Franking system PostBase One Service documentation

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1 Print system Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 1

2 Chapter 4.2 Printer System 1 MOTORS IN THE PRINTER SYSTEM 3 2 PIVOT ASSEMBLY POSITIONS 4 3 REMOVING THE CLEANING AND SEALING STATION (MTS) MTS maintenance Remove the Wiper Pad Remove Deflector Remove/Install the Rotary Encoder Find the values of the Rotary Encoder The measurement range of the Rotary Encoder Determine the resistance values for the upper and lower range Rotary Encoder adjustment 14 4 REMOVE THE PIVOT ASSEMBLY 17 5 REMOVE PENDRIVER BOARD WHEN PRINTER SYSTEM IS REMOVED 19 6 ADJUSTING THE SEALING POSITION 21 7 EXCHANGE THE FLEECE BEHIND THE FAN 22 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 2

1 MOTORS IN THE PRINTER SYSTEM The PostBase One printer system includes two motors.

(sealing, cleaning, blowing, and printing positions).

The second motor [2], the "MTS-Mover" (MTS, from "Maintenance Station" or "cleaning and sealing station"), moves the MTS

caps into position under the print heads. [3] To manually pivot the assembly, use a slotted screwdriver. Caution!

3 1 MOTORS IN THE PRINTER SYSTEM The PostBase One printer system includes two motors. One motor [1] (the oscillating motor) is responsible for swinging the print-heads (cartridges) to their various positions (sealing, cleaning, blowing, and printing positions). A rotary encoder [3] directs the motor to these positions in steps defined by degrees of movement. The second motor [2], the "MTS-Mover" (MTS, from "Maintenance Station" or "cleaning and sealing station"), moves the MTS [4] forward and backward, wiping the print heads clean, clearing a path for the pivot assembly and bringing the sealing caps into position under the print heads. [3] To manually pivot the assembly, use a slotted screwdriver. Caution! Never turn with a socket wrench!! [2] [1] [4] Figure 1 To manually cause MTS-Mover motion use a slotted screwdriver MTS Motor Oscillating Motor Figure 2 Figure 3 Figure 4 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 3

2 PIVOT ASSEMBLY POSITIONS When the machine is turned OFF or in "Stand-by"

Figure 6 Figure 5 Printhead position for flushing A cleaning cycle (flushing)

the way to the bottom, the MTS is in its rear-most position, and the print heads

4 2 PIVOT ASSEMBLY POSITIONS When the machine is turned OFF or in "Stand-by" status, the print heads are in a sealed position to the MTS (Figures 5+6). Figure 6 Figure 5 Printhead position for flushing A cleaning cycle (flushing) into the deflector is carried out prior to every pivot into the printing position or after printing 500 franks. (Figure 7) Figure 7 Deflector In print position, the deflector is swung out of the way to the bottom, the MTS is in its rear-most position, and the print heads are aligned for printing (Figure 8). Figure 8 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 4

To do this, manually drive the oscillating motor to move the print-heads away from the MTS (figure 9).

5 3 REMOVING THE CLEANING AND SEALING STATION (MTS) Whenever maintenance or repairs related to print quality are necessary, the cleaning and sealing station (MTS) must first be removed. To do this, manually drive the oscillating motor to move the print-heads away from the MTS (figure 9). Then manually turn the MTS motor to move the MTS from the sealing position into position for removal (figure 10). Figure 9 Removal position Sealing position Figure 10 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 5

- Place the printer system on a stable surface as shown in figure 11.

in the middle wall. This is the upper position for removal.

6 - Place the printer system on a stable surface as shown in figure Use a flat screwdriver to drive the MTS into its upper position, for easy removal (figure 12). Figure 11 Figure 12 In figure 13 the MTS can be seen in the cut-out in the middle wall. This is the upper position for removal. Figure 13 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 6

7 - Loosen the Phillips-screw and remove the holding plate (figure ) Figure 14 Figure 15 - withdraw MTS guidance axle (figure 16). - remove MTS (figure 17). Figure 16 Figure 17 Figure 18 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 7

8 3.1 MTS maintenance Warning! The final version of the MTS is equipped with three wiper blades! - Use tweezers to remove the sealing caps. Clean or replace as needed. Figure 19 - Loosen the wiper-blade retaining plate Figure 20 - (3x) Remove wiper blades. Clean or replace as needed. Figure 21 Figure 22 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 8

3.2 Remove the Wiper Pad - Move the print-heads into print position. - Now the wiper pad (for the wiper blades) can be removed and cleaned (figure 23).

3 Remove Deflector The deflector serves to protect the machine from excess ink released during the cleaning process necessary for the print-heads.

The cleaning process involves flushing the jets with ink.

See figure 7, page 4 Figure 25 shows the deflector with ink deposits. It should be removed for cleaning. Figure 25 Figure 26 Attention!

9 3.2 Remove the Wiper Pad - Move the print-heads into print position. - Now the wiper pad (for the wiper blades) can be removed and cleaned (figure 23). - The rubber wiper pads underneath the print-heads can be pushed off the axles if they need to be cleaned or replaced (figure 24). Figure 23 Figure Remove Deflector The deflector serves to protect the machine from excess ink released during the cleaning process necessary for the print-heads. The machine design calls for the print-head jets to be cleaned (flushed) every time the heads swing into print position, or every 500 prints. The cleaning process involves flushing the jets with ink. Before this is done, the deflector swings into position in front of the ink-jets to collect ink released in the flushing process. See figure 7, page 4 Figure 25 shows the deflector with ink deposits. It should be removed for cleaning. Figure 25 Figure 26 Attention! The final version of the printer system is to include an additional fan and filter in the side-wall (near the deflector, figure 26). This will help prevent ink spray from entering the machine's interior. Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 9

10 - Unhook the spring from the deflector (figure 27) - Use an 8 mm open-end spanner to remove the back-stop (figure 28+29). Figure 27 Figure 28 Figure 29 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 10

11 - Remove the C-clips from the left and right hinge points. Figure 30 Figure 31 - Extract the deflector (figure 32) Figure 32 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 11

3.4 Remove/Install the Rotary Encoder - Two Torx-screws must be loosened

Figure 33 Engaging piece - When installing, make sure the engaging piece

Figure 34 Engaging piece Figure 35 - Then re-insert the two screws and

Then tighten the screws lightly (figure 36) Figure 36 Caution!

12 3.4 Remove/Install the Rotary Encoder - Two Torx-screws must be loosened to remove the rotary encoder (figure 33). Figure 33 Engaging piece - When installing, make sure the engaging piece is in the correct position behind the plastic hook (nose) (figure 34+35) Figure 34 Engaging piece Figure 35 - Then re-insert the two screws and push the rotary encoder toward the front. Then tighten the screws lightly (figure 36) Figure 36 Caution! The encoder must be left loose! Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 12

3.5 Find the values of the Rotary Encoder 3.5.1 The measurement range of the Rotary Encoder 5 85 5 95 The Rotary Encoder can measure through a range of 95 (black zone).

13 3.5 Find the values of the Rotary Encoder The measurement range of the Rotary Encoder The Rotary Encoder can measure through a range of 95 (black zone). The steps of the angle are measured with a potentiometer. The possible resistance which you can measure is between 1.7 kω - 6 kω. All Rotary Encoders are individual and have a slightly different resistance for the upper and lower position! The Pivot Assembly can move in a max. angle of 85 (red zone). Using this method, the tolerance is 5 for the upper and lower position (if the adjustment is centred) Determine the resistance values for the upper and lower range Rotary Encoder PMR Figure 37 The first step is to use a multi meter and measure the resistance value in case of a released engaging arm. For this please follow these steps: - connect the red test prod to red cable and the black test prod to the green cable of the rotary encoder and note the resistance value (e.g. 5.8 kω). - now connect the red test prod to red cable and the black test prod to the yellow cable of the rotary encoder and note the resistance value for this again (e.g kω). If you measure the same value in case of a strained engaging arm, you will receive the same resistance values, however with reverse polarity of the test prods! Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 13

3.6 Rotary Encoder adjustment - Now place the rotary encoder in position (Torx IP 20; please use washers under the screws) Caution! Tighten the screws lightly. The encoder must be loose!

1kΩ (Cartridge exchange position; upper mechanical end stop) Rotary Encoder strained + 0.1kΩ (print position; lower mechanical end stop) 5.8KΩ 5.

14 3.6 Rotary Encoder adjustment - Now place the rotary encoder in position (Torx IP 20; please use washers under the screws) Caution! Tighten the screws lightly. The encoder must be loose! Figure 38 - Leave the test prods connected and adjusts the resistance value which you have found before, by rotating the Encoder: Rotary Encoder released 0.1kΩ (Cartridge exchange position; upper mechanical end stop) Rotary Encoder strained + 0.1kΩ (print position; lower mechanical end stop) 5.8KΩ 5.7KΩ Place the Encoder in position, tighten the screws softly e.g. Rotary Encoder released 5.8 kω so adjust 5.7 kω or Rotary Encoder strained 1.81 kω so adjust 1.9 kω! KΩ 1.81KΩ - If the encoder is adjusted tighten up the screws. On print systems where this adjustment is already done in the factory, a little tag with the resistance values is fixed on the Encoder cables (figure 39). After the Encoder is adjusted, tighten up the screws Figure 39 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 14

15 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 15

16 - Put the flat ribbon cable in place. 1. release O-ring 2. place the cables 3. put the O-ring back in position Figure 40 - If you loosen the mechanical upper end stop, please make them tight again. Upper mech. end stop Figure 41 Attention! To place the end stop in position, the pivot assembly must be moved downwards and after you tighten the screw, please run the assembly back into the upper position and check the resistance values again. Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 16

4 REMOVE THE PIVOT ASSEMBLY Before the pivot assembly can be removed, the

Figure 42 - Then remove the O-ring from the rotary encoder in order to

remove the inner C-clip on the pivot axle (figure 44) Figure 44 Andreas

17 4 REMOVE THE PIVOT ASSEMBLY Before the pivot assembly can be removed, the end-stop must first be loosened and pushed aside (figure 42). Figure 42 - Then remove the O-ring from the rotary encoder in order to release the two flat-cables to the printhead (figure 43) Figure 43 - Now remove the inner C-clip on the pivot axle (figure 44) Figure 44 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 17

- Remove the two Phillips-screws from the pivot bearing.

cut-out aligns with the screw to give the screwdriver access

and away (figure 47) Figure 47 Andreas Nagel VST;

18 - Remove the two Phillips-screws from the pivot bearing. To remove the right screw, turn the gearsegment to that the cut-out aligns with the screw to give the screwdriver access (figure 45+46) Figure 45 Figure 46 - Lift the pivot assembly up and away (figure 47) Figure 47 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 18

5 REMOVE PENDRIVER BOARD WHEN PRINTER SYSTEM IS REMOVED -

so that the print heads can be swung upward past the

remove from the pen driver cover. Caution!

Figure 50 Figure 51 - Then remove the spacer pins (with

Attention: The left spacer pins are slightly longer

19 5 REMOVE PENDRIVER BOARD WHEN PRINTER SYSTEM IS REMOVED - Release the end-stop and slide it to the left (figure 48) so that the print heads can be swung upward past the end-stop (figure 49) Figure 48 Figure 49-4x Torx 8-screws remove from the pen driver cover. Caution! Spring pressure! (Figure 50) and remove cover (figure 51). Figure 50 Figure 51 - Then remove the spacer pins (with springs). Attention: The left spacer pins are slightly longer (figure 52). Figure 52 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 19

- Open the collars for the flat-cable plugs on the pen driver board

Figure 53 Figure 54 - Now the pen driver board can be extracted

is slipped under the protruding plastic tab.

20 - Open the collars for the flat-cable plugs on the pen driver board (figure 53) and unplug the cables (figure 54). Figure 53 Figure 54 - Now the pen driver board can be extracted (figure 55) When installing, make sure the upper edge of the board is slipped under the protruding plastic tab. Figure 55 Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 20

6 ADJUSTING THE SEALING POSITION To adjust the sealing position, the machine must be in Service Mode. "Page 6 -> 3.

heads. Because these caps must be adjusted to within a tolerances measured in tenths of millimetres, a mechanical indicator with a 1 : 5 ratio has been provided.

when the sealing station moves. The indicator's pivot point is located to that the opposite end of the indicator moves at a 5 : 1 when the sealing station moves.

21 6 ADJUSTING THE SEALING POSITION To adjust the sealing position, the machine must be in Service Mode. "Page 6 -> 3.5 Adjust MTS Printhead cap" Refer to Chapter 03 Service Mode When installed, it is not possible to see the MTS sealing station to check the position of the sealing caps on the print heads. Because these caps must be adjusted to within a tolerances measured in tenths of millimetres, a mechanical indicator with a 1 : 5 ratio has been provided. This indicator must be correctly positioned in the adjusting window under the cartridge flap (figure 56+57) Figure 56 Figure 57 The indicator is linked to the MTS so that it moves when the sealing station moves. The indicator's pivot point is located to that the opposite end of the indicator moves at a 5 : 1 when the sealing station moves. The sealing station is correctly adjusted when the indicator is in the middle of the adjustment hole. MTS-indicator pick-up Adjustment hole Figure 58 Print-head / Sealing cap position Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 21

7 EXCHANGE THE FLEECE BEHIND THE FAN To protect the inside of the machine against ink dust,

running fan implemented into the print system.

450.000 imprints) (figure 59) Figure 59 For this remove 2 Torx screws (IP20) on the fan from the

(figure 60+61) Figure 60 Figure 61 You are now able to remove the fan including the filter

22 7 EXCHANGE THE FLEECE BEHIND THE FAN To protect the inside of the machine against ink dust, which is produced during any cleaning and spitting procedure, there is a fleece (filter) and a running fan implemented into the print system. This sucked ink dust is held in the filter fleece This fleece must be exchanged periodically during maintenance intervals (every 3 years or after imprints) (figure 59) Figure 59 For this remove 2 Torx screws (IP20) on the fan from the outside and disconnect the cable. (figure 60+61) Figure 60 Figure 61 You are now able to remove the fan including the filter channel to exchange the fleece. (figure 62+63) Figure 62 Figure 63 Note: During installation of the fan, please take care of the right direction (type plate visibly; see fig. 60), otherwise the ink dust becomes distributed into the machine! Andreas Nagel VST; ServDok_PostBase-One_Kap04_02_printer_system_003eng.docx Revision May, 10th/ 2016 page 22

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