Pitney Bowes DI380 Series Service Manual Download Page 3

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SDT335A MMI Service Manual & Parts List

• Contents

Page

secTION 1

Introduction

1.1 -

Purpose ............................................................................................ 1-1

1.2 -

Equipment Covered .......................................................................... 1-1

1.3 -

Related Publications ......................................................................... 1-1/1-2

1.4 -

Contents ........................................................................................... 1-1

1.5 -

Safety Summary ............................................................................... 1-2/1-3

1.6 -

Equipment Safety ............................................................................. 1-4

secTION 2

Specifications

2.1 -

Material Specification ........................................................................ 2-1/2-3

2.2 -

Machine Specification ....................................................................... 2-4

secTION 3

Theory of Operation

3.1 -

Introduction- To System Theory ........................................................ 3-1

3.2 -

Single Sheet Feeder Mode & Linked Feeder Mode........................... 3-2

Flow Diagram- Single Sheet Feeder Mode ............................. 3-3

3.3 -

Insert Feeder Mode ........................................................................... 3-4

Flow Diagram- Insert Feeder Mode ........................................ 3-5

3.4 -

Two Sheet Feeder Mode ................................................................... 3-6

Flow Diagram- Two Sheet Feeder Mode ................................ 3-7

3.5 -

Single Sheet Feeder Plus an Insert Mode ........................................ 3-8

Flow Diagram- Single Sheet Feeder Plus an Insert Mode .....

3-9

3.6 -

Two Sheet Feeders Plus an Insert Mode .......................................... 3-10

Flow Diagram- Two Sheet Feeders Plus an Insert Mode ....... 3-11

3.7-

The Fold Only Mode .......................................................................... 3-12

Flow Diagram- The Fold Only Mode ....................................... 3-13

3.8 -

Accumulation From Main Sheet Feeder ............................................ 3-14

Flow Diagram- Accumulation for Sheet Feeder 1 Mode ......... 3-15

3.9-

Double Detect Sensors ..................................................................... 3-16

3.10-

AC Motor ........................................................................................... 3-17

secTION 4

Removal & Replacement

4.1 -

Removing Covers and P.C.B. ........................................................... 4-1

4.2 -

Removal of Jam Access Plate .......................................................... 4-1

4.3 -

Removing Sheet Feeder Separator Roller & Pad ............................. 4-2

4.4-

Removing Carriage Assembly ........................................................... 4-3

4.5-

Removal of Lower Collation Roller .................................................... 4-4

4.6-

Removal of Upper Insert Drive Rollers .............................................. 4-5

4.7-

Fold Roller Removal/ Replacement ................................................... 4-5/4-6

4.8-

Dismantling Insert Feeder (DI380/SI330 Only) .................................. 4-7

4.9-

Dismantling Insert Feeder (DI425/SI3500 Only) ................................ 4-8

4.10-

Removal of Top Assembly .................................................................. 4-9

4.11-

Removal of Envelope Feed Rollers and Separator Pad (DI380/SI330

Only) ................................................................................................... 4-10

Summary of Contents for DI380 Series

Page 1: ...DI380 DI425 Series Document Inserting Systems Includes Secap models SI3300 SI3500 service Manual FORM SDT333A 4 06 ...

Page 2: ...osed to any third party or used for any purpose other than in the proper conduct of Pitney Bowes Limited s business and it must be returned to Pitney Bowes Limited immediately upon the person ceasing to be associated with Pitney Bowes Limited Pitney Bowes Limited 2006 IMPORTANT Model and feature availability varies by country Contact your machine supplier for more information This guide covers all...

Page 3: ...eet Feeder Plus an Insert Mode 3 9 3 6 Two Sheet Feeders Plus an Insert Mode 3 10 Flow Diagram Two Sheet Feeders Plus an Insert Mode 3 11 3 7 The Fold Only Mode 3 12 Flow Diagram The Fold Only Mode 3 13 3 8 Accumulation From Main Sheet Feeder 3 14 Flow Diagram Accumulation for Sheet Feeder 1 Mode 3 15 3 9 Double Detect Sensors 3 16 3 10 AC Motor 3 17 section 4 Removal Replacement 4 1 Removing Cove...

Page 4: ...I380 SI3300 Only 5 2 5 5 Envelope Separator Pad Height DI425 SI3500 Only 5 3 5 6 Insertion Flipper Actuation Height Hold Down Solenoid Adjustment 5 4 5 7 Insertion Hold Down Finger Rest Position 5 5 5 8 Transport Pivot Plate End Float 5 5 5 9 Transport Pivot Plate Setting 5 6 5 10 Fold Plates 1 and 2 Offset 5 7 5 11 Nesting Constant 5 8 5 12 Q Station Adjustments 5 8 5 10 5 12 1 Alignment 5 8 5 12...

Page 5: ... 1 7 5 7 2 1 Final Assembly Number 7 1 7 2 2 Set Default Job 7 2 7 2 3 Set 50 60Hz 7 2 7 2 4 Serial Interface 7 2 7 2 5 View Error Codes 7 2 7 2 6 Set DDD 7 2 7 2 7 Set Service Counter 7 2 7 2 8 Set Out of Material 7 2 7 2 9 Set Nesting Constant 7 2 7 2 10 Calibrate Q Station 7 3 7 2 11 Set Fold Plate Offsets 7 3 7 2 12 Set Env Stop Count 7 3 7 2 13 Set Serial Number 7 3 7 2 14 View Software Revis...

Page 6: ...ce 8 1 8 3 The 200k Service 8 2 section 9 Installation 9 1 Unpack and Check 9 1 9 2 Operator Training 9 2 9 3 Supervisor Training 9 2 section 10 Diagrams 10 1 Flow Diagrams 10 1 10 2 Component Locations 10 2 10 3 Switches Sensors Motors Solenoids Test Levels 10 3 10 6 10 4 PCB Layout 10 7 10 5 Drive Belt Routing 10 8 10 6 Schematic Insertion Moistener Exit Areas 10 9 10 7 Schematic Sheet Feeders C...

Page 7: ...es Branded SDC1069 DI380 Operating Guide French Secap Groupe PB Branded SDC651 DI380 Operating Guide Polish SDC730 DI380 Operating Guide Czech SDC652 DI425 Operating Guide English SDC653 DI425 Operating Guide German SDC654 DI425 Operating Guide Italian SDC655 DI425 Operating Guide Dutch SDC656 DI425 Operating Guide Norwegian SDC657 DI425 Operating Guide Finnish SDC658 DI425 Operating Guide Swedish...

Page 8: ...5 SAFETY SUMMARY Warning messages are used throughout this manual to alert you to potentially hazardous conditions These warnings are explained below WARNING calls attention to improper practices that could cause injury CAUTION calls attention to improper practices that could damage the equipment or the material being run IMPORTANT calls attention to practices that could adversely affect equipment...

Page 9: ...ned to ground equipment to make it safe If a live wire shorts to a grounded frame the only result is an open fuse If a live wire shorts to an ungrounded frame the frame itself becomes hot and potentially dangerous A fuse is a weak link in a circuit designed to break down before anything else does The maximum safe current in a circuit is determined by the designers Too large a fuse can pass excessi...

Page 10: ...h but the best guarantee is to turn the machine off but leave it plugged in and ground yourself on the chassis which is grounded through the three wire power cord If you have access to one bring a grounding strap and use it Be careful of rugs even a few steps can recharge you Re ground yourself whenever you ve walked away and returned to the machine Rugs are a major source of static buildup in the...

Page 11: ...s The maximum compressed thickness after folding should not exceed 2mm Glossy coated sheets are not recommended Fold Type and Overall Thickness Limits The table below shows the maximum number of sheets that can be accumulated or collated for each fold type based on different weights of paper It is important that jobs exceeding these maximums are NOT programmed into the machine or imposed by OMR co...

Page 12: ...rt Feeder Double Document Detector Material range 60g m2 Minimum 120g m2 Maximum Feed tray capacity DI380 SI3300 Up to a maximum of 100 Inserts DI425 SI3500 Up to a maximum of 300 Inserts Sealer The machine can seal up to a maximum of 1200 envelopes between refills Stacker The envelope Stacker can accommodate up to 150 filled envelopes Dependent on size and contents of the envelope Material Requir...

Page 13: ...at each side i e a minimum of 12mm overall This measurement should be taken with all Mail Piece contents placed into the envelope Depth Clearance The Mail Piece Contents must allow a minimum clearance of 3mm for unfolded inserts and 6mm for folded material below the flap crease after being fully inserted into the envelope Envelope flap and throat requirements DEPTH WIDTH Min 25 5mm Max 63mm Min 6m...

Page 14: ... Maximum Speed DI380 SI3300 Up to a maximum of 3 000 cycles per hour DI425 SI3500 Up to a maximum of 3 500 cycles per hour Depending on model fold type and material quality Compliance It is certified that the Folding Inserting machine complies with the requirements of the Low Voltage Directive 73 23 EEC and the EMC Directive 89 336 EEC The product was tested in a typical configuration For a formal...

Page 15: ...driven into fold plate 1 When the sheet reaches the deflector stop the paper is buckled This buckled edge is then pulled through fold rollers 2 and 3 which creates the first fold It then enters fold plate 2 until it reaches the deflector stop where the sheet is buckled again The edge is pulled into fold rollers 3 and 4 creating the second fold At this stage if an insert is programmed as part of th...

Page 16: ...olenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 It will then de energize the hold down solenoid L2 insertion solenoid L1 and the shoe horn solenoid L3 The envelope is then driven from the insertion area into the sealer area The next envelope is fed when the lead edge of the envelope pushes the moistener sensor S3 forward the software will increment by a...

Page 17: ...cked Sensor OP5 Envelope Motor M9 ON Envelope Sensor S1 ON Lead Edge Sensor S2 ON Delay Stop Insertion Solenoid L1 ON Hold Down Solenoid L2 ON Shoe Horn Solenoid L3 ON Finger Solenoid L4 ON Sealer Solenoid L5 ON Insertion Solenoid L1 OFF Hold Down Solenoid L2 OFF Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT SOFTWARE TRIGGER PAPER PATH Shoe Horn Solenoid L3 OFF S...

Page 18: ...noid is energized the software sends a signal to operate the insert collation motor M4 This will trigger the next insert to be fed into the collation insert area When the insert enters onto the pivot plate this moves the flag out of sensor OP5 When the insert is fully inserted the pivot plate moves backwards returning the flag to its home position This operation triggers the software to energize t...

Page 19: ...blocked Blocked Sensor OP5 Envelope Motor M9 ON Envelope Sensor S1 ON Lead Edge Sensor S2 ON Delay Stop Insertion Solenoid L1 ON Hold Down Solenoid L2 ON Shoe Horn Solenoid L3 ON Hold Down Solenoid L2 OFF Insertion Solenoid L1 OFF Shoe Horn Solenoid L3 OFF Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT SOFTWARE TRIGGER PAPER PATH Sealer Solenoid L5 ON Finger Solen...

Page 20: ...n solenoid L2 and finally by the shoe horn solenoid L3 The next sheet fed from the sheet feeder 1 is triggered by the previous sheet fed entering the fold plate 2 sensor OP14 When the folded sheet enters onto the pivot plate this moves the flag out of sensor OP5 When the folded sheet is fully inserted the pivot plate moves backwards returning the flag to its home position This operation triggers t...

Page 21: ...otor M9 ON Envelope Sensor S1 ON Lead Edge Sensor S2 ON Delay Stop Insertion Solenoid L1 ON Hold Down Solenoid L2 ON Shoe Horn Solenoid L3 ON Hold Down Solenoid L2 OFF Insertion Solenoid L1 OFF Shoe Horn Solenoid L3 OFF Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT SOFTWARE TRIGGER PAPER PATH Sealer Solenoid L5 ON Sheet Feeder Motor M2 Sheet Feeder DDD 2 Sensor F...

Page 22: ...the envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 When the sheet enters fold plate 2 covering sensor OP14 the software switches on the insert motor M4 after a timed delay This delay is the nesting constant set in the parameter screen The next insert is fed after the first insert is nested ...

Page 23: ...d Sensor OP5 Envelope Motor M9 ON Envelope Sensor S1 ON Lead Edge Sensor S2 ON Delay Stop Insertion Solenoid L1 ON Hold Down Solenoid L2 ON Shoe Horn Solenoid L3 ON Hold Down Solenoid L2 OFF Insertion Solenoid L1 OFF Shoe Horn Solenoid L3 OFF Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT SOFTWARE TRIGGER PAPER PATH Sealer Solenoid L5 ON Sheet Feeder Motor M1 Fold...

Page 24: ... at a predetermined time according to the size of envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 When the sheet enters fold plate 2 covering sensor OP14 the software switches on the insert motor M4 after a timed delay This delay is the nesting constant set in the parameter screen The next i...

Page 25: ...2 ON Delay Stop Insertion Solenoid L1 ON Hold Down Solenoid L2 ON Shoe Horn Solenoid L3 ON Hold Down Solenoid L2 OFF Insertion Solenoid L1 OFF Shoe Horn Solenoid L3 OFF Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT SOFTWARE TRIGGER PAPER PATH Sealer Solenoid L5 ON Stop Insert Motor M4 Delay Finger Solenoid L4 ON Sheet Feeder Motor M1 Sheet Feeder DDD 1 Sensor Sto...

Page 26: ...14 When the folded sheet enters onto the pivot plate this moves the flag out of sensor OP5 The pivot plate moves backwards and returns the flag to its home position This operation triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 The document is then driven from the insertion area into the sealer area The next...

Page 27: ...1 Sheet Feeder DDD 1 Sensor Stop Collation Motor M5 Fold Plate 2 Sensor OP14 Transport Pivot Plate Unblocked Blocked Sensor OP5 Finger Solenoid L4 ON Sealer Solenoid L5 ON Moistener Sensor Software Counter S3 Exit Sensor Machanical Item Counter S4 EXIT SOFTWARE TRIGGER PAPER PATH First cycle does not stop at the collation motor ...

Page 28: ...e envelope lifting the previous folded documents up The software sends the signal to turn on the collation motor M5 sending the next sheet down through the fold rollers and fold plates onto the pivot plate This happens until the predetermined sheets are inserted into the envelope After the last document has entered the envelope the pivot plate moves the flag out of the sensor OP5 This operation th...

Page 29: ...1 ON Hold Down Solenoid L2 ON OFF Shoe Horn Solenoid L3 ON OFF Finger Solenoid L4 ON Sealer Solenoid L5 ON Shoe Horn Solenoid L3 OFF Lead Edge Sensor S2 ON Transport Pivot Plate Unblocked Blocked Sensor OP5 Moistener Sensor S3 Software Counter Sheet Feeder DDD1 Sensor Exit Sensor S4 Mechanical Item Counter Stop Delay EXIT Collation Motor M5 SOFTWARE TRIGGER PAPER PATH Sheet Feeder Motor M1 OP9 Fol...

Page 30: ...ble is detected the machine will stop and the document will be in the collation nip area The machine will indicate which feeder the double has been fed from on the control panel On the MIDDLE position not available on the insert feeder the double detection will start halfway down the document This is taken from the length of paper entered in the Job Set Up Menu When a double is detected the machin...

Page 31: ...there is a mechanical relay which is used as a safety interlock The mechanical relay is powered from start up If a fault is detected in the A C circuit the relay is de energized until the power is recycled There are also a set of micro switches for use in jam clearance which will remove power from the relay To run the motor the motor start SSR1 and motor run SSR2 are energized together The motor s...

Page 32: ...3 18 SDT333A DI380 DI425 SI3300 SI3500 Service Manual 3 Theory of Operation ...

Page 33: ...efore removing control panel 7 Open the moistener cover and release the 2 springs on both sides of the machine and pull out cover It may be necessary to unclip the Q station 8 Disconnect all connectors including E I U port on the logic board P C B 1 Remove the 2 screws that holds the logic board backing plate Tilt and lift logic board and backing plate away from machine 2 Reassemble in reverse ord...

Page 34: ...19C P19D P20A P20B P20D and P20E 3 Remove 3 screws from the sheet feeder motor bracket and carefully remove bracket Take care not to lose bearings 4 On the rear side remove E clip that holds the bearing in place Slide the bearing inwards and remove E clip washer spring and clutched separator roller 5 The separator pad can be unclipped and replaced at this point Note All the old glue must be remove...

Page 35: ...Carriage assembly 1 Follow instruction for cover removal in section 4 1 2 Disconnect connector P23C on rear side 3 Remove the 2 holding plates see illustrations and screws on both the front and rear sides of the machine 4 Remove carriage assemble from the machine 5 Remove 4 self tapping screws from the assembly to expose sensor 6 Reassemble in reverse order ...

Page 36: ... deflector motor and PB16B from half fold encoder PCB 9 Remove 2 screws securing the half fold worm drive to the deflector plate 10 Remove the E clip and gear on the front side 11 Remove 2 springs from sheet feeder 2 separator pad plate on the front and rear sides 12 Removepivotscrewsholdingtheseparator pad plate and then remove the plate from the machine 13 Remove pivot screws holding the half fo...

Page 37: ... and rear sides of the upper insert plate 8 Remove both insert drive rollers and replace the bobbins and lower shaft with the roller bonded to the shaft 9 Reassemble in reverse order 4 7 Fold Roller Removal Replacement 1 The machine should be in a half fold mode before attempting to remove the fold roller 2 Follow instruction for cover and PCB removal in section 4 1 3 Release belt tension 4 Remove...

Page 38: ...ve 4 E clips wavy washers and bearings from the other end of the fold rollers on the rear side 8 Remove 2 screws that hold the bracket to the half fold deflector 9 Remove6screwsfromthefoldrolleraccess plate on the rear side 10 Remove half fold deflector and roller complete throughtherearframe Withdraw the other fold rollers from the machine 11 Reassemble in reverse order Note The idler fold roller...

Page 39: ... shaft but take care to note the orientation of the 1 way clutch 10 Remove the two nylon bearings from the cradle 11 Remove the four screws that secure the motor Two of the screws have 1 long spacers 12 Gently remove the motor from its location 13 Remove the nylon bearing e clips and pin behind the gear next to the separator rollers To remove the separator rollers from the housing t is necessary t...

Page 40: ... the paper sensor from the hot shoe 9 Remove any restricting cable ties to gain access to the unit 10 Remove the E Clips pins and pre feed rollers from the pre feed shafts Take note that the upper rollers are clutched and the lower pre feed rollers are fixed on the D shaft 11 Remove the screws holding the motor bracket assembly and bearing and then remove the motor bracket assembly and bearing 12 ...

Page 41: ...der sensor 5 Disconnect the cables to the hold down solenoid L2 6 Disconnect the cables for the motor encoder P29B and the motor P29A 7 Remove fold plate 2 motor M7 held by 3 screws and an E clip and washer on the drive pulley shaft 8 Remove the belt and drive pulley from the shaft to gain access to the top assembly locating screw 9 Remove the 4 screws that hold the top assembly to the base unit f...

Page 42: ...clip from the pre feed shaft 4 Remove the E clip washer and gear on the front side of the pre feed shaft 5 Moveseparatorassemblytowardsthefront of the machine 6 Remove pin pulley and belt from the front end of the separator shaft Note orientation of the pulley 7 Remove all bearings from the frame and remove the separator pre feed assembly 8 Remove the rollers and bearing from one side only 9 To re...

Page 43: ...e belt and remove 4 Remove screws B fixing plastic plate to the main side frames two screws each side 5 Lift envelope feeder and unhook from main machine 6 Reassemble in reverse order Removing the Envelope Feeder will give access to MTR 20 A B 4 13 REMOVING ENVELOPE FEED ROLLERS SEPARATOR PAD DI425 SI3500 Only 1 Remove envelope feeder covers 2 Remove Envelope Feed Motor M 9 and mounting bracket fr...

Page 44: ... on the rear side Withdrawtheshaftthroughtheonthesame side and separate the assembly from the base Blade 5 Remove 4 screws from the tinted cover 6 Remove the flapper unit springs noting the position of the different colour springs 7 Remove the 2 inner screws on each side of the assembly front and rear of the blade 8 Remove the 2 E clips on the inside of the 2 outer rollers 9 Withdraw one side of t...

Page 45: ...move roller 7 To remove screw and sensor limit arm 8 Using a 2 5mm allen key undo the Allen screws from both ends of the transport pivot plate then remove the sensor arm attached to the plate 9 Reassemble in reverse order Re align transport pivot plate to rollers ensuring that they do not bind 4 16 Removal of Sealer Rollers 1 Disconnect power 2 Remove the sealer covers only 3 Remove inverter plate...

Page 46: ... depth to 162mm before switching off This will give greater access to the rollers 2 Follow instruction for cover and PCB removal in section 4 1 3 Follow instruction for top assembly removal in section 4 9 4 Disconnect connector on the rotary solenoid in the Q station 5 Unclip the Q station from its location 6 Remove both springs and unclip sealer brush assembly 7 Remove sealer shield that is held ...

Page 47: ...lips and bearings from front and rear sides holding the arch roller 12 Withdraw the arching roller from the base by tilting it upwards at the front end 13 Loosen the water tank on non operator side 14 Undo belt tension on sealer exit drive belt 15 Remove the E clip on the operator side holding the transport drive roller 16 Push transport drive roller out of the bearing on the operator side and til...

Page 48: ...able for the Power Supply Unit is not trapped when refitting 4 20 Removal of the Lower Envelope Drive Roller 1 Follow instruction for cover and PCB removal in section 4 1 2 Remove E clip and plastic linkage from the rear end of the shaft 3 Remove all E clips linkage pin spring and plastic bearing on the front side 4 Roll the machine back making sure the water is removed from the sealer tank 5 Remo...

Page 49: ...screws retaining the AC motor 9 Tilt the machine back and undo the 4 feet holding the base plate and remove the plate 10 Disconnect connectors P35D sensor TB4 power supply unit and all other wiring into the power supply unit motor start capacitor and AC inputs 11 Undo the 4 screws holding the Power supply unit and remove the unit 12 Unclip the motor start capacitor from the holder as this is wired...

Page 50: ...4 18 SDT333A DI380 DI425 SI3300 SI3500 Service Manual 4 Removal Replacement ...

Page 51: ...justment screw A 3 Movesideguidestorequired position 4 Tighten Envelope Offset Adjustment screw 5 Cycle the machine with sheets inserts and check position of envelope in insertion area 5 1 Envelope feed tray guideS DI380 SI3300 Only 1 Wind Leadscrew so that side guides are at the middle of the tray 2 Loosen the Knurled Locking Nut and adjust the Bias Adjustment Nut until the guides are of equal di...

Page 52: ...eparator Pad Adjustment Separator Rollers Separator Pad 5 4 ENVELOPE SEPARATOR PAD HEIGHT DI380 SI3300 Only 1 Loosen the screws which hold the Separator Bracket to both side frames 2 Adjust the bracket until a gap of 6mm is achieved between the Separator Pad and Separator Roller A 6mm Allen Key may be used to check the height 3 Tighten the Separator Bracket screws Envelope Separator Pad Height Adj...

Page 53: ...pe Separator Pad Adjustment screw A 2 Adjust the bracket until a gap of 6mm is achieved between the Separator Pad and Separator Roller A 6mm Allen Key may be used to check the height 3 Tighten the Separator Pad Adjustment screw Separator Rollers Separator Pad 6mm Allen Key 6mm Envelope Separator Pad Height Adjustment DI425 SI3500 Screw A ...

Page 54: ...e hold down fingers pivot the flippers Move the hold down solenoid in its slots until the flippers raise to a height of 7mm above the deck measured from the points shown in the diagram 3 Fully tighten the solenoid fixing screws Flipper Actuator Height Setting Hold Down Solenoid Assemblies REST POSITION ACTUATED POSITION Hold Down Fingers Deck 7mm 7mm Solenoid Fixing Screws A Solenoid Plunger Hold ...

Page 55: ...END FLOAT 1 Adjust the Transport Plate end float with the pivot set screws located in both side frames Ensure that the plate has minimal end float but is free to pivot Also ensure that the Insertion Springs are set centrally between the Insertion Shaft Rollers by adjusting the setscrews equally on both sides Once set lock the setscrews with locktite or equivalent This adjustment will allow free mo...

Page 56: ...ntil it touches the transport plate arm Re tighten screw A This adjustment will achieve a 4 5mm gap when the transport plate is in its actuated position STEP 2 1 Re fix the Opto Bracket Setting Gauge but still allow movement of the bracket 2 Adjust the Opto Bracket until the underside of the transport plate arm contacts the leg of the bracket This adjustment will achieve the correct flag position ...

Page 57: ...o long 4 Take the actual fold dimension and subtract the displayed job setup figure e g 2mm 5 Enter this difference positive or negative into the Fold 1 Offset setting in the parameters menu then leave diagnostics 6 Run another standard 80g m2 sheet and check that the Fold 1 length in job setup now matches the actual fold length Step 2 Fold Plate 2 setting DO NOT carry out this adjustment until St...

Page 58: ...ately 0 5mm 6 Run another cycle and interrupt the machine with the sheets on the Transport Plate Re check the insert position and adjust again if necessary Insert Nesting Adjustment Mis nested distance Within 5mm is acceptable 5 12 Q STATION ADJUSTMENTS 5 12 1 Alignment This adjustment MUST be carried out BEFORE Q Station Calibration Refer to the illustration on the following page 1 Enter the Set ...

Page 59: ...he envelope is touching the Finger Stops 4 Using a ruler measure accurately the distance from the envelope lead edge to the insertion shaft on either side of the Finger Stops markedAand B in the illustration and record the measurements These measurements should be within 0 5mm of each other if the Alignment adjustment has previously been carried out correctly 5 Enter the measured distance using th...

Page 60: ...prevent overdrive of the envelope during the insertion process 1 Loosen the two Q Station height adjustment screws 2 Adjust the height from the deck to the top surface of the Q Station near the pivot spindle to a dimension of 30mm This is its nominal position 3 Tighten adjustment screws Note Ensure that both sides are of equal height Q Station Height Adjustment Adjust height to 30mm check both sid...

Page 61: ...h the cut outs of the Separator Stone The Separator Rollers can be adjusted after loosening the allen screw A located close to the Thumbwheel 5 13 2 Separator Roller Height 1 Remove the Insert Feeder Top Cover 4 screws 2 Move the Detent setting to the middle position 5 setting Insert Feeder Separator Roller Alignment Centralise rollers with cut outs on stone Screw A Middle Position Set lever to po...

Page 62: ...ert a sheet of 80 g m2 paper under the Separator Rollers Adjust the Separator Knob until you feel a slight drag on the paper without scoring 5 Retighten allen screw Separator Stone Setting DI380 SI3300 DI425 SI3500 Set lever to position D Set to position D Insert Feeder Separator Roller Height Adjustment Adjust for drag on 80g m2 paper Separator Thumbwheel ...

Page 63: ... Turn knob B fully open 4 Tighten allen screw A until there is a gap of between 11mm and 14mm between the InsertFeederSideGuidesandthePre Feed Roller 5 Reassemble the Insert Feeder Note Make sure there is no interference with the side guides and the pre feed rollers when you set the insert feeder to the minimum insert width Knob B Adjusting Screw A 14mm 0 55 Middle Position Detent Setting Separato...

Page 64: ...elpinintothecentralising hole 3 Tighten the fixing screw To reduce the output skew from a machine the following steps should be followed 1 Loosen the fixing screw 2 Run the machine and observe the skew output 3 Use a large flat bladed screwdriver in the adjustment vee and twist either left or right This will shift one side of the collation roller enabling you to correct the paper skew 4 Once the o...

Page 65: ... to 8 strips of 80g m2 paper on top of the 2nd and 4th arching rollers 4 Close the flapper assembly then rotate the flapper blade untilittouchesthespacersand resistance is felt 5 Tighten the adjustment plate screws both sides 6 Remove spacers and replace cover Flapper Assembly Cover Adjustment Plate Screws Adjust Flapper Cover locating screws Adjustment Plate screws Paper strips Rotate Flapper Bla...

Page 66: ...5 16 SDT333A DI380 DI425 SI3300 SI3500 Service Manual 5 Adjustments ...

Page 67: ...lace under the selective control of the OMR sheets You can also set up the insert feeder to be under the se lective control of the OMR sheets As a result OMR can be used to fill an envelope with a variable number of sheets from one feeder with or without a supplementary sheet and an insert A supplementary sheet and folded insert will be nested with the first sheet in the envelope As OMR allows eac...

Page 68: ...ope should not exceed 2mmm The paper width should be 203mm to 215mm 8 to 81 2 in This includes A4 and American Letter sizes Each mark position must be evenly spaced and at least 3mm apart An area around the marks should be kept clear from print etc that may be read by the scanner in error this area is called the Clear Zone There should be no print on the opposing face of the sheet immediately behi...

Page 69: ... CORNER Z Fold and Single Fold BOTTOM SCANNING BOTTOM RIGHT CORNER Standard OMR Positions 54mm min 96mm max 20mm min Clear Zone 20mm x 115mm min 69mm max 27mm min 20mm min Clear Zone 20mm x 100mm min Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold 115mm min 100mm min Vertically centre group within area indicated ...

Page 70: ...ows C Fold and Double Fold TOP SCANNING LEFT MARGIN Z Fold and Single Fold BOTTOM SCANNING RIGHT MARGIN Offset OMR Positions 125mm min 20mm min 80mm max 20mm min Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold 95mm max 65mm min 40mm min Bench Mark 65mm min 115mm min ...

Page 71: ...C Fold and Double Fold TOP SCANNING LEFT MARGIN Z Fold and Single Fold BOTTOM SCANNING RIGHT MARGIN Swiss Offset OMR Positions 125mm min 20mm min 130mm max 20mm min Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold 95mm max 65mm min 40mm min Bench Mark 65mm min 165mm min ...

Page 72: ...rmal Offset and 165 for Swiss Offset Any other values entered here are not supported and may cause scanning issues NOTE Select Feed cannot be used when using Offset or Swiss Offset this is due to the late scanning of the code making it too late to collate the supplementary sheet or nest the insert with in the sheet Group 2 OMR still can be used for AutoBatch The minimum paper weight when using Off...

Page 73: ...pe and the first sheet processed is the last of each set Benchmark fixed Safety fixed Not EOC Not BOC Parity Retiming fixed Select Feed 1 Select Feed 2 Auto Batch Retiming fixed if this group is in use Wrap Around Sequence 3 WAS3 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 1 WAS1 Retiming fixed if this group is in use Group 1 mandatory Group 2 Group 3 Feed Direction 6 3 2 Z Fold and Single Fo...

Page 74: ...rk out the length of the code 6 7 BOC NOT AND EOC NOT Two mark positions are allocated to this function one NOT BOC to indicate that a sheet is not the beginning of a set and one NOT EOC to indicate that a sheet is not the end of a set For a single sheet set neither mark is printed for intermediate sheets in a three or more sheet set both marks are printed See Figure Allowable Mark Combinations fo...

Page 75: ...varying as it feeds With Basic OMR only the first Retiming mark is needed if one or both of the other groups are used the Retime Mark associated with that group s must also be printed Retime Marks must be print on every sheet with in the prime set NOTES The beginning sheet of a set is defined as the first to be picked up and fed This is always the last logical page of a document whether reverse co...

Page 76: ...elect Feed 1 Mark is printed the supplementary sheet will be folded with the first sheet of the prime set and if Select Feed Mark 2 is printed a folded insert will be nested with it When using Select Feed the mark s must be printed on all of prime sheets with in the relevant set Limits on paper dimensions and weights remain as currently specified for the OMR in Section 2 the Specifications section...

Page 77: ...upplementary sheet Select Feed 2 on all sheets of a collation that includes an insert Auto Batch on all sheets of the last collation of a batch Re timing fixed if this group is in use Wrap Around Sequence 3 WAS3 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 1 WAS1 Re timing fixed if this group is in use Group 1 mandatory Group 2 Group 3 Identifying the OMR marks for 3 Series 13 SV70252 Rev A 3 ...

Page 78: ...us for OMR machines configured for Basic OMR If the customer has purchased the Enhanced OMR option the Pitney Bowes Service Representa tive enables the full set of OMR features through the Service Setup menu by entering the passcode 350350 when prompted Do NOT give this passcode to the customer To enable the Enhanced OMR option 1 Open the hinged cover to the right of the OMR display 2 Press the Ch...

Page 79: ...lack line is preferred but if the mark is printed using hyphens it must be at least two hyphens wide with no more than 0 8mm separation between the hyphens The marks should be black ink on a light background Scan Marks should NOT be positioned within 3mm of the left or right hand sides of the form No text should be positioned within 3mm of the left or right sides of the form Ensure that there is n...

Page 80: ...l OMR Set up Sheet 1 or 2 as selected 7 Press the Start key Display will show Load Blank Sheet START 8 For Sheet Feeder 1 place a BLANK sheet of paper under the set up sheet Manually advance the set up sheet until the Blank box is under the sensor 9 Press the Start key Display will show Load Marked Sheet START 10 The sensor light output will pulse slowly in Red Now manually advance the set up shee...

Page 81: ... The parameters menu allows the engineer to change the NVM settings that are set as defaults by the factory Note The settings are unique to every machine They are recorded on the inside of the Collation Top Cover This record should be updated when any setting s are changed 7 2 1 Final Assembly Number This is to set the machine s configuration F3E1 DI380 EAME 1 station F3E2 DI380 EAME 2 station F3E...

Page 82: ... 2 5 View Error codes This allows you to view the last 10 Error Codes E01 E126 7 2 6 Set DDD This sets the position of the reference point of the DDD Sheet feeders 1 and 2 Leading Edge Sample At Middle Trail edge Insert feeder Leading Edge 7 2 7 Set Service Counter This sets the software counter For EIU use only 7 2 8 Set Out of Material This setting allows the Out of Paper sensors to be switched ...

Page 83: ...ally set by the factory DI425 SI3500 15 DI380 SI3300 15 7 2 13 Set Serial Number This is to set the serial number of the machine EIU Use only 7 2 14 View Software Revision This displays the current level of software 7 2 15 Select OMR Basic Mode When code is entered the following functions will appear OMR Acc Mode is off OMR Acc Mode is on OMR Acc Mode is Acc only 7 2 16 Select OMR Enhanced Enter C...

Page 84: ...Standard setting for European envelopes is 122 7 2 20 T2 Envelope Hold Time Default setting is 0 This adjustment is basically the Envelope Hold time Set to a slightly higher figure if the glue needs longer to break down DI425 SI3500 0 Safe Seal Clutch 1 Without Safe Seal Clutch DI380 SI3300 0 Safe Seal Clutch 1 Without Safe Seal Clutch 7 2 21 T3 Table Offset Default setting is 0 Do not change this...

Page 85: ...chine so the Mailing Machine deck rollers and sensors stop being active before the Clear Deck function is carried out in the Inserting Machine The time is adjustable on the Inserting Machine through a new service parameter The perameter range is 0 to 101 seconds with a default value of 20 seconds The time is set on the Mailing Machine through the operations screen and timeouts menu It is advised t...

Page 86: ...Clear Envelope Clear Daily Mail Off On Insert Feeder Interlock Blocked Envelope Load Switch Off On DI425 SI3500 ONLY Test Paper Sensors Transport Plate Clear Envelope Feed Sensor Clear Envelope Lead Edge Sensor Clear Moistener Clear Exit Sensor Clear Test Home Positions Fold Plate 1 Clear Fold Plate 2 Clear Q Station Clear Inverter Clear Half Fold ON Blocked Clear Half Fold OFF Clear Blocked Envel...

Page 87: ... Start Motor Count Stop For this test enter the number of encoder counts and press START Note When testing lead screws be careful not to over drive the gear to the end as this may damage the assembly Sheet Feeder 1 Sheet Feeder 2 Collation Insert Pref Insert Drv Envelope Q Station Fold Plate 1 Fold Plate 2 Inverter Half Fold Env Platform DI425 SI3500 ONLY Reverse Motor Count Stop Q Station Fold Pl...

Page 88: ...ycle This will run the machine with all components being tested Note Make sure that there is no paper loaded To finish test press stop 7 3 7 Test Display All icons will be displayed 7 3 8 Test Clutch and A C Motor Press START to make the A C Motor run Toggle the START button to set the clutch on and off within this test 7 3 9 Test OMR Sensors Tray 1 OMR Sensor Clear Blocked Tray 2 OMR Sensor Block...

Page 89: ...at the materials being used are within specification The charts on the following pages are designed to help diagnose faults quickly and as accurately as possible If you are fault finding using a logic probe connect the red probe clips to P36 pin 3 5V and the black to pin 5 GND A low signal represents a blocked sensor which is the normal state A high signal represents an unblocked sensor If you are...

Page 90: ...er open the carriage complete assembly and check for any material Service Diagnostic Test end stops position Test fold plate sensor OP13 Test motor count and stop for fold plate 1 M6 Test end stops position Test fold plate sensor OP14 Test motor count and stop for fold plate 2 M7 Test end stops position Test sensor OP6 Test motor count and stop for M11 Test out of paper sensor OP9 Test out of pape...

Page 91: ...y dark areas on the document Check the paper is aerated Adjust the side guides Press the trial piece to re calibrate Check for any dark areas on the document Check orientation of the document Service Diagnostic Test envelope feed sensor S1 Visually check the separator pad and roller Visually check the separator pad and roller Visually check the separator pad roller and pre feed roller Visually che...

Page 92: ... feeder 2 and restart Aerate the material Check the side guide adjustment Open the top cover open jam access cover and check for any material Service Diagnostic Test exit sensor S4 Test moistener sensor S3 Test sensor OP5 Check for free movement of the transport pivot plate Test out of paper sensor OP9 Test Daily mail sensor OP3 Test Sheet feeder motor 1 Test Sheet feeder encoder Visually check th...

Page 93: ...still present call service Remove and refit the feeder 1 tray Remove and refit the feeder 2 tray Service Diagnostic Test out of paper sensor OP11 Test the insert feeder motor M3 Test encoder Test the collation motor M4 Test encoder Test lead edge sensor S2 Test envelope sensor S1 Check the main drive belts gear and pins Test fold plate sensors OP13 and OP14 Test collation motor M5 Test encoder Tes...

Page 94: ...servoir Switch the machine off on If the error is still there call service Service Diagnostic Test insert feeder sensor S12 Test envelope feeder interlock OP15 Test fold plate 1 interlock S6 Test fold plate 2 interlock S7 Test cover interlock S5 Test flapper interlock S8 Test inverter door interlock S10 Test moistener cover interlock S9 Test chain of interlocks S9 S10 S6 S5 S7 S11 S8 Test Q statio...

Page 95: ... Check that the material is not sticking together Aerate stack and reload Service Diagnostic Visually check that the daily mail lever is not broken or cracked Test manual feed OP3 Test out of paper sensor OP9 Check for binds on the flapper blade Check for damage or wear on flapper blade Check bearing position Check for bind on the lead screw Test half motor M8 Test encoder Test home position senso...

Page 96: ...ial piece to re calibrate the machine Service Diagnostic Check the condition of the separator roller and pad Test the condition of the Sheet feeder motor M2 Test Encoder Check the material is within spec Check the condition of the separator and pre feed rollers Test insert motor M3 Test Encoder Check the material is within spec Height of pad Check the condition of the separator and pre feed roller...

Page 97: ...move all material from the paper path Turn the machine off and on Is the machine turned on at the mains Check the fuse in the plug Service Diagnostic Check the material is within spec Check the condition of the separator pad and roller Check the material is within spec Check condition of the pre feed rollers Check separator rollers and stone Test all out of paper sensors Visually check closing of ...

Page 98: ...r machine on off Code type on paper does not match the setup Example setup has OMR Sequence but paper has OMR Select Feed Sequence A re timing scan mark is missing Check material Example mark 6 is missing from a 10 mark code The BOC mark position 4 was present when it was not expected First page of the set was expected The BOC mark position 4 was absent when it was expected Pages other than the fi...

Page 99: ... but the job setup does not include select feed The set contains too many sheets from the main feeder This indicates that the machine has stopped for End of Batch Allows the operator to manually sort the envelopes Check side guides separation from pre feed rollers Check RS232 cable is connected to the VPS and inserter Check power cord power off power on Remove mail from the stacker then press star...

Page 100: ...Power on Power off Reference to E120 If there are 4 mail pieces on the mailing deck refer to franking machine Is divert lever set to MMI position correct Move VPS to un docked position Remove any material from VPS entry area Press clear deck Re dock VPS Press start and see if this re installs the MMI Check RS232 cable Check DIN connector between inserter and mialing machine Power off Power on Pres...

Page 101: ... DI425 SI3300 SI3500 Service Manual 7 21 7 Service Menu Troubleshooting E126 Processor Reset Power off Power on Error Codes and fault Operator Check List Service Diagnostic Connector and Logic Test Replacement Parts ...

Page 102: ...7 22 SDT333A DI380 DI425 SI3300 SI3500 Service Manual 7 Service Menu Troubleshooting ...

Page 103: ...eck clean Separator Roller Check clean Carriage Rollers upper and lower Clean out of paper and carriage complete sensors Lightly lubricate shaft cam with grease 10 Fold Rollers Clean all Fold Rollers you must remove carriage complete assembly side brackets first for easy access Clean fold plate sensors 11 Sheet Feeders Check clean Separator Roller Check clean Separator Pad Check clean Lower Collat...

Page 104: ...th grease 10 Fold Rollers Clean all Fold Rollers you must remove carriage complete assembly side brackets first for easier access Clean fold plate sensors 11 Sheet Feeders Replace Separator Roller Replace Separator Pad Check clean Lower Collation Rollers Clean all out of paper and interlock sensors 12 Sealer Replace Sealer Felt Check clean Transport Rollers Check clean Sealer Brush 13 Inverter Exi...

Page 105: ...s Ensure the wedges are fitted to the correct trays 7 Fix Overlays and Badges supplied for machine 8 Fill the sealer Water Bottle 9 Connect the power lead and turn power ON 10 Check all functions of the machine 11 Make sure Envelope offset and Flapper Blade are set correctly Note Envelopes to feed through the machine centrally adjust if necessary Reference adjustment 5 15 in this manual 12 For OMR...

Page 106: ...ecking contents and using batch mode Explain operation of Start Stop Show how to load material while the machine is running 6 Finishing a job Show operator how to check all material has ejected out of machine 7 Material stoppage Explain stoppage location symbols and how to use the Clear Deck button and Manual Advance Knob Show removal of feeder and fold trays to gain access to jam areas 8 Operator...

Page 107: ... FOLD PLATE 2 INSERT FEEDER CARRIAGE ASSEMBLY Q STATION Flow Diagram DI380 SI3300 SHEET FEEDER 1 SHEET FEEDER 2 FOLD PLATE 1 FOLD PLATE 2 INSERT FEEDER CARRIAGE ASSEMBLY Q STATION SHEET FEEDER 1 SHEET FEEDER 2 FOLD PLATE 1 FOLD PLATE 2 INSERT FEEDER CARRIAGE ASSEMBLY Q STATION Flow Diagram DI425 SI3500 10 1 flow diagrams ...

Page 108: ...esent on system but included for backwards compatibility Not present on system but included for backwards compatibility DI380 SI3300 DI425 SI3500 10 2 cOMPONeNT LOcATIONs M7 M8 M9 M10 M11 M20 L1 L2 L3 L5 L4 M4 AC Motor M6 M2 M1 M5 M3 OP3 OP1 OP2 OP4 OP5 OP6 OP7 OP8 OP9 OP10 OP11 OP13 OP14 PS11 DD1 S5 S6 S7 S8 S9 S10 S11 S12 S13 IL13 IL14 IL16 DD2 DD3 S1 S2 S3 S4 Not present on system but included ...

Page 109: ...d Unblocked Sheet Feeder 1 Interlock OP1 P20 1 2 3 Wires still present but not in use Sheet Feeder 2 Interlock OP2 P19 4 5 6 Envelope Interlock OP15 P14 4 5 6 Manual Feed OP3 P23 1 2 3 Q Station Home OP4 P35 7 8 9 Yellow 5V high 5V high Pivot Transport Plate OP5 P14 1 2 3 White 0V low 5V high Inverter Home OP6 P36 3 4 5 Black 0V low 0V low Half Fold On OP7 P16 10 11 12 Half Fold Off OP8 P16 6 7 8 ...

Page 110: ...lue 0V low 24V high Shoe Horn L3 P34 1 2 White 24V high 24V high White 0V low 24V high Finger Solenoid L4 P33 1 2 Orange 24V high 24V high Grey 0V low 24V high Moistener L5 P32 1 2 Yellow 24V high 24V high Yellow 0V low 24V high Motors DC PCB Location PIN Location Wires ON OFF Sheet Feeder 1 M1 P21 1 2 Orange 24V high 24V high Sheet Feeder 2 M2 P18 1 2 Grey 10V low 24V high Insert Collation M4 P25...

Page 111: ...B Location PIN Location Wires Sealer clutch CL1 P39 1 2 Orange 24V Brown 0V Momentary Switch PCB Location PIN Location Wires Envelope Platform Up Down IL16 P40 7 9 Black 24V Black 0V Motor Stepper PCB Location PIN Location Envelope Platform M20 P41 1 2 3 4 Power Supply Unit PCB Location PIN Location 24 Volts P38 1 24 Volts 2 0 Volts GND 3 0 Volts GND 4 5 Volts Power Good Reset Signal 5 5 Volts Log...

Page 112: ... Volts TP2 Key PCB Location 5 Volts Indicator CR2 24 Volts Indicator CR3 3 3 Volts Indicator CR57 Micro Diagnostics Factory Use Only CR58 FPGA Indicator Flashes if OK CR61 Software U25 NVM U40 Control Panel P3 RS232 P5 Counter P28 OMR Sensors P4 Not Used Software Diagnostics P43 Not Used Software Diagnostics P42 ...

Page 113: ...3300 SI3500 Service Manual 10 7 10 Diagrams 10 4 PCB layout P18 P23 P22 P21 P20 P19 P33 P24 P32 P31 P30 P29 P28 P27 P25 P34 P15 P4 P16 P17 CR3 CR2 P41 P5 P42 P43 P40 P14 P3 CR61 CR58 CR57 P38 P39 P36 P35 P37 U25 U40 TP1 TP2 ...

Page 114: ...10 8 SDT333A DI380 DI425 SI3300 SI3500 Service Manual 10 Diagrams 10 5 drive belt routing Rear View Front View ...

Page 115: ... 1 3 1 2 3 4 P36C 4 2 1 3 4 3 2 1 P36B 2 1 2 1 P35 5 4 9 8 7 12 11 6 10 10 6 11 12 7 8 9 4 5 P14 2 1 3 2 1 3 P35C 2 1 3 3 1 2 P35B 2 1 3 2 1 3 P35D 2 1 1 2 P37A 2 1 2 1 2 1 P33 2 1 2 1 1 2 P31 2 1 1 2 2 1 P34 2 1 1 2 2 1 2 1 P30 P39 2 1 2 1 1 2 2 1 2 1 1 2 4 3 1 2 4 3 1 2 4 3 P37 1 2 1 2 P32 2 1 1 2 P35 3 2 2 3 P35 16 15 15 16 P35E 2 1 2 1 P35A 2 1 1 2 P36A 5 4 6 1 2 3 3 2 1 6 4 5 1 2 4 3 1 2 4 3 ...

Page 116: ... 1 3 P19B 2 1 3 3 1 2 P19 14 13 6 2 4 3 1 5 7 8 11 12 10 9 9 10 12 11 8 7 5 1 3 4 2 6 13 14 P19E 2 1 3 2 1 3 2 1 1 2 4 3 P20G 2 1 3 3 1 2 2 1 1 2 2 1 P20A 2 1 3 2 1 3 P20B 2 1 3 2 1 3 1 2 4 3 P22 2 1 1 2 1 2 4 3 P23A 2 1 3 2 1 3 P21 2 1 2 1 1 2 4 3 1 2 4 3 P20F 4 2 1 3 4 3 2 1 P20E 2 1 3 3 1 2 1 2 4 3 P20C 2 1 3 3 1 2 P20D 2 1 3 2 1 3 1 2 4 3 1 2 4 3 P23 2 1 3 3 1 2 P18 2 1 2 1 P20 7 21 12 11 19 2...

Page 117: ...12 8 7 6 13 13 6 7 8 10 11 12 P29 11 10 12 8 7 6 13 12 11 10 8 7 6 13 1 2 4 3 1 2 4 3 1 2 4 3 P29A 2 1 2 1 1 2 P29B 2 1 3 2 1 3 P17C 2 1 3 3 1 2 1 2 4 3 1 2 4 3 1 2 4 3 P29D 4 2 1 3 4 3 2 1 P29C 2 1 3 2 1 3 P17B 2 1 3 3 1 2 P17A 2 1 1 2 P16D 2 1 3 3 1 2 P16C 2 1 3 2 1 3 P16B 2 1 3 3 1 2 1 2 P16A 2 1 1 2 P16 6 2 4 3 1 5 7 8 10 11 12 6 2 4 3 1 5 7 8 10 11 12 1 2 4 3 P17 5 1 3 4 2 5 1 3 4 2 2 1 P29 5...

Page 118: ...ENV FEED SENSE S1 ENV TRAY EMPTY OP12 ENV FEEDER MOTOR M9 ENVELOPE FEEDER AC HAND CRANK I L S11 AC ENCODER AC HAND M 5 0 TO P14 24 5 0 22 21 19 7 10 9 6 5 12 11 13 15 14 24 4 16 18 20 8 23 26 25 22 21 19 7 10 9 6 5 12 11 13 15 14 24 4 16 18 20 8 23 26 25 P15 1 2 1 2 1 2 4 3 2 1 1 2 4 3 P14G 2 1 3 2 1 3 P14F 2 1 1 2 P14E 2 1 3 3 1 2 P14C 4 2 1 3 4 3 2 1 P15A 2 1 2 1 P14H 4 2 1 3 3 1 2 4 1 2 4 3 P14...

Page 119: ...olarising Key N C N C N C 1 2 3 1 2 3 Envelope Platform Down Sensor F382323 Envelope Sensor 200 7010 1 2 3 Envelope Platform Up Sensor F382323 Platform pushbutton 1 2 3 4 1 2 3 4 yellow orange red blue Platform Stepper Motor NX00418 M20 PB 261 2919 Molex 43020 0401 Qty 1 PB 085 1070 Molex 43031 0001 Qty 4 10 11 SCHEMATIC P41 ENVELOPE PLATFORM motor CONNECTOR DI425 SI3500 ...

Page 120: ...TRAY S12 I F TRAY EMPTY OP11 INSERT DRIVE ENC 5 0 5 0 CLEAR BLOCKED BLOCKED CLEAR 0 5 0 5 P23 8 4 5 6 8 4 5 6 P24 4 2 8 3 1 9 5 6 7 10 11 12 4 2 8 3 1 9 5 6 7 10 11 12 P27 1 2 2 1 2 1 2 1 1 2 P24B 2 1 3 3 1 2 P23B 2 1 3 2 1 3 P23C 2 1 1 2 1 2 4 3 1 2 4 3 1 2 4 3 P24A 12 11 10 9 8 7 5 1 3 4 2 6 13 13 6 2 4 3 1 5 7 8 9 10 11 12 P25 2 1 1 2 A C E K A C E K A C E K 10 12 schematic insert feeder ...

Page 121: ...4V 2 24V 3 0V GND 4 0V GND 5 5V PWRGOOD Reset Signal 7 5V Logic Pin No 8 24V 9 0V GND 10 0V GND 11 5V SSR1 Motor Start 12 5V SSR2 Motor Run 13 12 24V INTLK Relay 14 0 24V INTLK Relay CABLE P3 RIBBON 26 WAY START PSU RUN L N E N M L N E 8 8 8 8 8 1 2 P28 START CAP AC INLET 2 1 3 2 1 3 1 1 2 3 4 5 7 8 9 10 11 12 13 14 2 3 4 5 6 1 2 B A ...

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