SERVICE MANUAL - RENA Systems, Inc.
Contents
1. THE ENVELOPE XPS ProMail System XPS ProMail Base XPS ProMail 3 0 4 0 print system XPS ProDry 8 0 Base XPS ProFeed Shuttle amp TB 659 Conveyor SERVICE MANUAL Preliminary Revised 8 10 07 Part M RENA SYSTEMS INC 136 Green Tree Road STE 140 Oaks PA 19456 1069 Phone 610 650 9170 Fax 610 650 9171 E Mail support renausa com Web Site www renausa com INDEX Table of Contents Section Page DRYER SAFETY PRECAUTIONS a eU 4 GENERAL SAFETY PRECAUTIONS c cccccosssssssasacsossasacsassssacsocaasassncsasacsnsansacsnsensacsucesdassassnsassusnndassusnssasdusossacaeenss 5 SECTION 1 SERVICE DIAGNOSTIC TESTS eee e eese eee ee teen enetn ense tata sns n tne te tatnen aeneae teta 6 Loading Test Print Image e een IPRC ED BU RR EOD reete 6 SECTION 2 MAINTENANDGE ero ete trente en en vn E se sesoses sS oris ossosa PE Te Pr sor si Soins 10 RHE INKJET CARTRIDGE iter ae ete tu or T tette ie tie e E EE e eR ea 10 Replacing the Inkjet Cartridge 10 AI DIDI ERE 11 IUS RE 11 Cleaning the Printhead Inkjet Cartridge nennen nennen enne 12 Purging the Nozzles en esee dne See E uote eedem c ET 12 JAMS UNDER THE XPS PROMAIL 3 0 4 0 PRINTER eese trente entren ers2. Manual position Open the front panel Adjust the following potentiometers on the Speed Control PC Board as follows a CURRENT LIMIT 1 center of adjustment b IR COMP 4 slightly clockwise from fully off c DECEL 5 and ACCEL 6 adjust to minimum setting counterclockwise Connect a DC volt meter between terminals A1 and A2 Release the Emergence Stop switch and press the power button to turn the system on Then turn the Dryer Power switch ON 6 Adjust the Dryer Speed Control knob to the lowest speed setting all the way counterclockwise Then adjust the MIN SPD 3 to get 1 V DC Make sure that the belts are not moving after completing this adjustment Adjust the Speed Control knob on the feeder control panel to the highest speed setting clockwise Then Adjust the MAX SPD pot 2 to get 100 V DC Disconnect the meter and replace the control panel POWER MAXSPD MINSPD IRCOMP DECEL ACCEL 35 SECTION 4 ADJUSTMENTS TB 659 Conveyor Conveyor Drive Belt Adjustment Requirement The Conveyor Drive Belt must have the proper tension to drive the belt roller Adjustment 1 Remove the left hand end cover from the Conveyor Four screws 2 Loosen the four screws that attach the motor to the frame and slide the motor away from the drive roller to tighten the belt 36 SECTION 4 ADJUSTMENTS Conveyor Transport Belt Adjustment Requirement The belts must track straight and not s
3. DECEL ACCEL 33 SECTION 4 ADJUSTMENTS Dryer Base Dryer Base Transport Belt Adjustment Requirement The Dryer Base Transport Belts must track properly NOTE This adjustment should only be performed when changing the belts and is more easily accomplished before the transport assembly is installed back in the base Adjustment l 34 The non driven roller has two adjusting bolts 1 with lock nuts 2 one on each side that are screw against the roller shafts Loosen the two Allen screws 3 that lock the roller shafts in place on the frame Adjust the two adjusting screws 1 so that they hold the roller at the same distance from the adjusting screw mounting bracket Tighten the lock nuts 2 Turn the unit over and install it in the dryer base Check that the belts have at least 1 1 2 to 2 of stretch at their centers on the table Connect the electrical wires and run the dryer base to check that the belts track properly If the tracking is off the belts track to the left or right loosen the locking nuts 2 and readjust the side opposite of the direction of the track Retighten the nuts and retest Run the dryer base up to its highest speed to confirm the belts are tracking properly Dryer Base Speed Control Adjustment SECTION 4 ADJUSTMENTS REQUIREMENT To adjust the maximum speed of the Dryer unit ADJUSTMENT 1 2 3 Put the Dryer Auto Manual switch in the
4. across two printheads Reposition the text in the layout so that it does not print across two printheads Adjust the positioning of the two printheads in relationship to each other using the Head Alignment tool in the Properties window of the PCL version driver Ghosting and or skewed line of type RENA Systems Inc 0 136 Green Tree Road 1 Oaks PA 19456 1069 Media is slipping hesitating or skewing as it is transported or part of image is printed with a ghost image ghosting or is skewing Example shows part of the image STE 140 ghosting and skewing Check the side guide adjustment If guides are set too tight they can hold back on media Check that the printhead carriage is set at the proper height A printhead carriage that is set too high or too low may cause media to jam hesitate slip or skew THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS OF THE XPS ProMail SYSTEM 25 SECTION 3 TROUBLE SHOOTING Notes 26 SECTION 4 ADJUSTMENTS SECTION 4 Adjustments XPS PROFEED Shuttle Feeder XPS PROFEED Drive Belt Adjustment REQUIREMENT To adjust the main drive belt for proper tension ADJUSTMENT 1 Remove the upper and lower rear 3 Push the motor assembly in the covers from the Feeder direction of the arrow as show 2 Loosen the four Allen screws 1 that 4 Tighten the four Allen screws attach the motor to the frame of the 5 Check that
5. and adjust the screws 1 so that 4 Retighten the nuts and retest the belts can be raised approximately 5 Run the base up to its highest speed to V2 from the table at their centers confirm the belts are tracking 2 Tighten the lock nuts 2 and run the properly base unit at low speed to check the tracking of the belts in the belt guides 32 Base Unit Speed Control Adjustment REQUIREMENT To adjust the maximum speed of the base unit ADJUSTMENT 1 2 2 Put the Transporter Auto Manual switch in the Manual position Open the front panel Adjust the following potentiometers on the Speed Control PC Board as follows a CURRENT LIMIT 1 center of adjustment b IRCOMP 4 slightly clockwise from fully off c DECEL 5 and ACCEL 6 adjust to minimum setting counterclockwise Connect a DC volt meter between terminals A1 and A2 SECTION 4 ADJUSTMENTS Release the Emergence Stop switch and press the power to turn the system on Adjust the Transporter Speed Control knob to the lowest speed setting all the way counterclockwise Then adjust the MIN SPD 3 to get 1 V DC Make sure that the belts are not moving after completing this adjustment Adjust the Speed Control knob on the feeder control panel to the highest speed setting clockwise Then Adjust the MAX SPD pot 2 to get 100 V DC Disconnect the meter and replace the control panel POWER MAXSPD MINSPD IRCOMP
6. each half of the rollers to the roller shaft NOTE When replacing the Allen screw use a drop of Locktite 247 Threadlocker to prevent it from loosening during operation 3 Replace the covers and screws Replacing Upper Feed Rollers 1 Remove the Shuttle Feeder from the system 2 Remove the front cover from the Shuttle Feeder Raise the head assembly so that the upper and lower rollers are not touching each other 3 Disconnect the flexible drive shaft from the upper feed roller assembly by removing the two Allen screws 1 and moving the drive shaft to the right away from the upper roller assembly Then remove the Allen screws 2 from the Upper Feed rollers and remove the rollers from the shaft 4 Reassemble in reverse order 45 SECTION 5 DISASSEMBLY Replacing the Lower Feed Rollers 1 Remove the Shuttle Feeder from the system 2 Remove the front cover from the Shuttle Feeder Raise the head assembly so that the upper and lower rollers are not touching each other 3 Remove the Allen screw 1 from the drive pulley and remove the drive pulley The remove the Allen screws 2 from the collars and remove the collars Next loosen the Allen screws 3 that attach the lower feed rollers to the shaft and remove the shaft and rollers 4 Reassemble in reverse order Removing Rear Covers 1 Remove the two screws 1 and the cover over the Flexible Drive Shaft The remove the four screws 2 that attac
7. enabled If using a combined field barcode choose USPS barcode font Put zip code field in database or use another database Enable barcode Unwanted BOLD Italic Turned on in layout or Underlined type Open layout and change type style Not all addresses in Only some of the addresses Start new job and select database print in database have been entire database selected to print Data is being lost Database problem Check the database Parallel cable connection program loose Reconnect Graphics or text have a The graphic or text is set Move the copy or adjusts white line through them between the junction of two the printhead printheads Software Problems Refer to the manual for the application software being used 23 SECTION 3 TROUBLE SHOOTING Print Quality Problems CONDITION PROBLEM SOLUTION Black streaks in text Lint or paper dust on Clean the cartridge nozzles Frirteersempteottextshewing printhead with a clean lint free cloth black streaks inthe copy moistened with distilled water Cartridge will not print Sheet is blank even after it has Check to make sure the tape gone underneath cartridge s is off the printhead Remove and reinsert the cartridge into the carriage holder Install a new print cartridge White streaks in text or Lint or dust blocking Clean the cartridge nozzles graphics printhead holes with a clean lint free cloth Poor contact between moistened with distill
8. its agents or employees shall be responsible for any inaccuracies contained herein Hewlett Packard is a registered trademark of Hewlett Packard Corporation Windows 98 Windows 2000 Windows ME and Windows XP are registered trademarks of Microsoft Corporation IBM is a registered trademark of International Business Machines All other trademarks are the property of their respective holders All rights reserved No part of this book may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or any information storage and retrieval system without permission in writing from the Publisher SECTION 1 SERVICE DIAGNOSTIC TESTS SECTION 1 Service Diagnostic Tests TEST PRINT key Pressing the TEST PRINT key momentarily will place the printer into the Test Printing mode Press the ENTER key to print a test sheet To access the Service Menu mode press and hold the TEST PRINT key until Service Menu is displayed on the printer control panel Use the or key to step through the following test options Loading a Test Print Image 1 Create the Test Print layout using any common application MS Word Flex Mail 2 Connect the printer and computer via parallel port or USB port 3 Hold the Test Print key on printer control panel and turn the printer on Release the key when message Test Job to be saved Preparing the flash area appears Message will change to T
9. or 0 125 Press the ENTER key check for broken drive belt and replace check for loose set screws on drive pulley or belt drive roller pulley Replace Clutch Check motor circuit breaker or replace motor See Power Problems in this Section Adjust printhead height to accommodate the media thickness Clear jam and remove pieces remaining under printhead Instruct operator in proper loading of media Set feed ramp Adjust separators to thickness of media Uncurl media Clean or replace sensor Jams continued Worn separator tip Printhead adjusted too low Conveyor tape s under printhead broken Replace separator tip Raise printhead Replace tapes 21 SECTION 3 TROUBLE SHOOTING Print Placement Problems 22 CONDITION Print too close to leading or trailing edge of media PROBLEM Size of media not set correctly in Layout Bad or dirty sensor Feed ramp not used properly Printheads set incorrectly SOLUTION Check layout in layout for proper size Clean or replace sensor Set feed ramp Check the location and margins in layout software Check that the piece on the layout screen looks exactly the way you want the piece to look Remember that there is a 1 5 16 space that is always blank between Head 4 and 5 and the Head 1 2 and 3 bank Print too high or low on the media Physical location of printhead does not match the layout template Adjust the paper guid
10. the side frame to the tie bars and remove the frame 14 Remove the motor drive belt 4 and then slide the belts off the rollers Replacing Motor 15 To remove the motor remove the two screws 5 then remove the four motor mounting screws 6 Replacing Fans 16 To replace the fans continue the disassembly by removing the four screws 7 that attach the vacuum plate to the tie bars The remove the fans by removing the fan mounting screws 8 17 Reassemble in reverse order When assembled adjust the tension adjusting screws and tighten the lock nuts 59 SECTION 5 DISASSEMBLY Conveyor Replacing Conveyor Belts THE CONVEYOR IS VERY HEAVY TWO PEOPLE SHOULD BE USED TO LIFT THE UNIT FOR REPAIR OR REPLACEMENT Remove the three knobs 1 and the end guide then remove the three screws 2 and the right angle guide 2 Remove the three screws 3 and the Stacking guide 3 Carefully turn the Conveyor over onto two supports as shown and remove the six screws 4 from each leg Then remove the leg NOTE This should be accomplished by two people one holding the leg and the other removing the screws 60 SECTION 5 DISASSEMBLY 4 Remove the left and right cover plates by removing the four screws 5 5 Remove the two screws 6 and t
11. 0 4 0 Printer If a jam occurs STOP the Printer The missed addresses can be recovered at the computer from the control panel by stepping back to the place in the job where the jam occurred No data will be lost Some possible reasons for jamming are l 2 3 Feeding more than one piece of media Damaged media such a dog eared turn down corners Media that is not stiff enough and may not be usable Media that meets Postal stiffness requirements for automated feeding is acceptable in the XPS ProMail System Envelopes that are caught under the flap of another envelope or stuck to one another may cause jamming Removing Jammed Media The XPS ProMail 3 0 4 0 printer is equipped with a hinge device that permits it to be swung in the up position to remove any jammed media First turn off the system by pressing one of the STOP buttons To release the printer press down on the grab handle and release the two latches on the left hand side that lock the printer in place Then raise the printer using the grab handle Refer to the appropriate printer operating manual for job restart information 13 SECTION 2 MAINTENANCE Cleaning WARNING THE XPS ProMail SYSTEM IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE BEFORE PERFORMING ANY MAINTENANCE DISCONNECT THE MACHINE FROM ITS POWER SOURCE The XPS ProMail System must be cleaned regularly of accumulated paper dust and ink Depend
12. CTION 5 Disassembly XPS ProFeed Shuttle Feeder Control Panel Components Remove the two screws at the top of the control panel pull the control panel toward you and let it hang on its hinges 23 4 567 98 1 24 VAC Power Transformer 5 Interface Feed ON OFF Relay 2 Counter Relay 6 Main Power Relay 3 Safety Circuit Relay 7 Pump Power Relay 4 Main Fuse 7A Slow Blow 8 Motor Speed Control 43 SECTION 5 DISASSEMBLY Paper Length Selector 5 Jog Switch 2 Resettable Counter 6 Feeder Power ON OFF Switch 3 Emergency Stop Switch 7 Feeder Vacuum ON OFF Switch 4 Power Switch 8 Feeder Speed Control Potentiometer Replacing Separator and Shuttle Head 1 Remove the two Allen Screws A to remove the Sheet Separator Inspect the surface of the tip where the separator contacts the media it should be sharp without any dings or scratches If it is worn or scratched it should be replaced 2 There are four different shuttle heads used to feed media on the Shuttle Feeder The heads are replaced by removing the Philips head screw Shuttle heads should be replaced if they show signs of wear or damage 44 SECTION 5 DISASSEMBLY Replacing the Forwarding Feed Rollers The forwarding feed rollers should be replaced when they show signs of wear 1 Remove the eight Philips screws four each side from cover plate 2 The rollers are split rollers and can be removed by removing the Allen screw that attaches
13. GHT ELECTRICAL Inkjet 6 or 8 HP 51645A Cartridges Executive Quality 600 x 600 dpi Standard Quality 600 x 300 dpi Letter Quality 600 x 200 dpi Draft Quality 600 x 150 dpi 3 or4 x 17 Normal and Reverse TrueType fonts available on PC USPS certified Postnet barcodes Prints bitmapped graphics and logos Minimum 3 WxS L Maximum 15 Wx17 L 20 Bond up to 1 1 4 Standard and Versatile Black Red Blue Green Yellow and HP Bulk Ink Cartridges Water based May require drying assistance for coated stock Centronics Parallel One job counter and one lifetime counter 11 Hx 14 W x28 D 55 Ibs 100 240V AC 50 60 Hz The information electrical and physical dimensions etc on the XPS ProMail System is presented here for your reference Specifications are subject to change without notice 65 APPENDIX Appendix B Supplies The following supply items and optional hardware are available from your Rena Systems Dealer Supplies Black Inkjet Cartridge HP 51645A Fast Drying Black Inkjet Cartridge C6195A Yellow Inkjet Cartridge C6173A Red Inkjet Cartridge C6168A Green Inkjet Cartridge C6169A Blue Inkjet Cartridge C6170A Versatile Black C8842A RENA C8715A RENA EasylInk Aqueous requires dryer C9007A 66 APPENDIX Notes 67 Copyright 2006 AII rights reserved 08 16 2006
14. ITE STREAKS IN THE PRINT IMAGE SECTION 2 MAINTENANCE Storage Short term storage is defined as less than 2 days or less than 1 day in a hot and dry environment Long term storage is defined as more than 2 days or more than 1 day in a hot and dry environment Short term Storage Leave the cartridge in the XPS ProMail 3 0 4 0 printer for short periods of time 1 day or less The next time that the XPS ProMail 3 0 4 0 printer is used the printhead may have to be cleaned and purged Long term Storage Keep the printhead in an area that is relatively free of dust and paper particles that is not too dry Place the standard cartridges in a Tupperware container with a damp sponge or towel to maintain humidity and prevent the printhead from drying out When the cartridges are ready to be used again the printhead will need to be cleaned Disposal The cartridges may be disposed of in a normal manner If there should be an The ink in the cartridge may be harmful if ink spill use soap swallowed Keep new and used cartridges out of and water to clean up reach of children Discard empty cartridges any problem areas immediately Abrasive soap works well to get the ink off hands 11 SECTION 2 MAINTENANCE Cleaning the Printhead Inkjet Cartridge To maintain good print quality it is important that the printheads are kept clean During the printing process ink spray paper fibers and dust can cause a build up on th
15. N Printer does not respond to Connection problems Check that port is software communicating with printer by using another parallel cable Replace cable If port cannot communicate using another parallel cable check printer If port cannot communicate using another parallel and the printer is OK check parallel port Check cable connection to see if any of the pins are bent or missing If so replace cable Printer not responding to Poor connection between Turn printer off and on software printer and computer again Check connections 19 SECTION 3 TROUBLE SHOOTING LCD Display Problems CONDITION PROBLEM SOLUTION No LCD display Power not on Turn power switch on If still no display see Power Problems Contrast pot broken or Adjust pot or replace maladjusted display PC Board Broken solder joint on Repair or replace the contrast pot display PC Board LCD shows solid line of Power supply Check voltages and inspect characters or garbage the power supply connections to the processor PC Board Static electricity Turn printer off and then on LCD displays solid black Bad power supply Check all voltages line or lines No firmware BIOS Install firmware Bad processor PC Board Replace processor PC Board Feeding Problems CONDITION PROBLEM SOLUTION Intermittent Feed ramp not used The feed ramp adds a slope to the feeding stack and helps feeding Side guides set improperly Loosen the
16. Remove all of the screws circled that attach the top to the base of the feeder NOTE The screw with the arrow pointing to it also holds the stop plate for the rear guide 3 To remove the plate lift it from the machine and slide it to the rear 4 Replace in reverse order Do not forget the Rear Guide Stop 48 SECTION 5 DISASSEMBLY Removing the Drive Motor l The drive motor is mounted the feeder mechanism frame It is held in place with four Allen screws Remove the covers from the machine Disconnect the motor from the control panel and remove the four Allen screws two shown THE MOTOR IS VERY HEAVY MAKE SURE YOU SUPPORT IT BEFORE REMOVING THE MOUNTING SCREWS Removing the Main Drive Belt 1 2 4 5 Remove the rear and top covers Remove the two Allen screws that attach the flexible drive shaft to the drive mechanism Loosen the four Allen screws that attach the Driver Motor to the machine and slide it toward the front of the feeder Remove the belt Reassemble in reverse order Removing the Flexible Drive Shaft 1 Remove the rear and top cover Loosen the two Allen screws that attach the flexible drive shaft to the drive mechanism see above step 2 Remove the two Allen screws that attach the flexible drive shaft to the upper feed rollers 49 SECTION 5 DISASSEMBLY 3 Remove the drive shaft from the machine 4 Reassemble in reverse order Apply a s
17. Tum the feeder Power switch ON Adjust the Speed Control knob on the feeder control panel to the lowest speed setting all the way counterclockwise Then adjust the MIN SPD 3 to get 1 V DC Make sure that the rollers are not turning Adjust the Speed Control knob on the feeder control panel to the highest speed setting clockwise Then Adjust the MAX SPD pot 2 to get 100 V DC Turn the feeder OFF disconnect the meter and replace the control panel covert POWER MAXSPD MINSPD IRCOMP DECEL ACCEL 29 SECTION 4 ADJUSTMENTS XPS ProMail Base Base Drive Motor Belt Adjustment REQUIREMENT To adjust the proper tension on the main drive belt and encoder drive ADJUSTMENT 1 Disconnect the System from its power source 2 Remove the lower front cover from the Transporter Base Unit 3 Loosen the two Allen bolts 1 that attach the Encoder assembly to the frame of the Base 4 Loosen the four Allen bolts 2 that attach the Main Drive Motor its supports and push the motor in the direction of the arrow Hold the motor in position and tighten the four Allen bolts 2 NOTE The drive belt has to be tight with little flex when the adjustment is complete 5 Without pushing the encoder against the belt in either direction tighten the two Allen bolts 1 NOTE It is very important that the encoder drive and two idler pulleys are parallel to the belt and that they do not exert any pressure on
18. ansport Belt Adjustment esee eese eene nette enne trennen nette 37 INDEX Conveyor Speed Control Adjustment eese eerte nete eene enne teen teen enne nenne trennen ennt 38 XPS PROMAITE 0 4 0 PRINTER reet re ttr hne Estee evento lysis etes bte eee pee seti tea ree eu ues 39 Printer Power Supply Output Voltage Adjustment esee eene nennen ener 39 Printer Media Sensor Adjustment eese esee eee ne trennen innen nnne 40 Printer Speed Adjustmeni 3 oe ae d e REP Re EU te e EE Det 40 Printer Speed Adjustment uev p AERE PT pe EP Ru 41 Printer Base Auto Speed Adjustment esee esee eene nennen eene nrenneteet etre nr enee trennen nene 42 SECTION 5 DISASSEMBLY 5 ette tiae eia cea Mee Ere 43 XPS PROREED SHUTTLE FEEDER cesit 5 ee teo rt ihe etes teat is e ee Re e er et EUN e EE to e EX btebedsts ones 43 Control Panel Components T Hg Rd A eR 43 Replacing Separator and Shuttle Head 44 Replacing the Forwarding Feed Rollers sese ennemi 45 Replacing the Lower Feed Rollers e EAR AE 46 Removing Re r COVES rics ane ep eva eed me ON EO INR eee iie eee EAE 46 Removing Rear Media Guide entrent terne tenerent 46 Removing S
19. ct Features and then select 150DPI and High speed Click Apply and then OK Then click OK to start the printer Interface PC Board Set the Hi Speed pot R14 4 on the Interface PC Board to its middle position and adjust the MAX SPD 5 potentiometer on the Speed Control PC Board until the frequency reads 40KHz Then adjust R14 4 to obtain a frequency of 48 0 KHz 80 ips Feed one piece of media Restart the job above but set the speed at Medium High and adjust R11 3 to obtain a frequency of 36 0 KHz 60 ips Repeat Step 7 again but set the speed at Medium and adjust R7 2 to obtain a frequency of 27 0 KHz 45 ips Repeat Step 7 again but set the speed at Low and adjust R1 1 to obtain a frequency of 13 2 KHz 22 ips Then exit the CONTROL PANEL software and turn OFF the printer Apply lacquer such as nail polish to the nine potentiometers to prevent movement of the adjustments and replace the covers CURRENT LIMIT CURRENT LIMIT POWER C MAXSPD cpp IRCOMP DECEL ACCEL e e e e 6 7 8 910 Speed Control 41 SECTION 4 ADJUSTMENTS Printer Base Auto Speed Adjustment REQUIREMENT To provide the proper speed of the printer at each of the print quality settings ADJUSTMENT The Base must be in the AUTO mode for this adjustment 1 2 With the printer connected to the computer remove its rear panel Turn the printer ON Set the potentio
20. djustment NOTE The Drive Motor and the Encoder can be removed without removing the rollers and the drive belt Below is an exploded drawing of the Base transport assembly 56 SECTION 5 DISASSEMBLY Dryer Base Replacing Dryer Transport Belts 1 Unplug the Dryer from it power source 2 Unplug the Dryer control cable from the Main Base Unit 3 Remove the Covers from the dryer unit and the front cover from the base unit Disconnect the two cables from the dryer base to the main base 4 Remove the two Allen screws that attach the dryer base to the main base 5 Remove the eight screws that attach the Dryer to the Dryer Support Console and remove the dryer 6 Remove the six screws and the rear cover from the dryer unit 7 Remove the five screws that attach the Dryer Support Console to the Dryer Base 57 SECTION 5 DISASSEMBLY 8 Disconnect the motor and fan wires from the terminal bloc 9 Remove the four Allen screws that attach the Dryer top assembly to the Dryer base 10 Lift the Dryer top assembly turn it over and place it back on the base unit 58 SECTION 5 DISASSEMBLY The illustration below is an exploded view of the Dryer Transport assembly 11 To replace the Transport Belts loosen the two lock nuts and tension adjusting screws 1 one on each side 12 Remove the four screws 2 from the ends of the roller 13 Remove the six screws 3 from the motor side that attach
21. e printheads This build up will eventually degrade the print quality If you begin to notice problems with the quality of the print or to just prevent a build up from occurring with the printhead with a wet fiberless cloth such as Tex Wipes Cloth should be Cloth should not be v Soft X Abrasive v Fiberless X Made of small fibers v Moist with Water Distilled is best X Dry or containing chemical but tap works additives Wipe slowly across the long axis with the printhead facing down as shown Do not apply excessive force as this could scratch the nozzle area Purging the Nozzles If the printhead sits inactive for a period ink may dry in the nozzles Printing may not remove these ink plugs from the nozzles White streaks will then show up in the printed text or graphic In order to obtain better print quality these ink plugs need to be forced out or purged A Purge routine is built into the XPS ProMail 3 0 4 0 Printer It can be accessed from the LCD panel on the XPS ProMail 3 0 4 0 Printer If this does not solve the problem then proceed as follows 1 Wipe the printhead with a wet cloth as described in Cleaning the Printhead above 2 Perform the Purge routine from the XPS ProMail 3 0 4 0 Printer LCD Display panel 3 Wipe the printhead again with a moist cloth NOTE For more information refer to the Troubleshooting Print Heads in the Trouble Shooting Section SECTION 2 MAINTENANCE Jams under the XPS ProMail 3
22. e willing to accept those risks Do NOT leave the dryer unattended If a jam occurs under the dryer lamps a fire can result within a few seconds A fire extinguisher rated for energized electrical equipment and wood paper plastic cloth fires must be available and must be easily accessible at all times An inexperienced operator should NOT be allowed to use the dryer Severe personal injury and or property damage could result Keep hands hair and clothing clear of dryer dryer lamps dryer rollers belts and other moving parts Avoid touching moving parts or materials while the machine is in use Before clearing a jam be sure machine mechanisms come to a stop and dryer lamps are turned off Press the Emergency Stop button Allow the dryer lamps to cool down for at least 5 minutes lamps off blowers on before touching or cleaning the dryer or dryer lamps Always turn off the machine before making adjustments cleaning the machine or performing any maintenance covered in this manual The Dryer requires 240V and should be connected by a qualified electrician It must be properly grounded Failure to properly ground the dryer and dryer base can result in sever personal injury death and or fire The power cord and wall plug is the primary means of disconnecting the machine from the power supply DO NOT use an adapter plug on the line cord or wall outlet DO NOT route the power cord over sharp edges or trapped between furniture Avo
23. eans of disconnecting the machine from the power supply DO NOT use an adapter plug on the line cord or wall outlet DO NOT remove the ground pin from the line cord DO NOT route the power cord over sharp edges or trapped between furniture Avoid using wall outlets that are controlled by wall switches or shared with other equipment Make sure there is no strain on the power cord caused by jamming between the equipment walls or furniture SN SN S S S lt DO NOT remove covers Covers enclose hazardous parts that should only be accessed by a qualified service representative Report any damage of covers to your service representative lt This machine requires periodic maintenance Contact your authorized service representative for required service schedules Y To prevent overheating do not cover the vent openings Y Use this equipment only for its intended purpose In addition follow any specific occupational safety and health standards for your workplace or area WARNING THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS OF THE XPS ProMail SYSTEM This manual is intended solely for the use and information of Rena Systems Inc its designated agents customers and their employees The information in this guide was obtained from several different sources that are deemed reliable by all industry standards To the best of our knowledge that information is accurate in all respects However neither Rena Systems Inc nor any of
24. ed RENA ine printhead and printhead water Oaks PA 194561060 holder Clean interconnects Remove and reinsert the cartridge into the holder Insert a new Print Cartridge Extra lines losing data Database problem Check data in database program Improper output address Wrong interface settings Check software or data base information out of order Static electricity on PC miss feeding etc Close the software program Dirty media sensor the turn Printer of and on Clean media sensor Media jams Double feeding Adjust Sheet Separators on Media is curled or bent feeder Media is too thin Uncurl media Media must be at least 0 008 No communication Improper cabling connector Use Proper cable see Unit not receiving power Operator Manual Check plug connections on off switch and fuse on back panel see Operator Manual Not printing on media Media not positioned properly Adjust printhead vertically Adjust margin setting in layout software Print too light or missing Clogged or dirty printheads Purge or clean cartridges character dots Running out of ink Replace inkjet cartridges 24 CONDITION Blurry address PROBLEM Image is not sharp SECTION 3 TROUBLESHOOTING SOLUTION Printhead gap too high Adjust printhead closer to the media Split line of type RENA Systems Inc 136 Green Tree Road STE 140 Oaks PA 19456 1069 Line of type is placed
25. eder control panel to the highest speed setting clockwise Then Adjust the MAX SPD pot 2 to get 100 V DC Disconnect the meter and replace the control panel POWER MAXSPD MINSPD IRCOMP DECEL ACCEL SECTION 4 ADJUSTMENTS XPS ProMail 3 0 4 0 Printer Printer Power Supply Output Voltage Adjustment REQUIREMENT To provide proper output from power supply to machine ADJUSTMENT 1 Remove the rear cover and the right 3 Adjust R11 V1 ADJ potentiometer 3 hand front cover on the Power Supply module to obtain 14 2 Connect voltmeter probe to GOD 1 VDC 0 1 V and 15V 2 on the Interface PC 4 Turn the printer OFF apply lacquer such Board Turn the printer ON as nail polish to the potentiometer and replace the covers SPEED C1 EH xEFLDCce env r3 es CLUTCH D 014 ie RIE MET SPEED E re 2 9L gt SPEED 1 R14 2 gt 1 5 2 Iz 1 tu pw CONTROLLER Pree ret a Cam i Era ar Lt E J6 15 D0 IN Interface PC Board Power Supply 39 SECTION 4 ADJUSTMENTS Printer Media Sensor Adjustment REQUIREMENT To assure that the media sensor senses the media ADJUSTMENT 1 Remove the rear cover and connect 4 Remove the BLACK media from the voltmeter probe to GND 1 and TP4 2 sensor The voltage should read 3 5 on the Interface PC Board VDC minimu
26. es or printheads Use the 0 reference point in the center of the scale to help you align the print on the media Address prints upside down on media Layout and or stock direction incorrect Change direction from Normal to Inverted or Inverted to Normal in the Properties of the Driver Address too close to center of media Chosen media size in layout is too small The physical location of the printheads do not match the layout Set correct media width size in layout Check image on layout screen Adjust paper guide or printhead Feed ramp not set properly Adjust feed ramp Address printing partially Chosen media size in layout Set correct size from in off media is too large layout The physical location of the printheads do not match the layout Feed ramp not set properly Check image on layout screen Adjust paper guide or printhead Adjust feed ramp Print Content Incorrect CONDITION PROBLEM Information being printed Poor cable connections is wrong incomplete or garbage Interface problem Corrupted database file SECTION 3 TROUBLESHOOTING SOLUTION Check parallel cable is securely fastened at both ends Cable does not exceed 6 in length Check to be sure Printers internal parallel or USB cable is in good condition Check printer setup at computer Use another database file Barcode does not print Wrong font selected No zip code in database Barcode not
27. est Job to be Saved Waiting for job data and Test Print light will come on Printer is now ready for downloading 4 Send Print one record to the printer 5 Message will change to Test job s been Saved Saving xxxxxx size of file NOTE printing parameters such a head alignments feeder delay speed quality language and orientation will be stored in flash memory together with file Drive Speed Test Press the ENTER key to start the main drive motor and display the belt speed in inches per second Press the ENTER key to stop the main drive motor If the main drive motor does not start the main drive motor circuitry has a problem No reading in inches per second indicates an encoder problem Motor Test Press the ENTER key to start the main drive motor Press the ENTER key to stop the main drive motor The main drive motor not starting indicates a problem in the main drive motor circuitry Clutch Test Press the ENTER key to start the main drive motor and turn on the feed clutch Press the ENTER key to turn off the feed clutch If the clutch does not engage there is a problem with the clutch circuitry Sensor Test Press the ENTER key to display the state of the paper sensor Uncovered displays when the sensor is NOT covered Covered displays when the sensor IS covered Use a strip of paper inserted in the sensor area to test its function Failure to switch between the tow messages indicates a problem in the sensor circu
28. h the rear cover to the feeder One screw is found under the drive shaft cover 2 Reassemble in reverse order Removing Rear Media Guide 1 Remove the two locking knobs 1 one from each side of the Rear Guide The remove the eight screws 2 four from each side 2 Move the Rear Guide to the left and slide the four mounting blocks 3 that were attached to the rear guide with the screws 2 46 SECTION 5 DISASSEMBLY 3 Pull the Rear Guide toward the front of the feeder and lift it from the guide rail Then push it to the rear of the feeder so that it clears the rear guide rail and lift it from the machine 4 Reassemble in reverse order Removing Side Media Guides 1 Loosen the two knobs that hold the Side Media Guides in place on the machine Then remove the four screws 1 that attach the Side Media Guides to the mount Slide the guide toward the center of the machine and lift it off NOTE There is a flat spring attached to the Side Media Guide that is under the locking knob 2 Reassemble in reverse order Removing the Top Plate To gain access to the mechanism the top plate has to be removed Before this can be done the parts restricting the top plate s removal have to be removed from the feeder This includes all of the guides and covers above 1 Remove the two Allen head screws 1 that attach the rods for the rear media guide to the top plate 47 SECTION 5 DISASSEMBLY 2
29. haracters at 10 point size per address is PCL Version 600 X 600 DPI 50 000 addresses 300 X 600 DPI 100 000 addresses 200 X 600 DPI 150 000 addresses 150 X 600 DPI 200 000 addresses NOTE These figures can vary depending on the font selected The bulk ink cartridge will print approximately 10 times the number of address as a standard cartridge E acer the Inkjet Cartridge Remove the used cartridge from the cartridge holder by raising the latch lever to release the cartridge and then pull the cartridge up and out of the holder 2 Remove the new inkjet cartridge from its packaging taking care not to touch the copper contacts the metal plate or the gold printhead Remove the protective tape from the printhead 3 With the cartridge s printhead pointing down slide the cartridge into the holder and push down and toward the contacts in the holder 4 Make sure the cartridge is seated in the holder then close the lever to secure the cartridge in the holder Do not force the lever into place 5 Repeatthe above for the remaining cartridges NEVER SHAKE DROP OR HIT THE CARTRIDGE AGAINST THE PALM OF YOUR HAND OR ANY OTHER HARD SURFACE SHAKING THE PRINT CARTRIDGE DOES NOT MIX THE INK AND HITTING THE CARTRIDGE AGAINST A HARD SURFACE DOES NOT CLEAR THE NOZZLES BOTH OF THESE ACTIONS ACTUALLY HURT THE PRINT QUALITY BECAUSE THEY ALLOW BUBBLES TO FORM NEAR THE INK FIRING CHAMBERS THESE BUBBLES PREVENT THE NOZZLES FROM FIRING CAUSING WH
30. he one screw not shown and then remove the belt guide assembly 6 Loosen the two roller adjustment screws 7A and then remove the two screws 7 from the ends of the roller Remove the roller from the machine 7 Remove the two screws 8 and then remove the drive belt 9 from the motor and remove the drive roller 8 Remove the four screws 10 from the motor mounting plate and remove the motor 9 Remove the belts 11 10 The motor is fastened to the motor mounting plate with four screws and lock washers 12 Remove these to replace the motor 11 Reassemble in reverse order and adjust the belt tension 61 SECTION 5 DISASSEMBLY Printer Rear Cover Removal Remove the two screws 1 that attach the capping station to the printer s frame 2 Remove the four screws 2 that attach the rear cover to the printer and remove the cover NOTE If the Printer is a PCL model with a USB connector Unplug the USB cable from the Main PC Board when removing the cover 3 The following components are located under the rear cover 1 Main PC Board 2 Printhead Driver PC Boards 3 Power Supply 4 Interface PC Board 5 On Off Switch 6 Printer Fuse 62 4 The PC Boards are mounted to the chassis with screws Board and then remove the screws 5 Reassemble in reverse order Front Cover Removal 1 Remove the four screws 1 that attach the front cover to the printer 2 Disconnect
31. he sensor back to the sensor when no media is present As media passes under the sensor the reflection from the media tells the printer it is time to print The sensor and light source should be kept clean and free of dust The reflective strip should be kept clean of dust and dirt The sensor can be cleaned with a Q tip by gently dusting it The reflective strip can be cleaned with a mild soap solution on a damp cloth Should the reflective strip become scratched or worn it should be replaced as the system cannot function properly without it Cleaning the Dryer amp Dryer Lamps CAUTION Power the lamps off and allow them to cool for at least 5 minutes before touching the dryer Turn off the main power switch and or disconnect the dryer from the wall outlet before attempting to clean the dryer or dryer lamps Do not touch the dryer lamps with your bare hands even if they are cool Doing so will deposit oils on the lamps causing the lamps to overheat and be damaged The exterior of the dryer may be cleaned with any standard household cleaner which is non abrasive and does not contain plastic harming solvents After the lamps have cooled for at least 5 minutes use a soft dry cotton cloth and carefully wipe the lamps Do not use any liquids to clean the lamps 15 SECTION 2 MAINTENANCE Cleaning the XPS ProFeed Shuttle Media Sensor 1 The Shuttle Feeder Media Sensor is located below and between the lower Feed R
32. id using wall outlets that are shared with other equipment Make sure there is no strain on the power cord caused by jamming between the equipment walls or furniture DO NOT remove covers Covers enclose hazardous parts that should only be accessed by a qualified service representative Report any damage of covers to your service representative This machine requires periodic maintenance Contact your authorized service representative for required service schedules To prevent overheating do not cover the vent openings Use this equipment only for its intended purpose GENERAL SAFETY PRECAUTIONS CERTAIN SAFETY RULES MUST BE OBSERVED WHEN OPERATING THE XPS PROMAIL SYSTEM BEFORE USING OR SERVICING THE SYSTEM YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES SAFETY WARNINGS AND INSTRUCTIONS Y Keep hands hair and clothing clear of rollers and other moving parts Y Avoid touching moving parts or materials while the machine is in use Before clearing a jam be sure machine mechanisms come to a stop Y Always turn off the machine before making adjustments cleaning the machine or performing any maintenance covered in this manual Y Usethe power cord supplied with the machine and plug it into a properly grounded wall outlet located near the machine and easily accessible Failure to properly ground the machine can result in sever personal injury and or fire The power cord and wall plug is the primary m
33. ide Media Guides esses eee nennen nnne 47 Removing the Top Plate nns e dd ep a er idee met etu rea eee RE ARS 47 Removing the Drive Motor ani i e p ee RR sa ER eI Ye Qe ERES 49 Removing the Main Drive Belt esses ener entente tenete nne nene trennen 49 Removing the Vacuum Purpose tir d RERO ot en eed oy ek Dio ge A 50 Removing the Vacuum epe re Le eg spen da pete dede pee ees co Cep 50 Ly WB gd 51 Electrical Component Location Base Chassis top view esses eene enne 51 Replacing Transport and Motor Drive Belts esses enne nennen trennen enne 52 Removing Vacuum Transport Belts 53 Transport Belt Removal d ente OD ted ete Og teg ae 55 Removing and Replacing the Main Drive Belt sse ener 56 DRYER BASE c M 57 Replacing Dryer Transport Belts eese eee tne ee eane a ea ee ene iaeiaiai iatea 57 Replacing Motor nu a e e taie BS MERA aeaea Pg aa eea oet 59 Replacing Fans eg DEP rp RR ei rr npe PUTA UR debt OO pacis 59 CONVEYOR intonuit edm Dee LO n PAR er re gere e I erra 60 Replacing Conveyor Belts 2 uo pv I B e P e er Re UR P DL REPRE 60 PRINTER E E E E E S E EE SEE e 62 Rear Cover Rem
34. in Base Motor Speed Control 7 Dryer fuse 3A Slo Blo 15 Dryer Motor Speed control 8 Conveyor Motor Fuse 3A Slo Blo 16 Conveyor Motor Speed Control Electrical Components Base Switches view from rear 12 3456 78910 1112 1 Emergency Stop Switch 7 Dryer Auto Manual Switch 2 Main Power On Switch 8 Dryer Power On Switch 3 Transport Base Auto Manual Switch 9 Dryer Blower Switch 4 Transport Base Power On Switch 10 Dryer Manual Speed Control 5 Transport Base Vacuum On Switch 11 Conveyor Power On Switch 6 Transport Base Manual Speed Control 12 Conveyor Speed Control 51 SECTION 5 DISASSEMBLY Replacing Transport and Motor Drive Belts 52 l Remove the six screws 3 and Unplug system from power source 2 Remove the computer monitor keyboard and mouse from the monitor stand 3 4 Unlock the two Printer latches 1 on the front and Unplug and disconnect all of the wires from the printer rear of the printer Remove the two Allen bolts 2 that attach the Printer to the base unit and lift the printer from the Base and place it on a clean piece of cardboard or paper the rear cover from the monitor stand and then remove the three screws 4 that attach the monitor stand to the base and remove the monitor stand Next remove the four screws 5 and remove the base upper rear cover SECTION 5 DISASSEMBLY 7 Loosen the two control
35. ing on the types of media that are run paper dust may accumulate within the printer and on the transport Unplug the system from the power receptacle before removing the covers The internal areas are best cleaned with a vacuum that has a soft brush attachment to help loosen the dust particles Take care not to damage the PC Boards or electrical wiring The exterior of the machine may be cleaned with any standard household cleaner which is non abrasive and does not contain plastic harming solvents NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE XPS ProMail SYSTEM EXCESS LIQUID COULD HARM ELECTRONIC PARTS ALWAYS DAMPEN A RAG WITH THE CLEANER AND APPLY IT TO THE PARTS TO BE CLEANED Cleaning the Printer s Media Thickness Adjustment Mechanism At least on a yearly basis more often if the machine is operated in a dusty environment remove the covers and clean the PC Boards by blowing off the accumulated dust with air Clean the raise and lower mechanism lubricate the gears with white grease and lightly oil the bearings and shaft SECTION 2 MAINTENANCE Cleaning the Printer s Media Sensors Periodically check the media sensors A one is located on the printer and one is located just before the dryer The sensor is self contained in that the light source and the sensor are both in the assembly Directly below the sensor mounted on the base table is a reflective strip The reflective strip B reflects the light from t
36. itry Power Supply Test Press the ENTER key to display the voltage reading of the main power supply The nominal reading is between 13 5 and 14 5 volts The power supply may need adjusting to bring the value within the nominal range SECTION 1 SERVICE DIAGNOSTIC TESTS Encoder Test Press the ENTER key to display the current encoder count reading Move the exit roller If the number does not increase this indicates an encoder failure Keyboard Test Press the ENTER key to test the function of the individual keys on the keyboard When a key is pressed the display shows the key name To exit this test you must power the printer OFF Head Lift Test The head lift test is not applicable to this system as the head adjustment is mechanical Ink Levels The Ink Levels in each of the cartridges are displayed in this mode as a percentage This will only display properly if the operator resets the system when a new cartridge is installed SECTION 1 SERVICE DIAGNOSTIC TESTS Notes SECTION 2 MAINTENANCE SECTION 2 Maintenance This section discusses how to care for the inkjet cartridges clear paper jams and perform routine maintenance to the XPS ProMail System The Inkjet Cartridge The inkjet cartridges must be replaced when out of ink when print quality is poor or when purging and cleaning have not helped the image quality The Approximate life of the HP 516454 Inkjet cartridges based on three lines of 20 c
37. lip NOTE This adjustment should only be performed when changing the belts and is more easily accomplished before the Conveyor assembly s support legs are installed Adjustment 3 Loosen the two Allen screws 1 that 5 Tighten the two Allen screws 1 and attach the Conveyor roller to the frame then tighten the locking nuts 2 of the machine 6 Test run the Conveyor to make sure 4 Loosen the locking nuts 2 and adjust the belts track straight the adjusting screws 3 so that they exert an even pressure on both sides of the Conveyor roller EPA SECTION 4 ADJUSTMENTS Conveyor Speed Control Adjustment REQUIREMENT To adjust the maximum speed of the Conveyor ADJUSTMENT 1 2 38 Open the front panel of the Base unit Adjust the following potentiometers on the Speed Control PC Board as follows a CURRENT LIMIT 1 center of adjustment b IRCOMP 4 slightly clockwise from fully off c DECEL 5 and ACCEL 6 adjust to minimum setting counterclockwise Connect a DC volt meter between terminals A1 and A2 Release the Emergence Stop switch and press the power button to turn the system on Then turn the Conveyor Power switch ON 5 Adjust the Conveyor Speed Control knob to the lowest speed setting all the way counterclockwise Then adjust the MIN SPD 3 to get 1 V DC Make sure that the belts are not moving after completing this adjustment Adjust the Speed Control knob on the fe
38. m 2 Inserta BLACK media card over the 5 Apply lacquer such as nail polish to the sensor Turn the printer ON potentiometer to prevent movement of 3 Adjust R20 potentiometer 3 to read 0 5 the adjustment VDC maximum 6 Turn the printer OFF and replace the cover Interface PC Board 40 Printer Speed Adjustment SECTION 4 ADJUSTMENTS REQUIREMENT To provide the proper speed of the printer at each of the print quality settings ADJUSTMENT The Base must be in the AUTO mode for this adjustment l 2 With the printer connected to the computer remove the rear panel Turn the printer ON Set the potentiometers R1 1 R7 2 R11 3 and R14 4 on the Interface PC Board to their center or middle positions The CURRENT LIMIT 5 DECL 9 and ACCEL 10 potentiometers on the Speed Control PC Board are pre set at the factory and should not require adjustment There is an arrowhead on the adjustment slot of the potentiometers to indicate direction ft 5 9 10 The IRCOMP pot 8 is set at a different angle depending on the PC Board model If the motor does not maintain set speed as the load changes gradually adjust the IR COMP pot clockwise If the motor oscillates the IR COMP pot may be set too high Turn it counterclockwise to stabilize the drive Hook up a frequency meter to GND and SIG Encoder test point on Main Processor PCB Open a job and click on File then Print In the Properties window sele
39. mall amount of Locktite 247 Threadlocker to the Allen screws when reassembling Removing the Vacuum Pump The Vacuum Pump is attached to the base of the Feeder Disconnect the Power Cord and the Vacuum Hose Then remove the four Allen screws two shown that attach it to the base of the machine THE VACUUM PUMP ASSEMBLY IS VERY HEAVY USE PROPER LIFTING PROCEDURES WHEN REMOVING IT FROM THE MACHINE Removing the Vacuum Valve The Vacuum Valve is located below the feeder frame To access it you can remove the front cover of the machine and open the control panel 1 Remove the two hose clamps and hoses attached to the valve assembly 2 Remove the two Allen screws that attach the valve to the frame 3 Reassemble in reverse order 50 SECTION 5 DISASSEMBLY Base Unit Electrical Component Location Base Chassis top view Loosen the two control panel locking knobs located under the control panel on both side of the base unit and pull the front pane toward you Allow it to hang open 12 13 14 15 16 1 Transformer 24VA C Dryer and 9 Noise Filter Main Base Speed Emergency Stop Circuit Control 2 Main Power Relay 24VAC 10 Noise Filter Dryer Speed Control 3 Vacuum Pump Relay 115VAC Noise Filter Conveyor Speed Control 4 Emergency Stop Control Relay 12 Dryer On Off Timer 5 Safety Circuit Control Relay 13 Conveyor Relay 6 Motor and Pump Fuse 5A Slo Blo 14 Ma
40. meters R1 1 R7 2 and R14 3 on the Interface PC Board to their center or middle positions The CURRENT LIMIT 4 DECL 8 and ACCEL 9 potentiometers on the Speed Control PC Board are pre set at the factory and should not require adjustment There is an arrowhead on the adjustment slot of the potentiometers to indicate direction ft 4 amp 9 The IRCOMP pot 7 is set at a different angle depending on the PC Board model If the motor does not maintain set speed as the load changes gradually adjust the IR COMP pot clockwise If the motor oscillates the IR COMP pot may be set too high Turn it counterclockwise to stabilize the drive 1 2N A 3 INTERFACE PC BOARD 5 6 10 Download a job and start the printer in the DRAFT mode Then adjust R14 3 on the Power PC Board to obtain a speed of 80 IPS Then click on STOP Click on Standard resolution and adjust R7 2 to obtain a speed of 45 IPS Click on STOP and then click on High resolution then click GO Observe the speed in IPS Adjust R1 1 to obtain 22 IPS Click on STOP Exit the CONTROL PANEL software and turn OFF the printer Apply lacquer such as nail polish to the nine potentiometers to prevent movement of the adjustments and replace the cover NOTE R11 is not adjusted on the Interface PC Board for the Printer when using AstroJet Professional Software SPEED CONTROL 42 SECTION 5 DISASSEMBLY SE
41. ollers 2 Use a Q tip or photographic brush to remove any lint or paper particles DO NOT USE SOLVENTS OR ABRASIVES TO CLEAN THE SENSORS Vacuum Pump Service The Vacuum Shuttle Feeder is equipped with an Oilless Vacuum Pump It does not require lubrication however it does require cleaning 1 Remove the two Filter Assemblies in the front of the pump and brush the filters with a stiff brush regularly SECTION 2 MAINTENANCE 2 The vacuum shuttle feeder is also equipped with a filter in the Vacuum Shuttle line The jar should be removed and both it and the filter should be cleaned regularly THE VACUUM PUMP IN THE SHUTTLE FEEDER IS AN OILLESS PUMP DO NOT ATTEMPT TO PUT OIL OF ANY KIND IN THE PUMP SECTION 2 MAINTENANCE Notes SECTION 3 TROUBLESHOOTING SECTION 3 Troubleshooting This section is arranged by first the condition that might occur and then by possible problems their cause and recommended solutions THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS OF THE XPS ProMail SYSTEM Power Problems CONDITION PROBLEM SOLUTION Power is on nothing No power to Check that the power cord is plugged in happens printer or base Check that the power outlet is live Check the fuses on the power supply PC Board Requires disassembly Bad controller PC Board Bad power supply Interface Communication Problems CONDITION PROBLEM SOLUTIO
42. oval Nea e a ute adis tesi Pa ai 62 Front Cover Removal serae M Hae D EE E ERREUR eee Epp Ua ro Ro ded Seer pedea 63 APPENDIX A SPEGCIFICATIONS rtr tiet ertet toe tee eh eppure ies Eee 64 XPS PROMAIL SYSTEM cic s eoi n iro Or RE ERR ER ERE C ARI Be SE I RO P NEVER OR GP oen 64 XPS PROFEED SHUTTLE FEEDER Ae ene rt e EN oh ax eee toin 64 XPS PROMAIL 3 0 4 0 PRINTER Suck Stes de sedate Foie de tuo ie e n iEn 65 APPENDIX B SUPPLIES retient etre ten ott ede potero RE S E 66 SUPPLIES EX 66 DRYER SAFETY PRECAUTIONS THE FOLLOWING MUST BE READ AND UNDERSTOOD BEFORE OPERATING THE DRYER DUE TO THE NATURE OF THE DRYER IT PRESENTS UNIQUE HAZARDS AND RISKS THAT MUST BE UNDERSTOOD AND OBSERVED DUE TO THESE HAZARDS THE OPERATION AND USE OF THE DRYER REQUIRES SPECIAL ATTENTION THE DRYER PRESENTS THE FOLLOWING HAZARDS FIRE HAZARD f media is left under the dryer lamps for more than a few seconds it will ignite SEVERE PERSONAL INJURY or DEATH HAZARD If you touch the hot surface of the dryer or dryer base a serious burn will result Shock hazards are present when not properly used connected The XPS ProDry must be used correctly to prevent injury death and or property damage CX S X lt lt Do NOT use the dryer unless you fully understand the risks associated with the dryer and you ar
43. panel locking knobs located under the control panel on both side of the base unit and pull the front pane toward you Allow it to hang open 8 Loosen the knobs that attach the media guides to the bar and then remove the Allen cap screw 7 on the rear side of the assembly and remove the rod from the front of the assembly 9 Remove the six Allen screws 8 that attach the two cover panel to the base and remove the panels Removing Vacuum Transport Belts 10 Remove the Allen screw 9 from the center guide plate Lift the plate from the machine The plate is held in place with two pins on the opposite side 53 SECTION 5 DISASSEMBLY 11 On the operator side of the base unit remove the two screws 10 that attach the plate to the vacuum chamber and then remove the two screws 11 and the plate This will give access to removing the belts once the rollers are release from their bearings 12 The two end rollers are held in place by a lock nut 12 on each end of the roller shaft and an Allen screw 13 that applies tension to the roller shaft to align the belts Loosen the two lock nuts 12 then remove the two Allen screws 13 to remove the end rollers The end rollers can then be moved to the large hole and slid to the rear of the machine 13 Loosen the four drive motor mounting screws 14 to relieve tension on the main drive belt 14 Remove the four Allen screws 15 two each side that secure the
44. setsacsucensecsieessecssceniassnsestecsucestecsnssnsecsucentasstes 27 XPS PROFEED SHUTICE FEEDER nn eite on ett ete eee Rs 27 XPS PROFEED Drive Belt Adjustment eese eerte nete ener enne nren nennen etre nr enen trennen enne 27 XPS PROFEED Top Feed Roller Parallel Adjustment eese eere 28 XPS PROFEED SPEED CONTROL ADJUSTMENT eese trennen teee trennen nenne enne nnne nen ens 29 XPS PROMAIL BASE enne ette eC Ee b ER D n p ER EG Er be ERR ee Rr er eta Rien 29 XPS PROMAIL BASE netten tit e iret beg e t E GE E be E RECO e tpe re Rer ee Rte rena 30 Base Drive Motor Belt Adjustment eese eene eene nennen eene nenne trennt tne nennen nennen inneren nns 30 Base Input Belt Adjustment esee ener teinte tnter enee trennt test ethernet innen ennt 3l Base Vacuum Belt Adjustment eese eene nnen eene trennt teenet testen trennen enne tenete 32 Base Unit Speed Control Adjustment 33 DRYER BASE contes em ete mera e tera e eee tee edidere ete pres 34 Dryer Base Transport Belt Adjustment eese eerte enne enne eene trennen enne nnen nene 34 Dryer Base Speed Control Adjustment eese ener trene teen tnee teen nr enne tenn nnne 35 TB 659 CONVEYOR ponet iare ede am n Abode AMA dies ea eal aid toon ese 36 Conveyor Drive Belt Adjustment eee esses enne 36 Conveyor Tr
45. side guides slightly Dirty feed rollers Clean the feed roller with distilled water and a cloth DO NOT use any solvents or detergents as they may damage the feed rollers Paper stuck together Fan media before placing it in printer Bad or dirty sensor Clean sensor with compressed air or replace it Uneven mail piece Tap inserts to front of envelopes and retry Multiple feeds Separator gap not set Adjust separators to thickness of properly media Sensor bad or dirty Clean sensor with compressed air or replace it Media stuck together Fan media before feeding Multiple feeds Side guides too close to Push side guides away from media continued media Adjust brake see Section 4 Brake misadjusted Adjustments 20 CONDITION Failure to feed Jams PROBLEM Side guides too close to media ENTER key not pressed No power to printer Feed gap too tight Feed gap too loose Material is out of specification Motor on feed rollers not turning Clutch not engaging Motor failure No power Printhead adjustment too low Paper path obstruction Paper not loaded properly Feed ramp not used properly Separators improperly adjusted Media curled or bent Bad or Dirty Sensor SECTION 3 TROUBLESHOOTING SOLUTION Readjust side guides Check the power button is ON and that the power cord is plugged in Adjust separator to thickness of media Adjust separator to thickness of media Maximum thickness is 1 4
46. ten ene 13 Removing Jammed Media E nnne tenete teen enne neret tenente treten etre trennen 13 CLEANING 4 nini Arie ER URN D AE de e d ER EE RR PEE DINI E baee Qo dete etes eu ette 14 Cleaning the Printer s Media Thickness Adjustment Mechanism eene 14 Cleaning the Printer s Media Sensors esses esee renn trennen entren 15 Cleaning the Dryer amp Dryer Lamps CAUTION esses enne ener 15 Cleaning the XPS ProFeed Shuttle Media Sensor sss 16 Vacuum Pump Service de ee Ea bereiten A ect et IR tibus 16 SECTION TROUBLESHOOTING eere eee ee esee esent tatnen 19 POWER PROBLEMS 5 x Gate ar DEC een meme debaee m eh ee 19 INTERFACE COMMUNICATION PROBLEMS en einn enne tenete nete ne trennen trennen 19 LED DISPLAY PROBLEMS eee elus tes obe ies 20 FEEDING PROBLEMS iranian e been mete db ao ele ee eb ee HIE 20 PRINT PLACEMENT PROBLEMS cien a bene tek AUR ae iustos t ode eco pete 22 PRINT CONTENT INCORRECT 3 5 ente iet bee ima eed aee ea ee eb be ea 23 SOFTWARE PROBLEMS eee ebniecieaiqe i obeeeno Dee 23 PRINT QUALITY PROBEEMS 2 rhe tte ee itr hr des aeo ies s diee Ravens oe PR ERR onde 24 SECTION 4 ADJUSTMENTS iasssscciscssesssscsssssiscsecessacsucessicsasvasecsacsaiacsi
47. the belt in either direction for proper operation 30 SECTION 4 ADJUSTMENTS Base Input Belt Adjustment Requirement The Input Transport Belts on the Base Unit must track properly NOTE This adjustment should only be performed when changing the belts and should be accomplished before the machine is reassembled Adjustment 1 The non driven roller has two Allen 3 If the tracking is off the belts climb in adjusting screws 1 one on each the guides loosen the locking nuts 2 side that are screw into the roller and readjust the side opposite of the shafts Loosen the two locking nuts problem 2 and adjust the screws 1 so that 4 Retighten the nuts and retest the belts can be raised approximately V2 from the table at their centers 2 Tighten the lock nuts 2 and run the base unit at low speed to check the tracking of the belts in the belt guides 31 SECTION 4 ADJUSTMENTS Base Vacuum Belt Adjustment Requirement The Vacuum Transport Belts on the Base Unit must track properly NOTE This adjustment should only be performed when changing the belts and should be accomplished before the machine is reassembled Adjustment 1 The non driven roller has two Allen 3 Ifthe tracking is off the belts track to adjusting screws 1 one on each the left or right loosen the locking side that are screw into the roller nuts 2 and readjust the side opposite shafts Loosen the two locking nuts of the problem 2
48. the cable 2 to the display panel and remove the cover from the machine SECTION 5 DISASSEMBLY Unplug the wires at the PC 63 APPENDIX Appendix A Specifications XPS ProMail System DIMENSIONS WEIGHTS ELECTRICAL XPS ProMail Base 43 W x 35 Dx 51 H base only XPS ProDry Base 28 W x 28 Dx 48 H with dryer installed TB 659 Conveyor 82 W x 26 Dx 35 XPS ProFeed Shuttle Base 80 165 XPS ProMail Base 108 165 XPS ProDry Base 110 lbs TB 659 Conveyor 110 lbs XPS ProMail Base 250VAC 20A single phase 4 wire XPS ProFeed Shuttle 120V AC Connects to 120V switchable outlet inside XPS ProMail Base XPS ProDry Base Powered by XPS ProMail Base 8000W Dryer 240V 50 single phase 3 wire TB 659 Conveyor Powered by XPS ProMail Base XPS ProFeed Shuttle Feeder MATERIAL HANDLING THICKNESS TYPE SPEED ELECTRICAL DIMENSIONS SHIPPING WEIGHT 64 Minimum Size 5 127 mm L x 3 76 2 mm W Maximum Size 17 431 8 mm L x 14 355 6 mm W Single Sheet to 3 8 Open ended Z folded flyers Envelopes Small Booklets Card Stock 0 to 30 000 pieces per hour 120 VAC 50 60 Hz 220 VAC also available 20 Wx28 Dx48 H 150 Ibs APPENDIX XPS ProMail 3 0 4 0 Printer PRINT TECHNOLOGY PRINT QUALITY Dots Per Inch IMAGE AREA PRINT ORIENTATION FONTS PRINTS MATERIAL SIZE MATERIAL THICKNESS PRINT COLORS INK PC INTERFACE COUNTERS DIMENSIONS WEI
49. there is approximately 4 machine play in the belt 27 SECTION 4 ADJUSTMENTS XPS PROFEED Top Feed Roller Parallel Adjustment REQUIREMENT The top feed rollers must be parallel to the lower feed rollers ADJUSTMENT Rotate the rollers until the lower 3 Loosen the Hex Screw E and lever forwarding roller is in it upper most F until the drag on both sides is position Unlock the upper even forwarding roller by releasing the 4 Then tighten the Hex Screw E locking lever A 5 Lock locking lever A and test 2 Place 2 strips of 20 lb paper under again the upper forwarding rollers Then lower the rollers using the Media Thickness knob C until one of the strips has a slight drag in it 28 XPS ProFeed Speed Control Adjustment SECTION 4 ADJUSTMENTS REQUIREMENT To adjust the maximum speed of the feeder ADJUSTMENT 1 2 Turn off the feeder open the control panel cover Adjust the following potentiometers on the Speed Control PC Board as follows a CURRENT LIMIT 1 center of adjustment b IRCOMP 4 slightly clockwise from fully off c DECEL 5 and ACCEL 6 adjust to minimum setting counterclockwise Connect a DC volt meter between terminals A1 and A2 Plug the feeder into the power outlet release the Emergency Stop button and press the Power button NOTE The feeder must have the stop switch jumper in place or be connected to the system for it to operate
50. vacuum transport drive roller to the shaft Then remove the Allen screw 16 from the operator s side of the shaft and push the roller shaft toward the rear of the base 54 SECTION 5 DISASSEMBLY 15 The vacuum transport belts can then be removed one at a time from the operator s side of the base 16 Reassemble in reverse order and adjust the tension on the belts Transport Belt Removal 17 Follow steps 1 through 13 above Then remove the four screws 17 that attach the transporter plate to the frame and remove the transporter plate from under the belts by sliding it toward the rear of the machine 18 Remove the two screws 18 from each of the lower pins on each of the belt guides 19 Remove the two Allen screws 19 one each side that attach the belt guide to the frame and remove the belt guide 55 SECTION 5 DISASSEMBLY 20 Slide the belts off the rollers from the operator s side of the base 2 Replace the belts and reassemble in reverse order Removing and Replacing the Main Drive Belt 1 Begin by performing steps 1 through 14 above and then loosen the main motor mounting screws to release tension on the drive belt 2 Remove the Encoder Assembly by unplugging the encoder and removing the two mounting screws 3 With the two center roller shafts removed the belt can be slipped off the roller gears and removed from the assembly 4 Replace in reverse order Adjust the encoder tension a
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