situation 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 Possible cause Remark

machine
OFF / ON
24 V on
2201X13
No Connection 24 V CONSUPLV -> DRIVERS PBA
Connection 24 V DIVERS PBA -> CPU_IO PBA
CONSUPLV defect

25723, 25724, 25725, 25726, 25727 ORE:
~DEL BIN (2-6) open during delivery~
BIN not closed
19-2-16 / -20 / -24 / -28 / Possible cause Remark

-32
DELBIN(2-6)OPSE
Continuously OFF Actuator closed bin does not activate
the sensor
DISTRIBUTION PBA(2-6)
Connection PBA DISTRIBUTION
PBA(2-6) -> DELBIN(2-6)OPSE
DELBIN(2-6)OPSE defective

5 V regulated test
Failed LV power supply defective
+ 24 V not present
Connections LV Power supply ->
HCS CPU I/O
25728 ORE: ~DEL paper path not free at start~

Paper path not free Check

DELINSE
Continuously ON Sensor defective / blocked Only dur-
Connection DELSINSE -> PBA ing start
DISTRIBUTION7
DISTRIBUTION7

DELSYNSE
Connection DELSYNSE -> HCS ing start
CPU I/O

DELTRIOUTSE
Connection DELTRIOUTSE -> PBA ing start
DISTRIBUTION7
DISTRIBUTION7
19-2-09 DELVERTINSE Possible cause Remark

Continuously ON Sensor defective / blocked
Connection DELVERTINSE ->
PBA DISTRIBUTION5
DISTRIBUTION5
19-2-13 / -17 / -19 / -21 / Possible cause Remark

-25 / -29 / -33
DELOUTSE(1-6)
Continuously ON Sensor defective / blocked Only during
Connection DELOUTSE1 -> HCS start
CPU I/O
Connection DELOUTSE(2-6) ->
DISTRIBUTION(1-5)

25729 ORE: ~DELivery door(s) open~
Doors HCS not closed
TRI not correctly positioned to the
Oc 9800

DELUDOORSW
Continuously ON Switch defective / blocked Only during
Connection DELUDOORSW -> start
HCS CPU I/O

DELLDOORSW
Continuously ON Sensor defective / blocked Only during
Connection DELLDOORSW -> start
HCS CPU I/O

DELTRIOPSW
Connection DELTRIOPSW -> HCS start
CPU I/O

DELTRIPOSSW
Connection DELTRIPOSSW -> start
HCS CPU I/O
25734 ORE:~Bypass feed open~


25735 ORE: ~RU_DOORS_OPEN~
FOL2RUDOORSW
18-2-31
FOL2RUINTDOORSW
18-2-32
FOL2RUCOVERSW
Continuously ON Connection FOL2RUDOORSW1/2/3 >
Power_I/O PBA
Connection POWER_I/O PBA >
CPU_I/O PBA
FOL2RUDOORSW1/2/3 defect

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:
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:
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 mod-
ification is applicable (not the configuration type). When a modification is ex-
ecuted the modification number concerned at the modification record in the
machine type must be marked.

2 Model series and configuration types of the Oc 9800
The following 3 model series of the Oc 9800 are available:
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 9836 9837 9840 9841

Machine types
Engine (M) 9801 x x x x
Doc. Memory (A) 9802 x x
Set. Memory (A) 9803 x x
Memory modules (L) 9804 o o
Stamp unit (L) 9805 o o o o
Unfolded output (L) 9807 o o o o
Scanner (P) 9810 x x x x
INTERFACING
Controller (P) 9812
Long plot option (L) 9813
SCSI interface (L) 9814
VPI (L) 9815
Ethernet interface (L) 9816
Postscript (L) 9817

to be continued on next page

FINISHING
1st fold (P) 705 x x
2nd fold (P) 710 x x
2nd Fold with RU 712 x x
Transport unit and 1st 850 o o
belt (L)
2nd belt (L) 851 o o
Punch unit EUR (L) 730 o o
Punch unit USA (L) 720 o o
SOFTWARE APPLICATIONS
Scan to file (L) 9820
Repro station (L) 9821

Model series 9855: Printer

Machine types
Engine 9801 x x x x
Doc Memory 9802
Set Memory 9803 x x x x
Memory modules 9804 o o o o
Stamp unit 9805 o o o o
Unfolded output 9807 o o o o
Scanner 9810
INTERFACING
Controller 9812 x x x x
Long plot option 9813 o o o o
SCSI interface 9814 o o o o
VPI interface 9815 o o o o
Ethernet 9816 o o o o
Postscript 9817 x x
FINISHING
1st fold 705 x x
2nd fold 710 x x
Transport unit and 850 o o
1st belt
2nd belt 851 o o
Punch unit EUR 730 o o
Punch unit USA 720 o o
Scan to file 9820
Repro station 9821 o o o o

Model series 9875: Hybrid

Machine types
Engine 9801 x x x x
Doc Memory 9802
Set Memory 9803 x x x x
Memory modules 9804 o o o o
Stamp unit 9805 o o o o
Unfolded output 9807 o o o o
Scanner 9810 x x x x
INTERFACING
Controller 9812 x x x x
Long plot option 9813 o o o o

SCSI interface 9814 o o o o
VPI interface 9815 o o o o
Ethernet 9816 o o o o
Postscript 9817 x x
FINISHING
1st fold 705 x x
2nd fold 710 x x
Transport unit and 850 o o
1st belt
2nd belt 851 o o
Punch unit EUR 720 o o
Punch unit USA 730 o o
Scan to file 9820 o o o o
Repro station 9821 o o o o

Capacity Set memory
Name Capacity of originals

Set memory 5 - 15 A0 / E or 25 mixed (7% density)
PBA and 36 Mb

PBA and 72 Mb
PBA and 108
Mb
PBA and 144
Mb

SDS
1 CUStomer / environment
Analysis info tests

see SDS

see SDS

last 15 errors
mode
ice mode
34 ~Error top 10

see SDS
see SDS
see SDS

see SDS

Parameter test
25-1-01 ~DIN stamp X position 1 mm~

25-1-02 ~DIN stamp Y position 1 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

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 Preventive maintenance

Preventive Maintenance
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 pro-

grams:
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 Remove the top cover of the developing unit.

2 Remove the toner from the top of the doctor blade.
3 Mount the top cover.
4 Remove dust from the outside of the developing unit.
5 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 Preventive Maintenance

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.

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.

5 Consumables
Consumable Code number Reason of replace-

ment
Drum 1989.423 After cleaning of the
drum again background
appears with SDS test 54
Pin array charge corona 1989.410 (1 set of 3 pin Replace when replacing
arrays) the drum or min. target of
200.000 lm
Pin array discharge 1989.410 Replace when replacing
corona the drum or min. target of
200.000 lm
Paper guide cloth and 1990.142 Replace when replacing
guide strips the drum or min. target of
200.000 lm
Fuser roller cleaner 1988.334 SDS indication:
SWAR at 720 black
images
Pressure roller cleaner 1988.335 SDS indication:
roller SWAR at 300 black
images
Build up cleaner 1988.336 Replace at the same time
as pressure roller clean-
ing roller
Pressure roller 7040.881 min. target 100.000 lm
Fuser roller 1989.678 min. target 105.000 lm

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 cut-
ting 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 re-
turns 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: 1929 022
USA: 1929 023 (different label)
Silicon oil, bottle 60 ml, 7991 167

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.


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
Copier specifications
1 Copier specifications
Specifications
Model Scanner and separate print
engine
Scanning process CCD scanning with Oc resolution 400 dpi
image processing
Copying process Organic drum
LED Print head
Monocomponent toner
Compact Transfer trans-
Fuse (CTF)
Speed 10 m/min. 32.8 lf/min.

Reproduction scale 25-400% Autozoom
9 Fixed zoom steps
Manual selection:
- 1% steps
- fine adjustment 0.1%
Digital retention 1-999
Originals 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)
Original feed Soft feed
Automatic original align-
ment
ed.5 Miscellaneous 101

Specifications
Copies Size LxW
Min. 210 x 297 mm
8.5 x 11
Max. 6000 x 914 mm
20 ft x 36
max. guaranteed
Copies Type:
Plain paper 60-110 g/m2
16-30 lbs
Transparent paper 60 - 110 g/m2
16-30 lbs
Polyester 3.5 - 4.5 mil.
Vellum 16 - 20 lbs
Media feed 4 rolls synchro
standard cut
Maximum diameter roll
184 mm (7,2)
manual feed
Copy delivery 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 sort-
ing 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 origi-
nals
Special functions Pre-programming
Auto zoom / auto roll
Auto roll switch
Copying to standard sizes
Programmable default set-
tings
102 TSM Oc 9800 Copier specifications

Specifications
Job memory
Matrix copying
Leading / trailing edge +/- 100 mm
compensation
Editing functions Mirror
Image shift
Auto alignment
Stretch
Image erase inside / outside
Stamping (optional) 50 messages programma- 40 characters
ble
3 positions
2 fonts
4 grey scales
Toner consumption 0.7 g/m2
Dimensions (W x D x H) Scanner 1320 x 650 x 1230 mm
52 x 26 x 49
Engine 1720 x 1100 x 1370 mm

68 x 44 x 54
Folder (1st and 2nd) 1968 x 607 x 899 mm
77.5 x 24 x 35.5
Belt unit 730 x 500 x 1150 mm
29 x 20 x 45.5
Required floor space 16 m2 / --- square feet
Weight packed Scanner 175 kg / 387 lbs
Engine 765 kg / 1690 lbs
1st Fold 70 kg / 155 lbs
2nd Fold 110 kg / 243 lbs
Belt unit 98 kg / 217 lbs
Weight unpacked Scanner 145 kg / 320 lbs
Engine 735 kg / 1623 lbs
1st Fold 60 kg / 133 lbs
2nd Fold 100 kg / 220 lbs
Belt unit 90 kg / 200 lbs

Specifications
Mains supply 50 Hz 230 V, 3 phase,
14,11, 11 A.
400 V, 3 phase and neutral,
9, 4, 9 A.
9, 4, 9 A.
60 Hz 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.
9, 4, 9 A
9, 4, 9.
Power consumption Warming up 5 kW
Stand-by 1.0 kW
Run 3.5 kW
Warming up time 20 min.

2 Folder specifications
Specifications
1st Fold input min. 297 x 420 mm
11.5 x 16.5
max. 914.4 x 6000 mm
36x 236
1st and 2nd Fold input min. 297 x 420 mm
11.5 x 16.5
max. 914.4 x 2500 mm
36x 98.5
Material plain paper 60 - 110 g/m2
16 - 30 lbs
vellum 16 - 24 lbs
Folding methods standard DIN 190 x 297 mm

210 x 297 mm
210 x 297 mm including
filing edge 20 mm, left side
Ericsson 190 x 210 mm
210 x 297 mm
210 x 297 mm including
filing edge 20 mm, right
side
USA 8.5 x 11
9 x 12
8.5 x 11 with filing edge
9 x 12 with filing edge
Afnor like 210 x 297 mm
1st Fold 186 - 230 mm (7.3 - 9) default 210 mm
steps of 1 mm (0.1)
2nd Fold 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)
Belt unit 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
Punch Oc 730 (EUR) 2 or 4 holes
Oc 720 (USA) 3 holes

3 Belt unit
Specifications
Dimensions (W x D x H) 1Belt unit (Oc 850) 730 x 500 x 1150 mm
29 x 20 x 45.5
2 Belt units (Oc 851) 730 x 500 x 1470 mm
29 x 20 x 58
Weight Belt unit Oc 850 80 kg / 176 lbs
Weight Belt unit Oc 851 110 kg / 243 lbs
Belt capacity 75 g/m2 A0 / E : about 100
A1 / D : about100
A2 / C : about 150
A3 / B : about. 400
A4 / A : > 400
Maximum copy length 1220 mm (48)
Punch Oc 730 (EUR) 2 or 4 holes
Oc 720 (USA) 3 holes
Number of folds in pack- Maximum 2
age
Required floor space 1.4 m2 (15 square feet)
Power supply From the engine
Power consumption Additional 0.1 kW

4 High Capacity Stacker
Specifications
Machine type: High Capacity Stacker
Unfolded copies only
Dimensions: WxDxH 2280 x 1426 x 1370 mm
89.7 x 56.2 x 54
Weight: Including packing 425 kg (937 pounds)
Excluding packing 390 kg (860 pounds)
Speed: 7 m/min. adjusted by engine
Capacity: 200 copies per bin 75 g/m2
Materials: Plain paper 60 - 110g/m2
Vellum 16 - 20 lbs
Transparent 60 - 110 g/m2
Polyester not recommended
Number of output bins: 6

Features: Set / job separation on all All bins, except bin 1, are
output bins extensible for convenient
copy removal.
Copy size Minimum 210 x 297 mm (8.5 x 11)
Maximum 1220 x 914mm (48 x 36)
Noise level: Stand by <30 dB(A)
During operation 66 dB (A)
Power supply: 115 V, 230 V single fase 50 / 60 Hz.
From the engine
Power consumption Stand by 30 W
Run 100 W
Connection: Serial (RS 232)
Safety approval: TV-GS
Radio interference: TV-FS
Required floor space: 7 m2 (75.4 square feet)
Floor strength 100 kg/m2 (220 pound/m2
Power consumption: Stand by 30 W
During operation 100 W
Room conditions: Temperature: 17 -34 oC (63-93 oF)
R.H. 10 - 90 %

5 Reinforcement Unit specifications
Specifications
Dimensions (l x w x h) 575 x 23 x 450 mm
Weight 12.5 kg without tape
Power source 24 Volt supplied by folder
Power consumption 31 Watts maximum, in normal mode
Tape cutting length 111.125 0.5 mm
Tape glueing position in 37.5 1 mm from a hole in
longitudinal direction the tape to the M6 holes in
the rear frameplate
Tape glueing position in 80 1 mm from a hole in
transversal direction the tape to the outside of
the rear frameplate
Parallellism of tape and within 0.5 mm
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 inter-
vals

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

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
WxDxH Kg Lbs
Engine on pallet 1860 x 1250 x 1600 mm 74 x 50 x 63765 1690
Engine 1720 x 1100 x 1370 mm 68 x 44 x 54735 1623
Additional tools
pallet truck (1500 mm (59) long).
spirit-level.
open-end spanners 17 mm and 30 mm.
Remove:
1 The packing straps (if present).
2 The cardboard box upwards (if present).
3 The plastic bag.
4 The copy receiving tray from the engine.

5 The box with the start kit from the pallet.
6 The 4 wooden blocks from the pallet.
7 The long wooden bars at the front and rear side (4 bolts 17 mm).
8 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

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

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 Adjust the levelling feet at a height of 100 mm (3.9).

13 Move the engine down on the long wooden bars.
14 Remove the 4 blocks from the pallet truck.
15 Lift the engine again and remove the long bars.
16 Place the engine on its levelling feet.

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 Remove the left and right side top covers from the engine.
2 Remove the left and right side upper and lower covers from the engine.
3 Open the sheet feeding as far as possible by releasing the end stops.
4 Remove the side covers of the paper roll drawers, the screws are inside the
frame.
5 Remove the 4 red brackets from the main frame and the upper and lower paper
roll drawer.
6 Loosen inside the upper paper roll drawer the screws from the 2 metal blocks
from the transport security rod inside the drawer.
7 Remove on the left the screw from the transport security rod.
8 Remove the transport security bar to the left.
9 Remove on the left the transport security from the compressor unit.
10 Remove on the left the transport security from the preheating reservoir.
11 Remove the waste reservoir underneath the compressor.
12 Loosen the two screws from the left lower cover.
13 Remove the left lower cover.
14 Loosen the screw from the right lower cover.
15 Remove the right lower cover.
16 Disconnect the connector 06X8 from the compressor unit.
17 Unplug the air supply hose from the compressor unit.
18 Loosen the three mounting screws from the compressor unit.
19 Lift out the compressor unit.
20 Open the upper drawer.
21 Remove the 2 metal blocks.
22 Loosen inside the lower paper roll drawer the screws from the 2 metal blocks
from the transport security rod inside the drawer.
23 Remove on the left the screw from the transport security rod.
24 Remove the transport security rod to the left.
25 Open the lower drawer.
26 Remove the 2 metal blocks.

27 Remove from the drawers:
the 2 red brackets from the feed-opposite unit
the cable ties from the paper roll holders and the cutting mechanism
all foam blocks and transport tapes.
28 Open the chip tray and remove the foam strips from the cutting mechanism.
29 Place the lifting bar in the square holes in front of the upper paper roll drawer.
30 Close the paper roll drawers.
31 Close the sheet feeding.
Developing unit / Printhead
security
bolt DRUASV
probe
print-
head
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.
3 Disconnect on the right the connector 05X1 from the developing unit.
4 Remove the air supply tube on the left side.
5 Open the developing unit completely to the service position.
6 Remove the calibration plate of the DRUASV-probe.
7 Hold the bar with the DRUASV-probe and remove the cable ties .
8 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 print-
head and lock the printhead.

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.
.
red strip
brass stop
locking
plate

5 Remove the red locking plates at the left and the right side.
6 Remove the cable ties from the shaft ends of the fuser roller cleaner.
8 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.
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
and lower).
2 Remove the rails (2 screws each).
3 Carry out dis-/assembly 1 function 13 Paper sheet feed on page 401.
4 Remove the rail (3 nuts each).
5 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.
6 Remove the side covers.
7 Remove the supports of the side covers.
8 Remove the paper transport supports.
9 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.

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:
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 NEU-
TRAL 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.

4 Check if the transformer 22T1, on the left, is connected according to mains
supply voltage.
5 Mount the compressor unit.

6 Connect the air hose and connector 06X8.
7 Mount the waste reservoir.
8 Mount all covers, except the front cover.

Scanner
7 Unpacking the scanner

Dimensions
kg Lbs
Scanner on pallet W x D x H = 1540 x 760 x 1520 mm61 x 30 x 60 185 410
Scanner W x D x H = 1320 x 650 x 1230 mm52 x 26 x 49 140 310
Remove:
1 The packing straps (if present).
2 The cardboard box upwards (if present).
3 The plastic cover.
4 The lamp with box from the rear side of the scanner and put it on a save place.
5 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
2 Open the upper part of the scanner.

3 Remove the three foam strips on top of the gauge roller.
4 Remove the fixing bolts from the side covers of the upper part of the scanner.
5 Close the upper part and remove the side covers (disconnect the ground wires).
6 Open the upper part again.
7 Remove on one side the cover from the exposure lamp holder.
8 Remove the lamp fitting.
9 Place the exposure lamp in the scanner and mount the lamp fitting.
10 Turn the lamp 90 o.
11 Mount the cover over the exposure lamp holder.
12 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

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 Open the drawer of the cold process to service position.

2 Remove the cover from the cooling unit.
3 Pull out the return tube from the reservoir.
4 Place the funnel into the reservoir.
5 Add liquid to approx. 2 cm under the maximum indication on the reservoir.
6 Loosen the upper tube from the printhead.
7 Fill the last 2 cm from the reservoir via the tube.
8 Fit the upper tube back to the printhead.
9 Place the return tube into the reservoir.

12 Switch off the machine after the liquid is stabilised.
13 Remove the return tube.
14 Place the funnel into the reservoir.
16 Place the return tube into the reservoir.
18 Repeat the procedure if the level is still too low.
19 Put the funnel into the reservoir.
21 Close the drawer of the cold process unit.
22 Lock the printhead.

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.

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 Unpack the cardboard box.

2 Remove the lower cover plate of the engine.
3 Mount the two position snappers.
4 Check / adjust the position of the snappers with the LPE.
5 Remount the cover plate and place the LPE.
Snapper

11 Preparation of the engine for folder installation
2 Remove the black cover of the PTR unit.
3 Disconnect the connectors from PTRMO and PTRMOSE.
5 Remove PTRMO.
6 Remove the toothed gear.
7 Mount the new belt.
8 Remove the cable bundle and PBA 15.
9 Remove the connector 22X13 and on 18PBA 02 the connector 18X2.
10 Install 18PBA09 on the right side besides 18PBA02.
11 Connect the flat cable connector X1.
12 Cut the cable tie from the PTRUFOSO.

12 Connections belt unit and reinforcement unit (RU)
X5 X1 Belt
I/O int.
unit
18X24
18X25
X5 X1
I/O int. Belt
unit
18X24
18X25
X5 X1
I/O int. RU
18X24
18X25
X5 X1 X2/X3 X1
I/O int. RU 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.

Folder
Dimensions
kg Lbs
1st fold on pallet L x W x H = 1300 x 650 x 650 mm 52 x 26 x 26 70 155
2nd fold on pallet L x W x H = 1030 x 660 x 2050 mm41 x 26 x 81 110 243
without RU
2nd fold on pallet L x W x H = 2340 x 770 x 1075 mm92 x 31 x 43 140 310
with RU
13 Installation Oc 705 behind the Oc 9800

First folding unit
1 Remove the box of the first folding unit from the pallet (if present).
2 Remove the plastic bag.
3 Remove the four bolts with nuts, which fix the folding unit to the pallet.
4 Remove all transport tapes and foam strips.
5 Remove all side covers (for the left and right upper cover screws inside the
folding unit).
6 Remove the 2 upper screws from the cover plate underneath the first folding
unit.
7 Remove the cover.
8 Take the 2 red lifting handles.
9 Open all hinged covers from the first folding unit.
10 Fit the red lifting handles on the right and left frame plate in the appropriate
key holes.
11 Lift the unit with two persons and place it in the grooves of the bar on the rear
of the Oc 9800.
12 Connect the right side the power supply connector 1801G1 and the earth wire.
13 Check if the input voltage switch on the DC power supply is set to the 230 V
position.
14 Mount the cover plate with the 2 lifting handles in front of the power supply.
15 Open the paper transport unit.
16 Connect on the left side the connector 18X4.
17 Connect the new delivered bundle on the left side to the connectors 2201X5
and 18X4 in the first fold.
18 Connect the wires to PTRUFOSO, the earth wire and connector 22X13 in the
8engine.
19 Fasten the cable bundle with a cable tie to the main bundle.
20 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.
Second folding unit with reinforcement unit Oc 712

1 Remove the cardboard box (if present).
2 Remove the dust cover.
3 Remove the cartons with the covers and the FFD (first fold delivery) tray.
4 Loosen the bolts, which fix the unit to the pallet (13 mm).
5 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 Remove the cardboard box (if present).
2 Remove the cartons with the covers and the FFD (first fold delivery) tray.
3 Remove the four bolts (17 mm), which fix the unit to pallet.
4 Turn the unit on its wheels.
5 Remove the wooden bar from the frame of the 2nd folding unit (4 bolts 10
mm).
6 Remove all transport tapes and the cable ties from the first fold delivery rollers.
7 Remove the foam strips from between the folding rollers and 2 cable ties.
8 Remove the nut and ring from the position pin from the first folding unit.
9 Place the 2nd folding unit behind the 1st folding unit.
10 Check if the position pin of the 2nd folding unit fits with the first folding unit.
11 Mount on the left side the ring and nut which fix the 2nd with the first folding
unit.
12 Connect on the left side the connectors 18X1, 18X5, 18X8 and 18X19.
13 Mount the long rear cover.

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
bottom of the frame and the wheels (these plates are packed inside to the side
frame of the 2nd fold)
15 Adjust the height position of the second fold with respect to the first fold 12
mm and parallel.
16 Lock the 2nd folding unit with the nut and ring at the left side.
17 Remove the transport security bolt from the reinforcement unit (behind the
door of the unit).
18 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.
19 Mount the rear lower cover.
20 Mount all covers on the folder.
21 Mount the FFD tray.
23 Activate SDS.
24 Carry out test 90.
25 Configure the folder.
26 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 = 40.2 x 27.6 x

pallet (Oc 850) 1020 x 700 x 1350 mm 53.2
Upper belt unit in box LxWxH= 40.2 x 20.9 x
(Oc 851) 1020 x 530 x420 mm 16.5
Punch unit in box LxWxH= 17.7 x 7.9 x
Oc 720 (USA) / Oc 730 450 x 200 x 160 mm 6.3
(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
frame unit).
4 Remove the transport bolt (key 10 mm) in the bottom plate.
5 Open the side door.
6 Remove the transport bolt (key 10 mm) in the bottom plate.
7 Remove the frame belt unit from the pallet.
8 Remove all covers of the frame belt unit.

upper front cover
cover
output
cover
belt unit
rear covers
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).
15 Push earth wire from the output cover to the side against the frame.
16 Position the belt section (lift it at the front and hook it in the frame)
17 Lock the belt unit with the bolt (M4 x 7) from front side belt unit.
18 Mount the tooth drive belt:
remove the E clip of the upper gear
remove the gear
mount the timing belt together with the gear
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.
124 TSM Oc 9800 Folder optionals

receiving frame
rack
M3
screw nylon ring
metal
rings
15 Upper belt unit (Oc 851).

1 Open the box and unpack the unit.
2 Take the upper output unit and place it on the top of the frame belt unit.
3 Remove the cover.
4 Mount the 4 bolts (one star ring for grounding).
Note: Check if the unit is in line with the lower frame.
5 Mount the tooth drive belt between the upper and lower unit.
6 Remove the jumper connector and leave the jumper in side the unit.
7 Connect the connector of the motor from the upper unit.
8 Unpack the upper belt section.
9 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 low-
er shaft).
11 Push earth wire from the output cover to the side against the frame.
12 Position the belt section (lift it at the front and hook it in the frame)
13 Lock the belt unit with the M4 x 7 bolt at the front side.
14 Connect the earth wire and mount the output cover with a little cover.
15 Mount the output cover from the lower belt unit if not yet mounted.

16 Mount the drive belt:
remove the E clip of the upper gear

remove the gear

mount the timing belt together with the gear
mount the E clip
17 Mount the receiving rack (2 screws/ ring), the smallest washers against the
frame.
receiving
rack frame
M3
screw 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 Place the frame belt unit near the 2nd folding unit.
2 Guide the two cable bundles, through the holes, to rear of the unit.
3 Remove the bolts from the supports.
4 Place the unit against the second folding unit.
5 Carry out function 18 adjustment Height of the belt unit and zero-line on
page 307.
6 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.
7 Position the jumper connector at one of the cable guides.
8 Connect connector 1813X1 on the PBA.
9 Open the side door of the belt unit.

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
unit through the hole of the cover of the first folding unit and secure the strain
relief.
12 Connect the supply cable with connector 22X9.
13 Mount all covers of the belt units.
15 Activate SDS.
17 Configure the belt unit.
18 Select the SDS test 18-1-06 and set the belt capacity.
19 Switch off SDS and switch OFF and ON the engine.

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 Secure the unit with 2 screws M6.

8 Fix the 2 tension springs onto the brass brackets.
9 Mount the bracket with plastic bearings onto the punch unit.
10 Place the punch unit waste tray.
12 Activate SDS.
14 Configure the punch unit.
15 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.

Installation High Capacity Stacker (HCS)
Oc 880
17 Special tool
Magnetic nut driver 7 mm.
18 Unpacking and assembling

1 Remove the staples from the cardboard box.
2 Remove the cardboard box.
3 Remove the plastic bag.
4 Remove the shipping straps from the small box and the 2 ramps.
5 Remove the small box and the 2 ramps from the pallet.
6 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.

shipping brackets bin support frame
small box
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
(13 mm).
16 Remove the 4 shipping brackets of the castors from the wheels.
17 Turn the wheels to the same running direction.
18 Mount the 2 long wooden beams on the pallet at the left and right side.
19 Place the 2 ramps against the pallet.
20 Carefully roll off the HCS frame from the pallet.
21 Open the boxes.
130 TSM Oc 9800 Installation High Capacity Stacker (HCS) Oc 880

The small box contains:
the 2 inner corner covers of the frame

fixing material
The rectangle box contains:
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:

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

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

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
the earth connection is made properly.
33 Mount the triangular top cover (4 screws).
34 Remove at the right side the upper and lower side covers from the HCS frame.
35 Remove the long side cover at the right side (9 screws).
36 Mount the bin output covers to bin 3 and 6 (different covers).
37 Remount the long cover.
38 Assemble the delivery bins in the following sequence starting with the upper
delivery bin:
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.

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
rectangular catch bracket DELBIN(1-6)EMSE
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
each).
42 Remove the foam blocks.
43 Open the TRI.
44 Open the upper door from the frame.
45 Mount the 2 upper inner corner covers (4 screws).
46 Close the upper door and the TRI.
47 Remove the tape from the lower door.
48 Open the lower door and remove the tape from the input guide flap.
49 Close the lower door.
50 Mount the long side cover to the delivery bin support.
51 Before positioning the HCS behind the Oc 9700 / 9800, prepare this machine
according see Preparation of the Oc 9700 / 9800 on page 135.
52 Remove the aluminium blocks underneath the delivery bin support.
53 Roll the HCS behind the Oc 9700 / 9800.
54 Carry out function 19 adjustment The HCS with regard to Oc 9700 / 9800
on page 309.
55 Place the aluminium blocks underneath the delivery bin support levelling feet.
56 Adjust the height of the feet.
57 Connect the power supply cable and the data cable from the Oc 9700 / 9800
with the HCS.
58 Continue with FINAL see Final on page 136.

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 Remove the top cover from the Oc 9700 / 9800 at the right side.
2 Remove the side upper and lower cover at the right side.
3 Remove the cover underneath the PTR.
4 Remove the rear upper and lower cover at the left side.
5 Mount the new 18PBA1 I/O-INTERFACE PBA and connect with the CPU-I/O
PBA.
7 Mount the supply bundle to connector 22X9.
8 Connect the connector 2202X6 from the databundle to the new 18PBA1
I/O-INTERFACE on connector X6.
9 Mount 2 strain reliefs.
10 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 Loosen the 2 knurled screws and slide the brackets inwards.

12 Open the cover from the PTR.
13 Lift and swing the unit into the output section of the Oc 9800.
14 Slide the brackets outwards and tighten the knurled screws.
15 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:
test 51 ~Testprint adjust PHD~

test 54 ~DRU ASV test~
test 55 ~DEV unit adjustment~

20 Final
1 Switch on the HCS.
2 Switch the Oc 9700 / 9800 in SDS mode.
3 Execute SDS test 90 "Configuration" and configure the HCS.
4 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.

Packing the HCS
1 Open the TRI.
2 Open the upper door of the frame.
3 Disassemble the inner upper corner covers at the right and left side.
5 Close the TRI.
6 Place T form foam blocks between the frame and the upper door.
7 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
bracket magnet catch
bracket DELBIN(2-6)OPSE
bin wheel running support
8 Remove the bracket from the magnet catches (2 screws).

9 Remove the bracket from DELBIN(2-6)OPSE.
10 Remove the screw at the right side from the bracket of DELBIN(1-6)EMSE.
11 Loosen the screw at the left side and turn the bracket with the delivery bin emp-
ty PBA 900 downwards.
12 Slide out the delivery bin carefully.
13 Remount the bracket of DELBIN(1-6)EMSE.
14 Remove the bin wheel running supports from bin 2 up to 6 at the right side.
15 Remove the bin wheel running supports from bin 5 and 6 at the left side
16 Remove the triangle top cover (3 screws).
18 Remove the rear cover of the delivery bin support.
19 Remove the bracket with the DELBINTXEMSE PBA above the delivery bin
number 1.

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
bin support.
24 Turn the levelling feed from the frame upwards.
25 Remove the aluminium blocks.
26 Remove the levelling feed from the frame.
27 Mount the 2 long wooden beams on the pallet.
28 Place the 2 ramps to the pallet side.
29 Roll the frame on the pallet.
30 Mount the security brackets between the wheel and the wheel housing from the
frame.
31 Fix the security brackets with the pallet (2 bolts and 2 nuts).
32 Place the wooden transport plate on the bottom of the frame.
33 Mount the 4 transport security brackets to the delivery bin support.
34 Place the delivery bin support on the wooden plate and fix the delivery bin sup-
port with the 4 shipping brackets to the frame.
35 Remove the levelling feed from the bin support.
36 Mount the transport security brackets with eyes and space bushes (2 in the up-
per part of frame and 2 in the bottom).
37 Place the delivery bins on the wooden plate.
38 Place the wooden plate on top of the delivery bins.
39 Pack all disassembled parts in the boxes.
The small box contains:
2 inner upper corner cover

The rectangle box contains:
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
138 TSM Oc 9800 Packing the HCS

The square box contains:
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
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
brackets and tighten the straps.
43 Open the lower door of the frame and stick tape to the guide flap.
44 Close the lower door and tape the door.
45 Tape the bulge 2 fingers on top of the TRI.

46 Tape the small box with the 2 ramps together.
47 Tape the small box with ramps to the delivery bin support.
48 Place the square box on the pallet.
49 Mount the plastic bag across the unit.
50 Place the carton box.
51 Attach the carton box to the pallet.

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
2 Activate SDS.
If the first entry screen shows the BBR checksum / information error codes:
22901 SWAR
22902 SWAR
22102 PE
22103 PE
Execute the installation tests 70 / 71 / 72 / 73 / 74 completely (see SDS ~IN-

STALLATION~ tests (70 - 79) on page 1192.
3 Carry out SDS test 90 (configuration) and do the required settings.

4 Carry out 05 DEV ~DEV unit adjustment~ on page 301.
5 Carry out SDS test 41 WARM SDS.
6 Carry out SDS test 10-7-01, 10 SCA TL intensity adjust on page 301.
(not needed for the Printer Only version)
7 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
8 Carry out SDS test 73 (Install folder)
9 Carry out test 74 (Customer).
10 Make copies from the service test original and check the copy quality see
Service test original on page 115.
11 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 Switch off the engine and disconnect the mains supply.
2 Remove the right top cover and the two side covers.
3 Remove the right rear covers from the engine.
4 Disconnect the scanner data cable from the engine.
5 Remove the cover from the SET memory and the B/W PBAs (20 screws).
6 Connect the connector 1101X4 to the small PBA on the SET memory PBA
(data cable).
7 Connect the other connector to the CPU_IO PBA on the left upper side (control
cable).
8 Mount the cover with the 20 screws.
9 Mount two screws in the upper holes of the controller box.

10 Hang the controller to the frame.
11 Mount the controller with four screws.
12 Connect the supply connector to the controller.
13 Connect the data cable to the controller (lower connector).
14 Connect the control cable to the controller (upper connector).
15 Connect the scanner data cable.
16 Put the switch on the controller in the OFF position.
17 Mount all covers.
19 Activate SDS and select test 90.
20 Configure the controller.
21 Switch off the SDS.
22 Switch off and on again the engine.

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

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

1 Enter system administrator mode.
Set available ALS formats
Set default language settings
Set default connection settings
Print default controller settings (select machine / print settings and push the
start button).
2 Check the settings.
3 Connect the laptop via the centronics connector with the controller.
4 Check the controller functioning with the Oc 9800 Service Plot Tool.
5 Connect the controller to customer environment.
6 Check the controller functioning with customer plots.

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
Faults
1 Faults overview
Copy quality
Copy quality general / No image on copy on page 127
Blank copy
Copy quality general / Uneven image on page 127

Skeleton image middle
Skeleton image on sides of copy
Skeleton image on leading edge
Catskin
Uneven background
Moire effect
Copy quality general / Weak image on page 131

Weak image
Weak image not being copied correctly
Copy quality general / ghost image on page 133

Ghost image caused in 1st transfer
Ghost image caused in 2nd transfer
Digital ghost image
Copy quality general / Image erasable on page 134

Image erasable
Copy quality general / Black copy on page 135

Black copy unframed
Black copy framed
Copy quality general / Unsharp image on page 136

Unsharp image
ed.5 Faults 101

Spots,stains,stripes,scratches / Spots/stains on page 137
Missing image, white stains/spots
Black stains/spots
Soiled backside
Black spots / stains / background is digital
Analogue background
Spots,stains,stripes,scratches / Stripes, scratches on page 141

Missing image, stripes / scratches in feed direction
Missing image, stripes / scratches perpendicular to feed direction
Black stripes / scratches perpendicular to feed direction
Black stripes / scratches in feed direction
Wall paper
Black stripes first few copies, perpendicular to feed direction
Position,deforming,magnification / Image position on page 145

Image position in feed direction
Image distorted in width direction
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
Magnification ratio perpendicular to the feed direction incorrect
Receiving materials damaged, soiled in engine / Folds, wrinkles on page 150

Folds / wrinkles on leading edge
Wrinkles all over the copy
Moisture on copies
Receiving materials damaged, soiled / In 1st fold on page 151

Wrinkles
Dog ears
Damaged leading edge
Unsharp folds
Wrong fold length
102 TSM Oc 9800 Faults

Receiving materials damaged, soiled / In 2nd fold on page 153
Dog ears leading edge
Receiving materials damaged, soiled / in belt, punch unit on page 154

Dog ears
Punch holes wrong positioned
SDS not available
Machine is totally dead on page 155

CONCONEMS ON
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 phe-
nomena 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:
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.

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. back-
ground) 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 control-
ler.
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 print-
er process section.
Also the following test prints/copies might help you to find out in which sec-
tion the problem is caused:
Test Checks
SDS-50 Printer Error 01503
Oc 9800 Test chart Scanner-Printer
SDS-51 (Testprint PHD) Printer
SDS-52 (Black mode) Printer
SDS-43 (Cut sheet length) Printer
Service plot tool Controller / printer
Optical symptom
If a given copy quality phenomenon is caused in the optical section of the scan-
ner (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 re-
lated 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 re-
lated to the CTF roller.
CTF pressure roller

If a given copy quality problem repeats every 7 cm (2.75), the problem is re-
lated to the CTF pressure roller.
Developing unit
If a given copy quality problem repeats every 3 cm (1.2), the problem is relat-
ed 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)

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 di-
rection 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 2 3
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 densi-
ty can be seen. Also the copy material
might be deformed. This phenome-
non is on the copy an up building phe-
nomenon which means that on the
first part of the copy the image is cor-
rect 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:
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 "skel-
eton in the middle" phenomenon the "skeleton on the sides" phenomenon
appears. In this case also the fuser roller needs to be replaced.

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 de-
formed.
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 to-
wards 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:
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 ap-
pears. 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 de-

formed 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.
Solution:
Check the copy material transport
in the preheater.

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, com-
ing 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 sur-
rounded 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:
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).

Wax pollution
Recognizing wax pollution

If the drum is polluted with wax, toner will be developed on the drum via me-
chanical 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 melt-
ed wax will be transported to the CTF fuser roller. For that reason the CTF fus-
er 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 oc-
cur. 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:
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 cus-
tomer in order to reduce the service costs.
Summary
Background caused by talc pollution:
Clean drum
Background caused by wax pollution:
Replace CTF fuser roller

Execute the SDS test wax cleaning procedure.
Report to SPS Venlo via local Service and TUS organisation.

3 Service test original
Machine condition
When checking the copy quality specifications make sure that:
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: SDS system test 50- "testprint mode"
Check: Compare the optical density of the black stroke on 5

different points on the leading edge of the testprint,
with the Agfa greyscale
Norm: 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
Adjustment: Not applicable
Copier
Test: Make 5 copies of the Oc 9800 service test original :
- run length = 5
- exposure = 0
- ABC = on
Check: Compare on the 5 th copy the optical density of stroke
Ib on points XIIa, XIIe and XIIi.
Norm: 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
ed.5 Faults 115

Evenness in grey
Copier
Test: 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.
Check: 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.
Norm: The evenness of the grey information should be within
0.3 on the Agfa greyscale.
Adjustment: Not applicable.
Reproduction of weak lines

Copier
Test: Make 10 copies of the Oc 9800 Test Chart at different
exposure settings:
exposure setting = -4 up to +5
run length = 1
ABC = on
Check: Determine at how many exposure settings line Va is
printed without interrupts and also having no back-
ground.
Norm: At least 1 exposure setting should be possible.

Readability
Copier
Test: Make 5 copies of the Oc 9800 Test Chart:
exposure = 0
run length = 5
ABC = on.
Check: 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: Isomire 140 should be readable.

Adjustment Not applicable.
Synchronisation
Copier /
printer
Test: Make 5 copies of the Oc 9800 Test Chart :
Exposure = 0
Run length = 5
ABC = on.
Examine the 2.0 lp/mm stroke on the left side of the
copy (IIIa and IIIf).
Norm: The lines should be visible separately.
ed.5 Faults 117

Toner adhesion
Printer
Test: SDS test 52, "Black mode.
Make a fold after 25 cm (10) of the leading edge on
the copy.
Check: Measure the width of the interruptions in the fold.
Norm: The width of the interruptions should not exceed 0.25
mm.
Note: If the toner adhesion is good on Oc plain paper it is
also OK for Oc transparent and Oc polyester film
Copier
Test Make 5 copies of the Oc 9800 Test Chart :
Exposure = 0
Run length = 5
ABC = on.
Make a fold on position XIIe of the black stroke and
measure the width of the white area in the fold.
Norm: The width of the interruptions should not exceed 0.25
mm.

1 : 1 accuracy
Printer (feed direction

Test: SDS test 53, "1:1 mode"
Check: Measure the length of the white beam and adjust the
length accordingly.
Norm: Accuracy < 0.1%.
Adjustment: 06 CTF adjustment 1.
Copier (feed direction)
Exposure = -7
Run length = 1
ABC = off.
Check: Place the test original on the copy and measure the dif-
ference between the length of line Xa-Xd on the copy
and original.
Norm: The 1:1 accuracy of all 5 copies < 2.5 mm.
Adjustment: 09 ORIGINAL adjustment 2.
Modification 9810 -01

Copier (width direction)
Exposure = -7
Run length = 1
ABC = off.
Check: Place the test original on the copy and measure the dif-
ference between the length of line Xe-Xh on the copy
and original.
Norm: The 1:1 accuracy of all 5 copies < 3.5 mm.
ed.5 Faults 119

Copy length
Printer
Test: SDS test 43, "Cut sheet length"
Sheet length 600 mm.
Check: Measure the length of the cut sheet and adjust accord-
ingly.
Norm: 600 2 mm.
Adjustment: 12 PRD adjustment 1/2.
Copier
Exposure = -7
Run length = 1
ABC = off.
Check: Measure the length difference from the 5 copies , com-
pared with the original length.
Norm: The copy length accuracy < 4 mm.
Adjustment: 09 ORIGINALS adjustment 1.
Copier (in run of 25 copies)
Exposure = -7
Run length = 25
ABC = off.
Check: Measure the maximum length difference from the 25
copies.
Norm: The maximum difference must be < 3 mm.

Image position on leading edge
Copier
Exposure = -7
Run length = 1
ABC = off.
Check: Measure on the copies on the left hand side the dis-
tance Ca from the -10 line to the edge of the mate-
rial.
Measure on the copies on the right hand side the dis-
tance Cb from the -10 line to the edge of the mate-
rial.
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.
Norm: Image position on leading edge (a+b)/2 < 3 mm
Adjustment: 09 ORIGINALS adjustment 3
ed.5 Faults 121

Left/right differences in image position on leading edge
Copier
Exposure = -7
Run length = 1
ABC = off.
Check: Measure on the copies on the left hand side the dis-
tance Ca from the -10 line to the edge of the mate-
rial.
Measure on the copies on the right hand side the dis-
tance Cb from the -10 line to the edge of the mate-
rial.
Measure also the distances Oa and Ob on the left
and right hand side of the original.
a = Oa-Ca and b = Ob-Cb.
Norm: Left/right difference image position on leading edge
(a-b) < 2 mm

Image position on side edges
Copier
Exposure = -7
Run length = 1
ABC = off.
Check: 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 lead-
ing edge the distance Oc from the -10 line to the
edge of the material.
Calculate the difference c = Oc-Cc.
Norm: The image position on the edge c < 4 mm.
All copies should meet this norm.
ed.5 Faults 123

Image position on side edge, difference on leading and trailing edge.
Copier
Exposure = -7
Run length = 1
ABC = off.
Check: 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 trail-
ing 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.
c = Oc-Cc and d = Od-Cd.
Norm: The image position on the side edge (c-d) < 2 mm.

Framing at the leading edge.
Copier
Exposure = -7
Run length = 1
ABC = off.
Check: Measure on the copies the framing at the leading edge
on the left (K1) and on the right (K2) side.
Norm: The framing at the leading edge be: K1, K2 > 0.5 mm.
ed.5 Faults 125

Framing at the side edges.
Copier
Exposure = -7
Run length = 1
ABC = off.
Check: 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).
Norm: The framing at the side edges
left: K5, K6 > 0.5 mm,
right: K7, K8 > 0.5 mm

4 Copy quality
Copy quality general / No image on copy
Blank copy
Possible cause Checking procedure / Remark
Drum exposed by false Front cover not positioned
light
Position developing unit Check locking position
not correct
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 cor-

rect
Incorrect ABC Image processing not correctly initialised,
switch machine off and on
Incorrect configuration SDS: 90
Defective SIMMs PBA SDS: 11-6-05, check positioning
SET-MEMORY
Defective SDS: 11-6-05
PBA_SET-MEMORY
PBA_B/W-PROCESS-
ING
PBA_SCAN-PROCESS-
ING
Defective CONTROL- Controller SDS tests and try copying
LER
Electrical connections Check
IMP section
Printhead defect Carry out adjustment 04 Printhead see Check
Printhead on page 305
Scanlamp defect 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
Concave fuse SDS: 06-8-04 Check pressure roller gap cleaner on its
pinch 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
Convex fuse pinch SDS: 06-8-01 Check fuser roller on its evenness
Concave fuse SDS: 06-8-04 Check pressure roller gap cleaner on its
pinch 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.
Entrance to fuse pinch SDS: 14-8-01 Worn out paper guide cloth
not correct
Check preheating unit on its position
SDS: 14-4-02 PRETBR

Catskin
Description: Image density differences all over the copy (catskin structure).
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
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 inten-
sity 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 inten-
sity 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 dif-
ferent lightpath to the CCD PBAs.
No solution possible.
Scan-roller soiled / dam- Clean / replace scan-roller
aged
Copy glass not mounted Correct
correctly
Defective SLA SDS: 10-4-01 Scanner lamp
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 pro-
cedure.
Diaphragm PHD polluted Clean
ed.5 Faults 129

Moire effect
Description: Fine patterns on original are printed with uneven structure.
Photo mode not used Check with photo mode

Copy quality general / Weak image
Weak image
Description: Image density is too low, weak lines are not printed correctly
Developing unit out of SDS: 05-2-01 DEVTONSE
toner Frequency of development roller (3 cm (1.2)) visi-
ble on copy
Fuser roller temperature SDS: 06-1-01 CTFREFTEMPSE low, check resist-
too low ance value on sticker of CTFTEMPSE
SDS: 06-1-02 CTFREFTEMPSE high, check resist-
ance 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
First transfer step not SDS: 06-6-07 Check pneumatics

correct Check the air pressure
Printhead out of focus Check printhead position
Printhead diaphragm / Clean printhead diaphragm / lens
lens soiled
B/W_PROCESSING-PB SDS: 11-6-05
A defect
B/W_PROC-PBA
ed.5 Faults 131

Weak information not being copied correctly
Description: It is not possible to copy weak information without getting back-
ground
Exposure adjustment SDS test 51, see function 04 see ~Testprint adjust
printhead not correct PHD~ (every service visit) on page 301
Dirty OPC, uneven OPC SDS test 54, See function 01 ~DRU ASV test~
charge on page 302
Clean the drum according procedure
Printhead out of focus Check printhead position
Printhead diaphragm / Clean printhead diaphragm / lens
lens soiled
Image Processing not cor- Switch machine off and on
rectly initialised (ABC =
Automatic Background
Compensation)

Copy quality general / ghost image
Ghost images due to incorrect 1st transfer
Description: Image repeats every 62 cm (24.4)(Drum) in feed direction
Soiled discharge pin array SDS: 07-8-01, clean or replace pin array
Soiled discharge LEDs Clean discharge LEDs
Discharge current too low Residual image is weak
Defective discharge LED SDS: 07-4-01 Residual image is strong
After drum cleaning 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 direc-
tion
Fuser roller temperature SDS: 06-1-01 CTFREFTEMPSE low, check resistor
too low value on sticker CTFTEMPSE
SDS: 06-1-02 CTFREFTEMPSE high, check resis-
tor 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
Check air pressure
ed.5 Faults 133

Digital ghost image
Description: Image repeats every 22.7 cm (8.9 ) (perpendicular on feed
direction.
Bad connection B/W Check bundles / connectors
PBA -> PHD
Defective B/W PBA SDS: 11-6-05, Self test image processing
Defective PHD Check / replace
Copy quality general / Image erasable
Image is erasable
Description: Image is not fixed on receiving material and can be erased
easily
Level preheating liquid Check level and refill if necessary
too low
Preheater element defect SDS: 14-4-01 PREHE
SDS: 14-9-01 PREHETEMPSE
Fuser roller temperature SDS: 06-1-01 CTFREFTEMPSE low, check resis-
too low tor value on sticker
tor value on sticker
Check air pressure (5.4 bar)
Incorrect receiving mate- Receiving material out of specifications
rial
If receiving material is transparent material:
(14-PREHEATING see Brake force of the
pre-heater brake (PRETBR) on page 302).

Copy quality general / Black copy
Black copy, unframed
Description: Copy / print is black, including the framing sides in length direc-
tion
Incorrect configuration SDS: 90
Bad sliding contact drum Check carbon brushes
Connection between B/W Check bundle / connectors
PBA and Printhead
Defective printhead Carry out adjustment 04 Printhead see Check
Data receiver PBA defect Carry out adjustment 04 Printhead see Check
B/W PBA defect SDS: 11-6-05 Self test image processing
Black copy, framed

Description: Copy / print is black, excluding the framing sides
Scanlamp defect SDS: 10-4-01 SCALA
Connections CCD unit Check connections
SIMMs defect / bad SDS: 11-6-05 Self test image processing
contact
ed.5 Faults 135

Copy quality general / Unsharp image
Unsharp image
Description: Image on copy is unsharp
Printhead position Check printhead locking position
Self focusing lens array Clean SLA
(SLA) printer soiled
Printhead damaged (dia- Check / replace
phragm)

Spots,stains,stripes,scratches / Spots/stains
Missing image, white stains / spots
Description: On black parts to be seen as white stains / spots
Scratch on OPC drum SDS test 52, black mode
Fault repeats every 62 cm (24.4)
Clean or replace the drum
Toner or glue on OPC SDS test 52, black mode
drum Fault repeats every 62 cm(24.4)
Clean the drum
SDS: 01-9-01 check DRUM temperature
Scratch on fuser roller SDS test 52, black mode
Fault repeats every 33 cm(13)
Clean or replace the fuser roller
Scratch on CTF pressure SDS test 52, black mode
roller Fault repeats every 7 cm (2.75).
May also result in deformed images

Clean / replace pressure roller
ed.5 Faults 137

Black stains / spots
Description: Copy / print is polluted with black stains / spots
Toner fused on OPC drum SDS test 51, see function 04 see ~Testprint adjust
PHD~ (every service visit) on page 301
Too high drum temperature.
SDS: 06-1-01 CTFREFTEMPSE low, check resis-
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
Fault repeats every 62 cm(24.4)
Toner dosing procedure SDS: 06-6-07 Check pneumatics and toner dosing
not correctly functioning mechanism
Soiled backside
Description: Backside of copy / print is soiled with spots / stains
Scratches on CTF pres- SDS test 51, see function 04 see ~Testprint adjust
sure roller PHD~ (every service visit) on page 301
Occurs mostly after toner dosage.
Clean or replace the pressure roller.
Too low temperature SDS: 06-9-03 CTFPCLEHETEMPSE
pressure roller-cleaner
SDS: 06-4-04 CTFPCLEHE
Check heater
Pressure roller build up SDS: 06-4-05 Check evenness of the pressure roller
cleaner build up cleaner
Toner dosing procedure SDS: 06-6-07 Check pneumatics and toner dosing
not correctly functioning mechanism
Dirt in paperpath Check/clean

.
Black stains / spots / background is digital

Description: Copy is polluted with digital black stains / spots / background.
Pixels are recognizable spots
Scan-roller soiled Make copy of blank A0 transparent original.
Spots repeats every 10.5 cm (4.1)
Clean the gauge roller
Original glass soiled Make copy of blank A0 transparent original.
Always stripes.
Clean the original glass
Folds in original Instruct key operator / customer
ABC (Automatic Back- Instruct key operator / customer
ground Compensation)
not correct applied
ABC (Automatic Back- Only on first 15 mm (0.6) of the copy
ground Compensation)
start effect
ed.5 Faults 139

Analogue background
Description: Random toner soil, no pixel structure present
Toner fused on OPC drum SDS test 51, see function 04 see ~Testprint adjust
SDS: 06-1-01 CTFREFTEMPSE low, check resistor
value on sticker
DRUMFAN not turning, check fan, inverter PBA
Too high Drum temperature
Glue on OPC drum SDS test 51, see function 04 see ~Testprint adjust
Moisture on OPC drum SDS test 51, see function 04 see ~Testprint adjust
Inspect the drum,
Spots/stains repeat every 62 cm (24.4)
Disappears during copying
Drum not cleaned cor- Clean the drum according the procedure
rectly
V-rest out of specifica- SDS: 01-4-03 DRUASVCOMPPWM
tions (not compensated)
SDS: 01-9-02 DRUASVCOMPSE
Random stripes/strokes, often dependent of format
Exposure adjustment SDS test 51, see function 04 see ~Testprint adjust
printhead not correct PHD~ (every service visit) on page 301
Background with stripe structure
Talc pollution Clean the drum according the procedure
Wax pollution Wax cleaning procedure chapter 01-Drum OPC
wax cleaning procedure on page 410

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 direc-
tion, with less image
Drum exposed to false Close all covers
light
Scratch on OPC drum SDS test 52, black mode
Toner or glue on OPC SDS test 52, black mode
drum Fault repeats every 62 cm (24.4)
Scratch on fuser roller SDS test 52, black mode
Fault repeats every 33 cm (13)
Clean or replace the fuser roller
Scratch on CTF pres- SDS test 52, black mode

sure roller Fault repeats every 7 cm (2.25)
May also result in deformed images
Soiled development unit SDS test 52, black mode
Inspect and clean the developing roller / unit
Soil on / under original Make a copy of black original,
glass Inspect and clean the original glass
Polluted printhead 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.
Development unit out of SDS: 05-2-01 DEVTONSE
toner
Compressor defect Working pressure should be 5.4 bar
First transfer (drum - SDS: 06-6-07
CTF) step not correct
Second transfer (CTF - SDS: 06-6-07
paper) step not correct
Defective SIMMs 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 Check carbon brushes
drum
Defective PHD data SDS test 51, see function 04 see ~Testprint adjust
receiver PHD~ (every service visit) on page 301
Defective SIMMs SDS: 11-6-05 Self test image processing

Black stripes in feed direction
Defective printhead Carry out adjustment 04 Printhead see Check
Defective PHD data Carry out adjustment 04 Printhead see Check
receiver PBA Printhead on page 305
Soiled self focusing lens Clean SLA (could be caused by a polluted develop-
array printhead ment unit)
Soiled PHD diaphragm Clean diaphragm
Discharge LEDs polluted Clean discharge LEDs
Soiled exposure glass Clean exposure glass
scanner
Soiled gauge roller scan- Clean gauge roller
ner
Connections in CCD unit Check connections
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
Incorrect configuration SDS test 90 Configuration
Defective SIMM SDS 11-6-05 Self test image process
Check connections (11-Image processing
dis-/assemblies see SIMM PBA on SET MEM-
ORY PBA on page 401).
Defective SetMem PBA SDS: 11-6-05
Defective PBA SDS: 11-6-05
B/W-PROCESSING
Defective PBA SDS: 11-6-05
SCAN-PROCESSING
Defective CONTROLLER Controller SDS tests and try
IMP section
Black stripes first few copies, perpendicular to feed direction

Black stripes on first few copies perpendicular to feed direction. (62cm)
Incorrect pressure SDS: 06-7-01 and 53
between CTF
fuser and pressure roller
Fuse pressure incorrect SDS: 06-6-07
Check air pressure
CTF fuser roller polluted Replace fuser roller
by paper.
Pollution transported via Report via PR (copy material used)
slip after run to the Drum

Position,deforming,magnification / Image position
Image position in feed direction
Description: Image is not correctly positioned in feed direction
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 Check adjustment function 23 Main drive belt on
MADMO not correct page 301
Pulsdisc slipping Check
MADMO/CTFPRMO
Broken transmission Check joints
joint
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
ment not correct correction~ on page 301
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 Workaround: Tighten pin to plate.
defect Report via PR
PREheater guide Check guide cloth (position holes)
cloth wrongly
mounted
ed.5 Faults 145

Image position in width direction
Description: Image is not correctly positioned in the width direction
Image edit function De-select edit function
active
Developing unit not cor- Check adjustment function 05 DEVELOPMENT
rectly positioned ~DEV unit adjustment~ on page 301
Paper spool not correctly Check adjustment function 12 PRD Size label on
positioned page 310

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 lead-
tion is not correct ing edge correction~ on page 309
Check adjustment function 13 PSF ~PSF leading
Framing in the width Developing unit not correctly positioned
direction not correct 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.
Original is shifted during Check original path
scanning
Concave fuser 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
Entrance to fuser pinch Check position of preheating unit
not correct
SDS: 14-4-02 PRETBR

Position,deforming,magnification / Magnification ra-
tio
Magnification ratio in feed direction not correct
Incorrect zoom calibra- Check in key-operator mode
tion setting
Printer not correct Check adjustment function 06 CTF ~1 : 1 Image
adjusted length cor. engine~ on page 301
Check CTFTRANSE
Pulse disk defect / loose SDS: 23-2-01MADMOSE
on
Main drive motor
Scanner not correct Check adjustment function 09 ORIGINALS ~1 : 1
adjusted 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
Entrance to fuser pinch SDS: 14-8-01 Check preheating unit
not correct
SDS: 14-4-02 PRETBR
Entrance preheater not Inspect paper path
correct
PREheater guide cloth Check guide cloth (position holes)
wrongly mounted
Entrance fuser-pinch not Inspect paper path
correct
Entrance folder not correct Inspect paper path
Glue on preheater caused Clean preheater and report via PR
by fluor paper
Wrinkles all over the copy

Description: Copy material is deformed all over the copy
Humid copy material Check humidity
Wrinkles all over the copy in transparent copy material in machine num-
bers 980100098-980100407
Description: Copy material is deformed all over the copy
Too high force of partic- Execute modification 17
ular rollers in the PTR
unit
Moisture on copies
Description: Copy material has moisture spots on leading edge
Condensation at CTF Disappears after a few copies
output

Receiving materials damaged, soiled / In 1st fold
Wrinkles
Description: Wrinkles in 1st fold package
Wrong paper quality Use only Oc paper
(waved paper)
Environmental aspects Check environmental conditions (humidity, tempera-
ture)
Lift mechanism 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 proce-
A0/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
(waved paper)
ture)
Lift mechanism Check functioning FOL1LIMO SDS 18-6-11
smoothly between the pinch.
pressure roller
ed.5 Faults 151

Description: Damaged leading edge
(waved paper)
ture)
Lift mechanism Check functioning FOL1LIMO 18-6-11
smoothly between the pinch
pressure roller
Unsharp folds
Description: No sharp edges in the folding package
Lift mechanism remains Check lift mechanism FOL1LIMO SDS 18-6-11
open
Wrong fold length

Description: Folding length not according to specification
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

Receiving materials damaged, soiled / In 2nd fold
Dog ears leading edge
Description: Dog ears at the leading edge corner of the second fold pack-
age (especially A3 size copies)
Package is not entering Add a melinex strip on the lower profile of the 2nd
smoothly between the folding flap. Melinex strip should stick out 12mm of
folding roller and the the folding flap.
pressure roller.
Increase distance between pressure / folding roller at
problem side.

Description: Damaged leading edge of the folded package (especially A3)
copies)
Package is not entering Add a melinex strip on the lower profile of the 2nd
smoothly between the folding flap. Melinex strip should stick out 12mm of
folding roller and the the folding flap.
pressure roller.
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
Height position of the see Height of the belt unit and zero-line on page
Belt unit in respect with 307 function 18-Folding
the folder not correct.
Punch holes wrong positioned

Description: Punched holes not at the correct position.
Side adjustment mecha- Check position / adjust / instruct key operator.
nism not correct posi-
tioned Check the FOLOADJMU function (18-4-06)
Obstruction in copy path Check for piece of paper or object.
in punch unit

5 SDS not available
Machine is totally dead
Switch CON-
CON- CONEMS Possible cause
KEYSW switches
on (listen)
YES Continue with description: CONCOMEMS ON
NO Continue with next descriptions: CONCONEMS
OFF
Note: For all next tests the switch CONKEYSW must remain ON!
CONCONEMS OFF

on Terminal block
NO Ask assistance of local electrician
CONCONEMS OFF

on SSR PBA, connec-
tor X9 - 1 and 3
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 Possible cause

between TP2 and 3
> 20 V DC
NO SSR PBA defect
YES CONKEYSW defect
CONCONEMS defect
Electrical connection between SSR PBA and
CONKEYSW
Electrical connection between SSR PBA and
CONCONEMS
CONCONEMS ON

on CONSUPLV G1-1
and 3
NO Electrical connection between SSR PBA and CON-
SUPLV
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

(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

CONCONEMS ON
Disconnect MIXED SUPPLY G2 and G3

(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 CONLVSUP defect
printer)
Electrical connection between CONLVSUP and
CONSOLE CPU PBA
YES CONSOLE CPU PBA defect

Console Firmware defect
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 dis-
plays) are functioning.

Electrical connection between SUPPLY TL Lamp is off
TL INVERTER PBA and LCD
Electrical connection between CONSU- TL Lamp is off
PLV and SUPPLY TL INVERTER PBA
Electrical connection CONSOLE CPU TL Lamp is on
PBA and LCD
CONSOLE CPU PBA defect TL Lamp is on
LCD defect TL Lamp is on
SUPPLY TL INVERTER PBA defect TL Lamp is off

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, qual-
ity 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 out-
side 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 re-
turn 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 mani-
fests itself in toner contamination just around the position of printed informa-
tion, 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 Infor-
mation 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 im-
ages 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 ma-
chine 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 for-
mats. 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 (de-
fective 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-

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 Copy quality Action(s)

(targeted lifetime)
Drum 1.scratches-----> white lines/spots
---------------------> replace drum
2.(other) pollu-
tions (talc)-----> spots, background,
---------------------> new clean procedure
3.wax-----------> see IB
9700/9800-1012-> new wax clean pro-
cedure
Fuser roller 1.damages-----> white spots/areas

(>100.000 lm) ---------------------> replace fuser roller
2.swelling in the
middle ---------> skeleton at the sides
--------------> also check (life-
time) press roll
cleaners
Pressure roller wear-out format
(>75.000 lm) wise ------------> skeleton in the mid-
dle ------------> use test 52; check
also (lifetime) press
roll cleaners
Fuser roller cleaner cleaner full / ille-
(720/900 black gal toner
images) flow------------> run over, bumping
---------------------> check causes,
replace cleaner
exceeded life-
time (black
images, error
06902) ---------> ---------------------> preventive replace-
ment of the cleaner
total stop (error
06105) ---------> ---------------------> replace cleaner
ed.5 Faults 161

Failing consumable Cause Copy quality Action(s)
(targeted lifetime)
Pressure roller cleaner cleaner full / ille-
(320/400 black gal toner
images) flow----------> run over, bumping
---------------------> check causes,
replace cleaner
toner contamina-
tion in the mid-
dle----------> skeleton at the sides
--------------> replace cleaner
exceeded life-
time (black
images, error
06903) ---------> ---------------------> preventive replace-
ment of the cleaner
total stop (error
06106) ---------> ---------------------> replace cleaner
Pressure roller build-up toner contamina-
cleaner tion in the mid-
(< lifetime pressure dle ---------> skeleton at the sides
roller cleaner) ---------------> replace cleaner; also
press. roll hole
cleaner
cleaner full / ille-
gal toner
flow------------> bumping after a
cold start up------> replace cleaner; also
press. roll hole
cleaner

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

OFF OFF OFF Directly after switching on
2nd CPU does not boot (e.g. bootprom incor-
rectly inserted, service switch on). The control-
ler stays in hardware reset.
Also the error code 20811 will be displayed.
OFF OFF OFF After the selftest is finished:
All modules okay
ON OFF OFF OLB board in extension slot A defect.
OFF ON OFF OLB board in extension slot B defect.

ON ON OFF OLB board in extension slot C defect.
OFF OFF ON OLB board in extension slot D defect.
ON OFF ON OLB board in extension slot E defect.
OFF ON ON OLB board in extension slot F defect.
SEE Note
ON BLINK ON Mother board error
BLINK OFF OFF Mem. Frame Buffer 1_ SIMM 1 error, 20901
OFF BLINK OFF Mem. Frame Buffer 1_ SIMM 2 error, 20901
BLINK BLINK OFF Mem. Frame Buffer 1_ SIMM 3 error, 20901
OFF OFF BLINK Mem, Frame Buffer 2_ SIMM 1 error, 20901
BLINK OFF BLINK Mem. Frame Buffer 2_ SIMM 2 error, 20901
OFF BLINK BLINK Mem. Frame Buffer 2_ SIMM 3 error, 20901
BLINK BLINK BLINK Memory configuration error
BLINK OFF ON Primary DRAM (DLL) SIMM 1 error, 20809
OFF BLINK ON Secondary DRAM (RSR) SIMM 1 error, 20809
BLINK BLINK ON Cabled Hard Disk error
BLINK ON OFF Standard controller Firmware error
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.

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 FE ~Fatal Error~

xx100 - xx199 PE ~Permanent Error~
xx500 - xx599 MRE ~Machine Recoverable
Error~
xx700 - xx799 ORE ~Operator Recoverable
Error~
xx800 - xx899 OWAR ~Operator WARning~

xx900 - xx999 SWAR ~Service WARning~
The presentation of the error message uses always five digits (e.g. 04501):
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 function-
ality until service has solved the error.
Actions taken by the engine and the operator:
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 com-
partment. 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:
Paper roll drawer upper / lower

Upper / lower belt
Actions taken by the service technician:
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 mes-
sage (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 op-
erator 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 prob-
lem. 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

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 er-
rors 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~ 01 - 25
~Analysis tests~ 30 - 39
~System tests~ 40 - 69
~Installation~ ~Installation tests~ 70 - 79
~Registration~ ~Marketing information 80 - 89
tests~ (laptop only)
~Service information 90 - 99
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, pre-
sented 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
Func- Analy- System Instal- Market- Service

tion test sis test test lation ing info info
01 - 25 30 - 39 40 -69 70 -79 80-89 90 - 99
01 DRU 81 Marketing
02 COR counters
04 PHD
05 DEV 40 To cold SDS
06 CTF 41 To warm SDS
07 DCH 42 Service copy mode 70 Install
09 ORG 43 Cut sheet length machine
10 SCA 50 Testprint mode 71 Install engine
11 IMP 51 Testprint adjust 72 Install scan-
12 PRD PHD ner
13 PSF 52 Black mode 73 Install folder
14 PRE 53 1:1 mode 74 Customer
15 PTR 54 DRU ASV test install.
18 FOL 55 DEV unit adjust- 75 Reset consu.
19 Delivery ment
20 INT 56 Adjust scanner
22 CON mode 90 Configuration
23 MAD 57 Adjust ptr/fold1 91 Serial number
24 ACC 93 Paper series
25 CUS 94 Passwords
95 Modification
30 Reset PE & handicaps records
31 Log/res err&ser cnt 96 Language
0 Counters 32 Last error logging
1 Parame- 97 Preset copy
34 Error top ten counters
ters 35 Error counters > 0
2 Input 98 Hour counter
36 Consumable counters
4 Output 37 Parameters settings
6 Special 38 Serv. / mark. counters
7 Adjust 39 Error history (only laptop)
8 Consuma-
bles
9 Info

3 States of the SDS
In SDS 3 states are defined.
The function of these states is that the service technician, depending on the ma-
chine state, is limited in the possibilities of using the SDS, to avoid unsafe sit-
uations.
The states of the SDS are:
~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 Recovera-
ble 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~:
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:
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 han-
dling 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.

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: used for:
<START> going to next screen

start selected test
confirm input values
ending tests
<CORRECTION> immediately ending tests

going back to previous
screen
<0> .. <9> buttons for input number

<SCROLL UP> scrolling backwards

<COPY LIGHTER> scrolling backwards
<SCROLL DOWN> scrolling forwards

<COPY DARKER> scrolling forwards
scrolling forwards
<ZOOM STEP UP> input value positive
<SCROLL UP> input value positive
<ZOOM STEP DOWN> input value negative
<SCROLL DOWN> input value negative
The service engineer can use a remote switch to activate output and special
tests, this switch uses the function of the <START> button.

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 ma-
chine 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: Warnings:
Drum (l.m.) : 5040 01901 DRUm temp. too low: DRUFANTEMPSE
Fuse roller (l.m.) : 104271
Pressure roller (l.m.) : 2830
Fuse roller cleaner(bl.im.) : 285
Press. roll. hole cl.(bl.im.) : 142
Date counter reset: 21 feb 96

Copies since counter reset: 504
Software vers: Cons. 1.2, Eng. 1.2

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 ver-
sions.
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.
MACHINE : zero SECOND ENTRY for testmode screen
C for first entry screen
Automatic self test:
22-6-08 input Diagnoses
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 for second entry screen
TESTMODE : 30-39 analyse info 01-08 process functions

FUNCTION : 09-11 original functions
TESTTYPE : 12-21 paper functions
TESTNUMBER : .. 22-29 general functions
30-39 analyse info
40-69 system tests
70-79 installation
90-99 service info
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.

~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 Enter function or press

FUNCTION : cold C for testmode screen
Testmode : 01-08 Process functions 01 Drum

Function : .. 02 Corona
Testtype : . 04 Printhead
Test number : .. 05 Developing
06 CTF
07 Discharging
... 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)
MACHINE : cold Testtype Enter testtype or press

FUNCTION : cold
C for testmode screen
Testmode : 01-08 Process functions 0 Counters

Function : 04 Printhead 1 Parameters
Testtype : . 2 Inputs
Test number : .. 4 Outputs
6 Special
7 Adjustments
8 Consumables
9 Info
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.
Enter new value, zoom for + or -,

MACHINE : cold Test number to save & stop,
Function : cold Test active to stop.
C
Testmode : 01-08 Process functions
Function : 04 Printhead
Testtype : 1 Parameters
Test number : 01 Light-intensity PHD
value: : 50
min. value : 0
max. value : 255
new value : ...
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 press-
ing <START>.
When scrolling through the list, the error type and the error number are pre-
sented immediately.
1 ~Parameter tests~:
These tests can be read out and values can be changed.
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.

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.
The value is displayed: OFF = not active, ON = active.
A buzzer gives a signal when the input is active. Dont forget to activate or de-
activate the sensor for correct checking.
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.

Press <START> to activate the test.
The SDS state changes from Warm to Cold, the display shows the momen-
tary 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.
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.

Start the test with the <START> button or the remote switch, TEST
RUNNING is displayed, after the test TEST DONE is displayed.
8 ~Consumable tests~:
These tests show a list from the used consumables with their quantities.

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.
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.

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 Enter testnumber or press
Testmode : 30-39 Analysis info 30 Reset PE & handicaps

Function : 31 Log/Res. err & ser. cnt
Testtype : 32 Last error loggin
Test number : -- 34 Error top 10
35 Error counters > 0
36 Consumable counters
37 Parameter settings
38 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 & handi- Active PE errors & handicaps are
caps~ 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 dis-
played:
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
34 ~Error top 10~ The last 10 errors or warnings are dis-

played
Errors are sorted to absolute or rela-
tive numbers.
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
35 ~Error counters > 0~ 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

Analyse Name
info tests
36 ~Consumable Name, actual value and (if necessary)
counters~ the norm value are displayed.
These counters are not reset with test
31
37 ~Parameter settings~ Name, min., max., and actual value
are displayed
38 ~Serv. / Mark. counters~ Information about jobs and used
material is displayed
nr of jobs
nr of plot jobs
nr of upload jobs
nr of copy mem overflows when cop-
ying
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
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 C to leave test 1/3
Testmode : 30-39 Analyse info

Function : --
Testtype : --
Test number : 32 Last error logging
32.3 last error in service mode

H Error Name Cnt CopyCnt Date hh:mm:ss
0 23501 Speed MADMO out of range 1 14505 26mar96 09:10:45
0 18904 FOL1 lift roller error 1 14505 26mar96 12:00:16
0 12718 Chip.: PRDULEADSE too late at / free 1 14424 23mar96 16:00:23
0 25722 Powerdown in run 0 14424 23mar96 15:55:06
0 15701 Upper/lower paper roll draw open 0 14424 23mar96 15:52:55
0 12512 Too few pulses PRDULENSE 2 14424 23mar96 15:50:36
0 12515 Speed PRDUFEDMO1 too high 1 14424 23mar96 15:50:34
0 12705 PRDULEADSE1 too late free 1 14424 23mar96 15:50:29
0 12512 Too few pulses PRDULENSE 1 14424 23mar96 15:50:20
1 15705 Speed PTRMO/FOL1INMO out of range 3 14410 15mar96 11:22:33
... scroll for more ...
H 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).
Error The error code is displayed.
Name Gives the description of the error.
Cnt Number of errors since last visit.
Copy- Value of the copy counter on the moment the error occurs.
Cnt
Date Date when the error occurs.
hh: Time when the error occurs

mm:ss
On next page is another screen example presented.

Presented screen example is: test 34 Error topp 10.
MACHINE : zero Test number


Function : --
Testtype : --
Test number : 34 Error top 10
34.1 absolute error top ten

N Error Description Cnt Usage Relative
1 22004 Watchdog: Scanner failure 22PBA02 32 583 1 : 18
2 09703 Original too late at ORGPJSE 5 583 1 : 116
3 18703 Distance FOL1 copies too small 3 800 1 : 266
N Position in the top 10 list.
Error The error code is displayed.
Name Gives the description of the error.
Cnt The number of errors since last visit.
Usage 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 -
Rela- Result of the usage divided by absolute

tive
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 previ-
ous 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.

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 avail-
able, 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


Function :
Testtype :
Test number : 36 Consumable counters
tstnr. Counter name value norm value

01801 Drum (lm) 5040 --
02801 Corona pin array (lm) 5040 200000
06801 Fuse roller (lm) 104271 --
06802 Pressure roller (lm) 2830 --
06803 Fuse roller cleann. (bl. im.) 285 720
06804 Press. roll. hole cl. (bl. im.) 142 300
... 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.
Select a test number or scroll to the test number.

Activate the test with the <START> button, go back to the testmode screen
Testmode : 40 - 69 System tests 40 To cold SDS

Function : 41 To warm SDS
Testtype : 42 Service copy mode

Test number : .. 43 Cut sheet length
50 Testprint mode
51 Testprint adjust PHD
52 Black mode
53 1 to 1 mode
54 DRU ASV test
55 DEV unit adjustment
56 Adjust scanner mode
... Scroll for more...

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 Name
tests
40 ~To cold SDS~ Machine switches to cold SDS
41 ~To warm 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/WARM-
ING UP, WARM.
Stop the test with <CORRECTION>.
42 ~Service copy mode~ After activating this test, the machine

is ready for use as in operator mode.
An icon in copy counter shows a pick-
lock (warning machine still in SDS).
43 ~Cut sheet length~ Setting of necessary cut sheet length.

Cut sheets are used for adjustments
checking.
Used in several functions.
50 ~Testprint mode~ Copy with test patterns of black

strokes (see test 51).
51 ~Testprint adjust Copy with test patterns of black /

PHD~ white and grey strokes.
(see ~Testprint adjust PHD~ (every
service visit) on page 301 and see
~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 Name
tests
53 ~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).
54 ~DRU ASV test~ Preventive check of drum future dete-

rioration (see ~DRU ASV test~ on
page 302, function 01-DRU).
55 ~DEV unit adjust- Copy with black image of 30 cm

ment~ length and thin black line in the centre
of the white area.
(see ~DEV unit adjustment~ on
page 301, function 04-DEV).
56 ~Adjust scanner Copy of the (service test) original with

mode~ background and 3 cm white stroke at

the leading and trailing edge.
(See ~Original length correction~

on page 301,
~1 : 1 Image length correction
scanner~ on page 302,
~Scanning leading edge correc-
tion~ on page 303, and
~Scanning trailing edge correc-
tion~ 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).

11 ~INSTALLATION~ tests (70 - 79)
The installation screen appears when in the testmode screen a number between

Select setting with the <SCROLL UP> and <SCROLL DOWN> buttons.
Adjust / confirm setting with the <START> button.
Testmode : 70-74 Installation 70 Install machine

Function : 71 Install engine
Testtype : 72 Install scanner
Test number : .. 73 Install folder
74 Customer install
... Scroll for more ...
126 TSM Oc 9800 SDS

The following INSTALLATION tests are available:
Installa- Name Test

tion tests number
70 ~Install 22-6-06 ~Init BBR ENGINE~
machine~ (Battery Backup Ram)
22-6-07 ~Init BBR CONSOLE~
90 ~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)
95 ~Modification records~
on page 131)
97 ~Preset copy counters~
see ~SERVICE info~ tests (90 - 99)

on page 131)
98 ~Hour counter~
see ~SERVICE info~ tests (90 - 99)
on page 131)
71 ~Install 06-1-01 ~CTFREFTEMPSE resistance low

engine~ (Ohm) ~
Enter resistance value from sticker
06-1-02 ~CTFREFTEMPSE resistance high
(Ohm)~
Enter resistance value from sticker
06-7-01 ~Pressure roller torque~
approx. 5 min. when the machine is in
stand-by
(see ~Pressure roller torque~ on page
301, function 06-CTF)
43 + ~Cut sheet length~
12-1-01 ~Offset cutting length PRDU~
(see ~Offset cutting length PRDU~
on page 307, function 12-PRD)
43 + ~Cut sheet length~
12-1-02 ~Offset cutting length PRDL~
(see ~Offset cutting length PRDL~

Installa- Name Test
tion tests number
51 + ~Testprint adjust PHD~
04-1-01 ~Light intensity PHD~
(see ~Testprint adjust PHD~ (every
service visit) on page 301, function
04-PHD)
(see ~DEV unit adjustment~ on page
301, function 05-DEV)
53 + ~1 : 1 Image length corr. engine~
06-1-03 (see ~1 : 1 Image length cor. engine~
on page 301, function 06-CTF)
53 ~1 to 1 mode~
12-1-03 ~PRD leading edge correction~
(see ~PRD leading edge correction~
53 + ~1 to 1 mode~
13-1-01 ~PSF leading edge correction~
(see ~PSF leading edge correction~
on page 301, function 13-PSF)
72 ~Install 10-7-01 ~TL intensity adjust~, 6 min.

scanner~ (see TL intensity adjust on page
301, function 10-SCANNER)
09-1-01 ~Original length correction~
(see ~Original length correction~ on
page 301, function 09-ORIG.)
09-1-02 ~1 : 1 Image length correction scanner~.
(see ~1 : 1 Image length correction
scanner~ on page 302, function
09-ORIG.)
09-1-03 ~Scanning leading edge corr.~
(see ~Scanning leading edge correc-
tion~ on page 303, function 09-ORIG.)
09-1-04 ~Scanning trailing edge corr.~
(see ~Scanning trailing edge correc-
tion~ on page 304, function 09-ORIG.)
73 ~Install 18-1-01 ~Diameter roller FOL1INMO~

folder~ (value on roller/installation sheet)
18-1-02 ~Dist. FOL1STARTSE - FOL1 roll.~
(value in logbook/installation sheet)
128 TSM Oc 9800 SDS

Installa- Name Test
tion tests number
18-1-03 ~Diameter roller FOL2INMO~~
(value on roller/installation sheet)
18-1-04 ~Dist. FOL2STARTSE - FOL2 roll.~
(value in logbook/installation sheet)
57 ~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)
74 ~Cus- 93 ~Paper series~

tomer (see ~Paper series~ on page 130)
install.~
94 ~Passwords~

on page 131)
96 ~Language~
on page 131)
25-6-01 ~Fill default stamp strings 3 - 10~
(see SDS on page 201, function
25-CUSTOMER / ENV.)
18-1-05 ~Overlap correction FOL1 mm~
18-1-06 ~Max. nr. of copies on FOLO belts~
19-1-01 ~Max. nr. of copies in HCS bins~
25-1-01 ~Stamp positions for folding methodes
till DIN and Ericson~
25-1-12
42 ~Service copy mode~
(see ~SYSTEM~ tests (40 - 69) on
page 123)
75 ~Consum- Reset all the consumable counters

ables
counters~
Switch the scanner and engine OFF and ON again after you have finished the
INSTALLATION tests.

Configuration
Table 1 ~Configuration~ (test 90)
Memory doc memory set memory
Mem. size 36 MB 72 108 144
Clock 12 h clock 24 h clock
Value input inches metric
Copy counting meters square meters feet square
method feet
Original width 8 sensors 5 sensors
detection
Nr. of paper 4 rolls
rolls
Stamp selectied No Stamp Stamp
Folder No Folder 1 and 2 Fold 1 fold output
Deposit belts no belts 1 belt 2 belts
Punch unit No Yes
Reinforce unit No Yes
Longcopy No Yes
escape unit
High Capacity No Yes
Stacker
Copy No Yes
Plot No Yes
Upload No Yes
Controller type EPC (embedded) FBBS (embedded) DRI (external)
Primary (Vec- No plot 16 Mb 32 Mb
tor) cpu RAM
Frame buffer No plot 48 up/to 192 Mb in
memory size steps of 16 Mb
B1 paper size B1 = 700 mm B1 = 707 mm
Drum fan rota- No Yes
tion sensor
~Paper series~
Table 2 ~Paper series~ (test 93)
Paper size DIN, DIN and CARTO, only 8.5 inch serie,
mixed 8.5 and 9 inch serie
Number of chips roll 1 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

Select setting with the <SCROLL UP> and <SCROLL DOWN> buttons.
Adjust setting with the <START> button.
Testmode : 90-99 Service info 90 Configuration

Function : 91 Serial number
Testtype : 93 Paper sizes

Test number : .. 94 Passwords
95 Modification records
96 Language
97 Preset copy counter
98 Hour counter

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
91 ~Serial number~ Machine serial number
93 ~Paper series~ Paper size configuration setting (see
~Paper series~ on page 130)
94 ~Passwords~ Key operator and system administrator
password setting.
Default is 98000
95 ~Modification Modification records for
records~ 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.
96 ~Language~ Language setting:
Dutch / UK English
German / French
US English / Spanish
Danish / Italian
Swedish / Norwegian
Finnish/Portuguese
97 ~Preset copy Copy counter setting:
counters~ selection:
meters / m2 / feet / feet2
98 ~Hour counter~ Hours that machine has been switched
on
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:
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).

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:
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, informa-
tions 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 cor-
rectly with the ST application.
The main reasons why you should use ST are:
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 ed-
ited 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 with-
out 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 main-
tenance times.
Preventive maintenance. With ST you can execute preventive maintenance
because you can see the evaluation of faults per Cas-group per length me-
ters/originals etc. during the previous machine-visits.
Machine data. After a firmware-update (console or engine) or a PBA ex-
change (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-pa-
rameter 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 organ-
isation.
3 Working with ST during a normal machine visit.

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 ma-
chine 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 lap-
top 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 ma-
chine-logfloppy execute: Making a machine logfloppy at the end of this
chapter, otherwise skip this chapter.
5 Type at your DOS-prompt: st <Enter>

A screen similar as the next box, Main Menu, should appear.
Oc ST 5.3 Main Menu 13/02/96 16:22
Report
Logbook
Analysis
M&s
Config
eXit
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
Import
Datadump from Datadump
File: not available Job
Machine -travel
-visit
-tasks
-hours
-parts
-save
eXit
F1=Help
4 Select machine. The datadump from the machine to the laptop is made.

5 Select Job. A screen similar as the next box, Create Service Report, should ap-
pear.
Oc ST 5.3 Create Service Report 16/01/96

08:48
+ Job + + +
Jobnumber : Billable : Import
Modelseries : Datadump
Config.type : 9877 Job
Serial number : 0987700115 travel
Customer : visit
Cascode 01 : tasks
Cascode 02 : hours
Cascode 03 : parts
SDS message : save
eXit
+ +
+ +
F1=Help F8=Invoice
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 configura-
tion-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

Making a machine logfloppy.
The machine-logfloppy contains all the history of the machine. It should al-
ways 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:
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.
Insert an empty 1.44 Mb formatted floppy in the laptop. The diskette will be
labeled ##LOGFLOPPY during saving.

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 Analysis menu 14/02/96 16:22
Machine
Service report
Case-study Stored On ?
eXit 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.

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.

The next screen is similar as the next box, Second-Entry, should become visi-
ble.
OTS4904 ANALYSIS 5.3 13/02/96 16:22
9801.00105 SECOND ENTRY ENTER for testmode screen

ESCAPE for first entry screen
Systematic Call Approch No. of copies: --

Error description Abs
Proess Originals Paper

Date Abs Usage Rel Abs Usage Rel Abs Usage Rel
29/01/96 0 56 -- 1 31 1:....31 1 88 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.

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

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>.

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 updat-
ing 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 com-

plaints, 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.

5 Copy quality problems.
This chapter describes step by step how to solve copy quality problems via ST,
starting from the First Entry screen.
For example: totally black copy with framing.
1 <Enter> (2x).
2 Select test 100+ laptop specific info.
3 Select Copy quality.
4 Select Copy quality general.
5 Select Black copy.
6 Select Black Copy framed.
7 <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.

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 Select test 70 - 79 Installation in the ST application.

2 Select test 71 Memory Management.
3 Select test 71.1 Complete Memory.
4 Select Write (to machine/disk).
5 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.

OTS4904 ANALYSIS 5.3 13/02/96 16:22
9801.00105 INSTALLATION INFO ENTER for testnumber

ESCAPE for testtype
Testmode : 70-79 Installation 01 Write to machine

Function : 71.1 Complete memory 02 Write to logfloppy
Testtype : 3 Write <to machine/disk> 03 Write to tempory memory
Test number : 02 Write to logfloppy
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.

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 Make a datadump from the machine to the laptop.

2 Select test 70 - 79 Installation.
3 Select test 71 Memory Management.
4 Select test 71.4 Stamps.
5 Select Read (from machine/disk).
6 Select Read from logfloppy.
7 <Enter>.
8 <Esc>.
9 Select Modify/View.
10 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>.

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 da-
tadump from the laptop to the machine.
OTS4904 ANALYSIS 5.3 13/02/96 16:24
9801.00105 INSTALLATION INFO ENTER for testnumber

ESCAPE for testtype
Testmode : 70-79 Installation 01 Write to machine

Function : 71.4 Stamps 02 Write to logfloppy
Testtype : 3 Write <to machine/disk> 03 Write to tempory memory
Test number : 02 Write to machine
F1=Help
3 Pressing <Esc> (6x) takes ST back to the First Entry screen.

8 No SDS or Datadump available
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.

9 Short overview of the Information and Modification Bulletins.
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+

10 ST general info / hotnews page.
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+

Service Plot Tool
Note: For a complete description of the Service Plot Tool, see Information Bul-
letin 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 or-
igin, 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 . Plot-

ting these well known sample plots proves that the Oc 9800 configuration is
performing well, before the controller is connected to the customer environ-
ment.
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 cus-
tomer.
Oc 9800 Service Plot Test Release 1.0 June 23, 1995 code number 7991.487
Number of copies ......: 1

Media & Roll selection : Press ENTER for sub menu
Pen Widths & Patterns .: Press ENTER for sub menu
Scale, Rotate, Shift ..: Press ENTER for sub menu
Edge correction,Framing: Press ENTER for sub menu
Finishing Attributes ..: Press ENTER for sub menu
Special Features ......: Press ENTER for sub menu
File Format ...........: HPGL

Plotter Type ..........: 7585B
Origin ................: Center
Pen Zero Termination ..: Enabled
Selected HPGL File : >C:\SPT9800\HPGL1-A3.PLT

Configured destination : LPT1
Cursor = Select F1 = Print F2 = View RCF F3 = Quit F4 = Configure

222 TSM Oc 9800 Service Plot Tool

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Technical Service Manual

11.Image processing 557 Settings/Parameters 742 Fan(s)

909 Invertor main drive motor

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

No part of this publication may be reproduced or be made public in any form

1999 Oc-Technologies B.V.

ed.5 Preface 101

Why should you use the Technical Service Manual Oc 9800?

At whom is the TSM Oc 9800 targeted?

This TSM has certainly not been written as a teach-yourself manual.

102 TSM Oc 9800 Preface

This chapter contains a Document Change Request Form (DCRF).

ed.5 Preface 103

We would like to draw your attention to the general warnings, summarised on

2 AVOID ELECTRIC SHOCKS!

3 AVOID MOVING PARTS!

4 This equipment must be earthed.

5 This equipment is not suitable for connecting to an IT-power system, often

7 A blown fuse does not guarantee a powerless situation.

104 TSM Oc 9800 Preface

Whenever a measurement is indicated with the expression approximately or

After every service do the following functional test:

Make a copy of a typical original used by the customer.

ed.5 Preface 105

106 TSM Oc 9800 Preface

06 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5 ed.5

ed.5 Preface 107

8 MODIFICATION / INFORMATION BULLETIN SURVEY

108 TSM Oc 9800 Preface

Chapter / Page Changes

Please attach extra pages if necessary SIGNED : DATE :

Technicians send this request form to : Technical Coordination Department

Technical Coordination please send this Oc-Technologies B.V.

TSM Oc 9800 Contents

DRUm 01000 - 01999 code display

01001 FE: ~DRUmFAN not rotating~

01501 MRE: ~DRUFANTEMPSE open / short-circuit~

01-9-01 R NTC = Possible cause Remark

ed.5 01 Drum 101

01-4-01 DRUFAN Possible cause Remark

01504 MRE: ~DRUMFAN not connected: DRUFANSW~

01-2-01 Possible cause Remark

102 TSM Oc 9800 Diagnostics

01506 MRE: "Too high negative ASV in stand-by"

01507 MRE: "Too high positive ASV val. in run"

ed.5 01 Drum 103

01509 MRE: "ASV init. pulse not detected"

104 TSM Oc 9800 Diagnostics

01-4-01 Drumfan Possible cause Remarks

06-4-05 CONDRI- 1st trans- Possible cause Remarks

ed.5 01 Drum 105

Analysis info tests

30 ~Reset PE & handicaps~

31 ~Log / res err & ser cnt~

32 ~Last error logging

35 ~Error counters > 0~

38 ~Serv. / Mark. counters~

ed.5 01 Drum 201

01-2-01 01M1 DRUm FAN Drum fan switch

01-2-02 DRUM FAN Drum fan rotation sensor

01-4-01 01M1 DRUm FAN- Drum fan PWM

01-4-03 DRUm ASV Drum ASV compensation voltage