service manual SI 62 SI 62

Transcription

1 SI 6

2 Contents Section Page General Process description 0.0- Mechanical description 0.0- Electrical description 0.0- Parts lists 0.0-

3 General rev /

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5 Contents Section Page Function 6 Specifications 7. Machine specifications 7. Paper Insert specifications 8. Envelope insert specifications 8. Envelope and paper insert specifications 9 Preparing the machine for use 0. Unpacking 0 rev /

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7 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. rev /

8 Function figure. Refer to figure.. The SI 6 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 6 is equipped with a variety of special features as programmable jobs, Load N Go, FlexFeed (), double feed control, hopper swap, multifeed, daily mail and PowerFold () rev /00

9 Specifications. Machine specifications Model : SI 6 Type Overall Dimensions height width length : inserter system for medium office use. - station system : 670 mm (6. inch) : 0 mm (6.5 inch) : 00 mm (. inch) (with side exit 00 mm/7. inch receiving tray 50 mm/ 5. inch) Weight : 80 kg (76 lb) Noise level : < 70 db(a) (following ISO 0) Theoretical max. speed Operating temperature : 00 inserts p/h, depending on application. : 0-0 C (50-0 F) Humidity : 0-80% Power consumption Approvals : 00V AC / 50Hz /,0 Amps 5V AC / 60Hz /,0 Amps 0V AC / 50Hz /,5 Amps : EMC Certificate conform EMC-Directive. FCC Certificate conform 7CFR, part 5. CB Certificate conform IEC UL listed I.T.E. (Information Technology Equipment), conform UL-IEC 60950, file: E580. Conform NEN-EN-IEC and derivates. rev /

10 . Paper Insert specifications Paper sizes minimum maximum width* : 0 mm (5. inch) 6 mm (9. inch) length** : 90 mm (.5 inch) 56 mm (.0 inch) Quality*** : 60 gr/m 50 gr/m (5 lb bond) (6.5 lb bond) Booklets up to approximately mm (0.0 inch) thickness, depending on stiffness. Folding capacity : 5 sheets (max. 80 gr/m ) * When folded max. 0 mm (9. inch) ** The minimum document size used for the upper feeder is 5 mm (.5 inch) *** When folded max. 70 gr/m.. Envelope insert specifications Envelope sizes : Standard BRE (Business Reply Envelopes) minimum maximum Quality : 80 gr/m 0 gr/m (0 lb bond) (0 lb bond) rev /00

11 . 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. A B C D E F G minimum size maximum size mm g/m inches g/m mm 8 6 B - 5 A - ** B - 6.5* inches B -.5. A - 0.7** B * Booklets up to approximately mm (0.0 inch) thickness, depending on stiffness. ** When insert is more than mm: A - 5/A inch. 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 0 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 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. rev /

12 Preparing the machine for use First the machine must be unpacked. After unpacking and installing the machine is ready for use.. Unpacking Step Step Step Step 80 Kgs 76 Lbs Place the machine in the optional furniture or on a solid table figure rev /00

13 Process description rev /

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15 Contents Section Page Overview 5. Feeding documents 5. Vertical document transport 6. Transport to and from the collator 6. Folding 7.5 Envelope transport 8.6 Document input and insert 8.7 Envelope ejecting, sealing and exiting 9.8 Parallel processing 9.9 Legend rev /

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17 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 0.0) provide mechanical details.. Feeding documents Only feeders with automatic separation are used. The upper feeder (in position or ) 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 ½-station, a -station and a ½-station version. In the version with three feeders (the ½-station version) the lowest feeder (the "½", in position ) can only process documents with a length of up to about 50 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 79-8 (feeder ), 7-7 (feeder ) or (feeder ) and exited to the vertical track by 77 and 78 (feeder ), 70 and 7 (feeder ) or 6 and 6 (feeder ). The paper transport is monitored by the feeder photocell PH (feeder ), PH (feeder ) or PH (feeder ). The double feed security check is performed by the Double Feed Control unit DFC (feeder ), DFC (feeder ) and DFC (feeder ). The feeders are mechanically driven from the main motor M by a clutch (feeder clutches CL, CL and CL). The combination of CL and PH (CL and PH; CL and PH) 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, 7, 8) 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 (7, 8) 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 5 and 5 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 5-5 degrees free stroke, but as well by the rev /

18 fact that roller 67 (7, 8) has freewheel action in forward direction. The latter is necessary to enable the paper acceleration in the feeder.. Vertical document transport The vertical track consists of one driven axle per feeder (75, 68, 6), plus one driven axle in the lower vertical track (5). 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 RH. The driven rollers have their counterparts in rollers 76, 69, 6 and. If the OMR option is installed, the paper transport prior to entering the reading head is monitored by the reading head photocell PH. (The reading head RH is present if the OMR option is installed. In the overview it is located directly below PH.) 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. for details on the way in which a set is composed.. 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 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 (6, 50, 5, 56 and 60) that can be driven in both directions by the collator motor M, and a set of counter rollers 7, 8, 9, 5, rev /00

19 5, 55 and 58. In the IN direction of M 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 5 and 57 are not used.) During shunting the collator motor M 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 M 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 5 and 56 as well.. 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 and. Fold deflector moves up, so paper entering the first fold pocket will be directed in upward direction. At the appropriate time fold deflector moves down and the fold knife 0 (which hinges around axle 9) moves forward: the first fold will be made. Directly after the fold has been made fold knife 0 returns to the rest position. This process is controlled by the first fold pocket clutch CL, which drives the curve gear 7, which controls the movement of fold knife 0 and fold deflector. The axle for the curve gear also carries the brake disc 8, the status of which is monitored by slotted photocell SPH. The 60 degrees fold cycle of the brake disk consists of a 0 degrees part (fold deflector upwards) and a 0 degrees path (fold deflector downwards plus the impact action of 0). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle 9 also carries the lever for the actuator of fold deflector. In this way all movements related to the first fold pocket are synchronized. After leaving the fold rollers 5 and 6 the paper enters the second fold pocket. The fold deflector moves up, so paper entering the second fold pocket will be directed in upward direction. The paper guide 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 and a fixed guide plate (not shown in the figure, but to the left of ). At the appropriate time the fold deflector moves back and both the fold knife and the guide plate (which both hinge around axle ) move forward: the second fold will be made. Directly after the fold has been made, fold knife returns to its rest position. This process is controlled by the second fold pocket clutch CL5, which drives the curve gear 9, which controls the movement of fold knife, paper guide and fold deflector. The axle for the curve gear also carries the brake disc 0, the status of which is monitored by slotted photocell SPH. The 60 degrees fold cycle of the brake disk consists of a rev /

20 0 degrees part (fold deflector and paper guide upwards) and a 0 degrees path (fold deflector and paper guide downwards plus the impact action of ). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle also carries the lever for the actuator of fold deflector. 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 7 plus 8 and plus ) to the insert table..5 Envelope transport All the rollers for this process stage (,, 6, 8, 0 and ) 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, 5, 7, 9 and 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 and ) 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, 0 and is higher than the transport speed at rollers, 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 ( and ) an envelope is separated from the stack in the hopper and transported via three pairs of transport rollers ( - 8). The envelope track photocell PH7 detects the leading and trailing edge of the envelope. The envelope then passes the flap rollers 9 and 0. The combined action of the flap scraper and the lower linear speed of the flap rollers 9 and 0 (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 SPH) 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 and. (The envelope stop position can be corrected via the user interface of this machine.).6 Document input and insert Once the envelope is on the insert table, the fingers solenoid So is shortly activated. The fingers are moved forward into the envelope. The envelope stays in place, for it is fixed between and. 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 7 plus 8 and by plus ), is detected by the insert table photocell PH9 and passes under the fingers before entering the envelope rev /00

21 .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 So is shortly activated, resulting in the ejection roller 6 moving down. (By spring action, after switching So off, these driven rollers are pulled high again.) Now the envelope is ejected from the insert table. So is deactivated as soon as safely can be assumed that the filled envelope is between 7 and 8, so further transport is guaranteed. The filled envelope passes rollers 7 and 8, the moistening brushes, the sealing track rollers 9 and 0 and the lower sealing roller plus its counter roller. The leading envelope edge triggers flag switch FS. The upper reverse roller 5 is held high (i.e. this roller doesn't contact the lower reverse roller ) by a spring. A certain time after triggering FS the sealing solenoid So is activated. At this moment the envelope flap is still between and. 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 So 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 and, this is now the leading edge of the envelope being transported through the sealing rollers and. After passing the sealing rollers the envelope is exited to the exit of the machine. The sealing solenoid So is switched off as soon as the leading envelope edge is detected by the exit photocell PH0. The exit photocell PH0 monitors the passing envelope. As soon as PH0 has detected the trailing envelope edge, the next filled envelope can be transported from the insert table to the exit of the machine..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, 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 PH0. 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. the delay between to successive documents fed to the same feeder is discussed. rev /

22 DFC FE MS RX CL PH TX DFC FE PH RX RH TX RX PH MS TX RX SPH(PD) PH0 9 0 So FS CL So SPH(PD) 9 CL/5 SPH(PD) 8 0 So TX RX RX 0 9 TX PH RX PH9 9a TX PH8 TX DFC CL RX PH 6 65 TX 6 6 CL SPH(PD) 0 M 5 6 PH5 50 TX RX 8 9 TX 7 PH6 MS M 5 5 FE rev /00

23 .9 Legend Note. Parts with an arrow are mechanically driven (by the main motor M or by a the collator DC motor M). Note. For reasons of cross-reference the identification of sensors and actuators as used in the electrical description (document 0.0) is mentioned here as well. General M Main motor. Provides the primary mechanical drive for the feeder clutches CL CL, the folder clutches CL & CL5 and the envelope track clutch CL6. Directly drives the vertical track transport (75, 68, 6, 5), the folding subsystem (&; 5&6; 7&8) and the inserter main drive (5, 7, 9, 0,, ). If the upper unit is in place, items, 6, and 6) are driven as well. All items that are directly driven by M can be activated with the LH hand knob (behind the LH front cover). PD Pulse disc (mounted on roller 9). Monitored by slotted photocell SPH. Provides information on the process timing. MS Safety switch for the upper unit. MS Safety switch for the front cover. MS Safety switch that guards the part of the collator area that can be opened by the user. Feeders Lower feeder () CL Feeder clutch. Drives 6, 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. PH Feeder photocell. 6 Driven output rollers. 6 Counter rollers for 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 5 and 5 degrees) ensures a safe distance between successive separated documents, in order to prevent double feeds. DFC Double Feed Control unit for feeder. Middle feeder () CL Feeder clutch. Drives 70, 7 and 7. 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. PH Feeder photocell. 70 Driven output rollers. 7 Counter rollers for 70. rev /

24 Feeders 7 Lower separation roller. Connected to the feeder frame via a constant-torque device. 7 Feed axle with upper separation roller. Freewheel action in forward direction. 7 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 5 and 5 degrees) ensures a safe distance between successive separated documents, in order to prevent double feeds. DFC Double Feed Control unit for feeder. Upper feeder () CL Feeder clutch. Drives 77, 80 and 8. 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. PH Feeder photocell. 77 Driven output rollers 78 Counter rollers for 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. 8 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 5 and 5 degrees) ensures a safe distance between successive separated documents, in order to prevent double feeds. DFC Double Feed Control unit for feeder. Vertical track Counter roller of 5 (in the upper unit). 5 Driven vertical transport axle. 6 Driven vertical transport axle. On this axle feeder (lower) clutch CL is mounted (at the LH side of the machine). This clutch drives 6, 66 and Counter rollers for 6 (in upper unit). 68 Driven vertical transport axle. On this axle feeder (middle) clutch CL is mounted (at the LH side of the machine). This clutch drives 70, 7 and Counter rollers for 68 (in upper unit). 75 Driven vertical transport axle. On this axle feeder (upper) clutch CL is mounted (at the LH side of the machine). This clutch drives 77, 80 and Counter rollers for 75 (in upper unit). PH Reading head photocell. Only present and operational if OMR is installed. RH Reading head. Only present and operational if OMR is installed rev /00

25 Collator M Collator motor. Drives 6, 50, 5, 56 and 60 in forward or reverse direction. PD Pulse disc mounted on the axle of the collator motor M. Monitored by slotted photocell SPH. PH5 Collating area photocell. Guards the entry of documents from the vertical track. 6, 50, 5, Collator rollers driven (either forward or reverse) by the collator motor M. In collator 56, 60 arm. Actual transport is realized with three belts, driven by and driving 50, 5, 56 and Document stop position for 6-inch documents. Not used in this machine! 57 Document stop position for -inch and A-sized documents. Not used in this machine! 59 Document stop position for -inch documents. 7, 8, 9, Free running collator rollers. 5, 5, 55, 58 Fold unit PH6 Folder input photocell. Lower fold input roller. Upper fold input roller. 5 Lower fold roller for first fold pocket. 6 Upper fold roller for first fold pocket. In upper unit. 7 Lower fold roller for second fold pocket. 8 Upper fold roller for second fold pocket. In upper unit. 9 Control axle for first fold pocket. Hinge for 0. Moves the lever that in its turn moves the fold deflector actuator of upwards. 0 Fold knife for first fold pocket. Fold deflector for first fold pocket. 7 Curve gears for first fold pocket ( x LH, x RH). Controls movement of 0. 8 Brake disc for first fold pocket. Spring loading ensures two static mechanical states. PD Cam disc of first fold pocket. Monitored by slotted photocell SPH. Control axle for second fold pocket. Hinge for and. Moves the lever that in its turn moves the fold deflector actuator of upwards. 9 Curve gears for second fold pocket ( x LH, x RH). Controls movement of and. 0 Brake disc for second fold pocket. Spring loading ensures two static mechanical states. PD Cam disc of second fold pocket. Monitored by slotted photocell SPH. Fold knife for second fold pocket. Moving paper guide for second fold pocket. Fold deflector for second fold pocket. CL First fold pocket clutch. Drives 7. CL5 Second fold pocket clutch. Drives 9. rev /

26 Envelope feeding CL6 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 M driven subsystem and the envelope track subsystem. CL6 drives,, 6, 8, 0 and. Feed roller. Activated by the envelope track clutch CL6. Separation roller., 6, 8 Driven envelope transport rollers. Activated by the envelope track clutch CL6., 5, 7 Counter rollers for, 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. 0 Driven envelope transport roller (flap opening stage). Activated by the envelope track clutch CL6. Speed of 0 somewhat lower than that of 8, in order to assist flap opening. 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, Counter rollers for 0,. 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 exiting PH9 Insert table photocell. So Fingers solenoid. Moves fingers forward into envelope to enable inserting the set. Lower insert roller. Upper insert roller (in the upper unit). and provide final set transport prior to inserting in envelope. 5 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. 6 Upper first ejection roller (in the upper unit). Lowered by the action of the insert table solenoid So. So Insert table solenoid. Shortly activated. Deactivated as soon as 7&8 have taken over the transport function. 7 Lower second ejection roller. In this area the moistening brushes are located. 8 Upper second ejection roller (in the upper unit). 9 Driven sealing track roller. On the axle at the RH side of the machine the pulse disc PD (monitored by slotted photocell SPH) is mounted. 0 Driven sealing track roller. Counter roller for (in the upper unit). 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 (, 6,, 6) rev /00

27 Inserting, ejecting, sealing and exiting Upper sealing roller. FS Flag switch. Note. FS is actually mounted on the tangent line of and 5. So Sealing solenoid. Moves 5 down during a short time. Deactivated as soon as & have taken over the transport function. Lower reverse roller (in the upper unit). 5 Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid So. 6 Not used in this machine. PH0 Exit photocell. rev /

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29 Mechanical rev /

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31 Contents Section Page Covers and plates 8. RH side cover 9. LH side covers 9. Top cover feeders, covers collator area, power supply cover 0. Covers upper unit Electrical components. Main board. FRAM and Display board Feeder modules and vertical transport RH. Drive mechanism RH 5.. Belts 5.. Pulleys 6. Drive mechanism LH 6.. Belt 6.. Clutch and Pulley 6 Feeders 7. Top feeder (feeder ) 7. Middle feeder (feeder ) 9. Lower feeder (feeder ). Automatic separation feeder with daily mail.. Rubber paper pullers.. Pulley of paper puller axle 5.. Upper separation roller 6.. Lower separation roller 7..5 Gears 8.5 Automatic separation feeder 8 5 Vertical transport 9 6 Collating area 0 6. Belts 6.. Transportation belts 6. Guide rollers 7 Folder 7. RH drive mechanism 7.. Belts 7.. Pulleys 7.. Gears 7. LH drive mechanism Fold mechanism Clutches 7 rev /

32 7.. Curved folder gears 7 7. Rollers 7.. Input rollers 7.. Lower fold rollers 7.. Upper fold rollers 8 Main drive mechanism inserter 5 8. Belts PJ-belt Drive belt inserter Belt envelope feed 7 8. Pulleys 8 8. Gears 8 8. Clutches 9 9 Envelope feed 5 9. Hopper O-rings Separation roller Feed roller 5 9. Envelope track Lower rollers Upper rollers Rubber roller Finger solenoid 56 0 Upper unit Drive mechanism Belt Pulleys Gears Document inserting Rollers Gears Ejection solenoid 6 0. Envelope transport and sealing Rollers Sealing solenoid 6 Envelope transport 65. Lower ejection rollers 65. Sealing track transportation rollers 66 Envelope sealing and ejection 67. Upper sealing roller 67. Lower sealing roller 67 Sensors 68. Safety switches 68. DFC and photocells rev /00

33 .. Feeders 7.. Vertical transport 7.. Collator area 75.. Folder Inserter 78 Adjustments 8. Main drive PJ-belt 8. Main drive belt feeders/folder 8. Main drive belt inserter 85. RH drive belts 86.5 Drive belt upper folder section 87.6 Paper guide 88.7 Solenoids 89.8 Separation roller 9.9 Friction brake 9.0 Flap scraper 9 rev /

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35 General instructions Disconnect the mains supply before performing any maintenance. Warning The 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. rev /

36 Covers and plates RH LH 7 8 figure rev /00

37 . RH side cover Refer to figure. Open the loc by lifting the hand grip. Remove the six screws as shown and one screw inside the RH side cover. Remove the RH side cover.. LH side covers Refer to figure.. Open the loc by lifting the hand grip. 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 from the protect cover 9 and remove the cover. Remove the water tray carefully. Remove two screws from the wiring cover 0 and remove the cover. The manual for service and testing can be found inside the machine beside the LH side cover. rev /

38 . Top cover feeders, covers collator area, power supply cover RH LH figure. Refer to figure.. Remove the LH- and RH side covers as described in paragraph. and.. Remove the top cover feeder by removing two nuts and two tight-lipped on both sides. Loose two screws of the top cover 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 0 of the bottom plate 9 and remove the bottom rev /00

39 . Covers upper unit figure. Refer to figure.. The covers should be removed in the following order: lift the loc by lifting the hand grip remove two nut s and two screws inside the upper unit. rev /

40 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.. Main board Disconnect the wiring to the main board and remove the screw and lock washer and spacer. Carefully pull the main board from the board holders as shown rev /00

41 . FRAM and Display board # "! figure. Refer to figure.. Open the loc by lifting the hand grip as shown in figure.. Remove the screws and spacers from the cover plate, remove the cover plate as shown in figure.. Disconnect the wiring. Remove the display unit by removing the four screws. Remove cover plate, spacers and finally display board and rubber pad key pad 5. Note: Connect the wiring before replacing the display board. Be sure to replace the four spacers. rev /

42 Feeder modules and vertical transport RH The feeders, the vertical transport and the fold unit are driven by belt and the accompanying pulleys, gears, etc. as shown in figure.. When the machine is running the four transportation axles are continuously driven by the belts, 5 and 6. The three upper transportation axles are equipped with a clutch and a pulley. When, for example, the clutch is activated the accompanying feeder is driven by pulley and belt 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 rev /00

43 . Drive mechanism RH! " #! $ % ' & RH figure... Belts Refer to figure.. Belt (item 8) Slacken the two screws of belt tensioner 0 and shift the belt tensioner downwards. Remove the belt 8 from the pulleys. Belt (item ) Slacken the hex head screw of belt tensioner. Remove the belt from the pulleys. Belt (item ) The belt is removed in the same way as the belt. rev /

44 .. Pulleys Refer to figure. Pulleys (item, 5, 7, 9 and ) The pulleys, 5, 7, 9 and 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 ) Remove the hex head screw of the belt tensioner and withdraw the tensioner. Slide the pulley 5 from the axle, than remove the cyl. pins from the axle and slide the pulley of the axle.. Drive mechanism LH 6 5 LH figure. Refer to figure.... Belt Unhook the tension spring from the inside frame and remove the belt from the pulley... Clutch and Pulley Disconnect the wiring of the clutch. Remove the spring clip 6 and slide the clutch 5 and the disc and the pulley of the axle rev /00

45 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.), 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.. Top feeder (feeder ) Remove the top cover feeders figure. Refer to figure.. 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, clutch and the belt and the pulley 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 0 by moving it in the RH direction. rev /

46 B A figure. Refer to figure.. 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, the hinge pin at the RH side is locking the ball bearing rev /00

47 . Middle feeder (feeder )! " # $ % & RH ' LH figure. Refer to figure.. On the RH side of the feeder, unhook the tension spring from the screw. 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 0 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 of the middle feeder. rev /

48 RH * LH ) figure. Refer to figure.. 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). Note: Be careful when replacing feeder, the hinge pin at the RH side is locking the ball bearing rev /00

49 . Lower feeder (feeder ) LH RH! " # $ % & figure.5 Refer to figure.5. On the RH side of the feeder, onhook the tension spring from the screw. 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 from the inside frame. Remove the screws at the LH and RH side of hinge pin of the lowest feeder. rev /

50 RH * LH ) figure.6 Refer to figure.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). Note: Be careful when replacing feeder, the hinge pin at the RH side is locking the ball bearing rev /00

51 . 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.7... Rubber paper pullers LH! RH " $ # figure.7 Refer to figure.7 Remove cover to as follows: Remove the screws on the RH side. To remove cover, it s necessary to remove the top cover first, see figure. Pull the cover, and 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 backwards on the RH side and pull it out on the LH side. rev /

52 B D A C figure.8 Refer to figure.8 Remove the feed axle assy. in the right-hand side direction (A) until the left-hand side is clear from the axle. Tilt (B) the axle assy. 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 can simply be removed by pushing them of the axle. Hold the plastic cover in place with one hand and push (D) firmly against the rubber paper puller as indicated. Rotate the axle 80 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 (, figure.8) on the paper guide and that the feeder assy. is correctly fitted onto the axle. Ensure that the belt runs across the pulleys rev /00

53 .. Pulley of paper puller axle Remove the feed axle assy. as described in the paragraph "Rubber paper pullers". figure.9 Refer to figure.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 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. rev /

54 .. Upper separation roller /HA=IA KID ) figure.0 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.0. Click (A) the plastic cover 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 to the left hand side of the axle as indicated. Rotate the axle 80 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 as shown in figure.0. Replace the plastic cover with the belt and the rollers rev /00

55 .. Lower separation roller Note: The feeder unit does not need to be removed for replacing separation rollers. Remove the cover as shown in figure.7. ) * figure. Refer to figure.. Move the separator axle assy. in the right-hand side direction (A) until the left-hand side is clear from the hinge plate. Move (B) the axle assy. downwards side and withdraw the right-hand side of the axle from the hole in the feeder frame. Figure. shows how the roller should be slided of the axle assy.. figure. Note: Before replacing the feed roller ensure that the axle is free of grease. rev /

56 ..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 8T can be removed after the extension axle with the pulley etc. has been removed. Remove the spring clip securing the gear 6T, lift the feeder and slide the gear 6T of the axle..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 rev /00

57 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. shows the parts of the vertical transport track. figure 5. rev /

58 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 0.. figure 6. Refer figure 6.. Disconnect the wiring of the collator motor. Loosen the set screw 7 on bush 6 as shown in figure 6. and pull the motor outside the frame. Support the collating arm and remove the screws as shown in figure 6. (two at the LH side and two at the RH side). Carefully remove the collating arm rev /00

59 6. Belts RH 7 6 LH 5 figure Transportation belts Refer to figure 6. The transportation belts are only available as a set. If a belt is worn, all the belts should be replaced. Remove roller from the axle and slide the axle to the LH side out of the bearings. Take care of the tensioner, it is spring loaded. Remove the tensioner and the plate. At last remove the axles and 5 and the middle transportation belt can be replaced. 6. Guide rollers Refer to figure 6. The guide rollers 8 and 0 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. rev /

60 7 Folder 7. RH drive mechanism # "! figure Belts Lower folder section The removal of the drive belt (figure 7.) is described in chapter "Feeder modules and vertical transport RH rev /00

61 Upper folder section 0! " # $ ' & % figure 7. Refer to figure 7.. Slacken the two screws of the belt tensioner and remove the belt 5 from the pulleys and 6. rev /

62 7.. Pulleys Lower folder section Refer to figure 7.. Remove the belt as described in chapter "feeder modules and vertical transport RH". After the removal of the accompanying spring clip and clamping ring the pulleys and can be slided of the axles. Upper folder section Refer to figure 7.. Remove the belt 5 as described in the previous section. Remove the spring clip and the washers of the pulley and slide the pulley of the axle. Slacken the set screw of the pulley 6 and slide the pulley of the axle. 7.. Gears Lower folder section Refer to figure 7.. Gears, item and 5. The gears and 5 can easily be slided of the axles. Take care of the cyl. pins when removing the gears. Upper folder section Refer to figure 7.. The gears 8 and 0 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 rev /00

63 7. LH drive mechanism LH 5 figure 7. Refer to figure 7.. 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 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, and 5 and the spacers of the gears and. rev /

64 7.. Fold mechanism! " # $ % & ' 0! " % $ # figure 7. Refer to figure 7.. The fold plates and 5 are driven via the curved gears 6 (four in total) and two gears, activated by the two clutches on the drive axle. Gears T, drive axle Refer to figure 7.. Remove the belt, pulley and and freewheel clutch. Remove the locking plate 0 securing the bearing of the drive axle. Carefully move the axle 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 rev /00

65 5 LH RH 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 of the axle. To remove the gear the clutches must be disassembled. Cut the wire straps at the connectors of the clutches. Slide clutch 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. Slide clutch to the left-hand side of the axle. Now the gear can be removed from the drive axle. 7.. Clutches The removal of the two clutches is described in the previous section "Gears T 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.. Curved folder gears Remove the drive axle assembly as described in the section "Gears T, drive axle". Refer to figure 7.. Remove the bearings 9 from the axles 6. Remove the brake discs 5 (spring loaded), the springs, the brake strip 6 and the bearings 7 from the axles 8. rev /

66 LH figure 7.6 Refer to figure 7.6. Remove the following components: The levers for the flap actuators, the bearings, etc. ( upto 6) from the axles. Pin 6 has to be loosened by a set screw, to be accessed at axle end (). The brackets 7 with the sensors. The brake discs with the bearings ( upto 0) from the axles. 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 0 are mounted to the upper frames. Carefully lift each complete fold assembly upwards and withdraw it rev /00

67 First curved folder gears RH 5 8 LH RH 5 LH 7 6 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 of the axle. Now the curved gears and 8 can be pulled of the axle. rev /

68 Second curved folder gears Refer to figure 7.7. Remove the hinge plates 5 and 7 in the same way as described previously and pull the curved gears 9 and 0 of the axle. Wrong Right curved disc curved gear spring lever 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". Adjustments Check after replacing and securing the complete fold assembly the adjustment of the paper guides and (refer to figure 7.7), see section "Paper guide" rev /00

69 7. Rollers 7.. Input rollers Remove the drive belt as described in the chapter, section.. LH RH figure 7.9 Refer to figure 7.9. Remove the pulley, the gears of the upper () and lower () input rollers as described in 7. Remove the bearing locking plate. rev /

70 5 RH 6 7 LH 9 8 figure 7.0 Refer to figure 7.0. Remove the gear 7 of the lower input roller 6 and remove the bearing locking plate 5. Remove the guide strip and the guide bracket below it. Move the upper input roller 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 rev /00

71 7.. Lower fold rollers Remove the following parts: Refer to figure 7.0. The gears 8. Refer to figure 7. Loosen the two hex. head screws. Push down solenoid to get access to screw and remove screws. Remove bearing plate ; 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. 0 "! figure 7. Adjustments Check after replacing the adjustment of the solenoid, see paragraph.7. rev /

72 7.. Upper fold rollers RH! " #! LH figure 7. Refer to figure 7.. Remove the belt with the pulley 5 and the three gears at the right-hand side. For the removal of the first fold roller it is necessary to remove the guide strip. Next remove the bearing locking plates on both sides. To remove roller 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. Adjustments For belt adjustments refer to rev /00

73 8 Main drive mechanism inserter The main motor 9 (refer to figure 8.) provides the mechanical power to the SI 6, with exception of the collating area. The collating area is driven by a separate motor. 0 figure 8. # "! 8. Belts 8.. PJ-belt Before the PJ-belt can be removed the main drive belt for the feeder and folder section must be disassembled as described in.. Refer to figure 8.. Loose the two hex. head screws of the tensioner 5. Remove the belt from the main pulley and the motor pulley. rev /

74 figure Drive belt inserter Refer to figure 8.. All moving components of the inserter part are driven by belt 0. To remove belt 0 loosen the two hex. head screws of the tensioner. Then remove the belt from the pulleys rev /00

75 8.. Belt envelope feed! " # $ % & ' 0! " '& % $ # figure 8. Refer to figure 8.. Remove the support plate by which the intermediate axle 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. rev /

76 8. Pulleys Refer to figure 8.. The pulleys item 9 and 5 can easily be removed by removing the accompanying spring clips. The pulley 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.. For the removal of the pulleys and 9 it is necessary to remove the belt 5 as described in 8... Remove the accompanying spring clip and washer of the pulley 9 and slide the pulley of the envelope feed axle. Remove the bearings, washers and gears from the intermediate axle. To remove the pulley from the intermediate axle tap the tension pin and slide the pulley of the axle. 8. Gears Refer to figure 8.. Gears item (sealing rollers) After the removal of the pulley 5 all the gears can be slided of the axles by removing the accompanying spring clips and washers. Gear item The gear 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 to the right-hand side out of the RH inside frame. Tap the tension pin to remove the gear. Gear item The gear is also mounted to the pulse disc axle 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. Slide the pulse disc axle 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 After the removal of the pulley 9, gear can be slided of the axle. Refer to figure 8.. Gears item 8, 0, 5, 6, 8, 0 and The gears 8, 0, 5, 6, 8, 0 and can simply be removed by removing the accompanying spring clips and washers rev /00

77 Gear item For the removal of the gear 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 6 After the gear 8 has been removed the clutch 7 must be dissembled. Remove the support plate, disconnect the wiring of the clutch and slide the clutch of the axle. Remove gear 6. Gears item and Remove the support plate to free the intermediate axle with its components. Remove the bearings, washers and spring clip from the axle and slide the gears and from the axle. Gear item 7 To 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. Move the axle a little to the righthand side, slide the gear 7 to the left-hand side and remove the cyl. pin. Slide the gear 7 of the axle. Gear item 9 The gear 9 is mounted to the tansportation axle by a tension pin. For the removal of the gear 9 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 9 from the axle. 8. Clutches Slip clutch envelope feed axle Refer to figure 8.. 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 CW When the machine is switched on gear 6 it is constantly driven. By activating the clutch 7 all the gears shown in figure 8. 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 and the gear 8 must be removed. Disconnect the wiring of the clutch and slide it of the axle. rev /

78 8.5 Main motor (M)! figure 8. Refer to figure 8.. Remove the power supply cable. Remove the power supply cover. 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. 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 are fitted correctly in the guide rollers. Also take care to fit the microswitch correctly and ensure the correct functioning rev /00

79 0 # "! figure 8.5 Refer to figure 8.5. Remove the belt by releasing the belt tensioner. First remove the bottom of the machine than remove the four screws and the washers and withdraw the motor 5 from the machine. Take care of the wiring. Adjustments For belt adjustments refer to. and.. rev /

80 9 Envelope feed 9. Hopper 9.. O-rings RH LH figure 9. Refer to figure 9.. Remove the centre front plate 9. The hopper assembly 0 is fitted to the inside frames by three screws at the left-hand and three screws at the right-hand side. Remove the screws and withdraw the assembly from the machine. Remove the pulley and slip clutch as described in 8.. 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 rev /00

81 9.. Separation roller Note: Before removing the separation roller first check the adjustment procedure as described in.8. Refer to figure 9. Remove the centre front plate and the hopper assembly as described in the previous paragraph. Slacken the two screws and remove the separation spring with the separation roller. Remove the separation axle with roller from the separation spring, slacken the set screw of the separation roller and slide it of the separation axle. 9.. Feed roller Refer to figure 9. Remove the feed axle as described in 9... 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. Adjustments See paragraph.8 and.8. rev /

82 9. Envelope track 9.. Lower rollers To get access to the lower rollers of the envelope track it is necessary to remove the bottom plate RH 9 LH 0 figure 9. Refer to figure 9.. Remove the spring clip, washer and bearing (spring loaded) from the axle of the first set of rollers. 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 is removed in the same way. Remove from the third set of rollers at first the outer two rev /00

83 rollers. The removal procedure for the inner two rollers is the same as described for the first set of rollers. Refer to figure 9. Remove the flap scraper. Remove the pressure springs of the bearings of the fourth set of rollers 9. 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 9 from the axle. Adjustment: For the adjustment of the flap scaper see.0.. RH LH figure Upper rollers 0 9 Refer to figure 9.. To get access to the upper rollers remove the insert table as described in paragraph.. rev /

84 To remove the first set of rollers 5 slide the rollers of the axle 7, remove the cyl. pins. Remove the spring clip, washer and bearing at the left-hand side of the axle 7 and slide the axle to the righthand 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. To 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.). 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.. Rubber roller Remove the insert table and the transportation table (item 9, figure.). Slide the transportation table in direction as indicated over the second fold roller. Refer to figure 9.. Remove the knob and the spring clips 5 of the rubber roller. The gear at the right-hand side of the rubber roller must be removed as described in section 8.. 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 righthand side and withdraw the rubber roller from the machine. 9.. Finger solenoid! " figure 9. Refer to figure rev /00

85 Remove the draw bar and the tension spring. Disassemble the mounting bracket with solenoid. Remove the solenoid from the bracket. Adjustments For the adjustment of the solenoid see.7. rev /

86 0 Upper unit 0. Drive mechanism The drive mechanism of the upper unit is located at the right-hand of the machine. 0.. Belt figure 0. Refer to figure 0.. At first slide the belt 8 of the pulley 7. Then remove the belt from the pulley rev /00

87 0.. Pulleys Refer to figure 0.. Remove the spring clip of the pulley 0 and slide the pulley 0 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 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. Move the brake plate with assembled components carefully aside, take care of the wiring to the solenoid, the sensor and display. Remove plate. 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. 0.. 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 and remove the cyl. pins of the rollers. Slide the axle 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. rev /

88 0. Document inserting 0.. Rollers! " # $ ' & % figure 0. Refer to figure 0.. Remove the guide plates on both sides and slide the upper insert rollers of the axle. Take care of the cyl. pins. The first set of ejection rollers can simply be slided of the axle. Take care of the cyl. pins. Refer to figure 0.. To remove the second set of ejection rollers, remove spring clip 5 and remove roller from the axle. Remove spring clip and slide the axle to the LH side. Tap out the cyl. pin of roller and slide roller from the axle. 0.. Gears Refer to figure 0.. Remove the guide plates 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. Slide the outer bearings at the axle 8. Remove the tension springs. Slide the axle 8 with complete insert assembly through the slotted holes out of the frames rev /00

89 LH 6 5 RH figure 0. Refer to figure 0.. Once the frame plate 5 is removed the gears, 7 and 8 can be slided of the axles. Take care of the pressure springs 6. rev /

90 5 RH LH figure 0. Refer to figure 0.. Remove the screws 7 and withdraw the complete ejection assembly 9 together with the draw bar and the attached plunger (item, figure 0.) from the frames. Take care of the washers and the pressure spring of the plunger. Refer to figure 0.. After the frame plate 9 is removed the gears 0 and can be removed from the axles. 0.. Ejection solenoid To get access to the solenoid the covers of the loc must be removed as described in the section. Refer to figure 0.. Disconnect the wiring of the solenoid. Remove the two screws and remove the solenoid. Take care of the plunger the washers and the pressure spring. Adjustments See rev /00

91 0. Envelope transport and sealing 0.. Rollers RH figure 0.5 rev /

92 Sealing transport rollers Refer to figure 0.5. Open the upper unit and remove the spring clips of the axle 6. Slide the transport rollers of the axle. Take care of the pressure springs 5. Lower reverse rollers The removal of the lower reverse rollers is described in 0... Upper reverse rollers Remove the accompanying spring clips and washers and slide the rollers 7 of the axle. 0.. Sealing solenoid Refer to figure 0.5. Disconnect the wiring of the solenoid. Remove the screws and withdraw the solenoid. Take care of the pressure spring and the washers at the plunger. Adjustments See paragraph rev /00

93 Envelope transport. Lower ejection rollers LH figure. Refer to figure.. Remove four screws of the insert table 8 and four screws of the insert table. Remove the drive belt inserter as described in 8... Remove the locking plate of the bearing at the right-hand side of the transportation axle 0. Slide the axle 9 to the RH side. Remove the cyl. pin 7. Slide the roller 8 from the axle. Remove the spring clip, washer and bearing from the left-hand side of the axle. Slide the axle to the RH side. Slide the rollers from the axle. rev /

94 . Sealing track transportation rollers Refer to figure 8.. Remove the pulse disc 7 and pulley 8 with the from the pulse disc axle as described in 8.. Refer to figure.. Remove the pressure springs from the bearings of the axle 8. Slide the rollers aside to remove the cyl. pins. 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 0 when replacing again. On the LH side a spring with lower force has to be fitted than on the RH side rev /00

95 Envelope sealing and ejection. Upper sealing roller Refer to figure.. Remove the gear at the right-hand side of the sealing roller 6 as described in 8.. Next remove the pressure springs from the bearings and the spring clip at the left-hand side of the sealing roller. Take care of the washer 0 and the spring 9. Move the sealing roller 6 to righthand side to free the left-hand bearing from the LH inside frame and withdraw the upper sealing roller.. Lower sealing roller Refer to figure.. 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.. Remove the two screws 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. rev /

96 Sensors. Safety switches Upper unit safety switch The 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. Refer to figure.. Cut the wire strap and remove the bracket together with the safety switch. Remove the safety switch from the bracket rev /00

97 Safety switch LH side cover The safety switch is located at the left-hand side of the machine near the sealing rollers. figure.! Refer to figure.. Open the LH side cover and remove the cover. Remove the safety switch from the bracket. rev /

98 Safety switch collator area The safety switch is located at the right-hand side beneath the collator area and behind the supply cover. Remove the supply cover. figure. Refer to figure.. Remove the safety switch from the frame rev /00

99 Flag switch sealing area 5 6 RH LH figure. Refer to figure.. Remove the nuts and 6 than remove the frame complete. Take care of the wiring. Slacken the screw and remove the bracket with the flag switch 5. rev /

100 . DFC and photocells Note: whether or not photocells are replaced, it is advised to reset the photocells after finishing servicing. See sections. and.5 of the Electrical description for details... Feeders DFC Each feeder is equipped with a DFC. Remove the covers,, and (figure.7) as described in... When removing the DFC of feeder first remove the guide plate 5 (figure.) as described in..! figure.5 Refer to figure.5. Disconnect the wiring of the DFC and remove the screw securing the DFC to the bracket rev /00

101 Feeder photocells LH RH LH "! RH figure.6 Refer to figure.6. Transmitter (LED) Remove the bracket with the transmitter. Disconnect the transmitter and remove it from the bracket. Receiver (Sensor) Remove the bracket with the sensor. Disconnect the sensor and remove it from the bracket. rev /

102 .. Vertical transport Vertical transport photocells (optical, only with OMR). In the,5 stations version, the detectors are located beneath the upper vertical transport rollers.! " figure.7 Refer to figure.7. Transmitter (LED) Open the loc and remove the guide plate with assembled transmitter. 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 to bracket. Remove the bracket with the sensor and disconnect the wiring. Remove the sensor rev /00

103 .. Collator area LH figure.8 Refer to... Remove the set screw, remove the pulse disc and the sensor. Note: Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc. rev /

104 Collating area photocells! " # $ % figure.9 Refer to figure.9. Move the lower collator arm downwards. Remove the locking plate of the axle at the right-hand side of the machine and free the bearings of the frame. Remove the hinged guide plate together with the attached sensors and. Take care of the wiring. Transmitter (LED) Remove the transmitter from the guide plate. Receiver (Sensor) Remove the sensor from the guide plate rev /00

105 Folder input photocell Refer to figure.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... Folder Curve (pulse) disc sensor The sensors are located at left-hand side of the upper unit. Open the upper unit. figure.0 Refer to figure.0. Remove the bracket with the sensor. Cut the wire strap, disconnect the sensor and remove the sensor from the bracket. The sensor has to be removed in the same way. rev /

106 ..5 Inserter Pulse disc sensor The pulse disc sensor assy. is located at the right-hand side of the machine near the sealing rollers.! " figure. Refer to figure.. To avoid damage to the pulse disc remove the pulse disc. Disconnect the wiring of the sensor, remove the two srews 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, reposition the sensor and fasten the screw rev /00

107 Envelope track photocell To get access to the photocells remove the insert table and the bottom plate. "! figure. Refer to figure.. Transmitter (LED) Pull the air hose connector from the transmitter. Slacken the screw of the transmitter and remove the transmitter. Receiver (Sensor) Remove the bracket together with the sensor. Slacken the screw of the sensor and remove the sensor. rev /

108 Envelope flap detector To get access to the photocells remove the insert table and the bottom plate.! " # figure. Refer to figure.. Transmitter (LED) Once the bottom plate is removed, remove the bracket with the transmitter. Take care of the wiring. Disassemble the transmitter from the bracket. Receiver (Sensor) Pull the air hose connector from the sensor. Slacken the screw 6 and remove the bracket 5 with the sensor. Remove the sensor from the bracket. $ rev /00

109 Exit photocells! " figure. Refer to figure.. Remove the frame axles together with the cover. Take care of the wiring of the detectors. Remove the transmitter (LED) and the receiver (Sensor). rev /

110 Document insert photocells! " # figure.5 Refer to figure.5. Transmitter (LED) The transmitter is located in the upper unit. Open the upper unit and remove the screw to release the transmitter. Receiver (Sensor) Remove the transport table. Slacken the screw 5 and remove the bracket with the sensor. Remove the sensor from the bracket. Take care of the wiring rev /00

111 Adjustments. Main drive PJ-belt 0 mm (0. inch) figure. Refer to figure.. The maximum movement of the drive belt at the indicated position is 0 mm (0. inch). To adjust Slacken the two screws securing the belt tensioner. 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. rev /

112 . Main drive belt feeders/folder 0 mm (0. inch) figure. Refer to figure.. The maximum movement of the drive belt at the indicated position is 0 mm (0. inch). To adjust Slacken the two screws securing the belt tensioner. 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 rev /00

113 . Main drive belt inserter 0 mm (0. inch) figure. Refer to figure.. The maximum movement of the drive belt at the indicated position is 0 mm (0. inch). To adjust Slacken the two screws securing the belt tensioner. 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. rev /

114 . RH drive belts Note: The adjustment of the lower and upper drive belt is similar. upper drive belt 5 mm (0. inch) lower drive belt figure. Refer to figure.. The maximum movement of the drive belts at the indicated position is 5 mm (0. inch). To adjust Slacken the hex. head screw securing the belt tensioner. 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 rev /00

115 .5 Drive belt upper folder section 5 mm (0. inch) figure.5 Refer to figure.. The maximum movement of the drive belts at the indicated position is 5 mm (0. inch). To adjust Slacken the hex. head screw securing the belt tensioner. 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 rev /

116 .6 Paper guide! figure.6 Refer to figure.6. There must be a small gap between the fixed guide plate and the fold roller. The fold roller should just run free. To adjust Slacken the two round head screws to move the guide plate further away from the fold roller and tighten it to move it closer rev /00

117 .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.. 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.7 Refer to figure.7. To set this requirement: Slacken the two screws securing the solenoid coil. Push the plunger together, with the linkage 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 mm (0.0 inch) and retighten the two screws. Ensure the solenoid coil and the plunger are aligned in a straight line. rev /

118 Finger solenoid! " figure.8 Refer to figure.8. To adjust the finger solenoid: Slacken the two screws securing the solenoid coil. Push the plunger 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 mm (max.) (0.07 inch) above the insert table. Retighten the two screws rev /00

119 .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.9 Refer to figure.9. Use the adjusting nut and set the separation gap to the maximum. Slacken the set screws securing the separation roller. Rotate the separation roller about 0 degrees in the direction indicated, so that the unworn portion of the separation roller faces the feed roller. Retighten the set screw and re-adjust the separation gap. Note: After rotating the separation roller over 0 degrees it is necessary to replace it. rev /

120 .9 Friction brake 0 mm (0.79 inch) figure.0 Refer to figure.0. The friction brake is correctly adjusted when the distance between the inner faces of the two friction discs, i.e. the overall pressure spring length, is 0 mm (0.79 inch). To adjust Remove the outer nut securing the inner nut. 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 rev /00

121 .0 Flap scraper! figure. Refer to figure.. The flap scraper must be positioned so that its lower edge is aligned with the lower edge of the envelope guide. To adjust Slacken the two hex. head screws securing the flap scraper 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. rev /

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123 Electrical rev /

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125 Contents Section Page Electronic hardware 5. Circuit description 5. Test points. Jumper settings. LED information Service menu 6. General 6. System setting 9. Configuration 9. Localisation 0.5 Software versions 0.6 Folder settings.7 Reset data.8 Power up.9 Job settings.0 Document offset. BRE offset. Secure jobs. Flap closer. Service tests 5.5 Photocells 5.6 Digital inputs 7.7 Actuators 8.8 Run in 0.9 DFC test 0.0 Keyboard/display. Counters. OMR. OMR code definition. Read code test Error messages and error handling 6 rev /

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127 Electronic hardware. Circuit description General An 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 houses two controllers. An 8-bit controller handles the inserting functionality and the user interface. A 6 bit controller handles the feeding, reading and folding functionality. Both the 8-bit machine software and the 6-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. shows an overview of the machine-wide electronics. The schematics of the main board are divided into sheets (figure. through figure.). The components are numbered xyy; x is the sheet number, yy a number between 0 and 99. The component layout of figure. assists in locating connectors, test points, jumpers and LEDs. Processor and memory (6-bit) The 6-bit processor XA-S (U60) has kilobytes of internal program code. This code determines, based on certain RS-communicated information from the pc with the Windows-base software, whether communication with that pc or normal operation, i.e. executing the 6-bit machine software in flash ROM (U60), is relevant. The system operates with 6 kilobytes of system RAM (U60 & U6). 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 (U60 and U6) 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 U70 (U70 controls the feeder/folder clutches CL CL5), and reading data from the chip U70 (U70 receives digital versions of the outputs of the feeder/folder photocells PH PH6). These chips are addressed by so-called memory-mapped I/O, via the signals 6b_DigOutput and 6b_DigOutput (writing) and 6b_DigInput (reading) from the PAL chip U670. Processor and memory (8-bit) The 8-bit processor U0 executes the 8-bit machine software which is present in the flash ROM U0. The processor operates with kilobytes of system RAM (U50). The 8 kilobytes of non-volatile memory (U0) are used to store hardware and job related information. In addition to the 8-bit processor the CPLD U0 (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 6 kilobytes of program memory and that the flash ROM has 5 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 U0. 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. Communication The 8-bit controller (inserter and user interface) and the 6-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. rev /

128 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 SPH, which monitors pulse disc PD, which on its turn is driven by the main motor M. Communication between the machine and the outside world is based on serial (RS) communication. This communication is necessary for placing/updating machine software and possibly for other tasks. The RS data on the 9-pole RS connector goes to and from the RS driver U60. The CTS and RTS lines are only connected with the 8-bit controller. With the RS multiplexer either the 8-bit RX and TX signals or the 6-bit RX and TX signals are passed through to U60. This is necessary to place or update both the 8-bit and 6-bit machine software in one machine session. Power supply The machine is powered by a volt switched power supply unit. This eliminates the use of a heavy mains frequency-operated power transformer. From the V a 5 V supply VCC is derived with the switching voltage regulator U0. U0 takes care for the - V supply voltage. The ADCs in the 6- bit processor U60 require a separate positive supply voltage AVDD (.95 V). This voltage is derived from VCC by voltage divider R0 and R, followed by voltage follower U0B. Photocells The transmitter (TX) currents for the four inserter paper photocells (PH7 PH0) 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 U0. 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 (PH 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 U70. Its output (6b_Multiplexed_AD) is fed to an ADC input (Analogue to Digital Converter) of the 6-bit controller U60. In addition to this digital versions of the six RX signals are fed to the input chip U70. These signals are necessary to obtain timely process information. Cover switches The three cover microswitches MS (wired to the motor and relay board / ), MS (J00) and MS (J0) 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. Motors The main motor M 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 RE on the motor relay board (0 V)/ (5 V). The motor relay is controlled by the processor via the signals 8b_MOTOR_RELAY and 8b_START_RELAY from the 8-bit controller U0. 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 SPH via pulse disc PD) 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 rev /00

129 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 M is a DC motor than can and will turn in two directions. M is pulse-widthcontrolled via chip U0. The speed is controlled via a feedback circuit with slotted photocell SPH, which monitors pulse disc PD, which on its turn moves in line with M. Flag switch FS The optical flag switch FS 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 Solenoids Clutch CL6 in the inserter part of the machine is driven by the driver chip U0. The three solenoids in the inserter part are driven by transistor Q0A (finger solenoid So), Q0B (eject solenoid So) and Q50B (sealing solenoid So). The three feeder clutches (CL, CL and CL) in the feeder/folder part are driven by driver chip U970. The two folder clutches (CL and CL5) are driven by the driver chip U00. DFC Each 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/. The amplified DFC output voltages are fed to the ADC chip U70 via the analogue multiplexer U7. The ADC output signal is communicated to the 6-bit processor via the signals 6b_AD_CS, 6b_AD_DAT and 6b_AD_CLK. The reference voltage AVREF for the ADC chip is derived from the VCC voltage by a voltage divider with R7 and R7. 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 6-bit controller via the signals 6b_DAC_CS, 6b_DAC_DATA and 6b_DAC_CLK. OMR The OMR electronics are shown in sheet /. Two OMR output voltages (6b_ReadHead_Ana0 and 6b_ReadHead_Ana) are fed to an ADC input of the 6-bit processor via the analogue multiplexer chip U70. The DAC U980 supplies two offset voltages (6b_ReadHead_DAC0 and 6b_ReadHeadDAC). Output chip U700 supplies two signals (6b_ReadHead_S and 6b_ReadHead_S) for setting the amplification. Keyboard and display The 8-bit controller handles the control of both the keyboard and the display. Sheet / shows the interface electronics. As the main board is also used for other machines, two connectors (J00 and J0) are available. rev /

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131 service manual SI 6 PH9 LOC RX PH** VT TX FEEDER* FEEDER FEEDER CL CL CL FEED FEED FEED PH PH PH CL6 RPM ENV. TRACK PH9 LOC TX So SOLENOID EJECT So SEALING SOLENOID Fs SEALING FLAG SWITCH J0 So FINGERS SOLENOID J0 J60 J50 REAR SIDE ACTUATORS LOC CLOSER J0 SPH 86 MAIN PDISC 5 J00 J580 J50 J000 MAIN PDISC EXIT PHCELS FOLDERS DISPLAY J00 J0 TOP COVER SIDE COVER PH0 EXIT RX PH0 EXIT TX J500 ENV TRACK PHCELS READING HEAD J PH8 PH8 FLAP TX PH7 ENV TRACK RX ENV TRACK TX FLAP RX PH6 FOL RX ORION FOL TX COL RX PH7 PH6 PH5 PHCEL COLLATOR J WIRING J70 DONGLE FEEDER J900 FEEDER J90 FEEDER J950 FEEDER FEEDER FEEDER J0 J0 J00 UNIT POWER COLLATOR MAXI FEEDER WIRING WIRING 9890 WIRING X WIRING *** CONNECTOR D9 FEMALE NeoFlash Connection M DFC FEEDER TOP 7907 TMU MOTOR COLLATOR COL TX M 5 6 COLLATOR Motorboard Capacitor: 0V: 5µF (989006) 0V: 0µF (8) J MAXI FEEDER DFC FEEDER MIDDLE 7907 TMU OPTIONAL J V V DFC FEEDER BOTTOM 7907 TMU DFC DFC DFC SPH M PH MF- *** RUN START MS COLLATOR SWITCH LCD CURVE DISC FOLDING TABLE SPH VT RX PH** RH** READINGHEAD CURVE DISC FOLDING TABLE SPH RPM FOLDING TABLE CL RPM FOLDING TABLE CL POWER SUPPLY L (AC) N POWER INLET INCLUDES: MAINS FUSE L N 0V:.5 A 0V: 5 A PLUG TYPE: COUNTRY SPECIFIED EURO USA UK SWISS AUSTRAL MS TOP COVER SWITCH MS SIDE COVER SWITCH * Only for ½ station machine ** Only if OMRI is installed. INPUT: 00-0 VAC.5A 00-0 VAC.5A 50/60 Hz OUTPUT: + V.5A COM COM +V +V +V ADJ + V MAINS LEAD *** Only if MAXI BRE feeder is installed. figure. Total view of the electrical and electronic circuits, including external connections and sensor/actuator connections. DRAWN: J. Pijpker DATE: --00 FILE: SCALE: dsn REV. 00 CODE: rev /

132 Cover switches J00 V 5V power supply Top cover Side cover Unit power + Volt P COVER out COVER in Motor run relais Motor start relais Power RS RTS RS RXD RS CTS RS TXD RS JST J0 JST J JST RS_TXD RS_CTS (sht ) RS_RXD RS_RTS V F00 A P F0 A P COVERTRACK Q0 BC87 P COVERTRACK R0 56R Q00 BC87 R09 K7 P R 56R R0 K7 R07 K7 R00 K7 R0 K7 P R08 K7 R0 K R0 K R05 K R06 K7 C00 0nF C0 0nF C0 0nF U00A U00B 7HC 7HC 8b_TOP_COVER (sht ) 8b_SIDE_COVER (sht ) 8b_COLLATOR_COVER (sht ) 8b_MOTOR_RELAY (sht ) 8b_START_RELAY (sht ) P C0 70uF V CASE C 0nF R8 K V R K6 R0 0R C R K6 VCC R K6 R0 K7 R 6K8 50pF AVDD power supply C0 00nF & S Q R Ipk osc Ct U ref + - U0 MC06 R K6 5 + U0B LM R 56R R5 K R6 K C 50pF AVDD.95V Q0 BC87 R7 56R Q BC807 C0 00nF D0 BAT5S P-CHANNEL Q IRFR90 C 00nF C 00nF L0 50uH D STPS0U C 00uF VCC L 600R C5 00nF C6 00nF -V power supply C5 00nF VIN VIN 6 VIN 7 C VIN 00nF L 600R 5 VOUT L 600R L 600R U0 79L -V VCC_OUT TP0 VCC C7 µf C 00nF TP0 -V P P R50 0K Power down interrupt +V power supply VCC CO00 0nF VCC CO0 00nF MH00 MOUNTING HOLE CASE TP00 Keep mm clear surrounding this testpin. R5 K R5 00R R5 00R C50 nf VCC R5 K7 R55 K6 C5 nf VCC LM58 U0A POWER_DOWN (sht ) 0mSec time left for uc after interrupt V D0 V +V C0 00nF TP0 +V figure. Main board electronics: sheet of rev /00

133 (sht ) (sht ) (sht ) CO0 0nF 8b_CLK_MHz 8b_CPU_RESET 8b_PSEN 8b_ALE 8b_EJECT_SOL 8b_FINGER_SOL RS_RXD RS_CTS RS_TXD RS_RTS CO0 0nF VCC R06 00R C0 µf R60 K7 CO0 0nF C00 pf C0 pf +V X00.8MHz R07 00R C0 00nF 8 7 CO0 0nF R0 56R R0 00R R0 00R R0 K R05 K R08 00R RIN RIN TOUT TOUT VCC VCC VCC XTAL XTAL figure. Main board electronics: sheet of RST PSEN ALE EA EW PWM0 PWM AVDD AVSS VCC RS driver CO0 0nF VCC 6 7 AVREF+ STADC AVREF- ROUT ROUT 9 TIN TIN 0 C60 00nF C+ VCC C- C+ C6 00nF C- 5 V+ C6 00nF V- 6 U60 C6 MAXACSE 00nF CO00 0nF CO50 0nF CPU (ADC0) P5.0 (ADC) P5. (ADC) P5. (ADC) P5. (ADC) P5. (ADC5) P5.5 (ADC6) P5.6 (ADC7) P5.7 U0 80C55 CO60 0nF P0.0 P0. P0. P0. P0. P0.5 P0.6 P0.7 P.0 P. P. P. P. P.5 P.6 P.7 (INT/CT0I)P.0 (INT/CTI)P. (INT/CTI)P. (INT5/CTI)P. (T) P. (RT) P.5 (SCL) P.6 (SDA) P.7 (RXD) P.0 (TXD) P. (INT0) P. (INT) P. (T0) P. (T) P.5 (WR) P.6 (RD) P.7 (CMSR0) P.0 (CMSR) P. (CMSR) P. (CMSR) P. (CMSR) P. (CMSR5) P.5 (CMT0) P.6 (CMT) P.7 X Y VCC VCC CO6 0nF 8b_AD0 8b_AD 8b_AD 8b_AD 8b_AD 8b_AD5 8b_AD6 8b_AD7 8b_MUA8 8b_MUA9 8b_MUA0 8b_MUA 8b_MUA 8b_MUA 8b_MUA 8b_MUA5 8b_FRAM_WP 8b_NWR 8b_NRD 8b_SCL_SIM 8b_SDA_SIM 8b_AD[0..7] 8b_MUA[8..5] 8b_ENV_TRACK_INT (sht 5) POWER_DOWN (sht ) MAIN_PDISC (sht 5) 8b_CLOSERCEL (sht ) 8b_RPM_STACKER 8b_START_RELAY (sht ) 8b_RXD 8b_TXD 8b_RTS 8b_CTS RS MUX X0 X X 5 X Y0 Y 5 Y Y A 0 B 9 INH 6 U6 7HC05 8b_MOTOR_RELAY (sht ) 8b_RPM_ENV_TRACK (sht ) 8b_RS_MUX 8b_SEALING_SOL (sht ) 8b_OnDeck_SOL 8b_ANA_FLAP 8b_ANA_EXIT (sht 5) 8b_ANA_LOC 8b_SIDE_COVER (sht ) 8b_TOP_COVER 8b_ANA_ILED(sht 5) 8b_COLLATOR_COVER(sht ) 8b_ANA_ENV (sht 5) 8b_RXD 6b_RXD0(sht 6) 8b_TXD 6b_TXD0 8b_RS_MUX 8b_CTS 8b_RTS (sht 5) (sht 6) VCC R0 K7 VCC U00D 7HC 9 8 R K7 SCS_SCL SCS_SDA 6b_OTP_SEL 8b_AD[0..] (sht ) 8b_DISBUF_OE 8b_ORION_KB_RD 6b_RSTINn (sht 6) RESET_XA 8b_MUA[0..] 8b_NWR 8b_NRD 8b_CPU_RESET (sht ) 8b_DIS_ 8b_PSEN 8b_CLK_MHz 8b_MUA[0..] (sht 6) CPLD In circuit programming connection 8b_SDA_SIM 8b_SCL_SIM 8b_FRAM_WP VCC (sht 6) J HEAD8 R09 K 8b_MUA0 8b_MUA 8b_MUA 8b_MUA5 VCC D00 GREEN TESTLED TP00 8b_TST 8b_AD0 8b_AD 8b_AD 8b_AD R 50R C nF 8 Kbyte FRAM I/O0 I/O I/O I/O I/O I/O5 I/O6 I/O7 I/O8 I/O9 I/O0 I/O I/O I/O I/O I/O5 CLK0/IO CLK/I SDA SCL WP VCC VCC VCC 8 VCC VCC A0 A A U0 FMC6 CPLD I/O6 I/O7 I/O8 I/O9 I/O0 I/O I/O I/O I/O I/O5 I/O6 I/O7 I/O8 I/O9 I/O0 I/O TCK TMS TDI 0 TDO 5 U0 MA5-6/ ram_oe 8b_DIS_ 8b_DIS_ 6 8b_DISDIR 7 8b_DISBUF_OE b_MUA 8b_MUA 8b_MUA R 8b_MUA K (sht ) D GREEN FLASH RUN 8bit (sht ) R0 K D0 RED FLASH WRITE 8bit 8b_MUA[0..7] 8b_AD[0..7] 8b_ALE 8b_AD[0..7] 8b_MUA[0..] 8b_PSEN 8b_NWR BS_A5 BS_A6 BS_A7 BS_A8 8b_AD[0..7] 8b_MUA[0..5] flash_ce 8b_NWR DATA/ADRESS BUS Latch 8b_AD0 8b_AD 8b_AD 8b_AD 8b_AD 8b_AD5 8b_AD6 8b_AD7 R0 K 8b_MUA0 8b_MUA 8b_MUA 8b_MUA 8b_MUA 8b_MUA5 8b_MUA6 8b_MUA7 8b_MUA8 8b_MUA9 8b_MUA0 8b_MUA 8b_MUA 8b_MUA 8b_MUA 8b_MUA0 8b_MUA 8b_MUA 8b_MUA 8b_MUA 8b_MUA5 8b_MUA6 8b_MUA7 8b_MUA8 8b_MUA9 8b_MUA0 8b_MUA 8b_MUA 8b_MUA 8b_MUA 8b_MUA50 7 D D D D D5 D6 D7 D8 VCC 5Kbyte FLASH ROM Kbyte RAM A0 A A A A A5 A6 A7 A8 A9 A0 A A A A A5 A6 A7 A8 A0 A A A A A5 A6 A7 A8 A9 A0 A A A A C OC CE OE WE# CS WE OE VCC 0 0 VCC VCC 6 VCC VCC 8 Q Q Q Q Q5 Q6 Q7 Q U0 7HC57 D0 D D D D D5 D6 D7 U0 9F00 D0 D D D D D5 D6 D U50 656HF 8b_MUA0 8b_MUA 8b_MUA 8b_MUA 8b_MUA 8b_MUA5 8b_MUA6 8b_MUA7 8b_AD0 8b_AD 8b_AD 8b_AD 8b_AD 8b_AD5 8b_AD6 8b_AD7 8b_AD0 8b_AD 8b_AD 8b_AD 8b_AD 8b_AD5 8b_AD6 8b_AD7 rev /

134 Orion keyboard readout VCC VCC VCC VCC VCC VCC VCC VCC VCC ORION LCD connection VCC_OUT J00 R00 00R R0 00R 6 5 R0 00R R0 00R 8 7 R05 00R 0 9 R06 00R CE DISP. WRITE DISP. C/D DISP. RESET DISP. 6 5 READ DISP. 8 7 R R 6 5 R09 0K C0 50pF R0 0K C0 50pF R 0K C0 50pF R 0K C0 50pF R 0K C05 50pF R 0K C06 50pF R08 0K JP SEL0 R5 0K JP0 SEL A A A A A A A A VCC 0 U0 7HC 0 Y 8 Y 6 Y Y Y 9 Y 7 Y 5 Y G G 9 8b_AD0 8b_AD 8b_AD 8b_AD 8b_AD 8b_AD5 8b_AD6 8b_AD7 8b_AD[0..7] (SHT ) 8b_ORION_KB_RD (SHT ) CONBOX6 U00A 7HC (SHT ) 8b_DIS_ 8b_CPU_RESET 8b_DIS_ 8b_DIS_ 8b_NWR 8b_NRD 8b_DISBUF_OE A A A A A A A A VCC VCC 0 0 Y 8 Y 6 Y Y Y 9 Y 7 Y 5 Y G G 9 U0 7HC L0 L L L L L 600R 600R 600R 600R 600R 600R R0 R7 R R R R 00R 00R 00R 00R 00R 00R SI68 LCD connection VCC_OUT VCC_OUT J MicroMatch0 R5 R6 R7 R8 R9 R0 R R 00R 00R 00R 00R 00R 00R 00R 00R L5 L6 L7 L8 L9 L0 L L 600R 600R 600R 600R 600R 600R 600R 600R B B B B B5 B6 B7 B8 0 VCC VCC 0 A A A A 5 A5 6 A6 7 A7 8 A8 9 G 9 DIR U 7HCT5 8b_AD0 8b_AD 8b_AD 8b_AD 8b_AD 8b_AD5 8b_AD6 8b_AD7 8b_AD[0..7] (SHT ) 8b_DISBUF_OE (SHT ) 8b_DISDIR R90 K U00B 7HC U00F 7HC VCC_OUT COJ00 00nF VCC_OUT COJ0 00nF VCC CO00 0nF VCC CO0 0nF VCC CO0 0nF VCC CO 0nF figure. Main board electronics: sheet of rev /00

135 VCC Rear side actuators RPM env. track RPM stracker RPM FoReverse RPM FoForward finger sol. J JST0 V V O O O O O5 O6 O7 V COM 9 8 P D0 V P I I I I I5 5 I6 6 I7 7 U0 ULN00L C 00nF 8b_RPM_ENV_TRACK 8b_RPM_STACKER 6b_DigClutch_FoReverse 6b_DigClutch_FoForward (sht ) (sht 7) 8b_CLOSERCEL 8b_OnDeck_SOL U00D 9 8 7HC U00E 0 7HC C50 0nF R50 56R P V C70 50pF 8 7 R7 K D50 STPS0U Q50A SI96EY V R7 K7 VCC D STPS0U P P Q0A SI96EY 7 8 C0 0nF R0 56R P C 70uF U00C 6 5 7HC 8b_FINGER_SOL (sht ) (sht ) 8b_SEALING_SOL U00E 0 7HC C5 0nF R5 56R P P V D5 STPS0U 6 5 Q50B SI96EY R70 50R J JST8 CLOSER Closercel Pres. on deck solenoid Sealing solenoid P V 8b_EJECT_SOL U00F 7HC C60 0nF R60 56R P D60 STPS0U 6 5 Q0B SI96EY VCC_OUT V J60 JST LOC Eject solenoid TX loc-cel 8b_TX_LOC (sht 5) P figure.5 Main board electronics: sheet of. rev /

136 TP50 ENV VCC R5 K R50 0K C50 0nF 8b_ANA_ENV (sht ) R590 8K 8 R59 68K Enveloppe Track photcells ENV_TRACK TX ENV_TRACK RX FLAP TX FLAP RX LOC RX J JST0 VCC_OUT VCC_OUT VCC_OUT VCC_OUT VCC_OUT R5 00R R5 00R R5 K7 TP50 FLAP R50 0K TP50 LOC R50 0K C50 0nF C50 0nF 8b_ANA_FLAP (sht ) 8b_ANA_LOC (sht ) R59 K C590 nf R59 K + - U590A LM58 8b_ENV_TRACK_INT (sht ) ENV_TRACK +V VCC VCC Exit photocell EXIT TX EXIT RX VCC_OUT J50 JST5 5 8b_TX_LOC (sht ) FLAP LOC EXIT Q550 BC87 Q55 BC87 Q55 BC87 Q55 BC87 R550 8R R55 8R R55 8R R55 8R R558 R559 R560 R56 R56 R56 R56 R565 K 9 68K DAC0 0 K DAC 68K DAC K DAC 68K DAC K DAC5 5 68K DAC6 6 DAC7 U590B 5 + LM VP 8 N.C. 5 A0 6 A 7 SCL SDA VMAX U550 TDA8T C550 00nF Uout = x I VCC R556 0K R557 9K R55 K7.98V R555 K7 8b_SCL_SIM 8b_SDA_SIM (sht ) 8b_ANA_ILED (sht ) R57 R R57 R R570 C570 00K 0nF VCC CO560 00nF +V CO550 00nF Main PulsDisc J580 JST5 5 VCC_OUT R580 50R VCC R58 K7 R58 K U00C 7HC 5 6 C580 50pF VCC R57 K7 R58 K D580 GREEN MAIN PDISC R5 K7 R5 K7 TP50 EXIT R50 0K C50 0nF 8b_ANA_EXIT (sht ) MAIN_PDISC (sht, 6) figure.6 Main board electronics: sheet 5 of rev /00

137 0.0-5 rev /00 service manual SI 6 figure.7 Main board electronics: sheet 6 of. 6b_MUA7 6b_MapWRn 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA 6b_MUA6 6b_Reboot 6b_Map 6b_MUA8 6b_MUA9 6b_MUA 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA0 6b_Map0 6b_Map0 6b_MUA9 6b_Map 6b_MUA6 6b_MUA 6b_MUA5 6b_MUA8 6b_MUA7 6b_MUA 6b_R.en.D 6b_MUA7 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA 6b_MUA6 6b_MUA8 6b_MUA9 6b_MUA 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA0 6b_MUA7 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA 6b_MUA6 6b_MUA8 6b_MUA9 6b_MUA 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA0 6b_MUA6 6b_MUA8 6b_MUA7 6b_MUA 6b_MUA5 6b_MUA 6b_MUA 6b_MUA7 6b_MUA5 6b_MUA 6b_MUA6 6b_MUA8 6b_MUA9 6b_MUA 6b_MUA0 6b_MUA6 6b_MUA8 6b_MUA7 6b_MUA9 6b_MUD0 6b_MUD 6b_MUD 6b_MUD 6b_MUD8 6b_MUD0 6b_MUD 6b_MUD0 6b_MUD6 6b_MUD0 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD9 6b_MUD9 6b_MUD6 6b_MUD0 6b_MUD7 6b_MUD0 6b_MUD 6b_MUD9 6b_MUD9 6b_MUD5 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD6 6b_MUD5 6b_MUD 6b_MUD5 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD0 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD8 6b_MUD 6b_MUD6 6b_MUD5 6b_MUD0 6b_MUD 6b_MUD7 6b_MUD0 6b_MUD5 6b_MUD 6b_MUD 6b_MUD5 6b_MUD 6b_MUD6 6b_MUD 6b_MUD7 6b_MUD 6b_MUD7 6b_MUD 6b_MUD5 6b_MUD 6b_MUD 6b_MUD 6b_MUD7 6b_MUD5 6b_MUD0 6b_MUD 6b_MUD8 6b_MUD8 6b_MUD5 6b_MUA6 6b_MUA8 6b_MUA7 6b_MUA7 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA 6b_MUA6 6b_MUA8 6b_MUA9 6b_MUA 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA0 6b_MUA9 6b_MUA9 6b_MUA6 6b_MUA8 6b_MUA7 6b_MUA7 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA 6b_MUA6 6b_MUA8 6b_MUA9 6b_MUA 6b_MUA5 6b_MUA 6b_MUA 6b_MUA 6b_MUA0 6b_MUD8 6b_MUD0 6b_MUD 6b_MUD9 6b_MUD 6b_MUD 6b_MUD5 6b_MUD 6b_MUD 6b_OTP_SEL 6b_RSTINn 6b_WRLn 6b_RAMCSn 6b_OERAMn 6b_RAMCSn 6b_RSTINn 6b_MUD[0..] 6b_ALE 6b_MUD[0..5] 6b_MUD[0..5] 6b_MUD[0..5] 6b_PSENn 6b_MUD[0..5] 6b_WRHn 6b_FlashCSn 6b_MUA[..9] 6b_FMUA9 6b_PSENn 6b_MUA 6b_WRLn 6b_RDn 6b_ALE 6b_WRHn 6b_MUA 6b_RSTINn 6b_MUA 6b_MUA[..9] 6b_OERAMn 6b_RAMCSn 6b_WRHn 6b_WRLn 6b_MUA[..9] 6b_WRHn 6b_RAMCSn 6b_ALE 6b_MUA[..9] 6b_RDn 6b_PSENn 6b_RDn 6b_WRLn 6b_RAMCSn 6b_FlashCSn 6b_RAMCSn 6b_MUA[..9] 6b_PWM_Collator 6b_PWM_MaxiFeeder 6b_ReadHead_Ana MAIN_PDISC 6b_DongleCommunication 6b_PDisc_Collator 6b_AD_CS 6b_Multiplexed_AD 6b_IledCheck 6b_CurveDisc_FT 6b_CurveDisc_FT 6b_AD_DAT 6b_AD_CLK 6b_MUA[..9] 6b_DAC_DATA 6b_DAC_CLK 6b_DAC_CS 6b_FMUA9 6b_DigOutput 6b_DigOutput 6b_DigInput SCS_SCL SCS_SDA 6b_TXD0 6b_RXD0 6b_RSOUTn 6b_DAC_CS DfcMulPlex0 DfcMulPlex 6b_TXD 6b_RXD 6b_RXD 6b_TXD 6b_OERAMn 6b_PSENn DfcMulPlex SCS_SCL SCS_SDA 6b_DEBUG 6b_DEBUG RESET_XA VCC VCC AVDD AVDD VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC VCC_OUT 5V supervisor Scratch jumper Latches OTP/FLASH selector XA controller 6Kbyte system RAM Mbyte FLASH ROM Mbyte emulation RAM (sht 6) (sht ) (sht ) (sht ) (sht ) (sht 5) (sht ) (sht 7) (sht 7) (sht 8) (sht ) (sht 7) (sht 8) (sht 7) (sht 0) FLASH WRITE TEST MAP0 MAP (sht 7) (sht 9) (sht 7) (sht 7) (sht 7) (sht ) DEBUG CONNECTION (sht ) (sht) (sht 7) CO60 uf U6 HM685BLP-5 A8 A6 A5 A A7 5 A6 6 A5 7 A 8 A 9 A 0 A A0 DQ0 DQ DQ 5 6 DQ 7 DQ 8 DQ5 9 DQ6 0 DQ7 CS A0 OE A 5 A9 6 A8 7 A 8 A A7 0 WE 9 VCC CO66 0nF R6 K C650 00nF U67B 7HC7 D Q 9 CLK Q 8 PR 0 CL VCC 7 U68 7HC57 D Q 9 D Q 8 D Q 7 D 5 Q 6 D5 6 Q5 5 D6 7 Q6 D7 8 Q7 D8 9 Q8 C OC VCC 0 0 R6 K CO60 0nF C67 00nF D67 GREEN C65 00nF U660D 7HC08 C65 µf JP60 FLASH BOOT R650 K CO600 0nF U60 9F800 A8 6 A6 8 A5 A A7 8 A6 9 A5 0 A A A A A0 5 DQ0 9 DQ DQ 7 DQ 5 DQ 8 DQ5 0 DQ6 DQ7 CE 6 A0 6 OE 8 A 5 A9 7 A8 8 A A A7 7 WE VCC 7 DQ8 0 DQ9 DQ0 DQ 6 DQ 9 DQ DQ DQ5 5 RESET RY/BY 5 6 BYTE 7 R660 K R600 K CO60 0nF CO680 0nF CO6 0nF R60 56R U600 OSC. 9.9Mhz VDD OUT OE D67 RED U6 656HF A0 0 A 9 A 8 A 7 A 6 A5 5 A6 A7 A8 5 A9 A0 A A A 6 A CS 0 WE 7 OE D0 D D D 5 D 6 D5 7 D6 8 D7 9 VCC 8 U660A 7HC08 U650 TL7705A CT SEN 7 RESIN REF RST 6 RSET 5 U680 7HC57 D Q 9 D Q 8 D Q 7 D 5 Q 6 D5 6 Q5 5 D6 7 Q6 D7 8 Q7 D8 9 Q8 C OC VCC 0 0 D60 RED R6 0K C65 00nF U660C 7HC R60 56R R670 K U60 PXAS7KBBE SOT5- XTAL 68 XTAL 67 AVDD 8 AVDD 9 AVREF+ 7 AVREF- 6 AVSS 0 AVSS CLKOUT 6 ALE/PROG PSEN 5 RSTOUT RST 7 EA/WAIT/VPP 6 P.0/A0/WRH P./A P./A P./A 5 P./RXD 6 P.5/TXD 7 P.6/T 8 P.7/TEX 9 P.0/RXD0 P./TXD0 P./INT0 5 P./INT 6 P./T0 7 P.5/T/BUSW 8 P.6/WRL 9 P.7/RD 0 P.0/ECI 7 P./CEX0 7 P./CEX 75 P./CEX 76 P./CEX 77 P.5/CEX 78 P.6/A0 79 P.7/A P5.0/AD0 7 P5./AD 8 P5./AD 9 P5./AD 0 P5./AD P5.5/AD5 P5.6/AD6/SCL P5.7/AD7/SDA 5 P6.0/A 0 P6./A P0.0/AD0 P0./A5D P0./A6D 8 P0./A7D 9 P0./A8D 50 P0.5/A9D5 55 P0.6/A0D6 56 P0.7/AD7 57 P.0/AD8 58 P./AD9 59 P./AD0 6 P./A5D 6 P./A6D 6 P.5/A7D 6 P.6/A8D 65 P.7/A9D5 66 VDD 7 VDD 7 VDD 5 VDD 5 VDD VDD 5 VSS 69 VSS 70 VSS 5 VSS 5 VSS VSS R6 0K U660B 7HC TP60 6b_TST U67A 7HC7 D Q 5 CLK Q 6 PR CL VCC 7 R67 K CO660 0nF C60 00nF CO67 0nF CO6 0nF D60 GREEN R60 K CO600 0nF R680 K R65 K CO68 0nF J600 HEAD U670 V0PLCC I/CLK I I I 5 I5 6 I6 7 I7 9 I8 0 I9 I0 I I 6 O 7 O 6 O 5 O O5 O6 O7 0 O8 9 O9 8 O0 7 VCC 8 NC NC 8 NC 5 NC R65 K CO670 0nF U60 HM685BLP-5 A8 A6 A5 A A7 5 A6 6 A5 7 A 8 A 9 A 0 A A0 DQ0 DQ DQ 5 6 DQ 7 DQ 8 DQ5 9 DQ6 0 DQ7 CS A0 OE A 5 A9 6 A8 7 A 8 A A7 0 WE 9 VCC R68 K R65 K CO60 0nF R67 680K R67 K JP670 R&D U60 656HF A0 0 A 9 A 8 A 7 A 6 A5 5 A6 A7 A8 5 A9 A0 A A A 6 A CS 0 WE 7 OE D0 D D D 5 D 6 D5 7 D6 8 D7 9 VCC 8 CO60 0nF CO60 0nF C600 50pF

138 Digital outputs Analog multiplexer VCC VCC VCC VCC 6b_MUD[0..7] 6b_DigOutput 6b_RSOUTn 6b_Multiplexed_AD 6b_MUD0 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD5 6b_MUD6 6b_MUD D7 Q7 D6 Q6 5 D5 Q5 6 D Q 9 D Q D Q 5 D Q 6 D0 Q0 9 CLK CLR VCC 0 U700 7HC7 VCC 0 TP70 WINDOW 6b_DEBUG (sht 6) 6b_DEBUG 6b_DIR_Collator (sht ) 6b_ReadHead_S0 6b_ReadHead_S (sht ) (sht ) MU_AD_SEL0 MU_AD_SEL A X0 0 MU_AD_SEL B X 9 C X 5 X 6 INH X X5 5 X6 X7 X AVDD U70 7HC05 D700 BAT5S 6b_ANA_RX_Collator (sht 0) 6b_ANA_RX_ReadHead (sht ) 6b_ANA_RX_Folder (sht 0) 6b_ANA_RX_Feeder (sht 9) 6b_ANA_RX_Feeder (sht 9) 6b_ANA_RX_Feeder (sht 9) 6b_ReadHead_Ana0 (sht ) 6b_ReadHead_Ana (sht ) (sht 6) 6b_DongleCommunication R70 0K D70 BAT5S J70 UCAN CLIP 6b_MUD[0..7] 6b_MUD0 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD5 6b_MUD6 6b_MUD7 6b_DigClutch_FO (sht 0) 6b_DigClutch_FO (sht 0) 6b_DigClutch_FoForward (sht ) 6b_DigClutch_FE (sht 9) 6b_DigClutch_FE (sht 9) 6b_DigClutch_FE (sht 9) 6b_DigClutch_FoReverse (sht ) 6b_DigOutput 6b_RSOUTn U70 7HC7 R70 K7 Q70 BC87 VCC 6 8 R7 50R D7 D6 D5 D D D D D0 VCC 0 Q7 Q6 Q5 Q Q Q Q Q CLK CLR 0 R7 50R (sht 6) Digital inputs VCC 6b_MUD[0..7] 6b_MUD0 6b_MUD 6b_MUD 6b_MUD 6b_MUD 6b_MUD5 6b_MUD6 6b_MUD Y Y Y Y Y Y Y Y VCC 0 A A A A A A A A VCC 6b_DIG_FCEL_FE (sht 9) 6b_DIG_FCEL_FE (sht 9) 6b_DIG_FCEL_FE (sht 9) 6b_DIG_FCEL_COLL (sht 0) 6b_DIG_FCEL_RH (sht ) 6b_DIG_FCEL_FO (sht 0) 6b_SwitchMaxiFeeder (sht ) 6b_DigInput 9 G G U70 7HC 0 JP70 FE-SEL R70 0K VCC 0 bit ADC for DFC VCC VCC VCC VCC R70 R7 56R 56R CO700 CO70 CO70 0nF µf uf 6b_AD_CS CS 6b_AD_DAT 6 DOUT 6b_AD_CLK 7 CLK VCC 8 R7 56R +IN VREF 5 -IN U70 LTC97 (sht 6) R7 K R7 K DfcMulPlex0 DfcMulPlex DfcMulPlex C70 C7 00nF nf A B C INH X VCC 6 8 X0 X X 5 X X X5 5 X6 X7 U7 7HC05 JP70 Inter. trans. R75 0K JP7 Spare R76 0K 6b_DFC_FE (sht 9) 6b_DFC_FE (sht 9) 6b_DFC_FE (sht 9) 6b_MaxiFeederDetect (sht ) 6b_IledCheck(sht 8) VCC CO700 0nF CO70 0nF CO70 0nF CO70 0nF CO7 0nF figure.8 Main board electronics: sheet 7 of rev /00

139 Current Sink R808 8R Q800 BC87 6b_TX_Feeder R80 K R809 8R Q80 BC87 6b_TX_Feeder (sht 9) R80 K R80 8R Q80 BC87 6b_TX_Feeder (sht 6) 6b_DAC_CS 6b_DAC_DATA 6b_DAC_CLK.98V R800 0K R80 9K Photocel DAC VCC VCC 6 5 LDAC CS DIN SCLK DOUT REF C800 00nF VCC VDD DAC-A DAC-B DAC-C 6 DAC-D 5 DAC-E 7 DAC-F 8 DAC-G 9 DAC-H 0 U800 MAX558 R80 K R805 K R806 K R807 K R8 R R8 8R R8 8R R8 8R R8 R Q80 BC87 Q80 BC87 Q805 BC87 VCC R8 K7 U80A LM58 R80 00K C80 0nF Uout = x I 6b_TX_Collator (sht ) 6b_TX_Folder (sht 0) 6b_TX_ReadHead (sht 0) 6b_IledCheck (sht 6) VCC VCC U80B LM58 7 CO800 00nF CO80 00nF R85 K figure.9 Main board electronics: sheet 8 of. rev /

140 V VCC_OUT VCC +V V Feeder- J900 Clutch fe RX feeder- TX feeder DFC feeder 9 0 6b_Clutch_FE 6b_TX_Feeder(sht 7) TP900 FE- R900 R90 K K R90 0K C900 0nF R90 8K R90 K R905 68K U900A LM58 R906 0K 6b_DIG_FCEL_FE 6b_Clutch_FE 6b_Clutch_FE 6b_Clutch_FE O O O O O5 O6 O7 COM 9 D970 C970 V 00nF P I I I I I5 5 I6 6 I7 7 6b_DigClutch_FE 6b_DigClutch_FE 6b_DigClutch_FE (sht 7) JST0 R90 5K6 R9 9K C90 00nF R9 5K6 C9 R nF 9K 7 U900B LM58 R9 K TP90 DFC FE R95 C9 K 00nF 6b_ANA_RX_Feeder 6b_DFC_FE (sht 7) 8 U970 ULN00L P VCC VCC VCC Feeder- J90 Clutch fe RX feeder- TX feeder DFC feeder 9 0 V VCC_OUT 6b_Clutch_FE 6b_TX_Feeder (sht 7) TP90 FE- R90 R9 K K R9 0K C90 0nF VCC +V R9 8K R9 K R95 68K U90A LM58 R96 0K 6b_DIG_FCEL_FE (sht ) FE_DFC_OFFSET FE_DFC_OFFSET FE_DFC_OFFSET 6b_ReadHead_DAC0 6b_ReadHead_DAC DAC-A DAC-B DAC-C DAC-D DAC-E DAC-F DAC-G DAC-H VDD LDAC 6 CS DIN SCLK DOUT REF U980 MAX558 5 C980 00nF R980 Pulls BusWidth 0K select of XA high 6b_DAC_CS 6b_DAC_DATA (sht 6) 6b_DAC_CLK VCC R98 0K.98V R98 9K JST0 C9 00nF 6b_ANA_RX_Feeder (sht 7) R90 5K6 R9 9K C90 00nF R9 5K6 R K 7 U90B LM58 R9 K TP90 DFC FE R95 C8 K 00nF 6b_DFC_FE V VCC_OUT VCC +V Feeder- J950 Clutch fe RX feeder- TX feeder DFC feeder 9 0 6b_Clutch_FE 6b_TX_Feeder (sht 7) TP950 FE- R950 R95 K K R95 0K C950 0nF R95 8K R95 K R955 68K U950A LM58 R956 0K 6b_DIG_FCEL_FE JST0 C96 00nF 6b_ANA_RX_Feeder (sht 7) +V +V +V VCC R960 5K6 R96 9K C960 00nF R96 5K6 R K 7 U950B LM58 R96 K TP960 DFC FE R965 C96 K 00nF 6b_DFC_FE CO900 00nF CO90 00nF CO950 00nF CO980 00nF figure.0 Main board electronics: sheet 9 of rev /00

141 FOLDERS IN KAP Slotted switch FT RX Reading head Slotted switch FT Clutch FT Clutch FT J JST VCC_OUT V VCC VCC R00 K7 R00 K R0 K7 R0 K V U00A 7HC C000 50pF U00B 7HC C00 50pF VCC VCC R00 K D000 GREEN FT R0 K D00 GREEN FT 6b_CurveDisc_FT (sht 6) 6b_RX_ReadHead (sht ) 6b_CurveDisc_FT (sht 6) 6b_DIG_FCEL_COLL 6b_ANA_RX_Collator 6b_DIG_FCEL_FO R050 68K U050A LM58 VCC R05 K VCC VCC R06 50R (sht 8) 6b_TX_Folder (sht 7) R060 R06 (sht 8) 6b_TX_ReadHead 68K 8K TP060 FO 7 U050B LM R06 K R05 8K C050 0nF C060 0nF R05 0K R06 0K TP050 COLL R05 K R055 K R065 50R VCC_OUT J JST8 RX Collator TX Folder RX Folder TX Read head Photocells collator side D00 V C00 00nF 6b_ANA_RX_Folder O O O O O5 O6 O7 COM 9 8 P I I I I I5 5 I6 6 I7 7 U00 ULN00L 6b_DigClutch_FO 6b_DigClutch_FO (sht 7) P U00F 7HC R070 K VCC CO00 0nF VCC CO050 00nF figure. Main board electronics: sheet 0 of. rev /

142 VCC_OUT R00 0K VCC_OUT R0 0K MAXI FEEDER (sht 7) 6b_SwitchMaxiFeeder 6b_MaxiFeederDetect U00C 7HC 6 5 C00 00nF R0 0K C0 00nF R0 K J JST6 Motor MF Switch MF MF detect V VCC VCC V R 0K R 0K (sht 6) 6b_PWM_MaxiFeeder (sht 6) 6b_PWM_Collator (sht 7) 6b_DIR_Collator 0 U00E 7HC D0 BAT5S P C0 00nF R0 00R P C 0nF C 00nF C C 00nF 00nF P P VCC VCP INA INA INB INB EN_A 5 VBOOT P P P P EN_B P 9 VSa VSb OUTA 9 OUTA OUTB 8 OUTB SENA 8 SENB U0 L605PD P L0 COMMON MODE SUPPRESION COIL (sht 8) 6b_TX_Collator R 50R VCC_OUT J JST0 Collator Unit Pdisc collator - Collator motor + TX Collator VCC VCC (sht 6) 6b_PDisc_Collator D GREEN PD COLL. R6 K 8 U00D 7HC 9 C5 50pF R5 K R K7 V CO0 70uF P figure. Main board electronics: sheet of rev /00

143 Reading Head J AMP6 CASE -V +V R00 K7 R0 K7 C00 nf -V C0 nf R0 K7 U00A LM58 R0 6K8 C0 nf C0 0nF R0 6k8 +V 5 6 C0 0nF + - C05 nf U00B LM58 7 R05 K7 AVDD R0 7K R 00K VCC U0A LM U0B LM58 7 R6 00K TP0 OMR_OUT R0 K R K C0 00nF 6b_ReadHead_Ana (sht 6) C06 00nF -V R06 9K R07 00K R08 00K VCC R09 56R R 0K R0 8R D00 BAT5S R 680K -V R 00K R 7K R5 680K UA HC066 R7 7K R8 68K Rv=7K 5 UB HC066 R9 7K 6b_ReadHead_S (sht 7) 6b_ReadHead_S0 (sht 7) 6b_ReadHead_DAC(sht 9) 6b_ReadHead_Ana (sht 7) 6b_ReadHead_DAC0 (sht 9) 6b_ReadHead_Ana0 (sht 7) R 0K R 0K C07 00nF VCC VCC TP50 ReadHead R5 8K 8 R55 68K (sht 0) 6b_RX_ReadHead R50 50R R5 0K + - U50A LM58 6b_DIG_FCEL_RH (sht 7) R5 50R C50 0nF R5 K 6b_ANA_RX_ReadHead (sht 7) UC HC UD HC066 0 CO000 00nF +V -V CO00 00nF VCC CO0 00nF VCC CO50 00nF R56 K U50B LM58 figure. Main board electronics: sheet of. rev /

144 figure. Component layout of the main board rev /00

145 . Test points Test point Name Minimum Typical Maximum Remarks TP0 VCC.8 V 5.0 V 5. V Local +5 V supply. TP0 -V -.5 V -.0 V -.5 V Local - V supply. TP0 +V V.0 V V Local + V supply. TP00 8b_TST Test of the digital signal that drives LED D00. Normal flashing frequency Hz. During errors the frequency is Hz. TP50 ENV 0.0 V 0. V 0.5 V PH7. Paper present TP50 ENV 0.9 V. V.5 V PH7. No paper present. PH correctly adjusted. TP50 FLAP 0.0 V 0. V 0.5 V PH8. paper present. TP50 FLAP 0.9 V. V.5 V PH8. No paper present. PH correctly adjusted. TP50 LOC 0.0 V 0. V.5 V PH9. Paper present. TP50 LOC 0.9 V. V.5 V PH9. No paper present. PH correctly adjusted. TP50 EXIT 0.0 V 0. V 0.5 V PH0. paper present. TP50 EXIT 0.9 V. V.5 V PH0. No paper present. PH correctly adjusted. TP60 6b_TST Test of the digital signal that drives LED D60. Normal flashing frequency about Hz. During errors the frequency will increase. TP70 WINDOW This test point can be used as an oscilloscope trigger signal to synchronize OMR mark measurements. TP900 FE- 0.0 V 0. V 0.5 V PH. Paper present. TP900 FE- 0.9 V. V.5 V PH. No paper present. PH correctly adjusted. TP90 DFC FE-.0 V. V. V Output voltage of DFC. Result of DFC adjustment after passing of a document. TP90 FE- 0.0 V 0. V 0.5 V PH. Paper present. TP90 FE- 0.9 V. V.5 V PH. No paper present. PH correctly adjusted. TP90 DFC FE-.0 V. V. V Output voltage of DFC. Result of DFC adjustment after passing of a document. TP950 FE- 0.0 V 0. V 0.5 V PH. Paper present. TP950 FE- 0.9 V. V.5 V PH. No paper present. PH correctly adjusted. TP960 DFC FE-.0 V. V. V Output voltage of DFC. Result of DFC adjustment after passing of a document. rev /

146 Test point Name Minimum Typical Maximum Remarks TP050 COLL 0.0 V 0. V 0.5 V PH5. Paper present. TP050 COLL 0.9 V. V.5 V PH5. No paper present. PH correctly adjusted. TP060 FO 0.0 V 0. V 0.5 V PH6. Paper present. TP060 FO 0.9 V. V.5 V PH6. No paper present. PH correctly adjusted. TP0 OMR OUT. V - - OMR output voltage of reading head RH. TP50 ReadHea d 0.0 V 0. V 0.5 V PH. Paper present. TP50 table.. Jumper settings table. ReadHea d. LED information 0.9 V. V.5 V PH. No paper present. PH correctly adjusted. Jumper Meaning Remarks Not placed Placed JP0 SEL0 Load N Go text. Auto Set text JP SEL Load N Go text. Fill & Start text JP60 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 (U60 and U6) should be present. JP70 FE- SEL Reserved for gap separation feeder. JP70 Inter. Trans. Is placed if intermediate transport is installed. Not relevant in this machine. JP7 Spare Not used (yet). LED Name/Color Remarks D00 TESTLED/ Green Periodically 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 Hz. When an error occurs the flashing rhythm increases. D0 FLASH WRITE/Red Is ON during the programming (flashing) of the 8-bit machine software. The behaviour of D0 and D is similar to the behaviour of D67 and D67 for the 6-bits machine software (for diagnostics with flash programm problems) rev /00

147 LED Name/Color Remarks D FLASH RUN/ Green Is ON during normal operation of the 8-bit machine software. The behaviour of D0 and D is similar to the behaviour of D67 and D67 for the 6-bits machine software (for diagnostics with flash programm problems). D580 table. MAIN PDISC/ Green Reflects the optical state of slotted photocell SPH that monitors pulse disc PD, which moves in line with the main motor M driven items. Is ON if this motor is running AND if the mechanical drive is okay. D60 TEST/Green Periodically ON/OFF flashing. Signifies proper operation of the machine software of the 6-bit controller U60. If the software is in normal operation the flashing rhythm will be about Hz. When an error occurs the flashing rhythm increases. D60 FLASH WRITE/Red Flash LED. Is ON during the flashing (i.e. programming or reprogramming under supervision of external software) of the 6- bit machine software in flash ROM (U60). Full brightness during the erasing state, intermediate brightness during the flashing state proper. D67 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 5 kilobyte part. D67 MAP/Green Reflects the state of the Map signal. Is ON during normal operational use of the machine, including the one-second machine startup stage mentioned under D67. Is OFF if program code in system RAM (U60 & U6) (for instance flash software for programming or reprogramming the flash ROM U60) is executed, under supervision of external software. D000 FT/Green Reflects the optical state of slotted photocell SPH, which monitors the first fold pocket cam disc PD. Is ON if this photocell sees the cam disc. D00 FT/Green Reflects the optical state of slotted photocell SPH, which monitors the second fold pocket cam disc PD. Is ON if this photocell sees the cam disc. D PD COLL/ Green Reflects the optical state of slotted photocell SPH, which monitors collator motor M. rev /

148 Service menu. General Proceed as follows for access to the service menu: Navigate to the second screen of the main menu (see figure.). Press key (Job menu). The Job access screen of figure. appears. Enter the pin code. Now you will enter the first part of the service menu screen of figure.. This is the first part. With key you can switch to and back from the second part of the service menu screen of figure.5. Figure. shows a flow chart of the service menu. With the four soft keys through (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. If a menu offers the possibility to change settings, key is used to implement these changes and to go back to the next-higher menu level rev /00

149 Job Access Code Service, key key key key key key System. Job settings.9 Service tests. Counters. OMR. key key key key key key Configuration. Localisation. SW versions.5 OMR code definition. Read code test. key key key key key key key Folder offset.6 Reset data.7 Power up.8 Doc. offset.0 BRE offset. Secure jobs. Flap closer. key Photocells.5 key Digital inputs.6 key Actuators.7 key key Run in.8 key DFC.9 key Keyboard & display.0 figure. rev /

150 Key start/stop esc figure. Key figure. Key figure. from top to bottom.,.9, rev /00

151 Key figure.5 from top to bottom.,.. System setting Key figure.6 from top to bottom.,.,.5 Key figure.7 from top to bottom.6,.7,.8. Configuration This screen provides information on the various available options, i.e. the number of feeders, Fe limited "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 and switching the machine off and on again. rev /

152 Key figure.8. Localisation Key figure.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: A (97 mm), A5 (8 mm) and A6 (05 mm) for documents; C5 (6 mm) and C6/5 ( mm) for envelopes. Inches:.5" (90 mm), #9 (99 mm), " (0 mm), 6" (5 mm), 7" (78 mm), 8" (0 mm), 8.5" (6 mm), " (79 mm), " (05 mm) and " (56 mm) for documents; #9 (99 mm), #0 (05 mm) and 6x9 (5 mm) for envelopes..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 6-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 rev /00

153 Key figure.0.6 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. you first select the folder. Than you can set the equivalent shift in the folding position between -0 mm and +0 mm. By processing test material you can decide if subsequent corrections in these settings are necessary. Key figure..7 Reset data This menu offers the possibility (with key ) for initializing the system with default values (confirm with key ). In addition all photocells will be readjusted (so: remove all paper from the machine). All counter values are not affected. Use key to load default millimeter jobs (, and ). Use key to load default inch jobs (, and ). The only way to leave this screen is to use the Escape key. rev /

154 Key figure..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 or leave this menu without changes by using the Escape key. Key figure..9 Job settings Key figure. from top to bottom.0,.,.,..0 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.5 you can set for each job (select with key ) the extend to which the documents are not overlapping each other, i.e. the document offset value. The default 0.0- rev /00

155 value is 50 mm. With keys and the document offset can be varied between 0 mm and 75 mm in mm steps. Press key to store the changes or press the Escape key to ignore the changes. Key figure.5. 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.6. For all jobs 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 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 and to select a job. With key the BRE offset is switched on or off. Press key to store the changes or press the Escape key to ignore the changes. rev /

156 Key figure.6. 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 and to select a job. With key the selected job is locked on or unlocked. Press key to store the changes or press the Escape key to ignore the changes. Key figure.7. Flap closer In this menu the timing of the activation of the sealing solenoid (So) 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 -0 and + 0 mm (with respect to the default envelope position). Use key to select a job. With keys and the correction value for the envelope stop position prior to being sealed can be incremented or decremented. Press key to store the changes or press the Escape key to ignore the changes rev /00

157 Key figure.8. Service tests With key you toggle between the screen of figure.9 and the screen of figure.0. Key figure.9 from top to bottom.5,.6,.7 Key figure.0 from top to bottom.8,.9,.0.5 Photocells You can navigate to and from the screens of figure.,.,. or. with key. 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. rev /

158 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. 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.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 00%. The only way to leave this menu is to press on the Escape key. Key figure. PH7, PH8 Key figure. PH9, PH rev /00

159 Key figure. PH6, PH5, PH inclusive PH vertical track Key figure. PH, PH, PH.6 Digital inputs The four screens of figures.5,.6,.7 and.8 show the real-time status of the three safety switches (MS, MS and MS), the flag switch (FS), The two folder cam disks (SPH & PD; SPH and PD) and the two pulse discs (SPH for the main motor M and SPH for the collator motor M). 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.6) can be tested with key and key. 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 in figure.7 or figure.8) 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 5%, for the Pulse dist. (Duty cycle) the value should be in the range of 50% till 50% 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. 00%. rev /

160 Key figure.5 MS, MS, MS, FS Key figure.6 SPH&PD, SPH&PD Key figure.7 SPH&PD version with fill in values Key figure.8 SPH&PD version with fill in values.7 Actuators rev /00

161 In the three menu screens (figures.9,.0 and.) the correct operation of the two motors, three solenoids, six clutches and the Maxi Feeder motor (if present) can be verified. Keys and can be used to select the actuator to be tested. The test is performed with key. If (and as long as) key 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 M, 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 is pressed. Collator run out: Collator motor runs in the direction of the folder as long as key is pressed. Folding pocket /: The main motor M is switched on. The relevant fold pocket turns a half fold cycle. After two successive key presses the initial position prior to entering this menu is reached once again. Feeder clutches: The main motor M is switched on and the relevant feeder clutch is activated if and as long as key is pressed. The feeder clutch is only visible in the case of a ½-station version of the machine. The Maxi Feeder option is only available if the Maxi Feeder is present. As long as key is pressed, its motor runs. Key figure.9 M, So, So, So, CL6 Key figure.0 M IN, M OUT, CL, CL5 rev /

162 Key figure. CL, CL, CL.8 Run in The run in test screen of figure. shows a counter, of which the default value is 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 and you can set the counter at a value that differs from the default value If the counter value is 000 or higher, increments are 000 with a maximum value of if the counter value is lower than 000, decrements are 00 with a minimum value of 0. 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. Key figure..9 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. volt. If during the machine start a DFC unit does not "see" paper, the DFC voltage should be about.99 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. volt lower. For 80 g/m² paper DFC voltage about 0.5 volt lower rev /00

163 For 0 g/m² paper DFC voltage about 0.5 volt lower. For 60 g/m² paper DFC voltage about 0.5 volt lower. Key figure..0 Keyboard/display This menu screen offers the option to invert the screen display (with key, 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 cannot be tested, for this key is used for the toggle function. If the Start/Stop key, Escape key, key, key or key 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. Key figure.. Counters This menu (see figure.5) offers the possibility to read, set or reset the service counters. With key you can reset the Since last visit counter to zero. With key the Next visit after counter can be incremented in 5000 steps, with a maximum value of With key the Next visit after counter can be decremented in 5000 steps, with a minimum of A value under 5000 results in the value OFF. Use key 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.6 is displayed. rev /

164 This menu offers the possibility to set the Since installation counter. With key the counter value is incremented in 5000 steps. With key the counter value is decremented in 5000 steps. Use key (including changes) or the Escape key (without changes) to go back to the Service counters menu of figure.5. Key figure.5 Key figure.6. OMR Key figure.7 ferm top to botoom.,.. OMR code definition This menu offers the possibility to define OMR- reading codes, provided a level 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 0.0- rev /00

165 Safety mark. The various menu screens (of which figure.8 is an example; not all screens are shown in this document) share the same structure. With keys (repetitive key strokes) a code option is selected: Start mark, Insert on, Parity check, Safety mark and Line spacing. With key you choose between Yes and No (toggling function). In the Line spacing case keys and are used to increment (key ) or decrement (key ) the line spacing in steps of about 0,0 millimeter. The Lpi value reflects the number of lines per inch, the millimeter value is the distance between two successive marks. Use key 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.7. Key figure.8. Read code test Press key (Read code test, figure.7) to obtain the screen of figure.9. This menu screen informs the user about the mark quality, number of read marks and the gain setting. Every time the test key is pressed a sheet is forwarded and the screen will show the information. Key figure.9 The read code test submenu. Show marks (key ) The Show marks menu of figure.0 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. rev /

166 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.). 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 through 6 indicate where a mark is expected. The distance between the numbers is exactly the same as the programmed line spacing. With key you can scroll to the right, i.e. to a point later in time. With key you can scroll to the left, i.e. to an earlier situation. White paper/noise level Detection level Key Value of noise level Markposition Start reading window figure.0 The Show marks menu. After pressing the info key the information screen of figure. 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. Key figure. The Show marks info screen. Test (key ) 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 Good Very good Mark amplitude < 0.6 V Mark amplitude between 0.6 V and.5 V Mark amplitude higher than.5 V 0.0- rev /00

167 Adjustment (key ) 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 0 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 (Adjust) in the screen of figure.9. The adjustment menu of figure. appears. Press in the latter menu key (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. Key figure. The adjustment submenu rev /