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service manual SI 62

SI 62


Contents

Section Page

General 410.00-1

Process description 410.01-1

Mechanical description 410.02-1

Electrical description 410.03-1

Parts lists 410.04-1


410.00-1rev. 01.0 - 06/2004

General


410.00-2 rev. 01.0 - 06/2004


410.00-3rev. 01.0 - 06/2004

Contents

Section Page

1 Function 6

2 Specifications 72.1 Machine specifications 72.2 Paper Insert specifications 82.3 Envelope insert specifications 82.4 Envelope and paper insert specifications 9

3 Preparing the machine for use 103.1 Unpacking 10


410.00-4 rev. 01.0 - 06/2004


410.00-5rev. 01.0 - 06/2004

Used symbols

In this manual the following symbols are used.

Warning, this symbol indicates a wrong action which can cause a hazard to health or damage the machine.

Warning, this symbol indicates a hazard to life because of high voltage.


410.00-6 rev. 01.0 - 06/2004

1 Function

figure 1.1

Refer to figure 1.1.

The SI 62 feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.

The SI 62 is equipped with a variety of special features as programmable jobs, Load ’N Go™, FlexFeed™ (1), double feed control, hopper swap, multifeed, daily mail and PowerFold™(2).


410.00-7rev. 01.0 - 06/2004

2 Specifications

2.1 Machine specifications

Model : SI 62

Type : inserter system for medium office use.

Overall Dimensions 3- station system height : 670 mm (26.3 inch)width : 420 mm (16.5 inch) length : 1100 mm (43.3 inch)

(with side exit 1200 mm/47.2 inch receiving tray 1350 mm/ 53.1 inch)

Weight : 80 kg (176 lb)

Noise level : < 70 dB(A) (following ISO 11203)

Theoretical max. speed : 2200 inserts p/h, depending on application.

Operating temperature : 10 - 40°C (50 - 104°F)

Humidity : 30 - 80%

Power consumption : 100V AC / 50Hz / 3,0 Amps 115V AC / 60Hz / 3,0 Amps230V AC / 50Hz / 1,5 Amps

Approvals : EMC Certificate conform EMC-Directive. FCC Certificate conform 47CFR, part 15.CB Certificate conform IEC 60950. UL listed I.T.E. (Information Technology Equipment),conform UL-IEC 60950, file: E153801.Conform NEN-EN-IEC 60950 and derivates.


410.00-8 rev. 01.0 - 06/2004

2.2 Paper Insert specifications

Paper sizes minimum maximumwidth* : 130 mm (5.1 inch) 236 mm (9.3 inch)length** : 90 mm (3.5 inch) 356 mm (14.0 inch)

Quality*** : 60 gr/m2 250 gr/m2

(15 lb bond) (62.5 lb bond)

Booklets up to approximately 1 mm (0.04 inch) thickness,depending on stiffness.

Folding capacity : 5 sheets (max. 80 gr/m2)

* When folded max. 230 mm (9.1 inch)** The minimum document size used for the upper feeder is 115 mm (4.5 inch)

*** When folded max. 170 gr/m2.

2.3 Envelope insert specifications

Envelope sizes : Standard BRE (Business Reply Envelopes)

minimum maximum

Quality : 80 gr/m2 120 gr/m2

(20 lb bond) (30 lb bond)


410.00-9rev. 01.0 - 06/2004

2.4 Envelope and paper insert specifications

Maximum insert specifications are based on single sheets. When multiples are handled, more room inside the envelope is needed depending on application.

figure 2.1

Remarks• The specification of the paper handling equipment is often wider than that of the envelopes and

documents handled. The condition of material handled will limit the specified environmental conditions.

• We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.

• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material.

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410.00-10 rev. 01.0 - 06/2004

3 Preparing the machine for use

First the machine must be unpacked. After unpacking and installing the machine is ready for use.

3.1 Unpacking

figure 3.1

Step 1

Step 2

Step 3

Step 4

80 Kgs176 Lbs

Place the machine in the optional furniture or on a solid table


410.01-1rev. 01.0 - 06/2004

Process description


410.01-2 rev. 01.0 - 06/2004


410.01-3rev. 01.0 - 06/2004

Contents

Section Page

1 Overview 51.1 Feeding documents 51.2 Vertical document transport 61.3 Transport to and from the collator 61.4 Folding 71.5 Envelope transport 81.6 Document input and insert 81.7 Envelope ejecting, sealing and exiting 91.8 Parallel processing 91.9 Legend 11


410.01-4 rev. 01.0 - 06/2004


410.01-5rev. 01.0 - 06/2004

1 Overview

The processing of documents by the consists of a number of sequential processes:• Feeding documents.• Vertical document transport.• Transport to and from the collator.• Folding.• Envelope transport.• Document input and insert.• Envelope ejecting, sealing and exiting.• Parallel processing.The figure shows a schematic overview of the process. All mechanical items that are necessary to discuss the process are projected on the LH side of the machine. With a few exceptions auxiliary mechanical items (such as gears, belts et cetera) are shown. The parts lists (document 410.04) provide mechanical details.

1.1 Feeding documents

Only feeders with automatic separation are used.The upper feeder (in position 2 or 3) can be used for processing daily mail. To this purpose a mechanic switch is set in the daily mail position.The machine has two or three feeders. There is a 1½-station, a 2-station and a 2½-station version.In the version with three feeders (the 2½-station version) the lowest feeder (the "½", in position 1) can only process documents with a length of up to about 150 mm (6 inch). This feeder is fitted with a so-called short tray.For the documents to be fed the following rules apply:• Documents with the single fold and letter fold types are fed with the orientation face up and

leading. The address carrying document is to be fed from the highest active feeder.• Documents with the zigzag fold type must be fed with the orientation face down and trailing. The

address carrying document is to be fed from the lowest active feeder.

The physical feeding process is fairly straightforward: a document is separated by 79 - 81 (feeder 3), 72 - 74 (feeder 2) or 65 - 67 (feeder 1) and exited to the vertical track by 77 and 78 (feeder 3), 70 and 71 (feeder 2) or 63 and 64 (feeder 1). The paper transport is monitored by the feeder photocell PH3 (feeder 3), PH2 (feeder 2) or PH1 (feeder 1). The double feed security check is performed by the Double Feed Control unit DFC3 (feeder 3), DFC2 (feeder 2) and DFC1 (feeder 1). The feeders are mechanically driven from the main motor M1 by a clutch (feeder clutches CL1, CL2 and CL3).The combination of CL1 and PH1 (CL2 and PH2; CL3 and PH3) ensures a well-defined waiting position at the feeder output, prior to entering the vertical track.The separation process is based on separating the upper document in the document hopper. To this purpose the feeder rollers (67, 74, 81) adapt their vertical positions to the current amount of documents in the hopper.In order to further reduce the risk of double feeding documents (partial or full document overlapping) a mechanical delay is established between the current document and the next one to be separated from the document hopper. Soon after the current document leaves a feeder, there is a time when roller 67 (74, 81) no longer touches the leaving document. Without the mechanic delay the separation of the next document would immediately start. However, during a turn of between 135 and 225 degrees this roller will not turn, prior to the drive catching up. This causes a gap between the trailing edge of the current document and the leading edge of the next document. Note that this mechanical behaviour is possible, not only by the 135-225 degrees free stroke, but as well by the


410.01-6 rev. 01.0 - 06/2004

fact that roller 67 (74, 81) has freewheel action in forward direction. The latter is necessary to enable the paper acceleration in the feeder.

1.2 Vertical document transport

The vertical track consists of one driven axle per feeder (75, 68, 61), plus one driven axle in the lower vertical track (45). All these axles carry two rollers, except for 75 (at the top feeder), which carries four rollers. This is necessary for straightening the paper prior to passing the optional reading head RH1. The driven rollers have their counterparts in rollers 76, 69, 62 and 44. If the OMR option is installed, the paper transport prior to entering the reading head is monitored by the reading head photocell PH4. (The reading head RH1 is present if the OMR option is installed. In the overview it is located directly below PH4.) This monitoring is necessary for establishing the reading window.

Depending on the number of documents to be delivered by each feeder there are two ways in which documents can be transported along the vertical track:• One sheet per feeder per set (pane cycle). The various documents of a set are fed from the

feeders in such a way that these documents are partly overlapping each other. This pane-like overlapping ensures a higher throughput.

• More sheets from the same feeder per set (sequential cycle). This is relevant for multi feeding and OMR. Documents are transported along the vertical track without touching each other. Only after joining the set in the making they do touch each other.

Refer to section 1.3 for details on the way in which a set is composed.

1.3 Transport to and from the collator

Before discussing the physical aspects of collating a set it is relevant to discuss the way in which the set is collated (i.e. composed).Of course the operator must have full control over the order in which the various documents of a set are actually present in the filled envelopes. The following rules apply:• If a feeder adds more than one document to a set (multi feeding), these documents are first of

all processed, in the order in which they are separated from the feeder hopper.• The feeders are processed in the order highest active feeder first, lowest active feeder last. This

is independent of the fold type.

Based on the actual number of documents from each cycle, the machine composes a set based on the minimum amount of cycles and, if possible, a pane cycle in stead of a sequential cycle.

In the case of OMR processing the document(s) from feeder 3 is/are always processed via sequential cycles.Between two successive cycles of the collating process a process that is called shunting is necessary. Shunting implies that, prior to being joined by a new document (sequential cycle) or new documents (pane cycle), the partially completed set in the collator is partially moved out of the collator area, into the direction of the fold unit. This is necessary to prevent the leading edge (i.e. entering the collator area first) of the paper entering from the vertical track from interfering with the leading edge (i.e. leaving the collator area first) of the partially completed set.

Now for the physical details. The collator area consists of a set of rollers (46, 50, 53, 56 and 60) that can be driven in both directions by the collator motor M2, and a set of counter rollers 47, 48, 49, 52,


410.01-7rev. 01.0 - 06/2004

54, 55 and 58. In the IN direction of M2 documents are fed into the collator area, in the OUT direction they are moved out of the collator area.The entry of documents into the collator area is monitored by the collating area photocell PH5. A document set leaving the collator area is monitored by the folder input photocell PH6.Documents are fed into the collator area from the vertical track, or back into the collator area in the second stage of the shunt process. The documents are aligned against document stop position 59. (In this machine stop positions 51 and 57 are not used.)During shunting the collator motor M2 first turns in the IN direction, then in the OUT direction.Once a set is complete, documents are exited from the collator to the fold unit if a set is complete. In that case the collator motor M2 is activated in the OUT direction.Transport into and from the collator area is assisted by three collator belts. One belt is situated at the RH side, a second belt is situated at the LH side and the third belt is located at the centre line of the documents. All three belts are connected between pulleys on 50 and 60. In addition the middle belt drives 53 and 56 as well.

1.4 Folding

The folding process is based on the timed impact action of a fold knife: one per fold pocket.As soon as the paper enters a fold pocket and a fold is to be made, the fold deflector is turned upwards. The fold knife is in its rest position; it is turned backwards. The paper is directed into the fold pocket. At the right time the fold knife moves forward and pushes the paper between the fold rollers. The fold is located at the place where the paper touches the tangent between the upper and lower fold roller. The timing of the fold knife movement is based on the detection of the paper by the folder input photocell PH6, machine parameters and job fold settings.

Now for the folding details. The paper of a completed set leaves the collator area. This is detected by the folder input photocell PH6. The paper is transported to the first fold pocket by the fold input rollers 42 and 43. Fold deflector 41 moves up, so paper entering the first fold pocket will be directed in upward direction. At the appropriate time fold deflector 41 moves down and the fold knife 40 (which hinges around axle 39) moves forward: the first fold will be made. Directly after the fold has been made fold knife 40 returns to the rest position. This process is controlled by the first fold pocket clutch CL4, which drives the curve gear 37, which controls the movement of fold knife 40 and fold deflector 41. The axle for the curve gear also carries the brake disc 38, the status of which is monitored by slotted photocell SPH3. The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (fold deflector upwards) and a 240 degrees path (fold deflector downwards plus the impact action of 40). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle 39 also carries the lever for the actuator of fold deflector 41. In this way all movements related to the first fold pocket are synchronized.

After leaving the fold rollers 35 and 36 the paper enters the second fold pocket. The fold deflector 34 moves up, so paper entering the second fold pocket will be directed in upward direction. The paper guide 33 also moves up. This guide is necessary in the second fold pocket to retain the fold that has been made in the first fold pocket. The paper is limited to a small area between paper guide 33 and a fixed guide plate (not shown in the figure, but to the left of 33). At the appropriate time the fold deflector 34 moves back and both the fold knife 32 and the guide plate 33 (which both hinge around axle 31) move forward: the second fold will be made. Directly after the fold has been made, fold knife 32 returns to its rest position. This process is controlled by the second fold pocket clutch CL5, which drives the curve gear 29, which controls the movement of fold knife 32, paper guide 33 and fold deflector 34. The axle for the curve gear also carries the brake disc 30, the status of which is monitored by slotted photocell SPH4. The 360 degrees fold cycle of the brake disk consists of a


410.01-8 rev. 01.0 - 06/2004

120 degrees part (fold deflector and paper guide upwards) and a 240 degrees path (fold deflector and paper guide downwards plus the impact action of 32). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle 31 also carries the lever for the actuator of fold deflector 34. In this way all movements related to the second fold pocket are synchronized.Finally the paper leaves the fold unit on its way (transported by 27 plus 28 and 13 plus 14) to the insert table.

1.5 Envelope transport

All the rollers for this process stage (1, 4, 6, 8, 10 and 11) are engaged to the main drive by the envelope track clutch CL6. During the document and insert stage these rollers are disengaged. The envelope transport subsystem can be manually moved by the RH hand knob, at the LH side of the machine (behind the LH front cover). The counter rollers 3, 5, 7, 9 and 12 can be decoupled from there driven counterparts by a CCW movement of the release handle at the LH side of the machine. In the final ejecting, sealing and exiting stage the driven rollers are engaged once again to release the envelope (held between 11 and 12) and to feed the next envelope to the insert table. This envelope (and maybe the next one as well) has already been separated and is present somewhere in the envelope track.

Note. Roller 6 has freewheel action in the forward direction. This is necessary because for process reasons the envelope transport speed at rollers 8, 10 and 11 is higher than the transport speed at rollers 1, 4 and 6. Given the fact that, once an envelope has been separated, the next envelope is separated, you can notice an increasing distance between two successive envelopes as they travel through the envelope track.

First of all by the action of the feed and separation rollers (1 and 2) an envelope is separated from the stack in the hopper and transported via three pairs of transport rollers (3 - 8). The envelope track photocell PH7 detects the leading and trailing edge of the envelope.

The envelope then passes the flap rollers 9 and 10. The combined action of the flap scraper and the lower linear speed of the flap rollers 9 and 10 (compared with the speed of 7 and 8) results in some buckling and the opening of the envelope. The flap is the trailing part of the envelope passing the flap rollers and the envelope flap track photocell PH8.

Pulse measurements (measured via slotted photocell SPH1) during the presence of the envelope under PH7 and PH8 provide information on the length of the not yet opened envelope, the opened envelope and the time at which the envelope transport is suddenly stopped with the envelope on the insert table. The sudden stop is the result of disengaging by the envelope track clutch CL6 and the friction brake 9a. The envelope flap now is fixed between 11 and 12. (The envelope stop position can be corrected via the user interface of this machine.)

1.6 Document input and insert

Once the envelope is on the insert table, the fingers solenoid So1 is shortly activated. The fingers are moved forward into the envelope. The envelope stays in place, for it is fixed between 11 and 12. This is a preparation for inserting the document set into the envelope.Now the document set can be inserted. This set leaves the fold unit (transported by 27 plus 28 and by 13 plus 14), is detected by the insert table photocell PH9 and passes under the fingers before entering the envelope.

410.01-9rev. 01.0 - 06/2004


1.7 Envelope ejecting, sealing and exiting

The insert of the set is considered finished if and when the insert table photocell PH9 detects the trailing edge of the set. Then a number of actions take place: (a) clutch CL6 is activated to release the flap and to feed the next envelope to the insert table; (b) the insert table solenoid So2 is shortly activated, resulting in the ejection roller 16 moving down. (By spring action, after switching So2 off, these driven rollers are pulled high again.) Now the envelope is ejected from the insert table. So2 is deactivated as soon as safely can be assumed that the filled envelope is between 17 and 18, so further transport is guaranteed.

The filled envelope passes rollers 17 and 18, the moistening brushes, the sealing track rollers 19 and 20 and the lower sealing roller 22 plus its counter roller 21. The leading envelope edge triggers flag switch FS1.The upper reverse roller 25 is held high (i.e. this roller doesn't contact the lower reverse roller 24) by a spring. A certain time after triggering FS1 the sealing solenoid So3 is activated. At this moment the envelope flap is still between 21 and 22. The envelope body is between the upper and lower reverse rollers, so the envelope position is clearly defined. (This envelope sealing position can be corrected via the service menu.) By the So3 action the upper reverse roller now is temporarily lowered. Given the turning direction of the lower reverse roller, the transport direction of the envelope is abruptly changed from an "upstream" to a "downstream" direction. Assuming that the flap fold line of the envelope has passed 21 and 22, this is now the leading edge of the envelope being transported through the sealing rollers 22 and 23. After passing the sealing rollers the envelope is exited to the exit of the machine. The sealing solenoid So3 is switched off as soon as the leading envelope edge is detected by the exit photocell PH10. The exit photocell PH10 monitors the passing envelope.As soon as PH10 has detected the trailing envelope edge, the next filled envelope can be transported from the insert table to the exit of the machine.

1.8 Parallel processing

The process description discussed above deals with one specific set and one specific envelope as these items travel through the machine. However, as soon as a certain process stage has been completed for the current document, set or envelop, this process stage is repeated for the next document, set or envelope.• A very short time after the trailing edge of the separated envelope has passed roller 1, the next

envelope is separated. In the Auto mode on each time several envelopes are on their way to the insert table.

• The next filled envelope can be transported as soon as the previous one has completely passed the exit photocell PH10.

• Only after it has been established that (a) the previous set has passed the insert table photocell PH9; (b) the envelope with this set can be ejected and sealed; (c)the flap of the current envelope has been opened, the next set will be transported from the collator via the two fold pockets to the current envelope on the insert table.

• In section 1.1 the delay between to successive documents fed to the same feeder is discussed.

rev. 01.0 - 06/2004410.01-10


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410.01-11rev. 01.0 - 06/2004

1.9 Legend

Note 1. Parts with an arrow are mechanically driven (by the main motor M1 or by a the collator DC motor M2).

Note 2. For reasons of cross-reference the identification of sensors and actuators as used in the electrical description (document 410.03) is mentioned here as well.

GeneralM1 Main motor. Provides the primary mechanical drive for the feeder clutches CL1 –

CL3, the folder clutches CL4 & CL5 and the envelope track clutch CL6. Directly drives the vertical track transport (75, 68, 61, 45), the folding subsystem (42&43; 35&36; 27&28) and the inserter main drive (15, 17, 19, 20, 22, 23). If the upper unit is in place, items 14, 16, 24 and 26) are driven as well. All items that are directly driven by M1 can be activated with the LH hand knob (behind the LH front cover).

PD1 Pulse disc (mounted on roller 19). Monitored by slotted photocell SPH1. Provides information on the process timing.

MS1 Safety switch for the upper unit.MS2 Safety switch for the front cover.MS3 Safety switch that guards the part of the collator area that can be opened by the user.

FeedersLower feeder (1)

CL1 Feeder 1 clutch. Drives 63, 66 and 67. Activated during the transport of the separated document to its waiting position. Activated once again when this document is transported to the vertical track and (after a short delay) the next document is separated.

PH1 Feeder 1 photocell.63 Driven output rollers.64 Counter rollers for 63.65 Lower separation roller. Connected to the feeder frame via a constant-torque device.66 Feed axle with upper separation roller. Freewheel action in forward direction.67 Paper puller axle with two rubber rollers. Adapts its vertical position to the amount of

documents in the hopper. Freewheel action in forward direction. Free stroke (between 135 and 225 degrees) ensures a safe distance between successive separated documents, in order to prevent double feeds.

DFC1 Double Feed Control unit for feeder 1.

Middle feeder (2)CL2 Feeder 2 clutch. Drives 70, 73 and 74. Activated during the transport of the separated

document to its waiting position. Activated once again when this document is transported to the vertical track and (after a short delay) the next document is separated.

PH2 Feeder 2 photocell.70 Driven output rollers.71 Counter rollers for 70.


410.01-12 rev. 01.0 - 06/2004

72 Lower separation roller. Connected to the feeder frame via a constant-torque device.73 Feed axle with upper separation roller. Freewheel action in forward direction.74 Paper puller axle with two rubber rollers. Adapts its vertical position to the amount of



Upper feeder (3)CL3 Feeder 3 clutch. Drives 77, 80 and 81. Activated during the transport of the separated

document to its waiting position. Activated once again when this document is transported to the vertical track and (after a short delay) the next document is separated.

PH3 Feeder 3 photocell.77 Driven output rollers78 Counter rollers for 77.79 Lower separation roller. Connected to the feeder frame via a constant-torque device.80 Feed axle with upper separation roller. Freewheel action in forward direction.81 Paper puller axle with two rubber rollers. Adapts its vertical position to the amount of



Vertical track44 Counter roller of 45 (in the upper unit).45 Driven vertical transport axle.61 Driven vertical transport axle. On this axle feeder 1 (lower) clutch CL1 is mounted (at

the LH side of the machine). This clutch drives 63, 66 and 67.62 Counter rollers for 61 (in upper unit).68 Driven vertical transport axle. On this axle feeder 2 (middle) clutch CL2 is mounted

(at the LH side of the machine). This clutch drives 70, 73 and 74.69 Counter rollers for 68 (in upper unit).75 Driven vertical transport axle. On this axle feeder 3 (upper) clutch CL3 is mounted (at

the LH side of the machine). This clutch drives 77, 80 and 81.76 Counter rollers for 75 (in upper unit).PH4 Reading head photocell. Only present and operational if OMR is installed.RH1 Reading head. Only present and operational if OMR is installed.

Feeders


410.01-13rev. 01.0 - 06/2004

CollatorM2 Collator motor. Drives 46, 50, 53, 56 and 60 in forward or reverse direction.PD2 Pulse disc mounted on the axle of the collator motor M2. Monitored by slotted

photocell SPH2.PH5 Collating area photocell. Guards the entry of documents from the vertical track.46, 50, 53, 56, 60

Collator rollers driven (either forward or reverse) by the collator motor M2. In collator arm. Actual transport is realized with three belts, driven by and driving 50, 53, 56 and 60.

51 Document stop position for 6-inch documents. Not used in this machine!57 Document stop position for 12-inch and A4-sized documents. Not used in this

machine!59 Document stop position for 14-inch documents.47, 48, 49, 52, 54, 55, 58

Free running collator rollers.

Fold unitPH6 Folder input photocell.42 Lower fold input roller.43 Upper fold input roller.35 Lower fold roller for first fold pocket.36 Upper fold roller for first fold pocket. In upper unit.27 Lower fold roller for second fold pocket.28 Upper fold roller for second fold pocket. In upper unit.39 Control axle for first fold pocket. Hinge for 40. Moves the lever that in its turn moves

the fold deflector actuator of 41 upwards.40 Fold knife for first fold pocket.41 Fold deflector for first fold pocket.37 Curve gears for first fold pocket (1 x LH, 1 x RH). Controls movement of 40.

38 Brake disc for first fold pocket. Spring loading ensures two static mechanical states.

PD3 Cam disc of first fold pocket. Monitored by slotted photocell SPH3.31 Control axle for second fold pocket. Hinge for 32 and 33. Moves the lever that in its

turn moves the fold deflector actuator of 34 upwards.29 Curve gears for second fold pocket (1 x LH, 1 x RH). Controls movement of 32 and

33.30 Brake disc for second fold pocket. Spring loading ensures two static mechanical

states.PD4 Cam disc of second fold pocket. Monitored by slotted photocell SPH4.32 Fold knife for second fold pocket.33 Moving paper guide for second fold pocket.34 Fold deflector for second fold pocket.CL4 First fold pocket clutch. Drives 37.CL5 Second fold pocket clutch. Drives 29.


410.01-14 rev. 01.0 - 06/2004

Envelope feedingCL6 Envelope track clutch. Mounted on clutch shaft, at the RH side of the machine. On

this shaft two gears take care for the mechanical interface between the permanently M1 driven subsystem and the envelope track subsystem. CL6 drives 1, 4, 6, 8, 10 and 11.

1 Feed roller. Activated by the envelope track clutch CL6.2 Separation roller.4, 6, 8 Driven envelope transport rollers. Activated by the envelope track clutch CL6.3, 5, 7 Counter rollers for 4, 6 and 8. These rollers can be moved (by the release handle) in

order to solve a paper jam in the envelope track.PH7 Envelope track photocell.10 Driven envelope transport roller (flap opening stage). Activated by the envelope track

clutch CL6. Speed of 10 somewhat lower than that of 8, in order to assist flap opening.

11 Driven envelope transport roller (flap opening stage). Activated by the envelope track clutch CL6. On the axle at the LH side of the machine the RH hand knob (behind the LH front cover) is mounted.

9, 12 Counter rollers for 10, 11. These rollers can be moved (by the release handle) in order to solve a paper jam in the envelope flap track.

9a Friction brake.PH8 Envelope flap track photocell.

Inserting, ejecting, sealing and exitingPH9 Insert table photocell.So1 Fingers solenoid. Moves fingers forward into envelope to enable inserting the set.13 Lower insert roller.14 Upper insert roller (in the upper unit). 14 and 13 provide final set transport prior to

inserting in envelope.15 Lower first ejection roller. On the axle at the LH side of the machine the LH hand knob

(behind the LH front cover) is mounted. On this axle at the RH side of the machine the main pulley is mounted.

16 Upper first ejection roller (in the upper unit). Lowered by the action of the insert table solenoid So2.

So2 Insert table solenoid. Shortly activated. Deactivated as soon as 17&18 have taken over the transport function.

17 Lower second ejection roller. In this area the moistening brushes are located.18 Upper second ejection roller (in the upper unit).19 Driven sealing track roller. On the axle at the RH side of the machine the pulse disc

PD1 (monitored by slotted photocell SPH1) is mounted.20 Driven sealing track roller.21 Counter roller for 22 (in the upper unit).22 Lower sealing roller. A gear on the axle (on the RH side of the machine) provides via

an intermediate gear the mechanical interface to all the driven parts in the upper unit (14, 16, 24, 26).


410.01-15rev. 01.0 - 06/2004

23 Upper sealing roller.FS1 Flag switch. Note. FS1 is actually mounted on the tangent line of 24 and 25.So3 Sealing solenoid. Moves 25 down during a short time. Deactivated as soon as 22&23

have taken over the transport function.24 Lower reverse roller (in the upper unit).25 Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid

So3.26 Not used in this machine.PH10 Exit photocell.

Inserting, ejecting, sealing and exiting


410.01-16 rev. 01.0 - 06/2004


410.02-1rev. 01.0 - 06/2004

Mechanical


410.02-2 rev. 01.0 - 06/2004


410.02-3rev. 01.0 - 06/2004

Contents

Section Page

1 Covers and plates 81.1 RH side cover 91.2 LH side covers 91.3 Top cover feeders, covers collator area, power supply cover 101.4 Covers upper unit 11

2 Electrical components 122.1 Main board 122.2 FRAM and Display board 13

3 Feeder modules and vertical transport RH 143.1 Drive mechanism RH 153.1.1 Belts 153.1.2 Pulleys 163.2 Drive mechanism LH 163.2.1 Belt 163.2.2 Clutch and Pulley 16

4 Feeders 174.1 Top feeder (feeder 3) 174.2 Middle feeder (feeder 2) 194.3 Lower feeder (feeder 1) 214.4 Automatic separation feeder with daily mail 234.4.1 Rubber paper pullers 234.4.2 Pulley of paper puller axle 254.4.3 Upper separation roller 264.4.4 Lower separation roller 274.4.5 Gears 284.5 Automatic separation feeder 28

5 Vertical transport 29

6 Collating area 306.1 Belts 316.1.1 Transportation belts 316.2 Guide rollers 31

7 Folder 327.1 RH drive mechanism 327.1.1 Belts 327.1.2 Pulleys 347.1.3 Gears 347.2 LH drive mechanism 357.2.1 Fold mechanism 367.2.2 Clutches 37


410.02-4 rev. 01.0 - 06/2004

7.2.3 Curved folder gears 377.3 Rollers 417.3.1 Input rollers 417.3.2 Lower fold rollers 437.3.3 Upper fold rollers 44

8 Main drive mechanism inserter 458.1 Belts 458.1.1 PJ-belt 458.1.2 Drive belt inserter 468.1.3 Belt envelope feed 478.2 Pulleys 488.3 Gears 488.4 Clutches 49

9 Envelope feed 529.1 Hopper 529.1.1 O-rings 529.1.2 Separation roller 539.1.3 Feed roller 539.2 Envelope track 549.2.1 Lower rollers 549.2.2 Upper rollers 559.2.3 Rubber roller 569.2.4 Finger solenoid 56

10 Upper unit 5810.1 Drive mechanism 5810.1.1 Belt 5810.1.2 Pulleys 5910.1.3 Gears 5910.2 Document inserting 6010.2.1 Rollers 6010.2.2 Gears 6010.2.3 Ejection solenoid 6210.3 Envelope transport and sealing 6310.3.1 Rollers 6310.3.2 Sealing solenoid 64

11 Envelope transport 6511.1 Lower ejection rollers 6511.2 Sealing track transportation rollers 66

12 Envelope sealing and ejection 6712.1 Upper sealing roller 6712.2 Lower sealing roller 67

13 Sensors 6813.1 Safety switches 6813.2 DFC and photocells 72


410.02-5rev. 01.0 - 06/2004

13.2.1 Feeders 7213.2.2 Vertical transport 7413.2.3 Collator area 7513.2.4 Folder 7713.2.5 Inserter 78

14 Adjustments 8314.1 Main drive PJ-belt 8314.2 Main drive belt feeders/folder 8414.3 Main drive belt inserter 8514.4 RH drive belts 8614.5 Drive belt upper folder section 8714.6 Paper guide 8814.7 Solenoids 8914.8 Separation roller 9114.9 Friction brake 9214.10 Flap scraper 93


410.02-6 rev. 01.0 - 06/2004


410.02-7rev. 01.0 - 06/2004

General instructions

Disconnect the mains supply before performing any maintenance.

WarningThe covers and safety switches are fitted for your protection. Do not operate the machine with any cover removed and with a safety switch cheated, or a hazard to health will exist.

Throughout this manual the terms left and right-hand side and front and rear side of the machine are used. These are made with the machine viewed from the input (document feed) side of the machine.

The replacement procedures are the reversal of the removal procuderes.

LEAD: If you remove different parts of the machine, put the screws are nuts of bolts back in the removed part.


410.02-8 rev. 01.0 - 06/2004

1 Covers and plates

figure 1.1

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410.02-9rev. 01.0 - 06/2004

1.1 RH side cover

Refer to figure 1.1Open the loc by lifting the hand grip 4. Remove the six screws 1 as shown and one screw 3 inside the RH side cover 2. Remove the RH side cover.

1.2 LH side covers

Refer to figure 1.1.Open the loc by lifting the hand grip 4. Cover 8 is hinged to the inside frame and can be opened. Remove two screws 6 on the outside and three screws 5 inside the LH side cover 7. Remove the LH side cover. Remove three screws 13 from the protect cover 9 and remove the cover. Remove the water tray 12 carefully. Remove two screws 11 from the wiring cover 10 and remove the cover.

The manual for service and testing can be found inside the machine beside the LH side cover.


410.02-10 rev. 01.0 - 06/2004

1.3 Top cover feeders, covers collator area, power supply cover

figure 1.2

Refer to figure 1.2.Remove the LH- and RH side covers as described in paragraph 1.1 and 1.2. Remove the top cover feeder1 by removing two nuts 2 and two tight-lipped on both sides. Loose two screws 4 of the top cover 3 of the collator and remove the cover. Remove four screws 8 of the bottom cover 7 of the collator and remove the cover. Remove three screws of the power supply cover 6 and remove the cover. Remove the water tray and place the machine carefully at the right hand side on a felt path (very heavy). Loose three hex. head screws 10 of the bottom plate 9 and remove the bottom.

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410.02-11rev. 01.0 - 06/2004

1.4 Covers upper unit

figure 1.3

Refer to figure 1.3.The covers should be removed in the following order:• lift the loc by lifting the hand grip 1• remove two nut’s 2 and two screws 3 inside the upper unit 4.

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1


410.02-12 rev. 01.0 - 06/2004

2 Electrical components

Warning. Potential hazard may exist to electronic hardware in conditions with static electricity. It is advised that, when handling electronic parts, an earth connected wrist band is used in order to be permanently discharged from static electricity.

figure 2.1

2.1 Main board

Disconnect the wiring to the main board 1and remove the screw 2 and lock washer and spacer. Carefully pull the main board from the board holders as shown.

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410.02-13rev. 01.0 - 06/2004

2.2 FRAM and Display board

figure 2.2

Refer to figure 2.2.Open the loc by lifting the hand grip as shown in figure 1.1. Remove the screws and spacers from the cover plate, remove the cover plate as shown in figure 1.3.

Disconnect the wiring. Remove the display unit by removing the four screws 1. Remove cover plate 2, spacers 3 and finally display board 4 and rubber pad key pad 5.

Note: Connect the wiring before replacing the display board. Be sure to replace the four spacers .

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410.02-14 rev. 01.0 - 06/2004

3 Feeder modules and vertical transport RH

The feeders, the vertical transport and the fold unit are driven by belt 4 and the accompanying pulleys, gears, etc. as shown in figure 3.1.When the machine is running the four transportation axles are continuously driven by the belts 4, 5 and 6. The three upper transportation axles are equipped with a clutch and a pulley. When, for example, the clutch 2 is activated the accompanying feeder is driven by pulley 3 and belt 1 and a document is fed to the vertical transport track.

Note: With the one and a half and two stations versions, the belt 6 and upper transportation axle is not mounted.

figure 3.1

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410.02-15rev. 01.0 - 06/2004

3.1 Drive mechanism RH

figure 3.2

3.1.1 Belts

Refer to figure 3.2.Belt (item 8)Slacken the two screws of belt tensioner 10 and shift the belt tensioner downwards. Remove the belt 8 from the pulleys.

Belt (item 3)Slacken the hex head screw of belt tensioner 1. Remove the belt 3 from the pulleys.

Belt (item 12)The belt 12 is removed in the same way as the belt 3.

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410.02-16 rev. 01.0 - 06/2004

3.1.2 Pulleys

Refer to figure 3.2Pulleys (item 4, 5, 7, 9 and 11)The pulleys 4, 5, 7, 9 and 11 are "snapped" to their cyl. pins and can be removed by pulling them of the axle. Pulley (item 6)Loosen the main belt, PJ belt and drive belt inserter. Remove the spring clip and slide the main pulley of the axle.Pulley (item 13)Remove the hex head screw of the belt tensioner 2 and withdraw the tensioner. Slide the pulley 5 from the axle, than remove the cyl. pins from the axle and slide the pulley 13 of the axle.

3.2 Drive mechanism LH

figure 3.3


3.2.1 Belt

Unhook the tension spring 2 from the inside frame and remove the belt 1 from the pulley 3.

3.2.2 Clutch and Pulley

Disconnect the wiring of the clutch. Remove the spring clip 6 and slide the clutch 5 and the disc 4 and the pulley 3 of the axle.

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410.02-17rev. 01.0 - 06/2004

4 Feeders

The following section describes in which way the complete feeders must be removed. All the feeders are provided with dividable drive axles. Before working on the feeders remove the hoppers.After removing the extension part of the drive axle (axle 9, figure 4.1), each feeder can be removed separately. Take care that it is a left side screw-threaded axle end. When it is loosened, the main axle has to be fixed by a pin on one of the holes.

At the RH side the feeders are equipped with a tension spring for proper lifting of the feeder. The tension spring is hooked on a mounting bracket at the frame. Do not remove the mounting bracket or exchange the tension spring from one to another feeder. Each spring is specially adjusted from the factory by positioning the mounting bracket.

4.1 Top feeder (feeder 3)

Remove the top cover feeders.

figure 4.1

Refer to figure 4.1.On the RH side of the feeder, unhook tension spring 7 from the screw 8.On the LH side of the feeder the following components must be removed:• Disconnect the wiring of the feeder and cut the wire straps. • Remove the wiring from the LH inside frame.• The spring clip 1, clutch 2 and the belt 4 and the pulley 3 of the top transportation axle.• Unhook the tension springs 5 from the inside frame.• Remove the screw of the LH and RH side hinge pin 6 of the top feeder.• Remove top transportation axle 10 by moving it in the RH direction.

7 10 6 5 4 3 2

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410.02-18 rev. 01.0 - 06/2004

figure 4.2

Refer to figure 4.2.Remove the feeder as follows: • Move the feeder a bit downstream as indicated (A)• Lift the RH side of the feeder first and remove the feeder from the machine (B).

Note: Be careful when replacing feeder 3, the hinge pin at the RH side is locking the ball bearing.

B

A


410.02-19rev. 01.0 - 06/2004

4.2 Middle feeder (feeder 2)

figure 4.3

Refer to figure 4.3.On the RH side of the feeder, unhook the tension spring 2 from the screw 1.On the LH side of the feeder the following components must be removed:• Disconnect the wiring of the feeder and cut the wire straps. • Remove the wiring from the LH inside frame.• The spring clip, clutch 9 and the belt and the pulley of the middle transportation axle (remove

axle to the RH side).• Un hook the tension 10 spring from the inside frame.• Remove two hex head’s and the guide plate 5. • Remove the screw of the LH and RH side hinge pin 11 of the middle feeder.

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410.02-20 rev. 01.0 - 06/2004

figure 4.4

Refer to figure 4.4.Remove the middle feeder as follows:• Move the feeder a bit downstream (A)• Remove the feeder by turning it out of the machine as indicated (B).


RH LH

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410.02-21rev. 01.0 - 06/2004

4.3 Lower feeder (feeder 1)

figure 4.5


On the RH side of the feeder, onhook the tension spring 2 from the screw 1.On the LH side of the feeder the following components must be removed:• Disconnect the wiring of the feeder and cut the wire straps. • Remove the wiring from the LH inside frame.• The spring clip 7, clutch 6 and the belt 8 and the pulley 5 of the lower transportation axle.

Remove the axle to the RH side.• Unhook the tension springs 4 from the inside frame.• Remove the screws at the LH and RH side of hinge pin 3 of the lowest feeder.

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LH


410.02-22 rev. 01.0 - 06/2004

figure 4.6

Refer to figure 4.6.Remove the lower feeder as follows:• Move the feeder as far as possible downstream (A);• Remove the feeder by turning it out of the machine as indicated (B).


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410.02-23rev. 01.0 - 06/2004

4.4 Automatic separation feeder with daily mail

This section describes the replacement of the rollers and pulleys of the feeder. For several replacements it is necessary to remove some covers above or below the feeders. The removal of these covers is shown in figure 4.7.

4.4.1 Rubber paper pullers

figure 4.7

Refer to figure 4.7Remove cover 1 to 4 as follows:• Remove the screws on the RH side. To remove cover 1, it’s necessary to remove the top cover

first, see figure 1.2• Pull the cover 1,2 and 3 backwards on the RH side and pull it out on the LH side.• Loosen the screws 6 at the cover 5 and remove the cover:• Pull the cover 4 backwards on the RH side and pull it out on the LH side.

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410.02-24 rev. 01.0 - 06/2004

figure 4.8

Refer to figure 4.8Remove the feed axle assy. 2 in the right-hand side direction (A) until the left-hand side is clear from the axle 1. Tilt (B) the axle assy. 2 at the left-hand side and withdraw the right-hand side of the axle from the hole in the feeder frame. Remove (C) the axle assy. as indicated.

The rubber paper pullers 4 can simply be removed by pushing them of the axle. Hold the plastic cover 3 in place with one hand and push (D) firmly against the rubber paper puller as indicated. Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the paper puller can be pulled of the axle.

Note: Ensure on replacement that the plastic cover is replaced below the ridge (3, figure 4.8) on the paper guide and that the feeder assy. is correctly fitted onto the axle. Ensure that the belt runs across the pulleys.

A

D

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410.02-25rev. 01.0 - 06/2004

4.4.2 Pulley of paper puller axle

Remove the feed axle assy. as described in the paragraph "Rubber paper pullers".

figure 4.9

Refer to figure 4.9.Remove the axle from the plastic cover. Push the rubber paper puller of the axle and remove the spring clip, the washer and the bearing. The pulley 1 consists of two parts. Push the pulley assy. to the left to release it from the cyl. pin, remove the cyl. pin and slide the pulley assy. of the axle.

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410.02-26 rev. 01.0 - 06/2004

4.4.3 Upper separation roller

figure 4.10

Note: The feeder unit does not need to be removed for replacing separation rollers.

Remove the feed axle assy. as described above. Refer to figure 4.10. Click (A) the plastic cover 2 off the axle and remove it with the belt and the paper pulleys from the feed axle. Remove the grease from the left hand side of the feed axle with some alcohol. Push the feed roller 1 to the left hand side of the axle as indicated. Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the feed roller can be pulled of the axle.

Note: Before replacing the feed roller ensure that the axle is free of grease. After replacing the feed roller put some grease Molykote PG 65 on the plastic cover 2 as shown in figure 4.10. Replace the plastic cover with the belt and the rollers.

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410.02-27rev. 01.0 - 06/2004

4.4.4 Lower separation roller

Note: The feeder unit does not need to be removed for replacing separation rollers.

Remove the cover 3 as shown in figure 4.7.

figure 4.11

Refer to figure 4.11.Move the separator axle assy. 2 in the right-hand side direction (A) until the left-hand side is clear from the hinge plate 1. Move (B) the axle assy. 2 downwards side and withdraw the right-hand side of the axle from the hole in the feeder frame. Figure 4.12 shows how the roller 1 should be slided of the axle assy. 2.

figure 4.12

Note: Before replacing the feed roller ensure that the axle is free of grease.

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410.02-28 rev. 01.0 - 06/2004

4.4.5 Gears

For the removal of the gears at the LH side of the feeder it is not necessary to remove the feeder from the machine. The gear 48T can be removed after the extension axle with the pulley etc. has been removed. Remove the spring clip securing the gear 64T, lift the feeder and slide the gear 64T of the axle.

4.5 Automatic separation feeder

The removal procedure of the components of the automatic separation feeder is similar to that of the automatic separation feeder with daily mail as described in the previous section.


410.02-29rev. 01.0 - 06/2004

5 Vertical transport

To get access to several parts of the vertical transport track, remove the vertical transport cover as described in section Covers and plates. Figure 5.1 shows the parts of the vertical transport track.

figure 5.1


410.02-30 rev. 01.0 - 06/2004

6 Collating area

The parts which are described in this section are located in the upper arm of the collating area. It is recommended to remove the complete collator arm. Remove the collator area cover as described in the section See “Top cover feeders, covers collator area, power supply cover” on page 10.

.figure 6.1

Refer figure 6.1.Disconnect the wiring of the collator motor. Loosen the set screw 7 on bush 6 as shown in figure 6.2 and pull the motor outside the frame. Support the collating arm and remove the screws 1 as shown in figure 6.1 (two at the LH side and two at the RH side). Carefully remove the collating arm.

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410.02-31rev. 01.0 - 06/2004

6.1 Belts

figure 6.2

6.1.1 Transportation belts

Refer to figure 6.2The transportation belts are only available as a set. If a belt is worn, all the belts should be replaced. Remove roller 1 from the axle and slide the axle to the LH side out of the bearings. Take care of the tensioner 2, it is spring loaded. Remove the tensioner 2 and the plate 3. At last remove the axles 4 and 5 and the middle transportation belt can be replaced.

6.2 Guide rollers

Refer to figure 6.2The guide rollers 8 and 10 are spring loaded. Remove the accompanying spring clips and washers and slide the guide rollers of the axles. Remove the screw of the axle of the guide roller 9 and slide the axle to LH side. Remove the spring clip at the RH side of the guide roller and slide the roller of the axle.

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410.02-32 rev. 01.0 - 06/2004

7 Folder

7.1 RH drive mechanism

figure 7.1

7.1.1 Belts

Lower folder sectionThe removal of the drive belt 1 (figure 7.1) is described in chapter "Feeder modules and vertical transport RH.

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410.02-33rev. 01.0 - 06/2004

Upper folder section

figure 7.2

Refer to figure 7.2.Slacken the two screws 2 of the belt tensioner 1 and remove the belt 5 from the pulleys 3 and 6.

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410.02-34 rev. 01.0 - 06/2004

7.1.2 Pulleys

Lower folder sectionRefer to figure 7.1.Remove the belt 1 as described in chapter "feeder modules and vertical transport RH". After the removal of the accompanying spring clip and clamping ring the pulleys 2 and 3 can be slided of the axles.

Upper folder sectionRefer to figure 7.2.Remove the belt 5 as described in the previous section. Remove the spring clip and the washers of the pulley 3 and slide the pulley of the axle. Slacken the set screw 4 of the pulley 6 and slide the pulley of the axle.

7.1.3 Gears

Lower folder sectionRefer to figure 7.1.Gears, item 4 and 5.The gears 4 and 5 can easily be slided of the axles. Take care of the cyl. pins when removing the gears.

Upper folder sectionRefer to figure 7.2.The gears 8 and 10 can be removed after the removal of the accompanying spring clip, clamping ring and washers. Whem removing gear 8, take care of the cyl. pin.To remove gear 9, belt 5, pulley 6 and spacer 7 have to be removed. When removing gear 8, take care of the cyl. pin.


410.02-35rev. 01.0 - 06/2004

7.2 LH drive mechanism

figure 7.3

Refer to figure 7.3.To get access to the gears of the lower folder section at the LH side of the machine, the circuit board must be removed. Then gears 1 up to 5 can easily be removed by removing the accompanying spring clips, clamping rings and washers. Take care of the cyl. pin of the gears 1, 3 and 5 and the spacers of the gears 2 and 4.

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410.02-36 rev. 01.0 - 06/2004

7.2.1 Fold mechanism

figure 7.4

Refer to figure 7.4.The fold plates 1 and 5 are driven via the curved gears 6 (four in total) and two gears 3, activated by the two clutches 2 on the drive axle 4.

Gears 32T, drive axleRefer to figure 7.4.Remove the belt 13, pulley 12 and 14 and freewheel clutch 11. Remove the locking plate 10 securing the bearing of the drive axle 4. Carefully move the axle 4 to the RH-side until the bearing clears the frame. Carefully lift the axle assembly as far as possible upwards. Take care of the wiring of the clutches on the axle and the plastic bearing on the LH side.

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410.02-37rev. 01.0 - 06/2004

figure 7.5

Refer to figure 7.5.Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive axle assembly. Slide the gear 1 of the axle. To remove the gear 4 the clutches must be disassembled. Cut the wire straps at the connectors of the clutches. Slide clutch 2 to the left-hand side of the axle. Take care of the cyl. pin of the clutch. Next remove all the components between the clutches including the cyl. pin of the clutch 3. Slide clutch 3 to the left-hand side of the axle. Now the gear 4 can be removed from the drive axle.

7.2.2 Clutches

The removal of the two clutches is described in the previous section "Gears 32T drive axle".

Note: Ensure on replacement to secure the wiring of the clutches again and that both clutches are retained by the locking plate. Also ensure that the clutches CW and CCW are placed in the proper position.

7.2.3 Curved folder gears

Remove the drive axle assembly as described in the section "Gears 32T, drive axle". Refer to figure 7.4.Remove the bearings 9 from the axles 6. Remove the brake discs 15 (spring loaded), the springs, the brake strip 16 and the bearings 17 from the axles 8.

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410.02-38 rev. 01.0 - 06/2004

figure 7.6

Refer to figure 7.6.Remove the following components:• The levers for the flap actuators, the bearings, etc. (1 upto 6) from the axles 12. Pin 6 has to be

loosened by a set screw, to be accessed at axle end (12).• The brackets 7 with the sensors.• The brake discs with the bearings (22 upto 20) from the axles 13.

Next remove the screws at the left and right-hand side of the guide plate 9, unhook the guide plate and remove it. Remove the screws at the left and right-hand side by which the brackets 10 are mounted to the upper frames. Carefully lift each complete fold assembly upwards and withdraw it.

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410.02-39rev. 01.0 - 06/2004

First curved folder gears

figure 7.7

Refer to figure 7.7.Remove the two screws 6 and slide the hinge plate 7 and the hinge plate 5 together with the fold plate 4 of the axle. Now the curved gears 2 and 8 can be pulled of the axle.

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410.02-40 rev. 01.0 - 06/2004

Second curved folder gears

Refer to figure 7.7.Remove the hinge plates 15 and 17 in the same way as described previously and pull the curved gears 9 and 10 of the axle.

figure 7.8

Note: Ensure on replacement that the curved gears and the curved discs are replaced correctly onto the axle, refer to figure 7.8, and to secure the wiring of the clutches again.

The right-hand curved gear is marked with a "R" and the left-hand curved gear is marked with a "L".

AdjustmentsCheck after replacing and securing the complete fold assembly the adjustment of the paper guides 3 and 11 (refer to figure 7.7), see section "Paper guide".

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410.02-41rev. 01.0 - 06/2004

7.3 Rollers

7.3.1 Input rollers

Remove the drive belt as described in the chapter 3, section 3.1.

figure 7.9

Refer to figure 7.9.Remove the pulley, the gears of the upper (1) and lower (2) input rollers as described in 7.1Remove the bearing locking plate 3.

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410.02-42 rev. 01.0 - 06/2004

figure 7.10

Refer to figure 7.10.Remove the gear 7 of the lower input roller 6 and remove the bearing locking plate 5. Remove the guide strip 4 and the guide bracket below it. Move the upper input roller 2 to the right-hand side until the left-hand bearing is free of the LH inside frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH inside frame.

Move the lower input roller 6 to the right-hand side until the left-hand bearing is free of the LH inside frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH inside frame.

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410.02-43rev. 01.0 - 06/2004

7.3.2 Lower fold rollers

Remove the following parts:

Refer to figure 7.10.• The gears 8.

Refer to figure 7.11• Loosen the two hex. head screws 3. Push down solenoid 4 to get access to screw 2 and remove

screws 2. Remove bearing plate 1; • To remove a roller, move it to the right-hand side until the left-hand bearing is free of the LH

inside frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH inside frame.

figure 7.11

AdjustmentsCheck after replacing the adjustment of the solenoid, see paragraph 14.7.

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410.02-44 rev. 01.0 - 06/2004

7.3.3 Upper fold rollers

figure 7.12

Refer to figure 7.12.Remove the belt with the pulley 5 and the three gears 4 at the right-hand side.For the removal of the first fold roller it is necessary to remove the guide strip 2.Next remove the bearing locking plates 3 on both sides. To remove roller 1 move it to the right-hand side until the left-hand bearing is free of the LH frame. Move the left-hand side of the roller downwards and withdraw the roller out of the RH frame.

AdjustmentsFor belt adjustments refer to 14.5.

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410.02-45rev. 01.0 - 06/2004

8 Main drive mechanism inserter

The main motor 9 (refer to figure 8.1) provides the mechanical power to the SI 62, with exception of the collating area. The collating area is driven by a separate motor.

figure 8.1

8.1 Belts

8.1.1 PJ-belt

Before the PJ-belt 2 can be removed the main drive belt for the feeder and folder section must be disassembled as described in 3.1.

Refer to figure 8.1.Loose the two hex. head screws 4 of the tensioner 5. Remove the belt 2 from the main pulley 1 and the motor pulley 3.

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410.02-46 rev. 01.0 - 06/2004

figure 8.2

8.1.2 Drive belt inserter

Refer to figure 8.2.All moving components of the inserter part are driven by belt 10. To remove belt 10 loosen the two hex. head screws of the tensioner 1. Then remove the belt from the pulleys.

1 2 3 4

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6


410.02-47rev. 01.0 - 06/2004

8.1.3 Belt envelope feed

figure 8.3

Refer to figure 8.3.Remove the support plate 11 by which the intermediate axle 13 is supported. Take care of the bearings and the washers. Remove the belt 5 from the pulley on the intermediate axle and from the pulley on the envelope feed axle 3.

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410.02-48 rev. 01.0 - 06/2004

8.2 Pulleys

Refer to figure 8.2.The pulleys item 9 and 5 can easily be removed by removing the accompanying spring clips.The pulley 11 can be removed after the removal of the main pulley as described in the section " Drive mechanism RH". Before the pulley 8 can be slided of the axle the mounting plate 6 with the adjustment plate and the pulse disc sensor must be removed. Next remove the pulse disc 7 and slide the pulley 8 of the axle. Take care of the spacer.

Note. After replacement of the pulse disc sensor be sure that it clears the pulse disc on both sides.

Refer to figure 8.3.For the removal of the pulleys 14 and 9 it is necessary to remove the belt 5 as described in 8.1.3. Remove the accompanying spring clip and washer of the pulley 9 and slide the pulley of the envelope feed axle 3.Remove the bearings, washers and gears from the intermediate axle 13. To remove the pulley 14 from the intermediate axle tap the tension pin and slide the pulley 14 of the axle.

8.3 Gears


Gears item 3 (sealing rollers)After the removal of the pulley 5 all the gears 3 can be slided of the axles by removing the accompanying spring clips and washers.

Gear item 2The gear 2 is mounted to the axle by a tension pin. To tap the tension pin it is necessary to remove the axle. Remove the tension springs of the bearings of the axle. Next remove the spring clip with washer and bearing at the left-hand side of the axle. Slide the two rollers to the right-hand side and remove the cyl. pin from the axle. Slide the axle with the gear 2 to the right-hand side out of the RH inside frame. Tap the tension pin to remove the gear 2.

Gear item 4The gear 4 is also mounted to the pulse disc axle 14 by a tension pin. Remove the pulse disc 7 and pulley 8. Remove the spring clip at the left-hand side of the axle. Slacken the set screws of the two rollers. Remove the locking plate 13. Slide the pulse disc axle 14 to the right-hand side out of the RH inside frame. Remove during sliding the axle to the right-hand side the bearing and washer and the two rollers. After the axle is removed the gear can dissembled by tapping the tension pin.

Gear item 12After the removal of the pulley 9, gear12 can be slided of the axle.


Gears item 8, 10, 15, 16, 18, 20 and 22The gears 8, 10, 15, 16, 18, 20 and 22 can simply be removed by removing the accompanying spring clips and washers.


410.02-49rev. 01.0 - 06/2004

Gear item 21For the removal of the gear 21 the nuts etc. must be removed. Take care of the tension spring.Once the nuts are removed all the parts can be slided of the brake rod.

For adjustment of the friction brake, see section " Friction brake "

Gear item 6After the gear 8 has been removed the clutch 7 must be dissembled. Remove the support plate 11, disconnect the wiring of the clutch and slide the clutch of the axle. Remove gear 6.

Gears item 4 and 12Remove the support plate 11 to free the intermediate axle 13 with its components. Remove the bearings, washers and spring clip from the axle and slide the gears 12 and 4 from the axle.

Gear item 17To get access to the transportation axle it is advisable to remove the insert table. Remove the spring clip, washer and bearing at the left-side of the transportation axle 2. Move the axle a little to the right-hand side, slide the gear 17 to the left-hand side and remove the cyl. pin. Slide the gear 17 of the axle.

Gear item 19The gear 19 is mounted to the tansportation axle 1 by a tension pin. For the removal of the gear 19 the tension pin must be tapped. Remove the insert table and remove the spring clip, washer and bearing from the left-hand side of the axle. Slide the rollers to the right-hand side to remove the cyl. pins. Slide the axle to the right-hand side out of the RH inside frame. Take care of the two rollers. Tap the tension pin and remove the gear 19 from the axle.

8.4 Clutches

Slip clutch envelope feed axleRefer to figure 8.3.Remove the metal ring of the pulley 9. Slide the belt 5 of the pulley 9 and remove the pulley from the axle. Slide the slip clutch of the axle.

Clutch CWWhen the machine is switched on gear 6 it is constantly driven. By activating the clutch 7 all the gears shown in figure 8.3 and the accompanying axles and rollers of the envelope feed and envelope track will be driven. So to feed, open and place an envelope on the insert table the clutch 7 is activated.To remove clutch 7 the support plate 11 and the gear 8 must be removed. Disconnect the wiring of the clutch and slide it of the axle.


410.02-50 rev. 01.0 - 06/2004

8.5 Main motor (M2)

figure 8.4

Refer to figure 8.4.Remove the power supply cable. Remove the power supply cover 2. Disconnect the wiring and cut the wire straps. Fasten the collator arm with a wire strap so it will not fall down when removing the power supply assy. Remove the power supply assy 3. Cut all the wire straps by which the wiring of the motor is attached to the frames.

When replacing the power supply assy. ensure that the guide plates 1 are fitted correctly in the guide rollers. Also take care to fit the microswitch correctly and ensure the correct functioning.

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410.02-51rev. 01.0 - 06/2004

figure 8.5

Refer to figure 8.5.Remove the belt 1 by releasing the belt tensioner 2. First remove the bottom of the machine than remove the four screws 3 and the washers 4 and withdraw the motor 5 from the machine. Take care of the wiring.

Adjustments For belt adjustments refer to 14.1 and 14.3.

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410.02-52 rev. 01.0 - 06/2004

9 Envelope feed

9.1 Hopper

9.1.1 O-rings

figure 9.1

Refer to figure 9.1.Remove the centre front plate 9. The hopper assembly 10 is fitted to the inside frames by three screws 1 at the left-hand and three screws 11 at the right-hand side. Remove the screws and withdraw the assembly from the machine. Remove the pulley 13 and slip clutch 12 as described in 8.2. Next remove the spring clips, washers and bearings from envelope feed axle 5 and remove the axle from the machine. Slide the O-rings 7 from the joggers 6.

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410.02-53rev. 01.0 - 06/2004

9.1.2 Separation roller

Note: Before removing the separation roller first check the adjustment procedure as described in 14.8.

Refer to figure 9.1Remove the centre front plate and the hopper assembly as described in the previous paragraph. Slacken the two screws 3 and remove the separation spring 2 with the separation roller. Remove the separation axle with roller from the separation spring, slacken the set screw of the separation roller 4 and slide it of the separation axle.

9.1.3 Feed roller

Refer to figure 9.1Remove the feed axle as described in 9.1.1. Remove a jogger from the envelope feed axle. Slacken the set screw from the feed roller 8 and slide it of the axle.

Note: On replacement of the joggers and/or feed roller, position the feed roller in the middle of the shaft the removed joggers between the "forks" of the side guide. Take care to reassemble the rings between fork and jogger. Ensure that the set screws of the feed roller are tightened onto the groove of the feed shaft.

AdjustmentsSee paragraph 14.8 and 14.8.


410.02-54 rev. 01.0 - 06/2004

9.2 Envelope track

9.2.1 Lower rollers

To get access to the lower rollers of the envelope track it is necessary to remove the bottom plate.

figure 9.2

Refer to figure 9.2.Remove the spring clip, washer and bearing (spring loaded) from the axle of the first set of rollers 13. Move the axle to the left-hand side to free the cyl. pins and remove the cyl. pins. Lift the axle and slide the rollers of the axle. Take care of the pressure spring of the bearings. The second set of rollers 12 is removed in the same way. Remove from the third set of rollers 11 at first the outer two

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410.02-55rev. 01.0 - 06/2004

rollers. The removal procedure for the inner two rollers is the same as described for the first set of rollers.

Refer to figure 9.3Remove the flap scraper 21. Remove the pressure springs of the bearings of the fourth set of rollers 19. Slide the rollers to the LH side to remove the cyl. pin. Remove the spring clips and slide the axle to the RH side and remove the rollers 19 from the axle.

Adjustment:For the adjustment of the flap scaper see 14.10. .

figure 9.3

9.2.2 Upper rollers

Refer to figure 9.2.To get access to the upper rollers remove the insert table as described in paragraph 11.1.

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410.02-56 rev. 01.0 - 06/2004

To remove the first set of rollers 5 slide the rollers of the axle 7, remove the cyl. pins 4. Remove the spring clip 1, washer 2 and bearing 3 at the left-hand side of the axle 7 and slide the axle to the right-hand side. Remove the rollers from the axle.The second and third set of rollers are removed in the same way as the first set of rollers 5.

Refer to figure 9.2To get access to the fourth set of rollers of the envelope track remove the insert table. To get more room, you could remove the fixing plate envelope track (item 8, figure 9.2). Slide the rollers aside to remove the cyl. pins. Remove the spring clip, washer and bearing at the left-hand side of the axle and slide the axle to the left-hand side. Remove the rollers from the axle.

9.2.3 Rubber roller

Remove the insert table and the transportation table (item 19, figure 11.1). Slide the transportation table in direction as indicated over the second fold roller.

Refer to figure 9.3.Remove the knob 1 and the spring clips 5 of the rubber roller 11. The gear at the right-hand side of the rubber roller must be removed as described in section 8.3. Slide the roller to left-hand side to free the right-hand side of the rollers from RH inside frame. Take care of the bearing. Lift the right-hand side and withdraw the rubber roller from the machine.

9.2.4 Finger solenoid

figure 9.4


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410.02-57rev. 01.0 - 06/2004

Remove the draw bar 3 and the tension spring 4. Disassemble the mounting bracket 2 with solenoid 1. Remove the solenoid 1 from the bracket 2.

AdjustmentsFor the adjustment of the solenoid see 14.7.


410.02-58 rev. 01.0 - 06/2004

10 Upper unit

10.1 Drive mechanism

The drive mechanism of the upper unit is located at the right-hand of the machine.

10.1.1 Belt

figure 10.1

Refer to figure 10.1.At first slide the belt 8 of the pulley 7. Then remove the belt from the pulley 10.

1

2

3

4

5

6

7

8

9

10


410.02-59rev. 01.0 - 06/2004

10.1.2 Pulleys

Refer to figure 10.1.Remove the spring clip of the pulley 10 and slide the pulley 10 from the axle.To remove pulley 7 it is necessary to remove the axle 5 completely. Open the upper unit and remove the six screws by which the brake plate 2 is mounted to the upper frames.

Take in account the weight of the upper unit when removing the dampers.Close the upper unit and remove the axle 1. Move the brake plate 2 with assembled components carefully aside, take care of the wiring to the solenoid, the sensor and display. Remove plate 3. Remove the spring clips of the axle 5. Slide the rollers of axle 5 aside and remove the two cyl. pins. Slide the axle to the right-hand side out of the RH frame. Take care of the rollers, washers and bearings. Tap the tension pin of the gear 9 and slide the gear of the axle. Now the pulley 7 can be removed from the axle.

10.1.3 Gears

The removal of the gear 9 is described in the previous paragraph.For the removal of the gear 6 the brake plate has to be removed as described in the previous paragraph. Next remove the spring clips of the axle 4 and remove the cyl. pins of the rollers.Slide the axle 4 to the right-hand side out of the frame. Tap the tension pin of the gear 6 and slide the gear 6 of the axle.


410.02-60 rev. 01.0 - 06/2004

10.2 Document inserting

10.2.1 Rollers

figure 10.2

Refer to figure 10.2.Remove the guide plates1 on both sides and slide the upper insert rollers 3 of the axle. Take care of the cyl. pins. The first set of ejection rollers 11 can simply be slided of the axle. Take care of the cyl. pins.

Refer to figure 10.4.To remove the second set of ejection rollers, remove spring clip 5 and remove roller 4 from the axle. Remove spring clip 2 and slide the axle to the LH side. Tap out the cyl. pin of roller 1 and slide roller 1 from the axle.

10.2.2 Gears

Refer to figure 10.2.Remove the guide plates 1 on both sides. Remove the bracket 6 and the sensor, take care of the wiring of the sensor. Next remove the pulley 5 and the spring clip 12. Slide the outer bearings at the axle 8. Remove the tension springs 2. Slide the axle 8 with complete insert assembly through the slotted holes out of the frames.

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410.02-61rev. 01.0 - 06/2004

figure 10.3

Refer to figure 10.3.Once the frame plate 5 is removed the gears 4, 7 and 8 can be slided of the axles. Take care of the pressure springs 6.

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410.02-62 rev. 01.0 - 06/2004

figure 10.4

Refer to figure 10.2.Remove the screws 7 and withdraw the complete ejection assembly 9 together with the draw bar and the attached plunger (item 1, figure 10.3) from the frames. Take care of the washers and the pressure spring of the plunger.

Refer to figure 10.3.After the frame plate 9 is removed the gears 10 and 11 can be removed from the axles.

10.2.3 Ejection solenoid

To get access to the solenoid the covers of the loc must be removed as described in the section 1.

Refer to figure 10.3.Disconnect the wiring of the solenoid. Remove the two screws 3 and remove the solenoid 2. Take care of the plunger 1 the washers and the pressure spring.

AdjustmentsSee 14.7.

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410.02-63rev. 01.0 - 06/2004

10.3 Envelope transport and sealing

10.3.1 Rollers

figure 10.5

RH

12

7 6 5 4 3


410.02-64 rev. 01.0 - 06/2004

Sealing transport rollersRefer to figure 10.5.Open the upper unit and remove the spring clips of the axle 6. Slide the transport rollers 4 of the axle. Take care of the pressure springs 5.

Lower reverse rollersThe removal of the lower reverse rollers 3 is described in 10.1.2.

Upper reverse rollersRemove the accompanying spring clips and washers and slide the rollers 7 of the axle.

10.3.2 Sealing solenoid

Refer to figure 10.5.Disconnect the wiring of the solenoid 1. Remove the screws 2 and withdraw the solenoid. Take care of the pressure spring and the washers at the plunger.

AdjustmentsSee paragraph 14.7.


410.02-65rev. 01.0 - 06/2004

11 Envelope transport

11.1 Lower ejection rollers

figure 11.1


Remove four screws 13 of the insert table 18 and four screws 1 of the insert table 2. Remove the drive belt inserter as described in 8.1.2.Remove the locking plate of the bearing at the right-hand side of the transportation axle 20. Slide the axle 19 to the RH side. Remove the cyl. pin 17. Slide the roller 18 from the axle.

Remove the spring clip, washer and bearing from the left-hand side of the axle 22. Slide the axle to the RH side. Slide the rollers 21 from the axle.

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410.02-66 rev. 01.0 - 06/2004

11.2 Sealing track transportation rollers

Refer to figure 8.2.Remove the pulse disc 7 and pulley 8 with the from the pulse disc axle 14 as described in 8.2.

Refer to figure 11.1.Remove the pressure springs 11 from the bearings 12 of the axle 8. Slide the rollers 4 aside to remove the cyl. pins 3. Remove the spring clip, washer and bearing at the left-hand side of the axle. Slide the rollers of the axle.

Note: Take care of the pressure springs 10 when replacing again. On the LH side a spring with lower force has to be fitted than on the RH side.


410.02-67rev. 01.0 - 06/2004

12 Envelope sealing and ejection

12.1 Upper sealing roller

Refer to figure 11.1.Remove the gear at the right-hand side of the sealing roller 6 as described in 8.3.

Next remove the pressure springs 11 from the bearings 12 and the spring clip at the left-hand side of the sealing roller. Take care of the washer 10 and the spring 9. Move the sealing roller 6 to right-hand side to free the left-hand bearing from the LH inside frame and withdraw the upper sealing roller.

12.2 Lower sealing roller

Refer to figure 11.1.Remove the upper sealing roller as described in the previous paragraph. Remove the gear at the right-hand side of the sealing roller 5 as described in 8.3.

Remove the two screws 14 and the mounting plate 7 and the spring clip, washer and bearing at the left-hand side of the lower sealing roller 5. Move the sealing roller to the right-hand side and withdraw the lower sealing roller.


410.02-68 rev. 01.0 - 06/2004

13 Sensors

13.1 Safety switches

Upper unit safety switchThe safety switch of the upper unit is located at the right-hand side of the machine near the lowest feeder. To get access to the switch remove the RH side cover.

figure 13.1

Refer to figure 13.1.Cut the wire strap and remove the bracket 2 together with the safety switch 1. Remove the safety switch from the bracket.

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410.02-69rev. 01.0 - 06/2004

Safety switch LH side coverThe safety switch is located at the left-hand side of the machine near the sealing rollers.

figure 13.2

Refer to figure 13.2.Open the LH side cover and remove the cover 1. Remove the safety switch 3 from the bracket 2.

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410.02-70 rev. 01.0 - 06/2004

Safety switch collator areaThe safety switch is located at the right-hand side beneath the collator area and behind the supply cover. Remove the supply cover.

figure 13.3

Refer to figure 13.3.Remove the safety switch 2 from the frame 1.

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410.02-71rev. 01.0 - 06/2004

Flag switch sealing area

figure 13.4

Refer to figure 13.4.Remove the nuts 1 and 6 than remove the frame 2 complete. Take care of the wiring. Slacken the screw 3 and remove the bracket 4 with the flag switch 5.

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410.02-72 rev. 01.0 - 06/2004

13.2 DFC and photocells

Note: whether or not photocells are replaced, it is advised to reset the photocells after finishing servicing. See sections 2.14 and 2.15 of the Electrical description for details.

13.2.1 Feeders

DFCEach feeder is equipped with a DFC. Remove the covers 1, 2, 3 and 4 (figure 4.7) as described in 4.4.1. When removing the DFC of feeder 2 first remove the guide plate 5 (figure 4.3) as described in 4.2.

figure 13.5

Refer to figure 13.5.Disconnect the wiring of the DFC and remove the screw 2 securing the DFC 3 to the bracket 1.

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410.02-73rev. 01.0 - 06/2004

Feeder photocells

figure 13.6


Transmitter (LED)Remove the bracket 4 with the transmitter 3. Disconnect the transmitter and remove it from the bracket.

Receiver (Sensor)Remove the bracket 2 with the sensor 1. Disconnect the sensor and remove it from the bracket.

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LH RH


410.02-74 rev. 01.0 - 06/2004

13.2.2 Vertical transport

Vertical transport photocells (optical, only with OMR).In the 2,5 stations version, the detectors are located beneath the upper vertical transport rollers.

figure 13.7


Transmitter (LED)Open the loc and remove the guide plate 1 with assembled transmitter 2. Disconnect the wiring of the transmitter and remove the transmitter.

Receiver (Sensor)Remove the vertical transport cover. Cut the wire strap securing the wiring of the sensor 3 to bracket 4. Remove the bracket with the sensor and disconnect the wiring. Remove the sensor.

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410.02-75rev. 01.0 - 06/2004

13.2.3 Collator area

figure 13.8

Refer to 13.2.3.Remove the set screw 1, remove the pulse disc and the sensor 3.

Note: Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc.

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410.02-76 rev. 01.0 - 06/2004

Collating area photocells

figure 13.9


Move the lower collator arm downwards. Remove the locking plate of the axle 4 at the right-hand side of the machine and free the bearings of the frame. Remove the hinged guide plate 1 together with the attached sensors 2 and 3. Take care of the wiring.

Transmitter (LED)Remove the transmitter 3 from the guide plate.

Receiver (Sensor)Remove the sensor 2 from the guide plate.

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410.02-77rev. 01.0 - 06/2004

Folder input photocell

Refer to figure 13.9.Remove the bracket 5 with the transmitter 6 to the left-hand side out of the LH inside frame. Take care of the wiring.

Transmitter (LED)Cut the wire straps and remove the transmitter 6 from the bracket.

Receiver (Sensor)Cut the wire straps and remove the receiver 7 from the bracket.

13.2.4 Folder

Curve (pulse) disc sensor

The sensors are located at left-hand side of the upper unit. Open the upper unit.

figure 13.10

Refer to figure 13.10.Remove the bracket 1 with the sensor 2. Cut the wire strap, disconnect the sensor and remove the sensor from the bracket. The sensor 3 has to be removed in the same way.

1 2 3


410.02-78 rev. 01.0 - 06/2004

13.2.5 Inserter

Pulse disc sensorThe pulse disc sensor assy. is located at the right-hand side of the machine near the sealing rollers.

figure 13.11

Refer to figure 13.11.To avoid damage to the pulse disc 4 remove the pulse disc. Disconnect the wiring of the sensor 2, remove the two srews 3 and remove the sensor.

Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc. To adjust the position of the sensor slacken screw 1, reposition the sensor and fasten the screw 1.

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410.02-79rev. 01.0 - 06/2004

Envelope track photocell

To get access to the photocells remove the insert table and the bottom plate.

figure 13.12


Transmitter (LED)Pull the air hose connector 4 from the transmitter 3. Slacken the screw of the transmitter and remove the transmitter 3.

Receiver (Sensor)Remove the bracket 2 together with the sensor 1. Slacken the screw of the sensor and remove the sensor 1.

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410.02-80 rev. 01.0 - 06/2004

Envelope flap detectorTo get access to the photocells remove the insert table and the bottom plate.

figure 13.13


Transmitter (LED)Once the bottom plate is removed, remove the bracket 1 with the transmitter 2. Take care of the wiring. Disassemble the transmitter from the bracket.

Receiver (Sensor)Pull the air hose connector 3 from the sensor 4. Slacken the screw 6 and remove the bracket 5 with the sensor 4. Remove the sensor from the bracket.

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410.02-81rev. 01.0 - 06/2004

Exit photocells

figure 13.14

Refer to figure 13.14.Remove the frame axles 1 together with the cover 2. Take care of the wiring of the detectors.Remove the transmitter (LED) 3 and the receiver (Sensor) 4.

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410.02-82 rev. 01.0 - 06/2004

Document insert photocells

figure 13.15


Transmitter (LED)The transmitter is located in the upper unit. Open the upper unit and remove the screw 1 to release the transmitter 2.

Receiver (Sensor)Remove the transport table. Slacken the screw 5 and remove the bracket 4 with the sensor 3. Remove the sensor from the bracket. Take care of the wiring.

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410.02-83rev. 01.0 - 06/2004

14 Adjustments

14.1 Main drive PJ-belt

figure 14.1

Refer to figure 14.1.The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).

To adjustSlacken the two screws 1 securing the belt tensioner 2. Shift the belt tensioner to adjust the correct belt movement. Hold the belt tensioner in position and retighten the two screws. Check the adjustment and readjust if necessary.

Note: Do not adjust the drive belt too tight.

Note. When adjustment of the belt tensioner is not sufficient, re-adjust the motor position.

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410.02-84 rev. 01.0 - 06/2004

14.2 Main drive belt feeders/folder

figure 14.2




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410.02-85rev. 01.0 - 06/2004

14.3 Main drive belt inserter

figure 14.3




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410.02-86 rev. 01.0 - 06/2004

14.4 RH drive belts

Note: The adjustment of the lower and upper drive belt is similar.

figure 14.4

Refer to figure 14.4.The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch).

To adjustSlacken the hex. head screw 3 securing the belt tensioner 2.Shift the belt tensioner to adjust the correct belt movement.Hold the belt tensioner and retighten the hex. head screw.Check the adjustment and readjust if necessary.


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410.02-87rev. 01.0 - 06/2004

14.5 Drive belt upper folder section

figure 14.5

Refer to figure 14.4.The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch).

To adjustSlacken the hex. head screw 1 securing the belt tensioner 2.Shift the belt tensioner to adjust the correct belt movement.Hold the belt tensioner and retighten the hex. head screw.Check the adjustment and readjust if necessary.

Note: Do not adjust the drive belt too tight

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410.02-88 rev. 01.0 - 06/2004

14.6 Paper guide

figure 14.6

Refer to figure 14.6.There must be a small gap between the fixed guide plate 3 and the fold roller 2. The fold roller should just run free.

To adjustSlacken the two round head screws 1 to move the guide plate further away from the fold roller and tighten it to move it closer.

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410.02-89rev. 01.0 - 06/2004

14.7 Solenoids

Note: The adjustment procedure for all solenoids is described below. Only for the finger solenoids a different procedure is necessary refer figure 9.4.

Whenever a solenoid is actuated the plunger is pulled into the solenoid coil. To make sure that the pulling power of the solenoid coil on the plunger is maximal, the plunger should not touch the bottom of the solenoid coil whenever the solenoid is actuated.

figure 14.7

Refer to figure 14.7.To set this requirement:• Slacken the two screws 3 securing the solenoid coil 4. • Push the plunger 2 together, with the linkage 1 attached to it, as far as it will go in the direction

towards to the solenoid coil. Hold the plunger in this position and then slide the solenoid coil towards the plunger until the plunger bottoms the solenoid coil.

• Move the solenoid coil back by approximately 1 mm (0.04 inch) and retighten the two screws. Ensure the solenoid coil and the plunger are aligned in a straight line.

1 2 3 4


410.02-90 rev. 01.0 - 06/2004

Finger solenoid

figure 14.8

Refer to figure 14.8.To adjust the finger solenoid:• Slacken the two screws 2 securing the solenoid coil 1. • Push the plunger 3 down into the lowest position. • Move the solenoid coil (with the plunger in the lowest position) so that the middle fingers (slide

in) is adjusted approximately 2 mm (max.) (0.07 inch) above the insert table. Retighten the two screws.

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410.02-91rev. 01.0 - 06/2004

14.8 Separation roller

Because the separation roller does not reverse, a 'flat' gradually wears on the roller surface. This can be the cause of irregular feeding of the envelopes. Should this occur, carry out the following adjustment:

figure 14.9

Refer to figure 14.9.Use the adjusting nut 2 and set the separation gap to the maximum. Slacken the set screws 1 securing the separation roller. Rotate the separation roller about 30 degrees in the direction indicated, so that the unworn portion of the separation roller faces the feed roller 3. Retighten the set screw and re-adjust the separation gap.

Note: After rotating the separation roller over 330 degrees it is necessary to replace it.

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410.02-92 rev. 01.0 - 06/2004

14.9 Friction brake

figure 14.10

Refer to figure 14.10.The friction brake is correctly adjusted when the distance between the inner faces of the two friction discs 3, i.e. the overall pressure spring length, is 20 mm (0.79 inch).

To adjustRemove the outer nut 1 securing the inner nut 2.Turn the inner nut to adjust the correct distance. Replace the outer nut and check the adjustment.

Note: An increased variation of the envelope stop position can be caused by excessive play in the lower gear train. A slight reduction in the distance (increasing the pressure) may give the required result.

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410.02-93rev. 01.0 - 06/2004

14.10 Flap scraper

figure 14.11

Refer to figure 14.11.The flap scraper 3 must be positioned so that its lower edge is aligned with the lower edge of the envelope guide 1.

To adjustSlacken the two hex. head screws 2 securing the flap scraper 3 on both sides.Move the flapscraper to adjust the correct position.Retighten the two hex. head screws and check the adjustment.

Note: Depending on the envelope type and flap shape a different setting may be necessary.

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410.02-94 rev. 01.0 - 06/2004


410.03-1rev. 01.1 - 06/2004

Electrical


410.03-2 rev. 01.1 - 06/2004


410.03-3rev. 01.1 - 06/2004

Contents

Section Page

1 Electronic hardware 51.1 Circuit description 51.2 Test points 231.3 Jumper settings 241.4 LED information 24

2 Service menu 262.1 General 262.2 System setting 292.3 Configuration 292.4 Localisation 302.5 Software versions 302.6 Folder settings 312.7 Reset data 312.8 Power up 322.9 Job settings 322.10 Document offset 322.11 BRE offset 332.12 Secure jobs 342.13 Flap closer 342.14 Service tests 352.15 Photocells 352.16 Digital inputs 372.17 Actuators 382.18 Run in 402.19 DFC test 402.20 Keyboard/display 412.21 Counters 412.22 OMR 422.23 OMR code definition 422.24 Read code test 43

3 Error messages and error handling 46


410.03-4 rev. 01.1 - 06/2004


410.03-5rev. 01.1- 06/2004

1 Electronic hardware

1.1 Circuit description

GeneralAn important difference between previous machines with similar operational functionality and this machine is the fact that all electronics are present on one main board. The main board 98.90.01 houses two controllers. An 8-bit controller handles the inserting functionality and the user interface. A 16 bit controller handles the feeding, reading and folding functionality.Both the 8-bit machine software and the 16-bit machine software are located in flash ROM. With the help of external Windows-based software the machine software can be placed, and subsequently updated.Figure 1.1 shows an overview of the machine-wide electronics. The schematics of the main board 98.90.01 are divided into 12 sheets (figure 1.2 through figure 1.13). The components are numbered xyy; x is the sheet number, yy a number between 01 and 99.The component layout of figure 1.14 assists in locating connectors, test points, jumpers and LEDs.

Processor and memory (16-bit)The 16-bit processor XA-S3 (U610) has 32 kilobytes of internal program code. This code determines, based on certain RS232-communicated information from the pc with the Windows-base software, whether communication with that pc or normal operation, i.e. executing the 16-bit machine software in flash ROM (U630), is relevant.The system operates with 64 kilobytes of system RAM (U620 & U621). If in stead of the operational machine software the external Windows-based must operate, to this volatile memory program code is up loaded (i.e. software 'flashing' the flash ROM, thereby updating the machine software for passing the same files through to an upstream device; this program code is subsequently executed.The so-called emulation RAM (U640 and U641) is only used for R&D development; normally these two chips are not encountered in any field service situation.The processor operates with process-related I/O information by writing data to the chips U700 and U710 (U710 controls the feeder/folder clutches CL1…CL5), and reading data from the chip U720 (U720 receives digital versions of the outputs of the feeder/folder photocells PH1…PH6). These chips are addressed by so-called memory-mapped I/O, via the signals 16b_DigOutput1 and 16b_DigOutput 2 (writing) and 16b_DigInput1 (reading) from the PAL chip U670.

Processor and memory (8-bit)The 8-bit processor U201 executes the 8-bit machine software which is present in the flash ROM U230. The processor operates with 32 kilobytes of system RAM (U250).The 8 kilobytes of non-volatile memory (U210) are used to store hardware and job related information.In addition to the 8-bit processor the CPLD U240 (Complex Programmable Logic Device) is present for a variety of functions. One of these functions is bank switching. Note that the 8-bit controller can address 64 kilobytes of program memory and that the flash ROM has 512 kilobytes of memory. The CPLD is used to dynamically assign a part of the 8-bit machine software in flash ROM to be executed by the 8-bit processor U201. The CPLD also has an important function in the situation when machine software is placed or updated, in stead of the normal situation of executing the machine software.CommunicationThe 8-bit controller (inserter and user interface) and the 16-bit controller (feeding, reading and folding) talk to each other via the local SCS bus, consisting of the signals SCS_SCL and SCS_SDA. This machine has no SCS connection with the outside world.


410.03-6 rev. 01.1- 06/2004

In addition both controllers have the signal MAIN_PDISC in common. On this signal all timed processes are based. This signal is produced by slotted photocell SPH1, which monitors pulse disc PD1, which on its turn is driven by the main motor M1.Communication between the machine and the outside world is based on serial (RS232) communication. This communication is necessary for placing/updating machine software and possibly for other tasks. The RS232 data on the 9-pole RS232 connector goes to and from the RS232 driver U260. The CTS and RTS lines are only connected with the 8-bit controller. With the RS232 multiplexer either the 8-bit RX and TX signals or the 16-bit RX and TX signals are passed through to U260. This is necessary to place or update both the 8-bit and 16-bit machine software in one machine session.

Power supplyThe machine is powered by a 24 volt switched power supply unit. This eliminates the use of a heavy mains frequency-operated power transformer. From the 24 V a 5 V supply VCC is derived with the switching voltage regulator U110. U120 takes care for the -12 V supply voltage. The ADCs in the 16-bit processor U610 require a separate positive supply voltage AVDD (2.95 V). This voltage is derived from VCC by voltage divider R140 and R141, followed by voltage follower U140B.

PhotocellsThe transmitter (TX) currents for the four inserter paper photocells (PH7…PH10) are driven by the outputs of the Digital to Analogue Converter (DAC) U550. The analogue outputs of the photocell receivers (RX) are fed to ADC (Analogue to Digital Converter) inputs of the 8-bit processor U201. In this way a processor-controlled control circuit ensures that dust on the photocells is compensated for by an increase in the transmitter current. Control activity occurs if the photocells do not 'see' paper. The control of the transmitter current occurs in both directions; the current can be increased in case of dust build up and it can be decreased when dust falls off.The transmitter (TX) currents for the six feeder/folder photocells (PH1…PH6) are driven by the outputs of the Digital to Analogue Converter (DAC) U800. The analogue outputs of the photocell receivers (RX) are fed to the analogue multiplexer U701. Its output (16b_Multiplexed_AD4) is fed to an ADC input (Analogue to Digital Converter) of the 16-bit controller U610. In addition to this digital versions of the six RX signals are fed to the input chip U720. These signals are necessary to obtain timely process information.

Cover switchesThe three cover microswitches MS3 (wired to the motor and relay board 97.55.00/97.55.40), MS1 (J100) and MS2 (J101) are connected in series and pass their information to the system connector. The state of these microswitches is also passed to the processor via the signals 8b_TOP_COVER, 8b_SIDE-COVER and 8b_COLLATOR_COVER. If at least one of the three machine covers is opened, mechanical drive for the machine is immediately interrupted.

MotorsThe main motor M1 provides mechanical drive to all moving items (except the moving collator items) of the machine. This motor is switched on and off via the motor relay RE1 on the motor relay board 97.55.00 (230 V)/97.55.40 (115 V). The motor relay is controlled by the processor via the signals 8b_MOTOR_RELAY and 8b_START_RELAY from the 8-bit controller U201. For a sufficient starting torque a capacitor is temporarily switched in parallel with motor capacitor. After reaching a certain rpm rate (monitored by slotted photocell SPH1 via pulse disc PD1) the start relay is switched off. If the motor doesn't reach its nominal rpm rate within one second, it is switched off and an error message is issued.The motor is thermally protected against overheating due to mechanical blocking.


410.03-7rev. 01.1- 06/2004

A chain of three microswitches is included in series with the motor relay powering circuit. If this chain is broken by opening at least one of the safety covers, the motor relay current is immediately blocked or interrupted. This happens irrespective of the status of the two motor control signals mentioned above. The motor stops immediately or doesn't start at all. Thus no potentially unsafe human contact with moving parts is impossible.The collator motor M2 is a DC motor than can and will turn in two directions. M2 is pulse-width-controlled via chip U1110. The speed is controlled via a feedback circuit with slotted photocell SPH2, which monitors pulse disc PD2, which on its turn moves in line with M2.

Flag switch FS1The optical flag switch FS1 in the sealing track is based on a pawl which, when triggered by the leading edge of passing filled envelope, interrupts the infrared beam between a photo diode and a photo transistor. It starts a pulse count for determining the time at which the upper reverse roller is lowered to start the sealing process. After the trailing edge of the envelope has passed, the pawl returns to its rest position by spring action.Clutches and SolenoidsClutch CL6 in the inserter part of the machine is driven by the driver chip U440. The three solenoids in the inserter part are driven by transistor Q440A (finger solenoid So1), Q440B (eject solenoid So2) and Q450B (sealing solenoid So3).The three feeder clutches (CL1, CL2 and CL3) in the feeder/folder part are driven by driver chip U970. The two folder clutches (CL4 and CL5) are driven by the driver chip U1020.

DFCEach feeder has a DFC unit. (DFC stands for Double Feed Control.) This unit produces an output voltage which is proportional with the measured paper thickness. The three DFC output voltages are processed with the circuits on sheet 5/12. The amplified DFC output voltages are fed to the ADC chip U730 via the analogue multiplexer U731. The ADC output signal is communicated to the 16-bit processor via the signals 16b_AD_CS, 16b_AD_DAT and 16b_AD_CLK. The reference voltage AVREF for the ADC chip is derived from the VCC voltage by a voltage divider with R733 and R734.For a correct operation of the DFC units an offset voltage is necessary. The three voltages are supplied by the DAC U980, which is controlled by the 16-bit controller via the signals 16b_DAC2_CS, 16b_DAC_DATA and 16b_DAC_CLK.

OMRThe OMR electronics are shown in sheet 12/12. Two OMR output voltages (16b_ReadHead_Ana0 and 16b_ReadHead_Ana1) are fed to an ADC input of the 16-bit processor via the analogue multiplexer chip U701. The DAC U980 supplies two offset voltages (16b_ReadHead_DAC0 and 16b_ReadHeadDAC1). Output chip U700 supplies two signals (16b_ReadHead_S1 and 16b_ReadHead_S2) for setting the amplification.

Keyboard and displayThe 8-bit controller handles the control of both the keyboard and the display. Sheet 3/12 shows the interface electronics. As the main board 98.90.01 is also used for other machines, two connectors (J300 and J330) are available.


410.03-8 rev. 01.1- 06/2004

410.03-9rev. 01.1 - 06/2004


figure 1.1 Total view of the electrical and electronic circuits, including external connections and sensor/actuator connections.

DRAWN:

DATE:

FILE:

SCALE:

CODE:REV.

0011-12-2003

989008.dsn

989008J. Pijpker

6

TABLE1

RPM

432

FEED

1

FOLDINGTABLE2

RPMFOLDING

CURVEDISCFOLDINGTABLE1

READINGHEAD

5

989001

PHCEL COLLATOR

FEEDER2

FEEDER3

FEEDER1

MAXI FEEDER

COLLATOR

UNIT POWER

REAR SIDE ACTUATORS

LOC

CLOSER

ORION

MAIN PDISC

EXIT PHCELS

FOLDERS

ENV TRACK PHCELS

ENV TRACK TX

ENV TRACK RX

J330

LCDLCDLCDLCDLCD

J230

J450

SOLENOIDSEALING

J460

SOLENOIDEJECT

LOC TX

J440

COLLATOR

COLLATORMOTOR

COL TX

FOL TX

FOL RX

COL RX

VT TX

FLAP TX

FLAP RX

LOC RX

J580

J540

EXIT TX

EXIT RX

SEALING

5 6432

FEED

15 6432

FEED

1

L

MAINS LEAD

989052989051

UKUSAEURO

989053

COUNTRY SPECIFIEDPLUG TYPE:

230V: 2.5 A

N

INCLUDES: MAINS FUSE110V: 5 A

POWER INLET 989005

M

74

72

J1

1

52

54

124J3

1

55

51

Capacitor:

73

TOP COVER SIDE COVER

SIDE COVERSWITCH

TMU 1

790171TOPDFC FEEDER1

TMU 2

790171MIDDLEDFC FEEDER2

TMU 3

790171BOTTOMDFC FEEDER2FINGERS

ENV. TRACK

J300

DISPLAY

J100 J101

READING HEAD

J1200

TOP COVERSWITCH

J1000

J500

J1050 J900

J930

J950

J1100

J1110

J102

989026WIRING

RPM

SOLENOID

FLAGSWITCH

J740DONGLE

MAIN PDISC

MAXI FEEDER

CURVEDISCFOLDINGTABLE2

989028 WIRING

989032 WIRING 3X

Motorboard

975540 - 115V

COLLATORSWITCH

989018WIRING

OPTIONAL

989024WIRING

821622

975505

989408

989003

CL1 CL2 CL3

PH1 PH2 PH3

DFC1 DFC2 DFC3

***

***

Only if MAXIBRE feederis installed.

***

Only if OMRIis installed.

**

**

**

**

SPH1

PH10

PH10

PH9

PH8

PH8

PH7

PH7

PH4

PH6

PH6

PH5

SPH2

M2

PH5

NeoFlashConnection

MS3

MS2

MS1

RH1

SPH3

PH4

SPH4CL4 CL5

So1

CL6

PH9

So2

So3

+ 24 V

GND

MF-2

VT RX

Fs1

975500 - 230V

RUN

START

230V: 5µF (989006)110V: 20µF (121281)

* Only for 2½station machine

*FEEDER1 FEEDER2 FEEDER3

989002

SWISS 989054AUSTRAL989055

12

123

123

12

12

12345

FEEDER3

12345678910

123456

21

L

N(AC)

COM

+V

+V

+VADJ

POWER SUPPLY

INPUT: 100 - 120 VAC 3.15A 200 - 240 VAC 1.5A 50/60 Hz

OUTPUT: + 24 V 4.5A

COM

12345678

2 1

12

21

M

1 2 3 4 5 6 7 8

123456789

10

2 1

12

21

21

12

CONNECTOR D9 FEMALE

594837261

1 2

1234

1

2

4

12345

21

12

1

23 4

5

6

7

21

21

1

2

4

12

2 1

12

123456789

101112

FEEDER2

12345678910

2 1

21

2 1

12

12

12345678

2 1

123

12

123456789

101112

FEEDER1

12345678910

12

123456789

10

12345678910

1

2

4

410.03-10 rev. 01.1 - 06/2004


figure 1.2 Main board 98.90.01 electronics: sheet 1 of 12.

COVERTRACK2

COVERTRACK1

POWER_DOWN

8b_COLLATOR_COVER

8b_MOTOR_RELAY

8b_START_RELAY

RS232_RTS

RS232_CTSRS232_TXD

RS232_RXD

8b_SIDE_COVER

8b_TOP_COVER

GND

-12V

VCC

GND

PGND

GND GND GNDGND

CASE

GND

GNDGND GND

VCC AVDD

GND GND

GNDGND GND

VCC 24V

PGND

24V

GND

PGND

GND

GNDGND

GND

PGND PGND

PGND PGND

GND

PGNDGND

24V

CASE

GND

VCC

GND

VCC

VCC_OUT

VCC

24V

24V

+12V

GNDGND

Keep 4mm clearsurrounding thistestpin.

MOUNTINGHOLE

P-CHANNEL

2.95V

(sht 2)

Power down interrupt

5V power supply

-12V power supply

+12V power supply

AVDD power supply

Coverswitches

Unitpower

(sht 2)

(sht 2)

(sht 2)

(sht 2)

(sht 2)

(sht 2)

+24 VoltPGNDCOVER out

Motor run relaisMotor start relaisPower GNDRS232 RTSRS232 RXDRS232 CTSRS232 TXDRS232 GND

COVER in

Sidecover

Topcover

40mSec time leftfor uC after interrupt

C115100nF

R13156R

R1181K

R1024K7

Q100BC817

1

23 C121

100nF

TP100GND

R15010K

R1133K6

F1013A

+

-

U140ALM358

3

21

84

R1044K7

R1416K8

R1051K

F1003A

MH100

R1011K

R1161K

TP120-12V

C124100nF

CO10010nF

SR

Q&

IpkCtosc

U ref +-

U110MC34063

8

7

6

3

4

5

1

2

C112 150pF

R1143K6

C1511nF

C116100nF

R13056R

C1501nF

D120BAT54S

2 1

3

R1031K

600RL111

R153100R

R1074K7

J100

JST3

123

C140100nF U120

79L12

VIN2VIN3

GND

5

VIN6VIN7

VOUT 1

C10210nF

D13012V

C11110nF

600RL114

C113150pF

600RL113

Q111BC807

1

23

CO140100nF

C110470uF

R1113K6

R152100R

U100A

74HC14

12

J102

JST12

123456789101112

+

-

U140BLM3585

67

TP130+12V

C10010nF

R1544K7

C122100nF

R1084K7 U100B

74HC14

34

C125100nF

C123100nF

J101

JST3

123

R1511K

Q101BC817

1

23

R1123K6

R11756R

C130100nF

600RL112

C1142200uF

Q112IRFR9024

3

1

2

Q110BC817

1

23

R1151K

C120100nF

R14256R

R1064K7

R1553K6

C11722µF

TP110VCC

R1094K7

R1404K7

R1004K7

C10110nF

D111STPS340U2

1

R1100R1

L110150uH

410.03-11rev. 01.1 - 06/2004



8b_AD4

8b_AD5

8b_AD5

8b_AD58b_AD6

8b_AD6

8b_AD6

8b_AD0

8b_AD3

8b_AD7

8b_AD1

8b_AD0

8b_AD5

8b_AD4

8b_AD1

8b_AD3

8b_AD2

8b_AD7

8b_AD0

8b_AD2

8b_AD1

8b_AD1

8b_AD2

8b_AD48b_AD0

8b_AD2

8b_AD0

8b_AD3

8b_AD3

8b_AD4

8b_AD1

8b_AD7

8b_AD2

8b_AD7

8b_AD6

8b_AD3

8b_MUA3

8b_MUA4

8b_MUA15

8b_MUA13

8b_MUA2

8b_MUA3

8b_MUA8

8b_MUA14

8b_MUA5

8b_MUA3

8b_MUA12

8b_MUA2

8b_MUA6

8b_MUA13

8b_MUA10

8b_MUA3

8b_MUA5

8b_MUA10

8b_MUA7

8b_MUA8

8b_MUA12

8b_MUA2

8b_MUA14

8b_MUA4

8b_MUA15

8b_MUA11

8b_MUA8

8b_MUA6

8b_MUA11

8b_MUA11

8b_MUA7

8b_MUA12

8b_MUA1

8b_MUA14

8b_MUA13

8b_MUA14

8b_MUA0

8b_MUA10

8b_MUA4

8b_MUA9

8b_MUA18b_MUA0

8b_MUA9

8b_MUA9

8b_MUA5

8b_MUA7

8b_MUA1

8b_MUA6

8b_MUA15

8b_MUA08b_MUA1

8b_MUA12

8b_MUA0

8b_MUA13

8b_MUA2

8b_ALE

8b_PSEN

8b_CPU_RESET

8b_AD[0..7]

8b_ALE

8b_AD[0..7]

8b_MUA[8..15]

8b_AD[0..3]

8b_CLK_22MHz

8b_CLK_22MHz

8b_PSEN

8b_NWR8b_NRD

8b_CPU_RESET

8b_MUA[0..14]

8b_DIS_18b_DIS_2

8b_DIS_3

8b_NWR8b_NRD

SCS_SCL

8b_SCL_SIM

8b_ENV_TRACK_INT

MAIN_PDISC8b_CLOSERCEL

8b_START_RELAY

8b_MOTOR_RELAY8b_RPM_ENV_TRACK

8b_SEALING_SOL8b_OnDeck_SOL

8b_ANA_FLAP8b_ANA_EXIT8b_ANA_LOC

8b_ANA_ILED

8b_ANA_ENV

8b_RTS

SCS_SDA

8b_COLLATOR_COVER

8b_SDA_SIM

8b_CTS

8b_RPM_STACKER

8b_FINGER_SOL

8b_EJECT_SOL

8b_RXD16b_RXD0

8b_RS232_MUX

8b_RS232_MUX

8b_RTS

8b_CTS

8b_SCL_SIM

8b_SDA_SIM

POWER_DOWN

8b_TXD16b_TXD0

RS232_RXD

RS232_TXD

8b_FRAM_WP

8b_FRAM_WP

16b_OTP_SEL

RS232_CTS

RS232_RTS

8b_DISDIR

8b_MUA[0..14]

8b_DISBUF_OE

8b_TXD8b_RXD

8b_SIDE_COVER8b_TOP_COVER

8b_ORION_KB_RD8b_DISBUF2_OE

8b_AD[0..7]

8b_NWR

8b_AD[0..7]

8b_NWR8b_PSEN

8b_MUA[0..14]

8b_MUA[0..15]

8b_MUA[0..7]

RESET_XA16b_RSTINn

GND GND

VCC

GND

VCC

GND

GND

GND

VCC

VCC

VCC

GND GND

GND GND

GND GND

GND

VCC

GND

VCC

GND

GND

VCC

GND

GND

GND

GND

VCC

VCC+12V

VCC VCC

GND

VCC

VCC

VCC

GND

GND

GND

DATA/ADRESS BUS Latch

CPLD

RS232 driver

8 Kbyte FRAM

(sht 4)

(sht 4)

(sht 5)

(sht 4)

(sht 6)

(sht 5)

(sht 4)

(sht 4)

(sht 5)

(sht 1)

(sht 5)(sht 1)

(sht 5)

RS232 MUX

(sht 6)

(sht 3)

(sht 3)

(sht 6)

(sht 1)

TESTLED

CPLDIn circuitprogrammingconnection

(sht 6)

(sht 1)

(sht 5)

(sht 1)

(sht 1)

(sht 3)

ram_OE

FLASHWRITE8bit

(sht 3)

512Kbyte FLASH ROM

32Kbyte RAM

BS_A15

BS_A18BS_A17BS_A16

flash_CE

(sht 6)

FLASHRUN8bit

CPU

R208100R

J240

HEAD8

12345678

R2051K

D241GREEN

D240RED

C203100nF

U22074HC573

D12 Q1 19D23 Q2 18D34 Q3 17D45 Q4 16D56 Q5 15D67 Q6 14D78 Q7 13D89 Q8 12

C11OC1

VCC

20GND

10

TP2008b_TST

U25062256HF

A010A19A28A37A46A55A64A73A825A924A1021A1123A122A1326A141

CS120WE27OE22

D0 11D1 12D2 13D3 15D4 16D5 17D6 18D7 19

VCC

28GND

14

R242 150R

C260 100nF

R20156R

X20022.118MHz

CO20110nF

R2104K7

R206100R

CO26010nF

CO21010nF

R2091K

R207100R

R202100R

CO240110nF

R2604K7

R2201K

CO23010nF

C20022pF

R2114K7

D200GREEN

U26174HC4052

X0 12X1 14X2 15X3 11

Y0 1Y1 5Y2 2Y3 4

INH 6

A 10B 9

X13

Y3 VCC

16GND

8GND

7

U20180C552

P0.0 57P0.1 56P0.2 55P0.3 54P0.4 53P0.5 52P0.6 51P0.7 50

P2.0 39P2.1 40P2.2 41P2.3 42P2.4 43P2.5 44P2.6 45P2.7 46

(RXD) P3.0 24(TXD) P3.1 25(INT0) P3.2 26(INT1) P3.3 27(T0) P3.4 28(T1) P3.5 29(WR) P3.6 30(RD) P3.7 31

(CMSR0) P4.0 7(CMSR1) P4.1 8(CMSR2) P4.2 9(CMSR3) P4.3 10(CMSR4) P4.4 11(CMSR5) P4.5 12(CMT0) P4.6 13(CMT1) P4.7 14

(ADC0) P5.0 1(ADC1) P5.1 68(ADC2) P5.2 67(ADC3) P5.3 66(ADC4) P5.4 65(ADC5) P5.5 64(ADC6) P5.6 63(ADC7) P5.7 62

XTAL135

XTAL234

RST15

PSEN47

ALE48

EA49

EW6

PWM04

PWM15

STADC3 AVREF+59

AVREF-58

VCC

2GND1

36

AVSS60

AVDD61

GND2

37

(INT2/CT0I)P1.0 16(INT3/CT1I)P1.1 17(INT4/CT2I)P1.2 18(INT5/CT3I)P1.3 19

(T2) P1.4 20(RT2) P1.5 21(SCL) P1.6 22(SDA) P1.7 23

CO26110nF

U23029F040

A012A111A210A39A48A57A66A75A827A926A1023A1125A124A1328A1429A153A162

CE22OE24

A181

D0 13D1 14D2 15D3 17D4 18D5 19D6 20D7 21

VCC

32GND

16

A1730

WE#31

U260MAX232ACSE

R1IN13R2IN8

T1IN 11T2IN 10

C+ 1C1- 3C2+ 4C2- 5V+ 2V- 6

R1OUT 12R2OUT 9

T1OUT14T2OUT7

VCC

16GND

15 C240 10nF

C20122pF

R2401K

U210FM24C64

SDA5

SCL6

VCC

8

A0 1A1 2A2 3G

ND

4

WP7

C261 100nF

CO22010nF

R2041K

C20222µF

CO25010nF

R2411K

R203100R

U300D74HC14

9 8

U240M4A5-64/32

GND

1

I/O02I/O13I/O24I/O35I/O46I/O57I/O68I/O79

GND

12GND

23GND

34

TDI 10

TCK 13TMS 32

TDO 35

CLK0/IO11

CLK1/I133

VCC

44

VCC

22

I/O814I/O915I/O1016I/O1117I/O1218I/O1319I/O1420I/O1521

I/O16 24I/O17 25I/O18 26I/O19 27I/O20 28I/O21 29I/O22 30I/O23 31

I/O24 36I/O25 37I/O26 38I/O27 39I/O28 40I/O29 41I/O30 42I/O31 43

CO240010nF

C263100nF

C262 100nF

410.03-12 rev. 01.1 - 06/2004



8b_AD4

8b_AD1

8b_AD6

8b_AD3

8b_AD7

8b_AD2

8b_AD0

8b_AD5

8b_AD3

8b_AD08b_AD1

8b_AD6

8b_AD2

8b_AD48b_AD5

8b_AD7

8b_ORION_KB_RD

8b_DISDIR

8b_NRD8b_NWR

8b_DIS_18b_CPU_RESET

8b_DISBUF_OE

8b_AD[0..7]

8b_AD[0..7]

8b_DIS_28b_DIS_3

8b_DISBUF2_OE

GNDGND

VCC_OUT

GND GND

GNDGND

VCC_OUTVCC_OUT

VCC VCC VCC VCC VCC VCC

GND

VCC

GNDGND GND GND GND GND GND

GND

VCC

VCC_OUT

GND

VCC_OUT

GND GND

VCC

VCC

GND

GND

VCC

GND GND

VCC

GND

VCC

GND

VCC

GND

VCC

GNDREAD DISP.RESET DISP.WRITE DISP.

ORION LCD connection

C/D DISP.CE DISP.

SI68 LCD connection

(SHT 2)

Orion keyboard readout

(SHT 2)

(SHT 2)

(SHT 2)

(SHT 2)

CO32010nF

600R

L332R331

100R

R337

100R

JP321SEL0

R30810K

U300B74HC14

3 4

R3901K

U300F74HC14

13 12

R31410K

CO33010nF

R332

100R

J300

CONBOX26

135791113151719212325

2468101214161820222426

600R

L333

R317

100R

C303150pF

U33074HC244

1A12 1Y1 181A24 1Y2 161A36 1Y3 141A48 1Y4 122A111 2Y1 92A213 2Y2 72A315 2Y3 52A417 2Y4 3

1G 12G 19

VCC

20GND

10

R31210K

600R

L335

COJ330100nF

R316100R

R306 100R

COJ300100nF

R342

100R

R340

100R

JP320SEL1C306

150pF

600R

L330

R333

100R

600R

L342J330

MicroMatch20

135791113151719

2468101214161820

U33174HCT245

A1 2B118A2 3B217A3 4B316A4 5B415A5 6B514A6 7B613A7 8B712A8 9B811

G 19DIR 1

VCC

20GND

10

600R

L341

R338

100R

R31010K

600R

L334

600R

L340

U300A74HC14

12

600R

L339

R31510K

600R

L338

600R

L337

600R

L336R336

100R

CO30010nF

C301150pF

C304150pF

R31310K

R30910K

R301 100R R304 100R

U32074HC244

1A12 1Y1 181A24 1Y2 161A36 1Y3 141A48 1Y4 122A111 2Y1 92A213 2Y2 72A315 2Y3 52A417 2Y4 3

1G 12G 19

VCC

20GND

10

R334

100R

600R

L331

R305 100R

R330

100R

CO33110nF

600R

L343

R335

100R

R302 100R

R300 100R

R341

100R

C302150pF

C305150pF

R31110K

R339

100R

410.03-13rev. 01.1 - 06/2004



8b_OnDeck_SOL

8b_SEALING_SOL

8b_EJECT_SOL

8b_RPM_STACKER

8b_RPM_ENV_TRACK

16b_DigClutch_FoForward

16b_DigClutch_FoReverse

8b_FINGER_SOL

8b_TX_LOC

8b_CLOSERCEL

PGND

PGND

PGND

PGND

PGND

PGND

PGND

PGND

PGND

PGND

24V24V

24V

24V

24V

24V

24V

PGND

24VVCC_OUT

GND

GND

VCC

VCC

Pres. on deck solenoid

Sealing solenoid

Eject solenoid

TX loc-cel

(sht 2)

(sht 2)(sht 2)

(sht 7)

(sht 5)

Closercel

LOC

CLOSER

RPM env. track

RPM stracker

finger sol.

RPM FoReverse

RPM FoForward

Rearsideactuators

C470150pF

U100F

74HC14

13 12

R45056R

C46010nF

D441STPS340U 2

1

U100D

74HC14

9 8

U440ULN2003L

I1 1I2 2I3 3I4 4I5 5I6 6I7 7G

ND

8COM

9

O116O215O314O413O512O611O710

D451STPS340U2

1

Q450ASI4946EY2

81

7

Q450BSI4946EY4

63

5

D460STPS340U2

1

C441100nF

C44010nF

C442470uF

R4714K7

R44056R

J450

JST8

12345678

U100C

74HC14

56C45110nF

R45256RU100E

74HC14

11 10

R4721K

C45010nF

R46056R

J440

JST10

12345678910

Q440BSI4946EY4

63

5

U300E

74HC14

1110

D44012V

D450STPS340U2

1

J460

JST4

1234

R470150R

Q440ASI4946EY 2

81

7

410.03-14 rev. 01.1 - 06/2004



8b_ANA_ILED

8b_SCL_SIM8b_SDA_SIM

8b_ANA_ENV

8b_ANA_LOC

8b_ANA_FLAP

8b_ENV_TRACK_INT

8b_TX_LOC

MAIN_PDISC

8b_ANA_EXIT

+12V

GND GND

GND

VCC

GND

VCC_OUT

VCC_OUT

GND

GND

VCC_OUT

VCC_OUT

VCC_OUT

GND

GND

GNDGND

VCC

+12VVCC

GND GND

VCC VCC

GND

VCC

GND

VCC

GND

VCC_OUT

GND

VCC_OUT

EXIT RX

EXIT TX

FLAP TX

FLAP RX

LOC RX

EXIT

LOC

FLAP

ENV_TRACK

ENV_TRACK RX

ENV_TRACK TX

(sht 4)

(sht 2)

(sht 2)

(sht 2)

(sht 2)

(sht 2)

(sht 2)

(sht 2)

(sht 2, 6)

EnveloppeTrackphotcells

Exitphotocell

MainPulsDisc

Uout = 11 x I

3.98V

MAIN PDISC

R5554K7

R5831K

R5908K2

Q553BC817

1

23

C53010nF

R5931K

Q551BC817

1

23

TP510ENV

R559 68K

R55082R

R54010K

C550100nF

R570 100K

R5544K7

D580GREEN

R52010K

R59168K

R5314K7

C5901nF

R5424K7

R5714K7

+

- U590ALM358

3

21

84

R55610K

TP530LOC

R561 68K

J580

JST5

12345

R55182R

R5414K7

CO550100nF

R51010K

R563 68K

TP520FLAP

C52010nF

CO560100nF

R5721R

Q550BC817

1

23

R5821K

Q552BC817

1

23

R5814K7

R55739K

U300C74HC14

5 6

R565 68K

R580150R

TP540EXIT

R55282R

R560 1K

C51010nF

U550TDA8444T

DAC09DAC110DAC211DAC312DAC413DAC514DAC615DAC716

N.C. 5A0 6A1 7

SCL 4SDA 3

VMAX 2GND

8VP

1

R521100R

C54010nF

R562 1K

R5731R

R53010K

+

-

U590BLM3585

67

R5921K

C580150pF

J540

JST5

12345

R55382R

R522100R

R558 1K

R564 1K

R5111K

J500

JST10

12345678910

C570 10nF

410.03-15rev. 01.1 - 06/2004



16b_MUA7

16b_MapWRn

16b_MUA5

16b_MUA216b_MUA1

16b_MUA316b_MUA4

16b_MUA6

16b_Reboot

16b_Map1

16b_MUA816b_MUA9

16b_MUA13

16b_MUA1516b_MUA14

16b_MUA1216b_MUA1116b_MUA10

16b_Map0

16b_Map0

16b_MUA19

16b_Map1

16b_MUA16

16b_MUA1

16b_MUA15

16b_MUA1816b_MUA17

16b_MUA2

16b_R.en.D

16b_MUA7

16b_MUA5

16b_MUA216b_MUA1

16b_MUA316b_MUA4

16b_MUA6

16b_MUA816b_MUA9

16b_MUA13

16b_MUA1516b_MUA14


16b_MUA7

16b_MUA5

16b_MUA216b_MUA1

16b_MUA316b_MUA4

16b_MUA6

16b_MUA816b_MUA9

16b_MUA13

16b_MUA1516b_MUA14


16b_MUA16

16b_MUA1816b_MUA17

16b_MUA13

16b_MUA1516b_MUA14

16b_MUA12

16b_MUA7

16b_MUA516b_MUA4

16b_MUA6

16b_MUA816b_MUA9

16b_MUA1116b_MUA10

16b_MUA16

16b_MUA1816b_MUA17

16b_MUA19

16b_MUD0

16b_MUD3

16b_MUD11

16b_MUD11

16b_MUD8

16b_MUD0

16b_MUD2

16b_MUD10

16b_MUD6

16b_MUD0

16b_MUD3

16b_MUD14

16b_MUD3

16b_MUD13

16b_MUD9

16b_MUD9

16b_MUD6

16b_MUD0

16b_MUD7

16b_MUD10

16b_MUD13

16b_MUD9

16b_MUD9

16b_MUD15

16b_MUD2

16b_MUD2

16b_MUD4

16b_MUD11

16b_MUD6

16b_MUD5

16b_MUD4

16b_MUD15

16b_MUD1

16b_MUD4

16b_MUD12

16b_MUD2

16b_MUD14

16b_MUD1

16b_MUD10

16b_MUD14

16b_MUD13

16b_MUD4

16b_MUD11

16b_MUD8

16b_MUD1

16b_MUD616b_MUD5

16b_MUD0

16b_MUD2

16b_MUD7

16b_MUD10

16b_MUD15

16b_MUD1

16b_MUD4

16b_MUD15

16b_MUD1

16b_MUD6

16b_MUD12

16b_MUD7

16b_MUD13

16b_MUD7

16b_MUD3

16b_MUD5

16b_MUD3

16b_MUD12

16b_MUD12

16b_MUD7

16b_MUD5

16b_MUD0

16b_MUD14

16b_MUD8

16b_MUD8

16b_MUD5

16b_MUA16

16b_MUA1816b_MUA17

16b_MUA7

16b_MUA5

16b_MUA216b_MUA1

16b_MUA316b_MUA4

16b_MUA6

16b_MUA816b_MUA9

16b_MUA13

16b_MUA1516b_MUA14


16b_MUA19

16b_MUA19

16b_MUA16

16b_MUA1816b_MUA17

16b_MUA7

16b_MUA5

16b_MUA216b_MUA1

16b_MUA316b_MUA4

16b_MUA6

16b_MUA816b_MUA9

16b_MUA13

16b_MUA1516b_MUA14


16b_MUD8

16b_MUD10

16b_MUD12

16b_MUD9

16b_MUD1416b_MUD13

16b_MUD15

16b_MUD11

16b_MUD1

16b_OTP_SEL

16b_RSTINn

16b_WRLn16b_RAMCS2n

16b_OERAM1n

16b_RAMCS1n

16b_RSTINn

16b_MUD[0..1]

16b_ALE

16b_MUD[0..15]

16b_MUD[0..15]

16b_MUD[0..15]

16b_PSENn

16b_MUD[0..15]

16b_WRHn16b_FlashCSn

16b_MUA[1..19]

16b_FMUA19

16b_PSENn

16b_MUA3

16b_WRLn16b_RDn

16b_ALE

16b_WRHn16b_MUA1

16b_RSTINn

16b_MUA2

16b_MUA[4..19]

16b_OERAM1n

16b_RAMCS1n16b_WRHn

16b_WRLn

16b_MUA[1..19]

16b_WRHn16b_RAMCS2n

16b_ALE

16b_MUA[1..19]

16b_RDn

16b_PSENn

16b_RDn16b_WRLn

16b_RAMCS1n16b_FlashCSn

16b_RAMCS2n

16b_MUA[1..19]

16b_PWM_Collator16b_PWM_MaxiFeeder

16b_ReadHead_Ana1

MAIN_PDISC

16b_DongleCommunication

16b_PDisc_Collator

16b_AD_CS

16b_Multiplexed_AD416b_IledCheck

16b_CurveDisc_FT116b_CurveDisc_FT2

16b_AD_DAT16b_AD_CLK

16b_MUA[1..19]

16b_DAC_DATA16b_DAC_CLK16b_DAC1_CS

16b_FMUA19

16b_DigOutput116b_DigOutput2

16b_DigInput1

SCS_SCLSCS_SDA

16b_TXD016b_RXD0

16b_RSOUTn

16b_DAC2_CS

DfcMulPlex0

DfcMulPlex1

16b_TXD116b_RXD1

16b_RXD116b_TXD1

16b_OERAM1n16b_PSENn

DfcMulPlex2

SCS_SCLSCS_SDA16b_DEBUG116b_DEBUG2

RESET_XA

GNDGND

VCC

GND

VCC

AVDD

AVDD

VCCVCC

VCC

VCC

VCC

VCC

VCCVCC

VCC

VCC

VCC

VCC

VCC

VCC

VCC

VCC

VCC

GND

GND GND

GNDGND

GND

GND

GND

GND

GND

GND

GND

GND

GND

GNDGND

VCC

VCC

VCC

GND

GND

GND

GND

GND

GND

VCC

VCC

GND

GND

VCC_OUT

5V supervisor

Scratch jumper

LatchesOTP/FLASH selector

XA controller

64Kbyte system RAM

1Mbyte FLASH ROM

1Mbyte emulation RAM

(sht 6)

(sht 2)

(sht 2)

(sht 11)(sht 11)

(sht 5)(sht 11)

(sht 7)(sht 7)

(sht 8)

(sht 12)(sht 7)

(sht 8)

(sht 7)

(sht 10)

FLASH WRITE

TEST

MAP0

MAP1

(sht 7)

(sht 9)

(sht 7)

(sht 7)

(sht 7)

(sht 2)

DEBUG CONNECTION

(sht 2)

(sht2)

(sht 7)

CO61031uF

U641HM628512BLP-5

A18 1

A16 2A15 31

A12 4

A7 5A6 6A5 7A4 8A3 9A2 10A1 11A0 12DQ013DQ114DQ215

GND

16

DQ317DQ418DQ519DQ620DQ721

CS 22

A10 23

OE 24

A11 25

A9 26A8 27

A13 28A14 3

A17 30

WE 29

VCC

32

CO661

10nF

R6131K

C650100nF

U671B74HC74

D12 Q 9

CLK11

Q 8PR

10CL

13

VCC

14GND

7

U68174HC573


C11OC1

VCC

20GND

10

R6141K

CO6102

10nF

C671100nF

D672

GREEN

C653100nF

U660D74HC08

12 1311

C65222µF

JP610FLASH BOOT

R6501K

CO6100

10nF

U63029F800

A18 16

A16 48A15 1

A12 4

A7 18A6 19A5 20A4 21A3 22A2 23A1 24A0 25DQ029DQ131DQ233

GND

27


CE 26

A10 6

OE 28

A11 5

A9 7A8 8

A13 3A14 2

A17 17

WE 11

VCC

37

DQ830DQ932DQ1034DQ1136DQ1239DQ1341DQ1443DQ1545

RESET12 RY/BY15

GND

46

BYTE47

R6601K

R6001K

CO620

10nF

CO680

10nF

CO641

10nF

R610 56R

U600

OSC. 29.4912MhzVDD

4GND

2

OUT 3

OE 1

D671

RED

U62162256HF

A0 10A1 9A2 8A3 7A4 6A5 5A6 4A7 3A8 25A9 24A10 21A11 23A12 2A13 26A14 1

CS1 20WE 27OE 22

D011D112D213D315D416D517D618D719

VCC

28GND

14

U660A74HC08

1

23

U650TL7705A

CT3 SEN7 RESIN2

REF 1

RST 6RSET 5

U68074HC573


C11OC1

VCC

20GND

10

D630RED

R61110K

C651100nF

U660C74HC08

9

108

R60156R

R6701K

U610PXAS37KBBESOT315-1

XTAL168

XTAL267

AVDD28AVDD29AVREF+27AVREF-26AVSS30AVSS31

CLKOUT46ALE/PROG44PSEN45RSTOUT11RST47EA/WAIT/VPP16

P1.0/A0/WRH32P1.1/A133P1.2/A234P1.3/A335P1.4/RXD136P1.5/TXD137P1.6/T238P1.7/T2EX39

P3.0/RXD03P3.1/TXD04P3.2/INT05P3.3/INT16P3.4/T07P3.5/T1/BUSW8P3.6/WRL9P3.7/RD10

P4.0/ECI 73P4.1/CEX0 74P4.2/CEX1 75P4.3/CEX2 76P4.4/CEX3 77P4.5/CEX4 78P4.6/A20 79P4.7/A21 2

P5.0/AD0 17P5.1/AD1 18P5.2/AD2 19P5.3/AD3 20P5.4/AD4 22P5.5/AD5 23

P5.6/AD6/SCL 24P5.7/AD7/SDA 25

P6.0/A22 40P6.1/A23 41

P0.0/A4D0 42P0.1/A5D1 43P0.2/A6D2 48P0.3/A7D3 49P0.4/A8D4 50P0.5/A9D5 55P0.6/A10D6 56P0.7/A11D7 57

P2.0/A12D8 58P2.1/A13D9 59P2.2/A14D10 61P2.3/A15D11 62P2.4/A16D12 63P2.5/A17D13 64P2.6/A18D14 65P2.7/A19D15 66

VDD

71VDD

72VDD

52VDD

51VDD

14VDD

15

VSS

69VSS

70VSS

53VSS

54VSS

12VSS

13R612 10K

U660B74HC08

4 56

TP61016b_TST

U671A74HC74

D2 Q 5

CLK3

Q 6PR

4CL

1

VCC

14GND

7

R6721KCO660

10nF

C601100nF

CO671

10nF

CO621

10nF

D610GREEN

R6301K

CO600

10nF

R6801K

R6151K

CO681

10nF

J600

HEAD8

12345678

U67022V10PLCC

I1/CLK2I23I34I45I56I67I79I810I911I1012I1113I1216

O1 27O2 26O3 25O4 24O5 23O6 21O7 20O8 19O9 18O10 17

VCC

28GND

14

NC 1NC 8NC 15NC 22R6511K

CO670

10nF

U640HM628512BLP-5

A18 1

A16 2A15 31

A12 4

A7 5A6 6A5 7A4 8A3 9A2 10A1 11A0 12DQ013DQ114DQ215

GND

16


CS 22

A10 23

OE 24

A11 25

A9 26A8 27

A13 28A14 3

A17 30

WE 29

VCC

32

R6811K

R6521K

CO6101

10nF

R671680K

R6731K

JP670R&D

U62062256HF

A0 10A1 9A2 8A3 7A4 6A5 5A6 4A7 3A8 25A9 24A10 21A11 23A12 2A13 26A14 1

CS1 20WE 27OE 22

D011D112D213D315D416D517D618D719

VCC

28GND

14

CO630

10nF

CO640

10nF

C600150pF

410.03-16 rev. 01.1 - 06/2004



MU_AD_SEL0MU_AD_SEL1MU_AD_SEL2

16b_MUD616b_MUD7

16b_MUD0

16b_MUD4

16b_MUD2

16b_MUD5

16b_MUD3

16b_MUD1

16b_MUD616b_MUD7

16b_MUD0

16b_MUD4

16b_MUD2

16b_MUD5

16b_MUD3

16b_MUD1

16b_MUD616b_MUD7

16b_MUD0

16b_MUD4

16b_MUD2

16b_MUD5

16b_MUD3

16b_MUD1

16b_ReadHead_S016b_ReadHead_S1

16b_Multiplexed_AD4

16b_DIG_FCEL_FE116b_DIG_FCEL_FE216b_DIG_FCEL_FE316b_DIG_FCEL_COLL16b_DIG_FCEL_RH16b_DIG_FCEL_FO

16b_DigInput1

16b_MUD[0..7]

16b_RSOUTn16b_DigOutput2

16b_MUD[0..7]

16b_DigClutch_FO116b_DigClutch_FO216b_DigClutch_FoForward

16b_DigClutch_FoReverse

16b_DigClutch_FE1

16b_DigClutch_FE316b_DigClutch_FE2

16b_AD_CS

16b_AD_CLK

16b_DFC_FE116b_DFC_FE216b_DFC_FE3

16b_DIR_Collator

16b_DigOutput1

16b_MUD[0..7]

DfcMulPlex1DfcMulPlex0

16b_ANA_RX_Collator16b_ANA_RX_ReadHead16b_ANA_RX_Folder16b_ANA_RX_Feeder1

16b_ANA_RX_Feeder316b_ANA_RX_Feeder2

16b_ReadHead_Ana016b_ReadHead_Ana2

16b_DongleCommunication

16b_SwitchMaxiFeeder

16b_RSOUTn

16b_AD_DAT

DfcMulPlex216b_MaxiFeederDetect

16b_DEBUG116b_DEBUG2

16b_IledCheck

VCCVCC

VCC

GND

GND

GND

GND

GND

VCC

GND GND

VCC

GND

GND

GND

GND

VCC

VCC

GND GNDGND

VCC

GND

VCC

GND

VCC

GND

GND GND

VCC

AVDD

GND

GND GND GND

VCC VCC

Digital outputs

Digital inputs

10 bit ADC for DFC

(sht 6)

(sht 10)(sht 12)(sht 10)(sht 9)(sht 9)(sht 9)(sht 12)(sht 12)

(sht 10)(sht 10)(sht 4)

(sht 9)(sht 9)(sht 9)(sht 4)

(sht 9)(sht 9)(sht 9)(sht 10)(sht 12)(sht 10)(sht 11)

(sht 9)(sht 9)(sht 9)

(sht 12)(sht 12)

(sht 6)

Analog multiplexer

(sht 6)

(sht 11)

(sht 6)

(sht 8)

(sht 11)

JP730Inter. trans.

R7104K7

CO730010nF

CO73110nF

R73056R

D740BAT54S

21

3

R73256R

R74010K

U730LTC1197

CS1 +IN 2

-IN 3

GND

4VCC

8

CLK7

DOUT6 VREF 5

C7311nF

CO71010nF

R73510K

R72010K

Q710BC817

1

23

TP710WINDOW

U73174HC4051

X0 13X1 14X2 15X3 12X4 1X5 5X6 2X7 4

INH6

A11B10C9

X3 GND

8VCC

16

U70074HC273


CLK11CLR1

VCC

20GND

10

R73610K

CO72010nF

D700BAT54S

21

3

U70174HC4051

X0 13X1 14X2 15X3 12X4 1X5 5X6 2X7 4

INH6

A11B10C9

X3 GND

8VCC

16

JP731Spare

J740UCAN CLIP

2

1

U72074HC244

1A1 21Y1181A2 41Y2161A3 61Y3141A4 81Y4122A1 112Y192A2 132Y272A3 152Y352A4 172Y43

1G12G19

VCC

20GND

10

R741150R

R7341K

CO70010nF

JP720FE1-SEL

C730100nF

R711150R

R73156R

U71074HC273


CLK11CLR1

VCC

20GND

10

R7331K

CO73021uF

CO70110nF

CO730122µF

410.03-17rev. 01.1 - 06/2004



16b_DAC_DATA

16b_IledCheck

16b_TX_Feeder1

16b_TX_Feeder2

16b_TX_Feeder3

16b_TX_Collator

16b_TX_ReadHead

16b_TX_Folder

16b_DAC_CLK

16b_DAC1_CS

VCCVCC

VCC

GNDGNDGNDGND

VCC

GND GND

VCC VCC

GND

GND

3.98V

Current Sink

(sht 6)

Photocel DAC

(sht 9)

(sht 11)

(sht 10)

(sht 10)

(sht 6)Uout = 11 x I

R80010K

R8021K

Q803BC8171

2 3

+

-

U820ALM3583

21

84

R81182R

R81282R

U800MAX5258

DAC-A 2DAC-B 1DAC-C 16DAC-D 15DAC-E 7DAC-F 8DAC-G 9DAC-H 10

LDAC6

REF5

SCLK12 DIN13 CS11GND

3VDD

4

DOUT14

R8041K

R80882R

R8031K

CO820100nF

R8214K7

Q800BC8171

2 3

Q805BC8171

2 3

Q802BC8171

2 3

R81382R

R8051K

+

-

U820BLM3585

67

R8061K

R8221R

Q804BC8171

2 3

C800100nF

R820100K

C82010nF

Q801BC8171

2 3

R81082R

R8231R

R80982R

R8071K

CO800100nF

R80139K

R8251K

410.03-18 rev. 01.1 - 06/2004



FE1_DFC_OFFSET

FE3_DFC_OFFSETFE2_DFC_OFFSET

16b_DIG_FCEL_FE1

16b_DFC_FE1

16b_DigClutch_FE1

16b_DigClutch_FE2

16b_DigClutch_FE3

16b_ANA_RX_Feeder1

16b_DFC_FE2

16b_ANA_RX_Feeder2

16b_DIG_FCEL_FE2

16b_DFC_FE3

16b_ANA_RX_Feeder3

16b_DIG_FCEL_FE3

16b_Clutch_FE3

16b_Clutch_FE2

16b_Clutch_FE1

16b_DAC_DATA16b_ReadHead_DAC016b_ReadHead_DAC1 16b_DAC_CLK

16b_DAC2_CS

16b_Clutch_FE1

16b_TX_Feeder1

16b_Clutch_FE2

16b_TX_Feeder2

16b_Clutch_FE3

16b_TX_Feeder3

VCC_OUT +12V

PGND

+12V

GNDGND

VCC

GND

GND GND GND GND

GND

GND GND GND GND

GND

VCC

VCC

GND

GND GND

GND

GND

GND

GND

GND

GND

GND

GND

GND GND

GND

VCC VCC

VCC

GNDGND

VCC

GND GND

+12V +12V

GND

VCC

GND

+12V

GND

+12V

PGND

GND

GND

24V24V

VCC_OUT24V

VCC_OUT24V

Feeder-1

TX feeder-1

RX feeder-1

Clutch fe1

DFC feeder1

TX feeder-2

RX feeder-2

Clutch fe2

DFC feeder2

Feeder-2

TX feeder-3

RX feeder-3

Clutch fe3

DFC feeder3

Feeder-3

3.98V

(sht 6)

(sht 7)

(sht 7)

(sht 7)

(sht 7)

(sht 12)

Pulls BusWidthselect of XA high

(sht 7)

(sht 7)

(sht 7)

R90610K

TP950FE-3

R9141K

C970100nF

R9341K

R9651K

R91139K

R9625K6

C912100nF

TP960DFC FE3

R9048K2

CO900100nF

R9538K2

+

- U930ALM358

3

21

84

R94139K

C93010nF

R98239K

R9405K6

R9001K

U980MAX5258

DAC-A2DAC-B1DAC-C16DAC-D15DAC-E7DAC-F8DAC-G9DAC-H10

LDAC 6

REF 5

SCLK 12DIN 13CS 11

GND

3VDD

4

DOUT 14

R9641K

C962100nF

CO950100nF

C940100nF

R9425K6

R96139K

J950

JST10

12345678910

R9151K

+

-

U950BLM358

5

67

R9605K6

C842100nF

R9105K6

R9311K

J900

JST10

12345678910

R95568K

R9441K

TP930FE-2

D97012V

CO930100nF

R9011K

R98110K

C961 100nF

R9511K

R9501K

R9338K2

R943 39K

R90210K

R93210K

C95010nF

TP940DFC FE2

C960100nF

R90568K

+

-

U900BLM358

5

67

R95610K

R98010K

TP900FE-1

C941 100nF

C980100nF

TP910DFC FE1

R9451K

R913 39K

R9031K

+

-

U930BLM358

5

67

R9125K6

C911 100nF

+

- U900ALM358

3

21

84

R9301K

R95210K

R93610K

C90010nF

CO980100nF

R93568K

R963 39K

R9541K

C910100nF

+

- U950ALM358

3

21

84

U970ULN2003L

I1 1I2 2I3 3I4 4I5 5I6 6I7 7G

ND

8COM

9

O116O215O314O413O512O611O710

J930

JST10

12345678910

410.03-19rev. 01.1 - 06/2004



16b_CurveDisc_FT1

16b_CurveDisc_FT2

16b_ANA_RX_Collator

16b_DIG_FCEL_COLL

16b_ANA_RX_Folder

16b_DIG_FCEL_FO

16b_DigClutch_FO2

16b_DigClutch_FO1

16b_RX_ReadHead

16b_TX_ReadHead

16b_TX_Folder

VCC_OUT

VCC

PGND

GND

VCC

GND

VCC

GND

VCC

GND

VCC

VCCVCC

GND GND GNDGND

GNDGND

VCC

GND

GND

VCC

PGND

VCC_OUT

GND

24V

24V

Photocellscollatorside

(sht 6)

(sht 6)

(sht 7)

(sht 7) (sht 8)

FT1

FT2

RX Reading head

(sht 12)

Slotted switch FT1

Slotted switch FT2

Clutch FT1

Clutch FT2

FOLDERSIN KAP

RX Collator

RX Folder

TX Folder

TX Read head

(sht 8)

R1064150R

R106068K

R10541K

R10618K2

R10131K

R1065150R

R10521K

R105068K

R10114K7

U00F74HC14

13 12

C1020100nF

J1000

JST12

123456789101112

R105310K

D1010GREEN

R10021K

R10014K7

CO1050100nF

+

-U1050ALM358

3

21

84

R10701K

R10621K

C106010nF

TP1060FO

R106310K

R10121K

C1000150pF

U00A74HC14

1 2

R10518K2

D102012V

C105010nF

TP1050COLL

U1020ULN2003L

I1 1I2 2I3 3I4 4I5 5I6 6I7 7G

ND

8COM

9

O116O215O314O413O512O611O710

C1010150pF

D1000GREEN

J1050

JST8

12345678

CO0010nF

R10031K

U00B74HC14

3 4

+

-U1050BLM358

5

67

R10551K

410.03-20 rev. 01.1 - 06/2004



16b_PDisc_Collator

16b_PWM_Collator16b_DIR_Collator

16b_TX_Collator

16b_SwitchMaxiFeeder

16b_MaxiFeederDetect

16b_PWM_MaxiFeeder

VCC_OUT

GND

VCC

GND

VCC VCC

VCC

GND

PGND PGND

PGND

24V

24V

24V

VCC

PGND

PGND

PGND

PGND

GND

VCC_OUT VCC_OUT

GND

CollatorUnit

(sht 8)

(sht 6)

(sht 6)(sht 7)

(sht 7)

MAXIFEEDER

PD COLL.

Pdisc collator

TX Collator

Motor MF

Switch MF

MF detect

(sht 6)

-+ Collator motor

R11031K

J1110

JST10

12345678910

C1110100nF

U00C74HC14

56

R111210K

C1111100nF L1110

COMMON MODE SUPPRESION COIL

4

2

3

1

J1100

JST6

123456

C1113100nF

R1110100R

R110210K

U1110L6205PD

PGND1

1PGND2

10PGND3

11PGND4

20

VSa

2VSb

19

SENA 8

SENB 13

IN2A7

IN1B14IN2B15

OUT1A 9

OUT2A 3

OUT1B 12

OUT2B 18

VBOOT17

VCP4

EN_A

5

EN_B

16

IN1A6

C1100100nF

U00E74HC14

11 10

D1111GREEN

R111110K

D1110BAT54S

21

3

R11151K

C1114100nF

R1113150R

R11161K

R110010K

C1101100nF

R110110K

CO1110470uF

C111210nF

R11144K7

U00D74HC14

98

C1115150pF

410.03-21rev. 01.1 - 06/2004



16b_ReadHead_Ana1

16b_ReadHead_Ana2

16b_ReadHead_S0

16b_ReadHead_S1

16b_ReadHead_DAC1

16b_ReadHead_DAC0

16b_ReadHead_Ana0

16b_ANA_RX_ReadHead

16b_DIG_FCEL_RH16b_RX_ReadHead

-12V

-12V

-12V +12V

CASE

VCC

VCC

GND GND GND

GND GND GND

GND

GNDGND

GNDGND

GND

GND

GND

GND

GND

GND GND

GND

VCC

GND

VCC

GNDGND

VCC

GND

VCC

+12V

-12V

-12V+12V

AVDD

GND

GND

Rv=27K

ReadingHead

(sht 10)(sht 7)

(sht 7)

(sht 9)

(sht 9)

(sht 6)

(sht 7)

(sht 7)

(sht 7)

(sht 7)

+

-

U1220BLM3585

67

R120639K

U1221DHC4066

11 10

12

CO12000100nF

R12561K

C12041nF

C120310nF

R12036K8

R125568K

R120956R

R122947K

R1251150R

U1221CHC4066

8 9

6

R12301K

R12004K7

CO1220100nF

R1250150R

R12531K

+

- U1250BLM358

5

67

R1225680K

R121310K

TP1220OMR_OUT

CO1250100nF

C12001nF

R122447K

J1200

AMP6123456

C1220100nF

R12046k8

R122868K

R121210K

U1221AHC4066

12

13

R121082R

+

- U1220ALM358

3

21

84

R122047K

R1223100K

R12548K2

C12051nF

R12024K7

+

-

U1200BLM3585

67

C120210nF

TP1250ReadHead

R1208100K

U1221BHC4066

43

5

+

-

U1200ALM358

3

21

84

C1206100nF

C1207100nF

R1222680K

D1200BAT54S

21

3

R12014K7

+

- U1250ALM358

3

21

84

R125210K

R1207100K

R1226100K

R1221100K

CO12001100nF

R12311K

R122747K

C125010nF

C12011nF

R121110K

R12054K7

410.03-22 rev. 01.1 - 06/2004


figure 1.14 Component layout of the main board 98.90.01


410.03-23rev. 01.1 - 06/2004

1.2 Test points

Test point Name Minimum Typical Maximum RemarksTP110 VCC 4.8 V 5.0 V 5.2 V Local +5 V supply.TP120 -12V -12.5 V -12.0 V -11.5 V Local -12 V supply.TP130 +12V 11V 12.0 V 13V Local +12 V supply.TP200 8b_TST - - - Test of the digital signal that drives

LED D200. Normal flashing frequency 1 Hz. During errors the frequency is 2 Hz.

TP510 ENV 0.0 V 0.1 V 0.5 V PH7. Paper presentTP510 ENV 0.9 V 1.1 V 1.5 V PH7. No paper present. PH correctly

adjusted.TP520 FLAP 0.0 V 0.1 V 0.5 V PH8. paper present.TP520 FLAP 0.9 V 1.1 V 1.5 V PH8. No paper present. PH correctly

adjusted.TP530 LOC 0.0 V 0.1 V 1.5 V PH9. Paper present.TP530 LOC 0.9 V 1.1 V 1.5 V PH9. No paper present. PH correctly

adjusted.TP540 EXIT 0.0 V 0.1 V 0.5 V PH10. paper present.TP540 EXIT 0.9 V 1.1 V 1.5 V PH10. No paper present. PH

correctly adjusted.TP610 16b_TST - - - Test of the digital signal that drives

LED D610. Normal flashing frequency about 1 Hz. During errors the frequency will increase.

TP710 WINDOW - - - This test point can be used as an oscilloscope trigger signal to synchronize OMR mark measurements.

TP900 FE-1 0.0 V 0.1 V 0.5 V PH1. Paper present.TP900 FE-1 0.9 V 1.1 V 1.5 V PH1. No paper present. PH correctly

adjusted.TP910 DFC FE-1 4.0 V 4.1 V 4.2 V Output voltage of DFC1. Result of

DFC adjustment after passing of a document.








410.03-24 rev. 01.1 - 06/2004

table 1.1

1.3 Jumper settings

table 1.2

1.4 LED information

TP1050 COLL 0.0 V 0.1 V 0.5 V PH5. Paper present.TP1050 COLL 0.9 V 1.1 V 1.5 V PH5. No paper present. PH correctly

adjusted.TP1060 FO 0.0 V 0.1 V 0.5 V PH6. Paper present.TP1060 FO 0.9 V 1.1 V 1.5 V PH6. No paper present. PH correctly

adjusted.TP1220 OMR

OUT3.1 V - - OMR output voltage of reading head

RH1.TP1250 ReadHea

d0.0 V 0.1 V 0.5 V PH4. Paper present.

TP1250 ReadHead

0.9 V 1.1 V 1.5 V PH4. No paper present. PH correctly adjusted.

Jumper Meaning RemarksNot placed Placed

JP320 SEL0 Load ‘N Go text. Auto Set textJP321 SEL1 Load ‘N Go text. Fill & Start text

JP610 FLASH BOOT This jumper must not be placed! (If not present, the external flash software never could establish contact with the machine, which would always directly boot to the machine software.)

JP670 R&D This jumper is never present on a production board! This jumper is only relevant in an R&D environment, in which case emulation RAM (U640 and U641) should be present.

JP720 FE-1 SEL Reserved for gap separation feeder.JP730 Inter. Trans. Is placed if intermediate transport is installed. Not relevant in

this machine.JP731 Spare Not used (yet).

LED Name/Color RemarksD200 TESTLED/

GreenPeriodically ON/OFF flashing. Signifies proper operation of the machine software in the 8-bit controller. If the software is in normal operation the flashing rhythm will be about 1 Hz. When an error occurs the flashing rhythm increases.

D240 FLASH WRITE/Red

Is ON during the programming (flashing) of the 8-bit machine software. The behaviour of D240 and D241 is similar to the behaviour of D671 and D672 for the 16-bits machine software (for diagnostics with flash programm problems).

Test point Name Minimum Typical Maximum Remarks


410.03-25rev. 01.1 - 06/2004

table 1.3

D241 FLASH RUN/Green

Is ON during normal operation of the 8-bit machine software. The behaviour of D240 and D241 is similar to the behaviour of D671 and D672 for the 16-bits machine software (for diagnostics with flash programm problems).

D580 MAIN PDISC/Green

Reflects the optical state of slotted photocell SPH1 that monitors pulse disc PD1, which moves in line with the main motor M1 driven items. Is ON if this motor is running AND if the mechanical drive is okay.

D610 TEST/Green Periodically ON/OFF flashing. Signifies proper operation of the machine software of the 16-bit controller U610. If the software is in normal operation the flashing rhythm will be about 1 Hz. When an error occurs the flashing rhythm increases.

D630 FLASH WRITE/Red

Flash LED. Is ON during the flashing (i.e. programming or reprogramming under supervision of external software) of the 16-bit machine software in flash ROM (U630). Full brightness during the erasing state, intermediate brightness during the flashing state proper.

D671 MAP0/Red Reflects the state of the Map0 signal. Is OFF during normal operation of the machine. Is ON during about one second in the startup stage of the machine. Is also ON if during the flashing of flash ROM (under supervision of external software) code must be flashed into the upper 512 kilobyte part.

D672 MAP1/Green Reflects the state of the Map1 signal. Is ON during normal operational use of the machine, including the one-second machine startup stage mentioned under D671. Is OFF if program code in system RAM (U620 & U621) (for instance flash software for programming or reprogramming the flash ROM U630) is executed, under supervision of external software.

D1000 FT1/Green Reflects the optical state of slotted photocell SPH2, which monitors the first fold pocket cam disc PD3. Is ON if this photocell “sees” the cam disc.

D1010 FT2/Green Reflects the optical state of slotted photocell SPH3, which monitors the second fold pocket cam disc PD4. Is ON if this photocell “sees” the cam disc.

D1111 PD COLL/Green

Reflects the optical state of slotted photocell SPH2, which monitors collator motor M2.

LED Name/Color Remarks


410.03-26 rev. 01.1 - 06/2004

2 Service menu

2.1 General

Proceed as follows for access to the service menu:• ·Navigate to the second screen of the main menu (see figure 2.2).• ·Press key 3 (Job menu). The Job access screen of figure 2.3 appears.• ·Enter the pin code 4331. Now you will enter the first part of the service menu screen of figure

2.4. This is the first part. With key 4 you can switch to and back from the second part of the service menu screen of figure 2.5.

Figure 2.1 shows a flow chart of the service menu.With the four soft keys 1 through 4 (from top to bottom) you select a menu option.With the Escape key the next higher menu is re-entered without implementing changes.In the case of a menu consisting of multiple screens you can navigate through these screens by pressing key 4.If a menu offers the possibility to change settings, key 4 is used to implement these changes and to go back to the next-higher menu level.


410.03-27rev. 01.1 - 06/2004

figure 2.1

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410.03-28 rev. 01.1 - 06/2004

figure 2.2

figure 2.3

figure 2.4 from top to bottom §2.2, §2.9,§2.14

Key

start/stop esc

1

2

3

4

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410.03-29rev. 01.1 - 06/2004

figure 2.5 from top to bottom §2.21, §2.22

2.2 System setting

figure 2.6 from top to bottom §2.3, §2.4, §2.5


2.3 Configuration

This screen provides information on the various available options, i.e. the number of feeders, Fe 1limited "yes" or " no", Daily mail (DM) on feeder, the DFCs on feeders and the presence or absence of an OMR dongle. If the configuration as stored in the machine has been updated, the new configuration will be stored after pressing key 4 and switching the machine off and on again.

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410.03-30 rev. 01.1 - 06/2004

figure 2.8

2.4 Localisation

figure 2.9

In this menu you can set the language of the operational user interface, as well as the paper sizes.Languages: English, Dutch, French, German, Spanish, Italian and Katak[ana].Standard: ISO (i.e. metric), Inches or None.ISO sizes: A4 (297 mm), A5 (148 mm) and A6 (105 mm) for documents; C5 (162 mm) and C6/5 (114 mm) for envelopes.Inches: 3.5" (90 mm), #9 (99 mm), 4" (102 mm), 6" (152 mm), 7" (178 mm), 8" (203 mm), 8.5" (216 mm), 11" (279 mm), 12" (305 mm) and 14" (356 mm) for documents; #9 (99 mm), #10 (105 mm) and 6x9 (153 mm) for envelopes.

2.5 Software versions

This screen provides release information on the machine software (programmed in flash memory) for the inserter part (executed by the 8-bit controller) and the feeder/folder/reading part (executed by the 16-bit controller).Usually both machine software items should be updated simultaneously, using external software. When software indexes do not correspond, an error message will be displayed.

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410.03-31rev. 01.1 - 06/2004

figure 2.10

2.6 Folder settings

The folding process is implemented by the timing of two cam discs, one for each folding pocket. The timing is determined by the document length of the sheets to be folded. Given tolerances in the activation times of the clutches involved, this menu provides for an equivalent shift in the folding positions, thus compensating a clutch activation time that deviates from the average value.In the folder offset menu of figure 2.11 you first select the folder. Than you can set the equivalent shift in the folding position between -20 mm and +20 mm. By processing test material you can decide if subsequent corrections in these settings are necessary.

figure 2.11

2.7 Reset data

This menu offers the possibility (with key 2) for initializing the system with default values (confirm with key 4). In addition all photocells will be readjusted (so: remove all paper from the machine).All counter values are not affected.Use key 3 to load default millimeter jobs (1, 2 and 3).Use key 4 to load default inch jobs (1, 2 and 3).The only way to leave this screen is to use the Escape key.

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410.03-32 rev. 01.1 - 06/2004

figure 2.12

2.8 Power up

You can decide here whether or not (yes or No) the language menu will be shown after power up of the machine. Save your settings with key 4 or leave this menu without changes by using the Escape key.

figure 2.13

2.9 Job settings

figure 2.14 from top to bottom §2.10, §2.11, §2.12, §2.13

2.10 Document offset

The vertical transport of documents fed by the various feeders is arranged in such a way that the documents are partially overlapping each other. This overlapping scheme ensures that the documents are properly aligned in the collator area.In the document offset menu of figure 2.15 you can set for each job (select with key 1) the extend to which the documents are not overlapping each other, i.e. the document offset value. The default

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410.03-33rev. 01.1 - 06/2004

value is 50 mm. With keys 2 and 3 the document offset can be varied between 20 mm and 75 mm in 1 mm steps.Press key 4 to store the changes or press the Escape key to ignore the changes.

figure 2.15

2.11 BRE offset

If a document is longer than the set address fold but shorter than the envelope height, this document sometimes will be unnecessarily folded. Under certain conditions this document can be prevented from being folded. This can be implemented with the menu BRE offset (BRE means Business Reply Envelope) of figure 2.16.For all jobs 1 Lng (Load 'n Go) an offset can be switched on or off.In the case of offset on the last document that had been added to the set prior to further processing will be shifted from the rest of the set (offsetting), i.e. this document will be held back during a certain distance. This means that the trailing edge of this upper document leaves the collator as last. This document will not be folded. During the insertion into the envelope the documents of the set will be realigned.The conditions are:• The feeder that supplies this upper document (BRE) is set to one document per set (no multi

feeding).• The document directly beneath this document must be at least 60 mm longer than the BRE.• The upper document must be longer than the set address fold.• The folding mode is either single fold or letter fold (so no Z-fold).• The upper document must be shorter than the envelope height.Note: It is possible to use the BRE offset for a BRE and an enclosure (card) in 1 set. The extra condition is that this enclosure is equal to or smaller than the set address fold and should be placed direct underneath the BRE in the set.The whole BRE offset is based on friction between documents within a set. Therefore it is necessary to make use of these conditions to reduce the risk of bad transporting, folding and inserting.In some cases the BRE option is automatically switched off if one or more of the above-mentioned conditions are not met, so it is safe to switch the BRE option on, unless this option is never to be used.Use keys 1 and 2 to select a job. With key 3 the BRE offset is switched on or off.Press key 4 to store the changes or press the Escape key to ignore the changes.

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410.03-34 rev. 01.1 - 06/2004

figure 2.16

2.12 Secure jobs

With this menu the selected job can be secured, i.e. locked. This job can not be deleted and can not be changed in the job menu either. However, a locked job still can be copied into another job that can be modified.Use keys 1 and 2 to select a job. With key 3 the selected job is locked on or unlocked.Press key 4 to store the changes or press the Escape key to ignore the changes.

figure 2.17

2.13 Flap closer

In this menu the timing of the activation of the sealing solenoid (So3) can be adjusted on a per-job basis. This function can be used to improve the sealing process. The timing has influence on the position of the filled envelope (with its flap fixed between two rollers) prior to being transported between the sealing rollers. This position can be adjusted between -10 and + 10 mm (with respect to the default envelope position).Use key 1 to select a job. With keys 2 and 3 the correction value for the envelope stop position prior to being sealed can be incremented or decremented.Press key 4 to store the changes or press the Escape key to ignore the changes.

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410.03-35rev. 01.1 - 06/2004

figure 2.18

2.14 Service tests

With key 4 you toggle between the screen of figure 2.19 and the screen of figure 2.20.



2.15 Photocells

You can navigate to and from the screens of figure 2.21, 2.22, 2.23 or 2.24 with key 4.The status of the nine or ten (if OMR is installed) photocells is displayed in four screens.In this machine so-called intelligent photocells are used. This implies that within a certain control range the currents of the photocell transmitters are adjusted in such a way that the no-paper output voltage of the photocell receiver falls within a certain voltage range of the photocell receiver. In this way fair amounts of dust present on the photocell sensors are compensated for. The control mechanism ensures that very reliable paper/no paper decisions are being made, based on the paper photocell condition.

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410.03-36 rev. 01.1 - 06/2004

The four screens provide real time information on the various paper photocells. You also can see whether the relevant photocell "sees" paper.The various photocells can be readjusted by pressing the key 3.

Note. Before readjusting the photocell it is strongly recommended to remove all paper from the machines and to clean all the sensors (both transmitter and receiver!) of the photocells.

After the photocell adjustments the percentages as shown in the four screens should be lower, provided the cleaning advice is heeded.If no paper is present, the photocell output voltage should have a value between 0.8 V and 1.5 V. A value below this voltage range indicates a too heavily dusted photocell. A value above this voltage range may occur if after readjusting a photocell dust is removed. In both cases it is advised to readjust the photocells.If the photocell current percentage is below 75%, the message "OK" is shown. A percentage between 75% and 99% results in a "Clean" message. The photocell should be cleaned before resetting the photocells. The message "Defect" is shown when the percentage is 99% or 100%.The only way to leave this menu is to press on the Escape key.

figure 2.21 PH7, PH8

figure 2.22 PH9, PH10

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410.03-37rev. 01.1 - 06/2004

figure 2.23 PH6, PH5, PH4 inclusive PH vertical track

figure 2.24 PH3, PH2, PH1

2.16 Digital inputs

The four screens of figures 2.25, 2.26, 2.27 and 2.28 show the real-time status of the three safety switches (MS1, MS2 and MS3), the flag switch (FS1), The two folder cam disks (SPH3 & PD3; SPH4 and PD4) and the two pulse discs (SPH1 for the main motor M1 and SPH2 for the collator motor M2). Real-time means that a change is reflected in the displayed status.In this way you can easily check the correct operation of the three microswitches and the flag switch.The folder cam discs (figure 2.26) can be tested with key 2 and key 3. After pressing one of these keys the relevant cam disc will move one half cycle, i.e. the cam disc status changes from "open" to "covered" or from "covered" to "open". After pressing two successive times on a test key the cam disc has performed a full cycle and returns to its position prior to entering this menu.Both pulse discs can be tested as well. By keeping the Test key (key 1 in figure 2.27 or figure 2.28) pressed the pulse disc signal will be tested. Both the speed and the quality (duty cycle) are tested. Detailed information is obtained via the minimum (Min.) and maximum (Max.) value. For the Speed the range should be between 75% and 125%, for the Pulse dist. (Duty cycle) the value should be in the range of 50% till 150% resulting in the message 'Good'. If the value is out of these ranges the message will be 'Bad'.The speed is checked by measuring the average pulse width and compared to the initial value. When the speed is much lower than the initial value the mechanical load has to be checked. When it is higher it could be that the pulse disc has become loose.The Pulse dist. (duty cycle) is measured of each pulse and the minimum and maximum values are shown. When a pulse (an indented area) is not detected (for example because of dust build up) the pulse distance will show a value of Min. 0% and/or Max. 200%.

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410.03-38 rev. 01.1 - 06/2004

figure 2.25 MS1, MS2, MS3, FS1

figure 2.26 SPH3&PD3, SPH4&PD4

figure 2.27 SPH1&PD1 version with fill in values

figure 2.28 SPH2&PD2 version with fill in values

2.17 Actuators

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410.03-39rev. 01.1 - 06/2004

In the three menu screens (figures 2.29, 2.30 and 2.31) the correct operation of the two motors, three solenoids, six clutches and the Maxi Feeder motor (if present) can be verified. Keys 1 and 2 can be used to select the actuator to be tested. The test is performed with key 3.If (and as long as) key 3 is pressed, the selected actuator will be activated.The motor runs as long as the test key is pressed.If the fingers solenoid is selected, the fingers move forward as soon as the test key is pressed. Only after releasing the test key the fingers will move back to their rest position. The eject rollers and closer solenoids will be activated and after a short time deactivated during one period of test key pressing. During normal operational use these three actuators are always activated during a very short time. This test reflects this situation.Testing the envelope track clutch CL6 will result in switching on the motor M1, as well as activating the envelope track clutch.Collator run in: Collator motor runs in the direction of the document stop position as long as key 3 is pressed.Collator run out: Collator motor runs in the direction of the folder as long as key 3 is pressed.Folding pocket 1/2: The main motor M1 is switched on. The relevant fold pocket turns a half fold cycle. After two successive key 3 presses the initial position prior to entering this menu is reached once again.Feeder clutches: The main motor M1 is switched on and the relevant feeder clutch is activated if and as long as key 3 is pressed. The feeder 3 clutch is only visible in the case of a 2½-station version of the machine.The Maxi Feeder option is only available if the Maxi Feeder is present. As long as key 3 is pressed, its motor runs.

figure 2.29 M1, So1, So2, So3, CL6

figure 2.30 M2 IN, M2 OUT, CL4, CL5

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410.03-40 rev. 01.1 - 06/2004

figure 2.31 CL1, CL2, CL3

2.18 Run in

The run in test screen of figure 2.32 shows a counter, of which the default value is 6000. This is the number of process cycles that will be emulated, with no paper whatsoever present in the machine.After pressing the Start/Stop key the run in test will start. After each process cycle the counter is decremented. The machine stops automatically if the counter value is zero.With keys 2 and 3 you can set the counter at a value that differs from the default value 6000. If the counter value is 1000 or higher, increments are 1000 with a maximum value of 30000. if the counter value is lower than 1000, decrements are 100 with a minimum value of 10.If you have some covers removed (but not the safety covers!), you can observe the various sequences of mechanical actions, which reflect the sequence of events during normal operational use of the machine.After pressing the Start/Stop key again the run in test stops.

Note. It is also strongly recommended to perform the run in test without any documents present in the machine. The timing of the actions for a simulated process cycle are fixed, so they are not based on parameters such as the document length. A run in test with documents present in the machine would only result in severe paper jamming.

figure 2.32

2.19 DFC test

This menu informs you about the DFC unit output voltages of the two or three feeders. The values are real time. With no paper present in a feeder the DFC voltage should be about 4.1 volt. If during the machine start a DFC unit does not "see" paper, the DFC voltage should be about 4.992 volt.The DFC voltage is lower if the DFC unit "sees" paper. The following rules apply:• ·For 65 g/m² paper DFC voltage about 0.2 volt lower.• ·For 80 g/m² paper DFC voltage about 0.25 volt lower.

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410.03-41rev. 01.1 - 06/2004

• ·For 120 g/m² paper DFC voltage about 0.35 volt lower.• ·For 160 g/m² paper DFC voltage about 0.5 volt lower.

figure 2.33

2.20 Keyboard/display

This menu screen offers the option to invert the screen display (with key 1, and as long as this key is pressed) and to test three of the four soft keys and two hard keys. If you leave this menu the default screen settings as far as the invert option is concerned are applied once again. Key 1 cannot be tested, for this key is used for the toggle function.If the Start/Stop key, Escape key, key 2, key 3 or key 4 is pressed, this is indicated by an adjacent bar. Furthermore the decimal key value is displayed in the middle of the screen.Leave this menu by pressing the Escape key twice.

figure 2.34

2.21 Counters

This menu (see figure 2.35) offers the possibility to read, set or reset the service counters.With key 1 you can reset the Since last visit counter to zero.With key 2 the Next visit after counter can be incremented in 5000 steps, with a maximum value of 6.000.000.With key 3 the Next visit after counter can be decremented in 5000 steps, with a minimum of 5000. A value under 5000 results in the value OFF.Use key 4 to leave this menu including changes or use the Escape key to leave this menu without the changes that may be made.If you simultaneously press the Start/Stop key and the Escape key, the Total Counter menu of figure 2.36 is displayed.

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410.03-42 rev. 01.1 - 06/2004

This menu offers the possibility to set the Since installation counter. With key 1 the counter value is incremented in 5000 steps. With key 2 the counter value is decremented in 5000 steps. Use key 4 (including changes) or the Escape key (without changes) to go back to the Service counters menu of figure 2.35.

figure 2.35

figure 2.36

2.22 OMR

figure 2.37 ferm top to botoom §2.23, §2.24

2.23 OMR code definition

This menu offers the possibility to define OMR-2 reading codes, provided a level 1 dongle is present in the machine. Per system one OMR code can be set. This code can be used in one or more jobs. The most complex OMR code is:• Start• Insert/accumulate• Parity check

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410.03-43rev. 01.1 - 06/2004

• Safety mark.The various menu screens (of which figure 2.38 is an example; not all screens are shown in this document) share the same structure.With keys 1 (repetitive key strokes) a code option is selected: Start mark, Insert on, Parity check, Safety mark and Line spacing.With key 3 you choose between Yes and No (toggling function). In the Line spacing case keys 2 and 3 are used to increment (key 2) or decrement (key 3) the line spacing in steps of about 0,02 millimeter. The Lpi value reflects the number of lines per inch, the millimeter value is the distance between two successive marks.Use key 4 to leave this menu including changes or the Escape key to leave this menu without changes. You are back in the OMR main menu of figure 2.37.

figure 2.38

2.24 Read code test

Press key 2 (Read code test, figure 2.37) to obtain the screen of figure 2.39. This menu screen informs the user about the mark quality, number of read marks and the gain setting. Every time the test key 2 is pressed a sheet is forwarded and the screen will show the information.

figure 2.39 The read code test submenu.

Show marks (key 1)The Show marks menu of figure 2.40 offers a graphical representation of the marks that had been read (oscilloscope function). The information shown is derived from the most recently read document. The information screen shows the time-dependant OMR output voltage and the reading window. The start of the window is represented by a vertical line, the end of the reading window is also represented by a vertical line. In between the marks should be given where the position of the marks related to the window position is also giving some information, i.e. when the first mark is very close to the opening of the window; this could mean that the window position is programmed wrong.

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410.03-44 rev. 01.1 - 06/2004

The upper horizontal dotted line represents the noise level, i.e. the white level. The lower horizontal dotted line represents the level below which a mark (i.e. detection level) has been detected. The detection level is determined when the adjustment procedure is performed (see fig 2.41). The detection level is 60% of the top level. A mark is detected as an OMR-mark when more than 5 digital samples consecutively are below the detection level.The numbers 1 through 6 indicate where a mark is expected. The distance between the numbers is exactly the same as the programmed line spacing. With key 3 you can scroll to the right, i.e. to a point later in time. With key 4 you can scroll to the left, i.e. to an earlier situation.

figure 2.40 The Show marks menu.

After pressing the info key 1 the information screen of figure 2.41 shows additional OMR-related information. This information is based on the last read document and the job settings (OMR code type etc.). The displayed information is what is interpreted from the read OMR code.

figure 2.41 The Show marks info screen.

Test (key 2)This screen shows the mark quality and the number of read marks from the last processed document. Also the gain of the OMR amplifier is shown.The mark quality is shows as follows:

Bad Mark amplitude < 0.6 V

Good Mark amplitude between 0.6 V and 1.5 V

Very good Mark amplitude higher than 1.5 V

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410.03-45rev. 01.1 - 06/2004

Adjustment (key 3)There are a number of occasions in which it is very relevant to adjust the OMR electronics. In the case of OMR hardware repairs and replacements it is very obvious that the OMR electronics should be readjusted. But there may be operational reasons as well, for instance if non-standard paper is to be used. In such cases, after processing some test documents (see above) the mark quality may not be optimal. Readjust the OMR electronics and process some new documents, in order to obtain an improved mark quality.For the adjustment 10 documents are necessary (otherwise an empty feeder error occurs). In each document at least one mark must be present within the reading window. The test documents must be present in the feeder for the selected job.It is very important to align the centre of the reading head horizontally at the centre of the marks.Press key 3 (Adjust) in the screen of figure 2.39. The adjustment menu of figure 2.42 appears.Press in the latter menu key 3 (Start adjust) to start the adjustment.During the adjustment the text "Adjusting" appears.After the adjustment either the message Adjustment done: OK or the text Adjustment done: FAILED is shown. Press esc to go back to the next higher menu screen.

figure 2.42 The adjustment submenu

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410.03-46 rev. 01.1 - 06/2004

3 Error messages and error handling

In this chapter the various errors and warnings are discussed. The error screens have the following in common:• An error code X:YYY. X is a prefix number that indicates a specific machine part.• Message. The message that is displayed next to the exclamation mark triangle.• Action. The text that is displayed next to the finger pictogram.• Info. Additional information if the info key 1 is pressed.The following machine areas/prefixes apply: 1 Inserter 2 Folder 3 Collator, vertical transport and OMR. 4 Feeder 1. 5 Feeder 2. 6 Feeder 3.Now the various errors will be discussed.

Error 1:1Message: FRAM failure.Action: Call service.Info: Memory failure.Error during the writing of zero data (formatting) to FRAM memory. Press the Reset key and try again.Formatting is ended by pressing the Start/Stop key. The system starts with default values.

Error 1:2Message: FRAM failure.Action: Call service.Info: Memory failure.Error during the initialization of FRAM. Press the Reset key and try again. Initialization is ended by pressing the Start/Stop key. The system starts with default values.

Error 1:3Message: FRAM failure.Action: Call service.Info: Memory failure.FRAM not detected.

Error 1:4Message: FRAM failure.Action: Call service.Info: Memory failure.This error is issued after ten successive tries to write to or read from FRAM memory.

Error 1:5Message: FRAM failure.Action: Call service.Info: Memory failure.This error is issued after a checksum error occurred during writing to or reading from FRAM memory.


410.03-47rev. 01.1 - 06/2004

Error 1:10Message: Envelope too long.Action: Remove envelope.Info: Envelope length error.Envelope too long. Remove the envelope from the envelope track. A closed envelope is considered too long if its equivalent length exceeds 162 mm plus 20 mm tolerance = 182 mm or the programmed length plus 20 mm. An opened envelope is considered too long if its equivalent length exceeds 162 mm plus 130 mm flap length plus 20 mm tolerance = 312 mm.

Error 1:11Message: Document stoppage.Action: Remove documents.Info: Inserting failure.Document/envelope crash. The loc photocell PH9 remains covered too long. The equivalent document length exceeds 400 millimeter. Remove the envelope and the document from the insert table.

Error 1:12Message: Document stoppage.Action: Remove documents.Info: Document length error.Document/envelope crash. Two successive inserts show a document length change of more than 42 mm. The length is observed by the loc photocell PH9. The insert process is irregular, with varying mechanical slip.

Error 1:13Message: Envelope stoppage.Action: Remove envelope.Info: Transport failure.Envelope crash. The exit photocell PH10 remains covered too long. Remove the envelopes from the exit table and press the Reset key.

Error 1:15Message: Envelope stoppage.Action: Remove envelope.Info: Flap not opened.Envelope not opened. The envelope has no flap at all or its flap is not properly opened.

Error 1:16Message: Envelope stoppage.Action: Remove envelope.Info: Transport failure.Envelope crash. The filled envelope didn't arrive in time at the exit photocell PH10. The sealing stage takes too much time. Remove the paper from the exit area.

Error 1:17Message: Document stoppage.Action: Remove document.Info: Document too early.


410.03-48 rev. 01.1 - 06/2004

Document/envelope crash. Wrong timing of insertion of the document. Remove the document from the insert table. Between the ejecting of the filled envelope and the placing of a new envelope on the insert table, including the fingers moved in that envelope, no document is supposed to be present under the loc photocell PH9. In the fold only mode, also without envelopes involved, a new document is not allowed to cover PH9 before the previous document has been ejected and a new document call has been issued.

Error 1:18Message: Document stoppage.Action: Remove document.Info: Inserting failure.Document/envelope crash. The loc is opened or PH9 covered at the time at which a document call is issued. Close the loc or remove the PH9 covering paper.

Error 1:19Message: Envelope stoppage.Action: Remove envelope.Info: Flap sensor covered.The flap photocell PH8 is covered too long. Remove the envelopes form the envelope track, if necessary by turning the hand knob until the envelopes reach the insert table.

Error 1:22Message: Envelope stoppage.Action: Remove envelope.Info: Wrong envelope size.Envelope too short. The envelope currently called for is shorter than 75 mm, or the measured envelope length is at least 20 mm shorter than the set envelope length.

Error 1:23Message: Document stoppage.Action: Remove envelope.Info: Seal switch active.Envelope closer flag switch activated. At the moment that an envelope must be ejected from the insert position, the flag switch FS1 is covered. FS1 is not properly mounted or connected, or some other mechanical FS1 error occurs.

Error 1:24Message: Envelope stoppage.Action: Remove envelope.Info: Seal switch active.Envelope crash. The flag switch FS1 remains covered too long.

Error 1:26Message: Envelope stoppage.Action: Remove envelope.Info: Seal switch not covered.Document/envelope crash. The ejected document does not reach the flag switch FS1 in time.


410.03-49rev. 01.1 - 06/2004

Error 1:27Message: Document stoppage.Action: Remove document.Info: Document too late.Document arrives too late. A document call to the feeder/folder part does not result in a document arriving at the document photocell PH9.

Error 1:29Message: Document stoppage.Action: Remove document.Info: Insert area blocked.Insert area blocked. During startup paper is present on the insert table. Remove the paper and press the Reset key.

Error 1:30Message: Empty envelope hopper.Action: Load envelopes.Info: [none]Envelope hopper empty. An envelope is called for, but after a 15-second timeout it does not arrive on the insert table. There are two ways to resume the process: (a) press the Start/Stop key, the message disappears and the process resumes; (b) press the Reset key, followed by the Start/Stop key.

Error 1:34Message: No connection.Action: Check device connector.Info: Communication failure.Communication failure in the SCS communication between the inserter part (8-bit controller) and the feeder/folder part (16-bit controller). This reflects an electronic hardware failure on the main board 98.90.01.

Error 1:35Message: Preventive maintenance.Action: Call service.Info: [none].Maintenance message. This message appears during the start of the machine if the value of the counter Since last visit exceeds the value of the counter Next visit after. This message is issued at the system start.

Error 1:37Message: Technical failure.Action: Call service.Info: Main motor failure.Main motor (M1) failure. The pulse disc slotted photocell SPH1, which monitors pulse disc PD1, does not deliver any pulses at all or too few pulses. Apart from a defective PD1, this error message is issued if the motor is mechanically overloaded or blocked. It may help to wait until the motor has been cooled down.


410.03-50 rev. 01.1 - 06/2004

Error 1:44Message: Technical failure.Action: Call service.Info: Track sensor defective.During the photocell adjustment the transmitter LED current of the envelope track photocell PH7 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.

Error 1:45Message: Technical failure.Action: Call service.Info: Flap sensor defective.During the photocell adjustment the transmitter LED current of the flap photocell PH8 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.

Error 1:46Message: Technical failure.Action: Call service.Info: Loc sensor defective.During the photocell adjustment the transmitter LED current of the loc photocell PH9 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.

Error 1:47Message: Technical failure.Action: Call service.Info: Exit sensor defective.During the photocell adjustment the transmitter LED current of the exit photocell PH10 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.

Error 1:48Message: Track sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the envelope track photocell PH7 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.


410.03-51rev. 01.1 - 06/2004

Note. Error 1: 52 is the same error, but occurs during readjusting this photocell.

Error 1:49Message: Flap sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the flap photocell PH8 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 1: 53 is the same error, but occurs during readjusting this photocell.

Error 1:50Message: Loc sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the envelope loc photocell PH9 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 1: 54 is the same error, but occurs during readjusting this photocell.

Error 1:51Message: Exit sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the exit photocell PH10 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 1: 55 is the same error, but occurs during readjusting this photocell.

Error 1:52Message: Technical failure.Action: Call service.Info: Track sensor defective.During the adjustment of the track photocell PH7 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 1:48 is the same error, but occurs during the processing of paper.

Error 1:53Message: Technical failure.Action: Call service.Info: Flap sensor defective.During the adjustment of the flap photocell PH8 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed.Note. Error 1:49 is the same error, but occurs during the processing of paper.


410.03-52 rev. 01.1 - 06/2004

Error 1:54Message: Technical failure.Action: Call service.Info: Loc sensor defective.During the adjustment of the loc photocell PH9 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 1:50 is the same error, but occurs during the processing of paper.

Error 1:55Message: Technical failure.Action: Call service.Info: Exit sensor defective.During the adjustment of the exit photocell PH10 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 1:51 is the same error, but occurs during the processing of paper.

Error 1:56Message: Technical failure.Action: Call service.Info: Track sensor defective.Envelope track photocell (PH7) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.

Error 1:57Message: Technical failure.Action: Call service.Info: Flap sensor defective.Flap photocell (PH8) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.

Error 1:58Message: Technical failure.Action: Call service.Info: Loc sensor defective.Loc photocell (PH9) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start key the message reappears.


410.03-53rev. 01.1 - 06/2004

Error 1:59Message: Technical failure.Action: Call service.Info: Exit sensor defective.Exit photocell (PH10) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start key the message reappears.

Error 1:60Message: Track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the envelope track photocell PH7 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error 1:61Message: Flap sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the flap photocell PH8 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error 1:62Message: Loc sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the loc photocell PH9 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error 1:63Message: Exit sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the exit photocell PH10 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error 1:64Message: Track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the envelope track photocell PH7 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:44 is issued.


410.03-54 rev. 01.1 - 06/2004

Error 1:65Message: Flap sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the flap photocell PH8 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:45 is issued.

Error 1:66Message: Loc sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the loc photocell PH9 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:46 is issued.

Error 1:67Message: Exit sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the exit photocell PH10 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:47 is issued.

Error 1:80Message: Technical failure.Action: Call service.Info: Communication failure.CRC error at receiving mail via I²C communication.

Error 1:81Message: Technical failure.Action: Call service.Info: Communication failure.I²C delivered mail not accepted by the feeder/folder part.

Error 1:82Message: Technical failure.Action: Call service.Info: Communication failure.Command unknown by the slave.

Error 1:83


410.03-55rev. 01.1 - 06/2004

Message: Technical failure.Action: Call service.Info: Communication failure.The feeder/folder part doesn't accept the command.

Error 1:84Message: Technical failure.Action: Call service.Info: Communication failure.Command not identified by the feeder/folder part.

Error 1:85Message: Technical failure.Action: Call service.Info: Communication failure.The inserter part cannot communicate properly (by SCS) with the feeder/folder part. A checksum error occurred.

Error 1:86Message: Technical failure.Action: Call service.Info: Communication failure.The inserter part cannot communicate properly (by SCS) with the feeder/folder part. A hardware-related error occurred.

Error 1:87Message: Technical failure.Action: Call service.Info: Communication failure.Too many communication retries.

Error 1:88Message: Technical failure.Action: Call service.Info: Communication failure.Too many NACK signals received.

Error 1:89Message: Technical failure.Action: Call service.Info: Communication failure.The inserter part cannot communicate properly via the local I²C bus (timeout error).

Error 1:95Message: Sealing risk.Action: Check water level.Info: Brushes too dry.This warning message is issued after each 2500th process cycle. After pressing the Reset key this message will disappear.


410.03-56 rev. 01.1 - 06/2004

Error 1:101Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the feeding of an envelope (in the envelope track) one or more machine covers are opened.

Error 1:102Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the feeding of a document one or more machine covers are opened.

Error 1:103Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the ejecting of the filled envelope one or more machine covers are opened.

Error 1:104Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the exiting of the filled envelope one or more machine covers are opened.

Error 1:105Message: Technical failure.Action: Call service.Info: Communication failure.Communication failure. SCS-related problem in the communication between the inserter part and the feeder/folder part.

Error 2.11Message: Document stoppage.Action: Remove documents.Info: Stoppage at folder.First fold pocket mechanical or electrical failure.After activating the first fold pocket clutch CL4 the next state is not detected by slotted photocell VSPH3 within a certain time. This could be caused by either a faulty clutch or faulty slotted photocell or when material is present that cannot be folded.

Error 2.12Message: Document stoppage.Action: Remove documents.Info: Stoppage at folder.Second fold pocket mechanical or electrical failure.


410.03-57rev. 01.1 - 06/2004

After activating the second fold pocket clutch CL5 the next state is not detected by slotted photocell VSPH4 within a certain time. This could be caused by either a faulty clutch or a faulty slotted photocell or when material is present that cannot be folded.

Error 2.14Message: Load 'N Go not possible.Action: Go to job edit menu.Info: Fold not possible.A fold based on defined Load 'n Go formulas appears to be not feasible, due to fold pocket limitations (i.e. minimum or maximum distances).

Error 2:61Message: Technical failure.Action: Call service.Info: Sensor fold-in defective.During the photocell adjustment the transmitter LED current of the folder input photocell PH6 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.

Error 2:62Message: FO in sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the folder input photocell PH6 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 2: 63 is the same error, but occurs during readjusting this photocell.

Error 2:63Message: Technical failure.Action: Call service.Info: Sensor fold-in defective.During the adjustment of the folder input photocell PH6 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 2:62 is the same error, but occurs during the processing of paper.

Error 2:64Message: Technical failure.Action: Call service.Info: Sensor fold-in defective.Folder input photocell (PH6) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start key the message reappears.


410.03-58 rev. 01.1 - 06/2004

Error 2:65Message: FO in sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the folder input photocell PH6 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error 2:66Message: FO in sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the folder input photocell PH6 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 2:61 is issued.

Error 3:10Message: Document stoppage.Action: Remove documents.Info: Stoppage at vertical track.Vertical transport crash. After a certain time after leaving a feeder the paper doesn't arrive at the collator input photocell PH5. Remove the paper and press the Reset key.

Error 3:11Message: Document stoppage.Action: Remove documents.Info: Stoppage at collator.Collator run in error. During the collating of documents the collator input photocell PH5 is covered too long. This can happen if the paper is to sturdy to make the move from a vertical to a more or less horizontal direction, or if documents still present in the collating area prevent the arriving document from arriving there. Remove the documents and press the Reset key.

Error 3:12Message: Document stoppage.Action: Remove documents.Info: Stoppage at collator.Collator run out error. After starting to leave, to the folder or the divert, the paper stays too long in the collating area. This can be verified by the folder input photocell PH6. This is caused by either a paper crash or the fact that paper has been removed after a Stop command, followed by a Start command.

Error 3:14Message: Document stoppage.Action: Remove documents.Info: Stoppage at collator.Paper present at initialization (machine startup or job change) error. This message is displayed if during the initialization of the collating area a set or part of a set has been detected in this area.


410.03-59rev. 01.1 - 06/2004

Initialization of the collating area occurs after each job change, after fatal feeder errors or collating area errors.

Error 3:20Message: System not ready,Action: Remove all documents.Info: Documents in system.Folder/feeder not empty. After a job change documents are still present in the system. Remove all documents and press the Reset key.

Error 3:21Message: Empty feeders.Action: Load documents.Info: [none]Empty feeders during the Load 'N Go learning cycle.

Error 3:60Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. Remove all documents and press the Reset key.

Error 3:61 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Vertical track sensor defective.During the photocell adjustment the transmitter LED current of the vertical track photocell PH4 1 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.

Error 3:62 (only if OMR is present)Message: Vertical track sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the vertical track photocell PH4 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 3:63 is the same error, but occurs during readjusting this photocell.

Error 3:63 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Vertical track sensor defective.During the adjustment of the vertical track photocell PH4 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall


410.03-60 rev. 01.1 - 06/2004

within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 3:62 is the same error, but occurs during the processing of paper.

Error 3:64 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Vertical track sensor defective.Vertical track photocell (PH4) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.

Error 3:65 (only if OMR is present)Message: Vertical track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the vertical track photocell PH4 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error 3:66 (only if OMR is present)Message: Vertical track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the vertical track photocell PH4 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 3:61 is issued.

Error 3:70Message: Technical failure.Action: Call service.Info: Collator motor failure.Collator motor error. The collator motor M2 is checked via its accompanying pulse disc plus slotted photocell SPH2, Provided SPH2 is correctly operating (see the service software), this motor is probably defective.

Error 3:71Message: Technical failure.Action: Call service.Info: Collator sensor defective.During the photocell adjustment the transmitter LED current of the collator area input photocell PH5 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.


410.03-61rev. 01.1 - 06/2004

Error 3:72Message: Collator sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the collator input photocell PH5 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 3:73 is the same error, but occurs during readjusting this photocell.

Error 3:73Message: Technical failure.Action: Call service.Info: Collator sensor defective.During the adjustment of the collator input photocell PH5 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 3:72 is the same error, but occurs during the processing of paper.

Error 3:74Message: Technical failure.Action: Call service.Info: Collator sensor defective.Collator input photocell (PH5) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.

Error 3:75Message: Collator sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the collator input photocell PH5 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error 3:76Message: Collator sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the collator input photocell PH5 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 3:71 is issued.

Error 3:101 (only if OMR is present)Message: Technical failure.Action: OMR switched off.


410.03-62 rev. 01.1 - 06/2004

Info: Dongle not correct.The checksum and/or the serial check of the dongle is not correct.This error applies to a valid level 1 OMR dongle.

Error 3:102 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Defective reading head.The LED in the reading head is defective.

Error 3:112 (only if OMR is present)Message: Reading error.Action: Remove documents.Info: Wrong window position.The reading window is activated after the document that contains OMR info has passed the reading head. Adjust the reading window parameters.

Error 3:114 (only if OMR is present)Message: Suspected set.Action: Remove suspected set.Info: Suspected after error.This error is issued after a previous reading error and the reading of an insert mark. It is very likely that the reading error probably occurred during the processing of the current set, causing this set and the next set being not complete.

Error 3:120 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Not enough marks.Less marks have been detected than based on the applied reading code. The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.

Error 3:121 (only if OMR is present)Message: Reading error.Action: Remove documents.Info: Multiple basic command.More than one paper flow-related commands (accumulate, insert, divert or stop mark) have been detected. The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.

Error 3:122 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: No basic command.No mark defining the paper flow (accumulate, insert, divert or stop mark) has been detected. The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.


410.03-63rev. 01.1 - 06/2004

Error 3:126 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Wrong parity in code.The parity of the processed code appears to be not correct. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.

Error 3:127 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Undefined mark found.This error code is displayed if a mark is found at a position where no mark is supposed to be present (too many marks or mark conflicting with other marks). The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.

Error 3:128 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Wrong mark distance.This error message occurs if the position of a mark has shifted in such a way that is present in the so-called forbidden zone. This is defined as a percentage of the line distance around a line halfway between two successive lines. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.

Error 3:129 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Too many marks.This error code is displayed if more reading code marks have been detected than may be possible, based on the applied reading code. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.

Error 3:134 (only if OMR is present)Message: Too many sheets.Action: Remove documents.Info: Set size exceeded.The maximum set size is specified in the OMR settings menu. The maximum size is 5, including insets (i.e. selective feeds).Suppose this maximum is X. If sheet X is processed and an accumulation mark has been read or the insert mark has been read and selective feeds must be added to the set, this error is issued.Remove the paper from the collator, reset and press the Start/Stop key to restart the process.

Error 3:135 (only if OMR is present)Message: Final set part.Action: Remove documents.Info: Part of previous set.This is a follow-up of error 3:134. The rest of the oversized set is collated. After this is done, error 3:135 is issued. If the maximum set size is exceeded for the second time, error 3:134 is issued once again.


410.03-64 rev. 01.1 - 06/2004

Error (4:…6:)00Message: Empty feeder.Action: Load documents or ignore.Info: [none]Feeder empty. A feeder tries during 4 seconds to separate a document from the stack in its hopper. If after 4 seconds no paper arrives at the feeder photocell, this error message is displayed. The feeder transport stops. The user can continue the process by placing documents in the empty hopper and pressing the Reset key.

Error (4:…6:)10Message: Feeding failure.Action: Remove documents.Info: Document too thick.Document too thick. One of the feeders produces a double fed sheet during the processing of a document.

Error (4:…6:)11Message: Feeding failure.Action: Check previous set.Info: Wrong reference.Wrong reference. The sheet on which the DFC had been adjusted appears to be a double fed sheet. This error can only occur during the first sheet delivered by a feeder after adjusting the DFC unit.

Error (4:…6:)12Message: Document stoppage.Action: Remove documents.Info: Document too long.Document too long. A document delivered by a feeder appears to be more than 20% longer than the document length specified for this feeder in the current job.

Error (4:…6:)13Message: Document stoppage.Action: Remove documents.Info: Paper jam.Document crash. A document delivered by a feeder appears to be more than 50% longer than the document length specified for this feeder in the current job.

Error (4:…6:)14Message: Document stoppage.Action: Remove documents.Info: Document too short.Document too short. A document delivered by a feeder appears to be more than 45 mm shorter than the document length specified for this feeder in the current job.

Error (4:…6:)51Message: Technical failure.Action: Call service.Info: Feeder sensor defective.


410.03-65rev. 01.1 - 06/2004

During the photocell adjustment the transmitter LED current of the feeder photocell (FPH1..FPH6) is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.Error (4:…6:)52Message: Track sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the feeder photocell (PH1…PH3) is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error (4:…6:)53 is the same error, but occurs during readjusting this photocell.

Error (4:..6:)53Message: Technical failure.Action: Call service.Info: Feeder sensor defective.During the adjustment of the feeder photocell (PH1…PH3) adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears, provided the photocell is involved in the current job.Note. Error (4:…6:)52 is the same error, but occurs during the processing of paper.

Error (4:…6:)54Message: Technical failure.Action: Call service.Info: Track sensor defective.Feeder photocell (PH1…PH3) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears, provided the photocell is involved in the current job.

Error (4:…6:)55Message: Feeder sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the feeder photocell (PH1…PH3) is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.

Error (4:…6:)56Message: Feeder sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the feeder photocell (PH1…PH3) is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error (4:…6:)51 is issued.


410.03-66 rev. 01.1 - 06/2004

Error (4:…6:)60Message: Technical failure.Action: Call service.Info: DFC defective.DFC error. The DFC doesn't measure a difference between paper and no paper. After pressing the Reset key the defective DFC unit is switched off. The incomplete set is diverted. Pressing the Start/Stop key afterwards the process continues without DFC measurement.

Error (4:…6:)61Message: Technical failure.Action: Call service.Info: DFC defective.DFC adjustment error. The DFC unit can not be adjusted. After pressing the Reset key the DFC unit is switched off. After pressing the Start/Stop key the process continues without DFC measurement.

Error (4:…6:)62Message: Technical failure.Action: Call service.Info: DFC defective.DFC presence error. During startup a DFC unit in a certain feeder appears to be not present. During the previous machine session the DFC unit was present. This goes on until the configuration has been reset (see service software chapter). After pressing the Reset key the DFC unit of the relevant feeder is switched off. After pressing the Start/Stop key the process continues without DFC measurement. The DFC unit is still present in the configuration.


410.04-1rev. 01.0 - 06/2004

Parts lists


410.04-2 rev. 01.0 - 06/2004


410.04-3rev. 01.0 - 06/2004

Recommended spare parts

Some of these parts already could be stocked, being part of another recommended spare parts list.

Illustration Description Part code Stock qty.Code nr. Number per number

of installed machines1 10 50

Figure 410.04-61 Hopper complete (auto)* 79.01.53 1 1 2

Figure 410.04-812 Moistening cloth 04.03.06 1 2 4

Figure 410.04-1023 Separation roller (assy.) 95.71.03 1 1 227 Feed roller ∅ 42 mm 73.27.31 1 1 250 Pulley 15T (assy). 93.05.54 1 1 251 Timing belt 95.13.16 1 1 253 Slip clutch CCW 8 mm 95.71.27 1 1 2

56 Conductive bearing 10 mm 04.24.26 10 10 20 - O-ring (for jogger roller) 04.18.76 2 2 4

Figure 410.04-149 Transportation roller ∅ 30 mm 04.18.27 4 8 610 Sensor (including holder) 04.24.53 2 2 449 LED (including holder) 04.24.52 2 2 450 Transportation roller ∅ 30 mm 95.13.12 4 8 1653 Conductive bearing 8 mm 04.24.25 4 8 16 Figure 410.04-185 Rubber roller 96.41.90 1 1 228 Pressure roller (assy.) 96.45.56 4 4 8

Figure 410.04-201 Microswitch (including lever) 98.90.56 1 1 214 Upper sealing roller ∅ 36 mm 73.26.48 1 1 216 Lower sealing roller (assy.) 98.94.33 1 1 223 Conductive bearing 6 mm 04.24.24 4 8 1633 Solenoid 02.10.21 1 1 2

36 Finger 96.40.71 2 4 838 Leaf spring 96.45.64 1 1 241 Hex. head screw M4 x 8 (synthetic) 96.45.66 2 4 843 Adjustable finger 96.40.57 2 4 8


410.04-4 rev. 01.0 - 06/2004

Figure 410.04-2411 Timing belt 96.43.55 1 1 219 Pulse disc sensor (assy.) 82.16.22 1 2 420 Pulse disc 24.12.81 1 1 225 Tensioner roller 96.41.94 1 2 4

Figure 410.04-2610 Clutch CW 8 mm 12.16.66 1 2 4

Figure 410.04-2810 Upper input roller (assy.) 98.95.21 1 1 211 Lower input roller (assy.) 98.95.22 1 1 227 Fold roller (assy.) 98.95.20 1 2 4

Figure 410.04-3010 Timing belt 04.16.21 1 1 214 Drive belt PJ 96.41.55 1 1 2

Figure 410.04-328 Solenoid 12.12.87 1 1 217 Timing belt 04.15.37 1 1 226 Transportation roller ∅ 30 mm 96.43.64 2 2 441 Gear 15T 73.29.42 1 1 2

Figure 410.04-363 Transportation roller ∅ 38 mm 04.29.77 2 4 824 Brush 72.00.05 3 6 12

Figure 410.04-383 Flagswitch 02.10.76 1 1 210 Transportation roller (assy.) 84.17.04 2 4 8

Figure 410.04-401 Upper separation roller 95.11.67 1 2 45 Cover plate 95.11.25 1 1 28 Timing belt 95.11.45 1 1 213 Rubber paper puller 04.00.16 2 4 818 Pulley 28T (timing belt) 95.11.35 1 1 2

63 DFC 79.01.71 1 1 265 Separation roller (lower) 95.11.68 1 2 4

Figure 410.04-4439 Clutch CCW 8 mm 93.05.36 1 2 4

Figure 410.04-4628 Reading head assy. 98.94.34 1 2 4


410.04-5rev. 01.0 - 06/2004

Figure 410.04-4821 Pressure roller assy. (incl. O-ring) 95.20.11 1 2 430 Collating belt set (3 pcs.) 95.20.07 1 1 238 Motor 24V 98.94.09 1 1 250 Pressure roller ∅ 20 mm 95.14.08 2 4 8

Figure 410.04-5212 Motor relay board 230V 97.55.00 1 1 2 - Motor relay board 115V 97.55.40 1 1 218 Power inlet 98.90.05 1 1 2

Figure 410.04-5611 Curve disc RH 95.30.64 1 1 221 Curve disc LH 95.30.63 1 1 2

Figure 410.04-586 Clutch CCW 8 mm 12.14.61 1 1 29 Clutch CW (clockwise) 8 mm 12.14.63 1 1 2

Figure 410.04-601 Lever for flap actuator 95.30.31 1 1 212 Upper fold roller (assy.) 96.46.61 1 1 2

Figure 410.04-6219 Tensioner roller 95.13.19 1 1 2

Figure 410.04-648 Mainboard 98.90.01 1 1 218 Rubber keypad 98.91.3019 Display 98.90.03 1 1 2

Note: Parts marked with an asteriks (*) depending on configuration.


410.04-6 rev. 01.0 - 06/2004

Figure 1

21

35

46

7 8 9 10

21

22

18

19

20

26

25

27

28

30

29

RH

LH

24

11

12

13

14

23

17

16

15


410.04-7rev. 01.0 - 06/2004

Figure 410.04-6

Remarks illustration Description Part code Quantity Remarkscode number number

1 Hopper complete (auto) 79.01.53 22 Short tray 04.26.51 13 Nut M4 45.19.02 104 Hex. head screw M4 x 8 05.38.80 6

Neopost 5 Cover LH (2 station) 98.91.41 1

Hasler, Formax - Cover LH (2 station) 98.95.59 1Satas - Cover LH (2 station) 98.95.53 1Francotyp, blank - Cover LH (2 station) 98.95.68 1Neopost - Cover LH (3 station) 98.92.27 1Hasler, Formax - Cover LH (3 station) 98.95.60 1

Satas - Cover LH (3 station) 98.95.55 1Francotyp, blank - Cover LH (3 station) 98.95.70 1

6 Round head tapping screw 45.38.69 67 Mounting plate 98.91.32 18 Magnetic clip 95.70.90 2

9 Lower cover LH 98.91.99 110 Grommet 12.08.51 111 Spacer 95.73.63 112 Bellows 24.13.05 1

Neopost 13 Hinged cover 98.95.74 1

Hasler - Hinged cover 98.95.78 1Satas - Hinged cover 98.95.75 1Formax - Hinged cover 98.95.76 1Francotyp - Hinged cover 98.95.77 1blank - Hinged cover 98.95.80 1

14 Lower hinged cover 98.91.96 115 Strip 97.00.51 116 Nut M4 45.36.26 317 Washer ∅12 x ∅ 5.2 x 0.7 mm 43.05.35 2 18 Magnet mounting plate 98.91.61 1

19 Screening plate 96.46.13 120 Round head screw M4 x 8 45.38.68 421 Cover plate 96.46.12 122 Water tank 98.92.93 123 Tube 98.94.25 1

24 Countersunk head screw M4 x 10 05.38.75 225 Slide complete 04.23.20 126 Envelope tray (assy.) 98.92.59 127 Self-locking clip 05.26.02 228 Lower cover RH 98.91.56 1

Neopost, Hasler, Satas, Formax 29 Cover RH (2 station) 98.95.54 1Francotyp, blank - Cover RH (2 station) 98.95.61 1Neopost, Hasler, Satas, Formax - Cover RH (3 station) 98.95.58 1Francotyp, blank - Cover RH (3 station) 98.95.73 1

30 Mounting bracket 98.91.89 1


410.04-8 rev. 01.0 - 06/2004

Figure 2

2

3

5

6

8

9

10

18

7

11

12

13

14

LH

RH

19 20

1

4

17 16 15


410.04-9rev. 01.0 - 06/2004

Figure 410.04-8


Neopost, Hasler, Satas, Formax 1 Top cover feeders 98.91.48 1Francotyp, blank - Top cover feeders 98.92.29 1

2 Mounting strip 98.92.79 13 Screw M4 x 14 98.91.83 24 Nut M4 45.19.02 2

5 Collator area cover 96.43.10 16 Round head screw M4 x 8 45.38.68 97 Retaining ring 96.43.36 18 Power supply cover 98.91.55 19 Bottom cover collator area 96.43.18 1

10 Main lead 220V 98.90.51 1- Main lead 110V 98.90.52 -- Main lead 250V Switserland 98.90.54 -- Main lead 240V U.K. 98.90.53 -- Main lead 250V Australia 98.90.55 -

11 Support plate 26.04.52 112 Moistening cloth 04.03.06 113 Clamping strip 24.11.53 814 Water tank 98.92.93 115 Countersunk head screw M4 x 10 05.38.75 3

16 Stud 98.92.19 317 Hex. head screw M4 x 8 05.38.80 318 Bottom plate 98.92.16 1

Neopost, Hasler, Satas, Formax 19 Top cover 98.95.81 1Francotyp, blank - Top cover 98.95.82 1

Neopost, Hasler, Satas, Formax 20 Intermediate cover 98.92.71 1Francotyp, blank - Intermediate cover 98.92.72 1


410.04-10 rev. 01.0 - 06/2004

Figure 3

12

3

910

11

58

59

60

61

62

48

49

50

51

52

53

54

55

56

57

4 6 7 8

12

13

14

15

63

64

65

28

24

23

22

21

27

26

25

30

29

46

36

35

34

32

31

45

44

43

42

41

40

39

38

19

16

17

18

LH

RH

5

20

33

37

47


410.04-11rev. 01.0 - 06/2004

Figure 410.04-10


1 Side guide RH 98.92.26 12 Envelope support (assy.) 95.74.01 13 Side guide LH 98.91.64 14 Round head screw M4 x 16 05.38.71 65 Spring clip 11-15 mm 05.24.73 4

6 Round head screw M4 x 8 05.38.68 77 Lower damper pin RH 96.41.17 18 Support plate 96.41.85 19 Spring clip 6 - 8 mm 05.24.46 4

10 Damper 96.41.40 2

11 Inside frame RH 98.91.39 112 Hinge axle 96.41.14 113 Inside frame (upper unit) RH 98.91.62 114 Damper suspension axle 96.41.20 115 Inside frame (upper unit) LH 98.91.63 1

16 Inside frame LH 98.91.36 117 Spacer ∅ 25 x ∅ 5.5 x 8 mm 43.29.31 218 Rubber stud M6 x 20 04.12.12 219 Frontplate LH 96.45.08 120 Hex. head screw M4 x 8 05.38.80 2

21 Separation spring 95.71.04 122 Separation axle 95.71.05 123 Separation roller (assy.) 95.71.03 124 Set screw M4 x 4 08.28.01 125 Envelope feed axle 98.94.10 1

26 Jogger roller 97.59.52 2- O-ring 04.18.76 2

27 Feed roller ∅ 42 mm 73.27.31 128 Set screw M4 x 6 08.28.02 129 Centre frontplate 96.45.06 1

30 Countersunk head screw M4 x 16 45.38.77 231 Thumb wheel 24.13.58 132 Fixing plate-axle 95.71.26 133 Adj. nut LH 97.54.76 134 Round head screw M4 x 4 45.43.10 6

35 Countersunk head screw M4 x 10 45.38.75 1036 Feed table (assy.) 96.45.05 137 Slide frame 98.92.69 138 Bottom cover 98.92.61 139 Locking spring 03.63.36 2

40 Adj. axle 95.71.12 141 Adj. nut RH 97.54.77 142 Spring clip 9 - 12 mm 05.24.55 143 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 344 Nut M4 (self-locking) 05.36.21 2


410.04-12 rev. 01.0 - 06/2004

Figure 410.04-10


45 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 446 Crinkle washer 05.24.84 247 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 248 Spring clip 8 - 11 mm 05.24.54 149 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2

50 Pulley 15T (assy.) 93.05.54 151 Timing belt 95.13.16 152 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 153 Slip clutch CCW 8mm 95.71.27 154 Cyl. pin ∅ 2.5 x 12 05.23.47 1

55 Spring clip 10 - 14 mm 05.24.83 256 Conductive bearing 10 mm 04.24.26 257 Round head screw M4 x 6 05.38.66 658 Front plate RH 96.45.07 159 Separation frame 96.41.21 1

60 Nut M4 half d. 45.19.19 161 Round head screw M4 x 30 45.43.19 162 Adjusting nut 96.41.54 163 Separation slide 95.71.06 164 Round head screw M3 x 25 45.43.08 1

65 Round head screw M3 x 6 45.43.02 2


410.04-13rev. 01.0 - 06/2004


410.04-14 rev. 01.0 - 06/2004

Figure 4

33 32 31 30 29 28 27 263435363738

43 42 41 39

24 23

40

LH

RH

(10)

4 5 6 7 8 9

10 11 12 13

16 17 18

321

19 20 2221

44

45

46

48

49

47

55 54 53 52 51 50

14 15

25


410.04-15rev. 01.0 - 06/2004

Figure 410.04-14


1 Inside frame LH 98.91.36 12 Envelope guide plate LH 96.42.59 13 Hex. head screw M4 x 8 05.38.80 74 Spring clip 10 - 14 mm 05.24.83 65 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 6

6 Conductive bearing 10 mm 04.24.26 87 Upper frame env. track 96.41.22 18 Cyl. pin ∅ 2.5 x 16 05.23.46 149 Transportation roller ∅ 30 mm 04.18.27 6

10 Sensor (including holder) 04.24.53 2

11 Bracket 96.41.48 112 Nut M4 45.19.02 213 Pan head tapping screw 45.38.55 214 Brush lifter 04.30.20 115 Tension spring 03.11.75 1

16 Clutch shaft 96.41.72 117 Transportation axle 96.41.75 118 Freewheel transportation axle 96.41.88 119 Transportation axle 96.41.71 120 Envelope guide plate RH 96.42.60 1

21 Fixing plate envelope track 95.73.04 122 Inside frame RH 98.91.39 123 Round head screw M4 x 8 05.38.68 424 Round head screw M4 x 25 05.38.72 125 Lifting bracket 04.30.22 1

26 Tension spring 03.35.59 127 Nut M4 (self-locking) 05.36.21 228 Draw bar 96.41.28 129 Clamping ring 3 mm 05.24.63 430 Spacer 04.10.98 1

31 Lever 96.41.32 132 Lifting frame 96.41.24 133 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 134 Mounting plate 96.41.25 135 Lifting roller 96.41.26 1

36 Round head screw M4 x 16 05.38.71 137 Round head screw M4 x 25 45.43.18 138 Sleeve 04.12.16 139 Pressure spring 0.85 mm 43.11.12 240 Pressure spring 0.7 mm 03.11.11 4

41 Air hose 24.13.08 142 Spring clip 9 - 12 mm 05.24.55 243 Air tube plug 24.13.02 244 Air hose connector 04.13.23 245 Bracket 43.34.29 1


410.04-16 rev. 01.0 - 06/2004

Figure 410.04-14


46 Pan head tapping screw 45.38.53 147 Hinge axle 96.43.22 148 Lower frame env. track 96.41.23 149 Led (including holder) 04.24.52 150 Transportation roller ∅ 30 mm 95.13.12 8

51 Spring clip 8 - 11 mm 05.24.54 752 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 653 Conductive bearing 8 mm 04.24.25 654 Axle 96.41.53 155 Axle for pressure rollers 96.41.52 2


410.04-17rev. 01.0 - 06/2004


410.04-18 rev. 01.0 - 06/2004

Figure 5

13

45

67

89

10

11

12

13

14

15

16

17

18

30

29

35

36

24

22

21

20

19

25

28

27

26

34

33

32

31

LH

RH

2

23


410.04-19rev. 01.0 - 06/2004

Figure 410.04-18


1 Sleeve 96.43.70 22 Pin 96.43.71 13 Conductive bearing 10 mm 04.24.26 64 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 55 Rubber roller 96.41.90 1

6 Spring clip 9 - 12 mm 05.24.55 27 Spring clip 10 - 14 mm 05.24.83 38 Transportation axle 96.41.71 19 Cyl. pin ∅ 2.5 x 16 05.23.46 4

10 Transportation roller ∅ 30 mm 04.18.27 4

11 Round head screw M4 x 8 05.38.68 1212 Round head screw M4 x 6 05.38.66 413 Hex. head screw M4 x 8 05.38.80 514 Countersunk tapping screw 05.38.56 115 Bracket 96.45.55 1

16 Sensor (including holder) 04.24.53 117 Mounting plate 96.45.53 118 Hinge axle 96.45.54 119 Pressure spring 0.85 mm 43.11.12 220 Spring clip 7 - 9 mm 05.24.42 2

21 Lifting plate 96.41.29 222 Clamping ring 3 mm 05.24.63 423 Connecting rod 96.41.30 224 Hinge pin 96.41.31 225 Axle for pressure rollers 96.41.70 1

26 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 427 Pressure spring 03.35.51 428 Pressure roller (assy.) 96.45.56 429 Pan head tapping screw 45.38.53 130 Flap scraper 96.41.45 1

31 Nut M4 45.19.02 132 Washer ∅ 12 x ∅ 5.2 x 0.7 mm 43.05.35 133 Bracket 96.41.48 134 Led (including holder) 04.24.52 135 Flap opener 96.41.44 1

36 Draw bar 96.41.28 1


410.04-20 rev. 01.0 - 06/2004

Figure 6

12

35

67

89

10

11

12

13

15

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

48

49

50

51

52

62

63

64

65

66

61

60

59

56

55

54

LH

RH

58

57

14

16

4

47

53


410.04-21rev. 01.0 - 06/2004

Figure 410.04-20


1 Microswitch (incl. lever) 98.90.56 12 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 23 Round head screw M3 x 12 45.43.05 24 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 15 Cover 95.71.52 1

6 Frame axle 95.71.53 27 Pan head tapping screw 45.38.53 28 Protecting plate 95.73.13 19 Sensor (including holder) 04.24.53 1

10 Led (including holder) 04.24.52 1

11 Lock washer 5/32” 05.24.31 612 Round head screw M4 x 8 05.38.68 1013 Countersunk head screw M4 x 10 45.38.75 214 Upper sealing roller ∅ 36 mm 73.26.48 115 Mounting plate 95.72.04 1

16 Lower sealing roller (assy.) 98.94.33 117 Pressure spring 03.11.91 218 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 619 Conductive bearing 10 mm 04.24.26 720 Pressure spring 0.7 mm 03.11.11 2

21 Pressure spring 1.1 mm 03.11.15 122 Round head screw M4 x 6 45.43.12 623 Conductive bearing 6 mm 04.24.24 224 Tension pin ∅ 2 x 12 05.33.15 125 Round head screw M4 x 16 45.43.16 1

26 Actuator disc 96.40.61 127 Nut M4 45.19.02 728 Clamping ring 3 mm 05.24.63 429 Nut M4 (self-locking) 05.36.21 130 Draw bar 96.40.62 1

31 Tension spring 03.35.04 132 Mounting bracket 96.40.63 133 Solenoid 02.10.21 134 Lever for finger 96.40.65 435 Pressure spring 96.40.70 2

36 Finger 96.40.71 237 Cross connection (incl. corkrubber) 96.45.68 1

- Cork rubber 04.18.04 438 Leaf spring 96.45.64 139 Finger slide 96.40.66 2

40 Pressure spring 96.40.73 241 Hex. head screw M4 x 8 (synthetic) 96.45.66 242 Knurled nut 02.11.25 243 Adjustable finger 96.40.57 244 Pulley axle (assy.) 96.43.58 1


410.04-22 rev. 01.0 - 06/2004

Figure 410.04-20


45 Connecting ring 96.45.60 146 Transportation axle (assy.) 96.43.57 147 Transportation table (assy.) 96.45.67 148 Transportation roller 96.41.61 249 Cyl. pin ∅ 2.5 x 16 05.23.46 4

50 Transportation roller ∅ 30 mm 04.18.27 451 Transportation roller ∅ 30 mm 04.30.07 252 Pulse disc axle (assy.) 96.43.59 153 Hex. head screw M4 x 8 05.38.80 1054 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 1

55 Sleeve 96.43.70 256 Pin 96.43.71 157 Pressure spring 1 mm 03.11.14 1058 Wiring plate 98.91.58 159 Round head screw M3 x 6 45.43.02 2

60 Axle 96.41.69 161 Guide plate 96.45.59 162 Insert table 96.45.58 163 Countersunk screw M3 x 16 05.04.14 864 Axle for fingers 96.40.59 1

65 Mounting pin 43.61.75 266 Spring clip 6 - 8 mm 05.24.46 3


410.04-23rev. 01.0 - 06/2004


410.04-24 rev. 01.0 - 06/2004

Figure 7

34

56

78

910

11

12

16

18

19

20

21

22

23

25

24

30

RH

17

29

28

26

31

27

21

13

15

14


410.04-25rev. 01.0 - 06/2004

Figure 410.04-24


1 Belt tensioner 96.46.76 12 Hex. head screw M4 x 8 05.38.80 23 Tension pin ∅ 2.5 x 16 05.33.22 44 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 45 Gear 28T 24.02.61 2

6 Gear 18T 24.09.36 27 Spring clip 9 - 12 mm 05.24.55 38 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 49 Cyl. pin ∅ 2.5 x 20 96.41.93 4

10 Disc for pulley 96.43.56 3

11 Timing belt 96.43.55 112 Pulley 36T 96.41.60 113 Spring clip 10 - 14 mm 05.24.83 414 Mounting plate 96.41.80 115 Round head screw M4 x 6 05.38.66 1

16 Round head screw M3 x 8 05.38.65 317 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 318 Adj. plate 96.41.81 119 Pulse disc sensor (assy.) 82.16.22 120 Pulse disc 24.12.81 1

21 Clamping disc 43.30.46 122 Washer ∅ 20 x ∅ 6.2 x 2 mm 43.07.90 123 Countersunk head screw M4 x 8 45.42.12 124 Pulley 30T 96.41.64 225 Tensioner roller 96.41.94 2

26 Pulley 20T 96.41.57 127 Gear 35T 24.69.52 128 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 129 Gear 18T 96.43.51 230 Round head screw M4 x 8 05.38.68 2

31 Locking plate 96.41.65 2


410.04-26 rev. 01.0 - 06/2004

Figure 8

56

910

11

12

13

14

34

33

32

31

29

26

25

24

28

27

20

42

19

18

16

15

41

401

23

47

8

(23)

RH

39

17

22

(8)

23(1

9)

30

21

35

36


410.04-27rev. 01.0 - 06/2004

Figure 410.04-26


1 Cyl. pin ∅ 2.5 x 12 05.23.47 12 Slip clutch CCW 8mm 95.71.27 13 Timing belt 95.13.16 14 Pulley 15T (assy.) 93.05.54 15 Conductive bearing 10 mm 04.24.26 9

6 Countersunk head screw M4 x 10 45.42.13 27 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 18 Gear 35T 24.69.58 29 Catch disc 23.55.06 1

10 Clutch CW 8 mm 12.16.66 1

11 Cyl. pin ∅ 2.5 x 16 05.23.46 212 Gear 18T 96.41.74 113 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 314 Spring clip 6 - 8 mm 05.24.46 115 Round head screw M4 x 8 05.38.68 1

16 Support plate 96.41.85 117 Spring clip 10 - 14 mm 05.24.83 518 Gear 28T 24.11.40 119 Gear 35T 24.69.52 220 Freewheel clutch assy. 96.43.60 1

21 Spring clip 9 - 12 mm 05.24.55 222 Gear 28T 26.02.61 123 Gear 14T 96.41.79 224 Nut 45.19.20 225 Washer ∅ 17 x ∅ 8.4 x 1.6 mm 45.37.38 2

26 Spring holder disc 24.69.43 227 Pressure spring 1.5 mm 03.11.73 128 Spring clip 8 - 11 mm 05.24.54 229 Gear 18T 24.09.36 130 Gear 15T 96.41.68 1

31 Gear 21T 24.16.50 132 Gear 15T (assy.) 74.69.42 133 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 234 Brake rod 96.41.84 135 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 1

36 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 137 Not used38 Not used39 Tension pin ∅ 2.5 x 16 05.33.22 240 Pulley 13T 96.41.77 1

41 Intermediate axle 96.41.76 142 Tension pin ∅ 2.5 x 20 05.33.24 2


410.04-28 rev. 01.0 - 06/2004

Figure 9

12

34

56

78

9

13

12

11

10

22

21

20

19

18

17

16

15

14

23

24

25

LH

RH

(21)

(18)

(18)

34

33

32

31

30

29

28

27

26


410.04-29rev. 01.0 - 06/2004

Figure 410.04-28


1 Bearing locking plate 93.06.13 22 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 43 Countersunk head screw M4 x 10 05.38.75 64 Conductive bearing 6 mm 04.24.24 45 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 4

6 Spring clip 6 - 8 mm 05.24.46 47 Hex. head screw M4 x 8 05.38.80 58 Washer ∅ 20 x ∅ 6.2 x 2 mm 43.07.90 29 Bearing locking plate 93.06.12 2

10 Upper input roller (assy.) 98.95.21 1

11 Lower input roller (assy.) 98.95.22 112 Screening plate (assy.) 96.42.64 113 Wiring guide 96.42.58 114 Round head screw M3 x 8 05.38.65 415 Countersunk head screw M3 x 10 05.38.74 2

16 Round head screw M3 x 4 45.43.00 217 Cyl. pin ∅ 2.5 x 16 05.23.46 318 Gear 24T 93.05.25 319 Spring clip 10 - 14 mm 05.24.83 520 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 4

21 Gear 35T 24.69.58 222 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 223 Flap actuator 95.30.84 224 Cyl. pin ∅ 2 x 12 95.30.85 225 Round head screw M4 x 16 05.38.71 2

26 Sleeve 04.00.27 227 Fold roller (assy.) 98.95.20 228 Fixing screw M3 x 6 95.30.83 429 Flap assy. incl. torsion spring 04.27.71 230 Torsion spring 03.35.38 2

31 Flap assy. (incl. axle) 04.27.50 232 Synthetic leaf spring 93.06.54 433 Guide bracket 95.30.73 134 Guide strip 93.06.53 1


410.04-30 rev. 01.0 - 06/2004

Figure 10

12

3

45

67

89

10

11

13

14

15

23

24

25

26

RH

16

17

18

19

20

21

22

27

28

29

30

31

12

32


410.04-31rev. 01.0 - 06/2004

Figure 410.04-30


1 Mounting bracket for spring 98.91.16 32 Hex. head screw M4 x 8 05.38.80 83 Fixing plate 95.13.07 24 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 25 Axle for tensioner roller 95.13.10 2

6 Cyl. pin ∅ 2.5 x 16 05.23.46 57 Disc for pulley 93.05.42 48 Tensioner roller 96.43.68 19 Pulley 20T assy. (timing belt) 04.22.46 4

10 Timing belt 04.16.21 1

11 Spring clip 7 - 9 mm 05.24.42 212 Pulley 20T 96.41.57 113 Cyl. pin ∅ 2.5 x 32 05.23.48 114 Drive belt PJ 96.41.55 115 Main pulley 96.41.58 1

16 Spring clip 10 - 14 mm 05.24.83 117 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 218 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 219 Tensioner roller 96.41.67 120 Pulley 50 Hz 98.94.04 1

- Pulley 60 Hz 98.94.05 121 Set screw M4 x 8 08.28.06 122 Belt tensioner 96.41.66 123 Spring clip 9 - 12 mm 05.24.55 124 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 1

25 Gear 30T 96.46.74 126 Spacer ∅ 15 x ∅ 10.4 x 7.5 mm 04.08.28 127 Hex. head screw M4 x 12 45.38.82 428 Spacer ∅ 9 x ∅ 4.1 x 2.5 mm 43.08.51 429 Gear 24T 93.05.25 1

30 Timing belt 95.13.16 131 Motor 220-240V/50Hz 98.94.06 1

- Motor 100-115V/50-60Hz 98.94.07 132 Tensioner roller 95.13.19 1


410.04-32 rev. 01.0 - 06/2004

Figure 11

LH

RH

12

34

56

78

910

11

12

13

14

15

21

27

20

19

18

17

16

22

26

25

24

23

33

32

31

30

29

28

34

35

36

37

42

43

44

45

46

47

39

40

41

38

48

(33)


410.04-33rev. 01.0 - 06/2004

Figure 410.04-32


1 Inside frame (upper unit) LH 98.91.63 12 Loc frame 96.47.25 23 Hex. head screw M4 x 8 05.38.80 114 Round head screw M4 x 16 05.38.71 45 Connecting plate loc 95.72.60 2

6 Pressure spring 03.11.95 17 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 28 Solenoid 12.12.87 19 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 3

10 Round head screw M4 x 5 45.43.11 6

11 Bracket for photocell 96.47.31 112 Pan head tapping screw 45.38.55 113 Led (including holder) 04.24.52 114 Cross connecting plate 96.47.29 115 Inside frame (upper unit) RH 98.91.62 1

16 Spring clip 7 - 9 mm 05.24.42 117 Timing belt 04.15.37 118 Pulley 21T 04.18.70 119 Cyl. pin ∅ 2.5 x 16 05.23.46 620 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 9

21 Conductive bearing 10 mm 04.24.26 1022 Drive axle 96.47.23 123 Round head screw M4 x 8 05.38.68 424 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 225 Paper guide 96.47.30 2

26 Transportation roller ∅ 30 mm 96.43.64 227 Pressure spring 0.85 mm 43.11.12 328 Spring clip 10 - 14 mm 05.24.83 429 Tension spring 03.35.62 230 Bearing plate 96.47.20 1

31 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 332 Spacer ∅ 15 x ∅ 10.4 x 7.5 mm 04.08.28 233 Gear 15T 24.09.44 234 Gear 14T 96.41.79 135 Axle 96.47.17 1

36 Gear 20T 24.02.58 137 Bearing plate 96.47.19 138 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 239 Bearing plate 96.47.21 140 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 2

41 Gear 15T 73.29.42 142 Rod 43.26.81 143 Transportation axle 96.47.18 144 Bearing plate 96.47.22 145 Clamping ring 3 mm 05.24.63 4


410.04-34 rev. 01.0 - 06/2004

Figure 410.04-32


46 Draw bar 43.26.79 147 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 348 Transportation roller ∅ 30 mm 04.18.27 2


410.04-35rev. 01.0 - 06/2004


410.04-36 rev. 01.0 - 06/2004

Figure 12

LH

RH

12

34

56

78

910

11

12

13

14

16

17

18

20

19

21

22

23

24

28

27

26

25

15


410.04-37rev. 01.0 - 06/2004

Figure 410.04-36


1 Inside frame (upper unit) LH 98.91.63 12 Cyl. pin ∅ 2.5 x 16 05.23.46 23 Transportation roller ∅ 38 mm 04.29.77 24 Loc frame 96.47.25 25 Nut M4 (self-locking) 05.36.21 2

6 Hex. head screw M4 x 8 05.38.80 147 Spring lever 23.28.74 18 Tension spring 45.64.04 19 Nut M4 45.19.02 1

10 Countersunk head screw M4 x 10 05.38.75 3

11 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 212 Round head screw M4 x 16 05.38.71 113 Pressure spring 0.85 mm 43.11.12 214 Conductive bearing 10 mm 04.24.26 215 Spring clip 10 - 14 mm 05.24.83 2

16 Axle 23.29.10 117 Bracket 96.47.34 118 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 119 Inside frame (upper unit) RH 98.91.62 120 Cross bar 96.47.27 1

21 Buffer (assy.) 83.34.97 122 Retaining spring 03.11.87 323 Grommet 12.04.74 324 Brush 72.00.05 325 Locking bracket 04.30.23 1

26 Brush holder 04.29.94 127 Lifting bracket 96.47.33 128 Sleeve 04.09.77 1


410.04-38 rev. 01.0 - 06/2004

Figure 13

LH

RH

1 2 3 4

5 6 7 8 9

10

11

12

13

14

15

16

17

18

19

28

29

30

31

26

27

35

36

37

20

21

22

24

23

42

41

40

39

38

34

33

32

25


410.04-39rev. 01.0 - 06/2004

Figure 410.04-38


1 Round head screw M4 x 5 45.43.11 32 Bracket for flagswitch 96.47.13 13 Flagswitch 02.10.76 14 Solenoid 12.12.87 15 Mounting frame 96.47.11 1

6 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 47 Lever 96.47.03 18 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 89 Brake plate 98.92.77 1

10 Transportation roller (assy.) 84.17.04 2

11 Spring clip 6 - 8 mm 05.24.46 412 Hinge bracket 96.47.02 113 Hex. head screw M4 x 8 05.38.80 1414 Inside frame (upper unit) RH 98.91.62 115 Tension pin ∅ 2.5 x 16 05.33.22 2

16 Gear 15T 96.41.68 217 Pulley 15T 04.18.64 118 Timing belt 04.15.37 119 Cyl. pin ∅ 2.5 x 14 04.20.97 120 Round head screw M4 x 8 45.38.68 2

21 Cover plate 96.47.26 122 Loc frame 96.47.25 223 Cross bar 96.47.27 124 Inside frame (upper unit) LH 98.91.63 125 Grommet 98.92.75 1

26 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 127 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 428 Transportation axle 23.26.00 129 Conductive bearing 10 mm 04.24.24 630 Pressure spring 0.7 mm 03.11.11 2

31 Spring clip 10 - 14 mm 05.24.83 632 Transportation roller ∅ 38 mm 04.29.77 233 Cyl. pin ∅ 2.5 x 16 05.23.46 434 Transportation roller ∅ 30 mm 04.18.27 235 Ejection axle 96.47.24 1

36 Divert axle 96.47.16 237 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 438 Nut M4 45.19.02 239 Clamping ring 3 mm 05.24.63 440 Draw bar 96.47.08 1

41 Pressure spring 03.11.95 142 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2


410.04-40 rev. 01.0 - 06/2004

Figure 14

96

13

14

17

54

53

52

57

56

55 48

47

45

43

44

30

28

27

61

18

54

63

87

16

26

62

10

11

19

20

21

22

23

24

15

31

32

33

34

37

38

39

40

41

42

12

25

29

46

49

50

51

12

3

60

59

58

35

36

66

64

65


410.04-41rev. 01.0 - 06/2004

Figure 410.04-40


1 Upper separation roller 95.11.67 12 Tension pin ∅ 2.5 x 12 05.33.20 13 Pulley 95.11.42 14 Spring clip 7 - 9 mm 05.24.42 85 Cover plate 95.11.25 1

6 Transportation roller ∅ 30 mm 95.11.36 27 Transportation axle 95.11.37 18 Timing belt 95.11.45 19 Transportation axle (separation) 95.11.39 1

10 Pressure spring 03.11.14 1

11 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 1012 Self-lubricating bearing 06.09.31 113 Rubber paper puller 04.00.16 214 Spring clip 6 - 8 mm 05.24.46 915 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 5

16 Conductive bearing 6 mm 04.24.24 417 Cyl. pin ∅ 2.5 x 12 05.23.47 118 Pulley 28T (timing belt) 95.11.35 119 Transportation axle 95.11.34 120 Clamping bush 95.11.41 1

21 Mounting strip 98.93.21 122 Upper plate feeder 98.93.04 123 Bottom plate assy. (daily mail feeder) 98.93.26 124 Frame plate feeder 98.93.05 225 Pressure spring 03.35.20 2

26 Round head screw M4 x 30 45.43.19 127 Nut M4 (self-locking) 05.36.21 128 Spacer 95.13.37 129 Round head screw M4 x 8 05.38.68 1730 Conductive bearing 8 mm 04.24.25 2

31 Drive axle 96.42.16 132 Separation axle assy. (daily mail) 04.23.11 133 Cyl. pin ∅ 2.5 x 16 05.23.46 234 Transportation roller 95.13.12 235 Fixing strip 95.11.82 1

36 Fixing strip 98.93.18 137 Sleeve 04.11.57 138 Slide 95.11.78 139 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 640 Nut M4 45.19.02 2

41 Wire spring 95.11.79 142 Round head screw M3 x 4 45.43.00 143 Drive axle extension 96.42.20 144 Hinge arm 98.93.12 145 Curved spring assy. 04.28.80 1


410.04-42 rev. 01.0 - 06/2004

Figure 410.04-40


46 Spring lever 98.93.09 148 Gear 48T 95.11.32 147 Cyl. pin ∅ 2 x 16 05.23.69 249 Pulley 44T 95.11.51 150 Tensioner roller 95.11.59 1

51 Belt tensioner 98.93.22 152 Gear 64T (assy.) 95.11.38 153 Support axle extension 95.11.09 154 Tension pin ∅ 2.5 x 10 05.33.19 155 Fibre washer ∅ 10 x ∅ 5.2 x 1 mm 04.01.07 2

56 Bearing bush 04.13.32 157 Spring clip 5 - 7 mm 05.24.66 158 Led (including holder) 04.24.52 159 Bracket for photocell 98.93.10 160 Pan head tapping screw 45.38.55 2

61 Cork strip 95.11.26 262 Sensor (including holder) 04.24.53 163 DFC 79.01.71 164 Bottom plate assy. 98.93.08 165 Separation roller (lower) 95.11.68 1

66 Separation axle assy. (auto) 04.22.63 1


410.04-43rev. 01.0 - 06/2004


410.04-44 rev. 01.0 - 06/2004

Figure 15

LH

RH

45

67

89

10

11

12

13

14

19

20

21

32

31

30

29

28

27

26

25

23

22

33

24

34

41

42

40

39

38

37

3643

44

32

115

18

17

35

16


410.04-45rev. 01.0 - 06/2004

Figure 410.04-44


1 Countersunk head tapping screw 45.38.56 12 Led (including holder) 04.24.52 13 Hex. head screw M4 x 8 05.38.80 104 Guide plate 98.94.16 15 Round head screw M4 x 6 05.38.66 17

6 Hinge pin 98.93.23 67 Countersunk head screw M4 x 10 05.38.75 28 Round head screw M4 x 8 05.38.68 69 Pin 98.91.49 2

10 Mounting plate 96.53.31 1

11 Microswitch (incl. lever) 98.90.56 112 Mounting plate 98.91.87 113 Mounting bracket for spring 98.91.16 314 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 515 Nut M3 45.19.01 2

16 Tension spring 95.11.50 317 Top frame (2 station) 98.91.50 1

- Top frame (3 station) 98.91.14 118 Inside frame RH 98.91.39 119 Cover plate 95.13.27 1

20 Centre cover plate 96.46.25 121 Lower cover plate 96.46.15 122 Frame axle 95.13.24 323 Drive axle 96.46.52 124 Drive axle 95.13.04 2

25 Nylon bearing 04.12.71 626 Spring clip 9 - 12 mm 05.24.55 627 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 328 Lever 95.10.21 229 Tension pin ∅ 2.5 x 12 05.33.20 3

30 Torsion spring 95.13.28 331 Cyl. pin ∅ 2.5 x 16 05.23.46 832 Round head screw M3 x 16 05.38.67 333 Transportation roller ∅ 30 mm 04.18.27 834 Safety bracket 95.13.23 2

35 Inside frame LH 98.91.36 136 Blocking bracket 96.46.77 337 Pulley 44T 95.13.08 338 Disc pulley 93.05.39 339 Clutch CCW 8 mm 93.05.36 3

40 Spring clip 6 - 8 mm 05.24.46 341 Timing belt set (3 pcs) 84.15.74 142 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 643 Conductive bearing 8 mm 04.24.25 344 Tension spring 45.54.04 3


410.04-46 rev. 01.0 - 06/2004

Figure 16

LH

RH

11

12

16

35

17

18

19

13

14

15

28

27

26

25

24

23

22

21

20

34

33

32

31

30

29

12

67

34

58

910


410.04-47rev. 01.0 - 06/2004

Figure 410.04-46


1 Round head screw M4 x 16 05.38.71 22 Round head screw M4 x 20 45.43.17 43 Hinge pin 98.91.60 24 Selflocking nut M3 05.36.28 25 Tension spring 03.35.61 3

6 Nut M3 45.19.01 27 Lock 98.92.64 28 Nut M4 45.19.02 29 Retaining bush 98.92.65 2

10 Countersunk head screw M3 x 16 45.42.05 2

Neopost, Hasler, Satas, Formax 11 Handle 98.91.88 1Francotyp, blank - Handle 98.95.64 1

12 Locking plate 98.92.63 113 Frame vertical transport (2 station) 98.91.97 1

- Frame vertical transport (3 station) 98.91.70 1

14 Cable guide 93.09.54 115 Inside frame (upper unit) RH 98.91.62 116 Refer to 1217 Round head screw M4 x 8 05.38.68 1218 Positioning plate 98.91.57 1

19 Hex. head screw M4 x 8 05.38.80 620 Pan head tapping screw 45.38.53 121 Mounting bracket 96.41.43 122 Sensor (including holder) 04.24.53 123 Guide plate (upper) 98.91.98 ?

24 Guide plate (centre) 96.42.12 125 Guide plate (lower) 96.42.11 126 Rod 96.42.01 227 Paper guide 04.18.09 628 Reading head assy. 98.94.34 1

29 Transportation roller ∅ 30 mm 95.11.36 830 Pressure roller axle 95.14.16 331 Spring clip 6 - 8 mm 05.24.46 632 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 633 Conductive bearing 6 mm 04.24.24 6

34 Pressure spring 03.35.20 635 Inside frame (upper unit) LH 98.91.63 1


410.04-48 rev. 01.0 - 06/2004

Figure 17

LH

RH

12

34

56

78

52

54

53

44

45

13

12

51

50

55

40

39

38

37

36

35

34

33

32

31

42

43

10

16

15

14

11

22

21

19

18

23

24

25

26

27

28

29

49

48

47

46

30

20

17

9

41


410.04-49rev. 01.0 - 06/2004

Figure 410.04-48


1 Inside frame LH 98.91.36 12 Tension spring 03.35.39 23 Nut M4 45.19.02 14 Hinged guide plate 96.41.34 15 Sensor (including holder) 04.24.53 2

6 Pan head tapping screw 45.38.55 27 Leaf spring 98.94.23 18 Frame 96.43.04 19 Hex. head screw M4 x 8 05.38.80 7

10 Inside frame RH 98.91.39 1

11 Roller 98.94.01 612 Cyl. pin ∅ 2 x 16 05.23.69 613 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 1014 Conductive bearing 6 mm 04.24.24 215 Frame (collator area) 96.43.02 1

16 Axle 96.43.06 117 Tensioner 96.43.00 118 Pressure spring 96.43.32 219 Guide plate 96.43.01 120 Spring clip 6 - 8 mm 05.24.46 6

21 Pressure roller assy. (incl. O-ring) 95.20.11 322 Hinge axle 96.43.08 423 Pressure spring 03.35.43 224 Axle 96.43.09 1

25 Belt tensioner 95.20.15 226 Set screw M4 x 4 08.28.01 227 Nylon bearing 04.11.07 428 Spring clip 4 - 5 mm 05.24.47 829 Round head screw M3 x 8 05.38.65 3

30 Collating belt set (3 pcs.) 95.20.07 131 Drive axle (collator area) 98.94.35 132 Conductive bearing 8 mm 04.24.25 133 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 334 Set screw M4 x 4 08.28.01 135 Roller 98.94.00 3

36 Bushing ∅ 15 x ∅ 10.2 x 5.5 mm 75.37.51 137 Frame collator motor 98.94.21 138 Motor 24V 98.94.09 139 Pulse disc sensor (assy.) 97.55.05 140 Set screw M3 x 4 08.28.33 541 Pulse disc 96.43.43 1

42 Round head screw M4 x 6 05.38.66 243 Round head screw M4 x 16 05.38.71 444 Spring clip 8 - 11 05.24.54 145 Clamping ring 05.24.86 1


410.04-50 rev. 01.0 - 06/2004

Figure 410.04-48


46 Round head screw M4 x 8 05.38.68 347 Pan head tapping screw 45.38.53 248 Mounting bracket 96.43.12 149 Led (including holder) 04.24.52 250 Pressure roller ∅ 20 mm 95.14.08 2

51 Axle ∅ 6 mm 98.94.24 152 Cil. pin ∅ 2.5 x 16 05.23.46 253 Transportation roller ∅ 30 mm 04.18.27 254 Transportation axle (assy.) 96.46.54 155 Paper guide strip 96.41.33 1


410.04-51rev. 01.0 - 06/2004


410.04-52 rev. 01.0 - 06/2004

Figure 18

LH

RH

1 2 3

6

7

8

9

11

12

16 15 14 13

17

18

19

20

21

29

27

25

24

5

4

36 37 38 39 40 41 42

30

31

32

33

34

35

26

23

28

10

22


410.04-53rev. 01.0 - 06/2004

Figure 410.04-52


1 Collating plate 96.43.17 12 Paper stop 95.21.41 23 Round head screw M4 x 8 05.38.68 164 Cover plate RH 96.43.28 15 Frame collating area 96.43.16 1

6 Microswitch (incl. lever) 98.90.56 17 Screening plate 46.43.37 18 Round head screw M3 x 12 45.43.05 29 Countersunk head screw M4 x 10 45.38.75 1

10 Isolating plate 98.90.04 1

11 Printed board holder 04.10.75 412 Motor relay board 230V 97.55.00 1

- Motor relay board 115V 97.55.40 113 Guide plate 98.92.01 214 Spring clip 6 - 8 mm 05.24.46 6

15 Tension spring 03.35.36 216 Hinge axle 98.92.04 117 Fuse 2.5A/230V slow blow 97.55.43 1

- Fuse 5A/125V 12.15.49 118 Power inlet 98.90.05 1

19 Round head screw M4 x 25 05.38.72 220 Synthetic stud 24.14.62 221 Hex. head screw M4 x 8 05.38.80 222 Power supply 98.90.02 123 Power supply frame 98.92.03 1

24 Capacitor 5 mF (230 V) 98.90.06 1- Capacitor 20 mF (115 V) 12.12.81 1

25 Capacitor 5 mF (230 V) 98.90.06 1- Capacitor 20 mF (115 V) 12.12.81 1

26 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 2

27 Lock washer 5/32” 05.24.31 228 Guide roller 96.43.19 229 Cover plate LH 96.43.27 130 Hinge axle 96.43.22 131 Spring clip 10 - 14 mm 05.24.83 4

32 Clamping ring 4 mm 05.24.62 233 Rod 96.43.25 134 Spring clip 5 - 7 mm 05.24.66 3635 Counter roller 95.21.11 1836 Nut M4 45.19.02 4

37 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 438 Axle 95.21.12 239 Tilting plate 95.21.14 240 Tension spring 45.64.04 141 Roller 95.21.13 1


410.04-54 rev. 01.0 - 06/2004

Figure 410.04-52


42 Transportation axle 96.43.24 6


410.04-55rev. 01.0 - 06/2004


410.04-56 rev. 01.0 - 06/2004

Figure 19

3 4 5 6 7 8 9 10 11

12 13 14 15

20

18

17

16

21

22 23 24

25 26 27 28 29

LH

RH

LH

RH

19

1 2


410.04-57rev. 01.0 - 06/2004

Figure 410.04-56


1 Round head screw M4 x 16 05.38.71 42 Leaf spring 95.30.60 23 Round head screw M4 x 8 05.38.68 24 Locking plate 95.30.95 15 Bracket 95.30.90 2

6 Spring clip 10 - 14 mm 05.24.83 47 Conductive bearing 10 mm 04.24.26 48 Tension pin Ø 2.5 x 20 05.33.24 49 Curve axle 95.31.10 2

10 Mounting bracket 95.30.56 1

11 Curve disc RH 95.30.64 212 Guide plate (assy.) (first fold table) 95.30.51 113 Countersunk head screw M3 x 10 05.38.74 1414 Axle for fold plate 95.30.30 215 Hinge plate RH 95.30.11 2

16 Fold plate 96.42.07 117 Hinge strip (paper guide) LH 95.30.20 218 Hinge plate LH 95.30.10 219 Washer Ø 14 x Ø 8.2 x 0.8 mm 04.01.41 420 Spring clip 7 - 9 mm 05.24.42 4

21 Curve disc LH 95.30.63 222 Nut M4 45.19.02 223 Washer Ø 12 x Ø 4.3 x 1 mm 45.37.43 224 Mounting bracket 95.30.59 125 Guide plate (second fold table) 95.30.53 1

26 Paper guide 95.30.26 127 Hinge strip (paper guide) RH 95.30.21 128 Set screw M4 x 4 08.28.01 329 Fold plate 95.30.16 1


410.04-58 rev. 01.0 - 06/2004

Figure 20

12

34

5

67

8

9

10

LH

RH


410.04-59rev. 01.0 - 06/2004

Figure 410.04-58


1 Conductive bearing 8 mm 04.24.25 22 Spacer ∅ 12 x ∅ 8.3 x 3 mm 04.10.50 13 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 64 Spring clip 7 - 9 mm 05.24.42 45 Gear 32T (incl. catch) 96.42.19 2

6 Clutch CCW 8 mm 12.14.61 17 Cyl. pin ∅ 2.5 x 12 05.23.47 28 Spacer ∅ 18 x ∅ 12.8 x 3 mm 04.08.71 29 Clutch CW (clockwise) 8 mm 12.14.63 1

10 Drive axle (fold) 93.05.10 1


410.04-60 rev. 01.0 - 06/2004

Figure 21

LH

12

34

5

67

89

10

11

12

13

14

15

16

17

18

24

25

26

27

28

23

22

21

20

19


410.04-61rev. 01.0 - 06/2004

Figure 410.04-60


1 Lever for flap actuator 95.30.31 22 Cyl. pin ∅ 2 x 18 05.23.07 23 Spring clip 8 - 11 mm 05.24.54 24 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 45 Conductive bearing 8 mm 04.24.25 2

6 Inside frame (upper unit) LH 98.91.63 17 Bracket 97.54.61 28 Pulse disc sensor 97.55.05 29 Round head screw M4 x 5 45.43.11 8

10 Guide plate 96.41.38 1

11 Round head screw M4 x 6 05.38.66 112 Upper fold roller (assy.) 96.46.61 113 Fold roller (assy.) 98.95.20 114 Guide strip 95.30.73 115 Round head screw M3 x 8 05.38.68 1

16 Bearing locking plate 93.06.13 117 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 218 Countersunk head screw M4 x 10 05.38.75 219 Torsion spring 95.30.70 220 Round head screw M4 x 16 05.38.71 2

21 Ball bearing 03.12.81 222 Positioning lever 95.30.68 223 Nut M4 (self-locking) 05.36.21 224 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 625 Spring clip 9 - 12 mm 05.24.55 2

26 Brake disc 95.30.66 227 Cyl. pin ∅ 2.5 x 16 05.23.46 228 Conductive bearing 10 mm 04.24.26 2


410.04-62 rev. 01.0 - 06/2004

Figure 22

35

36

31

37

38

39

40

RH

56

43

21

7 8 9 10

12

13

14

15

16

17

18

19

20

21

22

30

29

28

27

26

32

25

24

23

33

34

11


410.04-63rev. 01.0 - 06/2004

Figure 410.04-62


1 Inside frame (upper unit) RH 98.91.62 12 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 73 Conductive bearing 8 mm 04.24.25 24 Countersunk head screw M4 x 10 05.38.75 45 Spring clip 8 - 11 mm 05.24.54 3

6 Belt tensioner 96.46.68 17 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 28 Round head screw M4 x 6 05.38.66 79 Tension axle 96.46.69 1

10 Spacer 04.10.98 1

11 Brush lever 04.30.21 112 Hex. head screw M4 x 8 05.38.80 113 Locking plate 96.41.65 114 Cyl. pin ∅ 2.5 x 12 05.23.47 115 Slip clutch CCW 8mm 95.71.27 1

16 Pulley 15T (assy.) 93.05.54 117 Washer ∅ 17 x ∅ 8.4 x 1.6 mm 45.37.38 118 Washer ∅ 14 x ∅ 6.5 x 0.8 mm 43.02.47 119 Tensioner roller 95.13.19 120 Timing belt 04.16.21 1

21 Set screw M4 x 6 08.28.02 122 Pulley 04.14.23 123 Spring clip 10 - 14 mm 05.24.83 224 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 125 Gear 24T 93.05.25 2

26 Cyl. pin ∅ 2.5 x 16 05.23.46 427 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 128 Gear 35T 24.69.58 129 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 230 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 2

31 Bearing locking plate 93.06.13 132 Pressure spring 95.31.00 233 Brake disc 95.30.94 434 Brake strip 95.30.97 135 Conductive bearing 10 mm 04.24.26 2

36 Round head screw M3 x 8 05.38.68 137 Guide strip 95.30.73 138 Fold roller (assy.) 98.95.20 139 Upper fold roller (assy.) 96.46.61 140 Guide plate 96.41.38 1


410.04-64 rev. 01.0 - 06/2004

Figure 23

54321

12

11

10

98

76

19

18

17

16

15

14

13

RH

LH


410.04-65rev. 01.0 - 06/2004

Figure 410.04-64


Neopost, Hasler, Satas, Formax 1 Top cover 98.95.81 1Francotyp, blank - Top cover 98.95.82 1

2 Inside frame (upper unit) RH 98.91.62 13 Mounting plate top cover 98.92.31 14 Hex. head screw M4 x 8 05.38.80 1

5 Inside frame (upper unit) LH 98.91.63 16 Round head screw M4 x 35 45.43.20 17 Lock washer 5/32” 05.24.31 18 Mainboard 98.90.01 19 Dongle socket Note 1

10 Spacer ∅ 8 x ∅ 4 x 25 mm 04.08.83 111 Inside frame LH 98.91.36 112 PCB holder 93.08.07 513 Nut M4 45.19.02 314 Screw 5 x 14 98.91.83 4

15 Round head screw M3 x 10 98.91.82 316 Mounting plate display 98.91.65 117 Spacer 04.08.49 418 Rubber key pad 98.91.30 119 Display 98.90.03 1

Note 1: Dongle (2 station) 98.90.70 1Dongle OMR 98.90.71 1


410.04-66 rev. 01.0 - 06/2004