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APAS - 72 - MAILERDOG

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9. RUN DATA FROM THE PREVIOUS JOB APAS 72 092011 APAS720perator ServiceManualREVO m Le Pitney Bowes Direct Mail Solutions 10 RESET PIECE COUNT KCOHFIEH PIESE COLIN Pressing YES will reset the piece count 11 ANALOG OUTPUT SCREEN LUE OUTPUT GLUE Gall DESCRIPTION FUNCTION MAIN SCREEN BRINGS YOU BACK TO THE MAIN SCREEN ANALOG OUTPUT GAIN NUMERICAL DISPLAY OF GLUE GAIN PREVIOUS SCREEN GOES BACK TO THE PREVIOUS SCREEN GLUE GAIN UP DOWN INCREASES OR DECREASES THE PRESSURE OF THE GLUE BUTTONS APAS 72 092011 APAS720perator ServiceManualREVO Pitney Bowes Direct Mail olutions 12 JOB REPORT DATA 0000000253 46 5D 7350 MI 45 00 00 ror DATE 01 28 2000 NULL OPER STOPS 000000 ERTS Para BERT MISS DIVERTS 00 2 00 200 UD 00 z 80 0104 BERYO 1 CON ER CUT GATE SLOW SHOWS THE DATA FOR THE CURRENT JOB RUN 13 LANGUAGE SCREEN APAS 72 092011 APAS72Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions 14 TROUBLESHOOT POS ET D 000 20252144 OPERAT POINTER H CLUTCH OFF Meere e FORM ADDAESE 152 872193 01991335192 1031976205 51141 585 1 0211552856 00000099155 00000000000 1000000006 00000000000 LOOK AHEAD BODREES 00000004956 00042559353 0
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16. Le Pitney Bowes Direct Mail Solutions APAS 72 Advanced Product Attaching System Operator amp Service Manual Eis Pitney Bowes 12050 49th STREET NORTH CLEARWATER FL 33702 4301 PHONE 727 571 3330 FAX 727 571 3443 TOLL FREE 1 5 O Copyright Pitney Bowes Inc 2011 All rights reserved APAS 72 092011 APAS720perator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions VERSION HISTORY The table below summarizes the history of this document as it is published onto the company website s lt identifies the version date of issue and revisions and changes VERSION DATE CHANGES APAS Operator Service Manual 9 20 11 REVISION CONVENTIONS DOCUMENT VERSION name of document with revision level of entire document level designates minor changes that do not require revision change DATE date of issue for copying and publication of document CHANGES details of document revision level APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Table of Contents Section I BL ja 10 EEE EE EE Page 3 APAS Intsallation SN Page 4 Floor Plan and Machine Requirements Page 6 20171 64111510 uu 7 Positioning the Components
17. AIG 2 3 1118 1391 942 Gg oozegL gt 25 pa id S Mo Do DO ZLQ ie 58 Ze gd VESLE NOLLNG 4015 522 1871 RES 6 95 gt gt 60022 ESL 559 235 lt V ac VES Y ISN HOON3A 40 02086 NOLLNE DOF 522 TTIB IHM 90097 ESL 59 55 59 404 LON 241 h 5 m w 2 m LSL EL086 178 13534 942 NIG LHM 3 99 91 5 m Lyga 920 90096 gl O 5 2 2 E 952591 2 w S31J3S ui saipuld M rw A OEZ NI NMOHS SuadWNr N ers NOLLdO YOGNAA OL 224 gt a 2 JSN YOONIA 404 LON 031 dOLS LYVLS 701 1209 MOLVM3dO OL ISN HOONIA LON 20 9 086 160 91086 6X 720 9 086 Af 60 91096 D Sif D 942 N18 LHM gO 922 n18 1HM me EEL E1086 NVIHLSNMOO LHL DOr dOLS LUVLS 3SV8 OL 35 8 JSN NOS LON 922 MIG LHM 60072681 8 022 8 60097 81 gt 3 3 9 x z Z 3 m m EX 120 9086 26 EX 3d uM 2 10 91086 0280 58 KS x 5 KF 520 N bo lt o N 2o AU NOD ST x x 2 i nr sy 288 8 88 NA 88 39 5 81018 522 NIS IHM x OO g 385 9 ISN SS oo aN O wa G 5 2 x 027 18 1 90090681 b SS lt EEE
18. 8 Electrical Setup Connections 9 Leveling the APAS Base Page 11 Section II Safety Features and Warning Page 12 Safety Locks and Warning Stickers Page 13 Safety Recommendations Page 14 Special Advisement h s 3 Page 15 Machine Lock Out Procedure 42 2 2 1 1 2 Page 16 Suggested Lock Out Devices Page 17 Section 111 General Set Up A Aser Page 19 APAS SAN M 4 20 e Paper Sensor Adjustment Page 20 Card Feeder Setup e M Qe Page 24 e Card Sensor Adjustment Page 27 Control Panel and Switch Operation Page 28 Operating the Attacher Page 4
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22. s o 5 A009 OIA LHM OMVZZ 3HIM 13A NMO A009 OMVEL Z6L 0L096 41144 5 15 V HONOHHL denso DNI DNIAVIT 53 NOILVJO 40 1 J9NNO Gad ig 48 A009 Q3M LHM OMVZZ 3MIM DOMVYZLH 220 01086 TIVHS 544 G9LVNDIS9IG 44 NO 7 LNSNOdWOD NO 0434 TIVAS SLNANOdWOD St X 406 188 I SHO 6C08LMV A009 IMVSL 0 096 A IILVUWIXOYHddV 240 99 TIVHS T 300 20 02086 A009 9 9 ZEL OLO86 SLNSANOdWOD SYHYOLIANNOD 11 GALVNOISSC AYSHM 2 1 lt 18 9L E SJA331S ONISNL MNIMHS LV3H 3n18 1HM A009 OMYVSL 802 0 086 GODE 96 OL 95 JAOYV GE y a 118 79 2 54343315 ONIGNL MNIHHS LVSH 0118 A009 OMVZZ 70L 0L096 2 LHM 6 WW G 7 HIMYVN 3018 1HM A009 OMVZZ 602 0 086 998 101 03450945 SSIMYSHLO SSSINN LHM WW 9 1141 18 1 A009 OMVZZH 80L 0L096 SALON ONVZNVWH 04 Wall G3GGV ONY S OL SNOILIENNOD AO 20 LHM WW ZXOL TSA NYD A009 DMVYLH CCO0 0L096 101 MULES ZL WS 50 31 024 139905 7 1350 22 00086 ON AINO ST PU ar M OL L GSM INI AVMO 7 4180 LZ0 SLO86 LL 9C 70 OOELEON SYSdWN LL AOEZ Q39NVH2 AZVEGL LY ILVNINHIL 6281 WOMJ DNINOD 3MIM 3AOW GYVISIG MV 9L 3MIM MOLIS 3dAL 9 M 22 4402 56 8 75Z 0L096 azr eai ONY 86281 WOYNS IMM HIANNF 3AOW3M OL 70 0
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25. 72 092011 APAS72Operator ServiceManualREV0 i Pitney Bowes Direct Mail Solutions Fig G7 e Press the Feeder Glue and Vacum buttons to turn the card feeder glue and vacuum on fig G7 e The background will turn red and will stay red until a card is staged e Press the ONE SHOT button to stage a card The background will turn blue once the card has been staged fig G8 Fig G8 APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions On the vacuum base turn on the VACUUM POWER Set the speed of the base belt by turning the BASE speed pot Set the gap between pieces by turning the GAP speed pot Press the green START button to turn on the base Press the FEEDER button to start feeding forms onto the base from the input feeder e Once the form passes the sensor on the vacuum base glue will be applied to the form and the card will feed onto the form APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes Direct Mail Solutions Section IV General Service APAS 72 sile p em Pitney Bowes 12050 49th STREET NORTH CLEARWATER FL 33762 4301 PHONE 727 571 3330 FAX 727 571 3443 TOLL FREE 1 800 1NSERTER APAS 72 092011 APAS720perator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions Section IV APAS Base Maintenance The general maintenance of the APAS base is limit
26. 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions 6 Set the height of the Material Separator to allow the thickness of one 1 piece of material to pass under it To do this turn the adjustment knob clock wise to raise the separator counter clock wise to lower the separator see figure 111 7 Note There should be a little resistance felt by hand when the material is directly under the material separator when this is properly set Helpful Tip The thinner the material is the more critical this setting is Figure 7 Material Separator Knob turn counter clock wise to lower clock wise to raise 7 Fill the feeder with material The feeders are designed to hold stack of material up to eighteen 18 inches in height or fifteen 15 pounds in weight depending on the characteristics of the material 8 Test the set up by pressing the blue Start button located at the left end of the control panel to activate the feeder Then press the yellow Jog button found on the control panel to advance one piece at a time Check the pieces as they feed to ensure proper separation has taken place See figures 11 11 amp 13 for details APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Paper Sensor Adjustment Card Feeder The paper sensor is located inside the feeder beneath the elevator belt This sensor is set to
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32. card feeder and is designed to run off line or in line with most feeders inserters inkjets and conveyors APAS 72 SETUP 1 Place a piece of the material that is to be run under the glue applicator onto the vacuum transport belt just beneath the nip rollers upstream of the glue applicator Adjust guide rollers per the following See figure 111 1 a Loosen thumbscrews on each guide roller bracket to locate rollers across the conveyor b Loosen thumbscrew on both side mounting brackets to move guide rollers back and forth along conveyor to adjust guide rollers so material piece hits rollers and vacuum belt at same time amp Guide roller Guide nip rollers w Figure 111 1 Optimum entry point of material Vacuum contacts vacuum belt and bottom of roller simultaneously Paper Sensor Adjustment Main Conveyor APAS The paper sensors are located at the In Feed end of the APAS base above the vacuum belt and upstream of and on the centerline of the glue nozzle and material feeder card These sensors are set to detect and confirm the presence of paper before passing under the glue applicator tip and material feeder These sensors do not normally need to be adjusted for each job once the setting has been made it should remain set unless otherwise disrupted In the event the settings have been disrupted perform the following APAS 72 092011 APAS720perator ServiceManualREVO m i
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34. ANALOG OUTPUT SELECTS THE ANALOG OUTPUT SCREEN MENU SCREEN APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions 6 ALARM HISTORY OG CURED TIME MESSAGE DETA EN FUR QK SERVO FAL M 1728 70 ATTACHER GUARD 007 JPEN 00144513 GE CARD BEFOR 11 APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions 7T FACTORY SETTINGS HEV META 11112010 uf OUT OF SF D HET 5 FEELFE DAN TAMCE 39 37 w T raum fi I I 1 MER MARE a tr DO 0 vek BELT ThE Out sec TAGMA 105850 0 79 a DESCRIPTION FUNCTION PLC REV CURRENT SOFTWARE VERSION SELECT STANDARD OR SELECTS BETWEEN INCHES OR METRIC METRIC GOT REV TOUCH SCREEN SOFTWARE VERSION STAND ALONE 1 DISTANCE INCREASES DISTANCE THE CARD FEEDER WITHOUT PRODUCT APAS 72 092011 APAS720perator ServiceManualREVO Pitney Bowes E Direct Mail Solutions 8 SCREEN FEFDFR FAULT Y iim THIS SCREEN ENABLES TESTING OF THE INPUTS AND OUTPUTS 9 PREVIOUS JOB REPORT REPORT DATA RUM TME 00 00 00 TME 0 00 JOB OEE 0104 PIECE COUNT 000179 ESTOPS SERVO FLTS FAULT STOPS 000000 COVER OPEN nin PER 1 CARDS DIVERTS GATE Yan Es 14 a ku
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40. Pitney Bowes Direct Mail Solutions 1 Position the sensor directly above the vacuum belt by turning the thumbscrew in the sensor mounting block in counter clock wise direction and sliding the sensor assembly across the sensor support bar Once the desired position is acquired tighten the thumbscrew in the sensor mounting block in counter clock wise direction 2 Place a blank piece of white paper on the vacuum belt directly under the paper sensor 3 Using small flat blade screwdriver remove the pan head screw in the plastic cover located on the sensor next to the electronic cable connection see figure 111 1 Note Depending on the APAS model this sensor may have detachable screw type cable connection or may have hard wire cable connection The sensitivity adjustments for both models are identical 4 Setthe Light Dark pot setting using a small flat blade screw driver slowly and very carefully turn the pot setting located next to the electronic cable connection in a counter clock wise direction until full range of motion is felt see figure 11 2 or 3 Note If this adjustment is performed correctly the screw driver slot in the pot setting should be pointing towards the DO in the range scale next to the pot setting Warning The stop point of this pot setting can be damaged if excessive force is applied 5 Setthe Gain pot setting by performing the following a Using a small flat blade screw dr
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42. clean off the machine beginning with the top surfaces then work your way down A Warning Be sure to keep the direction of compressed air blowing away from you Note High volume businesses running three 3 shifts five 5 days a week should plan this function once a week Businesses producing light to moderate volume should plan this function once month 5 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Cleaning Friction Belts Vacuum Belts and Conveyor Belts 1 Acquire and use eye protection safety goggles or safety glasses with side guards 2 Turn off the machine and disconnect the power lines 3 Clean the following material belts v Red Gum Friction Belts of the material Feeder v Vacuum Transport Belts of the APAS Base v Transport Belt of the Discharge Conveyor Apply a liberal amount of Simple Green general purpose cleaner or Isopropyl Alcohol 70 by volume see warning below to a soft cloth and wipe down the belt you wish to clean Advance the belt being cleaned by hand until the entire belt surface has been cleaned AN Warning Do not spray or pour Simple Green general purpose cleaner or Isopropyl Alcohol directly onto the belts free flowing liquids may seep into some electronic components and cause damage Note Simple Green general purpose cleaner and or Isopropyl Alcohol can be purchased at most local grocery stores and drug stores A
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44. sure to keep all washers in order fig CF 9 Fig CF 9 E clips washers lock collar Block APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions e With the block removed the and associated rollers along with the red belt can be replaced fig CF 10 Fig CF 10 APAS 72 092011 APAS720perator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions e Remove 4 screws from non operator side of tram bar to remove separator assembly for servicing fig CF11 amp 12 Fig CF 11 Fig CF 12 Replace all components in reverse order APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Section V Electrical Components APAS 72 Ditra Pitney Bowes 12050 49th STREET NORTH CLEARWATER FL 33762 4301 PHONE 727 571 3630 FAX 727 571 3443 TOLL FREE 1 800 1NSERTER APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions CARD FEEDER ELECTRICAL BOX MODULE SERVO 1 SERVO 2 EXTENSION RACK OUTPUT MODULE CPU LINE FILTER POWER SUPPLY CIRCUIT BREAKERS E FUSES z 5 TRANSFORMER a LINE FILTER TB2 1 1 5 LE T y K i 1 ar d M SAFETY 8 COVER POWER SUPPLY RELAYS APAS 72 092011 APAS720perator ServiceManualREVO Pitney Bow
45. 00000555 00000059508 895653597 1155844889 018335 16068 10183537 108 FORM RING BUFFER 00000000800 00000000000 00000000000 00000080080 TUPU DENTE PO0O0000000 00000000000 00000000000 11111111 00000000000 00000000000 USED WITH THE FACTORY FOR TROUBLESHOOTING 15 ERROR DISPLAY BI When the APAS goes into a fault the background will turn red APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes Direct Mail Solutions Operating the APAS Power 16 Turn power to the machine on by flipping the white power switch located on the electrical enclosure on the exit side of the APAS in an upward direction See figure 11 14 Main Power ON OFF Switch Flip switch Down to turn OFF Warning Drive Motors are Enabled when this switch is in the UP position Flip switch UP to turn ON Figure 11 14 e INITIAL DISPLAY AGED Tide GUT ARE DOOR OPEN The initial display of the APAS will show a red screen Press the reset button on the APAS base to clear the red screen APAS 72 092011 APAS72Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions e GLUE SYSTEM POWER UP o Turn the power to the glue system o Allow up to one hour for glue to heat to proper temperature 350 degrees Main Power Fig G2 Fig G1 o When the glue is a
46. 0Operator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions Material Feeder CARD Set Up 1 Loosen the ratchet handles and the thumb lock knob found on each of the material side guides The ratchet handle at the top of the clamp aligns the side guide vertically the thumb lock knob at the back of the clamp aligns the side guide horizontally See figure III 4 Figure 111 4 APAS 72 092011 APAS72Operator ServiceManualREV0 Le Pitney Bowes Direct Mail Solutions 2 Mark the center of the card and place the marked piece on the feeder friction belt see figure 111 9 Align the mark with the center of the friction belt of the material separator see figure 111 5 Figure 111 5 4 Setthe side guides of the feeder to the width of the material to be run Allow approximately 1 8 of space between the material and the material side guides to enable the material can slide freely to the friction belts of the feeder 5 Setthe Wedge under the material to obtain the proper stack angle for feeding see figure 111 6 The variables of this setting are dependent on the characteristics of the material Helpful Tip The more the wedge is pushed under the material the less critical the material separator setting becomes If the wedge is placed out from the material the separator setting will become more critical LOOSEN THUMB LOCK ADJUST THE Figure 111 6 BACK WEDGE APAS
47. 2 Section IV General Service 39 Page 49 APAS 50 General Cle ing 2 7 Page 51 Cleaning TNEBSSDOMEESIR __ Page 51 APAS Material Transport Belt Replacement Page 52 Card Feeder Belt s Replacement Page 60 Section V APAS Electrical Components Page 68 Section VI APAS Wiring Diagrams Page 72 Section VII Trouble Shooting METRE Page 99 APAS 72 092011 APAS72Operator ServiceManualREV0 i Pitney Bowes E Direct Mail Solutions Special Note oome pictures and illustrations may have color hue and contrast graphically altered for clearity when printing in black and white and may not necessarily reflect the actual color of the product when viewed on compact disk DEFINITIONS 0 AN VAC volts a c 1 WARNING or CAUTION 2 HAZARDOUS HEAT APAS 72 092011 APAS720Operator ServiceManualREVO i Pitn
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50. G GROUND TERMINAL 1 2 QUAD RELAY 46 1 END STOP TERMINAL This document data record is the property of R 1 Hi el 2 5 PE pk 98013 140 OPERATOR INTERFACE 57 IN jme PART OF 96013 46 KIT E e 93 gn 1 E FIT SCHEMATIC REQUIRED 16021 105 MIT SET 5 j MN 4444 S 5 BN RI RI NI ad oM M M OM M WM OM M WM M M M M WM RM WM M WM WI M R 81431 843138 8818 41141148 19148184 d 4 ae IN 2 2 AB am BLK BLK x gt gt gt PET mM UI 95588 50 6 133HS 31V2S LON OG 31 25 2 325 LV 780 LZO7L X30334 QNV2 WALSAS DNIHOVLIV LINGOYd 32NVAQV SVdV ITIL S3MO8 AINLIdEE DNISNOH 40 401 NO 5138971 32V ld 097438v1 38 01 SONISNOH YOLOW 5 gt lt quoa 0104 M0123NNO2 YOLOW das S3MIM XIAO 8Z0 61086 lt 1 ISN YOLOW 760 9086 3402 LVHL 40 HLONST ISN 91 9086 35 L NOILISOd SMOHS HOSNAS 1233130 QNV2 LSY EX 770 0086 ONOT S3H2NI OG 38 01 HLONIT WE 9 096
51. Humidity Pollution Level Pollution level 1 conforming to JIS B3501 Corrosion Gas There must be no combustible or corrosive gas Operating Altitude 2 000 m above sea level or lower Vibration Mechanical Resistance Conforming to JIS B 3502 Operating 10 to 57 Hz with single amplitude of 0 075 mm Conditions 57 to 150 Hz with fixed acceleration of 9 8 m s 10 sweeps each in X Y and Z directions sweep time 1 octave min Shock Resistance Conforming to JIS B 3502 Peak acceleration of 147 m s twice for 11 ms each in the X Y and Z directions Installation Ground Ground to 1000 max Requirements Cooling Method Natural cooling Figure 1 3 APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Installation Positioning the Components Once the APAS base has been removed from the shipping container perform the following 1 Inspect the location where the machine is to be set up Note The manufacture recommends that the area be a relatively flat and smooth concrete or hard wood surface similar substrates are acceptable The area should be free of holes divots loose floorboards etc and not subject to retaining moisture from water seepage Warning In the event the floor does not meet the recommended requirements seek an alternate location or reschedule the installation after repairs to the floor have been completed 2 The glue tank feeder and its associated mountin
52. IHSIENS LIW NOTE 2 PS2 record is the property of es Inc and contains PROPRIETARY an ormation a copied and is not to be This document data RN HOLOW das 20140500 55 705 3079 0140 MER AO me 0 Sein s _ 7 m gt 2 Oo 14021 084 APAS ADVANCE PRODUCT ATTACHING SYSTEM CARD FEEDER ENCLOSURE TB1 LAYOUT DRAWING NUMBER eli E TITLE ODIT TOE IO EK HEN C2 2 WO QQ Trt E HON 1642 57121 TO LO OT T O DIC IO TRENG 10 5711 11 11 1111 17 11 ES 2 n 1 I Ta E NO 0 NO NO 1 TERMINAL BLOCK LAYOUT Left to Right TEM QTY DESCRIPTION __29 2 TERMNAL DBL LAYER SHORTED 6 WAY __23 1 POWER SUPPLY 24 Volt 25 DC 74 1 SPRING CAGE DISCONNECT TERMINAL BLOCK SINGLE __29 2 TERMINAL DBL LAYER SHORTED 6 WAY 1 END COVER DBL LAYER 6 WAY __28 1 TERMINAL DBL LAYER 6 WAY 14 7 TERMNAL DBL LAYER 4 WAY 30 1 COVER DBL LAYER 6 WAY 17 1 END COVER DBL LAYER SHORTED 4 WAY 6 TERMINAL DBL LAYER 4 WAY 40 1 RELAY SPDT 24V AC DC W DINRAIL BASE 25 2 OUTPUT MODULE 24VDC W DINRAIL BASE 74 1 SPRING CAGE DISCONNECT TERMINAL BLOCK SINGLE 46 1 END STOP TERMINAL ___
53. JU VI LN3OIHNOO PUD ANV l3lMdONd SUIDJUOD PUD samog K aulld Jo AjJadoud pJ0234 DJDP JUSWNJOP SIUL 940 WNOYUH 491954 NIVELS Ad anis 0703 0105 G 609120 30 lt 133HS 31V2S LON OG 31 25 2 325 780 120 LNOAVT 81 3IDVLTOA JYNSOTDNI 30334 WALSAS DNIHJVLIV LINGOYd 32NVAQV SVdV ITIL S3MO8 ASNLIdEE OPPI 6 0104 DMM LBL A Ce V pup eec 221 2255 22 39 4 T gt lt 00 O T lt O 4 3 d3MO 1d AV 1481 d3MOd 4 5 2 5 L ALOJ ON WALI 9015 9 ONIHdS H3AO00 1 IL amp ONNOSD 45 S LIND ola 7 w Jsv8 VANIA M 072 voe 1090 0 2018 TVNIWH3I DV ONHdS Z v 3sv8 M 2092 VOE Ladd Avi3H L 02 JINIS 32018 IWNINNSL LISNNODSIG 3DVJ DNHdS Ob 7 JYNINSSL 4015 0431 L 9 OL 1441 LNOAVT 2 32018 TYNIKYIL jou SI PUD UONDWJOJU TVYILNIGISNOd PUD AYVLAIYdOYd SulDiU03 PUD Jo AjJadoud Pio3 J SIUL 0703 FOLD 1 439335 0105 SSN A7
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56. LC Check Power to MTR1 refer to Power MTR1 Check input to X13 normal when lit Check all stop buttons Vacuum Motor does not come on Check that K2 is on Check CB2 6A Feeder will not run Check fuse condition Check outlet power source Check power switch Feeder runs but no material is being Check material supply dispensed Remove all material and follow setup procedure Check rollers and belts for excessive wear or dirt Feeder does not create a gap between Lower separator adjustment and observe If a gap is pieces not present after this adjustment return separator to original position and move the back guide forward Lower rear elevator belts slightly Feeder does not detect material Adjust position of the sensor Thick material does not feed well Decrease the height at the back of the material stack Increase the opening at the separation device the thicker the material the less critical the setting is Thin material does not feed Adjust separation device as described in section 2 Remove material and fan the stack allowing air to separate the pieces Raise the rear of the material stack by moving the wedge forward APAS 72 092011 APAS720Operator ServiceManualREVO i Pitney Bowes Direct Mail Solutions APAS 72 092011 APAS720Operator ServiceManualREVO
57. NOD PUD AUVIIMdOMUd 405 PUD jo AjJedoJd ayy SI DJDP JUBWNJOP 141 m gt 07104 INN G LEARI606ZY0 L 20 Z 133HS ITVIS LON OQ 31 25 2 325 780 1207 ONILNOY 3 18V2 IIV L3Q IWH SYNSOTINA 30334 WALSAS DNIHOVLIV LINGOYd 32NVAQV 5 4 S3MO8 7 XZ anos ASN YOUNIA 04 LON JOU SI PUD UONDWJOJUI TVLLN3GIHNO2 PUD AUVIIMdOMUd 405 PUD jo AjJedoJd ayy S DjDP JUBWNJOP 141 G 18 34606270 50 EL 133HS ITVIS LON OG 3125 2 325 780 1207 NOLLVYDILNI SYNSOTINS 30334 WALSAS DNIHJVLIV LINGOYd 32NVAQV SVdV ITIL S3MO8 AINLIdEE NOISNALXS 58440444 2 YSACGOING ASSV EOL LZO7L TV EN VI F318V 124140 NEOH ASSV 60 LZ071 3 18v NOILVYDALNI 7 SVdV OL SVdV 60 407 AGLO ELO7L IV3S 2108 8 NOLLVYHDSLNI Nid ZE SVdV OL SVdV 060 LZOYL 200 086 415 AAOQWSY IN MOI 104 HJEL 38NSO0 DNI 490944 QHV2 ANZ NO 1 45444 SI 430344 GNOJAS SVaV OL SJONVH
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59. OHY JS AaS Sit INIKANMDOG 361 ONY VOLI dS OIW 3M0S012N3 Yva 7 2 8009 AVM 9 MJAV1 180 GN 21 10096 Siril E 1 L 45 9 VOL AGEZ 90 300 0086 TWNIWYSL NOLLISOd 2 300188 OEL LO086 ET LOOHLIM 04414 5 NidMHdH SV Lava 3dOMha VSI AOEZ 090 20096 JYNINHIL 3514 3708 G7 0096 0103 dO SHI 5 7913 039 TEEN S NN trc EE XO AN VOL AOEZ t 660 20086 IVYNINHdHl NOILISOd 64 70086 uer Sasa JIVANNVW dae OL S TYNKEAL 0 v9L AOEZ D 00L 0096 ado 39 921 10086 LHDISH 520445 5 444013 40 dad 1541 1 V SSVd OL ASSV 041410 54 1 lt V9 M3XV3M8 LINDH 060 70086 yy MIMVIYG LINDY 6890 70086 52 MOLSIS3M 3 VM8 DIAVNVAG LSL EL086 07 4 1 ASSV ZYL LZO9L OL 404 544 51 SLHOHS siis de 2600 39 TIVHS TENSSSV d 7 13 JOSWAS UNNOYD 7 ELO ZLOSL 9L 7L ITVNWIH 0520 LISNNODSIG 6 7 9 086 OHO YO UNV INVN YOUNSA CONV ISAS NOISIASYd 448 LYVd SWC NOILVWYOSNI DNIMO 11084 DMV9 8 DNIH 911 0096 3079 DMY 9 7 94 TVNIAM3 L 122 9086 s 0 Jy OL Z L 07Z dvVMIS OIA A009 DMVSLH 3M 902 0 086 AC i GO TISNNO St pai
60. PAS Base are by design in compliance to meet and or exceed the mandates and requirements as stated in the Community Legislation on Machinery Comments on Directive 98 37 EC By manufacture design the E Stop buttons are to be used in the event of an emergency once the E Stop button has been depressed a delay of 5 to 7 seconds must elapse before the E Stop button can be re set Once the E Stop button has been re set another delay of 5 to 7 seconds must elapse before normal machine operation can be resumed In the event the delays are not strictly observed before attempting to resume normal machine operation a conflict in the logic program may result causing an operator to power down the system and re boot to clear the conflict before resuming normal machine operation For a selective stop to interrupt normal machine operation depress the Black control Stop button The machine can be re started without delay at the operator s discretion See figure Ill 12 APAS 72 092011 APAS720Operator ServiceManualREVO i Pitney Bowes Direct Mail Solutions APAS Base Controls VACUUM TOWER FEEDER Figure III 9A 1 Run Button When pressed machine base will start 2 Status Indicator Solid Lamp running condition Rapid Flash Material jam on base Slow Flash Feeder jam or out of material 3 Stop Button When pressed machine base will stop 4 Jog Button When pressed the base will run at a slow
61. R APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions e Remove vacuum hoses and cover from card feeder fig CF1 amp 2 S WS 279 1 ul FIG CF 1 ROR lt ON aW 2 A 4 ny m G CY FIG CF 2 APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes Direct Mail Solutions e Remove gas strut from side frame and upper vacuum belt drive fig CF 3 Lift retainer with screwdriver amp pull strut off mount Fig CF 3 e Remove six screw mounting side frame to card feeder fig CF 4 Remove Fig CF 4 APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions Remove screws attaching side frame to card feeder fig CF 5 Fig CF 5 Remove 9 screws shown above APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions e Loosen ratchet lock and with the aid of a wooden mallet tap the side frame away from the card feeder fig CF 6 Fig CF 6 APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions e Atthis point the card feeder vacuum belt and exit rollers can be replaced fig CF 7 Fig CF 7 Remove the locking collar E clip washers and block fig CF 8 NOTE Be
62. RE THE CARD IS PLACED 277 CARD TO EDGE THE DISTANCE FROM THE LEAD EDGE OF THE FORM TO WHERE THE 2 CARD IS PLACED IF USED APAS 72 092011 APAS720perator ServiceManualREVO m Le Pitney Bowes Direct Mail Solutions 3 GLUE MENU SCREEN See figure III 19 GLUE MENU Het GLUE 181 GLUE end GLE FROM BOGE Mitten FROM EDGE DSD 1 000 OLE GLE ind 8 411 GLE FROM EDGI SELED T NUMAER OF GLUE STAIRS F URK GLUE CF Figure III 19 DESCRIPTION FUNCTION SELECT OF GLUE ENABLES FROM ONE TO FOUR GLUE STRIPS STRIPS TO BE USED ANALOG OUTPUT SELECTS THE ANALOG OUTPUT MENU SCREEN GLUE OFF TURNS THE GLUE ON OR OFF PRIMES THE GLUE HEAD STAYS ON WHILE BUTTON IS PRESSED THRU 4 PRODUCT 4 APAS 72 092011 APAS72Operator ServiceManualREV0 i Pitney Bowes E Direct Mail Solutions 4 Analog Output Screen ILGE GLU DAT DESCRIPTION FUNCTION MENU A BRINGS YOU BACK TO THE SCREEN NUMERICAL DISPLAY OF GLUE GOES BACK TO THE PREVIOUS SCREEN INCREASES OR DECREASES THE PRESSURE OF THE GLUE APAS 72 092011 APAS720perator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions 5 The MAINTENANCE SCREEN is now displayed on Human Machine Interface HMI See figure 111 20 FACTORY SE T TIERS AHALOS TROT CREE Figure 11 20 RESET PIECE COUNT SELECTS THE RESET PIECE COUNT MENU
63. Suv S38IM 77 14412345 3SIMH3HIO SS3TNN 1 88 SALON jou s PUD UONDWJOJUI TYILNIAIYNOD AAWWWPP XX 385 XX XXX XXXXXXX PUD SUIDJUOD PUD samog aUlld 1 35NVHJ WAS 507 138 jo AjJedojd S DJOP JU3WNJIOP 1 G N m gt 1104 Le Pitney Bowes Direct Mail Solutions Section VII Trouble Shooting APAS 72 p Pitney Bowes 12050 49th STREET NORTH CLEARWATER FL 33762 4301 PHONE 727 571 3630 FAX 727 571 3443 TOLL FREE 1 5 APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Problem Things to Check machine Check power to the machine Check CB1 amp CB3 4A Main vacuum belt does not move Check for power to MTR1 Check that K1 is on Check CB1 amp CB3 4A Check PLC in Run Mode Card Feeder is not feeding Check Feeder On Off Button Lamp illuminated On Check Connection at Base Feeder needs to be full Photocell Blocked Check MTR1 if off refer to No Power to MTR1 Base is not running Check main disconnect is ON Check PLC switch to RUN Lamp is on Check power to PLC refer to No Power P
64. Warning Isopropyl Alcohol is FLAMABLE do not use near an open flame or any other source or device that gives off heat APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions APAS Vacuum Transport Belt Replacement Prepare the work area clear off the top surface of the APAS base 1 Turn the main power switch to the off position 2 Disconnect the power cables 3 Shut off compressed air supply upstream of APAS system and disconnect air line from main filter regulator mounted on APAS base 4 Place support under the electrical cabinets to prevent machine from tipping See fig 1 support under electrical cabinets fig S1 APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Disassembly e Remove side covers from APAS fig 52 Remove 3 front and 2 end covers Fig 82 APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes Direct Mail Solutions e Remove operator side deck top retaining screws 4x fig 53 NOTE Loosen non operator side retaining screws 4x DO NOT REMOVE Remove Figure 53 APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions e Remove roller mount sensor glue mount and card feeders mounts on the operator side fig S4 Fig S4 APAS 72 092011 APAS720perator ServiceManualREVO i Pit
65. YSL 4015 NOILOJ OHA DIJSIDW JO 119 2 e 219101 JO 118 99 AVM 9 TYNINYIL HIAVT 180 43A02 ONS AVM 9 1VNIWH3 L 20 12000182 12011 NS NN 9 IWNIWHSL YSAV 1 180 4403 ANS AVM 9 GSLYOHS 190 IWNIWYSL 325 SIHL LJSNNOJISIG 304 3MIM TYNINYIL SSMOG TEX ETT EF 3svg TVANG M DAAYZ 31000W LNANI OLdO V 221 2 7 0172 008 0 00 0140 V CO 32v71d Lors Ewa DNG 33914 S va ING 30423 NYE LEONE AV EE Of VW GOO 33MHl VNlAH3I 4015 SJINVYHITOL Ne EE AINO S3SOdMfd DNIHNLIVH4NNVN 804 05918 Jung 08 dd dIHSNYWNHOM SJILSIHSLJVYVHJ JO NOILYJIIHISSYTD 51315395 4SIM54H10 INN ddv AJY NOILONGOUHd 5 LLL 2 11112211 e e 9 E T B zal ag
66. __ ___ undi Vi 1 4 N AZ IWH E 1129805 7 m gt 2 5 ADVANCE PRODUCT ATTACHING SYSTEM GLF 2110 3 DL 293 2 ec 11317171 112 TG E wir pe RE 2 SERES 460 2 2 T TG 5 112 01121 112 112 ER TE LOLO O ON H R AOO O TMO NE 5 lt EOLO O O NHO os KO KO Ze 31121711 T R 113 ua IK SS 6 KO KCO 11 s OLO O KO TG LKA COO 11 SOHO OK 11 7 11212121 1127 11 EKOLO CO 11 de 10240 134 5 E oo oo Algavs m QOL m re e QUOD OD 5 m ALIHVS 93 e 3 OR 99 io 8 Ke ee imi EN EO N 8 oe 5 ONES NO TEO NO PS1 ITEM NO QTY DESCRIPTION TERMINAL BLOCK LAYOUT LEFT TO RIGHT 29 4 TERMINAL DBL LAYER SHORTED 6 WAY 45 4 SPRING GROUND TERMINAL 27 2 RELAY DPDT 24V AC DC DINRAIL BASE 29 4 TERMINAL DBL LAYER SHORTED 6 WAY 30 1 END COVER DBL LAYER TERMINAL 6 WAY 74 1 SPRING Pitney Bowes Inc and contains PROPRIETARY and CONFIDENTIAL information and is not to be copied 45 4 SPRIN
67. detect and confirm the presence of paper card before passing onto the card feeder s vacuum belt This sensor does not normally need to be adjusted for each job once the setting has been made it should remain set unless otherwise disrupted In the event the settings have been disrupted perform the following 1 2 Place blank piece of white paper on the elevator belt directly above the paper sensor Set the Light Dark pot setting using small flat blade screw driver slowly and very carefully turn the pot setting located next to the electronic cable connection in counter clock wise direction until full range of motion is felt see figure III 8 Note If this adjustment is performed correctly the screw driver slot in the pot setting should be pointing towards the DO in the range scale next to the pot setting Warning The stop point of this pot setting can be damaged if excessive force is applied 3 Setthe Gain pot setting by performing the following a Using a small flat blade screw driver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a counter clock wise direction until fill range of motion is felt see figure 111 8 The green LED indicator light should be off at this point b Using a small flat blade screw driver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a clock wise direction until the gree
68. different options available but the only two that can be used are FIRST GLUE STRIP SELECTED or 1 amp 2 GLUE STRIP SELECTED o Enter the distance where the 1 glue strip will be placed from the lead edge of the form from the 1 GLUE FROM EDGE o Enter the length of the 1 glue strip from the 1 GLUE LENGTH 2 glue strip will be placed on the form enter that info from 2 GLUE FROM EDGE and 2 GLUE LENGTH NOTE Be sure the GLUE OFF button is being displayed before entering values NOTE 3 and 4 glue setting are only used when a second card feeder is being used In the display above only one glue strip is being placed It is starting from the lead edge of the form and will have a strip that is 1 in length APAS 72 092011 APAS720perator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions tet LUE Tet UE FROM LER a TH k ard LE ard a FRAM EDGE LENS TH end uu LE end aL LIE FROM EDGE TH 4th 4th LUE FROM ELE LETH Fig G5 Fig G4 e Once the glue has reached operating temperature and is in the ready mode place a piece of material under the glue head fig G3 On the Glue Menu press the GLUE OFF button to turn glue on fig G4 On the Glue Menu press the PRIME GLUE fig G5 button to dispense glue thru the glue head e As long as the PRIME GLUE button is held glue will continue to flow fig G6 Return to the Main Menu APAS
69. e the following recommendations for safe operation and maintenance of the APAS are as follows Recommendation gt Any persons designated to operate work on or near the APAS must be fully trained by a factory authorized representative gt Do not operate or perform any type of maintenance on the APAS while under the influence of drugs or alcohol gt Do not operate or perform any type of maintenance on the APAS in or around freestanding water gt Do not wear loose or baggie fitting shirts shirts with bellowing sleeves bracelets rings necklaces neckties or other loose apparel that may come into close proximity with moving parts of the machine gt Do not place any items near or over the Emergency Stop Switches that might inhibit or obstruct line of sight or access to the Emergency Stop Switches The Emergency Stop Switches must be clearly visible and accessible at all times APAS 72 092011 APAS720Operator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions gt Ware protective safety eyeglasses or goggles and use particle mask or similar device when cleaning off the APAS with compressed air Alert all other persons in the area to stand minimum of thirty 30 feet from the area where compressed air is put to such use Hearing protection is not required for safe operation of the APAS Typically decibel levels have been found to be less than 85 decibels in machines properly ma
70. ed due to the design and materials used in manufacturing The frequency of general cleaning required for the APAS base is dependent on the amount of running time put on the machine General Cleaning Removing debris from the machine with compressed air 1 Acquire and use eye protection safety goggles or safety glasses with side guards Also use respiratory protection a simple disposable cloth or paper style particle mask is sufficient 2 Alert all other people in the area to stand clear of the work area a minimum of 30 feet 7 7 meters where compressed air is being used to blow off machines 3 Turn off the machine and disconnect the power line Warning To prevent accidental injury refer to The Lock Out Tag Out Procedure on page 16 4 Remove any loose items from the surfaces of the machine i e Ballpoint pens pencils tape dispensers paper clips rubber bands etc 5 Open all service doors located on the front side of the machine and remove any loose items that might have been left inside i e spare parts tools personal effects such as purses car keys etc Note After a complete visual inspection has been completed and loose items removed leave the service doors open 6 Cover the Touch Screen enclosure with plastic to prevent air borne particles from getting into it Note if the base cabinet is being used to house a computer remove the computer from the cabinet 7 Hold the air nozzle firmly at arms length and
71. es Direct Mail olutions VACUUM BASE ELECTRICAL BOX TB3 14 oH Y b ex EUM mui PLC POWER SUPPLY LINE FILTER APAS 72 092011 FUSES CIRCUIT BREAKERS MOTOR CONTROLLER TB1 TRANSFORMER APAS72Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions CARD FEEDER amp BASE ELECTRICAL BOX POWER ON STATE INITIAL POWER UP CARD FEEDER ELECTRICAL BOX OUTPUT MODULE 2 amp 3 ON o MODULE MODE amp RUN LEDS ON MODULE DISPLAYS o SERVO ONE amp TWO DISPLAY E9 o CR1 amp CR2 LED ON o POWER SUPPLY 1 amp 2 GRN LED ON VACUUM BASE ELECTRICAL BOX o POWER SUPPLY GRN LED ON o PLC e POWER amp RUN LEDS ON e INPUT 15 ON e OUTPUT 5 FLASHING POWER UP AND RESET PRESSED e CARD FEEDER ELECTRICAL BOX OUTPUT MODULE 2 IS ON I O MODULE LED ON CPU MODE amp RUN LED ON SERVO 1 DISPLAYS 001 SERVO 2 DISPLAYS 002 BOTH POWER SUPPLYS GRN LED ON CR2 IS ON OO O O O O e VACUUM BASE ELECTRICAL BOX o CR1 amp 3LEDS ON o MOTOR CONTROL DISPLAYS 000 o POWER SUPPLY GRN LED ON o PLC e POWER amp RUN GRN LEDS ON e INPUT 13 ON e OUTPUT 0 amp 4 ON APAS 72 092011 APAS720Operator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions Section VI Wiring Diagrams for APAS 72 Pitney Bowes 12050 43th STREET NORTH CLEARWATER FL 33702 4301 PHONE 727 571 33
72. ey Bowes Direct Mail Solutions Section I Installation of the APAS 72 Advanced Product Attaching System Pitney Bowes 12050 49th STREET NORTH CLEARWATER FL 33762 4301 PHONE 727 571 3330 FAX 727 571 3443 TOLL FREE 1 800 INSERTER APAS 72 092011 APAS720Operator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions Section I Installation PITNEY BOWES APAS 72 Card Feeder Human Interface Module Glue Feeder Touch Screen Vacuum Transport Belt Figure 1 1 APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes E Direct Mail Solutions APAS 72 Base Floor Plan Shown without other conveyors 3 Requirements Floor Space 27 sa Ft Electrical 230 V 1 PH 50 60 HZ 20 A Vv Air 2 90 PSI Vacuum None 12 30 Weight 1300 lt gt Figure 1 2 Figure 1 3 APAS 72 092011 APAS72Operator ServiceManualREV0 ml i Pitney Bowes Direct Mail Solutions Environment The installation of the APAS is intended for operation in specific environment See Operating Environment Table below for details Operating Environment Table ITEM SPECIFICATION Ambient Environmental Operating to 55 C Conditions Temperature otorage Temperature 25 to 85 C Ambient Operating 30 to 95 RH with no condensation Humidity Ambient Storage 596 to 95 RH with no condensation
73. g removed from normal operating position during shipment must be re mounted See figure l 4 Figure 1 4 a Re install both gusseted style brackets packed in separate container onto left side of APAS base at in feed end of conveyor Use Allen socket head screws 4 provided Note Tapped holes are provided for mounting b Re mount anodized glue tank mounting plate shipped with glue tank strapped to conveyor bed to above brackets using provided Allen socket countersunk screws 4 c Re mount glue tank to mounting plate using Allen socket head screws and hex nuts 4 each provided d Re attach all electrical pneumatic and product piping tubing APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes E Direct Mail Solutions 4 The touch screen assembly packed in separate container must be re mounted See figure 1 5 Figure 1 5 Pull 2 cables power and communication associated with the touch screen from the APAS base and run through the post into touch screen enclosure Enclosure access panel must be opened b Install post enclosure onto APAS base pipe thread connection c Insert power and communication termination plugs into proper enclosure mounted socket and close access panel The side guides left and right hand must be re attached to the material feeder i e card feeder See later section for details Installation Electrical Setup Connections 5 Inspec
74. ide of the connect block opposite the Volt Value Labels Re locate this gray Do not move or in any wire if necessary way re locate any of to the port that the striped or gray best matches the wires from this side of line voltage the connection block Figure 1 6 b Insert the Dark Gray Voltage Select Wire in the connection port that is labeled for the best match for the line voltage discovered in step 3 see figure I 7 Secure by tightening the retaining screw using a medium tip Philips head screwdriver Caution Do not over tighten Line voltage tested at 208 V the Dark Gray Voltage Select Wire was originally pined to the 240V contact port now shown re located to the best matching volt value the 210 V contact port IA Figure 1 7 APAS 72 092011 APAS720Operator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions Installation Leveling the APAS Base 8 Position the APAS base in the designated location then lower the leveler pads to raise the base to comfortable operating height see figure 1 8 Figure 1 8 Turn the lock nut clock wise to tighten we Turn the leveler pad counter clock wise to lower 9 Place a level in the center of the APAS base and adjust the leveler pads as needed to level the machine at the desired height Once the machine has been leveled tighten the leveler pad lock nuts see figure l 9 Figure l 9 10 Check entire machine for any item
75. intained and in good operating condition All persons having hair greater than shoulder length who operate work on or near the APAS should keep their hair pulled back in ponytail fashion then pinned up or otherwise contained to the top of their head or confined under the back of their shirt Turn off the main power to the APAS before opening any of the service doors for general cleaning and or general maintenance Follow the Lock Out Procedures as stated on page 16 for extensive repairs involving disassembly of the machine either in whole or in part or replacing any of the electrical components Any persons working near any of the electrical motors or pump motors of the APAS should use caution Electrical motors and product heaters give off heat contact with or exposure to bare skin may result in burns The APAS was designed to feed and transport paper only Do not attempt to feed and or run materials made of or containing glass metal wood plastics liquids foods powders gasses explosives or toxic and hazardous chemicals on the APAS Note The manufacture recognizes and acknowledges that the APAS is capable of successfully running and or transporting compact disk and audio cassettes inserted into paper envelopes however the manufacture and other companies connected with the promotion and sale of the APAS do not assume any responsibility for any damage to the APAS or product and shall be held harmless for any damages and
76. iver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a counter clock wise direction until fill range of motion is felt see figure 111 2 or 3 The red LED indicator light should be off at this point b Using a small flat blade screw driver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a clock wise direction until the red LED light comes on continue turning the pot setting in a clock wise direction another half turn 6 Return the plastic cover removed in step 3 to its original position APAS 72 092011 APAS720Operator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions Remove the plastic cover from the sensor to gain access to the pot settings Sensor shown has detachable electrical cable fitting Fitting for electronic cable Figure 11 1 View of Detachable Cable style Sensor Shown in actual orientation as it appears on the APAS base Figure 11 2 4 Pin detachable cable fitting Liaht Dark Pot Settina Red LED Light Gain Pot Setting APAS 72 092011 APAS720Operator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions View of Hard Wired Cable style Sensor Shown in reverse orientation as it appears on the APAS base Gain Pot Setting Red LED Light Light Dark Pot Setting Hard wired electronic cable Figure 11 3 APAS 72 092011 APAS72
77. mage to the APAS and or any other components connected to or associated with the APAS as a result of failure to comply with the Lock Out Procedure 1 Turn the main power switch to the off position 2 Disconnect the power cable from its source by performing the following a Follow the main power line from the machine back to the receptacle or source of supplied power and disconnect it at the source b Place the plug connecter close to the machine in such a position that will remain in your field of vision while repairs or maintenance is being performed 3 Notify all other persons in the area where the work is being performed that the machine will be out of service especially if the work you are performing requires you to be crouched behind or beside the machine or in some other way obscured from the sight of other persons in the area 4 When the work has been completed reconnect the plug to the power source and then test cycle the machine to ensure that power has properly restored and the machine is fully functional 5 Notify all other persons in the area that the machine is fully operational and that the drive motors will become enabled when the power switch is placed in the on position APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Suggested Lock Out Devices The following are some suggested devices specifically designed to provide greater degree of safety when l
78. n LED light comes on continue turning the pot setting in a clock wise direction another half turn View of Hard Wired Cable style Sensor Stability indicator green Operation indicator jorangs Bensitivty adpuster scar Figure 11 8 32 061 5 72 092011 APAS720Operator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions Control Panel and Switch Operation APAS 72 Base Operator Control Panel MAIN MENU gt i za VACUUM MOTOR OFF GLUE SYSTEM OFF FEEDER OFF Mee tn DOO 00000 DESCRIPTION FUNCTION 1 1 FUNCTION Mode Menu Divert Menu Feeder Menu Feeder Off Fault Reset Start New Job Glue Off PRESSTOTOGGLEGLUEONOROFF ___ Vacum Off PRESS TO FEED AND SINGLE CARD ALSO USED TO STAGE A PIECE APAS 72 092011 APAS720perator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions Setting and Re Setting the Emergency Stop Switch Figure 11 10 Set Emergency Stop Switch by Re Set Emergency Stop Switch pushing downward by twisting to the right Warning The Emergency Stop Switches Must be Visible and Accessible at all times Special Note Pursuant to Community Legislation on Machinery Comments on Directive 98 37 EC 1 2 Controls and 1 2 1 Safety and reliability of control systems The E Stop button buttons found on the A
79. ney Bowes E Direct Mail Solutions e Remove drive motor and motor mount from underside of deck fig S5 o NOTE Assistance may be needed with motor removal Fig S5 Motor mount Motor mounting hardware location Under vacuum belt APAS 72 092011 APAS720perator ServiceManualREVO m Le Pitney Bowes Direct Mail Solutions e Remove Idler tensioning rollers fig 56 57 58 APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions e With rollers removed belt will have enough slack fig S9 to allow it to be removed from the drive side fig S10 Lift the deck to allow the belt to go between the deck and frame APAS 72 092011 APAS720perator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions e While lifting feeder mounts work the belt off of the machine fig 11 e Follow the previous instructions in reverse order to install the new belt o NOTE Be sure that all rollers are tensioned evenly APAS 72 092011 APAS720perator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions CARD FEEDER BELT REPLACEMENT Prepare the work area clear off the top surface of the APAS base 1 Turn the main power switch to the off position 2 Disconnect the power cables 3 Shut off compressed air supply upstream of APAS system and disconnect air line from main filter regulator mounted on APAS base APAS CARD FEEDE
80. ocking out the power supply to a machine These devices can be purchased from most safety equipment suppliers and vendors Lock Box designed for power cord plug connectors commonly used in combination with a key style padlock Note Appearance of Lock Out devices may vary depending on vendor Figure 1 4 Breaker Lock designed for use inside electrical breaker boxes commonly used in combination with a key style padlock Note Appearance of Lock Out devices may vary depending on vendor Figure 11 5 APAS 72 092011 APAS720perator ServiceManualREVO Pitney Bowes Direct Mail Solutions Warning Alert tags commonly used in combination with all lock out devices Front View of Lock Out Tag Back View of Lock Out Tag EQUIPMENT EQUIPMENT LOCKED OUT BY LOCKED OUT THIS TAG amp LOCK TO BE REMOVED ONLY BY THE PERSON SHOWN ON BACK Figure 1 6 APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Section General Set Up APAS 72 Advanced Product Attaching System zl rE pm p Pitney Bowes 12050 49th STREET NORTH CLEARWATER FL 33762 4301 PHONE 727 571 3330 FAX 727 571 3443 TOLL FREE 1 BOQ INSERTER APAS 72 092011 APAS720Operator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions Section This APAS system is comprised of a belt conveyor gluing applicator and a material feeder i e
81. oe Na Per F RT NO SO NO Mmmm MC xo Seded NR FIS suec OU MN ap EN 522 0005 Wy 20927 NMOHS 5342018 IVNIAH3A AAWWWPP XX 3DYd 395 XX XXX XX XXX XX 5 L N e vel SJON SANTAJ AG 041414 03 NOlLdlH2S3G 49 3 WAS JO 1 x 104 Shs AR gt a IHdIH OL 159 D LNOAV I 32018 1 NOLL c ALO ON hall dojs puj GL ADM O JSAD J8AO2 L Ot ADM O 4801 puwa 6 94 O 5 4340 2 62 ADM O DUIWIS 6 82 ADM O 5 J3 D Puwa 2 62 ADM O J340 DUIWJS 82 ADM 9 pajJJOus JDUIWJE 6c ADM O jpuiulJo 2 82 ivi 12491139 9091 GL 5 5 404 ages 3 paido q JOU SI PUD UONDWJOJUI TYLLNIGIYNO PUD AMV I IHdOXHd SUIDJUOJ PUD DU samog JO jJedoud au SI pipp lu un3op SIU OL Dap 2 d 104 P Sv 200221 25026 LJJHS ans INON 1734 LVZH OL 7 100 32018 TVNINYZ B C i 2 a g E INON Od HSINIJ NOI LdlH2S 3 ALO WILI TWNIN
82. or injuries resulting in this practice Special Advisement The manufacturer and other companies connected with the promotion and sale of the APAS shall be held harmless for any and all injuries sustained to any person or persons as a result of failure to comply with the recommendations for safe operation and maintenance of the APAS as shown and or described herein APAS 72 092011 APAS720Operator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions Machine Lock Out Procedure Before beginning extensive repairs involving disassembly of the machine either in whole or in part performing general maintenance or replacing any of the electrical components the machine must be locked out of service to ensure that power will not be restored to the machine while the work is being performed To lock a machine out of service perform the following Warning The following procedure is published herein for the expressed purpose of providing a safe work environment conducive to persons performing repairs and or maintenance and or general cleaning of the APAS and or any other components connected to or associated with the APAS This procedure must be followed without exception to ensure the safety of any person or persons performing the previous stated task The manufacturer and other companies connected with the promotion and sale of the APAS shall be held harmless for any and all injuries sustained to any person or persons and or da
83. r base above the door lock Figure 11 1 Label shown at actual size Shock Hazard oymbol indicating possible shock hazard Found posted above the lock of the service door on the Electrical box mounted on the backside of the Attacher base Figure 11 2 Label shown at actual size Mechanical Warning oymbol indicating pinch hazard Found posted on the mounting plate of the vacuum belt drive motor Figure 11 3 Label shown at actual size Note This symbol appears as visual alert in the text of this manual next to written warnings regarding possible safety issues and or possible machine damage that may occur as direct result of failure to follow specific instructions as written APAS 72 092011 APAS720Operator ServiceManualREVO m i Pitney Bowes Direct Mail Solutions Note The safety devices door locks warning labels and stickers are installed by the manufacturer to safeguard all persons operating and or working on or around the APAS Removing altering or disabling any of these items will void any and all warranties either real or implied purchased or offered with the APAS All companies connected with the manufacturing promotion and sale of the APAS shall be held harmless for any and all injuries and damage in the event the safety devices door locks warning labels and stickers are removed altered or disabled In addition to the safety devices and warnings installed on the APAS by the manufactur
84. s that may be obstructing proper operation This includes packing shipping components 11 Plug the power cables for the glue applicator and the APAS system remove front panel to access into the proper sized site receptacle A Warning To avoid possible damage to the machine and prevent possible injury keep the work areas free of all packing material and other debris APAS 72 092011 APAS72Operator ServiceManualREV0 Le Pitney Bowes Direct Mail Solutions Section Safety Features amp Warnings Rur Pitney Bowes 12050 49th STREET NORTH CLEARWATER FL 33762 4301 PHONE 727 571 3330 FAX 727 571 4443 TOLL FREE 1 BDO INSERTER APAS 72 092011 APAS720perator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions Section Il Safety Locks and Warning Stickers All APAS s have been designed with safety locks on all doors to cabinets containing moving parts as well as caution or warning labels or stickers to safeguard persons operating and or working on or around this equipment These are as follows All doors to cabinets containing moving parts are equipped with a mechanical lock that requires the use of a flat blade screwdriver to open The main power or electrical box door is equipped with a safety lock that requires a specific key to open General Warning oymbol indicating possible safety hazards Found posted on the left front service door of the Attache
85. speed 5 Feeder Button When pressed the product feeder will run while the base is running Button is illuminated when on 6 Gap Control This sets the gap between the product being fed 7 Base Control This sets the speed of the base 8 Reset Button Pressing this button will reset errors to the base 9 Emergency Stop Button Press this button when an immediate stop to the base is required 10 Vacuum Power Switch Turns on the vacuum pump APAS 72 092011 APAS720perator ServiceManualREVO Pitney Bowes Direct Mail olutions 1 MODE MENU Screen See figure 111 16 MODE MENU figure 111 16 MODE SCREEN zh E uml dL pg DIVERT MENU VIRTUAL TRIGGER MENU APAS 72 092011 APAS720perator ServiceManualREVO m i Pitney Bowes E Direct Mail Solutions 2 FEEDER MENU Screen See figure 111 17 FEEDER MENU figure 111 17 DESCRIPTION FUNCTION ONE SHOT PRESS TO FEED ONE CARD ALSO USED FOR STAGING THE CARD FAULT RESET PRESS TO RESET ERRORS FEEDEROFF PRESS TO TOGGLE CARD FEEDER ON or OFF MAIN SCREEN PRESS TO ACCESS THE MAIN SCREEN OF CARDS PRESS TO SELECT ONE OR TWO CARDS TO BE FED DOUBLE PERCENT PERCENTAGE OF CARD THAT IS SEEN BEYOND THE CARD LENGTH BEFORE DECLARING AN ERROR FORM LENGTH THE LENGTH OF THE FORM BEING FED CARD LENGTH THE LENGTH OF THE CARD BEING FED 1 CARD TO EDGE THE DISTANCE FROM THE LEAD EDGE OF THE FORM TO WHE
86. t the line current at the point where the power cable of the machine is to be plugged in Note Conventional wall sockets ceiling line drops and D Boxes should be free of cracks rust visible signs of heat stress and flash marks Special Note For installations in Europe check the condition of the voltage converter box or other voltage reducing device that may be in use In the event of a line voltage inspection failure report your findings to the person or persons in charge of the building and postpone the installation until corrections are made Check the line voltage to ensure that the minimum and maximum requirements are present Check to see what volt value the transformer is pinned out to at the voltage selection block see figure 1 6 If the volt value is different from the line voltage you checked in step 3 the transformer will need to be re pinned to match This can be done by a Using a medium tip Philips head screwdriver loosen the retaining screw in the connection block that the Dark Gray Voltage Select Wire is currently connected to see figure 1 6 APAS 72 092011 APAS720perator ServiceManualREVO ml i Pitney Bowes Direct Mail Solutions A Caution The Dark Gray Voltage Select Wire is located on the side of the connect block next to the Volt Value Labels It is the only wire that occupies this side of the block Do not move or in any way re locate any of the stripped or gray wires from the s
87. t the proper temperature LED fig G1 will be lit o Press fig G2 to turn on the pump the LED will illuminate NOTE Refer to the Nordson manual for further operation of this unit APAS 72 092011 APAS720perator ServiceManualREVO i Pitney Bowes E Direct Mail Solutions e FEEDER SETUP e From the main menu press the Feeder Menu button o Enter the length of the form being fed in FORM LENGTH Enter the length of the card being fed from the card feeder in CARD LENGTH o Enter the distance from the edge of the form to where the card will be placed in 157 CARD TO EDGE o card will be applied enter its placement in 2 CARD TO EDGE o If Two cards are going to be used select TWO from the OF CARDS Note Be sure that the FEEDER OFF button is displayed before entering data Note To enter data touch the numbers that need to be changed and a keypad will be displayed Enter the data and press enter to set that value APAS 72 092011 APAS720perator ServiceManualREVO Le Pitney Bowes Direct Mail Solutions GLUE SETUP Viet Ra 0 LJ p T w AH IE LENGTH FRU EDA V P c 00 22 SELECT NUMBER OF BLUE e From the main menu press the GLUE MENU button o Select the number of glue strips to be placed on the form from the SELECT NUMBER OF GLUE STRIPS button NOTE There are several
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