as800 pressure sealer - Neopost Technologies Ltd
Contents
1. Feed through paper to check unit function Check correct function of output conveyor Check cover microswitch operation Switch offmain machine Refitcovers Clean unit as required Note rubberrollers and wheels should be cleaned using only PFE Roller Cleaning Fluid except for pickup roller which must be cleaned using only a water damped cloth Pressure rollers should be cleaned using Isopropyl Alcohol or alcohol based cleaner Page 4 2 Bh i E World Leaders AS800 PRESSURE SEALER Service Manual 4 2 SERVICING AND ADJUSTMENTS 4 2 1 SEPARATOR GRIP ROLLER Control Knob E0113A Setting Peg C2186E Separator Grip Roller C807 1A FIG 1 The separator grip roller is set via the control knob see Fig 1 above to allow only one form through at a time As the roller wears a flat occurs across the face This is corrected by lifting setting peg and rotating the roller one stop to clear the worn section When all stop positions have been used the roller must be replaced To replace the roller remove the separator unit complete with feed wheel shaft The adjacent sensor shaft will have to be slackened and moved to allow withdrawal of the separator assem bly Exercise great care to avoid straining the wires Strip the assembly to remove the roller exploded view section 5 4 may assist Note that the roller pivot shaft is in two halves held together with a set screw After reassembly e2. 0V Refer to Fig 9 below for physical layout of Control Panel PCB u8 u9 U E AA area PANEL PCB o EE EE i a s4 U s3 s8 s7 s6 s5 O O Eset Page 4 13 Fes 2003 Ee Ei p World Leaders AS800 PRESSURE SEALER Service Manual 4 3 5 RECOMMENDED SPARES MECHANICAL Shown below are mechanical spare parts recommended to be held by Service Agents Note that some items are voltage specific Quantities indicated are for every 5 machines up to E1054A E1062A D0009A 12mm BALL BEARING BEARING HK3020 FEED WHEEL TYRE gt s gt gt gt gt C mosa iain BALL sean 10528 prar moo y pons FEED WHEEL rve i a P Issue 1 Page 4 14 Fes 2003 E i a World Leaders AS800 PRESSURE SEALER Service Manual Recommended Spares Mechanical contd PART NUMBER DESCRIPTION TY 0 2 C2414A SPRING PEG 8 EER Page 4 15 Fes 2003 Ee Ei p World Leaders AS800 PRESSURE SEALER Service Manual 4 3 6 RECOMMENDED SPARES ELECTRICAL Shown below are electrical spare parts recommended to be held by Service Agents Note that some items are voltage specific Quantities indicated are for every 5 machines upto 135 106 FUSE 20mm 6 3A 110V SEURT Page 4 16 Fes 2003
3. ED s are LEDBAR2 LED1 Feed Roller clutch LED2 Brake not fitted LED3 Diverter Solenoid LED4 N A LED5 N A LED6 N A LED7 Motor in forward drive direction LED8 Motor on LED9 N A LED10 N A 4 3 2 SETTING OF DIP SWITCH The DIP switch S1 on the CPU board may set for the following Switch 1 ON Auto calibrate on power up hopper empty Default OFF Switch 2 ON Stop machine after 2 consecutive doubles Default OFF Switch 3 Not for use OFF at all times Switch 4 Not for use OFF at all times See Fig 7 Section 4 3 4 for position of DIP switch on CPU PCB Issue 1 Page 4 z 9 Fes 2003 Ee Ei p World Leaders IN MAILROOM TECHNOLOGY AS800 PRESSURE SEALER Service Manual 4 3 3 ENGINEER SERVICE MODE ENTERING ENGINEER SERVICEMODE ace die O LON Switch machine off at power switch Fit link to J6 connecting pin 1 to pin 4 on CPU PCB Switch machine on The following key sequence must be executed while the display is showing HELLO AS800 and steps 5 to 7 must be completed within two seconds Press STOP and JOG FORWARD keys simultaneously Press RESET OUT countkey Press RESET IN count key The message Eng Ser will appear on the display if the above key sequence has been entered correctly and within 2 seconds Pressing the JOG FORWARD key steps through the engineer service facilities described below ENGINEER SERVICE FACILITIES Issue 1 Fes 2003 Software version Thisis the EPR
4. OM version fitted Display shows VER N NN Hour count This is the total number of hours the machine has has been run since production Display shows the hour count to one tenth hour resolution Hour HHHH H Total document count This is the total number of documents processed since production Display shows ten digit count NNNNNNNNNN Test 1 Lamp test Display shows TEST 1 Press GO key to execute test 1 This test flashes every led on the control panel Exited by pressing the STOP key returns to TEST 1 display Test 2 Control panel test Display shows TEST 2 Press GO key to execute test 2 This test acknowledges each key press with appropriate message Exited by pressing STOP and SETUP keys simultaneously returns to TEST 2 display Page 4 10 Bh i E World Leaders AS800 PRESSURE SEALER Service Manual 6 Test3 Mechanism test Displays shows TEST 3 Press GO key to execute test 3 This testexercises the mechanical parts ofthe machine other tests can treach Also doubles detector sensor testis carried outin while in test 3 Press GO key to execute test 3 STOP and SETUP keys to exit test 3 returns to TEST 3 display 6 1 Motor Test amp Speed Setting gt GO STOPkeys turn motor on off gt keyschange motor speed gt JOGFORWARD JOGREVERSE set motor direction FORWARD REVERSE butonly actioned with the motor stopped gt RESETINkey display the speed of the rolle
5. World Leaders IN MAILROOM TECHNOLOGY AS800 PRESSURE SEALER Service Manual SECTION 4 Operating and Service Adjustments Page 4 1 Issue 1 Fes 2003 Ee Ei p World Leaders IN MAILROOM TECHNOLOGY AS800 PRESSURE SEALER Service Manual 4 1 SERVICE CHECK LIST Issue 1 Fes 2003 DO VON ee a ODO eS 6 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2T Unplug power cord Removecovers Check all screws for tightness Check infeed rollers for wear and operation Replace ifrequired Clean infeed rollers Check operation of separator roller mechanism including increment stop Check separator roller for wear Adjust or replace if required Check separator roller mechanism for tightness Check all feed rollers and wheels for wear Replace if required Clean all feed rollers and wheels Clean pressure rollers Lubricate 8 needle roller bearings on pressure roller journals using light machine oil remove drive pulley amp roller gears on drive side of machine to gain access Check gear drive train for wear Lubricate Check diverter mechanism for smooth operation Ensure all diverters are aligned Check diverter solenoid is actuating correctly and also releasing Check side guide operation and alignment Clean all sensors with air duster or air compressor Check security of PCB connectors Check security of power cord plug Switchon machine Check and test all sensor settings
6. e pot adjust to give 0 25 0 35v Now turn sensor disc to blocked position Confirm gt 3 5v blocked between TP1 and Ov Connector J2 Hold Point Sensor Adjust VR1 to give 0 45v to 0 55v clear between TP2 and Ov If this range cannot be achieved or is confined to one end of the pot adjust to give 0 25 0 35v Now put 20 lbs bond 80gsm paper between sensors to block fully Confirm gt 3 5v blocked between TP2 and Ov Connector J3 Folder Output Sensor Adjust VR2 to give 0 45v to 0 55v clear between TP3 and Ov If this range cannot be achieved or is confined to one end of the pot adjust to give 0 25 0 35v Now put 20 Ibs bond 80gsm paper between sensors to block fully Confirm gt 4 0v blocked between TP3 and Ov Connector J4 Divert Sensor Adjust VR3 to give 0 45v to 0 55v clear between TP4 and Ov If this range cannot be achieved or is confined to one end of the pot adjust to give 0 25 0 35v Now put 20 Ibs bond 80gsm paper between sensors to block fully Confirm gt 3 5v blocked between TP4 and Ov Connector J5 Output Sensor Adjust VR4 to give 0 45v to 0 55v clear between TP5 and Ov If this range cannot be achieved or is confined to one end of the pot adjust to give 0 25 0 35v Now put 20 Ibs bond 80gsm paper between sensors to block fully Confirm gt 3 5v blocked between TP5 and Ov Connector J7 Folder Input Sensor Adjust VR5 to give 0 45v to 0 55v clear between TP7 and Ov If this
7. ld be set as follows 1 Remove clamping pressure beams or loosen the M10 set screws and locknuts to relieve spring tension on pressure rollers Also remove the inset retaining plates on both sides of the machine 2 Remove any existing shims at gap X i e The interface between upper and lower bearing housings so that the upper rollers are contacting those below with no tension applied 3 Using feeler gauges measure the distance at gap X 4 Fit shims in the interface at gap X equal to measured gap 002 05mm on the folder side and equal to gap X 001 025mm on the output side This applies to both LH and RH sides of the machine Shims are available in sizes 004 005 and 006 1mm 13mm and 15mm The lugs on the shims are located in the cut outs within the aluminium roller plates 5 Re fit the inset retaining plates and the pressure beams if removed The pressure roller spring tension must now be set as described in section 4 2 5 below 4 2 5 PRESSURE ROLLER TENSION The upper pressure rollers are tensioned by clamping down onto astack of 12 disc springs E0210A located in each counterbored hole in the four bearing housings for the upperrollers A Spring Peg C2414A is located through the springs for the set screws to bear upon The disc springs are arranged as illustrated in Fig 6 below Spring Peg ee TT SS FIG 6 Issue 1 Fee 2003 Page 4 6 E i a Wo
8. nsure that the hold point sensor is correctly adjusted see section 4 3 1 Adjustment of Sensors Issue 1 Page 4 _ 3 Fes 2003 Ee Ei p World Leaders AS800 PRESSURE SEALER Service Manual 4 2 2 DIVERTER ADJUSTMENT Clearance Adjustment screw Clearance x A E2537A va Feed roller oe Pressureroller C8056A a Ss NCS Ye ern C8058A i i Closed position Open position FIG 2 The diverters should be adjusted to meet the conditions shown in Fig 2 above A clearance of 005 13mm must exist between the leading tip of diverter and feed roller when closed and between trailing tip and pressure roller when open All diverters must be in line on the shaft To adjust the diverters proceed as follows 1 Move the solenoid bracket fully forward Slacken the diverter srews to adjust the solenoid lever to approx 10 past right angle to the solenoid centre line with the diverter tips just touching the roller in their closed position see Fig 3 below Turn in a piece of paper by hand so that it passes under the diverters 4 Slide the solenoid bracket back so opening the diverters until it just touches the paper at the tips in the closed position see Fig 2 above 5 Slide the solenoid on its bracket to the setting shown in Fig 3 6 Open the diverters to check clearance in the open position see Fig 2 above o Note if a diverter screw is replaced for any reason the threads must be greased using a gen eral pu
9. range cannot be achieved or is confined to one end of the pot adjust to give 0 25 0 35v Now put 20 Ibs bond 80gsm paper between sensors to block fully Confirm gt 3 5v blocked between TP7 and Ov Connector J9 Doubles Detector LED D12 only Put 4 thicknesses of 20 lbs bond 80gsm paper between the sensors and hold down with pressure wheel Turn VR6 clockwise until D12 just comes on Alternatively if D12 is already on turn VR6 anticlockwise until D12 goes off then clockwise until it comes on Ensure that both doubles detector and folder input sensors are blocked with paper Note to adjust the doubles Detector test 3 of the Engineer Service Mode must be entered This is fully described in section 4 3 3 Page 4 8 Bh i E World Leaders AS800 PRESSURE SEALER Service Manual Sensor adjustments can be confirmed via LEDBAR1 on the CPU PCB With voltage low sensor clear the relevant LED will light With voltage high sensor blocked the relevant LED will not light The relevant LED s are as follows LEDBAR1 LED1 Form Length Sensor LED2 Hold Point Sensor LED3 Folder Output Sensor LED4 Divert Sensor LEDS Output Sensor LED6 Service Plug In LED7 Folder Input Sensor LED8 Spare LED9 Cover 1 LEDIO Cover2 Similarly the operation of various machine functions can be checked via LEDBAR2 The relevant LED will light when voltage is applied to the items indicated even if those items fail to activate for any reason The relevant L
10. rld Leaders AS800 PRESSURE SEALER Service Manual Tension is adjusted via the M10 set screws acting on the disc springs Initially the screws are set by turning downwards until contact is just made with the springs then adding a further 1 2 turn Tighten the locknuts then start the machine and run several forms through to confirm that they are correctly sealed If not each of the sets screws must be tightened down by a further 1 8th turn at a time until effective form sealing is achieved Ensure that all locknuts are retightened afterwards Note if after adjustment the motor speed is heard to fluctuate when running forms the pressure being applied may be too great and should be reduced MCP pressure sensitive test paper should be run through the machine to check that pressure is equally exerted on both sides If the test paper is darker on one side then the roller pressure should be reduced on that side Back off the screws on that side 1 8th turn at a time until the test paper shows a consistent shade Issue 1 Page 4 _ 7 Fes 2003 Ee i p World Leaders IN MAILROOM TECHNOLOGY AS800 PRESSURE SEALER Service Manual 4 3 ELECTRONICS AND SOFTWARE 4 3 1 ADJUSTMENT OF SENSORS Issue 1 Fes 2003 All voltage adjustments to be made with respect to TP10 Ov on the CPU PCB Connector J1 Form Length Sensor Adjust VR8 to give 0 45v to 0 55v clear between TP1 and Ov If this range cannot be achieved or is confined to one end of th
11. rpose grease Solenoid lever B2561A Solenoid bracket B2650C Solenoid 22 24 179 305 5 6 6 1mm FIG 3 Issue 1 Page 4 4 Fes 2003 Bh i E World Leaders AS800 PRESSURE SEALER Service Manual 4 2 3 SENSOR ALIGNMENT Sensor x holder oa Receiver cy Q Transmitter Nar Fig 4a Fig 4b The hold point folder input double document folder output and output sensors are attached to cross shafts either in holders or drilled through In the case of the holder mounted sensors they should be adjusted so that their length is parallel with the top surface of the unit and the machined portion is rotationally positioned horizontally on the shaft See Fig 4a above The drilled through sensors should be rotationally adjusted so that the optical path between trans mitter and receiver is aligned see Fig 4b above To confirm correct operation of sensors see section 4 3 1 Adjustment of Sensors 4 2 4 PRESSURE ROLLER GAP Folder Side Roller Output Side Roller 025mm DG X PLUS 002 05mm PLUS 001 a GAP FIG 5 The pressure rollers are factory set and should not normally require attention However should this be necessary for any reason proceed as described Issue 1 Fee 2003 Page 4 5 Ee i p World Leaders AS800 PRESSURE SEALER Service Manual Referring to Fig 4 on the preceding page the proximity of the upper and lower pressure rollers shou
12. rs in rpm This display will be over ridden if another key is pressed Set machine speed using VR3 amp VR6 on PSU PCB as shown below Using button select Speed 9 Set max top speed using VR3 to read 168 1 on display Using button select Speed 0 Set min low speed using VR6 to read 148 1 on display Re check max top speed and set again if it has altered Fig 8 in section 4 3 4 shows the positions of the pots on the PSU PCB gt Coverswitches should prevent motor from running when open 6 2 ClutchTest gt SETUPkey pulses the clutch for approx 200 millisecs gt HANDFEED key toggles the clutch ON OFF 6 3 DivertTest gt RESETOUT key toggles divert solenoid ON OFF EXITING ENGINEER SERVICEMODE Press STOP and SETUP keys simultaneously to exit Sanah Page 4 11 Fes 2003 Ee i p World Leaders AS800 PRESSURE SEALER Service Manual 4 3 4 PHYSICAL LAYOUTS OF PCB s TP13 O O C g O lt GND gt pe VR TPS TP10 aris LEDBAR2 TP14 noonoo O oo 10 TP9 TP11 CPU PCB 180 138 LEDBAR1 VR3 ic TP1 O 10 1 VR2 TP2 O FIG 7 For circuit diagrams and component items lists of all circuit boards refer to section 6 of this manual Sate Page 4 12 E j a World Leaders AS800 PRESSURE SEALER Service Manual Refer to Fig 8 below for physical layout of Speed Control PSU PCB SPEED CONTROL PSU PCB 180 135 6 220V 11
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