DS-75_(075.1)_Service_Manual_r1.0

Service Manual 075.1

rev. 1.0 - 12/2009

Revision: rev. 1.0 - 12/2009

Date: December 2009

075.1

075.1 Service Manual

ii rev. 1.0 - 12/2009


iiirev. 1.0 - 12/2009

Table of Contents

1 This manual ................................................................................... 1-11.1 Abbreviations ..................................................................................... 1-11.2 Terminology ....................................................................................... 1-11.3 Typographical conventions ................................................................... 1-2

2 Health, safety and environment ..................................................... 2-12.1 Safety instructions .............................................................................. 2-1

2.1.1 General .................................................................................. 2-12.1.2 Electrical safety ....................................................................... 2-1

2.2 Symbols on the machine ...................................................................... 2-12.3 End of life .......................................................................................... 2-1

3 General description ........................................................................ 3-13.1 The system ........................................................................................ 3-13.2 Denominations ................................................................................... 3-13.3 Paper flow .......................................................................................... 3-23.4 Process description .............................................................................. 3-2

3.4.1 Document feeding ................................................................... 3-73.4.2 Document transport ................................................................. 3-83.4.3 Collating the document set ....................................................... 3-83.4.4 Document folding .................................................................. 3-113.4.5 Envelope feeding ................................................................... 3-123.4.7 Envelope exit process ............................................................ 3-14

3.5 Electronics ....................................................................................... 3-153.5.1 PCB functions ....................................................................... 3-153.5.2 Schematic overview ............................................................... 3-163.5.3 Connection with PC (Concorde application) ............................... 3-173.5.4 The ID-tag ........................................................................... 3-173.5.5 Software package compatibility check ...................................... 3-19

3.6 Optional features .............................................................................. 3-193.6.1 Reading ............................................................................... 3-193.6.2 Flex reading ......................................................................... 3-193.6.3 High capacity BRE maxiFeeder .............................................. 3-193.6.4 Insertn Frank .................................................................... 3-203.6.5 Online services ..................................................................... 3-203.6.6 High Capacity Vertical Stacker ................................................. 3-203.6.7 Side exit .............................................................................. 3-203.6.8 Mail Piece Production Control (MPPC) ....................................... 3-20


iv rev. 1.0 - 12/2009

4 User interface ................................................................................. 4-14.1 Operator menus ................................................................................. 4-14.2 Job and supervisor menus .................................................................... 4-14.3 Service menu ..................................................................................... 4-1

4.3.1 System settings ...................................................................... 4-24.3.2 Job settings ............................................................................ 4-34.3.3 Service tests .......................................................................... 4-44.3.4 Service counters ..................................................................... 4-74.3.5 Reading: OMR ........................................................................ 4-84.3.6 Reading: BCR ....................................................................... 4-114.3.7 Diagnostics .......................................................................... 4-144.3.8 Online service ....................................................................... 4-144.3.9 Remove blockage .................................................................. 4-154.3.10 Sealing on franking machine ................................................... 4-15

5 The 075.1 ........................................................................................ 5-15.1 Transport, storage and installation ........................................................ 5-1

5.1.1 Transport ............................................................................... 5-15.1.2 Unpacking, installation and storage ........................................... 5-1

5.2 Mechanical description ......................................................................... 5-65.2.1 General ................................................................................. 5-65.2.2 (Dis)assembly - Covers and plates ............................................ 5-75.2.3 (Dis)assembly - Electrical components ..................................... 5-115.2.4 (Dis)assembly - Feeder modules and vertical transport right-hand 5-145.2.5 (Dis)assembly - Feeders ........................................................ 5-195.2.6 (Dis)assembly - Vertical transport ........................................... 5-305.2.7 (Dis)assembly - Collating area ................................................ 5-315.2.8 (Dis)assembly - Folder ........................................................... 5-345.2.9 (Dis)assembly - Main drive mechanism inserter ......................... 5-475.2.10 (Dis)assembly - Envelope hopper ............................................ 5-555.2.11 (Dis)assembly - Upper unit ..................................................... 5-625.2.12 (Dis)assembly - Envelope transport ......................................... 5-695.2.13 (Dis)assembly - Envelope sealing and ejection .......................... 5-705.2.14 (Dis)assembly - Sensors ........................................................ 5-715.2.15 Adjustment .......................................................................... 5-88

5.3 Electrical description ......................................................................... 5-995.3.1 PCBs ................................................................................... 5-995.3.2 Display board ..................................................................... 5-1005.3.3 Keyboard ........................................................................... 5-1015.3.4 Motor relay board ................................................................ 5-1025.3.5 Connection board ................................................................ 5-1035.3.6 Communication board (optional) ........................................... 5-1055.3.7 Main board ......................................................................... 5-1095.3.8 ID-tag (2994504Z) .............................................................. 5-115

5.4 Maintenance .................................................................................. 5-1165.4.1 Preventive maintenance ....................................................... 5-1165.4.2 160k Service visit ................................................................ 5-1175.4.3 500k Service visit ................................................................ 5-118


vrev. 1.0 - 12/2009

6 Fault finding ................................................................................... 6-16.1 Resolve problems remotely .................................................................. 6-16.2 Troubleshooting Online Services ............................................................ 6-26.3 Error handling inserter ......................................................................... 6-2

6.3.1 Battery errors (BAT) ................................................................ 6-46.3.2 MPPC errors (CL) ..................................................................... 6-46.3.3 Closer errors (CLS) .................................................................. 6-46.3.4 Communication errors (COM) .................................................... 6-56.3.5 Collator errors (CT) ................................................................. 6-66.3.6 DFC errors (DC) ...................................................................... 6-66.3.7 Document feeder errors (DF) .................................................... 6-76.3.8 Dongle errors (DG) .................................................................. 6-76.3.9 Envelope hopper errors (EH) ..................................................... 6-86.3.10 Envelope open errors (EOP) ...................................................... 6-86.3.11 Folder errors (FOL) .................................................................. 6-96.3.12 Insert errors (INS) .................................................................. 6-96.3.13 Job errors (JOB) .................................................................... 6-106.3.14 Level detector errors (LD) ...................................................... 6-116.3.15 License errors (LIC) ............................................................... 6-116.3.16 Motor errors (M) ................................................................... 6-126.3.17 Modem errors (MOD) ............................................................. 6-126.3.18 Online service errors (OLS) ..................................................... 6-146.3.19 Reading head errors (OR) ....................................................... 6-156.3.20 Photocell errors (Pxx) ............................................................ 6-156.3.21 PCB errors (PBx) ................................................................... 6-186.3.22 Pulse disc errors (PD) ............................................................ 6-186.3.23 Production control errors (PRC) ............................................... 6-196.3.24 Reading errors (RE) ............................................................... 6-196.3.25 Machine state errors (SM) ...................................................... 6-226.3.26 Stacker errors (STK) .............................................................. 6-226.3.27 Switches errors (SW) ............................................................. 6-236.3.28 System errors (SYS) .............................................................. 6-236.3.29 Transport errors (TR) ............................................................. 6-24

6.4 Error handling franking machine ......................................................... 6-256.4.1 Communication errors (COM) .................................................. 6-266.4.2 External errors (EX) ............................................................... 6-266.4.3 Insertn Frank errors (INF) ................................................... 6-276.4.4 License errors (LIC) ............................................................... 6-346.4.5 Cover switch errors (SW) ....................................................... 6-34

7 Upgrading and installing accessories ............................................. 7-17.1 Reading (barcode en OMR) ................................................................... 7-17.2 MaxiFeeder ...................................................................................... 7-17.3 Insertn Frank .................................................................................. 7-17.4 Side exit ............................................................................................ 7-17.5 High Capacity Vertical Stacker .............................................................. 7-17.6 Mail Piece Production Control (MPPC) ..................................................... 7-17.7 Online services ................................................................................... 7-1

7.7.1 Preparations ........................................................................... 7-17.7.2 Connect the system ................................................................. 7-2


vi rev. 1.0 - 12/2009

8 Technical specifications .................................................................. 8-18.1 Machine specifications ......................................................................... 8-18.2 Documents ........................................................................................ 8-38.3 Envelopes .......................................................................................... 8-58.4 Capacity feeders and exit options .......................................................... 8-68.5 Fold types .......................................................................................... 8-78.6 Processing speed ................................................................................ 8-78.7 Configuration dimensions ..................................................................... 8-88.8 System operation control .................................................................... 8-88.9 Other general specifications ................................................................. 8-98.10 Quality .............................................................................................. 8-98.11 Reading (Optical Mark Recognition) ....................................................... 8-9

8.11.1 Concept ................................................................................. 8-98.11.2 Format of the marks ................................................................ 8-98.11.3 Reading head location .............................................................. 8-98.11.4 Options .................................................................................. 8-9

8.12 Reading (Barcode) .............................................................................. 8-98.12.1 Concept ................................................................................. 8-98.12.2 Format of the code .................................................................. 8-98.12.3 Reading head location .............................................................. 8-98.12.4 Options .................................................................................. 8-9

8.13 Product customization per country / organization .................................. 8-10


viirev. 1.0 - 12/2009

9 Illustrated parts list ....................................................................... 9-19.1 Covers, frames, and external parts 1/3 .................................................. 9-29.2 Covers, frames, and external parts 2/3 .................................................. 9-69.3 Covers, frames, and external parts 3/3 .................................................. 9-89.4 Envelope hopper 1/2 ......................................................................... 9-109.5 Envelope hopper 2/2 ......................................................................... 9-129.6 Envelope separation .......................................................................... 9-149.7 Lower envelope track 1/2 ................................................................... 9-169.8 Lower envelope track 2/2 ................................................................... 9-209.9 Insert table and upper envelope track .................................................. 9-229.10 Insert and eject mechanism ............................................................... 9-269.11 Moistening unit ................................................................................. 9-289.12 Envelope closing mechanism .............................................................. 9-309.13 Main drive mechanism ....................................................................... 9-329.14 Feeder/Folder driving mechanism ........................................................ 9-349.15 Envelope track driving mechanism 1/2 ................................................. 9-369.16 Envelope track driving mechanism 2/2 ................................................. 9-389.17 Document feeder unit (automatic) ....................................................... 9-409.18 Document feeder unit - special 1/2 ...................................................... 9-449.19 Document feeder unit - special 2/2 ...................................................... 9-469.20 Document feeder trays ...................................................................... 9-489.21 Vertical track (base) .......................................................................... 9-509.22 Vertical track (loc) ............................................................................ 9-529.23 Collating unit (upper) ........................................................................ 9-549.24 Collating unit (lower) and power supply ............................................... 9-589.25 Folder unit (base) ............................................................................. 9-629.26 Folder unit (loc) 1/4 .......................................................................... 9-649.27 Folder unit (loc) 2/4 .......................................................................... 9-669.28 Folder unit (loc) 3/4 .......................................................................... 9-689.29 Folder unit (loc) 4/4 .......................................................................... 9-709.30 Electrical components ........................................................................ 9-729.31 High capacity feeder 1/4 .................................................................... 9-749.32 High capacity feeder 2/4 .................................................................... 9-769.33 High capacity feeder 3/4 .................................................................... 9-789.34 High capacity feeder 4/4 .................................................................... 9-809.35 High capacity feeder tray ................................................................... 9-829.36 Side exit 1/3 .................................................................................... 9-849.37 Side exit 2/3 .................................................................................... 9-869.38 Side exit 3/3 .................................................................................... 9-88


viii rev. 1.0 - 12/2009

10 Appendix ....................................................................................... 10-110.1 Recommended spare parts ................................................................. 10-110.2 Electrical diagrams ............................................................................ 10-610.3 Product coding for CRM ................................................................... 10-32

10.3.1 Failure symptoms ................................................................ 10-3210.3.2 Module .............................................................................. 10-3210.3.3 Failure origins ..................................................................... 10-33

10.4 Checklist training operator ............................................................... 10-3910.5 High Capacity Vertical Stacker .......................................................... 10-43

10.5.1 Process description .............................................................. 10-4310.5.2 (Dis)assembly - High Capacity Vertical Stacker ....................... 10-4410.5.3 Preventive maintenance ....................................................... 10-5410.5.4 Troubleshooting .................................................................. 10-5410.5.5 Electrical diagram HCVS-1 (2825913J) ................................... 10-5510.5.6 Parts list ............................................................................ 10-5610.5.7 Recommended spare parts HCVS-1 ....................................... 10-6510.5.8 Specifications High Capacity Vertical Stacker .......................... 10-66

10.6 Total view electronics sheet 1/3 ........................................................ 10-6710.7 Total view electronics sheet 2/3 ........................................................ 10-6810.8 Total view electronics sheet 3/3 ........................................................ 10-69


1-1rev. 1.0 - 12/2009

1 This manual

1.1 Abbreviations

1.2 Terminology

Abbrev. Explanation Abbrev. Explanation

BRE Business Reply Envelope ISIS Interface Standard Inserting Systems

CCW Counter Clockwise LH Left Hand

CW Clockwise MPPC Mail Piece Production Control

DFC Double Feed Control MS Mailing System

DS Document System OLS OnLine Services

FM Franking Machine OMR Optical Mark Recognition

GUI Graphical User Interface PCB Printed Circuit Board

HMI Human Machine Interface RH Right hand

I2C Inter-Integrated Circuit SCS Serial Communication System

INF insertn Frank UI User Interface

Term Description

Double Feed Control (DFC)

Double Feed Control measures the thickness of a sheet to check if the inserting system does not accidentally take more sheets than intended. DFC sensors exist on feeders (double sheet detection). DFCs on the inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet.

Also the length of the document is measured so partly overlapping sheets will be detected.

Leading Situation in which the top of the sheet is closest to the separation unit in a document feeder.

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.

Sequential Cycle Documents are transported along the vertical track without touching each other. Only after joining the set in the making they do touch each other.

Shunting The partially completed set in the collator is moved from the collator area in the direction of the fold unit (short shunt) or into the fold unit (long shunt). See 3.4.3 Collating the document set on page 3-8.

Trailing Situation in which the bottom of the sheet is closest to the separation unit in a document feeder.


1-2 rev. 1.0 - 12/2009

1.3 Typographical conventions

NoteA note gives additional relevant information.

Warning

This symbol identifies situations where improper use of the machine can result in personal injury or permanent/catastrophic damage to the machine.

Warning

This symbol identifies situations in which electrical hazard exists.


2-1rev. 1.0 - 12/2009

2 Health, safety and environment

2.1 Safety instructions

2.1.1 General

This machine must be operated by competent personnel. The manufacturer accepts no responsibility for accidents or injuries caused by operation by incompetent personnel.

Covers may only be opened by skilled persons, who know the risks involved.For safety reasons, the machine will not function with opened covers.

Keep away long hair, fingers, jewelry, etc. from rotating and moving objects of the system. Switch off the system at the end of the day.

2.1.2 Electrical safety

The power connection must be easily accessible, preferably close to the machine. For safety reasons it is essential that the machine is connected to a socket outlet with

protective earth connection. Over-current protection in the equipment also relies on the branch circuit protection (max.

20 A). Disconnect the machine from the power supply when it is not in use for a longer time. 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.

2.2 Symbols on the machine

2.3 End of life

The objectives of the European Community's environment policy are, in particular, to preserve, protect and improve the quality of the environment, protect human health and utilise natural resources prudently and rationally. That policy is based on the precautionary principle and principles that preventive action should be taken, that environmental damage should as a priority be rectified at source.

Separate collection of waste is the precondition to ensure reuse and recycling of waste that is generated at the disposal of electrical or electronical equipment and is necessary to achieve the chosen level of protection of human health and the environment in the European Community.

More particularly, certain materials and components of waste electrical and electronical equipment needs selective treatment as their injudicious handling or disposing of on or into land, water or air would represent a major threat to the environment and human health.

Warning

This symbol identifies situations where improper use of the machine can result in personal injury or permanent/catastrophic damage to the machine.


2-2 rev. 1.0 - 12/2009

In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronical equipment is marked with the following logo:

Not only are you by law not allowed to dispose of the waste equipment via other waste-streams, but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations.

For more information on the correct disposal of this product please contact your local dealer.

Do not mix with normal domestic waste

collection system dedicated to electrical and electronical waste.

Please use the subjoined return or

Equipment produced after August 13, 2005.


3-1rev. 1.0 - 12/2009

3 General description

3.1 The system

The 075.1 feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes.

The system is equipped with a variety of special features as programmable jobs, loadn Go, flexFeed, double feed control, hopper swap, multifeed, daily mail, powerFold, and automatic collator stop positions.

3.2 Denominations

A catch tray K sensorsB envelope slide L bellowsC display with operating buttons M unlocking handle for rollers envelope trackD upper unit N water reservoirE locking hand grip upper unit O side cover (opened)F document feeder tray P rulerG collator arm Q thumb wheel for side guide adjustmentH collating area R side guides envelope hopperI power inlet, power switch,

RS232 connector / USB / modemS handle for separation adjustment

J handles for clearing stoppages T Envelope support bracket

Q OPRST JKL

N

JM

A B C

F

G

H

I

D

E


3-2 rev. 1.0 - 12/2009

3.3 Paper flow

The documents are vertically transported from the document feeder(s) (1) to the collator (2). When the required documents are collected, the document pile is transported horizontally to the document folder (3). After folding, the documents are inserted into an envelope by the inserter (5). Finally, the envelope is sealed and transported to the envelope receiving tray.

3.4 Process description

The processing of documents by the system can be divided into a number of distinct sequential partial processes. These processes will be discussed in some more detail: Document feeding Document transport Collating the document set Document folding Envelope feeding Inserting process Envelope exit process

The figure on the next page shows a schematic overview of the process. All mechanical items that are strictly necessary to explain the process are projected on the left-hand side of the machine. This implies that not all auxiliary mechanical items (such as gears and belts) are shown.

See Section 5.2 Mechanical description and Section 9 Illustrated parts list for more details on the mechanics.

1

2

3

4

6

5


3-3rev. 1.0 - 12/2009

1

2

34

56

7

8

9

10

9a

11

1213

14

1516

1718

19

20

21

2223

2425

26

272829

30

31

32

33 34353637

38

39

40

414243

4445

46

47

484950

51

52

53

54555

657

58

5960

6162

6364

656667

6869

7071

727374

7576

7778

798081

M2

M1

MS

3

MS

2

MS

1

PH

4

PH

1

PH

2

PH

5

PH

3

PH

6

PH

8

PH

7

PH

9

PH

10

PH

11

TX

TX

RX

RX

RX

TX

TX

RX

TX

RX

TXRX

TX

TX

RX

TX

RX

RX

TXRX T

XDFC

3

DFC

2

DFC

1

CL8

CL6

/7

CL5

CL1

CL2CL3

So3

So2

So4

So1

PD

1

PD

4

PD

3

PD

2

CL4

FE3

FE2

FE1


3-4 rev. 1.0 - 12/2009

Rollers

No. Description

1 Feed roller. Activated by the envelope track clutch CL8.

2 Separation roller.

3, 5, 7 Counter rollers for 4, 6 and 8. These rollers can be moved by the release handle in case of a paper jam in the envelope track.

4, 6, 8 Driven envelope transport rollers. Activated by the envelope track clutch CL8.

9, 12 Counter rollers for 10, 11. These rollers can be moved by the release handle in case of a paper jam in the envelope track.

9a Friction brake.

10 Driven envelope transport roller (flap opening stage). Activated by the envelope track clutch CL8.

11 Driven envelope transport roller (flap opening stage). Activated by the envelope track clutch CL8.

13 Lower insert roller.

14 Upper insert roller (in the upper unit).

15 Lower first ejection roller. On the axle at the LH side of the machine the LH hand knob is mounted. On this axle at the RH side of the machine the main pulley is mounted.

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

17 Lower second ejection roller. In this area the moistening brushes are located.

18 Upper second ejection roller (in the upper unit).

19 Driven sealing track roller. On the axle at the RH side of the machine the pulse disc PD1 (monitored by slotted photocell SPH1) is mounted.

20 Driven sealing track roller.

21 Counter roller for 22 (in the upper unit).

22 Lower sealing roller. A gear on the axle (on the RH side of the machine) provides via an intermediate gear the mechanical interface to all the driven parts in the upper unit (14, 16, 24, 26). Directly driven by M2.

23 Upper sealing roller.

24 Lower reverse roller (in the upper unit).

25 Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid So3.

26 Drive rollers for future use.

27 Lower fold roller for second fold table.

28 Upper fold roller for second fold table. In upper unit.

35 Lower fold roller for first fold table.

36 Upper fold roller for first fold table. In upper unit.


3-5rev. 1.0 - 12/2009

42 Lower fold input roller. On this axle on the RH side the folding forward clutch CL4 is mounted. This clutch drives 42, 43, 35, 36, 27 and 28. Operational during the fold process and during the first stage of a long shunt.

43 Upper fold input roller.

44 Counter roller of 45 (in the upper unit).

45 Driven vertical transport axle. On this axle the folding reverse clutch CL5 is mounted (at the RH side of the machine). This clutch drives 42, 43, 35, 36, 27 and 28 in the reverse direction during the second stage of a long shunt.

46, 50, 53, 56, 60

Collator rollers driven (either forward or reverse) by the collator motor M1. In collator arm.

47, 48, 49, 52, 54, 55, 58

Free running collator rollers.

61 Driven vertical transport axle. On this axle feeder 1 (lower) clutch CL1 is mounted (at the LH side of the machine). This clutch drives 63, 65 (only in feeder with manual separation), 66 and 67.

62 Counter rollers for 61 (in upper unit).

63 Driven output rollers.

64 Counter rollers for 63.

65 Lower separation roller. Turns CW in feeder with manual separation.

66 Feed axle with upper separation roller.

67 Paper puller axle with two rubber rollers.

68 Driven vertical transport axle. On this axle feeder 2 (middle) clutch CL2 is mounted (at the LH side of the machine). This clutch drives 70, 72 (only in feeder with manual separation), 73 and 74.







75 Driven vertical transport axle. On this axle feeder 3 (upper) clutch CL3 is mounted (at the LH side of the machine). This clutch drives 77, 79 (only in feeder with manual separation), 80 and 81.



No. Description


3-6 rev. 1.0 - 12/2009

Photocells

Clutches





No. Description

PH1 Envelope track cell

PH2 Flap cell

PH3 Insert table cell

PH4 Exit cell

PH5 Closer cell

PH6 Folder entry cell

PH7 Vertical track cell

PH8 Collating area cell

PH9 Feeder cell

PH10 Feeder cell

PH11 Feeder cell

No. Description

CL1 Feeder clutch. Drives 61, 63, 65 (only in feeder with manual separation), 66 and 67.



CL4 Fold forward clutch. Used during a fold cycle and in the first stage of a long shunt.

CL5 Fold reverse clutch. Used in the second stage of a long shunt.

CL6 First fold table clutch. Drives 37.

CL7 Second fold table clutch. Drives 29.

CL8 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 M2 driven subsystem and the envelope track subsystem. CL8 drives 1, 4, 6, 8, 10 and 11.

No. Description


3-7rev. 1.0 - 12/2009

Solenoids

3.4.1 Document feeding

Rollers 79 - 81 separate the document for feeder 3. Rollers 77 and 78 exit this document to the vertical track. DFC unit 3 measures the

thickness. Photocell PH11 monitors the document.

Clutch CL3, driven by main motor M2, drives feeder 3.

No. Description

So1 Finger solenoid. Moves the fingers into the envelope when the envelope is on the insert table.

So2 Insert table solenoid. Moves the ejection roller 16.

So3 Sealing solenoid. Moves roller 25 to transport the envelop to the sealing rollers.

So4 Brush solenoid. Lowers the brush to moisten the envelope flap.

77

78

79

80 81

PH11

TX

RX

TX

RX

RX

TX

RX

TX

DFC3

CL3

FE3

FE2

FE1


3-8 rev. 1.0 - 12/2009

3.4.2 Document transport

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: pane cycle and sequential cycle.

When reading is on the sequential cycle is used. The vertical track consists of one driven roller per feeder (75, 68, 61), plus one driven roller

in the lower vertical track (45). The driven rollers have their counterparts in rollers 76, 69, 62 and 44. If the OMR option is installed, the document transport is monitored by the reading head

photocell (PH7). This monitoring is necessary to establish the reading window.

3.4.3 Collating the document set

The following rules apply to the way in which a set is composed (collated): The highest active feeder is processed first, the lowest active feeder last. This is

independent of the fold type.

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.

Sequential Cycle: Documents are transported along the vertical track without touching each other.

1227

34 35

4445

6162

6869

7576

M1

PH7

PH9

TX

RXTX

TX

RX

TX

RX

RX

TX

RX

TX

CL5

CL1

CL2

CL3

FE3

FE2

FE1


3-9rev. 1.0 - 12/2009

If a feeder adds two or more documents to a set (multi-feeding), these documents are first processed.

The collating area consists of a set of rollers (46, 50, 53, 56 and 60) that can be driven in both directions by the collator motor (M1).

In the reverse direction of the collator motor documents are fed into the collator area. In the forward direction they are moved out.

Collating area photocell (PH8) monitors the entry of the paper into the collator area (not the leaving of paper!).

The documents are aligned against the relevant automatic document stoppers (51, 57 or 59).

Before a sheet is added to the set, the set moves out of the collator to prevent collision of the document against the set. When the document is added to the set the set moves back into the collator. The moving into and out of the collator is called shunting. The system can perform a long shunt or a short shunt. This depends on the mode selection (see System output on page 4-3).

42

43

4445

46

47

48 49

5051

52

53

54 55

56 57

58

59 60

70 72

M1

PH6

PH8

PH10

TX

RXTX

TX

RX

TXRXTX

CL5PD4

CL4

FE1


3-10 rev. 1.0 - 12/2009

Short shunt (mode 2)

1 PH8 detects a document in the document transport. The transport stops.2 M1 runs in the forward direction: the partially completed set is moved over a short distance

to the fold table.3 The document transport starts again and moves the document into the collator. M1 runs in

reverse direction and moves the set back into the collator. 4 The document moves over the set until it is aligned with the set against the paper stop.

Mode 2 focuses on minimal necessary paper displacement. This implies a higher processing speed. However there is longer paper contact between the new entering document and the partially completed set.

Long shunt (mode 1)

1 PH8 detects a document in the document transport. The transport stops.2 M1 runs in the forward direction and CL4 is activated: the partially completed set is moved

into the fold table.3 The document transport starts again. M1 runs in reverse direction and CL5 is activated.


3-11rev. 1.0 - 12/2009

4 The document and the set move together into the collator until they are aligned against the paper stop.

Mode 1 takes more time, but the paper-to-paper contact occurs over shorter distances.

When the set is complete M1 (forward direction) and CL4 are activated and the set is moved into the fold unit.

3.4.4 Document folding

The paper of a completed set leaves the collator area. This is detected by the folder entry photocell (PH6).

3.4.4.1 First fold The fold input rollers (42 and 43) transport the paper to the first fold table. The flap (41)

moves up. Paper that enters the first fold table will be directed in upward direction. At the appropriate time, the flap (41) moves back and the fold plate (40) moves forward.

This is the first fold. Directly after the fold has been made, the fold plate (40) returns to its rest position. The

movement of the fold plate (40) and the flap (41) is controlled by the first fold table clutch (CL6). The clutch drives the curve gear (37). The axle for the curve gear also carries the brake disc (38). Slotted photocell (SPH3) monitors the status of the curve gear.

The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap upwards) and a 240 degrees path (flap downwards plus karate action of 40). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle (39) also carries the lever for the actuator of flap 41. In this way all movements related to the first fold table are synchronized.

3.4.4.2 Second fold After leaving the fold rollers (35 and 36), the paper enters the second fold table. The flap

(34) moves up. Paper that enters the second fold table will be directed in upward direction. The paper guide (33) also moves up. This guide is necessary in the second fold table to

retain the fold that has been made in the first fold table. The paper is limited to a small area between the paper guide (33) and a fixed vertical guide

plate (not shown in the figure, but to the left of 33). At the appropriate time the flap (34) moves back and both the fold plate (32) and the guide

plate (33) move forward. This is the second fold.

13

14

27

28

29

30

31

32

33

34 35

36

37

38

39

40

41 42

43

M2

PH6

RX

TX

TX

RX

TX

RX

TX

TX

CL6/7

PD3

PD2

CL4


3-12 rev. 1.0 - 12/2009

Directly after the fold has been made, the fold plate (32) returns to its rest position. The movement of the fold plate (32), the paper guide (33) and the flap (34) is controlled by the second fold table clutch (CL7). The clutch drives the curve gear (29). The axle for the curve gear also carries the brake disc (30). The slotted photocell (SPH4) monitors the status of the curve gear.

The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap and paper guide upwards) and a 240 degrees path (flap and paper guide downwards plus karate action of 32). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle (31) also carries the lever for the actuator of flap 34. In this way all movements related to the second fold table are synchronized.

Finally the paper leaves the fold unit on its way (transported by 27 plus 28 and 13 plus 14) to the insert table.

The timing of the fold plate movement is based on the detection of the paper by the folder entry photocell PH6, on machine parameters and on operational fold parameters.

3.4.5 Envelope feeding

All the rollers for this process stage (1, 4, 6, 8, 10 and 11) are engaged to the main drive by the envelope track clutch (CL8). During the document and insert stage these rollers are disengaged.

The feed and separation rollers (1 and 2) separate an envelope from the stack in the hopper. The envelope is transported via three pairs of transport rollers (3 - 8). The envelope track photocell (PH1) detects the leading and trailing edge of the envelope.

The envelope then passes the flap rollers (9 and 10). The combined action of the flap scraper and the lower linear speed of the flap rollers (9 to

12) compared with the speed of rollers 3 to 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 flap photocell (PH2).

Pulse measurements (measured via slotted photocell SPH1) during the presence of the envelope under the photocells (PH1 and PH2) provide information on:- The length of the not yet opened envelope- The length of the opened envelope

1

2

3

4

5

6

7

8

9

10

9a

11

12

PH1

PH2

TX

TX

RX

RX

RX

TX

TX

RX

TX

RX

CL8


3-13rev. 1.0 - 12/2009

- 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 (CL8) and the friction brake (9a). The envelope flap now is fixed between two rollers (11 and 12).

In the final ejecting, sealing and exiting stage the driven rollers are engaged once again to release the envelope (held between 11 and 12) and to feed a new envelope to the insert table.

3.4.6 Inserting process

Once the envelope is on the insert table, the fingers solenoid (So1) is activated. The fingers are moved forward into the envelope. The envelope stays in place, it is fixed between the two rollers (11 and 12).

Now the document set is inserted. The set leaves the fold unit (transported by rollers 27 plus 28 and by 13 plus 14), is detected by the insert table photocell (PH3) and passes below the fingers before it enters the envelope.

When the insert table photocell (PH3) detects the trailing edge of the set, the set is inserted.

9a

11

1213

14

PH3

RX

TX

TX

RX

TX

RX

So1


3-14 rev. 1.0 - 12/2009

3.4.7 Envelope exit process

The clutch (CL8) is activated to release the flap (roller 11 and 12) and to feed a new envelope to the insert table. The insert table solenoid (So2) moves the ejection roller (16). Now the envelope is ejected from the insert table. So2 is deactivated after the complete passage of the filled envelope.

The filled envelope passes rollers 17 and 18. If sealing is on, So4 is activated and lowers the moistening brushes. The envelope passes the sealing track rollers (19 and 20) and the lower sealing roller (22) plus its counter roller (21).

Now the photocell (PH5) is triggered. The upper reverse roller (25) is held up by a spring. A certain time after triggering PH5 the sealing solenoid (So3) is activated. The envelope is

between the upper and lower reverse rollers. So3 lowers reverse roller 25. Given the turning direction of the lower reverse roller (24), the transport direction of the envelope is abruptly changed.

The envelope is transported through the sealing rollers 22 and 23. After passing the sealing rollers the envelope exits the system.

The exit photocell (PH4) monitors the passing envelope.

11

1213

14

15

16

17

1819

20

21

22

23

24

25

26MS2

PH4

PH5

PH3

TX

TX

RX

RX

RX

TX

TX

RX

TX

RX

CL8

So3

So2So4PD1


3-15rev. 1.0 - 12/2009

3.5 Electronics

3.5.1 PCB functions

The functions of the PCBs from the schematic overviews can be described as follows:

NoteThe regular connection board only provides connection to USB. The expanded connection board also provides connection to RS232 and the phone line.

See Section 5.3 Electrical description for the location of the PCBs in the system.

Board name Function

1 Display board Converts received data into understandable data for the display

2 Key board Contains the start and stop buttons

3 Motor relay board Turns the motor on and off

4a Connection board Provides connection to USB, RS232 and the phone line (see note)

4b Modem board(optional)

Converts digital data (from the processor) into analogue data (for external communication) and the other way around

5 Communication board(optional)

Controls the franking interface and external communication

6 Main PCB Operates the device and controls the user interface

7 ID-tag Contains information (serial number, encrypted machine options, encrypted total counter)


3-16 rev. 1.0 - 12/2009

3.5.2 Schematic overview

The electronics and the wiring between the boards in the 075.1 can be summarized in a schematic overview.

For a device without communication board:

For a device with communication board:

Display board

075.1

Motor relayboard

100/115,230V ac

24Vdc

Switch modePower supply

ID Tag

Connection boardregular

Host

Main PCB

Keyboard

USB device

USB cable

Display board

Connection boardExpanded

Communicationboard

USBcable

serial

RS232(INF)

Phone

Modemboard

Host

Host

Main PCB

Keyboard

ID Tag

USBdevice

Motor relayboard

Switch modePower supply

075.1

100/115,230V ac

24Vdc


3-17rev. 1.0 - 12/2009

3.5.3 Connection with PC (Concorde application)

If you want to upgrade the inserter software or backup information from the inserter, the inserter can be connected to a PC. Special software has to be installed on the PC to enable communication between the USB port of the PC and the machine. This application is called Concorde.

The primary functions of Concorde are: To flash software packages in a complete system (with multiple boards) To flash new software directly on a board (factory flash) To backup inserter information and export it to XML format To restore information into the inserter from a previous backup

The Concorde application has been developed in such a way so that it requires minimal upgrades in the future. For more information, please see the online help contained in the Concorde application.

3.5.4 The ID-tag

Each time the 075.1 is started, the presence of the ID-tag is checked. If the ID-tag is not present, all software controlled options are switched off.


3-18 rev. 1.0 - 12/2009

If the ID-tag is present, its serial number is compared to the serial number in the FRAM (refer to the following schedule) and the options are read out.

In this schedule, number 1 to 5 can be described by:

1 Normal situation

2 If either FRAM or TAG has been disconnected, the latest counter can be used.

3 Replacement of PCB or replacement of both the ID-Tag and PCB.

4 PCB replacement (Tag OK).

5 PCB and ID-Tag replacement (new ID-Tag)

Note: if incorrect Tag is installed, software controlled options and connectivity will not function correctly.

System deblockage inservice menu

END

System blockage errorCall Service

CopyFRAM Counter to

ID-TAG

Start up: Read ID-TAG and FRAM

OK

OK

No3

No2

Yes1Yes

FRAM correct

TAGcorrect

Yes4

No

Has the main board beenreplaced only?

Have the ID-TAG

and the main board been replaced?

CopySerial number

ID-TAG to FRAM

SynchronizeID-TAG

Counter to FRAM

CopyID-TAG Counter to

FRAM

Serial number ID-TAG= Serial number

FRAM

Definelatest

counter

Set Counter manually (ID-TAG

and FRAM)

Yes5 CopySerial number

ID-TAG to FRAM

ID-TAGcount=FRAM

count


3-19rev. 1.0 - 12/2009

The following information is stored on the ID-tag: Serial number of the machine. Encrypted machine options. Total insert counter (kept up to date when the 075.1 is running).

3.5.5 Software package compatibility check

For all systems with (optionally) multiple boards and software versions, NTBV will release packages that contain the supported software versions of each board. The following matrix may be applicable (EXAMPLE!):

Each software file contains all compatible software versions of the partner boards. The system will compare all available software files to know what the highest supported software package is. It is then decided whether the selected software versions are a valid combination or not.

3.6 Optional features

3.6.1 Reading

With this option, computer printed documents can be handled fully automatically. Optical Mark Recognition (OMR) and Barcode Reading (BCR) codes are possible. A code is printed on each document, that contains information about the processing of the

sheets. The code on the last sheet of the set always contains the insert instructions. The other sheets carry the accumulate instruction. If a parity check is used, this is checked on each sheet (only OMR). The code must appear in the same location on every page regardless of the actual code

length.

Reading can be activated by a system specific license code. You can find further information on reading in 4.3.5 Reading: OMR on page 4-8 and 4.3.6 Reading: BCR on page 4-11.

3.6.2 Flex reading

With this option, also non-Neopost (customer specific) codes and alternative document handling algorithms can be recognised. Flex reading can be activated by a system specific license code and by a customer specific setting that is saved in a physical dongle.

3.6.3 High capacity BRE maxiFeeder

The maxiFeederTM is a feeder that can be loaded with a high number of documents. This feeder is intended to be used for Business Reply Envelopes (BRE), but also standard documents up to 156 mm length can be processed with it. The maxiFeederTM is auto-detected by the system when it is switched ON. This makes it easy to switch over from the standard document feeder to the maxiFeederTM and vice versa.

To make use of a maxiFeederTM it is not necessary to (re-)program the jobs.

Examples Main PCB Communication board

Package 1 version A version A

Package 2 version A version B

Package 3 version B version B


3-20 rev. 1.0 - 12/2009

3.6.4 Insertn Frank

With this option, in line franking by a connected franking machine can be realised. When a functioning communication line with the franking machine is present, it is also possible to set the franking machine and to select a franking job.

Insertn Frank can be activated by a system specific license code. In order to do this, the communication board and the modem board need to be installed.

3.6.5 Online services

Online services enable the Sales Organisation to remotely manage and maintain a system that is installed at the customer.

This option needs to be activated per system by the sales organisation. In order to do this, the communication board and the modem board need to be installed.

3.6.6 High Capacity Vertical Stacker

The High Capacity Vertical Stacker is used to stack filled envelopes. The High Capacity Vertical Stacker can store up to 325 filled envelopes. The High Capacity Vertical Stacker can be equipped with Mail Piece Production Control (MPPC).

3.6.7 Side exit

The system can be equipped with a side exit and catch tray. The side exit can be fitted instead of the standard envelope receiving tray. The side exit allows a conveyor or a franking system to be fitted in line with the system.

The side exit can also be used with a receiving tray which is delivered with the side exit. The receiving tray can be fitted to the left or to the right of the side exit to achieve vertical stacking.

3.6.8 Mail Piece Production Control (MPPC)

The folding and inserting system can be equipped with Mail Piece Production Control. This option enables the system to verify the inserted documents or sets of documents with a database, which is generated when you print the documents. The system gives a warning when a mail piece is missing at the exit of the inserter.


4-1rev. 1.0 - 12/2009

4 User interface

4.1 Operator menus

For an explanation of the Operator menus, see the Operator Manual.

4.2 Job and supervisor menus

For an explanation of the Job menu and Supervisor menu, see the Operator Manual.

4.3 Service menu

See the following flowchart for an overview of the various menus:

2546

Menu

4351

Service Menu

Supervisor Menu

Supervisor menu

(See operator manual)

Job settingsSystem

settings

Service

tests

Service

countersReading Diagnostics

Online

services

Remove

blockage

Configuration

Start test

Error

counter

Last

error list

Server

settings

Reset CB

data

Test CB

OMR

BCR

Photocells

Digital

inputs

Actuator

tests

Run in

DFC test

Touch

screen

Envelope

only mode

Stop key

System

output

Document

offset

BRE offset

Secure jobs

Flap closerLocalisation

Software

versions

Reset data

Folder

ratio

Power up

Folder

offset

Flap closer

offset

Sealing on

franking

machine


4-2 rev. 1.0 - 12/2009

4.3.1 System settings

Power up

In this menu you select if you want to display the language menu after you switch on the system.

Folder offset

Two timed cams discs are used for the folding process. There is one cam disc for each folding table. The timing is determined by the 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 to compensate a clutch activation time that deviates from the average value.

In the folder offset menu:1 Select the folder. 2 Set the offset in the folding position between -20 mm and +20 mm. 3 Process test material to see if corrections in these settings are required.

Flap closer offset

Use this menu to adjust the timing of the activation of the sealing solenoid (So3). You can use this function to improve the sealing process. The timing has influence on the position of the filled envelope with its flap fixed between rollers 21 and 22 prior, before it is transported between the sealing rollers. This position can be adjusted between -10 and + 10 pulses (with respect to the default envelope position). You can also adjust the flap closer offset per job (Service menu, Job settings, flap closer). That setting overrules this system setting.

Configuration

Use this menu to view the configuration.

In this menu you can set the gap separation. In case the lowest feeder is not an automatic feeder but a special feeder, change the gap separation on feeder 1 to Yes.

Localisation

Use this menu to set: the language of the operational user interface

Currently the options are: English USA, English UK, Dutch, French, German, Spanish, Ital-ian, Katakana, Swedish, Norwegian, Danish, Portuguese, Russian, Hungarian and Czech.

the service telephone number the document standard size machine type date format

Software versions

The software version screen shows the software versions that are present in the total system.

Reset data

There may be situations in which it is necessary to restore the system settings to their states at the beginning of the systems operational life. To this purpose the menu item Reset Data is present.

Make sure all paper is removed from the machine, before you start Reset data. This is necessary because the data resetting includes readjusting of the photocells. Press Reset counters to reset all counters (daily counter, counter since last service visit and

counters for the envelope hopper and feeders).


4-3rev. 1.0 - 12/2009

Press Reset data to start the reset process. This results in clearing all the data in the FRAM memory of the system.

If you want to restore the default data in mm and ISO values, press Load defaults mm. If you want to restore the default data in inches, press Load defaults inch.

Note 1: The changes made by this reset data operation are irreversible! All changes made on the previous factory settings will be lost.

Note 2: The value of the counter Since installation, the Last error list and the Error counter are not deleted when you restore the system.

Folder ratio

The folder ration determines the speed at which the document set enters the folding table. The folder ratio is the ratio between pulses and mm. The ratio can be adjusted between 0.940 and 0.950. The optimum value is 0.945.

4.3.2 Job settings

System output

Use this menu to select operating mode Mode 1 or operating mode Mode 2, for each of the jobs and loadn Go. Mode 2 is the default setting. Mode 1 focuses on the versatility of paper parameters (paper thickness; document length),

i.e.: ensures for correct operation even under the most extreme paper conditions. Mode 1 should be used for a paper thickness of 65 g/m or less or a document length of 12 inch or higher.

Mode 2 focuses on high speed. Mode 2 should be used for all other jobs.

See 3.4.3 Collating the document set on page 3-8 for an explanation of Mode 1 and Mode 2.

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 you can set the extend to which the documents are not overlapping each other, i.e. the document offset value. The default value is 50 mm (2.0 inch). The document offset can be varied between 20 mm (0.8 inch) and 75 mm (3.0 inch).

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).

For each of the jobs 1 through 25 and Lng (loadn Go) an offset can be switched on or off using the arrow button.

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 last. This document will not be folded. During 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).


4-4 rev. 1.0 - 12/2009

The document directly beneath this document must be at least 60 mm (2.4 inch) 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 (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 one 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. Therefore it is safe to switch the BRE option on, unless this option will never be used.

Secure jobs

With the Secure job 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.

Flap closer

The flap closer offset is set in the System Settings menu, Flap closer offset. In the Flap closer menu in the Job Settings menu you can adjust the timing of the activation of the sealing solenoid (So3) on a per-job basis. You can use this function to improve the sealing process per job. The timing has influence on the position of the filled envelope with its flap fixed between rollers 21 and 22 prior, before it is transported between the sealing rollers. This position can be adjusted between -10 and + 10 mm (with respect to the default envelope position).

4.3.3 Service tests

Photocells

This machine uses so-called intelligent photocells. The currents of the photocell transmitters are adjusted in such a way that the no-paper output voltage of the photocell receiver is within a certain voltage range of the photocell receiver. In this way, a reasonable amount of dust on the photocell sensors can be compensated for. The control mechanism ensures that very reliable paper and no paper decisions are being made, based on the paper photocell condition.

The screens provide real-time information on the various paper photocells. You also can see if the relevant photocell sees paper.


4-5rev. 1.0 - 12/2009

Press the Cal. button to adjust the photocells.

Note: Before readjusting the photocells 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 have been adjusted, the percentages in the screens should be lower (if the cleaning advice was followed). If no paper is present, the photocell output voltage should have a value between 0.8 V and 1.5 V. A value below this voltage range indicates that the photocell is too dirty. A value above this voltage range may occur if after readjusting a photocell dust is removed. In both cases, the photocells must be adjusted.

If the photocell current percentage is below 75%, the message OK is shown. A percentage between 75% and 99% results in a Clean message. The photocell should be cleaned before resetting the photocells. The message Defect is shown when the percentage is 99% or 100%

Digital inputs

The digital input screens show: The status of the three safety switches: MS1 (collator switch), MS2 (front switch) and MS3

(loc switch)The status is real time: a change is reflected in the displayed status. This allows you to easily check the correct operation of the three microswitches.

The status of the collator stop sensors: if the sensor is covered (closed) or not (open). If the water reservoir is present and if the water level is sufficient The status of the two folder cam disks (SPH3 & PD3; SPH4 and PD4)

You can also test the folder cam discs. During the test the relevant cam disc moves one half cycle. The cam disc status changes from open to covered or from covered to open. If you press two times on a test key the cam disc has made a full cycle.

The pulse disc and SPH2 for the main motor M2 (pulse disc central)You can also test the pulse discs of the motors. Both the speed and the quality (duty cycle) are tested. Detailed information is obtained via the minimum (Min.) and maximum (Max.) value. The speed range should be between 75% and 125%. The Distance (Duty cycle) value should be between 50% and 150%. If this is the case the message 'Good' is dis-played. The speed is checked by measuring the average pulse width and comparing it to the initial value. When the speed is much lower than the initial value, check the mechanical load. If it is higher, the pulse disc might be loose.The Distance (duty cycle) is measured of each pulse and the minimum and maximum val-ues are shown. When a pulse (an indented area) is not detected (for example because of dust build up) the pulse distance will show a value of Min. 0% and/or Max. 200%.

The pulse discs SPH1 for the collator motor M1 (pulse disc collator)

Actuators tests

From this menu you can select an actuator and activate it. Some tests are only possible with running motor. With the upper button you can switch the motor off or let it run continuously during actuator tests.

The following tests are possible: Main motor (M2): the motor runs as long as the Test button is pressed. Fingers magnet (So1): the fingers move forward as soon as the Test button is pressed. Only

after releasing the Test button the fingers will move back to their rest position. Eject roller magnet (So2): press the Test button and keep it pressed: the solenoid is

activated and deactivated after a short time. Closer magnet (So3): press the Test button and keep it pressed: the solenoid is activated

and deactivated after a short time.


4-6 rev. 1.0 - 12/2009

Envelope track clutch (CL8): press the Motor ON button and press the Test button. The envelope track clutch is activated.

Stacker clutch: press the Motor ON button and press the Test button. The stacker clutch is activated.

Brush magnet (So4): press the Test button and keep it pressed: the solenoid is activated and deactivated after a short time.

Shunt forward: the collator motor M1 runs and clutch CL4 is activated Shunt reverse: the collator motor M1 runs and clutch CL5 is activated Collator run in: the collator motor M1 runs in the direction of the document stop position Collator run out: the collator motor M1 runs in the direction of the folder Folder: the collator motor M1 runs and clutch CL4 is activated Folding table 1: the folding table turns a half fold cycle. If you press the Test button for the

second time the folding table returns to its original position. Folding table 2: the folding table turns a half fold cycle. If you press the Test button for the

second time the folding table returns to its original position. Collatorstop to A: both collator stops move up and down Collatorstop to B: the centre collator stop moves up and down Collatorstop to C: no collator stop movement Feeder clutches: the main motor M2 is switched on and the relevant feeder clutch is

activated if the button is pressed. The maxiFeederTM option is only available if the maxiFeederTM is present. As long as the

button is pressed, its motor will run.

Run in

This screen has a counter (with default value of 500) that shows the number of process cycles that will be executed, without paper or envelopes present in the machine.

Note: Never execute the run in test with any documents present in the machine. The timing of the actions for a simulated process cycle are fixed, 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.

After pressing the Start/Stop key, the run in test will start/stop. The machine stops automatically if the counter value is zero.

If some covers are removed (but not the safety covers!), you can watch the sequence of the various mechanical actions, which reflect the sequence of events during normal operation.


4-7rev. 1.0 - 12/2009

DFC test

The DFC screen shows the real-time DFC output voltage, expressed in millivolt. For testing the DFC it is best to start the system with paper underneath the DFC sensor (and covering the feeder photocell too). This results in starting the adjustment procedure. The voltage should be approx. 4.1 V when a single sheet (80 grams/20 lb) is below the sensor (the voltage of a non-adjusted DFC, without paper, is approx. 5 V). When this sheet is removed the voltage will drop with approx. 0.25 V. The voltage drop depends on the thickness/quality of the paper. The table gives an indication how much the voltage will drop with the relevant paper qualities.

Although the readings are correct it still could be that the DFC is not functioning correctly in AUTO mode. It is recommended to clean the moving parts of the DFC to make sure that dust or paper particles are not affecting the DFC functioning.

If you restart the system, the DFC voltage is erased from memory, has no reference and shows some unexpected value. After a first sheet is passed through the feeder the DFC will be calibrated at about 3.96 voltage. For the next sheet the DFC is functioning correctly.

During normal operation the system automatically recalibrates. Manual DFC testing and calibration can be easily done by removing the cover (with an opened loc) and manually turning the feeder separation gear. In the service menu DFC test menu, the voltage can be verified.

Touch screen

In the Touch screen tests menu you can verify the correct functioning of the touch screen. If you press Test touch screen, a graphical object will be displayed on the screen at each point where the screen is touched. The screen can be touched with either a finger or a (non-scratching) pen.

If the area touched does not correspond with the displayed object, the touch screen should be calibrated. To do this, use the Calibrate touchscr. button and follow the commands on the screen.

Envelope only mode

If you set the envelop only mode to On, all jobs will only process envelopes. Use this mode for a service test without documents.

Stop key

For testing purposes it is possible to create a stop key in the user interface (Mode is On). This stop key appears as soon as the system runs a job. Deactivate this key (Mode is Off) when you have finished servicing the system.

If you press this extra stop key the system does not stop immediately, but on the first opportunity while processing. Because of this there can be incomplete sets in some parts of the system.

4.3.4 Service counters

This menu allows you to read, set, or reset the service counters: The Since last visit counter can be reset.

Paper quality (g/m2)

Voltage drop(V)

65 0.2

80 0.25

120 0.35

160 0.5


4-8 rev. 1.0 - 12/2009

The Since installation counter is displayed. The next visit after counter can be incremented in 5000 steps to a maximum value of

6.000.000 steps. A value under 5000 results in the value OFF. The feeder counters (1 through 3) can be reset to zero. The envelope hopper counter can be reset to zero.

4.3.5 Reading: OMR

OMR code definition

The OMR code definition menu allows you to define the OMR reading codes. The number of different menu items depends on the level of OMR, see the table.

Per item choose between Yes and No (toggling function). The line spacing can be changed in steps of approximately 0,03 millimetre. The Lpi value reflects the number of lines per inch, the millimetre value is the distance between two successive marks.

The Table summarizes the possibilities of the OMR code.

Note the following: When some functions are not used, marks will shift up. The minimum marks in Level 1 are: Start mark + accumulate or insert. That is 2 marks in

total. However, it is highly recommended to add a third mark, the safety mark in the minimum configuration.

The feeders programmed as selective feeder cannot be used as a reading feeder. Of the marks 'Insert', 'Divert' or 'Stop' only one should be printed on each single document

to indicate the end of the set. The marks are so called 'mutually exclusive'. The divert and continue mark cannot be used. The divert and stop mark will make the set

stop in the collating area. If a level increase occurs, the extra functions will use the default setting (= off). When the

level is decreased the not available functions will be switched off without giving any error message.

The sequence will be reset after power up; a job change; a successful clear action or an error message.

When parity is used the parity of the printed marks should be even.

Reading code parameter Value Description Level

Start mark Yes Start mark Basic, Advanced

No No start mark Basic, Advanced

Insert on Mark Mark is insert; space is accumulate Basic, Advanced

Space Mark is accumulate; space is insert Basic, Advanced

Divert mark Yes Divert mark (implemented as a stop mark)

Advanced

No No divert mark Advanced

Stop mark Yes Stop mark Advanced

No No stop mark Advanced

Selective feed 1 Yes Selective feed on station 1 Advanced

No No selective feed on station 1 Advanced


4-9rev. 1.0 - 12/2009

In the OMR code type menu you can choose Legacy. These definitions are meant for the former PFE code definition as used on the Minimailer 2, 4 and Easy start.

Within the code definition Legacy the following functions are available and can be defined:





Sealing control Yes Mark is no sealing, space is sealing Advanced

No No sealing control Advanced

Sequence check No No sequence check Advanced

1 (mark) Sequence check 1 with 1 mark Advanced

2 (marks) Sequence check 2 with 2 marks Advanced


Parity check Yes Parity check, based on a parity mark Basic, Advanced

No No parity check Basic, Advanced

Safety mark Yes Safety mark Basic, Advanced

No No safety mark Basic, Advanced

Line spacing 4 10 lpi Line spacing in increments/decrements of 1/32" (keys 4 and 5); Displayed in 2 digits in lpi and mm


Gate mark Not selectable, always on Basic, Advanced

Insert on Not selectable, always on (insert on mark)

Basic, Advanced

Parity Yes Parity check, based on a parity mark (even parity)

Advanced

No No parity check Advanced

Unseal Yes Mark is no sealing, space is sealing Advanced

No No sealing control Advanced







4-10 rev. 1.0 - 12/2009

OMR code test

Use this menu to test the OMR reading head (RH1) and, if necessary, to readjust the relevant OMR electronics. 1 Select Adjust to start testing the reading head.

The settings of the current job are used for this test. This implies that an OMR job must be selected, otherwise the text Select a job with OMR will appear. If the OMR codes on the paper used differ from the OMR codes for the current job, the number of marks that have been read are incorrect.After selecting Adjust, another menu appears. Information about the number of OMR test sheets to be placed in the upper feeder is first shown.

2 Select Start adjust to start the OMR adjustment. The text Adjusting appears. The end result will either be: - Adjusting OK- Adjusting FAILEDIf readjustment of the OMR electronics was successful, Save and exit is displayed.

3 Select Save and exit to return to the original OMR menu. This menu now shows the benefit of readjusting the OMR electronics.

Select the Test key to show: Mark quality (the quality of the marks: bad, good or very good)

The mark quality is either:Bad: Mark amplitude < 0.6 VGood: Mark amplitude between 0.6 V and 1.5 VVery good: Mark amplitude higher than 1.5 V

Marks (the number of marks that have been read) Gain (the gain of the amplifiers involved in the OMR electronics, the values are 1, 3, 5 or 7) Vp-p: peak to peak voltage

Select the OMR info key to display the information screen. This screen 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.

Selective feed insert Yes Selective feed on station 1 Advanced


Halt Yes Stop mark Advanced

No No stop mark Advanced

Sequence check Off No sequence check Advanced

1 (mark) Sequence check 1 with 1 mark Advanced





Line spacing 4 10 lpi Line spacing in increments/decrements of 1/32" (keys 4 and 5); Displayed in 2 digits in lpi and mm

Read direction Yes Reading direction is reversed Advanced

No Normal reading direction Advanced



4-11rev. 1.0 - 12/2009

Select Show OMR to display 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. See following figure.

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.

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. The detection level is 60% of the top level. A mark is detected as an OMR-mark when more than 5 digital samples consecutively are below the detection level.

The numbers 1 through 6 indicate where a mark is expected. The distance between the numbers is exactly the same as the programmed line spacing. Select the arrows to scroll to the left or the right. Scrolling to the right shows a later point in time; scrolling to the left shows an earlier situation.

4.3.6 Reading: BCR

Read config sheet

The button Read config sheet allows you to read Barcode Reading (BCR) settings from a BCR configuration sheet. Follow the instructions on the screen.

BCR code definition

The BCR Code definition allows you to define the reading codes for barcode reading.

Per item choose between Enabled, Disabled or Ignored.

The table in this section summarize the BCR code options.

Note the following: You can only select feeder 2 as a reading feeder if Selective feed 2 is set to Ignore. If a level increase occurs, the extra functions will use the default setting (= off). When the

level is decreased the not available functions will be switched off without giving any error message.

The sequence will be reset after power up; a job change; a successful clear action or an error message.

If a functionality is not available on the machine, but printed in barcodes, set this functionality to Ignore. This offers the possibility to use the same coding throughout different machine types.


4-12 rev. 1.0 - 12/2009

The position of a reading functionality depends on the availability of other functions and on the number of characters you choose for a function. If a functionality is disabled, the other functions shift upwards.

Note: The code always should start and end with an * (asterisk symbol).

Neopost barcode scheme

Reading code parameter

Code length

Default settinga

Description Level

Page N of M M: 0 - 2N: 0 - 2

D, 0D, 0

nm: invalid, sequence error, divertThe field Chars shows the number of character positions available for N / M:1, 2: 1 or 2 character positions1 S, 2 S: 1 or 2 character positions with N and M in reverse order (M first, then N)

basic

Sheet Sequence 0 - 3 E, 3 Sheet counterIf a sheet number is missing, an error is generated.

advanced

Group Sequence 0 - 3 D, 0 Set counterIf a set number is missing, an error is generated

advanced

Insert / Accumulate 1 bitb E Insert and accumulate command basic

Divert 1 1 bit E Divert and continueDivert and stop(see Divert on page 4-13)(On 075.1 both will be interpreted as divert to collator and stop)

advanced

Divert 2 1 bit E Not possible on 075.1, 080.1 and 086.1. If these functions are available in the barcode set them to Ignore.

advanced

Selective Feeds 1 bit each E A maximum of 7 feeders (086.1: feeder 7 is versaFeeder) is available for selective feed

advanced

Do not glue 1 bit E Sealing control: enable or disable sealing (086.1 only)

advanced

Envelope selection 1 - 3 1 bit each E Not possible on 075.1, 080.1 and 086.1 advanced

Exit. Sel. 1 1 bit E Stacker or side exit (086.1 only) advanced


4-13rev. 1.0 - 12/2009

Divert

In the BCR Code definition menu you will find the following settings that are not mentioned in the table: Divert and continue Divert and Stop Present on deck and continue Present on deck and stop

These settings are covered as follows:

Divert & Continue and Divert & Stop are directly linked to the Divert 1 function and the separate Stop function. This means: When you enable Divert & Continue, Divert 1 is also enabled automatically. When you enable Divert & Stop, both Divert 1 and the Stop function are enabled

automatically.

In both cases do not change the settings of the Divert 1 and the Stop function, because this will change the setting of the Divert & Continue and Divert & Stop function.

Note: The reason for this behavior is to have different DS systems support the coding scheme.

Exit. Sel. 2 1 bit E Present on deck & continue Present on deck and stop (086.1 only)

advanced

Exit. Sel. 3 1 bit E Not possible on 075.1, 080.1 and 086.1 advanced

Stop 1 bit E Stops the inserter advanced

Customer ID 0 - 16 D, 0 If customer ID equals the ID on the previous page: accumulateIf customer ID is different from ID on t