2400 GB

Oc
Technical Service Manual
Oc 2400 Family
2375 2400-2465-2475 3075
Code number of the TSM Oc 2400 family

0911400 Complete TSM Oc 2400 family English 0909916 0909938 0909934 0901400 0901409 0109311 0109546 Binder A5 height 60 mm Service Cover 60 mm Tabs A5, 4 sections Function level 1/25 Complete set of Source doc 2400 family Complete set of Diagrams 2400 family CAS-C Oc 2400 family English Parts Catalogue 2400 family
Oc 2400 Family
01. PHOTOCONDUCTOR 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 037 038 039 040 Unit positioning Locking Master Drive roller Transfer roller Bulge and tension roller Exposure plate mechanism Complementary developing rod Cooling roller and carbon brushes Shuttle mechanism Slack compensation mechanism Linkage slack comp. mechanism Set-up mechanism Set-up rod Timing belts and pulleys Gears 01BR1 set-up motor brake 01CL2 transfer clutch 01M1 master cooling motor 01M2 set-up mechanism motor 01SO1 master hole sensor 01SO2 master pulse sensor 01S1 set-up mechanism sensor Glue spots on master Mechanical connections Electrical connections Others 050 051 052 053 054 078 079 080 02PBA01 scorotron power supply Plectra 02M2 scorotron clean motor 02PBA02 scorotron clean driver Gear / housing Mechanical connections Electrical connections Others
03. FRAMING 081 082 083 084 085 086 087 088 118 119 120 Unit positioning Locking 03LA1/7 edge discharge lamp 03C1/C2 capacitor 03PBA01 interval flash 03PBA02 edge discharge
Mechanical connections Electrical connections Others
04. EXPOSURE 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 Glass plate Reflectors Mirror Lens Diaphragm Bellows Drive belt and tension cable Ignition strip Flashlamp cables and sockets ABC sensor 04LA1/2 flash lamps 04M1 optics positioning motor 04M2 exposure cooling motor 04SO1/2 optical sensor 04C1/2 flash capacitor 04FI1 filter flash supply
02. CHARGING 041 042 043 044 045 046 047 048 049 Unit positioning Locking Ozon outlet Corona wires Grid Ozone exhaust unit Locking suction mouth 02M1 ozone exhaust motor 02SO1 ozone exhaust sensor
SYMPTOMS 1 2 3 4 5 6 7 8 9 General copy quality Image position,-deformation, size Spots, stripes, pullution Fusing, finishing (ejection) Original or paper jammed, damaged ... Total stop Control Noise,odour,damage,others 1 2 3 4 5 6 7 8 9
ACTIONS Replace (lifr time) Replace (defective) Installation (missing part) Adjust,correct Repair,fix Clean,dismount Replenish,drain Instruction, installation
Edition 1, April 1997, Code no. 0109311
Confidential Oc-Nederland B.V.Venlo 1997
CAS-C
137 138 139 140 141 142 158 159 160 04PBA01 flash power supply 04PBA02 flash lamp ignition 04PBA03 optic control 04PBA04 ABC control 07. CLEANING 241 242 243 244 245 246 247 248 249 250 251 278 279 280 Unit positioning Locking Cleaning roller Doctor blade Toner brush, dirt, toner clumps Cleaner tray 07BAL1 ballast 07LA1 clean lamp 07PBA01 clean lamp detection
05. DEVELOPING 161 162 163 164 165 166 167 168 169 170 171 172 173 198 199 200 Unit positioning Locking One-way bearing Agitation mechanism Developing roller Doctor blade Toner brush, dirt, toner clumps Toner bridging Toner level mechanism 05M1 agitation motor 05S2 toner level sensor 05M2 cooling fan Mechanical connections Electrical connections Others
10. R.D.F. 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 Unit positioning top-unit Locking top-unit Unit positioning centre-unit Locking centre-unit Separation shoe Separation wheel Separation belt Supply belts DF belt Balance spring DF / centre-unit CFF mechanism Static eliminators Ruler mechanism Original tray Original guide / format detection Tension mechanism, DF belt and locking Timing belts 10M1/2/3/4 solenoids 10M1 DF feeder motor 10M2/4/5/6/7 motors 10M3 separation wheel motor 10M8 set separator motor 10SO1/2/4/5 rotary encoders 10SO1/5 "document present" sensor 10SO3/6/7/8/10/11/12/13/14 sensors 10SO9 CFF hole sensor 10S1 cover-up sensor 10PBA01 RDF control 10PBA02 sensor control 10PBA04/06/09 power control 10PBA05 track speed control 10PBA07 30V power supply 10PBA08 document size sensor Unit positioning belt-frame Rollers, gears and bearings 10PBA03 power control 10M1 Passive deflector Mechanical connections Electrical connections Others
06. T.T.F. 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 238 239 240 Unit positioning Locking Rail,guiding TTF belt Counterpressure belt Bearings Transfuse pressure mechanism Pinch rollers Counterpressure unit cleaner TTF hole cleaner Sheet on TTF cleaner Oldham clutch transfuse pinche Oldham clutch drive 06HE1/2 heater upper / lower 06HE3 heater cleaning roller 06S1 thermostat 06NTC1 NTC TTF 06SM1 TTF run sensor 06CL1/2 transfuse clutch TTF spiral cleaner 06S2 pinch open sensor Mechanical connections Electrical connections Others
Oc 2400 Family
12. PAPERTRAYS 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 478 479 480 Rail Lift mechanism and chain Supply wheel Separation wheel / roll Locking mechanism Side guide Transport rollers Paper path and locking First paper stop Timing belts 12CL2/3 separation clutches 12EM1 paper stop solenoid 12M1/2 lift motors 12M3/4 separation motors 12R1/2 level resistors 12LED1/2 LED's 12SO3/6 sensors optical 12S1/8 sensors 12PBA01/02 paper size sensors 607 608 609 610 611 612 613 614 638 639 640 Bearings Carbon brushes 16EM1 paper stop solenoid 16CL2/3 clutches 16M1 cooling motor 16SO1 sensor optical Strip assy Mechanical connections Electrical connections Others
17. INVERTER 641 642 643 644 645 646 647 648 649 650 678 679 680 Timing belts Bearings Carbon brushes Paper path Transport rollers Decurler 17EM1 solenoid 17CL2/3 clutches
15. PREHEAT 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 598 599 600 Unit positioning Locking Guide mat Timing belts Tensioners Transport rollers Carbon brushes Bearings Preheater / (duplex) opening mech. 15HE1/2 preheater plate 1 15HE3/4 preheater plate 2 15NTC1/2/3 NTC 15S1/2/3/4 thermostat 15S5 preheater door sensor 18. FINISHER FINISHER Oc 2400 / Oc 2475 681 682 683 684 685 686 687 688 689 690 691 692 693 694 695 696 697 698 699 700 701 702 703 704 705 Unit positioning Locking Hinge mechanism top lid Static eliminator Paper stop / delivery mechanism Transport rollers Ball bearings Carbon brushes Timing belts, gears Copy positioning belts One-way bearings Knocker mechanism Locking mechanism stapler Anvil Stapler 35 sheet** Copy guiding fork Paper path 18CL2/5 stapler clutches 18CL4 safety clutch 18EM1/3/4/5 solenoid 18M1/2/4/5 motors 18M3 cooling fan 18SO2/3/5/6/9/11 sensors optical 18S1/2/3/4/5/6 switch 18PBA01 finisher control*
16. DUPLEX / DELIVERY 601 602 603 604 605 606 Positioning funnel Transport rollers Funnel belts Timing belts Tensioners Duplex paper stop
Confidential 1997 Oc-Nederland B.V. Venlo
CAS-C
706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 18PBA02/03 receivers 18PBA04/05 transmitters* 18PBA08 paper size sensor* Bush bearing 18PBA01 finisher adapter** 18PBA02/03 finisher control** 18PBA04/09/11/13 transmitters** 18PBA05/06/08/10 receivers** 18PBA07/12 paper size sensor** Hinge mechanism internal tray** 22PBA13 Low voltage Supply** Stapler 50 sheet** Mechanical connections Electrical connections Others 855 856 857 858 859 860 861 862 863 864 865 866 867 878 879 880 22TR1/2/3 transformers 22PBA01 host CPU 22PBA02 host I/O 22PBA03 shut-off control 22PBA04 panel operating control* 22PBA05 panel operating keyboard* 22PBA06/7 SSR1/2 22PBA08 power supply 22PBA09 24V driver 22PBA10 SSR3 22PBA04 operating panel interface** 22PBA05 Control keyboard** Operating panel** Mechanical connections Electrical connections Others
* Oc 2400 ** Oc 2475 19. COPY RECEIVING UNIT
* Oc 2375, 2400, 2465, 2475 ** Oc 3075 23. DRIVE
721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739 740
Unit positioning Locking Hinge mechanism 19M1 motor tray position 19M2 cooling motor 19S1 switch 19SO1/2/3/4/5/6 CRU sensors 19EM1/2 solenoids Static eliminator Transport rollers Bearings Carbon brushes Toothed belts, gears 19PBA01 CRU control PBA
881 882 883 884 885 886 887 889 890 891 892 893 894 895 896 918 919 920
Timing belt main drive Timing belt standby drive Timing belt finisher drive Timing belt stapler drive Gears Tensioners Bearings One way bearing TTF drive Proces drive units 23M1 standby drive motor* 23M2 main drive motor 23M3 standby drive motor low noise** 23M4 Finisher motor** 23M5 drive assy CRU only** 23PBA03 duplex control PBA** Mechanical connections Electrical connections Others
* without low noise unit ** with low noise unit
22. POWER AND CONTROL 841 842 843 844 845 846 847 848 849 850 851 852 853 854 Main distribution board 22BAL01 ballast 22CO1 copy counter 22FI1/2 filters 22LA2 lamp 22VFD1 VFD display 22LCD1 LCD display 22RL1 main current relay 22RL2 24V relay 22ST1 starter 22S1 key switch 22S2 power on switch 22S3/4/5/6 cover safety switch 22S7 circuit breaker
24. ACCESSORIES 921 922 923 924 925 926 927 928 929 958 959 960 Locking kit Copy control device (CCD) Coin box 24CO1 department counter 24PBA01 CCD interface 24PBA02 department counter interface 24PBA03 PBA standard user bus 24PBA04 stapler supply off line stapler Mechanical connections Electrical connections Others
Oc 2400 Family
25. CUSTOMER/ENVIRONMENT/ SUPPLIES/ INSTALLATION CUSTOMER 961 No fault at arrival 962 Machine incorrectly operated 963 Original 964 970 Others customers ENVIRONMENT 971 972 973 974 975 980 Relative humidity Ambient temperature Interference mains supply to machine Main power supply Others environment
SUPPLIES 981 982 983 984 985 986 990 Paper Specialities Toner Staples Recycled paper Others supplies
INSTALLATION 991 992 993 999 Packing Covers Machine okay
Confidential 1997 Oc-Nederland B.V. Venlo
CAS-C
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PREFACE
PREFACE 1 Copyright notice

This publication is and remains the property of Oc-Nederland B.V. The information it contains is confidential and is solely intended as a personal aid for service personnel in carrying out service activities on the Oc equipment described in this publication. No part of this publication may be reproduced or be made public in any form or in any way whatsoever without the prior written permission of Oc-Nederland B.V.
Oc-Nederland B.V. 1996

Confidential 1997 Oc Nederland B.V.
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PREFACE
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Overview of machine types

Oc 2400 = 1230 + 1240 Oc 2465FIN = 1430 + 1240
Machine type 1240
Machine type 1230 or 1430
Oc 2375 = 1230 + 1241 Oc 2465CRU = 1430 + 1241
Machine type 1241
Machine type 1230 or 1430
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PREFACE
Oc 2475 = 1234 + 1244 stapling capcity 35 sheets

Machine type 1244
Machine type 1234
Oc 2475 = 1234 + 1250 Stapling capcity 50 sheets
Machine type 1250
Machine type 1234
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PREFACE
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Oc 3075 = 1277 +1278
Machine type 1278
Machine type 1277
The Oc 3075 is almost the same as the 2475-50 sheets except: The control panel is the same as the one of the Oc 3045; The design of the Oc 3075 is more rounded than the Oc 2475-50 sheets copier; All languages are intergreted into one eprom. The CFF is an optional.
2375 Copy speed simplex/duplex Stapling capcity (Sheets) Bin(s)
2465CRU
2400
2465FIN
2475/35
2475/50
3075
60/60
65/65
60/40
65/43
75/75
75/75
75/75
35
35
35
50
50
2 During copying
2 During copying
Off-line stapling
Standby
Standby
Standby
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PREFACE
Why should you use the TSM OCE 2400 family?

The Oc 2400-family has been designed and manufactured for the HV market segment (high volume). Customers in this market segment have very stringent requirements in terms of the response time, pricing and quality of service. They also demand a high uptime, i.e. the response time and repair time must be short. The Technical Service Manual, abbreviated to TSM, is one of the tools you need for your work and which will enable you to comply with customer requirements better and more quickly. In a clearly structured and accessible way, the TSM gives you the factual information you need for installation and both corrective and preventive maintenance of this large and complex machine.
4
At whom is the TSM OCE 2400 family targeted?

This TSM has definitely not been written as a teach yourself manual. During the Oc 2400-family 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 of how the machine functions. The TSM and service training course are complementary and are inextricably linked to each other. Taking a service training course without using the TSM is just as incomplete as using the TSM without having learnt how to use and interpret it in a service training course.
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PREFACE
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How is the TSM OCE 2400 family arranged?

On the basis of the tasks to be performed by the service technician, the TSM is arranged in four modules: 1. INSTALLATION 2. CORRECTIVE MAINTENANCE 3. PREVENTIVE MAINTENANCE 4. MISCELLANEOUS
1. Installation
The installation instructions are a summary of all the operations needed to install the complete machine.
2. Corrective maintenance
In order to remedy faults in the machine you must be able: - to name the fault unambiguously - to identify the cause of the fault - to eliminate the cause of the fault - to check that the fault has been remedied. This module - by far the longest - module of the TSM will help you to do these things. Faults which cannot be traced directly and unambiguously to one given function are known as faults at system level. This type of fault is indicated by complaints about copy quality. Faults which can be traced directly and unambiguously to one given function are known as faults at function level. This type of fault is indicated by a fault message in the display on the operating panel accompanied by the machine ceasing to copy. This four-figure fault message (code) is directly related to the CAS group classification (complaint analysis system) and is therefore directly related to the function ! The two figures on the left of the fault message show the number of the function as classified in the CAS group. This explains why the fault messages, SDS tests, sections in the TSM corrective maintenance at function level, parts lists and the CAS card are classified as follows:
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PREFACE
PROCESS 01- Photoconductor 02- Charging 03- Framing 04- Exposure 05- Developing 06- TTF 07- Cleaning ORIGINAL HANDLING 10- RDF
PAPER HANDLING 12- Paper 15- Preheat 16- Duplex COPY HANDLING 17- Inverter 18- Finisher 19- CRU GENERAL 22- Power and control 23- Drive 24- Accessories 25- Environment
The twenty-five sections at function level are all divided into paragraphs in accordance with a set pattern. The page numbering emphasises this pattern.
Paragraph: List of contents - Fault identification procedures - SDS test descriptions - Adjustments - Dis-/assemblies - Functional descriptions - Component locations - Electrical diagrams
Page no.: from 001 from 101 from 201 from 301 from 401 from 501 from 601 from 701
TSM part I and II TSM part I TSM part I TSM part I TSM part II TSM part II TSM part II TSM part I
3. Preventive maintenance
This module comprises the two programmes for preventive maintenance.
4. Miscellaneous
This module comprises: -Technical data -SDS user interface. The tab sheets (in English) make this classification of the TSM even easier to follow.
Conclusion
The compilers of this TSM hope that you will find adequate information so that you can do your work quickly, properly and with a sense of satisfaction on an on-going basis. Clearly, it will always be possible to improve this TSM and it is not impossible that you may find imperfections and/or errors. Oc would be grateful if you would communicate any errors, imperfections and suggestions for improvement to ITC (International Training Centre) in Venlo. There are two ways you can do this as follows:
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PREFACE
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You inform Technical Coordination via the Service Report, Technical Coordination informs SPS (Service Product Support) via the Problem Report/Field Suggestion and SPS informs ITC. You inform ITC directly via the Assessment Form 2 which will be given to you during the service training course. The address is: Oc-Nederland BV Postbus 101 5900 MA VENLO For the attention of: International Training Centre Mr. R. Hendriksma location 8T. We wish you every success!
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PREFACE
General warnings!
We expressly draw your attention to the general warnings summarised on this page. You will find specific warnings further on in the TSM in the descriptions of operations that have to be carried out in dangerous circumstances.
Avoid damaging PBAs via electrostatic discharges. You should wear the wriststrap with code no. 7991.320 and use the antistatic mat with code no. 7991.322.
7
2
Safety warnings!
TAKE CARE WITH LIVE PARTS ! When you start to work on the machine and the machine does not need to be running, switch off the electricity by removing the plug from the socket. TAKE CARE WITH MOVING PARTS ! When you remove panels from the machine, ensure that your fingers do not get caught between moving parts such as chains, cogs and toothed belts. Be especially careful during the startup phase as the machine starts to run ahead of time without warning! This equipment must be earthed. This equipment is not suitable for connection to an IT-power system, often used in stand-alone power systems ( for instance off-shore, mining). When in doubt consult your Technical Coordinator Keep wall mounted socket outlet or power switch easily accessible. A blown fuse does not guarantee a powerless situation. Replace a blown fuse only with correct type and rating. Overrule never the safety of a clixon. When replacing power cord/or main plug, use only components which comply with local regulations. USA only: Main plug shall withstand 20 AMP Before working on the exposure unit, especially the flash lamps and the flash supply, make sure that: - you only work with insulated tools when working on the terminals of the flash capacitors ! - the machine is switched off and the main voltage is disconnected - the flash capacitors are discharged. Both main drive and standby drive motors are provided with an automatic resetable thermal cutout. This may lead to spontaneous running of these motors when after initial overheating the temperature of the motors has dropped below the reset temperature
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4 5
6 7
10
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PREFACE
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Chapter division of the TSM.

PREFACE INSTALLATION CORRECTIVE MAINTENANCE
SYSTEM LEVEL COPY QUALITY FUNCTION LEVEL PROCESS 01- Photoconductor 02- Charging 03- Framing 04- Exposure 05- Developing 06- TTF 07- Cleaning 08ORIGINAL HANDLING 0910- RDF 11PAPER HANDLING 12- Paper 131415- Pre heat 16- Duplex COPY HANDLING 17- Inverter 18- Finisher 19- CRU 2021GENERAL 22- Power and control 23- Drive 24- Accessories 25- Environment
PREVENTIVE MAINTENANCE MISCELLANEOUS SDS USER INTERFACE TECHNICAL DATA
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EDITION REVIEW
EDITION REVIEW
From now on the Technical Service Manual (TSM) Oc 2400 family contains all information on the Oc 2375/2400/2465CRU/2465FIN, Oc 2475 and Oc 3075. For this reason we changed the name into TSM 2400 family. Because the TSM has grown too thick, we have decided to split the TSM into two parts, called part I and part II. The division of the parts are based on an experienced service technician (Oc 2400 family). Part I contains information which is used very frequently. Part II contains information which is not needed so frequently. In the header and footer you can find an indication to which part of the TSM, the section belongs. The sectional and functional division of the TSM is still the same as it used to be. The TSM is supplied in two parts, is for part I including tabs and part II without tabs, so please use the tabs you already have in your old TSM for part II.
PART I CAS-C Preface Edition review Copy Quality List of contents Diagnostic SDS test description Adjustments Electrical diagrams Partslist
PART II Preface Edition review Installation List of contents Dis/assembly Functional Description Component location Maintenance Miscellaneous Technical data
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EDITION DATE ed.8
CHAPTER
SECTION -complete - Contents - Functional description - Component location
January 1997 Preface 22-Power and Control
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June 1996Preface 18-Finisher 2475/50 22-Power and Control
-complete -complete -Component location - complete - complete - complete - complete - complete - complete - Contents - Diagnostic - SDS test description - Adjustments - Dis/assembly - Functional description - Component location - Electrical diagram
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April 1995
Preface Installation Copy quality Maintenance Miscellaneous Technical data ALL CHAPTERS
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EDITION REVIEW
The review of the TSM 2400 family until ed.6, april 1995 : EDITION DATE ed.0 june 1991 CHAPTER Copy quality ALL CHAPTERS ed.1 june 1991 Preface Installation 01 Photoconductor SECTION - complete - Diagnostic - complete - complete - Contents - SDS test description - Adjustments - Dis/assembly - Functional description - Component location - Contents - SDS test description - Adjustments - Functional description - Component location - Contents - SDS test description - Adjustments - Functional description - Component location - Contents - SDS test description - Adjustments - Functional description - Component location - Contents - SDS test description - Functional description - Component location
02 Charging
03 Framing
04 Exposure
05 Developing
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EDITION DATE ed.1 june 1991
CHAPTER 06 TTF
SECTION - Contents - SDS test description - Adjustments - Dis/assembly - Functional description - Component location - Contents - SDS test description - Functional description - Component location - Contents - SDS test description - Adjustments - Functional description - Component location - Contents - SDS test description - Adjustments - Dis/assembly - Functional description - Component location - Contents - SDS test description - Adjustments - Dis/assembly - Functional description - Component location - Contents - SDS test description - Adjustments - Dis/assembly - Functional description - Component location
07 Cleaning
10 RDF
12 Paper tray
15 Preheater
16Duplex/delivery
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CHAPTER 17 Inverter
SECTION - Contents - SDS test description - Adjustments - Functional description - Component location - Contents - SDS test description - Adjustments - Dis/assembly - Functional description - Component location
18 Finisher
22 Power and control- Contents - SDS test description - Adjustments - Dis/assembly - Functional description - Component location 23 Drive - Contents - SDS test description - Functional description - Component location - Contents - SDS test description - Accessories - complete - complete - complete - Electrical diagram
24 Accessories
Maintenance Miscellaneous Technical data ed.2 june 1991 ALL CHAPTERS
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EDITION DATE ed.2 september 1991
CHAPTER 10 RDF
SECTION - Contents - Diagnostic - SDS test description - Adjustments - Dis/assembly - Functional description - Component location - Electrical diagram : number 701B and 703B.
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september 1991
10 RDF
NEW CHAPTER : OC 2375
EDITION DATE ed.0 march 1992
CHAPTER
SECTION
19 Copy Receiving Unit CRU Oc 2375 - Contents - Installation - Diagnostic - SDS test description - Adjustments - Functional description - Component location - Electrical diagram
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July 1992
ALL CHAPTERS ALL CHAPTERS Copy quality
- Contents - Diagnostic - complete SECTION - complete - complete - complete - complete
CHAPTER Preface Installation Copy quality Maintenance
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EDITION REVIEW
EDITION DATE Ed.5 june 1993
CHAPTER Miscellaneous Technical data ALL CHAPTERS
SECTION - complete - complete - Contents - Diagnostic - SDS test description - Adjustments - Dis/assembly - Functional description - Component location - Electrical diagram
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CURRENT STATUS SHEET

CHAPTER Preface Installation Copy quality TOCI TOCII DIAG 01-Photocond. 02-Charging 03-Framing 04-Exposure 05-Developing 06-TTF 07-Cleaning 10-RDF 12-Paper 15-Preheater 16-Duplex-Del 17-Inverter 18-Finisher ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.8 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.6 ed.6 ed.6 ed.6 SDS ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.6 ed.6 ed.6 ed.6 TOC SECTION ed.8 ed.6 ed.6 ADJU DISA ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.8 ed.6 ed.6 ed.6 FUNC COMP ELEC ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.8 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.8 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.6 ed.7 ed.6 ed.8 ed.6 ed.6 ed.6
18-Fin 2475/35 ed.6 18-Fin 2475/50 ed.7 19-Cru 22-Pow &Cont 23-Drive ed.6 ed.8 ed.6
24-Accessories ed.6 25-Environment ed.6 Maintenance Miscellaneous Technical data
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Overview of implemented information and modification bulletins
Modification bulletins : 1230-02 1230-11A 1230-13 1230-21 1230-23 1230-26 1230-27 1230-31 1230-39A 1230-40A 1230-42A 1230-44 1230-48 1230-49 1230-52 1230-75 1234-99 1240-03 Software release 2.1 HOST-CPU 22PBA01 Software release 3.1 Prevention of scorotron grid pollution Bias voltage on developing roller Software release 4.2 1. Improved guiding paper in sec. preheater 2. Improved positioning sec. preheater Spiral cleaner Software release 5.1 First paperstop P/N kit 5799.837 Open TTF pinch in standby Software release 6.1 Software release 7.1 Software release 2.1 Increased engine speed: 65 cpm RRDF modification kit 50 sheets stapling finisher Finisher control PBA 18PBA01.
Modification status 3075 The modification status of the 3075 starting with zero. Meaning: All modifications from the Oc 2475; . 1234-1 up to and including 59 and 1234-99 and 1244-1 up to and including 12, are implemented
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Information bulletins : 1230-02 Department counter installation 1230-03A Copy control interface 1230-06 Description of new adjusting tools 1230-17 Master clean lamp detection 1230-23 Key counter interface 1230-26 Subframe mounting tools 1230-30 22PBA06 SSR1 1230-41 Adjustment 10M6 and 10M7 of the RDF 1230-50 Redesign RDF 1230-52 Locking kit p.n. 1034.298 1230-53A Right hand paper door adjustment 1230-55 Position of the front and rear frame plates of TTF unit 1230-59 Programme disturbance caused by ESD 1230-63 Possible causes of error code 1230-66 Copy control interface adapter 1230-69 Error code 612 1230-72 Glass strip (Z-1030 index 16) 1230-74A Separation shoe of new RDF 1230/34-44C Summary PBA changes 1230/34-91 Code 1233 and 1234 1230/1430-95 Off-line stapler Oc 74 1240-02 1240-07 1240-09A 1240-10 1241-01 Adjustment stapler solenoid 18CL2 Adjustment 18-13 of the finisher Stapler unit p.n. 1023.470 Adjustment 18-2 sideways tolerance stapler Safety information.
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SAFETY DATA
It is the responsibility of this manual to be informed about the latest edition of Safety Data Sheets with safety and environmental information when working with Oc equipment and materials. For information about the Safety Data Sheets we"ll advise you to - contact your local safety co-ordinator for a full set of Safety Data Sheets - look for the safety information in the user manual. For the Oc 2400 family the following Safety Data Sheets are available: Product Safety Data Sheets: Oc 2400 family 50Hz Oc 2400 family 60 Hz Material Safety Data Sheets: Oc Cleaner K Oc Cleaner O Oc Cleaner R
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TSM 2400 family
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ITC DOCUMENTATION CHANGE REQUEST FORM

Requested by: Approved by: DOCUMENT TO BE CHANGED Manual: Edition: Write brief description of the changes requested Page Changes Country: Department: Tel:
Please use print-script to fill-out this form for error free handling
Please attach extra pages if necessary Technicians send this request form to: Technical Coordination please send this request form to:
SIGNED:
DATE:
Technical Coordination Department
Oc - Nederland B.V. Attn. of: Manager International Training Centre - Service P.O. Box 101 5900 MA Venlo The Netherlands
inst
INSTALLATION
INSTALLATION 1 Introduction
A copier of the Oc 2400-family is delivered in one box. The copier also requires a language kit, and in certain areas, a 2-phase power supply kit. See the Contents of Box and Kits section for details. The installation is divided into six sections: - Contents of box and kits - Unpacking the box - Preparing the copier
- Connecting the mains power - Start up WARNING: WHEN THE SUBFRAME IS REMOVED, DO NOT PULL OUT THE MASTER SECTION, THE TTF SECTION AND THE PAPERTRAYS AT THE SAME TIME, OR THE COPIER WILL FALL FORWARD.
CAUTION: The exposure section must be in front when moving the copier over a large distance. CAUTION: When positioning the copier, do not push against the RDF covers or original receiving tray. Push against the lower covers. CAUTION: Do not position the copier next to a heater. The master inlet temperature may not exceed 34C.
ed.6 Part II
TSM 2400 family
Installation 1
INSTALLATION
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Contents of box and kits

The contents of the box and kits are listed below. The power supply kit will be provided by the operating company, if the standard power supply in the Oc 2400-family is not suitable for the local mains voltage or phase. The language kit will be added from local stock. Box - Copier : 1 1 1 1 tube containing a DF belt box containing a master box of F10 toner (6 bottles) box containing: 1 original receiving tray 2 spacers 1 handle
- 1 box containing: 3 staple rolls (not for Oc 2375) Language kit: - 1 EPROM - 1 user manual - 1 overlay Stickers 2-Phase kit (optional): - 2 circuit breakers - 1 filter - 1 type label
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Part II ed.6
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INSTALLATION
3
3.1
Unpacking the copier

Remove the box from the pallet. Remove the 4 M12 bolts which hold the copier to the pallet. Use a 19mm key. Remove the copier from the pallet using the depalleting tool (Transport Manual). Move the pallet aside. Lower the copier until it rests on its own wheels. Pack the 4 M12 bolts in a plastic bag. Store the plastic bag in the rear main frame at -A- (see figure below).
inst02
3.2. Remove the three boxes and one tube that are taped to the copier. 3.3. a)Remove the following covers: - front middle cover, - front right safety cover (behind door), - left cover, - rear left cover, - rear right cover.
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Installation 3
INSTALLATION
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b) -
Remove the following: Tape on original return path. Tape between DF unit handle and cover. Foam supporting DF unit frame. Tape holding power cord on top of subframe. Tape in manual bypass. Tape in paper tray (upper and lower). Foam holding separation unit. Cardboard in separation (UPT/LPT). 6 tapes and 2 pieces of foam (front and rear) from the master handling section. Tape on scorotron handle. Tape on framing unit handle. Foam between frame and developing unit. Tape on cleaning unit handle.
- The master installation tool at the left hand side of the copier. 3.4 Move the bracket in the exposure section from the transport position to its installed position: - Loosen 2 bolts -A-; - Move the bracket -B- to the right and set the lens block free; - Tighten 2 bolts -A-.
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Part II ed.6
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INSTALLATION
3.5
Move the transport brackets (front and rear) that support the master section from the transport position (down) to the installed position (up and left): - Loosen the two bolts -A-; - Move the bracket upward (front and rear); - Tighten the bolts -A- again.
inst04
3.6
Move the transport brackets (front and rear side of cleaning unit) that hold the cleaning unit from the transport position to the installed position. Front side: - Remove the two bolts -A-; - Remove the bracket -B- Turn over the bracket and replace it in the installed position; - Mount the two bolts -A- again.
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Installation 5
INSTALLATION
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Rear side: - Pull the master handling out of the copier, lift the front side of the rails and support it at the front side with two riems of paper; - Remove the gear -A-; - Remove the two bolts -B-; - Turn over the bracket and replace it in the installed position; - Mount the two bolts -B- again; - Mount the gear -A- again; - Lift the master handling back onto the rails and push it back into the copier.
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3.7
Remove from the finisher: - Tape and foam on top lid; - Foam between staple unit and anvil; - Foam between knocker and frame; - Foam between paper stop and top lid.
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Part II ed.6
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INSTALLATION
4
4.1 4.2 4.3 4.4
Preparing the copier

Install one or two staple rolls. See User Manual. Install the handle of the ozone exhaust unit. Install the master. See Dis/Assembly 01 PHOTOCONDUCTOR Install the Flash Power Supply (04PBA01) if necessary. WEAR ANTISTATIC WRIST STRAP! - Remove the black cover of the supply box. - Remove the flash supply cooling fan (04M2) (one M6 bolt). - Install the flash supply board (04PBA01) (5 bolts) -A-. - Install 3 connectors -B-. Install the DF belt. Install the language EPROM. Load both paper trays. Add one bottle of toner (F10) to the toner hopper. Put toner on the cleaning unit roller. Make sure that the rollers of both the cleaning unit and the developing unit have enough toner. Remove the protective sheet from the display, then apply the control panel overlay.
inst13
4.5 4.6 4.7 4.8
4.9
4.10 Apply the stickers. See left upper corner of the sticker sheet. 4.11 Install the 2 wall spacers at the rear of the copier. 4.12 Put the User Manual in the left front door.
ed.6 Part II
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Installation 7
INSTALLATION
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Connecting the mains power
5.1. CHECK THE MAINS POWER VOLTAGE! The drawings below shows the different mains configurations of the Oc 2400-family. Europe : Europe (with 2-phase kit) : UK and AUS : USA : 1-phase 220V 16A 50Hz, without transformer (see -A-); 2-phase 220V 10A 50Hz, without transformer (see -B-); 1-phase 240V 16A 50Hz, with transformer (see -C-); 1-phase 208/240V 20A 60Hz, with transformer (see -D-, -E-).
-A- Europe
1-phase 220V 16A 50Hz, without transformer.
inst15.gem
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INSTALLATION
-B- Europe (with 2-phase kit) : 2-phase 220V 10A 50Hz, without transformer.
inst18.gem
-C- UK and AUS
1-phase 240V 16A 50Hz, with transformer.
inst16.gem
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Installation 9
INSTALLATION
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-D- USA
inst17.pcx
-E- USA
inst19.gem
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INSTALLATION
5.2
If necessary, install a new power cord.
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-A- Brown -B- Blue -C- Yellow/green
(USA: (USA: (USA:
Black) White) Green)
As the colours of the cores in the mains lead of this equipment may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows: - The core which is coloured green and yellow must be connected to the terminal in the plug which is marked with the letter E or by the earth symbol or coloured green and yellow. - The core which is coloured blue must be connected to the terminal which is marked with the letter N or coloured black. - The core which is coloured brown must be connected to the terminal which is marked with the letter L or coloured red. 5.3 5.4 Connect the main power supply to the copier. Switch on the copier and enter SDS mode.
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Installation 11
INSTALLATION
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6
6.1
Start up
Perform SDS installation routine No. 70 (1) (2) (3) (4) (5) (6) (7) (8) Initialisation BBR: Test 22 6 06 Filling in configuration: Test 90 Filling in machine serial number: Test 91 Adjusting optics (P0): Test 04 1 02 Adjusting optics (P1): Test 04 1 03 Filling in telephone number: Test 92 Filling in paper sizes: Test 93 Filling in password key operator: Test 94 : : : : : : : : skip check/perform check/perform check/perform check/perform perform check/perform perform
6.2 6.3 6.4 6.5 6.6
Remount all remaining covers. Check copy quality and machine performance. Fill the toner hopper. Fill in the log book. Position the copier where required by the customer.
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INSTALLATION
Removal
Checklist for removing an Oc 2375/2400/2475:
Make both paper trays empty; Move the bracket in the exposure section from its installed to the transport position, use SDS test 04 6 07; Move the transport brackets to hold the cleaning unit from the installed position to the transport position, front and rear side; Move the transport brackets to support the master section from the installed position to the transport position, front and rear side; Tape the knocker in the finisher and the finisher assy (Z1820, index 103); Put about 150 sheets (A4, 80g/m2-20lb) on the original glass platen. Lock the DF cover and tape it; Tape all doors; Put the original receiving tray on top of the DF cover. Make sure that the DF cover is not damaged during transport by putting some sheets as protection in between the cover and the receiving tray; Preferably put the copier on a pallet; Put a plastic bag over the copier.
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Installation 13
INSTALLATION
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Splitting the copier

For splitting the copier, tools have been developed. They are delivered together with the copier.They are mounted in the inside of the rear cover of the base machine; Disconnect the main power! WARNING: Use all the tools to split the copier, especially when splitting the Oc 2475 ! Note: splitting the machine can be done with the finisher/CRU mounted.
When splitting the copier, proceed as follows: (see also the sticker on the inner side of the rear cover of the paper section). 8.1. Remove: - middle front cover; - inner cover of preheat section (blue) and cover above the inner cover; - rear covers of the paper section; - rear cover of the base machine and the small cover behind the original tray; - copy receiving tray(s); - black plastic cover behind the lower paper tray at the front and take out the plastic bag. Note: use your wrist strap. 8.2. Disconnect the following connectors of the host I/O board (if applicicable) : 2202CN8/9/10/11/13/15/16/17/22/23/26/30; remove the bundle from the paper section. 8.3. Disconnect the following connectors at the rear: 2209CN3 (of 22PBA09), 22CN8, CN10, EARTH1/3/4/5, N1-1, N2-1, L1-1 and L21. 8.4. Only for Oc 2475: Disconnect the connector 1801CN07 of 18PBA01 and the earth wire; remove the bundle by cutting three tywraps.
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INSTALLATION
8.5. Mount the tools, front and rear, at the bottom of the paper frame (see fig. 1); when splitting the machine, the spring must be positioned in the upper hole -A-. Note : Use the lower holes of support -C- when mounting it at the front side
8.6. Remove the two bolts which attach the paper section to the base machine. 8.7. Mount lever -D- to the rear frame of the machine (see fig. 3). 8.8 Ensure that the HOST I/O section is closed.
8.9. Hold the lever firmly and unlatch the hook, which keeps the machine together. 8.10. Move down the paper section slowly. 8.11. It can be necessary to pull over the paper section slightly, to allow the supports to be pulled into their vertical position. 8.12. Now the base machine can be pulled away from the paper section. 8.13. Before moving the paper section, position the springs in the lower hole -B- to allow the supports to be pulled in their horizontal position.
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Installation 15
INSTALLATION
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Installing a 2-phase kit

In case the Oc 2400 must be connected to a 220 Volt 10 A 50 Hz mains power source a 2 phase kit is available . The 2 phase kit Oc 2400 partno.5600290: Installation of a 2-phase kit is done in two steps: - A removal of the 1-phase parts - B installation of the 2-phase parts A Removal of the 1-phase parts 1 Disconnect the copier from mains supply. 2 Remove the following parts: - Cover rear Z-2540-35. - Loosen bolts A and B (drawing 1). - Remove bolts C and D (drawing 1). - Remove the circuit breaker Z-2210-20. B Installation of the 2-phase parts - Mount the new circuit breaker with the same screws at the same place. - Remount main distribution board and fix it with bolts A, B, C, and D (drawing 1). - Mount filter just below the already mounted filter, (drawing 2) using the 2 tap tites. - Remove the two jumpers from 22RL1 between 22RL1-13 and 22RL1-15 and between 22RL1-1 and 22RL1-3. - Connect the wires according to drawing 3, A and B. wireno. from to A 2002 N L2 B 2026 N - Start connecting the bundle, 40 according to drawing 3, start from C and continue with D, E and F. wireno. from to C 4001 22FI2 line-L 22S7B-2 D 4002 22FI2 line-N N E 4003 22FI2 line-L 22RL1-3 F 4004 22FI2 line-N 22RL1-13 - Connect the mains power cord according to drawing 3. - Place the new type label. - Remount the cover rear z-2540-35. - Connect the machine to the mains power source. 3 Remove the old mains cable from the machine.
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INSTALLATION
FIG. 1
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Installation 17
INSTALLATION
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18 Installation
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INSTALLATION
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Installation 19
INSTALLATION
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Part II ed.6
copyq
COPY QUALITY
COPY QUALITY 1 Introduction

The section on COPY QUALITY contains a range of examples of deviations in copy quality which you can use as a tool for remedying copy quality problems with the Oc 2400-family. 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 (drawing which shows the phenomenon as clearly as possible and an accompanying text), a list of possible causes and the corresponding check procedures/remarks.
2
Starting conditions
If copy quality problems are to be dealt with unambiguously, the following starting conditions must be met:
1. 2. 3. 4. 5. 6. 7. 8.
Remedy any SDS or operator fault message. Switch the machine off and on again; then the main functions are tested and you have a defined starting situation. Use white paper (80 g/m2, A4) as the receiving material unless otherwise indicated. Ensure that the developing unit is filled with the correct toner. (Oc UA3) Clean the original glass. Place the test chart on the correct place on the original glass (i.e. do not use RDF unless otherwise indicated). Make 16 copies and compare the first 8 copies with the second 8 copies. Evaluate the copy quality problem on the basis of these copies.
ed.6 Part I
TSM 2400 family
Copy quality 1
COPY QUALITY
copyq
Tools
It is possible to rule out or pinpoint certain fault causes using a few tests. The description of a copy quality problem indicates when you should use which test.
SDS system tests To judge the toner image on the photoconductor related to the glass original, test 43.1 (charge-develop-no transfer) can be performed. After completing this test the image can be examined by switching the machine of and by taking out the master section. To judge the toner image on the TTF belt, test 43.2 (charge-develop-transfer) can be performed. After this test, the TTF unit can be fold out of the machine. Also the image that recides on the photoconductor after transfer can be examined. Use test 42.3 (functions on/off ) and/or test 42.2 ( securities on/off) to obtain certain system behaviour; e.g. switch off exposure to obtain a black image/copy Erase test This is a test to determine the degree of fusing: Make a black copy (use test 42.3; exposure off). Fold this copy in two with a sharp crease with the black image inside. Unfold the copy and brush over the crease. Evaluate the resulting line. (see 1C, page 7) Optical symptom If a given phenomenon is repeated at the same place on each copy, the problem can probably be localised in the optical section (original glass, mirror, reflectors, lens). You can check this simply by making a reduction: the phenomenon will also be reduced. Master belt symptom When a given phenomenon is repeated at the same place on each 8th A4 copy (image position related), the problem lies with the master belt. N.B. For each case (A4 copying), there are commonly used areas on the photoconductor, but there are also exclusively used areas on the photoconductor. So it is possible that damages only appear in a particular case. TTF belt symptom If a given phenomenon is repeated irregularly (at the same height but not at the same distance from the leading edge), the problem lies with the TTF belt. Cleaning symptom When a given phenomenon changes after 8 copies, the problem lies with the master cleaning unit.
2 Copy quality
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Part I ed.6
copyq
COPY QUALITY
Guidelines
This section provides you with guidelines and values for evaluating copy quality on three main points: 1. evenness/optical density (OD) of the copy. 2. magnification ratio/image position of the copy 3. dirt/damage on the copy 1A. Evenness Using test chart 1, set the exposure so that box A(1) is just not visible. Use the copy lighter key to set the exposure 2 steps higher. Now make two sets of 16 copies of test chart 1: one set with the Oc logo top left and the other set with the Oc logo bottom right. The difference in the corresponding grey wedge may be up to 1 box. 1B. Background Use test chart 1 to set the exposure so that box A(1) is just not visible. There should not now be any background on the copy. If the exposure is increased or decreased by 1 step, there should still not be any background on the copy. 1C. Erasability Make a black copy. Fold this copy in two with a sharp crease. Unfold the copy and brush over the crease. The line thus created should not be wider than 0.3 mm. 2A. Enlargement factor Make a copy of test chart 19 with a magnification of 100%. Measure the diameter of the largest circle at the copy in the feed direction and at right angles to it. The diameter should be 150 1 mm. The maximum difference between the two values is allowed to be 1.0 mm. 2B. Parallelness/trapezoid form Make a copy of test chart 19. Measure the distance between the 6 lines at the top and bottom of the copy. The difference in distance between top and bottom should not be greater than 1.0 mm. 2C. Image position Important guidelines when executing the image positioning adjustments: Machine settings: simplex - simplex no margin shift 100% glass plate: testchart 19 against ruler and at zero point
ed.6 Part I
TSM 2400 family
Copy quality 3
COPY QUALITY
copyq
RDF: testchart 25 against zero stop, close up format slide The image positioning adjustments must be executed in the sequence as indicated to make sure that the adjustments are not interfering. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Ruler position with respect to the original glass, adjustment 10-14 exposure setting, adjustment 04-5 optic setting, adjustment 04-2 transfuse pinch pressure, adjustment 06-2 (Process) transfuse pinch pressure, adjustment 06-1 (Key-stone) interval flash discharge positioning, adjustment 03-2 edge discharge width, adjustment 03-1 paper skew/first paper stop, adjustment 12-1 timing first paper stop, adjustment 12-5 paper skew/ duplex paper stop, adjustment16-1 timing duplex paper stop, adjustment 16-5 zero positioning UPT/LPT, adjustment 12-2 zero positioning manual feed, adjustment 12-3 zero stop RDF original tray, adjustment 10-18 format slide RDF original tray zero stop MDF original feed, adjustment 10-20 The tolerance that the TSM specifies for the various function adjustments are shown under the corresponding adjustment.
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Part I ed.6
copyq
COPY QUALITY
Image position
Visually check if the image position is within the tolerances stated. To do this, make 10 copies of test chart 19 from the original glass platen both in the simplex and duplex modes. Make 10 copies of test chart 25 via the (R)RDF by using 10 test charts 25; do this also in the simplex and duplex modes. The image should be centred in the middle of the receiving material both in the length and width directions. image height deviation lateral deviation figure 1 figure 2
A
2 1 0 -1 -2 -3 -4 -5
B
-6 -5
-6
-4 -3 -2 -1 0
B
B
B
On each copy, measure the distance A and B and calculate the average over the 10 copies (A tot - B tot ) /10 = X The maximum deviation A - B of each copy with respect to X= Y Figure 1 - image height deviation Figure 2 - lateral deviation from original glass platen dev.X dev. Y Image height deviation simplex side 2 mm duplex side 2 mm Lateral image deviation simplex side 2 mm duplex side 4 mm Skew simplex side duplex side 1 mm 1 mm with MDF/RDF dev.X dev.Y
4 mm 4 mm 4 mm 6 mm 2 mm 2 mm
3 mm
2 mm
4 mm
1 mm 1 mm
2 mm 2 mm
note: If in doubt, or if not within the stated tolerances, then check the adjustments.
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Copy quality 5
COPY QUALITY
copyq
No image on the copy Blank copy

Description: Blank copy, both single-sided and double-sided. Note: Run SDS tests 43.1 and 43.2.
01 01 01 04 04 05 05
spring of one revolution clutch is broken or loose Transferclutch doesnt switch Transfer mechanism doesnt setup properly. Exposure set much too high. left side cover not mounted developing unit is not locked Too little toner in developing unit.
6 Copy quality
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Part I ed.6
copyq
COPY QUALITY
Uneven image OD too low at top or bottom

Description: OD too low at top or bottom of copy. No toner stripes visible. Use testchart 40.
02 04 04 04 04
Sealing foam of the suction box is damaged or loose. exposure is not even (reflector, tubes) C1/C9 on 04PBA02 defective (short circuit) mirror is dirty Incidence of sunlight
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Copy quality 7
COPY QUALITY
copyq
OD locally too low and toner stripes visible

Description: OD locally too low at copy. Toner stripes visible in feed direction. Use testchart 40.
05 05 05 05 05 05
doctor blade is not correct positioned developing unit is not correct positioned no earthpoint of developing counter roller Toner level low in developing uit Toner not flowing properly Agitation mechanism
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copyq
COPY QUALITY
Light areas (corrugated cardboard pattern)

Description: Light areas at top or bottom of copy. Corrugated cardboard pattern. Use testchart 40. Note: A small amount of unevennness is acceptable.
01 06
Transfer pinch pressure incorrect Dirt on pinch roller TTF
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Copy quality 9
COPY QUALITY
copyq
Uneven image
Description: Uneven image. Use testchart 20.
01 01 02 04 04 05
set-up bar is broken or adjustment is changed master end of life Scorotron polluted. Optic polluted. bellow defective leakage of toner level sensor 05S1
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copyq
COPY QUALITY
Weak image OD much too low

Description: OD much too low. Toner stripes visible in feed direction. Use testchart 40.
05 05 05 05 05 05 05 05 05
bad connection of drawer connector motor 05M1 defective or tonerrake stuck gear defect or drive defect tonerclod in developing unit developing cooling motor 05M2 defective toner level low sensor defective developing agitation motor 05M1 continue activated doctor blade is not correct positioned developing unit not correct positioned
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Copy quality 11
COPY QUALITY
copyq
Image has local deficiencies; light spot in black area

Description: Image has local deficiencies; light spot in black area.Depending on the previous image on the master, no ghost image visible. Use testchart 19 Note: This phenomenon is clearly visible in a run of 16 copies. You then have a sequence of eight with an eight without this phenomenon.
07 07 07 07
wrong height of toner brush gear and or drive defective cleanlamp 07LA1 defective ballast 07BAL1 defective/ open circuit
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copyq
COPY QUALITY
Ghost images Ghost images; residual image visible

Description: Ghost images. Residual image of previous copy visible. Use testchart 19. Note: As more copies are made, the background increases and the OD decreases.
07 07 07 07
wrong height of toner brush gear and or drive defective cleanlamp 07LA1 defective ballast 07BAL1 defective/ open circuit
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Copy quality 13
COPY QUALITY
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Image is erasable Copy is erasable

Description: Copy is erasable. Loss of small details of the image. Use testchart 19. Note: Run the erasable image test to make this phenomenon clearly visible.
06
TTF temperature too low 06NTC1.
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copyq
STRIPES/STAINS/SCRATCHES
STRIPES/STAINS/SCRATCHES 1 Stripes/tracks in feed direction Light stripe at random position

Description: Light stripe in feed direction at random position. Use testchart 40. Note: Run tests 43.1 or 43.2 If the phenomenon occurs (in a simplex-run) in eight copies but not in the next eight, the problem is in the cleaning section. Otherwise, the problem is in the developing section or the master.
01 01 05 05 05 05 06 07
bulge roller(s) are dirty master is damaged developing cooling motor 05M2 defective toner clod in developing unit developing agitation motor 05M1 continue activated motor 05M1 defective or tonerrake stuck TTF belt is damaged toner clod in cleaner unit
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Copy quality 15
copyq
Stripy image
Description: Stripy image. Narrow dark stripes visible.
02
scorotron is polluted
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copyq
Stripes/tracks perpendicular to feed direction Stripes/tracks in background

Description: Stripes/tracks in background. Use testchart 40.
05
Sometimes no bias voltage on developing roller (mod. 21).
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Copy quality 17
copyq
Dark stripe on the right edge

Description: A small dark stripe on the right hand side of the copy is visible; the stripe may be interrupted.
10 10 10
Glass transport not working properly DF belt motor not working properly Ruler not working properly
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copyq
Stains/scratches White stains/spots in background (starry sky)

Description: White stains and/or spots in background (starry sky). Phenomenon is visible every eight copies (image position related).Use testchart 40.
01 01 12
master is damaged bulge rollers paper quality is not according our specs
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Copy quality 19
copyq
White areas
Description: White areas. Pattern repeated - not at the same distance from the leading edge but at the same height. Phenomenon appears irregularly. Use testchart 40.
06
TTF belt is damaged
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copyq
White/black scratch
Description: White/black scratch. Scratch repeates quite regularly during run. Use testchart 40.
01 01 05 05 05 05 06 06 07
bulge roller(s) are dirty master is damaged developing cooling motor 05M2 defective toner clod in developing unit developing agitation motor 05M1 continue activated motor 05M1 defective or tonerrake stuck TTF belt is damaged TTF belt is dirty toner clod in cleaner unit
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Copy quality 21
copyq
Hole/groove pattern of TTF cleaning roller visible

Description: Hole/groove pattern of TTF cleaning roller visible on front and/or rearside of the copy.
06 06 06
Cleaning of TTF belt not operating optimally New TTF cleaning roller dirty. TTF temperature.
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copyq
IMAGE POSITION/DISTORSION/MAGNIFICATION RATIO
IMAGE POSITION/DISTORSION/MAGNIFICATION RATIO 1 Image displaced from the original glass Image displaced perpendicular to feed direction on simplex side
Description: Image displaced perpendicular to feed direction on simplex side. Use testchart 19. Note: Tolerance : see guidelines. Result from top and bottom paper tray may differ!
12 12 12
Transport rolls not working properly zero of paper tray(s) not correct Paper door (inner) not adjusted properly
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Copy quality 23
copyq
Image displaced perpendicular to feed direction on duplex side

Description: Image displaced perpendicular to feed direction on duplex side. Use testchart 19. Note: Tolerance : see guidelines. Check simplex side too.
06 16
Z-drift in funnel Z-drift in the second pre heater section
24 Copy quality
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copyq
Image displaced in feed direction on simplex side/duplex side

Description: Image displaced in feed direction on simplex side/duplex side. Use testchart 19. Note: Tolerance : see guidelines.
01 12 12 12 12 15 15 15 16 16
bulge roller does not return to start position first paper stop operates incorrect (mechanical) first paper stop timing incorrect (software adjustment) paper feeding problems Right side door Paper feed problems Preheat plate Preheat mat duplex paper stop operates incorrect (mechanical) duplex paper stop timing incorrect (software adjustment)
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Copy quality 25
copyq
Image skewed from glass Image skewed on simplex side/duplex side

Description: Image skewed from glass on simplex side/duplex side.Use testchart 19. Note: Tolerance : see guidelines.
12 12 12 12 15 15 16 16 16
first paper stop paper feed problems Right side door Transport rolls not working properly Preheat plate Preheat mat duplex paper stop paper path Transport rolls not working properly
26 Copy quality
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copyq
Image displaced when using RDF Image displaced perpendicular to feed direction (simplex side) when using RDF
Description: Image displaced perpendicular to feed direction (simplex side). Use RDF with testchart 25. Note: Tolerance: see guidelines. First check copies from the original glass
10
RDF side guides not set properly. (Zero positioning)
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Copy quality 27
copyq
Image displaced perpendicular to feed direction (duplex side) when using RDF
Description: Image displaced perpendicular to feed direction (duplex side). Use RDF with testchart 25. Note: Tolerance: see guidelines. First check copies from the original glass
01
Transport wheels in turnstation not working properly.
28 Copy quality
TSM 2400 family
Part I ed.6
copyq
Image displaced in feed direction (simplex and duplex) when using RDF
Description: Image displaced in feed direction.Use RDF with testchart 25. Note: Tolerance: see guidelines. First check copies from the original glass
10 10 10
Glass transport not working properly DF belt motor not working properly. Ruler not working properly.
ed.6 Part I
TSM 2400 family
Copy quality 29
copyq
Image skewed when using RDF Image skewed (simplex-side)

Description: Image skewed on simplex side. Use RDF with testchart 25. Note: Tolerance: see guidelines. First check copies from the original glass .
10 10 10
Separation not working properly Transport wheels of input not working properly. Glass transport not working properly
30 Copy quality
TSM 2400 family
Part I ed.6
copyq
Image skewed (duplex-side)

Description: Image skewed on duplex side. Use RDF with testchart 25. Note: Tolerance: see guidelines. First check copies from the original glass
10 10
Transport wheels of turn station not working properly. Glass transport not working properly. (DF belt pressure roll, 10EM2)
ed.6 Part I
TSM 2400 family
Copy quality 31
copyq
Image loss due to framing errors Image loss at bottom

Description: Image loss at bottom. Use testchart 19.
01 03 03 03 03
Master unit not locked in properly Lamp(s) activation-code wrong Framing unit positioning or locking is not correct Framing-unit adjustment not correct lamp(s) are constant on
32 Copy quality
TSM 2400 family
Part I ed.6
copyq
Image loss on leading and/or trailing edge

Description: Image loss on leading and/or trailing edge. Use testchart 19.
03 12
Framing flash not working properly Paper size detection error
ed.6 Part I
TSM 2400 family
Copy quality 33
copyq
Image distortion Local image distortion in feed direction

Description: Local image distortion in feed direction. Use testchart 19.
06 06
TTF belt deformed Build-up of toner in the middle of the cleaning roller.
34 Copy quality
TSM 2400 family
Part I ed.6
copyq
Trapezoidal image
Description: Trapezoidal image. Use testchart 19. Note: Tolerance: see guidelines.
06
transfuse pressure not correct
ed.6 Part I
TSM 2400 family
Copy quality 35
copyq
Magnification ratio incorrect Magnification ratio too large or too small

Description: Magnification ratio too large or too small, in feed direction and perpendicular to feed direction. Use testchart 19. Note: Tolerance: see guidelines
04 04
Lens calibration wrong. Lens positioning mechanism not working properly.
36 Copy quality
TSM 2400 family
Part I ed.6
copyq
Magnification ratio too large or too small, feed direction only

Description: Magnification ratio too large or too small, feed direction only. Use Testchart 19.
06
transfuse pressure not correct
ed.6 Part I
TSM 2400 family
Copy quality 37
RECEIVING MATERIALS DAMAGED/SOILED
copyq
RECEIVING MATERIALS DAMAGED/SOILED 1 Copy damaged Folds at top/bottom

Description: Folds at top/bottom of the copy.
06 06
TTF belt damaged Counter pressure belt damaged
38 Copy quality
TSM 2400 family
Part I ed.6
copyq
Folds parallel to the leading edge

Description: Folds parallel to the leading edge. Accompanied by long shiny stripes in dark areas. Use testchart 40 with a low exposure.
06 06 06
TTF belt Intermediate transport / funnel Counter pressure belt
ed.6 Part I
TSM 2400 family
Copy quality 39
copyq
Leading edge damaged

Description: Tear in the middle of the leading edge of the copy.
Possible causes Paper stopper mechanism not working properly. Paper guide plates no good. Transport rollers not working properly.
Func
Checking procedures/remarks
12 12/16
Check stopper for burrs/pollution. Plates are bent/polluted or have burrs.
12/16/17 Rollers are mounted askew. Securing points broken. Bearings ar not running smoothly. 15 Mat polluted due to inadequate preprinted paper. Clean mat if possible. Worn mat. Paper guiding mat unit is bent.
Paper guiding mat of preheating unit no good.
40 Copy quality
TSM 2400 family
Part I ed.6
copyq
Soiled copy Dirt at the top and/or bottom

Description: Dirt at the top and/or bottom of the copy. Lumps of toner along the edge including outside the image area.
Possible causes TTF cleaning not working properly.
Func
Checking procedures/remarks
06
TTF temperature too high.
06
Build-up of toner on the cleaning roller at the level of the paper edge. Replace cleaning roller. Toner dam to top or bottom of cleaning roller (toner can drip off the roller). Check the TTF temperature.
ed.6 Part I
TSM 2400 family
Copy quality 41
copyq
42 Copy quality
TSM 2400 family
Part I ed.6
01diag
DIAGNOSTIC
DIAGNOSTIC 1 Messages PE
0110 0111 0112 0113 0114 0115 master speed too low too many master pulses too few master pulses hole detection failure set up mechanism not up master stop length too long
MRE
0125 0126 0127 0128 0129 0130 master speed too low too many master pulses too few master pulses hole detection failure set up mechanism not up master stop length too long
Warnings
0175 set up mechanism not down
ed.6 Part I
TSM 2400 family
01 Photoconductor 101
DIAGNOSTIC
01diag
Fault table
CODES POSSIBLE FAILURES
M0125, P0110 - gear wheel loose or broken - bulge rollers not in holder - unsufficient friction between drive roller and master - master tensioning roller loose - masterdrive is not sufficient - flexible cable bulge-rollers is broken - pulssensor is fault (01SO2) - bearing of complementary cleaning roller is broken - bearing of lower guide rod are fault - pulse disk is fault (01SO2) - bearings of master cooling roller fault - ballbearing master drive roller broken - bearing of developing unit defective (FUNC 05) - bearing clean roller stuck (FUNC 07) - ballast 07BAL1 defective/ short circuit (FUNC 07) M0126, P0111 - masterhole-sensor is fault (01SO1) - bulge roller is stuck - locating pins or locating blocks are bent - bearing bulge-roller is broken - master is too long - locking of the guide-disk(s) is loose M0127, P0112 - masterhole-sensor is fault (01SO1) - bulge roller is stuck - locating pins or locating blocks are bent - bearing bulge-roller is broken - locking of the guide-disk(s) is loose - master is too short M0128, P0113 - masterhole-sensor is fault (01SO1) - bulge roller is stuck - locating pins or locating blocks are bent - bearing bulge-roller is broken - masterhole is too big Fault table continue : next page.
TSM 2400 family
Part I ed.6
01diag
DIAGNOSTIC
CODES
POSSIBLE FAILURES
M0129, P0114 - set-up motor sensor 01S1 is broken - brake of set-up motor 01M2 is broken - set up motor constant activated, brake isnt activated - bearings of set-up bracket are broken - locking of the guide-disk(s) is loose - output stage, 22PBA09 - output stage, 22PBA06 - SSR1 (22PBA06) defective M0130, P0115 - master stop is not correct - constant master transportation W0175 - brake of set-up motor 01M2 is broken - set-up motor sensor 01S1 is broken - bearings of set-up bracket are broken
ed.6 Part I
TSM 2400 family
DIAGNOSTIC
01diag
Protections MRE 0125 PE 0110

MASPULSE is checked continuously over periods of 300msec during run. Except for the first 200msec after master start and during master stop The nominal value is 50 pulses/300msec.
37 pulses or more/300msec = correct less than 37 pulses/300msec = master pulse frequency to low, MRE 0125 PE 0110
MRE 0126 PE 0111 MRE 0127 PE 0112

MASHOLSE pulses are used to check the master transport. The nominal number of master pulses between two MASHOLSE detections is 1268. The number of master pulses between two MASHOLSE detections is divided into three ranges: more than 1319 pulses = too many master pulses, MRE 0126 PE 0111 less than 1320 pulses but more than 1263 pulses = correct less than 1264 pulses = too few master pulses, MRE 0127 PE 0112
MRE 0128 PE 0113

MASHOLSE pulse duration is checked. The duration is expressed in master pulses. The number of master pulses can be divided into three ranges: less then 2 pulses, no master hole recognition more then 1 but less then10 pulses = correct 10 pulses or more, master hole detection failure, MRE 0128 PE 0113
MRE 0129 PE 0114

SUMSE is checked at the moment of every transfer to make sure the setup mechanism is up. 0 = correct 1 = setup mechanism not up at moment of transfer, MRE 0129 PE 0114 If this error code occurs due to malfunction of the SSR1 (22PBA06), replace this PBA by the A version of the PBA.
TSM 2400 family
Part I ed.6
01diag
DIAGNOSTIC
MRE 0130 PE 0115

MASPULSE is checked during 400msec after master stop, to determine the runout lenght. The nominal number of pulses is 22. 30 pulses (40 pulses, Oc 2475) or less/400msec = correct more than 30 pulses (40 pulses, Oc 2475) /400msec = stop length to long, MRE 0130 PE 0115
WARNING 0175
SUMSE is checked 4sec after master stop to make sure the setup mechanism is down.
1 = correct 0 = setup mechanism not down, WARNING 0175
ed.6 Part I
TSM 2400 family
DIAGNOSTIC
01diag
TSM 2400 family
Part I ed.6
01sds
SDS
SDS 1 SDS test description

SIGNAL -001SO2 01SO1 01SO1/01SO2 01SO1/01SO2 01S1 01SO2 01SO2 01SO1 01SO1/01SO2 01SO1/01SO2 01S1 01SO2 01S1 MASPULSE MASHOLSE MASPULSE MASHOLSE SUMSE MASPULSE MASPULSE MASHOLSE MASPULSE MASHOLSE SUMSE MASPULSE SUMSE master speed too low too many master pulses too few master pulses hole detection failure set-up mechanism not up master stop length too long master speed too low too many master pulses too few master pulses hole detection failure set-up mechanism not up master stop length too long set up mechanism not down number of copies with master DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 01 0 10 PE 01 0 11 PE 01 0 12 PE 01 0 13 PE 01 0 14 PE 01 0 15 PE 01 0 25 MRE 01 0 26 MRE 01 0 27 MRE 01 0 28 MRE 01 0 29 MRE 01 0 30 MRE 01 0 75 WAR 01 0 90 C PARAMETERS 01 1 90 INPUT TESTS 01 2 01 01 2 02 01SO1 01S1
-1no. of copies per master : Note 1 -2MASHOLSE SUMSE MASter HOle SEnsor Set Up Mechanism SEnsor
Note 1: If parameter is set at maximum value, and this value is exceeded, NO message will be displayed when entering SDS.
ed.6 Part I
TSM 2400 family
SDS
01sds
TESTNUMBER COMPONENT OUTPUT TESTS 01 4 01 01 4 02 01CL2 01M1
SIGNAL -4TFRCL FANSPCTRO
DESCRIPTION in SDS
TransFeR CLutch FAN SPeed ConTROl cooling motor
SPECIAL TESTS 01 6 01 01 6 02 01 6 03 01 6 04 01 6 05 01CL2
-6make function WARM make function COLD mask function protections master run / stop / read out master pulses : Note 2 transfer test
TFRCL -8-
REPLACE CONSUMABLES 01 8 90
replace routine new master
Note 2 : The master speed is measured and displayed every 300 ms. Nominal master speed is 50 pulses per 300 ms (Oc 2375,2400,2465 CRU en 2465 FIN) or 60 pulses per 300 ms (Oc 2475). The master length is displayed after every rotation of the master. Nominal length is 1268 pulses per rotation. Press <PRINT> to stop the master; run-out is measured and displayed. Nominal run-out length is 22 pulses.
TSM 2400 family
Part I ed.6
01adju
ADJUSTMENTS
ADJUSTMENTS 1 One revolution clutch first transfer step Aim:

To achieve a friction free rest position of the one revolution clutch.
Check:
Select transfer test 01 6 05. Activate the test using <PRINT>. Use <PRINT> to check the position of the release cam -R-.
01adju1a
01adju1b
ed.6 Part I
TSM 2400 family
ADJUSTMENTS
01adju
Correction:
NOTE: The default setting of plate -A- is: bolt -B- in the centre of the slotted hole. This corresponds with a gap -Y- of 1 to 3mm. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Loosen bolt -BMove plate -A- so bolt -B- is centered in the slotted hole; Tighten bolt -B-; Press <PRINT> to allow the one revolution clutch to make 1 revolution Check distance -Y-: correct is between 1 and 3mm; -Y- <1mm:move plate -A- upwards and proceed with 1.4; Tighten bolt -B-; Proceed with: CHECK adjustment 01-2.
01adju1d
01adju1c
TSM 2400 family
Part I ed.6
01adju
ADJUSTMENTS
Transfer cam position, first transfer pinch. Aim:

To achieve a defined distance between TTF belt and master,in set up position.
Check:
After each transfer the mark on cam -Cmust point at the centre of ball bearing -D-.
Correction:
2.1 2.2
2.3 2.4 2.5 2.6
2.7 2.8
Check adjustment 01-1 and adjust if necessary; Use transfer test 01 6 05 to get the set up position; Use <PRINT> to place the one revolution clutch in blocked position; Loosen bolts -A-; Keep drive belt -B- manually in position; Use an open ended spanner to turn the shaft with cam -C- opposite the point of contact; Tighten bolts -A-; Push <PRINT> and check the stop position of cam -C-; - If incorrect proceed with 2.4. NOTE: In case that bolts -A- touch the ends of the slotted holes in pulley -E- the geared belt -Bhas to be reinstalled. Proceed as follows: - loosen bolt -G- of the belt tensioner; - remove the geared belt from pulley -E- loosen bolts -A-; - turn pulley -E- so that bolts -A- are situated in the centre of the slotted holes; - tighten bolts -A-; - place cam -C- opposite the point of contact; - install the geared belt over pulley -E-;tighten bolt -G-, - proceed with point 2.2 of the adjustment.
01adju2a
01adju2b
01adju2c
ed.6 Part I
TSM 2400 family
ADJUSTMENTS
01adju
Switch set up mechanism. Aim:

To detect the set up position, to achieve the set up motor is switched off and the brake is switched on.
Check:
Select transfer test 01 6 05. Use <PRINT> to activate the test and check if the set up action starts, and stops when switch arm -C- falls in recess -D-.
Correction:
3.1 3.2 3.3 Loosen bolt -A- and -B-; Move the switch housing towards cam -E- so that the distance -Z- between housing and switch arm is 0,5mm; Tighten bolts -A- and -B-.
01adju3a
TSM 2400 family
Part I ed.6
01adju
ADJUSTMENTS
Brake set up motor. Aim:

To achieve minimum friction between the coupling plate and housing when the set up motor is running. And to ensure the set up mechanism stays in the set up position.
Check:
Start a copy run, the set up mechanism must stay in set up position.
Correction:
4.1 4.2 4.3
4.4 4.5 4.6
Remove the master. Loosen allen screw -A-. Place a 0,4 mm (+/- 0 mm) feeler gauge between coupling plate and housing; Eliminate the play; Tighten allen screw -A-; Install the master.
01adju4a
01adju4b
ed.6 Part I
TSM 2400 family
ADJUSTMENTS
01adju
First transfer pinch pressure, front and rear. Aim:

To achieve a defined and an equal pressure beween the transfer rollers at the front and rear.
Check:
Select and activate test 01 6 05, set up position. Press <PRINT>to activate transfer. Check during the revolution of the eccentric cam that the head of spindle -A- is just visable in hole -B-, at front and rear. (use a light).
Correction:
5.1 5.2 5.3 Start with checking adjustments 01-1, 01-2, 01-3, and 01-4; Select system test 40, to cold SDS; Use test 06 6 04, to read the ADC value of TTF temperature; NOTE: If value is 20 or less: proceed with 5.4; if value is more than 20: pull out the TTF unit and let it cool until the value is 20 or less, than proceed with 5.4. 5.4 Activate test 01 6 01 <PRINT>and wait for <WARM>; * initializing the master, no join at the transfer pinch; 5.5 Select system test 40, to cold SDS. 5.6 Disconnect 23CN2: main drive motor 23M2 turned off; 5.7 Loosen bolt -G-, detensioning the geared belt; 5.8 Remove geared belt -F- from pulley -E-; 5.9 Turn eccentric -C- 180, transfer pinch closed; 5.10 Activate test 23 4 01, set up position;
01adju5a
TSM 2400 family
Part I ed.6
01adju
ADJUSTMENTS
5.11 Loosen lock nut -D-; NOTE: Do not loosen allen screw -H-, it locks nut -J-. 5.12 Adjust spindle -A- so a 2mm Allen key is kept under pressure in both holes -B-; 5.13 Position the allen key horizontally; 5.14 Turn spindle -A- down until the 2mm allen key drops: * it should turn freely and just touch the top of spindle -A-; 5.15 Hold the spindle in position and tighten lock nut -D5.16 If necessary repeat this procedure at the other side, starting at point 5.11; 5.17 Deactivate test 23 4 01; 5.18 Turn eccentric -C- up with the mark at the point of contact with the ball bearing; (see adjustment 01.2) 5.19 Install geared belt -F- over pulley -E-; 5.20 Tighten bolt -G-; 5.21 Connect 23CN2.
01adju5b
ed.6 Part I
TSM 2400 family
ADJUSTMENTS
01adju
TSM 2400 family
Part I ed.6
01disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Master replacement
Disconnect the wall plug. Remove the original receiving tray, the centre front panel and left side panel. Release the master unit and pull it out of the copier. Remove the cleaning unit (1). Disconnect and remove the scorotron (2). Disconnect and remove the framing section (3). Put scorotron connector 22CN2 on top of the housing of the cooling roller, see fig. 1. Put the connectors of the framing section as shown in fig. 2.
FIG.1
FIG.2
1.9 Pull out the master hole sensor 01SO1(4), see fig. 3. 1.10 Remove the three master tension rollers (5), (6) and (7), see fig. 3.
FIG.3
ed.6 Part II
TSM 2400 family
DIS/ASSEMBLY
01disa
1.11 Remove the old master from the master section. 1.12 Push the master section into the copier. 1.13 Install the master installation tool at the front side on the main frame over screws -Y-, fig 4.
FIG.4
1.14 Tighten screws -Y-. 1.15 Remove the card board box from the master packing. 1.16 Place the three rods in the three holes, left side, of the tool, fig. 5.
FIG.5
TSM 2400 family
Part II ed.6
01disa
DIS/ASSEMBLY
FIG.6
1.17 Hold the box with the master so that the RED rectangle inside the cardboard box is at the front right, fig. 6. 1.18 Slide the box with the master over the three rods. 1.19 Remove the box from the master. 1.20 Move rod -3- from position -H- carefully to position -G-, fig. 7: * unroll the master. * Position the master joint 100 mm below tube -E- . 1.21 Unroll the master until it is suspended as shown in fig. 7: * keep at the end the turnable rod holder horizontal; * pay attention that the master does not touch the floor.
FIG.7
ed.6 Part II
TSM 2400 family
DIS/ASSEMBLY
01disa
1.22 Pull carefully the master section into the master loop: * take care not to touch the master. 1.23 Use the holder to place the tension rollers (see fig. 8) in the sequence as indicated in the description that follows. 1.24 Install roller -C- as shown in fig. 9:
FIG.8
FIG.9
- Clip the roller in the holder; - Keep the master in the centre of the cooling roller; - Push the roller straight against the master; - Roll the roller over the cooling roller into the guiders; - Push the roller at both ends in the locked position; - Pull the holder from the roller. 1.25 Remove card board tube with the rod at position -G- as shown in fig.10: - Take rod position -G- out of the tool; - Place carefully the master on the shuttle roller; - Move the tube downwards as far as possible and take it out as shown.
FIG.10
FIG.11
TSM 2400 family
Part II ed.6
01disa
DIS/ASSEMBLY
1.26 Remove rod with card board tube at position -F-, see fig. 10. 1.27 Remove rod with card board tube at position -E- as shown in fig. 11: - Take rod position -E- out of the tool; - Carefully move the rod with tube underneath the master: * first to the right over the shuttle roller; * then downwards as far as possible as shown in fig. 11; * Take the rod with tube out. 1.28 Place the master in the centre of the master drive roller. 1.29 Install roller -B- as shown in fig. 12: - Clip the roller in the holder; - Push the roller straight against the master; - Move the roller through the guiders into its locked position at both ends; - Pull the holder from the roller.
FIG.12
FIG.13
1.30 Install roller -A- loosely as shown in fig. 13: - Clip the roller in the holder; - Push the roller straight against the master; - Move the roller through the guiders into its locked position at both ends; - Pull the holder from the roller.
ed.6 Part II
TSM 2400 family
DIS/ASSEMBLY
01disa
1.31 Loosen the tape from the protection sheet. 1.32 Turn the knob on the master drive roller clockwise until the protection sheet is removed. 1.33 Check the master for damages, use the knob to turn it around. 1.34 Push the master hole sensor in position. 1.35 Store the auxiliary tools in the copier: - 3 rods in centre panel; - master installation tool in the frame at the left side; - roller holder in the cover at the left side. 1.36 Tighten the screws for installing the installation tool at the front side of the machine. 1.37 Reset counter 01 0 90 using sds-test 01 8 90 (replace master). 1.38 Check, and if necessary adjust, the exposure setting (SDS test 04 1 01). 1.39 Check, and if necessary adjust, the ABC (SDS test 04 6 11).
TSM 2400 family
Part II ed.6
01func
FUNCTIONAL DESCRIPTION
FUNCTIONAL DESCRIPTION 1 Master section

The master section performs several functions: Transporting the master through all the process functions (master handling). Moving the master from side to side (shuttle mechanism). Bringing the master into contact with the TTF belt (setup mechanism). Cooling the master. Monitoring the master speed. Providing data that allows the control to calculate each image position on the master. The master section consists of: Master handling Master Master shuttle mechanism Setup and transfer mechanism Master pulse sensor, 01SO2 Master hole sensor, 01SO1 Master cooling system
-A-B-C-D-E-F-G-
01func01
ed.6 Part II
TSM 2400 family
01func
The construction of the master section allows it to slide out of the copier very easily. The charging section, the cleaning section and the framing section also slide out with the master section. Before the master section can be pulled out, the following items have to be released: the developing section; the exposure plate; the suction mouth of the scorotron. Then the two master handling locks have to be loosened. Then pull out the master section until it locks in position.
TSM 2400 family
Part II ed.6
01func
Master handling
The master handling consists of:
-A-B-C-D-E-F-G-H-J-K-LConfidential 1996 Oc Nederland B.V.
Transfer roller Master drive roller First bulge roller Complementary developing rod Master tensioning roller Guide rods with exposure plate Lower guide roller Shuttle roller Second bulge roller Complementary cleaning roller with pulse disc Master cooling roller/complementary scorotron roller
01func02
ed.6 Part II
TSM 2400 family
01func
The function of the rollers are briefly explained in the following paragraphs. More details can be found in their own sections. Master drive roller The main drive motor is connected to the master drive roller by gears. The roller itself has a rubber coating to prevent the master from slipping. At the front of the roller is a knob that allows you to drive the master manually. This is used when installing a new master, and for fault finding. For example, when copy quality needs to be checked on the master. Transfer and bulge rollers The transfer roller brings the master into contact with the TTF belt in order to transfer the developed image. The reason the master is not in continuous contact with the TTF belt is that the heat from the TTF belt would quickly destroy the zinc oxide layer on the master. The TTF belt runs faster than the master, and when they are in contact, the master speeds up. To compensate for this, there are two bulge rollers which take up the slack when the master changes speed. See the BULGE ROLLERS section. Shuttle roller The shuttle roller moves the master sideways over a total distance of 5 mm. It is driven by a series of mechanical links: no electronics are used. See the SHUTTLE MECHANISM section. Master tension roller This roller pre-tensions the master after installation. Cooling roller This is a hollow roller that has air blown through the centre, which helps to remove the heat that the master receives from the TTF belt. Too much heat lets toner stick to the master and will damage the zinc oxide layer. See the COOLING SYSTEM section. The air also cools the operating panel and RDF control board by channels in the front cover. Guide rods at exposure plate These keep the master flat as it passes over the exposure plate. Complementary rollers These rollers help to guide the master.
TSM 2400 family
Part II ed.6
01func
Master
The master is an endless belt which is 2536mm long and 430mm wide. The short master length in combination with a long lifetime is the result of:
charging method (scorotron) improvements in master coating (ZnO-layer) Master cooling Mastershuttling Start/stop position The total length of the master is divided into 8 image sections and 8 distances:
8 image sections of 216mm (210 or 203 mm); 7 distances of 100mm (106 or 113 mm); 1 longer distance of 108mm where the master is joined (114 or 121 mm).
01func03.gem
ed.6 Part II
TSM 2400 family
01func
The 8 image sections have fixed positions on the master. This is achieved by using a masterhole for reference and a pulse disc for recording the master movement. The master hole is 82mm from the joint and 13mm from the edge. Using the signal from the hole sensor (01SO1) and the pulses from the pulse sensor (01SO2), the position of each image section on the master is determined. Every time the master hole passes the hole sensor, image sections are synchronized with respect to the master hole. The figure below shows the position of the image sections on the master in standby.
01func04
At the start of a run the first possible image section used, will always pass the cleaning unit, it is indicated with 1". The master always stops in this position with distances facing the unit that can damage the master surface, such as: scorotron developing roller TTF belt Cleaning roller
TSM 2400 family
Part II ed.6
01func
Master speed and position monitoring

The pulse sensor.(01SO2) The master displacement and speed is recorded by a pulse sensor and a pulse disc. The disc is mounted on the inside of the complementary cleaning roller. The circumference of the cleaning roller is designed that 1 pulse corresponds to 2mm of master displacement. The frequency of these pulses represents the speed of the master. The frequency is constantly scanned over periods of 300msec. The master of the 2375,2400,2465 CRU en 2465 FIN runs with a speed of about 20m/min, the master of the 2475 runs with a speed of 24 m/min. The hole sensor.(01SO1) The hole in the master is the reference point (zero point) for the control. This hole is sensed by the hole sensor. A hole detection is recognized if a hole is seen for the duration of at least 2 pulses by the hole sensor. Using this hole pulse and the counter pulses from the pulse sensor 01SO2, the position of each image section can be calculated. Between two master hole detections normally 1268 +/- 1 pulses should be detected. Due to motor speed and slip, the actual range is set between 1264 and 1319 pulses per revolution.
ed.6 Part II
TSM 2400 family
01func
Master shuttle mechanism

The shuttle mechanism moves the master sideways over a total distance of 5mm. This spreads the electrical and mechanical load over the image sections. The negative effect of copying originals with standard information at a fixed position (letterheads) is reduced. A shuttle distance of 5mm has been chosen because it is greater than the height of an average line of text from a printer. The figure below illustrates the master shuttle.
01func05.gem
TSM 2400 family
Part II ed.6
01func
The shuttle mechanism consists of the following items : -A-B-C-D-Eeccentric cam ; lever ; one way bearing ; worm-and-nut steering gear ; displacement eccentrict .
01func06
Master shuttle works as follows: The shuttle mechanism is driven by an eccentric cam -A- that is mounted on the shaft of the complimentary cleaning roller. The cam moves a lever -B- that drives a worm gear by a one way bearing -C-. The worm gear drives a gear -D-, which moves the shuttle roller by an eccentric -E-. The shuttle roller moves continuously (in steps), but at a very slow speed. The shuttle roller has a ribbed surface. This provides sufficient friction to move the master.
ed.6 Part II
TSM 2400 family
01func
Setup,transfermechanism and bulge rollers

The master is stationary during standby. It is very sensitive to heat; therefore the master is kept away from the TTF belt. In order to transfer the image to the TTF belt, the master must be brought into contact with the TTF belt. The setup works as follows:
1. 2. 3. 4. 5. 6.
During standby, the master is about 20mm from the TTF belt. When a copy run begins, the master is set up to within 1mm from the TTF belt by the setup mechanism. Every time a transfer is required, a one-revolution clutch turns the eccentrics -F- and closes the 1mm gap between the master and the TTF belt. The masterspeed increasement is compensated by the two bulge rollers. After the transfer, at the end of the revolution the gap is 1mm . At the end of the copy run, the gap opens to 20mm. Setup mechanism ; The figure below shows the main components of the setup mechanism.
-A-B-C-D-E-F-
Setup motor with brake; Setup drive with cam; Setup mechanism switch; Release spring setup position; Setup rods; Eccentrics
01func07
TSM 2400 family
Part II ed.6
01func
Circuit diagram description (see 701):

The setup motor (01M2) is energized when control line SUMMO is high 1 (LED4 on SSR1 22PBA06 is lit). The setup motor (01M2) drives, by transmission gears, a shaft with a cam on each end. On these cams two setup rods have been mounted so that when the cams are turning they make an eccentric movement. This movement narrows the distance between the two transfer rollers to about 1mm. The pressure springs on the two connecting rods are tensioned in the setup position. This achieves the necessary load to make the transfer pinch. When the setup mechanism reaches its upper position the setup mechanism sensor (01S1) switches and SUMSE becomes low 0. The setup motor (01M2) stops and the setup motor brake (01BR1) is energized. The setup mechanism motor brake is controlled from the HOST I/O (22PBA02) by the signal SUMMOBR, which activates a driver on the 24V driver board 22PBA09. When SUMMOBR is high 1, the brake is activated.
The setup mechanism remains in postion during a run. At the end of the run, the setup motor brake is released (SUMMOBR is low 0). Because of the tension spring and the shape of the eccentric automatically lowers the setup mechanism. When the setup mechanism leaves the upper position the setup mechanism sensor (01SO1) switches and NSUMSE becomes low 0". When the setup mechanism does not lower at the end of a run, no direct damage will occur to the master. The copier keeps operating, and a WARNING 0175 is displayed when SDS is entered.
ed.6 Part II
TSM 2400 family
01func
Transfer The figure below shows the transfer mechanism in more detail . -A-B-COne revolution clutch Drive mechanism Transfer roller shaft with eccentric cams
01func08
The transfer pinch is closed every time an image needs to be transferred from the master to the TTF belt. A one-revolution clutch (01CL2) is connected to the mainframe main drive. When the clutch is energised, a drive mechanism rotates the transfer roller shaft. Eccentric cams mounted on this shaft bring the two transfer rollers together. The rollers automatically released after the clutch has completed one revolution. One revolution is sufficient time for the image to be transferred.
Circuit diagram description (see 701):

The one revolution clutch (01CL2) is controlled from the HOST-I/O (22PBA02) by control line TFRCL, which activates a driver on the 24V driver board (22PBA09). Signal TFRCLD controls the clutch. When TFRCL is high 1, TFRCLD is grounded and the clutch is activated.
TSM 2400 family
Part II ed.6
01func
Bulge rollers The figure below shows the bulge rollers in more detail. -A-B-C-DFirst bulge roller; Second bulge roller; Wire and tension spring; Tensioning roller
01func09
When the transfer pinch is made, the master speed increases. A shortage of master arises before the pinch and a surplus after the pinch. To compensate for this, the first bulge roller lifts the master and the second bulge roller lowers. The bulge rollers are connected by a wire at the front and a wire at the rear. Each wire is tensioned by a spring. Both rollers move together and the master is kept at the proper tension. The first bulge roller always returns to a fixed startposition. This guarantees a fixed masterlength between the first bulge roller and the transfer pinch at the time the pinch is made. Otherwise image shift in transport direction would occur. The bulge rollers and the master tensioning roller are mounted in a frame, they must be removed when installing a new master. They are positioned on the photoconductor side of the master. The middle roll is smaller then the outside rolls so it is not touching the photoconductive layer.
ed.6 Part II
TSM 2400 family
01func
Master cooling system

The figure below shows the cooling system.
-A-B-
Master cooling fan 01M1; Cooling roller
01func10
The TTF belt operates at a temperature of about 119C. The master is heated every time a transfer occurs. There are 2 major reasons for cooling the master: to prevent toner melting on the master (clogging)(critical 45C) to prevent damage to the photoconductive layer (critical 50C)
TSM 2400 family
Part II ed.6
01func
Excess heat is transferred from the master to the hollow cooling roller. A fan blows cold air through the cooling roller to remove the excess heat. The operating panel and the RDF control board are cooled by channels in the front cover. Circuit diagram description: (see 701). The master cooling motor has two speeds: low speed during standby, and full speed during a copy run. During standby, signal FANSPCTR from the HOST-I/O (22PBA02) is low 0. Fan motor 01M1 is connected to ground through a series resistor and runs at low speed. During a run, signal FANSPCTR goes high 1. A transistor on the 24V driver board (22PBA09) short circuits the resistor and connects the motor directly to ground. It now runs at full speed.
ed.6 Part II
TSM 2400 family
01func
Operation
During power up / initialisation: The next actions start simultaneously: (see diagram 01/701 and 23/701).
The master cooling fan starts running at high speed, FANSPCTR is high 1. The setup mechanism goes up, SUMMO becomes high 1 The standby motor starts, STBMO is high 1 Master transport is started. MADR is high 1. Acceleration time is 200msec maximum. After these 200ms, the pulses (MASPULSE) from pulse sensor 01SO2 are continuously counted during periods of 300ms to check the master speed. Initialisation: The control checks for the master hole. When it is found the MASHOLSE pulse duration at least 2 counter pulses long is checked, the master hole is not detected within 1319 counter pulses, and MADR becomes low 0. After the second valid master hole detection (MASHOLSE) one complete master revolution is made. During this revolution the counter pulses are counted and checked. SUMSE is checked to make shure the setup mechanism is in the upper position. After the second master hole detection the master transport is stopped and a distance is facing the scorotron . During master stop the counter pulses are counted to check the master stop length. The master stop time is maximum 400ms. During standby: The master belt is stationary. All units that might damage the master are facing a distance. The master cooling fan (01M1) is running at low speed, FANSPCTRL is low 0. During run: The next actions start simultaneously:
The master cooling fan starts running at high speed, FANSPCTR is high 1. The setup mechanism goes up, SUMMO becomes high 1. Master transport is started MADR is high 1. After 200ms master pulses (MASPULSE) are continuously counted during periods of 300ms to check the master speed.
TSM 2400 family
Part II ed.6
01func
Everytime when the master hole is recognized the MASHOLSE pulse duration is checked. During every revolution between two holepulses the counter pulses are counted and the number of pulses is checked. About 2s after a flash the transfer pinch is closed. Just before activating the clutch the setup mechanism sensor is checked to verify that the setup mechanism is in the upper position, SUMSE should be low 0. The transfer clutch (01CL2) is activated by making control line TFRCL high 1 for about 30msec. During master stop the master pulses are counted to check the master stop length. The master stop time is maximum 400ms (less than 40 pulses). The master cooling fan is switched to low speed, FANSPCTR is low 0. Master transport is stopped when: the job is finished the last charged image section passed the cleaning unit a distance is facing the scorotron
ed.6 Part II
TSM 2400 family
01func
TSM 2400 family
Part II ed.6
01comp
COMPONENT LOCATION
COMPONENT LOCATION
01BR1 01CL2 22CN1 22CN2 01S1 01SO1 01M2 01SO2 : : : : : : : : set up motor brake transfer clutch drawer connector drawer connector set up mechanism sensor master hole sensor set up mechanism motor master pulse sensor
01comp01
ed.6 Part II
TSM 2400 family
COMPONENT LOCATION
01comp
01CN1 01M1
: connector master cooling fan : master cooling fan
01comp02
TSM 2400 family
Part II ed.6
01elec
ELECTRICAL DIAGRAM
ELECTRICAL DIAGRAM 1 Signal names

MADR MASHOLSE MASPULSE NSUMSE SUMSE SUMMO SUMMOBR TFRCL FANSPCTR MAin DRive MASter HOLe SEnsor MASter PULse SEnsor Not Set Up Mechanism SEnsor Set Up Mechanism SEnsor Set Up Mechanism MOtor Set Up Mechanism MOtor BRake TransFeR CLutch Fan Speed ConTRol
ed.6 Part I
TSM 2400 family
ELECTRICAL DIAGRAM
01elec
TSM 2400 family
Part I ed.6
Electrical Diagram
02diag
DIAGNOSTIC
0210 0211 corona voltage not present ozone exhaust failure
MRE
0225 0226 corona voltage not present ozone exhaust failure
Warnings
0275
exhaust sensor failure 02SO1
ed.6 Part I
TSM 2400 family
02 Charging 101
DIAGNOSTIC
02diag
Fault table
M0225, P0210 - corona is broken - corona wire unit is fault - scorotron roller not earthed, carbon brush is fault (FUNC 01) - power supply is fault, voltage too high - grid unit is fault ( springs ) - grid is broken - plectrum broken - gear broken - DC-motor not functioning - defective master/joint - power supply is fault, voltage not present or too low (02PBA01) - power supply constant activated, scoron is active (02PBA01) M0226, P0211 - airflow sensor is fault (02SO1) - ventilation is fault or broken (02M1) - ozon exhaust filters are silted up W0275 - airflow sensor is fault (02SO1)
102 Charging 02
TSM 2400 family
Part I ed.6
02diag
DIAGNOSTIC

SCORFAIL is checked 1x/sec after the scorotron supply is switched on. First check is done 50 ms after switching on. SCORFAIL must be active two times in succession (within two seconds) to cause MRE0225.
0 = correct 1 = defective scorotron supply, MRE 0225 PE 0210
MRE 0226 PE 0211

CHGEXHSE is checked 1x/sec during run. First check is done 20 sec after start of run.
0 = correct 1 for 2 checks after another = no ozone exhaust, MRE 0226 PE 0211
WARNING 0275
CHGEXHSE is checked 1x/sec during standby. First check is 60sec after end of run. 0 = correct 1 = defective vane sensor, WARNING 0275
ed.6 Part I
TSM 2400 family
02 Charging 103
DIAGNOSTIC
02diag
104 Charging 02
TSM 2400 family
Part I ed.6
02sds
SDS
TESTNUMBER COMPONENT COUNTERS 02 0 10 PE 02 0 11 PE 02 0 25 MRE 02 0 26 MRE 02 0 75 W

SIGNAL -0-
DESCRIPTION in SDS
02SO1 -1-202SO1 CHGEXHSE SCORFAIL -402M2 02M2 SCOMCW SCOMOCCW
corona voltage not present ozone exhaust failure corona voltage not present ozone exhaust failure exhaust sensor failure
PARAMETERS INPUT TESTS 02 2 01 02 2 02 OUTPUT TESTS 02 4 01 02 4 02
CHarGe EXHaust SEnsor SCORotron FAILure
SCOrotron MOtor ClockWise (02M2) (1.7s) SCOrotron MOtor Counter ClockWise (02M2) (1.7s)
ed.6 Part I
TSM 2400 family
02 Charging 201
SDS
02sds
TESTNUMBER COMPONENT SPECIAL TESTS 02 6 01 02 6 02 02 6 03 02 6 04
SIGNAL -6-
DESCRIPTION in SDS
CHGEXHSE
make function WARM make function COLD mask function protections CHarGe EXHaust motor/SEnsor on: Note 1
REPLACE CONSUMABLES
-8-
Note 1:
1.<PRINT><active>motor<ON>, sensor<ON>><OFF> 2.<PRINT> motor<OFF> 3. Wait few seconds : sensor<OFF>><ON>.
202 Charging 02
TSM 2400 family
Part I ed.6
02adju
ADJUSTMENTS
ADJUSTMENTS 1 Rear plate scorotron unit. Aim:

To achieve that the rear plate is in good contact with the suction mouth.This will prevent ozon from shortening the life-time of the master.
Check:
Lower the suction mouth. Look at the front and the rearside of the copier that rear plate -B- and side frame -Care at the same height.
Correction:
1.1 1.2 1.3 1.4 Remove the scorotron unit; Remove the power supply unit -D-; Loosen screws -A- (2x). Move rear plate -B-, so that plate and side frame are at the same level, front and back; Tighten screws -A-; Continue with CHECK adjustment 02-2. position suction mouth.
1.5 1.6
02adju1a
02adju1b
ed.6 Part I
TSM 2400 family
02 Charging 301
ADJUSTMENTS
02adju
Suction mouth ozone exhaust. Aim:

To achieve a good retainment between scorotron and suctionmouth, so that no ozone filled air can pollute the environment or can damage the master.
Check:
If the smell of ozone is present, proceed as follows: Use the grip to lower and raise the suction mouth. Observe the point of contact, front and rear. Situation a shows the correct position of the suction mouth. Both parts are touching.
Correction:
2.1 2.2 Check adjustment 02-1; Activate test 01 6 01 <PRINT> and wait for the message <WARM>; 2.3 Switch the machine off; 2.4 Remove the cleaning unit to have better access; 2.5 Remove the scorotron unit to get access to the suction mouth; 2.6 Slide the master handling into the copier. 2.7 Raise the suction mouth to the upper position, but make sure not to touch the master; 2.8 Visually check for: - parallelism between suction mouth and master; - a distance of 1.5 mm between suction mouth and master; if not correct loosen bolts -A- (5x) and move frame -B- to adjust; 2.9 Install the scorotron unit again; 2.10 Raise the suction mouth completely and check if the position of the suction mouth, front and rearside is correct; situation a. Only if not correct proceed with 2.11.
02adju2a
302 Charging 02
TSM 2400 family
Part I ed.6
02adju
ADJUSTMENTS
2.11 2.12 2.13 2.14 2.15 2.16
Lower the suction mouth using the grip; Loosen bolts -A- (5x); Raise the suction mouth to the upper position, close but not touching the scorotron; Move frame -B-, front and rearside, towards the scorotron unit; Tighten bolts -A- (5x); Loosen bolts -D- and move plate -C- towards to the suction box as indicated, tighten bolts -D-; 2.17 Raise the suction mouth completely and check if the position of the suction mouth, front and rearside is correct; situation a. 2.18 If still incorrect proceed with 2.11:
02adju2b
ed.6 Part I
TSM 2400 family
02 Charging 303
ADJUSTMENTS
02adju
304 Charging 02
TSM 2400 family
Part I ed.6
02func
FUNCTIONAL DESCRIPTION 1 Charging section

The function of the charging section is to charge the master electrically to a correct and controlled ASV (Apparent Surface Voltage). The charging section consists of: -A-B-Cthe scorotron unit; the complementary scorotron roller/master cooling roller; (refer to function 01, photoconductor) the ozone exhaust system;
02func01
ed.6 Part II
TSM 2400 family
02 Charging 501
02func
Scorotron unit
The scorotron unit consist of :
-A-B-C-D-E-F-
the grid unit; the corona wire unit; the power supply unit. connector 02CN3 connector 0201CN1 Scorotron clean motor (02M2)
02func07
The charge unit is called the SCOROTRON, which stands for: Screen-COROna-elecTRONs. The ionization of the air is created by a corona wire, consisting of 5 windings. The current to the master is no longer undefined, but controlled by a grid located between the wire and the master.This grid limits the current to the master, and therefore controls the Apparent Surface Voltage (ASV) of the master. The ASV on the master depends on: - the number of copies made , master detoriation; - the condition of the scorotron, toner pollution; - the environmental conditions, such as humidity, temperature, gases. The advantage of a scorotron unit as compared to a corona unit is that it keeps functioning under various conditions, such as: - low humidity ( dry weather) - low air pressure (high altitude) This is a result of the charge process being controlled.
502 Charging 02
TSM 2400 family
Part II ed.6
02func
The grid unit consists of a frame and 5 grids -A-. The grids are very thin, and made of steel. They are kept at a constant tension and do not need adjusting. The function of the grid is to control the Apparent Surface Voltage (ASV) on the master. For this reason the grid is connected to a negative voltage of -135V. The normal ASV is about -250V, but this will vary depending on conditions such as humidity, pollution etc. Because toner pollution of the grid has a bad influence on the ASV and so on the copy quality, the grid is periodically cleaned by a grid jogger. The grid jogger reduces toner pollution on the grid. It consist of a plectrum -F- on the synthetic belt -E-. The belt with the plectrum runs in a groove underneath the grid. The belt is rolled up on a gear on the scorotron clean motor -D- (02M2), which can turn in two directions, backwards and forwards. The toner which fall off the grid, is removed by the scorotron fan (02M1). The scorotron clean motor is positioned on the front side on top of the scorotron unit. During power-up, this unit is initialized by moving the plectrum to the outside and let it run to the rolled-up position. The grid jogger is activated every 5000 copies. It will be activated at 02func08 the end of the run and not during a copy run. When the grid jogger runs over the grid segments, the scorotron must not be activate. The scorotron can be activated again when the vibration of the grid segments has stopped. The motor of the grid jogger is activated by two signals, SCOMOCW and SCOMOCCW from scorotron clean driver (02PBA02). SCOMOCW (high) moves the plectrum to the outside and SCOMOCCW (high) moves the plectrum to the inside.
ed.6 Part II
TSM 2400 family
02 Charging 503
02func
The corona wire unit consists of a metal rear plate, a corona wire (5 windings) and 2 plastic profiles. Since it is one separate unit, it is easy to install a new wire. The corona wire is gold plated tungsten, with a diameter of 40m (Oc 1900 coronawire =25 m). To ionize the air around the wires and produce ions, a negative voltage of -6kV is connected to the corona wire.
The 5 windings spray ions at the rear plate and at the master. Ions moving towards the master have to pass the grid. A certain amount of these negative ions will drain away by the grid. Those that pass the grid will charge the master, but not beyond a maximum value. If the corona wire is polluted with toner dust, the charge on the master will be uneven. To overcome these pollution problems, a new corona wire must be installed regularly and the scorotron grid must be cleaned each visit.
504 Charging 02
TSM 2400 family
Part II ed.6
02func
The function of the scorotron power supply is: generate a grid voltage of -135VDC generate a corona wire voltage of -6kV
02func05
Circuit diagram description(see 701) : When the control makes control line MADR high 1, LED 7 on SSR1 (22PBA06) will lit. A triac on SSR1 is switched on and 220VAC is available for the scorotron supply. Together with the ozone exhaust motor (02M1). A 1.25A fuse (F3) is installed on SSR1 (22PBA06). When the control makes control line SCORON high (1), the charge proces is started so -135VDC and -6kV are available. Charging continues until SCORON goes low at the end of the run. Control line SCORFAIL reflects the status of the scorotron supply. In normal situation this line is low (0). In case of an error: control line SCORFAIL becomes high (1). Which will result in a machine recoverable error or a permanent error. A fuse of 4A (F3) is installed on SSR1 (22PBA06).
Normal situation : SCORFAIL = 0 Icorona = 2.8mA 2% -9kV < Vcorona < -1kV and Vgrid = -135V
Error = 1 Icorona > 2.8mA 2% Vcorona < -9kV or Vgrid > -100V
ed.6 Part II
TSM 2400 family
02 Charging 505
02func
Ozone exhaust system

The ozone exhaust system consist of:
-A-B-C-D-
Suction mouth Filter box Fan motor Air flow sensor, 02SO1
02func06
Charging the master with a high corona voltage causes ozone. This ozone has a bad effect on the dyes in the master layer and will decrease the lifetime of the master. A fan motor and a carbon filter exhaust and neutralise the ozone filled air.The ozone exhaust system is connected to the scorotron unit by a releasable suction mouth. The release mechanism makes it possible to pull out the master section including the scorotron unit. Circuit diagram description (see 701): When control line MADR becomes high (LED 7 is lit) 220VAC is supplied. The fan motor (02M1) is switched on by a triac on SSR1 (22PBA06). The correct operation of the exhaust, is checked by an air flow sensor (02SO1). As long as the air flow is sufficient, the vane of the sensor is operated and the feedback signal CHGEXHSE is low (0).
506 Charging 02
TSM 2400 family
Part II ed.6
02func
Operation
During power up / initialisation: While master transport takes place 220VAC is available at the connector of the scorotron supply. At the same time the ozone exhaust motor (02M1) is running. The ozone exhaust sensor control line CHGEXHSE is low 0. Control line MADR (LED7 is on) on SSR1 is high 1. Control line SCORON is low 0 and SCORFAIL is high 1, no charging takes place ( -135VDC and -6kV are not available). The scorotron clean motor (02M2) is switched on.
During standby: 220VAC is not available at the scorotron power supply and ozone exhaust motor.
Control lines SCORON and MADR are low 0, while CHGEXHSE and SCORFAIL are high 1. During run: At the beginning of the run control line MADR is activated (high 1). As a result the switched 220VAC becomes available which causes: main drive motor (23M2) starts running; clean lamp (07LA1) switches on; ozone exhaust motor (02M1) starts running; 220VAC is available on the board of the scorotron power supply (02PBA01). every 5000 copies the grid jogger is activated. About 2 sec before the first flash, control line SCORON becomes high 1. Charging then takes place and so -135VDC and -6kV are available at respectively the grid and the corona wire. SCORON stays high for two more image sections after the last exposed original/image section. MADR stays high for 5 more image sections until the last original is delivered in the finisher, when no new original is entered. SCORFAIL is low 0 when charging takes place and high 1 when no charging takes place or an error occurred.
ed.6 Part II
TSM 2400 family
02 Charging 507
02func
508 Charging 02
TSM 2400 family
Part II ed.6
02comp
COMPONENT LOCATION
COMPONENT LOCATION
02PBA01 02PBA02 22CN2 02CN1 02CN2 02CN3 02M2 : : : : : : : scorotron supply-PBA scorotron clean driver (see function 4) drawer connector connector scorotron supply connector connector scorotron clean motor scorotron clean motor
02comp01
ed.6 Part II
TSM 2400 family
02 Charging 601
COMPONENT LOCATION
02comp
02CN1 02C1
: connector ozone exhaust fan : capacitor ozone exhaust fan
02comp04
02SO1 02CN2 02M1
: ozone exhaust sensor : connector ozone exhaust sensor : ozone exhaust fan
02comp03
602 Charging 02
TSM 2400 family
Part II ed.6
02elec
ELECTRICAL DIAGRAM

CHGEXHSE MADR MT SCORON SCORFAIL SCOMOCW SCOMOCCW CHarGe (ozone) EXHaust SEnsor MAin DRive Main Transport SCORotron supply ON SCORotron FAILure SCOrotron Motor On ClockWise SCOrotron Motor On Counter ClockWise
ed.6 Part I
TSM 2400 family
02 Charging 701
ELECTRICAL DIAGRAM
02elec
702 Charging 02
TSM 2400 family
Part I ed.6
Electrical Diagram
02 CHARGING 701
03diag
DIAGNOSTIC
0310 0311 0312 edge discharge lamps failure flash capacitors not charged int. flash ignition failure
MRE
0325 0326 0327
edge discharge lamps failure flash capacitors not charged int. flash ignition failure
ed.6 Part I
TSM 2400 family
03 Framing 101
DIAGNOSTIC
03diag
Fault table
M0325, P0310 - Edge discharge lamps 1 - 7 is ( are ) blown - CN2 loose on 03PBA01 - CN1 loose on 03PBA01 - 03PBA02 defect M0326, P0311 - CN1 loose on 03PBA01 - 03PBA01 defect M0327, P0312 - Fuse F1 of 03PBA01 blown - CN1 loose on 03PBA01 - 03C1 or 03C2 short-circuited - CN2 loose on 03PBA01 - Open connection between 03C1 and 03C2 - Supply voltage low (mains) - One or both flash lamps on 03PBA01 not ignited - 03PBA01 defect - 03C1 and/or 03C2 defect
102 Framing 03
TSM 2400 family
Part I ed.6
03diag
DIAGNOSTIC

FRALACONT is checked 1x/sec during standby and run.
1 = correct 0 = defective edge discharge lamp(s), MRE 0325, PE 0310
MRE 0326 PE 0311

FRAFLCONT is checked 1x/sec during standby.
1 = correct 0 = defective interval flash pba 03PBA01, MRE 0326, PE 0311
MRE 0327 PE 0312

FRAFLCONT is checked 6-12msec after ignition during run 0 = correct 1 = no interval flash, MRE 0327, PE 0312
ed.6 Part I
TSM 2400 family
03 Framing 103
DIAGNOSTIC
03diag
104 Framing 03
TSM 2400 family
Part I ed.6
03sds
SDS

SIGNAL -0LA1-LA7 03C1-03C2 FRALACONT FRAFLCONT FRAFLCONT FRALACONT FRAFLCONT FRAFLCONT -1interval flash positioning, Default value : 80 -2LA1-LA7 LA1-LA2 FRALACONT FRAFLCONT -4LA1-LA7 FRALAD210 all edge discharge lamps on (111) (15s) edge discharge lamps control interval flash tubes control edge discharge lamps filament broken charge voltage capacitors too low no ignition of the flash tubes edge discharge lamps filament broken charge voltage capacitors too low no ignition of the flash tubes DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 03 0 10 PE 03 0 11 PE 03 0 12 PE 03 0 25 MRE 03 0 26 MRE 03 0 27 MRE PARAMETERS 03 1 01
LA1-LA7 03C1-03C2
INPUT TESTS 03 2 01 03 2 02 OUTPUT TESTS 03 4 01
ed.6 Part I
TSM 2400 family
03 Framing 201
SDS
03sds
SPECIAL TESTS 03 6 01 03 6 02 03 6 03 03 6 04 03 6 05
-6make function WARM make function COLD mask function protections Note 1 Note 2
LA1-LA7 LA1-LA2
FRALAD210 FRAFLCONT -8-
REPLACE CONSUMABLES
Note 1: all lamps / formats (001, 010,..,000) on one by one, using <PRINT>button. By pressing repeately the <PRINT> button, the framing lamps are switched on and the data (FRALAD) are displayed. See table below. Image length upto 356 mm upto 330 mm upto 297 mm upto 270 mm upto 254 mm no framing FRALAD 210 001 010 011 100 101 000
Note 2: interval flash active for 1 second at a frequency of 12Hz
202 Framing 03
TSM 2400 family
Part I ed.6
03adju
ADJUSTMENTS
ADJUSTMENTS 1 Edge discharge width. Aim:

To achieve a background free edge of 2mm on each side of the copy.
Check:

Select zoom position 100%. Copy paper and testchart must have the same format. Make 8 copies with testchart 19 at the zero point and against the ruler on the original glass. At both side edges on the copy (zero and format side) line -3" must be visible (testchart 19). NOTE : At each side of the board, scale divisions are present. Each division corresponds with one line on the copy. If a new lamp has to be installed, remember the position of the grate on the division scale.
Correction:
1.1 1.2 Check 04 adjustment 2. Determine on the copies which line is visable at the zero side and at the format side; Remove the framing section from the master section. ZERO" side. Loosen screws -A- and move the grate the determined number of divisions to the left or right. FORMAT side; Loosen screws -B- and move the grate block the determined number of devisions to the left or right; Tighten the screws.
03adju1a
1.3
1.4
1.5
03adju1b
1.6
ed.6 Part I
TSM 2400 family
03 Framing 301
ADJUSTMENTS
03adju
Interval flash discharge position. Aim:

To achieve a background free and equal discharge edge of 2 mm at lead and trail edge of the copy.
Check:
Select zoom position 100%. Copy paper and used testchart must have the same format. Make 1 copy with testchart 19 on the original glass platen. At both edges on the copy (lead and trail) line -3" must be visible; (testchart 19). NOTE : Interval flash positioning: Using SDS parameter 03 1 01 it is possible to change the timing of the interval flash. Default value is 80. It is adjustable between 0 and 160. Each point corresponds with 0,1mm displacement.
Correction:
2.1 2.2 2.3 2.4 Check and if necessary adjust the first paper stop; see 12,adjustment 5. Make 8 copies of testchart 40; Determine if the black image on the copies is in the centre of the paper; The value of parameter 03 1 01 must be: - decreased if the white band lead edge is larger than the trail edge. - increased if the white band lead edge is smaller than the trail edge.
302 Framing 03
TSM 2400 family
Part I ed.6
03func
FUNCTIONAL DESCRIPTION 1 Framing section

The function of the framing section is to discharge the parts of the master that do not carry an image. Framing section consists of: -A-BInterval flash unit Edge discharge unit
03func01
ed.6 Part II
TSM 2400 family
03 Framing 501
03func
The framing section consists of 2 separate systems: interval flash, which is responsible for discharging the distances between the used image sections on the master. edge discharge, which is responsible for discharging the edges of the master. These 2 discharge systems define the format of the image on the master. It will always correspond with the size of the paper being used. This means that the Oc 2400 will deliver a clean copy with a white frame of about 2mm. Pollution inside the copier will be kept to a minimum. To deliver a clean copy extra discharge is done when manually the reduction ratio is set to a value between 64% and 70%.
03func05.gem EDGE DISCHARGING
03func06.gem INTERVAL FLASH
502 Framing 03
TSM 2400 family
Part II ed.6
03func
Interval flash
The function of the interval flash is:
Discharge the distance between the master image sections Discharge unused image sections (duplex mode) Discharge parts of the image section that are not used because of margin shift Discharge the part of the master that is not used at the beginning or end of a run. The interval flash consists of: Interval flash pba, 03PBA01 Interval flash lamps, 03LA1 03LA2 Interval flash capacitors, 03C1 03C2
-A-B-C-
03func03
03func02
ed.6 Part II
TSM 2400 family
03 Framing 503
03func
One flash will discharge a master length of 66.5mm. There will always be at least two flashes between image sections: one for the trail edge, and one for the lead edge. The exact length to be discharged depends on 4 things: - the width of paper used - the selected margin shift - the duplex mode - the manual reduction < 70% There is no width detection in the Oc 2400. For standard paper sizes, the width corresponds to the length. The length is measured, by sensors in each paper tray. The table below shows how the widths of the standard paper sizes correspond with their lengths. length (mm) length (inches) width (mm)/ (inches) 203 mm / 8" 210 mm / 8,3" 216 mm / 8,5" 254 10" 270 279 11" 297 330 13" 356 14"
* * letter A4
* folio *
You will notice that 330mm long paper can have three different widths. The customer must indicate which size he will use. Service can then program this width into the software by using SDS test 93(2) paper sizes. The margin shift can vary between 4 and 20mm.
504 Framing 03
TSM 2400 family
Part II ed.6
03func
Circuit diagram description : (see 701).

The interval flash board (03PBA01) is connected to 2 power supplies: 220VAC; - for charging the flash capacitors (03C1, 03C2); - for charging the ignition capacitors; - for igniting the flash lamps LA1 and LA2, by using a local 15VDC; 12VDC, for the frame flash control circuit. The 220VAC power supply comes directly from the terminal block (L2 and N2). There is a fuse, F1 = 150mA, in the L2 supply on the interval flash board. At the moment the copier is powered up:
the flash capacitors (03C1, 03C2) are charged to 300-400VDC the ignition capacitors are charged to 240VDC When by control line FRAFLIGN has a positive pulse applied, the thyristor is triggered. The ignition capacitors discharge by this thyristor, an impulse transformer generates an ignition pulse of 7kV. This high voltage ignition pulse ionizes the interval flash lamps (LA1, LA2) and the flash capacitors (03C1, 03C2) discharge through the flash lamps which result in a flash. The ignition capacitors and flash capacitors are recharged immediately. If the copier is switched off, the flash capacitors discharge by resistors.
03func08.gem
ed.6 Part II
TSM 2400 family
03 Framing 505
03func
Frame flash check :

By means of signal FRAFLCONT the condition of the interval flash circuit is checked during standby and during a run. These checkes are done to be sure that no pollution can occur. If one or both flash capacitors (03C1,03C2) are charged FRAFLCONT is high 1. This is checked during standby. If both capacitors are not charged above a certain level an error message will be displayed. After an ignition pull, FRAFLIGN is high 1, FRAFLCONT becomes low 0 for a short period. This is checked by the control. If one or both flash capacitors are not discharged an error message will be displayed.
506 Framing 03
TSM 2400 family
Part II ed.6
03func
Edge discharge
The funtion of the edge discharge is to discharge :
The front edge of the master, zero side; The rear edge of the master over different distances, depending on the paper size, format side. Edge discharge consist of :
-A-B-C-D-
Zero lamp LA1 Format lamps LA2 - LA7 Grates Edge discharge pba, 03PBA02
03func04
One single lamp is positioned at the front side of the copier, the zero lamp. It discharges 37mm of the front edge of the master and is switched on during every run. Six lamps are positioned ar the rear side. They are separated by an adjustable grate.
ed.6 Part II
TSM 2400 family
03 Framing 507
03func
The number of lamps lit at the rear side during a run depends on the size of paper currently in use. The edge discharge can handle six different paper lengths. If one of the lamps needs to be changed, the grate will need to be readjusted. The lamps that are lit for different paper lengths are: length (mm) length (inches) lamps 1 2 3 4 5 6 7 254 10" * * * * * * * 270 * * * * * * 279 11" * 297 * 330 13" * 356 14" *
* * * *
* * *
* *
* = lamp lit Lamp 1 is zero lamp. The advantages of the type of lamp used are:
it does not need much space; it has a long filament, which guarantees an even discharge of the master. Below the decode table of signals FRALAD2-1-0 : L=Low , H=High , 1=lit , 0=off.
FRALAD2 L L L L H H H H L L H H L L H H
FRALAD1 FRALAD0 LA1 LA2 LA3 LA4 LA5 LA6 LA7 L H L H L H L H 0 1 1 1 1 1 1 1 0 0 0 0 0 0 1 1 0 0 0 0 0 1 1 1 0 0 0 0 1 1 1 1 0 0 0 1 1 1 1 1 0 0 1 1 1 1 1 1 0 1 1 1 1 1 1 1
508 Framing 03
TSM 2400 family
Part II ed.6
03func
Circuit diagram description : (see 701)

On the edge discharge pba there are 7 identical circuits, one for each lamp. The lamps LA1 to LA7 are controlled by 3 input lines: FRALAD0, FRALAD1, and FRALAD2. These 3 control signals come from the HOST I/O (22PBA02) and have 8 possible codes to switch on different combinations of lamps. Both outer lamps LA1 (the zero lamp) and LA7 will be switched on as soon as one of the input lines becomes high 1. The 5 other lamps, LA2 - LA6 are switched on in combination, depending on the paper size detected by the sensor in the paper tray. LA2 - LA6 are controlled by the code on the 3 input lines. Each lamp is switched on and off by an output stage. There will always be a current through the lamps. When the lamp is on, the voltage across the lamp is approximately 20V. When the lamp is off, the voltage is about 2.5V.
A broken edge discharge lamp causes system polution. A protection circuit on the edge discharge pba monitors the current in the lamps. If one or more filaments are broken, the output line FRALACONT becomes low 0, which will be reported to the control.
03func07.gem
ed.6 Part II
TSM 2400 family
03 Framing 509
03func
Operation
During power up / initialisation: The supply voltages 220VAC, 24VDC, 12VDC are available at the connectors. The ignition capacitors and flash capacitors (03C1, 03C2) are charged. All lamps are off. The voltage over the flash lamps (LA1, LA2) is 300-400VDC. The voltage over the edge discharge lamps is about 2.5VDC. The control lines FRAFLIGN, FRALAD0, FRALAD1, FRALAD2 are low (0). Control lines FRALACONT and FRAFLCONT are high (1). During standby: Identical to initialisation. During run: About 1 sec before the first exposure flash the appropriate edge discharge lamps are switched on. Lamps LA1 (front) and LA7 (rear) are switched on during every run, the other lamps LA2 - LA6 are swithed on in combination, depending on the paper size detected by the sensor in the paper tray. The voltage over the lamps that are switched on is about 20VDC, the voltage over the lamps that are switched off is about 2.5VDC. Control lines FRALAD0-2 indicate a binary coding corresponding with the detected paper size, while FRALACONT is high 1. The selected lamps remain on till the end of the copy run, as long as the scorotron is switched on. At the start of the run the first two image sections are discharged by the interval flash. During the run the distances and not used image sections are discharged by interval flashes. At the end of the run the last two image sections are discharged by interval flashes.
510 Framing 03
TSM 2400 family
Part II ed.6
03comp
COMPONENT LOCATION
COMPONENT LOCATION
0301CN1 03PBA01 03PBA02 : connector interval flash PBA : interval flash PBA : edge discharge PBA
03comp01
03CN1 0302CN1 0301CN2 03C1 03C2
: drawer connector 220V-supply interval flash PBA and 24V-supply edge discharge PBA : connector edge discharge PBA : connector interval flash PBA : framing flash capacitor : framing flash capacitor
03comp02
ed.6 Part II
TSM 2400 family
03 Framing 601
COMPONENT LOCATION
03comp
602 Framing 03
TSM 2400 family
Part II ed.6
03elec
ELECTRICAL DIAGRAM
ELECTRICAL DIAGRAM 1
FRAFLIGN FRAFLCONT FRALADx FRALACONT FRAming FLash IGNition FRAming FLash CONTrol FRAming LAmps Driver FRAming LAmps CONTrol
ed.6 Part I
TSM 2400 family
03 Framing 701
ELECTRICAL DIAGRAM
03elec
702 Framing 03
TSM 2400 family
Part I ed.6
Electrical Diagram
03 FRAMING 701
04diag
DIAGNOSTIC
0410 0411 0412 0413 0414 0415 0416 0417 0418 0419 0420 0421 charging level C1/C2 too low no discharge of capacitors continuously charged capacitors temp. flash power supply too high charge control failure charge level too low discharge failure optic time out 04SO2 too late free no movement of optic optic motor speed too high optic motor speed too low
MRE
0425 0426 0427 0428 0429 0430 0431 0432 0433 0434 charging level C1/C2 too low no discharge of capacitors temp. flash power supply too high charge control failure charge level too low optic time out 04SO2 too late free no movement of optic optic motor speed too high optic motor speed too low
ed.6 Part I
TSM 2400 family
04 Exposure 101
DIAGNOSTIC
04diag
Fault table
M0425, P0410 - CN1/CN2 on 04PBA01 loose - 04C1 and/or 04C2 defective (short circuit) - CN4 loose on 04PBA01/open circuit of 04C1 and 04C2 - 04S1 defective/open - 04FI1 defective coil open circuit - 04CN1 loose - 04C1 and 04C2 defective (open circuit) or loose - 04PBA01 defective - overvoltage protection on 04PBA01 defective - converter on 04PBA01 defective - charging current on 04PBA01 too low - flash lamps 04LA1 or/and 04LA2 : double flash M0426, P0411 - 04L1 open circuit - CN3 and CN5 of 04PBA02 loose - CN1 of 04PBA02 loose no power on PBA - flash lamps 04LA1 or/and 04LA2 defective - CN7 of 04PBA02 loose - CN2 of 04PBA02 loose - CN4 of 04PBA02 loose - 04PBA02 defective or C2/C8 on 04PBA02 defective P0412 - charge level control on 04PBA01 defective (not functioning) - power supply continuous switched on - spontaneous charging of 04C1/04C2 (converter continuous switched on)
M0427, P0413 - motor 04M2 defective (04PBA01) CN11/16 bad contact - polluted filter M0428, P0414 - power supply continuous switched on - 04CN1 loose - spontaneous charging of 04C1/04C2 (converter continuous switched on) - 04S1 defective/open - CN1/CN2 on 04PBA01 loose - 04FI1 defective coil open circuit - switch on current limitation of 04PBA01 defective - converter on 04PBA01 defective - 04PBA01 defective - loose nuts on capacitors Fault Table continue : next page.
102 Exposure 04
TSM 2400 family
Part I ed.6
04diag
DIAGNOSTIC
CODES
POSSIBLE FAILURES
M0429, P0415 - 04C1 and 04C2 defective (open circuit) or loose - CN4 loose on 04PBA01/open circuit of 04C1 and 04C2 - 04C1 and/or 04C2 defective (short circuit) - charging current on 04PBA01 too low - 04S2 can not be opened - discharge circuit defective (cont. closed) - converter on 04PBA01 defective - 04PBA01 defective P0416 - discharge circuit defective (cont. open) - converter on 04PBA01 defective - 04PBA01 defective
M0430, P0417 - motor 04M1 turns only clockwise - optics frame slide bearings are stuck - motor optics positioning is fault - cable optic drive is fault - bearing of steel belt guiding wheel is fault - mirror frame linear ball bearings are stuck - drive belt broken - motor speed too low - bearing of optic cable guide is stuck - optic motor sensor 04SO1 defective (constantly low) - main drive bearings are stuck - optics frame linear ball bearings are stuck - motor 04M1 not turning - optics frame longitudinal bearing is stuck - reference sensor 04SO2 defective - optics frame ball bearings are stuck - bearing of mirror rotation cam is stuck - main drive bearings are stuck M0431, P0418 - motor optics positioning is fault - reference sensor 04SO2 defective - bearing of steel belt guiding wheel is fault - optics frame ball bearings are stuck Fault Table continue : next page.
ed.6 Part I
TSM 2400 family
04 Exposure 103
DIAGNOSTIC
04diag
CODES
POSSIBLE FAILURES
M0431, P0418 - optic motor sensor 04SO1 defective (constantly low) - optics frame linear ball bearings are stuck - motor 04M1 turns only counter clockwise - bearing of optic cable guide is stuck - optics frame slide bearings are stuck - motor 04M1 not turning - mirror frame linear ball bearings are stuck - drive belt broken - cable optic drive is fault - optics frame longitudinal bearing is stuck - bearing of mirror rotation cam is stuck M0432, P0419 - optics frame linear ball bearings are stuck - bearing of optic cable guide is stuck - optic motor sensor 04SO1 defective (constantly low) - motor 04M1 turns constantly - optics frame slide bearings are stuck - optics frame ball bearings are stuck - optics frame longitudinal bearing is stuck - motor optics positioning is fault - main drive bearings are stuck - motor 04M1 not turning - bearing of steel belt guiding wheel is fault - mirror frame linear ball bearings are stuck - bearing of mirror rotation cam is stuck - pulley optic drive loose - output stage on 04PBA03 continue driven/control circuit defective - output stage on 04PBA03 short circuit M0433, P0420 - motor 04M1 turns constantly - motor speed too high - output stage on 04PBA03 continue driven/control circuit defective - output stage on 04PBA03 short circuit - optic motor sensor 04SO1 defective (constantly high)/HOST I/O 22PBA01 M0434, P0421 - motor speed too low
104 Exposure 04
TSM 2400 family
Part I ed.6
04diag
DIAGNOSTIC

EXPNRDY is checked just before the flash during operation,
0 = charge level correct 1 = requested charge level not reached, MRE 0425 PE 0410
MRE 0426 PE 0411

EXPNRDY is checked just after the flash during operation,
1 = correct, capacitors discharged 0 = charge level = 1900VDC after ignition, no flash, MRE 0426 PE 0411
PE 0412
EXPNOV is checked 1x/sec during standby. 0 = correct 1 = capacitors continuously charged to 4100VDC, PE 0412
MRE 0427 PE 0413

EXPTOK is checked 1x/sec during standby and run. 1 = correct 0 = temperature flash power supply too high (70C). MRE 0427 PE 0413
MRE 0428 PE 0414

during initialisation the voltage control is tested. The charge level is set on 361VDC. Next EXPNRDY is checked: 0 = correct 1 = voltage control error, MRE 0428 PE 0414
ed.6 Part I
TSM 2400 family
04 Exposure 105
DIAGNOSTIC
04diag
MRE 0429 PE 0415

during initialisation the discharge time (leakage current) is tested. The charge level is set on 314VDC. 500ms later EXPNRDY is checked: 0 = correct 1 = charge level not reached/discharge to fast, MRE 0429 PE 0415
PE 0416
during initialisation the operation of the electrical discharge protection is tested. The charge level is set on 63VDC. Next the relay contacts are closed. 4100ms later EXPNRDY is checked: 1 0 = correct, capacitors discharged below 63V = electrical discharge protection does not function correctly, capacitors are not discharged below 63VDC , PE 0416
MRE 0430 PE 0417

25s After EXPOPINT is active, 04M1 should be running, the reference sensor is still inactive. 2s After EXPOPINT is active, and 04M1 is running, the movement should be at least 100 pulses. EXPOPINT is checked 8s after start of an optic movement. Any movement should be completed during that time: no pulses (interrupts) pulses (interrupts) = correct = position not reached in time, MRE 0430 PE 0417
MRE 0431 PE 0418

EXPOPREFSE is checked, during initialisation, 100 pulses after starting the moving downward action beginning at EXPOPREFSE (04SO2) position: 0 = correct 1 = optic did not leave the reference sensor in time: MRE 0431 PE 0418
106 Exposure 04
TSM 2400 family
Part I ed.6
04diag
DIAGNOSTIC
MRE 0432 PE 0419

EXPOPINT is checked when a optic movement is being executed. Every 350ms at least 2 EXPOPINT pulses (interrupts) should be generated: 3 or more = correct 2 or less = optic movement speed incorrect, MRE 0432 PE 0419
MRE 0433 PE 0420 MRE 0434 PE 0421

EXPOPMOSL is checked 350ms after changing speed and next every 350ms.
changing from high to low speed, EXPOPMOSPO = 0 and EXPOPMOSL = 1: 1 = correct 0 = motor speed too high, MRE 0433 PE 0420 changing from low to high speed, EXPOPMOSPO = 1 and EXPOPMOSL = 0: 0 = correct 1 = motor speed too low, MRE 0434 PE 0421
ed.6 Part I
TSM 2400 family
04 Exposure 107
DIAGNOSTIC
04diag
108 Exposure 04
TSM 2400 family
Part I ed.6
04sds
SDS

SIGNAL -004C1/04C2 04C1/04C2 04C1/04C2 04PBA01 04PBA01 04C1/04C2 04S2 04M1/04PBA03 04M1/04PBA03 04M1/04PBA03 04M1/04PBA03 04M1/04SO2 04PBA01 04PBA01 04C1/04C2 04C1/04C2 04PBA01 04PBA01 04M1/04PBA03 04M1/04PBA03 04M1/04PBA03 04M1/04SO2 EXPNRDY EXPNRDY EXPNOV EXPTOK EXPNRDY EXPNRDY EXPNRDY EXPOREFSE EXPOREFSE EXPOPINT EXPOPINT EXPOPINT EXPNRDY EXPNRDY EXPTOK EXPNRDY EXPNRDY EXPOREFSE EXPOREFSE EXPOPINT EXPOPINT EXPOPINT -1nominal exposure setting, default = 8 optic setting P0 optic setting P1 charging level cap. too low no flash after ignition continuous charged flash cap temp. flash supply too high INIT charge control failure INIT charge level not reached INIT discharge failure INIT optic too late at 04SO2 INIT optic 04SO2 not free optic not moving optic motor speed too high optic motor speed too low charging level cap. too low no flash after ignition temp. flash supply too high INIT charge control failure INIT charge level not reached INIT optic too late at 04SO2 INIT optic 04SO2 not free optic not moving optic motor speed too high optic motor speed too low DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 04 0 10 PE 04 0 11 PE 04 0 12 PE 04 0 13 PE 04 0 14 PE 04 0 15 PE 04 0 16 PE 04 0 17 PE 04 0 18 PE 04 0 19 PE 04 0 20 PE 04 0 21 PE 04 0 25 MRE 04 0 26 MRE 04 0 27 MRE 04 0 28 MRE 04 0 29 MRE 04 0 30 MRE 04 0 31 MRE 04 0 32 MRE 04 0 33 MRE 04 0 34 MRE PARAMETERS 04 1 01 04 1 02 04 1 03
ed.6 Part I
TSM 2400 family
04 Exposure 201
SDS
02sds
INPUT TESTS 04 2 01 04 2 02 04 2 03 04 2 04 04 2 05 OUTPUT TESTS 04 4 01 04 4 02 04 4 03 SPECIAL TESTS 04 6 01 04 6 02 04 6 03 04 6 04 04 6 05 04 6 06 04 6 07 04 6 08 04 6 09 REPLACE CONSUMABLES
-2EXPNRDY EXPNOV EXPTOK EXPOREFSE EXPOPMOSL -4EXPNDIS RDFABCRST RDF-ABC -6make function WARM make function COLD mask function protections Note 1 Note 2 Note 3 optic transport lock position Note 4 Note 5 -8EXPosure capacitor Not DIScharged RDF ABC ReSeT RDF ABC lamp on EXPosure Not ReaDY EXPosure No OVervoltage EXPosure Temperature OK EXPosure Optic REFerence SEnsor EXPosure OPtic MOtor SLow
04SO2 04SO1
Note 1: flash check, 20x at 1Hz. Select between high/low energy. Note 2: exp. charging level codes. Select EXPVD0-7 by using <PRINT>, 0111111 > 10111111 >....>11111110; no charging or ignition. Note 3: optic test, 120%, 64%, 100% by using <PRINT> Note 4: ABC check with testchart 46, feed originals (3) via MDF, RDF. Measured value is displayed. Refer to adjustment , Note 5: ABC adjust, feed white originals (3) via MDF, RDF. Measured value is displayed. Refer to adjustment.
202 Exposure 04
TSM 2400 family
Part I ed.6
04adju
ADJUSTMENTS
ADJUSTMENTS 1 Optic motor sensor. Aim:

To achieve a defined stop/start position of the pulse disc.
Check:

Select SDS test 04 6 06; Turn the pulse disc and check to see if the motor stands in rest position, on a magnetpole (stable position). The centre of the sensor must be over the transition of the pulse disc.
Correction:
1.1 1.2 1.3 1.4 Loosen screws -A-; Position the pulse disc in a magnitic pole by turning the pulse disc; Place the centre of the sensor over a transition of the pulse disc as shown; Tighten screws -A-.
04adju1a
ed.6 Part I
TSM 2400 family
04 Exposure 301
ADJUSTMENTS
04adju
Installing optic setting P0 and P1. Aim:

Storing limit points for optic displacement in backup memory (BBR).
Check:
Select test 04 1 02, read value P0 and compare with value on sticker on main frame lens drive. Select test 04 1 03, read value P1 and compare with value on sticker on main frame lens drive. Note: Default for P0:1300000; Default for P1:1100; minimum: 0, maximum: 9999999; minimum: 0, maximum: 9999;
Correction:
2.1 2.2 Write parameter setting P0, shown Write parameter setting P1, shown on the sticker, using: test 04 1 02. on the sticker, using: test 04 1 03.
302 Exposure 04
TSM 2400 family
Part I ed.6
04adju
ADJUSTMENTS
ABC lamp housing position. Aim:

To achieve a defined and reliable background measurement.
Check:
NOTE: When installing the guide plate: Place the two combi bolts at the front and the two M4 metal coloured bolts at the rear.
Remove the bolts of guide plate -DDisconnect the sensor 10SO7; The top side of ABC lamp housing must touch the glass strip.
04adju3a
ed.6 Part I
TSM 2400 family
04 Exposure 303
ADJUSTMENTS
04adju
Correction:
3.1 3.2 3.3 3.4 Remove bolt -A-; Disconnect the lamp housing unit and remove it; Loosen bolt -B-; Mount the bracket to the lamp housing so that bracket -F- is in line with lamphousing -E-; 3.5 Tighten bolt -B-; 3.6 Connect and install the ABC lamp housing; 3.7 Push housing -E- upwards against window -C-; 3.8 Tighten bolt -A-; 3.9 Connect the sensor and install the guide plate; * pay attention to the used bolts (see NOTE). 3.10 Proceed with CHECK adjustment 04-4.
04adju3b
304 Exposure 04
TSM 2400 family
Part I ed.6
04adju
ADJUSTMENTS
ABC calibration. Aim:

To calibrate the ABC by determining the average reference setting for white originals. You have to do this after every replacement of the master belt.
Check:

Check P-mode programm 6K5: ABC is ON; Select test 04 6 08, ABC test; Place two testchart 46 in the RDF original tray; Press <PRINT> and read indicated value; Compare this value with reference value; test 04 6 09; * the value must be 50 %, +15 / -5 % Visual check if the copy quality is not too light or dark.
Correction:
4.1 4.2 4.3 4.4 4.5 4.6 Check adjustment 04-3, ABC housing position; Place a set of 4 unprinted white originals (80g/m2 /20lbs) in the RDF original tray; Select test 04 6 09, Adjust ABC; (the present value is displayed) Press <PRINT> to activate the procedure. Press <PRINT> to stop the procedure. To save this new ABC white value press <PRINT> once more. * The value must be between 75 and 250. NOTE: During this test the ABC-value of each original is determined and displayed. The average value is calculated and displayed during and at the end of the test.
ed.6 Part I
TSM 2400 family
04 Exposure 305
ADJUSTMENTS
04adju
Exposure setting. Aim:

To define the nominal exposure setting for a new master.
Check:
Place testchart 1 on the original glass and make 8 copies; Square A on the copies must just be visible. NOTE: Default: 8 ; minimum: 1, maximum: 30.
Correction:
NOTE: It is possible to change the setting using: P-mode programm 6, K5-1. or in SDS-mode using test 04 1 01. 5.1 5.2 5.3 5.4 In SDS-mode: Select system test 42-1, Service copy mode; Make a copy of testchart 1; Square A not visible: decrease the value of test 04 1 01; Square A too dark: increase the value of test 04 1 01.
306 Exposure 04
TSM 2400 family
Part I ed.6
04adju
ADJUSTMENTS
Supports original glass Aim:

To limit the bending of the original glass.
Check:
Knock on the original glass to check the following conditions: * Support -A-, -B- and -C- must support the glass * Support -D- must have a play of 0 + 0.3 - 0.01 mm * Support -E- and -F- must have a play of 0.3 + 0.3 - 0 mm
Correction
6.1 6.2 6.3 6.4 6.5 6.6 Raise the plate of the discharge security switch of the flash capacitors; Remove the front side and/or rear side reflector; Use a 0.3 mm feeler gauge to adjust the play at -D-; Use a 0.3 mm feeler gauge to adjust the play at -E- and -F-; Replace the reflector; Reposition the discharge security switch.
04adju6a
ed.6 Part I
TSM 2400 family
04 Exposure 307
ADJUSTMENTS
04adju
308 Exposure 04
TSM 2400 family
Part I ed.6
04func
FUNCTIONAL DESCRIPTION 1 Exposure section

The function of the exposure section is to create an electrical (latent) image of the original on the master. This is done by episcopic exposure with two flash lamps. The image is either 1:1 (100%), an enlargement (to 120%) or a reduction (to 64%). Enlargement/reduction is done with a fixed focus lens. The exposure section consists of: -A-BFlash exposure unit Optical unit
04func01
ed.6 Part II
TSM 2400 family
04 Exposure 501
04func
Flash exposure unit

A number of electrical precautions have been taken to reduce the negative effects of flash exposure:
The exposure section is grounded at 1 point to the main frame. The wires (supply, ignition) to the lamps are kept as short as possible. Wires (supply, ignition) are mounted close to the housing. Lamp housings are metal coated and grounded. The flash lamps ignition is mounted close to the flash lamps. The flash exposure unit consists of:
-A-B-C-D-
Original glass platen (refer to RDF) Reflectors Exposure lamps (04LA1 + LA2) Flash lamps ignition (board 04PBA02)
04func02
502 Exposure 04
TSM 2400 family
Part II ed.6
04func
At the rear side of the machine : -B-E-F-G-HReflectors Flash power supply (board 04PBA01) Mechanical discharge protection Flash capacitors (04C1 +C2) Cooling fan
04func03
ed.6 Part II
TSM 2400 family
04 Exposure 503
04func
Exposure flash lamps

The exposure of the original is performed by means of two flash lamps. Depending on a number of conditions (e.g. ABC,operator panel) the flash capacitors are charged to a certain value. This voltage is applied to the exposure lamps. The lamps behave as insulators unless the xenon gas inside the lamps is ionized. The ionisation is started by applying an ignition voltage to the ignition wire that is wound around the flash lamp. The value of the ignition pulse is about 10kV! The ignition pulse is given with respect to one electrode on the exposure lamp. The lamps should be treated with care to prevent damage to the contacts and ignition wire.
Keep the contacts free of grease. The lamps should not be turned in the sockets after positioning. The quartz glass must not be touched. The glass nipple in the middle of the tube must point to the ignition stripholder to ensure an even exposure. THE RED SPOTS ON EXPOSURE FRAME AND EXPOSURE LAMP ELECTRODE MUST MATCH!
504 Exposure 04
TSM 2400 family
Part II ed.6
04func
Flash voltage control

The charge voltage of the flash capacitors (04C1,04C2) will be between -1945V and -4000V, and is devided over 30 exposure steps.
The voltage level is determined by: - normal exposure setting - aging of master - manual adjustment on the operator panel - automatic adjustment by ABC The total range is divided into 30 steps. STEP DECIMAL VOLTAGE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 124 127 130 134 137 140 144 147 151 155 159 163 167 171 175 180 184 189 194 199 204 209 214 219 225 230 236 242 248 255 1945 1992 2039 2102 2149 2196 2259 2306 2369 2431 2494 2557 2620 2682 2745 2824 2886 2965 3043 3122 3200 3278 3357 3435 3529 3608 3702 3796 3890 4000 MANUAL SETTING 4 copy darker 3 2 1 0 normal exposure setting 1 2 3 4 copy lighter
ed.6 Part II
TSM 2400 family
04 Exposure 505
04func
Nominal exposure setting: The default zero level is step 8 in the table. By performing SDS test 04101 and using testchart 1, the zero level can be determined. The zero level can be adjusted in steps, within a total range of 1 - 30. The usual adjustment is between 5 and 16. Aging of master: To compensate for master degradation caused by usage, the normal exposure setting is incremented by one step in the table every 35.000 exposed images. Manual adjustment from the operator panel: On the operator panel the light output can be set 4 steps lighter or darker. Each step on the operator panel represents 2 steps in the table. So the operator panel covers 17 steps in the table. Automatic adjustment by ABC: The ABC can add upto 8 steps in the table depending on the measured background on the used original. The requested voltage (Vrequest) offered by the control to the flash power supply (via control lines EXPVOD0-7) consists off: Vrequest = nominal exposure setting + master aging + operator panel + ABC.
506 Exposure 04
TSM 2400 family
Part II ed.6
04func
Exposure flash control

Power supply : The 220VAC from the main power distribution board is connected by connector 04CN1 and cover switch (04S1) to the mains filter (04FI1). From this filter the 220VAC is fed to the FLASH POWER SUPPLY (04PBA01) and FLASH LAMPS IGNITION (04PBA02). Ignition : The flash ignition circuitry can be divided into a control and supply section. The control section converts the signal EXPFIGN from the HOST I/O into a trigger pulse for the thyristor (THR1). The local supply section generates: -+12VDC for the control circuit -+300VDC to charge the ignition capacitors (C8, C2) As soon as 220VAC is supplied to flash lamps ignition (04PBA02), the ignition capacitors are charged to aproximately 300VDC.
Grounding : The exposure section has only one ground connection to the main frame. This keeps high frequency disturbances as much as possible inside the exposure section, so that the microprocessor control busses are not influenced. The microprocessor operates continuously during the flash.
04func10.gem
ed.6 Part II
TSM 2400 family
04 Exposure 507
04func
The ground connection is a bolt that links the flash exposure box and a wire coming from the flash capacitors (+) (04C1, 04C2) to the mainframe. The exposure frame ground is connected to the flash power supply box. The flash lamps ignition (04PBA02) is connected by two wires to the ground (+) of the flash capacitors (04C1, 04C2).
508 Exposure 04
TSM 2400 family
Part II ed.6
04func
Automatic background compensation (ABC)

The ABC-system has been developed in order to minimize the difference in background between copies of light and dark originals. The background is determined by measuring the light reflected from the original. The exposure setting is adapted automatically to the original without any loss of information. A small incandescent lamp (04LA3) shines a defined amount of light onto the original. The reflected light is concentrated, and converted into an electrical signal by a photodiode. The electrical signal from the photodiode is an index for the background of the original. This signal is amplified on the ABC sensor (04PBA04) and send to a peak detection circuit on the ABC control (04PBA04). The output signal of the peak detector is send to the host CPU, which uses it to control the light output of the exposure flash lamps. The background is measured while the original is being fed onto the original glass platen. The measurement takes place at a length of 40 mm per original, independent of the original size. The measurement always starts 20 mm from the leading edge of each original.
04func18.gem
Scanning area on an original.
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The ABC system of the Oc 2400 consists of 2 PBAs: - 04PBA04 ABC sensor - 04PBA04 ABC control
ABC sensor (04PBA04)

The ABC sensor contains the optic part of the ABC system, a detector circuit and an amplifier. The optic part consists of an incandescent lamp, a small glass plate, a lens, a spring and a photodiode. -A-B-C-D-EThe ABC sensor housing : Original Small glass plate Incandescent lamp (04LA3) Photodiode (on 04PBA04) Lens
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510 Exposure 04
TSM 2400 family
Part II ed.6
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ABC control (04PBA4)

The ABC control contains: - a filter for the 12 V supply - a 5 V supply for the ABC lamp - a reference voltage supply for the ABC lamp detection circuit - a peak detector
04func11.gem
Block diagram ABC system. ABCMEAS When this input signal goes high the peak detector is activated and the actual measurement takes place. ABCLAMPON When this input signal goes high, the local 5 V power supply supplies 5 V to the lamp. The lamp is in standby state (0.63 V) when signal ABCLAMPON is low. ABCOUT This signal is the output of the peak detector and represents the background of the measured original, when signal ABCMEAS is high. The filter is designed to ensure that the 12 V supply of the sensitive circuits on the control PBA and sensor PBA is free of disturbances. The 5 V supply is to ensure that the amount of light of the incandescent lamp is independent from the variations of the 12 V supply voltage. The reference voltage supply is to ensure that the detection of the amount of reflected light on the sensor is independent from the variations of the 12 V supply voltage. After pushing the print button the first original is fed in. The ABC lamp is switched on. The original passes the ABC device and reflects the light of the lamp onto a photodiode. During transportation of the original, signal ABCMEAS goes high and the measurement takes place. The photodiode on the sensor PBA converts the received amount of reflected light into a voltage Vout. This voltage is amplified and fed to the ABC control (04PBA04).
ed.6 Part II
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The peak detector stores the highest value of Vout (= the lightest spot in the scanning area of the original) and sends this value (ABCOUT) to the host I/O. Depending on the value of ABCOUT, the control adapts the charge level of the flash capacitors up to 12 steps in the table. The ABC system has to be calibrated periodically, because, the light output of the incandescent lamp will decrease during lifetime. Adjusting the ABC in the field has to be performed every time a new master is placed using a parameter test. The potentiometer in the feedback line of IC1 is only used for adjustment in production. Note: if the ABC control (04PBA04) or the ABC sensor (04PBA04) or the ABC lamp (04LA3) is defective, all three have to be replaced because they are matched.
512 Exposure 04
TSM 2400 family
Part II ed.6
04func
Circuit diagram description :(see 701)

Flash supply : The flash power supply (04PBA01) provides the energy necessary to make the exposure lamps flash. This energy is stored in the flash capacitors (04C1 ,04C2).
Local power supply : On flash power supply (04PBA01), the 220VAC is rectified and converted into 12VDC local power supply; this line is protected by fuse F2-200mA. Switch mode current regulator : A switch mode current regulator converts the uncontrolled 220VAC into a controlled charge current. The capacitors are charged linearly with a charge current of 300mA. Voltage control : The charge voltage of the flash capacitors depends on: - normal exposure setting (04101) - manual adjustment on operator panel - automatic adjustment by ABC - aging of master The microprocessor offers this requested voltage as an 8 bit digital pattern (EXPVD0-7) to the flash power supply. On this PBA a digital/analog conversion is made. When control line EXPSUPON is high (1), charging of the flash capacitors can take place. During charging, the voltage of the flash capacitors (04C1, 04C2) is compared with the analog voltage from the microprocessor. As long as these voltages are not equal, the charge process continues. When the requested voltage is met, the signal EXPNRDY goes low (0).
Overvoltage detection : In case of a defective voltage control, the overvoltage protection limits the flash capacitors voltage to -4100V by switching off the switch mode current regulator. The overvoltage situation is reported to the processor by making the signal EXPNOV low (0). Electrical discharge protection : In some special cases, such as: - power loss - reset of microprocessor - flash capacitor voltage after flash < - 1900V (too high) control must discharge the FLASH CAPACITORS for safety reasons. By making EXPNDIS low 0 a relay switch is closed and the capacitors are shortcircuited by a resistor. The discharge guard takes care that: - The relay contacts are not opened during discharging. - The flash capacitors are not recharged.
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Mechanical discharge protection : To discharge the flash capacitors when the flash exposuresupply box is opened, a mechanical switch is installed. It consists of a metal strip that short-circuits the contacts of the capacitors. Operation of the switch is either done: - manually by the service technician - automatically by opening the door of the flash power supply box When the switch discharges the capacitors, the rapid discharge (high current) will make it necessary to install a new switch and flash capacitors. Conditions flash capacitors start charging : The conditions to switch on the flash power supply are: - EXPNRDY = 1, the voltage across the capacitors is below the requested value - EXPSUPON = 1, the processor gave the command to start charging, related to the process timing. - the local power supply 12VDC and therefore the 220VAC must be present. - EXPNDIS = 1, the processor enabled the flash supply. - EXPNOV = 1, there must be no overvoltage. - EXPTOK = 1, the temperature of the cooling plate must be below 70C. - EXPNDISE = 1, the discharge guard must be not active, so no discharging may take place. The mechanical discharge protection for the flash capacitors must be in place. If all these conditions are fullfilled the ignition pulse EXPFIGN can be generated. Flash/ignition :
Charging : As soon as the copier is powered up, 220 VAC is supplied to the flash lamp ignition (04PBA02). The ignition capacitors are charged. Ignition : A positive pulse applied by EXPFIGN will trigger thyristor THR1. The energy stored in the ignition capacitors is transformed into a high voltage pulse (+10kV) by means of the ignition transformers. The exposure flash lamps are ignited. The ignition capacitors are recharged immediately.
514 Exposure 04
TSM 2400 family
Part II ed.6
04func
Optical unit
The optical unit consists of:
-A-B-C-D-E-F-G-
Bellow Lens block Mirror Reference sensor Optic control Lens/mirror drive Optic motor
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TSM 2400 family
04 Exposure 515
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Light Path
The design is based on one fixed zero-point for: all original sizes on the original glass platen. the master Lens and mirror are placed on individual carriages which move up and down in the optics section. The carriages are coupled and driven by the same motor. For each magnification, the lens and mirror are positioned in the correct location. The mirror is moved in a vertical direction. The lens is moved in both the horizontal and vertical directions. This last feature guarantees the fixed zero-point. As the lens moves, a diaphragm is opened or closed.This generates a constant amount of light on the master at each magnification.
04func12.gem
516 Exposure 04
TSM 2400 family
Part II ed.6
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Lens/mirror drive mechanism

The lens drive mechanism consist of :
-A-B-C-D-E-F-G-H-I-
Optic control board Optic motor sensor Optic motor Cam mirror displacement Drum lens displacement Drive belt Steel belt Cable Optic reference sensor
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ed.6 Part II
TSM 2400 family
04 Exposure 517
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The function of the lens drive unit is to take care of the lens and mirror positioning. The drive is one unit and mounted at the front of the main frame close to the mirror. The 24VDC optic motor (04M1) drives the driving shaft by a gear box and a drive belt. On this shaft are mounted: -a drum, to wind a steel belt and return cable to position the lens. -a rotating cam, to position the mirror. The coupling between drive and lens block is achieved by a steel belt. The characteristics of this steel belt are: - exactly defined length. - very little elasticity. - defined mounting position. This steel belt garantees that the precision between lens, mirror and drive is maintained. To keep the steel belt tensioned a cable and spring are used. The steel belt and cable are connected to the drum. Although driven by one steel belt, the lens moves in three directions when changing magnifications. This is a result of one zero-point on the original glass and on the master at a fixed position.
518 Exposure 04
TSM 2400 family
Part II ed.6
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Lens mechanism
The lens positioning mechanism is the centre part of the optics section. The design used a fixed zero-point on original glass platen and master. The lens is moved in both a horizontal and vertical direction when changing magnitude. Only one lens with fixed focus is used. To the lens a diaphragm is coupled. As the lens moves the diaphragm is adjusted automatically in accordance with the lens position: - When the lens moves up, the diaphragm is opened and the image becomes larger - When the lens moves down, the diaphragm is closed and the image becomes smaller The lens mechanism consists off: Frame, which is mounted in the optics frame and guarantees parallelism between the original glass platen and lens. Slide for object distance. The magnification is adjusted by moving the lens up or down. Slide for zero axis. This slide moves the lens in left-right direction (seen from front) and alignes the left side of the original glass platen swith the master zero axis as the magnitude is changed. Cam for zero axis. The contact between the slide for zero axis and the cam for zero axis is realised by a bearing. Cam for diaphragm. A pin connected to the diaphragm is in contact with this cam and adjusts (open/close) the diaphragm when the magnitude is changed.
-A-B-CConfidential 1996 Oc Nederland B.V.
-D-E-
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P0 and P1 : Due to focus tolerances, each machine has a unique optical path length and positioning parameters. This is adjusted with special tools during production. Two parameters (P0 and P1) are put on a sticker to the frame. They are unique for that machine and must be entered by using SDS test 04102, 04103. There are no service adjustments in the optic area.
04func12.gem
Lens\mirror movement : y-direction: directly caused by the steel belt and the return cable. x-direction: the displacement in this direction is caused by the slide for zero axis which is coupled to a cam mounted on the lens frame. z-direction: two shafts which guide the slide for object distance are placed at an angle of 14; The deviation from the zero point for the complete range (64%-120%) is 0,5mm.
04func13.gem
520 Exposure 04
TSM 2400 family
Part II ed.6
04func
12
Lens positioning
The displacement of the optic is controlled by the optic control on 04PBA03. The displacement is achieved by an optic motor (04M1) and the displacement is measured by a pulse sensor (04SO1) mounted on the motor shaft. Each pulse equals a displacement of 0,2 mm. The distance between minimum (64%) and maximum (120%) position is 200 mm. The microprocessor uses relative measurement to position the optic. The previous optic location (stored in the BBR) is always used to calculate the displacement necessary to reach the new location.
Optic motor speed control

The displacement of the optic takes place with two speeds : -high speed for fast displacement to the new location; -low speed to approach the correct stop position.
The new location of the optic is always approached from the underside and at low speed. This to compensate for play always in the same direction.
Initialisation of the optic control

When the copier is powered up the optic control needs to be initialized. Therefore a reference sensor (04SO2) is installed at the most upper position of the optic. When the initialisation needs to be done the optic moves from a not defined position at low speed upwards to locate the reference sensor.If found this value is stored in the memory and the optic moves downwards at high speed until it reach the 100% position. This value is stored in the memory and uses as reference for calculating the next optic position.
04func14.gem
ed.6 Part II
TSM 2400 family
04 Exposure 521
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When a new location for the optic is needed there are two posibilities : -optic moving upwards; -optic moving downwards. Upwards movement : Displacement takes place at high speed only during the last 74 pulses before the new location is reached the speed is low. Downwards movement : Displacement takes place at high speed until the new location is reached. Then it moves down for 15 pulses and up again for 15 pulses at low speed, where it stops at the new location. Taking this information into account, some figures can be stated: time needed for displacement: from 100% to 120% 1.05 s 78% 1.94 s 70% 2.5 s 64% 3.16 s
The positioning is controlled by the microprocessor thru the optic control board (04PBA03).
04func15.gem
04func16.gem
522 Exposure 04
TSM 2400 family
Part II ed.6
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Optic motor control

The OPTIC MOTOR CONTROL has three functions: -Speed control -Turning direction -Frequency divider Speed control
This function consists of 5 parts. speed adjustment, which creates the setpoint for the control and is a reaction on control lines EXPOPMOON (high 1 = motor on, low 0 = motor off and brake) and EXPOPMOSP (low 0 = low speed , high 1 = high speed). frequency/voltage convertor, this circuit converts the signal EXPOPMOSE (pulses) into a DC voltage. Also a feed back signal EXPOPMOSL is sent to the control. This signal reflects the actual speed of the motor. This compensates the motor speed so it will not change speed instantaneously when EXPOPMOSP changes level. control, the difference between both input signals (set point from speed adjustment and converted EXPOPMOSE from frequency/voltage converter) is compared until they are equal. pulse width modulator, adjusts the duty cycle proportionally to the input signal. power amplifier, a FET switches the motor current.
04func17.gem
ed.6 Part II
TSM 2400 family
04 Exposure 523
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Turning direction The terminals of the DC optic motor are connected to a relay. With this relay, the 24 V supply to the motor can be reversed. The relay must be switched while no current is flowing, 100 ms after the motor has stopped. The relay is switched by the control line EXPOPMODI (high 1 = upward, low 0 = downward). Frequency Divider The function of this circuit is to send signals to the microprocessor which indicate the lens movement (EXPOPINT). When the motor is moving at high speed EXPOPMOSE is divided by 8. In this case one EXPOPINT pulse sent to the microprocessor represents 8 EXPOPMOSE pulses. When the motor is moving with low speed EXPOPMOSE is divided by 1. With each EXPOPMOSE pulse, one EXPOPINT pulse is generated. This is done to reduce the workload for the processor.
524 Exposure 04
TSM 2400 family
Part II ed.6
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14
Exposure cooling motor

The function of the exposure cooling motor (04M2) is:
cooling the flash power supply cooling the original glass platens The exposure cooling motor (04M2) is located at the rear next to the flash power supply box. Air is sucked in by a filter and passes through the hollow heatsink of the flash power supply towards original glass. The exposure cooling motor is only switched on during a copy run. A high 1 control signal MADR LED7 coming from the Host I/O (22PBA02) switches an SSR on SSR1 (22PBA06). 220VAC is supplied to the exposure cooling fan motor.
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04 Exposure 525
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Operation
During power up / initialisation: The exposure flash power supply is tested: - EXPNDIS becomes high 1, open electrical discharge protection - set charge voltage to 361VDC, by EXPVD7-0 - check if EXPNRDY is high 1, charge voltage not reached - start charging, EXPSUPON becomes high 1 - EXPNRDY switches from high 1 to low 0 - stop charging, EXPSUPON becomes low 0 - set charge voltage to 314VDC, by EXPVD7-0 - check if EXPNRDY is still low 0, otherwise the requested charge voltage was not treached or the discharge (leakage) current is too high - close the electrical discharge protection, EXPNDIS becomes low 0 - set the charge voltage to 63VDC, by EXPVD7-0 - check if EXPNRDY is high 1, the voltage over the capacitors is less then 63VDC - open electrical discharge protection, EXPNDIS becomes high 1 - set charge voltage to 0VDC, by EXPVD7-0 Initialisation the lens is moved to the 100% position: - the lens is moved at low speed upwards to the exposure optic reference sensor (04SO2), EXPOPMOON and EXPOPMODI are high 1, EXPOPMOSP is low 0 - when the reference sensor is reached EXPOPREFS becomes high 1, and the motor stops, EXPOPMOON becomes low 0 - the lens is moved down at high speed, EXPOPMOON is high 1, EXPOPMODI is low 0, EXPOPMOSP is high 1 - The motor speed switches from high to low, EXPOPMOSP switches from high 1 to low 0 at the moment 100% point is passed. - The lens moves down at low speed for another 15 pulses. - the motor stops EXPOPMOON becomes low 0 - the motor direction is reversed EXPOPMODI switches from low 0 to high 1 - the lens is moved 15 pulses upwards at low speed, EXPOPMOON and EXPOPMODI are high 1 and EXPOPMOSP is low 0 - the motor stops at the 100% position, EXPOPMOON becomes low 0 When master transport takes place the EXPOSURE COOLING FAN (04M2) is running.
526 Exposure 04
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Part II ed.6
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During standby: The flash power supply is not operating, EXPSUPON, EXPVD7-0 are low 0, while EXPTOK, EXPNOV, EXPNRDY, EXPNDIS are high 1. 220VAC is available at the flash power supply (04PBA01) and flash lamps ignition (04PBA02). The optic motor (04M1) is stationary, being at the last used position. The motor is not energized even no hold current. EXPOPMOON is low 0. The level of EXPOPMODI, EXPOPMOSP and EXPOPREFS depends on the last optic movement and current lens position. EXPOPINT is low 0. EXPOPMOSL is high 1. During run: MADR becomes high 1. Master and the exposure cooling fan (04M2) start running.
The optic motor (04M1) is energized and moves the lens to the new position if necessary. When the lens is at the correct position, the scorotron is switched on in the next distance. About 2s after switching on the scorotron, the exposure lamps are ingnited. This is the timing zero point. All synchronous actions (e.g. transfer moment, separation moment) are related to this moment. For every flash the following actions take place: 0.9s before the flash the requested charge voltage is put on EXPVD7-0. The charging of the flash capacitors (04C1, 04C2) is started. EXPSUPON becomes high 1 0.17s before the flash, the charge voltage is adjusted according to ABC measurement, by EXPVD7-0 12ms before the ignition charging is stopped, EXPSUPON becomes low 0. 6ms before the ignition, the charge voltage is checked, by EXPNRDY (EXPNRDY is low 0 when correct) ignition and flash !!! 6ms after the ignition the discharge of the flash capacitors is checked, by EXPNRDY (EXPNRDY is high 1 when discharge is correct).
ed.6 Part II
TSM 2400 family
04 Exposure 527
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528 Exposure 04
TSM 2400 family
Part II ed.6
04comp
COMPONENT LOCATION
COMPONENT LOCATION
04CN1 : 04CN2 : 04C1 : 04C2 : 04FI1 : 04L1 : 04LA2 : 04M2 : 04PBA01 : 04S1 : EFSCDISSE: connector 220V-supply flash power supply connector exposure cooling fan flash capacitor flash capacitor 220V-filter flash power supply coil exposure lamp exposure cooling fan flash power supply PBA exposure flash security cover sensor exposure flash security discharge switch
04comp01
ed.6 Part II
TSM 2400 family
04 Exposure 601
COMPONENT LOCATION
04comp
04LA1 04M1 04PBA02 04PBA03 04SO1 04SO2
: : : : : :
exposure lamp lens and mirror drive motor flash lamp ignition PBA optic control PBA exposure optics position motor sensor exposure optics reference sensor
04comp02
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Part II ed.6
04comp
COMPONENT LOCATION
04PBA04 10PBA01
: ABC-PBA (in RDF) : RDF control PBA (in RDF)
04comp03
ed.6 Part II
TSM 2400 family
04 Exposure 603
COMPONENT LOCATION
04comp
604 Exposure 04
TSM 2400 family
Part II ed.6
04elec
ELECTRICAL DIAGRAM

ABCOUT ABCLAMPON ABCMEAS EXPOPREFS EXPOREFSE EXPOPMODI EXPOPMOON EXPOPMOSP EXPOPMOSL EXPOPINT EXPOPMOSE EXPTOK EXPSUPON EXPNOV EXPNRDY EXPNDIS EXPVDx EXPFIGN MADR MT ABC OUTput ABC LAMP ON ABC MEASurement EXPosure Optics Position REFerence SEnsor EXPosure Optic REfernce SEnsor EXPosure Optics Position MOtor DIrection EXPosure Optics Position MOtor ON EXPosure Optics Position MOtor SPeed EXPosure Optics Position MOtor SLow EXPosure Optics Position EXPosure Optics Position MOtor SEnsor EXPosure Temperature OK EXPosure SUPply ON EXPosure No OVervoltage EXPosure Not ReaDY EXPosure No DIScharge EXPosure Voltage Data EXPosure Flash IGNition MAin DRive Main Transport
ed.6 Part I
TSM 2400 family
04 Exposure 701
ELECTRICAL DIAGRAM
04elec
702 Exposure 04
TSM 2400 family
Part I ed.6
Electrical Diagram
04 EXPOSURE 701
05diag
DIAGNOSTIC
DIAGNOSTIC 1 Messages
none
Fault table
none
3
Protections
none
ed.6 Part I
TSM 2400 family
05 Developing 101
DIAGNOSTIC
05diag
102 Developing 05
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Part I ed.6
05sds
SDS

COMPONENT -0number of copies since toner refill -1number of copies per toner bottle. Default value : 30 (k). -205S1 TONLLSE TONer Level Low detection SEnsor SIGNAL DESCRIPTION in SDS
TESTNUMBER COUNTERS 05 0 90 C
PARAMETERS
05 1 90
INPUT TESTS 05 2 01
OUTPUT TESTS 05 4 01 05M1
-4DEVAGIMO DEVeloper AGItation rack MOtor (1.3s)
SPECIAL TESTS 05 6 01 05 6 02 REPLACE CONSUMABLES 05 8 90
-6make function WARM make function COLD -8change number of copies since toner refill
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05 Developing 201
SDS
05sds
202 Developing 05
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FUNCTIONAL DESCRIPTION 1 Developing section

The function of the developing section is to supply toner particles to the charged master surface so that the latent image becomes visible. -A-B-CThe developing section consists of three subsections: Developing unit. Complimentary developing rod Developer cooling fan
05func01
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ed.6 Part II
TSM 2400 family
05 Developing 501
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Developing unit
The developing unit consist of :
-D-E-F-
Developing roller; Doctor blade; Toner tray.
05func03
The developing roller is driven by the main drive motor (23M2). The drive is transmitted by the main drive belt via a gear and a spring. The developing roller has a one way bearing so that it can turn only in one direction, which is important to prevent the formation of toner dust. A fly wheel guarantees a constant roller speed. The developing roller is a rotating tube with 12 stationary magnetic poles on the inside. The magnets exert a force on the iron in the toner particles causing toner to stick to the surface of the developing roller. The doctor blade determines the thickness of the toner layer on the developing roller. It is postioned in a dip of the toner brush. The distance between doctor blade and developing roller is 1mm and is not adjustable.
502 Developing 05
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The toner tray consist of: -G-H-J-KToner stock tray; Toner level sensor; Agitation rack; Agitation motor (05M1).
05func04
The toner stock tray can contain 4 bottles of F10 toner, which is about 4 kg. This is sufficient for approximately 120.000 copies. After making 30.000 copies a message is displayed in SDS (parameter 05190, counter 05090, reset counter 05890). At least 1 toner bottle can be refilled. The presence of toner is sensed by the toner level sensor (05S1). If the toner level is low 0 05S1 is open and control line TONLLSE is low 0. This control line is connected to the HOST I/O (22PBA02). A low 0 condition results in a display message REFILL TONER. The toner stock tray needs to be refilled within 20.000 copies otherwise copy quality drops (light copy). However it is possible to continue copying. To ensure that the toner is fed to the developing roller an agitation rack is used. This agitation rack is driven by the developing unit agitation motor (05M1) for a short time when the copier is switched on and every 80 copies during a run.

The developing unit agitation motor runs when control line DEVAGIMO is high 1. This line comes from the HOST I/O (22PBA02) and controls a SSR on SSR1 (22PBA06) which switches 220VAC on the motor. When control line DEVAGIMO is high 1 LED8 on SSR1 is lit. Fuse F2 (0.5As) is installed on SSR1 (22PBA06).
ed.6 Part II
TSM 2400 family
05 Developing 503
05func
Bias voltage
During exposure the light discharges those places on the master where no image is projected. However, there will always be a residual charge (rest ASV), which will attract toner particles. Increasing the light output is not possible, because this will effect the charged image parts. To solve this problem a negative voltage (bias voltage) of -8V is applied to the developing roller.
Complimentary developing rod.

The complimentary developing rod is part of the master unit. The complimentary rod is electrically interconnected (via earth) to have a closed electrical circuit between tonerparticle and charged master. This is necessary to garantee a good development. In this way the toner is only attracted to the master if the ASV is higher than -8V.
504 Developing 05
TSM 2400 family
Part II ed.6
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Developer cooling fan

The function of the developer cooling fan motor (05M2) is to keep the environment of the developing unit at a low temperature. The storage temperature of F10 toner is maximal 45C. The cooling fan motor is switched on during a copy run. When the signal MADR (LED7) becomes high 1, 220VAC is supplied to the cooling fan motor.
ed.6 Part II
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05 Developing 505
05func
Operation
During power up / initialisation:
The toner level sensor (05S1) is checked if closed (sufficient toner), control line TONLLSE is high 1. The bias voltage (-8V) is applied to the developing roller. The developing roller rotates during master transport, driven by the main drive motor (23M2). The developer cooling motor (05M2) is switched on. The developer agitation motor (05M1) is switched on for 1.3 s. During standby:
The toner level sensor (05S1) is checked, if closed (sufficient toner), control line TONLLSE is high 1. The bias voltage (-8V) is applied to the developing roller. During run:
MADR becomes high 1, master and developer cooling fan motor (05M2) start running. The toner level sensor (05S1) is checked if closed (sufficient toner), control line TONLLSE is high 1. The bias voltage (-8V) is applied to the developing roller. The developer cooling motor (05M2) is switched on. Every 80 copies the developing unit agitation motor will run for a short period (1.3s).
506 Developing 05
TSM 2400 family
Part II ed.6
05comp
COMPONENT LOCATION
COMPONENT LOCATION
05CN1 05M1 05S1 : connector agitation motor supply and toner low level sensor signal : developer agitation motor : toner level sensor
05comp01
ed.6 Part II
TSM 2400 family
05 Developing 601
COMPONENT LOCATION
05comp
05CN1 05M2
: connector agitation motor supply and toner low level sensor signal : developer cooling fan motor
05comp02
602 Developing 05
TSM 2400 family
Part II ed.6
05elec
ELECTRICAL DIAGRAM

TONLLSE DEVAGIMO TONer Level Low SEnsor DEVeloping AGItation MOtor
ed.6 Part I
TSM 2400 family
05 Developing 701
ELECTRICAL DIAGRAM
05elec
702 Developing 05
TSM 2400 family
Part I ed.6
Electrical Diagram
05 DEVELOPING 701
06diag
DIAGNOSTIC
0610 0611 warming up more than 30 min. TTF belt not rotating (not in Oc 2475 and not if MOD 42 is implemented). Run sensor (06SM1) and pinch sensor (06S2) not connected/defective (for Oc 2475 and if MOD 42 is implemented) pressure belt rotating/black image (not in Oc 2475 and not if MOD 42 is implemented) 06NTC1 open ciruit 06NTC1 short circuit TTF belt temperature too high TTF belt cleaner full TTF belt not rotating (for Oc 2475 and if MOD 42 is implemented) 2nd pinch failure (for Oc 2475 and if MOD 42 is implemented)
0612 0613 0614 0615 0616 0617 0618
MRE
0625 0626 0627 0628 TTF belt temperature too low 06NTC1 open circuit 06NTC1 short circuit 2nd pinch failure (for Oc 2475 and if MOD 42 is implemented)
Warnings
0675 warming up 15-30 min.
ed.6 Part I
TSM 2400 family
06 TTF 101
DIAGNOSTIC
06diag
Fault table
CODES P0610 POSSIBLE FAILURES - bad connection of drawer connector 06CN1 - bad positioning of TTF unit - clixon 06S1 defective continue open - heater element 06HE1 and/or 06HE2 defect - 22PBA06 (SSR1) defect - bad/no connection of drawer connector 06CN3 - TTF belt defective/teared - coupling of drive TTF defective - TTF runsensor 06SM1 defective continue low - one way bearing pulley of TTF drive unit defective - insufficient friction of TTF belt on drive roller - bearing of separation roller TTF belt stuck - timing belt drive broken - 2nd pinch clutch 06CL1 defective - inside bearing of counter pressure belt become loose - pressure belt defective/teared - 2nd pinch not correctly closed - inside bearing of 1st pinch roller become loose - coupling of 2nd pinch defective - bearing counter pressure roller of pressure belt cleaner stuck - inside bearing of counter pressure belt stuck - excenter bearing 2nd pinch defective/stuck - cam or bearing drive unit stapler defective (FUNC 18) - allen screw black image clutch loose - standby motor 23M1 (thermal switch) - inside bearing of counter pressure belt stuck - 2nd pinch clutch 06CL1 defective - excenter bearing 2nd pinch defective/stuck - TTF runsensor 06SM1 defective continue high - oldham clutch of 2nd pinch defective - transfuse pinch not completely opened during black image transfer - continue activated heaters 06HE1/2/3, (SSR1 defective) - too many black images on ttf spiral cleaner
P0611
P0612
P0615 P0616
Fault table continue : next page.
102 TTF 06
TSM 2400 family
Part I ed.6
06diag
DIAGNOSTIC
CODES P0617
POSSIBLE FAILURES - TTF belt defective/teared - coupling of drive TTF defective - TTF runsensor 06SM1 defective continue low - one way bearing pulley of TTF drive unit defective - insufficient friction of TTF belt on drive roller - bearing of separation roller TTF belt stuck - timing belt drive broken - clixon 06S1 defective continue open - bad positioning of ttf unit - bad connection of drawer connector 06CN1
M0625
M0626, P0613 - 06NTC1 open circuit

M0627, P0614 - 06NTC1 short circuit M0628, P0618 - 06S2 defective - 06CL1 2nd pinch clutch defective - allen screw 2nd pinch clutch loose - coupling of 2nd pinch defective (oldham) - 22PBA09 driver PBA defective (use volt meter to detect) - 22PBA02 HOST I/O defective W0675 - heater 06HE2 defective/broken - heater 06HE1 defective/broken
ed.6 Part I
TSM 2400 family
06 TTF 103
DIAGNOSTIC
06diag
Protections MRE 0626 PE 0613 MRE 0627 PE 0614 Warning 0675 PE 0610 MRE 0625 PE 0615
06NTC1 is checked 1x/1.28sec during initialisation, standby and run. The analogue value of the NTC is converted to a binary value (by an analogue digital converter ADC) and fed to the microprocessor. Interpretation of this binary value can result in a number of error messages/warning. - ADC value is 0 or 1 (open circuit NTC): MRE 0626 PE 0613 - ADC value is 254 or 255 (short circuit): MRE 0627 PE 0614 - Warm up time is between 15 and 30min ( nominal time is about 10min) before setpoint 119C is reached. WARNING 0675 - Warm up time is longer than 30min. Setpoint is not reached: PE 0610 - Temperature is to low (lower than 95C): MRE 0625 - Temperature is to high ( higher than 129C): PE 0615
PE 0611 (not for Oc 2475 and not if MOD 42 is implemented)

TTFRUNSE is checked 1x/sec during standby and run. - 1 (pulses) = correct - 0 ( no pulses) = drive defect, PE 0611
PE 0612 (not for Oc 2475 and not if MOD 42 is implemented)

TTFRUNSE is checked between 1 and 2sec after activation of TFSCL (06CL1) (black image). - 0 (no pulses ) = correct - 1 (pulses) = transfuse pinch not open: PE 0612
PE 0616
Parameter 06090 number of black images/TTF cleaner is exceeded by more than 200: PE 0616.
104 TTF 06
TSM 2400 family
Part I ed.6
06diag
DIAGNOSTIC
PE 0617 (only for Oc 2475 and if MOD 42 is implemented)

TTFRUNSE is checked 1x/sec during standby and run. - 1 (pulses) = correct - 0 ( no pulses) = drive defect, PE 0617
MRE0628 PE0618 (only for Oc 2475 and if MOD 42 is implemented)

TFSPINSE is checked 1x/sec during stand by and run. - TFSPINSE = 0, transfuse pinch open - TFSPINSE = 1, transfuse pinch closed.
ed.6 Part I
TSM 2400 family
06 TTF 105
DIAGNOSTIC
06diag
106 TTF 06
TSM 2400 family
Part I ed.6
06sds
SDS

SIGNAL -006NTC1 06SM1 06SM1 TTFNTC TTFRUNSE TTFRUNSE warming up longer than 30 min TTF belt not rotating pressure belt rotating/ black image (2nd pinch constantly closed) 06NTC1 open circuit 06NTC1 short circuit TTF belt temperature too high TTF belt cleaner full TTF belt not rotating 2nd pinch failure temperature TTF belt too low 06NTC1 open circuit 06NTC1 short circuit 2nd pinch failure warming up 15 - 30 minutes no. of blacks/TTF cleaner no. of copies TTF belt (K) no. of copies pressure belt (K) DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 06 0 10 PE 06 0 11 PE 06 0 12 PE
06 0 13 PE 06 0 14 PE 06 0 15 PE 06 0 16 PE 06 0 17 PE 06 0 18 PE 06 0 25 MRE 06 0 26 MRE 06 0 27 MRE 06 0 28 MRE 06 0 75 W 06 0 90 C 06 0 91 C 06 0 92 C PARAMETERS 06 1 01 06 1 90 06 1 91 06 1 92
06NTC1 06NTC1 06NTC1 06SM1 06S2 06NTC1 06NTC1 06NTC1 06S2 06HE1/HE2
TTFNTC TTFNTC TTFNTC TTFRUNSE TFSPINSE TTFNTC TTFNTC TTFNTC
-1paper quality factor black images per TTF cleaner (def. 1200) no. of copies per TTF belt (K) (def. 999) : Note 1 copies per pressure belt (K) (def. 999) : Note 1
Note 1: If the parameter is set at maximum value, and this value is exceeded, NO message will be displayed when entering SDS.
ed.6 Part I
TSM 2400 family
06 TTF 201
SDS
06sds
INPUT TESTS 06 2 01 06 2 02 OUTPUT TESTS 06 4 01 SPECIAL TESTS 06 6 01 06 6 02 06 6 03 06 6 04 06 6 05 06 6 06 06CL1 06SM1 06S2
-2TTFRUNSE TFSPINSE -4TFSCL -6make function WARM make function COLD mask function protections Note 2 open transfuse pinch/06SM1/06S2 Note 3 TransFuSe CLutch 06CL1 TTF RUN SEnsor 06SM1 TFS PINch SEnsor 06S2
06NTC1 06CL1 06HE1,2,3
TTFNTC TFRCLD TTFHEUP/LO -8-
REPLACE CONSUMABLES 06 8 90 06 8 91 06 8 92
replace routine new TTF cleaner replace routine new TTF belt repl.routine new pressure beltr
Note 2: TTF belt temperature 06NTC1. The setpoint value is 163 (corresponds with 119C) Note 3: TTF heaters test . All heaters are switched on until max TTF temperature is reached. The setpoint value is 192 (corresponds with 129C) The standby motor starts running, also the main drive motor runs for 0,5 sec.
202 TTF 06
TSM 2400 family
Part I ed.6
06adju
ADJUSTMENTS
ADJUSTMENTS 1 Transfuse pinch pressure, front and rear. (keystone distortion) Aim:
To assure an equal pinch pressure front and rear with an image on the copy with no key stone distortion. NOTE: For a correct adjusting sequence use the following procedure: Copy quality (system level) : image positioning adjustments.
Check:
Make 3 copies of testchart 19: Measure distance -D- on the copy: * -D- = 150mm 1.0 mm. If incorrect check Exposure adj. 04-2. Measure on the copy distance -X- and -Y-, between -6 lines: * X-copy equals Y-copy, tolerance 1.0mm;
06adju1a
ed.6 Part I
TSM 2400 family
06 TTF 301
ADJUSTMENTS
06adju
Correction:
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 Remove the TTF cover; Pull out the TTF unit and remove the two cleaner rollers; Remove drive member cup of the TTF drive roller; Turn the pinch pressure adjuster -E- in position A (release pressure); Loosen Allen screw -G-, front and/or rear; Close the TTF pinch manually; Turn rod -F- counter/clock wise using a screwdriver until the belts just touch; Open the TTF pinch; Disengage the tensioners of the TTFand counter pressure belt; Move the TTF- and counter pressure belt to the front/or rear to clear the roller; Tension both belts (tighten the TTF belt with the spring hooked on the pin instead of the bracket, this to eliminate the play); Close the TTF pinch; Adjust the distance between the rollers of the TTF- and counter pressure unit front and rear to 3.1 mm 0.1 mm using feeler gauges; Tighten Allen screw -G-, front and rear side; Replace the spring in its correct position and place both the TTF- and counter pressure belts in the centre of the TTF unit; Turn the pinch pressure adjuster in position 0 (zero); Proceed with CHECK adjustment 06-2.
1.11 1.12 1.13 1.14 1.15 1.16 1.17
302 TTF 06
TSM 2400 family
Part I ed.6
06adju
ADJUSTMENTS
Transfuse pinch pressure. (ratio of original image to copy image = 1 to 1)

NOTE: Perform this adjustment when a new TTF belt or counter pressure belt is installed.
Aim:
To assure an image on the copy with a ratio of 1 : 1 in transport direction. NOTE: For a correct adjusting sequence use the following procedure: - Copy quality (system level): image positioning adjustments.
Check:
Select zoom position 100%; Place testchart 19 on the original glass and make 8 copies; Measure distance -C- and -D- on the copy: * -C- equals -D- = 150mm 1.0 mm ; NOTE: If dimension -D- is not correct check Exposure adj. 04-2.
06adju2a
ed.6 Part I
TSM 2400 family
06 TTF 303
ADJUSTMENTS
06adju
Correction:
2.1 2.2 2.3 2.4 2.5 2.6 Remove the TTF cover; Place the pinch pressure adjuster -E- in 0 position; Select zoom position 100%; Make a copy of testchart 19 from the original glass platen; Determine the dimension -C- on the copy; Three situations can occur:
image magnification adjuster -Eenlargement more than 1% (> 151,5 mm) position - reduction more than 1% (< 148,5 mm) position + reduction 0% to 1% position 0 Position A is to release the pressure of the transfuse pinch. 2.7 Mount the TTF cover.
06adju2b
304 TTF 06
TSM 2400 family
Part I ed.6
06adju
ADJUSTMENTS
Paper quality factor. Aim:

To assure good cleaning of the TTF belt by the TTF belt cleaning roller.
Check:
Find out the quality of the used receiving material by checking the quality of the toner layer on the TTF belt cleaning roller: - is the toner on the cleaning roller looking: grey with paperdust? - is the toner building up on the roller instead of going into the roller? NOTE: Default: 1; Normal and good quality paper: P.Q.F. setting value 1". For paper that produces little paper dust, more copies between two black images; Bad quality paper: P.Q.F. setting value 2". For paper that produces more paper dust, less copies between two black images.
Correction:
3.1 3.2 Select test 06 1 01; Change the setting from 1" to 2". NOTE: If necessary install a new TTF belt cleaning roller.
ed.6 Part I
TSM 2400 family
06 TTF 305
ADJUSTMENTS
06adju
Transfuse clutch (06CL1) (if MOD 42 is implemented) Aim:

To ensure that no force is applied to the transfuse clutch when the clutch is in de-energized condition. NOTE: This adjustment has to be carried out with the TTF unit locked in the machine.
Check/Correction :
4.1 4.2 4.3 Remove timing belt -A-. Loosen bolts -B- and -C- of bracket -D-. Move bracket -D- upwards to move the pin of the clutch out of the slot, so that the clutch can move freely. Move the clutch into the vertical position (see fig. I, position 1) and let the clutch fall to the left side (position 2). NOTE: Do not push against the clutch. 4.5 Move bracket -D- as far as possible to the right and let it gently drop onto the pin of the clutch. It is possible that the pin slides into slot 1 or 2, or that the pin is positioned between slot 1 and 2 (see fig. II). Tighten bolt -B-. Lift bracket -D- and move the pin of the clutch to the right into the slot immediately next to the present position (see fig III). This means that when the rest position of the pin is in slot 1, the pin must be moved to slot 2; and if the rest position is in slot 2, the pin must be moved to slot 3. Tighten bolt -C-. NOTE: When tightening bolt -C- hold bracket -D- in the down position. 4.9 Remount timing belt -A-.
4.4
4.6 4.7
4.8
306 TTF 06
TSM 2400 family
Part I ed.6
06disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1 Procedure to remove and install the TTF belt and counter pressure belt. (not for Oc 2475 and not if MOD 42 is implemented)
Loosen two connectors, remove cover and pull out the TTF section. Remove the following parts from the TTF section: 1.2 1.3 1.4 cleaning roller -A- of the counter pressure belt. cleaning roller -B- of the TTF belt. the bracket with the run sensor housing: * bolts -C-. 1. 5 the eccentric on the counter pressure roller: * circlip -E-; * leaf spring -F-; * eccentric -G-. 1. 6 Pull off bracket -H-, to disengage the counter pressure belt. 1. 7 Remove bracket -J-; * circlip -K-; * bracket -H-, with spring.
1.1
06disa01
ed.6 Part II
TSM 2400 family
06 TTF 401
DIS/ASSEMBLY
06disa
Proceed with: 1.9 Pull off bracket -L-, to detension the TTF belt. 1.10 Turn the pinch pressure adjuster -M- in position A, to release the pinch pressure of the second transfer step. 1.11 Remove the TTF section from the rail, and place it with the drive side on the floor. 1.12 Remove bolts -N- (3x). 1.13 Remove the frame plate -P- of the TTF section. Now the TTF belt and the COUNTER PRESSURE belt can be removed. 1.14 Mount all parts in reversed order. NOTE : When remounting the frame plate(s) front and/or rear on the TTF-unit, the pins -Oand the corresponding holes should match perfectly when you tighten bolts -N-.
06disa02
402 TTF 06
TSM 2400 family
Part II ed.6
06disa
DIS/ASSEMBLY
2
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14
Procedure to remove and install the TTF belt and counter pressure belt. (for Oc 2475 and if MOD 42 is implemented)
Loosen two connectors, remove cover and pull out the TTF section. Remove cleaning roller -H- of the counter pressure belt. Remove cleaning roller -A- of the TTF belt. Remove bracket with switch and TTF run sensor (bolts -J-). Release the spring by turning bolt -K- half a turn (pinch open). Put a small screw driver into the hole of shaft -E- (inner front side) and remove bolt -K-. Turn the pinch pressure adjuster -C- in position A, to release the pinch pressure of the second transfer step. Remove bracket -B-. Remove eccentric -D-. Pull off bracket -F-, to disengage the counter pressure belt. Remove bracket -G-. Pull off bracket -L-, to disengage the TTF belt. Remove frame plate -M- (3 bolts). Now the TTF belt and the COUNTER PRESSURE belt can be removed. Mount all parts in reversed order. NOTE : When remounting the frame plate(s) front and/or rear on the TTF-unit, the pins -Oand the corresponding holes should match perfectly when you tighten bolts -N-.
ed.6 Part II
TSM 2400 family
06 TTF 403
DIS/ASSEMBLY
06disa
404 TTF 06
TSM 2400 family
Part II ed.6
06func
FUNCTIONAL DESCRIPTION 1 TTF section

The function of the TTF section is to transfer the image from the master onto the receiving material. There are two steps: -1-2transfer the toner image from the master onto the TTF belt, this is done by pressure; transfer the image from the TTF belt onto the paper, this is done by heat and pressure (transfuse). The TTF unit and counter pressure unit are installed in the same frame. This means that the forces are contained within the TTF frame. The complete section can slide out of the copier at the front. The TTF section consists of the following units:
-A-B-
the TTF unit, with the TTF belt cleaning system; the counter pressure unit, with the counter pressure belt cleaning system.
06func01
ed.6 Part II
TSM 2400 family
06 TTF 501
06func
TTF unit
The TTF unit and its belt cleaning system consist of the following items: -A- TTF belt drive roller; -B- TTF belt; -C- TTF belt guide roller, TTF run sensor 06SM1 (for Oc 2475 and if MOD 42 is implemented); -C"- counter pressure belt guide roller, TTF run sensor 06SM1 (not for Oc 2475 and not if MOD 42 is implemented -D- Transfuse pinch sensor 06S2 (for Oc 2475 and if MOD 42 is implemented); -E- pressure unit transfuse pinch; -F- pressure roller transfuse pinch; -G- upper and lower heater element for TTF belt; -H- transfer roller (first transfer step); -ITTF belt tension rod, with NTC resistor; -J- NTC, temperature sensor ; -K- clixon; -L- TTF belt cleaning roller (spiral cleaner); -M- heater element for the TTF belt cleaning roller.
06func07
502 TTF 06
TSM 2400 family
Part II ed.6
06func
The operation of the first transfer step is explained in function 01-PHOtoconductor. This description explaines the operation of the transfuse-system. The TTF belt is made of a hard wearing material, which is coated with a conductive silicon rubber layer. This silicon rubber is a soft and non-sticky material with the ability to pick up and release toner particles. It is also heat resistant and can withstand high temperatures. The silicon rubber used is made conductive to prevent for electrostatic charge. The pressure unit consists of a spring loaded mechanism that pushes against the transfuse pressure roller at the front and rear. The tension of the pressure springs is preset in the factory, but the pressure on this roller and the parallelism is adjustable. The pinch pressure affects the image enlargement factor. During the first transfer step the image is reduced to about 90% in transport direction. This is corrected to 100% in the second transfer step.
There are three heater elements installed in the TTF unit: two for heating the TTF belt (06HE1, 06HE2), and one for heating the TTF belt cleaning roller (06HE3). The two heater elements for the TTF belt (upper and lower) are identical, and rated at 750W. The upper and lower heater element, are controlled by one NTC (06NTC1) to keep the TTF belt temperature in the transfuse pinch constant at 119C. It takes approximately 10 minutes for the TTF belt to reach its working temperature. The temperature control is explained in a separate chapter. For safety reasons (over heating) the TTF run sensor (06SM1) detects if the TTF belt is running by generating pulses. The TTF run sensor is mounted on the front side of the TTF belt guide roller. The function of the TTF belt cleaning roller is to remove the residual toner from the TTF belt. Beside the toner also the paper dust is removed from the TTF belt. The collected toner is pressed through the slots into the cleaning roller. The viscosity of the toner is reduced by the collected paper dust. To prevent toner built up on the roller, the coating on the roller needs refreshment with toner (black images). The function of the heater element is to keep the toner soft so that the toner/paperdust mixture is pressed through the slots into the cleaning roller. The heater element of the TTF belt cleaning roller is rated at 150W and is only switched on during warming up of the copier. Depending on the number of black images made since the last replacement of the cleaning roller, the power of the heater element is switched between 50 - 100 %.
ed.6 Part II
TSM 2400 family
06 TTF 503
06func
3
-O-P-R-S-T-U-V-
Counter pressure unit

The counter pressure unit and its belt cleaning system consists of the following items: guide roller for counter pressure belt ; counter pressure belt, tension mechanism; counter pressure belt; counter pressure belt cleaning roller (sheet cleaner). release mechanism for transfuse pinch; counter pressure roller for the transfuse pinch; 1/2 revolution clutch for transfuse pinch;
06func03
504 TTF 06
TSM 2400 family
Part II ed.6
06func
The counter pressure unit is the fixed part of the transfuse pinch. The TTF belt drives the counter pressure belt when the pinch is closed. The transfuse pinch sensor (06S2) detects if the transfuse pinch is opened or closed (for Oc 2475 and if MOD 42 is implemented). Heat from the TTF belt is transfered to the counter pressure belt to keep the counter pressure belt at the correct temperature. The counter pressure belt must not take toner from the paper during duplex transfuse actions. The counter pressure pinch roller is kept in a fixed position. On the inside of this roller a shaft -A- is installed which is connected to the 1/2 revolution clutch at the rear. On each end of the shaft an eccentric -B- is mounted. When the 1/2 revolution clutch is energized the shaft and eccentrics turn 180 and opens the transfuse pinch. When a black image is made, the transfuse pinch is opened for 4 seconds. The black image can pass and a new layer of toner input on the TTF belt cleaning roller. To detect that the counter pressure belt is running or stands still a run sensor -D- is present. The sensor generates pulses when the pinch is closed and both belts are running (not for Oc 2475 and not if MOD 42 is implemented). MODIFICATION 42 and Oc 2475 : The run sensor is mounted on a roller in the TTF section and detects only if the TTF belt is running. A switch detects via an excenter on the pinch roller shaft if the TTF pinch is opened or closed. During warming up of the copier the transfuse pinch is closed. 6 Minutes after the copier has warmed up, the pinch is opened and remains open until a copy run is started. During stand by the pinch will be opened one minute after the last copy is made.
Modification 42 and Oc 2475
ed.6 Part II
TSM 2400 family
06 TTF 505
06func
Temperature control
Circuit diagram description : (see 701) The TTF belt is heated by two 750W elements: the upper heater element (06HE1), and the lower heater element (06HE2). The cleaning roller has a 150W heater element (06HE3) which makes the toner on the roller soft. When the control signal STBMO becomes high 1, RL1 on SSR1 (22PBA06) is energized and 220VAC is supplied to:
the standby motor 23M1 the three heater elements via a clixon (06S1). This combination is necessary to make sure that the standby motor is running when the heater elements are powered. The heater elements of the TTF belt are connected to neutral by two triacs on SSR1 (22PBA06). When control line TTFHEUP becomes high 1, the upper heater element (06HE1) is powered, while TTFHELO controls the lower (06HE2) heater element ( high 1 is powered). Both control lines are always switched on or off together. The control lines TTFHEUP and TTFHELO can only become high 1 while pulses from the run sensor TTFRUNSE (06SM1) are entering the HOST I/O (22PBA02). On the HOST I/O is a hardware circuit which makes sure that the output signal of the CPU and the feedback signal of the run sensor TTFRUNSE are linked. The heater element of the TTF cleaning roller is connected to neutral by a triac on 22PBA10 (SSR). When control line TTFCLEHE becomes high 1, heater element 06HE3 is powered. By controlling the duty cycle of the signal TTFCLEHE, the used power of the heating element is regulated between 50 - 100 %. The heater element of the TTF cleaning roller is only used during warming up of the copier. The temperature sensor (06NTC1) is measuring the temperature of the TTF belt and is located on the inside of the tension rod. The value of the NTC is 100kOHM at 25C. The set point of the TTF belt during standby is 119C. When the temperature reaches the set point the heater elements are switched off by the control by making the signals TTFHEUP/CLEHE and TTFHELO low 0. Every 1.28s a temperature check is done and is decided if the elements should be switched on or off. The warm-up time (from cold start, 20C) is about 10 minutes. From cold start (ADC value =10) the copier is released at an ADC value of 96 ( 96C), (ready to copy). During a run the setpoint is increased by 3 degrees to keep the temperature in the pinch at 119C. The NTC may also be damaged.
506 TTF 06
TSM 2400 family
Part II ed.6
06func
A clixon (06S1) is located above the tension rod at the front. The clixon switches off the 220VAC supply for the heater elements if its temperature exceeds 145C. The clixon will only respond if the TTF belt is running and heat is transferred from the TTF belt to the tension rod. After the TTF unit has cooled off, the clixon can be reset. Remember that resetting the clixon will not remove the cause of the problem!
ed.6 Part II
TSM 2400 family
06 TTF 507
06func
Black image for the TTF belt cleaning roller ( spiral cleaner)
The toner on the TTF belt cleaning roller needs to be renewed regularly, this to keep the viscosity of the toner low. To achieve this during copy runs, black images are made and they are transferred from the TTF belt to the cleaning roller. When a black image is made: the transfuse pinch is opened and the counter pressure belt stops, no flash is generated, and the paper separation/feed is interrupted. All other functions are kept on, the black image is made over the maximum width (all framing lamps are switched off). To release the transfuse pinch, control line TFSCL is made high 1 and via a driver on the 24V-driver board (22PBA09) the transfuse clutch (06CL1) is energized. The transfuse clutch makes a 1/2 revolution. This causes the pinch to be opened for about 4 sec. During this time the transfered black image passes 2 times the cleaning roller, to be sure all residual toner is removed from the belt. The dose frequency for black images is completely controlled by software. It depends on the number of images (flashes) made during the last 10 minutes and the current dose frequency setting. The average of these two values will be the new setting and is in the range between 267 - 800 images (in steps of 100). Every time the copier is powered up the dose frequency is set to 1 in 533 images. When the copier is powered up and the first copy run is started, a black image will be produced. It depends on the run lenght when it is produced : - At the end of the first copy run, if less than 100 images - After 100 images, if the run is longer than 100 images. The first black image due during a run is postponed and will be made at the end of a run. With long copy runs, the dosing point may be reached for a second time. In this case the second and all subsequent black images are produced during the copying process. A new cleaning roller must be installed between 1200 and 1400 black images. This parameter can be adjusted by test 06190. If the counter 06090 is exceeded by more than 200, the copying process will be stopped and a permanent error (PE0616) appears. When a new cleaning roller is installed the consumable counter 06090 must be reset to zero, using test 06890. When a run is started (in or outside SDS), three black images are made automatically and transferred to the new cleaning roller. This to guarantee an optimal clean function. The dose frequency can be changed in SDS according to the paper quality by using parameter 06101. This depends on the paper dust production.
508 TTF 06
TSM 2400 family
Part II ed.6
06func
Operation not for Oc 2475 and not if MOD 42 is implemented:

During power up / initialisation: The temperature sensor (06NTC1) is checked for open or short circuit: if incorrect an error message is displayed. The main drive motor (23M2) and standby motor (23M1) are switched on via MADR and STBMO respectively. Master transport takes place. The TTF belt and the counter pressure belt are running at high speed (20m/min). The 1/2 revolution clutch is energized 2 times, control line TFSCL becomes a pulse high 1. The pinch is opened by the eccentrics. Control line TFSCL becomes high 1, the transfuse pinch is closed again. The run sensor 06SM1 is checked for pulses ( 1.5Hz). When the master hole reaches the master hole sensor (01SO1) for the second time the maindrive is switched off. The master stops. The TTF belt and counter pressure belt continue to run at low speed (12m/min) driven by the standby motor. If the temperature sensor (06NTC1) check is correct and the run sensor (06SM1) generates pulses, the heater elements (06HE1, 06HE2, 06HE3) are switched on. This is done by making control lines TTFHELO, TTFHEUP and TTFCLEHE high 1. The two heaters (06HE1, 06HE2) are always switched on or off together. The two heaters are constantly switched on until the TTF belt reaches a temperature of 119C, LED3 and LED2 on SSR1 (22PBA06) are lit. The warm-up time (from cold start, 20C) is about 10 minutes. At that moment the copier enters the standby mode and the heater of the TTF cleaning roller is switched off. During standby: The TTF belt and counter pressure belt are running at low speed. The run sensor (06SM1) generates pulses with a frequency of about 1Hz. Heaters (06HE1 and 06HE2 ) are switched on and off to maintain the correct temperature. Consequently on SSR1 LED2 and LED3 switch on and off. The two heaters are always switched together. Every 1.28sec a temperature control check is executed. The heater of the cleaning roller remains switched off. The TTF unit keeps the cleaning roller on temperature.
ed.6 Part II
TSM 2400 family
06 TTF 509
06func
During run: At the beginning of the run control line MADR is activated (high 1). As a result the master starts running. The TTF belt and counter pressure belt start running at high speed. The run sensor (06SM1) generates pulses with a frequency of about 1.5Hz. The setpoint for the TTF belt heater elements is increased by 3C. So at the beginning of a run the heaters are switched on and remain on for a short period until the temperature difference has disappeared. After that time the heater elements keep switching on and off. The heater element of the TTF cleaning roller remains switched off. When the copier is warmed up and the first copy run is started, a black image will be produced. When it is produced depends on the run length : - At the end of the run if less than 100 images (flashes) - After 100 images if the run is longer than 100 images. During the run at intervals, depending on several aspects, black images are made with a frequency in the range from 267 - 800 copies.
510 TTF 06
TSM 2400 family
Part II ed.6
06func
Operation for Oc 2475 and if MOD 42 is implemented :

During power up / initialisation: The temperature sensor (06NTC1) is checked for open or short circuit: if incorrect an error message is displayed. The main drive motor (23M2) and standby motor (23M1) are switched on via MADR and STBMO respectively. Master transport takes place. The TTF belt and the counter pressure belt are running at high speed (20m/min). MODIFICATION 42 : The 1/2 revolution clutch is energized 2 or 3 times. If the transfuse pinch is closed when the copier is switched on, the 1/2 revolution clutch is energized twice. Control line TFSCL becomes a pulse high 1 and the pinch is opened by the eccentrics. Control line TFSCL becomes a pulse high 1 again and the transfuse pinch is closed again. If the transfuse pinch is open when the copier is switched on, the 1/2 revolution clutch is energized (by pulses) 3 times : first time to close the pinch, second time to open the pinch and the third time to close the pinch again for heating up. During these actions the signal TFSPINSE of the transfuse pinch sensor (06SM1) is checked continuously for pulses ( 1.5 Hz) When the master hole reaches the master hole sensor (01SO1) for the second time the maindrive is switched off. The master stops. The TTF belt and counter pressure belt continue to run at low speed (12m/min) driven by the standby motor. If the temperature sensor (06NTC1) check is correct and the run sensor (06SM1) generates pulses, the heater elements (06HE1, 06HE2, 06HE3) are switched on. This is done by making control lines TTFHELO, TTFHEUP and TTFCLEHE high 1. The two heaters (06HE1, 06HE2) are always switched on or off together. The two heaters are constantly switched on until the TTF belt reaches a temperature of 119C, LED3 and LED2 on SSR1 (22PBA06) are lit. The warm-up time (from cold start, 20C) is about 10 minutes. At that moment the copier enters the standby mode and the heater of the TTF cleaning roller is switched off. During standby: The transfuse pinch remains closed until 6 minutes after the copier has warmed up, if in between no copies are made. If copies are made then the transfuse pinch will be opened 1 minute after the last copy is made. The TTF belt and if the pinch is closed, the counterpressure belt are running at low speed. The run sensor generates pulses with a frequency of about 1 Hz. Heaters (06HE1 and 06HE2 ) are switched on and off to maintain the correct temperature. Consequently on SSR1 LED2 and LED3 switch on and off. The two heaters are always switched together. Every 1.28sec a temperature control check is executed. The heater of the cleaning roller remains switched off. The TTF unit keeps the cleaning roller on temperature.
ed.6 Part II
TSM 2400 family
06 TTF 511
06func
During run: At the beginning of the run control line MADR is activated (high 1). As a result the master starts running and the transfuse pinch is closed, (TFSPINSE goes high 1, 06S2). The TTF belt and counter pressure belt start running at high speed. The run sensor (06SM1) generates pulses with a frequency of about 1.5Hz. The setpoint for the TTF belt heater elements is increased by 3C. So at the beginning of a run the heaters are switched on and remain on for a short period until the temperature difference has disappeared. After that time the heater elements keep switching on and off. The heater element of the TTF cleaning roller remains switched off. When the copier is warmed up and the first copy run is started, a black image will be produced. When it is produced depends on the run length : - At the end of the run if less than 100 images (flashes) - After 100 images if the run is longer than 100 images. During the run at intervals, depending on several aspects, black images are made with a frequency in the range from 267 - 800 copies.
512 TTF 06
TSM 2400 family
Part II ed.6
06comp
COMPONENT LOCATION
COMPONENT LOCATION
06CN2 06CN3 06S1 06S2 06SM1 06NTC1 : : : : : : connector temperature sensor connector run sensor clixon TTF heaters transfuse pinch sensor (for Oc 2475 and if MOD 42 is implemented) TTF run sensor TTF temperature sensor
ed.6 Part II
TSM 2400 family
06 TTF 601
COMPONENT LOCATION
06comp
06CN1 06HE1 06HE2 06HE3
: : : :
connector power supply heaters upper TTF-heater lower TTF-heater TTF cleaning-heater
06comp03
06CL1 23M1 23M2
: : :
transfuse clutch standby motor maindrive motor
602 TTF 06
TSM 2400 family
Part II ed.6
06comp
COMPONENT LOCATION
COMPONENT LOCATION FOR BLUE ANGEL

06CL1 23M3 23M2 : : : transfuse clutch standby motor maindrive motor
24comp04.eps
ed.6 Part II
TSM 2400 family
06 TTF 603
COMPONENT LOCATION
06comp
604 TTF 06
TSM 2400 family
Part II ed.6
06elec
ELECTRICAL DIAGRAM

TTFHEUP TTFCLEHE TTFHELO TFSPINSE STBMO VNTC TTFNTC TTFRUNSE TFSCL TTF HEater UPper TTF CLEaning HEater TTF HEater LOwer TransFuSe PINch SEnsor STand By MOtor Voltage Negative Temperature Coefficient Transfer Transfer Fuse Negative Temperature Coefficient Transfer Transfer Fuse RUN SEnsor TransFuSe CLutch
ed.6 Part I
TSM 2400 family
06 TTF 701
ELECTRICAL DIAGRAM
06elec
702 TTF 06
TSM 2400 family
Part I ed.6
Electrical Diagram
06 TTF 701
07diag
DIAGNOSTIC
0710 master cleanlamp off
ed.6 Part I
TSM 2400 family
07 Cleaning 101
DIAGNOSTIC
07diag
Fault table
P0710 - cleanlamp 07LA1 defective - ballast 07BAL1 defective/ open circuit
102 Cleaning 07
TSM 2400 family
Part I ed.6
07diag
DIAGNOSTIC
Protections PE 0710
MASCLACO is checked 1x/s during standby and run. When control detects two times an incorrect level an error is reported if the option is installed. - 1 = correct - 0 = cleanlamp defect, PE 0710
Thermal fuse F1,

on 07BAL1 switches off at 121C and cannot be reset. When F1 switched off the cleaning lamp (07LA1) will not illuminate during run.
Thermal fuse F2,

on 07BAL1 switches off at 121C and cannot be reset. When F2 switched off the cleaning lamp (07LA1) will not be in pre-glowing condition during standby.
ed.6 Part I
TSM 2400 family
07 Cleaning 103
DIAGNOSTIC
07diag
104 Cleaning 07
TSM 2400 family
Part I ed.6
07sds
SDS

SIGNAL -007LA1 master cleanlamp failure number of copies per cleaner tray -1no. copies per cleaner tray (k), default = 500 (k) -207PBA01 MASCLACO -4MASter Clean LAmp COntrol DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 07 0 10 PE 07 0 90 C
PARAMETERS
07 1 90
INPUT TESTS 07 2 01 OUTPUT TESTS
SPECIAL TESTS 07 6 03 REPLACE CONSUMABLES 07 8 90
-6mask function protections -8replace routine new cleaner tray
ed.6 Part I
TSM 2400 family
07 Cleaning 201
SDS
07sds
202 Cleaning 07
TSM 2400 family
Part I ed.6
07func
FUNCTIONAL DESCRIPTION 1 Cleaning section

The function of the cleaning section is: to discharge the residual charge on the master which is done by the cleaning lamp. to remove the residual toner from the master, this is done by the cleaning roller. to collect the waste toner in a tray. This leaves the master discharged and free from toner, ready for the next process cycle. The cleaning section consists of: -A-B-CCleaning unit Cleaning lamp Complimentary cleaning roller
07func01
ed.6 Part II
TSM 2400 family
07 Cleaning 501
07func
Cleaning unit
The cleaning unit consists of:
-A-B-C-D-
Cleaning roller Toner inlet compartment Docter blade Waste toner tray
07func02
The cleaning roller is driven by the main motor. The cleaning roller removes residual toner from the master. The toner is magnetically attracted and wiped of the master by a toner brush on the cleaning roller. Inside the roller are 12 stationary magnets creating 12 tops and dips. The cleaning roller transports these toner particles towards a doctor blade which wipes off excess toner. The toner layer on the cleaning roller has to be renewed every time a new master is installed. The doctor blade keeps the toner layer at a defined thickness of 1mm in the dips. The excess toner is collected in a waste toner tray. The waste toner tray capacity is 3.25 kg. A new tray must be installed after about 700k copies. A message is displayed in SDS when the parameter copies per cleaner tray (07190) is exceeded. The function of the toner inlet compartment is: to keep the toner dust inside the cleaning unit to guide the airflow around the cleaning roller
502 Cleaning 07
TSM 2400 family
Part II ed.6
07func
Cleaning lamp
The function of the cleaning lamp is to expose the master over its entire width and thereby neutralize the residual charge on the master. It is a fluorescent lamp rated at 11W. The cleaning lamp has two states:
pre-glowing; illuminating. Pre-glowing: When MADR is low 0 (no run) the cleaning lamp is switched off. This keeps the lamp usage to a minimum number of hours and prevents the master from unnecessary degeneration caused by exposure. The cleaning lamp is kept in a pre-glowing condition so that rapid ignition is possible. Unswitched 220VAC (N1, L1) comes from SSR1 (22PBA06) to ballast (07BAL1) and is fed to a pre-glowing transformer (TR1). This transformer supplies a pre-glowing voltage of 5.4V to each filament of the cleaning lamp. Illuminating: When MADR is high 1 (run) a triac on the SSR1 (22PBA06) starts conducting and 220VAC is supplied to the cleaning lamp (pins 4 and 1) via L1 and MT. This second 220VAC circuit runs via choke-coil TR2. A capacitor (connected to a tab of the choke-coil) generates an ignition peak voltage over the lamp at the moment MADR is switched on. The lamp ignites at once and stays illuminated until control line MADR is low 0. Thermal fuse: A thermal fuse is built into each neutral line of the 220 VAC circuit (N1 and N1 switched). Each fuse switches off at a temperature of 121C. The thermal fuses cannot be reset so 07BAL1 has to be replaced. For option Ballast detection 07PBA01 refer to chapter 24.
ed.6 Part II
TSM 2400 family
07 Cleaning 503
07func
Operation
During power up / initialisation: While master transport takes place (control line MADR is high 1 and LED7 on SSR1 is on):
the cleaning roller is rotating the cleaning lamp is illuminated, 220VAC is available at connector 07CN1 between pins : 4-7, 1-2, 1-3 During standby: The cleaning lamp 07LA1 is kept in pre-glowing condition. A voltage of 5.4VAC is fed to both filaments. 220VAC is available at connector 07CN1 between pins 1-2 5.4VAC is available at connector 07CN1 between pins 4-6 and 7-9. Controlline MADR is low 0. During run: Master transport takes place (controlline MADR is high 1 and LED7 on SSR1 is on):
the cleaning roller is rotating the cleaning lamp is illuminated, 220VAC is available between connector 07CN1 pins: 4-7, 1-2, 1-3
504 Cleaning 07
TSM 2400 family
Part II ed.6
07comp
COMPONENT LOCATION
COMPONENT LOCATION
07BAL1 07CN1 07LA1 : cleaning lamp ballast : connector cleaning lamp ballast : cleaning lamp
07comp01
07comp02
ed.6 Part II
TSM 2400 family
07 Cleaning 601
COMPONENT LOCATION
07comp
602 Cleaning 07
TSM 2400 family
Part II ed.6
07elec
ELECTRICAL DIAGRAM

MASCLACO MADR MASter Clean LAmp COrrect MAin DRive
ed.6 Part I
TSM 2400 family
07 Cleaning 701
ELECTRICAL DIAGRAM
07elec
702 Cleaning 07
TSM 2400 family
Part I ed.6
Electrical Diagram
07 CLEANING 701
10diag
DIAGNOSTIC
1010 1011 1012 1013 1014 1015 1016 RDF supply absent 10M2 (not if s.w. rel. 7.1 and 2.1 is implemented) RDF supply absent 10M4 (not if s.w. rel. 7.1 and 2.1 is implemented) RDF supply absent 10M1 (not if s.w. rel. 7.1 and 2.1 is implemented) set separator failure 10SO8 communication failure doc.size detection failure 10SO16 RDF supply absent 10M5 (not if s.w. rel. 7.1 and 2.1 is implemented)
MRE
1025 1026 1027 1028 1029 1030
set separator failure 10SO8 communication failure RDF supply absent 10M2 (from s.w. rel. 7.1 and 2.1) RDF supply absent 10M4 (from s.w. rel. 7.1 and 2.1) RDF supply absent 10M1 (from s.w. rel. 7.1 and 2.1) RDF supply absent 10M5 (from s.w. rel. 7.1 and 2.1)
ORE
1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 1060 1061 1062 1063 1064 1065 1066 separation: too late at 10SO3 feed: 10SO3 too late free return: too late at 10SO6 return: 10SO6 too late free turn:too late at 10SO3 turn:10SO3 too late free setlength unequal 10SO8 (*) MDF: 10SO11 too late free CFF: hole pattern error 10SO9 10M1 motor speed too low 10M4 motor speed too low 10M2 motor speed too low 10M5 motor speed too low 10M1 load/current too high 10M4 load/current too high 10M2 load/current too high too many originals
ed.6 Part I
TSM 2400 family
10 RDF 101
DIAGNOSTIC
10diag
ORE
1067 illegal set separation 1068 10M5 load current too high 1070 set length decreased 10S08 1071 set length increased 10S08 (*) ONLY for the old RDF (until MOD 75)
Warnings
1075 1076 24V RDF supply failure -12V RDF supply failure
102 RDF 10
TSM 2400 family
Part I ed.6
10diag
DIAGNOSTIC
Fault table
P1010/M1027 - RDF 30V supply defect - 10M2 motor is defect - signal PRMOVSPABS is not correct - -12V is not present - RDF 30V supply output voltage lower than 22.5V - RDF 30V supply fuse is blown - 10M7 feed MDF/CFF is defect winding is short circuited - 10PBA06 is defect P1011/M1028 - RDF 30V supply output voltage lower than 22.5V - RDF 30V supply fuse is blown - 10M4 defect - signal DUALVSPABS is not correct - -12V is not present - 10PBA04 defect P1012/M1029 - RDF 30V supply defect - -12V is not present - signal DFMOVSPABS is not correct - RDF 30V supply output voltage lower than 22.5V - RDF 30V supply fuse is blown - 10PBA03 defect M1025, P1013 - 10SO08 document size detection defect: actuator is always on M1026, P1014 - 10PBA01 defect - eprom on 10PBA01 is defect or not mounted - communication between host I/O and RDF control is defect - signal RDFNRST always low - 12V local is not present - ESD (Electro Static Discharge) failure P1015 - Doc.size det.failure 10SO16 3x
P1016/M1030 - 10M5 defect O1050 - static eliminator of simplex feedback is defect - seperation belt motor defect (10M4) - pinch roller motor defect (10M2) - toothed belt of drawing/turning roller is broken
Fault table continue : next page
ed.6 Part I
TSM 2400 family
10 RDF 103
DIAGNOSTIC
10diag
CODES O1050
POSSIBLE FAILURES - 10SO15 document present sensor defect : it is always on - 10M3 seperation wheel is blocked - topunit not correct positioned with respect to centerunit - locking/unlocking of center unit is defect - too many originals in original tray - positioning of base unit on frame is not correct - 10M5 defect - separationwheel is defect, damaged or worn - positioning of center unit is not correct in respect of base unit - adjustment of pre-separation shield too low - 10M3 does not run - toothed belt of seperation belt is jumping over pulley - one of the two feed belts is defect - adjustment paperguide is defect bin is too small - 10SO3 defect - 10M8 set seperator motor keeps rotating : always activated - slide bearings of pinch roller are defect - pulleys, ball bearings of supply belts are stuck - adjustment paperguide is defect bin is too big - separationunit is stuck, shoe or pendant - simplex feedback guide is defect - 10M4 defect - toothed belt of supply belts is broken - 10PBA01 defect - separation belt is defect - 10EM4 is not operating - 10M5 cannot run in reverse direction - brush separation belt polluted - inside supply belts polluted by paper dust
O1051
- solenoid 10EM2/pressure roller DF belt is stuck/fault - pulleys, one directional bearing are stuck - one of the two feed belts is defect - earthing of original glass is defect - positioning of base unit on frame is not correct - static eliminator of DF belt is defect - seperationwheel is defect, damaged or worn - pulleys or ball bearings DF belt are stuck - adjustment paperguide is defect bin is too big - solenoid turning station is always up - pulleys, ball bearings pinch/turning roller are broken - toothed drive belt of DF has broken - slide bearings of pinch roller are defect Fault table continue : next page.
104 RDF 10
TSM 2400 family
Part I ed.6
10diag
DIAGNOSTIC
CODES O1051
POSSIBLE FAILURES - toothed belt of pinch/turning roller is broken - pressure roller DF belt is stuck/fault - 10PBA01 defect - DF belt is defect - topunit not correct positioned with respect to centerunit - 10SO15 document present sensor is defect: it is always on - separationunit is stuck, shoe or pendant - locking/unlocking of center unit is defect - positionong of center unit is not correct in respect of base unit - activation of 10M3 is defect - adjustment paperguide is defect bin is too small - locking or unlocking of DF tensionmechanism is defect - turning station is stuck/operating stiff - pulleys, one directional bearing are stuck - 10M3 defect - beltframe not correct positioned with respect to glass platen - 10PBA04 defect - positioning of base unit on frame is not correct - locking or unlocking of DF tensionmechanism is defect - earthing of original glass platen is defect - solenoid 10EM2/pressure roller DF belt is stuck/fault - toothed belt of simplex feedback is broken - pulleys, sliding bearings of simplex feedback are defect - beltframe not correct positioned with respect to original glass platen - solenoid turning station is always up - short circuit in +12V low voltage output stage - DF belt is defect - solenoid original bar always in/out - turning station is stuck/operating stiff - adjustment paperguide is defect bin is too big - locking/unlocking of center unit is defect - 10M7 defect - static eliminator of simplex feedback is defect - toothed drive belt of DF has broken - supply +12V, -12V, GND not present - signal TRACKFREQ is not correct - 10M7 defect stuck - solenoid 10EM2/pressure roller DF belt is stuck/fault - topunit not correct positioned with respect to centerunit - pressure roller DF belt is stuck/fault - 10M7 defect
O1052
ed.6 Part I
TSM 2400 family
10 RDF 105
DIAGNOSTIC
10diag
CODES O1052
POSSIBLE FAILURES - original bar is defect, positioning is arbitrary - positioning of center unit is not correct in respect of base unit - 10PBA05 defect - pulleys or ball bearings DF belt are stuck - signal TRACKDIR_L is not correct - simplex feedback guide is defect - 10SO06 sensor optic return is defect - static eliminator of DF belt is defect - 10EM4 defect - 10M3 defect - passive deflector adjusted incorrectly - 10PBA01 defect - short circuit in +12V low voltage output stage - topunit not correct positioned with respect to centerunit - locking/unlocking of center unit is defect - DF belt is defect - static eliminator of simplex feedback is defect - 10M7 defect - positionong of center unit is not correct in respect of base unit - locking or unlocking of DF tensionmechanism is defect - supply +12V, -12V, GND not present - beltframe not correct positioned with respect to original glass platen - earthing of original glass platen is defect - original bar is defect, positioning is arbitrary - pressure roller DF belt is stuck/fault - simplex feedback guide is defect - static eliminator of DF belt is defect - pulleys or ball bearings DF belt are stuck - adjustment paperguide is defect bin is too big - solenoid original bar always in/out - pulleys, sliding bearings of simplex feedback are defect - toothed belt of simplex feedback is broken - 10PBA05 defect - solenoid 10EM2/pressure roller DF belt is stuck/fault - DF belt is defect - pulleys, ball bearings pinch/turning roller are broken - slide bearungs of pinch roller are defect - toothed belt of pinch/turning roller is broken - turning station is stuck/operating stiff
O1053
O1054
106 RDF 10
TSM 2400 family
Part I ed.6
10diag
DIAGNOSTIC
CODES O1054
POSSIBLE FAILURES - solenoid 10EM2/pressure roller DF belt is stuck/fault - locking or unlocking of DF tensionmechanism is defect - pressure roller DF belt is stuck/fault - pulleys or ball bearings DF belt are stuck - beltframe not correct positioned with respect to original glass platen - earthing of original glass platen is defect - original bar is defect, positioning is arbitrary - static eliminator of DF belt is defect - solenoid turning station is always down - adjustment paperguide is defect bin is too big - topunit not correct positioned with respect to centerunit - solenoid original bar always in/out - locking/unlocking of center unit is defect - toothed drive belt of DF has broken - positioning of center unit is not correct in respect of base unit - active deflector adjusted incorrectly - 10PBA04 defect - pulleys or ball bearings DF belt are stuck - topunit not correct positioned with respect to centerunit - solenoid original bar always in/out - static eliminator of DF belt is defect - belt frame not correct positioned with respect to original glass plate - original bar is defect, positioning is arbitrary - toothed belt of pinch/turning roller is broken - locking or unlocking of DF tensionmechanism is defect - DF belt is defect - pressure roller DF belt is stuck/fault - earthing of original glass platen is defect - positioning of center unit is not correct in respect of base unit - adjustment paperguide is defect bin is too big - locking/unlocking of center unit is defect - toothed drive belt of DF has broken - slide bearings of drawing roller are defect - pulleys, ball bearings drawing/turning roller are broken - 10SO15 document present sensor is defect: it cannot see anything - 10SO08 document size detection defect: actuator is always seen - seperationwheel is defect, damaged or worn - 10SO08 document size detection defect: does not see actuator fall
O1055
O1056 (*)
(*) ONLY FOR THE OLD RDF (until MOD 75) Fault table continue : next page.
ed.6 Part I
TSM 2400 family
10 RDF 107
DIAGNOSTIC
10diag
CODES O1056 (*)
POSSIBLE FAILURES - 10M8 set seperator motor defect - seperationunit is stuck, shoe or pendant - 10M3 defect - 10M8 set seperator motor keeps rotating : always activated - activation of 10M3 is defect - current limiter on 10PBA01 for 10M3 is defect - positioning of base unit on frame is not correct - pulleys or ball bearings DF belt are stuck - toothed belt of MDF/CFF is broken - static eliminator of DF belt is defect - solenoid original bar always in/out - locking or unlocking of DF tensionmechanism is defect - 10M7 feed MDF/CFF is defect - earthing of original glass platen is defect - supply +12V, -12V, GND not present - pulleys, sliding bearings of MDF/CFF are defect - DF belt is defect - toothed drive belt of DF has broken - static eleminator of MDF/CFF output is defect - 10M7 feed MDF/CFF is defect - short circuit in +12V low voltage output stage - pressure roller DF belt is stuck/fault - passive defletor adjusted incorrectly - 10PBA05 is defect - locking or unlocking of DF tensionmechanism is defect - static eliminator of DF belt is defect - supply +12V, -12V, GND not present - DF belt is defect - short circuit in +12V low voltage output stage - earthing of original glass platen is defect - toothed drive belt of DF has broken - 10M7 feed MDF/CFF is defect blocked - pulleys, sliding bearings of MDF/CFF are defect - CFF hole detection sensor is defect - static eleminator of MDF/CFF output is defect - solenoid original bar always in/out - input in CFF cover is defect - pressure roller DF belt is stuck/fault
O1057
O1058
(*) ONLY FOR THE OLD RDF (until MOD 75) Fault table continue : next page.
108 RDF 10
TSM 2400 family
Part I ed.6
10diag
DIAGNOSTIC
CODES O1058
POSSIBLE FAILURES - toothed belt of MDF/CFF is broken - pulleys or ball bearings DF belt are stuck - 10PBA05 is defect - DF belt is defect - pressure roller DF belt is stuck/fault - pulleys or ball bearings DF belt are stuck - signal DFMOVAN is not correct - DF belt is blocked - DFMO ( document feeder ) is defective - winding is short circuited - signal DFMO_ON is not correct - locking or unlocking of DF tensionmechanism is defect - short circuit in +12V low voltage part of output stage on 10PBA03 - signal DFMOL_R is not correct - signal TRACKDIR_L is not correct - -12V is not present - supply +12V, -12V, GND not present - 10PBA03 is defect - signal SBMO_ON is not correct - 10M4 motor seperation belt is blocked - 10M4 defect - SUBMO is defective - signal FBMOVAN is not correct - supply +12V, -12V, GND not present - pulleys, one directional bearing are stuck - short circuit in +12V low voltage part of output stage on 10PBA04 - signal SBMOVAN is not correct - seperationunit is stuck, shoe or pendant - -12V is not present - signal FBMOSPEED is not correct - signal SBMOL_R is not correct - 10PBA04 is defect - rotary encoder of prmo ( pinch roller ) is defect - 10M2 defect
O1059
O1060
O1061
ed.6 Part I
TSM 2400 family
10 RDF 109
DIAGNOSTIC
10diag
CODES O1061
POSSIBLE FAILURES - supply +12V, -12V, GND not present - signal PRMOVAN is not correct - pulleys, ball bearings drawing/turning roller are broken - 10PBA06 is defect - rotary encoder of prmo ( pinch roller ) is defect - -12V is not present - slide bearings of drawing roller are defect - 10M2 motor drawing/turning roller is blocked - signal PRMOL_R is not correct - signal PRMO_ON is not correct - short circuit in +12V low voltage part of output stage on 10PBA06 - rotary encoder of sebmo ( seperation belt ) is defect - 10M5 defect - pulleys, ball bearings of supply belts are stuck - short circuit in +12V low voltage part of output stage on 10PBA08 - SEBMO is defective - 10M5 motor feed belts is blocked - one of the two feed belts is defect - -12V is not present - signal FBMO_ON is not correct - signal FBMOSPEED is not correct - supply +12V, -12V, GND not present - gear 10M5 defect - 10PBA08 is defect - solenoid 10EM2/pressure roller DF belt is stuck/fault - pressure roller DF belt is stuck/fault - DF belt is defect - pulleys or ball bearings DF belt are stuck - winding is short circuited - locking or unlocking of DF tensionmechanism is defect - 10M4 defect - seperationunit is stuck, shoe or pendant - seperation belt is defect - pulleys, one directional bearing are stuck - separation belt motor 10M4 is defect - SUBMO is defective - 10PBA04 defect
O1062
O1063
O1064
110 RDF 10
TSM 2400 family
Part I ed.6
10diag
DIAGNOSTIC
CODES O1065
POSSIBLE FAILURES - slide bearings of pinch roller are defect - 10M2 motor defect - pulleys, ball bearings pinch/turning roller are broken - 10M8 set seperator motor does not rotate, connector is loose - 10M8 set separator motor does not rotate, is stuck - 10M8 set separator motor does not rotate: not activated - 10M8 set separator motor does not rotate, winding is broken - 10SO08 document size detection defect: does not see actuator fall - too many originals in original tray - 10PBA02 defect - 10PBA01 defect - set separator stuck - originals removed by customer during a job recovery - feed belt motor 10M5 defect - gear 10M5 defect - 10PBA08 defect - 10SO15 document present sensor is defect: it cannot see anything - 10SO08 document size detection defect: actuator is always seen - seperationwheel is defect, damaged or worn - 10SO08 document size detection defect: does not see actuator fall - 10M8 set seperator motor defect - seperationunit is stuck, shoe or pendant - 10M3 defect - 10M8 set seperator motor keeps rotating : always activated - activation of 10M3 is defect - current limiter on 10PBA01 for 10M3 is defect - 10EM4 defect - separation wheel motor defect - static eliminator defect - 10PBA01 defect - 10M3 winding is short circuited - solenoid turning station is short circuited - solenoid original bar is short cut - solenoid 10EM2/pressure roller DF belt is stuck/fault - 24V local is not present - -12V is not present
O1066
O1067/2560
O1068
O1070/1071
W1075
W1076
ed.6 Part I
TSM 2400 family
10 RDF 111
DIAGNOSTIC
10diag
Protections PE 1010/M1027 PE 1011/M1028 PE 1012/M1029 PE 1016/M1030

After detection of ORE 1059, 1060, 1061, 1062 the status of the RDF power supplies is checked feedback lines to the RDF control (10PBA01). 30V 20W amplifier (10PBA06). The corresponding status line PRMOPSABS: - 0 = power supply correct - 1 = power supply defective, PE 1010 30V 20W amplifier (10PBA04). The corresponding status line SEBMOPSABS: - 0 = power supply correct - 1 = power supply defective, PE1011 30V 80W amplifier (10PBA03). The corresponding status line DFMOPSABS: - 0 = power supply correct - 1 = power supply defective, PE1012 30V-20W amplifier (10PBA08). The corresponding status line SUBMOPSABS: - 0 = power supply correct - 1 = power supply defective, PE1016
MRE 1025 PE 1013

At the start of a run from the original input tray the set separator sensor (10SO8) must be released. Control line RDFSSE: - 0 = correct - 1 = set separator not in down position, MRE 1025 PE 1013
PE 1014
During RDF power up the RDF control (10PBA01) is tested (ROM, RAM, etc). In case an error is detected the RDF will not communicate with the HOST CPU (22PBA01). Which results in PE 1014.
112 RDF 10
TSM 2400 family
Part I ed.6
10diag
DIAGNOSTIC
PE 1015
The RDF size sensor consists of three optical sensors. Eight different combinations can be generated of which six are valid. Two illegal combinations exist. The coding for these illegal combinations is: RDFDSSE1, RDFDSSE2, RDFDSSE3 are respectively 010 or 101. When one of these combinations is detected, PE 1015
MRE 1026
This message indicates a communication error between RDF control and HOST CPU. If one of the following situations occurs: Confidential 1996 Oc Nederland B.V.
no communication from RDF to host for more then 1s. no command acknowledge or command acknowledge too late and a non existing status from RDF to HOST CPU the RDF does not receive a status acknowledge from the host cpu after sending status information the RDF receives a non existing command from the HOST CPU, MRE 1026 is displayed. ESD (Electro Static Discharge) can occur in all places where grounding is needed.
ORE 1050
RDFDRSE (10SO3) is checked 643 ms after start of separation. - 1 = paper present, correct - 0 = paper too late at sensor, ORE 1050
ORE 1051
RDFDRSE (10SO3) is checked 330ms after start of feed action. - 0 = trailing edge of paper left the sensor in time, correct - 1 = trailing edge did not release sensor in time, ORE 1051
ORE 1052
RDFRETSSE (10SO6) is checked 335ms after start of return action. - 1 = leading edge arrived in time and paper is present, correct - 0 = leading edge paper arrived too late at sensor, ORE 1052
ed.6 Part I
TSM 2400 family
10 RDF 113
DIAGNOSTIC
10diag
ORE 1053
RDFRETSSE (10SO6) is checked 870ms after start of return action - 0 = trailing edge paper released sensor in time, correct - 1 = trailing edge paper released sensor too late, ORE 1053
ORE 1054
RDFDRSE (10SO3) is checked 377ms after start of turn action. - 1 = leading edge of paper arrived in time, correct - 0 = leading edge arrived too late, ORE 1054
ORE 1055
RDFDRSE (10SO3) is checked 330ms after start of feed during turn action. - 0 = trailing edge of paper released sensor in time, correct - 1 = trailing edge of paper released sensor too late, ORE 1055
ORE 1057
MDSASE (10SO11) is checked 350ms after start of MDF feed action. - 0 = trailing edge of paper released sensor in time, correct - 1 = trailing edge of paper released sensor too late, ORE 1057
ORE 1058
CFFHOLSE (10SO9) is checked during CFF feed. The hole pattern is compared with the programmed value. When: - more then two successive holes are closed - more then two pieces of paper between holes have disappeared ORE 1058 is displayed.
114 RDF 10
TSM 2400 family
Part I ed.6
10diag
DIAGNOSTIC
ORE 1059 ORE 1060 ORE 1061 ORE 1062

The difference between requested travelled distance and measured travelled distance of the paper may not exceed 25 mm. The travelled distance is measured by using rotary encoders which are mounted on the motors. The next list gives the relation between motor and message - DF belt motor (10M1) - ORE 1059 - separation belt motor (10M4) - ORE 1060 - pinch roller motor (10M2) - ORE 1061 - supply belts motor (10M5) - ORE 1062
ORE 1063 ORE 1064 ORE 1065 ORE 1068

The current to the RDF motors is measured. This is necessary because the motors can not handle the maximum output current continuously. The current over the last 8s is calculated and compared with a maximum value. If the maximum value is exceeded a message is displayed. The next list gives the relation between motor, maximum value and message. DF belt motor (10M1) - 4.0 Arms - ORE 1063 separation belt motor (10M4) - 1.76 Arms - ORE 1064 pinch roller motor (10M2) - 1.76 Arms - ORE 1065 supply belts motor (10M5) - 1.76 Arms ORE 1068
ORE 1066
The number of originals is counted in RDF and ADF mode. The maximum number of originals is 200, . The level of RDFSSMO (10SO8) is: - positive pulse before original count 200, = correct - low 0 during 200, original counts = too many originals, ORE 1066
ed.6 Part I
TSM 2400 family
10 RDF 115
DIAGNOSTIC
10diag
ORE 1067/2560
Illegal set separator occurs if : - 1 In case the separator finger drops while no separation is in progress the error: ORE 1067 - 2 If set separator drops too soon or too late, during separation : ORE 1067.
ORE 1070 ORE 1071

If the number of originals in the RDF is de- or in-creased during a run this is detected by 10SO8 and the situation setlength de- or in-creased occurs. Decreased, ORE 1070 Increased, ORE 1071
Warning 1075
The presence of the 24VDC on the RDF control (10PBA01) is checked 1x/s. In case the 24VDC is not present, Warning 1075
Warning 1076
The presence of the -12VDC on the RDF control (10PBA01) is checked 1x/s. In case the -12VDC is not present, Warning 1076
116 RDF 10
TSM 2400 family
Part I ed.6
10sds
SDS

SIGNAL -010M2 10M4 10M1 10SO8 10SO16 10M5 10SO8 10SO3 10SO3 10SO6 10SO6 10SO3 10SO3 10SO8 10SO11 10SO9 10M1 10M4 10M2 10M5 10M1 10M4 10M2 10SO8 10SO8 10M5 10SO8 10SO8 RDF supply absent RDF supply absent RDF supply absent set separator failure communication failure document size detection failure RDF supply absent set separator failure communication failure separation: too late at 10SO3 feed: 10SO3 too late free return: too late at 10SO6 return: 10SO6 too late free turn: too late at 10SO3 turn: 10SO3 too late free set length unequal 10SO8 MDF: 10SO11 too late free CFF: hole pattern error 10SO9 motor speed too low motor speed too low motor speed too low motor speed too low load/current too high load/current too high load/current too high too many originals illegal setsep. detection load current too high set length decreased 10SO8 set length increased 10SO8 24V RDF supply failure -12V RDF supply failure DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 10 0 10 PE 10 0 11 PE 10 0 12 PE 10 0 13 PE 10 0 14 PE 10 0 15 PE 10 0 16 PE 10 0 25 MRE 10 0 26 MRE 10 0 50 ORE 10 0 51 ORE 10 0 52 ORE 10 0 53 ORE 10 0 54 ORE 10 0 55 ORE 10 0 56 ORE 10 0 57 ORE 10 0 58 ORE 10 0 59 ORE 10 0 60 ORE 10 0 61 ORE 10 0 62 ORE 10 0 63 ORE 10 0 64 ORE 10 0 65 ORE 10 0 66 ORE 10 0 67 ORE 10 0 68 ORE 10 0 70 ORE 10 0 71 ORE 10 0 75 W 10 0 76 W
ed.6 Part I
TSM 2400 family
10 RDF 201
SDS
10sds
PARAMETERS INPUT TESTS 10 2 01 10 2 02 10 2 03 10 2 04 10 2 05 10 2 06 10 2 07 10 2 08 10 2 09 10 2 10 10 2 11 10 2 12 10 2 13 10 2 14 10 2 15 * 10 2 15 10SO8 10SO15 10SO16 10SO3 10SO6 10SO7 10SO10 10SO11 10SO12 10SO13 10SO14 10SO9 10S1 10M2 10M4
-1-2RDF Set Separation SEnsor RDF Document Present SEnsor RDF Document Size SEnsor : Note 1 RDF Document Ready SEnsor RDFDRSE RDF RETurn SEnsor RDFRETSE RDF Turn Path SEnsor RDFTPSE MDF Document Present SEnsor MDFDPSE MDF Size A SEnsor MDFSASE MDF Size B SEnsor MDFSBSE MDF Size C SEnsor MDFSCSE MDF Size D SEnsor MDFSDSE CFF HOLe SEnsor CFFHOLSE RDF COVer Up SEnsor RDFCOVUSE Pinch Roller MOtor Power PRMOPSABS Supply ABSent SEBMOPSABS SEparation Belt MOtor Power Supply ABSent SUBSEBMOP SUpply Belt/SEparation Belt SABS MOtor Power Supply ABsent RDFSSSE RDFDPSE RDFDSSE1-3 DFMOPSABS -12VPSABS 24VPSABS FBMOPSABS Document Feeder MOtor Power Supply ABSent -12V Power Supply ABSent 24V Power Supply ABSent Feeder Belt MOtor Power Supply ABSent
10M4/10M5
10 2 16 10 2 17 10 2 18 10 2 19 *
10M1
10M5
OLD SITUATION. (until MOD 75, 2375/2400)

Paper size 254 mm 270 mm 279 mm 297 mm 330 mm 356 mm >356 or <254 mm Decimal code (RDFDSSE1-3) 208 209 210 211 212 213 213
Note 1:
202 RDF 10
TSM 2400 family
Part I ed.6
10sds
SDS
OUTPUT TESTS 10 4 01 10 4 02 10 4 03 10 4 04 10 4 05 10 4 06 * 10 4 06 SPECIAL TESTS 10 6 01 10 6 02 10 6 03 10 6 04 10 6 05 10 6 06 10 6 07 10 6 08 10 6 09 10 6 10
-4RDFSEPWHMO RDFBRSO RDFDRSO RDFTDSO RDFSSMO RDFSHOESO RDF SEParation WHeel MOtor Note 2 Rdf DF Belt Roll SOlenoid RDF Document Roller SOlenoid RDF Turn Deflector SOlenoid RDF Set Separator MOtor RDF SHoe SOlenoid not available
-6make function WARM make function COLD mask function protections Note 3 Note 4 Note 5 Note 6 Note 7 Note 8 Supply belt motor speed/direction (0.5m/s) ; (same as DF-MO: see Note 6) Supply belt motor low speed (0,5 m/s) Note 9 Note 10 Note 11 Note 12 Note 13 RDF 1-sided document test (stand alone), min 3 originals RDF 2-sided document test (stand alone), min 3 originals -8-
10M8 10M7 10M6 10M1 10M4 10M2 10M5
* 10 6 10 10 6 11 10 6 12 10 6 13 10 6 14 10 6 15 10 6 16 10 6 17
10M5
REPLACE CONSUMABLES
OLD SITUATION. (until MOD 75, 2375/2400)
ed.6 Part I
TSM 2400 family
10 RDF 203
SDS
10sds
Note 2: To prevent damage to the separation belt, open the DF cover before activating this test. Note 3: Set separator motor on. Place one or more originals in the RDF tray. Select the test. Press <PRINT>. Set separator finger is placed on top. Test is terminated automatically. Pull the original(s) from underneath the set separator finger. Finger falls freely. Note 4: MDF motor low/high speed + adjust. Select MDF motor folowing DF belt motor <NO> or <YES>. Press <PRINT>. <NO> : MDF motor starts running at low speed. <YES> : MDF motor starts running together with DF belt motor at same speed 0,5 m/s (to adjust). Note 5: Return motor feed/return + adjust. Select turn direction DF belt motor. Press <PRINT>. DF belt motor starts running (1.0 m/s), return motor (10M6) follows (to adjust). Note 6: DF belt motor speed/direction. Select turning <SPEED LOW/HIGH/CURRENT> (0,5/1,0/fixed current m/s). Select turn direction feed/eject. Press <PRINT>. DF motor starts running in selected mode. Note 7: To prevent damage to the separation belt, open the DF cover before activating this test. Separation belt motor speed. Select <SPEED LOW/HIGH/CURRENT> (0.5/1,2/fixed current m/s). Press <PRINT>. Motor starts running in selected mode. Note 8: Pinch roller motor speed/direction. Select <SPEED LOW/HIGH/CURRENT> (0.5/1,2/fixed current m/s). Select <DIRECTION FEED/EJECT>.Press <PRINT>. Motor starts running in selected mode. When speed <HIGH> is selected only direction <FEED> is possible. Note 9: Communication test procedure. The LED on RDF control is flashing. Host CPU sends a test command and RDF control returns status. Consequently there is a level change on lines RDFCMD0-7 and RDFSTS0-7 every 3 sec (<10000000> to <01111111>). RDFCMDSTR, RDFSTSSTR have a level change every 1.5 sec. Also RDFSTSACK and RDFCMDACK have a level change every 3 sec. Note 10: RDF 1-sided document test. Put one original in tray. By pressing <PRINT> one step of the folowing cycle is executed: separation-feed-eject. Note 11: RDF 2-sided document test. Put one original in tray. By pressing <PRINT> one step of the folowing cycle is executed: separation-feed-turn-feed-eject Note 12: MDF document test. Put one original in MDF. By pressing <PRINT> one step of the folowing cycle is executed: feed-eject. FEED : ABC lamp on, DF belt motor on/off, ruler solenoid activated/deactivated, pressure roll solenoid activated. EJECT : ruler solenoid activated/deactivated, DF belt motor on/off, pressure solenoid deactivated. Note 13: CFF document test. Put original in CFF. By using copy darker/lighter buttons the number of holes/original is selected. By pressing <PRINT> one step of the folowing cycle is executed: feed-eject.
204 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
ADJUSTMENTS 1 Centre unit on base unit. Aim:

To assure the centre unit is positioned correctly on the callipers of the base unit.
Check:
Open the DF/top unit; Open and close the centre unit and see it is locked correctly; Measure the distance -X- and -Y- (front and rear): -X- top deflector shaft front with respect to top original glass platen; -Y- top deflector shaft rear with respect to top original glass platen; Difference between X and Y must be less than 0.5 mm, nominal distance is 3mm; x - y < 0.5 mm, proceed with adjustment 10 - 2; x - Y > 0.5 mm, proceed with adjustment 10 - 1.
10adju1a
NOTE: Adjust always with the supply/separation unit installed Always close the centre unit by pushing on the right side cover
ed.6 Part I
TSM 2400 family
10 RDF 301
ADJUSTMENTS
10adju
Correction:
1.1 1.2 1.3 1.4 Check if the original glass platen is resting on its three supporting points; Open the centre unit; Remove the two balance springs -E-; Loosen the following bolts of the two hinges:- bolts -A- (4x); - bolts -B- (4x); - bolts -C- (4x); - bolts -D- (2x); Tighten bolts -A-, -B- and -C- finger tight; Place the centre unit correctly on its callipers and position the hinges in such a way that they do not twist; Make sure the locking mechanism is not interfering with the adjustment; * If incorrect carry out adjustment 10-2; Push the centre unit to the rear to eliminate the play between the calliper -H- and base frame (left rear side); Tighten bolts -C-; Tighten bolts -A-; Slide positioning plates -F- against surface -G-; Tighten bolts -D-; Tighten bolts -B-; Install the balance springs -E-; Close the centre unit and check the play between the calipers NOTE: Play between centre and base unit, originated by installing the pressure springs, must be reduced to 0.2 mm. Therefore the centre unit will be pretensioned, using the special tool, code nr. 7991 436
1.5 1.6
10adju1b
1.7
1.8
1.9 1.10 1.11 1.12 1.13 1.14 1.15
10adju1e
10adju1d
302 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
1.16 Remove cover plate ; 1.17 Remove 3 bolts and cover plates ; 1.18 Install the tools -M- and -N- at the rear over the centre- and base unit frame. * pay attention to the harness; 1.19 Install the third tool at the front side between centre- and base unit frame above the lock mechanism of the centre unit; 1.20 Turn allen screw -G- clock wise until the play between calliper -H- and base unit frame is just zero mm; 1.21 Turn allen screw -I- clock wise until the play between calliper and base unit frame is just zero mm; 1.22 Loosen the bolts -B- of the left and right hinge at least 2 turns * the hinge will probably rise; 1.23 Tighten bolts -B- (4x) securely; 1.24 Remove the installed special tools; Check the play between the calipers: - if the tolerance at the rear side is not met proceed with step 1.18 - if the tolerance at the front side is not met proceed with 1.25 1.25 Loosen bolts -O-; 1.26 Move the locking block -Q- down until the play is within tolerance; 1.27 Tighten bolts -O-; 1.28 Loosen bolts -P-; 1.29 Lower the centre unit with the nose into the centering block; 1.30 Tighten bolts -P-;
10adju1c
10adju1g
10adju1f
ed.6 Part I
TSM 2400 family
10 RDF 303
ADJUSTMENTS
10adju
Lock mechanism centre unit Aim:

To achieve that the centre unit can be closed easily and the play between the callipers of centre and base unit is minimum.
Check:
Open the centre unit and close it again: * the centering nose must fall straight into the guide block; * the catch must fall smoothly in the locked position, with minimum play between the callipers front side.
Correction:
2.1 2.2 Check adjustment 10 - 1; Remove the two balance springs -Eof the centre unit;
Centering nose guide block: 2.3 Loosen bolts -B-; 2.4 Lower the centre unit with the nose into the centering block; 2.5 Tighten bolts -B-; Locking block catch: 2.6 Loosen bolts -A-; 2.7 Close the centre unit and push it down ( right front side) on the callipers; 2.8 Lower locking block -C- on catch -Dwith a play of 0.1 +0.1/-0 mm; 2.9 Tighten bolts -A-; 2.10 Install the two balance springs -E-.
10adju2b
10adju2a
304 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
DF frame and top unit with respect to centre unit. Aim:

To achieve a defined position of the top unit with respect to the centre unit when the DF frame is in locked position.
Check:

Remove the DF cover; Loosen connector 10CN6, 1003CN1, 1003CN2 and the earth tab; Remove the DF belt frame; Close the DF frame; Select test 10 4 04, RDF turn deflector solenoid; Determine the distance -R- between deflector flap and top unit, front -R1- and rear -R2-: * the discrepancy between front and rear must be less than 0.7 mm; Check that the callipers are positioned correctly.
10adju3a
Correction:
3.1 3.2 Check adjustments 10-1 and 10-2; Remove the operating panel;dis/assembly 22-1 Open the DF unit; Remove balance spring -E- of the DF unit;
3.3 3.4
ed.6 Part I
TSM 2400 family
10 RDF 305
ADJUSTMENTS
10adju
3.5
3.6 3.7 3.8 3.9
3.10 3.11 3.12 3.13
Loosen the following bolts and nuts: - bolts -A- (4x) (hinges on frame); - bolts -B- (4x) (hinges DF-frame); - bolts -C- (2x) (top and bracket); - bolts -D- (3x) (DF-frame and bracket); - nuts -F- (3x) (top and DF-frame); Place the top unit on the centre unit so the 4 callipers fit together; Push the top unit to the rear against the calliper stop; Keep top unit and centre unit in their callipers; Slide the DF frame to the rear and to the right, against the top unit, to eliminate the play at -X- and -Y-; Position the hinges in such a way that they do not twist; Tighten bolts -A- finger tight; Tighten bolts -B- finger tight; Use a vernier calliper to determine the distance -P-, rear and front, (top DF frame tube to original glass platen); * correct: P1(front) = (P2(rear) 0.5 mm);
10adju3c
10adju3d
10adju3e
306 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
NOTE: If the discrepancy between front and rear is more than 0.5 mm use the lock mechanism to correct the position of the DF frame. Proceed as follows: -Loosen nut -L-; -Turn Allen screw -M- until distance P1 =P2. If the locking mechanism is still interfering the adjustment loosen also: - bolts -K-; - bolt -H-.
10adju3f
3.14 Move bracket -Z- in the corner against DF and top unit frame; 3.15 Tighten bolts -D- finger tight; 3.16 Push the top unit firmly down on the rear callipers and tighten bolts -C securely, while keeping it down; 3.17 Push the top unit firmly down on the front callipers and tighten nuts -F- securely, while keeping it down; 3.18 Tighten bolts -D- securely; 3.19 Right hinge: tighten bolts -B- and then -A- securely; 3.20 Left hinge: tighten bolts -B- and then A- securely; 3.21 Install balance spring -E-; 3.22 Proceed with adjustment 10-4, DF cover lock mechanism; 3.23 Install the operator panel; 3.24 Install the DF belt frame; 3.25 Connect the electrical connections.
10adju3d
ed.6 Part I
TSM 2400 family
10 RDF 307
ADJUSTMENTS
10adju
Lock mechanism DF. Aim:

To assure correct positioning of top and centre unit on their callipers, and easy locking.
Check:
Open the DF, it must open very smoothly; Push on the left corner of the DF cover, it must lock very smoothly; The play between the callipers (front) of top and centre unit must be less than 0.1 mm.
10adju4a
WARNING: The DF cover is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is much higher. Be aware of the situation and take the necessary precautions to prevent unexpected releasing of the lock mechanism.
Correction:
4.1 4.2 4.3 4.4 Check adjustment 10-1, 10-2 and 10-3; Remove the DF cover; Remove the centre front cover; Remove the operating panel, dis/assembly 22-1;
308 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
4.5
4.6
4.7 4.8 4.9 4.10 4.11 4.12

4.13 4.14
Check distance -X- and adjust if necessary to X = 33 0.5 mm, using screws -G-; Check distance -Y- and adjust if necessary to Y=16.50.5 mm, using bolt -HTighten bolt -H-; Loosen bolts -K- and then tighten both finger tight; Loosen nut -L- and then tighten it finger tight; Turn Allen screw -M- CW to achieve that the DF closes easily; Push the DF frame in locked position; Check that the callipers of top and centre unit fit together; Tighten bolts -K- securely; Turn Allen screw -M- in steps CCW, until the play between the front callipers of top and centre unit is 0 mm; NOTE: Push after every turn step on the DF frame to check the play.
10adju4d
4.15 Turn Allen screw -M- 1 turn CW to achieve 0.1 mm play; 4.16 Tighten nut -L- securely; 4.17 Proceed with adjustment 10-5, DF frame supporting stud.
10adju4e
10adju4b
10adju4c
ed.6 Part I
TSM 2400 family
10 RDF 309
ADJUSTMENTS
10adju
Supporting stud DF frame. Aim:

To support the DF frame and protect it against distortion when leaning on the DF frame.
Check:
The distance between stud -B- and support -C- must be 2 mm 0.2 . WARNING: Be aware of the danger and take the necessary precautions to prevent unexpected releasing of the lock mechanism. The DF cover is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is much higher.
Correction:
10adju5a
5.1 5.2 5.3 5.4 5.5 5.6
Check that the cover with the supports is correctly positioned; Remove the DF cover; Loosen lock nut -A-; Adjust the distance between stud -Band support -C- to 2 mm 0.2 ; Tighten lock nut -A-; Install all removed parts.
10adju5b
310 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
6
*
GUIDE SHIELD OVER SEPARATION WHEEL.

OLD SITUATION. (until MOD 75)
Aim:
To assure a defined opening between shield and separation belt. This to prevent damage to the originals by the separation wheel, and achieve good guidance of the original stack towards the separation nip.
Check:
Determine the distance -Z- between shield and separation belt; This distance must be 0.7 0.2 mm. * Place 7 sheets (80 g/m2) one by one underneath the guide shield; * When putting the 7 th sheet underneath there must be some resistance between sheet and shield; * When putting an 8 th sheet underneath this must hit against the shield;
10adju6a
Correction:
Check the condition of the separation wheel and separation belt; 6.2 Remove the return path guide plate -A- and plate -B-; 6.3 Remove separation shoe -C-; 6.4 Loosen lock nut -D-; 6.5 Turn allen screw -E- counter clock wise to raise the guide shield; 6.6 Place 7 sheets (80 g/m2) underneath the guide shield; 6.7 While turning allen screw -E- clock wise pull the top sheet from underneath the shield and return it underneath the shield until resistance between shield and sheet is felt: Z = 0.7 0.2 mm 6.8 Tighten lock nut -D-; 6.9 Use a strip of paper (80g/m2) to check: * that the guide shield is touching the wheel at point -X-; * that the guide shield is free from the wheel at point -Y-; 6.10 Install all removed parts 6.11 Check for correct separation using test 10 6 16 6.1
10adju6b
ed.6 Part I
TSM 2400 family
10 RDF 311
ADJUSTMENTS
10adju
Glass strip. Aim:

To assure a defined height of the strip with respect to the original glass platen, so transport over the original glass platen is guaranteed.
Check:
Use the gauge (adjusting jig part nr. 7991.450) to check the strip is pointing 0.3 0.1 mm above the original glass plate, front and rear: * place gauges next to the roller; * do not push on the original glass platen; * put a sheet of 80 g/m2 paper under the gauge, the gauge should go over the glass strip; * put a sheet of 80 g/m2 paper on the glass strip, the gauge should hit the paper. WARNING: Be aware of the danger and take the necessary precautions to prevent unexpected releasing of the lock mechanism. The DF cover is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is even much higher.
10adju7a
Correction:
7.1 7.2 7.3 Remove plate -D- and lower the ABChousing. Remove cover plates, front and rear, to get access to the adjuster bolts; Open the DF;
10adju7b
312 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12
Loosen bolt -A-, at the front , finger tight; Loosen bolts -A- and -B- at the rear; Place the gauge -G- on the glass, rear, as shown; Lift the glass strip against the gauge and tighten bolts -A- and -B- rear; Repeat this procedure at the front; Tighten bolt -A-; Install all removed parts. Check adjustment 10-8, 10-15. Perform adjustments : - ABC lamp housing position, 04-3 - ABC calibration, 04-4
10adju7c
10adju7d
ed.6 Part I
TSM 2400 family
10 RDF 313
ADJUSTMENTS
10adju
DF belt frame, horizontal position. Aim:

To assure a defined position with respect to the glass strip and the DF belt nip roller.
Check:
Remove the DF cover and the DF belt; Place two gauges -Y/Z- in two holes -G- of the glass strip; Close the DF frame carefully over the two gauges (part nr. stud 7991.405): * the gauges must engage with the two blind holes in the DF belt roller * do not push the DF belt frame downwards
WARNING: Be aware of the danger and take the necessary precautions to prevent unexpected releasing of the lock mechanism. The DF is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is even much higher.
10adju8a
10adju8b
314 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
Correction:
8.1 8.2 8.3 8.4 8.5 8.6 8.7 Loosen bolts -A-, front; Loosen nut -B-, rear; Loosen bolts -DClose the DF frame with the blind holes in the roller over the two gauges Y/Z; Tighten nut -B-; Tighten bolts -A-: * keep the slotted hole -C- vertically; Tighten bolts -D-: * position the plates free from the hinge pin (0,5 +/-0,3).
10adju8c
8.8
Remove gauges -Y- and -Z-;
10adju8d
ed.6 Part I
TSM 2400 family
10 RDF 315
ADJUSTMENTS
10adju
DF belt frame, vertical position. Aim:

To assure a defined height of the DF belt frame with respect to the original glass platen.
Check:
The front and rear glass cover plates with supports must be mounted completely down; Remove the DF cover and the DF belt; Put the hinged parts correctly in their locked position (front/rear); Place underneath all four studs a strip of paper, and close the DF frame; Push the 2 mm gauge underneath DF belt roller -M-, front and rear (part nr. 7991.450); Check for resistance when pulling the paper strip from underneath the nearest stud, with and without the gauge: * Resistance too few: stud too high; * Resistance too high: stud too low; Repeat this procedure for all four supporting points; use for the DF belt drive roller -
10adju9a
N- the gauge size 2.4 mm (part nr. 7991.450). WARNING: Be aware of the danger and take the necessary precautions to prevent unexpected releasing of the lock mechanism. The DF cover is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is even much higher.
316 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
Correction:
NOTE : Make sure that during adjusting of pin P and P1 (front and rear) does not touch bracket -W- and -X- . 9.1 Check that the position of the glass strip is 0.3 mm above the original glass plate, see adjustment 10-7; Loosen lock nut -K- of the studs -Lwhich have to be adjusted; * Front: proceed with 9.4; * Rear : proceed with 9.7; Activate SDS test 10 4 03, ruler down;
10adju9f
9.2
9.3
Front: 9.4 Place roller -M- on the 2 mm gauge -aand roller -N- on the 2.4 mm gauge -d-. 9.5 Adjust the 2 studs, front, so that the distances at -aand -d- are 2 mm and 2.4 mm 0.1 mm; 9.6 Tighten lock nut -K-; Rear: 9.7 Place roller -N- on the 2.4 mm gauge -c- and roller -M- on 2 mm gauge -b-; 9.8 Adjust the 2 studs rear, so that the distances at -c- and -b- are 2.4 mm and 2 mm 0.1mm; 9.9 Tighten lock nut -K-; 9.10 Loosen nut -Y-; * 9.10 Loosen nut -R-; 9.11 Adjust plate -X- vertically to obtain play -Z- = 0,5 0,3 mm; * 9.12 * 9.13 *
OLD SITUATION (UNTIL MODIFICATION 75)
9.14 9.15 9.16 *
9.11 Adjust stud -P- in such a way that distance S = 2 0.3 mm; Tighten nut -Y-; 9.12 Tighten nut -R-; Loosen nut -R-; 9.13 Install the DF belt and check the ruler is not touching ; if yes perform adjustment 10.13, ruler position. Adjust stud -P- in such a way that distance S = 10.3 mm; Tighten nut -R-; Install the DF belt and check the ruler is not touching; OLD SITUATION. (until MOD 75)
ed.6 Part I
TSM 2400 family
10 RDF 317
ADJUSTMENTS
10adju
10
Passive deflector with respect to DF-belt Aim:

To obtain a minimal gap between the passive deflector and the DF-belt while keeping the ability to feed 200 g/m2 originals via the MDF.
Check:
Adjustments DF belt frame, vertical and horizontal position must be correct. Measure a gap of 10.2 mm between the DF-belt and the passive deflector, using a 1 mm feeler gauge. The measurement should be done in the middle of the DFbelt. When moving the feeler gauge between belt and deflector one should feel a slight resistance.
Correction:
10.1 Loosen bolt -A- and nut -B-. 10.2 Adjust the passive deflector with respect to the DF-belt to obtain a gap of 10.2 mm 10.3 Tighten bolt -A- and nut -B-.
10adj10c
318 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
11
DF belt pressure roll (rest position) Aim:

To achieve that the DF roll is free from the DF belt in rest position. So the friction between DF belt and original only increases during return and ejection of the original.
Check:
Use test 10 4 02 to check the operation of the DF belt pressure roll; In rest position the DF belt pressure roll must not touch the DF belt; When active the roll must rest on the DF belt. WARNING: Be aware of the danger and take the necessary precautions to prevent unexpected releasing of the lock mechanism. The DF is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is even much higher.
Correction:
11.1 11.2 11.3 11.4 11.5 Remove the DF cover; Remove the DF belt; Remove bracket -C- with the roll. Loosen screws -A-; Place a 3 mm feeler gauge underneath lever -B-; 11.6 Push the lever on the gauge and move coil until the distance between O-ring and solenoid is 6 + 0.5/ - 0 mm; 11.7 Tighten screws -A-; 11.8 Install all removed parts.
10adj10b
10adj10a
ed.6 Part I
TSM 2400 family
10 RDF 319
ADJUSTMENTS
10adju
12
DF-up switch. Aim:

To detect DF is in open or closed position.
Check:
Use test 10 2 13 to check the operation of the DF-up switch. WARNING: Be aware of the danger and take the necessary precautions to prevent unexpected releasing of the lock mechanism. The DF is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is even much higher.
Correction:
12.1 12.2 12.3 12.4 Remove the cover plate; Loosen screw -A-; Close the DF; Move the switch plate so far down until the gap between housing and switch arm is 0.5 mm; 12.5 Tighten screw -A-.
10adj11a
10adj11b
320 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
13
*
Drive belt tensioner DF belt

OLD SITUATION. (until MOD 75)
Aim:
To achieve a correct tension of the drive belt that drives the DF belt.
Check:
Remove the DF cover; Distance -Z- must be 0.5 - 0/+ 1.5 mm. WARNING: The DF cover is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is much higher. Be aware of the situation and take the necessary precautions to prevent unexpected releasing of the lock mechanism.
Correction:
13.1 Loosen bolts -A- (3x); 13.1 Loosen bolts -A- (3x); 13.2 Tighten bolts -B-; 13.2 Loosen bolts -B- and -D-; 13.3 Turn the DF belt motor against the stop in the frame: * pretensioning the drive belt; 13.4 Tighten bolts -A-; 13.5 Push tensioner -Cagainst the drive belt and set it free; 13.6 Tighten bolt -B-; 13.7 Tighten bolt -D-; 13.8 Install the DF cover. 13.8 Install the DF cover.
OLD SITUATION (UNTIL MODIFICATION 75)
10adj12b
ed.6 Part I
TSM 2400 family
10 RDF 321
ADJUSTMENTS
10adju
14
Ruler position with respect to the original glass platen. Aim:

To catch and stop the original in the correct way. WARNING: The DF is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is much higher. Be aware of the situation and take the necessary precautions to prevent unexpected releasing of the lock mechanism.
Check:
10adj13a
Remove DF cover; Open the DF ; The ruler must protrude 1.2 0.1 mm above the glass, front and rear; Check that the DF belt does not touch the ruler, turn the DF belt one complete revolution by hand: * check also adjustment 10-8, DF belt frame horizontal position.
Correction:
Left - Right adjustment NOTE : Only perform this basic adjustment if brackets -B- have been displaced 14.1 Loosen bolts -A- (6x); 14.2 Move ruler frame upward by turning allen screws -D- clockwise, make sure that the ruler stays clear from the original glass platen; 14.3 Adjust distance -Y- to 4.2 0.1 mm by moving brackets -B- (rear and front);
10adj13b
10adj13c
322 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
Height adjustment 14.4 Loosen bolts -A- (6x) and tighten them finger tight; 14.5 Turn Allen screws -D- CCW until distance -Z- is 1.2 0.1 mm, front and rear; 14.6 Close the DF ; 14.7 Check that there is a minimum play between DF belt and ruler fingers of 0.1 mm. * If the belt touches the ruler, lower the ruler 0.1 mm on both sides using allen screws -D-; If the ruler still touches the DF belt it is in this special case possible to lower the ruler again, out of tolerances too a absolute minimum of -Z- =0.85 - 0 mm. The measurement -Y- can be lower to its abolute minimum of 3.85 - 0 mm. NOTE : When you adjust the ruler out of tolerances, the possibility of dama-ging of the originals is much bigger ! 14.8 Tighten bolts -A- securely;
10adj13d
10adj13f
10adj13e
ed.6 Part I
TSM 2400 family
10 RDF 323
ADJUSTMENTS
10adju
15
DF belt ejection nip rolls. Aim:

To create a pinch that assures correct ejection of the originals into the delivery tray.
Check:
Open the DF ; Select test 10 4 03, to raise the nip rolls; The nip rolls -C- must protrude 2.5 0.2 mm above the glass; WARNING: The DF is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is much higher. Be aware of the situation and take the necessary precautions to prevent unexpected releasing of the lock mechanism.
Correction:
15.1 15.2 15.3 15.4 Remove the ruler cover; Loosen Allen screw -B-; Select test 10 4 03; Turn clamping piece -A- over the shaft until roll -C- protrudes 2.5 mm above the original glass; 15.5 Tighten Allen screw -B* line-up clamping piece with roll bracket;
10adj14a
10adj14b
324 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
16
Duplex turn deflector. Aim:

To achieve a defined situation for the lower and upper position of the deflector flap.
Check:

Remove the DF cover; Remove the DF belt frame; Close the DF frame; Select test 10 4 04, flap lifted; Flap -F- must be opened maximum, but not touching the upper guide: * If not correct: proceed with 16.1; Deactivate the SDS test; Flap -F- must not touch the bottom, and must not protrude; * If not correct: proceed with 16.9. WARNING: The DF is, in closed position, kept under high tension by a balance spring. When the top cover is removed the opening force is much higher. Be aware of the situation and take the necessary precautions to prevent unexpected releasing of the lock mechanism.
Correction:
16.1 Check first adjustment 10-1 and 10-3; 16.2 Select test 10 4 04, to place flap -F- in upper position;
10adj15b
16.3 Loosen nut -E-; * in case of old situation continue with 16.17 (until MOD 75). 16.4 Place two sheets 80 g/m2 (20lbs) between flap -F- and bracket -G-: * to achieve a gap of 0.2 0.1 mm; 16.5 Turn eccentric -B- against bracket -C-; 16.6 Tighten nut -E16.7 Remove the sheets; 16.8 Deactivate test 10 4 04;
10adj15d
ed.6 Part I
TSM 2400 family
10 RDF 325
ADJUSTMENTS
10adju
16.9 Open the DF frame; 16.10 Loosen the screw holding the cover plate and open the centre unit to remove the cover plate; 16.11 Close the centre unit; 16.12 Place 2 sheets 80g/m2 /20lbs underneath the flap; 16.13 Determine the play, and open the centre unit to adjust nut -D-; 16.14 Adjust for minimum play: - turn nut -D- upwards (clockwise) to raise flap -F-, - turn nut -D- down (counter clockwise) to lower the flap; 16.15 Install all removed cover plates and DF belt frame. 16.16 Use to test the original handling the following tests: - simplex mode: 10 6 16 - duplex mode: 10 6 17
10adj15c
Old situation: (until MOD 75) 16.17 Loosen allen screw -A16.18 Place 2 sheets 80g/m2 /20 lbs on top of the flap 16.19 Close the DF frame 16.20 Push flap -F- up against the sheets 16.21 Tighten allen screws -A16.22 Continue wit step 15.7
10adj15a
326 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
17
Supports return path cover. Aim:

To achieve a pinch between the return and delivery rollers.
Check:
Knock with your finger on top of the return path cover at both supports: * the cover must just be free from the supports. Place two strips paper (80 g/m2, 20lbs) left and right as indicated in figure and close the return path cover. If you pull out the strips, you have to feel a slight resistance, if not proceed with 17.1.
Correction:
17.1 Loosen lock nut -B- front and/or rear; 17.2 Adjust the height of the supports front and/or rear to X = 8 mm (basic setting); 17.3 Lower or raise the support until there is just some play between support and cover: * now the delivery roller has a pinch achieved by the weight of the cover, check this with two strips paper between the rollers, you have to feel a slight resistance if you pull out the strips.
10adj16a
10adj16c 10adj16b
ed.6 Part I
TSM 2400 family
10 RDF 327
ADJUSTMENTS
10adju
18
Supply belts with respect to RDF original tray. Aim:

To achieve sufficient friction between original and supply belts to stop and supply the bottom original.
Check:
Determine distance -X- in the centre between the two supply belts. * The supply belts must protrude an average distance above the top of the ribs on the tray bottom : X = 4 0.3mm
Correction:
18.1 Open the centre unit; 18.2 Loosen lock nut -B-; 18.3 Turn allen screw -A- so that the average distance between the two supply belts is: X = 4 0.3 mm.
10adj17a
10adj17b
328 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
19
Image positioning: ZERO stop RDF original tray. Aim:

To achieve a centered image on the copy when using the RDF.
Check:
NOTE: See also Copy Quality (system level): Image positioning adjustments
Place 10 testcharts of 25 in the RDF original tray; Make a copy of these testcharts 25;
10adj18a
Measure the distance A and C and calculate the average value: (A tot - C tot ) /10 =0+/- 2 mm (=X)
A A
Correction:
19.1 Remove cover -D- at the rear of the RDF original tray; 19.2 Place testchart 25 in the RDF original tray, against zero stop -Z-; 19.3 Close up the format slide -F- against the testchart: in click position; 19.4 Make 1 copy; 19.5 Measure the distance -A-, from -10" line to the edge of the paper; * -A- must be 10 1 mm; 19.6 Determine the difference between real and desired value; 19.7 Loosen screws -B- (4x); 19.8 Distance -A- >11 mm: Slide stop -Z- the determined distance to the inside, using the marks; Distance -A- < 11 mm: Slide stop -Z- the determined distance to the outside, using the marks; 19.9 Place stop -Z- in parallel on the marks; 19.10 Tighten screws -B-. The maximum deviation A - C may not be larger than +/- 4 mm with respect to
-6 -5 -4 -3 -2 -1 0
C
10adj18b
ed.6 Part I
TSM 2400 family
10 RDF 329
-1 -2 -3 -4 -5 -6
ADJUSTMENTS
10adju
20
Format slide RDF original tray. Aim:

To assure a correct detection of the RDF original format.
Check:
Place an original in the RDF original tray against zero stop -Z-; Slide format slide -F- to the closest click position of the used original size; Between slide and original must be a gap -G- of about 2 +1/-0 mm.
Correction:
20.1 20.2 20.3 20.4 20.5 Check adjustment 10-19; Remove the nut and cover plate -B-; Loosen screws -A- (2x); Place slide -F- in position: 356/14"; Adjust the position of the slide to: 358 + 1/- 0 mm, from the zero stop; 20.6 Tighten screws -A-; 20.7 Install the cover plate.
10adj19a
330 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
21
Image positioning: ZERO stop MDF original feed. Aim:

To achieve a centered image on the copy when using the MDF.
Check:
NOTE: See also COPY QUALITY (system level) : Image positioning adjustments Make a copy of testchart 25 using the MDF bypass; The image must be situated in the centre of the paper.
A A
Correction:
-6
-5 -4 -3 -2 -1 0
C
10adj20a
10adj20b
ed.6 Part I
TSM 2400 family
10 RDF 331
21.1 Place testchart 25 in the MDF bypass against zerostop -Z-; 21.2 Make 10 copies; 21.3 Measure the distance A and C: calculate the average value: (A tot - C tot ) /10=0+/- 4 mm 21.4 Loosen screw -B-; 21.5 Move the zero stop to the correct position; 21.6 Tighten screw -B-.
-1 -2 -3 -4 -5 -6
10adj20c
ADJUSTMENTS
10adju
22
Pressure balance spring for DF/top unit. Aim:

To assure an opened situation of the DF/top unit, after unlocking, of 5 cm, and to stabilize the opening angle at 60.
Check:
Unlock the DF/top unit ; The DF/top unit must stay open for about 30 mm; Place the DF/top unit under an angle of 60; In this position it must stay.
Correction:
22.1 Open the DF/top unit; 22.2 Turn nut -A- clockwise to increase the pressure and opening height; turn nut -A- counter clockwise to decrease the spring pressure.
10adj21a
332 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
23
Speed synchronisation return motor/MDF motor with DF belt motor. (10M6/10M7 with 10M1) Aim:
To assure a correct speed synchronisation with respect to the DF belt motor 10M1.
Check:
NOTE: This adjustment has to be carried out when: - a new 10PBA05 is installed; - a new return motor 10M6 is installed; - a new MDF motor 10M7 is installed. - If return motor (10M6) has to be adjusted start with step 23.1 - If MDF motor (10M7) has to be adjusted start with step 23.12
10adj23a
ed.6 Part I
TSM 2400 family
10 RDF 333
ADJUSTMENTS
10adju
Correction:
RETURN motor 10M6: 23.1 Connect a digital voltmeter across TP1 and TP7; 23.2 Select and activate test 10 6 06: < direction (eject)>; * DF belt motor and return motor run in return direction; 23.3 Use R14 to adjust the voltage on TP7 to 11VDC 0.1; 23.4 Connect the digital voltmeter across TP1 and TP5; 23.5 Measure the voltage on TP5; 23.6 Search in table 1 for the measured value (or nearest) of TP5 to determine the voltage to adjust TP7 to; 23.7 Connect the digital voltmeter across TP1 and TP7; 23.8 Adjust, using R14, the voltage on TP7 to the determined value of table 1; 23.9 Connect the digital voltmeter across TP1 and TP5; 23.10 The measured value must be in between 0.15 and 0.40VDC: * if incorrect check for mechanical damage 23.11 Use <PRINT> to stop the test;
Table 1 TP5 V 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 TP7 V 9.79 10.20 10.56 10.88 11.17
10adj23a
11.41 11.62 11.78 11.90 11.99 12.03
10adj23b
334 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
MDF motor 10M7: 23.12 Connect a digital voltmeter across TP1 and TP8; 23.13 Select and activate test 10 6 05: <MDF following DF (yes)>; 23.14 Use R15 to adjust the voltage on TP8 to 4VDC 0.1; 23.15 Connect the digital voltmeter across TP1 and TP6; 23.16 Measure the voltage on TP6; 23.17 Search in tabel 2 for the measured value (or nearest) of TP6 to determine the voltage to adjust TP8 to; 23.18 Connect the digital voltmeter across TP1 and TP8; 23.19 Adjust, using R15, the voltage on TP8 to the determined value of table 2; 23.20 Connect the digital voltmeter across TP1 and TP6; 23.21 The measured voltage must be in between 0.1 and 0.55VDC: * if incorrect check for mechanical damage 23.22 Use <PRINT> or <CANCEL> to end the test.
Table 2 VTP6 VTP8 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 3.39 3.69 3.97 4.22 4.46 4.67 4.87 5.04 5.19 5.32 5.43 5.51 5.58 5.62 5.65
10adj23b
ed.6 Part I
TSM 2400 family
10 RDF 335
ADJUSTMENTS
10adju
24
Drive belt tension return motor/MDF motor. (10M6/10M7) Aim:

To assure a correct tension on both drive belts.
Check:
Check that there is sufficient tension on both belts so that no slipping can occur. NOTE:This adjustment has to be carried out when: - a new return motor 10M6 is installed; - a new MDF motor 10M7 is installed.
Correction:
24.1 24.2 24.3 24.4 Loosen nuts -A-; Loosen screws -B-; Remove spring -C- (return motor) from point -D-; Tighten nuts -A-;
24.5 Fit spring -C-; 24.6 Tighten screws -B-.
10adj24a
336 RDF 10
TSM 2400 family
Part I ed.6
10adju
ADJUSTMENTS
25
Separation shoe solenoid (EM4) Purpose:

To avoid that the additional pressure on the separator shoe is not obstructed by the solenoid housing.
Check:
Close the RDF. Check that there is a play of 0.3 + 0.5 mm between arm -A- and the solenoid housing.
Correction:
25.1 Loosen bolts -C- and move the solenoid housing sideways to obtain the correct gap. 25.2 Tighten bolts -C-.
10adj25a
ed.6 Part I
TSM 2400 family
10 RDF 337
ADJUSTMENTS
10adju
26
Adjustment MDF sensor 10SO12 Aim :

To be sure that sensor 10SO12 will always be activated when feeding 11" originals into the MDF.
Check :
NOTE : This adjustment can only be done after readjustment or checking of the image position : zero stop MDF original feed (adj 10-21). Take a sheet of paper of 273.7 +/- 0.2 mm and activate SDS test 10 2 09, input test sensor 10SO12. The sensor must just not be activated when you put the sheet of paper in the MDF.
Correction :
26.1 Remove the DF cover. 26.2 Loosen 3 bolts of sensor -C-. 26.3 Adjust distance -X- to 273.7 0.2 mm. -X- is the distance between the vane of the sensor -C- and the zero point of the MDF (DF cover). 26.4 Tighten bolts of sensor -C-. 26.5 Put the DF cover on the RDF without fixing it. 26.6 do the check again : If not correct, adjust once more. If correct, fix the DF cover.
338 RDF 10
TSM 2400 family
Part I ed.6
10disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1 DF - belt unit Aim

Since the passive deflector near the belt is longer in the redesigned RDF a slightly different dis/assembly procedure is needed for the DF - Belt Unit.
Disassembly :
1 2 3
Disconnect three connectors and the earth strip at the rear of the DF - Belt Unit. Lift the DF - Belt Unit up and to the left whereby the studs -A- of the unit glide through the rails -B- at front and rear. While keeping the Belt Unit in the upward position turn shaft -C- clockwise (using key 7). This causes first the latch -D- to be released and secondly the belt subframe -E- to swing clockwise. Release latch -F- and remove the Belt Unit. To re-assemble the DF-Belt Unit into the DF - Belt Frame.
Assembly :
1 2 3 Place the DF - Belt Unit with its studs -A- into the rails -B- again. Lift the unit to the upward position again. Turn the belt subframe -E- counterclockwise again by hand until it latches, (dont use a key).
10disa01
ed.6 Part II
TSM 2400 family
10 RDF 401
DIS/ASSEMBLY
10disa
402 RDF 10
TSM 2400 family
Part II ed.6
10func
FUNCTIONAL DESCRIPTION 1 Original Handling

The Oc 2400 is equiped with a document feeder which can be used in 5 standard modes : RDF mode ADF mode MDF mode CFF mode Priority copy mode In the RDF mode, originals from 65-120 g/m2 can be processed at a speed of 60 changes per minute in case of the Oc 2375/2400, and at at speed of 65 changes per minute in case of the Oc 2465 CRU/2465 FIN, and at a speed of 75 changes per minute in case of the Oc 2475. This means that an original is transported on and off the original glass within 920msec. For this reason a reliable speed synchronization is necessary. Using the RDF allows you to make simplex or duplex copies, from simplex or duplex originals fully automatically. The copy speed for the Oc 2465 CRU is: - Single sided copying : 65 images/minute - double sided copying : 65 images/minute. The copy speed for the Oc 2465 FIN is: - Single sided copying : 65 images/minute - double sided copying : 43,5 images/minute. The copy speed for the Oc 2400 is: - Single sided copying : 60 images/minute - double sided copying : 40 images/minute. The copy speed of the Oc 2375 is: - Single side copying : 60 images/minute - Double side copying : 60 images/minute. The copy speed for the 2475 : - Single side copying : 75 images/minute - Double side copying : 75 images/minute. The RDF can process originals of the following sizes : - Minimum 254 203 mm and maximum 216 356 mm. Depending on the standard size of the originals the copies will automatically be reduced to the standard size of the paper in the selected paper tray. At the end of a run the originals always return into the RDF-original tray. Originals always return in the same order as when the job was started.
ed.6 Part II
TSM 2400 family
10 RDF 501
10func
It means that when an odd number of sets is needed an extra original turn action is necessary at the end of the run. In the ADF mode it is possible to produce simplex copies from simplex or duplex originals. The copy speed is 60 copies/minute (Oc 2375/2400), 65 copies/minute (Oc 2465CRU/2465FIN) and 75 copies/minute (Oc 2475). The ADF mode is selected by : finish > batch.
502 RDF 10
TSM 2400 family
Part II ed.6
10func
In the MDF mode loose leaf originals and computerforms can be processed. The originals are delivered in the original tray. In the MDF mode only simplex copies can be produced from simplex originals. Via an MDF bypass originals can be fed one by one at a maximum speed of 30 originals/minute. The MDF has one zero point for feeding all original formats. The MDF can process originals with a weight from 60 - 160 g/m2, and with the sizes min. 254 203 mm, max. 297 432 mm (A3). When an original is larger than the copy material, fed from one of the paper trays, the image is automatically reduced to the size of the copy material. Automatic reduction takes place in case automatic reduction is selected K5.2 and one of the sensors 10SO11, 12, 13, 14 detects a larger original format. In the CFF mode simplex and duplex copies can be produced from simplex computer forms. Via the MDF bypass, passing the CFF hole sensor, the Computer Form Feeder is a standard feature. In the program (P) mode it is possible to change the default of the hole pattern. The CFF can process originals with widths : min. 180, max. 440 mm, and lenghts : min. 203, max. 305 mm (16 - 24 holes). The computer form package can contain max. 1000 sheets. The priority copy mode makes it possible to make one single copy of several originals. When during an RDF or ADF job an original is placed in the MDF bypass, and the print button is pressed, the job in progress is interrupted for one single copy. This original is processed the same way as an original fed via the MDF bypass. Original processing priorities. There is a certain priority in sequence of original processing. Each copy mode has its own original detection. When the DF unit is not closed this is detected by a switch. When an original is presented in the MDF bypass this is detected by sensors. Also the RDF original tray has an original detection sensor. The priorities are as follows : 1 - DF unit open >>glass job;(10SO1) 2 - DF unit closed, no originals detected >>glass job 3 - DF unit closed, and MDF bypass engaged >>MDF job;(10SO11,12) 4 - DF unit closed, MDF bypass and CFF engaged >>CFF job 5 - DF unit closed, MDF bypass empty, RDF engaged and 10SO3 activated >> glass job 6 - DF unit closed, RDF engaged, finish is batch and number of copies >1 >> ADF job 7 - DF unit closed, MDF bypass empty, and RDF engaged >>RDF job;(10SO15)
ed.6 Part II
TSM 2400 family
10 RDF 503
10func
RDF section
The RDF consists of five units. Three units are installed on the copier main frame, the other two units are attached with hinges. The units are shown in the figure below.
-A-B-C-D-E-
Base unit Original glass Ruler unit Centre unit with original tray DF unit with top unit and DF belt unit
10func01
10func02
504 RDF 10
TSM 2400 family
Part II ed.6
10func
To ensure a reliable original transport in the RDF it is very important that no electrostatic charge can build up. A number of precautions are taken: a conductive coating on the top of the original glass, which is connected to ground; a DF belt made of a conductive material; electrostatic brushes to discharge the DF belt, and the originals; a ground connection to each unit; rollers connected to ground.
ed.6 Part II
TSM 2400 family
10 RDF 505
10func
RDF motors / solenoids

The RDF transports are all motor driven. All solenoids and motors are controlled from the RDF control board (10PBA01). See the figure below for the location of the motors and solenoids. 10M1 10M2 10M3 10M4 10M5 10M6 10M7 10M8 10EM1 10EM2 10EM3 10EM4 DF belt motor Pinch roller motor Separation wheel motor Separation belt motor Supply belts motor Return motor MDF feed motor Set separator motor Turn deflector solenoid DF belt pressure solenoid Document ruler solenoid Separation shoe solenoid
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Note: 10EM4 not present before MOD 75
506 RDF 10
TSM 2400 family
Part II ed.6
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Circuit diagram description : (see 701, 702)

DF belt motor (10M1), Pinch roller motor (10M2), Separation belt motor(10M4) These motors are controlled by the microprocessor on RDF control board 10PBA01. When running at the same time for the same original, the motor speeds are synchronized. The speed increases and decreases follow a microprocessor controlled speed curve. All three motors have a rotary encoder. The rotary encoder sends pulses to the RDF control board, which gives data about distance travelled, speed and direction of rotation. The DF belt motor (10M1) runs in two directions. Control signals: :30V-80W-AMP. :high 1= motor on; low 0 = motor off; :high 1= CCW (feed); low 0 = CW (eject/brake)(speed curve); :analog voltage (speed curve) between 0 and 5.35V :30V-20W-AMP. :high 1 = motor on; low 0 = motor off; :high 1 = feed, low 0 = brake; :analog voltage (speed curve) between 0 and 5.35V :30V-20W-AMP. :high 1 = motor on; low 0 = motor off :high 1 = feed, low 0 = brake; :analog voltage (speed curve) between 0 and 5.35V.
10M1: 10PBA03 DFFMO-ON DFMOL-R DFMOVAN 10M2: 10PBA06 PRMO-ON PRMOL-R PRMOVAN 10M4: 10PBA04 SEBMO-ON SEBMOL-R SEBMOVAN
Supply belts motor (10M5) The speed of the supply belts motor (10M5) is hardware regulated. The motor has a rotary encoder, that sends pulses to the RDF control board (10PBA01). It gives data about the speed (SUBMOSPEED) of 10M5. When running, the speed is synchronized with the speed of the separation belt motor (10M4) and the pinch roller motor (10M2). The Supply Belts motor can run in two directions. Control signals: :30V-20W-AMP: :high 1 = motor on; low 0 = motor off :analog voltage (speed curve) between 0 and 5,35V; :pulse shaped signal. : high 1 = ccw (feed); low 0 cw (retrackt)
10M5: 10PBA08 SUBMO-ON SUBMOVAN SUBMOSPEED SUBMOL-R
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Return motor (10M6), MDF feed motor (10M7) Normally these motors run at a constant low speed. However when transporting an original, they are track speed controlled, which means that they follow the speed of the DF belt motor (10M1) if it runs faster than their preset speed. The speed of both motors is analog controlled. The speed needs adjusting when a new return motor (10M6), MDF feed motor (10M7), or track speed control board (10PBA05) is installed. Control signals: 10M6: 10PBA05 RETMO-ON TRACKDIR-L :Track speed control :high 1 = motor on; low 0 = motor off; :high 1 = motor runs at constant low speed, :low 0 = motor follows DFMO speed (via TRACKFREQ); TRACKFREQ :frequency modulated (FM) signal, giving the DFMO speed; 10M7: 10PBA05 :Track speed control MDFMO-ON :high 1 = motor on; low 0 = motor off; MDFMOLSP :high 1 = motor runs at constant low speed, :low 0 = motor follows DFMO speed (via TRACKFREQ); TRACKFREQ :frequency modulated (FM) signal, giving the DFMO speed. Separation wheel motor (10M3) The separation wheel motor (10M3) runs only for 50 ms during retrackt, and is switched on and off by the RDF control. Control signals: 10M3: 10PBA01 :RDF control RDFSEWHMO :low 0 = motor on; high 1 = motor off Note: The Separation Wheel Motor also turns during supply and separation before MOD75. Also before machine 2563 there is no retrackt action. Set separator motor (10M8) The set separator finger is placed on top of the originals by the set separator motor (10M8). The drive mechanism consists of a catch that swings the separator finger during one revolution of the motor on top of the set. The motor is switched on and off by the RDF control board (10PBA01). Control signals: 10M8: RDFSSMO :high 1 = motor on; low 0 = motor off
508 RDF 10
TSM 2400 family
Part II ed.6
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Turn deflector solenoid (10EM1) With duplex originals the turn deflector is lifted every time the original has to be turned. When signal RDFTDSO goes low 0, the solenoid energises and lifts the turn deflector. DF belt pressure roll solenoid (10EM2) The DF belt pressure roll is lowered onto the DF belt every time an original is transported from the original glass. When the signal RDFBRSO goes low 0, the solenoid energises and lowers the pressure roll onto the belt. Document ruler solenoid (10EM3) The ruler is lowered when an original has to be ejected: - at the start of a run; - in CFF mode (continuously); - in manual feed mode (MDF or priority copy job). When the signal RDFDRSO goes low 0, the solenoid energises and lowers the ruler and lifts the ejection rolls. Shoe up solenoid (10EM4) Prior to each new separation, additional pressure has to be put onto the separator shoe, so the shoe can guide the original set into the separation nip. The shoe up solenoid is de-activated. While separating the bottom original the additional pressure has to be taken off the shoe again to avoid double separations and contamination of the second original. The shoe up solenoid is activated.
Note: 10EM4 not present before MOD 75.
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RDF sensors
The figure below indicates the RDF sensors. 10S1 10SO1 10SO2 10SO3 10SO4 10SO5 10SO6 10SO7 10SO8 10SO9 10SO10 10SO11 10SO12 10SO13 10SO14 10SO15 10SO16 RDF cover sensor Rotary encoder DF belt motor Rotary encoder pinch roller motor Document ready sensor Rotary encoder separation belt motor Rotary encoder supply belts motor Return path sensor Turn path sensor Set separator sensor CFF hole sensor MDF present sensor Size A / stop sensor Size B sensor Size C sensor Size D sensor Original stack sensor RDF size sensor
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510 RDF 10
TSM 2400 family
Part II ed.6
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RDF mode :
10S1 RDF cover sensor This sensor detects if the RDF cover is closed or open. When the cover is open, signal RDFCOVUSE is low 0. When the RDF control detects that the cover is open, it will always copy in the original glass mode. 10SO3 Document ready sensor Stops the orignal after the separation action and after the turn action, to achieve a defined start position of an original. RDFDRSE low 0 = sensor actuated. 10SO6 Return sensor This sensor detects the original when it is being transported from the original glass to the RDF original tray. The sensor must be free when a run is started. RDFRETSE low 0 = sensor actuated (paper present) 10SO7 Turn path sensor This sensor has no detecting function during a run. The sensor must be free when a run is started. RDFTPSE high 1 = sensor actuated (paper present). 10SO8 Set separator sensor This sensor detects the last original in a set (set separator falls through) RDFSSSE gives positive pulse when the set separator falls. 10SO15 Original stack sensor This sensor detects originals presented for an RDF job. Presence detected by reflection. RDFDPSE is low 0 when a document is present. 10SO16 RDF size sensor By positioning the original guide in the click position nearest to the original stack, the format is detected automatically. RDFDSSE1, RDFDSSE2, RDFDSSE3 are low 0 when the strip is in the sensor.
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Rotary encoders :
The rotary encoder sends information about speed, travel distance and rotaring direction to the RDF control. 10SO1 Rotary encoder DF belt motor Rotary encoder for the DF belt motor (10M1). DFMOSE1 and DFMOSE2 are pulse signals. Feed direction: DFMOSE1 before DFMOSE2 Return turn direction: DFMOSE2 before DFMOSE1 10SO2 Rotary encoder pinch roller motor Rotary encoder for the pinch roller motor (10M2). PRMOSE1 and PRMOSE2 are pulse signals. Feed direction: PRMOSE2 before PRMOSE1 10SO4 Rotary encoder separation belt motor Rotary encoder for the separation belt motor (10M4). SEBMOSE1 and SEBMOSE2 are pulse signals. Feed direction: SEBMOSE2 before SEBMOSE1 10SO5 Rotary encoder supply belts motor Rotary encoder for the supply belts motor (10M5). SUBMOSE1 and SUBMOSE2 are pulse signals. Feed direction: SUBMOSE1 before SUBMOSE2
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512 RDF 10
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Part II ed.6
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MDF/CFF mode
10SO9 CFF hole sensor This sensor detects the computer form and counts the holes in computer forms. Important for transport length and positioning. CFFHOLSE goes low 0 when a hole is detected. 10SO10 MDF present sensor This sensor start the MDF motor 10M7 for original prefeed. The MDF motor positions an original for an MDF, interleaf or CFF job. MDFDPSE high 1 = sensor actuated (original present) 10SO11 Size A/stop sensor This sensor stops the MDF motor 10M7 during the prefeed action. It is also used for MDF original size detection, together with three other sensors: 10SO12, 10SO13 and 10SO14. MDSASE high 1 = sensor actuated (original present). 10SO12 Size B sensor, 10SO13 Size C sensor, 10SO14 Size D sensor Together with sensor 10SO11, these sensors detect standard formats of originals in the MDF mode. Because there is only one zero point, these three sensors are positioned at the front.
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Processing originals
Processing originals consists of a number of actions that are interrelated. In the introduction the actions are mentioned and their timing relation is presented. Following the introduction the actions are described separately in detail. Finally the detailed actions are integrated in the time sequence diagram. A - Before the run A couple of requirements have to be met before a run can start B - Preparing the RDF At run start a couple of preparations are carried out. C - Supply C1 - First Supply of the set of originals A set of originals put into the RDF original tray is supplied into the separation nip by the Supply Belts (10M5). To obtain a proper supply, additional pressure is put onto the separation shoe. C2 - Next supply of the set of originals Before every next separation the set of originals is retrackted from the separation nip and supplied into the separation nip once more. The retracktion and supply are carried out by the Supply Belts (10M5). The retracktion is assisted by the Separation Wheel (10M3). To obtain a proper supply additional pressure is put onto the separation shoe. D - Separation The bottom original is separated from the set. During separation there is no additional shoe pressure. The shoe lies on the set with its own weight. E - Feed The separated original is fed onto the original glass. F - Turn In case of a duplex run the original is turned after which it can be fed onto the original glass again. G - Feed after Turn After the original is turned it is fed onto the original glass again. H - Return After exposure (once or twice) the original is returned to the set.
514 RDF 10
TSM 2400 family
Part II ed.6
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Some of the actions are carried out simultaniously for two subsequent originals. The picture below shows the relationship between actions for a simplex and a duplex job.
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A - Before the run(simplex, duplex)

Before the run starts the following requirements have to be met: 1 2 3 4 5 RDF cover closed, 10S1 closed. Originals in RDF original tray, original detection by 10SO15. Close up original side guide for format detection 10SO16. MDF present sensor (10SO10), and CFF HOLE sensors (10SO9) are not engaged. All original path sensors must be free.
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B - Preparing the RDF

When the run is started the following actions take place within the first 400msec: (See the picture on the next page) 1 2 Checking return path (10SO6), and turn path (10SO7) for originals. Both sensors must not be engaged. Clearing original glass: - ruler (10EM3) in down position; - pressure roll (10EM2) active; - DF belt (10M1) running at low speed in feed direction - ruler, pressure roll and DF belt off again. Now the set of originals can be supplied into the separation nip.
516 RDF 10
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Part II ed.6
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C1 - First supply of the original set..

The set of originals that was placed into the original tray has to be transport to the separation area and then forced into the separation nip. Transporting the set to the separation area is done by the supply belts that run for a short period of time with low speed. Forcing the set into the separation nip is also done by the suppply belts. During the entire action the shoe-up solenoid is deactiveted to apply additional pressure onto the separation shoe. Transport the set of originals to the separation area: - supply belts (10M5) running at low constant speed for 400msec (pre-supply). Forcing the set into the separation nip: - supply belts (10M5) start running again.
1 2
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Shoe-up solenoid is activated to take pressure off the shoe. Set separator (10M8) placed on top of the original stack. Note: 10EM4 not present before MOD 75.
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D - Separation Action (simplex, duplex)

The separation action is started by the control after a fixed period of time and stopped when the leading edge of the original is monitored by 10SO3. During separation the shoe up solenoid is activated to take the pressure off the shoe. 1
Separation wheel starts running.(10M3) (Before MOD 75) Separation belt (10M4), and pinch roller (10M2)start running. Supply belt motor (10M5) was already turning since the supply action. Only the speed of the motor will be increased. The bottom original is separated from the set that is forced against the separation shoe, separation wheel and guide plate since the supply action..
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Leading edge reaches 10SO3, active braking for separation belt, supply belt and pinch roller starts. The sensor 10SO3 has to be activated within a certain time. Separation wheel (10M3), separation belt (10M4), supply belts (10M5), and pinch roller (10M2) stop running. The original is ready for the feed action. Note: In the RDF before MOD 75 the separation wheel is turning constantly during the separation action
518 RDF 10
TSM 2400 family
Part II ed.6
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E - Feed Action (simplex, duplex)

The feed action starts at a moment predetermined by the RDF control. The motors involved switch off after a preset time, independently of the state of the original. 1 2 Separation belt (10M4), pinch roller (10M2) and DF belt (10M1) start running in feed direction. After a preset time the separation belt (10M4) stops first , then the pinch roller (10M2) stops and a short time later the DF belt stops. The DF belt (10M1) stops gradually, so the original is smoothly positioned against the ruler. During every feed the set of originals is retrackted to ensure that at the end of a run, when the last original is fed , all originals are out of the separation nip. The retracktion is described in detail in Next supply of set of originals
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C2 - Next Supply of Original Set

This action is split up in Retracktion (RET) of the set followed by a Supply (SUP) into the separation nip. In software the retracktion is connected to the Feed Action. So in a simplex run the set is retrackted just before it is supplied. In a duplex run the retracktion takes place when side one is fed, and the corresponding supply takes place when side two is fed. 1 2 3 4 Retracktion: The supply belts (10M5) start running in reverse direction. The separation wheel (10M3) starts running in reverse direction. The separation wheel (10M3 stops running. The supply belts (10M5) stop running.
- Supply 5 Pressure is put onto the separation shoe by de-activating the shoe up solenoid (10EM4). 6 The supply belts (10M5) start running in feed direction and supply the set of originals into the separation nip, against the separation shoe. 7 Before the separation starts the additional shoe pressure is taken off the shoe by activating the shoe up solenoid (10EM4) 8 The speed of the supply belts is increased, the separation belts (10M4) and pinch rollers (10M2) start running as the next separation starts. See Separation. Note: In the machines before MOD 75 the retracktion of the set of originals is not taking place.
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Part II ed.6
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F - Turn Action (duplex)

To turn a duplex original an active original deflector is installed. It is lifted when the original leaves the glass and guides it into the turn path where the original make a loop. This way it is turned upside down and returns to the original glass. After the exposure flash (once or twice) the TURN ACTION starts.
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1 2 3
DF belt (10M1) starts running in return direction, also pinch rollers (10M2) start running DF belt pressure roll (10EM2) active. Turn deflector (10EM1) is lifted.
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10SO3 must be reached within a predefined time. Before sensor 10SO3 is reached, the DF belt (10M1) and the pinch rollers (10M2) reduce the speed by electronic braking. The speed changes to a constant slow speed until the lead edge reaches 10SO3, when electronic braking starts again, stopping the DF belt and the pinch rollers. 4 5 6 7 Pressure roll (10EM2) is switched off. Turn deflector (10EM1) in rest position. Lead edge reaches (10SO3). DF belt (10M1) and pinch rollers (10M2) stop.
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522 RDF 10
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Part II ed.6
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G - Feed Action After Turn (duplex)

1 2 3 Pinch rollers (10M2) start running, and DF belt (10M1) starts running in feed direction. After a preset time, the pinch rollers (10M2) stop. A short time later the DF belt (10M1) stops. Just before the original reaches the ruler, electronic braking slows down the DF belt.The speed is kept slow so that the original is positioned against the ruler smoothly.
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H - Return Action
After the exposure flash (once or twice) has occured the RETURN ACTION starts. DF belt transports the original from the glass into the return path, with aid of a passive baffle. 1 2 3 4 5 6 DF belt (10M1) starts running in return direction, also return and delivery rollers (10M6) start running. DF belt pressure roll (10EM2) active during original transport. Return and delivery rollers (10M6) follow the speed of DF belt (10M1). Pressure roll (10EM2) is switched off. After a preset time, from start of return action the DF belt (10M1) stops. Return and delivery rollers (10M6) keep running at a constant speed until the original has left the delivery roller pinch.
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524 RDF 10
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Part II ed.6
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Set Length
The first original is delivered in the RDF original tray, on top of the set separator. The next original is ready for feed action. All other originals of the set are following the same procedure as the previous originals, starting from FEED ACTION on. During the production of the first copy set the originals are counted. When the last original of the set is separated the set separator falls, it passes sensor 10SO8 (RDFSSSE).
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Last set of a run in progress. (duplex originals)

When the set of originals has passed the RDF for the first time, the originals are returned into the RDF-tray upside down. So the even numbered pages (rear side) are face down (2-4-6-8 etc.). This means that if an odd number of sets has to be copied, during the last run every original makes an extra turn action before it is delivered.
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526 RDF 10
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Circuit description RDF motors

The RDF control board 10PBA01 is a micro controller board that controls all RDF functions. It controls 19 sensors, 8 motors and 4 solenoids. The RDF control is able to process series of commands on its own after one command of the HOST control. There are four digital controlled motors : 10M1, 10M2,10M4 and 10M5. Respectively DF belt motor, pinch roller motor, separation belt motor and supply belts motor. Each motor has a rotary encoder to measure the motor speed. Each motor also has a power amplifier. The power amplifiers for the motors are situated on separate PBAs: for 10M1 this is 10PBA03, 30V-80W-4AMP ; for 10M2 this is 10PBA06, 30V-20W-AMP ; for 10M4 this is 10PBA04, 30V-20W-AMP ; for 10M5 this is 10PBA08, 30V-20W-AMP.
The return motor 10M6 and the MDF motor 10M7 have the same speed as the DF belt motor 10M1, during a run. The two speed controllers are situated on a separate board 10PBA05, TRACK-SPEED-CONTROL. These controllers use the signal TRACKFREQ as a reference for the speed of DF belt motor 10M1. The separation wheel motor 10M3 and the set separator motor 10M8 are controlled by the RDF control 10PBA01.
RDF solenoids.
The solenoids 10EM1, 10EM2, 10EM3 and 10EM4 respectively turn deflector, DF belt pressure roll, ruler and shoe up solenoids are controlled with a 24V voltage by the RDF control 10PBA01.
528 RDF 10
TSM 2400 family
Part II ed.6
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RDF control board : 10PBA01.

The RDF control board 10PBA01 is the microprocessor board for the RDF. There are two output signals on the board which are derived from two other input signals: TRACKFREQ and TRACKDIR-L. All other input and output signals controlled by the microprocessor (read-in and write-out). Test points TP and LED. On 10PBA01 there is installed a red LED. This LED is indicating the status of the communication process of the RDF. In case of a communication problem between HOST and RDF, and the cause is on the RDF side, the LED will not flash. When the microprocessor of the RDF has started up without problems the LED will flash. SDS test 10 6 11 can be used to check the communication between HOST and RDF. On RDF control board 10PBA01 there are 17 test points :
TP1
ground
INPUT signals from rotary encoders : TP2 SUBMOSE1 channel A, supply belt motor ; TP3 SUBMOSE2 channel B TP4 SEBMOSE1 channel A, separation belt motor ; TP5 SEBMOSE2 channel B TP6 PRMOSE1 channel A, pinch roller motor ; TP7 PRMOSE2 channel B TP8 DFMOSE1 channel A, DF belt motor ; TP9 DFMOSE2 channel B
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SUPPLY voltages : TP10 TP11 TP12 +5V +12V -12V
INPUT signals original path sensors : TP13 TP14 TP15 RDFDRSE RDFRETSE RDFTPSE document ready sensor 10SO3 ; return sensor 10SO6 ; turn path sensor 10SO7 ;
Motor speed check : TP16 TP17 SEBMOMEAS PRMOMEAS speed separation belt motor ; speed supply belts motor.
-12V supply voltage absence detection TP12 : The -12V supply is connected to the input bus. Because the -12V supply is not used by the microprocessor it is possible to test this voltage on TP12. If the voltage level is lower than -3,3V the input is low (0), is the voltage level higher than -3,3V than the input is high (1). SDS test 10 2 18 can also be used for present detection. +24V present detection : The +24V supply is also connected to the input bus. For the detection the microprocessor is used. If the voltage level is higher than 5,6V the input is high (1), is the voltage level is lower than 5,6V than the input is low (0). SDS test 10 2 19 can be used to for present detection.
530 RDF 10
TSM 2400 family
Part II ed.6
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Power amplifier boards 10PBA03, 10PBA04, and 10PBA06.

The power amplifier circuits for the motors M1, M2, M4 and M5 are situated on four PBAs : the circuit for DF belt motor 10M1 on 10PBA03, 30V/50W board ; the circuit for pinch roller motor 10M2 on 10PBA06, 30V/20W board ; the circuit for separation belt motor 10M4 on 10PBA04, 30V/20W board; the circuit for the supply belts motor 10M5 on 10 PBA08, 30V/20W board.
All four amplifier circuits are operating in a similar way. The control of the motors takes place by three signals comming from the RDF control board : - xxMOL/R - xxMO-ON - xxMOVAN
determines the current flow direction through the motor ; enable signal for the driver of the motor ; analog input voltage 0-5V, for current control.
Description of the 10PBA03, 30V/80W/AMP board : The current through the motors can be changed in direction while the motor is running, and the motor can be braked proportionally. The amplifier performs a lineair relationship between the input voltage DFMOVAN and the output current Imotor. The direction of the current is chosen by the signal DFMOL-R.
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Supplies : The board is supplied with +30V, +12V and -12V. Internally a +5V supply is generated for the amplifier. The separate +5V supply for the rotary encoder is made from the +12V supply. The +12V and -12V supplies are buffered on the board with separate electrolitics and separated from the main supply with 10 ohm resistors to avoid high frequency loops. The board also includes a supply supervisor which gives a signal DFVSPABS to indicate that the 30V power suply is present. This signal goes high (1) if the 30V drops out.
Grounds : The 30VGND is connected to the board ground. The GND12V is connected via a resistor of 10 ohm to the board ground. The ground of the rotary encoder supply is connected with a separate line to the ground of the control board, to avoid ground noise on the rotary encoder signals.
Track-speed-control board 10PBA05. This board controls two motors : return motor 10M6 and MDF motor 10M7. It contains two amplifiers, two speed controllers and a frequency voltage convertor.
Supplies : The board has a +30V supply, +12V and -12V. Internally an additional +5V supply is generated for the amplifiers. The +12V and -12V supply are buffered on the board with separate electrolytics and separated from the main supply by 10 ohm resistors to avoid high frequency loops.
Grounds : The ground GND30V is connected to the board ground. The ground GND12V is coupled to the board ground with a series resistor of 10 ohm.
Motor drive : The signal from the rotary encoder of the DF belt motor 10M1 is converted into a tracking signal. The control signals TRACKDIR-L (10M6) and MDFMOLOSP (10M7) releases one of the motor drive circuits. The signals xxxMO-ON enable the driver.
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Adjustment : To compensate for initial misalignments of the motor/controller combination two resistors trimmers R14 and R15 are foreseen. The MDF motor and return motor are the same. The voltage constant Ke is determined in the production of the motor assembly. It is related to the voltage on which the test points TP7, TP8 on 10PBA05 have to be adjusted. The value of the voltage to which Vtp has to be adjusted is determined by measuring and using a table. These speed adjustments only have to be processed when a new motor or new 10PBA05 or 10 6 06 (return 10M6) has to be installed. use SDS test 10 6 05 (MDF 10M7)
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The speed controller for the return motor 10M6 The controller performs a linear relationship between the input voltage TRACKFREQ and the voltage across the motor 10M6. The driver is enabled by signal RETMO-ON high 1. Motor 10M6 can run at 2 speeds. This speed is determined by the voltage level of signal TRACKDIR-L : - low speed, high 1 ; - following DF belt motor speed, low 0. Whenever it is higher than the low constant speed.
The speed controller for the MDF motor 10M7. The controller performs a linear relationship between the input voltage TRACKFREQ and the output voltage across the motor 10M7. The driver is enabled by signal MDFMO-ON high 1. If signal MDFMOLOSP is high 1 the voltage is fixed and motor 10M7 is running at a constant speed. If signal MDFMOLOSP becomes low 0 the voltage follows the DF belt motor speed signal TRACKFREQ. In the driver circuit an active brake circuit is applied. This is achieved by short circuiting the motor terminals, which will effectively brake the motor
Format sensor PBA 10SO16 The format sensor PBA consist of three opto-sensors. With a code ruler the light beams of the sensors are interrupted. With the three sensors eight different positions can be detected. When a light beam is interrupted the output signal RDFDSSE1-3 of the particular sensor is low 0.
Stack sensor 10SO15. The reflection sensor 10SO15 consist of a transmitter and a receiver circuit. The transmitter part consist of an oscillator that changes the voltage level from 3V to 9V in a frequency of 11kHz. The receiver part consist of a convertor, a bandpass filter, and a detection circuit. All noise signals with a frequency below 8kHz and above 12kHz are filtered out. The bandpass filter operates as an amplifier for signals with a frequency of 11kHz. If there are no documents present in the RDF original tray the level of signal RDFDPSE is high 1.
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RDF-30V-supply board 10PBA07. The power supply consist of : a constant voltage transformer, a rectifier circuit, three fuses, and one LED. It is a stabilized power supply with a low voltage output of 30VDC. The constant voltage transformer gives a roughly stabilized secundary voltage by means of a resonance circuit. The resonance circuit consist of a capacitor and an additional winding on the transformer. The advantage is that it makes the output voltage almost independent of the input voltage and the output current. The output voltage will never exceed 36VDC. A thermal switch (self restoring) interrupts the primary side of the transformer at 160 C. To indicate that the power is on and the output voltages are present an LED is installed in the circuit before the fuses.
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MDF section
The MDF section is part of the RDF section. The MDF section consist of : The original pre-feed/feed unit ; Original present detection ; (10SO10) Original format detection ; (10SO11,12,13,14) DF belt unit ; Ruler unit.
The CFF section is part of the MDF unit with its own original presents detection (10SO9). MDF feed If an original is placed in the MDF, it is detected by sensor 10SO10. Pre-feed of the original is started : The MDF feed motor (10M7) starts running at low speed. The feed rollers start running and transport the original towards the stop sensor (10SO11). When the original activates the stop sensor (10SO11), the MDF feed motor (10M7) stops. The sensors 10SO10 and 10SO11 are activated the control knows that an original is ready for a MDF job. Automatic format detection (MDF mode) is realized by 4 sensors (10SO11,12,13,14). To each of these sensors a preset standard format can be given by means of SDS test 93 (Europe/USA) 10SO11 : until 274 mm 10SO12 : until 310 mm 10SO13 : until 381 mm 10SO14 : from 381 mm ; ; ; ; default 270 210 mm default A4, 11 8,5 default folio, 14 8,5 default A3, 17 11
If automatic reduction (P6. K5,2) is switched on, the format of the receiving material is compared with the original format and if applicable automatic standard reduction takes place.
536 RDF 10
TSM 2400 family
Part II ed.6
10func
Starting a run. To start an MDF run the DF unit must be closed. This is detected by sensor 10S1. When the PRINT button is pressed the following actions take place :
Clearing the glass to eject an original that is left on the glass. - ruler solenoid 10EM3 is activated. - DF belt motor 10M1 is running in eject/feed direction at a constant low speed. - pressure roll solenoid 10EM2 is activated. After a preset time the clearing action stops. Feeding the original. - The ABC lamp is switched on. - The MDF feed motor (10M7) and DF belt motor (10M1) start running at the same speed. - During a preset time 10M7 is following the speed of 10M1. - The ABC measures the background on the original. - Before the original hits the ruler, the speed is reduced, so it hits the ruler smoothly. - The original is lined up against the ruler. - The DF belt motor (10M1) and MDF feed motor stop.
Delivering the original. After the flash, the original is delivered into the original receiving tray. To achieve this the following actions take place : - The ruler solenoid (10M3) and the pressure roll solenoid (10M2) are activated. - The DF belt motor (10M1) starts running. - After a preset time the delivery action stops.
CFF feed. If a computer form is fed via the installed special guide plate it passes the CFF hole sensor 10SO9. Then the form is detected by sensor 10SO10 and the pre-feed action starts. Sensor 10SO11 stops the pre-feed action. When the sensors 10SO9, 10SO10 and 10SO11 are activated, the RDF control knows that an original is ready for a CFF job. To start a CFF run the same actions take place as during a MDF run with one exception : - The ruler solenoid 10EM3 is activated until the end of the CFF original stack is delivered.
ed.6 Part II
TSM 2400 family
10 RDF 537
10func
538 RDF 10
TSM 2400 family
Part II ed.6
10comp
COMPONENT LOCATION
COMPONENT LOCATION
10EM1 10M2 10M8 10PBA02 10SO2 10SO3 10SO8 10SO15 10SO16 : : : : : : : : : turn deflector solenoid pinch roller motor set separator motor sensor control PBA rotary encoder pinch roller motor document ready sensor set separator sensor original stack sensor RDF size sensor
10comp01
ed.6 Part II
TSM 2400 family
10 RDF 601
COMPONENT LOCATION
10comp
10PBA01 10SO7
: RDF control PBA : turn path sensor
10comp02
602 RDF 10
TSM 2400 family
Part II ed.6
10comp
COMPONENT LOCATION
10CN1 10CN4 10M3 10M4 10M5 10PBA04 10SO4 10SO5 10EM4
: : : : : : : : :
connector 10M3 connector 30V-supply 10PBA04 separation wheel motor separation belt motor supply belts motor 30V dual 20W amplifier PBA rotary encoder separation belt motor rotary encoder supply belts motor separation shoe solenoid
10comp03
ed.6 Part II
TSM 2400 family
10 RDF 603
COMPONENT LOCATION
10comp
10CN5 10CN7 10M6 10M7 10PBA05 10PBA06 10SO9 10SO10 10SO11 10SO12 10SO13 10SO14
: : : : : : : : : : : :
connector 10M7 connector return motor return motor MDF feed motor track speed control PBA 30V 20W amplifier PBA CFF hole sensor MDF present sensor size A / stop sensor size B sensor size C sensor size D sensor
10comp04
604 RDF 10
TSM 2400 family
Part II ed.6
10comp
COMPONENT LOCATION
10CN6 10EM2 10M1 10PBA03 10SO1 10PBA08
: : : : :
connector 10EM2 DF belt pressure roll solenoid DF belt motor 30V 50W amplifier PBA, 10M1 rotary encoder df belt motor printed circuit board for 10M5, Supply Belts Motor
10comp05
ed.6 Part II
TSM 2400 family
10 RDF 605
COMPONENT LOCATION
10comp
10M6 10SO6
: return motor : return sensor
10comp06
10PBA07
: RDF 30V supply PBA
10comp09
606 RDF 10
TSM 2400 family
Part II ed.6
10comp
COMPONENT LOCATION
10S1 10EM3
: RDF cover sensor : document ruler solenoid
10comp07
10comp08
ed.6 Part II
TSM 2400 family
10 RDF 607
COMPONENT LOCATION
10comp
608 RDF 10
TSM 2400 family
Part II ed.6
10elec
ELECTRICAL DIAGRAM

RDFDPSE RDFDSSE1 RDFDSSE2 RDFDSSE3 RDFSSSE RDFSSMO SEBMOL-R SEBMO-ON SEBMOVAN SEBMOPSABS * SUBSEBMOPSABS
SEBMOSE1 SEBMOSE2 SUBMOPSABS * SUBMOSPEED SUBMOL-R SUBMOVAN SUBMO-ON SUBMOSE1 SUBMOSE2 PRMOL-R PRMO-ON PRMOVAN PRMOPSABS PRMOSE1 PRMOSE2 RDFDRSE RDFTDSO RDFTPSE
RDF Document Present SEnsor RDF Document Size SEnsor 1 RDF Document Size SEnsor 2 RDF Document Size SEnsor 3 RDF Set Separator SEnsor RDF Set Separator MOtor SEparation Belt MOtor Left - Right SEparation Belt MOtor ON SEparation Belt MOtor 10M4 SEparation Belt MOtor Power Supply ABSent SUpply Belt/SEparation Belt MOtor Power Supply ABSenT SEparation Belt MOtor SEnsor 1 SEparation Belt MOtor SEnsor 2 SUpply Belt MOtor Power Supply ABSent SUpply Belt MOtor SPEED SUpply Belt MOtor Left - Right SUpply Belt MOtor 10M5 SUpply Belt MOtor ON SUpply Belt MOtor SEnsor 1 SUpply Belt MOtor SEnsor 2 Pinch Roller MOtor Left - Right Pinch Roller MOtor ON Pinch Roller MOtor 10M2 Pinch Roller MOtor Power Supply ABSent Pinch Roller MOtor SEnsor 1 Pinch Roller MOtor SEnsor 2 RDF Document Ready SEnsor RDF Turn Deflector SOlenoid RDF Turn Path SEnsor
* OLD SITUATION : until MOD 75.
ed.6 Part I
TSM 2400 family
10 RDF 701
ELECTRICAL DIAGRAM
10elec
702 RDF 10
TSM 2400 family
Part I ed.6
10elec
ELECTRICAL DIAGRAM
Signal names
RDFSEWHMO RETMO-ON SHOEUPSO MDFMO-ON TRACKFREQ TRACKDIR-L MDFMOLOSP RDFRETSE CFFHOLSE MDFDPSE MDSASE MDSBSE MDSCSE MDSDSE DFMOL-R DFMO-ON DFMOVAN DFMOPSABS DFMOSE1 DFMOSE2 RDFBRSO RDFCOVUSE RDFDRSO RDF SEparation WHeel MOtor RETurn MOtor ON SHOE UP SOlenoid MDF MOtor ON TRACK FREQuency TRACK DIRection Left MDF MOtor LOw SPeed RDF RETurn SEnsor CFF HOLe SEnsor MDF Document Present SEnsor MDF Size A SEnsor MDF Size B SEnsor MDF Size C SEnsor MDF Size D SEnsor DF MOtor Left - Right DF MOtor ON DF MOtor 10M1 DF MOtor Power Supply ABSent DF MOtor SEnsor 1 DF MOtor SEnsor 2 RDF df Belt Roll SOlenoid RDF COVer Up SEnsor RDF Document Ruler SOlenoid
ed.6 Part I
TSM 2400 family
10 RDF 703
ELECTRICAL DIAGRAM
10elec
704 RDF 10
TSM 2400 family
Part I ed.6
Electrical Diagram
10 RDF/MDF/CFF 701A
Electrical Diagram
10 RDF/MDF/CFF 701B
Electrical Diagram
10 RDF/MDF/CFF 702
Electrical Diagram
10 RDF/MDF/CFF 703A
Electrical Diagram
10 RDF/MDF/CFF 703B
12diag
DIAGNOSTIC
1210 upper tray out/no drive up 1211 lower tray out/no drive up 1212 upper tray in/no drive up 1213 lower tray in/no drive up 1214 upper tray not going down 1215 lower tray not going down 1216 UPT level resistor failure 1217 LPT level resistor failure 1218 UPT level sensor defect detection 1219 LPT level sensor defect detection
MRE
1225 upper tray out/no drive up 1226 lower tray out/no drive up 1227 upper tray in/no drive up 1228 lower tray in/no drive up 1229 upper tray not opened 12S2 1230 lower tray not opened 12S3 1231 upper tray not going down 1232 lower tray not going down 1233 UPT level resistor failure 1234 LPT level resistor failure 1235 UPT level sensor defect detection 1236 LPT level sensor defect detection
ORE
1250 UPT paper too late at 12SO5 1251 LPT paper too late at 12SO5 1252 12SO5 too late free
ed.6 Part I
TSM 2400 family
12 Paper 101
DIAGNOSTIC
12diag
Fault table
M1225, P1210 - 12SO3 does not agree with the lift level UPT - chain UPT has loosened - latch on chain is fault - drive rotary potentiometer is fault - UPT lift motor 12M1 is fault, 12C1 (capacitor) is fault - lift motor runs in wrong direction caused by a fault relais on 22PBA07 - UPT lift motor 12M1 is always on ( up-, or downwards ), 22PBA07 M1226, P1211 - 12SO4 does not agree with the lift level LPT - chain LPT has loosened - latch on chain is fault - drive rotary potentiometer is fault - LPT lift motor 12M2 is fault, 12C2 (capacitor) is fault - lift motor runs in wrong direction caused by a fault relais on 22PBA07 - LPT lift motor 12M2 is always on ( up-, or downwards ), 22PBA07 M1227, P1212 - chain UPT has loosened - UPT table level sensor 12SO3, sensor always position o.k. - drive rotary potentiometer is fault - UPT is seen closed but papertray is open, 12S2 - UPT lift motor 12M1 is fault, 12C1 (capacitor) is fault - lift motor runs in wrong direction caused by a fault relais on 22PBA07 M1228, P1213 - chain LPT has loosened - LPT table level sensor 12SO4, sensor always position o.k. - drive rotary potentiometer is fault - LPT is seen closed but papertray is open, 12S3 - LPT lift motor 12M2 is fault, 12C2 (capacitor) is fault - lift motor runs in wrong direction caused by a fault relais on 22PBA07 M1229, P1211 - chain UPT has loosened - drive rotary potentiometer is fault - UPT lift motor 12M1 is fault, 12C1 (capacitor) is fault - switch 12S2 - lift motor runs in wrong direction caused by a fault relais on 22PBA07 M1230, P1211 - chain lpt has loosened - LPT lift motor 12M2 is fault, 12C2 (capacitor) is fault - switch 12S3 - drive rotary potentiometer is fault - lift motor runs in wrong direction caused by a fault relais on 22PBA07 Fault table continue : next page.
102 Paper 12
TSM 2400 family
Part I ed.6
12diag
DIAGNOSTIC
CODES
POSSIBLE FAILURES
M1231, P1214 - chain UPT has loosened - drive rotary potentiometer is fault - UPT lift motor 12M1 is fault, 12C1 (capacitor) is fault - lift motor runs in wrong direction caused by a fault relais on 22PBA07 M1232, P1215 - chain LPT has loosened - drive rotary potentiometer is fault - LPT lift motor 12M2 is fault, 12C2 (capacitor) is fault - lift motor runs in wrong direction caused by a fault relais on 22PBA07 M1233, P1216 - chain tension UPT has loosened - rotary potentiometer upt fault, opened or short cut - UPT lift motor 12M1 is always on ( up-, or downwards ), 22PBA07
M1234, P1217 - chain tension LPT has loosened - rotary potentiometer LPT fault, opened or short cut - LPT lift motor 12M2 is always on ( up-, or downwards ), 22PBA07 M1235, P1218 - feed wheel holder assy UPT is stuck - sensor, level sensor 12SO3 is fault M1236, P1219 - feed wheel holder assy LPT is stuck - sensor, level sensor 12SO4 is fault O1250 - separation roll has loosened from its shaft - separation roll is worn - paperfeed wheel has loosened from its shaft - paperfeed roll is worn - paperfeed clutch is fault, no linkage - paperpile too high/low - papertransport rollers are worn - bearings of transport rollers stuck - leaf spring paper transport rollers are bent - one way bearing separation wheel is acting as a normal bearing or stuck - tension spring shoe guide too low or high - one way bearing paperfeed wheel is acting as a normal bearing or stuck - motor separation wheel (12M3) is fault - brake of liftmotor UPT 12M1 is fault - sensor 12SO5 defective or wrongly adjusted - belt is broken - torsion springs separation wheel units are broken or placed wrong - timing belt defective (Func 15) - adjusting inner paper door not correctly Fault table continue : next page.
ed.6 Part I
TSM 2400 family
12 Paper 103
DIAGNOSTIC
12diag
CODES O1251
POSSIBLE FAILURES - separation roll has loosened from its shaft - separation roll is worn - paperfeed wheel has loosened from its shaft - paperfeed roll is worn - paperfeed clutch is fault, no linkage - paperpile too high/low - papertransport rollers are worn - bearings of transport rollers stuck - leaf spring paper transport rollers are bent - one way bearing separation wheel is acting as a normal bearing or stuck - tension spring shoe guide too low or high - one way bearing paperfeed wheel is acting as a normal bearing or stuck - motor separation wheel (12M4) is fault - brake of liftmotor LPT 12M2 is fault - sensor 12SO4 defective or wrongly adjusted - belt is broken - torsion springs separation wheel units are broken or placed wrong - timing belt defective (Func 15) - adjusting inner paper door not correctly - paper stop 12EM1 is always closed - paper guide towards preheater 1 is too small, plate is bent or not adjusted - paperfeed clutch is stuck - paper stop is bent - paper stop is not high enough - stopper pinch too low - preheat unit 1 not correct positioned or flap damaged (Func 15) - plate first preheater not correct positioned (Func 15)
O1252
104 Paper 12
TSM 2400 family
Part I ed.6
12diag
DIAGNOSTIC
Protections ORE 1250 ORE 1251 ORE 1252

12SO5 paper stop present sensor (PASPSE) is used to make synchronous checks on the presence of paper at the paper stop. Synchronisation is done on master pulses. paper arriving from the UPT should be present about 1.3s (Oc 2375,2400,2465 CRU and 2465 FIN) or 1.15s (Oc 2475) after the exposure flash: - 1 = correct - 0 = paper arrived too late, ORE1250 paper arriving from the LPT should be present about 1.3s (Oc 2375,2400,2465 CRU and 2465 FIN) or 1.15s (Oc 2475) after the exposure flash: - 1 = correct - 0 = paper arrived too late, ORE1251 paper leaving the paper stop should release the sensor 1.9s (Oc 2375,2400,2465 CRU and 2465 FIN) or 1.5s (Oc 2475) after the flash: - 0 = correct - 1 = paper left too late, ORE1252
MRE 1225 PE 1210 MRE 1226 PE 1211

12R1/12R2 is used to check the position of the plate and so the lift table. 3s after opening the tray in the release position the plate should be in between the release position and close/low position. Otherwise lift table drive up is not correct: - UPT, MRE1225, PE1210 - LPT, MRE1226, PE1211
MRE 1227 PE 1212 MRE 1228 PE 1213

12SO3/12SO4 (UPTLLSE, LPTLLSE) is used to detect if the lift table is at working position. 15s after closing the tray the working position should be reached. Otherwise tray or the lift does not function correctly. - 1 = correct - 0 = lift table not at working position, UPT, MRE1227, PE1212 LPT, MRE1228, PE1213
ed.6 Part I
TSM 2400 family
12 Paper 105
DIAGNOSTIC
12diag
MRE 1229 MRE 1230

12S2/12S3 (UPTAVSE, LPTAVSE) is used to detect that the tray is pushed out. Starting from the low/close position the lift motor drives down in steps. After 7/11 steps (operator request/ control request) the tray should be opened. - 0 = correct - 1 = tray does not open, UPT, MRE1229 LPT, MRE1230
MRE 1231 PE1214 MRE 1232 PE1215

15s after start driving down (starting from working position) the plate and so lift table should be in between the close/low position and release position. Otherwise the lift table drive down is not correct: - UPT, MRE1231, PE1214 - LPT, MRE1232, PE1215
MRE 1233 PE 1216 MRE 1234 PE 1217

The ADC value of the potentiometers is checked 1x/s during standby and run. This is to check if the lift motor is driving up or down continuously. ADC values 0,1,2 or 254,255 are incorrect. - UPT, MRE1233, PE1216 - LPT, MRE1234, PE1217
MRE 1235 PE 1218 MRE 1236 PE1219

12SO3/12SO4 (UPTLLSE,LPTLLSE), level sensor defect detection : check : the tray should be opened. - UPT, MRE 1235, PE 1218 - LPT, MRE 1236, PE 1219.
106 Paper 12
TSM 2400 family
Part I ed.6
12sds
SDS

SIGNAL -0upper tray out/no drive up lower tray out/no drive up upper tray in/no drive up lower tray in/no drive up upper tray not going down lower tray not going down upper tray level resistor failure lower tray level resistor failure upper tray level sensor failure lower tray level sensor failure upper tray out/no drive up lower tray out/no drive up upper tray in/no drive up lower tray in/no drive up upper tray not opened lower tray not opened upper tray not going down lower tray not going down upper tray level resistor failure lower tray level resistor failure upper tray level sensor failure lower tray level sensor failure upper tray paper too late at 12SO5 lower tray paper too late at 12SO5 12SO5 too late free DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 12 0 10 PE 12 0 11 PE 12 0 12 PE 12 0 13 PE 12 0 14 PE 12 0 15 PE 12 0 16 PE 12 0 17 PE 12 0 18 PE 12 0 19 PE 12 0 25 MRE 12 0 26 MRE 12 0 27 MRE 12 0 28 MRE 12 0 29 MRE 12 0 30 MRE 12 0 31 MRE 12 0 32 MRE 12 0 33 MRE 12 0 34 MRE 12 0 35 MRE 12 0 36 MRE 12 0 50 ORE 12 0 51 ORE 12 0 52 ORE PARAMETERS 12 1 01 12EM1
12SO3 12SO4
UPTLLSE LPTLLSE
12R1 12R2 12SO3 12SO4
12SO3 12SO4 12S2 12S3
UPTLLRE LPTLLRE UPTLLSE LPTLLSE UPTLLSE LPTLLSE UPTLLSE LPTLLSE UPTAVSE LPTAVSE
12R1 12R2 12SO3 12SO4 12SO5 12SO5 12SO5
UPTLLRE LPTLLRE UPTLLSE LPTLLSE PASPSE PASPSE PASPSE -1FPSSO
first paper stop open (def. = 80)
ed.6 Part I
TSM 2400 family
12 Paper 201
SDS
12sds
INPUT TESTS 12 2 01 12 2 02 12 2 03 12 2 04 12 2 05 12 2 06 12 2 07 12 2 08 12 2 09 12 2 10 12 2 11 12 2 12 12 2 13 12 2 14 12 2 15 12 2 16 OUTPUT TESTS 12 4 01 12 4 02 12 4 04 12 4 05 12 4 06 12 4 07 12 4 08 12 4 09 12LED1 12LED2 12M3 12M3 12M4 12M4 12CL2 12CL3 12SO1 12SO1 12SO3 12S2 12S4 12S6 12SO2 12SO2 12SO4 12S3 12S5 12S7 12SO5 12SO6 12S1 12S8
-2UPTPSSE UPTPSSE3 UPTLLSE UPTAVSE UPTADPSE UPTSPESE LPTPSSE LTPSSE3 LPTLLSE LPTAVSE LPTADPSE LPTSPESE PASPSE SPTPSSE PAPDSE ENADPSE -4UPT ADd Paper LEd LPT ADd Paper LEd UPT SEParation MOtor (Separation) UPTSEPMOPO UPT SEParation MOtor (Pinch Open) LPT SEParation MOtor (Separation) LPTSEPMOS LPT SEParation MOtor LPTSEPMOPO (Pinch Open) UPT SEParation CLutch LPT SEParation CLutch UPTSEPCL LPTSEPCL UPTADPLE LPTADPLE UPTSEPMOS UPT Paper Size SEnsor : Note 1 UPT adjust Paper Size SEnsor bit3 UPT LeveL SEnsor UPT AVailable SEnsor UPT ADd Paper SEnsor UPT SPEciality SEnsor LPT PAper Size SEnsor : Note 1 LPT adjust paper Size SEnsor bit3 LPT LeveLSEnsor LPT AVailable SEnsor LPT ADd Paper SEnsor LPT SPEciality SEnsor PAper Stop Present SEnsor SPEciality Paper Size SEnsor PAPer Path Door SEnsor ENable ADd Paper SEnsor
202 Paper 12
TSM 2400 family
Part I ed.6
12sds
SDS
SPECIAL TESTS 12 6 01 12 6 02 12 6 03 12 6 04 12 6 05 12 6 06 12 6 07 12 6 08 12 6 09 12 6 10 12 6 11 12 6 12
-6make function WARM make function COLD mask function protections Note 2 Note 3 Note 4 Note 5 Note 6 Note 7 Note 8 Note 9 First Paper Stop SOlenoid
12EM1
FPSSO -8-
REPLACE CONSUMABLES
Note 1:
Paper size < 270 mm 4 270 - 279 mm 279 - 297 mm 297 - 330 mm 330 - 356 mm > 356 mm 0
Code 6 7 3 1
Note 2: UPT function test up/down. By pressing <PRINT> the paper tray moves to the top position. By pressing <PRINT> again the paper tray moves to the bottom position and the paper tray opens. During the test the adc value of 12R1 is dis-played. Check the value in the lowest (block) position if it is between 7 and 9. If not, adjust the potentionmeter (12-8). Note 3: LPT function test up/down. By pressing <PRINT> the paper tray moves to the top position. By pressing <PRINT> again the paper tray moves to the bottom position and the paper tray opens. During the test the adc value of 12R2 is displayed. Check the value in the lowest (block) position if it is between 7 and 9. If not, adjust the potentionmeter (12-8). Note 4: adjust ADC UPT low position, refer to adjustment 12-8 Note 5: adjust ADC UPT up position empty, refer to adjustment 12-8 Note 6: adjust ADC UPT up position full, refer to adjustment 12-8 Note 7: adjust ADC LPT low position, refer to adjustment 12-8 Note 8: adjust ADC LPT up position empty, refer to adjustment 12-8 Note 9: adjust ADC LPT up position full, refer to adjustment 12-8
ed.6 Part I
TSM 2400 family
12 Paper 203
SDS
12sds
204 Paper 12
TSM 2400 family
Part I ed.6
12adju
ADJUSTMENTS
ADJUSTMENTS 1 Paper skew/first paper stop (Oc 2475 and from machine nr.7800) Aim:
To correct paper skew with respect to the image. NOTE: For a correct adjusting sequence use the following procedure: - Copy quality (system level): image positioning adjustments. - Use in both the upper and lower paper tray, the same paper weight/brand.
Check:
Put testchart 19 on the original glass platen straight against the ruler. Make 20 copies, 100% / simplex-simplex / sort / no margin shift / upper paper tray. Measure S1 and S2: Calculate the average value: (S1 tot - S2 tot ) /20 =0+/- 1.0 mm.
12adj01b
Correction:
1.1 1.2 Remove the safety cover for preheat section behind the paper path front door. S1 > S2 + 1.0 mm: turn screw -B- to move paper stop -A- S1 S1 as many mm in the X-direction as the difference between S1 and S2. S1 < S2 - 1.0 mm: turn screw -B- to move paper stop -A- as many mm in the Y-direction as the difference between S1 and S2. S2 S2 Proceed with check adjustment 12-2.
12adj01d 12adj01a
1.3
ed.6 Part I
TSM 2400 family
12 Paper 301
ADJUSTMENTS
12adju
Paper skew/first paper stop (Oc 2375/2400 and upto machine nr. 7800) Aim:
To correct paper skew with respect to the image. NOTE: For a correct adjusting sequence use the following procedure: - Copy quality (system level): image positioning adjustments. - Use in both the upper and lower paper tray, the same paper weight/brand.
Check:
Put testchart 19 on the original glass platen straight against the ruler. Make 10 copies, 100% / simplex-simplex / sort / no margin shift / upper paper tray. Measure S1 and S2: Determine the average value : S1 = S2 1.0 mm.
Correction:
1.1 1.2 Remove the safety cover for preheat section behind the paper path front door. S1 > S2 + 1.0 mm: loosen bolt -B- and move paper stop -A- as many mm in the X-direction as the difference between S1 and S2. S1 < S2 - 1.0 mm: loosen bolt -B- and move paper stop -A- as many mm in the Y-direction as the difference between S1 and S2. Proceed with check adjustment 12-2.
1.3
S1
S1
S2
S2
302 Paper 12
TSM 2400 family
Part I ed.6
12adju
ADJUSTMENTS
Zero position upper/lower paper tray Aim:

To achieve a correct zero position on the paper with respect to the image. NOTE: For a correct adjusting sequence use the following procedure: - Copy quality (system level): image positioning adjustments. - Use in both the upper and lower paper tray, the same paper weight/brand.
Check:

Select upper or lower paper tray. Put testchart 19 on the original glass platen, at 0"point and straight against the ruler. Make 10 copies, 100% / simplex-simplex/sort / no margin shift / upper or lower paper tray. Measure the distance E and F and calculate the average value over the 10 copies (E tot - F tot ) /10 =Z If Z = 0+/-2 mm: no correction.
12adj02b
Correction:
2.1 2.2 Check adjustment 12-1. Distance >7 mm : loosen bolt -A- and move the front bracket of the paper tray in the X-direction as many mm as the difference. Distance <5 mm : loosen bolt -A- and move the front bracket of the paper tray in the Y-direction as many mm as the difference. Read out the position of the bracket on the front scale. Loosen bolt -C-. Adjust plate -B- at the format slide to the same value of the front scale. Check adjustment 12-4. If necessary carry out the whole procedure for the other paper tray. Proceed with the check of adjustment 12-3. The maximum deviation E - F must not be larger than +/- 4 mm with respect to Z If incorrect: check paperpath.
12adj02c
E E
2.3 2.4 2.5 2.6 2.7 2.8
12adj02a
ed.6 Part I
TSM 2400 family
12 Paper 303
ADJUSTMENTS
12adju
Zero position manual feed (bypass) Aim:

To achieve a correct zero position on the speciality with respect to the image. NOTE: For a correct adjusting sequence use the following procedure: - Copy quality (system level): image positioning adjustments. - Use in both the upper and lower paper tray, the same paper weight/brand.
Check:
Put testchart 19 on the original glass platen, at 0" point and straight against the ruler. Put 1 sheet of paper in the manual feed against paper guide -A-. Make 10 copies by the manual feed, 100%. Measure the distance between the -6 line and the top edge of each copy at -Z-. If the average distance is 6 1 mm : no correction.
Correction:
3.1 3.2 3.3 Check adjustment 12-1. Loosen bolts -B-. Distance >7 mm : move bracket -A- in the Y-direction as many mm as the difference; Distance <5 mm : move bracket A- in the X-direction as many mm as the difference. Tighten bolts -B-.
12adj02a
3.4
12adj03b
304 Paper 12
TSM 2400 family
Part I ed.6
12adju
ADJUSTMENTS
Paper format detection upper/lower paper tray Aim:

To achieve a correct detection of the paper size in the paper trays. NOTE: For a correct adjusting sequence use the following procedure: - Copy quality (system level): image positioning adjustments. - Use in both the upper and lower paper tray, the same paper weight/brand.
Check:
Put paper of a standard size in the paper trays, close it up by the slide guide and check if the paper size indication in the display corresponds with the paper format.
Correction:
4.1 4.2 4.3
4.4 4.5
4.6 4.7 4.8 4.9
Check adjustment 12-2, 0-position, point 2.5. Empty the paper tray. Position the slide guide at a distance of 294 0.5 mm from the front guide (e.g. with the aid of a ruler). Slowly close the tray. Select input test for: - upper tray 12 2 02 - lower tray 12 2 08 Loosen bolts -A- (2x); Move the sensor-PBA forward (-X-) until the buzzer turns off. Move the sensor-PBA outward (-Y-) until the buzzer turns on. Tighten bolts -A- (2x).
12adj04a
ed.6 Part I
TSM 2400 family
12 Paper 305
ADJUSTMENTS
12adju
Timing first paper stop (parameter test 12 1 01) Aim:

To achieve a correct starting moment of the paper. NOTE: For a correct adjusting sequence use the following procedure: - Copy quality (system level): image positioning adjustments. - Use in both the upper and lower paper tray, the same paper weight/brand.
Check:
Put test chart 19 on the original glass platen,straight against the ruler. Make 10 copies, 100% / simplex-simplex / sort / no margin shift / upper paper tray. Measure A and B and calculate the average value over the 10 copies, (A tot - B tot ) /10 =Y If Y = 0 +/- 2 mm: no correction.
Correction:
5.1 Select test 12 1 01. 1 step corresponds with 0.1 mm. - If Y = positive: increase the actual value. - If Y = negative : decrease the actual value. NOTE: Default value minimum maximum
A B
2 1 0 -1 -2 -3 -4 -5 -6
-6 -5 -4 -3 -2 -1 0
: 80; : 0; : 160.
12adj05a
The maximum deviation A - B must not be larger than +/-4 mm with respect to Y: If incorrect : Check paperpath incl. its adjustments.
306 Paper 12
TSM 2400 family
Part I ed.6
12adju
ADJUSTMENTS
First paper stop lifting heigth Aim:

To achieve a correct stroke of the solenoid and paper stop mechanism.
Check:
Activate test 12 6 12 and check if the paper stop fingers are just protruding plate -B-.
Correction:
6.1 6.2 6.3
6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13
Remove the subframe rear cover. Remove the safety cover for preheat section, front side; preheat section is closed. Select and activate output test 12 6 12 (12EM1): the solenoid is actuated, the paper stop is lifted, Loosen bolts -A-. Move the solenoid up or down: the paper stop should protrude slightly above the plate -B-. Tighten bolts -A-. Deactivate the solenoid: the paper stop is lowered. Position a special tool with a thickness of 5 mm (codenr. 7991.193) between the solenoid and the core. Loosen nut -E-. Activate the solenoid and adjust buffer -C- in such a way that it just touches bracket -D-. Lock buffer -C- with nut -E-. De-activate the solenoid. Remove special tool and proceed with check adjustment 12-7.
12adj06a
ed.6 Part I
TSM 2400 family
12 Paper 307
ADJUSTMENTS
12adju
First paper stop feed rollers (soft feed/hard feed) Aim:

To achieve a correct paper feed into the first preheater section.
Check:
Place a sheet of paper in the manual feed. Soft feed check: - pull the sheet out: this should go very smoothly. - put the sheet in once more: it should be positioned straight against the paper stop. Hard feed check: - place a sheet against the paper stop. - hold the sheet tight between two fingers. - push the print button: the sheet should be fed in.
Correction:
7.1 Check adjustment 12-6. NOTE: Make sure that test 12 6 12 is deactivated. 7.2 7.3 7.4 7.5 Loosen nut -A-. Insert a feeler gauge of 0.5 mm as shown in the drawing. Loosen allen screw -B- so that you have no resistance on the feeler gauge. Tighten allen screw -B- so that you feel a little resistance when moving the feeler gauge. Lock allen screw -Bwith nut -A- and make sure that allen screw -B- is is not turned anymore.
12adj07a
7.6
12adj07b
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Part I ed.6
12adju
ADJUSTMENTS
Initialisation of the paper trays Aim:

To achieve a correct detection of the lift table position and thus the amount of paper in the paper trays. NOTE: This adjustment must be performed, when the position of the potentiometer has been changed with respect to the drive mechanism.
Check:

If the display does not indicate reload paper tray while the paper tray is completely empty or if the display indicates reload paper tray while the paper tray is still filled with more than 100 sheets of 80 g/m2(20 lb) . Select SDS test 12 6 04 (upper tray), or 12 6 05 (lower tray). Check if the value in the lowest (block) position is between 7 and 9, if not proceed with 8.1.
Correction:
NOTE : Check the chain tension: - while the tray is opened ensure that the lift table catch is in nearly horzontal position - if not move the lift motor to tension the chain 8.1 8.2 8.3 8.4 Remove the potentiometer assembly from the machine. As viewing the potentiometer facing the gear, turn the gear fully counter clockwise. Put the potentiometer assy back into the machine. Place bolt -A- in the slotted hole and turn plate -B- clockwise until it blocks (upper position) and tighten it. Select test 12 6 06 (upper tray) or 12 6 09 (lower tray). Select by means of the copy darker button the direction <DOWN>. Lower the chain using the Remote Copy Switch (RCS, the red button on 22 PBA 09 at the rear side of the subframe) until the locking arm starts moving.
12adj08a
8.5 8.6 8.7
12adj08b
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12 Paper 309
ADJUSTMENTS
12adju
8.8 Lower the chain step by step with the R.C.S. until the blocking position is reached. 8.9 Loosen bolt -A- one turn. 8.10 Turn plate -B- counterclockwise until it blocks and then clockwise against the stop, while holding the plate between your fingers . 8.11 Tighten bolt -A-. 8.12 Select by means of the copy lighter button direction <UP>. 8.13 Push the RCS until the locking arm of the paper tray is in the locking position (horizontal). 8.14 Select by means of the copy darker button direction <DOWN>. 8.15 Briefly push the R.C.S. to lower the chain step by step until the lever starts moving the locking arm. 8.16 Store the actual position of the potentiometer in the memory by pushing the print button twice. 8.17 Select test 12 6 07 (upper tray), 12 6 10 (lower tray) to store the highest possible lift position of the empty paper tray. 8.18 Follow the display messages to open, empty and close the tray as the test is performed automatically. 8.19 Select test 12 6 08 (upper tray), 12 6 11 (lower tray) to store the highest possible lift position of the full paper tray. 8.20 Follow the display messages to open, to fill the tray with 1500 sheets of 80g/m2 (20 lb) paper and to close the tray as the test is performed automatically.
12adj08b
310 Paper 12
TSM 2400 family
Part I ed.6
12adju
ADJUSTMENTS
Separation wheel nip pressure Aim:

NOTE: Carry out this adjustment only with new separation wheel and roll. The separation wheel and roll have to be replaced if the diameter of the separation wheel < 40.6 mm. To achieve a correct separation of paper of 60 - 120 g/m2 (16-32 lb).
Check:
Remove the separation unit from the machine (dis/assembly 12-1). Remove guarding plate -A- from the unit; Put the unit back into the machine. Push the separation unit completely upwards. Switch the separation motor on by means of output test 12 4 04 (upper tray) 12 4 06 (lower tray) respectively. Measure -B- with a feeler gauge. Measure visually horizontally. If B = 2.8 0.2 mm : no correction. Proceed with 9.3.
Correction:
9.1 9.2 9.3 9.4 Take the unit out of the machine. If B > 3.0 mm : decrease measure -C- with the difference between B and 2.8 mm. If B < 2.6 mm : increase measure -C- with the difference between B and 2.8 mm. Mount guarding plate -A-. Put the unit back into the machine. NOTE: Basically the separation units of the upper and lower paper tray can be interchanged, but if you do so, BOTH have to be adjusted.
12adj09a
ed.6 Part I
TSM 2400 family
12 Paper 311
ADJUSTMENTS
12adju
10
Separation shoe pressure Aim:

To achieve a correct guidance of the paper.
Check:
Remove the separation unit from the machine. Put the unit on a table. Push the separation wheel so far downward, that the separation shoe still can move freely. Put a weight of 50 grams (special tool codenr. 7991.328) on the part of the shoe indicated with arrow -F- ; If the shoe protrudes the cover plate with approximately 2 mm: no correction.
Correction:
10.1 Adjust the spring in the holes -A- so that the shoe is protruding the cover plate of the unit with 2mm. 10.2 Mount the unit.
12adj10a
312 Paper 12
TSM 2400 family
Part I ed.6
12adju
ADJUSTMENTS
11
Paper tray switches Aim:

To achieve a correct functioning of the specialities and paper tray switches.
Check:
Paper tray switches: When pushing against the tray, the cover switch must not operate. When pushing the button it must start the lift motor. Paper specialities indication switches: The lever must actuate the switch, so SP appears in the display.
Correction:
11.1 Remove the centre front cover. 11.2 Upper tray: - Open the upper right hand door. - Remove the safety cover of the preheat section.. Lower tray: - Open the upper tray. 11.3 Close the paper tray of the switch block you want to adjust. 11.4 Loosen bolts -B-. 11.5 Place bracket -A- in such a way that the upper switch is activated when you push in button -C- for 3 mm (place the bracket visually vertically). 11.6 Tighten bolts -B-. 11.7 Adjust buffer -D-in such a way that there is a space of 1 0.3 mm between the buffer and plate -E-.
12adj11a
ed.6 Part I
TSM 2400 family
12 Paper 313
ADJUSTMENTS
12adju
12
First paper stop present/skew detection sensor (12SO5) Aim:

To achieve a correct detection of paper in front of the paper stop.
Check:
Check if the sensor is activated when you put a sheet of paper of 65 g/m2 (16 lb) through the bypass against the paper stop. The display must indicate: bypass selected. Put 10 sheets of paper of 80 g/m2 (20 lb) underneath the sensor and check if the sensor does not block the paper when you pull them backwards.
Correction:
12.1 Loosen bolts -A- one turn; 12.2 If one sheet is not detected: - activate test 12 2 13; - put one sheet underneath the sensor; - lower bracket -B- until the buzzer is activated; - check if 10 sheets are not blocked. - If 10 sheets are blocked by the sensor: - lift bracket -B- until the sheets are released; - check if one sheet is detected. 12.3 Place bracket -B- horizontally. 12.4 Tighten bolts -A-. 12.5 Check adjustment 12-13.
12adj12a
314 Paper 12
TSM 2400 family
Part I ed.6
12adju
ADJUSTMENTS
13
Speciality paper size sensor (12SO6) Aim:

To achieve a correct detection of paper in the bypass.
Check:
Check if the sensor is activated when you put a sheet of paper of 65 g/m2 (16 lb) through the bypass against the paper stop. The display must indicate: bypass selected. Also put 10 sheets of paper of 80 g/m2 (20 lb) underneath the sensor and check if the sensor does not block the paper when you pull them backwards.
Correction:
13.1 Loosen bolts -A- one turn; 13.2 If one sheet is not detected: - activate test 12 2 14; - put one sheet underneath the sensor; - lower bracket -B- until the buzzer is activated; - check if 10 sheets are not blocked. - If 10 sheets are blocked by the sensor: - lift bracket -B- until the sheets are released; - check if one sheet is detected. 13.3 Place bracket -B- horizontally. 13.4 Tighten bolts -A-. 13.5 Check adjustment 12-12.
12adj13a
ed.6 Part I
TSM 2400 family
12 Paper 315
ADJUSTMENTS
12adju
14
Paper path door (right-hand side) Aim:

To obtain a reliable paper transport to the first paper stop by adjusting for a uniform pinch pressure.
Check:
Remove the panelling from the paper path door. Close the door. With a pair of vernier callipers, measure the distance -A- between the door and the plate at point -B- (the side where the lock is situated), and at point -C- (the side where the hinge is situated): the distance measured -A- must be 8 0.2 mm. - if the distance at -B- is not correct, proceed with 14.1; - if the distance at -C- is not correct, proceed with 14.6.
Correction:
14.1 Open both paper trays; 14.2 Remove panelling -H- on the front righthand side; 14.3 Loosen bolts -D-; 14.4 With bracket -E-, adjust the distance at -Bto 8 0.2 mm; 14.5 Tighten bolts -D-; 14.6 Remove the rear panelling of the sub-frame; 14.7 Loosen bolts -F-; 14.8 With hinge bracket -G-, adjust the distance at -A- to 8 0.2 mm; 14.9 Tighten bolts -G-; 14.10 Remount all removed parts.
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ADJUSTMENTS
15
Height of the paper path door Aim:

To ensure that the paper path door can be easily opened and closed.
Check:
When you close the door, it must lock easily.
Correction:
15.1 15.2 15.3 15.4 15.5
Remove the panelling of the door and paper path; Loosen bolts -K- and then tighten them by hand; Close the paper path door; Completely tighten bolts -K-; Remount all removed parts.
12adj14a
ed.6 Part I
TSM 2400 family
12 Paper 317
ADJUSTMENTS
12adju
318 Paper 12
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Part I ed.6
12disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13
Separation unit upper/lower papertray

Open the papertrays. Remove inner side right cover (black). Block tension spring -A- with excentric knob -B-. Open the right hand paper path doors. Remove the connector protection bracket at the rear of the unit. Loosen connector 12CN1 (upper drawer) or 12CN2 (lower drawer). Remove the E-ring of shaft -C-. Support the unit with your left hand. Turn knob -D- on shaft -C- a quarter of a turn counter clockwise and pull it off the shaft. Slide the unit a little forward. Move the rear side of the unit to left. Remove the unit. Mount the unit in the reversed order.
12disa01
ed.6 Part II
TSM 2400 family
12 Paper 401
DIS/ASSEMBLY
12disa
Separation wheel / separation roll / feed roll Separation wheel:
2.1 2.2 2.3 2.4 2.5
Remove the separation unit from the machine (disassembly 12-1). Remove the black cover of the unit. Remove separation shoe -A- of the unit (2 bolts -B- in the black bracket). Release clip -C- and slide wheel -D- of spindle -E-. Mount the new wheel in reversed order.
12disa02
402 Paper 12
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Part II ed.6
12disa
DIS/ASSEMBLY
Separation roll / feed roll:

2.6 2.7 2.8 2.9 2.10 2.11 2.12 Loosen connector 12CN7 (upper drawer) or 12CN8 (lower drawer). Loosen bolt -F-. Remove the roll unit off the machine. Remove the E-rings -G-. Remove the separation rolls -H-. Mount the new rolls in reversed order. Mount the separation unit into the machine (assembly 12-1).
12disa03
12disa04
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TSM 2400 family
12 Paper 403
DIS/ASSEMBLY
12disa
Lift motor Note that:
3.1
3.2 3.3 3.4
Make sure that you mount the gear on the motor shaft in the correct way. The gears of the upper and lower lift motor have to be mounted differently (the other way around). When mounting the lift motor, first mount it with one bolt at the top. This facilitates the mounting of the chain. Make sure the chain is tensioned correctly. After mounting the lift motor the potentiometer has to be initialised. (see adjustment 12-8)
404 Paper 12
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Part II ed.6
12func
FUNCTIONAL DESCRIPTION 1 Paper tray section

The function of the paper tray section is: Act as a stockpile of paper Separate one sheet of paper from the pile Accept receiving material via the bypass Transport the receiving material against the first paper stop The paper section consists off: -A-B-C-D-E -F-G-H-ILower paper tray (LPT) LPT lift table drive mechanism LPT feed and separation mechanism Paper path Upper paper tray (UPT) UPT lift table drive mechanism UPT feed and separation mechanism Bypass feed (specialities) First paper stop
12func01
ed.6 Part II
TSM 2400 family
12 Paper 501
12func
Lift table drive mechanism

The function of the lift table drive mechanism is to raise and lower the lift table in the paper tray. This is the same for both upper and lower paper trays. The lift table drive mechanism consists of:
-A-B-C-D-E-
Paper tray (drawer) Lift table Lift table catch Lift table carrier plate Lift table drive
12func02
The lift motor drives a sprocket, which is connected to a chain. The chain has a small plate, the lift table carrier, attached to it. When the tray is pushed in, a tongue, the lift table catch, is positioned over the carrier. Thus when the chain is moving up or down, the lift table also rises or lowers, carrying the paper stack with it. The tray gets pushed in and pulled out. The lift table, which carries the paper stack, is the part that is actually raised and lowered. When the tray has to be opened the lift table always moves into the lowest position. Automatically a release mechanism pushes the tray out.
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12func
Tray lock / release mechanism

The function of the lock / release mechanism is :
To keep the paper tray closed when the lift table is in raised position. To release and open the paper tray to reload paper. The lock / release mechanism consist of :
-A-B-C-D-E-F-
Lift table Lift table carrier plate Lift table chain Tray release spring Locking latch Paper tray bottom
12func03
Locking : As the tray is pushed in, a pressure spring at the rear of the tray is compressed. When the tray is fully pushed in, a spring loaded latch hooks in the bottom of the paper tray. This latch keeps the tray locked. Releasing : As the paper tray button is pushed the lift motor drives down, the lift table will come to its release position and stop in its low closing position. As the motor continues to drive down, plate -B- presses against the top of latch -E-. This releases the paper tray. Spring -D- that was compressed when the tray was pushed in, now causes the paper tray to be pushed out a few cm.
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12 Paper 503
12func
Manual unlocking
If the tray gets stuck, locking latch -A- can be released manually. Simply by lifting lever -C- (UPT or LPT) at the rear of the subframe. ATTENTION: When the lift table is not in the lowest position it will drop down !
12func04
Mechanical interlock
The function of the mechanical interlock is to avoid that the paper tray is pushed in and locked while plate -B- is not in the low/closing position. Interlock bar -C- blocks the paper tray and prevents latch -A- from locking the paper tray.
12func05
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Part II ed.6
12func
When the paper tray is released (opened), the lift table carrier plate -Bkeeps the interlock bar -C- in horizontal position, so the paper tray can be closed again. If the lift table carrier plate -B- is not in the correct position (low/closing), it is not possible to close the paper tray. Attention : After the paper tray has been opened manually, the copier must be switched off and on. Otherwise the software setting of the lift table positions might be affected.
12func06
Paper tray available sensor. (12S2, 12S3)

The function of the tray available sensor is to detect if the paper tray is opened or closed. Lever -A- is placed at the rear of the paper tray. Switch -B- is installed at the rear on the sub-frame. As the paper tray is pushed in and locked in position, lever -A- activates switch -B-.
12func07
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TSM 2400 family
12 Paper 505
12func
Lift table positions

The lift table consist of :
-A-B-C-D-E-
Lift motor Driven sprocket Chain with carrier Sprocket Gears driving the lift level resistor
12func08
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Part II ed.6
12func
Lift motors
Each lift motor (UPT, LPT) consists of two rotor windings on one shaft and two stator windings. The drive direction of the motor shaft (up or down) depends on which stator winding is connected to 220VAC. When the motor is not moving, a mechanical brake holds the motor shaft in position.
Circuit diagram description : (see 701/702)

Solid state relays on SSR2 (22PBA07) connect the 220VAC to the lift motors. A mechanical relay switches the triac output between the up and down windings. For the upper paper tray: The signal UPTLMO controls lift motor 12M1 : - high 1 switches the lift motor ON, LED4 is on - low 0 switches the lift motor OFF, LED4 is off The signal UPTLMODIR determines the drive direction of the lift motor: - low 0 switches the drive UP, LED5 is off - high 1 switches the drive DOWN, LED5 is on For the lower paper tray: The signal LPTLMO controls lift motor 12M2 : - high 1 switches the lift motor ON, LED3 is on - low 0 switches the lift motor OFF, LED3 is off The signal LPTLMODIR determines the drive direction of the lift motor: - low 0 selects the drive UP, LED6 is off - high 1 selects the drive DOWN, LED6 is on
ed.6 Part II
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12 Paper 507
12func
Lift table positions

The figure below shows the different lift table positions. These positions will be referred to in this section.
12func09
working position This is is the position where the paper stack is at working height and sheets can be fed and separated, the position is detected by the tray level sensor (12SO3, 12SO4). low/closing position This is the position where the lift table is lowered but the locking latch keeps the tray in closed position, the position is sensed by a rotary potentiometer (12R1, 12R2). This is also the position to which the lift table chain returns after the release position has been reached and the paper tray is opened. release position This is the position where the locking latch is released and the tray is pushed outward, the position is sensed by a rotary potentiometer. The tray available sensor (12S2, 12S3) senses if the tray is closed. blocking position This is the position where the lift table chain is mechanically blocked. For adjustment only. A lift level resistor (rotary potentiometer)(12R1, 12R2) is connected to the lower sprocket by gears. As the motor and chain turn, so does the potentiometer. The resistance of the potentiometer indicates the position of the lift table and so the stack of paper is displayed on the operating panel. The resistance (analog value) is converted to an 8 bit digital signal by an ADC on the HOST-I/O (22PBA02).
508 Paper 12
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12func
Paper path
Paper is supplied and fed from the UPT and LPT by the separation unit. The UPT/LPT transport rollers respectively transport the paper to the first paper stop. The paper path consist of :
-A-B-C-
Separation section Paper path transport rollers First paper stop section
12func10
The paper path can be opened in order to get access. First the right side cover door must be opened, then the paper path door can be opened. When the right side cover door is open, the paper tray cover sensor (12S1) is open, PTCOVSE goes low 0. There is no paper sensing in the paper path itself. The first place in which paper is detected is at the first paper stop, by the paper stop present sensor (12S05).
ed.6 Part II
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12 Paper 509
12func
Separation section
The separation section is the same for both paper trays. The separation section consists of two units : The feed unit and the separation wheel unit.
-A-B-C-D-
The feed unit consists of : Lift level sensor Feed roll Separation roll Drive gear, driven by the separation clutch.
12func11
-E-F-
The separation wheel unit consists of : Separation shoe Separation wheel, driven by the separation motor -G-
Transport roller.
12func12
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12func
Feed unit : The feed roll and separation roll are driven by the main drive via the separation clutch (12CL2, 12CL3). Every time control line UPTSEPCL/LPTSEPCL goes high 1, one sheet is separated and transported to the transport roller.
Separation wheel unit : The upper/lower separation motor (12M3, 12M4) is a 24VDC motor that can be driven in either direction. A forward (separation) direction and a reverse (pinch open) direction. Separation : Control line UPTSEPMOS/LPTSEPMOS goes high 1. On the 24V-driver (22PBA09) line SEPARATION is connected to 24VDC while line PINCH OPEN is connected to ground. The motor turns in forward direction. Pinch open : Control line UPTSEPMOPO/LPTSEPMOPO goes high 1. On the 24V-driver (22PBA09) line PINCH OPEN is connected to 24VDC while line SEPARATION is connected to ground. The motor turn in reverse direction. Separation sequence: The feed roll and separation roll are driven via the upper/lower separation clutch (12CL2, 12CL3). One or more sheets of the paper stack are fed towards the separation nip. The sheet(s) hit the separation shoe which directs them upwards so that they always contact the separation roll first and next the separation wheel. The separation wheel is driven against the direction of the paper feed, which causes all but the top sheet to be held back. The separation roll feeds the top sheet through to the transport rollers. The feed roll and separation roll turn slightly slower than the transport rollers. This means that the transport rollers pull the paper through the separation nip, thus preventing buckling. To avoid tearing the sheet, the feed and separation rolls are fitted with one way bearings. Pinch open sequence When the lift table is lowered, the UPT/LPT separation wheel motor (12M3, 12M4) drives in reverse direction. The separation wheel lowers by 5 - 6mm with respect to the separation roll. So opening the separation nip allows any paper in the nip to fall back onto the stack. If a jam occurs in the paper path, the right side door and cover have to be opened. There are two handles on the left as you look at the paper path. Both are spring loaded. The top handle releases the UPT transport rollers and lowers the UPT separation wheel. The bottom handle releases the LPT transport rollers and lowers the LPT separation wheel.
1.
2.
1. 2. 3. 4. 5. 6.
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12func
Circuit diagram description : (see 701/702)

Lift drive up(working position) When the tray is pushed in and latched, the tray available sensor (12S2,12S3) is closed. The signal UPTAVSE/LPTAVSE goes from low 0 to high 1. When the control sees the signal go high 1, it sends a signal to start the lift motor (12M1,12M2) driving up. When the paper stack raises the feed roll of the separation mechanism, a vane attached to the feed unit interrupts the UPT/LPT lift level sensor (12SO3,12SO4) and the signal UPTLLSE/LPTLLSE goes from low 0 to high 1. This signal stops the lift motor directly via hardware on the HOST I/O (22PBA02). The lift table is at working position. By using the value of the potentiometer UPTLLRE/LPTLLRE (12R1,12R2) the control can calculate how much paper there is in the tray. Each bar on the display corresponds with 300 sheets 80gr/m2 (20 lb). When the papertray opens while the lifttable is not in low/closing position then the lift will automatically go to the low/closing position.
Working height The control sends a signal to monitor the lift level sensor after every five paper feed actions. When the tray is at working height, that is, UPTLLSE/LPTLLSE is high 1, nothing happens. As paper is fed from the stack, the feed wheel will lower, the vane will lower and the lift level sensor signal will revert to low 0. This allows the control to start the lift motor, which drives up until the vane interrupts the beam again, only between separation actions. Between 5 and 15 sheets will be fed before the motor drives up again (approx 0.5 - 1.5mm). When there is less then 60 sheets left detected by the lift level resistor, the tray is lowered automatically to the low position. The paper tray stays closed until the add paper sensor button (12S4, 12S5) is depressed. When continuous copying is selected, no SP indication is present and as the same paper size is used, automatically the other paper tray will be selected.
512 Paper 12
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12func
Lift table drive down There are three situation that the lift table drives down :
Operator request. The add paper key (12S4, 12S5) is depressed, while no locking set is installed. Control request. The lift level resistor (12R1, 12R2) senses that the paper stack is less than 60 sheets 80 gr/m2 (20 lb). SDS test request. A SDS test is selected to lower the lift table chain with open or closed paper tray. Sequence after depressing the add paper key (if the tray is not in use) .
a)
b) c) d)
e) f)
When the operator presses the add paper key (12S4,12S5), the signal UPTADPSE/LPTADPSE goes from low 0 to high 1 momentarily and the lift motor will drive the lift table chain down. The paper tray add paper led (12LED1, 12LED2) is flashing. The lift table will stop at the low position (determined by the potentiometer, 12R1/12R2). The lift motor continues to drive down in steps. The step size is in the range of 1.45-6 mm depending on the amount of paper in the tray. 400ms after each step the tray available sensor (12S2,12S3) is monitored. As long as it is still high 1 (tray not released), the lift motor is driven down one step more. The maximum number of steps is 7. When the table reaches the release position the tray will pop out and the tray available sensor is released and control line UPTAVSE / LPTAVSE becomes low 0. The lift motor will then automatically drive the lift table carrier plate up to the low/closing position. The lift table chain is in position to latch the paper tray when pushed in.
ed.6 Part II
TSM 2400 family
12 Paper 513
12func
Sequence after a paper stock of less than 60 sheets. a) b) The lift motor will drive the lift table chain down. The lift table will stop at the low position (determined by the potentiometer, (12R1/12R2). The operator must then press the Add Paper Key (12S4,12S5). The signal UPTADPE/LPTADPE goes from low 0 to high 1 momentarily. The paper tray add paper led (12LED1, 12LED2) is flashing. The lift motor continues to drive down in steps. The step size is approx. 1.45 mm (empty paper tray). 400ms after each step the Tray Available Sensor (12S2,12S3) is monitored. As long as it is still high 1 (tray not released), the lift motor is driven down one step more. The maximum number of steps is 11. When the table reaches the release position the tray will pop out and the tray available sensor is released and control line UPTAVSE / LPTAVSE becomes low 0. The lift motor will then automatically drive the lift table carrier plate up to the low/ closing position. If the tray available sensor has not switched after the maximum number of steps an MRE is generated. Posibilities in SDS to lower the lift table chain. If a SDS test is used to open the paper tray or if the lift motor is activated with open paper tray, the lift table carrier plate can be in any position. Never use a SDS test to lower the lift table chain uncontrolled this to avoid that the rotary potentiometer gets out of adjustment. To avoid damage or incorrect adjustment of the lift table position, do not close the paper tray but first initialize the paper tray by making the paper tray function warm using SDS test 12 6 01.
c) d)
e) f)
514 Paper 12
TSM 2400 family
Part II ed.6
12func
Paper transport path

Paper is fed from the UPT and LPT by transport rollers which make hard pinches. In the paper path are four sets of paper transport rollers for the lower tray and two sets for the upper tray, which transport the paper to the first paper stop.
-A-B-C-D-E-
UPT transport rollers UPT / LPT transport rollers LPT transport rollers Paper path door Outer cover door
12func13
The paper path can be opened in order to get access. First the right side outer door must be opened, then the paper path door can be opened. When the outer cover door is open, the PAper Path Door Sensor (12S1) is open, PAPDSE goes low 0. After depressing the PRINT button it will be displayed which door is open. There is no paper sensing in the paper path itself. The first place in which paper is detected is at the first paper stop, by Paper Stop Present Sensor (12SO5) . PASPSE goes high 1 when paper is present.
ed.6 Part II
TSM 2400 family
12 Paper 515
12func
10
First paper stop section

The function of the first paper stop section is to stop and line up the sheet and to start the paper feed towards the transfer pinch at the correct time. This to achieve a correct positioning of the image on the receiving material fed from UPT/LPT or speciality bypass.
-A-B-C-
Paper stop Turn shaft paper stop First paper stop solenoid
12func15
-D-E-F-
Soft/hard feed rolls Hard feed pressure mechanism Paper stop present sensor
12func14
516 Paper 12
TSM 2400 family
Part II ed.6
12func
In rest position the first paper stop solenoid (12EM1) is not energised. The paper stop are in the paper path to stop the sheet. Control line FPSSO is low 0. The soft feed rolls turn, driven by the subframe drive, forming a nip (soft feed). So when the paper arrives it is postioned against the paper stop and any skew is removed. Confidential 1996 Oc Nederland B.V.
Sequence of operation after sheet present detection : The first paper stop solenoid (12EM1) is energised, by FPSSO going high 1. The paper stop lifts, clearing the paper path. A split second later the soft feed rolls are pinched in hard to drive the paper to the transport rollers. The lead edge is fed past the paper stop. The solenoid deactivates. The length of time during which the solenoid is energised is determined by a timer on the HOST I/O (22PBA02) The paper stop falls onto the paper as it is passing. The trail edge of the paper passes, and the paper stop immediately falls back, ready to stop the next sheet.
ed.6 Part II
TSM 2400 family
12 Paper 517
12func
11
Paper size detection

The paper size detection is the same for both paper trays. When putting paper in the tray, the operator must position the rear paper guide so that it supports the paper stack. When the paper tray is closed the guide pushes a spring loaded code strip plate into a sensing unit.
-A-B-C-D-E-F-
Lift table Rear paper guide Lever, to position plate with code strips Plate with code strips Sensor PBA Tension spring
12func16
518 Paper 12
TSM 2400 family
Part II ed.6
12func
The sensing unit (12SO1) is mounted in the subframe, it carries three opto-sensors. A rod attached to the plate with code strip guides the spring loaded plate. On the underside of the plate are code strips that interrupt the sensor as the plate is pushed in.
12func17
The position of the code strips causes a digital code to be generated. This digital code is used to program the edge discharge lamps and the interval flash timing. The following table shows the different outputs possible and the corresponding paper sizes. Sensor 1 0 0 0 0 1 1 1 1 UPTPSSE1 LPTPSSE1 Sensor 2 0 0 1 1 0 0 1 1 UPTPSSE2 LPTPSSE2 Sensor 3 0 1 0 1 0 1 0 1 UPTPSSE3 LPTPSSE3 Paper size 356mm (14") 254mm (10") note 270mm 330mm (13") note 297mm (A4) 279mm (11") Upper Paper Tray Lower Paper Tray
NOTE : If the combination 010" or 101" is detected by the control, it will assume that the sensor is defective and frame the image on the smallest paper size, 254 x 203mm (10"). The front paper guide determines the zero of the paper with respect to the image. It can be adjusted.
ed.6 Part II
TSM 2400 family
12 Paper 519
12func
12
Specialities
Specialities can be supplied via the paper trays or via the speciality bypass. For specifications of specialities please refer to Technical Data or User Manual.
Specialities via paper tray.

For specifications of specialities please refer to Technical Data. Each tray has a switch that indicates when specialities are present. The operator must open the tray and move a lever at the front of the tray so that when the tray is closed the UPT/LPT speciality key (12S6, 12S7) is actuated. The signal UPTSPESE/LPTSPESE is always sent to the control and <SP> will appear behind the relevant tray on the operator panel. -A-BUPT speciality key (12S6) LPT speciality key (12S7)
12func18
Normal position When the lever is in the normal position, it leaves a hole in the left side of the tray open. When the tray is closed, the switch plunger goes into the hole and the switch is not actuated. Specialities position When the tray lever is moved to the specialities position, the hole is closed, so when the tray is closed, the switch is actuated. The status of the control line is: UPTSPESE/LPTSPESE = high 1.
520 Paper 12
TSM 2400 family
Part II ed.6
12func
Specialities via bypass

For specification of specialities please refer to Technical Data. Specialities can be fed manually into the slot on the right side of the machine. When they are inserted soft feed rolls position it against the first paper stop. ABClose to the first paper stop are two sensors: Paper stop present sensor (12SO5) Speciality paper size sensor (12SO6) Both sensors work in combination.
12func19
The paper stop present sensor (12SO5) detects the availability of receiving material at the first paper stop. PASPSE = high 1 means speciality is present. The speciality paper size sensor (12SO6) prevents for copying onto specialities, that are smaller than A4/Letter standaard. SPTPSSE = high 1 means speciality present. The soft feed rolls are driven in standby by the standby motor and the subframe drive. If both sensors are made, the message bypass selected is displayed. If only one sensor is made, the message material too small or incorrectly positioned : check bypass is displayed. If the speciality paper size sensor (12SO6) is activated always the framing is set to standard sizes A4 or Letter Standard (11"8,5"). This setting depends on the selection in SDS test 93 paper sizes : EUROPE/USA.
ed.6 Part II
TSM 2400 family
12 Paper 521
12func
13
Operation
During power up / initialisation: The paper tray available sensor (12S2/12S3) of UPT/LPT is checked. When UPTAVSE/LPTAVSE is high 1 the lift table is driven up to working position. The working position is reached when the lift level sensor is interrupted. Control line UPLLSE/LPTLLSE is high 1. During standby: On operator request the paper trays can be opened. The soft feed rollers in front of the paper stop are turning, driven by the subframe standby drive. During run: On operator request a not used paper tray can be opened. UPT selected: - 66 (master) pulses* after the exposure flash the UPT separation clutch (12CL2) is energised, UPTSEPCL goes high 1. At the same time the UPT separation motor is started, UPTSEPMOS goes high 1. - 56 pulses later ( 122 pulses after exposure flash) the UPT separation clutch (12CL2) is deenergised again, UPTSEPCL goes low 0. - 57 pulses later ( 181 pulses after exposure flash) the UPT separation motor is stopped, UPTSEPMOS goes low 0. - 216 pulses after the exposure flash the presence of paper at the paper stop is checked, PASPSE should be high 1. - 1 pulse later the first paper stop is opened by energising the first paper stop solenoid (12EM1), FPSSO goes high 1. - 308 pulses after the exposure flash the paper should have released the paper stop presence sensor, PASPSE is low 0.
* Oc 2375,2400,2465 CRU and 2465 FIN Oc 2475 :
: 1 master pulse = 6 ms 1 master pulse = 5 ms.
522 Paper 12
TSM 2400 family
Part II ed.6
12func
LPT selected: - 48 (master) pulses* before the exposure flash the LPT separation clutch (12CL3) is energised, LPTSEPCL goes high 1. At the same time the LPT separation motor is started, LPTSEPMOS goes high 1. - 56 pulses later ( 8 pulses after exposure flash) the LPT separation clutch (12CL3) is de-energised again, LPTSEPCL goes low 0. - 59 pulses later ( 67 pulses after exposure flash) the LPT separation motor is stopped, LPTSEPMOS goes low 0. - 216 pulses after the exposure flash the presence of paper at the paper stop is checked, PASPSE should be high 1. - 1 pulse later the first paper stop is opened by energising the first paper stop solenoid (12EM1), FPSSO goes high 1. - 308 pulses after the exposure flash the paper should have released the paper stop presence sensor, PASPSE is low 0.
* Oc 2375,2400,2465 CRU and 2465 FIN Oc 2475 :
: 1 master pulse = 6 ms 1 master pulse = 5 ms.
After every fifth separation action the control sends a signal to start the lift motor, but only between separations. When the tray is at working position, UPTLLSE/LPTLLSE = high 1, nothing happens. However when the tray is not at working position, UPTLLSE/LPTLLSE = 0, the lift will drive up until UPLSE/LPTLLSE goes high 1 again.
ed.6 Part II
TSM 2400 family
12 Paper 523
12func
This page intentionnally left blank
524 Paper 12
TSM 2400 family
Part II ed.6
12comp
COMPONENT LOCATION
COMPONENT LOCATION
12C2 12CL3 12CN3 12CN4 12CN6 12M2 12R1 12R2 12S2 12S3 12SO1 12SO2 : : : : : : : : : : : : capacitor lower paper tray separation motor lower paper tray separation clutch connector upper paper tray lift level resistor connector lower paper tray lift level resistor connector lower paper tray separation clutch lower paper tray lift motor upper paper tray lift level resistor lower paper tray lift level resistor upper paper tray available sensor lower paper tray available sensor upper paper tray paper size sensor lower paper tray paper size sensor
12comp01
ed.6 Part II
TSM 2400 family
12 Paper 601
COMPONENT LOCATION
12comp
12C1 12CL2 12CN1 12CN2 12CN5 12EM1 12M1
: : : : : : :
capacitor upper paper tray separation motor upper paper tray separation clutch connector upper paper tray separation motor connector lower paper tray separation motor connector upper paper tray separation clutch first paper stop solenoid upper paper tray lift motor
12comp02
12comp06
602 Paper 12
TSM 2400 family
Part II ed.6
12comp
COMPONENT LOCATION
COMPONENT LOCATION WITH BLUE ANGEL

12C1 12CL2 12EM1 12M1 23M5 : : : : : capacitor upper paper tray separation motor upper paper tray separation clutch first paper stop solenoid upper paper tray lift motor Bypass motor
12comp06.eps
ed.6 Part II
TSM 2400 family
12 Paper 603
COMPONENT LOCATION
12comp
12CN7 12CN8 12CN9 12CN10 12LED1 12LED2 12M3 12M4 12S1 12S4 12S5 12S6 12S7 12SO3 12SO4
: : : : : : : : : : : : : : :
connector upper paper tray lift level sensor connector lower paper tray lift level sensor connector upper tray add paper LED connector lower tray add paper LED upper paper tray add paper LED lower paper tray add paper LED upper paper tray separation motor lower paper tray separation motor paperpath door sensor upper paper tray add paper sensor lower paper tray add paper sensor upper paper tray speciality sensor lower paper tray speciality sensor upper paper tray lift level sensor lower paper tray lift level sensor
12comp03
604 Paper 12
TSM 2400 family
Part II ed.6
12comp
COMPONENT LOCATION
12S8
: enable add paper sensor
12comp04
12SO5 12SO6
: paper stop present sensor : speciality paper size sensor
12comp05
ed.6 Part II
TSM 2400 family
12 Paper 605
COMPONENT LOCATION
12comp
606 Paper 12
TSM 2400 family
Part II ed.6
12elec
ELECTRICAL DIAGRAM
ELECTRICAL DIAGRAM 1 Signal names upper paper tray

UPTPSSE UPTLLSE UPTAVSE UPTADPSE UPTSPESE UPTLLRE UPTADPLE UPTLMO UPTLMODIR UPTSEPCL UPTSEPMOS UPTSEPMOPO
Upper Paper Tray Paper Size SEnsor Upper Paper Tray LeveL SEnsor Upper Paper Tray AVailable SEnsor Upper Paper Tray ADd Paper SEnsor Upper Paper Tray SPEciality SEnsor Upper Paper Tray LeveL REsistor Upper Paper Tray ADd Paper LEd Upper Paper Tray Lift MOtor Upper Paper Tray Lift MOtor DIRection Upper Paper Tray SEParation CLutch Upper Paper Tray SEParation MOtor Separation Upper Paper Tray SEParation MOtor Pinch Open
ed.6 Part I
TSM 2400 family
12 Paper 701
ELECTRICAL DIAGRAM
12elec
702 Paper 12
TSM 2400 family
Part I ed.6
12elec
ELECTRICAL DIAGRAM
Signal names lower paper tray

LPTPSSE LPTLLSE LPTAVSE LPTADPSE LPTSPESE LPTLLRE LPTADPLE LPTLMO LPTLMODIR LPTSEPCL LPTSEPMOS LPTSEPMOPO Lower Paper Tray Paper Size SEnsor Lower Paper Tray LeveL SEnsor Lower Paper Tray AVailable SEnsor Lower Paper Tray ADd Paper SEnsor Lower Paper Tray SPEciality SEnsor Lower Paper Tray LeveL REsistor Lower Paper Tray ADd Paper LEd Lower Paper Tray Lift MOtor Lower Paper Tray Lift MOtor DIRection Lower Paper Tray SEParation CLutch Lower Paper Tray SEParation MOtor Separation Lower Paper Tray SEParation MOtor Pinch Open
ed.6 Part I
TSM 2400 family
12 Paper 703
ELECTRICAL DIAGRAM
12elec
704 Paper 12
TSM 2400 family
Part I ed.6
12elec
ELECTRICAL DIAGRAM
Signal names
PASPSE SPTPSSE PAPDSE FPSSO ENADPSE PAper Stop Present SEnsor SPeciality Paper Size SEnsor PAper Path Door SEnsor First Paper Stop SOlenoid ENable ADd Paper SEnsor
ed.6 Part I
TSM 2400 family
12 Paper 705
ELECTRICAL DIAGRAM
12elec
706 Paper 12
TSM 2400 family
Part I ed.6
Electrical Diagram
12 PAPER 701
Electrical Diagram
12 PAPER 702
Electrical Diagram
12 PAPER 703
15diag
DIAGNOSTIC
1510 1511 1512 1513 1514 1515 1516 1517 1518 1519 1520 1521 warming up 15HE1 (P1) more than 30 min warming up 15HE3 (P2a)more than 30 min warming up 15HE4 (P2b)more than 30 min 15NTC1 15HE1 (P1) short circuit 15NTC2 15HE3 (P2a) short circuit 15NTC3 15HE4 (P2b) short circuit 15NTC1 15HE1 (P1) open circuit 15NTC2 15HE3 (P2a) open circuit 15NTC3 15HE4 (P2b) open circuit 15HE1 (P1) temperature too high 15HE3 (P2a) temperature too high 15HE4 (P2b) temperature too high
MRE
1525 1526 1527 1528 1529 1530 1531 1532 1533 15HE1 (P1) temperature too low 15HE3 (P2a) temperature too low 15HE4 (P2b) temperature too low 15NTC1 15HE1 (P1) short circuit 15NTC2 15HE3 (P2a) short circuit 15NTC3 15HE4 (P2b) short circuit 15NTC1 15HE1 (P1) open circuit 15NTC2 15HE3 (P2a) open circuit 15NTC3 15HE4 (P2b) open circuit
ed.6 Part I
TSM 2400 family
15 Preheater 101
DIAGNOSTIC
15diag
Fault table
CODES M1525 POSSIBLE FAILURES - clixon 15S1 or S2 activated - pre-heater 15HE1/15HE2 defective - temperature too high because of wrong value 15NTC1 - triac on 22PBA07 defective - clixon 15S3 or 15S4 activated - Pre-heater 15HE3 defective 11"-size - temperature too high because of wrong value 15NTC2 - triac on 22PBA06 defective - clixon 15S3 or 15S4 activated - Pre-heater 15HE4 defective 14"-size - temperature too high because of wrong value 15NTC3 - triac on 22PBA06 defective - clixon 15S1 or 15S2 activated - pre-heater 15HE1/15HE2 defective - temperature too high because of wrong value 15NTC1 - triac on 22 PBA07 defective - clixon 15S3 or 15S4 activated - Pre-heater 15HE3 defective 11"-size - temperature too high because of wrong value 15NTC2 - triac on 22PBA06 defective - clixon 15S3 or 15S4 activated - Pre-heater 15HE4 defective 14"-size - temperature too high because of wrong value 15NTC3 - triac on 22PBA06 defective
M1526
M1527
P1510
P1511
P1512
M1528, P1513 - 15NTC1 short circuit M1529, P1514 - 15NTC2 short circuit M1530, P1515 - 15NTC3 short circuit M1531, P1516 - 15NTC1 broken or not connected M1532, P1517 - 15NTC2 broken or not connected M1533, P1518 - 15NTC3 broken or not connected Fault table continue : next page.
102 Preheater 15
TSM 2400 family
Part I ed.6
15diag
DIAGNOSTIC
CODES P1519
POSSIBLE FAILURES - value 15NTC1 wrong - clixon 15S1 or 15S2 defective or not touching pre-heater - 22PBA07 defective - value 15NTC2 wrong - clixon 15S3 or 15S4 defective or not touching pre-heater - 22PBA07 defective - value 15NTC3 wrong - clixon 15S3 or 15S4 defective or not touching pre-heater - 22PBA07 defective
P1520
P1521
ed.6 Part I
TSM 2400 family
15 Preheater 103
DIAGNOSTIC
15diag
Protections PE 1510 MRE 1525 MRE 1528 PE 1513 MRE 1531 PE 1516 PE 1519
15NTC1 is checked 1x/1.28sec during initialisation, standby and run. The analogue value of the NTC is converted to a binary value (by an analogue digital converter ADC) and fed to the microprocessor. Interpretation of this binary value can result in a number of error messages. The first preheater has only one NTC which controls both heaters (15HE1, 15HE2). - Warm up time is longer than 30min. Setpoint is not reached : PE 1510 - Temperature is to low (lower than 40C): MRE 1525 - ADC value is 254 or 255 (short circuit): MRE 1528 PE 1513 - ADC value is 0 or 1 (open circuit NTC): MRE 1531 PE 1516 - Temperature is to high ( higher than 90C): PE 1519
PE 1511 MRE 1526 MRE 1529 PE 1514 MRE 1532 PE 1517 PE 1520
15NTC2 is checked 1x/1.28sec during initialisation, standby and run. The analogue value of the NTC is converted to a binary value (by an analogue digital converter ADC) and fed to the microprocessor. Interpretation of this binary value can result in a number of error messages. The second preheater has two NTCs. 15NTC2 controls the large heater plate (15HE3). - Warm up time is longer than 30min. Setpoint is not reached. PE 1511 - Temperature is to low (lower than 90C): MRE 1526 - ADC value is 254 or 255 (short circuit): MRE 1529 PE 1514 - ADC value is 0 or 1 (open circuit NTC): MRE 1532 PE 1517 - Temperature is to high ( higher than 120C): PE 1520
104 Preheater 15
TSM 2400 family
Part I ed.6
15diag
DIAGNOSTIC
PE 1512 MRE 1527 MRE 1530 PE 1515 MRE 1533 PE 1518 PE 1521
15NTC3 is checked 1x/1.28sec during initialisation, standby and run. The analogue value of the NTC is converted to a binary value (by an analogue digital converter ADC) and fed to the microprocessor. Interpretation of this binary value can result in a number of error messages. The second preheater has two NTCs. 15NTC3 controls the small heater plate (15HE4). - Warm up time is longer than 30min. Setpoint is not reached. PE 1512 - Temperature is to low (lower than 90C): MRE 1527 - ADC value is 254 or 255 (short circuit): MRE 1530 PE 1515 - ADC value is 0 or 1 (open circuit NTC): MRE 1533 PE 1518 - Temperature is to high ( higher than 120C): PE 1521
Clixon 15S1
First preheater front, switching temperature 150C.
Clixon 15S2
First preheater rear, switching temperature 150C.
Clixon 15S3
Second preheater front, switching temperature 150C.
Clixon 15S4
Second preheater rear, switching temperature 150C.
ed.6 Part I
TSM 2400 family
15 Preheater 105
DIAGNOSTIC
15diag
106 Preheater 15
TSM 2400 family
Part I ed.6
15sds
SDS

SIGNAL -015HE1/2 15HE3 15HE4 15NTC1 15NTC2 15NTC3 15NTC1 15NTC2 15NTC3 15HE1/2 15HE3 15HE4 15HE1/2 15HE3 15HE4 15NTC1 15NTC2 15NTC3 15NTC1 15NTC2 15NTC3 FPHRHEFR/RR warming up P1 more than 30 min warming up P2a more than 30 min SPHRHEFR warming up P2b more than 30 min SPHRHERR P1 15NTC1 short circuit P2a 15NTC2 short circuit FPHRNTC P2b 15NTC3 short circuit SPHRNTCFR P1 15NTC1 open circuit SPHRNTCRR P2a 15NTC2 open circuit FPHRNTC P2b 15NTC3 open circuit SPHRNTCFR P1 temperature too high SPHRNTCRR FPHRHEFR/RR P2a temperature too high P2b temperature too high SPHRHEFR P1 temperature too low SPHRHERR FPHRHEFR/RR P2a temperature too low P2b temperature too low SPHRHEFR P1 15NTC1 short circuit SPHRHERR P2a 15NTC2 short circuit FPHRNTC P2b 15NTC3 short circuit SPHRNTCFR P1 15NTC1 open circuit SPHRNTCRR P2a 15NTC2 open circuit FPHRNTC P2b 15NTC3 open circuit SPHRNTCFR SPHRNTCRR -1DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 15 0 10 PE 15 0 11 PE 15 0 12 PE 15 0 13 PE 15 0 14 PE 15 0 15 PE 15 0 16 PE 15 0 17 PE 15 0 18 PE 15 0 19 PE 15 0 20 PE 15 0 21 PE 15 0 25 MRE 15 0 26 MRE 15 0 27 MRE 15 0 28 MRE 15 0 29 MRE 15 0 30 MRE 15 0 31 MRE 15 0 32 MRE 15 0 33 MRE
PARAMETERS
ed.6 Part I
TSM 2400 family
15 Preheater 201
SDS
15sds
INPUT TESTS 15 2 01 15S5
-2FPHRDOSE First PreHeater DOor SEnsor 15S5
OUTPUT TESTS SPECIAL TESTS 15 6 01 15 6 02 15 6 03 15 6 04 15 6 05 15 6 06 15 6 07
-4-6make function WARM make function COLD mask function protections Note 1 Note 2 Note 3 Note 4
15HE1/2,3,4 15NTC1 15NTC2 15NTC3
FPHRNTC SPHRNTCFR SPHRNTCRR
Note 1: Read out temperature preheater. By pressing <PRINT> the measured NTC values (binary) of the first and second preheater plates are displayed. Setpoints of preheater plates: First preheater (15NTC1): 86 (corresponds with 50C) (Oc 2375,2400.2465 CRU and 2465 FIN) First preheater (15NTC1): 150 (corresponds with 70C) (Oc 2475) Second preheater front (15NTC2): 110 (corresponds with 100C) (Oc 2375,2400.2465 CRU and 2465 FIN) Second preheater front (15NTC2): 123 (corresponds with 105C) (Oc 2475) Second preheater rear (15NTC3): 110 (corresponds with 100C)(Oc 2375,2400.2465 CRU and 2465 FIN) Second preheater rear (15NTC3): 123 (corresponds with 105C)(Oc 2475) Note 2: P1 temperature control test. By pressing <PRINT> the preheater plate is switched on continuously until the maximum temperature is reached. Next the preheater plate is switched off. During the test the NTC value (binary) is displayed. Max temperature 221 (corresponds with 90C). Note 3: P2a temperature control test. By presssing <PRINT> the preheater plate is switched on continuously until the maximum temperature is reached. Next the preheater plate is switched off. During the test the NTC value (binary) is displayed. Max temperature 166 (corresponds with 120C) Note 4: P2b temperature control test. By presssing <PRINT> the preheater plate is switched on continuously until the maximum temperature is reached. Next the preheater plate is switched off. During the test the NTC value (binary) is displayed. Max temperature 166 (corresponds with120C)
202 Preheater 15
TSM 2400 family
Part I ed.6
15adju
ADJUSTMENTS
ADJUSTMENTS 1 Stops second preheater plate (not for Oc 2475 and if MOD 40 and 41 are implemented) Aim:
To guarantee a minimum gap of 1 mm for the paper to pass through the second preheater
Check:
Remove the cover in front of the first preheater Open the paper path using the green handle Place 9 sheets of paper 80g/m2 (20 lb) on the first preheater plate -DSlide the 9 sheets underneath guide plate -CClose the paper path Check that the first and second preheater plates are touching over the entire length: X = 0 mm Check if there is a gap between plate -C- and stops -A- of at least 0.1 mm (use a piece of paper as a gauge)
15adj01a
Correction:
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Remove the duplex unit; Loosen bolts -EPush plate -C- completely down ; Tighten bolts -E-; Loosen nuts -F- front and rear; Place 10 sheets 80g/m2 (20 lb) of paper between plates -B- and -C-; Push the two plates -B- and -C- together with the 10 sheets in between; Turn the stops -A- front and rear against plate -C-; Tighten lock nuts -F-; NOTE: If, after installation of the duplex unit, measure X > 0 mm then raise plate C- until plates -B- and -D- touch: X = 0 mm
15adj01b
ed.6 Part I
TSM 2400 family
15 Preheater 301
ADJUSTMENTS
15adju
302 Preheater 15
TSM 2400 family
Part I ed.6
15disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15
First preheating plate

Remove the TTF unit. Remove finisher receiving tray(s). Remove the funnel. Remove the duplex unit. Open the first pre heater/paper path. Loosen connectors -A- (15CN1 - front) and -B- (15CN2 - rear). Loosen 3 bolts -F- at front and rear. Move plate -E- to the right. Loosen bolt -C- and slide it to the right. Lift plate -D- at the front side and pull it to the front. Also lift plate -D- at the rear and turn the rear to the left. Remove plate -D-. Mount all parts in reversed order. Move plate -E- the the left against preheating plate -D-. Tighten bolts -F-.
15disa01
ed.6 Part II
TSM 2400 family
15 Preheater 401
DIS/ASSEMBLY
15disa
First preheating mat Disassembly (not for Oc 2475 and not if MOD 35 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN):
2.1 2.2 2.3 2.4 2.5 2.6
Remove the TTF-unit. Remove finisher receiving tray(s). Remove the funnel. Remove the duplex-unit. Loosen bolt -A-, open the paper path and loosen bolt -B-. Close the paper path: the mat unit will drop and bracket -C- will disappear behind the frame plate.
Disassembly : (for Oc 2475 and if MOD 35 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN) :
2.1 2.2 2.3 2.4 2.5 2.6 Remove the TTF-unit. Remove the finisher receiving trays. Remove the funnel. Remove the duplex-unit. Loosen bolt -A-. Open the paper path, while firmly holding bracket -C- in position, so that it will slide out of the slot. Note: the spring tension of bracket -C- is high. 2.7 2.8 2.9 2.10 2.11 Release bracket -C- slowly. Close the paper path. Loosen bolt -B-. Push the preheating mat slightly to the right and open the paper path slightly. Pull preheating mat to the left and remove it.
402 Preheater 15
TSM 2400 family
Part II ed.6
15disa
DIS/ASSEMBLY
Assembly: (not for Oc 2475 and not if MOD 35 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN)
2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 Put the paper path handle in position open. Put the mat unit on the heater plate. Put the paper path handle carefully in the position closed. Hook in pins -D- (2x, front and rear). Pull the mat unit to the left Secure pins -D- with bolt -B-. Put the handle in position open. Pull bracket -C- downwards. Hook in pins -E- (2x, front and rear). Pull the mat unit left by means of roller -F-. Secure pins -E- with bolt -A-.
Assembly : (for Oc 2475 and if MOD 35 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN)
2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 Put the paper path handle in position open. Put the mat unit on the heater plate. Put the paper path handle carefully in the position closed. Hook in pins -D- (2x, front and rear). Pull the mat unit to the left to slide the unit into the slot. Secure pins -D- with bolt -B-. Put the handle in position open. Pull bracket -C- downwards. Hook in pins -E- (2x, front and rear) into the bracket -C-. Close the preheater/paper path. Secure pins -E- with bolt -A-.
ed.6 Part II
TSM 2400 family
15 Preheater 403
DIS/ASSEMBLY
15disa
3
3.1 3.2 3.3 3.4 3.5 3.6
Second preheating plate ( not for Oc 2475 and not if MOD 40 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN)
Remove the duplex unit out of the copier. Loosen the power wires underneath the preheating plate. Remove plate -A-. Loosen earth tab -B-. Remove bolts of the locking plates -C-(front and rear). Unhook the locking springs -E- of roller -F- (front and rear). NOTE: Do not interchange the two locking springs (until MOD 26).
3.7 3.8 3.9 3.10 3.11 3.12 3.13
Remove roller -F-. Mark the NTC-wires -G- e.g. with the pin numbers of connector 15CN3. Extract the NTC-wires from the connector. Cut the cable tie that fixes the NTC wires to the frame of the preheating plate. Remove heater plate -D-. Mount all parts in reversed order; Check adjustment 15-1.
15disa03
404 Preheater 15
TSM 2400 family
Part II ed.6
15disa
DIS/ASSEMBLY
4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10
Second preheating plate (for Oc 2475 and if MOD 40 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN)
Remove the duplex unit out of the copier. Loosen the power wires underneath the preheating plate. Loosen earth tab -B-. Remove bolts of the locking plates -C- (front and rear). Unhook the locking springs -E- of roller -F- (front and rear). Remove roller -F-. Extract the NTC-wires from the connector 15CN3. Cut the cable tie that fixes the NTC wires to the frame of the preheating plate. Remove heater plate -D-. Mount all parts in reversed order. NOTE : Check that the numbering of the wires matches with connector 15CN3.
4.11 Check if the preheating plate rests on the circular part of the bearing housing on both sides. (see detail). 4.12 Check if the two inner transport rollers just protude the preheating plate, -X- = 0.2 + 0.2/- 0 mm.
ed.6 Part II
TSM 2400 family
15 Preheater 405
DIS/ASSEMBLY
15disa
Second preheating mat (not for Oc 2475 and not if MOD 40 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN) Disassembly:
4.1 4.2 4.3 4.4
Remove the unit out of the copier. Release timing belt -A- with bolt -B-. Remove gear -C-. Turn the unit upside down.
4.5
Remove 4 bolts -D- from the guide plates -E- and -F-. 4.6 Remove bolt -G- of the earth spring of roller -H-. 4.7 Remove locking bracket -I-. 4.8 Slide roller -H- forward. 4.9 Remove bottom guide plate -F-. 4.10 Remove roller -H- through the hole in the frame plate. 4.11 Remove screws -J- of the upper guide plate -E-. 4.12 Remove guide plate -E- with mat -K-.
15disa04
15disa05
406 Preheater 15
TSM 2400 family
Part II ed.6
15disa
DIS/ASSEMBLY
Assembly:
4.13 Mount all parts in reversed order: - make sure that roller -L- is properly locked by the two leaf springs on top of plate -E- (remove plate -M- to check) - slide guide plate -F- in the up position and tighten it - reinstall the unit again; 4.14 Check adjustment 15-1.
ed.6 Part II
TSM 2400 family
15 Preheater 407
DIS/ASSEMBLY
15disa
Second preheat mat (for Oc 2475 and if MOD 40 is implemented for Oc 2375,2400,2465 CRU and 2465 FIN) Disassembly :
5.1 5.2 5.3 5.4 5.5 5.6
Shift circlip -A- to the rear. Shift paper feed wheel -B- to the rear and remove rod -C-. Fold back the paper feed wheels. Remove bolts -D-. Shift and lift the preheating plate with mat to the rear and remove it. Mount all parts in reversed order.
408 Preheater 15
TSM 2400 family
Part II ed.6
15func
FUNCTIONAL DESCRIPTION 1 Preheat section

The function of the preheat section is: to raise the temperature of the receiving material to enable a correct transfuse. transport the receiving material from the first paper stop to the transfuse pinch. The preheat section consists of: -A-BFirst preheater; Second preheater.
15func01
The first preheater is located in the subframe, while the second preheater is in the mainframe. The main reason for having 2 preheaters is: mainframe and subframe can be separated, what divides the preheat section in 2 parts Additional reasons are: the temperature rise of the paper can be controlled in steps. the temperature of a simplex copy which is returned to receive the duplex image passes only the second preheater.
ed.6 Part II
TSM 2400 family
15 Preheater 501
15func
First preheater
The first preheater consists of :
-C-D-E-F-G-
Preheater plate with heaterelements and NTC; Clixons; Silicon rubber mat unit; Silicon rubber mat; 2 Pairs hard pinched transport rollers;
15func02
There are two heating elements. The larger (15HE1) at the front is rated at 895W and the smaller (15HE2) at the rear at 180W. The large element provides heat for A4/11" size paper. The small element provides extra heat when larger paper sizes are used. Only paper coming from the paper tray or speciality bypass go through the first preheater.
502 Preheater 15
TSM 2400 family
Part II ed.6
15func
-A-B-C-
The elements heat an aluminium plate. The surface of the aluminium plate is provided with teflon to form a smooth surface. A silicon rubber mat provided with extra weight rests on top of the heater plate, ensuring that the paper is in full contact with the heated surface. This gives an efficient heat transfer. The first preheater raises the temperature of the paper to about 50C. The heating elements consist of : NTC; Heating element front; Heating element rear.
Circuit diagram description : (see 701) The supply to each heater is controlled by a signal from the HOST I/O (22PBA02). HEATER 15HE1 15HE2 POWER 895W 180W SIGNAL FPHRHEFR FPHRHERR LED LED1 LED2 NAME First preheater front First preheater rear
During standby both heater elements are switched on. If A4 or 11" paper is used the rear heating element will be switched off during a run. If the paper format is equal or larger than 330 mm the rear element stays on. When the control line is high 1 an SSR on SSR2 (22PBA07) is switched and the heater is powered by 220VAC. The corresponding LED on SSR2 (22PBA07) is lit. Each element is protected by its own clixon (front = 15S1, rear = 15S2). If necessary, these can be reset via the upper paper tray area. In the first preheater, the temperature is measured by a single NTC (15NTC1). The output from this NTC, signal FPHRNTC, is used to control both heaters. Every 1.28s a temperature check is done. The temperature set point is 50C (Oc 2375,2400.2465 CRU and 2465 FIN), for the Oc 2475 the set point is 70C. The output of the NTC is fed to an ADC (analog/digital converter) on the HOST I/O PBA. For additional information refer to chapter 22 CONTROL.
ed.6 Part II
TSM 2400 family
15 Preheater 503
15func
Second preheater
The second preheater consists of :
-J-K-L-M-N-
Preheater plate with heater elements and NTCs; Clixons; Two pairs of hard pinched rollers; Silicon rubber mat; Paper path opening mechanism.
15func04
It also has two heater elements. The larger (15HE3) at the front is rated at 843W and the smaller (15HE4) at the rear at 157W. The heating elements in the second preheater are controlled independently by their own NTC. The elements heat an aluminium plate. The surface of the aluminium plate has been provided with teflon to make the surface smooth. A silicon rubber mat with extra weight rests on top of the heater plate, ensuring that the paper is in full contact with the heated surface. This gives an efficient heat transfer. The second preheater raises the temperature of the paper to about 105C. All receiving material, for single sided or double sided copies, pass through the second preheater. Copies leave the transfuse pinch at a temperature of approximately 118C. When a single sided copy is turned and refed to the duplex paper stop, it will have cooled, so the additional heat provided by the second preheater is necessary to receive the side-2 image.
504 Preheater 15
TSM 2400 family
Part II ed.6
15func
The heating element consists of : -A-B-CHeating element front; Heating element rear; NTCs.
15func05
Circuit diagram description : (see 701) The supply to each heater is controlled by a signal from the HOST I/O (22PBA02). HEATER POWER SIGNAL LED NAME
15HE3 843W SPHRHEFR LED5 Second preheater front 15HE4 157W SPHRHERR LED6 Second preheater rear When the control line is high 1 an SSR on SSR1 (22PBA06) is switched and the heater is powered by 220VAC. The corresponding LED on SSR1 (22PBA06) is lit. Each element is protected by its own clixon (front = 15S3, rear = 15S4). In the second preheater, each heating element has its own temperature control : The plate temperature is measured by 2 NTCs. 15NTC2 (signal SPHRNTCFR) controls the temperature of 15HE3, 15NTC3 (signal SPHRNTCRR) controls the temperature of 15HE4. During standby both heater elements are separately controlled. If A4 or 11" paper is used the rear heater element will be switched off during a run. If the paper format is equal or larger than 330 mm the rear element stays on. Every 1.28s a temperature check is done. The temperature set point is 100C, (Oc 2375,2400.2465 CRU and 2465 FIN), for the Oc 2475 the set point is 105C. The outputs of the NTCs are fed to an ADC on the HOST I/O. For additional information refer to chapter 22 CONTROL.
ed.6 Part II
TSM 2400 family
15 Preheater 505
15func
Paper path release mechanism

Moving the lever in the direction indicated on the sticker: lifts the first preheater silicon mat lowers the second preheater plate raises the top guide of the duplex paper path This allows sufficient access to the paper path of the first preheater, second preheater and the duplex turn station. The next figures show the paper path in its closed position and opened position.
15func06
15func07
506 Preheater 15
TSM 2400 family
Part II ed.6
15func
Access to the the first preheater and the duplex turn station is possible for any user. The second preheater is protected by a plastic cover because of the high temperature. WARNING: The first preheater area is WARM (50C - 70C). The second preheater area is HOT (100C - 105C).
ed.6 Part II
TSM 2400 family
15 Preheater 507
15func
Operation
During power up / initialisation: The temperature sensors 15NTC1, 15NTC2 and 15NTC3 are checked on open circuit and short circuit. If correct the heating of the preheat section is started. The first preheater elements (15HE1, 15HE2) are switched on and off together. The setpoint is 50C (2375,2400.2465 CRU and 2465 FIN), 70C (2475). The second preheater elements (15HE3, 15HE4) are switched on and off independently until the setpoint is reached (100C) (2375,2400.2465 CRU and 2465 FIN), 105C (2475). During warming up the heaters (15HE1-4) only operate at 40% of their maximum power, because the warming up time is determined by the TTF section. Every 1.28 sec the temperature is checked. Warming up is ended when the setpoint is reached. During standby: Every 1.28 sec a temperature/protection check is done. The first preheater elements (15HE1, 15HE2) are switched on and off together. The temperature is kept at about 50C (2375,2400.2465 CRU and 2465 FIN), 70C (2475). The second preheater elements (15HE3, 15HE4) are switched on and off independently. The temperature is kept at about 100C (2375,2400.2465 CRU and 2465 FIN), 105C (2475). During run: Every 1.28 sec a temperature/protection check is done. The first preheater element front (15HE1) is switched on and off. The first preheater element rear (15HE2) is only switched on and off if the paper size is equal or larger then 330mm. The temperature of the heater plate is kept at 50C (2375,2400.2465 CRU and 2465 FIN), 70C (2475). The second preheater elements (15HE3, 15HE4) are both switched on and off independently. The temperature is kept at 100C (2375,2400.2465 CRU and 2465 FIN), 105C (2475).
508 Preheater 15
TSM 2400 family
Part II ed.6
15comp
COMPONENT LOCATION
COMPONENT LOCATION 1 First preheater

15CN1 15CN2 15NTC1 15HE1 15HE2 15S1 15S2 : : : : : : : connector 15NTC1 connector 220 V supply heating elements NTC, temperature control pre heater plate heater element front heater element rear clixon rear heater element clixon front heater element
15comp01
15comp03
ed.6 Part II
TSM 2400 family
15 Preheater 601
COMPONENT LOCATION
15comp
Second preheater
15CN3 15HE3 15HE4 15S3 15S4 15S5 : : : : : : connector second pre heater NTCs rear and front heater element front heater element rear clixon heater element front clixon heater element rear first pre heater door sensor
15comp04
15comp05
602 Preheater 15
TSM 2400 family
Part II ed.6
15comp
COMPONENT LOCATION
22CN5 15NTC2 15NTC3
: connector 220 V supply heating elements : second pre heater NTC front : second pre heater NTC rear
15comp06
15comp02
ed.6 Part II
TSM 2400 family
15 Preheater 603
COMPONENT LOCATION
15comp
604 Preheater 15
TSM 2400 family
Part II ed.6
15elec
ELECTRICAL DIAGRAM

FPHRDOSE FPHRNTC FPHRHEFR FPHRHERR SPHRNTCFR SPHRNTCRR SPHRHEFR SPHRHERR First PreHeateR DOor SEnsor First PreHeateR NTC First PreHeateR HEater FRont First PreHeateR HEater ReaR Second PreHeateR NTC FRont Second PreHeateR NTC ReaR Second PreHeateR HEater FRont Second PreHeateR HEater ReaR
ed.6 Part I
TSM 2400 family
15 Preheater 701
ELECTRICAL DIAGRAM
15elec
702 Preheater 15
TSM 2400 family
Part I ed.6
Electrical Diagram
15 PREHEATER 701
16diag
DIAGNOSTIC
DIAGNOSTIC 1 Messages ORE

1650 1651 1652 1653 copy too late at 16SO1 side1 16SO1 too late free 1-2sided 16SO1 too late free turn copy too late at 16SO1 side2
ed.6 Part I
TSM 2400 family
16 Duplex/delivery 101
DIAGNOSTIC
16diag
Fault table
CODES O1650 POSSIBLE FAILURES - belts of funnel defective - transport rollers accelerate pinch wear or polluted - rack not correct positioned or locked - bearings duplex feed defective - pieces of paper or toner on paper path - duplex paper present sensor 16SO1 continue high - funnel not correct positioned - bearings throughput rollers stuck (FUNC 15) - paper or toner on 1st preheater/duplex copies from paper tray - pre-heat unit 1 not correct positioned or flap damaged (FUNC 15) - pre-heat unit 2 not correct positioned or flap damaged (FUNC 15) - spring mechanism 2nd transport pinch defective (FUNC 15) - timing belt pre-heater 2 defective FUNC 15) - bearings shaft assys duplex turnstation defective - rolls on shaft assys duplex turnstation worn - rack not correct positioned or locked - pieces of paper or toner on paper path - clutch 16CL3 defective or not activated - clutch 16CL2 stuck - duplex paper stop solenoid half activated or wrong adjustment - duplex paper stop solenoid continue activated - bearings shaft assys duplex turnstation defective - rolls on shaft assys duplex turnstation worn - clutch 16CL2 defective or not activated - clutch 16CL3 stuck - rack not correct positioned or locked - deflector polluted or bent - duplex paper stop solenoid defective or not activated - pieces of paper or toner on paper path - bearings shaft assys duplex turnstation defective - rolls on shaft assys duplex turnstation worn - transport rollers accelerate pinch wear or polluted - deflector polluted or bent - duplex paper stop solenoid half activated or wrong adjustment - bearings duplex feed defective - funnel not correct positioned - pieces of paper or toner on paper path
O1651
O1652
O1653
TSM 2400 family
Part I ed.6
16diag
DIAGNOSTIC
CODES O1653
POSSIBLE FAILURES - rack not correct positioned or locked - belts of funnel defective - pre-heat unit 2 not correct positioned or flap damaged (FUNC 15) - timing belt pre-heater 2 defective (FUNC 15) - bearings shaft assys duplex turnstation defective - rolls on shaft assys duplex turnstation worn
ed.6 Part I
TSM 2400 family
DIAGNOSTIC
16diag
Protections
16SO1 duplex paper present sensor is used to make synchronous checks on the presence of paper. Synchronisation is done on the master pulses.
ORE 1650
When the receiving material is released at the first paper stop: the leading edge needs a fixed time to reach the sensor. This is checked. In case it arrives too late : ORE 1650
ORE 1651 (simplex / duplex copy)

The time that the duplex sensor is activated by the receiving material, is checked. In case the sensor is released too late : ORE 1651.
ORE 1652 (duplex copy)

The time that the duplex sensor is activated by the receiving material during turning of the receiving material (duplex), is checked. In case it is released too late : ORE 1652
ORE 1653
When the receiving material is released at the duplex paper stop: the leading edge needs a fixed time to reach the sensor. This is checked. In case it arrives too late : ORE 1653
TSM 2400 family
Part I ed.6
16sds
SDS

SIGNAL -016SO1 16SO1 16SO1 16SO1 DUXPPSE DUXPPSE DUXPPSE DUXPPSE -116EM1 DUXPSSO DUplex Paper Stop SOlenoid (def. = 80) copy too late at 16SO1 side1 16SO1 too late free 1-2sided 16SO1 too late free turn copy too late at 16SO1 side2 DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 16 0 50 ORE 16 0 51 ORE 16 0 52 ORE 16 0 53 ORE

PARAMETERS 16 1 01
INPUT TESTS 16 2 01 OUTPUT TESTS 16 4 01 16 4 02 16 4 03 16CL2 16CL3 16EM1 16S01
-2DUXPPSE -4DUXRVCL DUXTPCL DUXPSSO -6mask function protections Note 1 DUpleX ReVerse CLutch DUpleX ThroughPut CLutch DUpleX Paper Stop SOlenoid DUpleX Paper Present SEnsor
SPECIAL TESTS 16 6 03 16 6 04
16CL2/ 16CL3
DUXRVCL/ DUXTPCL
ed.6 Part I
TSM 2400 family
16 Duplex/Delivery 201
SDS
16sds
Note 1: Duplex clutch function test. By pressing <PRINT> the function photoconductor is made warm (initialized). The message start is displayed. When the initialisation is ready the message active is displayed. By using the copy darker/lighter buttons the turn direction of the rollers in the duplex turn station can be selected (throughput/reverse).
TSM 2400 family
Part I ed.6
16adju
ADJUSTMENTS
ADJUSTMENTS 1 Paper skew / duplex paper stop Aim:

To correct paper skew with respect to the image on the duplex side of the copy.
S1
Check:

Put testchart 19 on the original glass. Put machine in SDS Make 20 copies, 100% / simplex-duplex / sort / no margin shift / upper paper tray. 2 Measure S1 and S2 on the duplex side of the copy. Calculate the average value (S1 tot - S2 tot ) /20 =0 +/- 1 mm
S2
Correction:
1.1 1.2 Remove the center front cover; S1 > S2 + 1 mm : Turn screw -B- and move stopper -A- as many mm to the left as the difference between S1 and S2. S1 < S2 - 1 mm : Turn screw -B- and move stopper -A- as many mm to the right as the difference between S1 and S2.
16adj01b
ed.6 Part I
TSM 2400 family
ADJUSTMENTS
16adju
Duplex paper stop lifting height Aim:

To achieve a correct stroke of the solenoid and duplex paper stop mechanism.
Check:
Manually activate the solenoid. The paper stop fingers should just protrude plate -E-
Correction:
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 Remove the pre heating2/duplex unit from the machine. Loosen nut and allen screw of feed wheels ( refer to adj. 16-3) Pull core -A- of solenoid -B- in, stopper -C- is lifted; Loosen bolts -D- (4x). Move solenoid -B- in such a way, that stopper -C- is just above plate -E-. Tighten bolts -D- (4x). Put a special tool (codenr. 7991.193) between solenoid -B- and core -A-. Pull core -A- of solenoid -B- in. Loosen nut -H-. Adjust stop -F-in such a way that it just touches bracket -G-. Tighten nut -H-. Carry out adjustment 16-3.
16adj02a
TSM 2400 family
Part I ed.6
16adju
ADJUSTMENTS
Feed wheels duplex stopper Aim:

To achieve a correct functioning of the duplex feed.
Check:
The distance underneath allen screw -B- should be 0.6 0.1 mm.
Correction:
3.1 3.2 3.3 3.4
3.5
3.6
3.7
Check adjustment 16-2; Remove the preheating2/duplex unit from the machine; Loosen nut -A- ; Place a feeler gauge of 0.6 mm underneath allen screw -B-; Loosen allen screw -B- so far that you dont feel any resistance on the feeler gauge; Tighten allen screw -B- so that there is a minimal resistance when moving the feeler gauge; Tighten nut -A- while holding allen screw -B- in place;
16adj03a
ed.6 Part I
TSM 2400 family
ADJUSTMENTS
16adju
Duplex sensor (16SO1) Aim:

To achieve a correct detection of paper in the duplex path.
Check:
Activate test 16 2 01. Open the right front door. Remove the safety cover of the preheat section; Open the paper path with the green handle. Put a sheet of paper of 65 g/m2 (16 lb),underneath the sensor. Close the paper path. Check if the sensor is activated. Open the paper path. Remove the paper. Put a steel ruler of 1 mm (10 sheets of 80 gr/m2, 20 lb) thickness underneath the sensor. Close the paper path. Check if the sensor vane has a vertical play of 1mm.
Correction:
4.1 4.2 4.3 4.4 4.5 Remove the copy receiving tray. Loosen screws -A- (2x) a quarter of a turn; Adjust the sensor. Place bracket -B- visually horizontaly. Tighten screws -A- (2x). NOTE : Make sure that two star washers are mounted between the sensor and the metal bracket.
16adj04a
TSM 2400 family
Part I ed.6
16adju
ADJUSTMENTS
Timing duplex paper stopper (parameter test 16 1 01) Aim:

To achieve a correct starting moment of the paper.
Check:
Put test chart 19 on the original glass platen. Make 10 copies, 100% / simplex-duplex / sort / no margin shift / upper paper tray. Measure A and B on the duplex side of the copy, and calculate the average value, (A tot - B tot ) /10 = Y If Y = 0 +/- 2 mm : no correction;
Correction:
5.1
Select test 16 1 01 (1 step corresponds with 0.1 mm). - If Y = positive: increase the actual value - If Y = negative:
2 1 0 -1 -2 -3 -4 -5 -6
-6 -5 -4 -3 -2 -1 0
16adj05a
decrease the actual value The maximum deviation A - B must not be larger than +/- 4 mm with respect to Y: If incorrect: check funnel, duplexrack en duplex unit incl. its adjustments.
ed.6 Part I
TSM 2400 family
ADJUSTMENTS
16adju
TSM 2400 family
Part I ed.6
16disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1 Installing new belt(s) in the intermediate transport unit, funnel Disassembly:
1.1 1.2 1.3 1.4 Remove the upper drive gear -A- (white) and lower drive gear -B-(black). Remove connecting rod -C-. Remove the 2 screws -D- of the handle plate. Remove the side frames from the rollers.
16disa01
Assembly:
1.5 Install new belt(s) over the drive roller: * the long belts over thick roller -E-; * the short belts over thin roller -F-. 1.6 Slide the brackets on the handle plate -D- over the drive roller -E-. 1.7 Install two drive rollers -E- and -F- with belts, eject roller -G- and plate -H- between the side frames. 1.8 Position the ball bearings correctly in the side frames. 1.9 Place the connecting rod -C- and tighten its screws. 1.10 Place the handle bracket and tighten screws -D-.
ed.6 Part II
TSM 2400 family
DIS/ASSEMBLY
16disa
Installing the rollers of the small belts: 1.11 Follow the instructions as indicated on the side frame: - Install the rollers 20 mm and 13 mm on the inside of the small belts; - Push both rollers (1) and (2) in their holder in the frame; - Install tube (3) at the inside of the belts between the two frames; - Place the 8 mm roller (4) in its holder in the frame, the belts are tensioned. Installing the rollers of the large belts: 1.12 Follow the instructions on the side frame: - Place 1 roller of 8 mm on top of the small belts; - Place 3 rollers, 1 x 8 mm (5) and 2 x 13 mm (7 and 8), on the inside of the long belts; - Place these 4 rollers in the holders of the frame in the sequence as indicated on the side frame, starting with 5. 1.13 Install the white gear -A- on the upper drive roller (long belts). 1.14 Install the black gear -B- on the lower drive roller. 1.15 Centre the belts on the drive rollers.
16disa01
TSM 2400 family
Part II ed.6
16disa
DIS/ASSEMBLY
Intermediate transport Note that :
2.1 2.2
2.3
If the intermediate transport is difficult to remove, it might help if you turn the white gear on the drive side. On the drive side frame plate you find a picture that tells you the path of the belts and where to put the different shafts and rollers. The other figures tell you the diameter of the shafts you have to use. The white gear is the one at the top of the intermediate transport.
ed.6 Part II
TSM 2400 family
DIS/ASSEMBLY
16disa
TSM 2400 family
Part II ed.6
16func
FUNCTIONAL DESCRIPTION 1 Duplex section

The function of the duplex section is to catch, transport and guide the copy when it leaves the transfuse pinch and:
In case of a simplex copy: transport the copy through the duplex turn station to the inverter In case of a duplex copy: transport the copy to the duplex turn station; reverse transport direction; transport the copy to the duplex paper stop. The duplex section consists of:
-A-B-C-D-
Intermediate transport unit (funnel) Duplex turn station Duplex paper present sensor Duplex paper stop
16func01
ed.6 Part II
TSM 2400 family
16func
Intermediate transport unit (funnel)

When a copy leaves the transfuse pinch, it enters the funnel. The funnel is a collection of soft rubber belts positioned in such a way that they catch, transport and guide the copy. The belts of the funnel are moving at about 50 m/min (Oc 2375,2400.2465 CRU and 2465 FIN), or about 60 m/min (Oc 2475). The copy leaving the transfuse pinch is only travelling at 20m/min (Oc 2375,2400.2465 CRU and 2465 FIN), or 24 m/min (Oc 2475). Because of the difference in speed, the funnel has a soft pinch, otherwise it would tear the paper. At the end of the funnel is a hard pinch. This means that when a copy enters the pinch at the end of the funnel, it accelerates to 50 m/min (Oc 2375,2400.2465 CRU and 2465 FIN), or about 60 m/min (Oc 2475). This acceleration is necessary to create a time gap between two successive copies in order to have sufficient time for finisher actions. The figure below shows the construction of the funnel, which is one complete unit. It is kept in position by a rod. There are no sensors, and is driven directly from the mainframe main drive. The intermediate transport unit consist of :
-A-B-
Soft rubber belts Funnel drive -CHard pinch rollers
16func02
TSM 2400 family
Part II ed.6
16func
Duplex turn station

The function of the duplex turn station is :
To detect copies To transport copies toward the finisher To return copies to the transfuse pinch The duplex turn station consist of :
-A-B-C-D-EConfidential 1996 Oc Nederland B.V.
Transport rollers Duplex throughput clutch Duplex reverse clutch Drive belt with drive gears Duplex paper present sensor The turn station has two sets of rollers. Two sets are used to have sufficient grip on the paper, because the handling speed is high, 50m/min (Oc 2375,2400.2465 CRU and 2465 FIN), or about 60 m/min (Oc 2475). Via one of two clutches, duplex throughput clutch (16CL3) or duplex reverse clutch (16CL2), the rollers are connected to the subframe main drive (paper transport). The rotating direction of the rollers depends on which clutch is energized.
16func04
ed.6 Part II
TSM 2400 family
16func
The turn station rollers can turn in two directions : Throughput mode A copy leaving the funnel is transported towards the inverter/finisher. This can either be a simplex copy or a duplex copy. The duplex throughput clutch (16CL3) is energized when the rollers rotate in throughput direction. The duplex throughput clutch is controlled by control line DUXTPCL. When DUXTPCL is high 1 a driver on 24V-DRIVER (22PBA09) is switched and the clutch is energized. Reverse mode A simplex copy leaving the funnel is stopped and transported again towards the transfuse pinch to receive the side-2 image.

When the copy leaving the funnel is transported into the turn station the rollers rotate in thoughput direction. The duplex throughput clutch is controlled by control line DUXTPCL. When DUXTPCL is high 1 the clutch is energized. When the trailing edge of the copy has left the funnel the clutch is de-energized, DUXTPCL goes low 0. When the copy is transported to the duplex paper stop the rollers rotate in reverse direction. The duplex reverse clutch (16CL2) is energized. The duplex reverse clutch is controlled by control line DUXRVCL. When DUXRVCL is high 1 a driver on 24V-driver (22PBA09) is switched and the clutch is energized. The copy is transported towards the soft pinch rolls of the duplex paper stop, guided by a passive guide. The copy is stopped and lined up against the duplex paper stop. The trial edge has left the hard pinch of the turn station and has been placed against the paper stop fingers by the soft pinch rolls. The duplex paper present sensor 16SO1 is still activated. Control line DUXPPSE is low 0.
TSM 2400 family
Part II ed.6
16func
Duplex paper stop

The function of the duplex paper stop is to stop and line-up the copies and to start the sheet at the correct time. The duplex paper stop consist of :
-A-B-C-D-E-F-G-
Passive guide Paper stop Paper stop lifting mechanism Duplex paper stop solenoid (16EM1) Hard feed pressure mechanism Soft/hard feed rolls Transport rollers
16func05
ed.6 Part II
TSM 2400 family
16func
A simplex copy which has to receive a side-2 image is fed by the turn station rollers towards the duplex paper stop. The duplex paper stop solenoid (16EM1) is de-energised and consequently the paper stop fingers are in the paper path. The feed rolls form a nip (soft feed). So when the paper arrives at the paper stop, any skew is removed and the paper is driven against the paper stop.

The duplex paper stop solenoid 16EM1 is activated by signal DUXPSSO going high 1. The paper stop lifts, clearing the paper path. A split second later, the soft feed rollers are pinched in hard to drive the paper to the transport rollers. The lead edge of the paper is fed past the paper stop. The solenoid (16EM1) deactivates signal DUXPSSO goes low 0. The paper stop falls onto the paper as it is passing. The trail edge releases sensor 16SO1 DUXPPSE goes high 1. The trail edge of the paper passes the paper stop fingers, and the paper stop immediately falls back, ready for the next sheet.
TSM 2400 family
Part II ed.6
16func
Paper detection (16SO1)

There is only one sensor in the paper path between the first paper stop sensor (12SO5) and the finisher input sensor (18SO1) to detect lead and trail edge of the copies : The duplex paper present sensor 16SO1. When paper is present the signal DUXPPSE to the HOST I/O (22PBA02) is low 0. Throughput mode : (simplex copies) Lead edge and trail edge are detected as the copy passes the sensor. Operator recoverable errors (ORE) are displayed if a sheet arrives too late or leaves too late 16SO1. Reverse mode : (duplex copies) The lead edge is detected as the copy arrives at the sensor. The copy stops momentarily in the turn station as duplex throughput clutch (16CL3) de-energises. During this time, the copy is over the sensor. Then the duplex reverse clutch (16CL2) energises and the copy is fed against the duplex paper stop. The copy is still over the sensor. When the duplex paper stop is lifted the trail edge of the copy is detected when it left the sensor. Also in case of delays in transport of the copy, Operator Recoverable Errors (ORE) will be displayed. NOTE : The height adjustment of sensor 16SO1 is critical. Mechanical friction on a sheet by the sensor vane can influence the transport in duplex mode. This can result in : - Head margin deviations - Skewed paper transport - Delayed paper transport - Mechanical damage of the paper
ed.6 Part II
TSM 2400 family
16func
Operation
During power up / initialisation: Control line DUXPPSE is checked on a high 1 condition, which indicates no paper over the duplex paper present sensor (16SO1). When master transport takes place the duplex throughput clutch (16CL3) is energized. Control line DUXTPCL is high 1. Any paper is transported to the finisher. The duplex paper stop is not energized (16EM1). Control line DUXPSSO is low 0. Any paper at the duplex paper stop is transported to the finisher by the transport rollers in the turn station. During standby: DUXPPSE is high 1, no paper present over duplex paper present sensor. Both clutches of the turn station (16CL2, 16CL3) are de-energized. Control lines DUXRVCL and DUXTPCL are low 0. During run: Two different modes exist:
Throughput mode: When master tranport takes place the duplex throughput clutch (16CL3) is energized. Control line DUXTPCL is high 1. A few seconds after the exposure flash the leading edge of the copy reaches the duplex paper present sensor (16SO1). Control line DUXPPSE goes low 0. Within 1 second DUXPPSE must go high 1 again, because the trailing edge of the copy releases the sensor. Reverse mode: When master transport takes place the duplex throughput clutch (16CL3) is energized. Control line DUXTPCL is high 1. A few seconds after the side-1 exposure flash the leading edge of the copy reaches the duplex paper present sensor (16SO1). Control line DUXPPSE goes low 0. When the trailing edge of the copy passed the passive guide the duplex throughput clutch is de-energized. DUXTPCL goes low 0. The copy stops in the turn station. Within 35 ms after stopping, the duplex reverse clutch (16CL2) is energized. DUXRVCL goes high 1. The copy is transported towards the duplex paper stop. The duplex reverse clutch (16CL2) remains energized for a present time. Control line DUXRVCL goes low 0 again. Within 35 ms after de-energizing the duplex reverse clutch, the duplex throughput clutch is energized again. DUXTPCL goes high 1.
TSM 2400 family
Part II ed.6
16func
Within 2s after the side-2 exposure flash, the duplex paper stop is lifted. Control line DUXPSSO goes high 1. 300ms after lifting the duplex paper stop is checked if the duplex paper present sensor (16SO1) is released. DUXPPSE goes high 1. A few seconds after the side-2 exposure flash the leading edge of the copy reaches the duplex paper present sensor (16SO1). Control line DUXPPSE goes low 0. Within 1 second DUXPPSE must go high 1 again because the trailing edge of the copy released the sensor.
ed.6 Part II
TSM 2400 family
16func
TSM 2400 family
Part II ed.6
16comp
COMPONENT LOCATION
COMPONENT LOCATION
22CN5 16EM1 16SO1 : connector 16EM1 : duplex paper stop solenoid : duplex paper present sensor
16comp01
16comp02
ed.6 Part II
TSM 2400 family
COMPONENT LOCATION
16comp
16CL2 16CL3 16CN1 16CN2 16CN3 16M1
: : : : : :
duplex reverse clutch duplex throughput clutch connector duplex cooling fan connector duplex paper stop clutch connector duplex reverse clutch duplex cooling fan
16comp03
TSM 2400 family
Part II ed.6
16elec
ELECTRICAL DIAGRAM

DUXPPSE DUXPSSO DUXRVCL DUXTPCL DUpleX Paper Present SEnsor DUpleX Paper Stop SOlenoid DUpleX ReVerse CLutch DUpleX ThroughPut CLutch
ed.6 Part I
TSM 2400 family
ELECTRICAL DIAGRAM
16elec
TSM 2400 family
Part I ed.6
Electrical Diagram
16 DUPLEX 701
17diag
DIAGNOSTIC
none
2
Fault table
none
Protections
None
ed.6 Part I
TSM 2400 family
17 Inverter 101
DIAGNOSTIC
17diag
102 Inverter 17
TSM 2400 family
Part I ed.6
17sds
SDS
TESTNUMBER COMPONENT COUNTERS PARAMETERS INPUT TESTS

SIGNAL -0-1-2-4-
DESCRIPTION in SDS
OUTPUT TESTS 17 4 01 17 4 02 17 4 03 SPECIAL TESTS 17 6 04 17CL2/ 17CL3 17EM1 17CL2 17CL3
INVDSO INVINCL INVOUTCL -6INVINCL/ INVOUTCL -8-
INVerter Deflector SOlenoid INVerter INput CLutch INVerter OUTput CLutch
Note 1
REPLACE CONSUMABLES
Note 1: Inverter clutch function test. By pressing <PRINT> the photoconductor function is made warm (initialized). The message start is displayed. When the photoconductor function is initialized the message active is displayed. By using the copy darker/lighter buttons the turn direction of the rollers in the inverter can be selected (input/output).
ed.6 Part I
TSM 2400 family
17 Inverter 201
SDS
17sds
202 Inverter 17
TSM 2400 family
Part I ed.6
17adju
ADJUSTMENTS
ADJUSTMENTS 1 Deflector solenoid (17EM1) Aim:

To achieve a correct transport of the copy into and out of the inverter.
Check:
Activate SDS-test 17 4 01. Check if the distance between -A- and -B- = 0mm;
Correction:
1.1 1.2 1.3
1.4
Loosen bolts -C- (2x). Activate SDS-test 17 4 01. Adjust solenoid -D-, so that: distance between deflector -A- and buffer -B- = 0mm. Check if the solenoid operates, the solenoid pin extends at least 7.5 mm above the solenoid housing when the deflector touches buffer -B-; Tighten bolts -C- (2x).
17adj01a
ed.6 Part I
TSM 2400 family
17 Inverter 301
ADJUSTMENTS
17adju
302 Inverter 17
TSM 2400 family
Part I ed.6
17func
FUNCTIONAL DESCRIPTION 1 Inverter section

The function of the inverter section is to turn duplex copies in order to deliver the copies side-1 face down in the finisher/CRU. This is necessary while making: double sided copies from single sided originals (simplex > duplex), ALWAYS; double sided copies from double sided originals (duplex > duplex) for odd sets only (Oc 2400/2465 FIN); double sided copies from double sided originals (duplex > duplex) for odd sets only (Oc 2375/2475/2465 CRU); The inverter section is part of the finisher. The inverter section consists of: Inverter transport rolls Inverter deflector Inverter deflector solenoid (17EM1) Inverter output clutch (17CL3) inverter input clutch (17CL2) Uncurl input rollers
-A-B-C-D-E-F-
17func01
17func02
17func03
ed.6 Part II
TSM 2400 family
17 Inverter 501
17func
Inverter deflector
The inverter deflector is installed in the finisher/CRU side door. When copies need to be turned, the inverter deflector solenoid (17EM1) is energized (throughout the set which needs inverting). Control line INVDSO is high 1 in this case. Every copy coming out of the duplex turn station is directed into the inverter by the inverter deflector. The shape of the deflector and the stiffness of the paper cause the copy to be fed to the finisher.
17func04
In case copies do not have to be turned then the inverter deflector solenoid (17EM1) is not energized. Control line INVDSO is low 0. Every copy coming out of the duplex turn station is directly fed to the finisher.
17func05
502 Inverter 17
TSM 2400 family
Part II ed.6
17func
Inverter transport rolls

The inverter transport rolls are driven by a drive belt via two clutches, the inverter input clutch (17CL2) and inverter output clutch (17CL3). The inverter output clutch (17CL3) is connected via a pulley to the finisher/CRU main drive, while the inverter input clutch (17CL2) is connected via gears to this pulley. Consequently the turning direction of both clutches is opposite.
17func06

All inverter control lines are activated via a driver on FINISHER CONTROL board (Oc 2375/2465 CRU : 19PBA01, Oc 2400/2465 FIN : 18PBA01, Oc 2475 : 18PBA02). If copies have to be inverted the inverter deflector solenoid (17EM1) is activated, control line INVDSE is high 1. Copies are fed into the inverter by energizing the inverter input clutch (17CL2). This is done by making control line INVINCL high 1. Copies are transported into the inverter until the trailing edge passes the inverter deflector. Next the inverter input clutch (17CL2) is de energized, INVINCL becomes low 0. The copy stops in the inverter. The inverter output clutch (17CL3) is then activated, driving the rolls in the other direction and transporting the copy to the finisher. In this case control line INVOUTCL is high 1.
ed.6 Part II
TSM 2400 family
17 Inverter 503
17func
Processing originals (Oc 2400)

The originals as well as the copies can be handled single sided (simplex mode) and double sided (duplex mode). Lets first have a look at what happens to originals which are handled double-sided in the RDF. When we look at a set of two double-sided originals (page 1-4) on the original tray of the RDF we see the following happen :
-A-
The first original is introduced with page 1 facing downwards.
17func07
-B-
After the flash the first original is turned by the RDF and fed on the original glass again with page 2 facing downwards.
17func08
504 Inverter 17
TSM 2400 family
Part II ed.6
17func
-C-
After the second flash, the first original is fed back to the tray, but now page 2 is facing downwards. The same will happen with page 3 and 4 of the second original.
17func09
After this set is processed once, the sequence of the originals is disturbed; the originals return upside down. When this set of two originals is processed once more the originals in the tray of the RDF have the right sequence again. In other words : the sequence of the originals in the RDF tray depends of the number of sets which have to be copied : ODD numbered set : the originals return UPSIDE DOWN. The last set needs an extra turn action before it is delivered. EVEN numbered set : the originals return AS PLACED ORIGINALLY. Consequently, when duplexing, the odd numbered sets would arrive in the copy receiving tray of the finisher in the wrong sequence. The inverter mechanism corrects this situation : The copies of the odd numbered sets will be TURNED in the inverter. The copies of the even numbered sets are directly fed to the finisher.
ed.6 Part II
TSM 2400 family
17 Inverter 505
17func
Processing originals and copies.

Duplex originals > Duplex copies odd sets (1st, 3th, 5th,..)
17func10
17func11
506 Inverter 17
TSM 2400 family
Part II ed.6
17func
Duplex originals > duplex copies even sets (2nd, 4th, 6th,..)
17func12
17func13
ed.6 Part II
TSM 2400 family
17 Inverter 507
17func
Duplex originals > duplex copies ; punched or preprinted paper. For odd sets the procedure is similar to the normal duplex > duplex mode. For even sets extra turn actions for the originals are necessary before and after being exposed. The copies are handled the same way as for odd sets ; so each copy will pass the inverter station.
EVEN SET :
508 Inverter 17
TSM 2400 family
Part II ed.6
17func
Processing originals (Oc 2375/2475)

The originals as well as the copies can be handled single sided (simplex mode) and double sided (duplex mode). Lets first have a look at what happens to originals which are handled double-sided in the RDF. When we look at a set of two double-sided originals (page 1-4) on the original tray of the RDF we see the following happen :
-A-
The first original is introduced with page 1 facing downwards.
17func07
-B-
After one or two flashes the first original is turned by the RDF and fed on the original glass again with page 2 facing downwards.
17func08
ed.6 Part II
TSM 2400 family
17 Inverter 509
17func
-C-
After exposing page 2 once or twice, the first original is fed back to the tray, but now page 2 is facing downwards. The same will happen with page 3 and 4 of the second original.
17func09
After this set is processed once, the sequence of the originals is disturbed; the originals return upside down. When this set of two originals is processed once more the originals in the tray of the RDF have the right sequence again. In other words : the sequence of the originals in the RDF tray depends of the number of sets which have to be copied : Set A (*): the originals return UPSIDE DOWN. The last set needs an extra turn action before it is delivered. Set B (**): the originals return AS PLACED ORIGINALLY. When duplexing, the odd numbered sets would arrive in the copy receiving trays of the finisher or CRU in the wrong sequence. The inverter mechanism corrects this situation : The copies of set A (*) will be TURNED in the inverter. The copies of set B (**) are directly fed to the finisher.
(*) Set A applies to a job in which the flashes are numbered 1,2/5,6/9,10/.... (**) Set B applies to the same job but in which the flashes are numbered 3,4/7,8/11,12/....
510 Inverter 17
TSM 2400 family
Part II ed.6
17func
Processing originals and copies.

Duplex originals > Duplex copies Set A(1,2/5,6/9,10/....)
17func10
17func11
ed.6 Part II
TSM 2400 family
17 Inverter 511
17func
Duplex originals > duplex copies Set B (3,4/7,8/11,12/...)
17func12
17func13
512 Inverter 17
TSM 2400 family
Part II ed.6
17func
Duplex originals > duplex copies ; punched or preprinted paper. For set A the procedure is similar to the normal duplex > duplex mode. For set B extra turn actions for the originals are necessary before and after being exposed. The copies are handled the same way as for odd sets ; so each copy will pass the inverter station.
EVEN SET :
(*) Set A applies to a job in which the flashes are numbered 1,2/5,6/9,10/.... (**) Set B applies to the same job but in which the flashes are numbered 3,4/7,8/11,12/....
ed.6 Part II
TSM 2400 family
17 Inverter 513
17func
Inverter main drive

The inverter main drive is driven by the inverter input clutch (17CL3) or the inverter output clutch (17CL2). Both clutches are connected to the finisher main drive. The inverter main drive consist of :
-A-B-C-D-E-
Inverter drive pulley Inverter output clutch (17CL3) Inverter transport roller gears Drive belt tensioner Inverter input clutch (17CL2)
17func18
514 Inverter 17
TSM 2400 family
Part II ed.6
17func
Operation
During power up / initialisation: When master transport takes place none of the inverter clutches (17CL2, 17CL3) is energized. The inverter deflector solenoid (17EM1) is not energized, INVDSO is low 0. During standby: The inverter deflector is in rest (non turn) position, INVDSO is low 0. None of the inverter clutches (17CL2, 17CL3), is energized. INVINCL and INVOUTCL are low 0. During run : All inverter actions are synchronised with the masterpulses. The mode for the inverter section is valid for one complete set. Two different modes exist:
non turn mode : None of the inverter clutches, inverter input clutch (17CL2) and inverter output clutch (17CL3), is energized. INVINCL and INVOUTCL are low 0. 580 pulses (*) after the exposure flash the inverter deflector is put in non turn position (if it was not already in that position).Control line INVDSO becomes low 0. turn mode : 580 pulses after the exposure flash the inverter deflector is put in turn position (if it was not already in that position). Control line INVDSO becomes high 1. Again 60 pulses later (640 pulses after exposure flash) the inverter input clutch (17CL2) is energized. Control line INVINCL becomes high 1. The clutch stays energized for 52 pulses. The copy stops in the inverter. Control line INVINCL becomes low 0. The inverter output clutch (17CL3) is energized 4 pulses after de activation of the inverter input clutch (17CL2), driving the copy towards the finisher. Control line INVOUTCL is high 1. The inverter output clutch (17CL3) stays active for 63 pulses. So 759 pulses after the exposure flash the inverter output clutch is de energized. INVOUTCL becomes low 0. (*) Oc 2375,2400.2465 CRU and 2465 FIN : Oc 2475 : 1 pulse = 6 ms 1 pulse = 5 ms.
ed.6 Part II
TSM 2400 family
17 Inverter 515
17func
516 Inverter 17
TSM 2400 family
Part II ed.6
17comp
COMPONENT LOCATION
COMPONENT LOCATION
17CL2 17CL3 17CN1 17CN2 18CN3 18CN5 18PBA02 : : : : : : : inverter input clutch inverter output clutch connector inverter output clutch connector inverter input clutch connector inverter deflector solenoid connector 24V-supply finisher control PBA finisher control lower (Oc 2475)
OCE 2475
ed.6 Part II
TSM 2400 family
17 Inverter 601
COMPONENT LOCATION
17comp
17EM1 18PBA01 18PBA01 19PBA01
: : : :
inverter deflector solenoid finisher control PBA (2400/2465 FIN) finisher adapter PBA (2475) CRU control (2375/2465 CRU)
OCE 2375/2465 CRU
OCE 2400/2465 FIN
OCE 2475
OCE 2475
602 Inverter 17
TSM 2400 family
Part II ed.6
17elec
ELECTRICAL DIAGRAM

INVDSO INVINCL INVOUTCL INVerter Deflector SOlenoid INVerter INput CLutch INVerter OUTput CLutch
ed.6 Part I
TSM 2400 family
17 Inverter 701
ELECTRICAL DIAGRAM
17elec
702 Inverter 17
TSM 2400 family
Part I ed.6
Electrical Diagram
17 INVERTER 701A
Electrical Diagram
17 INVERTER 701B
18diag
DIAGNOSTIC
1810 1811 set delivery mechanism error fin.knocker position failure
MRE
1825 1826 set delivery mechanism error fin.knocker position failure
ORE
1850 1851 1852 1853 1854 1855 copy too late at 18SO1 18SO1 too late free copy too late at 18SO4 18SO4 too late free speciality too late at 18SO6 18SO6 too late free
Warnings
1875 1876 no stapling/18CL2 Copy tray shift failure
ed.6 Part I
TSM 2400/2465 FIN
18 Finisher 101
DIAGNOSTIC
18diag
Fault table
M1825, P1810 - set delivery motor 18M1 defective or not activated - set delivery motor 18M1 continuous activated - set delivery sensor 18SO3 defective - stopper/delivery mechanism stuck or defective - 24 V absent, 18PBA01/18CN5 - 18PBA01 defective M1826, P1811 - one way bearing knocker positioning defective, loose - knocker/tray shift motor 18M2 defective or not activated - knocker position sensor 18SO7 defective - guide of knocker positioning stuck - 18PBA01 defective O1850 - pulleys, bearings or tensioner of main transport defective - transport rollers side door stuck - deflector specialities stuck - internal tray input sensor 18SO1 defective or polluted - 18EM1 speciality tray solenoid continuous activated or defective - spring too weak of 18EM1 - timing belt main transport broken - timing belt decurl unit defective (FUNC 17) - deflector stuck or run heavily or spring too weak 18EM1 (FUNC 17) - inverter deflector solenoid 17EM1 continuous activated (FUNC17) - timing belt inverter broken (FUNC 17) - inverter deflector solenoid 17EM1 defective or not activated ( 17) - bearings decurl unit defective (FUNC 17) - inverter output clutch 17CL3 defective or not activated FUNC 17) - inverter output clutch 17CL3 continuous activated (FUNC 17) - inverter input clutch 17CL2 defective or not activated (FUNC 17) - inverter input clutch 17CL2 continuous activated (FUNC 17) - bearings or pulley of inverter defctive (FUNC 17)
O1851
- bearing of cam stapler stuck - timing belt roller brush broken - static eliminator internal tray defective - stopper/delivery mechanism stuck or defective - stapler spring broken - timing belt positioning belts broken - unlock mechanism stapler defective - one way bearing knocker positioning defective, stuck - plunger of stapler stuck Fault table continue : next page.
102 Finisher 18
TSM 2400/2465 FIN
Part I ed.6
18diag
DIAGNOSTIC
CODES O1851
POSSIBLE FAILURES - knocker solenoid 18EM3 continue activated - knocker mechanism stuck - positioning belts defective or worn - knocker position sensor 18SO7 defective - 18PBA01 defective - plunger of stapler stuck - knocker position sensor 18SO7 defective - unlock mechanism stapler defective - one way bearing knocker positioning defective, stuck - bearing of cam stapler stuck - timing belt roller brush broken - stapler spring broken - knocker solenoid 18EM3 continue activated - stopper/delivery mechanism stuck or defective - knocker mechanism stuck - static eliminator internal tray defective - stapler spring broken - bearing of cam stapler stuck - static eliminator of set delivery defective - internal tray output sensor 18SO4 defective - unlock mechanism stapler defective - stopper/delivery mechanism stuck or defective - static eliminator internal tray defective - plunger of stapler stuck - 18PBA01 defective - 18EM1 speciality tray solenoid defective or not activated - speciality sensor 18SO6 defective, continuous low - deflector specialities stuck - transport rollers side door stuck - bearings decurl unit defective (FUNC 17) - timing belt decurl defective (FUNC 17) - No staples - staples pulled back - staple transport not correct - stapler spring broken - standby motor does not run, check pressure timing belt - stapling safety clutch 18CL4 defective or not activated(SDS test 18406) - stapling safety clutch 18CL4 slips, test on sets of 35 sheets, use grease
O1852
O1853
O1854
W1875
ed.6 Part I
TSM 2400/2465 FIN
18 Finisher 103
DIAGNOSTIC
18diag
CODES W 1875
POSSIBLE FAILURES - stapler clutch 18CL2 defective or not activated (SDS test 18 4 05) - stapler clutch 18CL2 slips (test on sets of 35 sheets), use grease - stapler clutch 18CL2 adjusted wrongly, do adjustment 18-13 (critical adjustment !) - bearing of cam stapler stuck - unlock mechanism stapler defective - stapler sensor 18S4 defective, open - anvil of stapler defective - timing belt stapler defective - plunger of stapler stuck - stapler defective
NOTE : If staples are deformed or crown-shaped, mount new driver (blank steel) and do adjustment 18-3. W1876 - one way bearing shift copy tray defective, loose - copy tray shift sensor 18SO2 defective - guide of copy tray stuck - knocker/tray shift motor 18M2 defective or not activated - 18PBA01 defective
104 Finisher 18
TSM 2400/2465 FIN
Part I ed.6
18diag
DIAGNOSTIC
Protections ORE 1850 ORE 1851

18SO1, finisher internal tray input sensor, is used for synchronous checks when making copies (not interleaf, bypass, fault copies). - if the leading edge of a copy arrives too late, ORE1850 - if the trailing edge releases the sensor too late, ORE1851
ORE 1852 ORE 1853

18SO4, finisher internal tray output sensor, is used to make synchronous checks when a set (stapling) or single copies (batch, sort) are ejected to the output tray (not interleaf, bypass, fault copies). - if the leading edge of set/copy arrives too late, ORE1852 - if the trailing edge releases the sensor too late, ORE1853
ORE 1854 ORE 1855

18SO6, finisher speciality sensor, is used for synchronous checks when bypass/interleaf copies are made. - if the leading edge of the copy arrives too late, ORE1854 - if the trailing edge releases the sensor too late, ORE1855
MRE 1825 PE 1810

18SO3, finisher set delivery sensor, is used to check if the set delivery motor/mechanism operates. - after starting the set delivery motor an edge should be recognised within 300ms/600ms for respectively a half/whole revolution. Otherwise, MRE1825, PE1810
ed.6 Part I
TSM 2400/2465 FIN
18 Finisher 105
DIAGNOSTIC
18diag
MRE 1826 PE 1811

FINKPASE is used as feedback signal to check if the requested knocker position is reached. 2520ms after starting the knocker/tray shift motor the position should be reached: - FINKPASE = 1 , correct - FINKPASE = 0 , new position not reached in time, MRE1826, PE1811
Warning 1875
18S4, finisher staple sensor, detects if a staple is inserted successfully. 400ms after the staple command the level of FINSSE is checked. - 1, correct - 0, staple not fixed correctly, WARNING 1875
Warning 1876
18SO2, finisher copy tray shift sensor, is used to check if the output tray shift operates. - 700ms after starting the knocker / tray shift motor an edge should be recognised. Otherwise, WARNING 1876
106 Finisher 18
TSM 2400/2465 FIN
Part I ed.6
18sds
SDS
TESTNUMBER COMPONENT COUNTERS 18 0 10 PE 18 0 11 PE 18 0 25 MRE 18 0 26 MRE 18 0 50 ORE 18 0 51 ORE 18 0 52 ORE 18 0 53 ORE 18 0 54 ORE 18 0 55 ORE 18 0 75 W 18 0 76 W 18 0 90 C PARAMETERS 18 1 90
SIGNAL -0-
DESCRIPTION in SDS
18SO7 18SO7 18SO1 18SO1 18SO4 18SO4 18SO6 18SO6
set delivery mechanism error finisher knocker position failure set delivery mechanism error finisher knocker position failure copy too late at 18SO1 18SO1 too late free copy too late at 18SO4 18SO4 too late free speciality too late at 18SO6 18SO6 too late free no stapling INIT: copy tray shift failure number of staples with head (K) -1no. of staples per head (K)
ed.6 Part I
TSM 2400/2465 FIN
18 Finisher 201
SDS
18sds
TESTNUMBER COMPONENT INPUT TESTS 18 2 01 18 2 02 18 2 03 18 2 04 18 2 05 18 2 06 18 2 07 18 2 08 18 2 09 18 2 10 18 2 11 18S1 18S2 18S3 18SO1 18SO2 18SO3 18SO4 18SO5 18S4 18SO6 18SO7
SIGNAL -2FINTCOSE FINSDOSE FINOLSSE FINITISE FINCTSSE FINSDSE FINITOSE FINCTFSE FINSSE FINSPECSE FINKNPSE
DESCRIPTION in SDS
FINisher Top COver SEnsor FINisher Side DOor SEnsor FINisher Off-Line Stapling SEnsor FINisher Internal Tray Input SEnsor FINisher Copy Tray Shift SEnsor FINisher Set Delivery SEnsor FINisher Internal Tray Output SEnsor FINisher Copy Tray Full SEnsor FINisher Stapling SEnsor FINisher SPECiality SEnsor FINisher KNocker Position SEnsor
OUTPUT TESTS 18 4 01 18 4 02 18 4 03 18 4 04 18 4 05 18 4 06 18M1 18M2 18EM1 18EM3 18CL2 18CL4
-4FINSDMO FINKNTSMO FINSTSO FINKNSO FINSCL FINSSCL FINisher Set Delivery MOtor FINisher KNocker/Tray Shift MOtor FINisher Speciality Tray SOlenoid FINisher KNocker SOlenoid FINisher Stapler CLutch FINisher Stapling Safety CLutch
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18sds
SDS
TESTNUMBER COMPONENT SPECIAL TESTS 18 6 01 18 6 02 18 6 03 18 6 04 18 6 05 18 6 06 18 6 07 18 6 08

SIGNAL -6-
DESCRIPTION in SDS
make function WARM make function COLD mask function protections Note 1 Note 2 Note 3 Note 4 Note 5 -8preset nr. of staples
REPLACE CONSUMABLES 18 8 90
Note 1: Finisher knocker position test. By pressing <PRINT> the knocker is moved to the 356mm position, while the format is displayed. Every time after pressing <PRINT> the knocker is moved to the next format while the format is displayed. The sequence is: 356>330>297>279>270>254>356>... mm. Note 2: Finisher set delivery full rotation. By pressing <PRINT> FINSDMO becomes high until a half revolution is made. Next the motor will make another half revolution. The test is automatically ended when a full revolution is made. Note 3: Finisher set delivery half revolution. By pressing <PRINT> FINSDMO becomes high for a short moment. The motor will make a half revolution. The test is automatically ended after a half revolution. Note 4: Finisher copy tray shift test. By pressing <PRINT> the copy receiving tray is shifted. The direction depents on the current position. Note 5: The finisher section is made warm (initialized). Next the set delivery motor is switched on for a period of time, while the edges of the finisher set delivery sensor (18SO3) are counted. The nominal value is 30. Refer to adjustment 18-12.
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SDS
18sds
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18adju
ADJUSTMENTS
ADJUSTMENTS 1 Heigth stapler head Aim:

To achieve a correct stapling pressure and to garantee staple belt transport. NOTE: Make sure that the eccentric -D- is in stand by position.
Check:
Use special tool 7991.328 to check the gap between the stapler and the anvil.
Correction:
1.1 1.2 1.3 1.4 1.5 1.6 1.7
Remove the front and rear cover of the finisher; Place the stapler clutch in the basic position; Loosen nut -A-; Place special tool codenr. 7991.328, as shown; Turn excentric shaft -B- to adjust the gap; Eliminate the play between arm -C- and cam -D- ; Lock excentric shaft -B- with nut -A-;
18adj01b
18adj01a
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18 Finisher 301
ADJUSTMENTS
18adju
Sideways tolerance stapler Aim:

To achieve a correct stapler movement.
Check:
Remove: - the finisher front cover. - the copy receiving tray - the left side cover of the finisher. Close the top lid. Measure A = 8.3 0.1 mm. If incorrect proceed with 2.1. Push the stapler against B and check with a feeler gauge gap C = 0.1 0.1 mm. If incorrect proceed with 2.4.
Correction:
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Loosen nut -D-. Adjust bolt -B-: A = 8.3 0.1 mm. Tighten nut -D-. Remove the internal receiving tray bottom plate. Loosen nut -F-. Push the stapler against -B-. Adjust bolt -E-: -C- = 0.1 0.1 mm. Tighten nut -F-. Proceed with check adjustment 18-3.
18adj02a
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18adju
ADJUSTMENTS
Anvil position Aim:

To achieve a correctly formed staple.
Check:
Staple several sets of 2 sheets 80g/m2 (20 lb), off line. Check the shape of the pins: * Figure a. shows the correct shape. * Figure b. and c. showing the wrong shape.
18adj03c
Correction:
3.1 3.2 3.3 3.4
Check adjustment 18-2. Remove the finisher front cover. Loosen bolts -A- (2x). Place special tool 7991.333 in stapler head -C-. NOTE : Do not use special tool 7991.333 more than 10 times !
18adj03b
3.5 3.6 3.7 3.8
Position the stapler head with the green handlebar against the anvil -B- and move the anvil in such a way that the ridge of the special tool fits exactly in the anvil. Hold the anvil in place and tighten bolts -A- (2x) carefully. Remove the special tool. Mount all removed parts.
18adj03a
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ADJUSTMENTS
18adju
Height of the top lid. Aim:

To achieve a defined position of the top lid
Check:
The maximum allowed space between the two callipers -C- at the rear is 0.6 mm.
Correction:
4.1 Remove: - the cover of the finisher top lid - the rear cover of the finisher. - the left side finisher cover. Loosen bolts -A- (2x) and -B- (2x). Push the top lid on the callipers by putting a weight of approximately 20 kg, e.g. 2 boxes (5000 sheets) of plain paper, on the top lid, close to the hinges. Tighten bolts -B-. Tighten bolts -A-. Proceed with check adjustment 18-5.
4.2 4.3 4.4 4.5 4.6
18adj04a
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18adju
ADJUSTMENTS
Lock plate top lid Aim:

To achieve a correct locking of the top lid.
Check:
Open and close the top lid; the maximum allowed play between catch -A- and lock plate -B- is 0.2mm.
Correction:
5.1 5.2 5.3 5.4 5.5 5.6 5.7 Close the top lid. Check adjustment 18-4. Loosen bolts -C- (2x) (fingertight). Hook catch -A- into locking bracket -B-. Push the top lid downwards (at the front). Move locking bracket -B- against catch -A-. Tighten bolts -C- (2x).
18adj05a
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18 Finisher 305
ADJUSTMENTS
18adju
Internal receiving tray bottom plate Aim:

To achieve reliable set delivery.
Check:
If rollers -A- level with plate -B-.
Correction:
6.1 6.2 6.3 6.4 Remove the cover at the rear side of the finisher. Loosen nut -C- at the rear. Turn excentric shaft -D- in such a way, that the top of the internal receiving tray -Blevels with roller -A-. Lock shaft -D- with nut -C-.
18adj06a
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18adju
ADJUSTMENTS
Hinges finisher side door Aim:

To achieve a defined position of the finisher side door.
Check:
Close the door; push on all 4 corners. Maximum allowed play between the callipers is 0.15 mm. Too much play at frontside: proceed with adjustment 18-8. Too much play at rear side: proceed with 7.1.
Correction:
7.1 7.2 7.3 7.4 7.5 7.6
7.7 7.8
Remove the cover of the side door and the rear cover of the finisher. Remove the bracket with the spring loaded pin -D- from the door. Lock the door. Loosen bolts -A-, -B- and -C- (2x) of the hinge(s). Push the door against all 4 callipers. Tighten the bolts in the following order: - bolt -A-; - bolts -C- (2x); - open the door, tighten bolt -B-. Remount the spring loaded pin -D- and the covers. Proceed with check adjustment 18-8.
18adj07a
18adj07b
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18 Finisher 307
ADJUSTMENTS
18adju
Lock finisher side door Aim:

To achieve a correct locking of the finisher side door.
Check:
Open and close the finisher side door; the door should lock smoothly. Maximum allowed play is 0.1mm.
Correction:
8.1 8.2 8.3 8.4 8.5 8.6 8.7 Remove the front cover of the finisher. Close the side door. Loosen bolts -C- (2x). Hook catch -A- into locking bracket -B-. Push the door against the front callipers. Move locking bracket -B- against catch -A-. Tighten bolts -C- (2x).
18adj08a
18adj08b
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18adju
ADJUSTMENTS
Deflector solenoid (18EM1) Aim:

To achieve a correct position of the deflector and to achieve a noise free deflector movement.
Check:
Make several copies by the manual speciality feed. Check that the copies are delivered correctly into the speciality copy receiving tray.
Correction:
9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 Open the side door. Remove the cover plate, bolt -A-. Loosen bolts -B- (2x). Move bracket -C- upwards until deflector -D- just touches buffer -E-. Tighten bolts -B- (2x). Close the side door. Activate sds-test 18 4 03. Check if the solenoid operates. If necessary proceed with 9.3. Mount the cover carefully and tighten bolt -A-.
18adj09a
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ADJUSTMENTS
18adju
10
Copy receiving tray fork. Aim:

To achieve a free movement of copy receiving tray fork.
Check:
Lift and lower the fork manually: * It should not touch the side of the copy receiving tray.
Correction:
10.1 Remove the cover of the finisher top lid. 10.2 Make sure fork -C- is at the bottom of the copy receiving tray. 10.3 Loosen bolt -A- . 10.4 Adjust bracket -B- so that -D- is 10 1 mm 10.5 Tighten bolt -A-.
18adj10a
18adj10c 18adj10b
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18adju
ADJUSTMENTS
11
Copy receiving tray full detection Aim:

To achieve a correct detection of a full copy receiving tray.
Check:
Lift the fork: when it reaches a heigth of 70 2mm above the copy receiving tray the display must indicate copy tray full.
Correction:
Remove the cover of the finisher top lid. Select and activate test 18 2 08. Loosen nut -D-. Put fork -C- on a level of 70 2 mm above the copy receiving tray. 11.5 Adjust sensor -A- with bolt -B- in such a way that the sensor is just active (buzzer on). 11.6 Tighten nut -D-. 11.1 11.2 11.3 11.4
18adj11a
18adj11b
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18 Finisher 311
ADJUSTMENTS
18adju
12
Speed set delivery motor Aim:

Check:
Close the finisher top lid. Select and activate test 18 6 08. * The motor initializes and then runs for approximately 4.9 s and stops. The value the display shows must be 30.
Correction:
NOTE: This adjustment has to be carried out if a new finisher controlboard (18PBA01) and/or the set delivery motor (18M1)has/have been installed. The top cover has to be mounted. 12.1 Open the finisher top lid. 12.2 Remove the internal receiving tray. 12.3 Select and activate test 18 6 08. In the display appears a value : value <30: the motor runs too slowly: - Turn potentiometer R35 on 18PBA01 one turn clockwise; - Repeat the procedure until the read out is 30. value >30: the motor runs too fast: - Turn potentiometer R35 on 18PBA01 one turn counter clockwise; - Repeat the procedure until the read out is 30.
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18adju
ADJUSTMENTS
13
Stapler clutch (18CL2) Aim:

To achieve a reliable function of the stapler clutch.
Correction:
13.1 Remove the rear cover ; Also for the lower stapler : Remove rear covers paper trays 13.2 Loosen bolts -A- of solenoid -B- 1/2 a turn; 13.3 Loosen screws -E- of buffer -F- and move the stop downwards; 13.4 Activate test 18 4 05; 13.5 Place a feeler gauge of 1 mm between the lever -C- of solenoid -B- and clutch -D-; 13.6 Move the solenoid against the gauge and tighten bolts -A-;
18adj13a
13.7 Deactivate test 18 4 05; 13.8 Place a feeler gauge of 0.5 0.1mm between the lever -C- of solenoid -Band stop -F-; 13.9 Move buffer -F- against lever -C- of solenoid -B-; 13.10 Tighten screws -E-; 13.11 Mount all removed parts.
18adj13b
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ADJUSTMENTS
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18disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1 1.2 1.3 1.4
Stapler
Open the finisher top lid and the finisher side door. Open the stapler with the green knob. Remove the green knob. Remove: - the finisher front cover; - the copy receiving tray; - the finisher left cover - the internal receiving tray. Remove the lid of the staple storage compartment. Gently split the belt of staples, slide the left part to the left out of the stapler and take the roll out off the storage compartment. Loosen screw -A- and remove the staple storage compartment. Loosen connector -B-. Gently slide the plastic cover -C- of the stapler to the right (take care of the metal paper stopper on top of this cover!) and remove it.
1.5 1.6
1.7 1.8 1.9
18disa01
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18 Finisher 401
DIS/ASSEMBLY
18disa
18disa02
1.10 Loosen screw -D- and remove bracket -E-. 1.11 Loosen the left setting screw -F-. 1.12 Slide the stapler to the left and take it out of the copier. 1.13 1.14 1.15 1.16 Disassemble the stapler as shown in fig. 18disa05 upto 18disa10. Clean the stapler. Mount all parts in reversed order and lubricate both plates of the stapler driver. Check adjustment 18-1, 18-2, 18-3. Use specialtool partnr. 7991329.
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18disa
DIS/ASSEMBLY
18disa05
18disa06
18disa07
18disa08
18disa09
18disa10
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DIS/ASSEMBLY
18disa
2
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
Knocker mechanism
Remove the internal receiving tray. Loosen bolt -A- of the sensor PBA Turn ruler -B- 90 upwards and remove it. Loosen the connectors of the knocker solenoid -C-. Loosen knocker head -H-. Loosen bolt -E-. Unhook spindle -F-. Remove bracket -G-. Slide arms -D- to the right and remove them.
18disa11
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18disa
DIS/ASSEMBLY
3
3.1 3.2 3.3 3.4 3.5 3.6 3.7
Knocker/tray shift motor

Remove the internal receiving tray. Remove the copy receiving tray. Remove the left finisher cover. Remove the rail of the copy receiving tray. Loosen 3 bolts -ALoosen arms -B- from the spindle. Slide bracket -C- to the left out of the finisher.
18disa12
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18 Finisher 405
DIS/ASSEMBLY
18disa
4
4.1
Removal of the finisher

Remove : - Cover in front of finisher; - Front/rear covers finisher; - Guiding fork; - Copy receiving tray; - Rear cover paper handling; - Internal receiving tray plate; - Finisher drive belts. Loosen : - Connector 18CN5 and earth strap; - Connectors 18CN1 and 18CN2 of 18PBA01; - Cut the tywraps and remove the bundle out of the finisher; - Remove the locking brackets front and rear; - Remove the two M6 bolts. Now you can take off the finisher of the copier.
4.2
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Part II ed.6
18func
FUNCTIONAL DESCRIPTION 1 Finisher section

The function of the finisher section is: to deliver copies (sorted, stapled or batched) in the copy tray to direct bypass, interleaf or fault copies to the specialty tray. The finisher section consists of: -A-B-C-D-E-F-G-K-L-MSet delivery unit Paper path Stapling unit Internal tray with set positioning Knocker Copy tray full detection Finisher top unit Copy tray Speciality tray Cooling system
18func01
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18func
Delivery Unit
The function of the delivery unit is to deliver stapled set or single sheets into the copy tray. The delivery unit consists of:
-A-B-C-D-E-F-H-J-
Delivery lifting mechanism; Delivery drive mechanism with motor (18M1); Set delivery sensor (18SO3); Internal tray bottom; Delivery pressure roller; Delivery transport roller; Eject rolls; Pinch pressure spring
18func03
The delivery unit has two positions : Pressure roller up / paper stop down / positioning belts down (staple mode). This is the position in standby and when sheets have to be collected in the internal tray for stapling. To deliver the stapled set, the set delivery motor (18M1) makes one complete revolution. During this revolution the delivery pinch is made, the paper stop and the positioning belts are lifted and the set is delivered into the copy tray. Pressure roller down / paper stop up / positioning belts up (sort/batch mode). This is the position to transport single sheets through the internal tray into the copy tray. NOTE : In SDS test 90, configuration deposit finisher must be selected : otherwise the delivery unit will be placed in this position (through feed) when no deposit is selected. Deposit tray and deposit tray-ext is not possible.
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18func
Delivery drive mechanism

-A-B-C-DThe drive mechanism consist of : Set delivery motor (18M1); Cam with vane; Finisher set delivery sensor (18SO3); Top unit
18func04

The motor 18M1 is controlled by signal FINSDMO from the HOST-I/O (22PBA02). When signal FINSDMO goes low 0 and signal FINMOEN is high 1, the set delivery motor (18M1) turns. The motor always turns clockwise, as viewed from the front. The set delivery sensor (18SO3) monitors the position of the delivery pressure roller by a vane. The vane is attached to a cam. The cam is driven by the set delivery motor (18M1) and moves the set delivery pressure roller up and down. When the set delivery rolls are up, the beam is not interrupted and the signal FINSDSE is high 1. When the set delivery pressure roller is down, the beam is interrupted and the signal FINSDSE is low 0. Delivery of stapled sets When making stapled sets, the set delivery mechanism is in the rest position at the start of the run. As each copy arrives it is positioned against the finisher paper stop by the two positioning belts, and towards the front of the copier by the knocker. When the complete set is collated in the internal tray, the stapler operates, fixing a staple to the corner of the set.
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18 Finisher 503
18func
The set delivery motor (18M1) drives an eccentric through one complete revolution when a set needs to be ejected. The set delivery motor is started by making control line FINSDMO high 1.
18func13.gem
1 2 3 4 5 6
During the first half-revolution of the cam : The cam on the motor shaft causes the set delivery mechanism to move downwards. The pressure roller is supported at each end by plastic plates which can move up and down freely in slotted brackets. The delivery lifting mechanism moves down and the pressure roller touches the top of the copy set. At the same time the paper stop and positioning belts move upwards, allowing the copy set to be fed out by the eject rolls. The delivery pressure roller presses downwards, making a pinch and thus feeding the set towards the eject rolls (hard pinch). The paper stop moves up until it touches the stop. If there is a thick copy set in the internal tray, the turning action of the delivery mechanism will extend the pinch pressure spring. This provides extra force to the set, making it easier to feed out a thick copy set.
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18func
7 8 9
During the second half-revolution of the eccentric: The set delivery mechanism moves upwards, driven by the cam. The delivery pressure roller returns to its upper position. The paper stop falls onto the copy set as it leaves the finisher, and then falls into position ready to stop the next copies.
Delivery of single copies (unstapled sets, batched or single copies)

When making single copies, batches or unstapled sets, the set delivery motor (18M1) turns one-half revolution at the start of the run. This raises the paper stop and positioning belts clear of the paper path and lowers the delivery pressure roller so that the pinch is made. This means that as soon as a copy enters the internal tray, it is delivered into the copy tray.
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18 Finisher 505
18func
Paper path
The paper path brings copies from the duplex station or inverter to the copy receiving tray or speciality tray. If stapling is selected the sheets are collected in the internal tray and stapled and than delivered into the copy receiving tray.
-A-B-C-D-E-F-G-H-K-L-M-N-O-P-R-S-T-U-
The paper path consists off: Copy receiving tray; Set eject rolls; Internal tray output sensor (18SO4), (off-line stapling detection); Speciality tray; Set delivery rollers; Brush roller; Internal tray input sensor (18SO1); Speciality output sensor (18SO6); Speciality eject rollers; Speciality transport rollers; Output deflector; Internal tray input rollers; Deflector solenoid; Paper path transport rollers; Paper path side door; Internal tray; Stapler Uncurl roller
18func06
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18func

RDF, MDF, CFF, glass platen copies. In these modes all copies go to the internal tray, where they are either : delivered directly to the copy receiving tray or collected, stapled and than delivered to the copy receiving tray. The finisher specialty tray solenoid (18EM1) is off, FINSTSO is low 0. The finisher internal tray input sensor (18SO1) senses the lead edge and the trail edge of each copy when it enters the internal tray. Control line FINITISE is high 1 when the copy is present between transmitter and receiver. The finisher internal tray output sensor (18SO4) senses the lead and trail edge of each copy set when it leaves the internal tray. Control line FINITOSE is high 1 when the copy set is present between transmitter and receiver.
Bypass/interleaf/fault copies. In these modes copies always are delivered into the finisher specialty tray. The finisher specialty tray solenoid (18EM1) is on, FINSTSO is high 1. The finisher specialty sensor (18SO6) senses the lead edge and trail edge of the copy as it enters the finisher specialty tray. FINSPECSE is high 1 when the copy is activating the sensor.
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18func
Stapling unit
The stapling mechanism consists off:
-A-B-C-D-E-F-G-H-J-K-L-
Stapler drive belt; Top cover switch (18S1); Stapler safety clutch (18CL4); Stapler clutch (18CL2); Anvil; Stapler unit; Internal tray input sensor (18SO1); Roll of staples; Stapler unit lifting mechanism; Off-line stapling switch (18S3); Internal tray output sensor (18SO4)
18func07
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18func
The stapler can operate in two modes : set stapling during a run After the last copy of a set has been delivered into the internal receiving tray (that is, the trail edge of the copy has cleared 18SO1) and positioned, the set is ready to be stapled. For stapling both the stapler clutch (18CL2) and the stapler safety clutch (18CL4) must be energised in order to connect the stapler drive to the stapler mechanism. The stapler safety clutch (18CL4) is interlocked with the top cover sensor (18S1) and side door sensor (18S2), so that when the top cover or the side door is open, the stapler cannot operate. This is an additional safety precaution. When signal FINSSCL goes high 1, the stapler safety clutch (18CL4) is energised, it connects the stapler drive to the stapler clutch (18CL2). When signal FINSCL goes high 1, the stapler clutch (18CL2) is energised. This is a one revolution clutch, the shaft driven by this clutch is connected via an eccentric to the stapler lifting mechanism. It makes the stapler go up and down. When the staple is inserted successfully, it closes the contacts of the finisher staple sensor (18S4) (this is the circuit between anvil and stapler unit). The signal FINSSE goes low 0. If a staple is not detected, an error message will be displayed, but the copy run in progress will continue. The operator will then have to reload the stapler, and staple the sets offline. Off line stapling When a set is inserted (face down) from the front of the copier, and pushed against the offline stop, the set will break the light beam of the internal tray output sensor (18SO4). The signal FINITOSE goes low 0. By moving the set slightly to the right, it will actuate the finisher offline stapling sensor (18S3) via a lever. This sensor is attached to the front cover and not to the finisher frame. The signal FINOLSSE goes low 0. When both sensors are made and the side door is closed (18S2), the stapler will be activated.
18func08
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18 Finisher 509
18func
Internal set positioning

The set positioning unit consists off:
-A-B-C-D-E-F-
Positioning belts; Finisher paper stop fingers; Knocker; Finisher Knocker solenoid (18EM3); Roller with brush wheels; Front stop
18func09
When making stapled sets, the paper stop and positioning belts are down. When making batch/sort sets or single copies, the finisher paper stop and positioning belts are up. See the DELIVERY UNIT description. As each copy arrives in the internal tray, it hits a roller with brush wheels. They guide the sheet into the internal tray. The positioning belts then push the copy against the paper stop. The paper stop is inclined to prevent the lead edge of the paper from climbing up the paper stop. The roller with brush wheels and positioning belts are driven by the finisher main drive. To achieve a set of copies with a minimum of shifted sheets a knocker mechanism is used. The knocker mechanism knocks each copy twice towards the front of the tray against the front stop. The knocker hammer is inclined at 3 to ensure that it always knocks the top sheet in a set of copies.

When the signal FINKNSO from the HOST-I/O (22PBA02) goes high 1. Via an inverter on the finisher control board (18PBA01) the solenoid (18EM3) becomes energised.
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18func
Knocker / Copy tray shift mechanism

The knocker position mechanism and copy tray shift mechanism are both driven by the same motor : the knocker / copy tray shift motor (18M2). The knocker positioning copy tray shift mechanism consist of :
-A-B-C-D-E-F-G-H-JConfidential 1996 Oc Nederland B.V.
Knocker positioning / tray shift motor (18M2); Drive mechanism; Tray displacement cam with one way bearing; Copy tray shift sensor (18SO2); Knocker arm; Knocker positioning mechanism; Knocker position sensor (18SO7); Coding strip knocker position sensor; Knocker displacement cam with one way bearing
18func10
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18 Finisher 511
18func
The finisher knocker/tray shift motor (18M2) has 2 functions: Shift the copy tray Position the knocker mechanism. The motor is connected to the copy tray shift mechanism by a one-way bearing, and to the knocker positioning mechanism by another one-way bearing. Thus when the motor turns counter-clockwise (viewed from the gear-box end) it will move the copy tray, and when it turns clockwise it will move the knocker. It is never required to perform both functions at the same time.

The motor (18M2) is controlled by the signals FINKNTSMO1 and FINKNTSMO2 from the finisher control board (18PBA01). When FINKNTSMO1 is connected to ground and FINKNTSMO2 is connected to +24V, the motor turns counter-clockwise and drives the copy tray. When FINKNTSMO1 is connected to +24V and FINKNTSMO2 is connected to ground, the motor turns clockwise and positions the knocker mechanism. Copy tray shift The finisher motor enable signal FINMOEN must be high 1 before the motor will drive. When the copy tray shift signal FINTTMO is high 1, it will cause the motor to turn counter-clockwise thus moving the copy tray. A cam moves the copy tray over a total distance of 30mm (front - rear). A vane on the cam interrupts / releases the beam of the copy tray shift sensor (18SO2) every 1/2 revolution. When the copy tray is at the rear or front control stops the motor (18M2). When the beam is interrupted signal FINCTSSE goes high 1.
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Part II ed.6
18func
Knocker positioning mechanism The knocker has six positions, corresponding with the six paper lengths that are detected by the paper format sensor in the paper tray. The knocker position sensor (18SO7) (three optical sensors) is used to detect the knocker position. The 3 signals FINKNPSE1,2,3 are sent to the finisher control (18PBA01) where they are compared with the paper size information from the control FINKNFOR1,2,3. The signals are decoded according to the following table. FINISHER SENSORS Sensor 1: FINKNPSE1 Sensor 2: FINKNPSE2 Sensor 3: FINKNPSE3 PAPER SENSORS Sensor 1: UPTPPSE1 or LPTPSSE1 Sensor 2: UPTPSSE2 or LPTPSSE2 Sensor 3: UPTPSSE3 or LPTPSSE3
sensor 1 0 0 0 1 1
sensor 2 0 1 1 1 1
sensor 3 1 1 0 0 1
paper size 254 mm 270 mm 279 mm 297 mm 330 mm
sensor 1 0 0 1 1 1
sensor 2 0 1 1 1 0
sensor 3 1 1 1 0 0
NOTE: The strips used by the finisher knocker sensor and the paper size sensors are not the same! Any codes not shown in the above table are not recognised by the control and will result in an error code. The exact position is determined by a spring loaded arm that finds notches in one of the knocker mechanism guide shafts.
18func11
ed.6 Part II
TSM 2400/2465 FIN
18 Finisher 513
18func
When positioning the knocker, the motor (18M2) always turns clockwise. A cam connected to a hingable arm mechanism makes an eccentric movement and causes the knocker to move backwards and forwards. Before the motor will start, the finisher motor enable signal FINMOEN must be high 1. A high pulse on the finisher knocker motor control line FINKNMO causes the motor to start. The signal FINKNMO also energises relay RL1, which reverses the voltage to the motor (before it starts), causing it to drive clockwise and thus move the knocker. A new knocker position is always approached from the rear. 1 2 3 1 2 3 4 5 6 7 From a large size to a smaller size : The motor starts to drive; The cam will drive the knocker to the front; The knocker moves forward until the new size is detected by sensor 18SO7. From a small size to a larger size : The motor starts to drive. The cam will drive the knocker to the front and then to the rear. The control will detect (sensor 18SO7)that the knocker is in the largest position (356mm) while moving from front to the rear. The knocker continues moving backwards past the largest position (356mm). It then reapproaches the largest position (356mm), now moving from the rear to the front. So when the control detects the largest position (356mm) for the second time, it knows that the knocker is now moving from the rear to the front. The knocker continues moving to the front until the new size is detected (18SO7).
18func12.gem
514 Finisher 18
TSM 2400/2465 FIN
Part II ed.6
18func
Copy tray full detection

As the number of copies in the copy tray increases, the fork will rise. There is a vane attached to the fork that will actuate the finisher tray full sensor (18SO5) when there are approx. 600 copies (80 gsm) in the copy tray. This causes the signal FINCTFSE to go high 1 and a message will be displayed to the operator.
-A-B-C-D-
Copy tray; Fork; Vane; Finisher copy tray full sensor (18SO5)
18func14
ed.6 Part II
TSM 2400/2465 FIN
18 Finisher 515
18func
Finisher door switches

The finisher top cover sensor (18S1) (microswitch) senses when the top cover is closed. When the cover is closed, signal FINTCSE is high 1. Having the top cover open it is not possible to switch on the stapler. Via a safety clutch (18CL4) the drive is interrupted. The finisher side door sensor (18S2) (microswitch) senses when the side door is open it is not possible to switch on the stapler. When the door is closed, signal FINSDOSE is high 1.
-A-B-C-D-
Top cover Finisher top cover sensor (18S1) Side door Finisher side door sensor (18S2)
18func15 18func16
516 Finisher 18
TSM 2400/2465 FIN
Part II ed.6
18func
Finisher cooling system

The fan sucks cold air via the internal tray into the finisher and blows it down into the preheat area. This prevents hot air from the preheaters and TTF rising into the finisher. If the motor fails, the internal receiving tray can reach a temperature of 70C. Such temperatures can:
damage the finisher control PBA (18PBA01) cause copy transport problems There are no error messages if the motor fails. The motor (18M3) runs continuously during a run and is controlled by signal MADR. The motor is protected by a thermal fuse that will automatically stop the motor if the temperature exceeds 130C. The thermal fuse will reset itself automatically as the temperature decreases.
-A-
Finisher cooling motor (18M3);
18func17
ed.6 Part II
TSM 2400/2465 FIN
18 Finisher 517
18func
10
Finisher Drive
The finisher drive consists of three parts:
-A-B-C-
Finisher main drive; Subframe main drive; Finisher standby drive The inverter drive is driven by the finisher main drive (see INVERTER). Each of these drive system is explained in the next section.
18func18
18func19
518 Finisher 18
TSM 2400/2465 FIN
Part II ed.6
18func
Finisher main drive The finisher main drive is connected to all the paper path rollers in the finisher and inverter. Via the finisher main drive pulley it is connected to the subframe main drive (finisher). This finisher main drive consists of:
-A-B-C-D-E-F-G-HConfidential 1996 Oc Nederland B.V.
Finisher lid drive-transmit pulley; Set delivery roller pulley; Eject roller pulley; Drive belt tensioner; Finisher main drive pulley; Paper path transport roller pulley; Internal tray input roller pulley; Speciality transport roller pulley;
18func20
ed.6 Part II
TSM 2400/2465 FIN
18 Finisher 519
18func
Finisher standby drive The function of the finisher standby drive is to drive the stapler mechanism. This to make off line stapling possible. The finisher standby drive is driven by the subframe standby drive. The finisher standby drive consists of:
-A-B-C-
Finisher stapler safety clutch (18CL4); Finisher standby drive; Finisher stapler clutch (18CL2)
18func21
520 Finisher 18
TSM 2400/2465 FIN
Part II ed.6
18func
11
Operation
During Power up / initialisation: When master transport starts (signal MADR), the finisher speciality tray solenoid (18EM1) is energised, FINSTSO goes high 1. Any paper left in the paper path is delivered in the speciality tray. The solenoid stays energised until master transport stops. The set delivery motor is started, FINSDMO goes high 1. Any paper in the internal tray is delivered in the copy tray. The set delivery motor stops when the set delivery mechanism is in rest position (set delivery rolls are up and paper stop is down). The signal from the set delivery sensor (18SO3), FINSDSE is high 1. The knocker/tray shift motor (18M2) will: - move the copy tray and stop in the rear position. FINMOEN and FINTTMO are high 1 to start the motor (18M2). When the tray is in the rear position the finisher copy tray shift sensor (18SO2) signal FINCTSSE is high 1. - move the knocker to the largest paper size position. FINMOEN and FINKNMO go high 1 to start the motor (18M2). When the knocker is positioned correctly, the knocker position sensor (18SO7) has the status : FINKNPSE1, FINKNPSE2, FINKNPSE3 are respectively 1, 0, 1. During standby: Off line stapling is possible : A set is inserted for stapling. Internal tray output sensor (18SO4) detects the set, signal FINITOSE goes low 0. The finisher off-line stapling sensor (18S3) is activated by the set, signal FINOLSSE goes low 0. The top cover sensor (18S1) is closed, signal FINTCOSE is high 1. The side door sensor (18S2) is closed, signal FINDOSE is 1. The stapler safety clutch (18CL4) and the stapler clutch (18CL2) are energized, signals FINSSCL and FINSTCL go high 1. When the staple is inserted successfully, the contact of the staple sensor (18S4) is closed, signal FINSSE goes low 0. During run: 1.5s after the exposure flash the knocker is put in the correct position according to the paper size (1.9s incase the copy has to be turned first in the inverter). When a copy must be put in the speciality tray (bypass input, interleaf) than the finisher speciality tray solenoid (18EM1) is activated 3.8s after the exposure flash. Control line FINSTSO goes high 1. The finish command is given 4.2s after the exposure flash. The command consist of one or more tasks, such as: - staple - copy tray shift - batch - sort
ed.6 Part II
TSM 2400/2465 FIN
18 Finisher 521
18func
522 Finisher 18
TSM 2400/2465 FIN
Part II ed.6
18comp
COMPONENT LOCATION
COMPONENT LOCATION
18CL2 18CL4 18S1 18S2 18S3 18S4 18PBA03/18SO1R 18PBA05/18SO1T 18PBA02/18SO4R 18PBA04/18SO4T 18SO6 : : : : : : : : : : : finisher stapler clutch finisher stapler safety clutch finisher top cover sensor finisher side door sensor finisher offline stapling sensor finisher stapler sensor finisher internal tray input sensor receiver finisher internal tray input sensor transmitter finisher internal tray output sensor receiver finisher internal tray output sensor transmitter finisher speciality sensor
18comp01
ed.6 Part II
TSM 2400/2465 FIN
18 Finisher 601
COMPONENT LOCATION
18comp
18CN1 18CN4 18M1 18SO3 18SO5
: : : : :
connector finisher set delivery motor connector finisher set delivery motor and sensors 18SO3/4/5 finisher set delivery motor finisher set delivery sensor finisher copy tray full sensor
18comp02
602 Finisher 18
TSM 2400/2465 FIN
Part II ed.6
18comp
COMPONENT LOCATION
18CN2 18EM3 18M2 18PBA01 18SO2 18SO7
: : : : : :
connector finisher knocker/tray shift motor finisher knocker solenoid finisher knocker/tray shift motor finisher control PBA finisher copy tray shift sensor finisher knocker position sensor
18comp03
ed.6 Part II
TSM 2400/2465 FIN
18 Finisher 603
COMPONENT LOCATION
18comp
18M3
: finisher cooling fan
18comp04
18CN5 18EM1 18CN3
: connector finisher cooling fan : finisher speciality tray solenoid : connector finisher speciality tray solenoid
18comp05
604 Finisher 18
TSM 2400/2465 FIN
Part II ed.6
18elec
ELECTRICAL DIAGRAM

FINTCOSE FINSDOSE FINOLSSE FINSSE FINITISE FINCTSSE FINSDSE FINITOSE FINCTFSE FINSPECSE FINKNPASE FINMOEN FINKNMO FINKNFORx FINSDMO FINTTMO FINKNPSEx FINKNTSMO FINSTSO FINSCL FINKNSO FINSSCL FINisher Top COver SEnsor FINisher Side DOor SEnsor FINisher Off-Line Stapling SEnsor FINisher Stapler SEnsor FINisher Internal Tray Input SEnsor FINisher Copy Tray Shift SEnsor FINisher Set Delivery SEnsor FINisher Internal Tray Output SEnsor FINisher Copy Tray Full SEnsor FINisher SPECiality SEnsor FINisher KNocker Paper Achieved SEnsor FINisher MOtor ENable FINisher KNocker MOtor FINisher KNocker FORmat x FINisher Set Delivery MOtor FINisher Tray Transport MOtor FINisher KNocker Position SEnsor x FINisher KNocker Tray Shift MOtor FINisher Speciality Tray SOlenoid FINisher Stapler CLutch FINisher KNocker SOlenoid FINisher Stapler Safety CLutch
ed.6 Part I
TSM 2400/2465 FIN
18 Finisher 701
ELECTRICAL DIAGRAM
18elec
702 Finisher 18
TSM 2400/2465 FIN
Part I ed.6
Electrical Diagram
18 FINISHER 701A
Electrical Diagram
18 FINISHER 702
18diag
DIAGNOSTIC
1810 1811 1812 1813 lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up finisher knocker position failure
MRE
1825 1826 1827 1828 lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up finisher knocker position failure
ORE
1850 1851 1852 1853 1854 1855 1856 1857 1858 1859 copy too late at 18SO1 18SO1 too late free copy too late at 18SO4 18SO4 too late free speciality too late at 18SO6 18SO6 too late free copy too late at 18SO8 18SO8 too late free copy too late at 18SO10 18SO10 too late free
Warnings
1875 1876 1877 no lower stapling/18CL2 Copy tray shift failure no upper stapling/18CL5
ed.6 Part I
TSM 2475
18 Finisher 101
DIAGNOSTIC
18diag
Fault table
M1825, P1810 - lower set delivery motor 18M1 defective or not activated - lower set delivery motor 18M1 continuous activated - lower set delivery sensor 18SO3 defective - lower stopper/delivery mechanism stuck or defective - 24 V absent - 18PBA02 defective - 18PBA01 defective M1826, P1811 - one way bearing knocker positioning defective, loose - lower knocker/tray shift motor 18M2 defective or not activated - lower knocker position sensor 18PBA07 defective - lower guide of knocker positioning stuck - 18PBA02 defective - 18PBA01 defective M1827, P1812 - upper set delivery motor 18M4 defective or not activated - upper set delivery motor 18M4 continuous activated - upper set delivery sensor 18SO9 defective - upper stopper/delivery mechanism stuck or defective - 24 V absent - 18PBA03 defective - 18PBA01 defective M1828, P1813 - one way bearing knocker positioning defective, loose - upper knocker motor 18M5 defective or not activated - upper knocker position sensor 18PBA12 defective - upper guide of knocker position stuck - 18PBA03 defective - 18PBA01 defective O1850 - pulleys, bearings or tensioner of main transport defective - transport rollers side door stuck - deflector specialities stuck - internal tray input sensor 18SO1 defective - 18EM1 speciality tray solenoid continuous activated or defective - spring too weak of 18EM1 - timing belt main transport broken - timing belt decurl unit defective (FUNC 17) - deflector stuck or run heavily or spring too weak 18EM1 (FUNC 17) - inverter deflector solenoid 17EM1 continuous activated (FU17)
102 Finisher 18
TSM 2475
Part I ed.6
18diag
DIAGNOSTIC
CODES O1850
POSSIBLE FAILURES - timing belt inverter broken (FUNC 17) - inverter deflector solenoid 17EM1 defective or not activated ( 17) - bearings decurl unit defective (FUNC 17) - inverter output clutch 17CL3 defective or not activated FUNC 17) - inverter output clutch 17CL3 continuous activated (FUNC 17) - inverter input clutch 17CL2 defective or not activated (FUNC 17) - inverter input clutch 17CL2 continuous activated (FUNC 17) - bearings or pulley of inverter defctive (FUNC 17) - bearing of cam stapler stuck - timing belt roller brush broken - static eliminator internal tray defective - stopper/delivery mechanism stuck or defective - stapler spring broken - timing belt positioning belts broken - unlock mechanism stapler defective - one way bearing knocker positioning defective, stuck - plunger of stapler stuck - knocker solenoid 18EM3 continue activated - knocker mechanism stuck - positioning belts defective or worn - knocker position sensor 18SO7 defective - 18PBA01 defective - plunger of stapler stuck - knocker position sensor 18SO7 defective - unlock mechanism stapler defective - one way bearing knocker positioning defective, stuck - bearing of cam stapler stuck - timing belt roller brush broken - stapler spring broken - knocker solenoid 18EM3 continue activated - stopper/delivery mechanism stuck or defective - knocker mechanism stuck - static eliminator internal tray defective - stapler spring broken - bearing of cam stapler stuck - static eliminator of set delivery defective - internal tray output sensor 18SO4 defective - unlock mechanism stapler defective - stopper/delivery mechanism stuck or defective
O1851
O1852
O1853
ed.6 Part I
TSM 2475
18 Finisher 103
DIAGNOSTIC
18diag
CODES O1853
POSSIBLE FAILURES - static eliminator internal tray defective - plunger of stapler stuck - 18PBA01 defective - 18EM1 speciality tray solenoid defective or not activated - speciality sensor 18SO6 defective, continuous low - deflector specialities stuck - transport rollers side door stuck - bearings decurl unit defective (FUNC 17) - timing belt decurl defective (FUNC 17) - deflector specialities stuck - transport rollers side door stuck - bearings decurl unit defective (FUNC 17) - timing belt decurl defective (FUNC 17) - plunger of stapler stuck - unlock mechanism stapler defective - one way bearing knocker positioning defective, stuck - bearing of cam stapler stuck - timing belt roller brush broken - stapler spring broken - upper knocker solenoid 18EM4 continue activated - stopper/delivery mechanism stuck or defective - knocker mechanism stuck - static eliminator internal tray defective - upper knocker position sensor 18PBA12 defective - stapler spring broken - bearing of cam stapler stuck - static eliminator of set delivery defective - upper internal tray output sensor 18SO10 defective - unlock mechanism stapler defective - stopper/delivery mechanism stuck or defective - static eliminator internal tray defective - plunger of stapler stuck - 18PBA03 defective - plunger of stapler stuck - unlock mechanism stapler defective - one way bearing knocker positioning defective, stuck - bearing of cam stapler stuck
O1854
O1855
O1856
O1857
O1858
104 Finisher 18
TSM 2475
Part I ed.6
18diag
DIAGNOSTIC
CODES O1858
POSSIBLE FAILURES - timing belt roller brush broken - stapler spring broken - upper knocker solenoid 18EM4 continue activated - stopper/delivery mechanism stuck or defective - knocker mechanism stuck - static eliminator internal tray defective - upper knocker position sensor 18PBA12 defective - stapler spring broken - bearing of cam stapler stuck - static eliminator of set delivery defective - upper internal tray output sensor 18SO10 defective - unlock mechanism stapler defective - stopper/delivery mechanism stuck or defective - static eliminator internal tray defective - plunger of stapler stuck - 18PBA03 defective
O1859
W1875 - No staples (lower stapler) - staples pulled back - staple transport not correct - stapler spring broken - standby motor does not run, check pressure timing belt - stapling safety clutch 18CL4 defective or not activated (SDS test 18 4 09) - stapling safety clutch 18CL4 slips, test on sets of 35 sheets, use grease - stapler clutch 18CL2 defective or not activated (SDS test 18 4 08) - stapler clutch 18CL2 slips (test on sets of 35 sheets), use grease - stapler clutch 18CL2 adjusted wrongly, do adjustment 18-10 (critical adjustment !) - bearing of cam stapler stuck - unlock mechanism stapler defective - stapler sensor 18S4 defective, open - anvil of stapler defective - timing belt stapler defective - plunger of stapler stuck - stapler defective NOTE : If staples are deformed or crown-shaped, mount new driver (blank steel) and do adjustment 18-3. Fault table continue : next page.
ed.6 Part I
TSM 2475
18 Finisher 105
DIAGNOSTIC
18diag
CODES W1876
POSSIBLE FAILURES - one way bearing shift copy tray defective, loose - copy tray shift sensor 18SO2 defective - guide of copy tray stuck - knocker/tray shift motor 18M2 defective or not activated - 18PBA02 defective
W1877 - No staples (upper stapler) - staples pulled back - staple transport not correct - stapler spring broken - standby motor does not run, check pressure timing belt - stapling safety clutch 18CL4 defective or not activated (SDS test 18 4 09) - stapling safety clutch 18CL4 slips, test on sets of 35 sheets, use grease - stapler clutch 18CL5 defective or not activated (SDS test 18 4 10) - stapler clutch 18CL5 slips (test on sets of 35 sheets), use grease - stapler clutch 18CL5 adjusted wrongly, do adjustment 18-10 (critical adjustment !) - bearing of cam stapler stuck - unlock mechanism stapler defective - stapler sensor 18S6 defective, open - anvil of stapler defective - timing belt stapler defective - plunger of stapler stuck - stapler defective NOTE : If staples are deformed or crown-shaped, mount new driver (blank steel) and do adjustment 18-3.
106 Finisher 18
TSM 2475
Part I ed.6
18diag
DIAGNOSTIC

18SO1, finisher lower internal tray input sensor, is used for synchronous checks when making copies (not interleaf, bypass, fault copies). - if the leading edge of a copy arrives too late, ORE1850 - if the trailing edge releases the sensor too late, ORE1851
ORE 1852 ORE 1853

18SO4, finisher lower internal tray output sensor, is used to make synchronous checks when a set (stapling) or single copies (batch, sort) are ejected to the output tray (not interleaf, bypass, fault copies). - if the leading edge of set/copy arrives too late, ORE1852 - if the trailing edge releases the sensor too late, ORE1853
ORE 1854 ORE 1855

ORE 1856 ORE 1857

18SO8, finisher upper internal tray input sensor, is used for synchronous checks when making copies (not interleaf, bypass, fault copies). - if the leading edge of set/copy arrives too late, ORE1856 - if the trailing edge releases the sensor too late, ORE1857
ed.6 Part I
TSM 2475
18 Finisher 107
DIAGNOSTIC
18diag
ORE 1858 ORE 1859

18SO10, finisher upper internal tray output sensor, is used to make synchronous checks when a set (stapling) or single copies (batch, sort) are ejected to the upper output tray (not interleaf, bypass, fault copies). - if the leading edge of set/copy arrives too late, ORE1858 - if the trailing edge releases the sensor too late, ORE1859
MRE 1825 PE 1810

18SO3, finisher lower set delivery sensor, is used to check if the set delivery motor/mechanism operates. - after starting the set delivery motor an edge should be recognised within 300ms/600ms for respectively a half/whole revolution. Otherwise, MRE1825, PE1810
MRE 1826 PE 1811

FINLOKNPA is used as feedback signal to check if the requested lower knocker position is reached. 2520ms after starting the knocker/tray shift motor the position should be reached: - FINLOKNPA = 1 , correct - FINLOKNPA = 0 , new position not reached in time, MRE1826, PE1811
MRE 1827 PE 1812

18SO3, finisher upper set delivery sensor, is used to check if the set delivery motor/mechanism operates. - after starting the set delivery motor an edge should be recognised within 300ms/600ms for respectively a half/whole revolution. Otherwise, MRE1827, PE1812
108 Finisher 18
TSM 2475
Part I ed.6
18diag
DIAGNOSTIC
MRE 1828 PE 1813

FINUPKPASE is used as feedback signal to check if the requested upper knocker position is reached. 2520ms after starting the knocker motor the position should be reached: - FINUPKPASE = 1 , correct - FINUPKPASE = 0 , new position not reached in time, MRE1828, PE1813
Warning 1875
18S4, finisher lower staple sensor, detects if a staple is inserted successfully. 400ms after the staple command the level of FINLOSSE is checked. - 1, correct - 0, staple not fixed correctly, WARNING 1875
Warning 1876
18SO2, finisher copy tray shift sensor, is used to check if the output tray shift operates. - 700ms after starting the knocker / tray shift motor an edge should be regognised. Otherwise, WARNING 1876
Warning 1877
18S6, finisher upper staple sensor, detects if a staple is inserted successfully. 400ms after the staple command the level of FINUPSSE is checked. - 1, correct - 0, staple not fixed correctly, WARNING 1877
ed.6 Part I
TSM 2475
18 Finisher 109
DIAGNOSTIC
18diag
110 Finisher 18
TSM 2475
Part I ed.6
18sds
SDS
TESTNUMBER COMPONENT COUNTERS 18 0 10 PE 18 0 11 PE 18 0 12 PE 18 0 13 PE 18 0 25 MRE 18 0 26 MRE 18 0 27 MRE 18 0 28 MRE 18 0 50 ORE 18 0 51 ORE 18 0 52 ORE 18 0 53 ORE 18 0 54 ORE 18 0 55 ORE 18 0 56 ORE 18 0 57 ORE 18 0 58 ORE 18 0 59 ORE 18 0 75 W 18 0 76 W 18 0 77 W 18 0 90 C PARAMETERS 18 1 90
SIGNAL -0-
DESCRIPTION in SDS
18PBA07 18PBA12 18PBA07 18PBA12 18SO1 18SO1 18SO4 18SO4 18SO6 18SO6 18SO8 18SO8 18SO10 18SO10
lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up fin. knocker position failure lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up fin. knocker position failure copy too late at 18SO1 18SO1 too late free copy too late at 18SO4 18SO4 too late free speciality too late at 18SO6 18SO6 too late free copy too late at 18SO8 18SO8 too late free copy too late at 18SO10 18SO10 too late free no lower stapling copy tray shift failure no upper stapling number of staples with head (K) -1no. of staples per head (K) : Note 1
Note 1: Number of staples are counted only for the lower head.
ed.6 Part I
TSM 2475
18 Finisher 201
SDS
18sds
TESTNUMBER COMPONENT INPUT TESTS 18 2 01 18 2 02 18 2 03 18 2 04 18 2 05 18 2 06 18 2 07 18 2 08 18 2 09 18 2 10 18 2 11 18 2 12 18 2 13 18 2 14 18 2 15 18 2 16 18 2 17 18 2 18 18S1 18S2 18S3 18S4 18S5 18S6 18SO1 18SO2 18SO3 18SO4 18SO5 18SO6 18SO8 18SO9 18SO10 18SO11
SIGNAL -2FINCOUSE FINCORSE FINOLSSE FINLOSSE FINCOFSE FINUPSSE FINLOTISE FINCTSHSE FINLOSDSE FINLOTOSE FINLOTFSE FINSPECSE FINUPTISE FINUPSDSE FINUPTOSE FINUPTFSE FINLOKNPA FINUPKNPA
DESCRIPTION in SDS
FINisher COver Up SEnsor FINisher COver Right SEnsor FINisher Off-Line Stapling SEnsor FINisher LOwer Stapling SEnsor FINisher COver Front SEnsor FINisher UPper Stapling SEnsor FINisher LOwer internal Tray Input SEnsor FINisher Copy Tray SHift SEnsor FINisher LOwer Set Delivery SEnsor FINisher LOwer internal Tray Output SEnsor FINisher LOwer copy Tray Full SEnsor FINisher SPECiality SEnsor FINisher UPper internal Tray Input SEnsor FINisher UPper Set Delivery SEnsor FINisher UPper internal Tray Output SEnsor FINisher UPper copy Tray Full SEnsor FINisher LOwer KNocker Position Arrived FINisher UPper KNocker Position Arrived
202 Finisher 18
TSM 2475
Part I ed.6
18sds
SDS
TESTNUMBER COMPONENT OUTPUT TESTS 18 4 01 18 4 02 18 4 03 18 4 04 18 4 05 18 4 06 18 4 07 18 4 08 18 4 09 18 4 10 18M1 18M2 18M4 18EM1 18EM3 18EM4 18EM5 18CL2 18CL4 18CL5
SIGNAL -4FINLOSDMO FINCTSHMO FINUPSDMO FINSTSO FINLOKNSO FINUPKNSO FINUTSO FINLOSCL FINSSCL FINUPSCL
DESCRIPTION in SDS
FINisher LOwer Set Delivery MOtor FINisher Copy Tray SHift MOtor FINisher UPper Set Delivery MOtor FINisher Speciality Tray SOlenoid FINisher LOwer KNocker SOlenoid FINisher UPper KNocker SOlenoid FINisher Upper Tray SOlenoid FINisher LOwer Stapler CLutch FINisher Stapling Safety CLutch FINisher UPper Stapler CLutch
ed.6 Part I
TSM 2475
18 Finisher 203
SDS
18sds
TESTNUMBER COMPONENT SPECIAL TESTS 18 6 01 18 6 02 18 6 03 18 6 04 18 6 05 18 6 06 18 6 07 18 6 08 18 6 09 18 6 10 18 6 11 18 6 12 REPLACE CONSUMABLES 18 8 90
SIGNAL -6-
DESCRIPTION in SDS
FINKNFOR1..3 FINUPSDMO FINUPSDMO
FINKNFOR1..3 FINLOSDMO FINLOSDMO
make function WARM make function COLD mask function protections FINisher KNocker FORmat1..3 : Note 2 Note 3 Note 4 FIN. adj. upper set del. motor : Note 6 Note 2 Note 3 Note 4 FIN. adj. lower set del. motor : Note 6 Note 5
-8repl. routine new staplehead (K): only for the lower staplehead
Note 2: Finisher knocker position test (upper, lower). By pressing <PRINT> the knocker is moved to the 356mm position, while the format is displayed. Every time after pressing <PRINT> the knocker is moved to the next format while the format is displayed. The sequence is: 356>330>297>279>270>254>356>... mm. Note 3: Finisher set delivery full rotation. By pressing <PRINT> FINUPSDMO, or FINLOSDMO becomes high until a half revolution is made. Next the motor will make another half revolution. The test is automatically ended when a full revolution is made. Note 4: Finisher set delivery half revolution. By pressing <PRINT> FINUPSDMO, or FINLOSDMO becomes high for a short moment. The motor will make a half revolution. The test is automatically ended after a half revolution. Note 5: Finisher copy tray shift test. By pressing <PRINT> the copy receiving tray is shifted. The direction depents on the current position. Note 6: The finisher section is made warm (initialized). Next the set delivery motor is switched on for a period of time, while the edges of the finisher set delivery sensor (18SO3, or 18SO9) are counted. The nominal value is 30. Refer to adjustment.
204 Finisher 18
TSM 2475
Part I ed.6
18adju
ADJUSTMENTS
ADJUSTMENTS 1 Heigth stapler head Aim:

To achieve a correct stapling pressure and to garantee staple belt transport.
Check:
Use special tool 7991.328 to check the gap between the stapler and the anvil. NOTE: Make sure that eccentric -D- is in stand by position, for both the upper and lower stapler. Lower stapler : Remove copy receiving trays and side covers to check the gap. Upper stapler : Open top lid and internal tray unit and remove guarding plate upper stapler;
Correction:
1.1 Remove the stapler release handle (2x), top cover preheat section and front cover of the finisher; NOTE : Do not forget to disconnect connector 18S03 of the off line stapling sensor (18S3). 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Place the stapler clutch in the home position; Loosen nut -A-; Place special tool codenr. 7991.328, as shown; Turn excentric shaft -B- to adjust the gap; Eliminate the play between arm -Cand cam -D- ; Lock excentric shaft -B- with nut -A-; Mount all removed parts.
18adj01b
18adj01a
ed.6 Part I
TSM 2475
18 Finisher 301
ADJUSTMENTS
18adju
Sideways tolerance stapler Aim:

To achieve a correct stapler movement.
Check:
Lower stapler : Remove copy receiving trays and side covers. Upper stapler : Open top lid and internal tray unit and remove guarding plate upper stapler; - both the internal receiving tray bottom plates. Close the internal tray unit and top lid. Measure A = 8.3 0.1 mm for both the staplers. If incorrect proceed with 2.1. Push the stapler against -B- and check with a feeler gauge gap C =0.10.1 mm. If incorrect proceed with 2.5.
Correction:
2.1 Remove the stapler release handle (2x), top cover preheat section and front cover of the finisher; Loosen nut -D-; Adjust bolt -B-: A = 8.3 0.1 mm; Tighten nut -D-. Loosen nut -F-. Push the stapler against -B-; Adjust bolt -E-: C = 0.1 0.1 mm; Tighten nut -F-; NOTE : Check measurement C = 0.1 0.1 mm after closing the internal tray unit ! 2.9 Mount the guarding plate upper stapler; NOTE : When mounting the guarding plate by pushing it down in the slot of the frame, be sure that it is completely down when tightening the bolt. 2.10 Check adjustment 18-3.
2.2 2.3 2.4 2.5 2.6 2.7 2.8
18adj02a
302 Finisher 18
TSM 2475
Part I ed.6
18adju
ADJUSTMENTS
Anvil position Aim:

To achieve a correctly formed staple.
Check:
For both the upper and lower stapler : Staple several sets of 2 sheets 80g/m2 (20 lb). Check the shape of the pins: * Figure a. shows the correct shape. * Figure b. and c. showing the wrong shape.
Correction:
18adj03c
3.1 3.2 3.3 3.4 3.5
Check adjustment 18-2. Remove the stapler release handle (2x), top cover preheat section and front cover of the finisher; Remove both the copy receiving trays and side covers; Loosen bolts -A- (2x). Place special tool 7991.333 in stapler head -C-. NOTE : Do not use plastic tool 7991.333 more than 10 times ! Wear out can damage the precision of the tool.
3.6 3.7 3.8 3.9
Position the stapler head with the green handlebar against the anvil -B- and move the anvil in such a way that the ridge of the special tool fits exactly in the anvil. Hold the anvil in place and tighten bolts -A- (2x) carefully. Remove the special tool. Mount all removed parts.
18adj03b
18adj03a
ed.6 Part I
TSM 2475
18 Finisher 303
ADJUSTMENTS
18adju
Lock plate internal tray unit and top lid Aim:

To achieve a correct locking of the internal tray unit and top lid.
Check:
Open and close the top lid; the maximum allowed play between catch -A- and lock plate -B- is 0.2mm. Open and close the internal tray unit; the maximum allowed play between catch -A- and lock plate -B- is 0.2mm.
Correction:
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Remove the stapler release handle (2x), top cover preheat section and front cover of the finisher; Close the internal tray unit; Loosen bolts -C- (2x) (fingertight); Hook catch -A- into locking bracket -B-; Push the internal tray unit downwards (at the front); Move locking bracket -B- against catch -A-; Tighten bolts -C- (2x); Follow the same procedure for the top lid; Mount all removed parts.
247506
304 Finisher 18
TSM 2475
Part I ed.6
18adju
ADJUSTMENTS
Internal receiving tray bottom plate (upper and lower finisher). Aim:
Check:
Correction:
5.1 5.2 5.3
5.4 5.5
The same correction for both the internal receiving tray bottom plates; Remove the cover at the rear side of the finisher; Loosen nut -C- at the rear; Turn excentric shaft -D- (allen screw) in such a way, that the top of the internal receiving tray -B- levels with roller -A-; Lock shaft -D- with nut -C-; Mount all removed parts.
ed.6 Part I
TSM 2475
18 Finisher 305
ADJUSTMENTS
18adju
Finisher speciality tray solenoid (18EM1) Aim:

Check:
Make several copies (minimum of 2 originals) via bypass and via the two paper trays. Check that the copies are delivered correctly into the speciality tray or into the upper copy receiving tray.
Correction:
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 Open the finisher side door; Remove side door cover; Remove the black cover, bolts -A-; Loosen bolts -B- (inner side) (2x); Move solenoid -C- upwards until deflector -D- just touches buffer -E-; Tighten bolts -B- (2x); Close the finisher side door; Activate sds-test 18 4 04; Check if the solenoid operates, the solenoid pin extends at least 7.5 mm above the solenoid housing when the deflector touches buffer -E-; 6.10 If necessary proceed with 6.4; 6.11 Mount all removed parts.
306 Finisher 18
TSM 2475
Part I ed.6
18adju
ADJUSTMENTS
Finisher upper tray solenoid (18EM5) Aim:

Check:
Make several copies (minimum of 2 originals) via the two paper trays Check that the copies are delivered correctly into the lower and upper copy receiving tray.
Correction:
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 Open the finisher side door; Remove the rear cover (2 bolts -A-); Remove the tensioner of the finisher main drive belt; Loosen bolts -B- (2x); Move solenoid -C- upwards until deflector -D- just touches buffer -E-; Tighten bolts -B- (2x); Close the finisher side door; Activate sds-test 18 4 07; Check if the solenoid operates, the solenoid pin extends at least 7.5 mm above the solenoid housing when the deflector touches buffer -E-; 7.11 If necessary proceed with 7.4; 7.12 Mount the tensioner of the finisher drive belt and rear cover.
ed.6 Part I
TSM 2475
18 Finisher 307
ADJUSTMENTS
18adju

To achieve a correct detection of a full copy receiving tray for both the upper and lower finisher.
Check:
Correction:
8.1 8.2 8.3 8.4 Open the finisher top lid; Select and activate sequencely test 18 2 11 (18SO5, lower tray) or 18 2 16 (18SO11, upper tray); Loosen bolt -A- and turn nut -B-; Put fork -C- on a level of 68 2 mm above the copy receiving tray, the sensor is just active (buzzer on) and tighten bolt -A-, otherwise proceed with 8.3.
308 Finisher 18
TSM 2475
Part I ed.6
18adju
ADJUSTMENTS

To achieve reliable set delivery for the upper and lower output tray.
Check:
Close the finisher top lid. Select and activate test 18 6 07 (upper) or 18 6 11 (lower). * The motor initializes and then runs for approximately 4.9 s and stops. The value the display shows must be 30.
Correction:
NOTE: This adjustment has to be carried out if a new finisher controlboard (18PBA03 = upper, -B- or 18PBA02 = lower, -A-) and/or the set delivery motor (18M1 or 18M4) has/have been installed. The top cover has to be mounted. 9.1 9.2 9.3 Open the finisher side door; Open the paper guide plate and pull out the PBA tray; Select and activate test 18 6 07 (upper) or 18 6 11 (lower). In the display appears a value : Value < 30: the motor runs too slowly: - Turn potentiometer R35 on -A- (18PBA02) or -B- (18PBA03) one turn clockwise; - Repeat the procedure until the read out is 30. Value > 30: the motor runs too fast: - Turn potentiometer R35 on -A- (18PBA02) or -B- (18PBA03) one turn counter clockwise; - Repeat the procedure until the read out is 30.
ed.6 Part I
TSM 2475
18 Finisher 309
ADJUSTMENTS
18adju
10
Stapler clutch upper and lower finisher (18CL5 and 18CL2) Aim:
To achieve a reliable function of the stapler clutch.
Correction:
10.1 Remove the rear cover (2 bolts); Also for the lower stapler : Remove rear covers paper trays 10.2 Loosen bolts -A- of solenoid -B- 1/2 a turn; 10.3 Activate test 18 4 10 or 18 4 08; 10.4 Place a feeler gauge of 1 mm between the lever -C- of solenoid -B- and cam -D-; 10.5 Move the solenoid against the gauge and tighten bolts -A-;
10.6 Deactivate test 18 4 10 or 18 4 08; 10.7 Loosen screws -E- of buffer -F-; 10.8 Place a feeler gauge of 0.5 mm between the lever -C- of solenoid -Band stop -F-; 10.9 Move buffer -F- against lever -C- of solenoid -B-; 10.10 Tighten screws -E-; 10.11 Mount all removed parts.
18adj13a
18adj13b
310 Finisher 18
TSM 2475
Part I ed.6
18adju
ADJUSTMENTS
11
Adjustment plate of the side door switch (18S2) Aim:

To achieve a reliable function of the side door switch.
Check :
Select test 18 2 02 and check if 18S2 operates by opening and closing of the side door.
Correction :
NOTE :Adjustment only with closed side door; 11.1 Remove the rear cover (2 bolts); 11.2 Loosen bolts -A-; 11.3 Place the plate in position with respect to the micro switch, 5 0.5 mm by turning the plate; 11.4 Tighten bolts -A-; 11.5 Check (SDS 18 2 02) if the switch operates by opening and closing of the side door; 11.6 Mount all removed parts.
ed.6 Part I
TSM 2475
18 Finisher 311
ADJUSTMENTS
18adju
12
Adjustment transport rollers Aim :

To realise a correct transport of the copies to the upper output tray of the finisher.
Check :
Remove top cover and guide plates paper transport; Check if the gap between the two rollers is 22.5 - 0.5 mm, if not proceed with 12.1.
Correction :
NOTE : Guide plates paper path must not been mounted ! 12.1 Remove guarding plate front; 12.2 Loosen bolts -A- hand tight; NOTE : The slide bearings of the rollers have to be mounted with the recess below. 12.3 Turn the plates -C- on their turning point -B- to adjust the gap between the rollers -D- and -E- (22.5 - 0.5 mm); 12.4 Tighten bolts -A-; 12.5 Mount all removed parts.
247504
312 Finisher 18
TSM 2475
Part I ed.6
18adju
ADJUSTMENTS
13
Adjustment bracket top lid switch (18S1) Aim :

To achieve a reliable function of the top lid switch.
Check :
Select test 18 2 01 and check if 18S1 operates by opening and closing of the top lid.
Correction :
13.1 13.2 13.3 13.4 13.5 13.6 Open the top lid and remove top cover (4 bolts); Loosen bolts -A- and -B- (hand tight); Close the internal tray upper, check if bracket -C- operates the switch -D-; Turn the bracket until the buzzer operates; Tighten the bolts -A- and -B- sequencely; Check if the switch operates by opening and closing of the internal tray, SDS test 18 2 01.
247505
ed.6 Part I
TSM 2475
18 Finisher 313
ADJUSTMENTS
18adju
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314 Finisher 18
TSM 2475
Part I ed.6
18disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1 1.2
Dis/assembly of top plate of the top unit.

Disassembly and assembly of the plate must be done when the top unit is opened. When mounting the plate back again, tighten the bolts in the sequence indicated in the figure below ! This to prevent twisting of the top unit.
ed.6 Part II
TSM 2475
18 Finisher 401
DIS/ASSEMBLY
18disa
Tilt procedure finisher Oc 2475

If the 2475 has to be transported through small areas, it is possible to reduce the size of the copier without removing the finisher. When you follow the procedure below, you can tilt the finisher on the copier.
2.1
2.2
2.3 2.4
2.5
2.6 2.7
Remove : - Front door of the finisher, rear cover of the finisher, rear covers of the paper section; - Rear frame cover behind the original tray; - Receiving trays and lower left-hand side cover of the finisher; - Slide rail assy of the receiving trays (2 bolts); - Open the preheater section and remove the top cover, the handle and preheater section cover (blue); - Frame cover at the front of the finisher; - Main drive belt and standby drive belt (loosen the tensioners of both drive belts); - Finisher locking plates (front and rear); - Original input tray (RDF) Disconnect : - connector 18CN5 and the earth strap at the rear of the finisher; - connector 1801CN04, 1801CN05 and 1801CN06 on 18PBA01 at the front; Loosen (do not remove) the two M10 bolts (front and rear) which attach the finisher to the frame. Take one rod of the master mounting tool and insert it through the holes at the left of the finisher (see figure). Take the plastic rollers out of the bag which also contains the tools to split the machine (located at fig.1 the rear side in a plastic bag of the machine). Slide these rollers over the rod at the front and rear.
Take out the locking bracket from the inside of the rear cover of the copier. 2.8 Now you can tilt the finisher: lift the finisher at the right-hand side and move the finisher gently with the plastic rollers onto the main frame. 2.9 Rear side : Mount one side of the locking bracket onto the shaft of the finisher and mount the other side of the bracket (with the slot) onto the main frame. The other side of the bracket in the most right mounting hole of the finisher locking plate, by using one of the bolts of the locking plate of the machine; do not yet tighten the bolts. 2.10 Pull back the finisher carefully, so that the bolt which holds the bracket moves into the upper slot of the bracket (see fig.2); 2.11 Tighten the bolt.
fig.2
402 Finisher 18
TSM 2475
Part II ed.6
18disa
DIS/ASSEMBLY
3
3.1
Removing the finisher of the Oc 2475

Remove : - Front door of the finisher, rear cover of the finisher, rear covers of the paper section; - Rear frame cover behind the original tray; - Receiving trays and lower left-hand side cover of the finisher; - Frame cover at the front of the finisher; - Main drive belt and standby drive belt (loosen the tensioners of both drive belts); - Finisher locking plates (front and rear); - Front door of the finisher; - Front inner cover finisher; - Cover of the right-hand side door and top cover of the finisher; Disconnect : - connector 18CN5 and the earth strap at the rear of the finisher; - connector 1801CN04, 1801CN05 and 1801CN06 on 18PBA01 at the front; Right-hand side door; - To remove the right-hand side door, remove the metal cable from the finisher (when the door is closed!). - Remove the shoulder bolt from the metal strip. - Remove the blank plate (2 bolts) at the rear of the finisher and remove the connector of the solenoid. - Remove the cover above the bypass. fig.3 Remove the two bolts (M10) front and rear, which attach the finisher to the main frame. Take two rods of the master mounting tool and place them into the holes of finisher frame (see fig.4). Now you can remove the finisher with two persons. Place the finisher on a flat surface as indicated.
3.2
3.3
3.4 3.5
3.6
fig.4
ed.6 Part II
TSM 2475
18 Finisher 403
DIS/ASSEMBLY
18disa
Stapler
See chapter finisher Dis/assembly of the Oc 2400, the procedure is the same for the Oc 2475.
Knocker mechanism

404 Finisher 18
TSM 2475
Part II ed.6
2475func
FUNCTIONAL DESCRIPTION 1 Finisher Oc 2475

The double finisher enables the base machine to operate with full speed duplex (75 copies/min). With full speed duplex two copies of the same original are processed simultaneously. Therefore the finisher is equipped with two receiving trays with a capacitiy of 500 sheets of 80 gr/m2 each. Bypass copies, fault copies and interleaves are delivered into the speciality tray.
Operating modes:
Sorting (using the RDF) If the runlength is greater than 1, copies are delivered alternating in the upper and lower tray. In both single and double sided copy mode copies are made in the sequence 11 22 33 44 etc. This results in a most efficient usage of the copy trajectory (full speed duplexing). No master image is skipped, because during turning of the first sheet (copied on one side), the second sheet is in the transfuse pinch (copied). During turning of the second sheet, the first sheet is in the transfuse pinch (copied on the duplex side). With odd numbered run lengths the last copy of the set is made in the sequence 123 resulting in a reduction in speed for the last run (when turning the copy, one master image is skipped). Batching : Copies are batched, first in the lower tray until it is full. After that it will continue in the upper tray. Continuous copying is possible in this mode if the trays are emptied in time.
ed.6 Part II
TSM 2475
18 Finisher 501
2475func
Finisher section
The function of the finisher section is:
to deliver copies (sorted, stapled or batched) in the copy trays; to direct bypass, interleaf or fault copies to the speciality tray. The finisher section consists of: Set delivery unit Stapling unit Internal tray with set positioning Copy tray full detection Finisher top unit Copy tray Paper path Speciality tray
-A-B-C-D-E-F-G-H-
502 Finisher 18
TSM 2475
Part II ed.6
2475func
Delivery Unit
The function of the delivery unit is to deliver stapled sets or single sheets into the copy tray. The delivery unit consists of:
-A-B-C-D-E-F-H-J-
Delivery lifting mechanism; Delivery drive mechanism with motor (18M1, 18M4); Set delivery sensor (18SO3, 18SO9); Internal tray bottom; Delivery pressure roller; Delivery transport roller; Eject rolls; Pinch pressure spring.
18func03
The delivery unit has two positions : Pressure roller up / paper stop down / positioning belts down (staple mode). This is the position in standby and when sheets have to be collected in the internal tray for stapling. To deliver the stapled set, the set delivery motor (18M1, 18M4) makes one complete revolution. During this revolution the delivery pinch is made, the paper stop and the positioning belts are lifted and the set is delivered into the copy tray. Pressure roller down / paper stop up / positioning belts up (sort/batch mode). This is the position to transport single sheets through the internal tray into the copy tray. NOTE : In SDS test 90, configuration deposit fin must be selected, when no deposit is selected, the delivery unit will be placed in through feed position.
ed.6 Part II
TSM 2475
18 Finisher 503
2475func

-A-B-C-DThe drive mechanism consist of : Set delivery motor (18M1, 18M4); Cam with vane; Finisher set delivery sensor (18SO3, 18SO9); Top unit
18func04

The motor 18M1 (18M4) is controlled by signal FINLOSDMO (FINUPSMDO) from the HOST-I/O (22PBA02). When signal FINLOSDMO (FINUPSDMO) goes low 0 and signal FINLOMOEN (FINUPMOEN)is high 1, the set delivery motor (18M1, 18M4) turns. The motor always turns clockwise, as viewed from the front. The set delivery sensor (18SO3, 18SO9) monitors the position of the delivery pressure roller by a vane. The vane is attached to a cam. The cam is driven by the set delivery motor (18M1, 18M4) and moves the set delivery pressure roller up and down. When the set delivery rolls are up, the beam is not interrupted and the signal FINLOSDSE (FINUPSDSE) is high 1. When the set delivery pressure roller is down, the beam is interrupted and the signal FINLOSDSE (FINUOSDSE) is low 0. Delivery of stapled sets When making stapled sets, the set delivery mechanism is in the rest position at the start of the run. As each copy arrives it is positioned against the finisher paper stop by the two positioning belts, and towards the front of the copier by the knocker. When the complete set is collated in the internal tray, the stapler operates, fixing a staple to the corner of the set.
504 Finisher 18
TSM 2475
Part II ed.6
2475func
The set delivery motor (18M1, 18M4) drives an eccentric through one complete revolution when a set needs to be ejected. The set delivery motor is started by making control line FINLOSDMO (FINUPSDMO) high 1. 1 2 3 4 5 6
During the first half-revolution of the cam : The cam on the motor shaft causes the set delivery mechanism to move downwards. The pressure roller is supported at each end by plastic plates which can move up and down freely in slotted brackets. The delivery lifting mechanism moves down and the pressure roller touches the top of the copy set. At the same time the paper stop and positioning belts move upwards, allowing the copy set to be fed out by the eject rolls. The delivery pressure roller presses downwards, making a pinch and thus feeding the set towards the eject rolls (hard pinch). The paper stop moves up until it touches the stop. If there is a thick copy set in the internal tray, the turning action of the delivery mechanism will extend the pinch pressure spring. This provides extra force to the set, making it easier to feed out a thick copy set. During the second half-revolution of the eccentric: The set delivery mechanism moves upwards, driven by the cam. The delivery pressure roller returns to its upper position. The paper stop falls onto the copy set as it leaves the finisher, and then falls into position ready to stop the next copies.
7 8 9

ed.6 Part II
TSM 2475
18 Finisher 505
2475func
Paper path
The paper path brings copies from the duplex station or inverter to the copy receiving trays or speciality tray. If stapling is selected the sheets are collated in the internal trays, stapled and then delivered into the copy receiving trays. The paper path consists of:
-A-B-C-D-E-F-G-H-J-K-
Copy receiving tray; Internal tray output sensor (18SO4), (off-line stapling detection); Internal tray input sensor (18SO1); Internal tray input rollers; Speciality output sensor (18SO6); finisher speciality tray solenoid (18EM1); finisher upper tray solenoid (18EM5); Speciality tray; inverter deflector solenoid (17EM1); Uncurl rollers.
506 Finisher 18
TSM 2475
Part II ed.6
2475func
Circuit diagram description : (see 701) Copies via RDF

If the run length is greater than 1, the first copy is going to the upper finisher. The finisher upper tray solenoid (18EM5) is energized, FINUTSO (coming from the I/O board) is high 1. The finisher speciality tray solenoid (18EM1) is not energized, FINSTSO (coming from the I/O board) is low 0. The finisher speciality sensor (18SO6) senses the leading edge and trailing edge of the copy, when it goes upwards. The finisher upper internal tray input sensor (18PBA8/9) senses the leading edge and the trailing edge of each copy when it enters the internal tray. Control line FINUPTISE is high 1 when the copy is present between transmitter and receiver. The finisher upper internal tray output sensor (18PBA10/11) senses the leading and trailing edge of each copy set when it leaves the internal tray. Control line FINUPTOSE is high 1 when the copy set is present between transmitter and receiver. The second copy is going to the lower finisher. The finisher upper tray solenoid (18EM5) is not energized, FINUTSO (coming from the I/O board) is low 0.The finisher low internal tray input sensor (18PBA04/05) senses the leading edge and the trailing edge of each copy when it enters the internal tray. Control line FINLOTISE is high 1 when the copy is present between transmitter and receiver. The finisher low internal tray output sensor (18PBA06/13) senses the leading and trailing edge of each copy set when it leaves the internal tray. Control line FINLOTOSE is high 1 when the copy set is present between transmitter and receiver. The third copy is going to the upper finisher again. If the run length is equal to 1, all the copies are going to the lower finisher. See description below.
Copies via MDF, CFF, glass platen.

In these modes all copies go to the lower internal tray, where they are either : delivered directly to the lower copy receiving tray or collated, stapled and then delivered to the copy receiving tray. The finisher upper tray solenoid (18EM5) is not energized, FINUTSO (coming from the I/O board) is low 0. The finisher low internal tray input sensor (18PBA04/05) senses the leading edge and the trailing edge of each copy when it enters the internal tray. Control line FINLOTISE is high 1 when the copy is present between transmitter and receiver. The finisher low internal tray output sensor (18PBA06/13) senses the leading and trailing edge of each copy set when it leaves the internal tray. Control line FINLOTOSE is high 1 when the copy set is present between transmitter and receiver.
ed.6 Part II
TSM 2475
18 Finisher 507
2475func
Bypass/interleaf/fault copies.
In these modes copies always are delivered into the finisher speciality tray. The finisher upper tray solenoid (18EM5) is energized, FINUTSO (coming from the I/O board) is high 1. The finisher speciality tray solenoid (18EM1) is also energized, FINSTSO (coming from the I/O board) is high 1. The finisher speciality sensor (18SO6) senses the leading edge and trailing edge of the copy as it enters the finisher speciality tray. FINSPECSE is high 1 when the copy is activating the sensor.
508 Finisher 18
TSM 2475
Part II ed.6
2475func
Stapling unit
The stapling mechanism consists of:
Top cover switch (18S1); Stapler clutch (18CL5; Stapler clutch (18CL2); Stapler safety clutch (18CL4); Stapler unit; Roll of staples; Internal tray output sensor (18SO4); Off-line stapling switch (18S3); Anvil; Internal tray input sensor (18SO1).
ed.6 Part II
TSM 2475
18 Finisher 509
2475func
The lower stapler can operate in two modes: set stapling during a run and off-line stapling. The upper stapler can only staple during run. set stapling during a run After the last copy of a set has been delivered into the internal receiving tray (that is, the trailing edge of the copy has cleared 18PBA04/05, 18PBA08/09) and positioned, the set is ready to be stapled. For stapling both the stapler clutch (18CL2, 18CL5) and the stapler safety clutch (18CL4) must be energized in order to connect the stapler drive to the stapler mechanism. The stapler safety clutch (18CL4) is interlocked with the fin cover up sensor (18S1) and fin cover front sensor (18S5), so that when the top cover or the side door is open, the stapler cannot operate. This is an additional safety precaution. When signal FINSSCL goes high 1, the stapler safety clutch (18CL4) is energized, it connects the stapler drive to the stapler clutch (18CL2, 18CL5). When signal FINLOSCL (FINUPSL) goes high 1, the stapler clutch (18CL2, 18CL5) is energized. This is a one revolution clutch, the shaft driven by this clutch is connected via an eccentric to the stapler lifting mechanism. It makes the stapler go up and down. When the staple is inserted successfully, it closes the contacts of the finisher staple sensor (18S4, 18S6) (this is the circuit between anvil and stapler unit). The signal FINLOSSE (FINUPSSE) goes low 0. If a staple is not detected, an error message will be displayed, but the copy run in progress will continue. The operator will then have to reload the stapler, and staple the sets off-line. Off-line stapling When a set is inserted (face down) from the front of the copier, and pushed against the off-line stop, the set will block the light beam of the low internal tray output sensor (18PBA06/13). The signal FINLOTOSE goes low 0. By moving the set slightly to the right, it will actuate the finisher off-line stapling sensor (18S3) via a lever. The signal FINOLSSE goes low 0. When both sensors are made and the top cover (18S1) and front cover (18S5) are closed, the stapler will be activated.
510 Finisher 18
TSM 2475
Part II ed.6
2475func

The set positioning unit consists of:
-A-B-C-D-E-F-
Positioning belts; Finisher paper stop fingers; Knocker; Finisher Knocker solenoid (18EM3, 18EM4); Roller with brush wheels; Front stop.
18func09
When making stapled sets, the paper stop and positioning belts are down. When making batch/sort sets or single copies, the finisher paper stop and positioning belts are up. See the DELIVERY UNIT description. As each copy arrives in the internal tray, it hits a roller with brush wheels. They guide the sheet into the internal tray. The positioning belts then push the copy against the paper stop. The paper stop is inclined to prevent the leading edge of the paper from climbing up the paper stop. The roller with brush wheels and positioning belts are driven by the finisher main drive. To achieve a set of copies with a minimum of shifted sheets a knocker mechanism is used. The knocker mechanism knocks each copy twice towards the front of the tray against the front stop. The knocker hammer is inclined at 3 to ensure that it always knocks the top sheet in a set of copies.

When the signal FINLOKNSO (FINUPKNSO) from the HOST-I/O (22PBA02) goes high 1, the solenoid (18EM3, 18EM4) becomes energized, via an inverter on the finisher control board (18PBA02, 18PBA03).
ed.6 Part II
TSM 2475
18 Finisher 511
2475func

The lower knocker position mechanism and the copy trays shift mechanism are both driven by the same motor : finisher copy tray shift lower knocker motor (18M2). The finisher upper knocker motor only drives the upper knocker position mechanism. The knocker positioning copy tray shift mechanism (lower) consists of :
-A-B-C-D-E-F-G-H-J-
Finisher copy tray shift lower knocker motor (18M2); Drive mechanism; Tray displacement cam with one way bearing; Copy tray shift sensor (18SO2); Knocker arm; Knocker positioning mechanism; Knocker position sensor (18SO7); Coding strip knocker position sensor; Knocker displacement cam with one way bearing.
18func10
512 Finisher 18
TSM 2475
Part II ed.6
2475func
The finisher copy tray shift lower knocker motor (18M2) has 2 functions: Shift the copy trays; Position the lower knocker mechanism. The motor is connected to the copy tray shift mechanism by a one-way bearing, and to the knocker positioning mechanism by another one-way bearing. The two copy trays are connected to each other mechanically. Thus when the motor turns counterclockwise (viewed from the gear-box end) it will move the copy trays, and when it turns clockwise it will move the knocker. It is never required to perform both functions at the same time.

The motor (18M2) is controlled by the signals FINLOKNMO1 and FINLOKNMO2 from the finisher control board (18PBA02). When FINLOKNMO1 is connected to ground and FINLOKNMO2 is connected to +24V, the motor turns counter-clockwise and drives the copy trays. When FINKNTSMO1 is connected to +24V and FINKNTSMO2 is connected to ground, the motor turns clockwise and positions the loer knocker mechanism. Copy tray shift The finisher low motor enable signal FINLOMOEN must be high 1 before the motor will drive. When the copy tray shift signal FINCTSHMO is high 1, it will cause the motor to turn counter-clockwise thus moving the copy trays. A cam moves the copy tray over a total distance of 30mm (front - rear). A vane on the cam interrupts / releases the beam of the copy tray shift sensor (18SO2) every 1/2 revolution. When the copy trays are at the rear or front, the control stops the motor (18M2). When the beam is interrupted signal FINCTSHE goes high 1.
ed.6 Part II
TSM 2475
18 Finisher 513
2475func
Knocker positioning mechanism The knocker has six positions, corresponding with the six paper lengths that are detected by the paper format sensor in the paper tray. The knocker format sensor (18PBA07, 18PBA12) (three optical sensors) is used to detect the knocker position. The 3 signals FINLOFORSE1,2,3 (FINUPFORSE1,2,3) are sent to the finisher control (18PBA02, 18PBA3) where they are compared with the paper size information from the control FINKNFOR1,2,3. The signals are decoded according to the following table. sensor 1 0 0 0 1 1 1 sensor 2 0 1 1 1 1 0 sensor 3 1 1 0 0 1 1 paper size 254 mm 270 mm 279 mm 297 mm 330 mm 356 mm sensor 1 0 0 1 1 1 0 sensor 2 0 1 1 1 0 0 sensor 3 1 1 1 0 0 0
FINISHER SENSORS Sensor 1: FINLOFORSE1/FINUPFORSE1 Sensor 2: FINLOFORSE2/FINUPFORSE2 Sensor 3: FINLOFORSE3/FINUPFORSE3
PAPER SENSORS Sensor 1: UPTPPSE1 or LPTPSSE1 Sensor 2: UPTPSSE2 or LPTPSSE2 Sensor 3: UPTPSSE3 or LPTPSSE3
NOTE: The strips used by the finisher knocker sensor and the paper size sensors are not the same! Any codes not shown in the above table are not recognised by the control and will result in an error code. The exact position is determined by a spring loaded arm that finds notches in the knocker mechanism guide shafts.
18func11
514 Finisher 18
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Part II ed.6
2475func
When positioning the knocker, the motor (18M2, 18M5) always turns clockwise. A cam connected to a hingable arm mechanism makes an eccentric movement and causes the knocker to move backwards and forwards. Before the motor will start, the finisher motor enable signal FINMOEN must be high 1. A high pulse on the finisher knocker motor control line FINLOKNMO (FINUPKNNMO) causes the motor to start. The signal FINKNMO also energizes a relay on the finisher control board, which reverses the voltage to the motor (before it starts), causing it to drive clockwise and thus move the knocker. A new knocker position is always approached from the rear. 1 2 3 From a large size to a smaller size : The motor starts to drive; The cam will drive the knocker to the front; The knocker moves forward until the new size is detected by sensor 18PBA07 (18PBA12). From a small size to a larger size : The motor starts to drive. The cam will drive the knocker to the front and then to the rear. The control will detect (sensor 18PBA07, 18PBA12) that the knocker is in the largest position (356mm) while moving from front to the rear. The knocker continues moving backwards past the largest position (356mm). It then reapproaches the largest position (356mm), now moving from the rear to the front. So when the control detects the largest position (356mm) for the second time, it knows that the knocker is now moving from the rear to the front. The knocker continues moving to the front until the new size is detected (18PBA07, 18PBA12).
1 2 3 4 5 6 7
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18 Finisher 515
2475func

As the number of copies in the copy tray increases, the fork will rise. There is a vane attached to the fork that will actuate the finisher tray full sensor (18SO5, 18SO11) when there are approx. 500 copies (80 gsm) in the copy tray. This causes the signal FINLOTFSE (FINUPTFSE) to go high 1 and a message will be displayed to the operator.
-A-B-C-D-
Copy tray; Fork; Vane; Finisher copy tray full sensor (18SO5, 18SO12).
516 Finisher 18
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Part II ed.6
2475func

damage the finisher control PBAs (18PBA02, 18PBA03); cause copy transport problems. There are no error messages if the motor fails. The motor (18M3) runs continuously during a run and is controlled by signal MADR. The motor is protected by a thermal fuse that will automatically stop the motor if the temperature exceeds 130C. The thermal fuse will reset itself automatically as the temperature decreases.
ed.6 Part II
TSM 2475
18 Finisher 517
2475func
10
Finisher Drive
The finisher drive consists of two parts:
-A-B-
Finisher main drive; Finisher standby drive. The inverter drive is driven by the finisher main drive (see INVERTER). Each of these drive system is explained in the next section.
518 Finisher 18
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Part II ed.6
2475func
Finisher main drive The finisher main drive is connected to all the paper path rollers in the finisher and inverter. Via the finisher main drive pulley it is connected to the subframe main drive (finisher).
Finisher standby drive The function of the finisher standby drive is to drive the stapler mechanism. This to make off line stapling possible. The finisher standby drive is driven by the subframe standby drive.
ed.6 Part II
TSM 2475
18 Finisher 519
2475func
11
Operation
During Power up / initialisation: When master transport starts (signal MADR), the finisher speciality tray solenoid (18EM1) is energized, FINSTSO goes high 1, and the finisher upper tray solenoid (18EM5) is energized (FINUTSO goes high 1"). The solenoid remains energized until master transport stops. The set delivery motors are started, FINLOSDMO and FINUPSDMO go high 1. Any paper in the internal trays is delivered in the copy trays. The set delivery motors stop when the set delivery mechanisms are in rest position (set delivery rolls are up and paper stops are down). The signal from the set delivery sensors (18SO3, 18SO9), FINLOSDSE/FINUPSDE are high 1. The knocker/tray shift motor (18M2) will: - move the copy trays and stop in the rear position. FINMOEN and FINCTSHMO are high 1 to start the motor (18M2). When the trays are in the rear position the finisher copy tray shift sensor (18SO2) signal FINCTSHE is high 1. - move the knocker to the largest paper size position. FINMOEN and FINLOKNMO (FINUPKNMO) go high 1 to start the motor (18M2, 18M5). When the knocker is positioned correctly, the knocker format sensor (18SO7) has the status : FINFORSE1, FINFORSE2, FINFORSE3 are respectively 1, 0, 1. During standby: Off-line stapling is possible via the lower stapler: A set is inserted for stapling. Lower internal tray output sensor (18PBA06/13) detects the set, signal FINLOTOSE goes low 0. The finisher off-line stapling sensor (18S3) is activated by the set, signal FINOLSSE goes low 0. The finisher cover up sensor (18S1) is closed, signal FINCOUSE is high 1. The finisher cover right sensor (18S2) is closed, signal FINCORSE is 1. The stapler safety clutch (18CL4) and the lower stapler clutch (18CL2) are energized, signals FINSSCL and FINLOSCL go high 1. During run: 1.3s after the exposure flash the knockers is put in the correct position according to the paper size (1.7s in case the copy has to be turned first in the inverter). The finish command is given about 4s after the exposure flash. The command consist of one or more tasks, such as: - staple - copy tray shift - batch - sort
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Part II ed.6
18comp
COMPONENT LOCATION
COMPONENT LOCATION
18CN4 18CN5 18CN6 18CN7 18M1 18M4 18PBA01 18PBA05 (18SO1) 18PBA04 18PBA06 (18SO4) 18PBA13 18PBA10 (18SO10) 18PBA11 18SO5 18SO11 18S3 18S4 18S5 18S6 : : : : : : : : : : : : : : : : : : : connector connector connector connector finisher lower set delivery motor finisher upper set delivery motor finisher adapter finisher lower internal tray input sensor (receiver) finisher lower internal tray input sensor (transmitter) finisher lower internal tray output sensor (receiver) finisher lower internal tray output sensor (transmitter) finisher upper internal tray output sensor (receiver) finisher upper internal tray output sensor (transmitter) finisher lower tray full sensor finisher upper tray full sensor finisher off line stapling sensor finisher lower stapling sensor finisher cover front sensor finisher upper stapling sensor
ed.6 Part II
TSM 2475
18 Finisher 601
COMPONENT LOCATION
18comp
18M1 18M4 18SO3 18SO9
: : : :
finisher lower set delivery motor finisher upper set delivery motor finisher lower set delivery sensor finisher upper set delivery sensor
18comp13
18PBA08 (18SO8) : 18PBA09 : 18S1 :
finisher upper internal tray input sensor (receiver) finisher upper internal tray input sensor (transmitter) finisher cover up sensor
18comp09
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Part II ed.6
18comp
COMPONENT LOCATION
17EM1 18EM1
: :
inverter deflector solenoid finisher speciality tray solenoid
18comp10
18PBA02 18PBA03 18SO6
: : :
finisher control lower finisher control upper finisher speciality sensor
18comp08
ed.6 Part II
TSM 2475
18 Finisher 603
COMPONENT LOCATION
18comp
17CL2 17CL3 18CL2 18CL4 18CL5 18CN5 18EM5 18S2
: : : : : : : :
inverter input clutch inverter output clutch finisher lower stapling clutch finisher stapling safety clutch finisher upper stapling clutch connector finisher upper tray solenoid finisher cover right sensor
18comp11
604 Finisher 18
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Part II ed.6
18comp
COMPONENT LOCATION
18CN2 18EM4 18M5 18PBA12
: : : :
connector upper knocker motor finisher upper knocker solenoid finisher upper knocker motor finisher upper knocker format sensor
18CN6 18EM3 18M2 18PBA07 18SO2
: : : : :
connector copy tray shift lower knocker motor finisher lower knocker solenoid finisher copy tray shift lower knocker motor finisher lower knocker format sensor finisher copy tray shift sensor
ed.6 Part II
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18 Finisher 605
COMPONENT LOCATION
18comp
606 Finisher 18
TSM 2475
Part II ed.6
18elec
ELECTRICAL DIAGRAM

FINCOFSE FINCORSE FINCOUSE FINCTSHMO FINCTSHSE FINKNFOR1..3 FINLOKNMO FINLOKNPA FINLOKNSO FINLOMOEN FINLOSCL FINLOSDMO FINLOSSE FINLOSDSE FINLOTFSE FINLOTISE FINLOTOSE FINOLSSE FINSPECSE FINSSCL FINSTSO FINUPKNMO FINUPKNPA FINUPKNSO FINUPMOEN FINUPSCL FINUPSDMO FINUPSDSE FINUPSSE FINUPTFSE FINUPTISE FINUPTOSE FINUTSO FINisher COver Front SEnsor FINisher COver Right SEnsor FINisher COver Up SEnsor FINisher Copy Tray SHift MOtor FINisher Copy Tray SHift SEnsor FINisher KNocker FORmat bits FINisher LOwer KNocker MOtor FINisher LOwer KNocker Position Arrived FINisher LOwer KNocker SOlenoid FINisher LOwer MOtor ENable FINisher LOwer Stapling CLutch FINisher LOwer Set Delivery MOtor FINisher LOwer Stapling SEnsor FINisher LOwer Set Delivery SEnsor FINisher LOwer copy Tray Full SEnsor FINisher LOwer internal Tray Input SEnsor FINisher LOwer internal Tray Output SEnsor FINisher Off Line Stapling SEnsor FINisher SPECiality SEnsor FINisher Stapling Safety CLutch FINisher Speciality Tray SOlenoid FINisher UPper KNocker MOtor FINisher UPper KNocker Position Arrived FINisher UPper KNocker SOlenoid FINisher UPper MOtor ENable FINisher UPper Stapler CLutch FINisher UPper Set Delivery MOtor FINisher UPper Set Delivery SEnsor FINisher UPper Stapling SEnsor FINisher UPper Tray Full SEnsor FINisher UPper internal Tray Input SEnsor FINisher UPper internal Tray Output SEnsor FINisher UPper Tray SOlenoid
ed.6 Part I
TSM 2475
18 Finisher 701
ELECTRICAL DIAGRAM
18elec
702 Finisher 18
TSM 2475
Part I ed.6
Electrical Diagram
18 FINISHER 701B
Electrical Diagram
18 FINISHER 701C
Electrical Diagram
18 FINISHER 702B
18diag
DIAGNOSTIC
1810 1811 1812 1813 1814 1815 1816 1817 lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up finisher knocker position failure lower finisher motor failure (stapler) upper finisher motor failure (stapler) lower finisher motor blocked (stapler) upper finisher motor blocked (stapler)
MRE
1825 1826 1827 1828 1829 1830 1831 1832 lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up finisher knocker position failure lower finisher motor failure (stapler) upper finisher motor failure (stapler) lower finisher motor blocked (stapler) upper finisher motor blocked (stapler)
ORE
1850 1851 1852 1853 1854 1855 1856 1857 1858 1859 1860 1861 copy too late at 18SO1 18SO1 too late free copy too late at 18SO4 18SO4 too late free speciality too late at 18SO6 18SO6 too late free copy too late at 18SO8 18SO8 too late free copy too late at 18SO10 18SO10 too late free lower finisher motor blocked (stapler) upper finisher motor blocked (stapler)
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18 Finisher 101
DIAGNOSTIC
18diag
Warnings
1876 Copy tray shift failure
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18diag
DIAGNOSTIC
Fault table
M1825, P1810 - lower set delivery motor 18M1 defective or not activated - lower set delivery motor 18M1 continuous activated - lower set delivery sensor 18SO3 defective - lower stopper/delivery mechanism stuck or defective - 24 V absent - 18PBA02 defective - 18PBA01 defective M1826, P1811 - one way bearing knocker positioning defective, loose - lower knocker/tray shift motor 18M2 defective or not activated - lower knocker position sensor 18PBA07 defective - lower guide of knocker positioning stuck - 18PBA02 defective - 18PBA01 defective M1827, P1812 - upper set delivery motor 18M4 defective or not activated - upper set delivery motor 18M4 continuous activated - upper set delivery sensor 18SO9 defective - upper stopper/delivery mechanism stuck or defective - 24 V absent - 18PBA03 defective - 18PBA01 defective M1828, P1813 - one way bearing knocker positioning defective, loose - upper knocker motor 18M5 defective or not activated - upper knocker position sensor 18PBA12 defective - upper guide of knocker position stuck - 18PBA03 defective - 18PBA01 defective M1829, P1814 - 18PBA14 defective (lower stapler) - stapler defective/blocked - 22PBA13 defective - switch 18S5/18S1 defective/not activated M1830, P1815 - 18PBA14 defective (upper stapler) - stapler defective/blocked - 22PBA13 defective - switch 18S5/18S1 defective/not activated Fault table continue : next page.
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18 Finisher 103
DIAGNOSTIC
18diag
CODES
POSSIBLE FAILURES
M1831, P1816 - stapler unit defective/blocked (lower stapler) - 18PBA14 defective - 22PBA13 defective M1832, P1817 - stapler unit defective/blocked (upper stapler) - 18PBA14 defective - 22PBA13 defective O1850 - pulleys, bearings or tensioner of main transport defective - transport rollers side door stuck - deflector specialities stuck - internal tray input sensor 18SO1 defective - 18EM1 speciality tray solenoid continuous activated or defective - spring too weak of 18EM1 - timing belt main transport broken - timing belt decurl unit defective (FUNC 17) - deflector stuck or run heavily or spring too weak 18EM1 (FUNC 17) - inverter deflector solenoid 17EM1 continuous activated (FU17) - timing belt inverter broken (FUNC 17) - inverter deflector solenoid 17EM1 defective or not activated ( 17) - bearings decurl unit defective (FUNC 17) - inverter output clutch 17CL3 defective or not activated FUNC 17) - inverter output clutch 17CL3 continuous activated (FUNC 17) - inverter input clutch 17CL2 defective or not activated (FUNC 17) - inverter input clutch 17CL2 continuous activated (FUNC 17) - bearings or pulley of inverter defctive (FUNC 17) - timing belt roller brush broken - static eliminator internal tray defective - stopper/delivery mechanism stuck or defective - timing belt positioning belts broken - one way bearing knocker positioning defective, stuck - knocker solenoid 18EM3 continue activated - knocker mechanism stuck - positioning belts defective or worn - knocker position sensor 18SO7 defective - 18PBA01 defective
O1851
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18diag
DIAGNOSTIC
CODES O1852
POSSIBLE FAILURES - knocker position sensor 18SO7 defective - one way bearing knocker positioning defective, stuck - timing belt roller brush broken - knocker solenoid 18EM3 continue activated - stopper/delivery mechanism stuck or defective - knocker mechanism stuck - static eliminator internal tray defective - static eliminator of set delivery defective - internal tray output sensor 18SO4 defective - stopper/delivery mechanism stuck or defective - static eliminator internal tray defective - 18PBA01 defective - 18EM1 speciality tray solenoid defective or not activated - speciality sensor 18SO6 defective, continuous low - deflector specialities stuck - transport rollers side door stuck - bearings decurl unit defective (FUNC 17) - timing belt decurl defective (FUNC 17) - deflector specialities stuck - transport rollers side door stuck - bearings decurl unit defective (FUNC 17) - timing belt decurl defective (FUNC 17) - one way bearing knocker positioning defective, stuck - upper knocker solenoid 18EM4 continue activated - stopper/delivery mechanism stuck or defective - knocker mechanism stuck - static eliminator internal tray defective - upper knocker position sensor 18PBA12 defective - static eliminator of set delivery defective - upper internal tray output sensor 18SO10 defective - stopper/delivery mechanism stuck or defective - static eliminator internal tray defective - 18PBA03 defective
O1853
O1854
O1855
O1856
O1857
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18 Finisher 105
DIAGNOSTIC
18diag
CODES O1858
POSSIBLE FAILURES - one way bearing knocker positioning defective, stuck - timing belt roller brush broken - upper knocker solenoid 18EM4 continue activated - stopper/delivery mechanism stuck or defective - knocker mechanism stuck - static eliminator internal tray defective - upper knocker position sensor 18PBA12 defective - static eliminator of set delivery defective - upper internal tray output sensor 18SO10 defective - stopper/delivery mechanism stuck or defective - static eliminator internal tray defective - 18PBA03 defective
O1859
O1860 - staple stuck (lower stapler) - stapler motor has not rotated 1 revolution O1861 - staple stuck (upper stapler) - stapler motor has not rotated 1 revolution W1876 - one way bearing shift copy tray defective, loose - copy tray shift sensor 18SO2 defective - guide of copy tray stuck - knocker/tray shift motor 18M2 defective or not activated - 18PBA02 defective
106 Finisher 18
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18diag
DIAGNOSTIC

18SO1, finisher lower internal tray input sensor, is used for synchronous checks when making copies (not interleaf, bypass, fault copies). - if the leading edge of a copy arrives too late, ORE1850 - if the trailing edge releases the sensor too late, ORE1851
ORE 1852 ORE 1853

18SO4, finisher lower internal tray output sensor, is used to make synchronous checks when a set (stapling) or single copies (batch, sort) are ejected to the output tray (not interleaf, bypass, fault copies). - if the leading edge of set/copy arrives too late, ORE1852 - if the trailing edge releases the sensor too late, ORE1853
ORE 1854 ORE 1855

ORE 1856 ORE 1857

18SO8, finisher upper internal tray input sensor, is used for synchronous checks when making copies (not interleaf, bypass, fault copies). - if the leading edge of set/copy arrives too late, ORE1856 - if the trailing edge releases the sensor too late, ORE1857
ed.7 Part I
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18 Finisher 107
DIAGNOSTIC
18diag
ORE 1858 ORE 1859

18SO10, finisher upper internal tray output sensor, is used to make synchronous checks when a set (stapling) or single copies (batch, sort) are ejected to the upper output tray (not interleaf, bypass, fault copies). - if the leading edge of set/copy arrives too late, ORE1858 - if the trailing edge releases the sensor too late, ORE1859
ORE 1860 ORE 1861

Lower and Upper Finisher (stapler) motor blocked.
MRE 1825 PE 1810

18SO3, finisher lower set delivery sensor, is used to check if the set delivery motor/mechanism operates. - after starting the set delivery motor an edge should be recognised within 300ms/600ms for respectively a half/whole revolution. Otherwise, MRE1825, PE1810
MRE 1826 PE 1811

FINLOKNPA is used as feedback signal to check if the requested lower knocker position is reached. 2520ms after starting the knocker/tray shift motor the position should be reached: - FINLOKNPA = 1 , correct - FINLOKNPA = 0 , new position not reached in time, MRE1826, PE1811
MRE 1827 PE 1812

18SO3, finisher upper set delivery sensor, is used to check if the set delivery motor/mechanism operates. - after starting the set delivery motor an edge should be recognised within 300ms/600ms for respectively a half/whole revolution. Otherwise, MRE1827, PE1812
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18diag
DIAGNOSTIC
MRE 1828 PE 1813

FINUPKPASE is used as feedback signal to check if the requested upper knocker position is reached. 2520ms after starting the knocker motor the position should be reached: - FINUPKPASE = 1 , correct - FINUPKPASE = 0 , new position not reached in time, MRE1828, PE1813
MRE 1829 PE 1814

After starting the lower finisher (stapler) motor, the motor must work within 700 msec, otherwise MRE 1829, PE 1814
MRE 1830 PE 1815

After starting the upper finisher (stapler) motor, the motor must work within 700 msec, otherwise MRE 1829, PE 1814
MRE 1831 PE 1816

The lower finisher (stapler) motor does not move back.
MRE 1832 PE 1817

The upper finisher (stapler) motor does not move back.
Warning 1876
18SO2, finisher copy tray shift sensor, is used to check if the output tray shift operates. - 700ms after starting the knocker / tray shift motor an edge should be regognised. Otherwise, WARNING 1876
ed.7 Part I
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18 Finisher 109
DIAGNOSTIC
18diag
110 Finisher 18
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Part I ed.7
18sds
SDS

SIGNAL -0lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up fin. knocker position failure lower finisher motor failure upper finisher motor failure lower finisher motor blocked upper finisher motor blocked lo set delivery mechanism error lo finisher knocker position failure up set delivery mechanism error up fin. knocker position failure lower finisher motor failure upper finisher motor failure lower finisher motor blocked upper finisher motor blocked copy too late at 18SO1 18SO1 too late free copy too late at 18SO4 18SO4 too late free speciality too late at 18SO6 18SO6 too late free copy too late at 18SO8 18SO8 too late free copy too late at 18SO10 18SO10 too late free lower finisher motor blocked upper finisher motor blocked copy tray shift failure DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 18 0 10 PE 18 0 11 PE 18 0 12 PE 18 0 13 PE 18 0 14 FE 18 0 15 FE 18 0 16 FE 18 0 17 FE 18 0 25 MRE 18 0 26 MRE 18 0 27 MRE 18 0 28 MRE 18 0 29 MRE 18 0 30 MRE 18 0 31 MRE 18 0 32 MRE 18 0 50 ORE 18 0 51 ORE 18 0 52 ORE 18 0 53 ORE 18 0 54 ORE 18 0 55 ORE 18 0 56 ORE 18 0 57 ORE 18 0 58 ORE 18 0 59 ORE 18 0 60 ORE 18 0 61 ORE 18 0 76 W
18PBA07 18PBA12
18PBA07 18PBA12
18SO1 18SO1 18SO4 18SO4 18SO6 18SO6 18SO8 18SO8 18SO10 18SO10
ed.7 Part I
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18 Finisher 201
SDS
18sds
TESTNUMBER COMPONENT PARAMETERS 18 1 90
SIGNAL -1-
DESCRIPTION in SDS
no. of staples per head (K) : Note 1 -218S1 18S2 18S3 18S4 18S5 18S6 18SO1 18SO2 18SO3 18SO4 18SO5 18SO6 18SO8 18SO9 18SO10 18SO11 FINCOUSE FINCORSE FINOLSSE FINLOSSE FINCOFSE FINUPSSE FINLOTISE FINCTSHSE FINLOSDSE FINLOTOSE FINLOTFSE FINSPECSE FINUPTISE FINUPSDSE FINUPTOSE FINUPTFSE FINLOKNPA FINUPKNPA FINisher COver Up SEnsor FINisher COver Right SEnsor FINisher Off-Line Stapling SEnsor FINisher LOwer Stapling SEnsor FINisher COver Front SEnsor FINisher UPper Stapling SEnsor FINisher LOwer internal Tray Input SEnsor FINisher Copy Tray SHift SEnsor FINisher LOwer Set Delivery SEnsor FINisher LOwer internal Tray Output SEnsor FINisher LOwer copy Tray Full SEnsor FINisher SPECiality SEnsor FINisher UPper internal Tray Input SEnsor FINisher UPper Set Delivery SEnsor FINisher UPper internal Tray Output SEnsor FINisher UPper copy Tray Full SEnsor FINisher LOwer KNocker Position Arrived FINisher UPper KNocker Position Arrived
INPUT TESTS 18 2 01 18 2 02 18 2 03 18 2 04 18 2 05 18 2 06 18 2 07 18 2 08 18 2 09 18 2 10 18 2 11 18 2 12 18 2 13 18 2 14 18 2 15 18 2 16 18 2 17 18 2 18
Note 1: Number of staples are counted only for the lower head.
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18sds
SDS
TESTNUMBER COMPONENT OUTPUT TESTS 18 4 01 18 4 02 18 4 03 18 4 04 18 4 05

SIGNAL -4-
DESCRIPTION in SDS
18M1 18M2 18M4 18EM1 18EM3 18EM4 18EM5 18CL4
FINLOSDMO FINCTSHMO FINUPSDMO FINSTSO FINLOKNSO FINUPKNSO FINUTSO FINLOS FINSSCL FINUPS FINMODIR
FINisher LOwer Set Delivery MOtor FINisher Copy Tray SHift MOtor FINisher UPper Set Delivery MOtor FINisher Speciality Tray SOlenoid FINisher LOwer KNocker SOlenoid FINisher UPper KNocker SOlenoid FINisher Upper Tray SOlenoid FINisher LOwer Stapler FINisher Stapling Safety CLutch FINisher UPper Stapler FINisher stapler MOtor DIRection
18 4 06 18 4 07 18 4 08 18 4 09 18 4 10 18 4 11
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18 Finisher 203
SDS
18sds
TESTNUMBER COMPONENT SPECIAL TESTS 18 6 01 18 6 02 18 6 03 18 6 04 18 6 05 18 6 06 18 6 07 18 6 08 18 6 09 18 6 10 18 6 11 18 6 12 18 6 13 REPLACE CONSUMABLES 18 8 90
SIGNAL -6-
DESCRIPTION in SDS
FINKNFOR1..3 FINUPSDMO FINUPSDMO
FINKNFOR1..3 FINLOSDMO FINLOSDMO
make function WARM make function COLD mask function protections FINisher KNocker FORmat1..3 : Note 2 Note 3 Note 4 FIN. adj. upper set del. motor : Note 6 Note 2 Note 3 Note 4 FIN. adj. lower set del. motor : Note 6 Note 5 Note 7
-8repl. routine new staplehead (K): only for the lower staplehead
Note 2: Finisher knocker position test (upper, lower). By pressing <PRINT> the knocker is moved to the 356mm position, while the format is displayed. Every time after pressing <PRINT> the knocker is moved to the next format while the format is displayed. The sequence is: 356>330>297>279>270>254>356>... mm. Note 3: Finisher set delivery full rotation. By pressing <PRINT> FINUPSDMO, or FINLOSDMO becomes high until a half revolution is made. Next the motor will make another half revolution. The test is automatically ended when a full revolution is made. Note 4: Finisher set delivery half revolution. By pressing <PRINT> FINUPSDMO, or FINLOSDMO becomes high for a short moment. The motor will make a half revolution. The test is automatically ended after a half revolution. Note 5: Finisher copy tray shift test. By pressing <PRINT> the copy receiving tray is shifted. The direction depents on the current position. Note 6: The finisher section is made warm (initialized). Next the set delivery motor is switched on for a period of time, while the edges of the finisher set delivery sensor (18SO3, or 18SO9) are counted. The nominal value is 30. Refer to adjustment. Note7: Finisher stapler imputs test. After pressing <PRINT >you can get 2 situations stapler motor blocked or no staples
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18adju
ADJUSTMENTS
ADJUSTMENTS 1 Lock plate internal tray unit and top lid Aim:
To achieve a correct locking of the internal tray unit and top lid.
Check:
Open and close the top lid; the maximum allowed play between catch -A- and lock plate -B- is 0.2mm. Open and close the internal tray unit; the maximum allowed play between catch -A- and lock plate -B- is 0.2mm.
Correction:
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
Remove the stapler release handle (2x), top cover preheat section and front cover of the finisher; Close the internal tray unit; Loosen bolts -C- (2x) (fingertight); Hook catch -A- into locking bracket -B-; A Push the internal tray unit downwards (at the front); Move locking bracket -B- against catch -A-; Tighten bolts -C- (2x); + 0.2 Follow the same procedure for the top lid; 0 - 0 MM Mount all removed parts.
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Internal receiving tray bottom plate (upper and lower finisher). Aim:
Check:
Correction:
2.1 2.2 2.3 The same correction for both the internal receiving tray bottom plates; Remove the cover at the rear side of the finisher; Loosen nut -C- at the rear; Turn excentric shaft -D- (allen screw) in such a way, that the top of the internal receiving tray -B- levels with roller -A-; Lock shaft -D- with nut -C-; Mount all removed parts.
2.4 2.5
D
+0 0 - 0.3 mm
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Finisher speciality tray solenoid (18EM1) Aim:

Check:
Make several copies (minimum of 2 originals) via bypass and via the two paper trays. Check that the copies are delivered correctly into the speciality tray or into the upper copy receiving tray.
Correction:
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Open the finisher side door; Remove side door cover; Remove the black cover, bolts -A-; Loosen bolts -B- (inner side) (2x); Move solenoid -C- upwards until deflector -D- just touches buffer -E-; Tighten bolts -B- (2x); Close the finisher side door; Activate sds-test 18 4 04; Check if the solenoid operates, the solenoid pin extends at least 7.5 mm above the solenoid housing when the deflector touches buffer -E-; 3.10 If necessary proceed with 6.4; 3.11 Mount all removed parts.
E D B C
A
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Finisher upper tray solenoid (18EM5) Aim:

Check:
Make several copies (minimum of 2 originals) via the two paper trays Check that the copies are delivered correctly into the lower and upper copy receiving tray.
Correction:
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Open the finisher side door; Remove the rear cover (2 bolts -A-); Remove the tensioner of the finisher main drive belt; Loosen bolts -B- (2x); Move solenoid -C- upwards until deflector -D- just touches buffer -E-; Tighten bolts -B- (2x); Close the finisher side door; Activate sds-test 18 4 07; Check if the solenoid operates, the solenoid pin extends at least 7.5 mm above the solenoid housing when the deflector touches buffer -E-; 4.11 If necessary proceed with 7.4; 4.12 Mount the tensioner of the finisher drive belt and rear cover.
D E
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ADJUSTMENTS

To achieve a correct detection of a full copy receiving tray for both the upper and lower finisher.
Check:
Correction:
5.1 5.2
5.3 5.4
Open the finisher top lid; Select and activate sequencely test 18 2 11 (18SO5, lower tray) or 18 2 16 (18SO11, upper tray); Loosen bolt -A- and turn nut -B-; Put fork -C- on a level of 68 2 mm above the copy receiving tray, the sensor is just active (buzzer on) and tighten bolt -A-, otherwise proceed with 8.3.
B
C 68 2 mm
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To achieve reliable set delivery for the upper and lower output tray.
Check:
Close the finisher top lid. Select and activate test 18 6 07 (upper) or 18 6 11 (lower). * The motor initializes and then runs for approximately 4.9 s and stops. The value the display shows must be 30.
Correction:
NOTE: This adjustment has to be carried out if a new finisher controlboard (18PBA03 = upper, -B- or 18PBA02 = lower, -A-) and/or the set delivery motor (18M1 or 18M4) has/have been installed. The top cover has to be mounted. 6.1 6.2 6.3 Open the finisher side door; Open the paper guide plate and pull out the PBA tray; Select and activate test 18 6 07 (upper) or 18 6 11 (lower). In the display appears a value : Value < 30: the motor runs too slowly: - Turn potentiometer R35 on -A- (18PBA02) or -B- (18PBA03) one turn clockwise; - Repeat the procedure until the read out is 30. Value > 30: the motor runs too fast: - Turn potentiometer R35 on -A- (18PBA02) or -B- (18PBA03) one turn counter clockwise; - Repeat the procedure until the read out is 30.
R35
B
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ADJUSTMENTS
Adjustment plate of the side door switch (18S2) Aim:

To achieve a reliable function of the side door switch.
Check :
Select test 18 2 02 and check if 18S2 operates by opening and closing of the side door.
Correction :
NOTE :Adjustment only with closed side door; 7.1 7.2 7.3
7.4 7.5 7.6
Remove the rear cover (2 bolts); Loosen bolts -A-; Place the plate in position with respect to the micro switch, 5 0.5 mm by turning the plate; Tighten bolts -A-; Check (SDS 18 2 02) if the switch operates by opening and closing of the side door; Mount all removed parts.
5 0.
5 mm
A
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Adjustment transport rollers Aim :

To realise a correct transport of the copies to the upper output tray of the finisher.
Check :
Remove top cover and guide plates paper transport; Check if the gap between the two rollers is 22.5 - 0.5 mm, if not proceed with 12.1.
Correction :
NOTE : Guide plates paper path must not been mounted ! 8.1 8.2 Remove guarding plate front; Loosen bolts -A- hand tight; NOTE : The slide bearings of the rollers have to be mounted with the recess below. 8.3 8.4 8.5 Turn the plates -C- on their turning point -B- to adjust the gap between the rollers -D- and -E- (22.5 - 0.5 mm); Tighten bolts -A-; Mount all removed parts.
E A
+0 22.5-0.5 mm
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ADJUSTMENTS
Adjustment bracket top lid switch (18S1) Aim :

To achieve a reliable function of the top lid switch.
Check :
Select test 18 2 01 and check if 18S1 operates by opening and closing of the top lid.
Correction :
9.1 9.2 9.3 9.4 9.5 9.6 Open the top lid and remove top cover (4 bolts); Loosen bolts -A- and -B- (hand tight); Close the internal tray upper, check if bracket -C- operates the switch -D-; Turn the bracket until the buzzer operates; Tighten the bolts -A- and -B- sequencely; Check if the switch operates by opening and closing of the internal tray, SDS test 18 2 01.
B A
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10
Position o f the Micro Switches Aim:

To ensure that the microswitches switch at the correct moment.
Check:
Place two sheets of paper against the guides -C-, and check if the switches have activated.
Correction:
10.1 Loosen bolts -B- (4x). 10.2 Place 2 sheets of paper -D- against both guides -C- as shown in the figure below. 10.3 Slide the microswitches -A- towards the guides until both microswitches are activated. 10.4 Tighten bolts -B- (4x).
C A
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11
Staple position for the off-line stapler Aim:

To ensure that the staple is positioned correctly.
Check:
Make an off-line staple action and check if the measurements are as indicated.
Correction:
62 mm
62 mm
11.1 Loosen bolts -D- and -E-. 11.2 Position bracket-assy -A- so that the staple position conforms to the indicated measurements of staple -G-. 11.3 The position of staple -G- is: F =6 +/-2 mm H =6 +/-2 mm 11.4 Tighten bolts -D- and -E-.
G
2 m m
F=
=6
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12
Adjusting the off-line stapler Aim:

To ensure that the off-line stapler is positioned correctly.
Check:
Visually check if the off-line stapler is centred with respect to the guide of cover -C-
Correction:
12.1 Slightly loosen bolts -E-, -F- and -G-. 12.2 Slide bracket -A- in the horizontal direction until guides -H- are centred with respect to the guide of cover -C-. 12.3 Align the base of bracket-assy -B- in the vertical direction with respect to cover -C-, by turning bracket -A- on bolt -E-. 12.4 Then tighten bolts -E-, -F- and -G-.
G E
B H
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ADJUSTMENTS
13
Plate guide Aim:

To ensure that sheets are correctly positioned with respect to the on-line stapler
Check:
Visually check if plate guide -E- is lower than plate guide -F-.
Correction:
13.1 13.2 13.3 13.4
Check if adjustment 2 (Internal receiving tray bottom plate) is correct. Loosen bolt -C- (2x) and bolt -D-. Then adjust plate guide -E- according to the measurements indicated. Ensure that plate guide -E- is parallel to plate guide -F- (within the tolerances indicated). 13.5 Tighten first bolt -C- (2x) and then bolt -D-.
F E
0 1 -0,3 mm
A -A
0,4
A E E C
D
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14
Adjustment instruction on-line staplers Aim:

To ensure that the stapler is positioned correctly.
Check:
Make a set of 25 copies and check if the stapler is positioned according to the measurements indicated.
62 mm
62 mm
Correction:
14.1 Dismantle the cover 14.2 Check if the on-line stapler -D- is in the working position. 14.3 Loosen bolts -C- (2x). 14.4 Place the stapler -D- perpendicular and parallel according to the tolerances indicated with respect to plate guide -E-, so that the staple enters the paper perpendicular. 14.5 Adjust the stapler -D- in accordance with the measurement B =14.6 1 mm 14.6 Tighten bolts -C- (2x). 14.7 Slightly loosen bolts -F- (2x) and position the Clincher anvil of the stapler -D- to the indicated vertical measurement with respect to the plate guide -EMeasurement -A- must be between 13,6 mm and 14 mm. 14.8 Tighten bolts -F- (2x). 14.9 Check if the staple is punched into the packet in the position indicated. 14.10 Mount the cover.
A=14 -0,6 mm
B = 14,61 mm
E F
C D
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15
Adjustment of switch 18S5 Aim:

To ensure that the switch is activated at the correct moment.
Check:
Close the door and check if the switch is activated.
Correction:
15.1 Check that pin -B- does not touch cover -C- when closing door -A-. If it does, slide cover -C- so that the pin does not touch it. 15.2 Adjust pin -B- so that Button, Manual -D- is just not activated when the door -A- is closed. 15.3 Turn pin -B- 4 revolutions anti-clockwise. 15.4 Lock pin -B- with nut -E-.
B A
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DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1 1.2
Dis/assembly of top plate of the top unit.

Disassembly and assembly of the plate must be done when the top unit is opened. When mounting the plate back again, tighten the bolts in the sequence indicated in the figure below ! This to prevent twisting of the top unit.
10
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Tilt procedure finisher Oc 2475/50 sheets.

If the 2475 has to be transported through small areas, it is possible to reduce the size of the copier without removing the finisher. When you follow the procedure below, you can tilt the finisher on the copier.
2.1
2.2 2.3
2.4
Open the upper papertray Remove: (at the front) - Middle panel and operating panel the handle and the guarding cap (base machine); - Front door -A- of the finisher (see fig 3), ; - Lower off-line cover -I- of the off-line stapler (see fig 1); Disconnect : (at the front) - 18S3, 18S6 and1801CN07 (remove the cabletie); Remove: (at the front see fig 3); - Front cover -B-; - The plate under the front cover -C-; - Plate -D-; Remove: (at the Rear see fig 3) - Rear cover -E- of the finisher; - Rear covers -F- and -G- of the paper section; - Rear frame cover behind the original tray; - Receiving trays; - Lower cover -H- behind the lower receiving tray and 18PBA06; - Slide rail assy (behind cover -H-) for the receiving trays (2 bolts); fig.1 - Mount the 2 lifting brackets in the 2 holes of the slide rail assy with the 2 bolts (see fig 1); - Main drive belt and standby drive belt (loosen the tensioners of both drive belts); - Finisher locking plates (front and rear);
2.5
2.6
2.7 2.8 2.9
Disconnect : - connector 18CN5 and 18CN13 and the earth strap at the rear of the finisher; - connector 1801CN04, 1801CN05 and 1801CN06 on 18PBA01 at the front; Take one rod of the master mounting tool and insert it through the holes of the 2 lifting brackets, and make sure its free of the lip at the front (see fig 1). fig.2 Take out the locking bracket from the inside of the rear cover of the copier. Now you can tilt the finisher: lift the finisher at the right-hand side and move the finisher gently onto the main frame. Rear side : Mount one end of the locking bracket onto the shaft of the finisher. Now mount the other end of the bracket (with the slots) onto the subframe,
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make sure that the bolt is in the right most slot (see fig 2a) of the finisher locking plate, (using one of the bolts from the locking plate of the machine) do not tighten the bolt yet; 2.10 Pull back the finisher carefully, so that the bolt which holds the bracket moves into the upper slot (see fig.2b) of the finisher locking plate ; 2.11 Tighten the bolt.
E F A G D H C B
Fig 3
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DIS/ASSEMBLY
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3
3.1
Removing the finisher of the Oc 2475/50 sheets.

Open the upper papertray Remove: (at the front) - Middle panel, the handle and the guarding cap (base machine); - Front door -A- of the finisher (see fig 6), ; - Lower off-line cover -I- of the off-line stapler (see fig 4); Disconnect : (at the front) - 18S3, 18S6 and1801CN07 (remove the cabletie); Remove: (at the front see fig 6); - Front cover -B-; - The plate under the front cover -C-; - Plate -D-; - Cover of the right-hand side door -L- and top cover of the finisher -K-; Remove: (at the Rear see fig 6) - Rear cover -E- of the finisher; - Rear covers -F- and -G- of the paper section; - Receiving trays; - Lower cover -H- behind the lower receiving tray; - Slide rail assy behind cover -H- for the receiving trays (2 bolts); - Mount the 2 lifting brackets in the 2 holes of the slide rail assy with the 2 bolts (see fig 4); - Main drive belt and standby drive belt (loosen the tensioners of both drive belts); - Finisher locking plates (front and rear); Disconnect : - connector 18CN5 and 18CN13 and the earth strap at the rear of the finisher; - connector 1801CN04, 1801CN05 and 1801CN06 on 18PBA01 at the front; Right-hand side door; - To remove the right-hand side door, remove the metal cable from the finisher (when the door is closed!). - Remove the shoulder bolt from the metal strip. - Remove the blank plate (2 bolts) at the rear of the finisher and remove the connector of the solenoid. - Remove the cover above the bypass. Take two rods of the master mounting tool and insert one rod through the holes of the 2 lifting brackets and one into the holes of finisher frame (see fig.4). Now you can remove the finisher with two persons.
3.2 3.3
3.4
fig.4
3.5
3.6
3.7
fig.5
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E F
A G D H C B
Fig 6
3.8 3.9
Remove the two bolts (M6) front and rear, which attach the finisher to the main frame. Place the finisher on a flat surface as indicated.
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Knocker mechanism

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2475func
FUNCTIONAL DESCRIPTION 1 Finisher Oc 2475

The double finisher enables the base machine to operate with full speed duplex (75 copies/min). With full speed duplex two copies of the same original are processed simultaneously. Therefore the finisher is equipped with two receiving trays with a capacitiy of 500 sheets of 80 gr/m2 each. Bypass copies, fault copies and interleaves are delivered into the speciality tray.
Operating modes:
Sorting (using the RDF) If the runlength is greater than 1, copies are delivered alternating in the upper and lower tray. In both single and double sided copy mode copies are made in the sequence 11 22 33 44 etc. This results in a most efficient usage of the copy trajectory (full speed duplexing). No master image is skipped, because during turning of the first sheet (copied on one side), the second sheet is in the transfuse pinch (copied). During turning of the second sheet, the first sheet is in the transfuse pinch (copied on the duplex side). With odd numbered run lengths the last copy of the set is made in the sequence 123 resulting in a reduction in speed for the last run (when turning the copy, one master image is skipped). Batching : Copies are batched, first in the lower tray until it is full. After that it will continue in the upper tray. Continuous copying is possible in this mode if the trays are emptied in time.
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Finisher section
The function of the finisher section is:
to deliver copies (sorted, stapled or batched) in the copy trays; to direct bypass, interleaf or fault copies to the speciality tray. The finisher section consists of: Set delivery unit Stapling unit Internal tray with set positioning Copy tray full detection Finisher top unit Copy tray Paper path Speciality tray
-A-B-C-D-E-F-G-H-
A C
F B C
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Delivery Unit
The function of the delivery unit is to deliver stapled sets or single sheets into the copy tray. The delivery unit consists of:
-A-B-C-D-E-F-H-J-
Delivery lifting mechanism; Delivery drive mechanism with motor (18M1, 18M4); Set delivery sensor (18SO3, 18SO9); Internal tray bottom; Delivery pressure roller; Delivery transport roller; Eject rolls; Pinch pressure spring.
A
G F
18func03
The delivery unit has two positions : Pressure roller up / paper stop down / positioning belts down (staple mode). This is the position in standby and when sheets have to be collected in the internal tray for stapling. To deliver the stapled set, the set delivery motor (18M1, 18M4) makes one complete revolution. During this revolution the delivery pinch is made, the paper stop and the positioning belts are lifted and the set is delivered into the copy tray. Pressure roller down / paper stop up / positioning belts up (sort/batch mode). This is the position to transport single sheets through the internal tray into the copy tray. NOTE : In SDS test 90, configuration fin-50-offl. must be selected, when no deposit is selected, the delivery unit will be placed in through feed position.
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2475func

-A-B-C-DThe drive mechanism consist of : Set delivery motor (18M1, 18M4); Cam with vane; Finisher set delivery sensor (18SO3, 18SO9); Top unit
A B C
18func04

The motor 18M1 (18M4) is controlled by signal FINLOSDMO (FINUPSMDO) from the HOST-I/O (22PBA02). When signal FINLOSDMO (FINUPSDMO) goes low 0 and signal FINLOMOEN (FINUPMOEN)is high 1, the set delivery motor (18M1, 18M4) turns. The motor always turns clockwise, as viewed from the front. The set delivery sensor (18SO3, 18SO9) monitors the position of the delivery pressure roller by a vane. The vane is attached to a cam. The cam is driven by the set delivery motor (18M1, 18M4) and moves the set delivery pressure roller up and down. When the set delivery rolls are up, the beam is not interrupted and the signal FINLOSDSE (FINUPSDSE) is high 1. When the set delivery pressure roller is down, the beam is interrupted and the signal FINLOSDSE (FINUOSDSE) is low 0. Delivery of stapled sets When making stapled sets, the set delivery mechanism is in the rest position at the start of the run. As each copy arrives it is positioned against the finisher paper stop by the two positioning belts, and towards the front of the copier by the knocker. When the complete set is collated in the internal tray, the stapler operates, fixing a staple to the corner of the set.
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The set delivery motor (18M1, 18M4) drives an eccentric through one complete revolution when a set needs to be ejected. The set delivery motor is started by making control line FINLOSDMO (FINUPSDMO) high 1. 1 2 3 4 5 6
During the first half-revolution of the cam : The cam on the motor shaft causes the set delivery mechanism to move downwards. The pressure roller is supported at each end by plastic plates which can move up and down freely in slotted brackets. The delivery lifting mechanism moves down and the pressure roller touches the top of the copy set. At the same time the paper stop and positioning belts move upwards, allowing the copy set to be fed out by the eject rolls. The delivery pressure roller presses downwards, making a pinch and thus feeding the set towards the eject rolls (hard pinch). The paper stop moves up until it touches the stop. If there is a thick copy set in the internal tray, the turning action of the delivery mechanism will extend the pinch pressure spring. This provides extra force to the set, making it easier to feed out a thick copy set. During the second half-revolution of the eccentric: The set delivery mechanism moves upwards, driven by the cam. The delivery pressure roller returns to its upper position. The paper stop falls onto the copy set as it leaves the finisher, and then falls into position ready to stop the next copies.
7 8 9

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Paper path
The paper path brings copies from the duplex station or inverter to the copy receiving trays or speciality tray. If stapling is selected the sheets are collated in the internal trays, stapled and then delivered into the copy receiving trays. The paper path consists of:
Copy receiving tray; Internal tray output sensor (18SO4), (off-line stapling detection); Internal tray input sensor (18SO1); Internal tray input rollers; Speciality output sensor (18SO6); finisher speciality tray solenoid (18EM1); finisher upper tray solenoid (18EM5); Speciality tray; inverter deflector solenoid (17EM1); Uncurl rollers.
B A
E F G H J K
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Circuit diagram description : (see 701) Copies via RDF

If the run length is greater than 1, the first copy is going to the upper finisher. The finisher upper tray solenoid (18EM5) is energized, FINUTSO (coming from the I/O board) is high 1. The finisher speciality tray solenoid (18EM1) is not energized, FINSTSO (coming from the I/O board) is low 0. The finisher speciality sensor (18SO6) senses the leading edge and trailing edge of the copy, when it goes upwards. The finisher upper internal tray input sensor (18PBA8/9) senses the leading edge and the trailing edge of each copy when it enters the internal tray. Control line FINUPTISE is high 1 when the copy is present between transmitter and receiver. The finisher upper internal tray output sensor (18PBA10/11) senses the leading and trailing edge of each copy set when it leaves the internal tray. Control line FINUPTOSE is high 1 when the copy set is present between transmitter and receiver. The second copy is going to the lower finisher. The finisher upper tray solenoid (18EM5) is not energized, FINUTSO (coming from the I/O board) is low 0.The finisher low internal tray input sensor (18PBA04/05) senses the leading edge and the trailing edge of each copy when it enters the internal tray. Control line FINLOTISE is high 1 when the copy is present between transmitter and receiver. The finisher low internal tray output sensor (18PBA06/13) senses the leading and trailing edge of each copy set when it leaves the internal tray. Control line FINLOTOSE is high 1 when the copy set is present between transmitter and receiver. The third copy is going to the upper finisher again. If the run length is equal to 1, all the copies are going to the lower finisher. See description below.
Copies via MDF, CFF, glass platen.

In these modes all copies go to the lower internal tray, where they are either : delivered directly to the lower copy receiving tray or collated, stapled and then delivered to the copy receiving tray. The finisher upper tray solenoid (18EM5) is not energized, FINUTSO (coming from the I/O board) is low 0. The finisher low internal tray input sensor (18PBA04/05) senses the leading edge and the trailing edge of each copy when it enters the internal tray. Control line FINLOTISE is high 1 when the copy is present between transmitter and receiver. The finisher low internal tray output sensor (18PBA06/13) senses the leading and trailing edge of each copy set when it leaves the internal tray. Control line FINLOTOSE is high 1 when the copy set is present between transmitter and receiver.
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Bypass/interleaf/fault copies.
In these modes copies always are delivered into the finisher speciality tray. The finisher upper tray solenoid (18EM5) is energized, FINUTSO (coming from the I/O board) is high 1. The finisher speciality tray solenoid (18EM1) is also energized, FINSTSO (coming from the I/O board) is high 1. The finisher speciality sensor (18SO6) senses the leading edge and trailing edge of the copy as it enters the finisher speciality tray. FINSPECSE is high 1 when the copy is activating the sensor.
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Stapling unit
The stapling mechanism consists of:
-A-B-C-D-E-F-
Top cover switch (18S1); Off-line stapler unit; Online-stapler unit; Internal tray input sensor (18SO1); Internal tray output sensor (18SO4); Cassette of staples;
F C
B E
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Introduction
The finisher for Oc 2475/50 sheets is equipped with two 50-sheet stapler units. In addition, it has a third 50-sheet stapler unit for off-line stapling. The 50-sheet stapler units operate independent of the machine drive. A built-in DC-motor drives the mechanism.
Stapler
The 50-sheet stapler unit is driven with the aid of a built-in DC-motor and has two built-in sensors. NHOME x (1,2 of 3) Home-sensor : photo-interupter, detects the position of the stapler head to check whether the complete stapling operation has been completed. LOWSTA x (1,2 of 3) Low Staple sensor: mircoswitch, detects staple stock. The motor is activated for a fixed time, long enough to make a complete stapling operation under all conditions. During the stapling operation, the Home-sensor first goes high (=Not HOME) and then, when the stapling operation has been completed, it goes low (=HOME), the motor is then switched off immediately. If the stapling operation has not been completed, (staple-jam) then the motor will remain active for the complete drive time. The moment the motor is switched off, the Home signal will still be high (=Not HOME). In such a case, a return stroke will follow automatically: the motor is driven in the reverse direction until the Home sensor is high again (stapler unit is back into its start position). When there are no more staples in the stapler, the high level of the LOWSTA x (1,2 of 3) blocks the motor drive.
set stapling during a run

After the last copy of a set has been delivered into the internal receiving tray (that is, the trailing edge of the copy has cleared 18PBA04/05, 18PBA08/09) and positioned, the set is ready to be stapled.
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Off-line stapling
The off-line stapler is started by activating two microswitches (18S3 and 18S6) which are connected to the Stapler Control. The stapling operation is then started (after a short delay to allow the set to be positioned)on the condition that the off-line stapler has been released for use.
18S3
18S6
Owing to the capacity of the supply, it is not possible to drive two staplers at the same time. For this reason, the off-line stapler is switched off 1,5 sec. before stapling takes place during a run. This results in a time delay with off-line stapling.
ed.7 Part II
TSM 2475/50 SHEETS
18 Finisher 511
2475func

The set positioning unit consists of:
-A-B-C-D-E-F-
Positioning belts; Finisher paper stop fingers; Knocker; Finisher Knocker solenoid (18EM3, 18EM4); Roller with brush wheels; Front stop.
B C
D F E
18func09
When making stapled sets, the paper stop and positioning belts are down. When making batch/sort sets or single copies, the finisher paper stop and positioning belts are up. See the DELIVERY UNIT description. As each copy arrives in the internal tray, it hits a roller with brush wheels. They guide the sheet into the internal tray. The positioning belts then push the copy against the paper stop. The paper stop is inclined to prevent the leading edge of the paper from climbing up the paper stop. The roller with brush wheels and positioning belts are driven by the finisher main drive. To achieve a set of copies with a minimum of shifted sheets a knocker mechanism is used. The knocker mechanism knocks each copy twice towards the front of the tray against the front stop. The knocker hammer is inclined at 3 to ensure that it always knocks the top sheet in a set of copies.

When the signal FINLOKNSO (FINUPKNSO) from the HOST-I/O (22PBA02) goes high 1, the solenoid (18EM3, 18EM4) becomes energized, via an inverter on the finisher control board (18PBA02, 18PBA03).
512 Finisher 18
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Part II ed.7
2475func

The lower knocker position mechanism and the copy trays shift mechanism are both driven by the same motor : finisher copy tray shift lower knocker motor (18M2). The finisher upper knocker motor only drives the upper knocker position mechanism. The knocker positioning copy tray shift mechanism (lower) consists of :
-A-B-C-D-E-F-G-H-JConfidential 1996 Oc Nederland B.V.
Finisher copy tray shift lower knocker motor (18M2); Drive mechanism; Tray displacement cam with one way bearing; Copy tray shift sensor (18SO2); Knocker arm; Knocker positioning mechanism; Knocker position sensor (18SO7); Coding strip knocker position sensor; Knocker displacement cam with one way bearing.
D C
18func10
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18 Finisher 513
2475func
The finisher copy tray shift lower knocker motor (18M2) has 2 functions: Shift the copy trays; Position the lower knocker mechanism. The motor is connected to the copy tray shift mechanism by a one-way bearing, and to the knocker positioning mechanism by another one-way bearing. The two copy trays are connected to each other mechanically. Thus when the motor turns counterclockwise (viewed from the gear-box end) it will move the copy trays, and when it turns clockwise it will move the knocker. It is never required to perform both functions at the same time.

The motor (18M2) is controlled by the signals FINLOKNMO1 and FINLOKNMO2 from the finisher control board (18PBA02). When FINLOKNMO1 is connected to ground and FINLOKNMO2 is connected to +24V, the motor turns counter-clockwise and drives the copy trays. When FINKNTSMO1 is connected to +24V and FINKNTSMO2 is connected to ground, the motor turns clockwise and positions the loer knocker mechanism. Copy tray shift The finisher low motor enable signal FINLOMOEN must be high 1 before the motor will drive. When the copy tray shift signal FINCTSHMO is high 1, it will cause the motor to turn counter-clockwise thus moving the copy trays. A cam moves the copy tray over a total distance of 30mm (front - rear). A vane on the cam interrupts / releases the beam of the copy tray shift sensor (18SO2) every 1/2 revolution. When the copy trays are at the rear or front, the control stops the motor (18M2). When the beam is interrupted signal FINCTSHE goes high 1.
514 Finisher 18
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Part II ed.7
2475func
Knocker positioning mechanism The knocker has six positions, corresponding with the six paper lengths that are detected by the paper format sensor in the paper tray. The knocker format sensor (18PBA07, 18PBA12) (three optical sensors) is used to detect the knocker position. The 3 signals FINLOFORSE1,2,3 (FINUPFORSE1,2,3) are sent to the finisher control (18PBA02, 18PBA3) where they are compared with the paper size information from the control FINKNFOR1,2,3. The signals are decoded according to the following table. sensor 1 0 0 0 1 1 1 sensor 2 0 1 1 1 1 0 sensor 3 1 1 0 0 1 1 paper size 254 mm 270 mm 279 mm 297 mm 330 mm 356 mm sensor 1 0 0 1 1 1 0 sensor 2 0 1 1 1 0 0 sensor 3 1 1 1 0 0 0
FINISHER SENSORS Sensor 1: FINLOFORSE1/FINUPFORSE1 Sensor 2: FINLOFORSE2/FINUPFORSE2 Sensor 3: FINLOFORSE3/FINUPFORSE3
PAPER SENSORS Sensor 1: UPTPPSE1 or LPTPSSE1 Sensor 2: UPTPSSE2 or LPTPSSE2 Sensor 3: UPTPSSE3 or LPTPSSE3
NOTE: The strips used by the finisher knocker sensor and the paper size sensors are not the same! Any codes not shown in the above table are not recognised by the control and will result in an error code. The exact position is determined by a spring loaded arm that finds notches in the knocker mechanism guide shafts.
SO3 SO2 SO1
18func11
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18 Finisher 515
2475func
When positioning the knocker, the motor (18M2, 18M5) always turns clockwise. A cam connected to a hingable arm mechanism makes an eccentric movement and causes the knocker to move backwards and forwards. Before the motor will start, the finisher motor enable signal FINMOEN must be high 1. A high pulse on the finisher knocker motor control line FINLOKNMO (FINUPKNNMO) causes the motor to start. The signal FINKNMO also energizes a relay on the finisher control board, which reverses the voltage to the motor (before it starts), causing it to drive clockwise and thus move the knocker. A new knocker position is always approached from the rear. 1 2 3 From a large size to a smaller size : The motor starts to drive; The cam will drive the knocker to the front; The knocker moves forward until the new size is detected by sensor 18PBA07 (18PBA12). From a small size to a larger size : The motor starts to drive. The cam will drive the knocker to the front and then to the rear. The control will detect (sensor 18PBA07, 18PBA12) that the knocker is in the largest position (356mm) while moving from front to the rear. The knocker continues moving backwards past the largest position (356mm). It then reapproaches the largest position (356mm), now moving from the rear to the front. So when the control detects the largest position (356mm) for the second time, it knows that the knocker is now moving from the rear to the front. The knocker continues moving to the front until the new size is detected (18PBA07, 18PBA12).
1 2 3 4 5 6 7
516 Finisher 18
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Part II ed.7
2475func

As the number of copies in the copy tray increases, the fork will rise. There is a vane attached to the fork that will actuate the finisher tray full sensor (18SO5, 18SO11) when there are approx. 500 copies (80 gsm) in the copy tray. This causes the signal FINLOTFSE (FINUPTFSE) to go high 1 and a message will be displayed to the operator.
-A-B-C-D-
Copy tray; Fork; Vane; Finisher copy tray full sensor (18SO5, 18SO12).
C
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18 Finisher 517
2475func

damage the finisher control PBAs (18PBA02, 18PBA03); cause copy transport problems. There are no error messages if the motor fails. The motor (18M3) runs continuously during a run and is controlled by signal MADR. The motor is protected by a thermal fuse that will automatically stop the motor if the temperature exceeds 130C. The thermal fuse will reset itself automatically as the temperature decreases.
518 Finisher 18
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Part II ed.7
2475func
10
Finisher Drive
The finisher drive consists of: Finisher main drive; The inverter drive is driven by the finisher main drive (see INVERTER).
Finisher main drive The finisher gets its drive from the base machine (subframe) via pulley -A- . The timingbelt distrubute the drive to all the paper path rollers in the finisher and inverter.
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18 Finisher 519
2475func
11
Operation
During Power up / initialisation: When master transport starts (signal MADR), the finisher speciality tray solenoid (18EM1) is energized, FINSTSO goes high 1, and the finisher upper tray solenoid (18EM5) is energized (FINUTSO goes high 1"). The solenoid remains energized until master transport stops. The set delivery motors are started, FINLOSDMO and FINUPSDMO go high 1. Any paper in the internal trays is delivered in the copy trays. The set delivery motors stop when the set delivery mechanisms are in rest position (set delivery rolls are up and paper stops are down). The signal from the set delivery sensors (18SO3, 18SO9), FINLOSDSE/FINUPSDE are high 1. The knocker/tray shift motor (18M2) will: - move the copy trays and stop in the rear position. FINMOEN and FINCTSHMO are high 1 to start the motor (18M2). When the trays are in the rear position the finisher copy tray shift sensor (18SO2) signal FINCTSHE is high 1. - move the knocker to the largest paper size position. FINMOEN and FINLOKNMO (FINUPKNMO) go high 1 to start the motor (18M2, 18M5). When the knocker is positioned correctly, the knocker format sensor (18SO7) has the status : FINFORSE1, FINFORSE2, FINFORSE3 are respectively 1, 0, 1. During run: 1.3s after the exposure flash the knockers is put in the correct position according to the paper size (1.7s in case the copy has to be turned first in the inverter). The finish command is given about 4s after the exposure flash. The command consist of one or more tasks, such as: -staple -copy tray shift -batch -sort
520 Finisher 18
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Part II ed.7
18comp
COMPONENT LOCATION
COMPONENT LOCATION
1801CN04 1801CN05 1801CN06 18CN7 18M1 18M4 18PBA01 18PBA05 (18SO1) 18PBA04 18PBA06 (18SO4) 18PBA13 18PBA14 18PBA10 (18SO10) 18PBA11 18SO5 18SO11 18S5 : : : : : : : : : : : : : : : : : connector connector connector connector finisher lower set delivery motor finisher upper set delivery motor finisher adapter finisher lower internal tray input sensor (receiver) finisher lower internal tray input sensor (transmitter) finisher lower internal tray output sensor (receiver) finisher lower internal tray output sensor (transmitter) finsiher stapler control finisher upper internal tray output sensor (receiver) finisher upper internal tray output sensor (transmitter) finisher lower tray full sensor finisher upper tray full sensor finisher cover front sensor
18M4
18PBA11
18M1
18PBA10 (18SO10) 18SO11
18PBA14 18PBA04 18PBA05 (18SO1) 18S5
18SO5 18PBA13 18PBA06 (18SO4)
1801CN05 1801CN04 18CN7 18PBA01 1801CN06
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18 Finisher 601
COMPONENT LOCATION
18comp
18M1 18M4 18SO3
: : :
finisher lower set delivery motor finisher upper set delivery motor finisher lower set delivery sensor
18SO9(upper) 18SO3(lower)
18M4(upper) 18M1(lower)
18comp13
18SO9 18PBA08 (18SO8) 18PBA09 18S1
: : : :
finisher upper set delivery sensor finisher upper internal tray input sensor (receiver) finisher upper internal tray input sensor (transmitter) finisher cover up sensor
18PBA09 18PBA08(18SO8) 18S1
18comp09
602 Finisher 18
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Part II ed.7
18comp
COMPONENT LOCATION
17EM1 18EM1
: :
inverter deflector solenoid finisher speciality tray solenoid
18EM1
17EM1
18comp10
18PBA02 18PBA03 18SO6
: : :
finisher control lower finisher control upper finisher speciality sensor
18PBA02
18PBA03 18SO6
18comp08
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18 Finisher 603
COMPONENT LOCATION
18comp
17CL2 17CL3 18CN5 18CN13 18EM5 18S2
: : : : : :
inverter input clutch inverter output clutch connector connector finisher upper tray solenoid finisher cover right sensor
18S2 18EM5 18CN5 18CN13 17CL2 17CL3

18comp11
604 Finisher 18
TSM 2475/50 SHEETS
Part II ed.7
18comp
COMPONENT LOCATION
18CN2 18EM4 18M5 18PBA12
: : : :
connector upper knocker motor finisher upper knocker solenoid finisher upper knocker motor finisher upper knocker format sensor
18EM4
18PBA12
18CN2
UPPER TRAY
18M5
18CN6 18EM3 18M2 18PBA07 18SO2 : : : : : connector copy tray shift lower knocker motor finisher lower knocker solenoid finisher copy tray shift lower knocker motor finisher lower knocker format sensor finisher copy tray shift sensor
18EM3
18PBA07
18CN6
LOWER TRAY
18SO2
18M2
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18 Finisher 605
COMPONENT LOCATION
18comp
606 Finisher 18
TSM 2475/50 SHEETS
Part II ed.7
18elec
ELECTRICAL DIAGRAM

FINCOFSE FINCORSE FINCOUSE FINCTSHMO FINCTSHSE FINHOMSE FINKNFOR1..3 FINLOKNMO FINLOKNPA FINLOKNSO FINLOMO FINLOMOEN FINLOSDMO FINLOSDSE FINLOSE FINLOTFSE FINLOTISE FINLOTOSE FINMODIRR FINSPECSE FINSTSO FINUPKNMO FINUPKNPA FINUPKNSO FINUPMO FINUPMOEN FINUPSDMO FINUPSDSE FINUPSE FINUPTFSE FINUPTISE FINUPTOSE FINUTSO NHOME1..3 LOWSTA1..3 OLSSE FINisher COver Front SEnsor FINisher COver Right SEnsor FINisher COver Up SEnsor FINisher Copy Tray SHift MOtor FINisher Copy Tray SHift SEnsor FINisher HOMe SEnsor FINisher KNocker FORmat bits FINisher LOwer KNocker MOtor FINisher LOwer KNocker Position Arrived FINisher LOwer KNocker SOlenoid FINisher LOwer MOtor FINisher LOwer MOtor ENable FINisher LOwer Set Delivery MOtor FINisher LOwer Set Delivery SEnsor FINisher LOwer SEnsor FINisher LOwer copy Tray Full SEnsor FINisher LOwer internal Tray Input SEnsor FINisher LOwer internal Tray Output SEnsor FINisher stapler MOtor DIRection/Read FINisher SPECiality SEnsor FINisher Speciality Tray SOlenoid FINisher UPper KNocker MOtor FINisher UPper KNocker Position Arrived FINisher UPper KNocker SOlenoid FINisher UPper MOtor FINisher UPper MOtor ENable FINisher UPper Set Delivery MOtor FINisher UPper Set Delivery SEnsor FINisher UPper SEnsor FINisher UPper Tray Full SEnsor FINisher UPper internal Tray Input SEnsor FINisher UPper internal Tray Output SEnsor FINisher UPper Tray SOlenoid Not HOME 1..3 LOW STAple1..3 Off-Line Stapler SEnsor
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18 Finisher 701
ELECTRICAL DIAGRAM
18elec
702 Finisher 18
TSM 2475/50 SHEETS
Part I ed.7
Electrical Diagram
18 FINISHER 701
Electrical Diagram
18 FINISHER 702
Electrical Diagram
18 FINISHER 703
19diag
DIAGNOSTIC

1950 1951 1952 1953 1954 1955 the leading edge of a copy arrives too late at 19SO2 the trailing edge of a copy arrives too late at 19SO2 the leading edge of a copy arrives too late at 19SO4 the trailing edge of a copy arrives too late at 19SO4 the leading edge of a copy arrives too late at 19SO6 the trailing edge of a copy arrives too late at 19SO6
Warnings
1975
650 ms after starting the tray shift motor, an edge should be detected. Otherwise, WARNING 1975
ed.6 Part I
TSM 2375/2465 CRU
19 CRU 101
DIAGNOSTIC
19diag
Fault table
CODES O1950 POSSIBLE FAILURES - timing belt main transport broken - pulleys, or tensioner of main transport defective - bearings main transport stuck - transport rollers side door stuck - deflector of special output stuck - 19EM2 of special deflector defective or not activated - 19M2 fan defective - deflector of lower tray runs heavily - 19EM1 of lower tray deflector continuously activated - 19SO2 upper tray output sensor defective - copy release handle defective - 19SO1 upper tray full sensor defective - static eliminator upper tray defective - pressure springs feed out nips loose - copy release handle defective - 19SO2 upper tray output sensor defective - timing belt main transport broken - timing belt paper main transport broken - pulleys, or tensioner of main transport defective - bearings main transport stuck - transport rollers side door stuck - 19M2 fan defective - deflector of lower tray runs heavily - 19EM1 of lower deflector defective or not activated - copy release handle defective - static eliminator lower tray defective - 19SO3 lower tray full sensor defective - pressure springs feed out nips loose - 19SO4 lower tray output sensor defective - copy release handle defective - timing belt main transport broken - timing belt paper main transport broken - pulleys, or tensioner of main transport defective - bearings main transport stuck - transport rollers side door stuck
O1951
O1952
O1953
O1954
Fault table continue : next page
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Part I ed.6
19diag
DIAGNOSTIC
CODES O1954
POSSIBLE FAILURES - deflector of specialty output stuck - 19EM2 of lower tray deflector continuously activated - 19M2 fan defective - 19SO6 specialty output sensor defective - deflector of lower tray runs heavily - static eliminator specialty tray defective - 19SO6 specialty output sensor defective - pressure springs feed out nips loose - 19M1 tray transport motor defective - tray transport rail stuck - 19SO5 tray transport sensor defective - bearings, pulleys tray transport defective - timing belt tray transport defective - 19EM1 of lower tray deflector continuously activated
O1955
W1975
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19 CRU 103
DIAGNOSTIC
19diag
Protections ORE1950 ORE1951

19SO2 the upper tray output sensor is used for synchronous checks of leading and trailing edge of copies entering the upper tray.
if the leading edge of a copy arrives too late, ORE 1950 if the trailing edge releases the sensor too late, ORE 1951
ORE1952 ORE1953
19SO4 the lower tray output sensor is used for synchronous checks of leading and trailing edge of copies entering the lower tray. if the leading edge of a copy arrives too late, ORE 1952 if the trailing edge releases the sensor too late, ORE 1953
ORE1954 ORE1955
19SO6 the specialty tray output sensor is used for synchronous checks of leading and trailing edge of copies entering the specialty tray. if the leading edge of a copy arrives too late, ORE 1954 if the trailing edge releases the sensor too late, ORE 1955
Warning 1975
19SO5, CRU copy tray shift sensor, is used to check if the output tray shift operates 650 ms after starting the tray shift motor an edge should be detected. Otherwise, WARNING 1975
104 CRU 19
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Part I ed.6
19sds
SDS
TESTNUMBER COMPONENT COUNTERS 19 0 50 ORE 19 0 51 ORE 19 0 52 ORE 19 0 53 ORE 19 0 54 ORE 19 0 55 ORE 19 0 75 W PARAMETERS INPUT TESTS 19 2 01 19 2 02 19 2 03 19 2 04 19 2 05 19 2 06 19 2 07 OUTPUT TESTS 19 4 01 19 4 02 19 4 03 19M1 19EM1 19EM2 19S1 19SO1 19SO2 19SO3 19SO4 19SO5 19SO6 19SO2 19SO2 19SO4 19SO4 19SO6 19SO6
SIGNAL -0-
DESCRIPTION in SDS
copy too late at 19SO2 19SO2 too late free copy too late at 19SO4 19SO4 too late free copy too late at 19SO6 19SO6 too late free INIT: Copy trays shift failure. -1-2CRUCOVSSE CRUUTFSE CRUUTOSE CRULTFSE CRULTOSE CRUTTSE CRUSPECSE -4CRUTTMO CRULTSO CRUUTSO CRU Tray Transport MOtor CRU Lower Tray SOlenoid CRU Upper Tray SOlenoid CRU COVer Side door SEnsor CRU Upper Tray Full SEnsor CRU Upper Tray Output SEnsor CRU LOwer Tray Full SEnsor CRU Lower Tray Output SEnsor CRU Tray Transport SEnsor CRU SPECialty output SEnsor
ed.6 Part I
TSM 2375/2465 CRU
19 CRU 201
SDS
19sds
SPECIAL TESTS 19 6 01 19 6 02 19 6 03 19 6 04 REPLACE CONSUMABLES
-6make function WARM make function COLD mask function protections CRU copy tray shift test -8-
202 CRU 19
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Part I ed.6
19adju
ADJUSTMENTS
ADJUSTMENTS 1 Hinges CRU side door Aim:

To achieve a defined position of the CRU side door.
Check:

Close the door; push on all 4 corners. Maximum allowed play between the callipers is 0.1 mm. The door should not hang askew more than 3 mm. Measure at pin -E-. Too much play at frontside: proceed with adjustment 19-2. Too much play at rear side and/or door askew: proceed with 19-1.
Correction:
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Remove the cover of the side door and the rear cover of the CRU. Remove the bracket with the spring loaded pin -D- from the door. Lock the door. Loosen bolts -A-, -B- and -C- (2x) of the hinge(s). Push the door against all 4 callipers. Tighten the bolts in the following order:: - bolt -A-; - bolts -C- (2x); - open the door, tighten bolt -B-. Remount the spring loaded pin -D- and the covers. Proceed with check adjustment 19-2. Attention: Make sure the side door switch is actuated when the door is closed.
ed.6 Part I
TSM 2375/2465 CRU
19 CRU 301
ADJUSTMENTS
19adju
Lock CRU side door Aim:

To achieve a correct locking of the finisher side door.
Check:
Open and close the CRU side door; the door should lock smoothly. Maximum allowed play is 0.1 mm.
Correction:
2.1 2.2 2.3 2.4 2.5 2.6 2.7 Remove the front cover of the CRU. Close the side door. Loosen bolts -C- (2x). Hook catch -A- into locking bracket -B-. Push the door against the front callipers. Move locking bracket -B- against catch -A-. Tighten bolts -C- (2x). Attention: Make sure the side door switch is actuated when the door is closed.
19adju02
302 CRU 19
TSM 2375/2465 CRU
Part I ed.6
19adju
ADJUSTMENTS
Tray entry deflectors (19EM1, 19EM2) Aim:

To ensure the deflectors are correctly moved by the solenoids.
Check:
Select SDS test 19 4 02 (lower tray solenoid) or 19 4 03 (upper tray solenoid) and check whether the deflector touches the buffer -A- and that the solenoid pin extends at least 7.5 mm above the solenoid housing.
Correction:
3.1 3.2
3.3
Loosen the two screws -B-. Select SDS test 19 4 02 or 19 4 03. (19EM1 or 19EM2) Adjust the solenoid until the deflector touches the buffer -A-. Tighten the two screws -B-. De- activate the deflector a couple of times and check once more whether the deflector touches the buffer and whether the solenoid pin extends at least 7.5mm above the solenoid housing.
19adju03
ed.6 Part I
TSM 2375/2465 CRU
19 CRU 303
ADJUSTMENTS
19adju
Copy receiving tray full detection (19SO1, 19SO3) Aim:

To achieve a correct detection of a full copy receiving tray.
Check:
Lift the fork: when it reaches a height of 30 2mm above the copy receiving tray the display must indicate copy tray full.
Correction:
4.1 4.2 4.3 4.4 Open the CRU side door. Select and activate test 19 2 02 (upper tray) or 19 2 04 (lower tray). Loosen nut -A-. Keep nut -B- tightened. Put fork -C- on a level of 30 2 mm above the copy receiving tray. Vertically adjust sensor bracket D- with bolt -A- in such a way that the sensor is just active (buzzer is just on). Tighten nut -A-.
4.5
4.6
19adju04
304 CRU 19
TSM 2375/2465 CRU
Part I ed.6
19disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1
Removal of the CRU

Remove : - Copy receiving trays; - Base cover; - Both vertical and horizontal rear covers; - Both vertical and horizontal covers; - Cru drive belts. Loosen : - Connector 19CN3 of 19PBA01; - Cut the tywraps and remove the bundle out of the CRU; - Remove the locking brackets front and rear; - Remove the two M6 bolts. Now you can take off the CRU of the copier.
1.2
ed.6 Part II
TSM 2375/2465 CRU
19 CRU 401
DIS/ASSEMBLY
19disa
402 CRU 19
TSM 2375/2465 CRU
Part II ed.6
19func
FUNCTIONAL DESCRIPTION 1 Copy Receiving Unit - CRU (Oc 2375/2465 CRU)

The Copy Receiving Unit enables the base machine to operate with full speed duplex. (63 cpm). With full speed duplex two copies of the same original are processed simultaneously. Therefore the CRU is equipped with two receiving trays with a capacitiy of 350 sheets of 80 gr/m2 each. Error copies and interleaves are deposited into the specialty tray.
Operating modes:
Sorting If the runlength is greater than 1, copies are deposited alternating in the upper and lower tray. In both single and double sided copy mode copies are made in the sequence 11 22 33 44 etc. This results in a most efficient usage of the copy trajectory (full speed duplexing). No master image is skipped, because during turning of the first sheet (copied on one side), the second sheet is in the transfuse pinch. During turning of the second sheet, the first sheet is in the transfuse pinch (copied on the duplex side). With odd numbered run lengths the last copy of the set is made in the sequence 123 resulting in a reduction in speed for the last run. Batching : Copies are batched, first in the lower tray until it is full. After that it will continue in the upper tray. Continuous copying is possible in this mode if the trays are emptied in time. Specialties : Specialties (by-pass) jobs are batched in the lower tray first until it is full. - Set separation is done by a simultaneous sideways movement (shift) of the trays. - All trays have a copy output sensor that is used to detect both the leading edge and trailing edge of the copies. - Both lower trays have a tray full detection.
ed.6 Part II
TSM 2375/2465 CRU
19 CRU 501
19func
2
-A-B-C-D-E-F-G-H-I-J-K-L-M-N-O-P-Q-R-S-T-
Parts
LOWER TRAY: vertical transport roller lower tray entry deflector (CRULTSO - 19EM1) lower tray output sensor (CRULTOSE-19SO4) lower tray output rollers lower tray full sensor (CRULTFSE-19SO3) lower tray level detection arm UPPER TRAY: vertical transport roller upper tray entry deflector (CRUUTSO - 19EM2) upper tray output sensor (CRUUTOSE-19SO2) upper tray output rollers upper tray full sensor (CRUUTFSE-19SO1) upper tray level detection arm SPECIALTY TRAY: specialty output sensor (CRUSPECSE-19SO6) specialty output rollers GENERAL: tray transport sensor (CRUTTSE-19SO5) tray transport motor (CRUTTMO - 19M1) inverter deflector (CRURVSO - 17EM1) inverter transport rolls CRU side door sensor (CRUCOVSSE-19S1) CRU cooling motor
19func02
502 CRU 19
TSM 2375/2465 CRU
Part II ed.6
19func
Shifting the Trays

To separate sets the trays can be shifted between front and rear positions. Shifting is done by the CRU Tray Transport Motor (19M1) -A- which drives an eccentric -B- to which the trays are mounted. The trays can slide on a rail. On the motor shaft a moon shaped disk -C- is mounted that rotates between transmitter and receiver of the Tray Transport Sensor -D-. Sensor and disk monitor the position of the trays.
19func04
During machine startup the trays position has to be initialized. This means the trays has to be in the rear position. When the trays are in front position it is sent to the rear position. When the trays were already in the rear position it is first sent to the front position and then back to the rear position again. After the last sheet of a set has been deposited the trays are shifted as the signal CRUTTMO activates the motor. The motor keeps running until the trays transport sensor changes the signal CRUTTSE. The motor then stops and the trays are in the other position. However, if the trays are mechanically obstructed the trays will also stop after a 690msec timeout has expired.
ed.6 Part II
TSM 2375/2465 CRU
19 CRU 503
19func
Tray Full Detection

Both the lower and upper tray have a level detection arm -A- that pivots upwards as copies fill the tray. The arm causes the sensor actuator -B- to pivot also. When the tray becomes full the sensor -C- is blocked and the signal CRUUTFLSE or CRULTFSE is given. The sensor is vertically adjustable to determine the number of (80 gr/m2) sheets with which the tray full signal is given.
19func05
504 CRU 19
TSM 2375/2465 CRU
Part II ed.6
19func
Paper Jams
Whenever paper is jammed in the vertical path to the trays it can be removed by opening the CRU door. Whenever paper is jammed in the tray near the output sensors it can be removed by lifting a handle at the front of the CRU. The two upper guide plates in the horizontal transport to the trays are then lifted, giving room to remove the paper.
ed.6 Part II
TSM 2375/2465 CRU
19 CRU 505
19func
Copy Receiving Unit Drive

The CRU is driven from the base machine via pulley -A-. A timing belt distributes the drive to the various transport rollers. Following the timing belt (clockwise), the first part that is driven is a gear mechanism (B and C) for the drive of the inverter rollers. The gears give drive to the electromachnetic clutches CRURVCL (B) and CRUIMCL (C). When -B- is activated the copy is driven out of the inverter path (reversed) when -C- is driven the copy is driven into the inverter path (imported), by a separate small timing belt.
-D-E-F-G-H-
The long timing belt rotates upwards and drives: the lower vertical transport rollers the upper vertical transport rollers the specialty tray horizontal output rollers the upper tray horizontal output rollers the lower tray horizontal output rollers With the belt tensioner at position -I- the service engineer can adjust the correct belt tension.
506 CRU 19
TSM 2375/2465 CRU
Part II ed.6
19func
Circuit diagram description (see 701)

Controlling and monitoring the CRU is done via the CRU Control Board 19PBA01. It receives control signals from the Host I/O Board and passes them on to the CRU (Output). It receives signals from the CRU sensors/switches and feeds them back to the Host I/O board (Input). The CRU Control Board uses both +12V and +24 V.
Output All clutches and solenoids operate on +24 V. Therefore the signals that come from the Host I/O board are amplified on the CRU Control Board. The Tray Transport Motor is driven by a pulse width modulated signal with a frequency of approximately 20 kHz. The signal CRUTTMO from the Host I/O board enables a control circuitry on the CRU Control Board. This circuit consists of a speed control section and a motor current limit section. The speed control is done by a differential amplifier that gets both a feedback voltage from the motor and a reference voltage. The amplifier will control the pulse width at the output to obtain a constant voltage over the motor. Limiting the motor current is especially needed during startup and in case of mechanical obstruction. The current to the motor is sensed by a serial resistor that sends a current sense signal back to the current limit section. The current is limited to approximately 0.6 Amps. The motor current is supplied via a serial power transistor. When the motor has to be stopped it is short circuited by a parallel transistor.
Inputs All inputs from switches in the CRU are directly coupled back to the Host I/O board. Only the signal from the Specialty Sensor CRUSPESE is buffered.
ed.6 Part II
TSM 2375/2465 CRU
19 CRU 507
19func
Operation
Destinations for copies can be the lower tray (LT), the upper tray (UT) or the specialty tray (ST). Copies can either come directly from the TTF or can come via the inverter. For the actions in the CRU this makes no difference other than the timing; when the copy comes via the inverter all actions are carried out approximately 0.4 seconds later. The inverter action is described in function 17. For depositing a copy in the specialty tray there are almost no actions. No deflectors are actuated, only the output sensor is monitored.
Copies to Lower Tray The lower tray entry deflector is activated by the lower tray solenoid 19EM1. The solenoid is activated by the signal CRULTSO. Leading- and trailing edge of the copy are monitored by 19SO4 giving the signal CRULTOSE. After the copy has entered the tray the lower tray entry deflector is deactivated. In the sorting mode when the run length is greater than 1 the lower tray entry deflector is activated for every second copy of the run because the copies have to be deposited one after another in the upper and lower tray.
Copies to Upper Tray The lower tray entry deflector has to be deactivated and the upper tray entry deflector has to be activated. The deflector is activated at the start of a run by the upper tray solenoid 19EM2. This solenoid is activated by the signal CRUUTSO. Leading- and trailing edge of the copy are monitored by 19SO2 giving the signal CRUUTOSE. Copies to Specialty Tray To deposite a copy in the specialty tray none of both tray solenoids are activated. Leading- and trailing edge of the copy are monitored by 19SO6 giving the signal CRUSPECSE.
508 CRU 19
TSM 2375/2465 CRU
Part II ed.6
19comp
COMPONENT LOCATION
COMPONENT LOCATION
19CN1 19M1 19M2 19PBA01 19S1 19SO1 19SO2 19SO3 19SO4 19SO5 19SO6 connector CRU tray transport motor CRU cooling motor CRU control CRU cover side sensor CRU upper tray full sensor CRU upper tray output sensor CRU lower tray full sensor CRU lower tray output sensor CRU tray transport sensor CRU specialty tray sensor input
19comp01
ed.6 Part II
TSM 2375/2465 CRU
19 CRU 601
COMPONENT LOCATION
19comp
17EM1 19EM1 19EM2
inverter deflector solenoid CRU lower tray solenoid CRU upper tray solenoid
19comp02
602 CRU 19
TSM 2375/2465 CRU
Part II ed.6
19elec
ELECTRICAL DIAGRAM

CRUSPECSE CRUSPECSEI CRUCOVSSE CRUIMCL CRUIMCLO CRULTFSE CRULTOSE CRULTSO CRURVSO CRURVCL CRURVCLO CRUTTMOx CRUTTSE CRUUTFSE CRUUTOSE CRUUTSO Copy Receiving Unit SPECialty SEnsor Copy Receiving Unit SPECialty SEnsor Input Copy Receiving Unit COVer Side SEnsor Copy Receiving Unit IMport CLutch Copy Receiving Unit IMport CLutch Output Copy Receiving Unit Lower Tray Full SEnsor Copy Receiving Unit Lower Tray Output SEnsor Copy Receiving Unit Lower Tray SOlenoid Copy Receiving Unit ReVerse SOlenoid Copy Receiving Unit ReVerse CLutch Copy Receiving Unit ReVerse CLutch Output Copy Receiving Unit Tray Transport MOtorx Copy Receiving Unit Tray Transport SEnsor Copy Receiving Unit Upper Tray Full SEnsor Copy Receiving Unit Upper Tray Output SEnsor Copy Receiving Unit Upper Tray SOlenoid
ed.6 Part I
TSM 2375/2465 CRU
19 CRU 701
ELECTRICAL DIAGRAM
19elec
702 CRU 19
TSM 2375/2465 CRU
Part I ed.6
Electrical Diagram
19 CRU 701
Electrical Diagram
19 CRU 702
22diag
DIAGNOSTIC
DIAGNOSTIC 1 Messages FE
2201 2202 2203 2204 2205 2206 2207 2208 2209
CPU 22PBA01 ROM-failure CPU 22PBA01 Fatal Error illegal software interrupt software failure 1 software failure 2 software failure 3 software failure 4 software failure 5 I/O 22PBA02 failure
PE
2210 2211 2212 2213 2214 checksum BBR failure copycounter not connected 22CO1 watchdog failure I/O 22PBA02 watchdog failure CPU 22PBA01 ADC failure
MRE
2225 2226 ADC failure operating panel failure
Warnings
2275 2276 2277 2278 BBR information failure CPU 22PBA01 warning retransmission warning TXRDY time out warning
ed.6 Part I
TSM 2400 family
22 Power and control 101
DIAGNOSTIC
22diag
Fault table
CODES F 2201 POSSIBLE FAILURES - EPROM Host defect - HOST CPU 22PBA01 defect - HOST CPU 22PBA01 defect - ESD (Electro Static Discharge) failure - illegal interrupt CPU 22PBA01 - illegal interrupt HOST I/O 22PBA02 - illegal interrupt 04PBA03 optic control - illegal interrupt 10PBA01 RDF control - illegal interrupt 22PBA04 panel operating control
F 2202 F 2203
F 2204 - HOST CPU 22PBA01 defect (software failure 1) F 2205 - (softw. failure 2) F 2206 - (softw. failure 3) F 2207 - (softw. failure 4) F 2208 - (softw. failure 5) These error codes occur if internal in the software something goes wrong. If these error codes occur repeatedly replace the software with a different (newer) release. F 2209 - 22PBA02 HOST I/O defect - 22PBA01 CPU defect
P2210, W2275 - HOST CPU 22PBA01 - jumper on CPU board not installed - software design error P 2211 - copy counter 22CO1 not connected - HOST I/O 22PBA02 defect - 24 V-driver 22PBA09 defect - HOST I/O 22PBA02 defect - HOST CPU 22PBA01 watchdog defect (no 1200 Hz) - HOST CPU 22PBA01 watchdog defect (1200 Hz available)
P 2212
P 2213
TSM 2400 family
Part I ed.6
22diag
DIAGNOSTIC
CODES
POSSIBLE FAILURES
P 2214, MRE 2225 - HOST I/O 22PBA02 - power supply 22PBA08 MRE 2226 - operating panel defect (see Fault tree next page) - ESD (Electro Static Discharge) failure - BBR information failure (ESD) - HOST CPU 22PBA01 defect - bundle interface laptop defect/ bad connected - laptop defect - HOST I/O 22PBA02 defect - HOST CPU 22PBA01 defect - Problem : - Possible cause : machine resets to default display during run. power supply overheating, cooling ventilator on power supply defective
W 2275 W 2276 W 2277, W2278
General:
ed.6 Part I
TSM 2400 family
DIAGNOSTIC
22diag
Fault tree
Machine dead NO - check mains cable - circuit breaker - check mains distribution - check all low voltage consumers(see page 509) - check power supply 22PBA08 ON, OFF, 2Hz - check HOST firmpack led ON CPU PBA - 22PBA01 HOST CPU - 22PBA02 HOST I/O - 22PBA08 power supply
Power supply leds ON
YES
0.5 Hz - switch machine off - switch to service mode - switch machine on (console selftest)
Console selftest OK ? YES
NO
- check 12V operating panel - check power distribution on operating panel PBAs - console PBAs, VDF, LCD etc. - console code EPROM (no.1)
use console test to check : - 22PBA02 HOST I/O - 22PBA04 op. panel control - check language EPROM (no.2)
TSM 2400 family
Part I ed.6
22diag
DIAGNOSTIC
Protections FE 2201
ROM is tested during initialization/SDS ROM test. If a new calculated checksum is not equal to the checksum stored in ROM: FE2201
FE 2202
RAM, interrupt controler and internal I/O are tested during initialization/SDS RAM test. A non destructive test is executed. If the test is not successful: FE2202
FE 2209
Test HOST I/O during initialization, LED on CPU-board continuously on.
MRE 2226
Operating Panel is tested during initialization/SDS test and during operation. In case of error: MRE2226
PE 2210 Warning 2275

BBR is checked during initialization. The test consists of two parts: Checksum test, a new checksum is calculated and compared with a checksum stored in the BBR: -checksums are equal = correct -checksums are not equal = not correct, PE2210 The validity of the BBR customer information is checked, such as counters, reference programs: In case of invalid information = WARNING2275
ed.6 Part I
TSM 2400 family
DIAGNOSTIC
22diag
FE 2203 FE 2204 FE 2205 FE 2206 FE 2207 FE 2208

During operation a number of errors can occur which cause control to generate an error: - illegal interrupt, FE2203 - software control program too slow, FE2204 - dividing by zero, FE2205 - error in RTX, FE2206 - error in RTX queue, FE2207 - mailbox queue full, FE2208
PE 2212 PE 2213
WATCHDOG circuit test : The availability of 1200Hz clock signal is tested. If not available, PE2212 If 1200 Hz is available , PE2213
PE 2211
COCPRES is tested (if copy counter is necessary) just before starting a run and just before transfer. - 1 = correct - 0 = copy counter not present, PE2211
MRE 2225 PE 2214

ADC is tested in two ways: - 1x/10ms after starting a conversion ADC ready is checked - 1x/80ms the reference voltage is checked In case of an error, MRE2225, PE2214
TSM 2400 family
Part I ed.6
22sds
SDS

SIGNAL -022PBA01 22PBA01 22PBA01 22PBA01 22PBA01 22PBA01 22PBA01 22PBA01 22PBA02 22PBA01 22CO1 22PBA02 22PBA02 22PBA02 22PBA02 22PBA04 22PBA01 22PBA01 22PBA02 22PBA02 CPU 22PBA01 ROM failure CPU 22PBA01 RAM failure illegal software interrupt software failure 1 software failure 2 software failure 3 software failure 4 software failure 5 Host I/O failure checksum BBR failure copy counter not connected watchdog failure I/O 22PBA02 watchdog failure CPU 22PBA01 ADC failure ADC failure operating panel failure BBR information failure Host CPU warning retransmission warning (serial interface) TXRDY time out warning (serial interface) -1-222CO1 COCPRES REMCSE COpy Counter PRESent REMote Copy SEnsor DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 22 0 01 FE 22 0 02 FE 22 0 03 FE 22 0 04 FE 22 0 05 FE 22 0 06 FE 22 0 07 FE 22 0 08 FE 22 0 09 FE 22 0 10 PE 22 0 11 PE 22 0 12 PE 22 0 13 PE 22 0 14 PE 22 0 25 MRE 22 0 26 MRE 22 0 75 W 22 0 76 W 22 0 77 W 22 0 78 W
PARAMETERS INPUT TESTS 22 2 01 22 2 02
ed.6 Part I
TSM 2400 family
22 Power and Control 201
SDS
22sds
OUTPUT TESTS 22 4 01 22 4 02 22 4 03 SPECIAL TESTS 22 6 04 22 6 05 22 6 06 22 6 07 REPLACE CONSUMABLES
-4beeper shut-off COpy CouNTeR Count
22CO1
COCNTRC -6-
Note 1 Note 2 Note 3 Read out software version -8-
Note 1: Operating panel test. By pressing <PRINT> the test is started. A pattern is displayed which changes every 2 sec. With every display change also a different LED is switched on. The cycle is interrupted by pressing any button on the operator panel. Next buttons can be tested on correct functioning. By pressing a button the code of this button (01-22) is displayed on the VFD. This test is ended by pressing <PRINT>+ <CORRECTION> simultaneously or by switching the machine off and on again. Note 2: Enable/disable beeper. By pressing <PRINT> the current mode of the beeper is displayed. By using the copy darker/lighter buttons the mode can be changed. When off is selected the beeper is not audible during e.g. input tests. Note 3: Initialize BBR. By pressing <PRINT> the test is started. The message print is confirm is displayed. By pressing <PRINT> again the BBR is initialized and the test is automatically ended. All software settings change to default values.
TSM 2400 family
Part I ed.6
22disa
DIS/ASSEMBLY
DIS/ASSEMBLY 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10
Operating panel (only 2375/2400/2465CRU and 2465FIN)

Remove the centre front cover. Remove the front reflector cover. Remove the gray plastic air funnel. Remove the black metal protection cover at the bottom of the operating panel. Loosen connectors 2204CN1 and 2204CN2. Remove the four 7 mm securing nuts underneath the operating panel left and right. Lift the operating panel. Loosen connector 22CN4. Remove the operating panel. Mount in reversed order.
ed.8 Part II
TSM 2400 family
DIS/ASSEMBLY
22disa
TSM 2400 family
Part II ed.8
22func
FUNCTIONAL DESCRIPTION 1 Power supply section

The function of the power supply section is: establish the connection to the mains supply convert the mains voltage to 220VAC (50/60Hz) supply all 220VAC, 24VDC users The power supply section consists off: -A-B-C-D-E-F-G-HSSR2 (22PBA07) 24V-driver (22PBA09) Step down transformer (USA/UK) Mains distribution board SSR1 (22PBA06) Interlock switch rear panel main frame (22S5) Interlock switch rear panel subframe (22S6) SSR (22PBA10)
22func01
ed.8 Part II
TSM 2400 family
22func
-H-J-
Circuit breakers (22S7 A/B) Power supply 24/12/5/-12 (22PBA08)
22func02
-K-L-M-
Shut off control (22PBA03) Interlock switch left side panel (22S4) Interlock switch front panel (22S3)
22func03
TSM 2400 family
Part II ed.8
22func
Mains distribution
The main distribution board consists off:
-A-B-C-D-E-F-G-H-
Circuit breakers (22S7) Terminal block (220V distribution before main current relay) Main current relay (22RL1) 24V transformer (22TR1) Terminal block (220V distribution behind main current relay) Terminal block (mains lead) Mains filter(s) (FI1, FI3) 24V relay (22RL2)
22func04
The Oc 2400 family can be wired to 4 different mains supplies: 1 phase + 1 neutral 220V-16A 50Hz (Eur) 2 phase + 1 neutral 220V-10A 50Hz (Eur) 1 phase + 1 neutral 240V-16A 50Hz (UK + AUSTR) 1 phase + 1 neutral 208/240V-20A 60Hz (USA) For each of these situations an electrical diagram is included. (see 701A, B, C)
ed.8 Part II
TSM 2400 family
22func
Power distribution circuit diagram description : (see 701A, B, C)

The mains supply is fed to circuit breakers (22S7) before it enters the mains filter (22FI1, FI3). The circuit breakers, which can be operated by the user by opening the right side cover door, switch off at a current of: 16A for 1 phase 1 neutral 50Hz 10A for 2 phase 1 neutral 50Hz 20A for 1 phase 1 neutral 60Hz After passing the mains filter (22FI1) the mains supply is connected to a terminal block. When the mains voltage differs from 220V AC an additional step down/up transformer (22TR2 for UK and AUSTR, 22TR3 for USA) is used to adapt the mains voltage to 220V. Electrically this transformer is positioned between the mains filter and the terminal block. Physically this transformer is mounted upside down under the base plate of the lower paper tray as indicated in the component location . From the terminal block the 220VAC mains supply is fed to 3 different locations: the switch contacts of the main current relay (22RL1) a 220/24V transformer (22TR1) a service mains plug (only powered if the machine is switched off) Throughout the whole machine 2 different phases (L1 and L2) and corresponding neutrals (N1 and N2) are used. In the case of mains connections with only 1 phase these 2 pairs are interconnected on the mains side of the main current relay. WARNING: L = line and N = neutral can also be L = neutral and N = line, depending on the mains plug.
TSM 2400 family
Part II ed.8
22func
Block diagram power distribution
22func05.gem
Tabel with all connections of terminal block for 220VAC distribution behind main current relay :
ed.8 Part II
TSM 2400 family
22func
The loads for the different phases are: L1-N1 = SSR1 (22PBA06)
=DEVAGIMO =05M1 =SPHRHEFR =15HE3 =SPHRHERR =15HE4 =SUMMO =01M2 =02PBA01 =02M1 = =04M2 = =05M1 = =05M2 = =07LA1 = =18M3 = =23M2 = RDF-30V-SUPPLY =10PBA03 =10M1 (10PBA07) =10PBA06 =10M2 =10PBA04 =10M4 =10PBA04 =10M5 =10PBA05 =10M6 =10PBA05 =10M7 L2-N2 = SSR2 (22PBA07) =FPHRHEFR =15HE1 =FPHRHERR =15HE2 =UPTLMO =12M1 =LPTLMO =12M2 = POWER SUPPLY 24/12/5/-12V (22PBA08) = SSR1 (22PBA06) =TTFHEUP = 06HE1 =TTFCLEHE = 06HE3 =STBMO = 23M1 =DUXCOOLMO = 16M1 =OPBLLA = 22LA2 = SSR (22PBA10) =TTFHELO = 06HE2 = EXPOSURE FLASH SUPPLY =04PBA01 = 04C1 =04PBA02 = 04C2 = EXPOSURE FLASH IGNITION =04PBA02 = 04LA1 = = 04LA2 = INTERVAL-FLASH =03PBA01 = 03C1 = = 03C2 = CCD/CMS INTERFACE =24PBA01 = KEYCOUNTER INTERFACE =24PBA02 Generally, it can be stated that the 220V and 24V wiring is located at the rear side of the machine while the other voltages (12, 5, -12V) are at the front.
TSM 2400 family
Part II ed.8
22func
Power on/off
To power up the machine the main current relay (22RL1) must be energized.This is done by activating the 24V relay (22RL2). The supply for this relay comes from 24V transformer 22TR1 which is connected to the terminal block. The 24V supply is fed to the 24V relay (22RL2) via the shut-off-control (22PBA03) and the following switches:
Key switch - 22S1 Shut-off relay contact - RL1 Left side panel interlock switch - 22S4 Main frame panel interlock switch - 22S5 Sub frame panel interlock switch - 22S6 Front centre panel interlock switch - 22S3 The shut-off-control (22PBA03) is a PBA that contains logic circuits used to switch on and off the 24V relay (22RL2) and so the machine. Switching on can be done in two ways :
Jumper shut-off control board (22PBA03) in position OFF : By pressing the power on/off switch 22S2 Jumper shut-off control board (22PBA03) in position ON : By powering up or plug in the main supply. Some hardware circuitry energizes an on board relay which connects the 24V supply to the 24V relay (22RL2). As a result, the main current relay is energized. At the same time, the key switch lamp (22LA1) is switched on. Switching off can be done in two ways :
By pressing the on/off switch (22S2). The on board relay is de-energized and consequently, via the 24V relay (22RL2), the main current relay (22RL1). via the control line SHUT-OFF coming from the HOST I/O (22PBA02). A positive pulse on this line will de-energize the on board relay. This software controlled switch off is built in to guarantee that the machine is switched off after a preprogrammed time while not being used. The programming of this time can be done in key operator mode (K 6.5). The range is 1 - 8 hours. Default time is 3 hours. NOTE : Shut off is only working in normal mode if installed, not in SDS with Service Copy Mode.
ed.8 Part II
TSM 2400 family
22func
Solid state relay boards

Solid state relays are used on 3 different PBAs in this machine, 22PBA06 (SSR1), 22PBA07 (SSR2) and 22PBA10 (SSR). SSR1 takes care of most of the 220V circuits (with and without solid state relays) in the main frame, while SSR2 does the same for the subframe. The boards SSR1, SSR2 and SSR are in fact the change from control lines with 12V signals to power lines 220VAC. Basically there are two different types of solid state relays on the SSR boards. SSR with thyristor load switch: This type of SSR is used for low-power applications. The maximum continuous current is less than 500mA. The applications are: DEVAGIMO SSR1 LED 8 developer agitation motor (05M1) UPTLMO SSR2 LED 4 upper paper tray lift motor (12M1) LPTLMO SSR2 LED 3 lower paper tray lift motor (12M2) SSR with thyristor drive and triac load switch: This type of SSR is used for high-power applications. The maximum continuous current is 5A. The applications in this machine are: MADR SSR1 LED 7 master clean lamp (07LA1) main drive motor (23M2) exposure cooling fan (04M2) ozone exhaust fan (02M1) scorotron supply (02PBA01) finisher cooling fan (18M3) developer cooling fan (05M2) SPHRHERR SSR1 LED 6 second preheater rear (15HE4) SPHRHEFR SSR1 LED 5 second preheater front (15HE3) FPHRHERR SSR2 LED 1 first preheater rear (15HE2) FPHRHEFR SSR2 LED 2 first preheater front (15HE1) TTFHEUP/ SSR1 LED 3 upper TTF heater (06HE1) TTFCLEHE SSR LED TTF cleaning heater (06HE3) TTFHELO SSR1 LED 2 lower TTF heater (06HE2) SUMMO SSR1 LED 4 set up mechanism motor (01M2) No load switch or with relay : 220VAC 220VAC STBMO SSR1 SSR1 SSR1 duplex cooling fan (16M1) operating panel lamp (22LA2) standby motor (23M1)
LED1
TSM 2400 family
Part II ed.8
22func
Power supply 24/12/5/-12V (22PBA08)

This power supply takes care of the complete low voltage supply for the whole system except for the RDF motors 10M1...10M7. The most important technical data are: Input : 220VAC, 48.5 - 61.2Hz Fuse F1 : 5AT Output : Voltage Min/Max load +24V +12V + 5V -12V 0 - 8.5A 1.3 - 6.5A 0.4 - 1.5A 0 - 0.25A
DC range
Vripple max
22.8 - 26V 200mV 11.4 - 13V 100mV 4.9 - 5.25V 100mV -10.5 - 13.8V 100mV
Each output voltage has a LED which signals the presence. The output voltages have 1 common ground. For safety reasons the power supply will switch to the hiccough mode if an overvoltage or overcurrent situation occurs. The applications for +24V supply are : 24V driver PBA Framing edge discharge PBA Optic control PBA RDF control PBA (10EM1, 10EM2, 10EM3, 10M3) - Finisher control PBA The applications for +12V supply are : - HOST I/O PBA - RDF control PBA - Operating panel control PBA The application for +5V supply are : - HOST I/O PBA The applications for -12V supply are : - HOST I/O PBA - RDF control PBA - Operating panel control PBA 22PBA02 22PBA02 10PBA01 22PBA04 22PBA09 03PBA02 04PBA03 10PBA01 18PBA01
22PBA02 10PBA01 22PBA04
ed.8 Part II
TSM 2400 family
22func
Circuit diagram description : (see block diagram)

The power supply is a 290 Watt switch-mode power supply with 4 different output voltages with 1 common ground. The power supply does not need any forced cooling if the ambient temperature stays below 50C. The supply has its own radio interference filter. An inrush limiter ensures that the current at power on is less than 12A peak. After rectification the DC supply is fed to a Buck converter. Here the DC supply is transformed into a DC block wave. The DC blockwave is passed to a push-pull converter which creates an AC blockwave. The AC signal is fed to the primary winding of a transformer. At the secondary side 3 output voltages are generated, 24V, 12V, -12V. A separate regulator is available to generate the 5V supply by using the 12V supply as input. The 24/12/5V supplies have an overcurrent protection which switches the power supply into the hiccough mode in case of overcurrent or short circuit (refer to specification). All output voltages have an overvoltage protection which will switch the power supply to hiccough mode in case of an over voltage (refer to specification). The hiccough time is in the range 100-1000msec (1-10Hz). At the secondary side there is a MAINSFAIL signal (open collector) to give an indication of the status of the primary line voltage. The signal MAINSFAIL meets the following specification: normal operating < 0.2 V mains failure > 4.85V The MAINSFAIL signal is connected to the interrupt line of the Host-CPU with highest priority (NMI, non maskable interrupt).
TSM 2400 family
Part II ed.8
22func
24V-Driver board
The 24V-driver board (22PBA09) drives all 24V components (motors, counter, clutches, solenoids) in the mainframe as well as in the subframe. The next blockdiagram shows the functions.
22func08.gem
The remote copying switch is a push button which is connected to an input on the HOST I/O (22PBA02). The signal is called REMCOPSE. This switch offers the oppertunity to start an SDS output or special test while at the rear of the copier. The buzzer is activated by making the signal BEEPER high. This buzzer is used to as an audio indication of an SDS input test. The separation mechanism and master cooling motor have some additional circuitry. This is explained in the corresponding functions, respectively 12-PAPER and 01PHOTOCONDUCTOR.
ed.8 Part II
TSM 2400 family
22func
The 24V components connected to these drivers are wired to the 24V supply (22PBA08). A high level 1 on the input of the driver will connect the load via an open collector circuit to ground. The load is then energized. There are two types of 24V drivers used: 500mA continuous output current types. The applications are : Control line FANSPCTR DUXRVCL DUXTPCL COCNTRC SUMMOBR UPTSEPCL UPTSEPMOS UPTSEPMOPO DEPCOC LPTSEPCL LPTSEPMOS LPTSEPMOPO Connected device master cooling fan (01M1) duplex reverse clutch (16CL2) duplex throughput clutch (16CL3) copy counter (22CO1) set up mechanism motor brake (01BR1) upper paper tray separation clutch (12CL2) upper paper tray separation motor (12M3) (separate) upper paper tray separation motor (12M3) (pinch open) key counter (24CO1) lower paper tray separation clutch (12CL3) lower paper tray separation motor (12M4) (separate) lower paper tray separation motor (12M4) (pinch open)
1.5A continuous output current types. The applications are : Control line DUXPSSO FPSSO TFRCL TFSCL Connected device duplex paper stop solenoid (16EM1) first paper stop solenoid (12EM1) transfer clutch (01CL2) transfuse clutch (06CL1)
TSM 2400 family
Part II ed.8
22func
Control section
The function of the control section is to initiate all activities for making copies in a proper and safe manner. The control section consits off:
-A-B-
HOST-CPU (22PBA01) HOST I/O (22PBA02)
22func09
ed.8 Part II
TSM 2400 family
22func
The blockdiagram below shows how the PBAs are linked together.
22func10.gem
TSM 2400 family
Part II ed.8
22func
HOST CPU
The figure below shows the blockdiadram HOST CPU.
22func11.wmf
Microprocessor The central processing unit is an Intel 8088 microprocessor. The processor has an 8 bit data bus interface but a 16 bit internal architecture. It operates on a 8MHz clockrate. The instruction set consists 133 different types of instruction. The average execution time per instruction is 1.8s.
ed.8 Part II
TSM 2400 family
22func
Clock generation Two output signals are generated by this circuit: 8MHz clock signal for the microprocessor 4MHz auxiliary clock The auxiliary clock is used to generate: 10KHz clock for precision timing aspects, FPSSO, DUXPSSO, FRAFLIGN 100KHz as real time clock interrupt Reset/Watchdog circuit The reset circuit serves three purposes: power up, the reset line to the processor is kept low 0 until the supply voltage is stable power down, a hard reset is generated before the power goes down, the processor gets time to save important information into BBR. manual reset, a hard reset is generated by pressing the reset button. The watchdog circuit is a hardware security to check if software did not lose control. Every 160ms the processor must reset a downcounter otherwise a processor reset situation will occur.
Interrupt controller The processor has two interrupt levels: NMI, non maskable interrupt, is the highest level and is always accepted. It is connected to the signal MAINSFAIL. When this line goes high 1 a power down is about to occur. INT is connected to an interrupt controller to which eight different interrupt lines are connected. EPROM Three EPROMS are installed in sockets on the HOST CPU (22PBA01). The machine control program and SDS program are stored here. The EPROMS are 1MB (27CO10) types. This means that the total EPROM capacity is 3MB. The language dependent part is stored in EPROMS on the operating panel control (22PBA04). All languages in the Oc 3075 are stored in EPROM of 1Mbyte.
TSM 2400 family
Part II ed.8
22func
BBRAM The HOST CPU contains a 32kbyte memory chip with very low power consumption. The supply voltage is either coming from the 24/12/5/-12V power supply (22PBA08) or from a battery. When the power supply is on the battery is recharged. 24kbyte is used as ordinary RAM. 8kbyte is used as keyed RAM. In the keyed RAM important information is stored, such as parameters, counters etc. The keyed RAM can only be written to when an enable line, NRAMEN, is actvated high 1 first. This prevents for uncontrolled write actions. Timer For the timing of some actions the master pulses are not suitable. Activation of those actions has to take place in between master pulses. A timer circuit with three identical channels is used start the actions on the correct moment after being triggered by the processor. The control lines involved are: DUXPSSO Duplex paper stop solenoid FPSSO First paper stop solenoid FRAFLIGN Frame flash ignition
ed.8 Part II
TSM 2400 family
22func
HOST I/O
The HOST I/O (22PBA02) is the interface between the HOST CPU (22PBA01) and the controlled devices. The HOST I/O has 5 interfacing functions: digital input signals analogue input signals digital output signals service bus critical outputs All digital input and output signals are 12V. This voltage level is on the HOST I/O converted to and from 5V.
22func12.wmf
These 5 functions are illustrated in the block diagram.
TSM 2400 family
Part II ed.8
22func
Digital input signals Input signals are necessary for the CPU to get information from the controlled devices. All input lines are treated in the same way. Coming from the connector, the input line is fed through a filter to an input register. At the moment the CPU selects the input register, via the control and address lines, the data goes via the level shift to a data buffer and next to the data bus. The level shift is a resistor network and takes care of 12V to 5V conversion of input signals.
Analogue input signals There is one 8 bit ADC (analogue digital converter) available in the system. By using a multiplexer 8 different analogue signals can be fed to the ADC (one at a time). These analogue input signals are:
ABCOUT LPTLLRE UPTLLRE SPHRNTCRR SPHRNTCFR FPHRNTC TTFNTC
automatic background compensation lower paper tray lift level resistor upper paper tray lift level resistor second preheating NTC rear second preheating NTC front first preheating NTC TTF heating NTC
All sensors are connected to a known voltage (VP=5V, Vntc = 8V). This voltage is related to a 2.5V reference voltage which is also connected to 1 line of the ADC itself. This reference voltage is used to check the ADC. This is necessary for correct conversions. The analogue input voltages are in the range 0 < Vin < 5V. Digital output signals By means of output lines, the CPU can activate or deactivate circuits in the machine. The CPU datalines are fed via a level shift and a data buffer to the output registers. A conversion is made from 5 to 12V. The register that has to be written to is detected by the selection circuit. The output enable circuit ensures that the output signals stay in their inactive state during power up, with the exception of some signals, for instance the operating panel signals. This is done by using the 2.5V as a threshold voltage.
ed.8 Part II
TSM 2400 family
22func
Service bus The interface for the service bus is located on the HOST I/O board. The communication with an external device is controlled by an 8251 USART (universal synchronous / asynchronous receiver transmitter). The USART is programmed by the CPU in asynchronous mode, 1 stopbit, even parity, baudrate 1/16 of clock frequency, 8 bit character length, transmit/receive enabled and RTS low. The clock frequency is generated by a special clock circuit. The output of a crystal oscillator (4.9152MHz) is devided by 256 and fed to the USART (=19.2KHz) as clock frequency. A 1200Hz signal (4.9152MHz/4096) is also derived and fed to the HOST CPU.
Critical actions Three output signals must be activated at very specific moments with specific durations. The moment of activation is controlled by the HOST-CPU in that the HOST CPU supplies a pulse to the HOST I/O. On the HOST I/O this pulse is fed to a one-shot generator which creates a pulse with the exact duration. CPU TIM1 TIM2 TIM3 > HOST I/O > FRAFLIGN FPHRPSSO DUXPSSO UNIT PULSE DURATION
frame flash ignition 4.75 msec first paper stop solenoid 129 msec duplex paper stop solenoid463 msec
TSM 2400 family
Part II ed.8
22func
10
Operating panel for Oc 2375/2400/2465/2475.

The Operating Panel is one of two intelligent devices in this copier (the RDF is the other one). It has an own microprocessor and memory. Two EPROMS carry the language dependent messages and SDS messages stored on the operating panel control (22PBA04). The function of the Operating panel is to communicate with the user by displaying messages or reading keys. The operating panel consists off:
-A-B-C-D-EConfidential 1997 Oc Nederland B.V.
VFD, vacuum fluorescence display (22VFD1) LCD, liquid cristal display (22LCD1) Fluorescent lamp for LCD OPERATING-PANEL-KEYBOARD (22PBA05) OPERATING-PANEL-CONTROL (22PBA04)
22func13
22func14
ed.8 Part II
TSM 2400 family
22func
Operating panel control The functions of the operating panel control are: - communication between operating panel and HOST I/O; - control of other operating panel modules (VFD, LCD, keyboard); - generation of supply voltages for the operating panel modules. The communication from the operating panel control (22PBA04) to the HOST-IO (22PBA02) is done via a parallel bus. The bus operates on a 12V level to reduce noise influences. On both boards is a level shift to 5V. Control is done by a 8031 processor. On board are 2 EPROMS that contain data: EPROM1= basic program and service messages (only English) EPROM2 =language dependent contents of the graphic display messages (all languages). Both EPROMs are 64kbyte types. For each EPROM a carrier socket is used to create the possibility of easy exchange. The power supply part converts the incoming 12VDC to 5VDC, 93VDC and 4.9VDC. VFD, vacuum fluorescent display The display is a 240 x 64 dots graphic fluorescence display. The display is one complete unit consisting of the display part and 2 PBAs containing control logic. For the operating-panel-control (22PBA04) the VFD acts like a RAM. One bit of this RAM corresponds with one dot on the display. The RAM is split up in 4 equal parts of 2k8 bytes (240 x 64 = a page). Each of these parts can be selected separately. This offers the possibility to prepare a new page while another page is being displayed. LCD, liquid cristal display The status display is 120 elements custom made display. The electronics are integrated as chip-on-glass technology. The LCD is transmissive and uses a fluorescent lamp (4 W ) as background illumination. The supply for the fluorescent lamp is completely separated from the operating panel. It can be reached via the upper tray removing a cover at the left. The elements of the display cannot be controlled individually but by group commands.
TSM 2400 family
Part II ed.8
22func
Keys The operating panel contains 22 keys. These keys are scanned by the panel operating control itself. Scanning means detection when a key is depressed, a debounce function, and detection when a key is released. Keys are contacts that interconnect printed wiring on the board (Rcontact < 200 Ohm). The operating panel indicates to the HOST CPU when a key is depressed and released. Communication between HOST CPU and Operating panel The only way for the HOST CPU to change information on the Operating Panel is by sending commands. These commands have a fixed layout. The commands can be split up into 3 groups as the operating panel has 3 different communication areas with the user. The groups are: VFD,LCD,LED. Additionally the host can start 2 test commands. These are: SELF TEST: The operating panel will execute a VFD RAM test, a RAM test and an EPROM checksum test. The result is reported to the host. If a failure is detected the LED on host cpu flashes with a frequency of 0.5Hz. This test is automatically started after power up. The response is also used as communication test. SERVICE TEST: This test offers a visual check of the functioning of the operating panel and a test of all keys. This test can be stopped by switching the machine off and on. Status information is sent to the HOST CPU. This test can be started in SDS, test 22604. This test is automatically started when the operating panel is disconnected from the HOST I/O. SPECIAL TEST : With the aid of a testwire, the beeper and an automatically generated block wave of 1 Hz on the outputlines of 22CN13 (pin 1-8), you can check the bundle, input- and output-buffers of 22PBA02 and 22PBA04. Connect one of the pins 13-20 of 22PBA04 CN1 with each 5, 6, 7, 8, 9, or 10 of the same CN1. The beeper wil be activated if the bundle, or the input- output-buffers of both 22PBA02 and 22PBA04 are correct. The blockwave of 1 Hz is only generated in case the self test has detected an operating panel failure and the HOST/CPU led flashes with the frequency of 0.5 Hz.
ed.8 Part II
TSM 2400 family
22func
11
Operating panel for the Oc 3075

The operating panel forms the link between an existing main control unit of the Oc 2400 and the operating panel coming from the Oc 3045. The interface to the Oc 2400 and the operating panel to the Oc 3045 are maintained. The operating panel is characterized by the following features:
80c188 micro-controller; 10 MHz clock-frequency 32 Kbyte static RAM 32 Kbyte display RAM (two pages) 1Mbyte eprom control logic for a 640 * 200 pixel LCD-display a reset control circuit one diagnose LED digital outputs digital inputs digital interrupt inputs
Description
The operating panel is partitioned into serveral blocks. The operating panel is based on an 80c188 micro-controller. The micro-controller Memory consists of Read Only Memory and Random Access Memory. The interface to the Oc 3075 is realised by the Host interface. The connection to the operating panel is realised by a KeyMemory board interface and an LCD i n t e r fa c e . T h e p o w e r DC/DC converts the supply Keyboard voltage from the Host interInterface face into separate voltages for the operating panel and Host the LCD interface. 80c188
Interface Display Interface
DC/DC Conversion
Block diagram Operating panel
TSM 2400 family
Part II ed.8
22func
Microprocessor
The PBA, Operating panel is built up around an 80c188 micro-controller (10 MHz). The 80c188 is a micro-controller with a 16-bit internal arhitecture and an 8-bit data bus interface. It combines the most common micro-processor system components onto one chip and allows a one Mbyte physical address space.
DC/DC Power
The power supply of the operating panel is coming from the host (CN2). This voltage of +12V is converted into +5V and -24V. The internal logic of the operating panel uses the +5V voltage supply and the +12V (level shifting interface-signals to host). The operating panel (Keyboard and LCD interface) is using the +5V (internal logic), -24V (LCD power supply) and +12V (Backlight LCD).
ed.8 Part II
TSM 2400 family
22func
12
Operation
During power up / initialization: When the machine is switched on 220VAC is supplied to the 24/12/5/-12V Power Supply, four LEDs corresponding with the low voltages are lit. Control starts a number of tests: - ROM test, if this test fails the LED on HOST CPU is switched off - RAM test, if this test fails the LED on HOST CPU starts flashing with a frequency of 2Hz. - HOST I/O test, if this test fails the LED on HOST CPU is continuously on. If both tests were successfull the real time clock is enabled and machine initialization (functions) takes place.
operating panel test, if the operating panel reports an error or if the communication with the operating panel is incorrect the LED on the HOST-CPU starts flashing with a frequency of 0.5Hz. If all tests are successfull the LED flashes with a frequency off 1Hz. After this the Service switch is checked and it is decided if normal mode or SDS mode is entered. During standby: The four LEDs on the 24/12/5/-12V Power Supply are switched on. The LED on the HOST CPU is flashing with a frequency of 1Hz. During run: Identical to standby.
TSM 2400 family
Part II ed.8
22comp
COMPONENT LOCATION
COMPONENT LOCATION
22PBA01 22PBA02 22PBA08 22PBA13 22CN3 22S7A/B : : : : : : Host CPU PBA Host I/O PBA Power supply PBA 24/12/5/-12V Stapler power supply connector service bus circuit breaker
22comp01
ed.8 Part II
TSM 2400 family
COMPONENT LOCATION
22comp
22CN2 22CN9 22CN11 22CO1 22F1 22F2 22LA1 22PBA03 22PBA04 22PBA08 22S1 22S2 22S3 22S4 22TR2 22TR3
: : : : : : : : : : : : : : : :
drawer connector master handling (front) connector service socket department counter fuse 5A fuse 5A on/off lamp shut off control PBA panel operating control PBA Power supply PBA 24/12/5/-12V key switch on/off on/off switch cover switch cover switch 240-220V step down transformer (only UK and Australia) 208/240-220V transformer (only USA)
22comp02
TSM 2400 family
Part II ed.8
22comp
COMPONENT LOCATION
22CN1 22CN5 22CN10
: connector master handling (rear) : connector : connector : SSR1 PBA : SSR2 PBA : : : : : : SSR PBA 24V-driver PBA cover switch cover switch 240-220V step down transformer (only UK and Australia) 200/230-220V transformer (only USA)
* *
22PBA06 22PBA07 22PBA10 22PBA09 22S5 22S6 22TR2 22TR3
In certain cases, integrated on one circuit.
22comp03
ed.8 Part II
TSM 2400 family
COMPONENT LOCATION
22comp
22CN5 22CN7 22L1 22ST1
: : : :
connector connector ballast/starter (not in the Oc 3075) coil 22LA2 (not in the Oc 3075) starter 22LA2 (not in the Oc 3075)
22comp04
TSM 2400 family
Part II ed.8
22comp
COMPONENT LOCATION
Oc 2375/2400/2465/2475 panel
22CN4 22LA2 22LCD1 22PBA04 22PBA05 22VFD1 : : : : : : connector lamp LCD display (not in the Oc 3075) fluorescent lamp 22LCD1 (not in the Oc 3075) liquid crystal display (not in the Oc 3075) panel operating control PBA operating panel keyboard PBA vacuum fluoresence display (not in the Oc 3075)
22comp05
ed.8 Part II
TSM 2400 family
COMPONENT LOCATION
22comp
Oc 3075 panel
22PBA04 22PBA05 22PBA11 22PBA12 : : : : Operating panel interface Control keyboard Control display Supply Fl. inverter
22PBA11 22PBA05
22PBA12 EPROMS 22PBA04
TSM 2400 family
Part II ed.8
22comp
COMPONENT LOCATION
22CN6 22CN8 22FI1 22FI3 2RL1 22RL2 22S7A/B 22TR1
: : : : : : : :
24 V connector 24 V connector mains filter mains filter (euro 2-phase) main relay safety relay circuit breaker 220-24V transformer
22func06.gem
22comp06
ed.8 Part II
TSM 2400 family
COMPONENT LOCATION
22comp
TSM 2400 family
Part II ed.8
22elec
ELECTRICAL DIAGRAM

Dx Ax NIOR NIOW NIOSEL NOE NRES IRQx TIMx NIORDY
Data line x Address line x Not Input Output Read Not Input Output Write Not Input Output SELect Not Output Enable Not RESet Interrupt ReQuest x TIMer x Not Input Output ReaDY HOLD COpy Counter PRESent COpy CouNTeR Control Operator Panel CoMmanD Data xr Operator Panel CoMmanD STroBe Operator Panel CoMmanD ACKnowledge Operator Panel STatuS Data x Operator Panel STatuS STroBe Operator Panel STatuS ACKnowledge Operator Panel Not RESet Not WRite Not ReaD Not Memory REQuest Not Chip Select Data Input Reset Frequency oscillatorL Load Data CLock frequency
HOLD COCPRES COCNTRC OPCMDDx PCMDSTB OPCMDACK OPSTSDx OPSTSSTB OPSTSACK OPNRES NWR NRD NMREQ NCS DI R FL LD CL
ed.8 Part I
TSM 2400 family
ELECTRICAL DIAGRAM
22elec
Signal names for the Oc 3075

CPAENASWMAA CPAENASWMAB CPAENASWMAC CPATESSWMAA CPATESSWMAB CPATESSWMAC CPATESSWMAD CPATESSWMAE CPATESSWMAF CPATESSWMAG CPATESSWMAH OPCMDSTB OPCMDACK OPCMDD0-7 OPSTSSTB OPSTSACK OPSTSD0-5 OPNRES CPADICCL1 CPADICCL2 CPADICDAA CPADICDAB CPADICDAC CPADICDAD CPADICM CPADICFLM CPADICINH Control PAnel ENAble SWitch MAtrix A Control PAnel ENAble SWitch MAtrix B Control PAnel ENAble SWitch MAtrix C Control PAnel TESt SWitch MAtrix A Control PAnel TESt SWitch MAtrix B Control PAnel TESt SWitch MAtrix C Control PAnel TESt SWitch MAtrix D Control PAnel TESt SWitch MAtrix E Control PAnel TESt SWitch MAtrix F Control PAnel TESt SWitch MAtrix G Control PAnel TESt SWitch MAtrix H Control PAnel CoMmanD STroBe Control PAnel CoMmanD ACKnowledge Control PAnel CoMmanD bus D0-7 Control PAnel StatuS STroBe Control PAnel StatuS ACKkowledge Control PAnel StatuS bus D0-5 Control PAnel RESet Control PAnel DIsplay Control CL1 Control PAnel DIsplay Control CL2 Control PAnel DIsplay Control DAta A Control PAnel DIsplay Control DAta B Control PAnel DIsplay Control DAta C Control PAnel DIsplay Control DAta D Control PAnel DIsplay Control M Control PAnel DIsplay Control FLM Control PAnel DIsplay Control INHibit
TSM 2400 family
Part I ed.8
Electrical Diagram
22 CONTROL 701A
Electrical Diagram
22 CONTROL 701B
Electrical Diagram
22 CONTROL 701C
Electrical Diagram
22 CONTROL 702
Electrical Diagram
22 CONTROL 703
23diag
DIAGNOSTIC
none
2
Fault table
none
Protections Standby motor (23M1) Main drive motor (23M2)

Standby motor (23M1) and main drive motor (23M2) are both protected by an internal auto resetable thermal fuse. The switch off temperature is 125C. The main drive motor (23M2) has a fuse F3 (4A) in a supply line.
Warning
In SDS mode it is possible to activate the output tests (23 04 01 : main motor and 23 04 02 : standby motor) to check the operation of the motors. There is no protection active during this test. This means that the clixon which has switched off the motor while the output is still active also can switch on the motors at any moment ! In the copier a sticker is added as special attention.
ed.6 Part I
TSM 2400 family
23 Drive 101
DIAGNOSTIC
23diag
102 Drive 23
TSM 2400 family
Part I ed.6
23sds
SDS

SIGNAL -0-1-2NOIRED -423M2 23M1 23M4 MADMO STBMO FINMO -623M3 STBMO STand-By MOtor 23M3 test. NOTE 5 MAin Drive MOtor on;NOTE 1 STand By MOtor on ;NOTE 1, 3: FIN MOtor 23M4 ; NOTE 4 NOIse REDuced drive; NOTE 2 DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS PARAMETERS INPUT TESTS 23 2 01 OUTPUT TESTS 23 4 01 23 4 02 23 4 03 SPECIAL TESTS 23 6 04
REPLACE CONSUMABLES
-8-
NOTE1 : There is no protection active during this test. This means that the clixon which has switched off the motor while the output is still active also can switch on the motors at any moment ! In the copier a sticker is added as special attention. NOTE2 : If massage is on the machine is configured for low noise drive. NOTE3 : Stand by motor 23M1 starts running. However if the low noise kit is built in, only the message on will be activated. NOTE4 : Fin. motor 23M4, if the low noise kit is built in, will start running. However if the kit is not built in, only SDS message on will be displayed.
ed.6 Part I
TSM 2400 family
23 Drive 201
SDS
23sds
NOTE 5: Standby motor 23M3 test. In case the low noise kit is built in, the standby motor start running, also the main drive motor start running for approx. 0,5 sec. It is necessary to have the main drive motor running for 0,5 sec. because the new standby motor has not power enough to start the TTF drive. However if no low noise kit is built in, only the message done will appear, no output will be activated.
202 Drive 23
TSM 2400 family
Part I ed.6
23func
FUNCTIONAL DESCRIPTION 1 Drive section

The figure below shows the main drive belts of the drive section. -A-B-C-D-EMainframe main drive Mainframe standby drive Subframe main drive (finisher/CRU) Subframe standby drive (finisher) Subframe main drive (paper transport)
23func01
ed.6 Part II
TSM 2400 family
23 Drive 501
23func
Mainframe main drive

The mainframe main drive consists of :
-A-B-C-D-E-F-G-H-J-
Main drive motor (23M2) Guiding wheel Master drive roller pulley Developing roller pulley Cleaning roller pulley Inter main drive/2nd preheat/funnel pulley Inter main drive gear Main drive belt tensioner TTF belt pulley
23func02
502 Drive 23
TSM 2400 family
Part II ed.6
23func
The Oc 2400-family uses one central drive system. All units to be driven are connected to this drive. The major advantages of one central drive are: fairly simple design synchronisation between units is guaranteed no complex synchronisation necessary easy to service Master drive roller/developing roller/cleaning roller pulley. The master handling, developing unit and cleaning unit are connected to the appropriate pulleys via gearwheels, because these units can slide out to the front. TTF belt pulley One way bearings are mounted on the TTF belt pulley. This is done to make the TTF belt run at high speed when the main drive starts, while running at low speed in standby mode. So the belt is always rotating when the copier is switched on! The connection between TTF unit and drive is made by an oldham coupling. It engages automatically when the TTF unit is pushed back into place. The reason for using an oldham coupling is that the drive direction is transfered directly to the TTF belt roller, without needing extra gears. Inter main drive/2nd preheat/funnel pulley The drive to the subframe is achieved by gearwheels. When the mainframe and subframe are separated no belts have to be removed. On the inside of the mainframe, gearwheels are connected to the pulley. These gearwheels take care of the transmission to the 2nd preheat, funnel and duplex path. Protections main drive motor. (23M2) The main drive motor (23M2) has a software protection to prevent the motor from being overheated if the load is extremely high. This protection is achieved by counting the number of pulses from the puls sensor (01SO2) within a certain time. Beside this protection the main drive motor has been provided with an automatic thermal clixon to detect internal temperature increasement of the motor windings. When the temperature has decreased a certain number of degrees, the clixon switches on again automatically !
ed.6 Part II
TSM 2400 family
23 Drive 503
23func
This can happen during normal copy mode or during SDS mode : Normal copy mode : If the clixon has been switched off because of a too high temperature (>125C) an error code (PE 0110) is displayed. This makes the control line MADR low 0. The error has to be detected in SDS so the main motor cannot start running spontaneously. SDS mode : It is possible to activate the output test 23 4 01 to check the operation of the motor. There is no protection active during this test. This means that the clixon which has switched off the motor while the output test is still active also can switch on the motor any moment. WARNING : Be aware of this fenominon. In the copier a sticker is added as special attention.
504 Drive 23
TSM 2400 family
Part II ed.6
23func
Mainframe standby drive

The mainframe standby drive consists of :
-A-B-C-D-E-
Standby motor (23M1) Standby drive pulley TTF drive drive roller pulley Standby drive belt tensioner Transfuse pinch pulley
23func03
ed.6 Part II
TSM 2400 family
23 Drive 505
23func
The main function of the standby drive is to keep the TTF belt/counter pressure belt rotating in standby mode. This is necessary for even heat distribution from the heater elements to the belts and to prevent the belt from overheating. Other functions are: open the transfuse pinch when a black image is made; open the transfuse pinch during standby (Oc 2475 + MOD 42); supply the subframe with a standby drive, for stapling and bypass feed.(not in case of Blue Angel option) The transfuse pinch roller is connected to the drive via a clutch. The clutch is only energised when a black image is made. Both the transfuse pinch and the TTF drive roller are connected to the drive via oldham couplings (see previous section). The drive to the subframe is transmitted by gear wheels. When mainframe and subframe are separated, no belts have to be removed. Protections standby motor. (23M1)(in case of Blue Angel 23M3) The standby motor (23M1) has a software protection by means of the TTF run sensor (06SM1). It detects a nearly total stop of the TTF belt or TTF counter pressure belt which are driven by the standby motor. So this way a total stop of the standby motor is detected during standby mode. Beside this protection the standby motor has been provided with an automatic thermal clixon to detect internal temperature increasement of the motor windings. The clixon can switch on and off during normal copy mode or during SDS mode : Normal copy mode : If the temperature becomes too high (>125C) the clixon switches off and an error code (PE 0611 or PE 0617) is displayed. This makes the control line STBMO inactive. The error has to be detected in SDS, so the standby motor cannot start running spontaneously. SDS mode : With output test 23 4 02 activated there is no protection active. So when the clixon is switched off and the test is active, the motor can be switched on spontaneously by the clixon. Warning : Be aware that in SDS mode with output test 23 4 02 active the standby motor 23M1 can start running spontaneously
506 Drive 23
TSM 2400 family
Part II ed.6
23func
Subframe main drive/standby drive (finisher)

The subframe main drive (finisher) consists of:
-A-B-C-
Finisher/CRU main drive pulley Finisher/CRU main drive belt tensioner Inter main drive pulley The subframe standby drive (finisher) consists of:
-D-E-F-G-
Inter standby drive pulley Subframe standby drive belt tensioner Feed roller paper stop pulley Finisher standby drive shaft pulley
23func04
ed.6 Part II
TSM 2400 family
23 Drive 507
23func
Subframe main drive (finisher) The function of the subframe main drive (finisher/CRU) is to couple the finisher/CRU unit drive to the copier main drive. As stated in the mainframe main drive section there is only one central drive. A drive belt in the finisher/CRU itself takes care of driving the individual pulleys of the finisher/CRU. This belt is described in chapter 18 Finisher or 19 CRU. Subframe standby drive (finisher) The function of the standby drive subframe finisher is to: enable offline stapling (not for Oc 2375, CRU) drive the soft feed rollers located just before the first paper stop. One way bearings are mounted on the feed roller paper stop pulley. When the copier is in standby mode the feed rollers turn at slow speed and form a nip (soft feed). Specialities being inserted into the bypass are fed against the paper stop and any skew is removed. During run the feed rollers are driven by the subframe main drive (paper transport).
508 Drive 23
TSM 2400 family
Part II ed.6
23func
Subframe main drive (paper transport)

The subframe main drive (paper transport) consists of:
-A-B-C-D-E-F-G-H-I-J-KConfidential 1996 Oc Nederland B.V.
Inter maindrive pulley Guiding wheels First preheat transport roller pulley Lower paper tray feed/separation roller pulley Lower paper tray transport roller pulley Paper path transport rollers pulley Upper paper tray feed/separation roller pulley Upper paper tray transport roller pulley Feed roller paper stop pulley Turnstation throughput clutch pulley Turnstation reverse clutch pulley
23func05
ed.6 Part II
TSM 2400 family
23 Drive 509
23func
The function of the subframe main drive (paper transport) is to drive the rollers that: - feed paper into the separation unit (upper/lower paper tray) - feed a sheet through the separation unit (upper/lower paper tray) - transport paper to the first paper stop - transport the paper to the 2nd preheat - drive the turnstation clutches All paper transport / paper path rollers form pinches (hard feed). Once a sheet of paper enters the paper path it stays in a pinch until it enters the finisher. The only exception is the funnel. The belts form a nip (soft feed). On leaving the funnel the sheet of paper is again in a pinch.
510 Drive 23
TSM 2400 family
Part II ed.6
23func
Mainframe main drive with low noise kit.

The mainframe main drive consists of :
-A-B-C-D-E-F-G-H-J-
Main drive motor (23M2) Guiding wheel Master drive roller pulley Developing roller pulley Cleaning roller pulley Inter main drive/2nd preheat/funnel pulley Inter main drive gear Main drive belt tensioner TTF belt pulley
23func02
ed.6 Part II
TSM 2400 family
23 Drive 511
23func
Mainframe standby drive with low noise kit.

The mainframe standby drive consists of :
-A-C-D-E-
Standby motor (23M3) TTF drive drive roller pulley Standby drive belt tensioner Transfuse pinch pulley
23func03.eps
512 Drive 23
TSM 2400 family
Part II ed.6
23func
Description modifications for the low noise kit

The noise-reduction package requires a different motor configuration. The motors affected are the main motor, the standby motor and the finisher motor. Because the mechanical couplings are different, the control has been modified. The overview below shows which mechanical function is driven by which motor. Function: Driven by: Standard TTF-unit standby TTF-unit run TTF-pinch bypass standby bypass run stbmo 23M1 madmo 23M2 stbmo 23M1 stbmo 23M1 madmo 23M2 stbmo 23M1 Low noise stbmo 23M3 madmo 23M2 stbmo 23M3 finmo 23M4 *) madmo 23M2 finmo 23M4
stapler (only Finisher)
*) The CRUs have a separate motor (23M5 make:Buehler), which drives the bypass during standby without the intervention of the control. To remain within the limits of the power consumption, it must be avoided that the finmo/madmo/stbmo turn simultaneously, while the temperature control is active. During toner dosage (black area) the standby-motor runs to energize the transfusepinch and when the finisher-motor is still busy with the completion of the stapling job, the power is limited by the SSR which switches off the heaters for a short period. If a job is started while the finisher motor is still running (about 10 seconds to finisher an off-line stapling job), the finisher motor will stop abruptly when the main drive is started.. When the machine is started, the main drive turns until it finds the master hole. During this phase the off-line stapler is disabled. The noise-free standby-motor is not able to activate the TTF-unit from the stationary position. The main drive must therefore supply a torque for a short period. The standby-motor is only switched on after the main motor has reached full speed. The off-line stapler is only switched on after the main motor has been switched off (about 20 seconds later).
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23 Drive 513
23func
Subframe main drive/standby drive (CRU) with low noise kit.

The subframe main drive (CRU) consists of:
-A-B-C-D-
Finisher/CRU main drive pulley Finisher/CRU main drive belt tensioner Inter main drive pulley Bypass motor 23M5
23func06.eps
514 Drive 23
TSM 2400 family
Part II ed.6
23comp
COMPONENT LOCATION
COMPONENT LOCATION
23M2 23C2 23CN2 : main drive motor : capacitor main drive motor : connector 220V main drive motor
23comp01
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TSM 2400 family
23 Drive 601
COMPONENT LOCATION
23comp
23M1 23C1 23CN1
: standby motor (with Blue Angel option 23M4 : Finisher-motor) : capacitor standby motor : connector 220V standby motor
23comp02
Right side main frame
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Part II ed.6
23comp
COMPONENT LOCATION
COMPONENT LOCATION WITH BLUE ANGEL OPTION

23PBA1 23PBA2 23PBA3 : : : SSR4 PBA (in Finisher and CRU) SSR5 PBA (only in Finisher) Bypass driver (only in CRU)
23comp03.eps
23M3
: Standby motor
23comp04.eps
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23 Drive 603
COMPONENT LOCATION
23comp
23M5
: Bypass motor
23comp05.eps
604 Drive 23
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Part II ed.6
23elec
ELECTRICAL DIAGRAM

MADR MT STBMO MAin DRiver Main Transport STandBy MOtor
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23 Drive 701
ELECTRICAL DIAGRAM
23elec
1 Drive 23
TSM 2400 family
Part I ed.6
Electrical Diagram
23 DRIVE 701
Electrical Diagram
23 DRIVE 702
24diag
DIAGNOSTIC
DIAGNOSTIC 1 Messages MRE

2425 department counter removed during run.
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24 Accessories 101
DIAGNOSTIC
24diag
Fault table
CODES M2425 POSSIBLE FAILURES - customer removed department counter during a copy job - 24CO1 key counter defect - 24PBA02 key counter interface defect (when used, only 93V counter) - 22PBA09 defect (24V-driver) - 22PBA02 defect (HOST I/O)
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24diag
DIAGNOSTIC
Protections MRE 2425

This error occurs when the department counter is removed during a run. Check on department counter present before transfer action. - 1"= dep. counter present - 0"= dep. counter removed.
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DIAGNOSTIC
24diag
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24sds
SDS

SIGNAL -0Department counter removed during run -1Pay blank sheets : Note 1 -224CO1 24PBA01 KEYCNTSE CCDENA -424CO1 24PBA01 24PBA01 24PBA01 DEPCOC CCDCNTPLS CCDTSTDEB CCDHLDCRD -6DEPartment COunter Count 24C01 CCD CouNT PuLSe CCD TeST DEBit CCD HoLD CaRD KEY CouNTer SEnsor, Copy Control Device ENAble DESCRIPTION in SDS
TESTNUMBER COMPONENT COUNTERS 24 0 25
PARAMETERS
24 1 02 INPUT TESTS 24 2 01 24 2 02 OUTPUT TESTS 24 4 01 24 4 02 24 4 03 24 4 04 SPECIAL TESTS
Note 1: Pay blank sheets. When activating this test (enter 1 + press <PRINT>), blank sheets will be counted by the department counter, ICCS and the CCD device. A blank sheet will NEVER be counted by the hardware or software copy counter.
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SDS
24sds
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24func
ACCESSORIES
ACCESSORIES 1 Copy Control Interface (CCI)

When a customer wants to use a Copy Control Device it is necessary to provide the machine with a Copy Control Interface. The actual interface is the same as used in the Oc 2500, for the Oc 2400-family it is available as a kit. The Copy Control Interface (CCI) kit contains : Qty 1 1 2 2 1 4 20 2 Description 24PBA01, Copy Control Interface Bundle 38 Brackets Bolt hex. washer M4 x 8 B Washer lock-A 4,3 Bolt hexagon M4 x 8 Cable tie A 140 Nut D sub-unc4-40.
Installation :
1 2 3 4 Switch off the machine and disconnect the wallplug. Remove cover rear side and disconnect connector CN1 from 22PBA07 (SSR2). Remove bolt hex. washer of holder 22PBA07 and turn away 22PBA07. Loosen bolts -A- and -B- and remove bolts -C- and -D- . Loosen the main distribution board in such a way that you can mount a bundle to the HOST CPU.
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ACCESSORIES
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5 6 7 8
Open the side doors paper path and side flap of the HOST CPU. Take your wrist strap and mount interface 24PBA01 on the large bracket using 4 bolts M4 x 8. Mount flat cable with D connector (25p) on the large bracket and connect connector 24CN5 at 24PBA01; use 1 cable tie to attach the flat cable to the large bracket. Hook bracket assy with angle in frame and mount bracket assy on frame with 1 bolt hex. washer M4 x 8. ATTENTION : Between frame and bracket mount a lock washer !
9 10
11 12 13
Mount the small bracket on the large bracket with bolt hex. washer M4 x 8. Mount cable bundle 38 with cable ties on the small bracket and route with existing bundle to the HOST CPU (22PBA01) in such a way that connector 24CN3 connects with 24PBA01 interface, and connector 22CN25 with the HOST CPU. Close 22PNA07 (SSR2) and fix the bracket with the PBA to the frame. Connect 22CN1, remount main distribution board and fix it with bolts -A-, -B-, -C- and -D-. Close all doors and covers and change machine configuration to include the Copy Control Interface, with or without test credit, in SDS test 90. Test the interface.
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24func
ACCESSORIES
Copy Control Interface Adapter (CCIA)

If a CCD (Copy Control Device) is to be connected to the Oc 2400, this must be done via the CCI (Copy Control Interface, 24PBA01). There are 2 types of CCD :
CCD with internal supply. CCD without internal supply. The first type of CCD can be connected directly to the CCI. For safety reasons the latter type of CCD may not be obtain the required supply directly from the Oc 2400. The Copy Control Interface Adapter (CCIA) must be used for this purpose. See diagram below.
The CCIA allows the CCD to be provided with a supply. The CCIA itself does not have a supply. This has to be connected externally. A simple mains adapter suffices as a supply source, though it must meet the following requirements : Output voltage between 9 and 15 VDC. Minimum output current 120 mA. The adapter must be doubly insulated. This can be seen from the mark : The mains adapter must be connected to connectors X3-1 and X3-2. The polarity is of no importance. A diode circuit on the CCIA ensures the correct polarity of the supply voltage. An LED on the CCIA indicates when the supply voltage is connected.
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In the following chapters the various input and output signal definitions for the CCD connection are given. When counting copies the following general rules apply: - a copy is called completed if the image is fully transferred onto the paper - a duplex copy is counted twice A simultaneous connection of copy control products is possible ( copy control device, department counter). In order to handle priority, the device which established the last ENABLE signal is considered to have highest priority. This priority remains until the job has finished. This also means that in case the credit of a connected and activated device expires the signals of the copies in progress are available on that devices interface connection.
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24func
ACCESSORIES
Copy Control Device (CCD)

Signal name : ENABLE (input, active high) Func descr : this signal indicates that the machine may be used; as soon as this signal becomes active the job may be started Signal descr : an active enable signal must prevent the machine from being used. This signal becomes active when a credit is generated and it becomes as soon as there is no credit left upon receiving the COUNT PULSE. The machine tests this signal for each copy, in case the credit expires during the job, the job must be ended appropriately which means that no not-accounted for copies may leave the machine Signal nome : COUNT PULSE (output, active high) Func descr : this signal becomes active when the copying process has produced a valid and chargeable result Signal descr : copies which are not completed may not generate a pulse and every completed copy which leaves the machine must generate a pulse. Signal name : TEST DEBIT (output, active high) Func descr : this signal generates a pulse in order to check if there is credit for just one copy; when no credit is left the ENABLE signal will become inactive Signal descr : in case the ENABLE signal becomes inactive the copies which are in progress wil generate COUNT PULSES on successive completion. Signal name : HOLD CARD (output, active high) Func descr : this signal becomes active when a job is started and signals that the CCD card must stay in the copy control device Signal descr : this signal will become active when the job is started and will become inactive when the job is stopped. Function of the TEST DEBIT signal : When in SDS test 90 the Copy Control Device configuration has been set to a device with test debit, duplex copies with an image on one side only, when the credit on the card is zero, will be avoided. Procedure for determination/verification of configuration setting for CCD :
Connect the CCD to the copier and set CCD configuration (SDS test 90) to a CCD with test debit. Put a card in the CCD with just one credit and make one duplex copy. If the message Copy Control Interface no longer active is being displayed before the copy is made, (after the PRINT button is pushed), the CCD has test debit and the machine configuration is right.
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Otherwise if the duplex copy is completely made (an image on both sides), the CCD has no test debit function and the configuration must be set to CCD without test debit. Put a card in the CCD with one credit and make a duplex copy. The copy you get will only have an image on one side and the message copy control system no longer active will be displayed.
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Part II ed.6
24func
ACCESSORIES
Department counter
A department counter can be installed in the Oc 2400-family. It is the same unit as used in the Oc 1990-family. When using a 24 Vdc counter, it is connected directly to the 24V driver (22PBA09) and the HOST I/O without an interface PBA.
Installation :
1 2 3 4 5 6 7 8
Switch off the machine and disconnect the wallplug. Open front door above the paper trays. Open side door and remove finisher front cover and panel. Remove the two screws which hold the guarding plate, keep the srews for later use. Disconnect the four wires and remove the plate. Take the holder and connect the four wires to the holder. (see drawing below) Mount the holder in the position of the guarding plate, using the original screws. Change the machine configuration to include the department counter (SDS test 90), test the counter.
Signal name : KEYCNTE (input, active low) Func descr : A low pulse on this input line energizes the counter coil Signal name : KEYCNTSE (output, active high) Func descr : A high level on this line signals the presence of a counter Signal name : NKEYSE (output, active low) Func descr : A low level on this line signals the presence of a counter. In case a 93 V key counter is used, a 93 V key counter interface is needed. This interface is available as an optional.
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ACCESSORIES
24func
Key counter interface kit :

The department counter interface is used to power electro mechanical counters of 93 Vdc. The circuit permits short circuits of the counter coil, without damage to the electronics. An on board power supply charges a buffer capacitor. A current source feeds the buffered energy to the counter coil. I. The counter coil is connected bewteen connector pins CN2-1 and CN2-2. If a counter is placed connector pins CN2-3 and CN2-4 are interconnected by wiring of the counter. The key counter interface kit contains : Qty. Description 1 24PBA02 Key counter interface 1 Bundle 37 1 Holder counter 1 Plate support 1 Bolt hex. washer M4 x 8 3 Bolt M4 x 8 3 Cable tie
Installation :
Attention : Use your wrist strap ! 1 2 3 4 5 6 7 8 9 Switch off the machine and disconnect the wallplug. Open front door above the paper trays. Open side door and remove finisher front cover and panel. Remove the two screws which hold the guarding plate, keep the screws for later use. Remove guarding plate and loosen connector 2402CN1 by cutting the cable tie. Mount the two lips of the plate support into the two gaps on the right side of the sub frame, mount this plate with the bolt hex. washer M4 x 8. Connect the four wires to connector 24CN3. (see drawing below). Mount the PBA with the three bolts and connect the connectors, mount the holder. Mount the bundle with the cable ties, mount the covers. Switch on the machine, change the configuration to include the key counter (SDS test 90) and test the key counter.
508 Accessories 24
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Part II ed.6
24func
ACCESSORIES
Lock-option
To limit access to the innerside of the Oc 2400-family, a locking kit is available. With this kit the developer unit and paper trays are locked, while the manual bypass is made inoperable. The locking kit contains : - a lock for the left front door - a switch to disable the bypass - to lock the paper trays (via the software). NOTE : The switch 12S8 will not be deactivated by the door. The straight lock bracket in the kit can be discarded. The lock kit contains : Qty Description 1 1 1 1 Lock Plate Bracket Switch push/pull
Installation :
1 2 3 4 5 Make a hole in the left hand front door of 20 mm . For the correct measurements see Fig. 1, in case you have a door with no markings for correct drilling of the hole. Dismount the blue plastic exposure cover. Mount the cilinder lock, plate and bracket. Mount the switch, and connect the wires 13098 (com) and 13099 (no). (See Fig.2) Check for correct functioning and remount all covers.
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24 Accessories 509
ACCESSORIES
24func
Clean lamp detection kit

A Clean lamp Detection is available for the Oc 2375/2400/2475 as a kit. This Cleanlamp Detection contains: Qty. 1 1 3 12 Description PBA Ballast Detection, 07PBA01 Bundle 39 Fastener PBA Tie, cable
Description:
The PBA Ballast Detection senses the current from the ballast coil of the cleanlamp. If the current is not within a defined range (for example caused by a defect cleanlamp or ballast coil) a signal is generated by the PBA Ballast Detection to the HOST I/O 22PBA02. This results in a permanent error 0710 (master cleanlamp off).
Refer to electrical diagram, page 07-701.

The detection can be used at customers that require security (for instance military organizations). This because a defect clean function can cause a copy to show information from copies made by a previous user. The detection can also be used at customers that run a high copy volume. At normal service intervals a defect clean function could cause an excessive toner pollution at the machine of such a customer.
510 Accessories 24
TSM 2400 family
Part II ed.6
24func
ACCESSORIES
Installation:
The installation is as follows: 1 2 3 4 5 Open lower paper tray. Switch off the machine and disconnect the wallplug. Split the machine. Mount the 3 fasteners -A- on the bracket. Mount 07PBA01 on the 3 fasteners. NOTE : Use your wrist strip. Disconnect connector 07CN1 and remove the wire link on 5 and 8 of connector 07CN1, this wire is not longer needed. Take from bundle 39 wire 3902 and mount this wire in connector 07CN1-8 and wire 3901 in connector 07CN1-5. Connect 07CN1 and 07CN2 at the PBA clean lamp detection and bundle the both bundles with the cable ties. Mount main-frame and sub-frame together. Connect at the HOST I/O (22PBA02) connector 22CN24. Switch the machine on and change the configuration by test 90 to clean lamp detection. To check this optional, take out the cleaning lamp, and switch on the machine. Now the machine will give a PE message 0710 (ref. chapter 07 DIAGNOSTIC).
6 7 8
9 10
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TSM 2400 family
24 Accessories 511
ACCESSORIES
24func
Installing a 2-phase kit

In case the Oc 2400 must be connected to a 220 Volt 10 A 50 Hz power source a 2 phase kit is available . The 2 phase kit Oc 2400 partno.5600290: Installation of a 2-phase kit is done in two steps: - A removal of the 1-phase parts - B installation of the 2-phase parts A Removal of the 1-phase parts 1 Disconnect the copier from mains supply. 2 Remove the following parts: - Cover rear Z-2540-35. - Loosen bolts A and B (drawing 1). - Remove bolts C and D (drawing 1). - Remove the circuit breaker Z-2210-20. B Installation of the 2-phase parts - Mount the new circuit breaker with the same screws at the same place. - Remount main distribution board and fix it with bolts A, B, C, and D (drawing 1). - Mount filter just below the already mounted filter, (drawing 2) using the 2 tap tites. - Remove the two jumpers from 22RL1 between 22RL1-13 and 22RL1-15 and between 22RL1-1 and 22RL1-3. - Connect the wires according to drawing 3, A and B. wireno. from to A 2002 N L2 B 2026 N - Start connecting the bundle 40 according to drawing 3, start from C and continue with D, E and F. wireno. from to C 4001 22FI2 line-L 22S7B-2 D 4002 22FI2 line-N N E 4003 22FI2 line-L 22RL1-3 F 4004 22FI2 line-N 22RL1-13 - Connect the power cord according to drawing 3. - Place the new type label. - Remount the cover rear z-2540-35. - Connect the machine to the power source.
3 Remove the old mains cable from the machine.
512 Accessories 24
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Part II ed.6
24func
ACCESSORIES
FIG 1
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24 Accessories 513
ACCESSORIES
24func
514 Accessories 24
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Part II ed.6
24func
ACCESSORIES
ed.6 Part II
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24 Accessories 515
ACCESSORIES
24func
Off-line stapler:
The installation of the Oc 74 (off-line stapler) on the Oc 2375 and the Oc 2465 CRU. The off-line stapler is manufactured by MAX.
Instruction:
(Fitting instructions Offline stapler) Disconnect the copier from the mains supply, and remove the two rear panels. 1. 2. Remove the middle panel (pos. 4, fig. 3) from the Oc 2375 or the Oc 2465 CRU (parts list Z-1940, index 6). Position support bracket (pos. 3, fig. 2) against the inside of the middle panel. Drill holes A, B, C, D & E, referring to fig. 2. Hole diameters: A = 9 mm B, C, D & E = 6 mm Remove the three screws, remove the upper cover (pos. 1 fig. 3) from the stapler. Dismount the stapler from the base plate, remove the 2 x M4 screws and nuts. If necessary drill hole A in the base plate of the stapler, refer to fig. 1. Locate the brass tube (pos. 8, fig. 3), loosely fit the base plate against the middle panel, using M8 nut, washer and spring washer (pos. 9, 10, 11, fig. 3). Note: Fit a wedge spacer (pos. 12, fig. 3) between the stapler base plate and the middle panel. Secure the assembled stapler to the support bracket (pos. 3, fig. 3) with two M4 x 40 mm screws, spring washer and washer (pos. 13,14,15, fig.3). Note: The thick edge of the wedge must face towards the front of the copier! (See detail fig. 3). 6. Fit the cable loom (power cable, stapler pos. 5, fig. 3) through the brass tube (pos. 8, fig. 3). With two crimp connectors (pos. 2, fig. 3), connect: wire no 1. to black wire from stapler wire no 2. to white wire from stapler. Note: Bind the two wires to the cable loom inside the stapler (at the rear of the PBA). 7. 8. 9. Fit the PBA (pos. 6, fig. 3), and secure it with 5 x lock screws M4 x 8. Connect the connector to CN3 on the PBA (pos.6, fig. 3): Wire no. 1 to connector pin 1. Wire no. 2 to connector pin 2. Attach the safety label to the middle panel (pos. 16, fig. 2).
3. 4. 5.
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Part II ed.6
24func
ACCESSORIES
10. 11. 12. 13.
Fit the power supply cable (bundle stapler main 17, fig. 4), and secure it with cable ties and cable tie holders. connect wire 1 to N1 connect wire 2 to earth tab connect wire 3 to L1 Plug CN1 in the socket on the PBA. Refit the middle panel, complete with stapler, to the copier. Insert staples. Test the operation of stapler.
0,8 112 0,4 78 0,2
8,2 0,1
A B
+0,3 5,5 0
58,4 0,2
1
Fig 1
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ACCESSORIES
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16
H D B E F C I
3 4
Fig2
Fig 3
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24func
ACCESSORIES
fig 4
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ACCESSORIES
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Part II ed.6
24elec
ELECTRICAL DIAGRAM

CCDIN CCDOUT1..11 DEPCOC KEYCNTSE CCD INput CCD OUTputs DEPartment COunter Count KEY CouNT SEnsor
ed.6 Part I
TSM 2400 family
24 Accessories 701
ELECTRICAL DIAGRAM
24elec
702 Accessories 24
TSM 2400 family
Part I ed.6
Electrical Diagram
24 ACCEDDORIES 701
25diag
DIAGNOSTIC

2550 2551 2552 2553 2554 2555 2556 2557 2558 2559 2560 2561 original path not free start run : DF cover open start run : doors open paper path not free in run : speciality present in run : finisher cover opened in run : DF cover opened in run : doors opened stapling : finisher not empty stapling : finisher doors opened in run : originals removed MDF : 10SO11 too early free
ed.6 Part I
TSM 2400 family
25 Environment 101
DIAGNOSTIC
25diag
Fault table
none
102 Environment 25
TSM 2400 family
Part I ed.6
25diag
DIAGNOSTIC
Protections ORE 2550

Start run with a XDF : the paper path of the RDF is not free (10SO3, 10SO6 or 10SO7 are not free). This message occurs only during a job recovery situation.
ORE 2551
DF cover open (10S1) at start run in MDF - RDF or CFF-job during a job recovery situation. If it is not a job recovery, the copier starts a original glass platen job.
ORE 2552
Door paper path open at start run (12S1, 15S5, 18S1, 18S2, 19S1 not active)
ORE 2553
Paper path copier not free at at start run (16SO1, 18SO1, 18SO4, 18SO6, 19SO2, 19SO4, 19SO6, active)
ORE 2554
The presence of a speciality is detected by paper stop present sensor 12SO5 and speciality paper size sensor 12SO6 being acctuated at start run, only during a job recovery situation. If it is not a job recovery situation, the copier starts a bypass job.
ORE 2555
Finisher cover opened (18S1) during a run. Sensor 18S1 is checked every 100 ms during a run.
ORE 2556
DF cover opened during a run. Every 8 ms check on 10S1.
ed.6 Part I
TSM 2400 family
25 Environment 103
DIAGNOSTIC
25diag
ORE 2557
Doors opened during a run. Every 100 ms check on 12S1, 15S5, 18S2, and 19S1.
ORE 2558
Internal receiving tray of the finisher not empty with off-line stapling. 18S3 and 18SO4 active while some sheets are still in the finisher.
ORE 2559
Finisher door (18S2) or finisher cover (18S1) open during off-line stapling. When 18S3 and 18SO4 are activated, there will be a security check on 18S1 and 18S2.
ORE 2560
When the set separator of the RDF falls through, while no RDF-action is on. - Originals are removed during a job recovery or paper path fault, etc.
ORE 2561
Fault message generated if after a start of a MDF-job the original is removed. (10SO11 released too early).
104 Environment 25
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Part I ed.6
25sds
SDS
TESTNUMBER COMPONENT COUNTERS 25 0 50 25 0 51 25 0 52

SIGNAL -0-
DESCRIPTION in SDS
25 0 53 25 0 54 25 0 55 25 0 56 25 0 57
10SO3,10SO6, 10SO7 10S1 12S1, 15S5, 18S1, 18S2 16SO1,18SO1, 18SO4,18SO6 12SO5,12SO6 18S1 10S1 12S1,15S5, 18S2 -1-2-4-6-8-
start run: org.path not free start run: RDF cover open start run: doors open start run: pap.path not free speciality pres. during run FIN cover opened during run RDF cover opened during run doors opened during run
PARAMETERS INPUT TESTS OUTPUT TESTS SPECIAL TESTS REPLACE CONSUMABLES
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25 Environment 201
SDS
25sds
202 Environment 25
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Part I ed.6
main
MAINTENANCE
MAINTENANCE
INTRODUCTION
To keep the Oc 2400 family in good condition, regular maintenance is necessary. Program A must be performed at every repair visit. Program B must be performed when a new master is installed.
2
1. 2. 3. 4.
PROGRAM A (EVERY REPAIR VISIT)

Ask the customer about the functioning of the copier. Read out the top 10" error counter (test 34) and note in the logbook. Carry out the necessary repairs. Check the consumable warnings (test 36). When the appropriate warnings are active, replace: a. TTF belt cleaning roller. b. Waste toner tray. c. Check TTF- and counter pressure belt. If TTF- or counter pressure belt needs to be replaced, in most cases it is not necessary to replace both TTF- and CP belt at the same time. Check the sheet that cleans the counter pressure belt. If it is dirty, cut off one winding from the cleaning sheet. Clean the original glass top surface and finisher knocker plate with cleaner K and a dry cloth.
5. 6.
NOTE: Do not use cleaners containing silicones (cleaner A). 7. 8. Clean scorotron grid, use cleaner R and dry cloth. Fill the toner hopper with UA3 toner. Reset counter 05.8.90. NOTE: Check copy quality. 9. Exposure: make 10 copies of testchart 1. Set the exposure 9.(test 04101) so that: a. A is just visible. b. There is no background. If the exposure cannot be adjusted to meet these criteria, go to program B. Image positioning. Make 10 duplex copies of test chart 19. See the copy quality section of the TSM. Framing: see the copy quality section of the TSM. Developing, Fusing and Charging: Make 10 copies of test chart 40. If there are any spots or scratches, go to the copy quality section of the TSM. Check (if necessary tighten) all allen screws of black image and stapler clutches. Check (if necessary tighten) the bolts of the drive units (Z2300-109) that drives the Developing and clean units. Check (if necessary tighten) the bolt of the drive gear unit (Z2300-27) that drives the paper module.
10. 11. 12. 13. 14. 15.
ed.6 Part II
TSM 2400 family
Maintenance 1
MAINTENANCE
main
16. 17. 18.
Reset all error/service counters (test 31). Check stapler roll(s) (not Oc 2375 and 2465 CRU). Fill out the logbook.
PROGRAM B (WHEN A NEW MASTER IS INSTALLED) Preparation
1.
2. 3.
Check the staple counter (test 81). If more that 70.000 staples have been used, you will need to perform the stapler maintenance. See the TSM 18 Finisher 401 and up. Switch off the copier. Clean machine (paper dust/toner) with vacuum cleaner/brush.
RDF/MDF
1. a. Check the DF-belt: If dirty, clean the belt with soap and water. NOTE: DO NOT USE ABRASIVE CLEANERS OF ANY KIND! 2. Check the RDF supply belts: a. If dirty, clean the belts (both sides) with cleaner K. b. If damaged, install new belts. NOTE: The Separation Wheels and Belt must be replaced together ! 3. Check the separation wheels and belt: a. if dirty, clean the wheels and belt with cleaner K. b. If damaged, install new wheels and belt. Check the brush underneath the separation belt. a. If dirty, clean the brush. b. If damaged, install a new brush. Remove paper dust, and paper clips behind the turn loop plate of the RDF center unit.
4.
5.
Optics
1. Check the underside of the original glass. If dirty clean with cleaner O and a dry cloth. NOTE: Do not use cleaners containing silicones (cleaner A). 2. 3.
Clean the mirror with cleaner O and a dry/soft cloth. Check the filters on the rear side of the copier. If dirty, clean with a vacuum cleaner.
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MAINTENANCE
Master
1 a. Pull out the master section. b. Remove all units. c. Remove the old master. Master unit: Check the rollers and wheels in the master section. If dirty clean with cleaner K and a dry cloth. Framing unit: Check the flash lamps and bulbs. If dirty: a. Clean the flash lamps with cleaner K and a dry cloth, or replace the PBA. b. Clean the bulbs with cleaner K and a dry cloth, or turn the bulbs through 180. Scorotron unit: Clean the grid and plate with cleaner R and a dry cloth. Install a new corona wire. If there is a need to install new ozone filter (e.g. because of ozone smell) it is necessary to install a complete ozone exhaust filter box. The ozone exhaust filter box is delivered as an assembly, however the fan motor have to be reinstalled. Cleaning unit: a. Remove the toner brush and clean the spoiler with a vacuum cleaner, and the apply fresh F10 toner. b. Check the cleaning lamp. If dirty, clean with a dry cloth and cleaner K. Developing unit: Check the toner brush. If the brush is irregular, remove it with a vacuum cleaner. Then apply fresh F10 toner to the roll to form a new toner brush.
2.
3.
4.
5.
6.
TTF
1. a. b. c. d. Check TTF belt. Install a new belt if damaged and reset counter (06.08.91). Check counter pressure belt. Install a new belt if damaged and reset counter (06.08.92). Check TTF belt cleaning roller (damage, counter) and replace if necessary. Reset counter (06.08.90). Cut off one winding of the counter pressure belt cleaning roller.
Funnel
1. a. Inspect funnel unit. If necessary, take action.
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Preheaters
1. a. b. Check the 2nd preheater plate and guide. If dirty, clean with cleaner K and a dry cloth. Check the silicon rubber mats. If dirty, clean with cleaner K and a dry cloth. Replace the mats of there is any mechanical damage that causes paper feed problems.
Papertrays
1. Check the feed roll, separation roll and wheel. a. Replace the separation wheel if: - the diameter of the wheel is less than 40.6 mm. - the wheel is mechanically damaged. b. Replace the separation roll if: - the white layer is partly worn and the dark substrate is visible. - the roller is mechanically damaged (flat spots). C. Replace the feed roll if: - the white layer is partly worn and the dark material is visible. - the roll is mechanically damaged. NOTE: The Separation Roll and the Separation Wheel must be replaced together
Finisher
1. Check the staple counter. If more than 70.000 staples have been used, carry out the stapler maintenance program. See the TSM 18 finisher 401 and up (part II). Do not forget to clean the stapler and lubricate both plates of the stapler driver (use grease Polylub GLY 801 code no.7991.393). Empty the staple receiving bin. Check the positioning belts. Replace if: - the white layer is partly worn and the substrate is visible. - the belts are mechanically damaged. Clean the ribs in the turn station with cleaner K. Clean the plastic covers of the sensor PBAS. Check, if necessary clean finisher safety clutch.
2. 3.
4. 5. 6.
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Reassembly
1. Install the new master, see the TSM 01 Photoconductor 401 and up. Reset counter 01.08.90. Replace all the units. Switch on the copier and enter SDS mode. Visually inspect the master drive while making a copy. Check the ABC adjustment (Test 04 6 11, adjustment 04-4, ABCcalibration) .
2. 3.
4.
Check copy quality

1. Exposure: make 10 copies of testchart 1. Set the exposure (test 04.01.01) so that: a. A is just visible. b. There is no background. Image positioning: make 10 duplex copies of testchart 19. See the copy quality section of the TSM. Framing: see the copy quality section of the TSM. Developing, Fusing and Charging: make 10 copies of testchart 40. If there are any sport or scratches, go to the copy quality section of the TSM. Reset all error/service counters (test 31). Have you reset the consumable counters: Refill toner 05.08.90 New master 01.08.90 New TTF belt 06.08.91 New TTF belt cleaner 06.08.90 New counter pressure belt cleaner: 06.08.92 Fill out the logbook.
2.
3. 4. 5. 6.
7.
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SDS 1 General
The purpose of the Service Diagnosis System (SDS) is to support the service technician in identifying the causes of errors and to provide information on the errors themselves. It is also an important tool for adjusting and installing the copier. The service technician can work with the SDS by activating the SDS tests. These tests are classified into a number of categories: Diagnosis: function tests analysis information tests system tests installation tests marketing information tests service information tests
Registration:
The function tests have a standard subdivision. Function tests: counters parameters input tests output tests special tests replace consumables
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SDS Diagnosis Functions Analysis 01 - 25 30 - 39 System Info 40 - 49 - 01 - 02 - 03 - 04 - 05 - 06 - 07 - 10 - 12 - 15 - 16 - 17 - 18 - 19 - 22 - 23 - 24 - 25 30 31 32 33 34 35 36 37 38 39 40 To cold SDS 41 To warm SDS 42 - 1 Service copy mode - 2 Protections on/off - 3 Functions on/off 43 - 1 Charge - develop - no transfer - 2 Charge - develop - transfer 44 Production test Registration
Reset active error Reset error and service counters Old error logging (PE, MRE, ORE, FE) System error logging (PE, MRE, FE) Error top ten Counters Consumable counters Parameters Service counters Preset service counters
Master Charging Framing Exposure Developing TTF Cleaning RDF Paper Pre heat Duplex /delivery Inverter Finisher CRU (not 2475) Power and Control Drive Accessories Environment
Presets 70 - 79
Marketing 80 - 89
Service 90 - 99 - 90 Configuration - 91 Serial number - 92 Tel.no. - 93 Paper sizes - 94 Password - 95 basic mach. mod nrs. - 96 deposit unit mod nrs. - 99 BBR dump Reset marketing counters Marketing counters Limit runlength class 1
-80 -81 -82 - 70 Administration - 71 Adjustments
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2 Start up/exit and state of the SDS 2.1 Start up the SDS
The Service Diagnose System is activated when is detected that the service switch is in postion service mode. This detection can take place in 2 different situations: (1)Service switch is in service mode when the machine is switched on: SDS is always started up in state ZERO. (2)Service switch is set in service mode when the machine is on: SDS starts up in a state that depends on the state of the machine Before the SDS is activated a few tests are executed during the start up of the machine:
ROM-test When an error occurs the led is switched off and the processor is stopped (in position HALT). If possible the message error code 2201 is displayed. RAM-test When an error occurs the led flashes with a frequency of 2 Hz. The message error code 2202 is displayed.
When the previously described tests are processed correct, the led is continuously on. The test procedure will continue with:
I/O test Operation of the I/O is tested. In case of an error the led stays on and the processor is stopped (in position HALT).
When this test is well proceeded, RTX is started up and the 10 ms interrupt is released. Also software initialisations take place. Then the test cycle is continued with:
Operating panel There is a communication check with the console. When an error occurs the led flashes in a frequency of 0.5 Hz.
If no errors occur the outputs are enabled. The led flashes with a frequency of 1 Hz. Successively are, despite if the service switch is in normal or service mode, the following checks executed.
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Permanent Error active If a permanent error is put in BBR, this is displayed. In service mode an analysis can be executed by means of the tests which can be activated in ZERO SDS state. BBR Check if the sum of the machine settings and service technician settings in the BBR match with an earlier given and saved value. With an incorrect result Permanent Error 2210 is generated. All other BBR data are checked; with a faulty result Warning 2275 is generated and the faulty variable gets the initial value. ADC The half reference voltage is put on one of the eight analog inputs of the multiplexer. If the test result is not within the given tolerances Permanent Error 2214 is displayed. The ADC test is executed repeatedly (not only with start up).
With the service switch in normal mode all machine functions are started after the test cycle. Initialisation of each function can lead to errors. With an active error present the SDS can still be started . With starting the SDS the following tests are executed: - Check if a handicap is present. If so a message with a description of the handicap is given. - Check if one or more consumable counters have exceed their nominal value. If so, then a message is given and is refered to test 36, where information of the consumable counters can be get. - Check if an active error or warning is present. In this case the error code is given and the SDS comes in the state ZERO. A state change to COLD can only be realized, if the cause of the active error is removed and the error message is removed by means of test 30. The starting up of the RDF-slave takes place if the RDF function is made warm. The reset line of the RDF-slave is made inactive. After this the communication test is executed. If the result of this test is incorrect, the led of the RDF-slave board will be switched off and an error message is generated (code 1014).
2.2 Leaving the SDS

The SDS is deactivated by switching the service switch S-1 to the position normal. Two states are distinguished when leaving the SDS: (1) The machine is on: when no SDS-test is active SDS is left, after pushing the reset switch for at least 3 seconds. (2) The machine is first switched off before switching the service switch: the information that the machine was in service is saved.
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When leaving the SDS the watchdog-test is executed. When the machine is switched off in service, the next time, when switching on the machine, the watchdog-test is executed. The watchdog-test leads to resetting the processor. The machine must be restarted again by switching off/on. When the watchdog-test is not running correctly, an error message is given (2212 or 2213).
2.3 States of the SDS

In SDS 4 states are defined. The function of these states is, that the user, depending on the state of the machine, is limited in the possibilities of the SDS, to avoid unsafe situations. The states of the SDS are: Zero SDS Cold SDS Medium SDS Warm SDS
2.3.1 Zero SDS

The machine gets in this state, after power up with S-1 in the position service, or after switching S-1 when an error occurs, or after an error occurs during the states Cold, Medium and Warm SDS. In this state is only a limited part of the totall SDS available, namely that part that is absolutely neccessary to get insight in the possibly occured error and tests to solve these faults. In Zero SDS is possible: test type 30 untill 39: Analysis info (among others reset active error) test type 70: Administration (amongst others initialize BBR) and also when no error is active: system test 40: to Cold SDS
2.3.2 Cold SDS

Cold SDS is the state of the SDS, when one or more functions are cold. In the state Cold SDS all tests are accessible. The machine functions are not initialised. In this state several function intialisations can be completed by activating them separately (special test xx 6 01 per function 1 untill 22), or by activating them all in one time (system test 41: to Warm SDS). This is the normal initialisation procedure, where occuring errors are mentioned. When detecting an error that function will go again in the cold state. When neccessary its possible to switch off the fault detection of a few functions, after which once more can be initialised. For each test is checked in what state the functions have to be to execute the test after which the functions are set in the required state. Protections and error messages (provided not masked) maintained.
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From functions which are in the cold state can all tests be executed without influencing the test by the functionality. E.g. the button for opening the paper tray can be checked by means of an input test, while the function (open paper tray) is not executed. By means of system test 41 Warm SDS can be started
2.3.3 Medium SDS

This is a state of transition where the machine is in if the functions are initialised. This state becomes automatically Warm SDS when all functions are initialised. So e.g. master hole found, temperature allright etc..
2.3.4 Warm SDS

This state is attained when all machine functions are in the warm state. When a test is done in this state that switches one or more functions to the cold state, then the Warm SDS is left. An overview of the states in SDS and the tests that can be activated is given below.
Tests ZERO 01..29 Functions 30..39 Analysis info 40..49 System tests 40 To Cold SDS 41..44 Remaining 70 Administration 71 Adjustments 80..89 Marketing info 90..99 Service info * * * (only 70) COLD * * * * * * * *
States MEDIUM * * * * * * * *
WARM * * * * * * * *
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3 Operating the SDS 3.1 Console and SDS

In SDS only a limited number of parts of the console are used. When using the SDS an input part and an output part can be distinguished. The input part covers only a limited number of buttons for the operation of the SDS. With these the service technician can operate the SDS. The different buttons with their functions are: <print> <correction> <0..9> <darker> <lighter>
: : : :
: starting selected tests, confirming input values and ending tests. immediately ending tests, correction on wrong input of data. number buttons for inputting numbers. scrolling backward. scrolling forward.
The output part covers for the SDS only the VFD-display. The display is located between the buttons <print> and <correction>.In here all messages in relation to the state and the possibilities of the SDS are displayed.
3.2 Start up messages SDS

As described before, when entering the SDS, a number of tests are executed. These tests will give a message, depending on the test result. When the key operator programmed a handicap, the message of the handicap is displayed first. release x.x <state> SDS Active handicap: description After pressing <correction> the handicap is erased. The code of the error that caused the problem is reported. In case of consumable counter(s) where the norm is exceeded, a message is displayed: release x.x <state> SDS Check consumables: test 36 Pressing <correction> will remove the message. One of the start displays will be shown. When an error or warning is active, then in stead of <state> SDS an error message in the form of error <error code> is shown.
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3.3 Start displays of the SDS

As described before the SDS can be entered in different states. Depending on the state of the SDS, one of the start displays will be shown. The start displays are: - In case of Zero SDS: release x.x 30-39 analysis info 70-79 presets 40 to cold sds When the error has been reset by means of test 30, <ZERO> SDS is shown in stead of the error message. - In case of COLD SDS: <COLD> SDS 01-29 functions 70-79 presets 30-39 analysis info 80-89 marketing info 40-49 system tests 90-99 service info - In case of MEDIUM SDS: <MEDIUM> SDS 01-29 functions 70-79 presets 30-39 analysis info 80-89 marketing info 40-49 system tests 90-99 service info - In case of WARM SDS: <WARM> SDS 01-29 functions 70-79 presets 30-39 analysis info 80-89 marketing info 40-49 system tests 90-99 service info From this situation a test is selected by typing a test number. Operation of the separate test types will be explained in the next paragraphs. error <error code>
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3.4 Operating function tests

The function tests are selected by pressing a five digit code. This code consists of two digits for the function, one digit for the selection of the test group and two digits for the selection of the test in the group. EXAMPLE: - selection of a function from the start display. Typing a two digit code for the function, in this case <0> <1>. Display: function 0 counts 1 params 01 master <state > 2 input 4 output 6 special 8 consums
When a code is pressed where no function is defined, the message xx not present is displayed in stead of the function description. Hereby is xx the pressed code. After typing the two digit function code a previous/next function can be selected by means of the copy darker/lighter buttons . In the field <state> is the state of the selected function displayed. State changes are given with a delay of app. 1 sec. Pressing <correction> results in returning to the start display. - selection of a test group of the function. Typing of the test group code, in this case <2> Display: function 2 input 01 master <state>
0199 test number Typing a test group code that is unknown, or not defined for the selected function results in that the message x not present is displayed in stead of the test group description. Also the message 01-99 test number is not displayed. After typing a group code a previous/next test group can be selected by means of the copy darker/lighter buttons. Hereby are all test groups selected that are defined for the choosen function. Pressing <correction> results in returning to the start display.
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- selection of a certain function test. Pressing a two digit code of the function test, in this case <0> <2>. Display: function 01 master <state> 2 input 02 Set Up Mechanism SEnsor 01S1 Pressing a function test code which is not defined for the selected function results in the message xx not present in stead of the function test description. After typing the function test code a previous/next function can be selected by means of the copy darker/lighter buttons. Hereby are only tests selected that are defined for the choosen function. Pressing <correction >results in returning to the test group choice display. Pressing <print > actvates the selected test.
3.4.1 Operating counter tests

After activating the test the counter value is displayed. EXAMPLE: function 02 charging <state> 0 counters 10 corona voltage not present 2 Counter tests are also used to read descriptions of error codes. EXAMPLE: The description of error 2275 can be accessed by selecting the counter test with test code 22 0 75. When selecting an error description of which no counter is kept, results in the field with the counter position staying empty after activating the test The counter test is immediately ended after activation, this means that the SDS is going in the state as described in the function test selection screen.
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3.4.2 Operating parameter tests

After activation the parameter value is displayed and information about the max. and min. value. EXAMPLE: function 03 framing<state> 1 parameters 01 interval flash positioning 80 min = 0 [ -] max = 160 By means of <print> or < correction> the test can be ended, or a new value can be entered. When entering a new value this value is displayed in the field [ -].
function 03 framing<state> 1 parameters 01 interval flash positioning 80 min = 0 [ 100 ] max = 160 By pressing <print> the new value is copied in the field where the original value was positioned. When the set value exceeds the given max. or min.value, then the message not in range is displayed and the original value is not replaced. In this case the test can be proceeded by pressing <print>. function 03 framing<state> 1 parameters 01 interval flash positioning 100 min = 0 [ -] max = 160 By means of <print> or <correction> the test is ended and the parameter gets the new value. Its also possible in the described situation to enter again a new parameter value. After ending the test SDS is going in the state as described in the function test selection screen.
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3.4.3 Operating of input tests

After activating the test the state of the selected sensor is displayed. Also the buzzer is audible (provided that it is enabled), when the state of the sensor is ON. function 04 exposure <state> 2 input 04 EXP. Optic REFerence SEnsor 04S02 OFF The test is active untill <correction> or <print> is pressed. After ending the test the SDS is going in the state as described in the function test selection screen. When executing an input test the state of the functions and the SDS becomes COLD to maintain a safe situation. Only the RDF stays WARM during the input tests of this function.
3.4.4 Operating of the output tests

After activating the test the selected output is made active and the message ON is displayed. Depending on the kind of output, the output will stay active untill <print> or <correction> is pressed, or it will automatically become inactive after a defined time. Then OFF is displayed. EXAMPLE: function 05 developing <state> 4 output 01 DEVopment AGItation MOtor 05M1 ON When OFF is displayed the test is ended and the SDS returns in the state as described in the function test selection screen. When executing an output test the state of the functions and the SDS becomes COLD to maintain a safe situation. Only the RDF stays WARM during the output tests of this function.
3.4.5 Operating of the special tests

After activating the selected test, in general the state of the test will be displayed behind the test description. EXAMPLE: function 06 TTF <state> 6 special 06 TTF heaters test 06HE1,2,3 active The state of the test can be:
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- start: - active: - done:
machine is set in the desired state. the test is active, actions are executed or the machine is waiting for instructions. the test is ended.
When the test is ended the SDS returns in the state as described in the function test selection screen.
3.4.6 Operating of the replace consumables tests

After activating the test the selected consumable counter is reset done is displayed and the test is ended. EXAMPLE: function 07 cleaning <state> 8 replace consumables 90 replace routine new cleaner tray done After ending the SDS returns in the state as described in function test selection screen.
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3.5 Operating of the Analysis, Marketing and Service info tests

The tests are selected by pressing a two digit code. The first digit of the code determines the test group, the second the specific test. EXAMPLE: Typing <3> shows display: analysis info 3 <state> SDS
Successively typing <2> shows the selected test: analysis info <state> SDS 32 old error logging By means of the copy darker/ lighter buttons a previous/next test be selected within the choosen test group. After ending a test, pressing <correction> returns to one of the SDS start displays.
3.6 Operating of the system tests

The system tests are selected by typing a two or three digit code beginning with <4>. The tests 40, 41 and 44 are selected with a two digit code, while the test groups 42 service copy mode and 43 image position have subtests The presence of subtests in a test group is showed with a subtest menu on the display. EXAMPLE: Typing <4> and <2> shows display: system test <state> SDS 42 service copy mode 1 copy 3 functions on/off 2 protections on/off
On this level can by means of the copy darker/lighter buttons a previous/next system test (group) be selected. When a test from the test group must be selected, the corresponding number has to be pressed.
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EXAMPLE: Typing <1> in the described situation shows the following display: system test <state> SDS 42 service copy mode 1 copy On this level can by means of the copy darker/lighter buttons a previous/next subtest be selected. By pressing <print> the tests are activated. When a test is selected or ended, can by pressing <correction> be jumped back to one of the SDS start displays. NOTE: If the SDS is in the state ZERO, only system test 40 to cold sds can be selected.
3.7 Operating of the installation test

The installation test covers the test group 70-79 Presets and has got the test numbers 70 and 71. Selecting a test is done by typing from the start display <7> and <0>. On the display appears: presets <state> SDS 70 Administration The installation test consists of a series of one function special test, parameter tests and service info tests. When the test is activated by pressing <print>, the description of the first subtest is displayed: presets <state> SDS 70 Administration active 1 initialize BBR The subtest can be activated by pressing <print>. The operation of the subtest is identical to the function special test or service info test. When the subtest is ended, automatically the description of the next subtest is displayed. When a subtest does not have to be executed it can be skipped by pressing the copy light button. When the last subtest is ended the message done is displayed: presets <state> SDS 70 Administration done By pressing <correction> returns to the SDS start displays.
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4 SDS tests 4.1 Analysis info (30 - 39) 4.1.1 General

In this chapter the contents of each analysis info test is explained. The presentation for each test is as follows: NAME: NUMBER: DESCRIPTION: PRESENTATION: Name of the test. The relevant test number. Short description of the test. The display presentation and test procedure.
4.1.2 Contents of the analysis info tests

NAME: Reset active error. NUMBER: 30 DESCRIPTION: Test of resetting the active fault. PRESENTATION: When an active fault or warning is present this is displayed in the right top corner of the display The fault code is xxxx. analysis info error xxxx 30 reset active error When activating the test by pressing <print > the error disappears and the state of the SDS or a next error or warning appears in the right top corner of the display. Also done appears in the display. analysis info ZERO> SDS 30 reset active error done NAME: Reset error and service counters. NUMBER: 31 DESCRIPTION: Test for resetting all fault and service counters. (also counters stored in T32, 33, 34, 35) PRESENTATION: After activating done appears in the display and the test is ended. analysis info <state> SDS 31 reset error and service cntr
done
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NAME: NUMBER: DESCRIPTION: PRESENTATION:
Old error logging 32 Presentation of the last 15 faults (PE,MRE,ORE,FE) and warnings.
After activating the test the last registrated faults are displayed on the bottom 3 lines of the display. The information consists of a fault code, a description of the fault and (when present) the fault counter (xxxx behind the fault description). When the list consists of more than 3 faults ,more appears behind the test description. By pressing <print> the next faults (max. 3) appear in the display. When the last faults of the list are displayed more is disappeares from the display. By pressing <print > the test is ended. analysis info <state> SDS 32 old error logging more code description last fault xxxx code second last fault xxxx code third last fault xxxx When no faults are registrated no error record appears behind the test description. The test is then automatically ended. NAME: NUMBER: DESCRIPTION: PRESENTATION: NAME: NUMBER: DESCRIPTION: PRESENTATION: Beside fault code, fault description and counter, also the position in the list (yy) is displayed. System error logging. 33 Presentation of the last 15 system faults (PE,MRE,FE). Presentation and operation is identical to test 32. Error top ten 34 The 10 fault counters with the highest value (unequal 0) are displayed.
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analysis info <state> SDS 34 info more yy code description most occured fault yy code second most occured fault yy code third most occured fault
xxxx xxxx xxxx
The operation of the test is identical to test 32. NAME: NUMBER: DESCRIPTION: counters 35 Presentation of all fault counters unequal 0, in order of function group. PRESENTATION: Presentation and operation is identical to test 32. NAME: Consumable counters. NUMBER: 36 DESCRIPTION: All consumable counters with their parameters are displayed. PRESENTATION: The information on the display consists successively of number of counter, description of counter, counter (xxx), number of norm parameter and parameter value (yyy). analysis info <state> SDS 36 consumable counters more 01090 master xxx K 01190 parm yyy K 05090 toner xxx K 05190 parm yyy K 06090 cleaner xxxx 06190 parm yyyy The operation of the test is identical to test 32. NAME: Parameters. NUMBER: 37 DESCRIPTION: All parameters are displayed in order of function group. PRESENTATION: On the display appear after activating the test the parameter number (yyyyy), the parameter description and the parameter value (xxxx). analysis info <state> SDS 37 parameters more yyyyy description parm1 xxxx yyyyy description parm2 xxxx yyyyy description parm3 xxxx The operation of the test is identical to test 32.
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NAME: Service counters NUMBER: 38 DESCRIPTION: The service counters are displayed. PRESENTATION: After activating the test appear the description and the values of the service counters in the display. Service counters are kept for: Number of copies (number of image sides) Number of separations in RDF (duplex originals are counted once) Number of sheets (duplex copies are counted once) Number of times that more than 50 originals are selected in the original tray (counted after every set processing). Number of separated bypass sheets. Number of sheets from paper tray of which the front and back side remain blank. The display presentation: analysis info <state> SDS 38 service counters more 1 total nr. copies xxxx 2 total nr. originals xxxx 3 total nr. separations xxxx 4 total nr. more than 50 origs 5 total nr. bypass sheets 6 total nr. blank sheets By pressing <print > the test is ended. NAME: Preset Service Copy Counter NUMBER: 39 DESCRIPTION: The copy counter for service is displayed and can be preset to a certain value PRESENTATION: After activating the test the value of the copy counter is displayed. A new 7 digits value can be entered. By pressing <print> the new value overrides the old value. By pressing <correction> the test is ended. The display presentation: analysis info <state> SDS 39 preset service copycounter current value: new value: xxxxxxx [ ]
By pressing <print > the test is ended.
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4.2 System tests (40 - 49) 4.2.1 General

In this chapter is the contents of each system test explained. The presentation for each test is as follows: NAME: NUMBER: DESCRIPTION: PRESENTATION: Name of the test. The relevant test number. Short description of the test. The display presentation and test procedure.
4.2.2 Contents of the system tests

NAME: To cold SDS NUMBER: 40 DESCRIPTION: All functions (when possible) are set cold. PRESENTATION: system test <state> SDS 40 to cold sds After executing the test it is automatically ended. NAME: To warm SDS NUMBER: 41 DESCRIPTION: All functions (when possible) are set warm. PRESENTATION: system test <state> SDS 41 to warm sds After executing the test it is automatically ended. NAME: Service copy mode NUMBER: 42 1 DESCRIPTION: Test to go under SDS in copying mode. PRESENTATION: system test <state> SDS 42 service copy mode 1 copy After activating the test by pressing <print > the normal mode display appears. In this display appears service copy mode on the bottom line. The machine can be used normally now. Returning to the service display is possible, by pressing <correction>.
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Protections on/off 42 2 Test to switch on/off the function protections in service copy mode.
After activating the test appears on the bottom line of the display the name of the first function with the state of the protections. The state can be ON or OFF. The state of the protections can be changed by using the copy darker/lighter buttons. When an adjustment for a function protection is made, this is confirmed by pressing <print >. Then automatically the next function is displayed. Switching off the function protections is only applicable in service copy mode. When test 42 1 is executed, the protections masked is displayed in the normal mode display, when protections from one or more functions are switched off. The functions from which protections can be switched off: - photoconductor - charging - framing - exposure - transfer (TTF) - cleaning - original handling (XDF) - paper trays (paper) - preheater - duplex - deposit unit The display presentation is: system test <state> SDS 42 service copy mode 2 protections on/off master ON After the selection of the last function is confirmed, the test is ended.
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NAME: Functions on/off NUMBER: 42 3 DESCRIPTION: Test for switching on/off functions in service copy mode. PRESENTATION: After activating the test appears on the bottom line of the display the name of the first function with its state . The state can be ON or OFF. The state of the functions can be changed by using the copy darker/lighter buttons. When an adjustment for a function protection is made, this is confirmed by pressing <print >. Then automatically the next function is displayed. Switching off the function is only applicable in service copy mode. When test 42 1 is executed, the message functions masked is displayed in the normal mode display, when one or more functions are switched off. When a function is masked, the protections of that function are also not active. The functions which can be switched off: - transfer (master) - charging - framing - exposure - optics - paper trays (paper) - accessories The display presentation is: system test <state> SDS 42 service copy mode 3 functions on/off charging ON
After the choice at the last function is confirmed, the test is ended.
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NAME: Charge-develop-no transfer. NUMBER: 43 1 DESCRIPTION: Test to examine the toner image on the master. PRESENTATION: Before activating the test, an original (A4), must be placed on the platen glass. After activating the test the machine is set in the desired state. During the starting up the message start is displayed. system tests <state> SDS 43 image position 1 charge-develop-no transfer start When the machine is already in the desired state the test starts automatically, otherwise the text wait for ready appears in the display. As soon as the desired state is achieved the text disappears again and the text print is continue appears. After pressing <print> this text disappears and the test automatically will go on. The message active is displayed. When the cycle is executed done is displayed. The master handling can be pulled out (for security reasons the machine must be switched off). The toner image is visible just before the place of the transfer pinch. The test is ended by pressing <print >. NAME: NUMBER: DESCRIPTION: PRESENTATION: Charge-develop-transfer 43 2 Test to examine the toner image on the TTF belt. The test is identical to test 43 1, the toner image is visible by pulling the TTF out of the machine and is placed just before the transfuse pinch. Production test 44 Test to fill the P- mode with reference programs for production After activating this test, the P-mode is filled with 10 reference programs (P0 - P9). These programs can be carried out in the service copy mode by activating a program in the P-mode. See table : next page.
NAME: NUMBER: DESCRIPTION: tests. PRESENTATION:
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Table reference programs test 44.

reference program 0 1 2 3 4 5 6 7 8 9 originals RDF RDF RDF RDF RDF RDF RDF RDF RDF MDF set length 2 15 2 23 7 21 4 10 10 5 run length 20 4 52 8 23 6 15 4 7 2 job type 2s/2s 2s/1s 1s/1s 1s/1s 1s/2s 1s/1s 2s/2s 2s/1s 2s/1s 1s/1s output margin shift sort no staple yes batch no staple no sort no staple no staple yes sort no staple yes sort no covers paper tray no upper no upper no lower no lower no upper no upper no lower yes both yes both no upper
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4.3 Presets ( 70 - 79 )
NAME: NUMBER: DESCRIPTION: CONTENTS: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Initialisation BBR: Test 22 6 06. Filling in configuration: Test 90. Filling in machine serial number: Test 91. Adjusting optics (P0): Test 04 1 02 Adjusting optics (P1): Test 04 1 03 Basic machine modification nrs. Test 95. Deposit unit modification nrs. Test 96. Filling in telephone number: Test 92. Filling in paper sizes: Test 93 Filling in password key operator: Test 94. Administration 70 Test consisting of several parts (tests), to initialize functions in the machine.
Scrolling through the tests is possible by using the copy darker/lighter buttons. NAME: NUMBER: DESCRIPTION: CONTENTS: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (10) (11) Adjusting RDF MDFMO : Test 10 6 05 Adjusting RDF RETSMO : Test 10 6 06 Adjusting the ABC: Test 04 6 09 Adjusting paper tray, UPT low position:Test 12 6 06 Adjusting paper tray, LPT low position:Test 12 6 09 Adjusting paper tray, UPT up position empty:Test 12 6 07 Adjusting paper tray, UPT up position full:Test 12 6 08 Adjusting paper tray, LPT up position empty:Test 12 6 10 Adjusting paper tray, LPT up position full:Test 12 6 11 Adjusting FINSDMO : Test 18 6 08 ; Oc 2375/2400/2465CRU/2465FIN Adjusting FINLOSDMO : Test 18 6 11 ; Oc 2475 Adjusting FINUPSDMO : Test 18 6 07 ; Oc 2475. Adjustments 71 Test consisting of several parts (tests), to adjust functions in the machine.
Scrolling through the tests is possible by using the copy darker/lighter buttons. The adjustments of paper stops and framing can be done via service copy mode.
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4.4 Marketing info (80 - 89) 4.4.1 General

In this chapter is the contents of each marketing info test explained. The presentation for each test is as follows: NAME: NUMBER: DESCRIPTION: PRESENTATION: Name of the test. The relevant test number. Short description of the test. The display presentation and test procedure.
4.4.2 Contents of the marketing info tests

NAME: Reset marketing counter. NUMBER: 80 DESCRIPTION: Marketing counters are set at 0. PRESENTATION: After activating the test the marketing counters, described in test 81 are set at 0. Then the test is automatically ended. marketing info <state> SDS 80 reset marketing counters done NAME: Marketing counters NUMBER: 81 DESCRIPTION: Reading out the marketing counters. PRESENTATION: After activating the test the description and the marketing counters are displayed. Because it is not possible to get all counters displayed in one time, <print > has to be pressed to get the last counters displayed. The display presentation: marketing info <state> SDS 81 counters more 1 description counter xxxx 2 description counter xxxx 3 description counter xxxx The marketing counters include: (1) Totall copy counter (images). (2) Totall number of staples. (3) Number of original images (duplex original is counted twice). Only new originals are counted, so with original retention the counter is increased only the first time.
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(4)
Totall run length in class I (number of copies in a run length of this class).
Operation of the run length counters is illustrated by the next example: top limit run length class I = 10 set size = 5 requested run length = 12 requested job ss > ss or ss > duplex After executing this job, counter (4) is increased with 10 x 5 = 50 (all copies made in run 1 - 10). When the last counters are displayed the test is ended by pressing <print >. NAME: NUMBER: DESCRIPTION: DEFAULT: PRESENTATION: Limit runlength class I. 82 Reading out and/or changing top limit run length class I. 1
After the test is activated the present value of the top limit of run length class I is displayed: marketing info <state> SDS 82 limit runlength class1 1 new limit [ -] The test can directly be ended by pressing <print >. The value of the top limit will be unchanged. When a new value has to be set, this is possible by using the buttons <0> - <9>. The set value appears in the field [ -]. Setting 0 is not possible and the max. set value is 999. By pressing <print > the new set set value is confirmed. This appears in stead of the original value. Now a new value can be set or the test is ended by pressing <print >.
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4.5 Service info (90 - 99) 4.5.1 General

In this chapter is the contents of each service info test explained. The presentation for each test is as follows: NAME: NUMBER: DESCRIPTION: PRESENTATION: Name of the test. The relavant test number. Short description of the test. The display presentation and test procedure.
NAME: Configuration NUMBER: 90 DESCRIPTION: Setting the configuration of the machine. PRESENTATION: After activating the test an overview of the configuration of the machine is displayed. At the first item of the configuration (RDF) a cursor (>) is placed. The setting of this item can be done by using the copy darker/lighter buttons. When a choice is made, this can be confirmed by pressing <print >. The cursor is placed automatically to the next item. service info <state> SDS 90 configuration > rdf no-CCD double p tray no- ICCS shutoff no-deposit fin no-depco no-cleanlamp check The configuration includes: (1) RDF: yes / no. (2) ICCS / NO-ICCS (3) Department counter: yes/no. (4) no-CCD / CCD-no-testdb / CCD-testdb (5) Shut off: shutting off the machine automatically yes/no. (6) Clean lamp: clean lamp protection yes/no. (7) Paper tray: double or single paper tray. (8) Delivery: finisher or nothing ; Oc 2475. (8) Delivery : finisher, deposit tray, extented deposit tray or nothing. When the choice of the last item is done, the test is automatically ended by pressing <print > and the configuration is set. Is the test earlier interrupted by pressing <correction> the configuration is unchanged.
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NAME: Serial number NUMBER: 91 DESCRIPTION: Reading out/filling in the machine serial number. PRESENTATION: When the test is activated the present serial number is displayed behind the message current nr. The test can directly be ended by pressing <print >, or a new serial number can be set by using the buttons <0> - <9> (max. of 20 characters!!). service info <state> SDS 91 serial number current nr: new nr:
When a new serial number is set, this is confirmed by pressing <print >. The new serial number is now visible behind the message current nr. Now a new serial number can be set, or the test is ended by pressing <print>. NAME: Telephone number NUMBER: 92 DESCRIPTION: Read out/fill in the telephone number of the service organisation. PRESENTATION: When the test is activated the present telephone number is displayed behind the message current nr. The test can directly be ended by pressing <print>, or a new serial number can be set by using the buttons <0> - <9> and <print> (max. of 20 characters!!). The button <print> is used tmake the sign - in the telephone number. EXAMPLE: The number 077-593304 is set by pressing successively: <0> <7> <7> <print> <5> <9> <3> <3> <0> <4> service info <state> SDS 92 telephone number current nr : 077-825689 new nr : 077-593304 When a new serial number is set, this is confirmed by pressing <print> twice. The new serial number is now visible behind the messagecurrent nr. Now a new serial number can be set, or the test is ended by pressing <print>.
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NAME: Paper sizes NUMBER: 93 DESCRIPTION: Setting the paper sizes belonging to the size sensors. PRESENTATION: After activating the test the first size item where a choice has to be set is displayed. By using the copy darker/lighter buttons the choice possibilities are displayed. When a setting is done, this is confirmed by pressing <print>. The next size item appears automatically in the display. service info <state> SDS 93 paper sizes continent: Europe The setting paper sizes are: (1) Continent: USA or Europe. (2) Paper tray/RDF 328 mm untill 354 mm: 330 x 203 mm = 13 x 8" 330 x 210 mm = folio default Europe 330 x 216 mm = 13 x 8.5" default USA (3) MDF untill 274 mm: 254 x 203 mm = quarto 270 x 210 mm = commercial french default (4) MDF 274 untill 310 mm: 279 x 216 mm = 11 x 8.5" 297 x 210 mm = A4
default USA default Europe
(5) MDF 310 untill 381 mm: 330 x 203 mm = 13 x 8" (*) 330 x 210 mm = folio (*) 330 x 216 mm = 13 x 8.5" (*) 356 x 216 mm = 14 x 8.5" default USA (*) If a width of 330 mm is choosen, automatically the length that is choosen at the setting of the paper tray/RDF is taken (6) MDF from 381 mm: 394 x 292 mm = 15.5 x 11.5" 420 x 297 mm = A3 default Europe 432 x 279 mm = 17 xdefault USA 11" When the choice of the last item is made, the test is automatically ended.
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NAME: NUMBER: DESCRIPTION: DEFAULT: PRESENTATION:
Password 94 Reading out/filling in the password of the operator. 24000
When the test is activated the present password is displayed. The test can directly be ended by pressing <print>, or a new password can be set by using the buttons <0> - <9> (max. of 5 characters and dont begin with 0!!). service info <state> SDS 94 password current password xxxxx new password [ -] When a new password is set, this is confirmed by pressing <print>. The new serial number is now visible at the place of the old password. Now a new password can be set, or the test is ended by pressing <print>. NAME: NUMBER: DESCRIPTION: PRESENTATION: After doing a modification to the machine, the list of modification numbers can be updated by adding the modification number in test 95. When entering the sub menu nr. 1 (add mod. nrs), the modification number can be added to the list. The adding in SDS is identical to password, parameters, etc.. service info <state> SDS 95 basic machine mod. nrs 1 add mod. nrs 2 delete mod. nrs modification number [ -] When a new number is added and confirmed, the display is as shown above. When pressing the <PRINT> button, the test is ended and you get the display with all the mod. nrs. For removing af a mod. nr. , the procedure is the same way as discribed for adding of mod. nrs. If you want to remove all mod.nrs in the list, you must chose remove mod. nrs and number 00 for the removing mod. number, with confirming with <PRINT>, the list of mod. nrs is empty. Basic machine mod. nrs 95 Reading out/filling in the modification numbers of the basic machine..
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Deposit unit mod. nrs 96 Reading out/filling in the modification numbers of the deposit unit..
You have access to this test only if there is a deposit unit configurated in test 90. After doing a modification to the machine, the list of modification numbers can be updated by adding the modification number in test 96. When entering the sub menu nr. 1 (add mod. nrs), the modification number can be added to the list. The adding in SDS is identical to password, parameters, etc.. service info <state> SDS 96 deposit unit mod. nrs 1 add mod. nrs 2 delete mod. nrs modification number [ -] When a new number is added and confirmed, the display is as shown above. When pressing the <PRINT> button, the test is ended and you get the display with all the mod. nrs. For removing af a mod. nr. , the procedure is the same way as discribed for adding of mod. nrs. If you want to remove all mod.nrs in the list, you must chose remove mod. nrs and number 00 for the removing mod. number, with confirming with <PRINT>, the list of mod. nrs is empty. NAME: BBR dump. NUMBER: 99 DESCRIPTION: Reading out/filling in information via service terminal. PRESENTATION: This test can only be started from a service terminal while one of the start displays of SDS is shown. The display presentation is: service info 99 BBR dump <state> SDS
During execution of this test the operating panel will not react anymore. When the service terminal stops the test then the original start display of SDS is shown again. When for a couple of minutes no commands are sent from the service terminal to the copier then the copier will automatically stop the communication
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5 Safety mechanisms and fault procedures

This section describes the functional operation of error processes.
5.1 Classes of error

The following actions are carried out after every error signalled by the machine: errors processed in the machine error administration message on the screen error recovery The errors in the Oc 2400 family can be subdivided into four categories: fatal errors (FE) permanent errors (PE) machine recoverable errors (MRE) operator recoverable errors (ORE)
5.1.1 Fatal errors

A fatal error is an error in the control mechanism. The correct functioning of the control mechanism is not guaranteed after a fatal error.
Error processing If possible, the following actions will be carried out after an FE:
(1) (2) (3) (4) disable interrupts set all outputs to the safe status place a message on the screen (if possible) set the processor to HALT (after which no actions can be carried out on the BBR)
If possible, a fatal error is administered.
Message on screen: The system will try to place a message on the operating panel.
switch machine off and on again error code: xxxx
Error recovery: This status can only be abandoned by switching the machine off and on again. If the error has then been eliminated, the machine will start up; if not, another fatal error will be generated.
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5.1.2 Permanent errors

If a function that is important for the copying process (or administration) is defective, this will result in a permanent error. In the event of such an error, it is not possible or desirable to make copies. Error processing There are two possible error processes: (1) The machine stops immediately, i.e. all the functions except the error, console and service handlers are switched off. The error handler ensures that all outputs are set to the safe status. (2) Paper path is cleared and the first process(1) is then carried out. The software remembers that a permanent error has occurred and which PE it is.
Message on the screen The error handler will place a message on the screen indicating that Service should be called. Once the key operator has called Service, he can use the p_mode to set a message that Service has been called. Possible message on screen immediately after detection of a PE:
Please wait Message on screen if the master is stationary during a PE: service needed call: xxxxxxxxx error code: xxxx Message on screen after key operator has called Service: machine non-operational Oc Service already notified error code: xxxx If there is a detected PE and there is a possibility of using the machine in a limited level of functioning, you have the following display message : service needed use K63 for limited functioning call : xxxxxxxxx error code : xxxx
Error recovery If you notice that there is a permanent error when starting up the control software, only the error, console and service handler functions will start up. The error must be remedied by the service technician and the error can then be reset using SDS test 30.
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5.1.3 Machine recoverable errors

A machine recoverable error is a less serious machine error. Some MREs can be promoted to permanent errors if they occur a second time.
Error processing Machine recoverable errors are processed in the same way as permanent errors. Error administration Following every MRE a counter indicating how often the error has occurred is updated. These counters can be read out in the SDS using the counter tests in the SDS. Message on screen A message will appear on the screen telling the customer that he can restart the machine by pressing the <PRINT> key (if the master is stationary). Possible message on screen immediately after detection of an MRE:
please wait Message once the master is stationary: error located: press PRINT to restart the machine error code: xxxx
Error recovery Once the <PRINT> key has been pressed, the machine restarts. If the same error occurs again (without an intervening MRE or if the previous error has been successfully remedied only once), some MREs may be promoted to permanent errors.
5.1.4 Operator recoverable errors

Operator recoverable errors are errors that can be remedied by the operator, e.g. paper or original path errors.
Error processing In the event of an operator recoverable error, only the function in which the error has occurred is switched off. The machine stops copying and the paper path is cleared(if possible). No new jobs can be started until the error has been remedied. Error administration A counter is increased by one after an error. These counters can be used to see how often a given error has occurred. Message on screen As long as the master is still running a message appears on the screen showing that an error has occurred.
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Once the master is stationary, a message (text plus diagram) appears on the screen showing how the error can be remedied. A diagram of the copier is used to indicate which door(s) have to be opened to do this. Stickers on or near these doors show how the operator can remedy the error. Message immediately after detection of an ORE: please wait ORE message if master is stationary: error 1. open doors 2. remove sheet 3. shut doors
Error recovery After the error(s) (paper or original jam) has/have been remedied or the <correction>key has been pressed, the operator can continue with a job recovery or a new job as applicable. Pressing the <correction> key can be used to abandon the error recovery procedure provided that there are no copies or originals on sensors
5.2 Error priorities

Priorities are from important to less important: fatal errors, permanent errors, machine recoverable errors, operator recoverable errors. If an error occurs, it is always administered and a general error process is arranged regardless of priority. If an error proves to have higher priority than the current error, the message for the latter error disappears and the higher priority error is processed first. In the case of FE, PE, MRE only the error with the highest priority is processed via the screen. In the case of OREs with the same priority, errors are processed in chronological order.
5.3 Handicaps
In the case of some permanent errors in certain functions, the machine can still be used but at a more limited level of functioning. PE processing with handicap situation: (1) Normal error processing as described. (2) Key operator can set the handicap situation in key operator mode. Once the handicap situation has been set, the machine restarts automatically. (3) In the case of a setting using the handicap function, a message appears on the screen and disappears when the setting is changed. If the <PRINT> key is pressed before the settings are changed, the run will not start.
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(4) Only one handicap situation at a time will be accepted. (5) If you enter the SDS, the handicap situation is cancelled and there is a message indicating that there has been a handicap situation. The error causing the handicap situation becomes active again and this can be seen in an error code message. Below is a list of handicaps. error no power to M2+M6+M7 no power to M4 no power to M1 comm. check on init no power to M5 set separator non-operational illegal form. detection. timeouts on upper paper tray movements adc check upt check UPTLLSE when opening tray timeouts on lower paper tray movements adc check lpt check LPTLLSE when opening tray heating of preheat 2b takes too long NTC preheat 2b short circuit NTC preheat 2b open circuit set delivery mechanism error finisher knocker position failure error code PE1010 PE1011 PE1012 PE1014 PE1016 PE1013 handicap only original glass platen job (no rdf) screen message message on line 3, 4 or 5 (continue)
PE1015 PE1210 PE1212 PE1214 PE1216 PE1218 PE1211 PE1213 PE1215 PE1217 PE1219 PE1512 PE1515 PE1518 PE 1810 PE1811 PE1812 PE1813
only mdf, cff or original glass platen jobs no autozoom or autopaper no upper paper tray
message on line 3, 4 or 5 (continue) no message message when add key pressed (flashing) and when setting upt to covers
no lower paper tray
message when add key pressed (flashing) and when setting lpt to covers
only A4 (11") or smaller
message when selecting tray having too large paper format
no stapling ONLY 2475
message when selecting stapling
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5.4 Warnings
A warning is a safety mechanism which is only displayed in the SDS. If such an error occurs in the normal mode, its occurrence is stored in the memory. The customer will be unaware of such errors. When the SDS is entered, there is a message to show that a warning has occurred. Once this error has occurred in the SDS, it is displayed in the field reserved for this purpose (status message in the top righthand corner of the SDS screen).
5.5 Errors in combination with the SDS

Counters record the frequency of machine recoverable, fatal and operator recoverable errors (plus a number of warnings). These counters can be read out and reset using the SDS tests. Errors and warnings can be eliminated using SDS test 30. A buffer of the last fifteen errors is held for the SDS. A list of the last fifteen machine recoverable, fatal and permanent errors is also kept. Both lists can be read out using SDS tests. The number to be phoned (as shown on the screen after a PE) can be changed in the SDS.
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TECHNICAL DATA
TECHNICAL DATA Configurations

The Oc 2400-family has the following configuration: - RDF/finisher (2400/2465FIN) - RDF/Copy Receiving Unit; CRU (2375/2465CRU) - RDF/double finisher (2475)
Delivery
The Oc 2375/2400/2465CRU/2465FIN/2475 will be delivered as one unit. The Oc 2375/2400/2465CRU/2465FIN/2475 can be divided into two smaller units: - main frame - subframe (with or without the finisher) -A- Main frame -B- Subframe -C- Double finisher or CRU
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Cross sectional view

-1-2-3-4-5-6-7-8-9-10Original glass RDF (original handling) Developing unit TTF unit Funnel Counter pressure unit Copy output tray Duplex turn station Speciality tray Inverter -11- Upper paper tray -12- Lower paper tray -13- 1st preheater -14- 2nd preheater -15- Cleaning unit -16- Framing unit -17- Scorotron -18- Photoconductor (master) -19- Mirror -20- Lens
CRU OCE 2375
FINISHER OCE 2475
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TECHNICAL DATA
Shut-off timer
Automatic switching off is achieved by a timer, programmable between 1 and 8 hours (in steps of 1 hour).
Warming up time
Approx. 10 minutes
Print run selector

Maximum 999; RDF: MDF/ADF: CFF: counts down. number of sets number of copies number of copies
Copying speed Oc 2375 (2465CRU) :

RDF: MDF: ADF: CFF:
single sided, 60 (65) copies per minute, first copy after 9.5 seconds double sided, 60 (65) prints per minute, first copy after 11.5 seconds 30 (33)copies per minute 60 (65)copies per minute 30 (33)copies per minute
Copying speed Oc 2400 (2465FIN) :

RDF: MDF: ADF: CFF: single sided, 60 (65) copies per minute, first copy after 9.5 seconds double sided, 40 (43) prints per minute, first copy after 11.5 seconds 30 (33) copies per minute 60 (65) copies per minute 30 (33) copies per minute
Copying speed Oc 2475 :

RDF: MDF: ADF: CFF: single sided, 75 copies per minute, first copy after 9.5 seconds double sided, 75 prints per minute, first copy after 11.5 seconds 37.5 copies per minute 75 copies per minute 37.5 copies per minute
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Originals
General: RDF/ADF: all types of loose leaf originals and books. Format: Min: 203x254mm (8x10") = Quarto Max: 356mm (8.5x14") = Legal Standard Detection of 6 original sizes Weight: 60-120 gsm (16-32 lb) Nr. of originals: 50 according to user manual,
MDF:
Min: 127x210mm (5x8.3") = A5 Max: 297x432mm (11.7x17") Detection of 4 original sizes Weight: 40-200 gsm (10-53 lb) Nr. of originals: 1 original at a time
Format:
Original glass: Format: Max: 297x432mm (11.7x17") Weight: Max: 10 kg (22 lbs) Nr. of originals: Max. thickness with RDF closed: 10mm Max. thickness with RDF open: no limit. CFF: Nr. of originals: unlimited
Receiving materials
Bypass: All Oc copying materials Smaller than 8.5 x 11"(216 x 279mm) is not accepted by machine. For more detailed information, see the Operator Manual. Weight: 60 - 170 gsm(16 - 32 lb bond)
Paper trays:
Paper only. Capacity: upper tray = 1500 sheets 80 gsm (20 lb) lower tray = 1500 sheets 80 gsm (20 lb) Minimum stock = 100 sheets Weight: 60 - 120 gsm (16 - 32 lb bond) Size: min. 203 x 254mm (8 x 10") max. 216 x 356mm (11 x 14") Special functions: Continuous copying with both trays (paper size in both trays must be the same) Paper format: total of 8 different formats. 6 formats can be used at one time and are selected automatically. One must be programmed in SDS.
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TECHNICAL DATA
NAME Quarto Commercial Letter Standard A4 Foolscap folio Folio Legal Legal standard
FORMAT/mm 254 x 203 270 x 210 279 x 216 297 x 210 330 x 203 330 x 210 330 x 216 356 x 216
FORMAT/inches 10 x 8 10.6 x 8.3 11 x 8.5 11.7 x 8.3 13 x 8 13 x 8.3 13 x 8.5 14 x 8.5
Double sided copying

Automatically, only when using the RDF; copying speed is 40 prints per minute for Oc 2400. Automatically, only when using the RDF; copying speed is 43 prints per minute for Oc 2465FIN. Automatically, only when using the RDF; copying speed is 60 prints per minute for Oc 2375. Automatically, only when using the RDF; copying speed is 65 prints per minute for Oc 2465CRU. Automatically, only when using the RDF; copying speed is 75 prints per minute for Oc 2475.
Copy handling
Speciality receiving tray: Capacity: max 50 sheets 80 gsm (20 lb). Copy receiving trays: Capacity: 500 sheets unstapled 80 gsm (20 lb). Stapling: one staple at top left corner. Max. 35 sheets. Machine will staple all weights up to 35 sheets. when stapling sheets having a weight over 80 gsm (20 lb) stapling quality degrades.
Special programs
P - mode: See Operator Manual.
Special copy modes

See Operator Manual.
ed.6 Part II
TSM 2400 family
Technical data 5
TECHNICAL DATA
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Accessories
Copy control device: Department counter: Standard interface. 24V or 93V department counters can be used when the appropriate adaptor is installed. Locking set: Prevents an unauthorised operator having access to the paper trays, paper path and finisher. Cleaning lamp detection: Switches the copier off if the cleaning lamp fails. ICCS: Internal Copy Control System. Counts copies in up to 200 software counters, which can be read out by the key operator.
Photoconductor
Endless belt with photosensitive layer; 8 image sections (2536 x 430 mm).
Charging system
Scorotron: max ASV -240V corona wire -6kV
Framing
Edge discharge: Interval flash: 7 lamps: 1 zero lamp plus 6 others that are used according to the paper size. 2 flash lamps, two independent circuits.
Exposure system
General: Copying ratio: Episcopic exposure by two flash lamps. Max 50mJ/m2 at -4000V. Flash frequency is max. 75 flashes per minute. Copy size adjustable with zoom lens between 64% and 120% in 1% steps. Automatic ratio selection when programmed. Operating panel: between +4 and -4. ABC: between 0 and +8
Exposure setting:
6 Technical data
TSM 2400 family
Part II ed.6
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TECHNICAL DATA
Developing system
General: Magnetic brush developing with one-component toner (F10). Toner hopper contains 6kg (13.2 lbs), which is sufficient for approx. 120,000 copies. A message is displayed in SDS after 30,000 copies. One bottle can be added. When the message refill toner is displayed in user mode, the hopper is almost empty (20,000 copies to go). 5 bottles can then be added.
Refilling toner :
Transfer transfuse system

With pressure and heat.
Safety and environmental aspects

Radiation:
Below the Threshold Limit Value (TLV) for ultraviolet (UV) radiation given by ACGIH.
Room volume: recommendation min. 30 m3 Room ventilation: recommendation min. 15 m3/h (natural ventilation) Sound pressure level (at operator position): Standby 46 dB(A) Copying 69 dB(A) Impulse 73 dB(A) Operating temperature: Between 17C and 34C. Relative humidity: Between 10 % and 90 %. Vapour/gases: Ozone: less than 0.02 ppm; 0.01 mg/m3 at continuous operation. RF emissions: - Europe: complies with 82/499/EEC and standard VDE 0871B - USA: complies with FCC rules and regulations, part 15, subpart J, class A. Electrical/mechanical safety: - Europe approved according to standard IEC950 and EN60950 - USA listed according to standard UL478
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TSM 2400 family
Technical data 7
TECHNICAL DATA
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Consumables
consumables Master TTF Master cleaner Counter pressure belt TTF cleaner Staples Toner (new) lifetime 250k images 500k images 500k images 500k images 1200 black images 70k/roll (10,000 staples) 20k images/bottle (average) Place tray with toner in waste bag or other sealed container to prevent dust. Do not burn. remarks
Toner (waste)
Maximum storage temperature: 45C Place tray with toner in waste bag or other sealed container to prevent dust. Do not burn.
Power consumption
Standby: Warm up: Operating: copying 120 gsm : 850 VA 2650 VA 2750 VA 3500 VA(worst case)
Electrical connections
Europe: UK / Australia: USA: Saudi Arabia: 1 phase, 220V, 16A, 50Hz. 2 phase, 220V, 10A, 50Hz (with 2 phase kit) 1 phase, 240V, 16A, 50Hz. 1 phase, 208/240V, 20A, 60Hz. 1 phase, 220V, 16A, 60Hz.
8 Technical data
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Part II ed.6
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TECHNICAL DATA
Weight (without packing, paper and toner)

Main frame: Subframe: Finisher: Total weight: 400 kg (882 lbs) 135 kg (297 lbs) 45 kg (99 lbs); Oc 2475 : 95 kg (209 lbs) 574 kg (1267 lbs); Oc 2475 : 630 kg (1388 lbs)
Floor loading
Maximum weight on one wheel (with paper and toner) : rear right: 256 kg (562 lbs); Oc 2475 : 296 kg (652 lbs) rear left : 111 kg (243 lbs); Oc 2475 : 95 kg (210 lbs) front left : 61 kg (134 lbs); Oc 2475 : 86 kg (189 lbs) front right : 146 kg (319 lbs); Oc 2475 : 273 kg (601 lbs)
Maximum concentrated loading (rear right wheel): 82 kg/cm2 (1166 lb/in2); Oc 2475 : 95 kg/cm2 (1350 lbs/sq") Average floor loading: 175 kg/m2 (2487 lb/in2); Oc 2475 : 190 kg/m2 (39 lbs/sqft)
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TSM 2400 family
Technical data 9
TECHNICAL DATA
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Dimensions for Oc 2375/2400/2465CRU/2465FIN

See figures. All dimensions in mm.
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10 Technical data
TSM 2400 family
Part II ed.6
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TECHNICAL DATA
Dimensions for Oc 2475

See figures.
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Technical data 11
TECHNICAL DATA
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Service area
Free space required: To front: 1000mm (39.4") To rear : 80mm (3.2") To left : 750mm (29.5") To right: 750mm (29.5") See figure below.
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12 Technical data
TSM 2400 family
Part II ed.6

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Oc

Technical Service Manual

2375 2400-2465-2475 3075

Code number of the TSM Oc 2400 family

Mechanical connections Electrical connections Others

Edition 1, April 1997, Code no. 0109311

Confidential Oc-Nederland B.V.Venlo 1997

Mechanical connections Electrical connections Others

Mechanical connections Electrical connections Others

Mechanical connections Electrical connections Others

Mechanical connections Electrical connections Others

Mechanical connections Electrical connections Others

Edition 1, April 1997, Code no. 0109311

Confidential 1997 Oc-Nederland B.V. Venlo

* Oc 2400 ** Oc 2475 19. COPY RECEIVING UNIT

* Oc 2375, 2400, 2465, 2475 ** Oc 3075 23. DRIVE

Mechanical connections Electrical connections Others

* without low noise unit ** with low noise unit

INSTALLATION 991 992 993 999 Packing Covers Machine okay

Edition 1, April 1997, Code no. 0109311

Confidential 1997 Oc-Nederland B.V. Venlo

PREFACE 1 Copyright notice

Oc-Nederland B.V. 1996

TSM 2400 family

Overview of machine types

Machine type 1230 or 1430

Oc 2375 = 1230 + 1241 Oc 2465CRU = 1430 + 1241

Machine type 1241

Machine type 1230 or 1430

TSM 2400 family

Oc 2475 = 1234 + 1244 stapling capcity 35 sheets

Confidential 1997 Oc Nederland B.V.

Machine type 1234

Oc 2475 = 1234 + 1250 Stapling capcity 50 sheets

Machine type 1250

Machine type 1234

TSM 2400 family

Oc 3075 = 1277 +1278

Machine type 1278

Machine type 1277

2375 Copy speed simplex/duplex Stapling capcity (Sheets) Bin(s)

TSM 2400 family

Why should you use the TSM OCE 2400 family?

At whom is the TSM OCE 2400 family targeted?

TSM 2400 family

How is the TSM OCE 2400 family arranged?

TSM 2400 family

TSM 2400 family

TSM 2400 family

TSM 2400 family

Chapter division of the TSM.

PREVENTIVE MAINTENANCE MISCELLANEOUS SDS USER INTERFACE TECHNICAL DATA

TSM 2400 family

TSM 2400 family

EDITION DATE ed.8

SECTION -complete - Contents - Functional description - Component location

January 1997 Preface 22-Power and Control

June 1996Preface 18-Finisher 2475/50 22-Power and Control

TSM 2400 family

Confidential 1997 Oc Nederland B.V.

TSM 2400 family

EDITION DATE ed.1 june 1991